Yale Forklift G813 (GP080-120VX, GLP080-120VX, GDP080-120VX) Service Manual PDF

Yale Forklift G813 (GP080-120VX, GLP080-120VX, GDP080-120VX) Service Manual – PDF DOWNLOAD

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Yale Forklift G813 (GP080-120VX, GLP080-120VX, GDP080-120VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4598
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift G813 (GP080-120VX, GLP080-120VX, GDP080-120VX) 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
524223764 1600YRM1133 (07 2013) US EN 2191
toc 2191
Steering Axle 2191
Safety Precautions Maintenance and Repair 2192
General 2195
Steering Axle Assembly Repair 2197
Remove 2197
Disassemble 2198
Clean 2206
Inspect 2206
Assemble 2206
Install 2212
Spindles, Bearings, and Tie Rods Repair 2214
Spindles and Bearings 2214
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2214
Remove 2214
Disassemble 2216
Clean 2217
Inspect 2217
Assemble 2217
Install 2218
Spindles and Bearings 2221
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2221
Remove and Disassemble 2221
Assemble and Install 2222
Tie Rods 2222
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2222
Remove 2222
Install 2223
Tie Rods 2224
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2224
Remove 2224
Install 2230
Steering Cylinder Repair 2230
Remove and Disassemble 2230
Clean and Inspect 2231
Assemble and Install 2231
Torque Specifications 2232
524223766 1900YRM1136 (11 2017) US EN 2237
General 2241
Hydraulic Gear Pump Assembly 2242
Variable Displacement Pump Assembly 2243
Single Gear Pump Assembly Repair 2243
Remove 2243
Disassemble 2250
Clean 2250
Inspect 2252
Assemble 2252
Install 2252
Tandem Gear Pump Assembly 2256
Remove 2257
Disassemble 2259
Clean 2261
Inspect 2261
Assemble 2261
Install 2262
Gear Pump Specifications 2262
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2268
Remove 2268
Disassemble 2278
Clean 2281
Inspect 2281
Assemble 2281
Install 2282
63 0 cc/rev – Variable Displacement Pump Repair 2285
Remove 2285
Disassemble 2288
Clean 2288
Inspect 2288
Assemble 2290
Install 2290
Variable Displacement Pump Checks and Adjustments (Single Pump) 2292
Margin Pressure Check 2292
Flow Compensator Adjustment 2293
Pressure Compensator Adjustment 2293
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2294
Variable Displacement Pump Specifications 2297
Torque Specifications 2298
Hydraulic Gear Pump 2299
Variable Displacement Pump 2300
Special Tools 2300
524223767 2000YRM1137 (01 2017) US EN 2305
General 2311
Electro-Hydraulic Main Control Valve 2312
Description 2312
Remove 2320
Electro-Hydraulic Control Valve Sections 2325
General 2325
Outlet Control Valve Section 2325
Remove 2325
Disassemble 2326
Clean 2328
Inspect 2328
Assemble 2328
Install 2329
Auxiliary Control Valve Sections 2329
Remove 2329
Disassemble 2336
Clean 2337
Inspect 2338
Assemble 2338
Install 2340
Tilt Control Valve Section 2341
Remove 2341
Disassemble 2341
Clean 2347
Inspect 2347
Assemble 2347
Install 2348
Lift/Lower Control Valve Section 2349
Remove 2349
Disassemble 2349
Clean 2358
Inspect 2358
Assemble 2358
Install 2359
Mid-Inlet Section 2359
Remove 2359
Clean 2360
Inspect 2360
Install 2360
Install 2360
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2365
Lift Pilot Pin 2365
Lower Pilot Pin 2369
Abnormal/Erroneous EHPV Adjustment 2371
Manual Main Control Valve 2372
Description 2372
Remove 2376
OPS Solenoid Assembly 2384
General 2384
Remove 2385
Clean and Inspect 2388
Install 2388
Manual Control Valve Sections 2389
General 2389
Outlet Control Valve Section 2389
Remove 2389
Disassemble 2389
Clean 2392
Inspect 2392
Assemble 2392
Install 2393
Auxiliary Control Valve Sections 2393
Remove 2393
Disassemble 2393
Clean 2396
Inspect 2396
Assemble 2396
Install 2397
Lift/Tilt Control Valve Section 2397
Remove 2397
Disassemble 2397
Clean 2404
Inspect 2404
Assemble 2405
Install 2406
Mid-Inlet Section 2407
Remove 2407
Clean 2407
Inspect 2407
Install 2407
Install 2408
Pressure Relief Valve Check and Adjustment 2414
Primary Relief Valve 2415
Secondary Relief Valve 2419
Steering Control Unit Repair 2426
Steering Control Unit, Remove 2426
Steering Control Unit, Disassemble 2430
Steering Control Unit, Clean 2432
Steering Control Unit, Inspect 2432
Steering Control Unit, Assemble 2432
Relief Valve, Disassemble 2433
Relief Valve, Clean 2433
Relief Valve, Inspect 2434
Relief Valve, Assemble 2434
Steering Control Unit, Install 2434
524223768 2100YRM1139 (02 2014) US EN 2439
524223769 2200YRM1128 (01 2023) US EN 2487
Series Code / Model Designation Reference Table 2495
General 2497
Deutsch Crimping Tool 2498
How to Strip a Wire for Use With Deutsch Crimping Tool 2498
How to Crimp With the Deutsch Crimping Tool 2499
Calibration Test for the Deutsch Crimping Tool 2501
Deutsch Connectors 2503
DT, DTM, and DTP Series Connectors 2503
HD Series Connectors 2546
Metri-Pack Connectors 2568
Remove and Install 2568
Micro-Pack Connectors 2571
Weather-Pack Connectors 2572
AMPSEAL Crimping Tools 2574
AMP Hand Crimping Tool With Certi-Crimp 2574
Description 2574
Stripping Wire for Use with AMP Hand Crimping Tool 2575
Insulation Crimp Adjustment 2576
Maintenance and Inspection for AMP Hand Crimping Tool 2576
AMP Hand Crimping Tool 2576
Crimp Height Inspection 2576
How to use AMP Hand Crimping Tool 2577
AMP Pro-Crimper II Tool 2577
Description 2577
Remove and Install Die Set and Locator Assembly 2578
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2578
Contact Support Adjustment 2579
Crimp Height Adjustment 2580
Maintenance and Inspection Procedures 2580
PRO-CRIMPER II Tool 2580
Crimp Height Inspection 2580
How to Use AMP PRO-CRIMPER II Tool 2581
AMPSEAL Connector Assemblies 2582
Description for Plug Connector Assembly 2582
Seal Plug 2583
Contact Crimping 2583
Description for Plug Connector and Header Assembly 2588
Voltage Reading 2591
Seal Plug 2591
Contact Crimping 2591
AMP Superseal 1 5 Crimping Tools 2598
Mini Mic Receptacle and Tab Contacts 2598
Description 2598
Crimping Conditions and Measurements 2598
Insertion of Rubber Seal on Cable 2600
AMP Hand Application Tool 2605
Description 2605
Maintenance and Inspection 2605
Crimp Height Inspection 2605
Crimp Height Adjustment 2606
How to Use AMP Hand Application Tool 2606
AMP Pro-Crimper II Tool 2607
Description 2607
Remove and Install Die Set and Locator Assembly 2607
Adjustments 2608
Contact Support 2608
Crimp Height 2609
Inspections and Maintenance 2610
Crimp Height Inspection 2610
Visual Inspection 2610
Maintenance 2611
How to Use Pro-Crimper II Tool 2611
AMP Superseal 1 5 Connector Assemblies 2612
Description 2612
Repair and Maintenance 2619
Panel Mount Option 2619
AMP Fastin-Faston Hand Tools 2620
Description – AMP Double Action Hand Tool 2620
Maintenance and Inspection Procedures 2620
Daily Maintenance 2620
Periodic Tool Inspection 2621
Lubrication 2621
Visual Inspection 2621
Crimp Height Inspection 2621
Certi-Crimp Ratchet Inspection 2622
How to Use AMP Double Action Hand Tool 2623
Description – AMP Extraction Tool 2624
Maintenance and Inspection 2625
How to Use AMP Extraction Tool 2625
AMP Fastin-Faston Receptacles and Housings 2627
Description 2627
Wire Repair 2635
Wire Splicing Requirements 2635
Deutsch Jiffy Splice 2636
Twisted/Shielded Cable and Leads Repair 2642
Special Tools 2644
524223769 2200YRM1128 (07 2020) US EN 2653
Series Code / Model Designation Reference Table 2659
General 2662
Deutsch Crimping Tool 2662
How to Strip a Wire for Use With Deutsch Crimping Tool 2662
How to Crimp With the Deutsch Crimping Tool 2663
Calibration Test for the Deutsch Crimping Tool 2665
Deutsch Connectors 2667
DT, DTM, and DTP Series Connectors 2667
HD Series Connectors 2709
Metri-Pack Connectors 2732
Remove and Install 2732
Micro-Pack Connectors 2734
Weather-Pack Connectors 2735
AMPSEAL Crimping Tools 2737
AMP Hand Crimping Tool With Certi-Crimp 2737
Description 2737
Stripping Wire for Use with AMP Hand Crimping Tool 2737
Insulation Crimp Adjustment 2738
Maintenance and Inspection for AMP Hand Crimping Tool 2738
AMP Hand Crimping Tool 2738
Crimp Height Inspection 2738
How to use AMP Hand Crimping Tool 2739
AMP Pro-Crimper II Tool 2739
Description 2739
Remove and Install Die Set and Locator Assembly 2740
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2741
Contact Support Adjustment 2741
Crimp Height Adjustment 2742
Maintenance and Inspection Procedures 2742
PRO-CRIMPER II Tool 2742
Crimp Height Inspection 2742
How to Use AMP PRO-CRIMPER II Tool 2743
AMPSEAL Connector Assemblies 2744
Description for Plug Connector Assembly 2744
Seal Plug 2745
Contact Crimping 2745
Description for Plug Connector and Header Assembly 2750
Voltage Reading 2752
Seal Plug 2752
Contact Crimping 2752
AMP Superseal 1 5 Crimping Tools 2759
Mini Mic Receptacle and Tab Contacts 2759
Description 2759
Crimping Conditions and Measurements 2759
Insertion of Rubber Seal on Cable 2761
AMP Hand Application Tool 2766
Description 2766
Maintenance and Inspection 2766
Crimp Height Inspection 2766
Crimp Height Adjustment 2767
How to Use AMP Hand Application Tool 2767
AMP Pro-Crimper II Tool 2768
Description 2768
Remove and Install Die Set and Locator Assembly 2769
Adjustments 2769
Contact Support 2769
Crimp Height 2770
Inspections and Maintenance 2771
Crimp Height Inspection 2771
Visual Inspection 2771
Maintenance 2772
How to Use Pro-Crimper II Tool 2772
AMP Superseal 1 5 Connector Assemblies 2773
Description 2773
Repair and Maintenance 2780
Panel Mount Option 2780
AMP Fastin-Faston Hand Tools 2781
Description – AMP Double Action Hand Tool 2781
Maintenance and Inspection Procedures 2781
Daily Maintenance 2781
Periodic Tool Inspection 2782
Lubrication 2782
Visual Inspection 2782
Crimp Height Inspection 2782
Certi-Crimp Ratchet Inspection 2783
How to Use AMP Double Action Hand Tool 2784
Description – AMP Extraction Tool 2785
Maintenance and Inspection 2785
How to Use AMP Extraction Tool 2786
AMP Fastin-Faston Receptacles and Housings 2787
Description 2787
Wire Repair 2794
Wire Splicing Requirements 2794
Deutsch Jiffy Splice 2795
Twisted/Shielded Cable and Leads Repair 2800
Special Tools 2803
524223770 2200YRM1130 (03 2020) US EN 2811
General 2815
Description 2815
Dash Display Menu Access 2815
Menu Navigation 2816
Standard Display 2816
Main Menu 2816
Passwords Menu 2817
Password Administration 2817
Add Password 2817
Delete Password 2818
Edit Password 2818
Other Password Functions 2819
Operator Passwords – Enable/Disable 2819
Password Time-Out Delay 2819
Passwords – Number Wrong to Disable 2820
Lockout Reset Password 2820
View Password Log 2821
View Versions 2822
VSM Versions 2822
Dash Display Versions 2823
Engine Controller Version 2824
Transmission (Xmsn) Controller Version 2825
Truck Serial Number 2826
Diagnostics 2827
View Fault Log 2827
Set Travel and Braking 2828
Speed Limit 2828
Acceleration Rate 2829
Auto-Deceleration Rate 2829
Set Power Reversal Rate 2830
Set Inching/Brake Overlap 2831
Setup Display Menu 2832
Set Operator Language 2832
Set Units 2833
Set Time Format (12/24 Hour) 2833
Set Daylight Saving Time 2833
Set Time 2836
Set Date Format 2837
Set Date 2837
Setup Hydraulics 2838
Return to Set Tilt Delay/On/Off 2838
Setup General Items 2839
Light Shutdown Time-Out 2839
Impact Sensor – Enable/Disable 2840
Impact Sensor – Soft Impact Settings 2841
Impact Sensor – Hard Impact Settings 2842
Adjust Impact Sensor Settings 2842
Initial Adjustment of Soft and Hard Impact Settings 2844
Readjustment of Soft and Hard Impact Settings 2844
Impact Sensor – Impact Alarm/Shutdown Reset 2845
Impact Sensor – Alarm Time Duration and Deactivation 2846
Impact Sensor – View Impact Event Log 2847
Engine Mode Indicator 2848
Generation 1 (ECO-eLo ONLY) 2848
Generation 2 2849
Operator Checklist 2850
Operator Checklist Off-On Mode 2850
Edit Operator Checklist 2850
Set Operator Checklist Expiration 2851
View Checklist Log 2851
Clear Operator Checklist Log 2852
Clear Operator Checklist Fault 2852
Calibrations 2853
Set Tilt Stop Point 2853
Calibrate Loaded Weight 2853
524223771 2200YRM1131 (03 2020) US EN 2855
Series Code / Model Designation Reference Table 2861
General 2863
Description 2863
Dash Display Menu Access 2863
Menu Navigation 2864
Main Menu 2864
Passwords 2865
Adding Passwords 2865
Hourmeters 2867
View Versions 2868
VSM Versions 2868
Dash Display Versions 2869
Engine Controller Version 2870
Transmission (Xmsn) Controller Version 2871
Truck Serial Number 2872
Truck Configuration 2873
Diagnostics 2874
Clear Fault Log 2874
View Fault Log 2875
No-Run Data Display 2876
Engine Accelerator and Throttle Data Display 2876
Engine Speeds and Governor Data Display 2877
Engine Fuel and Emissions Data Display 2878
Engine General Data Display 2880
XMSN/Brake Data Display 2881
Hydraulic Data Display 2884
General Truck Data Display 2886
Set Travel and Braking 2887
Speed Limit 2887
Acceleration Rate 2888
Auto-Deceleration Rate 2889
Set Power Reversal Rate 2889
Set Inching/Brake Overlap 2890
Setup Hydraulics 2890
Lift Maximum Speed 2891
Lower Maximum Speed 2891
Tilt Maximum Speed 2892
Auxiliary Function One, Direction A, Maximum Speed 2894
Auxiliary Function One, Direction B, Maximum Speed 2896
Auxiliary Function Two, Direction A, Maximum Speed 2896
Auxiliary Function Two, Direction B, Maximum Speed 2897
Auxiliary Function Three, Direction A, Maximum Speed 2898
Auxiliary Function Three, Direction B, Maximum Speed 2898
Lift/Lower Ramp Rate 2899
Hydraulic Auxiliary Ramp Rate 2899
Return to Set Tilt Delay/On/Off 2900
Hydraulic Input Device 2901
Auxiliary Solenoid 2901
Dual Function 2902
Setup Display 2903
Set Service Language 2903
Setup General Items 2903
Motion Alarm Activation Type 2904
Light Shutdown Time-Out 2905
Restore Default Settings 2905
Restore Engine Controller Default Calibration 2906
Impact Sensor – Enable/Disable 2906
Impact Sensor – Soft Impact Settings 2907
Impact Sensor – Hard Impact Settings 2908
Adjust Impact Sensor Settings 2909
Initial Adjustment of Soft and Hard Impact Settings 2911
Readjustment of Soft and Hard Impact Settings 2911
Impact Sensor – Impact Alarm/Shutdown Reset 2912
Impact Sensor – Alarm Time Duration and Deactivation 2913
Impact Sensor – View Impact Event Log 2914
Engine Mode Indicator 2914
Generation 1 (ECO-eLo ONLY) 2914
Generation 2 2915
Diesel Particulate Filter (DPF) Display 2916
General Description 2916
Passive Regeneration Only 2916
Regeneration Level 0 2916
Auto/Active Regeneration Inhibited 2917
Auto/Active Regeneration 2917
Regeneration Level 1 2917
Parked Regeneration Request 2918
Regeneration Level 2 2918
Warning Level 2918
Regeneration Level 3 2918
Service Level 2919
Regeneration Level 4 2919
Display, Diesel Particulate Filter (DPF), Revised 2919
Operator Interface 2919
Refer to Operator Manual 2919
CAN Communication Lost 2920
Passive Regeneration Only 2920
Regeneration Level 0 2920
Auto/Active Regeneration Inhibited 2920
Auto/Active Regeneration 2921
Regeneration Level 1 2921
Idle-up Auto/Active Regeneration 2921
Parked Regeneration Request 2921
Regeneration Level 2 2921
Warning Level 2923
Regeneration Level 3 2923
Service Level 2923
Regeneration Level 4 2923
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2923
Display, Diesel Particulate Filter (DPF), Stage V Engine 2923
Operator Interface 2924
Refer to Operator Manual 2924
CAN Communication Lost 2924
Passive Regeneration Only 2924
Regeneration Level 0 2924
Auto/Active Regeneration Inhibited 2925
Auto/Active Regeneration 2925
Regeneration Level 1 2925
Idle-up Auto/Active Regeneration 2926
Parked Regeneration Request 2926
Regeneration Level 2 2926
Warning Level 2927
Regeneration Level 3 2927
Service Level 2928
Regeneration Level 4 2928
Stage V Content 2928
Emissions System Malfunction 2928
Ash Load 2928
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2929
Operator Interface 2929
Refer to Operator Manual 2929
CAN Communication Lost 2930
Passive Regeneration Only 2930
Regeneration Level 0 2930
Auto/Active Regeneration Inhibited 2930
Auto/Active Regeneration 2931
Regeneration Level 1 2931
Idle-up Auto/Active Regeneration 2931
Parked Regeneration Request 2931
Regeneration Level 2 2931
Warning Level 2933
Regeneration Level 3 2933
Service Level 2933
Regeneration Level 4 2933
Calibrations 2934
Calibrate Transmission Valve 2936
Set Tilt Stop Point 2936
Calibrate Loaded Weight 2936
Calibrate Travel Speed Sensor 2937
Calibrate Mazda LP and Gas Accelerator Pedal 2937
524223772 2200YRM1142 (01 2020) US EN 2939
General 2949
Display Switch Cluster 2952
Remove 2952
Install 2955
Direction Control and Turn Signal Levers 2955
Remove 2955
Install 2957
Key Switch 2957
Remove 2957
Install 2958
Display Switch Cluster Panel Bezel and Overlay 2958
Remove 2958
Install 2958
Steering Column Repair 2958
Remove 2958
Disassemble 2961
Assemble 2961
Install 2961
Sensors and Switches 2962
General 2962
Dash and Kick Panel, Remove and Install 2962
Remove 2962
Install 2963
Accelerator Pedal Position Sensor 2964
Remove 2964
Install 2967
Brake Fluid Level Switch 2968
Remove 2968
Install 2970
Service Brake Pedal Position Sensor 2971
Remove 2971
Install 2974
Parking Brake Sensor 2975
Remove 2975
Install 2976
Service Brake Pressure Sensor 2977
Remove 2977
Install 2979
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2980
Remove 2980
Install 2980
Sensor Microswitch (Foot Directional Control Pedal) 2981
Remove 2981
Install 2984
Low Coolant Level Sensor 2985
Remove 2985
Install 2988
Fuel Level Sensor, Gas and Diesel Engines Only 2989
Remove 2989
Install 2990
Armrest Switch 2990
Remove 2990
Install 2992
Seat Sensor (Operator Presence System) 2992
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) 2992
Remove 2992
Install 2993
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2993
Remove 2993
Install 2994
Full Suspension Seats; All Lift Truck Models 2994
Remove 2994
Install 2994
Hood Shut Off Switch 2994
Remove 2994
Install 2997
Remote Key Switch 2998
Remove 2998
Install 2998
Hydraulic Filter Pressure Switch 2999
Remove 2999
Install 3001
Transmission Speed Sensor 3001
Remove 3001
Install 3004
Transmission Pressure Sensors 3005
Remove 3005
Install 3007
Transmission Temperature Sensor 3008
Remove 3008
Install 3010
Engine Speed Sensor 3012
Remove 3012
Install 3012
Intermediate Speed Sensor 3013
Remove 3013
Install 3013
Return to Set Tilt (Tilt Angle) Sensor 3013
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) 3013
Remove 3013
Install 3014
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) 3015
Remove 3015
Install 3016
Rear Horn Button Switch 3016
Remove 3016
Install 3017
Impact Sensor 3018
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) 3018
Remove 3018
Install 3021
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) 3021
Remove 3021
Install 3022
Load Weight Sensor 3023
Remove 3023
Install 3024
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3025
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3025
Crankshaft Position (CKP) Sensor 3025
Camshaft Position (CMP) Sensor 3025
Oil Pressure Sensor 3025
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3025
Engine Coolant Temperature (ECT) Sensor 3026
Air Flow Restriction Switch 3026
Remove for GM 2 4L Gas and LPG Trucks 3026
Install for GM 2 4L Gas and LPG Trucks 3026
Oxygen Sensor 3027
Remove 3027
Install 3030
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3031
Crankshaft Position (CKP) Sensor 3031
Camshaft Position (CMP) Sensor 3031
Oil Pressure Sensor 3031
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3031
Engine Coolant Temperature (ECT) Sensor 3031
Air Flow Restriction Switch 3031
Oxygen Sensor 3031
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3031
Low LPG Pressure Switch 3031
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3032
Air Filter Restriction Switch 3032
Remove 3032
Install 3032
Oil Pressure Sensor 3032
Remove 3032
Install 3032
Engine Speed Sensor 3032
Remove 3032
Install 3032
Engine Coolant Temperature (ECT) Sensor 3032
Remove 3032
Install 3032
Throttle Position Sensor (TPS) 3035
Remove 3035
Install 3036
Fuel/Water Separator Sensor 3036
Remove 3036
Install 3036
Glow Plug Relay 3037
Remove 3037
Install 3039
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3039
Air Filter Restriction Switch 3039
Remove 3039
Install 3039
Engine Oil Pressure Sensor 3044
Remove 3044
Install 3044
Engine Speed Sensor 3044
Remove 3044
Install 3045
Engine Coolant Temperature (ECT) Sensor 3045
Remove 3045
Install 3046
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3047
Remove 3047
Install 3047
Fuel/Water Separator Sensor 3048
Remove 3048
Install 3048
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3049
Intake Air Temperature Sensor 3049
Remove 3049
Install 3050
Intake Air Pressure Sensor 3050
Remove 3050
Install 3050
Air Inlet Heater 3050
Remove 3050
Install 3051
Engine Oil Pressure Sensor 3051
Remove 3051
Install 3051
Engine Coolant Temperature (ECT) Sensor 3051
Remove 3051
Install 3051
Crankshaft Position Sensor 3052
Remove 3052
Install 3052
Adjust Shim Procedure 3053
Camshaft Position Sensor 3054
Remove 3054
Install 3054
Air Flow Restriction Sensor 3055
Remove 3055
Install 3055
Fuel/Water Separator 3055
Remove 3055
Install 3056
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3056
Intake Air Temperature Sensor 3060
Remove 3060
Install 3061
Boost Sensor 3061
Remove 3061
Install 3062
Throttle Valve Assembly and Air Intake Heater 3062
Remove 3062
Install 3062
Engine Coolant Temperature (ECT) Sensor 3063
Remove 3063
Install 3063
Engine Oil Pressure Sensor 3063
Remove 3063
Install 3064
Crankshaft Position Sensor 3064
Remove 3064
Install 3064
Adjust Shim Procedure 3065
Camshaft Position Sensor 3066
Remove 3066
Install 3067
Differential Pressure Sensor 3067
Remove 3067
Install 3067
Mass Air Flow Sensor 3068
Remove 3068
Install 3069
Fuel/Water Separator 3069
Remove 3069
Install 3070
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3070
Engine Coolant Temperature (ECT) Sensor 3071
Remove 3071
Install 3071
Throttle Position Sensor 3072
Engine Oil Pressure Sensor 3072
Remove 3072
Install 3072
Engine Speed Sensor 3072
Remove 3072
Install 3072
Fuel Shut Off Solenoid 3072
Remove 3072
Install 3072
Vehicle System Manager (VSM) 3073
General 3073
VSM Replacement 3073
Remove 3073
Install 3075
Programming a New VSM and/or Display Switch Cluster 3075
General 3075
PC Service Tool Software 3076
Data Transferring 3076
New VSM 3076
New (Blank) Display Switch Cluster 3076
Used (Non-Blank) Display Switch Cluster 3076
Power Distribution Module (PDM) and Component Parts 3078
Remove 3078
PDM as a Unit 3078
Install 3082
PDM as a Unit 3082
Remove and Install 3083
PDM Component Parts 3083
Transmission Control Unit 3083
Remove 3083
Install 3087
Battery 3089
Remove 3089
Install 3089
Lights 3090
Work Lights (Front and Rear) 3090
Remove 3090
Install 3090
Strobe Light 3091
Remove 3091
Install 3091
LED Tail, Backup, and Brake Lights 3092
Remove 3092
Install 3093
Front Marker/Turn Signal Lights 3094
Replacing Whole Front Marker/Turn Signal Light Assembly 3094
Remove 3094
Install 3094
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3095
Remove 3095
Install 3095
Diesel Particulate Filter (DPF) Display 3095
Remove 3095
Clean and Inspect 3096
Install 3096
Electronic-Hydraulic Controls – Generation 1 3097
E-Hydraulic Controls – Test 3097
Mini-Levers 3097
Full Stroke Test 3097
Function Returns to Neutral Test 3097
Push Button Switch 3097
General 3098
Mini-Lever Replacement 3098
Remove 3098
Clean and Inspect 3099
Install 3099
Push Button Switch Replacement 3100
Remove 3100
Install 3102
Mini-Lever Module (MLM) 3102
Remove 3102
Install 3102
Joystick 3103
Remove and Disassemble 3103
Inspect 3103
Assemble and Install 3103
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3104
General 3104
Mini-levers, Remove and Install 3104
Armrest Assembly 3105
Remove 3105
Install 3108
Horn Button 3108
Remove 3108
Install 3108
Direction Control Switch 3109
Remove 3109
Install 3109
push (override) buttons and Toggle Switch 3109
Remove 3110
Install 3111
Joystick 3112
Remove and Disassemble 3112
Inspect 3112
Assemble and Install 3112
Joystick Armrest Slider Assembly 3113
Remove 3113
Install 3114
Electronic-Hydraulic Controls, After January, 2020 3114
E-Hydraulic Controls – TEST 3114
Mini-Levers 3114
Full Stroke Test 3114
Function Returns to Neutral Test 3114
Push (Override) Button 3115
General 3115
Mini-levers, Remove and Install 3115
Armrest Assembly 3116
Remove 3116
Install 3119
Horn Button 3119
Remove 3119
Install 3119
Direction Control Switch 3119
Remove 3119
Install 3120
Push (Override) buttons and Toggle Switch 3120
Remove 3121
Install 3123
Special Tools 3124
524223780 8000YRM1134 (05 2022) US EN 3127
Series Code / Model Designation Reference Table 3133
Description 3136
Proc_Cal_001: Service Password Entry 3138
When to Perform 3138
Why Perform 3138
How to Perform 3138
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3139
When to Perform 3139
Calibration Order 3139
Why Perform 3139
How to Perform 3139
Proc_Cal_003: Save and Exit 3141
When to Perform 3141
Why Perform 3141
How to Perform 3141
Proc_Cal_004: Lift Valve Output Threshold 3142
When to Perform 3142
Calibration Order 3142
Why Perform 3142
How to Perform 3142
Proc_Cal_005: Lower Valve Output Threshold 3145
When to Perform 3145
Calibration Order 3145
Why Perform 3145
How to Perform 3145
Proc_Cal_006: Tilt Back Valve Output Threshold 3148
When to Perform 3148
Calibration Order 3148
Why Perform 3148
How to Perform 3148
Proc_Cal_007: Tilt Forward Valve Output Threshold 3151
When to Perform 3151
Calibration Order 3151
Why Perform 3151
How to Perform 3151
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3154
When to Perform 3154
Calibration Order 3154
Why Perform 3154
How to Perform 3154
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3157
When to Perform 3157
Calibration Order 3157
Why Perform 3157
How to Perform 3157
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3160
When to Perform 3160
Calibration Order 3160
Why Perform 3160
How to Perform 3160
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3163
When to Perform 3163
Calibration Order 3163
Why Perform 3163
How to Perform 3163
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3166
When to Perform 3166
Calibration Order 3166
Why Perform 3166
How to Perform 3166
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3169
When to Perform 3169
Calibration Order 3169
Why Perform 3169
How to Perform 3169
Proc_Cal_014: Load Weight Zero Point 3172
When to Perform 3172
Calibration Order 3172
Why Perform 3172
How to Perform 3172
Proc_Cal_015: Loaded Weight Calibration 3174
When to Perform 3174
Calibration Order 3174
Why Perform 3174
How to Perform 3174
Proc_Cal_016: Transmission Valve Calibration 3177
Applicable System/Option 3177
When to Perform 3177
Calibration Order 3177
Why Perform 3177
How to Perform 3177
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3179
Applicable System/Option 3179
When to Perform 3179
Calibration Order 3179
Why Perform 3179
How to Perform 3179
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3182
Applicable System/Option 3182
When to Perform 3182
Calibration Order 3182
Why Perform 3182
How to Perform 3182
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3185
Required Tools 3185
When to Perform 3185
Calibration Order 3185
Why Perform 3185
How to Perform 3185
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3187
When to Perform 3187
Why Perform 3187
How to Perform 3187
Proc_Cal_026: Travel Speed Calibration 3189
When to Perform 3189
Calibration Order 3189
Why Perform 3189
How to Perform 3189
524262274 0100YRM1243 (11 2016) US EN 3193
General 3197
Description 3198
Hood, Seat, and Side Covers Replacement 3200
Remove 3200
Install 3200
Steering Column 3207
Description 3208
Steering Column Repair 3208
Remove 3208
Disassemble 3210
Clean 3213
Inspect 3213
Assemble 3213
Install 3213
LPG Tank and Bracket Replacement 3214
Counterweight Replacement 3214
Remove 3214
Install 3217
Tow Pin 3221
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) 3221
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) 3221
Overhead Guard Replacement 3222
Remove 3222
Install 3223
LED Tail, Backup, and Brake Lights, Replace 3223
Operator Restraint System Replacement 3224
Description 3224
Engine Replacement 3225
Remove Engine Only 3225
Install Engine only 3252
Remove Engine and Transmission 3255
Install Engine and Transmission 3259
Electronic Throttle Replacement 3263
Cummins 4 5L Diesel Engine With Electronic Throttle 3263
Remove 3263
Install 3266
Pull Actuator Linkage Adjustment 3268
Low Idle Adjustment 3268
Throttle Pedal and Cable Adjustment 3269
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3269
Kubota 3 6L Diesel Engine 3269
Exhaust System Repair 3272
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) 3272
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) 3272
Remove 3272
Inspect 3272
Install 3274
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) 3274
Remove 3274
Inspect 3276
Install 3276
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 3276
Remove 3276
Inspect 3278
Install 3278
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) 3278
Remove 3278
Inspect 3281
Diesel Particulate Filter 3283
Disassemble 3283
CLEAN AND INSPECT 3284
Assembly 3284
Install 3285
Cooling System 3286
Description 3286
Hydraulic Filter Assembly Repair 3287
Remove 3287
Disassemble 3287
Clean 3288
Inspect 3288
Assemble 3288
Install 3288
Fuel and Hydraulic Tanks Repair 3288
Inspect 3288
Clean 3289
Steam Method of Cleaning 3289
Chemical Solution Method of Cleaning 3290
Additional Preparations for Repair 3290
Small Leaks, Repair 3290
Large Leaks, Repair 3290
Preparations for Use After Repair 3290
Safety Labels 3290
524262275 0900YRM1242 (04 2018) US EN 3301
General 3307
Hoses Replacement 3307
LPG Tank and Bracket Replacement 3308
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) 3308
Remove 3308
Install 3311
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) 3312
Remove 3312
Install 3312
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) 3312
Remove 3312
Install 3314
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3315
Remove 3315
Install 3317
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3317
Remove 3317
Install 3317
High Pressure Fuel Filter Unit Repair 3317
Fuel Filter Element 3318
Remove 3318
Clean/Inspect 3319
Install 3319
Fuel Filter Housing 3319
Remove 3319
Disassemble 3320
Assemble 3320
Install 3320
Electronic Throttle Body Repair 3321
Remove 3321
Clean/Inspect 3322
Install 3322
Fuel Injector Repair 3323
Fuel Rail 3323
Remove for Lift Trucks Built Before January, 2010 3323
Remove for Lift Trucks Built After January, 2010 3325
Install for Lift Trucks Built Before January, 2010 3326
Install for Lift Trucks Built After January, 2010 3327
Fuel Injectors and Adapters 3327
Remove for Lift Trucks Built Before January, 2010 3327
Remove for Lift Trucks Built After January, 2010 3329
Clean 3330
Install for Lift Trucks Built Before January, 2010 3330
Install for Lift Trucks Built After January, 2010 3332
LPG Regulator Repair 3332
LPG Regulator 3332
Remove for Lift Trucks Built Before January, 2010 3332
Remove for Lift Trucks Built After January, 2010 3333
Install for Lift Trucks Built Before January, 2010 3335
Install for Lift Trucks Built After January, 2010 3335
LPG Regulator Fuel Filter 3336
Remove 3336
Install 3337
Lock-Off Solenoid and Cartridge 3337
Remove 3337
Install 3338
Control System 3338
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3338
Remove 3338
Install 3339
Electronic Control Unit (ECU) 3340
Remove 3340
Install 3340
Injector Driver Modules 3341
Remove 3341
Install 3341
Fuel Pressure Sensor 3342
Remove 3342
Install 3342
Low LPG Pressure Switch 3342
Remove 3342
Install 3343
LPG Pressure Sensor 3343
Remove 3343
Install 3344
Oxygen Sensor 3344
Exhaust System Repair 3345
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3345
Remove for Lift Trucks Built Before January, 2010 3345
Remove for Lift Trucks Built After January, 2010 3347
Inspect 3349
Install for Lift Trucks Built Before January, 2010 3349
Install for Lift Trucks Built After January, 2010 3349
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) 3350
Remove for Lift Trucks Built Before January, 2010 3350
Remove for Lift Trucks Built After January, 2010 3352
Inspect 3355
Install for Lift Trucks Built Before January, 2010 3355
Install for Lift Trucks Built After January, 2010 3356
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3357
Remove for Lift Trucks Built Before January, 2010 3357
Remove for Lift Trucks Built After January, 2010 3360
Inspect 3361
Install for Lift Trucks Built Before January, 2010 3362
Install for Lift Trucks Built After January, 2010 3362
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3363
Remove for Lift Trucks Built Before January, 2010 3363
Remove for Lift Trucks Built After January, 2010 3366
Inspect 3367
Install for Lift Trucks Built Before January, 2010 3368
Install for Lift Trucks Built After January, 2010 3368
Oxygen Sensor 3369
Remove 3369
Install 3370
LPG Fuel Testing 3370
General 3370
Available Fuel Tests 3370
Composition Test (ASTM D-2163) 3370
Ammonia Test (ASTM D-4490) 3371
Basic Nitrogen Test (ASTM UOP269-90) 3371
Residues Test (ASTM D-2158) 3371
Vapor Pressure Test (ASTM D-2598) 3371
Sulfur Compounds Test (ASTM D-5623) 3371
Methanol Test (ASTM D-4864) 3371
Copper Corrosion (ASTM D-1838) 3371
Where To Send LPG Fuel Samples For Testing 3371
524262276 0900YRM1244 (06 2012) US EN 3375
toc 3375
Gasoline Fuel System 3375
Safety Precautions Maintenance and Repair 3376
General 3379
Electronic Throttle Body Repair 3379
Electronic Throttle Body 3379
Remove 3379
Clean/Inspect 3379
Install 3380
Fuel System Repair 3381
Before Repair Procedure 3381
After Repair Procedure 3381
Fuel Leakage Check for Lift Trucks Built Before January, 2010 3381
Fuel Leakage Check for Lift Trucks Built After January, 2010 3382
Fuel Line Pressure Check 3384
Fuel Injector Repair 3385
Remove 3385
Install 3395
Control System 3396
Electronic Control Unit (ECU) 3396
Remove for Lift Trucks Built Before January, 2010 3396
Remove for Lift Trucks Built After January, 2010 3397
Install for Lift Trucks Built Before January, 2010 3398
Install for Lift Trucks Built After January, 2010 3399
Exhaust System Repair 3400
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; ( 3400
Remove for Lift Trucks Built Before January, 2010 3400
Remove for Lift Trucks Built After January, 2010 3402
Inspect 3402
Install for Lift Trucks Built Before January, 2010 3404
Install for Lift Trucks Built After January, 2010 3404
GM 4 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45 3405
Remove for Lift Trucks Built Before January, 2010 3405
Remove for Lift Trucks Built After January, 2010 3407
Inspect 3409
Install for Lift Trucks Built Before January, 2010 3409
Install for Lift Trucks Built After January, 2010 3410
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (G 3411
Remove for Lift Trucks Built Before January, 2010 3411
Remove for Lift Trucks Built After January, 2010 3413
Inspect 3415
Install for Lift Trucks Built Before January, 2010 3415
Install for Lift Trucks Built After January, 2010 3416
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (G 3416
Remove for Lift Trucks Built Before January, 2010 3416
Remove for Lift Trucks Built After January, 2010 3419
Inspect 3419
Install for Lift Trucks Built Before January, 2010 3421
Install for Lift Trucks Built After January, 2010 3421
Oxygen Sensor 3422
Remove 3422
Install 3422
524262277 1400YRM1245 (01 2012) US EN 3425
toc 3425
Drive Axle and Differential Assembly Repair 3425
Safety Precautions Maintenance and Repair 3426
General 3429
Drive Axle Repair 3429
Remove and Disassemble 3429
Clean and Inspect 3432
Assemble and Install 3432
Differential Repair 3434
Remove 3434
Support Differential Assembly From Differential Housing Assembly 3434
Differential Assembly From Differential Assembly Support 3436
Differential Assembly Support from Drop Box 3439
Drive Pinion and Pinion Gear, From Differential Assembly Support 3441
Disassemble 3442
Differential Assembly 3442
Drop Box Housing 3444
Differential Assembly Support 3445
Differential Housing 3446
Clean and Inspect 3447
Assemble 3447
Differential Housing 3447
Differential Assembly Support 3448
Drop Box Housing 3449
Differential Assembly 3450
Install 3454
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 3454
Drive Pinion and Pinion Gear Into Differential Assembly Support 3456
Differential Assembly Into Differential Assembly Support 3458
Ring Gear Backlash, Adjust 3461
Gear Set, Tooth Contact Pattern Check 3462
Differential Assembly Support Into Differential Housing 3465
Torque Specifications 3466
tables 3425
Table 1 Pinion Variation Numbers Examples 3455
Table 2 Ring and Pinion Tooth Contact Adjustment 3463
Table 3 Correct Tooth Contact 3463
Table 4 Incorrect Tooth Contact 3464
524262278 1400YRM1246 (02 2018) US EN 3469
General 3473
Identification Plate 3474
Drive Axle Removal 3474
Hub Seal Replacement 3486
Planetary Reduction Repair 3495
Clean and Inspect 3504
Brake Repair 3517
Clean and Inspect 3533
Wet Brake Noise Reduction 3549
General 3549
Adding Additive To Transmission 3550
Bevel Pinion 3551
Clean and Inspect 3556
Differential Unit 3568
Disassemble 3579
Clean and Inspect 3585
Assemble 3586
Drive Axle Installation 3609
Special Tools 3619
Torque Specifications 3619
524262279 1800YRM1247 (09 2018) US EN 3623
General 3627
Dry Brake System 3627
Wet Brake System 3628
Service Brakes Repair (Dry Brake) 3632
Remove and Disassemble 3632
Clean 3634
Inspect 3635
Assemble and Install 3635
Adjust 3639
Parking Brake Repair 3639
Dry Brake System 3640
Remove and Disassembly 3640
Assemble and Install 3642
Wet Brake System 3642
Remove and Install 3643
Assemble and Install 3649
Adjust 3649
Dry Brake System 3649
Wet Brake System 3650
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3650
Master Cylinder Repair 3651
Remove 3651
Disassemble 3656
Clean and Inspect 3657
Assemble 3658
Install and Adjust 3658
Accumulator 3660
Pre-Charge Check 3661
Remove 3662
Install 3664
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3664
Remove 3665
Modulating Brake Valve 3666
Disassemble 3666
Clean and Inspect 3668
Assemble 3668
Accumulator Charge Valve 3669
Disassemble 3669
Clean and Inspect 3671
Assemble 3671
Install 3672
Pressure Checks 3673
Accumulator Charge Valve Check 3673
Accumulator Check 3673
Service Brakes Adjustment (Dry Brake) 3674
Service Brakes Adjustment 3674
Brake System Air Removal 3675
Using Pressure Bleed System 3675
Using Brake Pedal Pressure 3676
Lift Truck Models with Master Cylinder 3676
Lift Truck Models with Modulating Brake Valve 3676
Brake Pedal Adjustment 3677
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) 3677
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3678
Free Pedal Adjustment 3680
Torque Specifications 3681
524262280 8000YRM1248 (12 2018) US EN 3685
General 3691
Serial Number Data 3691
How to Move Disabled Lift Truck 3692
How to Tow Lift Truck 3692
How to Put Lift Truck on Blocks 3694
How to Raise Drive Tires 3694
How to Raise Steering Tires 3694
How to Clean a Lift Truck 3695
Maintenance Schedule 3696
Maintenance Procedures Every 8 Hours or Daily 3716
How to Make Checks With Engine Stopped 3716
Tires and Wheels 3716
Safety Labels 3717
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3717
Operator Restraint System 3718
Emergency Locking Retractor (ELR) 3718
Adjust Seat – Full Suspension 3719
Adjust Seat – Internal Suspension 3720
Hood and Seat Latches 3721
Engine Compartment 3721
Paper Application 3721
Fuel, Oil, and Coolant Leaks, Check 3722
Hydraulic Hoses 3722
Coolant Hoses 3722
Steering Column Gas Cylinder 3722
Transmission 3723
Hydraulic System Oil 3723
Engine Oil 3723
Air Filter 3728
Forks 3728
Remove 3728
Inspect 3731
Install 3732
Adjust 3732
How to Make Checks With Engine Running 3732
Indicator Lights, Horn, Fuses, and Relays 3732
Service Brakes 3735
Brake Fluid Level 3735
Operation, Check 3735
Parking Brake 3736
Engine Oil Pressure 3736
Cooling System 3737
Steering System 3738
Control Levers and Pedals 3738
Lift System, Operate 3738
First Service After First 100 Hours of Operation 3738
GM 4 3L Engine Oil and Oil Filter 3738
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3739
Maintenance Procedures Every 250 Hours or 6 Months 3739
GM 4 3L Engine Oil and Oil Filter 3739
Drive Belt 3740
GM 4 3L Engine 3740
Fan and Alternator Drive Belt 3740
Drain Tar From LPG Converter 3740
Drain Tar From LPG Regulator 3741
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 3742
Maintenance Procedures Every 500 Hours or 6 Months 3744
Hydraulic System Oil 3744
Hydraulic Tank Breather 3745
Inspect 3745
Battery 3745
Cummins 4 5L and QSB 3 3L Engine Oil and Oil Filter 3746
Fuel/Water Separator Filter Replacement, Cummins 4 5L and QSB 3 3L Engine 3746
Remove 3746
Install 3746
Final Fuel Filter Replacement (Cummins QSB 3 3L Engine) 3750
Priming the Fuel System (Cummins 4 5L and QSB 3 3L Engine) 3751
Controlled Venting 3751
Manual Bleeding 3751
Drive Belt 3752
Cummins 4 5L and QSB 3 3L Diesel Engine 3752
Fan and Alternator Drive Belt 3752
Clean Debris From Radiator Core 3753
Transmission Oil Level 3753
Wet Brake Center Body Oil Level Check 3755
Forks 3756
Mast Lubrication 3756
Header Hose Checks 3760
Lift Chain Lubrication 3760
Tilt Cylinder Lubrication 3760
Master Brake Cylinder Rod End Pin Lubrication 3761
Manual Hydraulic Levers Lubrication 3762
Brake Oil 3762
Tie Rod Lubrication for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 3763
Tie Rod Lubrication for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 3763
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 3763
Parking Brake Adjustment 3764
Maintenance Procedures Every 1000 Hours or 6 Months 3765
Valve Clearance, Check and Adjust 3765
Ignition System 3765
GM 4 3L Engine 3765
LPG Fuel Filter Element Replace, GM 4 3L Engine 3765
Remove 3765
Install 3766
In-Line Filter Replacement, Cummins 4 5L Engine 3766
Remove 3766
Install 3767
Lift Chains Wear Check 3769
Lift Chain Lubrication 3769
Integral Sideshift Carriage, Check Sliding Surfaces 3769
Steering Axle (Spindle Bearings) for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) 3771
Steering Axle (Spindle Bearings) for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813) 3771
Control Levers and Pedals 3771
Parking Brake Lever Lubrication, Wet Brake Axle 3771
Normal Operating Environment 3772
Heavy Duty or Contaminated Environment 3773
Remove 3773
Clean and Inspect 3774
Install 3774
Inspect Engine Electrical System, Connectors 3775
Maintenance Procedures Every 2000 Hours or Annually 3775
Hydraulic System 3775
Hydraulic Filter, Replace 3775
Hydraulic Tank Breather, Replace 3776
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 3777
Cooling System 3777
Air Filter 3777
Oxygen Sensor GM 4 3L LPG Engines with GFI Installed 3779
LPG Regulator Fuel Filter, GM 4 3L Engines Equipped with GFI Installed 3780
Remove 3780
Install 3780
Gasoline Fuel Filter 3781
Remove and Replace for Lift Trucks Equipped with GFI 3781
Remove and Replace for Lift Trucks Equipped with PSI 3781
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 3782
Gasoline Fuel Injector, GM Engines 3782
Fuel Injector, Cummins 4 5L and QSB 3 3L Engine 3782
Forks 3782
Transmission Oil and Filter (Dry Brake), Replace 3782
Transmission and Wet Brake Planetary Carrier Housing Oil Change 3784
Wet Brake Center Section Oil Change 3787
Remove 3787
Install 3787
Brake Oil (Master Cylinder), Change 3788
Brake Oil (Dry Brake), Remove 3789
Service Brakes (Dry Brake) 3789
Differential (Dry Brake) 3790
Test LPG/GAS Regulator Pressure 3791
Test LPG Regulator Pressure 3791
Check Throttle Shaft for Sticking 3791
Inspect Exhaust Manifold and Piping for Leaks 3791
Valve Clearance, Check and Adjust for Cummins QSB 3 3L Diesel Engine 3791
Wheel Bearings 3792
Steer Wheels, Lubrication 3792
Maintenance Procedures Every 4000 Hours or 2 Years 3792
Hydraulic Oil, Replace 3793
Valve Clearance, Check and Adjust for Cummins 4 5L Diesel Engine 3794
Weld Inspection 3796
Safety Procedures When Working Near Mast 3799
Fuel Filter Water Removal 3801
Hood Latch Check 3801
Lift Chain Adjustments 3802
Jump-Starting the Lift Truck 3804
Jump-Starting Using a Battery Charger 3804
Jump-Starting a Lift Truck Using Another Lift Truck 3804
Welding Repairs 3805
Overhead Guard Changes 3805
Wheel and Tire Replacement 3805
General 3805
Solid Rubber Tire, Change (GC/GLC Series) 3805
Remove and Install Tire on Wheel 3806
Pneumatic Tire With Tube, Repair 3807
Remove Wheels From Lift Truck 3807
Remove Tire From Wheel 3807
Install Wheel in Tire 3810
Install Tire on Two-Piece Wheel 3812
Add Air to Pneumatic Tires With Tube 3813
Install the Wheels 3813
Dual Drive Wheels, Install 3814
Pneumatic Tubeless Tire, Repair 3815
Remove Wheels From Lift Truck 3815
Add Air to Pneumatic Tubeless Tire 3820
Wheels, Install 3820
Solid Rubber Tires on Pneumatic Wheels, Change 3820
Adhesives and Sealants 3824
524262281 8000YRM1249 (11 2017) US EN 3827
Lift Truck Lifting Capacity 3831
Counterweight Weights 3831
Tire Sizes 3832
Capacities 3832
Electrical System 3838
Transmission Oil Pressures 3840
Hydraulic System Relief Pressures 3843
Steering System 3844
Stall Speeds (in RPM ±100 rpm) 3844
GM 4 3L Gas 3845
GM 4 3L LPG 3845
Cummins 4 5L Diesel 3845
Cummins QSB 3 3L Diesel 3845
Mast Speeds 3845
Tilt Angles 3847
Front End Equipment – Mast Creep 3847
Mast Creep 3848
Engine Specifications 3848
Torque Specifications 3850
Frame 3851
Mast 3851
Steering System 3851
Steer Axle 3851
Drive Axle (Wet Brake) 3851
Drive Axle (Dry Brake) 3852
Transmission 3852
Engine – GM 4 3L 3853
Engine – Cummins 4 5L and QSB 3 3L Diesel 3854
524265337 0600YRM1251 (09 2015) US EN 3857
General 3863
Engine Removal and Installation 3863
Cylinder Head Repair 3863
Remove and Disassemble 3863
Clean and Inspect 3865
Valve Oil Seals 3868
Remove and Disassemble 3868
Cylinder Leak Down Test 3868
Clean and Inspect 3869
Assemble and Install 3869
Valve Guides and Seats, Repairs 3871
Valves, Repair 3871
Valve Seats, Repair 3872
Valve Springs 3873
Assemble and Install 3874
Engine Block Cleaning and Inspection 3877
Clean and Inspect 3878
Piston Bore Preparation 3880
Engine Mounts Installation 3880
Remove 3880
Clean and Inspect 3881
Install 3881
Lubrication System Repair 3882
Oil Pump, Remove and Disassemble 3882
Clean and Inspect 3883
Oil Pump, Assemble and Install 3884
Oil Pan, Install 3886
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3888
Timing Cover 3888
Remove 3888
Install 3890
Timing Sprockets 3890
Remove 3890
Install 3890
Camshaft 3890
Remove 3890
Inspect 3891
Install 3891
Balance Shaft 3892
Remove 3892
Install 3893
Valve Lifters 3894
Remove 3894
Clean and Inspect 3894
Install 3895
Crankshaft Repair 3895
Remove 3896
Inspect and Repair 3896
How to Check Clearance Between Main Bearings and Their Journals 3897
Install 3898
Piston and Connecting Rod Assemblies Repair 3900
Connecting Rod Bearings, Replace 3900
Piston and Connecting Rod Assemblies, Remove 3901
Disassemble 3901
Piston, Clean and Inspect 3902
Cylinder Bores, Inspect and Repair 3902
Piston Rings 3903
Assemble 3904
Piston and Connecting Rod Assemblies, Install 3904
Flywheel and Flywheel Housing Repair 3904
Flywheel, Remove 3905
Clean 3905
Inspect 3905
Flywheel, Install 3906
Coolant Pump Repair 3906
Remove 3906
Clean and Inspect 3907
Install 3907
Thermostat Replacement 3907
Remove 3908
Thermostat Operation Check 3908
Install 3908
Starter Replacement 3909
3909
Remove 3909
Install 3912
Fan Assembly Replacement 3913
Remove 3913
Inspect 3915
Install 3915
Drive Belt Installation 3916
Remove 3916
Clean 3916
Inspect 3916
Installation 3917
Compression Check 3918
Engine Specifications 3918
Engine Data 3918
Cylinder Head 3918
Hydraulic Valve Lifter 3919
Camshaft 3919
Pistons 3919
Crankshaft 3920
Connecting Rods 3920
Balance Shaft 3921
Cooling System 3921
Lubrication System 3921
Torque Specifications 3922
524265342 4000YRM1250 (09 2018) US EN 3927
Safety Procedures When Working Near Mast 3933
Fork Replacement 3935
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3935
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3937
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) 3938
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3939
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3940
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) 3941
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3941
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) 3943
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3943
Fixed Carriage Replacement 3945
Remove, Carriage With Hook Forks 3945
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3954
Install, Carriage With Hook Forks 3955
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3955
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3956
Connecting Attachment Hydraulic Quick Disconnect Hoses 3956
Integral Sideshift Carriage Repair 3957
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) 3957
Disassemble 3957
Clean and Inspect 3960
Assemble 3960
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) 3961
Hang On Sideshift Carriage Repair 3961
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) 3961
Disassemble 3973
Clean and Inspect 3982
Assemble 3983
Install 3984
Bolzoni Hang-On Sideshift Carriage Repair 3986
Remove 3986
Disassemble Carriage 3988
Clean and Inspect 3991
Assemble 3991
Install 3994
Fork Positioner 3996
Two-Stage Mast With Limited Free-Lift Repair 3997
Remove 3997
Disassemble 4001
Clean and Inspect 4004
Assemble 4021
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) 4023
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) 4024
Header Hose Alignment 4036
Two-Stage Mast With Full Free-Lift Repair 4046
Remove 4046
Disassemble 4048
Clean and Inspect 4060
Assemble 4061
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) 4063
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) 4066
Header Hose Installation and Adjustment 4070
Installation 4070
Adjustment 4070
Three-Stage Mast With Full Free-Lift Repair 4071
Remove 4071
Disassemble 4073
Clean and Inspect 4103
Assemble 4104
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) 4108
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) 4113
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) 4120
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) 4126
Mast Operation Check 4130
Tilt Cylinder Adjustment 4130
Lift Chains Adjustment 4131
Mast Adjustments 4132
Load Roller Adjustment 4132
Mast Side Kicking Adjustment 4134
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 4135
Carriage Adjustments 4138
524306203 0100YRM1290 (04 2014) US EN 4141
524329117 8000YRM1387 (03 2020) US EN 4245
General Information About Diagrams and Schematics 4249
Symbol Definitions 4249
Diagrams Manual Applications 4250
Diagrams and Schematics 4252
550001092 8000YRM1409 (03 2020) US EN 4317
General Information About Diagrams and Schematics 4321
Symbol Definitions 4321
Diagrams Manual Applications 4322
Diagrams and Schematics 4324
550043436 1300YRM1529 (11 2018) US EN 4405
General 4409
Serial Number 4409
Charge Pump Repair 4409
Lift Trucks Manufactured Before July, 2013 4409
Remove 4409
Inspect 4409
Install 4409
Lift Trucks Manufactured After July, 2013 4410
Remove 4410
Inspect 4410
Install 4410
Torque Converter Replace 4411
Remove 4411
Install 4420
Housings and Chain Drive Repair 4426
Remove 4426
Clean 4437
Inspect 4437
Install 4437
Clutch Packs Repair 4444
Remove and Disassemble 4444
Transmission, Remove and Disassemble 4444
Clean 4463
Inspect 4463
Assemble and Install 4464
Transmission, Assemble and Install 4472
Control Valve Repair 4476
Remove and Disassemble 4476
Clean 4480
Inspect 4480
Assemble and Install 4480
Foot Directional Control Pedal Repair 4481
Remove and Disassemble 4481
Assemble and Install 4485
Direction Control Lever 4486
Remove 4486
Install 4486
550043871 0900YRM1556 (04 2018) US EN 4491
General 4495
LPG Tank and Bracket 4495
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) 4495
Remove 4495
Install 4503
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) 4504
Remove 4504
Install 4506
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4506
Remove 4506
Install 4508
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4508
Remove 4508
Install 4508
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) 4509
Remove 4509
Install 4511
Fuel Filter Unit 4511
Fuel Filter Element 4512
Remove 4512
Clean and Inspect 4512
Install 4513
Fuel Filter Housing with LP Vapor Sensor 4513
Remove 4513
Disassemble 4515
Clean and Inspect 4516
Assemble 4516
Install 4517
Throttle Body 4518
Remove 4518
Clean 4522
Install 4522
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4523
Remove 4523
Install 4524
Control System 4524
Engine Control Unit (ECU) 4525
Remove 4525
Install 4526
Low Pressure Switch 4526
Remove 4526
Install 4526
Low Fuel Sensor 4527
Remove 4527
Install 4527
LP Converter 4528
Remove and Disassemble 4528
Assemble and Install 4529
LPG Lock-Off 4529
Remove 4530
Install 4531
Exhaust System 4532
Counterweight Exhaust 4532
Remove and Disassemble 4532
Inspect 4534
Assemble and Install 4534
Overhead Exhaust 4535
Remove and Disassemble 4535
Inspect 4537
Assemble and Install 4537
Exhaust Manifold 4537
Remove 4537
Install 4539
Oxygen (HEGO) Sensor 4539
Remove 4539
Install 4539
LPG Fuel Testing 4540
General 4540
Available Fuel Tests 4540
Composition Test (ASTM D-2163) 4540
Ammonia Test (ASTM D-4490) 4540
Basic Nitrogen Test (ASTM UOP269-90) 4540
Residues Test (ASTM D-2158) 4540
Vapor Pressure Test (ASTM D-2598) 4540
Sulfur Compounds Test (ASTM D-5623) 4540
Methanol Test (ASTM D-4864) 4541
Copper Corrosion (ASTM D-1838) 4541
Where To Send LPG Fuel Samples For Testing 4541
550048401 0900YRM1570 (03 2015) US EN 4545
550073240 1900YRM1620 (01 2023) US EN 4575
Proper Flushing after Major Hydraulic Repairs 4581
Introduction 4581
The Phases of Wear 4581
Causes of Hydraulic System Failure 4581
Progression of Contaminant Caused Hydraulic System Failure 4582
Hydraulic System Flushing Techniques 4582
Double Oil and Filter Change 4582
Mechanical Cleaning 4583
Cleaning of Components 4583
How to Clean Tubes and Hoses 4583
Filter Caddy 4583
Start-Up Procedure for Cleaned System 4584
Contaminated Oil Coolers 4584
Additional Filter Caddy Functions 4585
How to Handle Different Fluids 4585
Water Removal Filters 4585
Fluid Conditioning and System Flushing Procedures 4586
Operation of the Filter Caddy 4586
Filter Caddy operation 4586
Fluid Conditioning Procedure 4586
Filter Caddy Start-Up 4587
System Flushing Procedure 4587
Component Cleaning Procedure 4588
Reservoir Cleaning Procedure 4588
Cylinder Cleaning Procedure 4588
Hose and Tube Cleaning Procedure 4588
Valve Cleaning Procedure 4589
Front-End Attachment Cleaning Procedure 4590
System Flushing Procedure 4590
Filter Caddy Start-Up 4591
System Start-Up and Flushing 4591
Reservoir Fluid Cleaning Times 4592
Dealing With Different Fluid Types 4593
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4593
Filter Caddy Maintenance 4593
Servicing the Strainer 4593
DC Motor 4593
Hydraulic Oil Sampling Method and Procedure 4594
Hydraulic Oil Sampling Method 4594
Objective 4594
General Guidelines 4594
Synopsis 4595
Hydraulic Oil Analysis Report Guidelines 4596
Sampling Conditions 4596
Equipment 4596
Sampling Procedure 4597
Hydraulic Oil Sampling 4597
Sample Labeling 4597
Results Documentation 4597