Yale Forklift H813 (GLPGDP40VX5, 40VX6, 45VX6, 45SVX5, 50VX, 55VX Europe) Service Manual PDF

Yale Forklift H813 (GLPGDP40VX5, 40VX6, 45VX6, 45SVX5, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift H813 (GLPGDP40VX5, 40VX6, 45VX6, 45SVX5, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4844
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift H813 (GLPGDP40VX5, 40VX6, 45VX6, 45SVX5, 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) UK 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 (03 2020) UK EN 3149
Series Code / Model Designation Reference Table 3155
Description 3157
Proc_Cal_001: Service Password Entry 3159
When to Perform 3159
Why Perform 3159
How to Perform 3159
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3160
When to Perform 3160
Calibration Order 3160
Why Perform 3160
How to Perform 3161
Proc_Cal_003: Save and Exit 3162
When to Perform 3162
Why Perform 3162
How to Perform 3162
Proc_Cal_004: Lift Valve Output Threshold 3163
When to Perform 3163
Calibration Order 3163
Why Perform 3163
How to Perform 3164
Proc_Cal_005: Lower Valve Output Threshold 3166
When to Perform 3166
Calibration Order 3166
Why Perform 3166
How to Perform 3166
Proc_Cal_006: Tilt Back Valve Output Threshold 3169
When to Perform 3169
Calibration Order 3169
Why Perform 3169
How to Perform 3169
Proc_Cal_007: Tilt Forward Valve Output Threshold 3172
When to Perform 3172
Calibration Order 3172
Why Perform 3172
How to Perform 3172
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3175
When to Perform 3175
Calibration Order 3175
Why Perform 3175
How to Perform 3175
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3178
When to Perform 3178
Calibration Order 3178
Why Perform 3178
How to Perform 3178
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3181
When to Perform 3181
Calibration Order 3181
Why Perform 3181
How to Perform 3181
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3184
When to Perform 3184
Calibration Order 3184
Why Perform 3184
How to Perform 3184
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3187
When to Perform 3187
Calibration Order 3187
Why Perform 3187
How to Perform 3187
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3190
When to Perform 3190
Calibration Order 3190
Why Perform 3190
How to Perform 3190
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 3203
Applicable System/Option 3203
When to Perform 3203
Calibration Order 3203
Why Perform 3203
How to Perform 3204
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3205
Required Tools 3205
When to Perform 3205
Calibration Order 3205
Why Perform 3206
How to Perform 3206
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3207
When to Perform 3207
Why Perform 3207
How to Perform 3207
Proc_Cal_026: Travel Speed Calibration 3209
When to Perform 3209
Calibration Order 3209
Why Perform 3209
How to Perform 3209
524262274 0100YRM1243 (11 2016) UK EN 3213
General 3217
Description 3218
Hood, Seat, and Side Covers Replacement 3220
Remove 3220
Install 3220
Steering Column 3227
Description 3228
Steering Column Repair 3228
Remove 3228
Disassemble 3230
Clean 3233
Inspect 3233
Assemble 3233
Install 3233
LPG Tank and Bracket Replacement 3234
Counterweight Replacement 3234
Remove 3234
Install 3237
Tow Pin 3241
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) 3241
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) 3241
Overhead Guard Replacement 3242
Remove 3242
Install 3243
LED Tail, Backup, and Brake Lights, Replace 3243
Operator Restraint System Replacement 3244
Description 3244
Engine Replacement 3245
Remove Engine Only 3245
Install Engine only 3272
Remove Engine and Transmission 3275
Install Engine and Transmission 3279
Electronic Throttle Replacement 3283
Cummins 4 5L Diesel Engine With Electronic Throttle 3283
Remove 3283
Install 3286
Pull Actuator Linkage Adjustment 3288
Low Idle Adjustment 3288
Throttle Pedal and Cable Adjustment 3289
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3289
Kubota 3 6L Diesel Engine 3289
Exhaust System Repair 3292
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) 3292
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) 3292
Remove 3292
Inspect 3292
Install 3294
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) 3294
Remove 3294
Inspect 3296
Install 3296
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 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) (J813) 3298
Remove 3298
Inspect 3301
Diesel Particulate Filter 3303
Disassemble 3303
CLEAN AND INSPECT 3304
Assembly 3304
Install 3305
Cooling System 3306
Description 3306
Hydraulic Filter Assembly Repair 3307
Remove 3307
Disassemble 3307
Clean 3308
Inspect 3308
Assemble 3308
Install 3308
Fuel and Hydraulic Tanks Repair 3308
Inspect 3308
Clean 3309
Steam Method of Cleaning 3309
Chemical Solution Method of Cleaning 3310
Additional Preparations for Repair 3310
Small Leaks, Repair 3310
Large Leaks, Repair 3310
Preparations for Use After Repair 3310
Safety Labels 3310
524262275 0900YRM1242 (04 2018) UK EN 3321
General 3327
Hoses Replacement 3327
LPG Tank and Bracket Replacement 3328
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) 3328
Remove 3328
Install 3331
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) 3332
Remove 3332
Install 3332
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) 3332
Remove 3332
Install 3334
LPG Tank, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3335
Remove 3335
Install 3337
LPG Tank Bracket, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) 3337
Remove 3337
Install 3337
High Pressure Fuel Filter Unit Repair 3337
Fuel Filter Element 3338
Remove 3338
Clean/Inspect 3339
Install 3339
Fuel Filter Housing 3339
Remove 3339
Disassemble 3340
Assemble 3340
Install 3340
Electronic Throttle Body Repair 3341
Remove 3341
Clean/Inspect 3342
Install 3342
Fuel Injector Repair 3343
Fuel Rail 3343
Remove for Lift Trucks Built Before January, 2010 3343
Remove for Lift Trucks Built After January, 2010 3345
Install for Lift Trucks Built Before January, 2010 3346
Install for Lift Trucks Built After January, 2010 3347
Fuel Injectors and Adapters 3347
Remove for Lift Trucks Built Before January, 2010 3347
Remove for Lift Trucks Built After January, 2010 3349
Clean 3350
Install for Lift Trucks Built Before January, 2010 3350
Install for Lift Trucks Built After January, 2010 3352
LPG Regulator Repair 3352
LPG Regulator 3352
Remove for Lift Trucks Built Before January, 2010 3352
Remove for Lift Trucks Built After January, 2010 3353
Install for Lift Trucks Built Before January, 2010 3355
Install for Lift Trucks Built After January, 2010 3355
LPG Regulator Fuel Filter 3356
Remove 3356
Install 3357
Lock-Off Solenoid and Cartridge 3357
Remove 3357
Install 3358
Control System 3358
Electronic Control Unit (ECU) and Injector Driver Modules Assembly 3358
Remove 3358
Install 3359
Electronic Control Unit (ECU) 3360
Remove 3360
Install 3360
Injector Driver Modules 3361
Remove 3361
Install 3361
Fuel Pressure Sensor 3362
Remove 3362
Install 3362
Low LPG Pressure Switch 3362
Remove 3362
Install 3363
LPG Pressure Sensor 3363
Remove 3363
Install 3364
Oxygen Sensor 3364
Exhaust System Repair 3365
GM 4 3L Engine for Lift Truck Model GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) 3365
Remove for Lift Trucks Built Before January, 2010 3365
Remove for Lift Trucks Built After January, 2010 3367
Inspect 3369
Install for Lift Trucks Built Before January, 2010 3369
Install for Lift Trucks Built After January, 2010 3369
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) 3370
Remove for Lift Trucks Built Before January, 2010 3370
Remove for Lift Trucks Built After January, 2010 3372
Inspect 3375
Install for Lift Trucks Built Before January, 2010 3375
Install for Lift Trucks Built After January, 2010 3376
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 3377
Remove for Lift Trucks Built Before January, 2010 3377
Remove for Lift Trucks Built After January, 2010 3380
Inspect 3381
Install for Lift Trucks Built Before January, 2010 3382
Install for Lift Trucks Built After January, 2010 3382
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 3383
Remove for Lift Trucks Built Before January, 2010 3383
Remove for Lift Trucks Built After January, 2010 3386
Inspect 3387
Install for Lift Trucks Built Before January, 2010 3388
Install for Lift Trucks Built After January, 2010 3388
Oxygen Sensor 3389
Remove 3389
Install 3390
LPG Fuel Testing 3390
General 3390
Available Fuel Tests 3390
Composition Test (ASTM D-2163) 3390
Ammonia Test (ASTM D-4490) 3391
Basic Nitrogen Test (ASTM UOP269-90) 3391
Residues Test (ASTM D-2158) 3391
Vapor Pressure Test (ASTM D-2598) 3391
Sulfur Compounds Test (ASTM D-5623) 3391
Methanol Test (ASTM D-4864) 3391
Copper Corrosion (ASTM D-1838) 3391
Where To Send LPG Fuel Samples For Testing 3391
524262277 1400YRM1245 (01 2012) UK EN 3395
toc 3395
Drive Axle and Differential Assembly Repair 3395
Safety Precautions Maintenance and Repair 3396
General 3399
Drive Axle Repair 3399
Remove and Disassemble 3399
Clean and Inspect 3402
Assemble and Install 3402
Differential Repair 3404
Remove 3404
Support Differential Assembly From Differential Housing Assembly 3404
Differential Assembly From Differential Assembly Support 3406
Differential Assembly Support from Drop Box 3409
Drive Pinion and Pinion Gear, From Differential Assembly Support 3411
Disassemble 3412
Differential Assembly 3412
Drop Box Housing 3414
Differential Assembly Support 3415
Differential Housing 3416
Clean and Inspect 3417
Assemble 3417
Differential Housing 3417
Differential Assembly Support 3418
Drop Box Housing 3419
Differential Assembly 3420
Install 3424
Pinion Inner Shim Set, Adjust Thickness (Depth of Pinion) 3424
Drive Pinion and Pinion Gear Into Differential Assembly Support 3426
Differential Assembly Into Differential Assembly Support 3428
Ring Gear Backlash, Adjust 3431
Gear Set, Tooth Contact Pattern Check 3432
Differential Assembly Support Into Differential Housing 3435
Torque Specifications 3436
tables 3395
Table 1 Pinion Variation Numbers Examples 3425
Table 2 Ring and Pinion Tooth Contact Adjustment 3433
Table 3 Correct Tooth Contact 3433
Table 4 Incorrect Tooth Contact 3434
524262278 1400YRM1246 (02 2018) UK EN 3439
General 3443
Identification Plate 3444
Drive Axle Removal 3444
Hub Seal Replacement 3456
Planetary Reduction Repair 3465
Clean and Inspect 3474
Brake Repair 3487
Clean and Inspect 3503
Wet Brake Noise Reduction 3519
General 3519
Adding Additive To Transmission 3520
Bevel Pinion 3521
Clean and Inspect 3526
Differential Unit 3538
Disassemble 3549
Clean and Inspect 3555
Assemble 3556
Drive Axle Installation 3579
Special Tools 3589
Torque Specifications 3589
524262279 1800YRM1247 (09 2018) UK EN 3593
General 3597
Dry Brake System 3597
Wet Brake System 3598
Service Brakes Repair (Dry Brake) 3602
Remove and Disassemble 3602
Clean 3604
Inspect 3605
Assemble and Install 3605
Adjust 3609
Parking Brake Repair 3609
Dry Brake System 3610
Remove and Disassembly 3610
Assemble and Install 3612
Wet Brake System 3612
Remove and Install 3613
Assemble and Install 3619
Adjust 3619
Dry Brake System 3619
Wet Brake System 3620
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3620
Master Cylinder Repair 3621
Remove 3621
Disassemble 3626
Clean and Inspect 3627
Assemble 3628
Install and Adjust 3628
Accumulator 3630
Pre-Charge Check 3631
Remove 3632
Install 3634
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3634
Remove 3635
Modulating Brake Valve 3636
Disassemble 3636
Clean and Inspect 3638
Assemble 3638
Accumulator Charge Valve 3639
Disassemble 3639
Clean and Inspect 3641
Assemble 3641
Install 3642
Pressure Checks 3643
Accumulator Charge Valve Check 3643
Accumulator Check 3643
Service Brakes Adjustment (Dry Brake) 3644
Service Brakes Adjustment 3644
Brake System Air Removal 3645
Using Pressure Bleed System 3645
Using Brake Pedal Pressure 3646
Lift Truck Models with Master Cylinder 3646
Lift Truck Models with Modulating Brake Valve 3646
Brake Pedal Adjustment 3647
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) 3647
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3648
Free Pedal Adjustment 3650
Torque Specifications 3651
524265337 0600YRM1251 (09 2015) UK EN 3655
General 3661
Engine Removal and Installation 3661
Cylinder Head Repair 3661
Remove and Disassemble 3661
Clean and Inspect 3663
Valve Oil Seals 3666
Remove and Disassemble 3666
Cylinder Leak Down Test 3666
Clean and Inspect 3667
Assemble and Install 3667
Valve Guides and Seats, Repairs 3669
Valves, Repair 3669
Valve Seats, Repair 3670
Valve Springs 3671
Assemble and Install 3672
Engine Block Cleaning and Inspection 3675
Clean and Inspect 3676
Piston Bore Preparation 3678
Engine Mounts Installation 3678
Remove 3678
Clean and Inspect 3679
Install 3679
Lubrication System Repair 3680
Oil Pump, Remove and Disassemble 3680
Clean and Inspect 3681
Oil Pump, Assemble and Install 3682
Oil Pan, Install 3684
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3686
Timing Cover 3686
Remove 3686
Install 3688
Timing Sprockets 3688
Remove 3688
Install 3688
Camshaft 3688
Remove 3688
Inspect 3689
Install 3689
Balance Shaft 3690
Remove 3690
Install 3691
Valve Lifters 3692
Remove 3692
Clean and Inspect 3692
Install 3693
Crankshaft Repair 3693
Remove 3694
Inspect and Repair 3694
How to Check Clearance Between Main Bearings and Their Journals 3695
Install 3696
Piston and Connecting Rod Assemblies Repair 3698
Connecting Rod Bearings, Replace 3698
Piston and Connecting Rod Assemblies, Remove 3699
Disassemble 3699
Piston, Clean and Inspect 3700
Cylinder Bores, Inspect and Repair 3700
Piston Rings 3701
Assemble 3702
Piston and Connecting Rod Assemblies, Install 3702
Flywheel and Flywheel Housing Repair 3702
Flywheel, Remove 3703
Clean 3703
Inspect 3703
Flywheel, Install 3704
Coolant Pump Repair 3704
Remove 3704
Clean and Inspect 3705
Install 3705
Thermostat Replacement 3705
Remove 3706
Thermostat Operation Check 3706
Install 3706
Starter Replacement 3707
3707
Remove 3707
Install 3710
Fan Assembly Replacement 3711
Remove 3711
Inspect 3713
Install 3713
Drive Belt Installation 3714
Remove 3714
Clean 3714
Inspect 3714
Installation 3715
Compression Check 3716
Engine Specifications 3716
Engine Data 3716
Cylinder Head 3716
Hydraulic Valve Lifter 3717
Camshaft 3717
Pistons 3717
Crankshaft 3718
Connecting Rods 3718
Balance Shaft 3719
Cooling System 3719
Lubrication System 3719
Torque Specifications 3720
524265342 4000YRM1250 (09 2018) UK EN 3725
Safety Procedures When Working Near Mast 3731
Fork Replacement 3733
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3733
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3735
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) 3736
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3737
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3738
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) 3739
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3739
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) 3741
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3741
Fixed Carriage Replacement 3743
Remove, Carriage With Hook Forks 3743
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3752
Install, Carriage With Hook Forks 3753
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3753
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3754
Connecting Attachment Hydraulic Quick Disconnect Hoses 3754
Integral Sideshift Carriage Repair 3755
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) 3755
Disassemble 3755
Clean and Inspect 3758
Assemble 3758
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) 3759
Hang On Sideshift Carriage Repair 3759
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) 3759
Disassemble 3771
Clean and Inspect 3780
Assemble 3781
Install 3782
Bolzoni Hang-On Sideshift Carriage Repair 3784
Remove 3784
Disassemble Carriage 3786
Clean and Inspect 3789
Assemble 3789
Install 3792
Fork Positioner 3794
Two-Stage Mast With Limited Free-Lift Repair 3795
Remove 3795
Disassemble 3799
Clean and Inspect 3802
Assemble 3819
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) 3821
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) 3822
Header Hose Alignment 3834
Two-Stage Mast With Full Free-Lift Repair 3844
Remove 3844
Disassemble 3846
Clean and Inspect 3858
Assemble 3859
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) 3861
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) 3864
Header Hose Installation and Adjustment 3868
Installation 3868
Adjustment 3868
Three-Stage Mast With Full Free-Lift Repair 3869
Remove 3869
Disassemble 3871
Clean and Inspect 3901
Assemble 3902
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) 3906
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) 3911
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) 3918
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) 3924
Mast Operation Check 3928
Tilt Cylinder Adjustment 3928
Lift Chains Adjustment 3929
Mast Adjustments 3930
Load Roller Adjustment 3930
Mast Side Kicking Adjustment 3932
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3933
Carriage Adjustments 3936
524306203 0100YRM1290 (04 2014) UK EN 3939
550031265 2000YRM1457 (10 2015) UK EN 4043
General 4047
Main Control Valve Repair 4049
Remove 4049
Main Control Valve Sections 4052
General 4052
Outlet Control Valve Section 4052
Remove 4052
Disassemble 4052
Clean 4052
Inspect 4052
Assemble 4054
Install 4054
Auxiliary Control Valve Section 4054
Remove 4054
Disassemble 4054
Clean 4056
Inspect 4056
Assemble 4056
Install 4056
Tilt Control Valve Section 4057
Remove 4057
Disassemble 4057
Clean 4057
Inspect 4057
Assemble 4058
Install 4059
Lift/Lower Control Valve Section 4059
Remove 4059
Disassemble 4059
Clean 4059
Inspect 4059
Assemble 4060
Install 4061
Transition Section 4061
Remove 4061
Disassemble 4061
Clean 4061
Inspect 4061
Assemble 4062
Install 4062
Install 4063
Pressure Relief Valve Check and Adjustment 4067
General 4067
Secondary Relief Valve 4067
Steering Control Unit Repair 4068
Remove 4069
Disassemble 4069
Clean 4073
Inspect 4073
Assemble 4073
Install 4074
System Relief Valve 4075
Disassemble 4075
Clean 4075
Inspect 4075
Assemble 4075
Accumulator Replacement 4076
Remove 4076
Install 4076
550043871 0900YRM1556 (04 2018) UK EN 4081
General 4085
LPG Tank and Bracket 4085
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) 4085
Remove 4085
Install 4093
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) 4094
Remove 4094
Install 4096
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4096
Remove 4096
Install 4098
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4098
Remove 4098
Install 4098
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) 4099
Remove 4099
Install 4101
Fuel Filter Unit 4101
Fuel Filter Element 4102
Remove 4102
Clean and Inspect 4102
Install 4103
Fuel Filter Housing with LP Vapor Sensor 4103
Remove 4103
Disassemble 4105
Clean and Inspect 4106
Assemble 4106
Install 4107
Throttle Body 4108
Remove 4108
Clean 4112
Install 4112
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4113
Remove 4113
Install 4114
Control System 4114
Engine Control Unit (ECU) 4115
Remove 4115
Install 4116
Low Pressure Switch 4116
Remove 4116
Install 4116
Low Fuel Sensor 4117
Remove 4117
Install 4117
LP Converter 4118
Remove and Disassemble 4118
Assemble and Install 4119
LPG Lock-Off 4119
Remove 4120
Install 4121
Exhaust System 4122
Counterweight Exhaust 4122
Remove and Disassemble 4122
Inspect 4124
Assemble and Install 4124
Overhead Exhaust 4125
Remove and Disassemble 4125
Inspect 4127
Assemble and Install 4127
Exhaust Manifold 4127
Remove 4127
Install 4129
Oxygen (HEGO) Sensor 4129
Remove 4129
Install 4129
LPG Fuel Testing 4130
General 4130
Available Fuel Tests 4130
Composition Test (ASTM D-2163) 4130
Ammonia Test (ASTM D-4490) 4130
Basic Nitrogen Test (ASTM UOP269-90) 4130
Residues Test (ASTM D-2158) 4130
Vapor Pressure Test (ASTM D-2598) 4130
Sulfur Compounds Test (ASTM D-5623) 4130
Methanol Test (ASTM D-4864) 4131
Copper Corrosion (ASTM D-1838) 4131
Where To Send LPG Fuel Samples For Testing 4131
550048607 0600YRM1557 (07 2019) UK EN 4135
General 4141
Engine Identification 4141
Major Engine Component Identification 4141
Location of Labels 4141
Crankcase Description 4142
Engine Removal and Installation 4143
Cylinder Head Assembly Repair 4144
Valve Covers and Fuel Injectors 4144
Remove 4144
Clean and Inspect 4150
Install 4150
Rocker Arm Assembly 4151
Remove 4151
Disassemble 4152
Clean and Inspect 4153
Push Rods 4153
Rocker Arm Assembly 4153
Assemble 4153
Install 4154
Valve Clearance Adjustments 4154
Cylinder Head Assembly 4155
Remove 4155
Disassemble 4167
Valves and Valve Springs, Remove 4167
Valve Guides, Remove 4168
Clean and Inspect 4168
Cylinder Head 4169
Valve Guides 4169
Valves 4169
Valve Sink 4169
Valve Seat 4170
Valve Springs 4170
Assemble 4171
Valve Guides, Install 4171
Valves and Valve Springs, Install 4172
Install 4173
Timing Gear Case and Timing Gears Repair 4177
Timing Gear Case Cover 4177
Remove 4177
Clean and Inspect 4178
Install 4178
Timing Gears 4179
Crankshaft Gear 4180
Remove 4180
Install 4180
Idler Gear 4180
Remove 4180
Inspect 4181
Install 4181
Camshaft Gear 4181
Remove 4181
Install 4182
Timing Gear Case 4182
Remove 4182
Clean and Inspect 4183
Install 4183
Drive Train, Camshaft, and Cylinder Block Repair 4184
Remove 4184
Disassemble 4184
Pistons and Connecting Rods 4184
Crankshaft 4185
Camshaft 4187
Clean and Inspect 4189
Cylinder Block 4189
Honing and Boring 4191
Cylinder Correction (Oversize) 4192
Pistons 4192
Piston Pin 4193
Connecting Rod 4193
Tappets 4194
Crankshaft 4194
Camshaft 4196
Camshaft Bushing 4197
Assemble 4197
Camshaft 4197
Crankshaft 4197
Pistons and Connecting Rods 4198
Install 4200
Angular Deviation Procedure 4200
Lubrication System Repair 4203
Engine Oil and Oil Filter Change 4203
Oil Pan 4204
Remove 4204
Install 4205
Oil Suction Tube 4205
Remove 4205
Clean 4206
Install 4206
Oil Pump 4206
Remove 4206
Clean and Inspect 4207
Outer Rotor Outside Clearance 4207
Outer Rotor to Inner Rotor Tip Clearance 4207
Outer Rotor Side Clearance 4208
Rotor Shaft Clearance 4208
Install 4208
Fuel System Repair 4209
Fuel Injectors 4209
Remove 4209
Inspect 4209
Clean 4209
Replace 4209
Install 4210
Test 4210
Fuel Injection Pump 4210
Remove 4210
Clean and Inspect 4215
Install 4215
Cooling System Repair 4216
Serpentine Belt 4216
Remove 4216
Inspect 4216
Install 4216
Serpentine Belt, Adjustment 4217
Water Pump 4217
Remove 4217
Install 4220
Thermostat 4222
Remove 4222
Inspect 4222
Install 4223
Flywheel and Flywheel Housing 4224
Flywheel 4224
Remove 4224
Install 4224
Flywheel Housing 4224
Remove 4224
Install 4224
Electrical Equipment Repair 4225
Alternator 4225
Remove 4225
Install 4226
Starter 4227
Remove 4227
Install 4227
Engine Specifications 4228
Engine Data For Lift Truck Models and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (H813)GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (E879) 4228
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 4229
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879) 4230
Engine Tuning 4231
Cylinder Head 4231
Intake/Exhaust Valve and Guide 4232
Valve Spring 4232
Rocker Arm and Shaft 4232
Push Rod 4232
Gear Train and Camshaft 4233
Camshaft 4233
Idle Gear Shaft and Bushing 4233
Backlash of Each Gear 4233
Cylinder Block 4233
Crankshaft 4233
Piston 4234
Piston Ring 4234
Connecting Rod 4234
Rod Small End 4234
Tappet 4235
Oil Pump 4235
Engine Oil Pressure 4235
Outer Rotor Outside Clearance 4235
Outer Rotor Side Clearance 4235
Inner Rotor to Cover 4235
Standard Torque Specifications 4236
Standard Torque Chart 4236
Special Torque Specifications 4236
Special Tools 4238
550048681 1300YRM1569 (11 2018) UK EN 4251
General 4255
Serial Number 4255
Charge Pump Repair 4255
Lift Trucks Manufactured Before July, 2013 4255
Remove 4255
Inspect 4256
Install 4256
Lift Trucks Manufactured After July, 2013 4256
Remove 4256
Inspect 4257
Install 4257
Torque Converter Replace 4257
Remove 4257
Install 4263
Housings and Chain Drive Repair 4268
Remove 4269
Clean 4277
Inspect 4277
Install 4277
Clutch Packs Repair- 1 Speed Transmission 4283
Remove and Disassemble 4283
Transmission, Remove and Disassemble 4283
Clean 4295
Inspect 4295
Assemble and Install 4296
Transmission, Assemble and Install 4304
Clutch Packs Repair- 2 Speed Transmission 4307
Remove and Disassemble 4308
Transmission, Remove and Disassemble 4308
Clean 4322
Inspect 4322
Assemble and Install 4323
Transmission, Assemble and Install 4332
Control Valve Repair 4334
Remove and Disassemble 4335
Clean 4338
Inspect 4338
Assemble and Install 4338
Foot Directional Control Pedal Repair 4339
Remove and Disassemble 4339
Assemble and Install 4343
Direction Control Lever 4344
Remove 4344
Install 4344
550048683 8000YRM1559 (04 2018) UK EN 4349
Lift Truck Lifting Capacity 4353
Counterweight Weights 4353
Tire Sizes 4353
Capacities 4353
Electrical System 4358
Transmission Oil Pressures 4359
Hydraulic System Relief Pressures 4360
Steering System 4361
Stall Speeds (in RPM ±100 rpm) 4362
PSI (GM) 4 3L Gas 4362
PSI (GM) 4 3L LPG 4362
Kubota 3 6L Diesel 4362
Kubota 3 8L Diesel 4362
Mast Speeds 4363
Tilt Angles 4366
Front End Equipment – Mast Creep 4367
Mast Creep 4367
Engine Specifications 4367
Diesel Fuel Cleanliness Levels 4369
Torque Specifications 4370
Frame 4370
Mast 4370
Steering System 4370
Steer Axle 4370
Drive Axle, Wet Brake
(Dana Spicer Axle) 4370
Drive Axle, Wet Brake
(NMHG Axle) 4370
Drive Axle (Dry Brake) 4370
Transmission 4371
Engine – PSI (GM) 4 3L 4371
Engine – Kubota 3 6L Diesel 4372
Engine – Kubota 3 8L Diesel 4373
550048690 8000YRM1558 (05 2019) UK EN 4377
General 4383
Serial Number Data 4383
How to Move Disabled Lift Truck 4383
How to Tow Lift Truck 4383
How to Put Lift Truck on Blocks 4384
How to Raise Drive Tires 4384
How to Raise Steering Tires 4385
How to Clean a Lift Truck 4385
Maintenance Schedule 4386
Maintenance Procedures Every 8 Hours or Daily 4401
How to Make Checks With Engine Stopped 4401
Tires and Wheels 4401
Safety Labels 4402
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4402
Operator Restraint System 4403
Emergency Locking Retractor (ELR) 4403
Adjust Seat – Full Suspension 4404
Adjust Seat – Internal Suspension 4405
Hood and Seat Latches 4405
Engine Compartment 4405
Paper Application 4406
Fuel, Oil, and Coolant Leaks, Check 4406
Hydraulic Hoses 4407
Coolant Hoses 4407
Steering Column Gas Cylinder 4407
Transmission 4407
Hydraulic System Oil 4407
Engine Oil 4407
Air Filter 4411
Forks 4411
Remove 4411
Inspect 4412
Install 4412
Adjust 4413
Integral Sideshift Carriage 4413
How to Make Checks With Engine Running 4413
Indicator Lights, Horn, Fuses, and Relays 4414
Service Brakes 4416
Brake Oil Level 4416
Operation, Check 4417
Parking Brake 4417
Engine Oil Pressure 4417
Cooling System 4417
Steering System 4418
Control Levers and Pedals 4418
Fuel/Water Separator Filter, Kubota Diesel Engine 4418
Lift System, Operate 4418
First Service After First 100 Hours of Operation 4419
GM 4 3L Engine Oil and Oil Filter 4419
Kubota Diesel Engine Oil and Oil Filter 4420
Maintenance Procedures Every 500 Hours or 1 Year 4420
Hydraulic System Oil 4420
Hydraulic Tank Breather 4421
Inspect 4421
Battery 4421
Kubota Diesel Engine Oil and Oil Filter 4422
GM 4 3L Engine Oil and Oil Filter 4422
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4422
Remove 4422
Install 4423
Priming the Fuel System (Kubota 3 8L Engine) 4424
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4424
Remove 4424
Install 4425
Priming the Fuel System (Kubota 3 6L Engine) 4425
Drain Tar From LPG Regulator 4426
Drain Tar From LPG Converter 4426
Drive Belt 4427
GM 4 3L Engine 4427
Fan and Alternator Drive Belt 4427
Kubota Diesel Engine 4427
Fan and Alternator Drive Belt 4427
Clean Debris From Radiator Core 4428
Transmission Oil Level 4428
Wet Brake Center Body Oil Level Check (Dana Drive Axle) 4429
Wet Brake Oil Level Check (NMHG Drive Axle) 4429
Forks 4430
Mast Lubrication 4431
Header Hose Checks 4433
Lift Chain Lubrication 4433
Tilt Cylinder Lubrication 4434
Master Brake Cylinder Rod End Pin Lubrication 4434
Manual Hydraulic Levers Lubrication 4435
Brake Oil 4435
Tie Rod Lubrication 4436
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 4436
Parking Brake Adjustment 4437
Maintenance Procedures Every 1000 Hours or 1 Year 4437
Valve Clearance, Check and Adjust, GM 4 3L Engine 4437
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 4438
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4438
Ignition System 4438
GM 4 3L Engine 4438
LPG Fuel Filter Element Replace, GM 4 3L Engine 4438
Remove 4438
Install 4439
In-Line Strainer Replacement, Kubota Diesel Engine 4439
Remove 4439
Install 4439
Lift Chains Wear Check 4440
Lift Chain Lubrication 4441
Integral Sideshift Carriage, Check Sliding Surfaces 4441
Steering Axle (Spindle Bearings) 4441
Control Levers and Pedals 4442
Parking Brake Lever Lubrication, Dana Wet Brake Axle 4442
Normal Operating Environment 4442
Heavy Duty or Contaminated Environment 4443
Remove 4443
Clean and Inspect 4444
Install 4444
Inspect Engine Electrical System, Connectors 4445
Crankcase Breather Element, Kubota 3 8L Diesel Engine 4445
Remove 4445
Clean and Inspect 4445
Install 4446
Maintenance Procedures Every 2000 Hours or Annually 4446
Hydraulic System 4446
Hydraulic Filter, Replace 4446
Hydraulic Tank Breather, Replace 4447
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4447
Cooling System, GM 4 3L and Kubota Diesel Engines 4447
Air Filter 4448
Oxygen Sensor, GM 4 3L LPG Engines With GFI Installed 4450
LPG Regulator Fuel Filter, GM 4 3L Engines With GFI Installed 4450
Remove 4450
Install 4451
LPG Fuel Injector, GM 4 3L Engines With GFI Installed 4451
Fuel Injector, Kubota 3 8L Engine 4451
Fuel Injector, Kubota 3 6L Engine 4451
Forks 4451
Transmission Oil and Filter (Dry Brake), Replace 4451
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 4453
Wet Brake Center Section Oil Change (Dana Drive Axle) 4456
Remove 4456
Install 4456
Wet Brake Oil Change (NMHG Drive Axle) 4457
Brake Oil (Master Cylinder), Change 4458
Brake Oil (Dry Brake), Remove 4459
Service Brakes (Dry Brake) 4459
Differential (Dry Brake) 4460
Check Throttle Shaft for Sticking 4460
Inspect Exhaust Manifold and Piping for Leaks 4460
Wheel Bearings 4461
Steer Wheels, Lubrication 4461
Maintenance Procedures Every 4000 Hours or 2 Years 4461
Hydraulic Oil, Replace 4461
Safety Procedures When Working Near Mast 4462
Fuel Filter Water Removal 4465
Kubota Diesel Engine 4465
3 8L Diesel Engine 4465
3 6L Diesel Engine 4466
Hood Latch Check 4467
Lift Chain Adjustments 4468
Jump-Starting the Lift Truck 4469
Jump-Starting Using a Battery Charger 4470
Jump-Starting a Lift Truck Using Another Lift Truck 4470
Welding Repairs 4470
Overhead Guard Changes 4471
Wheel and Tire Replacement 4471
General 4471
Pneumatic Tire With Tube, Repair 4471
Remove Wheels From Lift Truck 4471
Remove Tire From Wheel 4471
Install Wheel in Tire 4474
Install Tire on Two-Piece Wheel 4476
Add Air to Pneumatic Tires With Tube 4477
Install the Wheels 4477
Dual Drive Wheels, Install 4478
Pneumatic Tubeless Tire, Repair 4479
Remove Wheels From Lift Truck 4479
Add Air to Pneumatic Tubeless Tire 4484
Wheels, Install 4484
Solid Rubber Tires on Pneumatic Wheels, Change 4484
Snap-On-Tire, Change 4488
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 4490
Adhesives and Sealants 4495
550055279 0600YRM1579 (11 2019) UK EN 4499
General 4505
Engine Identification 4505
Major Engine Component Identification 4505
Location of Labels 4505
Crankcase Description 4506
Engine Removal and Installation 4507
Cylinder Head Assembly Repair 4507
Valve Covers and Fuel Injectors 4507
Remove 4507
Clean and Inspect 4511
Install 4512
Rocker Arm Assembly 4513
Remove 4513
Disassemble 4515
Clean and Inspect 4515
Push Rods 4515
Rocker Arm Assembly 4515
Assemble 4516
Install 4516
Valve Clearance Adjustments 4516
Cylinder Head Assembly 4517
Remove 4517
Disassemble 4525
Valves and Valve Springs, Remove 4525
Valve Guides, Remove 4527
Clean and Inspect 4527
Cylinder Head 4528
Valve Guides 4528
Valves 4528
Valve Sink 4529
Valve Seat 4529
Valve Springs 4529
Assemble 4530
Valve Guides, Install 4530
Valves and Valve Springs, Install 4530
Install 4531
Timing Gear Case and Timing Gears Repair 4536
Timing Gear Case Cover 4536
Remove 4536
Clean and Inspect 4536
Install 4537
Timing Gears 4538
Crankshaft Gear 4538
Remove 4538
Install 4538
Idler Gear 4538
Remove 4538
Inspect 4539
Install 4539
Camshaft Gear 4539
Remove 4539
Install 4540
Timing Gear Case 4540
Remove 4540
Clean and Inspect 4541
Install 4541
Drive Train, Camshaft, and Cylinder Block Repair 4541
Remove 4541
Disassemble 4542
Pistons and Connecting Rods 4542
Crankshaft 4543
Camshaft 4545
Clean and Inspect 4546
Cylinder Block 4547
Honing and Boring 4549
Cylinder Correction (Oversize) 4550
Pistons 4550
Piston Pin 4551
Connecting Rod 4551
Tappets 4551
Crankshaft 4552
Camshaft 4554
Camshaft Bushing 4555
Assemble 4555
Camshaft 4555
Crankshaft 4555
Pistons and Connecting Rods 4555
Install 4557
Lubrication System Repair 4558
Engine Oil and Oil Filter Change 4558
Oil Pan 4559
Remove 4559
Install 4560
Oil Suction Tube 4560
Remove 4560
Clean 4561
Install 4561
Oil Pump 4561
Remove 4561
Clean and Inspect 4561
Outer Rotor Outside Clearance 4562
Outer Rotor to Inner Rotor Tip Clearance 4562
Outer Rotor Side Clearance 4562
Rotor Shaft Clearance 4563
Install 4563
Fuel System Repair 4564
Fuel Injectors 4564
Remove 4564
Inspect 4564
Clean 4564
Replace 4564
Install 4564
Electronic Throttle System 4564
Remove 4564
Throttle Position Sensor Proceedures After September 2018 GDP60-70VX (GDP135-155VX) (F878), GDP60VX, GDP70VX, GP70VXS6 (GDP135VX GDP155VX, GP155VXS) (G878), and GP080VX, GP090VX, GP100VX, GP100VX, GP120VX, (GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5, GDP50VX, GDP55VX) (K813) 4568
Bearing Replacement 4568
Install 4569
Adjustment 4570
Fuel Injection Pump 4570
Remove 4570
Disassemble 4574
Clean and Inspect 4576
Assemble 4576
Install 4577
Cooling System Repair 4578
Serpentine Belt 4578
Remove 4578
Inspect 4578
Install 4578
Serpentine Belt, Adjustment 4578
Water Pump 4579
Remove 4579
Install 4581
Thermostat 4582
Remove 4582
Inspect 4583
Install 4583
Flywheel and Flywheel Housing 4584
Flywheel 4584
Remove 4584
Install 4585
Flywheel Housing 4585
Remove 4585
Install 4585
Electrical Equipment Repair 4585
Alternator 4585
Remove 4585
Install 4586
Starter 4587
Remove 4587
Install 4587
Engine Specifications 4589
Engine Data 4589
Engine Tuning 4590
Cylinder Head 4590
Intake/Exhaust Valve and Guide 4591
Valve Spring 4591
Rocker Arm and Shaft 4591
Push Rod 4591
Gear Train and Camshaft 4592
Camshaft 4592
Idle Gear Shaft and Bushing 4592
Backlash of Each Gear 4592
Cylinder Block 4592
Crankshaft 4592
Piston 4593
Piston Ring 4593
Connecting Rod 4593
Rod Small End 4593
Tappet 4594
Oil Pump 4594
Engine Oil Pressure 4594
Outer Rotor Outside Clearance 4594
Outer Rotor Side Clearance 4594
Inner Rotor to Cover 4594
Standard Torque Specifications 4595
Standard Torque Chart 4595
Special Torque Specifications 4595
Special Tools 4597
550055280 1400YRM1582 (01 2019) UK EN 4607
General 4611
Identification Plate 4611
Drive Axle Removal 4612
Reduction Gear Assembly 4617
Remove 4617
Disassemble 4620
Clean and Inspect 4624
Assemble 4624
Install 4633
Wet Disc Brake Repair 4636
General 4636
Remove 4637
Clean and Inspect 4640
Install 4641
Initial Steps For Install 4641
Final Steps For Install 4648
Wet Brake Noise Reduction 4651
General 4651
Adding Additive To Transmission 4651
Piston Housing 4653
Remove 4653
Disassemble 4654
Clean and Inspect 4655
Assemble 4655
Install 4656
Parking Brake Control Lever 4657
Remove 4657
Clean and Inspect 4658
Install 4658
Differential Repair 4660
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 4660
Input Pinion Carrier 4660
Remove 4661
Disassemble 4661
Clean and Inspect 4662
Assemble 4662
Preload Pinion Bearings 4664
Differential Housing and Drive Axle Trumpet Arm (Right Side) 4664
Remove 4666
Disassemble 4666
Clean and Inspect 4667
Assemble 4667
Install 4669
Ring Gear Backlash 4669
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 4670
Pinion and Motor Carrier 4671
Install 4671
Drive Axle Installation 4674
Special Tools 4679
Special Tools 4679
Torque specifications 4681
550055283 8000YRM1585 (07 2020) UK EN 4685
General Information About Diagrams and Schematics 4689
Symbol Definitions 4689
Diagrams Manual Applications 4690
Diagrams and Schematics 4692
550064329 1800YRM1597 (03 2017) UK EN 4781
Wet Brake System 4785
Service Brake Repair 4786
Parking Brake Repair 4786
Remove and Disassemble 4786
Assemble and Install 4787
Adjust 4788
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 4788
Master Cylinder and Booster 4788
Remove 4788
Disassemble 4790
Clean and Inspect 4791
Assemble 4791
Install and Adjust 4791
Brake System Air Removal 4793
Using Pressure Bleed System 4793
Using Brake Pedal Pressure 4794
Lift Truck Models with Master Cylinder 4794
Brake Pedal Adjustment 4795
Free Pedal Adjustment 4796
Torque Specifications 4796
550073240 1900YRM1620 (01 2023) US EN 4799
Proper Flushing after Major Hydraulic Repairs 4805
Introduction 4805
The Phases of Wear 4805
Causes of Hydraulic System Failure 4805
Progression of Contaminant Caused Hydraulic System Failure 4806
Hydraulic System Flushing Techniques 4806
Double Oil and Filter Change 4806
Mechanical Cleaning 4807
Cleaning of Components 4807
How to Clean Tubes and Hoses 4807
Filter Caddy 4807
Start-Up Procedure for Cleaned System 4808
Contaminated Oil Coolers 4808
Additional Filter Caddy Functions 4809
How to Handle Different Fluids 4809
Water Removal Filters 4809
Fluid Conditioning and System Flushing Procedures 4810
Operation of the Filter Caddy 4810
Filter Caddy operation 4810
Fluid Conditioning Procedure 4810
Filter Caddy Start-Up 4811
System Flushing Procedure 4811
Component Cleaning Procedure 4812
Reservoir Cleaning Procedure 4812
Cylinder Cleaning Procedure 4812
Hose and Tube Cleaning Procedure 4812
Valve Cleaning Procedure 4813
Front-End Attachment Cleaning Procedure 4814
System Flushing Procedure 4814
Filter Caddy Start-Up 4815
System Start-Up and Flushing 4815
Reservoir Fluid Cleaning Times 4816
Dealing With Different Fluid Types 4817
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4817
Filter Caddy Maintenance 4817
Servicing the Strainer 4817
DC Motor 4817
Hydraulic Oil Sampling Method and Procedure 4818
Hydraulic Oil Sampling Method 4818
Objective 4818
General Guidelines 4818
Synopsis 4819
Hydraulic Oil Analysis Report Guidelines 4820
Sampling Conditions 4820
Equipment 4820
Sampling Procedure 4821
Hydraulic Oil Sampling 4821
Sample Labeling 4821
Results Documentation 4821
550073240 1900YRM1620 (03 2020) UK EN 4823
Proper Flushing after Major Hydraulic Repairs 4827
Introduction 4827
The Phases of Wear 4827
Causes of Hydraulic System Failure 4827
Progression of Contaminant Caused Hydraulic System Failure 4828
Hydraulic System Flushing Techniques 4828
Double Oil and Filter Change 4828
Mechanical Cleaning 4829
Cleaning of Components 4829
How to Clean Tubes and Hoses 4829
Filter Caddy 4829
Start-Up Procedure for Cleaned System 4830
Contaminated Oil Coolers 4830
Additional Filter Caddy Functions 4830
How to Handle Different Fluids 4830
Water Removal Filters 4831
Fluid Conditioning and System Flushing Procedures 4831
Operation of the Filter Caddy 4831
Filter Caddy operation 4831
Fluid Conditioning Procedure 4832
Filter Caddy Start-Up 4832
System Flushing Procedure 4833
Component Cleaning Procedure 4833
Reservoir Cleaning Procedure 4833
Cylinder Cleaning Procedure 4833
Hose and Tube Cleaning Procedure 4834
Valve Cleaning Procedure 4834
Front-End Attachment Cleaning Procedure 4835
System Flushing Procedure 4835
Filter Caddy Start-Up 4836
System Start-Up and Flushing 4836
Reservoir Fluid Cleaning Times 4837
Dealing With Different Fluid Types 4837
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4837
Filter Caddy Maintenance 4838
Servicing the Strainer 4838
DC Motor 4838
Hydraulic Oil Sampling Method and Procedure 4838
Hydraulic Oil Sampling Method 4838
Objective 4838
General Guidelines 4838
Synopsis 4839
Hydraulic Oil Analysis Report Guidelines 4840
Sampling Conditions 4841
Equipment 4841
Sampling Procedure 4841
Hydraulic Oil Sampling 4841
Sample Labeling 4842
Results Documentation 4842