Yale Forklift G813 (GLPGDP40VX5, 40VX6,45VX6, GLPGDP45SVX5, 50VX, 55VX Europe) Service Manual - PDF

Yale Forklift G813 (GLPGDP40VX5, 40VX6,45VX6, GLPGDP45SVX5, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift G813 (GLPGDP40VX5, 40VX6,45VX6, GLPGDP45SVX5, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4578
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift G813 (GLPGDP40VX5, 40VX6,45VX6, GLPGDP45SVX5, 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
524223764 1600YRM1133 (07 2013) US EN 2213
toc 2213
Steering Axle 2213
Safety Precautions Maintenance and Repair 2214
General 2217
Steering Axle Assembly Repair 2219
Remove 2219
Disassemble 2220
Clean 2228
Inspect 2228
Assemble 2228
Install 2234
Spindles, Bearings, and Tie Rods Repair 2236
Spindles and Bearings 2236
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2236
Remove 2236
Disassemble 2238
Clean 2239
Inspect 2239
Assemble 2239
Install 2240
Spindles and Bearings 2243
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2243
Remove and Disassemble 2243
Assemble and Install 2244
Tie Rods 2244
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2244
Remove 2244
Install 2245
Tie Rods 2246
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2246
Remove 2246
Install 2252
Steering Cylinder Repair 2252
Remove and Disassemble 2252
Clean and Inspect 2253
Assemble and Install 2253
Torque Specifications 2254
524223766 1900YRM1136 (11 2017) UK EN 2259
General 2263
Hydraulic Gear Pump Assembly 2264
Variable Displacement Pump Assembly 2265
Single Gear Pump Assembly Repair 2265
Remove 2265
Disassemble 2272
Clean 2272
Inspect 2274
Assemble 2274
Install 2274
Tandem Gear Pump Assembly 2278
Remove 2279
Disassemble 2281
Clean 2283
Inspect 2283
Assemble 2283
Install 2284
Gear Pump Specifications 2284
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2290
Remove 2290
Disassemble 2300
Clean 2303
Inspect 2303
Assemble 2303
Install 2304
63 0 cc/rev – Variable Displacement Pump Repair 2307
Remove 2307
Disassemble 2310
Clean 2310
Inspect 2310
Assemble 2312
Install 2312
Variable Displacement Pump Checks and Adjustments (Single Pump) 2314
Margin Pressure Check 2314
Flow Compensator Adjustment 2315
Pressure Compensator Adjustment 2315
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2316
Variable Displacement Pump Specifications 2319
Torque Specifications 2320
Hydraulic Gear Pump 2321
Variable Displacement Pump 2322
Special Tools 2322
524223767 2000YRM1137 (01 2017) UK EN 2327
General 2333
Electro-Hydraulic Main Control Valve 2334
Description 2334
Remove 2342
Electro-Hydraulic Control Valve Sections 2347
General 2347
Outlet Control Valve Section 2347
Remove 2347
Disassemble 2348
Clean 2350
Inspect 2350
Assemble 2350
Install 2351
Auxiliary Control Valve Sections 2351
Remove 2351
Disassemble 2358
Clean 2359
Inspect 2360
Assemble 2360
Install 2362
Tilt Control Valve Section 2363
Remove 2363
Disassemble 2363
Clean 2369
Inspect 2369
Assemble 2369
Install 2370
Lift/Lower Control Valve Section 2371
Remove 2371
Disassemble 2371
Clean 2380
Inspect 2380
Assemble 2380
Install 2381
Mid-Inlet Section 2381
Remove 2381
Clean 2382
Inspect 2382
Install 2382
Install 2382
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2387
Lift Pilot Pin 2387
Lower Pilot Pin 2391
Abnormal/Erroneous EHPV Adjustment 2393
Manual Main Control Valve 2394
Description 2394
Remove 2398
OPS Solenoid Assembly 2406
General 2406
Remove 2407
Clean and Inspect 2410
Install 2410
Manual Control Valve Sections 2411
General 2411
Outlet Control Valve Section 2411
Remove 2411
Disassemble 2411
Clean 2414
Inspect 2414
Assemble 2414
Install 2415
Auxiliary Control Valve Sections 2415
Remove 2415
Disassemble 2415
Clean 2418
Inspect 2418
Assemble 2418
Install 2419
Lift/Tilt Control Valve Section 2419
Remove 2419
Disassemble 2419
Clean 2426
Inspect 2426
Assemble 2427
Install 2428
Mid-Inlet Section 2429
Remove 2429
Clean 2429
Inspect 2429
Install 2429
Install 2430
Pressure Relief Valve Check and Adjustment 2436
Primary Relief Valve 2437
Secondary Relief Valve 2441
Steering Control Unit Repair 2448
Steering Control Unit, Remove 2448
Steering Control Unit, Disassemble 2452
Steering Control Unit, Clean 2454
Steering Control Unit, Inspect 2454
Steering Control Unit, Assemble 2454
Relief Valve, Disassemble 2455
Relief Valve, Clean 2455
Relief Valve, Inspect 2456
Relief Valve, Assemble 2456
Steering Control Unit, Install 2456
524223768 2100YRM1139 (02 2014) UK EN 2461
524223769 2200YRM1128 (01 2023) US EN 2509
Series Code / Model Designation Reference Table 2517
General 2519
Deutsch Crimping Tool 2520
How to Strip a Wire for Use With Deutsch Crimping Tool 2520
How to Crimp With the Deutsch Crimping Tool 2521
Calibration Test for the Deutsch Crimping Tool 2523
Deutsch Connectors 2525
DT, DTM, and DTP Series Connectors 2525
HD Series Connectors 2568
Metri-Pack Connectors 2590
Remove and Install 2590
Micro-Pack Connectors 2593
Weather-Pack Connectors 2594
AMPSEAL Crimping Tools 2596
AMP Hand Crimping Tool With Certi-Crimp 2596
Description 2596
Stripping Wire for Use with AMP Hand Crimping Tool 2597
Insulation Crimp Adjustment 2598
Maintenance and Inspection for AMP Hand Crimping Tool 2598
AMP Hand Crimping Tool 2598
Crimp Height Inspection 2598
How to use AMP Hand Crimping Tool 2599
AMP Pro-Crimper II Tool 2599
Description 2599
Remove and Install Die Set and Locator Assembly 2600
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2600
Contact Support Adjustment 2601
Crimp Height Adjustment 2602
Maintenance and Inspection Procedures 2602
PRO-CRIMPER II Tool 2602
Crimp Height Inspection 2602
How to Use AMP PRO-CRIMPER II Tool 2603
AMPSEAL Connector Assemblies 2604
Description for Plug Connector Assembly 2604
Seal Plug 2605
Contact Crimping 2605
Description for Plug Connector and Header Assembly 2610
Voltage Reading 2613
Seal Plug 2613
Contact Crimping 2613
AMP Superseal 1 5 Crimping Tools 2620
Mini Mic Receptacle and Tab Contacts 2620
Description 2620
Crimping Conditions and Measurements 2620
Insertion of Rubber Seal on Cable 2622
AMP Hand Application Tool 2627
Description 2627
Maintenance and Inspection 2627
Crimp Height Inspection 2627
Crimp Height Adjustment 2628
How to Use AMP Hand Application Tool 2628
AMP Pro-Crimper II Tool 2629
Description 2629
Remove and Install Die Set and Locator Assembly 2629
Adjustments 2630
Contact Support 2630
Crimp Height 2631
Inspections and Maintenance 2632
Crimp Height Inspection 2632
Visual Inspection 2632
Maintenance 2633
How to Use Pro-Crimper II Tool 2633
AMP Superseal 1 5 Connector Assemblies 2634
Description 2634
Repair and Maintenance 2641
Panel Mount Option 2641
AMP Fastin-Faston Hand Tools 2642
Description – AMP Double Action Hand Tool 2642
Maintenance and Inspection Procedures 2642
Daily Maintenance 2642
Periodic Tool Inspection 2643
Lubrication 2643
Visual Inspection 2643
Crimp Height Inspection 2643
Certi-Crimp Ratchet Inspection 2644
How to Use AMP Double Action Hand Tool 2645
Description – AMP Extraction Tool 2646
Maintenance and Inspection 2647
How to Use AMP Extraction Tool 2647
AMP Fastin-Faston Receptacles and Housings 2649
Description 2649
Wire Repair 2657
Wire Splicing Requirements 2657
Deutsch Jiffy Splice 2658
Twisted/Shielded Cable and Leads Repair 2664
Special Tools 2666
524223769 2200YRM1128 (07 2020) UK EN 2675
Series Code / Model Designation Reference Table 2681
General 2684
Deutsch Crimping Tool 2684
How to Strip a Wire for Use With Deutsch Crimping Tool 2684
How to Crimp With the Deutsch Crimping Tool 2685
Calibration Test for the Deutsch Crimping Tool 2687
Deutsch Connectors 2689
DT, DTM, and DTP Series Connectors 2689
HD Series Connectors 2731
Metri-Pack Connectors 2754
Remove and Install 2754
Micro-Pack Connectors 2756
Weather-Pack Connectors 2757
AMPSEAL Crimping Tools 2759
AMP Hand Crimping Tool With Certi-Crimp 2759
Description 2759
Stripping Wire for Use with AMP Hand Crimping Tool 2759
Insulation Crimp Adjustment 2760
Maintenance and Inspection for AMP Hand Crimping Tool 2760
AMP Hand Crimping Tool 2760
Crimp Height Inspection 2760
How to use AMP Hand Crimping Tool 2761
AMP Pro-Crimper II Tool 2761
Description 2761
Remove and Install Die Set and Locator Assembly 2762
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2763
Contact Support Adjustment 2763
Crimp Height Adjustment 2764
Maintenance and Inspection Procedures 2764
PRO-CRIMPER II Tool 2764
Crimp Height Inspection 2764
How to Use AMP PRO-CRIMPER II Tool 2765
AMPSEAL Connector Assemblies 2766
Description for Plug Connector Assembly 2766
Seal Plug 2767
Contact Crimping 2767
Description for Plug Connector and Header Assembly 2772
Voltage Reading 2774
Seal Plug 2774
Contact Crimping 2774
AMP Superseal 1 5 Crimping Tools 2781
Mini Mic Receptacle and Tab Contacts 2781
Description 2781
Crimping Conditions and Measurements 2781
Insertion of Rubber Seal on Cable 2783
AMP Hand Application Tool 2788
Description 2788
Maintenance and Inspection 2788
Crimp Height Inspection 2788
Crimp Height Adjustment 2789
How to Use AMP Hand Application Tool 2789
AMP Pro-Crimper II Tool 2790
Description 2790
Remove and Install Die Set and Locator Assembly 2791
Adjustments 2791
Contact Support 2791
Crimp Height 2792
Inspections and Maintenance 2793
Crimp Height Inspection 2793
Visual Inspection 2793
Maintenance 2794
How to Use Pro-Crimper II Tool 2794
AMP Superseal 1 5 Connector Assemblies 2795
Description 2795
Repair and Maintenance 2802
Panel Mount Option 2802
AMP Fastin-Faston Hand Tools 2803
Description – AMP Double Action Hand Tool 2803
Maintenance and Inspection Procedures 2803
Daily Maintenance 2803
Periodic Tool Inspection 2804
Lubrication 2804
Visual Inspection 2804
Crimp Height Inspection 2804
Certi-Crimp Ratchet Inspection 2805
How to Use AMP Double Action Hand Tool 2806
Description – AMP Extraction Tool 2807
Maintenance and Inspection 2807
How to Use AMP Extraction Tool 2808
AMP Fastin-Faston Receptacles and Housings 2809
Description 2809
Wire Repair 2816
Wire Splicing Requirements 2816
Deutsch Jiffy Splice 2817
Twisted/Shielded Cable and Leads Repair 2822
Special Tools 2825
524223770 2200YRM1130 (03 2020) UK EN 2833
General 2837
Description 2837
Dash Display Menu Access 2837
Menu Navigation 2838
Standard Display 2838
Main Menu 2838
Passwords Menu 2839
Password Administration 2839
Add Password 2839
Delete Password 2840
Edit Password 2840
Other Password Functions 2841
Operator Passwords – Enable/Disable 2841
Password Time-Out Delay 2841
Passwords – Number Wrong to Disable 2842
Lockout Reset Password 2842
View Password Log 2843
View Versions 2844
VSM Versions 2844
Dash Display Versions 2845
Engine Controller Version 2846
Transmission (Xmsn) Controller Version 2847
Truck Serial Number 2848
Diagnostics 2849
View Fault Log 2849
Set Travel and Braking 2850
Speed Limit 2850
Acceleration Rate 2851
Auto-Deceleration Rate 2851
Set Power Reversal Rate 2852
Set Inching/Brake Overlap 2853
Setup Display Menu 2854
Set Operator Language 2854
Set Units 2855
Set Time Format (12/24 Hour) 2855
Set Daylight Saving Time 2855
Set Time 2858
Set Date Format 2859
Set Date 2859
Setup Hydraulics 2860
Return to Set Tilt Delay/On/Off 2860
Setup General Items 2861
Light Shutdown Time-Out 2861
Impact Sensor – Enable/Disable 2862
Impact Sensor – Soft Impact Settings 2863
Impact Sensor – Hard Impact Settings 2864
Adjust Impact Sensor Settings 2864
Initial Adjustment of Soft and Hard Impact Settings 2866
Readjustment of Soft and Hard Impact Settings 2866
Impact Sensor – Impact Alarm/Shutdown Reset 2867
Impact Sensor – Alarm Time Duration and Deactivation 2868
Impact Sensor – View Impact Event Log 2869
Engine Mode Indicator 2870
Generation 1 (ECO-eLo ONLY) 2870
Generation 2 2871
Operator Checklist 2872
Operator Checklist Off-On Mode 2872
Edit Operator Checklist 2872
Set Operator Checklist Expiration 2873
View Checklist Log 2873
Clear Operator Checklist Log 2874
Clear Operator Checklist Fault 2874
Calibrations 2875
Set Tilt Stop Point 2875
Calibrate Loaded Weight 2875
524223771 2200YRM1131 (03 2020) UK EN 2877
Series Code / Model Designation Reference Table 2883
General 2885
Description 2885
Dash Display Menu Access 2885
Menu Navigation 2886
Main Menu 2886
Passwords 2887
Adding Passwords 2887
Hourmeters 2889
View Versions 2890
VSM Versions 2890
Dash Display Versions 2891
Engine Controller Version 2892
Transmission (Xmsn) Controller Version 2893
Truck Serial Number 2894
Truck Configuration 2895
Diagnostics 2896
Clear Fault Log 2896
View Fault Log 2897
No-Run Data Display 2898
Engine Accelerator and Throttle Data Display 2898
Engine Speeds and Governor Data Display 2899
Engine Fuel and Emissions Data Display 2900
Engine General Data Display 2902
XMSN/Brake Data Display 2903
Hydraulic Data Display 2906
General Truck Data Display 2908
Set Travel and Braking 2909
Speed Limit 2909
Acceleration Rate 2910
Auto-Deceleration Rate 2911
Set Power Reversal Rate 2911
Set Inching/Brake Overlap 2912
Setup Hydraulics 2912
Lift Maximum Speed 2913
Lower Maximum Speed 2913
Tilt Maximum Speed 2914
Auxiliary Function One, Direction A, Maximum Speed 2916
Auxiliary Function One, Direction B, Maximum Speed 2918
Auxiliary Function Two, Direction A, Maximum Speed 2918
Auxiliary Function Two, Direction B, Maximum Speed 2919
Auxiliary Function Three, Direction A, Maximum Speed 2920
Auxiliary Function Three, Direction B, Maximum Speed 2920
Lift/Lower Ramp Rate 2921
Hydraulic Auxiliary Ramp Rate 2921
Return to Set Tilt Delay/On/Off 2922
Hydraulic Input Device 2923
Auxiliary Solenoid 2923
Dual Function 2924
Setup Display 2925
Set Service Language 2925
Setup General Items 2925
Motion Alarm Activation Type 2926
Light Shutdown Time-Out 2927
Restore Default Settings 2927
Restore Engine Controller Default Calibration 2928
Impact Sensor – Enable/Disable 2928
Impact Sensor – Soft Impact Settings 2929
Impact Sensor – Hard Impact Settings 2930
Adjust Impact Sensor Settings 2931
Initial Adjustment of Soft and Hard Impact Settings 2933
Readjustment of Soft and Hard Impact Settings 2933
Impact Sensor – Impact Alarm/Shutdown Reset 2934
Impact Sensor – Alarm Time Duration and Deactivation 2935
Impact Sensor – View Impact Event Log 2936
Engine Mode Indicator 2936
Generation 1 (ECO-eLo ONLY) 2936
Generation 2 2937
Diesel Particulate Filter (DPF) Display 2938
General Description 2938
Passive Regeneration Only 2938
Regeneration Level 0 2938
Auto/Active Regeneration Inhibited 2939
Auto/Active Regeneration 2939
Regeneration Level 1 2939
Parked Regeneration Request 2940
Regeneration Level 2 2940
Warning Level 2940
Regeneration Level 3 2940
Service Level 2941
Regeneration Level 4 2941
Display, Diesel Particulate Filter (DPF), Revised 2941
Operator Interface 2941
Refer to Operator Manual 2941
CAN Communication Lost 2942
Passive Regeneration Only 2942
Regeneration Level 0 2942
Auto/Active Regeneration Inhibited 2942
Auto/Active Regeneration 2943
Regeneration Level 1 2943
Idle-up Auto/Active Regeneration 2943
Parked Regeneration Request 2943
Regeneration Level 2 2943
Warning Level 2945
Regeneration Level 3 2945
Service Level 2945
Regeneration Level 4 2945
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2945
Display, Diesel Particulate Filter (DPF), Stage V Engine 2945
Operator Interface 2946
Refer to Operator Manual 2946
CAN Communication Lost 2946
Passive Regeneration Only 2946
Regeneration Level 0 2946
Auto/Active Regeneration Inhibited 2947
Auto/Active Regeneration 2947
Regeneration Level 1 2947
Idle-up Auto/Active Regeneration 2948
Parked Regeneration Request 2948
Regeneration Level 2 2948
Warning Level 2949
Regeneration Level 3 2949
Service Level 2950
Regeneration Level 4 2950
Stage V Content 2950
Emissions System Malfunction 2950
Ash Load 2950
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2951
Operator Interface 2951
Refer to Operator Manual 2951
CAN Communication Lost 2952
Passive Regeneration Only 2952
Regeneration Level 0 2952
Auto/Active Regeneration Inhibited 2952
Auto/Active Regeneration 2953
Regeneration Level 1 2953
Idle-up Auto/Active Regeneration 2953
Parked Regeneration Request 2953
Regeneration Level 2 2953
Warning Level 2955
Regeneration Level 3 2955
Service Level 2955
Regeneration Level 4 2955
Calibrations 2956
Calibrate Transmission Valve 2958
Set Tilt Stop Point 2958
Calibrate Loaded Weight 2958
Calibrate Travel Speed Sensor 2959
Calibrate Mazda LP and Gas Accelerator Pedal 2959
524223772 2200YRM1142 (01 2020) UK EN 2961
General 2971
Display Switch Cluster 2974
Remove 2974
Install 2977
Direction Control and Turn Signal Levers 2977
Remove 2977
Install 2979
Key Switch 2979
Remove 2979
Install 2980
Display Switch Cluster Panel Bezel and Overlay 2980
Remove 2980
Install 2980
Steering Column Repair 2980
Remove 2980
Disassemble 2983
Assemble 2983
Install 2983
Sensors and Switches 2984
General 2984
Dash and Kick Panel, Remove and Install 2984
Remove 2984
Install 2985
Accelerator Pedal Position Sensor 2986
Remove 2986
Install 2989
Brake Fluid Level Switch 2990
Remove 2990
Install 2992
Service Brake Pedal Position Sensor 2993
Remove 2993
Install 2996
Parking Brake Sensor 2997
Remove 2997
Install 2998
Service Brake Pressure Sensor 2999
Remove 2999
Install 3001
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3002
Remove 3002
Install 3002
Sensor Microswitch (Foot Directional Control Pedal) 3003
Remove 3003
Install 3006
Low Coolant Level Sensor 3007
Remove 3007
Install 3010
Fuel Level Sensor, Gas and Diesel Engines Only 3011
Remove 3011
Install 3012
Armrest Switch 3012
Remove 3012
Install 3014
Seat Sensor (Operator Presence System) 3014
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) 3014
Remove 3014
Install 3015
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3015
Remove 3015
Install 3016
Full Suspension Seats; All Lift Truck Models 3016
Remove 3016
Install 3016
Hood Shut Off Switch 3016
Remove 3016
Install 3019
Remote Key Switch 3020
Remove 3020
Install 3020
Hydraulic Filter Pressure Switch 3021
Remove 3021
Install 3023
Transmission Speed Sensor 3023
Remove 3023
Install 3026
Transmission Pressure Sensors 3027
Remove 3027
Install 3029
Transmission Temperature Sensor 3030
Remove 3030
Install 3032
Engine Speed Sensor 3034
Remove 3034
Install 3034
Intermediate Speed Sensor 3035
Remove 3035
Install 3035
Return to Set Tilt (Tilt Angle) Sensor 3035
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) 3035
Remove 3035
Install 3036
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) 3037
Remove 3037
Install 3038
Rear Horn Button Switch 3038
Remove 3038
Install 3039
Impact Sensor 3040
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) 3040
Remove 3040
Install 3043
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) 3043
Remove 3043
Install 3044
Load Weight Sensor 3045
Remove 3045
Install 3046
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3047
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3047
Crankshaft Position (CKP) Sensor 3047
Camshaft Position (CMP) Sensor 3047
Oil Pressure Sensor 3047
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3047
Engine Coolant Temperature (ECT) Sensor 3048
Air Flow Restriction Switch 3048
Remove for GM 2 4L Gas and LPG Trucks 3048
Install for GM 2 4L Gas and LPG Trucks 3048
Oxygen Sensor 3049
Remove 3049
Install 3052
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3053
Crankshaft Position (CKP) Sensor 3053
Camshaft Position (CMP) Sensor 3053
Oil Pressure Sensor 3053
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3053
Engine Coolant Temperature (ECT) Sensor 3053
Air Flow Restriction Switch 3053
Oxygen Sensor 3053
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3053
Low LPG Pressure Switch 3053
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3054
Air Filter Restriction Switch 3054
Remove 3054
Install 3054
Oil Pressure Sensor 3054
Remove 3054
Install 3054
Engine Speed Sensor 3054
Remove 3054
Install 3054
Engine Coolant Temperature (ECT) Sensor 3054
Remove 3054
Install 3054
Throttle Position Sensor (TPS) 3057
Remove 3057
Install 3058
Fuel/Water Separator Sensor 3058
Remove 3058
Install 3058
Glow Plug Relay 3059
Remove 3059
Install 3061
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3061
Air Filter Restriction Switch 3061
Remove 3061
Install 3061
Engine Oil Pressure Sensor 3066
Remove 3066
Install 3066
Engine Speed Sensor 3066
Remove 3066
Install 3067
Engine Coolant Temperature (ECT) Sensor 3067
Remove 3067
Install 3068
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3069
Remove 3069
Install 3069
Fuel/Water Separator Sensor 3070
Remove 3070
Install 3070
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3071
Intake Air Temperature Sensor 3071
Remove 3071
Install 3072
Intake Air Pressure Sensor 3072
Remove 3072
Install 3072
Air Inlet Heater 3072
Remove 3072
Install 3073
Engine Oil Pressure Sensor 3073
Remove 3073
Install 3073
Engine Coolant Temperature (ECT) Sensor 3073
Remove 3073
Install 3073
Crankshaft Position Sensor 3074
Remove 3074
Install 3074
Adjust Shim Procedure 3075
Camshaft Position Sensor 3076
Remove 3076
Install 3076
Air Flow Restriction Sensor 3077
Remove 3077
Install 3077
Fuel/Water Separator 3077
Remove 3077
Install 3078
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3078
Intake Air Temperature Sensor 3082
Remove 3082
Install 3083
Boost Sensor 3083
Remove 3083
Install 3084
Throttle Valve Assembly and Air Intake Heater 3084
Remove 3084
Install 3084
Engine Coolant Temperature (ECT) Sensor 3085
Remove 3085
Install 3085
Engine Oil Pressure Sensor 3085
Remove 3085
Install 3086
Crankshaft Position Sensor 3086
Remove 3086
Install 3086
Adjust Shim Procedure 3087
Camshaft Position Sensor 3088
Remove 3088
Install 3089
Differential Pressure Sensor 3089
Remove 3089
Install 3089
Mass Air Flow Sensor 3090
Remove 3090
Install 3091
Fuel/Water Separator 3091
Remove 3091
Install 3092
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3092
Engine Coolant Temperature (ECT) Sensor 3093
Remove 3093
Install 3093
Throttle Position Sensor 3094
Engine Oil Pressure Sensor 3094
Remove 3094
Install 3094
Engine Speed Sensor 3094
Remove 3094
Install 3094
Fuel Shut Off Solenoid 3094
Remove 3094
Install 3094
Vehicle System Manager (VSM) 3095
General 3095
VSM Replacement 3095
Remove 3095
Install 3097
Programming a New VSM and/or Display Switch Cluster 3097
General 3097
PC Service Tool Software 3098
Data Transferring 3098
New VSM 3098
New (Blank) Display Switch Cluster 3098
Used (Non-Blank) Display Switch Cluster 3098
Power Distribution Module (PDM) and Component Parts 3100
Remove 3100
PDM as a Unit 3100
Install 3104
PDM as a Unit 3104
Remove and Install 3105
PDM Component Parts 3105
Transmission Control Unit 3105
Remove 3105
Install 3109
Battery 3111
Remove 3111
Install 3111
Lights 3112
Work Lights (Front and Rear) 3112
Remove 3112
Install 3112
Strobe Light 3113
Remove 3113
Install 3113
LED Tail, Backup, and Brake Lights 3114
Remove 3114
Install 3115
Front Marker/Turn Signal Lights 3116
Replacing Whole Front Marker/Turn Signal Light Assembly 3116
Remove 3116
Install 3116
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3117
Remove 3117
Install 3117
Diesel Particulate Filter (DPF) Display 3117
Remove 3117
Clean and Inspect 3118
Install 3118
Electronic-Hydraulic Controls – Generation 1 3119
E-Hydraulic Controls – Test 3119
Mini-Levers 3119
Full Stroke Test 3119
Function Returns to Neutral Test 3119
Push Button Switch 3119
General 3120
Mini-Lever Replacement 3120
Remove 3120
Clean and Inspect 3121
Install 3121
Push Button Switch Replacement 3122
Remove 3122
Install 3124
Mini-Lever Module (MLM) 3124
Remove 3124
Install 3124
Joystick 3125
Remove and Disassemble 3125
Inspect 3125
Assemble and Install 3125
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3126
General 3126
Mini-levers, Remove and Install 3126
Armrest Assembly 3127
Remove 3127
Install 3130
Horn Button 3130
Remove 3130
Install 3130
Direction Control Switch 3131
Remove 3131
Install 3131
push (override) buttons and Toggle Switch 3131
Remove 3132
Install 3133
Joystick 3134
Remove and Disassemble 3134
Inspect 3134
Assemble and Install 3134
Joystick Armrest Slider Assembly 3135
Remove 3135
Install 3136
Electronic-Hydraulic Controls, After January, 2020 3136
E-Hydraulic Controls – TEST 3136
Mini-Levers 3136
Full Stroke Test 3136
Function Returns to Neutral Test 3136
Push (Override) Button 3137
General 3137
Mini-levers, Remove and Install 3137
Armrest Assembly 3138
Remove 3138
Install 3141
Horn Button 3141
Remove 3141
Install 3141
Direction Control Switch 3141
Remove 3141
Install 3142
Push (Override) buttons and Toggle Switch 3142
Remove 3143
Install 3145
Special Tools 3146
524223780 8000YRM1134 (05 2022) US EN 3149
Series Code / Model Designation Reference Table 3155
Description 3158
Proc_Cal_001: Service Password Entry 3160
When to Perform 3160
Why Perform 3160
How to Perform 3160
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3161
When to Perform 3161
Calibration Order 3161
Why Perform 3161
How to Perform 3161
Proc_Cal_003: Save and Exit 3163
When to Perform 3163
Why Perform 3163
How to Perform 3163
Proc_Cal_004: Lift Valve Output Threshold 3164
When to Perform 3164
Calibration Order 3164
Why Perform 3164
How to Perform 3164
Proc_Cal_005: Lower Valve Output Threshold 3167
When to Perform 3167
Calibration Order 3167
Why Perform 3167
How to Perform 3167
Proc_Cal_006: Tilt Back Valve Output Threshold 3170
When to Perform 3170
Calibration Order 3170
Why Perform 3170
How to Perform 3170
Proc_Cal_007: Tilt Forward Valve Output Threshold 3173
When to Perform 3173
Calibration Order 3173
Why Perform 3173
How to Perform 3173
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3176
When to Perform 3176
Calibration Order 3176
Why Perform 3176
How to Perform 3176
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3179
When to Perform 3179
Calibration Order 3179
Why Perform 3179
How to Perform 3179
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3182
When to Perform 3182
Calibration Order 3182
Why Perform 3182
How to Perform 3182
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3185
When to Perform 3185
Calibration Order 3185
Why Perform 3185
How to Perform 3185
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3188
When to Perform 3188
Calibration Order 3188
Why Perform 3188
How to Perform 3188
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3191
When to Perform 3191
Calibration Order 3191
Why Perform 3191
How to Perform 3191
Proc_Cal_014: Load Weight Zero Point 3194
When to Perform 3194
Calibration Order 3194
Why Perform 3194
How to Perform 3194
Proc_Cal_015: Loaded Weight Calibration 3196
When to Perform 3196
Calibration Order 3196
Why Perform 3196
How to Perform 3196
Proc_Cal_016: Transmission Valve Calibration 3199
Applicable System/Option 3199
When to Perform 3199
Calibration Order 3199
Why Perform 3199
How to Perform 3199
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3201
Applicable System/Option 3201
When to Perform 3201
Calibration Order 3201
Why Perform 3201
How to Perform 3201
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3204
Applicable System/Option 3204
When to Perform 3204
Calibration Order 3204
Why Perform 3204
How to Perform 3204
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3207
Required Tools 3207
When to Perform 3207
Calibration Order 3207
Why Perform 3207
How to Perform 3207
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3209
When to Perform 3209
Why Perform 3209
How to Perform 3209
Proc_Cal_026: Travel Speed Calibration 3211
When to Perform 3211
Calibration Order 3211
Why Perform 3211
How to Perform 3211
524262274 0100YRM1243 (11 2016) UK EN 3215
General 3219
Description 3220
Hood, Seat, and Side Covers Replacement 3222
Remove 3222
Install 3222
Steering Column 3229
Description 3230
Steering Column Repair 3230
Remove 3230
Disassemble 3232
Clean 3235
Inspect 3235
Assemble 3235
Install 3235
LPG Tank and Bracket Replacement 3236
Counterweight Replacement 3236
Remove 3236
Install 3239
Tow Pin 3243
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) 3243
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) 3243
Overhead Guard Replacement 3244
Remove 3244
Install 3245
LED Tail, Backup, and Brake Lights, Replace 3245
Operator Restraint System Replacement 3246
Description 3246
Engine Replacement 3247
Remove Engine Only 3247
Install Engine only 3274
Remove Engine and Transmission 3277
Install Engine and Transmission 3281
Electronic Throttle Replacement 3285
Cummins 4 5L Diesel Engine With Electronic Throttle 3285
Remove 3285
Install 3288
Pull Actuator Linkage Adjustment 3290
Low Idle Adjustment 3290
Throttle Pedal and Cable Adjustment 3291
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3291
Kubota 3 6L Diesel Engine 3291
Exhaust System Repair 3294
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) 3294
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) 3294
Remove 3294
Inspect 3294
Install 3296
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) 3296
Remove 3296
Inspect 3298
Install 3298
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 3298
Remove 3298
Inspect 3300
Install 3300
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) 3300
Remove 3300
Inspect 3303
Diesel Particulate Filter 3305
Disassemble 3305
CLEAN AND INSPECT 3306
Assembly 3306
Install 3307
Cooling System 3308
Description 3308
Hydraulic Filter Assembly Repair 3309
Remove 3309
Disassemble 3309
Clean 3310
Inspect 3310
Assemble 3310
Install 3310
Fuel and Hydraulic Tanks Repair 3310
Inspect 3310
Clean 3311
Steam Method of Cleaning 3311
Chemical Solution Method of Cleaning 3312
Additional Preparations for Repair 3312
Small Leaks, Repair 3312
Large Leaks, Repair 3312
Preparations for Use After Repair 3312
Safety Labels 3312
524262275 0900YRM1242 (04 2018) UK EN 3323
General 3329
Hoses Replacement 3329
LPG Tank and Bracket Replacement 3330
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) 3330
Remove 3330
Install 3333
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) 3334
Remove 3334
Install 3334
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) 3334
Remove 3334
Install 3336
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3337
Remove 3337
Install 3339
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3339
Remove 3339
Install 3339
High Pressure Fuel Filter Unit Repair 3339
Fuel Filter Element 3340
Remove 3340
Clean/Inspect 3341
Install 3341
Fuel Filter Housing 3341
Remove 3341
Disassemble 3342
Assemble 3342
Install 3342
Electronic Throttle Body Repair 3343
Remove 3343
Clean/Inspect 3344
Install 3344
Fuel Injector Repair 3345
Fuel Rail 3345
Remove for Lift Trucks Built Before January, 2010 3345
Remove for Lift Trucks Built After January, 2010 3347
Install for Lift Trucks Built Before January, 2010 3348
Install for Lift Trucks Built After January, 2010 3349
Fuel Injectors and Adapters 3349
Remove for Lift Trucks Built Before January, 2010 3349
Remove for Lift Trucks Built After January, 2010 3351
Clean 3352
Install for Lift Trucks Built Before January, 2010 3352
Install for Lift Trucks Built After January, 2010 3354
LPG Regulator Repair 3354
LPG Regulator 3354
Remove for Lift Trucks Built Before January, 2010 3354
Remove for Lift Trucks Built After January, 2010 3355
Install for Lift Trucks Built Before January, 2010 3357
Install for Lift Trucks Built After January, 2010 3357
LPG Regulator Fuel Filter 3358
Remove 3358
Install 3359
Lock-Off Solenoid and Cartridge 3359
Remove 3359
Install 3360
Control System 3360
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3360
Remove 3360
Install 3361
Electronic Control Unit (ECU) 3362
Remove 3362
Install 3362
Injector Driver Modules 3363
Remove 3363
Install 3363
Fuel Pressure Sensor 3364
Remove 3364
Install 3364
Low LPG Pressure Switch 3364
Remove 3364
Install 3365
LPG Pressure Sensor 3365
Remove 3365
Install 3366
Oxygen Sensor 3366
Exhaust System Repair 3367
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3367
Remove for Lift Trucks Built Before January, 2010 3367
Remove for Lift Trucks Built After January, 2010 3369
Inspect 3371
Install for Lift Trucks Built Before January, 2010 3371
Install for Lift Trucks Built After January, 2010 3371
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) 3372
Remove for Lift Trucks Built Before January, 2010 3372
Remove for Lift Trucks Built After January, 2010 3374
Inspect 3377
Install for Lift Trucks Built Before January, 2010 3377
Install for Lift Trucks Built After January, 2010 3378
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3379
Remove for Lift Trucks Built Before January, 2010 3379
Remove for Lift Trucks Built After January, 2010 3382
Inspect 3383
Install for Lift Trucks Built Before January, 2010 3384
Install for Lift Trucks Built After January, 2010 3384
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3385
Remove for Lift Trucks Built Before January, 2010 3385
Remove for Lift Trucks Built After January, 2010 3388
Inspect 3389
Install for Lift Trucks Built Before January, 2010 3390
Install for Lift Trucks Built After January, 2010 3390
Oxygen Sensor 3391
Remove 3391
Install 3392
LPG Fuel Testing 3392
General 3392
Available Fuel Tests 3392
Composition Test (ASTM D-2163) 3392
Ammonia Test (ASTM D-4490) 3393
Basic Nitrogen Test (ASTM UOP269-90) 3393
Residues Test (ASTM D-2158) 3393
Vapor Pressure Test (ASTM D-2598) 3393
Sulfur Compounds Test (ASTM D-5623) 3393
Methanol Test (ASTM D-4864) 3393
Copper Corrosion (ASTM D-1838) 3393
Where To Send LPG Fuel Samples For Testing 3393
524262277 1400YRM1245 (01 2012) UK EN 3397
toc 3397
Drive Axle and Differential Assembly Repair 3397
Safety Precautions Maintenance and Repair 3398
General 3401
Drive Axle Repair 3401
Remove and Disassemble 3401
Clean and Inspect 3404
Assemble and Install 3404
Differential Repair 3406
Remove 3406
Support Differential Assembly From Differential Housing Assembly 3406
Differential Assembly From Differential Assembly Support 3408
Differential Assembly Support from Drop Box 3411
Drive Pinion and Pinion Gear, From Differential Assembly Support 3413
Disassemble 3414
Differential Assembly 3414
Drop Box Housing 3416
Differential Assembly Support 3417
Differential Housing 3418
Clean and Inspect 3419
Assemble 3419
Differential Housing 3419
Differential Assembly Support 3420
Drop Box Housing 3421
Differential Assembly 3422
Install 3426
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 3426
Drive Pinion and Pinion Gear Into Differential Assembly Support 3428
Differential Assembly Into Differential Assembly Support 3430
Ring Gear Backlash, Adjust 3433
Gear Set, Tooth Contact Pattern Check 3434
Differential Assembly Support Into Differential Housing 3437
Torque Specifications 3438
tables 3397
Table 1 Pinion Variation Numbers Examples 3427
Table 2 Ring and Pinion Tooth Contact Adjustment 3435
Table 3 Correct Tooth Contact 3435
Table 4 Incorrect Tooth Contact 3436
524262278 1400YRM1246 (02 2018) UK EN 3441
General 3445
Identification Plate 3446
Drive Axle Removal 3446
Hub Seal Replacement 3458
Planetary Reduction Repair 3467
Clean and Inspect 3476
Brake Repair 3489
Clean and Inspect 3505
Wet Brake Noise Reduction 3521
General 3521
Adding Additive To Transmission 3522
Bevel Pinion 3523
Clean and Inspect 3528
Differential Unit 3540
Disassemble 3551
Clean and Inspect 3557
Assemble 3558
Drive Axle Installation 3581
Special Tools 3591
Torque Specifications 3591
524262279 1800YRM1247 (09 2018) UK EN 3595
General 3599
Dry Brake System 3599
Wet Brake System 3600
Service Brakes Repair (Dry Brake) 3604
Remove and Disassemble 3604
Clean 3606
Inspect 3607
Assemble and Install 3607
Adjust 3611
Parking Brake Repair 3611
Dry Brake System 3612
Remove and Disassembly 3612
Assemble and Install 3614
Wet Brake System 3614
Remove and Install 3615
Assemble and Install 3621
Adjust 3621
Dry Brake System 3621
Wet Brake System 3622
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3622
Master Cylinder Repair 3623
Remove 3623
Disassemble 3628
Clean and Inspect 3629
Assemble 3630
Install and Adjust 3630
Accumulator 3632
Pre-Charge Check 3633
Remove 3634
Install 3636
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3636
Remove 3637
Modulating Brake Valve 3638
Disassemble 3638
Clean and Inspect 3640
Assemble 3640
Accumulator Charge Valve 3641
Disassemble 3641
Clean and Inspect 3643
Assemble 3643
Install 3644
Pressure Checks 3645
Accumulator Charge Valve Check 3645
Accumulator Check 3645
Service Brakes Adjustment (Dry Brake) 3646
Service Brakes Adjustment 3646
Brake System Air Removal 3647
Using Pressure Bleed System 3647
Using Brake Pedal Pressure 3648
Lift Truck Models with Master Cylinder 3648
Lift Truck Models with Modulating Brake Valve 3648
Brake Pedal Adjustment 3649
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) 3649
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3650
Free Pedal Adjustment 3652
Torque Specifications 3653
524262281 8000YRM1249 (11 2017) UK EN 3657
Lift Truck Lifting Capacity 3661
Counterweight Weights 3661
Tire Sizes 3662
Capacities 3662
Electrical System 3668
Transmission Oil Pressures 3670
Hydraulic System Relief Pressures 3673
Steering System 3674
Stall Speeds (in RPM ±100 rpm) 3674
GM 4 3L Gas 3675
GM 4 3L LPG 3675
Cummins 4 5L Diesel 3675
Cummins QSB 3 3L Diesel 3675
Mast Speeds 3675
Tilt Angles 3677
Front End Equipment – Mast Creep 3677
Mast Creep 3678
Engine Specifications 3678
Torque Specifications 3680
Frame 3681
Mast 3681
Steering System 3681
Steer Axle 3681
Drive Axle (Wet Brake) 3681
Drive Axle (Dry Brake) 3682
Transmission 3682
Engine – GM 4 3L 3683
Engine – Cummins 4 5L and QSB 3 3L Diesel 3684
524262298 8000YRM1248 (05 2019) UK EN 3687
General 3693
Serial Number Data 3693
How to Move Disabled Lift Truck 3694
How to Tow Lift Truck 3694
How to Put Lift Truck on Blocks 3695
How to Raise Drive Tires 3695
How to Raise Steering Tires 3696
How to Clean a Lift Truck 3697
Maintenance Schedule 3697
Maintenance Procedures Every 8 Hours or Daily 3712
How to Make Checks With Engine Stopped 3712
Tires and Wheels 3712
Safety Labels 3713
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3713
Operator Restraint System 3714
Emergency Locking Retractor (ELR) 3714
Adjust Seat – Full Suspension 3715
Adjust Seat – Internal Suspension 3716
Hood and Seat Latches 3716
Engine Compartment 3717
Paper Application 3717
Fuel, Oil, and Coolant Leaks, Check 3717
Hydraulic Hoses 3718
Coolant Hoses 3718
Steering Column Gas Cylinder 3718
Transmission 3718
Hydraulic System Oil 3718
Engine Oil 3718
Air Filter 3722
Forks 3722
Remove 3722
Inspect 3722
Install 3722
Adjust 3723
Integral Sideshift Carriage 3723
How to Make Checks With Engine Running 3724
Indicator Lights, Horn, Fuses, and Relays 3724
Service Brakes 3726
Brake Oil Level 3726
Operation, Check 3727
Parking Brake 3727
Engine Oil Pressure 3727
Cooling System 3727
Steering System 3728
Control Levers and Pedals 3728
Lift System, Operate 3728
First Service After First 100 Hours of Operation 3729
GM 4 3L Engine Oil and Oil Filter 3729
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3730
Maintenance Procedures Every 500 Hours or 1 Year 3730
Hydraulic System Oil 3730
Hydraulic Tank Breather 3731
Inspect 3731
Battery 3731
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3732
GM 4 3L Engine Oil and Oil Filter 3732
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 3732
Remove 3732
Install 3733
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 3735
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 3736
Controlled Venting 3736
Manual Bleeding 3736
Drain Tar From LPG Regulator 3737
Drain Tar From LPG Converter 3737
Drive Belt 3738
GM 4 3L Engine 3738
Fan and Alternator Drive Belt 3738
Cummins 4 5L and QSB 3 3L Diesel Engine 3738
Fan and Alternator Drive Belt 3738
Clean Debris From Radiator Core 3739
Transmission Oil Level 3740
Wet Brake Center Body Oil Level Check 3741
Forks 3743
Mast Lubrication 3743
Header Hose Checks 3746
Lift Chain Lubrication 3746
Tilt Cylinder Lubrication 3746
Master Brake Cylinder Rod End Pin Lubrication 3747
Manual Hydraulic Levers Lubrication 3748
Brake Oil 3748
Tie Rod Lubrication for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (E818) 3749
Tie Rod Lubrication for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (F813, G813) 3749
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 3749
Parking Brake Adjustment 3750
Maintenance Procedures Every 1000 Hours or 1 Year 3751
Valve Clearance, Check and Adjust 3751
Ignition System 3751
GM 4 3L Engine 3751
LPG Fuel Filter Element Replace, GM 4 3L Engine 3751
Remove 3751
Install 3752
In-Line Filter Replacement, Cummins 4 5L Engine 3753
Remove 3753
Install 3753
Lift Chains Wear Check 3755
Lift Chain Lubrication 3755
Integral Sideshift Carriage, Check Sliding Surfaces 3755
Steering Axle (Spindle Bearings) for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (E818) 3756
Steering Axle (Spindle Bearings) for Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (F813, G813) 3756
Control Levers and Pedals 3757
Inspect Engine Electrical System, Connectors 3757
Maintenance Procedures Every 2000 Hours or Annually 3757
Hydraulic System 3757
Hydraulic Filter, Replace 3757
Hydraulic Tank Breather, Replace 3759
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 3759
Cooling System 3759
Air Filter 3760
Oxygen Sensor GM 4 3L LPG Engines with GFI Installed 3761
LPG Regulator Fuel Filter, GM 4 3L Engines With GFI Installed 3761
Remove 3761
Install 3762
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 3762
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 3762
Forks 3762
Transmission Oil and Filter (Dry Brake), Replace 3763
Transmission and Wet Brake Planetary Carrier Housing Oil Change 3764
Wet Brake Center Section Oil Change 3766
Remove 3766
Install 3767
Brake Oil (Master Cylinder), Change 3768
Brake Oil (Dry Brake), Remove 3768
Service Brakes (Dry Brake) 3769
Differential (Dry Brake) 3769
Test LPG Regulator Pressure 3770
Check Throttle Shaft for Sticking 3770
Inspect Exhaust Manifold and Piping for Leaks 3770
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 3770
Wheel Bearings 3771
Steer Wheels, Lubrication 3771
Maintenance Procedures Every 4000 Hours or 2 Years 3771
Hydraulic Oil, Replace 3772
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 3773
Weld Inspection 3775
Safety Procedures When Working Near Mast 3778
Fuel Filter Water Removal 3780
Hood Latch Check 3780
Lift Chain Adjustments 3781
Jump-Starting the Lift Truck 3783
Jump-Starting Using a Battery Charger 3783
Jump-Starting a Lift Truck Using Another Lift Truck 3783
Welding Repairs 3784
Overhead Guard Changes 3784
Wheel and Tire Replacement 3784
General 3784
Solid Rubber Tire, Change ( Series)GLC 3784
Remove and Install Tire on Wheel 3785
Pneumatic Tire With Tube, Repair 3786
Remove Wheels From Lift Truck 3786
Remove Tire From Wheel 3786
Install Wheel in Tire 3789
Install Tire on Two-Piece Wheel 3791
Add Air to Pneumatic Tires With Tube 3792
Install the Wheels 3792
Dual Drive Wheels, Install 3792
Pneumatic Tubeless Tire, Repair 3794
Remove Wheels From Lift Truck 3794
Add Air to Pneumatic Tubeless Tire 3799
Wheels, Install 3799
Solid Rubber Tires On Pneumatic Wheels, Change 3799
Remove Tire From Wheel 3799
Install Tire on Wheel 3800
Snap-On-Tire, Change 3801
Adhesives and Sealants 3804
524265337 0600YRM1251 (09 2015) UK EN 3807
General 3813
Engine Removal and Installation 3813
Cylinder Head Repair 3813
Remove and Disassemble 3813
Clean and Inspect 3815
Valve Oil Seals 3818
Remove and Disassemble 3818
Cylinder Leak Down Test 3818
Clean and Inspect 3819
Assemble and Install 3819
Valve Guides and Seats, Repairs 3821
Valves, Repair 3821
Valve Seats, Repair 3822
Valve Springs 3823
Assemble and Install 3824
Engine Block Cleaning and Inspection 3827
Clean and Inspect 3828
Piston Bore Preparation 3830
Engine Mounts Installation 3830
Remove 3830
Clean and Inspect 3831
Install 3831
Lubrication System Repair 3832
Oil Pump, Remove and Disassemble 3832
Clean and Inspect 3833
Oil Pump, Assemble and Install 3834
Oil Pan, Install 3836
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3838
Timing Cover 3838
Remove 3838
Install 3840
Timing Sprockets 3840
Remove 3840
Install 3840
Camshaft 3840
Remove 3840
Inspect 3841
Install 3841
Balance Shaft 3842
Remove 3842
Install 3843
Valve Lifters 3844
Remove 3844
Clean and Inspect 3844
Install 3845
Crankshaft Repair 3845
Remove 3846
Inspect and Repair 3846
How to Check Clearance Between Main Bearings and Their Journals 3847
Install 3848
Piston and Connecting Rod Assemblies Repair 3850
Connecting Rod Bearings, Replace 3850
Piston and Connecting Rod Assemblies, Remove 3851
Disassemble 3851
Piston, Clean and Inspect 3852
Cylinder Bores, Inspect and Repair 3852
Piston Rings 3853
Assemble 3854
Piston and Connecting Rod Assemblies, Install 3854
Flywheel and Flywheel Housing Repair 3854
Flywheel, Remove 3855
Clean 3855
Inspect 3855
Flywheel, Install 3856
Coolant Pump Repair 3856
Remove 3856
Clean and Inspect 3857
Install 3857
Thermostat Replacement 3857
Remove 3858
Thermostat Operation Check 3858
Install 3858
Starter Replacement 3859
3859
Remove 3859
Install 3862
Fan Assembly Replacement 3863
Remove 3863
Inspect 3865
Install 3865
Drive Belt Installation 3866
Remove 3866
Clean 3866
Inspect 3866
Installation 3867
Compression Check 3868
Engine Specifications 3868
Engine Data 3868
Cylinder Head 3868
Hydraulic Valve Lifter 3869
Camshaft 3869
Pistons 3869
Crankshaft 3870
Connecting Rods 3870
Balance Shaft 3871
Cooling System 3871
Lubrication System 3871
Torque Specifications 3872
524265342 4000YRM1250 (09 2018) UK EN 3877
Safety Procedures When Working Near Mast 3883
Fork Replacement 3885
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3885
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3887
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) 3888
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3889
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3890
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) 3891
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3891
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) 3893
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3893
Fixed Carriage Replacement 3895
Remove, Carriage With Hook Forks 3895
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3904
Install, Carriage With Hook Forks 3905
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3905
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3906
Connecting Attachment Hydraulic Quick Disconnect Hoses 3906
Integral Sideshift Carriage Repair 3907
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) 3907
Disassemble 3907
Clean and Inspect 3910
Assemble 3910
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) 3911
Hang On Sideshift Carriage Repair 3911
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) 3911
Disassemble 3923
Clean and Inspect 3932
Assemble 3933
Install 3934
Bolzoni Hang-On Sideshift Carriage Repair 3936
Remove 3936
Disassemble Carriage 3938
Clean and Inspect 3941
Assemble 3941
Install 3944
Fork Positioner 3946
Two-Stage Mast With Limited Free-Lift Repair 3947
Remove 3947
Disassemble 3951
Clean and Inspect 3954
Assemble 3971
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) 3973
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) 3974
Header Hose Alignment 3986
Two-Stage Mast With Full Free-Lift Repair 3996
Remove 3996
Disassemble 3998
Clean and Inspect 4010
Assemble 4011
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) 4013
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) 4016
Header Hose Installation and Adjustment 4020
Installation 4020
Adjustment 4020
Three-Stage Mast With Full Free-Lift Repair 4021
Remove 4021
Disassemble 4023
Clean and Inspect 4053
Assemble 4054
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) 4058
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) 4063
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) 4070
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) 4076
Mast Operation Check 4080
Tilt Cylinder Adjustment 4080
Lift Chains Adjustment 4081
Mast Adjustments 4082
Load Roller Adjustment 4082
Mast Side Kicking Adjustment 4084
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4085
Carriage Adjustments 4088
524306203 0100YRM1290 (04 2014) UK EN 4091
524329117 8000YRM1387 (03 2020) UK EN 4195
General Information About Diagrams and Schematics 4199
Symbol Definitions 4199
Diagrams Manual Applications 4200
Diagrams and Schematics 4202
550001092 8000YRM1409 (03 2020) UK EN 4267
General Information About Diagrams and Schematics 4271
Symbol Definitions 4271
Diagrams Manual Applications 4272
Diagrams and Schematics 4274
550031265 2000YRM1457 (10 2015) UK EN 4355
General 4359
Main Control Valve Repair 4361
Remove 4361
Main Control Valve Sections 4364
General 4364
Outlet Control Valve Section 4364
Remove 4364
Disassemble 4364
Clean 4364
Inspect 4364
Assemble 4366
Install 4366
Auxiliary Control Valve Section 4366
Remove 4366
Disassemble 4366
Clean 4368
Inspect 4368
Assemble 4368
Install 4368
Tilt Control Valve Section 4369
Remove 4369
Disassemble 4369
Clean 4369
Inspect 4369
Assemble 4370
Install 4371
Lift/Lower Control Valve Section 4371
Remove 4371
Disassemble 4371
Clean 4371
Inspect 4371
Assemble 4372
Install 4373
Transition Section 4373
Remove 4373
Disassemble 4373
Clean 4373
Inspect 4373
Assemble 4374
Install 4374
Install 4375
Pressure Relief Valve Check and Adjustment 4379
General 4379
Secondary Relief Valve 4379
Steering Control Unit Repair 4380
Remove 4381
Disassemble 4381
Clean 4385
Inspect 4385
Assemble 4385
Install 4386
System Relief Valve 4387
Disassemble 4387
Clean 4387
Inspect 4387
Assemble 4387
Accumulator Replacement 4388
Remove 4388
Install 4388
550043436 1300YRM1529 (11 2018) UK EN 4393
General 4397
Serial Number 4397
Charge Pump Repair 4397
Lift Trucks Manufactured Before July, 2013 4397
Remove 4397
Inspect 4397
Install 4397
Lift Trucks Manufactured After July, 2013 4398
Remove 4398
Inspect 4398
Install 4398
Torque Converter Replace 4399
Remove 4399
Install 4408
Housings and Chain Drive Repair 4414
Remove 4414
Clean 4425
Inspect 4425
Install 4425
Clutch Packs Repair 4432
Remove and Disassemble 4432
Transmission, Remove and Disassemble 4432
Clean 4451
Inspect 4451
Assemble and Install 4452
Transmission, Assemble and Install 4460
Control Valve Repair 4464
Remove and Disassemble 4464
Clean 4468
Inspect 4468
Assemble and Install 4468
Foot Directional Control Pedal Repair 4469
Remove and Disassemble 4469
Assemble and Install 4473
Direction Control Lever 4474
Remove 4474
Install 4474
550043871 0900YRM1556 (04 2018) UK EN 4479
General 4483
LPG Tank and Bracket 4483
LPG Tank, Lift Truck Models GLC40-55VX; GLC55SVX; GLC080-120VX; GLC080-100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 4483
Remove 4483
Install 4491
LPG Tank Bracket, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 4492
Remove 4492
Install 4494
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4494
Remove 4494
Install 4496
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4496
Remove 4496
Install 4496
LPG Tank Bracket Alignment Pin, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (F813, G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 4497
Remove 4497
Install 4499
Fuel Filter Unit 4499
Fuel Filter Element 4500
Remove 4500
Clean and Inspect 4500
Install 4501
Fuel Filter Housing with LP Vapor Sensor 4501
Remove 4501
Disassemble 4503
Clean and Inspect 4504
Assemble 4504
Install 4505
Throttle Body 4506
Remove 4506
Clean 4510
Install 4510
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4511
Remove 4511
Install 4512
Control System 4512
Engine Control Unit (ECU) 4513
Remove 4513
Install 4514
Low Pressure Switch 4514
Remove 4514
Install 4514
Low Fuel Sensor 4515
Remove 4515
Install 4515
LP Converter 4516
Remove and Disassemble 4516
Assemble and Install 4517
LPG Lock-Off 4517
Remove 4518
Install 4519
Exhaust System 4520
Counterweight Exhaust 4520
Remove and Disassemble 4520
Inspect 4522
Assemble and Install 4522
Overhead Exhaust 4523
Remove and Disassemble 4523
Inspect 4525
Assemble and Install 4525
Exhaust Manifold 4525
Remove 4525
Install 4527
Oxygen (HEGO) Sensor 4527
Remove 4527
Install 4527
LPG Fuel Testing 4528
General 4528
Available Fuel Tests 4528
Composition Test (ASTM D-2163) 4528
Ammonia Test (ASTM D-4490) 4528
Basic Nitrogen Test (ASTM UOP269-90) 4528
Residues Test (ASTM D-2158) 4528
Vapor Pressure Test (ASTM D-2598) 4528
Sulfur Compounds Test (ASTM D-5623) 4528
Methanol Test (ASTM D-4864) 4529
Copper Corrosion (ASTM D-1838) 4529
Where To Send LPG Fuel Samples For Testing 4529
550073240 1900YRM1620 (01 2023) US EN 4533
Proper Flushing after Major Hydraulic Repairs 4539
Introduction 4539
The Phases of Wear 4539
Causes of Hydraulic System Failure 4539
Progression of Contaminant Caused Hydraulic System Failure 4540
Hydraulic System Flushing Techniques 4540
Double Oil and Filter Change 4540
Mechanical Cleaning 4541
Cleaning of Components 4541
How to Clean Tubes and Hoses 4541
Filter Caddy 4541
Start-Up Procedure for Cleaned System 4542
Contaminated Oil Coolers 4542
Additional Filter Caddy Functions 4543
How to Handle Different Fluids 4543
Water Removal Filters 4543
Fluid Conditioning and System Flushing Procedures 4544
Operation of the Filter Caddy 4544
Filter Caddy operation 4544
Fluid Conditioning Procedure 4544
Filter Caddy Start-Up 4545
System Flushing Procedure 4545
Component Cleaning Procedure 4546
Reservoir Cleaning Procedure 4546
Cylinder Cleaning Procedure 4546
Hose and Tube Cleaning Procedure 4546
Valve Cleaning Procedure 4547
Front-End Attachment Cleaning Procedure 4548
System Flushing Procedure 4548
Filter Caddy Start-Up 4549
System Start-Up and Flushing 4549
Reservoir Fluid Cleaning Times 4550
Dealing With Different Fluid Types 4551
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4551
Filter Caddy Maintenance 4551
Servicing the Strainer 4551
DC Motor 4551
Hydraulic Oil Sampling Method and Procedure 4552
Hydraulic Oil Sampling Method 4552
Objective 4552
General Guidelines 4552
Synopsis 4553
Hydraulic Oil Analysis Report Guidelines 4554
Sampling Conditions 4554
Equipment 4554
Sampling Procedure 4555
Hydraulic Oil Sampling 4555
Sample Labeling 4555
Results Documentation 4555
550073240 1900YRM1620 (03 2020) UK EN 4557
Proper Flushing after Major Hydraulic Repairs 4561
Introduction 4561
The Phases of Wear 4561
Causes of Hydraulic System Failure 4561
Progression of Contaminant Caused Hydraulic System Failure 4562
Hydraulic System Flushing Techniques 4562
Double Oil and Filter Change 4562
Mechanical Cleaning 4563
Cleaning of Components 4563
How to Clean Tubes and Hoses 4563
Filter Caddy 4563
Start-Up Procedure for Cleaned System 4564
Contaminated Oil Coolers 4564
Additional Filter Caddy Functions 4564
How to Handle Different Fluids 4564
Water Removal Filters 4565
Fluid Conditioning and System Flushing Procedures 4565
Operation of the Filter Caddy 4565
Filter Caddy operation 4565
Fluid Conditioning Procedure 4566
Filter Caddy Start-Up 4566
System Flushing Procedure 4567
Component Cleaning Procedure 4567
Reservoir Cleaning Procedure 4567
Cylinder Cleaning Procedure 4567
Hose and Tube Cleaning Procedure 4568
Valve Cleaning Procedure 4568
Front-End Attachment Cleaning Procedure 4569
System Flushing Procedure 4569
Filter Caddy Start-Up 4570
System Start-Up and Flushing 4570
Reservoir Fluid Cleaning Times 4571
Dealing With Different Fluid Types 4571
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4571
Filter Caddy Maintenance 4572
Servicing the Strainer 4572
DC Motor 4572
Hydraulic Oil Sampling Method and Procedure 4572
Hydraulic Oil Sampling Method 4572
Objective 4572
General Guidelines 4572
Synopsis 4573
Hydraulic Oil Analysis Report Guidelines 4574
Sampling Conditions 4575
Equipment 4575
Sampling Procedure 4575
Hydraulic Oil Sampling 4575
Sample Labeling 4576
Results Documentation 4576