Yale Forklift F813 (GPGDPGLP080VX, 090VX,100VX, 110VX, 120VX) Service Manual PDF

Yale Forklift F813 (GPGDPGLP080VX, 090VX,100VX, 110VX, 120VX) Service Manual – PDF DOWNLOAD

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Yale Forklift F813 (GPGDPGLP080VX, 090VX,100VX, 110VX, 120VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4510
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift F813 (GPGDPGLP080VX, 090VX,100VX, 110VX, 120VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (03 2020) US EN 1
General 5
Threaded Fasteners 5
Nomenclature, Threads 5
Strength Identification 6
Cotter (Split) Pins 7
Fastener Torque Tables 12
Conversion Table 14
524208014 2200YRM1097 (03 2020) US EN 21
Series Code / Model Designation Reference Table 25
Description 26
Distributor Ignition (DI) System 26
Crankshaft Position (CKP) Sensor 26
Camshaft Position (CMP) Sensor 26
Ignition Coil and Ignition Control Module (ICM) 26
Secondary Ignition Components 26
Spark Plugs and Wires 27
Spark Plug Wire Inspection 27
Spark Plug Wire Replacement 27
Remove 27
Install 28
Spark Plug Inspection 28
Usage 28
Inspection 28
Visual Inspection 30
Spark Plug Replacement 30
Remove 30
Install 30
Distributor Repair 31
Inspect 31
Overhaul 31
Disassemble 31
Assemble 34
Replace 35
Remove 35
Install Procedure 1 37
Install Procedure 2 38
Ignition Coil Replacement 39
Remove 39
Install 39
Ignition Control Module Replacement 40
Remove 40
Install 40
Starter Replacement 41
Remove 41
Install 44
Sensors and Switches 45
Gas and LPG Trucks 45
Crankshaft Position (CKP) Sensor 45
Remove 45
Install 45
Camshaft Position (CMP) Sensor 46
Remove 46
Install 48
Oil Pressure Sensor 48
Remove 48
Install 49
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 50
Remove 50
Install 50
Engine Coolant Temperature (ECT) Sensor 51
Remove 51
Install 52
Air Flow Restriction Switch 52
Remove 52
Install 53
Specifications and Special Tools 54
524221866 9000YRM1112 (10 2020) US EN 59
SECTION 9010 Operational Diagnostic Procedures 75
Group 05 – Operational Checkout 77
SECTION 9020 Engine 95
Group 10 – Principles of Operation 105
Group 30 – Observed Symptoms 303
Group 40 – Tests and Adjustments 405
SECTION 9030 Electrical System 437
Group 03 – General Maintenance and Diagnostic Data 461
Group 10 – Principles of Operation 555
Group 20 – Diagnostic Trouble Codes 579
Group 30 – Observed Symptoms 1551
SECTION 9040 Drive Train 1607
Group 10 – Principles of Operation 1611
Group 30 – Observed Symptoms 1667
Group 40 – Tests and Adjustments 1717
SECTION 9050 Hydraulic Systems 1727
Group 10 – Principles of Operation 1731
Group 30 – Observed Symptoms 1789
Group 33 – Observed Symptoms-Gear Pump 1791
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1879
Group 40 – Tests and Adjustments 1923
Group 43 – Tests and Adjustments-Gear Pump 1925
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1949
SECTION 9060 Operators Station 1967
Group 10 – Principles of Operation 1969
SECTION 9070 Front End (Mast) and Chassis 2005
Group 10 – Principles of Operation 2007
Group 30 – Observed Symptoms 2029
SECTION 9080 Supplementary Data 2087
Group 50 – Abbreviations and Acronyms 2089
Group 60 – Special Tools List 2097
Group 70 – Fault Mode Indicator Reference 2107
Group 80 – Supplier Specification Data 2109
524223757 0700YRM1123 (06 2016) US EN 2113
General 2117
Cooling System Checks 2117
Exhaust Leaks Into Cooling System 2117
Water Flow Restrictions in Radiator 2117
Radiator Hoses 2117
Water Pump 2118
Flushing the Cooling System 2118
Cooling System, Clean 2118
Radiator Replacement 2119
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) 2120
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 2135
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2138
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) 2141
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) 2148
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 2153
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2155
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) 2158
Fan Assembly Replacement 2170
Fan Removal 2170
Inspect 2185
Fan Installation 2185
524223762 1300YRM1129 (11 2018) US EN 2191
General 2195
Serial Number 2195
Charge Pump Repair 2195
Remove 2195
Inspect 2196
Install 2196
Torque Converter Replace 2196
Remove 2196
Install 2204
Front Cover Housing and Chain Drive Repair 2210
Remove 2210
Clean 2219
Inspect 2219
Install 2219
Clutch Packs Repair 2228
Remove and Disassemble 2228
Transmission, Remove and Disassemble 2228
Clean 2247
Inspect 2247
Assemble and Install 2248
Transmission, Assemble and Install 2256
Control Valve Repair 2262
Remove and Disassemble 2262
Clean 2266
Inspect 2266
Assemble and Install 2266
Foot Directional Control Pedal Repair 2267
Remove and Disassemble 2267
Assemble and Install 2271
Direction Control Lever 2272
Remove 2272
Install 2272
524223764 1600YRM1133 (07 2013) US EN 2277
toc 2277
Steering Axle 2277
Safety Precautions Maintenance and Repair 2278
General 2281
Steering Axle Assembly Repair 2283
Remove 2283
Disassemble 2284
Clean 2292
Inspect 2292
Assemble 2292
Install 2298
Spindles, Bearings, and Tie Rods Repair 2300
Spindles and Bearings 2300
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2300
Remove 2300
Disassemble 2302
Clean 2303
Inspect 2303
Assemble 2303
Install 2304
Spindles and Bearings 2307
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2307
Remove and Disassemble 2307
Assemble and Install 2308
Tie Rods 2308
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2308
Remove 2308
Install 2309
Tie Rods 2310
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2310
Remove 2310
Install 2316
Steering Cylinder Repair 2316
Remove and Disassemble 2316
Clean and Inspect 2317
Assemble and Install 2317
Torque Specifications 2318
524223766 1900YRM1136 (11 2017) US EN 2323
General 2327
Hydraulic Gear Pump Assembly 2328
Variable Displacement Pump Assembly 2329
Single Gear Pump Assembly Repair 2329
Remove 2329
Disassemble 2336
Clean 2336
Inspect 2338
Assemble 2338
Install 2338
Tandem Gear Pump Assembly 2342
Remove 2343
Disassemble 2345
Clean 2347
Inspect 2347
Assemble 2347
Install 2348
Gear Pump Specifications 2348
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2354
Remove 2354
Disassemble 2364
Clean 2367
Inspect 2367
Assemble 2367
Install 2368
63 0 cc/rev – Variable Displacement Pump Repair 2371
Remove 2371
Disassemble 2374
Clean 2374
Inspect 2374
Assemble 2376
Install 2376
Variable Displacement Pump Checks and Adjustments (Single Pump) 2378
Margin Pressure Check 2378
Flow Compensator Adjustment 2379
Pressure Compensator Adjustment 2379
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2380
Variable Displacement Pump Specifications 2383
Torque Specifications 2384
Hydraulic Gear Pump 2385
Variable Displacement Pump 2386
Special Tools 2386
524223767 2000YRM1137 (01 2017) US EN 2391
General 2397
Electro-Hydraulic Main Control Valve 2398
Description 2398
Remove 2406
Electro-Hydraulic Control Valve Sections 2411
General 2411
Outlet Control Valve Section 2411
Remove 2411
Disassemble 2412
Clean 2414
Inspect 2414
Assemble 2414
Install 2415
Auxiliary Control Valve Sections 2415
Remove 2415
Disassemble 2422
Clean 2423
Inspect 2424
Assemble 2424
Install 2426
Tilt Control Valve Section 2427
Remove 2427
Disassemble 2427
Clean 2433
Inspect 2433
Assemble 2433
Install 2434
Lift/Lower Control Valve Section 2435
Remove 2435
Disassemble 2435
Clean 2444
Inspect 2444
Assemble 2444
Install 2445
Mid-Inlet Section 2445
Remove 2445
Clean 2446
Inspect 2446
Install 2446
Install 2446
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2451
Lift Pilot Pin 2451
Lower Pilot Pin 2455
Abnormal/Erroneous EHPV Adjustment 2457
Manual Main Control Valve 2458
Description 2458
Remove 2462
OPS Solenoid Assembly 2470
General 2470
Remove 2471
Clean and Inspect 2474
Install 2474
Manual Control Valve Sections 2475
General 2475
Outlet Control Valve Section 2475
Remove 2475
Disassemble 2475
Clean 2478
Inspect 2478
Assemble 2478
Install 2479
Auxiliary Control Valve Sections 2479
Remove 2479
Disassemble 2479
Clean 2482
Inspect 2482
Assemble 2482
Install 2483
Lift/Tilt Control Valve Section 2483
Remove 2483
Disassemble 2483
Clean 2490
Inspect 2490
Assemble 2491
Install 2492
Mid-Inlet Section 2493
Remove 2493
Clean 2493
Inspect 2493
Install 2493
Install 2494
Pressure Relief Valve Check and Adjustment 2500
Primary Relief Valve 2501
Secondary Relief Valve 2505
Steering Control Unit Repair 2512
Steering Control Unit, Remove 2512
Steering Control Unit, Disassemble 2516
Steering Control Unit, Clean 2518
Steering Control Unit, Inspect 2518
Steering Control Unit, Assemble 2518
Relief Valve, Disassemble 2519
Relief Valve, Clean 2519
Relief Valve, Inspect 2520
Relief Valve, Assemble 2520
Steering Control Unit, Install 2520
524223768 2100YRM1139 (02 2014) US EN 2525
524223769 2200YRM1128 (01 2023) US EN 2573
Series Code / Model Designation Reference Table 2581
General 2583
Deutsch Crimping Tool 2584
How to Strip a Wire for Use With Deutsch Crimping Tool 2584
How to Crimp With the Deutsch Crimping Tool 2585
Calibration Test for the Deutsch Crimping Tool 2587
Deutsch Connectors 2589
DT, DTM, and DTP Series Connectors 2589
HD Series Connectors 2632
Metri-Pack Connectors 2654
Remove and Install 2654
Micro-Pack Connectors 2657
Weather-Pack Connectors 2658
AMPSEAL Crimping Tools 2660
AMP Hand Crimping Tool With Certi-Crimp 2660
Description 2660
Stripping Wire for Use with AMP Hand Crimping Tool 2661
Insulation Crimp Adjustment 2662
Maintenance and Inspection for AMP Hand Crimping Tool 2662
AMP Hand Crimping Tool 2662
Crimp Height Inspection 2662
How to use AMP Hand Crimping Tool 2663
AMP Pro-Crimper II Tool 2663
Description 2663
Remove and Install Die Set and Locator Assembly 2664
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2664
Contact Support Adjustment 2665
Crimp Height Adjustment 2666
Maintenance and Inspection Procedures 2666
PRO-CRIMPER II Tool 2666
Crimp Height Inspection 2666
How to Use AMP PRO-CRIMPER II Tool 2667
AMPSEAL Connector Assemblies 2668
Description for Plug Connector Assembly 2668
Seal Plug 2669
Contact Crimping 2669
Description for Plug Connector and Header Assembly 2674
Voltage Reading 2677
Seal Plug 2677
Contact Crimping 2677
AMP Superseal 1 5 Crimping Tools 2684
Mini Mic Receptacle and Tab Contacts 2684
Description 2684
Crimping Conditions and Measurements 2684
Insertion of Rubber Seal on Cable 2686
AMP Hand Application Tool 2691
Description 2691
Maintenance and Inspection 2691
Crimp Height Inspection 2691
Crimp Height Adjustment 2692
How to Use AMP Hand Application Tool 2692
AMP Pro-Crimper II Tool 2693
Description 2693
Remove and Install Die Set and Locator Assembly 2693
Adjustments 2694
Contact Support 2694
Crimp Height 2695
Inspections and Maintenance 2696
Crimp Height Inspection 2696
Visual Inspection 2696
Maintenance 2697
How to Use Pro-Crimper II Tool 2697
AMP Superseal 1 5 Connector Assemblies 2698
Description 2698
Repair and Maintenance 2705
Panel Mount Option 2705
AMP Fastin-Faston Hand Tools 2706
Description – AMP Double Action Hand Tool 2706
Maintenance and Inspection Procedures 2706
Daily Maintenance 2706
Periodic Tool Inspection 2707
Lubrication 2707
Visual Inspection 2707
Crimp Height Inspection 2707
Certi-Crimp Ratchet Inspection 2708
How to Use AMP Double Action Hand Tool 2709
Description – AMP Extraction Tool 2710
Maintenance and Inspection 2711
How to Use AMP Extraction Tool 2711
AMP Fastin-Faston Receptacles and Housings 2713
Description 2713
Wire Repair 2721
Wire Splicing Requirements 2721
Deutsch Jiffy Splice 2722
Twisted/Shielded Cable and Leads Repair 2728
Special Tools 2730
524223769 2200YRM1128 (07 2020) US EN 2739
Series Code / Model Designation Reference Table 2745
General 2748
Deutsch Crimping Tool 2748
How to Strip a Wire for Use With Deutsch Crimping Tool 2748
How to Crimp With the Deutsch Crimping Tool 2749
Calibration Test for the Deutsch Crimping Tool 2751
Deutsch Connectors 2753
DT, DTM, and DTP Series Connectors 2753
HD Series Connectors 2795
Metri-Pack Connectors 2818
Remove and Install 2818
Micro-Pack Connectors 2820
Weather-Pack Connectors 2821
AMPSEAL Crimping Tools 2823
AMP Hand Crimping Tool With Certi-Crimp 2823
Description 2823
Stripping Wire for Use with AMP Hand Crimping Tool 2823
Insulation Crimp Adjustment 2824
Maintenance and Inspection for AMP Hand Crimping Tool 2824
AMP Hand Crimping Tool 2824
Crimp Height Inspection 2824
How to use AMP Hand Crimping Tool 2825
AMP Pro-Crimper II Tool 2825
Description 2825
Remove and Install Die Set and Locator Assembly 2826
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2827
Contact Support Adjustment 2827
Crimp Height Adjustment 2828
Maintenance and Inspection Procedures 2828
PRO-CRIMPER II Tool 2828
Crimp Height Inspection 2828
How to Use AMP PRO-CRIMPER II Tool 2829
AMPSEAL Connector Assemblies 2830
Description for Plug Connector Assembly 2830
Seal Plug 2831
Contact Crimping 2831
Description for Plug Connector and Header Assembly 2836
Voltage Reading 2838
Seal Plug 2838
Contact Crimping 2838
AMP Superseal 1 5 Crimping Tools 2845
Mini Mic Receptacle and Tab Contacts 2845
Description 2845
Crimping Conditions and Measurements 2845
Insertion of Rubber Seal on Cable 2847
AMP Hand Application Tool 2852
Description 2852
Maintenance and Inspection 2852
Crimp Height Inspection 2852
Crimp Height Adjustment 2853
How to Use AMP Hand Application Tool 2853
AMP Pro-Crimper II Tool 2854
Description 2854
Remove and Install Die Set and Locator Assembly 2855
Adjustments 2855
Contact Support 2855
Crimp Height 2856
Inspections and Maintenance 2857
Crimp Height Inspection 2857
Visual Inspection 2857
Maintenance 2858
How to Use Pro-Crimper II Tool 2858
AMP Superseal 1 5 Connector Assemblies 2859
Description 2859
Repair and Maintenance 2866
Panel Mount Option 2866
AMP Fastin-Faston Hand Tools 2867
Description – AMP Double Action Hand Tool 2867
Maintenance and Inspection Procedures 2867
Daily Maintenance 2867
Periodic Tool Inspection 2868
Lubrication 2868
Visual Inspection 2868
Crimp Height Inspection 2868
Certi-Crimp Ratchet Inspection 2869
How to Use AMP Double Action Hand Tool 2870
Description – AMP Extraction Tool 2871
Maintenance and Inspection 2871
How to Use AMP Extraction Tool 2872
AMP Fastin-Faston Receptacles and Housings 2873
Description 2873
Wire Repair 2880
Wire Splicing Requirements 2880
Deutsch Jiffy Splice 2881
Twisted/Shielded Cable and Leads Repair 2886
Special Tools 2889
524223770 2200YRM1130 (03 2020) US EN 2897
General 2901
Description 2901
Dash Display Menu Access 2901
Menu Navigation 2902
Standard Display 2902
Main Menu 2902
Passwords Menu 2903
Password Administration 2903
Add Password 2903
Delete Password 2904
Edit Password 2904
Other Password Functions 2905
Operator Passwords – Enable/Disable 2905
Password Time-Out Delay 2905
Passwords – Number Wrong to Disable 2906
Lockout Reset Password 2906
View Password Log 2907
View Versions 2908
VSM Versions 2908
Dash Display Versions 2909
Engine Controller Version 2910
Transmission (Xmsn) Controller Version 2911
Truck Serial Number 2912
Diagnostics 2913
View Fault Log 2913
Set Travel and Braking 2914
Speed Limit 2914
Acceleration Rate 2915
Auto-Deceleration Rate 2915
Set Power Reversal Rate 2916
Set Inching/Brake Overlap 2917
Setup Display Menu 2918
Set Operator Language 2918
Set Units 2919
Set Time Format (12/24 Hour) 2919
Set Daylight Saving Time 2919
Set Time 2922
Set Date Format 2923
Set Date 2923
Setup Hydraulics 2924
Return to Set Tilt Delay/On/Off 2924
Setup General Items 2925
Light Shutdown Time-Out 2925
Impact Sensor – Enable/Disable 2926
Impact Sensor – Soft Impact Settings 2927
Impact Sensor – Hard Impact Settings 2928
Adjust Impact Sensor Settings 2928
Initial Adjustment of Soft and Hard Impact Settings 2930
Readjustment of Soft and Hard Impact Settings 2930
Impact Sensor – Impact Alarm/Shutdown Reset 2931
Impact Sensor – Alarm Time Duration and Deactivation 2932
Impact Sensor – View Impact Event Log 2933
Engine Mode Indicator 2934
Generation 1 (ECO-eLo ONLY) 2934
Generation 2 2935
Operator Checklist 2936
Operator Checklist Off-On Mode 2936
Edit Operator Checklist 2936
Set Operator Checklist Expiration 2937
View Checklist Log 2937
Clear Operator Checklist Log 2938
Clear Operator Checklist Fault 2938
Calibrations 2939
Set Tilt Stop Point 2939
Calibrate Loaded Weight 2939
524223771 2200YRM1131 (03 2020) US EN 2941
Series Code / Model Designation Reference Table 2947
General 2949
Description 2949
Dash Display Menu Access 2949
Menu Navigation 2950
Main Menu 2950
Passwords 2951
Adding Passwords 2951
Hourmeters 2953
View Versions 2954
VSM Versions 2954
Dash Display Versions 2955
Engine Controller Version 2956
Transmission (Xmsn) Controller Version 2957
Truck Serial Number 2958
Truck Configuration 2959
Diagnostics 2960
Clear Fault Log 2960
View Fault Log 2961
No-Run Data Display 2962
Engine Accelerator and Throttle Data Display 2962
Engine Speeds and Governor Data Display 2963
Engine Fuel and Emissions Data Display 2964
Engine General Data Display 2966
XMSN/Brake Data Display 2967
Hydraulic Data Display 2970
General Truck Data Display 2972
Set Travel and Braking 2973
Speed Limit 2973
Acceleration Rate 2974
Auto-Deceleration Rate 2975
Set Power Reversal Rate 2975
Set Inching/Brake Overlap 2976
Setup Hydraulics 2976
Lift Maximum Speed 2977
Lower Maximum Speed 2977
Tilt Maximum Speed 2978
Auxiliary Function One, Direction A, Maximum Speed 2980
Auxiliary Function One, Direction B, Maximum Speed 2982
Auxiliary Function Two, Direction A, Maximum Speed 2982
Auxiliary Function Two, Direction B, Maximum Speed 2983
Auxiliary Function Three, Direction A, Maximum Speed 2984
Auxiliary Function Three, Direction B, Maximum Speed 2984
Lift/Lower Ramp Rate 2985
Hydraulic Auxiliary Ramp Rate 2985
Return to Set Tilt Delay/On/Off 2986
Hydraulic Input Device 2987
Auxiliary Solenoid 2987
Dual Function 2988
Setup Display 2989
Set Service Language 2989
Setup General Items 2989
Motion Alarm Activation Type 2990
Light Shutdown Time-Out 2991
Restore Default Settings 2991
Restore Engine Controller Default Calibration 2992
Impact Sensor – Enable/Disable 2992
Impact Sensor – Soft Impact Settings 2993
Impact Sensor – Hard Impact Settings 2994
Adjust Impact Sensor Settings 2995
Initial Adjustment of Soft and Hard Impact Settings 2997
Readjustment of Soft and Hard Impact Settings 2997
Impact Sensor – Impact Alarm/Shutdown Reset 2998
Impact Sensor – Alarm Time Duration and Deactivation 2999
Impact Sensor – View Impact Event Log 3000
Engine Mode Indicator 3000
Generation 1 (ECO-eLo ONLY) 3000
Generation 2 3001
Diesel Particulate Filter (DPF) Display 3002
General Description 3002
Passive Regeneration Only 3002
Regeneration Level 0 3002
Auto/Active Regeneration Inhibited 3003
Auto/Active Regeneration 3003
Regeneration Level 1 3003
Parked Regeneration Request 3004
Regeneration Level 2 3004
Warning Level 3004
Regeneration Level 3 3004
Service Level 3005
Regeneration Level 4 3005
Display, Diesel Particulate Filter (DPF), Revised 3005
Operator Interface 3005
Refer to Operator Manual 3005
CAN Communication Lost 3006
Passive Regeneration Only 3006
Regeneration Level 0 3006
Auto/Active Regeneration Inhibited 3006
Auto/Active Regeneration 3007
Regeneration Level 1 3007
Idle-up Auto/Active Regeneration 3007
Parked Regeneration Request 3007
Regeneration Level 2 3007
Warning Level 3009
Regeneration Level 3 3009
Service Level 3009
Regeneration Level 4 3009
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 3009
Display, Diesel Particulate Filter (DPF), Stage V Engine 3009
Operator Interface 3010
Refer to Operator Manual 3010
CAN Communication Lost 3010
Passive Regeneration Only 3010
Regeneration Level 0 3010
Auto/Active Regeneration Inhibited 3011
Auto/Active Regeneration 3011
Regeneration Level 1 3011
Idle-up Auto/Active Regeneration 3012
Parked Regeneration Request 3012
Regeneration Level 2 3012
Warning Level 3013
Regeneration Level 3 3013
Service Level 3014
Regeneration Level 4 3014
Stage V Content 3014
Emissions System Malfunction 3014
Ash Load 3014
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 3015
Operator Interface 3015
Refer to Operator Manual 3015
CAN Communication Lost 3016
Passive Regeneration Only 3016
Regeneration Level 0 3016
Auto/Active Regeneration Inhibited 3016
Auto/Active Regeneration 3017
Regeneration Level 1 3017
Idle-up Auto/Active Regeneration 3017
Parked Regeneration Request 3017
Regeneration Level 2 3017
Warning Level 3019
Regeneration Level 3 3019
Service Level 3019
Regeneration Level 4 3019
Calibrations 3020
Calibrate Transmission Valve 3022
Set Tilt Stop Point 3022
Calibrate Loaded Weight 3022
Calibrate Travel Speed Sensor 3023
Calibrate Mazda LP and Gas Accelerator Pedal 3023
524223772 2200YRM1142 (01 2020) US EN 3025
General 3035
Display Switch Cluster 3038
Remove 3038
Install 3041
Direction Control and Turn Signal Levers 3041
Remove 3041
Install 3043
Key Switch 3043
Remove 3043
Install 3044
Display Switch Cluster Panel Bezel and Overlay 3044
Remove 3044
Install 3044
Steering Column Repair 3044
Remove 3044
Disassemble 3047
Assemble 3047
Install 3047
Sensors and Switches 3048
General 3048
Dash and Kick Panel, Remove and Install 3048
Remove 3048
Install 3049
Accelerator Pedal Position Sensor 3050
Remove 3050
Install 3053
Brake Fluid Level Switch 3054
Remove 3054
Install 3056
Service Brake Pedal Position Sensor 3057
Remove 3057
Install 3060
Parking Brake Sensor 3061
Remove 3061
Install 3062
Service Brake Pressure Sensor 3063
Remove 3063
Install 3065
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3066
Remove 3066
Install 3066
Sensor Microswitch (Foot Directional Control Pedal) 3067
Remove 3067
Install 3070
Low Coolant Level Sensor 3071
Remove 3071
Install 3074
Fuel Level Sensor, Gas and Diesel Engines Only 3075
Remove 3075
Install 3076
Armrest Switch 3076
Remove 3076
Install 3078
Seat Sensor (Operator Presence System) 3078
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) 3078
Remove 3078
Install 3079
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3079
Remove 3079
Install 3080
Full Suspension Seats; All Lift Truck Models 3080
Remove 3080
Install 3080
Hood Shut Off Switch 3080
Remove 3080
Install 3083
Remote Key Switch 3084
Remove 3084
Install 3084
Hydraulic Filter Pressure Switch 3085
Remove 3085
Install 3087
Transmission Speed Sensor 3087
Remove 3087
Install 3090
Transmission Pressure Sensors 3091
Remove 3091
Install 3093
Transmission Temperature Sensor 3094
Remove 3094
Install 3096
Engine Speed Sensor 3098
Remove 3098
Install 3098
Intermediate Speed Sensor 3099
Remove 3099
Install 3099
Return to Set Tilt (Tilt Angle) Sensor 3099
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) 3099
Remove 3099
Install 3100
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) 3101
Remove 3101
Install 3102
Rear Horn Button Switch 3102
Remove 3102
Install 3103
Impact Sensor 3104
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) 3104
Remove 3104
Install 3107
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) 3107
Remove 3107
Install 3108
Load Weight Sensor 3109
Remove 3109
Install 3110
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3111
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3111
Crankshaft Position (CKP) Sensor 3111
Camshaft Position (CMP) Sensor 3111
Oil Pressure Sensor 3111
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3111
Engine Coolant Temperature (ECT) Sensor 3112
Air Flow Restriction Switch 3112
Remove for GM 2 4L Gas and LPG Trucks 3112
Install for GM 2 4L Gas and LPG Trucks 3112
Oxygen Sensor 3113
Remove 3113
Install 3116
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3117
Crankshaft Position (CKP) Sensor 3117
Camshaft Position (CMP) Sensor 3117
Oil Pressure Sensor 3117
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3117
Engine Coolant Temperature (ECT) Sensor 3117
Air Flow Restriction Switch 3117
Oxygen Sensor 3117
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3117
Low LPG Pressure Switch 3117
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3118
Air Filter Restriction Switch 3118
Remove 3118
Install 3118
Oil Pressure Sensor 3118
Remove 3118
Install 3118
Engine Speed Sensor 3118
Remove 3118
Install 3118
Engine Coolant Temperature (ECT) Sensor 3118
Remove 3118
Install 3118
Throttle Position Sensor (TPS) 3121
Remove 3121
Install 3122
Fuel/Water Separator Sensor 3122
Remove 3122
Install 3122
Glow Plug Relay 3123
Remove 3123
Install 3125
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3125
Air Filter Restriction Switch 3125
Remove 3125
Install 3125
Engine Oil Pressure Sensor 3130
Remove 3130
Install 3130
Engine Speed Sensor 3130
Remove 3130
Install 3131
Engine Coolant Temperature (ECT) Sensor 3131
Remove 3131
Install 3132
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3133
Remove 3133
Install 3133
Fuel/Water Separator Sensor 3134
Remove 3134
Install 3134
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3135
Intake Air Temperature Sensor 3135
Remove 3135
Install 3136
Intake Air Pressure Sensor 3136
Remove 3136
Install 3136
Air Inlet Heater 3136
Remove 3136
Install 3137
Engine Oil Pressure Sensor 3137
Remove 3137
Install 3137
Engine Coolant Temperature (ECT) Sensor 3137
Remove 3137
Install 3137
Crankshaft Position Sensor 3138
Remove 3138
Install 3138
Adjust Shim Procedure 3139
Camshaft Position Sensor 3140
Remove 3140
Install 3140
Air Flow Restriction Sensor 3141
Remove 3141
Install 3141
Fuel/Water Separator 3141
Remove 3141
Install 3142
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3142
Intake Air Temperature Sensor 3146
Remove 3146
Install 3147
Boost Sensor 3147
Remove 3147
Install 3148
Throttle Valve Assembly and Air Intake Heater 3148
Remove 3148
Install 3148
Engine Coolant Temperature (ECT) Sensor 3149
Remove 3149
Install 3149
Engine Oil Pressure Sensor 3149
Remove 3149
Install 3150
Crankshaft Position Sensor 3150
Remove 3150
Install 3150
Adjust Shim Procedure 3151
Camshaft Position Sensor 3152
Remove 3152
Install 3153
Differential Pressure Sensor 3153
Remove 3153
Install 3153
Mass Air Flow Sensor 3154
Remove 3154
Install 3155
Fuel/Water Separator 3155
Remove 3155
Install 3156
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3156
Engine Coolant Temperature (ECT) Sensor 3157
Remove 3157
Install 3157
Throttle Position Sensor 3158
Engine Oil Pressure Sensor 3158
Remove 3158
Install 3158
Engine Speed Sensor 3158
Remove 3158
Install 3158
Fuel Shut Off Solenoid 3158
Remove 3158
Install 3158
Vehicle System Manager (VSM) 3159
General 3159
VSM Replacement 3159
Remove 3159
Install 3161
Programming a New VSM and/or Display Switch Cluster 3161
General 3161
PC Service Tool Software 3162
Data Transferring 3162
New VSM 3162
New (Blank) Display Switch Cluster 3162
Used (Non-Blank) Display Switch Cluster 3162
Power Distribution Module (PDM) and Component Parts 3164
Remove 3164
PDM as a Unit 3164
Install 3168
PDM as a Unit 3168
Remove and Install 3169
PDM Component Parts 3169
Transmission Control Unit 3169
Remove 3169
Install 3173
Battery 3175
Remove 3175
Install 3175
Lights 3176
Work Lights (Front and Rear) 3176
Remove 3176
Install 3176
Strobe Light 3177
Remove 3177
Install 3177
LED Tail, Backup, and Brake Lights 3178
Remove 3178
Install 3179
Front Marker/Turn Signal Lights 3180
Replacing Whole Front Marker/Turn Signal Light Assembly 3180
Remove 3180
Install 3180
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3181
Remove 3181
Install 3181
Diesel Particulate Filter (DPF) Display 3181
Remove 3181
Clean and Inspect 3182
Install 3182
Electronic-Hydraulic Controls – Generation 1 3183
E-Hydraulic Controls – Test 3183
Mini-Levers 3183
Full Stroke Test 3183
Function Returns to Neutral Test 3183
Push Button Switch 3183
General 3184
Mini-Lever Replacement 3184
Remove 3184
Clean and Inspect 3185
Install 3185
Push Button Switch Replacement 3186
Remove 3186
Install 3188
Mini-Lever Module (MLM) 3188
Remove 3188
Install 3188
Joystick 3189
Remove and Disassemble 3189
Inspect 3189
Assemble and Install 3189
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3190
General 3190
Mini-levers, Remove and Install 3190
Armrest Assembly 3191
Remove 3191
Install 3194
Horn Button 3194
Remove 3194
Install 3194
Direction Control Switch 3195
Remove 3195
Install 3195
push (override) buttons and Toggle Switch 3195
Remove 3196
Install 3197
Joystick 3198
Remove and Disassemble 3198
Inspect 3198
Assemble and Install 3198
Joystick Armrest Slider Assembly 3199
Remove 3199
Install 3200
Electronic-Hydraulic Controls, After January, 2020 3200
E-Hydraulic Controls – TEST 3200
Mini-Levers 3200
Full Stroke Test 3200
Function Returns to Neutral Test 3200
Push (Override) Button 3201
General 3201
Mini-levers, Remove and Install 3201
Armrest Assembly 3202
Remove 3202
Install 3205
Horn Button 3205
Remove 3205
Install 3205
Direction Control Switch 3205
Remove 3205
Install 3206
Push (Override) buttons and Toggle Switch 3206
Remove 3207
Install 3209
Special Tools 3210
524223779 8000YRM1152 (03 2020) US EN 3213
General Information About Diagrams and Schematics 3217
Symbol Definitions 3217
Diagrams Manual Applications 3218
Diagrams and Schematics 3220
524223780 8000YRM1134 (03 2020) US EN 3283
Series Code / Model Designation Reference Table 3289
Description 3291
Proc_Cal_001: Service Password Entry 3293
When to Perform 3293
Why Perform 3293
How to Perform 3293
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3294
When to Perform 3294
Calibration Order 3294
Why Perform 3294
How to Perform 3295
Proc_Cal_003: Save and Exit 3296
When to Perform 3296
Why Perform 3296
How to Perform 3296
Proc_Cal_004: Lift Valve Output Threshold 3297
When to Perform 3297
Calibration Order 3297
Why Perform 3297
How to Perform 3298
Proc_Cal_005: Lower Valve Output Threshold 3300
When to Perform 3300
Calibration Order 3300
Why Perform 3300
How to Perform 3300
Proc_Cal_006: Tilt Back Valve Output Threshold 3303
When to Perform 3303
Calibration Order 3303
Why Perform 3303
How to Perform 3303
Proc_Cal_007: Tilt Forward Valve Output Threshold 3306
When to Perform 3306
Calibration Order 3306
Why Perform 3306
How to Perform 3306
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3309
When to Perform 3309
Calibration Order 3309
Why Perform 3309
How to Perform 3309
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3312
When to Perform 3312
Calibration Order 3312
Why Perform 3312
How to Perform 3312
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3315
When to Perform 3315
Calibration Order 3315
Why Perform 3315
How to Perform 3315
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3318
When to Perform 3318
Calibration Order 3318
Why Perform 3318
How to Perform 3318
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3321
When to Perform 3321
Calibration Order 3321
Why Perform 3321
How to Perform 3321
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3324
When to Perform 3324
Calibration Order 3324
Why Perform 3324
How to Perform 3324
Proc_Cal_014: Load Weight Zero Point 3328
When to Perform 3328
Calibration Order 3328
Why Perform 3328
How to Perform 3328
Proc_Cal_015: Loaded Weight Calibration 3330
When to Perform 3330
Calibration Order 3330
Why Perform 3330
How to Perform 3330
Proc_Cal_016: Transmission Valve Calibration 3333
Applicable System/Option 3333
When to Perform 3333
Calibration Order 3333
Why Perform 3333
How to Perform 3333
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3335
Applicable System/Option 3335
When to Perform 3335
Calibration Order 3335
Why Perform 3335
How to Perform 3335
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3337
Applicable System/Option 3337
When to Perform 3337
Calibration Order 3337
Why Perform 3337
How to Perform 3338
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3339
Required Tools 3339
When to Perform 3339
Calibration Order 3339
Why Perform 3340
How to Perform 3340
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3341
When to Perform 3341
Why Perform 3341
How to Perform 3341
Proc_Cal_026: Travel Speed Calibration 3343
When to Perform 3343
Calibration Order 3343
Why Perform 3343
How to Perform 3343
524223780 8000YRM1134 (05 2022) US EN 3347
Series Code / Model Designation Reference Table 3353
Description 3356
Proc_Cal_001: Service Password Entry 3358
When to Perform 3358
Why Perform 3358
How to Perform 3358
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3359
When to Perform 3359
Calibration Order 3359
Why Perform 3359
How to Perform 3359
Proc_Cal_003: Save and Exit 3361
When to Perform 3361
Why Perform 3361
How to Perform 3361
Proc_Cal_004: Lift Valve Output Threshold 3362
When to Perform 3362
Calibration Order 3362
Why Perform 3362
How to Perform 3362
Proc_Cal_005: Lower Valve Output Threshold 3365
When to Perform 3365
Calibration Order 3365
Why Perform 3365
How to Perform 3365
Proc_Cal_006: Tilt Back Valve Output Threshold 3368
When to Perform 3368
Calibration Order 3368
Why Perform 3368
How to Perform 3368
Proc_Cal_007: Tilt Forward Valve Output Threshold 3371
When to Perform 3371
Calibration Order 3371
Why Perform 3371
How to Perform 3371
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3374
When to Perform 3374
Calibration Order 3374
Why Perform 3374
How to Perform 3374
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3377
When to Perform 3377
Calibration Order 3377
Why Perform 3377
How to Perform 3377
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3380
When to Perform 3380
Calibration Order 3380
Why Perform 3380
How to Perform 3380
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3383
When to Perform 3383
Calibration Order 3383
Why Perform 3383
How to Perform 3383
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3386
When to Perform 3386
Calibration Order 3386
Why Perform 3386
How to Perform 3386
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3389
When to Perform 3389
Calibration Order 3389
Why Perform 3389
How to Perform 3389
Proc_Cal_014: Load Weight Zero Point 3392
When to Perform 3392
Calibration Order 3392
Why Perform 3392
How to Perform 3392
Proc_Cal_015: Loaded Weight Calibration 3394
When to Perform 3394
Calibration Order 3394
Why Perform 3394
How to Perform 3394
Proc_Cal_016: Transmission Valve Calibration 3397
Applicable System/Option 3397
When to Perform 3397
Calibration Order 3397
Why Perform 3397
How to Perform 3397
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3399
Applicable System/Option 3399
When to Perform 3399
Calibration Order 3399
Why Perform 3399
How to Perform 3399
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3402
Applicable System/Option 3402
When to Perform 3402
Calibration Order 3402
Why Perform 3402
How to Perform 3402
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3405
Required Tools 3405
When to Perform 3405
Calibration Order 3405
Why Perform 3405
How to Perform 3405
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3407
When to Perform 3407
Why Perform 3407
How to Perform 3407
Proc_Cal_026: Travel Speed Calibration 3409
When to Perform 3409
Calibration Order 3409
Why Perform 3409
How to Perform 3409
524262274 0100YRM1243 (11 2016) US EN 3413
General 3417
Description 3418
Hood, Seat, and Side Covers Replacement 3420
Remove 3420
Install 3420
Steering Column 3427
Description 3428
Steering Column Repair 3428
Remove 3428
Disassemble 3430
Clean 3433
Inspect 3433
Assemble 3433
Install 3433
LPG Tank and Bracket Replacement 3434
Counterweight Replacement 3434
Remove 3434
Install 3437
Tow Pin 3441
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) 3441
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) 3441
Overhead Guard Replacement 3442
Remove 3442
Install 3443
LED Tail, Backup, and Brake Lights, Replace 3443
Operator Restraint System Replacement 3444
Description 3444
Engine Replacement 3445
Remove Engine Only 3445
Install Engine only 3472
Remove Engine and Transmission 3475
Install Engine and Transmission 3479
Electronic Throttle Replacement 3483
Cummins 4 5L Diesel Engine With Electronic Throttle 3483
Remove 3483
Install 3486
Pull Actuator Linkage Adjustment 3488
Low Idle Adjustment 3488
Throttle Pedal and Cable Adjustment 3489
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3489
Kubota 3 6L Diesel Engine 3489
Exhaust System Repair 3492
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) 3492
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) 3492
Remove 3492
Inspect 3492
Install 3494
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) 3494
Remove 3494
Inspect 3496
Install 3496
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 3496
Remove 3496
Inspect 3498
Install 3498
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) 3498
Remove 3498
Inspect 3501
Diesel Particulate Filter 3503
Disassemble 3503
CLEAN AND INSPECT 3504
Assembly 3504
Install 3505
Cooling System 3506
Description 3506
Hydraulic Filter Assembly Repair 3507
Remove 3507
Disassemble 3507
Clean 3508
Inspect 3508
Assemble 3508
Install 3508
Fuel and Hydraulic Tanks Repair 3508
Inspect 3508
Clean 3509
Steam Method of Cleaning 3509
Chemical Solution Method of Cleaning 3510
Additional Preparations for Repair 3510
Small Leaks, Repair 3510
Large Leaks, Repair 3510
Preparations for Use After Repair 3510
Safety Labels 3510
524262275 0900YRM1242 (04 2018) US EN 3521
General 3527
Hoses Replacement 3527
LPG Tank and Bracket Replacement 3528
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) 3528
Remove 3528
Install 3531
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) 3532
Remove 3532
Install 3532
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) 3532
Remove 3532
Install 3534
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3535
Remove 3535
Install 3537
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3537
Remove 3537
Install 3537
High Pressure Fuel Filter Unit Repair 3537
Fuel Filter Element 3538
Remove 3538
Clean/Inspect 3539
Install 3539
Fuel Filter Housing 3539
Remove 3539
Disassemble 3540
Assemble 3540
Install 3540
Electronic Throttle Body Repair 3541
Remove 3541
Clean/Inspect 3542
Install 3542
Fuel Injector Repair 3543
Fuel Rail 3543
Remove for Lift Trucks Built Before January, 2010 3543
Remove for Lift Trucks Built After January, 2010 3545
Install for Lift Trucks Built Before January, 2010 3546
Install for Lift Trucks Built After January, 2010 3547
Fuel Injectors and Adapters 3547
Remove for Lift Trucks Built Before January, 2010 3547
Remove for Lift Trucks Built After January, 2010 3549
Clean 3550
Install for Lift Trucks Built Before January, 2010 3550
Install for Lift Trucks Built After January, 2010 3552
LPG Regulator Repair 3552
LPG Regulator 3552
Remove for Lift Trucks Built Before January, 2010 3552
Remove for Lift Trucks Built After January, 2010 3553
Install for Lift Trucks Built Before January, 2010 3555
Install for Lift Trucks Built After January, 2010 3555
LPG Regulator Fuel Filter 3556
Remove 3556
Install 3557
Lock-Off Solenoid and Cartridge 3557
Remove 3557
Install 3558
Control System 3558
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3558
Remove 3558
Install 3559
Electronic Control Unit (ECU) 3560
Remove 3560
Install 3560
Injector Driver Modules 3561
Remove 3561
Install 3561
Fuel Pressure Sensor 3562
Remove 3562
Install 3562
Low LPG Pressure Switch 3562
Remove 3562
Install 3563
LPG Pressure Sensor 3563
Remove 3563
Install 3564
Oxygen Sensor 3564
Exhaust System Repair 3565
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3565
Remove for Lift Trucks Built Before January, 2010 3565
Remove for Lift Trucks Built After January, 2010 3567
Inspect 3569
Install for Lift Trucks Built Before January, 2010 3569
Install for Lift Trucks Built After January, 2010 3569
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) 3570
Remove for Lift Trucks Built Before January, 2010 3570
Remove for Lift Trucks Built After January, 2010 3572
Inspect 3575
Install for Lift Trucks Built Before January, 2010 3575
Install for Lift Trucks Built After January, 2010 3576
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3577
Remove for Lift Trucks Built Before January, 2010 3577
Remove for Lift Trucks Built After January, 2010 3580
Inspect 3581
Install for Lift Trucks Built Before January, 2010 3582
Install for Lift Trucks Built After January, 2010 3582
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3583
Remove for Lift Trucks Built Before January, 2010 3583
Remove for Lift Trucks Built After January, 2010 3586
Inspect 3587
Install for Lift Trucks Built Before January, 2010 3588
Install for Lift Trucks Built After January, 2010 3588
Oxygen Sensor 3589
Remove 3589
Install 3590
LPG Fuel Testing 3590
General 3590
Available Fuel Tests 3590
Composition Test (ASTM D-2163) 3590
Ammonia Test (ASTM D-4490) 3591
Basic Nitrogen Test (ASTM UOP269-90) 3591
Residues Test (ASTM D-2158) 3591
Vapor Pressure Test (ASTM D-2598) 3591
Sulfur Compounds Test (ASTM D-5623) 3591
Methanol Test (ASTM D-4864) 3591
Copper Corrosion (ASTM D-1838) 3591
Where To Send LPG Fuel Samples For Testing 3591
524262276 0900YRM1244 (06 2012) US EN 3595
toc 3595
Gasoline Fuel System 3595
Safety Precautions Maintenance and Repair 3596
General 3599
Electronic Throttle Body Repair 3599
Electronic Throttle Body 3599
Remove 3599
Clean/Inspect 3599
Install 3600
Fuel System Repair 3601
Before Repair Procedure 3601
After Repair Procedure 3601
Fuel Leakage Check for Lift Trucks Built Before January, 2010 3601
Fuel Leakage Check for Lift Trucks Built After January, 2010 3602
Fuel Line Pressure Check 3604
Fuel Injector Repair 3605
Remove 3605
Install 3615
Control System 3616
Electronic Control Unit (ECU) 3616
Remove for Lift Trucks Built Before January, 2010 3616
Remove for Lift Trucks Built After January, 2010 3617
Install for Lift Trucks Built Before January, 2010 3618
Install for Lift Trucks Built After January, 2010 3619
Exhaust System Repair 3620
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 3620
Remove for Lift Trucks Built Before January, 2010 3620
Remove for Lift Trucks Built After January, 2010 3622
Inspect 3622
Install for Lift Trucks Built Before January, 2010 3624
Install for Lift Trucks Built After January, 2010 3624
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 3625
Remove for Lift Trucks Built Before January, 2010 3625
Remove for Lift Trucks Built After January, 2010 3627
Inspect 3629
Install for Lift Trucks Built Before January, 2010 3629
Install for Lift Trucks Built After January, 2010 3630
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 3631
Remove for Lift Trucks Built Before January, 2010 3631
Remove for Lift Trucks Built After January, 2010 3633
Inspect 3635
Install for Lift Trucks Built Before January, 2010 3635
Install for Lift Trucks Built After January, 2010 3636
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 3636
Remove for Lift Trucks Built Before January, 2010 3636
Remove for Lift Trucks Built After January, 2010 3639
Inspect 3639
Install for Lift Trucks Built Before January, 2010 3641
Install for Lift Trucks Built After January, 2010 3641
Oxygen Sensor 3642
Remove 3642
Install 3642
524262277 1400YRM1245 (01 2012) US EN 3645
toc 3645
Drive Axle and Differential Assembly Repair 3645
Safety Precautions Maintenance and Repair 3646
General 3649
Drive Axle Repair 3649
Remove and Disassemble 3649
Clean and Inspect 3652
Assemble and Install 3652
Differential Repair 3654
Remove 3654
Support Differential Assembly From Differential Housing Assembly 3654
Differential Assembly From Differential Assembly Support 3656
Differential Assembly Support from Drop Box 3659
Drive Pinion and Pinion Gear, From Differential Assembly Support 3661
Disassemble 3662
Differential Assembly 3662
Drop Box Housing 3664
Differential Assembly Support 3665
Differential Housing 3666
Clean and Inspect 3667
Assemble 3667
Differential Housing 3667
Differential Assembly Support 3668
Drop Box Housing 3669
Differential Assembly 3670
Install 3674
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 3674
Drive Pinion and Pinion Gear Into Differential Assembly Support 3676
Differential Assembly Into Differential Assembly Support 3678
Ring Gear Backlash, Adjust 3681
Gear Set, Tooth Contact Pattern Check 3682
Differential Assembly Support Into Differential Housing 3685
Torque Specifications 3686
tables 3645
Table 1 Pinion Variation Numbers Examples 3675
Table 2 Ring and Pinion Tooth Contact Adjustment 3683
Table 3 Correct Tooth Contact 3683
Table 4 Incorrect Tooth Contact 3684
524262278 1400YRM1246 (02 2018) US EN 3689
General 3693
Identification Plate 3694
Drive Axle Removal 3694
Hub Seal Replacement 3706
Planetary Reduction Repair 3715
Clean and Inspect 3724
Brake Repair 3737
Clean and Inspect 3753
Wet Brake Noise Reduction 3769
General 3769
Adding Additive To Transmission 3770
Bevel Pinion 3771
Clean and Inspect 3776
Differential Unit 3788
Disassemble 3799
Clean and Inspect 3805
Assemble 3806
Drive Axle Installation 3829
Special Tools 3839
Torque Specifications 3839
524262279 1800YRM1247 (09 2018) US EN 3843
General 3847
Dry Brake System 3847
Wet Brake System 3848
Service Brakes Repair (Dry Brake) 3852
Remove and Disassemble 3852
Clean 3854
Inspect 3855
Assemble and Install 3855
Adjust 3859
Parking Brake Repair 3859
Dry Brake System 3860
Remove and Disassembly 3860
Assemble and Install 3862
Wet Brake System 3862
Remove and Install 3863
Assemble and Install 3869
Adjust 3869
Dry Brake System 3869
Wet Brake System 3870
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3870
Master Cylinder Repair 3871
Remove 3871
Disassemble 3876
Clean and Inspect 3877
Assemble 3878
Install and Adjust 3878
Accumulator 3880
Pre-Charge Check 3881
Remove 3882
Install 3884
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3884
Remove 3885
Modulating Brake Valve 3886
Disassemble 3886
Clean and Inspect 3888
Assemble 3888
Accumulator Charge Valve 3889
Disassemble 3889
Clean and Inspect 3891
Assemble 3891
Install 3892
Pressure Checks 3893
Accumulator Charge Valve Check 3893
Accumulator Check 3893
Service Brakes Adjustment (Dry Brake) 3894
Service Brakes Adjustment 3894
Brake System Air Removal 3895
Using Pressure Bleed System 3895
Using Brake Pedal Pressure 3896
Lift Truck Models with Master Cylinder 3896
Lift Truck Models with Modulating Brake Valve 3896
Brake Pedal Adjustment 3897
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) 3897
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3898
Free Pedal Adjustment 3900
Torque Specifications 3901
524262280 8000YRM1248 (12 2018) US EN 3905
General 3911
Serial Number Data 3911
How to Move Disabled Lift Truck 3912
How to Tow Lift Truck 3912
How to Put Lift Truck on Blocks 3914
How to Raise Drive Tires 3914
How to Raise Steering Tires 3914
How to Clean a Lift Truck 3915
Maintenance Schedule 3916
Maintenance Procedures Every 8 Hours or Daily 3936
How to Make Checks With Engine Stopped 3936
Tires and Wheels 3936
Safety Labels 3937
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3937
Operator Restraint System 3938
Emergency Locking Retractor (ELR) 3938
Adjust Seat – Full Suspension 3939
Adjust Seat – Internal Suspension 3940
Hood and Seat Latches 3941
Engine Compartment 3941
Paper Application 3941
Fuel, Oil, and Coolant Leaks, Check 3942
Hydraulic Hoses 3942
Coolant Hoses 3942
Steering Column Gas Cylinder 3942
Transmission 3943
Hydraulic System Oil 3943
Engine Oil 3943
Air Filter 3948
Forks 3948
Remove 3948
Inspect 3951
Install 3952
Adjust 3952
How to Make Checks With Engine Running 3952
Indicator Lights, Horn, Fuses, and Relays 3952
Service Brakes 3955
Brake Fluid Level 3955
Operation, Check 3955
Parking Brake 3956
Engine Oil Pressure 3956
Cooling System 3957
Steering System 3958
Control Levers and Pedals 3958
Lift System, Operate 3958
First Service After First 100 Hours of Operation 3958
GM 4 3L Engine Oil and Oil Filter 3958
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3959
Maintenance Procedures Every 250 Hours or 6 Months 3959
GM 4 3L Engine Oil and Oil Filter 3959
Drive Belt 3960
GM 4 3L Engine 3960
Fan and Alternator Drive Belt 3960
Drain Tar From LPG Converter 3960
Drain Tar From LPG Regulator 3961
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 3962
Maintenance Procedures Every 500 Hours or 6 Months 3964
Hydraulic System Oil 3964
Hydraulic Tank Breather 3965
Inspect 3965
Battery 3965
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3966
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 3966
Remove 3966
Install 3966
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 3970
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 3971
Controlled Venting 3971
Manual Bleeding 3971
Drive Belt 3972
Cummins 4 5L and QSB 3 3L Diesel Engine 3972
Fan and Alternator Drive Belt 3972
Clean Debris From Radiator Core 3973
Transmission Oil Level 3973
Wet Brake Center Body Oil Level Check 3975
Forks 3976
Mast Lubrication 3976
Header Hose Checks 3980
Lift Chain Lubrication 3980
Tilt Cylinder Lubrication 3980
Master Brake Cylinder Rod End Pin Lubrication 3981
Manual Hydraulic Levers Lubrication 3982
Brake Oil 3982
Tie Rod Lubrication for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 3983
Tie Rod Lubrication for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 3983
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 3983
Parking Brake Adjustment 3984
Maintenance Procedures Every 1000 Hours or 6 Months 3985
Valve Clearance, Check and Adjust 3985
Ignition System 3985
GM 4 3L Engine 3985
LPG Fuel Filter Element Replace, GM 4 3L Engine 3985
Remove 3985
Install 3986
In-Line Filter Replacement, Cummins 4 5L Engine 3986
Remove 3986
Install 3987
Lift Chains Wear Check 3989
Lift Chain Lubrication 3989
Integral Sideshift Carriage, Check Sliding Surfaces 3989
Steering Axle (Spindle Bearings) for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 3991
Steering Axle (Spindle Bearings) for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 3991
Control Levers and Pedals 3991
Parking Brake Lever Lubrication, Wet Brake Axle 3991
Normal Operating Environment 3992
Heavy Duty or Contaminated Environment 3993
Remove 3993
Clean and Inspect 3994
Install 3994
Inspect Engine Electrical System, Connectors 3995
Maintenance Procedures Every 2000 Hours or Annually 3995
Hydraulic System 3995
Hydraulic Filter, Replace 3995
Hydraulic Tank Breather, Replace 3996
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 3997
Cooling System 3997
Air Filter 3997
Oxygen Sensor GM 4 3L LPG Engines with GFI Installed 3999
LPG Regulator Fuel Filter, GM 4 3L Engines Equipped with GFI Installed 4000
Remove 4000
Install 4000
Gasoline Fuel Filter 4001
Remove and Replace for Lift Trucks Equipped with GFI 4001
Remove and Replace for Lift Trucks Equipped with PSI 4001
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 4002
Gasoline Fuel Injector, GM Engines 4002
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 4002
Forks 4002
Transmission Oil and Filter (Dry Brake), Replace 4002
Transmission and Wet Brake Planetary Carrier Housing Oil Change 4004
Wet Brake Center Section Oil Change 4007
Remove 4007
Install 4007
Brake Oil (Master Cylinder), Change 4008
Brake Oil (Dry Brake), Remove 4009
Service Brakes (Dry Brake) 4009
Differential (Dry Brake) 4010
Test LPG/GAS Regulator Pressure 4011
Test LPG Regulator Pressure 4011
Check Throttle Shaft for Sticking 4011
Inspect Exhaust Manifold and Piping for Leaks 4011
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 4011
Wheel Bearings 4012
Steer Wheels, Lubrication 4012
Maintenance Procedures Every 4000 Hours or 2 Years 4012
Hydraulic Oil, Replace 4013
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 4014
Weld Inspection 4016
Safety Procedures When Working Near Mast 4019
Fuel Filter Water Removal 4021
Hood Latch Check 4021
Lift Chain Adjustments 4022
Jump-Starting the Lift Truck 4024
Jump-Starting Using a Battery Charger 4024
Jump-Starting a Lift Truck Using Another Lift Truck 4024
Welding Repairs 4025
Overhead Guard Changes 4025
Wheel and Tire Replacement 4025
General 4025
Solid Rubber Tire, Change (GC/GLC Series) 4025
Remove and Install Tire on Wheel 4026
Pneumatic Tire With Tube, Repair 4027
Remove Wheels From Lift Truck 4027
Remove Tire From Wheel 4027
Install Wheel in Tire 4030
Install Tire on Two-Piece Wheel 4032
Add Air to Pneumatic Tires With Tube 4033
Install the Wheels 4033
Dual Drive Wheels, Install 4034
Pneumatic Tubeless Tire, Repair 4035
Remove Wheels From Lift Truck 4035
Add Air to Pneumatic Tubeless Tire 4040
Wheels, Install 4040
Solid Rubber Tires on Pneumatic Wheels, Change 4040
Adhesives and Sealants 4044
524262281 8000YRM1249 (11 2017) US EN 4047
Lift Truck Lifting Capacity 4051
Counterweight Weights 4051
Tire Sizes 4052
Capacities 4052
Electrical System 4058
Transmission Oil Pressures 4060
Hydraulic System Relief Pressures 4063
Steering System 4064
Stall Speeds (in RPM ±100 rpm) 4064
GM 4 3L Gas 4065
GM 4 3L LPG 4065
Cummins 4 5L Diesel 4065
Cummins QSB 3 3L Diesel 4065
Mast Speeds 4065
Tilt Angles 4067
Front End Equipment – Mast Creep 4067
Mast Creep 4068
Engine Specifications 4068
Torque Specifications 4070
Frame 4071
Mast 4071
Steering System 4071
Steer Axle 4071
Drive Axle (Wet Brake) 4071
Drive Axle (Dry Brake) 4072
Transmission 4072
Engine – GM 4 3L 4073
Engine – Cummins 4 5L and QSB 3 3L Diesel 4074
524265337 0600YRM1251 (09 2015) US EN 4077
General 4083
Engine Removal and Installation 4083
Cylinder Head Repair 4083
Remove and Disassemble 4083
Clean and Inspect 4085
Valve Oil Seals 4088
Remove and Disassemble 4088
Cylinder Leak Down Test 4088
Clean and Inspect 4089
Assemble and Install 4089
Valve Guides and Seats, Repairs 4091
Valves, Repair 4091
Valve Seats, Repair 4092
Valve Springs 4093
Assemble and Install 4094
Engine Block Cleaning and Inspection 4097
Clean and Inspect 4098
Piston Bore Preparation 4100
Engine Mounts Installation 4100
Remove 4100
Clean and Inspect 4101
Install 4101
Lubrication System Repair 4102
Oil Pump, Remove and Disassemble 4102
Clean and Inspect 4103
Oil Pump, Assemble and Install 4104
Oil Pan, Install 4106
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4108
Timing Cover 4108
Remove 4108
Install 4110
Timing Sprockets 4110
Remove 4110
Install 4110
Camshaft 4110
Remove 4110
Inspect 4111
Install 4111
Balance Shaft 4112
Remove 4112
Install 4113
Valve Lifters 4114
Remove 4114
Clean and Inspect 4114
Install 4115
Crankshaft Repair 4115
Remove 4116
Inspect and Repair 4116
How to Check Clearance Between Main Bearings and Their Journals 4117
Install 4118
Piston and Connecting Rod Assemblies Repair 4120
Connecting Rod Bearings, Replace 4120
Piston and Connecting Rod Assemblies, Remove 4121
Disassemble 4121
Piston, Clean and Inspect 4122
Cylinder Bores, Inspect and Repair 4122
Piston Rings 4123
Assemble 4124
Piston and Connecting Rod Assemblies, Install 4124
Flywheel and Flywheel Housing Repair 4124
Flywheel, Remove 4125
Clean 4125
Inspect 4125
Flywheel, Install 4126
Coolant Pump Repair 4126
Remove 4126
Clean and Inspect 4127
Install 4127
Thermostat Replacement 4127
Remove 4128
Thermostat Operation Check 4128
Install 4128
Starter Replacement 4129
4129
Remove 4129
Install 4132
Fan Assembly Replacement 4133
Remove 4133
Inspect 4135
Install 4135
Drive Belt Installation 4136
Remove 4136
Clean 4136
Inspect 4136
Installation 4137
Compression Check 4138
Engine Specifications 4138
Engine Data 4138
Cylinder Head 4138
Hydraulic Valve Lifter 4139
Camshaft 4139
Pistons 4139
Crankshaft 4140
Connecting Rods 4140
Balance Shaft 4141
Cooling System 4141
Lubrication System 4141
Torque Specifications 4142
524265342 4000YRM1250 (09 2018) US EN 4147
Safety Procedures When Working Near Mast 4153
Fork Replacement 4155
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4155
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4157
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) 4158
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4159
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4160
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) 4161
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 4161
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) 4163
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 4163
Fixed Carriage Replacement 4165
Remove, Carriage With Hook Forks 4165
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4174
Install, Carriage With Hook Forks 4175
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 4175
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4176
Connecting Attachment Hydraulic Quick Disconnect Hoses 4176
Integral Sideshift Carriage Repair 4177
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) 4177
Disassemble 4177
Clean and Inspect 4180
Assemble 4180
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) 4181
Hang On Sideshift Carriage Repair 4181
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) 4181
Disassemble 4193
Clean and Inspect 4202
Assemble 4203
Install 4204
Bolzoni Hang-On Sideshift Carriage Repair 4206
Remove 4206
Disassemble Carriage 4208
Clean and Inspect 4211
Assemble 4211
Install 4214
Fork Positioner 4216
Two-Stage Mast With Limited Free-Lift Repair 4217
Remove 4217
Disassemble 4221
Clean and Inspect 4224
Assemble 4241
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) 4243
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) 4244
Header Hose Alignment 4256
Two-Stage Mast With Full Free-Lift Repair 4266
Remove 4266
Disassemble 4268
Clean and Inspect 4280
Assemble 4281
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) 4283
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) 4286
Header Hose Installation and Adjustment 4290
Installation 4290
Adjustment 4290
Three-Stage Mast With Full Free-Lift Repair 4291
Remove 4291
Disassemble 4293
Clean and Inspect 4323
Assemble 4324
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) 4328
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) 4333
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) 4340
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) 4346
Mast Operation Check 4350
Tilt Cylinder Adjustment 4350
Lift Chains Adjustment 4351
Mast Adjustments 4352
Load Roller Adjustment 4352
Mast Side Kicking Adjustment 4354
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4355
Carriage Adjustments 4358
524306203 0100YRM1290 (04 2014) US EN 4361
550073240 1900YRM1620 (01 2023) US EN 4465
Proper Flushing after Major Hydraulic Repairs 4471
Introduction 4471
The Phases of Wear 4471
Causes of Hydraulic System Failure 4471
Progression of Contaminant Caused Hydraulic System Failure 4472
Hydraulic System Flushing Techniques 4472
Double Oil and Filter Change 4472
Mechanical Cleaning 4473
Cleaning of Components 4473
How to Clean Tubes and Hoses 4473
Filter Caddy 4473
Start-Up Procedure for Cleaned System 4474
Contaminated Oil Coolers 4474
Additional Filter Caddy Functions 4475
How to Handle Different Fluids 4475
Water Removal Filters 4475
Fluid Conditioning and System Flushing Procedures 4476
Operation of the Filter Caddy 4476
Filter Caddy operation 4476
Fluid Conditioning Procedure 4476
Filter Caddy Start-Up 4477
System Flushing Procedure 4477
Component Cleaning Procedure 4478
Reservoir Cleaning Procedure 4478
Cylinder Cleaning Procedure 4478
Hose and Tube Cleaning Procedure 4478
Valve Cleaning Procedure 4479
Front-End Attachment Cleaning Procedure 4480
System Flushing Procedure 4480
Filter Caddy Start-Up 4481
System Start-Up and Flushing 4481
Reservoir Fluid Cleaning Times 4482
Dealing With Different Fluid Types 4483
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4483
Filter Caddy Maintenance 4483
Servicing the Strainer 4483
DC Motor 4483
Hydraulic Oil Sampling Method and Procedure 4484
Hydraulic Oil Sampling Method 4484
Objective 4484
General Guidelines 4484
Synopsis 4485
Hydraulic Oil Analysis Report Guidelines 4486
Sampling Conditions 4486
Equipment 4486
Sampling Procedure 4487
Hydraulic Oil Sampling 4487
Sample Labeling 4487
Results Documentation 4487
550073240 1900YRM1620 (03 2020) US EN 4489
Proper Flushing after Major Hydraulic Repairs 4493
Introduction 4493
The Phases of Wear 4493
Causes of Hydraulic System Failure 4493
Progression of Contaminant Caused Hydraulic System Failure 4494
Hydraulic System Flushing Techniques 4494
Double Oil and Filter Change 4494
Mechanical Cleaning 4495
Cleaning of Components 4495
How to Clean Tubes and Hoses 4495
Filter Caddy 4495
Start-Up Procedure for Cleaned System 4496
Contaminated Oil Coolers 4496
Additional Filter Caddy Functions 4496
How to Handle Different Fluids 4496
Water Removal Filters 4497
Fluid Conditioning and System Flushing Procedures 4497
Operation of the Filter Caddy 4497
Filter Caddy operation 4497
Fluid Conditioning Procedure 4498
Filter Caddy Start-Up 4498
System Flushing Procedure 4499
Component Cleaning Procedure 4499
Reservoir Cleaning Procedure 4499
Cylinder Cleaning Procedure 4499
Hose and Tube Cleaning Procedure 4500
Valve Cleaning Procedure 4500
Front-End Attachment Cleaning Procedure 4501
System Flushing Procedure 4501
Filter Caddy Start-Up 4502
System Start-Up and Flushing 4502
Reservoir Fluid Cleaning Times 4503
Dealing With Different Fluid Types 4503
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4503
Filter Caddy Maintenance 4504
Servicing the Strainer 4504
DC Motor 4504
Hydraulic Oil Sampling Method and Procedure 4504
Hydraulic Oil Sampling Method 4504
Objective 4504
General Guidelines 4504
Synopsis 4505
Hydraulic Oil Analysis Report Guidelines 4506
Sampling Conditions 4507
Equipment 4507
Sampling Procedure 4507
Hydraulic Oil Sampling 4507
Sample Labeling 4508
Results Documentation 4508