Yale Forklift F813 (GLPGDP 40VX5, 40VX6, GLPGDP 45SVX5, 45VX6, 50VX, 55VX Europe) Service Manual PDF

Yale Forklift F813 (GLPGDP 40VX5, 40VX6, GLPGDP 45SVX5, 45VX6, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift F813 (GLPGDP 40VX5, 40VX6, GLPGDP 45SVX5, 45VX6, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4416
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift F813 (GLPGDP 40VX5, 40VX6, GLPGDP 45SVX5, 45VX6, 50VX, 55VX 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
524223762 1300YRM1129 (11 2018) UK EN 2213
General 2217
Serial Number 2217
Charge Pump Repair 2217
Remove 2217
Inspect 2218
Install 2218
Torque Converter Replace 2218
Remove 2218
Install 2226
Front Cover Housing and Chain Drive Repair 2232
Remove 2232
Clean 2241
Inspect 2241
Install 2241
Clutch Packs Repair 2250
Remove and Disassemble 2250
Transmission, Remove and Disassemble 2250
Clean 2269
Inspect 2269
Assemble and Install 2270
Transmission, Assemble and Install 2278
Control Valve Repair 2284
Remove and Disassemble 2284
Clean 2288
Inspect 2288
Assemble and Install 2288
Foot Directional Control Pedal Repair 2289
Remove and Disassemble 2289
Assemble and Install 2293
Direction Control Lever 2294
Remove 2294
Install 2294
524223764 1600YRM1133 (07 2013) UK EN 2299
toc 2299
Steering Axle 2299
Safety Precautions Maintenance and Repair 2300
General 2303
Steering Axle Assembly Repair 2305
Remove 2305
Disassemble 2306
Clean 2314
Inspect 2314
Assemble 2314
Install 2320
Spindles, Bearings, and Tie Rods Repair 2322
Spindles and Bearings 2322
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2322
Remove 2322
Disassemble 2324
Clean 2325
Inspect 2325
Assemble 2325
Install 2326
Spindles and Bearings 2329
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2329
Remove and Disassemble 2329
Assemble and Install 2330
Tie Rods 2330
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2330
Remove 2330
Install 2331
Tie Rods 2332
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2332
Remove 2332
Install 2338
Steering Cylinder Repair 2338
Remove and Disassemble 2338
Clean and Inspect 2339
Assemble and Install 2339
Torque Specifications 2340
524223766 1900YRM1136 (11 2017) UK EN 2345
General 2349
Hydraulic Gear Pump Assembly 2350
Variable Displacement Pump Assembly 2351
Single Gear Pump Assembly Repair 2351
Remove 2351
Disassemble 2358
Clean 2358
Inspect 2360
Assemble 2360
Install 2360
Tandem Gear Pump Assembly 2364
Remove 2365
Disassemble 2367
Clean 2369
Inspect 2369
Assemble 2369
Install 2370
Gear Pump Specifications 2370
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2376
Remove 2376
Disassemble 2386
Clean 2389
Inspect 2389
Assemble 2389
Install 2390
63 0 cc/rev – Variable Displacement Pump Repair 2393
Remove 2393
Disassemble 2396
Clean 2396
Inspect 2396
Assemble 2398
Install 2398
Variable Displacement Pump Checks and Adjustments (Single Pump) 2400
Margin Pressure Check 2400
Flow Compensator Adjustment 2401
Pressure Compensator Adjustment 2401
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2402
Variable Displacement Pump Specifications 2405
Torque Specifications 2406
Hydraulic Gear Pump 2407
Variable Displacement Pump 2408
Special Tools 2408
524223767 2000YRM1137 (01 2017) UK EN 2413
General 2419
Electro-Hydraulic Main Control Valve 2420
Description 2420
Remove 2428
Electro-Hydraulic Control Valve Sections 2433
General 2433
Outlet Control Valve Section 2433
Remove 2433
Disassemble 2434
Clean 2436
Inspect 2436
Assemble 2436
Install 2437
Auxiliary Control Valve Sections 2437
Remove 2437
Disassemble 2444
Clean 2445
Inspect 2446
Assemble 2446
Install 2448
Tilt Control Valve Section 2449
Remove 2449
Disassemble 2449
Clean 2455
Inspect 2455
Assemble 2455
Install 2456
Lift/Lower Control Valve Section 2457
Remove 2457
Disassemble 2457
Clean 2466
Inspect 2466
Assemble 2466
Install 2467
Mid-Inlet Section 2467
Remove 2467
Clean 2468
Inspect 2468
Install 2468
Install 2468
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2473
Lift Pilot Pin 2473
Lower Pilot Pin 2477
Abnormal/Erroneous EHPV Adjustment 2479
Manual Main Control Valve 2480
Description 2480
Remove 2484
OPS Solenoid Assembly 2492
General 2492
Remove 2493
Clean and Inspect 2496
Install 2496
Manual Control Valve Sections 2497
General 2497
Outlet Control Valve Section 2497
Remove 2497
Disassemble 2497
Clean 2500
Inspect 2500
Assemble 2500
Install 2501
Auxiliary Control Valve Sections 2501
Remove 2501
Disassemble 2501
Clean 2504
Inspect 2504
Assemble 2504
Install 2505
Lift/Tilt Control Valve Section 2505
Remove 2505
Disassemble 2505
Clean 2512
Inspect 2512
Assemble 2513
Install 2514
Mid-Inlet Section 2515
Remove 2515
Clean 2515
Inspect 2515
Install 2515
Install 2516
Pressure Relief Valve Check and Adjustment 2522
Primary Relief Valve 2523
Secondary Relief Valve 2527
Steering Control Unit Repair 2534
Steering Control Unit, Remove 2534
Steering Control Unit, Disassemble 2538
Steering Control Unit, Clean 2540
Steering Control Unit, Inspect 2540
Steering Control Unit, Assemble 2540
Relief Valve, Disassemble 2541
Relief Valve, Clean 2541
Relief Valve, Inspect 2542
Relief Valve, Assemble 2542
Steering Control Unit, Install 2542
524223768 2100YRM1139 (02 2014) UK EN 2547
524223769 2200YRM1128 (01 2023) US EN 2595
Series Code / Model Designation Reference Table 2603
General 2605
Deutsch Crimping Tool 2606
How to Strip a Wire for Use With Deutsch Crimping Tool 2606
How to Crimp With the Deutsch Crimping Tool 2607
Calibration Test for the Deutsch Crimping Tool 2609
Deutsch Connectors 2611
DT, DTM, and DTP Series Connectors 2611
HD Series Connectors 2654
Metri-Pack Connectors 2676
Remove and Install 2676
Micro-Pack Connectors 2679
Weather-Pack Connectors 2680
AMPSEAL Crimping Tools 2682
AMP Hand Crimping Tool With Certi-Crimp 2682
Description 2682
Stripping Wire for Use with AMP Hand Crimping Tool 2683
Insulation Crimp Adjustment 2684
Maintenance and Inspection for AMP Hand Crimping Tool 2684
AMP Hand Crimping Tool 2684
Crimp Height Inspection 2684
How to use AMP Hand Crimping Tool 2685
AMP Pro-Crimper II Tool 2685
Description 2685
Remove and Install Die Set and Locator Assembly 2686
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2686
Contact Support Adjustment 2687
Crimp Height Adjustment 2688
Maintenance and Inspection Procedures 2688
PRO-CRIMPER II Tool 2688
Crimp Height Inspection 2688
How to Use AMP PRO-CRIMPER II Tool 2689
AMPSEAL Connector Assemblies 2690
Description for Plug Connector Assembly 2690
Seal Plug 2691
Contact Crimping 2691
Description for Plug Connector and Header Assembly 2696
Voltage Reading 2699
Seal Plug 2699
Contact Crimping 2699
AMP Superseal 1 5 Crimping Tools 2706
Mini Mic Receptacle and Tab Contacts 2706
Description 2706
Crimping Conditions and Measurements 2706
Insertion of Rubber Seal on Cable 2708
AMP Hand Application Tool 2713
Description 2713
Maintenance and Inspection 2713
Crimp Height Inspection 2713
Crimp Height Adjustment 2714
How to Use AMP Hand Application Tool 2714
AMP Pro-Crimper II Tool 2715
Description 2715
Remove and Install Die Set and Locator Assembly 2715
Adjustments 2716
Contact Support 2716
Crimp Height 2717
Inspections and Maintenance 2718
Crimp Height Inspection 2718
Visual Inspection 2718
Maintenance 2719
How to Use Pro-Crimper II Tool 2719
AMP Superseal 1 5 Connector Assemblies 2720
Description 2720
Repair and Maintenance 2727
Panel Mount Option 2727
AMP Fastin-Faston Hand Tools 2728
Description – AMP Double Action Hand Tool 2728
Maintenance and Inspection Procedures 2728
Daily Maintenance 2728
Periodic Tool Inspection 2729
Lubrication 2729
Visual Inspection 2729
Crimp Height Inspection 2729
Certi-Crimp Ratchet Inspection 2730
How to Use AMP Double Action Hand Tool 2731
Description – AMP Extraction Tool 2732
Maintenance and Inspection 2733
How to Use AMP Extraction Tool 2733
AMP Fastin-Faston Receptacles and Housings 2735
Description 2735
Wire Repair 2743
Wire Splicing Requirements 2743
Deutsch Jiffy Splice 2744
Twisted/Shielded Cable and Leads Repair 2750
Special Tools 2752
524223769 2200YRM1128 (07 2020) UK EN 2761
Series Code / Model Designation Reference Table 2767
General 2770
Deutsch Crimping Tool 2770
How to Strip a Wire for Use With Deutsch Crimping Tool 2770
How to Crimp With the Deutsch Crimping Tool 2771
Calibration Test for the Deutsch Crimping Tool 2773
Deutsch Connectors 2775
DT, DTM, and DTP Series Connectors 2775
HD Series Connectors 2817
Metri-Pack Connectors 2840
Remove and Install 2840
Micro-Pack Connectors 2842
Weather-Pack Connectors 2843
AMPSEAL Crimping Tools 2845
AMP Hand Crimping Tool With Certi-Crimp 2845
Description 2845
Stripping Wire for Use with AMP Hand Crimping Tool 2845
Insulation Crimp Adjustment 2846
Maintenance and Inspection for AMP Hand Crimping Tool 2846
AMP Hand Crimping Tool 2846
Crimp Height Inspection 2846
How to use AMP Hand Crimping Tool 2847
AMP Pro-Crimper II Tool 2847
Description 2847
Remove and Install Die Set and Locator Assembly 2848
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2849
Contact Support Adjustment 2849
Crimp Height Adjustment 2850
Maintenance and Inspection Procedures 2850
PRO-CRIMPER II Tool 2850
Crimp Height Inspection 2850
How to Use AMP PRO-CRIMPER II Tool 2851
AMPSEAL Connector Assemblies 2852
Description for Plug Connector Assembly 2852
Seal Plug 2853
Contact Crimping 2853
Description for Plug Connector and Header Assembly 2858
Voltage Reading 2860
Seal Plug 2860
Contact Crimping 2860
AMP Superseal 1 5 Crimping Tools 2867
Mini Mic Receptacle and Tab Contacts 2867
Description 2867
Crimping Conditions and Measurements 2867
Insertion of Rubber Seal on Cable 2869
AMP Hand Application Tool 2874
Description 2874
Maintenance and Inspection 2874
Crimp Height Inspection 2874
Crimp Height Adjustment 2875
How to Use AMP Hand Application Tool 2875
AMP Pro-Crimper II Tool 2876
Description 2876
Remove and Install Die Set and Locator Assembly 2877
Adjustments 2877
Contact Support 2877
Crimp Height 2878
Inspections and Maintenance 2879
Crimp Height Inspection 2879
Visual Inspection 2879
Maintenance 2880
How to Use Pro-Crimper II Tool 2880
AMP Superseal 1 5 Connector Assemblies 2881
Description 2881
Repair and Maintenance 2888
Panel Mount Option 2888
AMP Fastin-Faston Hand Tools 2889
Description – AMP Double Action Hand Tool 2889
Maintenance and Inspection Procedures 2889
Daily Maintenance 2889
Periodic Tool Inspection 2890
Lubrication 2890
Visual Inspection 2890
Crimp Height Inspection 2890
Certi-Crimp Ratchet Inspection 2891
How to Use AMP Double Action Hand Tool 2892
Description – AMP Extraction Tool 2893
Maintenance and Inspection 2893
How to Use AMP Extraction Tool 2894
AMP Fastin-Faston Receptacles and Housings 2895
Description 2895
Wire Repair 2902
Wire Splicing Requirements 2902
Deutsch Jiffy Splice 2903
Twisted/Shielded Cable and Leads Repair 2908
Special Tools 2911
524223770 2200YRM1130 (03 2020) UK EN 2919
General 2923
Description 2923
Dash Display Menu Access 2923
Menu Navigation 2924
Standard Display 2924
Main Menu 2924
Passwords Menu 2925
Password Administration 2925
Add Password 2925
Delete Password 2926
Edit Password 2926
Other Password Functions 2927
Operator Passwords – Enable/Disable 2927
Password Time-Out Delay 2927
Passwords – Number Wrong to Disable 2928
Lockout Reset Password 2928
View Password Log 2929
View Versions 2930
VSM Versions 2930
Dash Display Versions 2931
Engine Controller Version 2932
Transmission (Xmsn) Controller Version 2933
Truck Serial Number 2934
Diagnostics 2935
View Fault Log 2935
Set Travel and Braking 2936
Speed Limit 2936
Acceleration Rate 2937
Auto-Deceleration Rate 2937
Set Power Reversal Rate 2938
Set Inching/Brake Overlap 2939
Setup Display Menu 2940
Set Operator Language 2940
Set Units 2941
Set Time Format (12/24 Hour) 2941
Set Daylight Saving Time 2941
Set Time 2944
Set Date Format 2945
Set Date 2945
Setup Hydraulics 2946
Return to Set Tilt Delay/On/Off 2946
Setup General Items 2947
Light Shutdown Time-Out 2947
Impact Sensor – Enable/Disable 2948
Impact Sensor – Soft Impact Settings 2949
Impact Sensor – Hard Impact Settings 2950
Adjust Impact Sensor Settings 2950
Initial Adjustment of Soft and Hard Impact Settings 2952
Readjustment of Soft and Hard Impact Settings 2952
Impact Sensor – Impact Alarm/Shutdown Reset 2953
Impact Sensor – Alarm Time Duration and Deactivation 2954
Impact Sensor – View Impact Event Log 2955
Engine Mode Indicator 2956
Generation 1 (ECO-eLo ONLY) 2956
Generation 2 2957
Operator Checklist 2958
Operator Checklist Off-On Mode 2958
Edit Operator Checklist 2958
Set Operator Checklist Expiration 2959
View Checklist Log 2959
Clear Operator Checklist Log 2960
Clear Operator Checklist Fault 2960
Calibrations 2961
Set Tilt Stop Point 2961
Calibrate Loaded Weight 2961
524223771 2200YRM1131 (03 2020) UK EN 2963
Series Code / Model Designation Reference Table 2969
General 2971
Description 2971
Dash Display Menu Access 2971
Menu Navigation 2972
Main Menu 2972
Passwords 2973
Adding Passwords 2973
Hourmeters 2975
View Versions 2976
VSM Versions 2976
Dash Display Versions 2977
Engine Controller Version 2978
Transmission (Xmsn) Controller Version 2979
Truck Serial Number 2980
Truck Configuration 2981
Diagnostics 2982
Clear Fault Log 2982
View Fault Log 2983
No-Run Data Display 2984
Engine Accelerator and Throttle Data Display 2984
Engine Speeds and Governor Data Display 2985
Engine Fuel and Emissions Data Display 2986
Engine General Data Display 2988
XMSN/Brake Data Display 2989
Hydraulic Data Display 2992
General Truck Data Display 2994
Set Travel and Braking 2995
Speed Limit 2995
Acceleration Rate 2996
Auto-Deceleration Rate 2997
Set Power Reversal Rate 2997
Set Inching/Brake Overlap 2998
Setup Hydraulics 2998
Lift Maximum Speed 2999
Lower Maximum Speed 2999
Tilt Maximum Speed 3000
Auxiliary Function One, Direction A, Maximum Speed 3002
Auxiliary Function One, Direction B, Maximum Speed 3004
Auxiliary Function Two, Direction A, Maximum Speed 3004
Auxiliary Function Two, Direction B, Maximum Speed 3005
Auxiliary Function Three, Direction A, Maximum Speed 3006
Auxiliary Function Three, Direction B, Maximum Speed 3006
Lift/Lower Ramp Rate 3007
Hydraulic Auxiliary Ramp Rate 3007
Return to Set Tilt Delay/On/Off 3008
Hydraulic Input Device 3009
Auxiliary Solenoid 3009
Dual Function 3010
Setup Display 3011
Set Service Language 3011
Setup General Items 3011
Motion Alarm Activation Type 3012
Light Shutdown Time-Out 3013
Restore Default Settings 3013
Restore Engine Controller Default Calibration 3014
Impact Sensor – Enable/Disable 3014
Impact Sensor – Soft Impact Settings 3015
Impact Sensor – Hard Impact Settings 3016
Adjust Impact Sensor Settings 3017
Initial Adjustment of Soft and Hard Impact Settings 3019
Readjustment of Soft and Hard Impact Settings 3019
Impact Sensor – Impact Alarm/Shutdown Reset 3020
Impact Sensor – Alarm Time Duration and Deactivation 3021
Impact Sensor – View Impact Event Log 3022
Engine Mode Indicator 3022
Generation 1 (ECO-eLo ONLY) 3022
Generation 2 3023
Diesel Particulate Filter (DPF) Display 3024
General Description 3024
Passive Regeneration Only 3024
Regeneration Level 0 3024
Auto/Active Regeneration Inhibited 3025
Auto/Active Regeneration 3025
Regeneration Level 1 3025
Parked Regeneration Request 3026
Regeneration Level 2 3026
Warning Level 3026
Regeneration Level 3 3026
Service Level 3027
Regeneration Level 4 3027
Display, Diesel Particulate Filter (DPF), Revised 3027
Operator Interface 3027
Refer to Operator Manual 3027
CAN Communication Lost 3028
Passive Regeneration Only 3028
Regeneration Level 0 3028
Auto/Active Regeneration Inhibited 3028
Auto/Active Regeneration 3029
Regeneration Level 1 3029
Idle-up Auto/Active Regeneration 3029
Parked Regeneration Request 3029
Regeneration Level 2 3029
Warning Level 3031
Regeneration Level 3 3031
Service Level 3031
Regeneration Level 4 3031
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3031
Display, Diesel Particulate Filter (DPF), Stage V Engine 3031
Operator Interface 3032
Refer to Operator Manual 3032
CAN Communication Lost 3032
Passive Regeneration Only 3032
Regeneration Level 0 3032
Auto/Active Regeneration Inhibited 3033
Auto/Active Regeneration 3033
Regeneration Level 1 3033
Idle-up Auto/Active Regeneration 3034
Parked Regeneration Request 3034
Regeneration Level 2 3034
Warning Level 3035
Regeneration Level 3 3035
Service Level 3036
Regeneration Level 4 3036
Stage V Content 3036
Emissions System Malfunction 3036
Ash Load 3036
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3037
Operator Interface 3037
Refer to Operator Manual 3037
CAN Communication Lost 3038
Passive Regeneration Only 3038
Regeneration Level 0 3038
Auto/Active Regeneration Inhibited 3038
Auto/Active Regeneration 3039
Regeneration Level 1 3039
Idle-up Auto/Active Regeneration 3039
Parked Regeneration Request 3039
Regeneration Level 2 3039
Warning Level 3041
Regeneration Level 3 3041
Service Level 3041
Regeneration Level 4 3041
Calibrations 3042
Calibrate Transmission Valve 3044
Set Tilt Stop Point 3044
Calibrate Loaded Weight 3044
Calibrate Travel Speed Sensor 3045
Calibrate Mazda LP and Gas Accelerator Pedal 3045
524223772 2200YRM1142 (01 2020) UK EN 3047
General 3057
Display Switch Cluster 3060
Remove 3060
Install 3063
Direction Control and Turn Signal Levers 3063
Remove 3063
Install 3065
Key Switch 3065
Remove 3065
Install 3066
Display Switch Cluster Panel Bezel and Overlay 3066
Remove 3066
Install 3066
Steering Column Repair 3066
Remove 3066
Disassemble 3069
Assemble 3069
Install 3069
Sensors and Switches 3070
General 3070
Dash and Kick Panel, Remove and Install 3070
Remove 3070
Install 3071
Accelerator Pedal Position Sensor 3072
Remove 3072
Install 3075
Brake Fluid Level Switch 3076
Remove 3076
Install 3078
Service Brake Pedal Position Sensor 3079
Remove 3079
Install 3082
Parking Brake Sensor 3083
Remove 3083
Install 3084
Service Brake Pressure Sensor 3085
Remove 3085
Install 3087
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3088
Remove 3088
Install 3088
Sensor Microswitch (Foot Directional Control Pedal) 3089
Remove 3089
Install 3092
Low Coolant Level Sensor 3093
Remove 3093
Install 3096
Fuel Level Sensor, Gas and Diesel Engines Only 3097
Remove 3097
Install 3098
Armrest Switch 3098
Remove 3098
Install 3100
Seat Sensor (Operator Presence System) 3100
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) 3100
Remove 3100
Install 3101
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3101
Remove 3101
Install 3102
Full Suspension Seats; All Lift Truck Models 3102
Remove 3102
Install 3102
Hood Shut Off Switch 3102
Remove 3102
Install 3105
Remote Key Switch 3106
Remove 3106
Install 3106
Hydraulic Filter Pressure Switch 3107
Remove 3107
Install 3109
Transmission Speed Sensor 3109
Remove 3109
Install 3112
Transmission Pressure Sensors 3113
Remove 3113
Install 3115
Transmission Temperature Sensor 3116
Remove 3116
Install 3118
Engine Speed Sensor 3120
Remove 3120
Install 3120
Intermediate Speed Sensor 3121
Remove 3121
Install 3121
Return to Set Tilt (Tilt Angle) Sensor 3121
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) 3121
Remove 3121
Install 3122
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) 3123
Remove 3123
Install 3124
Rear Horn Button Switch 3124
Remove 3124
Install 3125
Impact Sensor 3126
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) 3126
Remove 3126
Install 3129
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) 3129
Remove 3129
Install 3130
Load Weight Sensor 3131
Remove 3131
Install 3132
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3133
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3133
Crankshaft Position (CKP) Sensor 3133
Camshaft Position (CMP) Sensor 3133
Oil Pressure Sensor 3133
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3133
Engine Coolant Temperature (ECT) Sensor 3134
Air Flow Restriction Switch 3134
Remove for GM 2 4L Gas and LPG Trucks 3134
Install for GM 2 4L Gas and LPG Trucks 3134
Oxygen Sensor 3135
Remove 3135
Install 3138
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3139
Crankshaft Position (CKP) Sensor 3139
Camshaft Position (CMP) Sensor 3139
Oil Pressure Sensor 3139
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3139
Engine Coolant Temperature (ECT) Sensor 3139
Air Flow Restriction Switch 3139
Oxygen Sensor 3139
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3139
Low LPG Pressure Switch 3139
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3140
Air Filter Restriction Switch 3140
Remove 3140
Install 3140
Oil Pressure Sensor 3140
Remove 3140
Install 3140
Engine Speed Sensor 3140
Remove 3140
Install 3140
Engine Coolant Temperature (ECT) Sensor 3140
Remove 3140
Install 3140
Throttle Position Sensor (TPS) 3143
Remove 3143
Install 3144
Fuel/Water Separator Sensor 3144
Remove 3144
Install 3144
Glow Plug Relay 3145
Remove 3145
Install 3147
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3147
Air Filter Restriction Switch 3147
Remove 3147
Install 3147
Engine Oil Pressure Sensor 3152
Remove 3152
Install 3152
Engine Speed Sensor 3152
Remove 3152
Install 3153
Engine Coolant Temperature (ECT) Sensor 3153
Remove 3153
Install 3154
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3155
Remove 3155
Install 3155
Fuel/Water Separator Sensor 3156
Remove 3156
Install 3156
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3157
Intake Air Temperature Sensor 3157
Remove 3157
Install 3158
Intake Air Pressure Sensor 3158
Remove 3158
Install 3158
Air Inlet Heater 3158
Remove 3158
Install 3159
Engine Oil Pressure Sensor 3159
Remove 3159
Install 3159
Engine Coolant Temperature (ECT) Sensor 3159
Remove 3159
Install 3159
Crankshaft Position Sensor 3160
Remove 3160
Install 3160
Adjust Shim Procedure 3161
Camshaft Position Sensor 3162
Remove 3162
Install 3162
Air Flow Restriction Sensor 3163
Remove 3163
Install 3163
Fuel/Water Separator 3163
Remove 3163
Install 3164
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3164
Intake Air Temperature Sensor 3168
Remove 3168
Install 3169
Boost Sensor 3169
Remove 3169
Install 3170
Throttle Valve Assembly and Air Intake Heater 3170
Remove 3170
Install 3170
Engine Coolant Temperature (ECT) Sensor 3171
Remove 3171
Install 3171
Engine Oil Pressure Sensor 3171
Remove 3171
Install 3172
Crankshaft Position Sensor 3172
Remove 3172
Install 3172
Adjust Shim Procedure 3173
Camshaft Position Sensor 3174
Remove 3174
Install 3175
Differential Pressure Sensor 3175
Remove 3175
Install 3175
Mass Air Flow Sensor 3176
Remove 3176
Install 3177
Fuel/Water Separator 3177
Remove 3177
Install 3178
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3178
Engine Coolant Temperature (ECT) Sensor 3179
Remove 3179
Install 3179
Throttle Position Sensor 3180
Engine Oil Pressure Sensor 3180
Remove 3180
Install 3180
Engine Speed Sensor 3180
Remove 3180
Install 3180
Fuel Shut Off Solenoid 3180
Remove 3180
Install 3180
Vehicle System Manager (VSM) 3181
General 3181
VSM Replacement 3181
Remove 3181
Install 3183
Programming a New VSM and/or Display Switch Cluster 3183
General 3183
PC Service Tool Software 3184
Data Transferring 3184
New VSM 3184
New (Blank) Display Switch Cluster 3184
Used (Non-Blank) Display Switch Cluster 3184
Power Distribution Module (PDM) and Component Parts 3186
Remove 3186
PDM as a Unit 3186
Install 3190
PDM as a Unit 3190
Remove and Install 3191
PDM Component Parts 3191
Transmission Control Unit 3191
Remove 3191
Install 3195
Battery 3197
Remove 3197
Install 3197
Lights 3198
Work Lights (Front and Rear) 3198
Remove 3198
Install 3198
Strobe Light 3199
Remove 3199
Install 3199
LED Tail, Backup, and Brake Lights 3200
Remove 3200
Install 3201
Front Marker/Turn Signal Lights 3202
Replacing Whole Front Marker/Turn Signal Light Assembly 3202
Remove 3202
Install 3202
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3203
Remove 3203
Install 3203
Diesel Particulate Filter (DPF) Display 3203
Remove 3203
Clean and Inspect 3204
Install 3204
Electronic-Hydraulic Controls – Generation 1 3205
E-Hydraulic Controls – Test 3205
Mini-Levers 3205
Full Stroke Test 3205
Function Returns to Neutral Test 3205
Push Button Switch 3205
General 3206
Mini-Lever Replacement 3206
Remove 3206
Clean and Inspect 3207
Install 3207
Push Button Switch Replacement 3208
Remove 3208
Install 3210
Mini-Lever Module (MLM) 3210
Remove 3210
Install 3210
Joystick 3211
Remove and Disassemble 3211
Inspect 3211
Assemble and Install 3211
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3212
General 3212
Mini-levers, Remove and Install 3212
Armrest Assembly 3213
Remove 3213
Install 3216
Horn Button 3216
Remove 3216
Install 3216
Direction Control Switch 3217
Remove 3217
Install 3217
push (override) buttons and Toggle Switch 3217
Remove 3218
Install 3219
Joystick 3220
Remove and Disassemble 3220
Inspect 3220
Assemble and Install 3220
Joystick Armrest Slider Assembly 3221
Remove 3221
Install 3222
Electronic-Hydraulic Controls, After January, 2020 3222
E-Hydraulic Controls – TEST 3222
Mini-Levers 3222
Full Stroke Test 3222
Function Returns to Neutral Test 3222
Push (Override) Button 3223
General 3223
Mini-levers, Remove and Install 3223
Armrest Assembly 3224
Remove 3224
Install 3227
Horn Button 3227
Remove 3227
Install 3227
Direction Control Switch 3227
Remove 3227
Install 3228
Push (Override) buttons and Toggle Switch 3228
Remove 3229
Install 3231
Special Tools 3232
524223779 8000YRM1152 (03 2020) UK EN 3235
General Information About Diagrams and Schematics 3239
Symbol Definitions 3239
Diagrams Manual Applications 3240
Diagrams and Schematics 3242
524223780 8000YRM1134 (03 2020) UK EN 3305
Series Code / Model Designation Reference Table 3311
Description 3313
Proc_Cal_001: Service Password Entry 3315
When to Perform 3315
Why Perform 3315
How to Perform 3315
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3316
When to Perform 3316
Calibration Order 3316
Why Perform 3316
How to Perform 3317
Proc_Cal_003: Save and Exit 3318
When to Perform 3318
Why Perform 3318
How to Perform 3318
Proc_Cal_004: Lift Valve Output Threshold 3319
When to Perform 3319
Calibration Order 3319
Why Perform 3319
How to Perform 3320
Proc_Cal_005: Lower Valve Output Threshold 3322
When to Perform 3322
Calibration Order 3322
Why Perform 3322
How to Perform 3322
Proc_Cal_006: Tilt Back Valve Output Threshold 3325
When to Perform 3325
Calibration Order 3325
Why Perform 3325
How to Perform 3325
Proc_Cal_007: Tilt Forward Valve Output Threshold 3328
When to Perform 3328
Calibration Order 3328
Why Perform 3328
How to Perform 3328
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3331
When to Perform 3331
Calibration Order 3331
Why Perform 3331
How to Perform 3331
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3334
When to Perform 3334
Calibration Order 3334
Why Perform 3334
How to Perform 3334
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3337
When to Perform 3337
Calibration Order 3337
Why Perform 3337
How to Perform 3337
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3340
When to Perform 3340
Calibration Order 3340
Why Perform 3340
How to Perform 3340
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3343
When to Perform 3343
Calibration Order 3343
Why Perform 3343
How to Perform 3343
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3346
When to Perform 3346
Calibration Order 3346
Why Perform 3346
How to Perform 3346
Proc_Cal_014: Load Weight Zero Point 3350
When to Perform 3350
Calibration Order 3350
Why Perform 3350
How to Perform 3350
Proc_Cal_015: Loaded Weight Calibration 3352
When to Perform 3352
Calibration Order 3352
Why Perform 3352
How to Perform 3352
Proc_Cal_016: Transmission Valve Calibration 3355
Applicable System/Option 3355
When to Perform 3355
Calibration Order 3355
Why Perform 3355
How to Perform 3355
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3357
Applicable System/Option 3357
When to Perform 3357
Calibration Order 3357
Why Perform 3357
How to Perform 3357
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3359
Applicable System/Option 3359
When to Perform 3359
Calibration Order 3359
Why Perform 3359
How to Perform 3360
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3361
Required Tools 3361
When to Perform 3361
Calibration Order 3361
Why Perform 3362
How to Perform 3362
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3363
When to Perform 3363
Why Perform 3363
How to Perform 3363
Proc_Cal_026: Travel Speed Calibration 3365
When to Perform 3365
Calibration Order 3365
Why Perform 3365
How to Perform 3365
524223780 8000YRM1134 (05 2022) US EN 3369
Series Code / Model Designation Reference Table 3375
Description 3378
Proc_Cal_001: Service Password Entry 3380
When to Perform 3380
Why Perform 3380
How to Perform 3380
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3381
When to Perform 3381
Calibration Order 3381
Why Perform 3381
How to Perform 3381
Proc_Cal_003: Save and Exit 3383
When to Perform 3383
Why Perform 3383
How to Perform 3383
Proc_Cal_004: Lift Valve Output Threshold 3384
When to Perform 3384
Calibration Order 3384
Why Perform 3384
How to Perform 3384
Proc_Cal_005: Lower Valve Output Threshold 3387
When to Perform 3387
Calibration Order 3387
Why Perform 3387
How to Perform 3387
Proc_Cal_006: Tilt Back Valve Output Threshold 3390
When to Perform 3390
Calibration Order 3390
Why Perform 3390
How to Perform 3390
Proc_Cal_007: Tilt Forward Valve Output Threshold 3393
When to Perform 3393
Calibration Order 3393
Why Perform 3393
How to Perform 3393
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3396
When to Perform 3396
Calibration Order 3396
Why Perform 3396
How to Perform 3396
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3399
When to Perform 3399
Calibration Order 3399
Why Perform 3399
How to Perform 3399
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3402
When to Perform 3402
Calibration Order 3402
Why Perform 3402
How to Perform 3402
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3405
When to Perform 3405
Calibration Order 3405
Why Perform 3405
How to Perform 3405
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3408
When to Perform 3408
Calibration Order 3408
Why Perform 3408
How to Perform 3408
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3411
When to Perform 3411
Calibration Order 3411
Why Perform 3411
How to Perform 3411
Proc_Cal_014: Load Weight Zero Point 3414
When to Perform 3414
Calibration Order 3414
Why Perform 3414
How to Perform 3414
Proc_Cal_015: Loaded Weight Calibration 3416
When to Perform 3416
Calibration Order 3416
Why Perform 3416
How to Perform 3416
Proc_Cal_016: Transmission Valve Calibration 3419
Applicable System/Option 3419
When to Perform 3419
Calibration Order 3419
Why Perform 3419
How to Perform 3419
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3421
Applicable System/Option 3421
When to Perform 3421
Calibration Order 3421
Why Perform 3421
How to Perform 3421
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3424
Applicable System/Option 3424
When to Perform 3424
Calibration Order 3424
Why Perform 3424
How to Perform 3424
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3427
Required Tools 3427
When to Perform 3427
Calibration Order 3427
Why Perform 3427
How to Perform 3427
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3429
When to Perform 3429
Why Perform 3429
How to Perform 3429
Proc_Cal_026: Travel Speed Calibration 3431
When to Perform 3431
Calibration Order 3431
Why Perform 3431
How to Perform 3431
524262274 0100YRM1243 (11 2016) UK EN 3435
General 3439
Description 3440
Hood, Seat, and Side Covers Replacement 3442
Remove 3442
Install 3442
Steering Column 3449
Description 3450
Steering Column Repair 3450
Remove 3450
Disassemble 3452
Clean 3455
Inspect 3455
Assemble 3455
Install 3455
LPG Tank and Bracket Replacement 3456
Counterweight Replacement 3456
Remove 3456
Install 3459
Tow Pin 3463
Remove and Install For Lift Truck
Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813) 3463
Remove and Install For Lift Truck
Models GLC55SVX (GC/GLC80XVBCS,
GC/GLC100VXBCS; GC/GLC120SVX; and
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(J813) 3463
Overhead Guard Replacement 3464
Remove 3464
Install 3465
LED Tail, Backup, and Brake Lights, Replace 3465
Operator Restraint System Replacement 3466
Description 3466
Engine Replacement 3467
Remove Engine Only 3467
Install Engine only 3494
Remove Engine and Transmission 3497
Install Engine and Transmission 3501
Electronic Throttle Replacement 3505
Cummins 4 5L Diesel Engine With Electronic Throttle 3505
Remove 3505
Install 3508
Pull Actuator Linkage Adjustment 3510
Low Idle Adjustment 3510
Throttle Pedal and Cable Adjustment 3511
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3511
Kubota 3 6L Diesel Engine 3511
Exhaust System Repair 3514
GM 4 3L Engine for Lift Truck Models 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) 3514
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813) 3514
Remove 3514
Inspect 3514
Install 3516
Cummins QSB 3 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) 3516
Remove 3516
Inspect 3518
Install 3518
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Equipped with Kubota 3 6L Diesel Engine 3518
Remove 3518
Inspect 3520
Install 3520
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 3520
Remove 3520
Inspect 3523
Diesel Particulate Filter 3525
Disassemble 3525
CLEAN AND INSPECT 3526
Assembly 3526
Install 3527
Cooling System 3528
Description 3528
Hydraulic Filter Assembly Repair 3529
Remove 3529
Disassemble 3529
Clean 3530
Inspect 3530
Assemble 3530
Install 3530
Fuel and Hydraulic Tanks Repair 3530
Inspect 3530
Clean 3531
Steam Method of Cleaning 3531
Chemical Solution Method of Cleaning 3532
Additional Preparations for Repair 3532
Small Leaks, Repair 3532
Large Leaks, Repair 3532
Preparations for Use After Repair 3532
Safety Labels 3532
524262275 0900YRM1242 (04 2018) UK EN 3543
General 3549
Hoses Replacement 3549
LPG Tank and Bracket Replacement 3550
LPG Tank, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 3550
Remove 3550
Install 3553
LPG Tank Bracket, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 3554
Remove 3554
Install 3554
LPG Tank Bracket Alignment Pin, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813), and GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879) 3554
Remove 3554
Install 3556
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3557
Remove 3557
Install 3559
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3559
Remove 3559
Install 3559
High Pressure Fuel Filter Unit Repair 3559
Fuel Filter Element 3560
Remove 3560
Clean/Inspect 3561
Install 3561
Fuel Filter Housing 3561
Remove 3561
Disassemble 3562
Assemble 3562
Install 3562
Electronic Throttle Body Repair 3563
Remove 3563
Clean/Inspect 3564
Install 3564
Fuel Injector Repair 3565
Fuel Rail 3565
Remove for Lift Trucks Built Before January, 2010 3565
Remove for Lift Trucks Built After January, 2010 3567
Install for Lift Trucks Built Before January, 2010 3568
Install for Lift Trucks Built After January, 2010 3569
Fuel Injectors and Adapters 3569
Remove for Lift Trucks Built Before January, 2010 3569
Remove for Lift Trucks Built After January, 2010 3571
Clean 3572
Install for Lift Trucks Built Before January, 2010 3572
Install for Lift Trucks Built After January, 2010 3574
LPG Regulator Repair 3574
LPG Regulator 3574
Remove for Lift Trucks Built Before January, 2010 3574
Remove for Lift Trucks Built After January, 2010 3575
Install for Lift Trucks Built Before January, 2010 3577
Install for Lift Trucks Built After January, 2010 3577
LPG Regulator Fuel Filter 3578
Remove 3578
Install 3579
Lock-Off Solenoid and Cartridge 3579
Remove 3579
Install 3580
Control System 3580
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3580
Remove 3580
Install 3581
Electronic Control Unit (ECU) 3582
Remove 3582
Install 3582
Injector Driver Modules 3583
Remove 3583
Install 3583
Fuel Pressure Sensor 3584
Remove 3584
Install 3584
Low LPG Pressure Switch 3584
Remove 3584
Install 3585
LPG Pressure Sensor 3585
Remove 3585
Install 3586
Oxygen Sensor 3586
Exhaust System Repair 3587
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3587
Remove for Lift Trucks Built Before January, 2010 3587
Remove for Lift Trucks Built After January, 2010 3589
Inspect 3591
Install for Lift Trucks Built Before January, 2010 3591
Install for Lift Trucks Built After January, 2010 3591
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) 3592
Remove for Lift Trucks Built Before January, 2010 3592
Remove for Lift Trucks Built After January, 2010 3594
Inspect 3597
Install for Lift Trucks Built Before January, 2010 3597
Install for Lift Trucks Built After January, 2010 3598
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3599
Remove for Lift Trucks Built Before January, 2010 3599
Remove for Lift Trucks Built After January, 2010 3602
Inspect 3603
Install for Lift Trucks Built Before January, 2010 3604
Install for Lift Trucks Built After January, 2010 3604
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3605
Remove for Lift Trucks Built Before January, 2010 3605
Remove for Lift Trucks Built After January, 2010 3608
Inspect 3609
Install for Lift Trucks Built Before January, 2010 3610
Install for Lift Trucks Built After January, 2010 3610
Oxygen Sensor 3611
Remove 3611
Install 3612
LPG Fuel Testing 3612
General 3612
Available Fuel Tests 3612
Composition Test (ASTM D-2163) 3612
Ammonia Test (ASTM D-4490) 3613
Basic Nitrogen Test (ASTM UOP269-90) 3613
Residues Test (ASTM D-2158) 3613
Vapor Pressure Test (ASTM D-2598) 3613
Sulfur Compounds Test (ASTM D-5623) 3613
Methanol Test (ASTM D-4864) 3613
Copper Corrosion (ASTM D-1838) 3613
Where To Send LPG Fuel Samples For Testing 3613
524262278 1400YRM1246 (02 2018) UK EN 3617
General 3621
Identification Plate 3622
Drive Axle Removal 3622
Hub Seal Replacement 3634
Planetary Reduction Repair 3643
Clean and Inspect 3652
Brake Repair 3665
Clean and Inspect 3681
Wet Brake Noise Reduction 3697
General 3697
Adding Additive To Transmission 3698
Bevel Pinion 3699
Clean and Inspect 3704
Differential Unit 3716
Disassemble 3727
Clean and Inspect 3733
Assemble 3734
Drive Axle Installation 3757
Special Tools 3767
Torque Specifications 3767
524262279 1800YRM1247 (09 2018) UK EN 3771
General 3775
Dry Brake System 3775
Wet Brake System 3776
Service Brakes Repair (Dry Brake) 3780
Remove and Disassemble 3780
Clean 3782
Inspect 3783
Assemble and Install 3783
Adjust 3787
Parking Brake Repair 3787
Dry Brake System 3788
Remove and Disassembly 3788
Assemble and Install 3790
Wet Brake System 3790
Remove and Install 3791
Assemble and Install 3797
Adjust 3797
Dry Brake System 3797
Wet Brake System 3798
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3798
Master Cylinder Repair 3799
Remove 3799
Disassemble 3804
Clean and Inspect 3805
Assemble 3806
Install and Adjust 3806
Accumulator 3808
Pre-Charge Check 3809
Remove 3810
Install 3812
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3812
Remove 3813
Modulating Brake Valve 3814
Disassemble 3814
Clean and Inspect 3816
Assemble 3816
Accumulator Charge Valve 3817
Disassemble 3817
Clean and Inspect 3819
Assemble 3819
Install 3820
Pressure Checks 3821
Accumulator Charge Valve Check 3821
Accumulator Check 3821
Service Brakes Adjustment (Dry Brake) 3822
Service Brakes Adjustment 3822
Brake System Air Removal 3823
Using Pressure Bleed System 3823
Using Brake Pedal Pressure 3824
Lift Truck Models with Master Cylinder 3824
Lift Truck Models with Modulating Brake Valve 3824
Brake Pedal Adjustment 3825
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) 3825
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3826
Free Pedal Adjustment 3828
Torque Specifications 3829
524262281 8000YRM1249 (11 2017) UK EN 3833
Lift Truck Lifting Capacity 3837
Counterweight Weights 3837
Tire Sizes 3838
Capacities 3838
Electrical System 3844
Transmission Oil Pressures 3846
Hydraulic System Relief Pressures 3849
Steering System 3850
Stall Speeds (in RPM ±100 rpm) 3850
GM 4 3L Gas 3851
GM 4 3L LPG 3851
Cummins 4 5L Diesel 3851
Cummins QSB 3 3L Diesel 3851
Mast Speeds 3851
Tilt Angles 3853
Front End Equipment – Mast Creep 3853
Mast Creep 3854
Engine Specifications 3854
Torque Specifications 3856
Frame 3857
Mast 3857
Steering System 3857
Steer Axle 3857
Drive Axle (Wet Brake) 3857
Drive Axle (Dry Brake) 3858
Transmission 3858
Engine – GM 4 3L 3859
Engine – Cummins 4 5L and QSB 3 3L Diesel 3860
524262298 8000YRM1248 (05 2019) UK EN 3863
General 3869
Serial Number Data 3869
How to Move Disabled Lift Truck 3870
How to Tow Lift Truck 3870
How to Put Lift Truck on Blocks 3871
How to Raise Drive Tires 3871
How to Raise Steering Tires 3872
How to Clean a Lift Truck 3873
Maintenance Schedule 3873
Maintenance Procedures Every 8 Hours or Daily 3888
How to Make Checks With Engine Stopped 3888
Tires and Wheels 3888
Safety Labels 3889
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3889
Operator Restraint System 3890
Emergency Locking Retractor (ELR) 3890
Adjust Seat – Full Suspension 3891
Adjust Seat – Internal Suspension 3892
Hood and Seat Latches 3892
Engine Compartment 3893
Paper Application 3893
Fuel, Oil, and Coolant Leaks, Check 3893
Hydraulic Hoses 3894
Coolant Hoses 3894
Steering Column Gas Cylinder 3894
Transmission 3894
Hydraulic System Oil 3894
Engine Oil 3894
Air Filter 3898
Forks 3898
Remove 3898
Inspect 3898
Install 3898
Adjust 3899
Integral Sideshift Carriage 3899
How to Make Checks With Engine Running 3900
Indicator Lights, Horn, Fuses, and Relays 3900
Service Brakes 3902
Brake Oil Level 3902
Operation, Check 3903
Parking Brake 3903
Engine Oil Pressure 3903
Cooling System 3903
Steering System 3904
Control Levers and Pedals 3904
Lift System, Operate 3904
First Service After First 100 Hours of Operation 3905
GM 4 3L Engine Oil and Oil Filter 3905
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3906
Maintenance Procedures Every 500 Hours or 1 Year 3906
Hydraulic System Oil 3906
Hydraulic Tank Breather 3907
Inspect 3907
Battery 3907
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3908
GM 4 3L Engine Oil and Oil Filter 3908
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 3908
Remove 3908
Install 3909
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 3911
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 3912
Controlled Venting 3912
Manual Bleeding 3912
Drain Tar From LPG Regulator 3913
Drain Tar From LPG Converter 3913
Drive Belt 3914
GM 4 3L Engine 3914
Fan and Alternator Drive Belt 3914
Cummins 4 5L and QSB 3 3L Diesel Engine 3914
Fan and Alternator Drive Belt 3914
Clean Debris From Radiator Core 3915
Transmission Oil Level 3916
Wet Brake Center Body Oil Level Check 3917
Forks 3919
Mast Lubrication 3919
Header Hose Checks 3922
Lift Chain Lubrication 3922
Tilt Cylinder Lubrication 3922
Master Brake Cylinder Rod End Pin Lubrication 3923
Manual Hydraulic Levers Lubrication 3924
Brake Oil 3924
Tie Rod Lubrication for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (E818) 3925
Tie Rod Lubrication for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (F813, G813) 3925
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 3925
Parking Brake Adjustment 3926
Maintenance Procedures Every 1000 Hours or 1 Year 3927
Valve Clearance, Check and Adjust 3927
Ignition System 3927
GM 4 3L Engine 3927
LPG Fuel Filter Element Replace, GM 4 3L Engine 3927
Remove 3927
Install 3928
In-Line Filter Replacement, Cummins 4 5L Engine 3929
Remove 3929
Install 3929
Lift Chains Wear Check 3931
Lift Chain Lubrication 3931
Integral Sideshift Carriage, Check Sliding Surfaces 3931
Steering Axle (Spindle Bearings) for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (E818) 3932
Steering Axle (Spindle Bearings) for Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (F813, G813) 3932
Control Levers and Pedals 3933
Inspect Engine Electrical System, Connectors 3933
Maintenance Procedures Every 2000 Hours or Annually 3933
Hydraulic System 3933
Hydraulic Filter, Replace 3933
Hydraulic Tank Breather, Replace 3935
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 3935
Cooling System 3935
Air Filter 3936
Oxygen Sensor GM 4 3L LPG Engines with GFI Installed 3937
LPG Regulator Fuel Filter, GM 4 3L Engines With GFI Installed 3937
Remove 3937
Install 3938
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 3938
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 3938
Forks 3938
Transmission Oil and Filter (Dry Brake), Replace 3939
Transmission and Wet Brake Planetary Carrier Housing Oil Change 3940
Wet Brake Center Section Oil Change 3942
Remove 3942
Install 3943
Brake Oil (Master Cylinder), Change 3944
Brake Oil (Dry Brake), Remove 3944
Service Brakes (Dry Brake) 3945
Differential (Dry Brake) 3945
Test LPG Regulator Pressure 3946
Check Throttle Shaft for Sticking 3946
Inspect Exhaust Manifold and Piping for Leaks 3946
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 3946
Wheel Bearings 3947
Steer Wheels, Lubrication 3947
Maintenance Procedures Every 4000 Hours or 2 Years 3947
Hydraulic Oil, Replace 3948
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 3949
Weld Inspection 3951
Safety Procedures When Working Near Mast 3954
Fuel Filter Water Removal 3956
Hood Latch Check 3956
Lift Chain Adjustments 3957
Jump-Starting the Lift Truck 3959
Jump-Starting Using a Battery Charger 3959
Jump-Starting a Lift Truck Using Another Lift Truck 3959
Welding Repairs 3960
Overhead Guard Changes 3960
Wheel and Tire Replacement 3960
General 3960
Solid Rubber Tire, Change ( Series)GLC 3960
Remove and Install Tire on Wheel 3961
Pneumatic Tire With Tube, Repair 3962
Remove Wheels From Lift Truck 3962
Remove Tire From Wheel 3962
Install Wheel in Tire 3965
Install Tire on Two-Piece Wheel 3967
Add Air to Pneumatic Tires With Tube 3968
Install the Wheels 3968
Dual Drive Wheels, Install 3968
Pneumatic Tubeless Tire, Repair 3970
Remove Wheels From Lift Truck 3970
Add Air to Pneumatic Tubeless Tire 3975
Wheels, Install 3975
Solid Rubber Tires On Pneumatic Wheels, Change 3975
Remove Tire From Wheel 3975
Install Tire on Wheel 3976
Snap-On-Tire, Change 3977
Adhesives and Sealants 3980
524265337 0600YRM1251 (09 2015) UK EN 3983
General 3989
Engine Removal and Installation 3989
Cylinder Head Repair 3989
Remove and Disassemble 3989
Clean and Inspect 3991
Valve Oil Seals 3994
Remove and Disassemble 3994
Cylinder Leak Down Test 3994
Clean and Inspect 3995
Assemble and Install 3995
Valve Guides and Seats, Repairs 3997
Valves, Repair 3997
Valve Seats, Repair 3998
Valve Springs 3999
Assemble and Install 4000
Engine Block Cleaning and Inspection 4003
Clean and Inspect 4004
Piston Bore Preparation 4006
Engine Mounts Installation 4006
Remove 4006
Clean and Inspect 4007
Install 4007
Lubrication System Repair 4008
Oil Pump, Remove and Disassemble 4008
Clean and Inspect 4009
Oil Pump, Assemble and Install 4010
Oil Pan, Install 4012
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4014
Timing Cover 4014
Remove 4014
Install 4016
Timing Sprockets 4016
Remove 4016
Install 4016
Camshaft 4016
Remove 4016
Inspect 4017
Install 4017
Balance Shaft 4018
Remove 4018
Install 4019
Valve Lifters 4020
Remove 4020
Clean and Inspect 4020
Install 4021
Crankshaft Repair 4021
Remove 4022
Inspect and Repair 4022
How to Check Clearance Between Main Bearings and Their Journals 4023
Install 4024
Piston and Connecting Rod Assemblies Repair 4026
Connecting Rod Bearings, Replace 4026
Piston and Connecting Rod Assemblies, Remove 4027
Disassemble 4027
Piston, Clean and Inspect 4028
Cylinder Bores, Inspect and Repair 4028
Piston Rings 4029
Assemble 4030
Piston and Connecting Rod Assemblies, Install 4030
Flywheel and Flywheel Housing Repair 4030
Flywheel, Remove 4031
Clean 4031
Inspect 4031
Flywheel, Install 4032
Coolant Pump Repair 4032
Remove 4032
Clean and Inspect 4033
Install 4033
Thermostat Replacement 4033
Remove 4034
Thermostat Operation Check 4034
Install 4034
Starter Replacement 4035
4035
Remove 4035
Install 4038
Fan Assembly Replacement 4039
Remove 4039
Inspect 4041
Install 4041
Drive Belt Installation 4042
Remove 4042
Clean 4042
Inspect 4042
Installation 4043
Compression Check 4044
Engine Specifications 4044
Engine Data 4044
Cylinder Head 4044
Hydraulic Valve Lifter 4045
Camshaft 4045
Pistons 4045
Crankshaft 4046
Connecting Rods 4046
Balance Shaft 4047
Cooling System 4047
Lubrication System 4047
Torque Specifications 4048
524265342 4000YRM1250 (09 2018) UK EN 4053
Safety Procedures When Working Near Mast 4059
Fork Replacement 4061
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4061
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4063
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) 4064
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4065
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4066
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) 4067
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4067
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) 4069
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4069
Fixed Carriage Replacement 4071
Remove, Carriage With Hook Forks 4071
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4080
Install, Carriage With Hook Forks 4081
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4081
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4082
Connecting Attachment Hydraulic Quick Disconnect Hoses 4082
Integral Sideshift Carriage Repair 4083
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) 4083
Disassemble 4083
Clean and Inspect 4086
Assemble 4086
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) 4087
Hang On Sideshift Carriage Repair 4087
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) 4087
Disassemble 4099
Clean and Inspect 4108
Assemble 4109
Install 4110
Bolzoni Hang-On Sideshift Carriage Repair 4112
Remove 4112
Disassemble Carriage 4114
Clean and Inspect 4117
Assemble 4117
Install 4120
Fork Positioner 4122
Two-Stage Mast With Limited Free-Lift Repair 4123
Remove 4123
Disassemble 4127
Clean and Inspect 4130
Assemble 4147
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) 4149
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) 4150
Header Hose Alignment 4162
Two-Stage Mast With Full Free-Lift Repair 4172
Remove 4172
Disassemble 4174
Clean and Inspect 4186
Assemble 4187
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) 4189
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) 4192
Header Hose Installation and Adjustment 4196
Installation 4196
Adjustment 4196
Three-Stage Mast With Full Free-Lift Repair 4197
Remove 4197
Disassemble 4199
Clean and Inspect 4229
Assemble 4230
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) 4234
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) 4239
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) 4246
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) 4252
Mast Operation Check 4256
Tilt Cylinder Adjustment 4256
Lift Chains Adjustment 4257
Mast Adjustments 4258
Load Roller Adjustment 4258
Mast Side Kicking Adjustment 4260
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4261
Carriage Adjustments 4264
524306203 0100YRM1290 (04 2014) UK EN 4267
550073240 1900YRM1620 (01 2023) US EN 4371
Proper Flushing after Major Hydraulic Repairs 4377
Introduction 4377
The Phases of Wear 4377
Causes of Hydraulic System Failure 4377
Progression of Contaminant Caused Hydraulic System Failure 4378
Hydraulic System Flushing Techniques 4378
Double Oil and Filter Change 4378
Mechanical Cleaning 4379
Cleaning of Components 4379
How to Clean Tubes and Hoses 4379
Filter Caddy 4379
Start-Up Procedure for Cleaned System 4380
Contaminated Oil Coolers 4380
Additional Filter Caddy Functions 4381
How to Handle Different Fluids 4381
Water Removal Filters 4381
Fluid Conditioning and System Flushing Procedures 4382
Operation of the Filter Caddy 4382
Filter Caddy operation 4382
Fluid Conditioning Procedure 4382
Filter Caddy Start-Up 4383
System Flushing Procedure 4383
Component Cleaning Procedure 4384
Reservoir Cleaning Procedure 4384
Cylinder Cleaning Procedure 4384
Hose and Tube Cleaning Procedure 4384
Valve Cleaning Procedure 4385
Front-End Attachment Cleaning Procedure 4386
System Flushing Procedure 4386
Filter Caddy Start-Up 4387
System Start-Up and Flushing 4387
Reservoir Fluid Cleaning Times 4388
Dealing With Different Fluid Types 4389
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4389
Filter Caddy Maintenance 4389
Servicing the Strainer 4389
DC Motor 4389
Hydraulic Oil Sampling Method and Procedure 4390
Hydraulic Oil Sampling Method 4390
Objective 4390
General Guidelines 4390
Synopsis 4391
Hydraulic Oil Analysis Report Guidelines 4392
Sampling Conditions 4392
Equipment 4392
Sampling Procedure 4393
Hydraulic Oil Sampling 4393
Sample Labeling 4393
Results Documentation 4393
550073240 1900YRM1620 (03 2020) UK EN 4395
Proper Flushing after Major Hydraulic Repairs 4399
Introduction 4399
The Phases of Wear 4399
Causes of Hydraulic System Failure 4399
Progression of Contaminant Caused Hydraulic System Failure 4400
Hydraulic System Flushing Techniques 4400
Double Oil and Filter Change 4400
Mechanical Cleaning 4401
Cleaning of Components 4401
How to Clean Tubes and Hoses 4401
Filter Caddy 4401
Start-Up Procedure for Cleaned System 4402
Contaminated Oil Coolers 4402
Additional Filter Caddy Functions 4402
How to Handle Different Fluids 4402
Water Removal Filters 4403
Fluid Conditioning and System Flushing Procedures 4403
Operation of the Filter Caddy 4403
Filter Caddy operation 4403
Fluid Conditioning Procedure 4404
Filter Caddy Start-Up 4404
System Flushing Procedure 4405
Component Cleaning Procedure 4405
Reservoir Cleaning Procedure 4405
Cylinder Cleaning Procedure 4405
Hose and Tube Cleaning Procedure 4406
Valve Cleaning Procedure 4406
Front-End Attachment Cleaning Procedure 4407
System Flushing Procedure 4407
Filter Caddy Start-Up 4408
System Start-Up and Flushing 4408
Reservoir Fluid Cleaning Times 4409
Dealing With Different Fluid Types 4409
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4409
Filter Caddy Maintenance 4410
Servicing the Strainer 4410
DC Motor 4410
Hydraulic Oil Sampling Method and Procedure 4410
Hydraulic Oil Sampling Method 4410
Objective 4410
General Guidelines 4410
Synopsis 4411
Hydraulic Oil Analysis Report Guidelines 4412
Sampling Conditions 4413
Equipment 4413
Sampling Procedure 4413
Hydraulic Oil Sampling 4413
Sample Labeling 4414
Results Documentation 4414