Yale Forklift H813 (GPGLPGDP080, 090, 100, 110, 120VX) Service Manual PDF

Yale Forklift H813 (GPGLPGDP080, 090, 100, 110, 120VX) Service Manual – PDF DOWNLOAD

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Yale Forklift H813 (GPGLPGDP080, 090, 100, 110, 120VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4832
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift H813 (GPGLPGDP080, 090, 100, 110, 120VX) 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) US 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) US 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) US 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) US EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223764 1600YRM1133 (07 2013) US EN 2213
toc 2213
Steering Axle 2213
Safety Precautions Maintenance and Repair 2214
General 2217
Steering Axle Assembly Repair 2219
Remove 2219
Disassemble 2220
Clean 2228
Inspect 2228
Assemble 2228
Install 2234
Spindles, Bearings, and Tie Rods Repair 2236
Spindles and Bearings 2236
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2236
Remove 2236
Disassemble 2238
Clean 2239
Inspect 2239
Assemble 2239
Install 2240
Spindles and Bearings 2243
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2243
Remove and Disassemble 2243
Assemble and Install 2244
Tie Rods 2244
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2244
Remove 2244
Install 2245
Tie Rods 2246
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2246
Remove 2246
Install 2252
Steering Cylinder Repair 2252
Remove and Disassemble 2252
Clean and Inspect 2253
Assemble and Install 2253
Torque Specifications 2254
524223766 1900YRM1136 (11 2017) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US EN 3939
550043871 0900YRM1556 (04 2018) US EN 4043
General 4047
LPG Tank and Bracket 4047
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) 4047
Remove 4047
Install 4055
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) 4056
Remove 4056
Install 4058
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4058
Remove 4058
Install 4060
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 4060
Remove 4060
Install 4060
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) 4061
Remove 4061
Install 4063
Fuel Filter Unit 4063
Fuel Filter Element 4064
Remove 4064
Clean and Inspect 4064
Install 4065
Fuel Filter Housing with LP Vapor Sensor 4065
Remove 4065
Disassemble 4067
Clean and Inspect 4068
Assemble 4068
Install 4069
Throttle Body 4070
Remove 4070
Clean 4074
Install 4074
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4075
Remove 4075
Install 4076
Control System 4076
Engine Control Unit (ECU) 4077
Remove 4077
Install 4078
Low Pressure Switch 4078
Remove 4078
Install 4078
Low Fuel Sensor 4079
Remove 4079
Install 4079
LP Converter 4080
Remove and Disassemble 4080
Assemble and Install 4081
LPG Lock-Off 4081
Remove 4082
Install 4083
Exhaust System 4084
Counterweight Exhaust 4084
Remove and Disassemble 4084
Inspect 4086
Assemble and Install 4086
Overhead Exhaust 4087
Remove and Disassemble 4087
Inspect 4089
Assemble and Install 4089
Exhaust Manifold 4089
Remove 4089
Install 4091
Oxygen (HEGO) Sensor 4091
Remove 4091
Install 4091
LPG Fuel Testing 4092
General 4092
Available Fuel Tests 4092
Composition Test (ASTM D-2163) 4092
Ammonia Test (ASTM D-4490) 4092
Basic Nitrogen Test (ASTM UOP269-90) 4092
Residues Test (ASTM D-2158) 4092
Vapor Pressure Test (ASTM D-2598) 4092
Sulfur Compounds Test (ASTM D-5623) 4092
Methanol Test (ASTM D-4864) 4093
Copper Corrosion (ASTM D-1838) 4093
Where To Send LPG Fuel Samples For Testing 4093
550048401 0900YRM1570 (03 2015) US EN 4097
550048607 0600YRM1557 (07 2019) US EN 4127
General 4133
Engine Identification 4133
Major Engine Component Identification 4133
Location of Labels 4133
Crankcase Description 4134
Engine Removal and Installation 4135
Cylinder Head Assembly Repair 4136
Valve Covers and Fuel Injectors 4136
Remove 4136
Clean and Inspect 4142
Install 4142
Rocker Arm Assembly 4143
Remove 4143
Disassemble 4144
Clean and Inspect 4145
Push Rods 4145
Rocker Arm Assembly 4145
Assemble 4145
Install 4146
Valve Clearance Adjustments 4146
Cylinder Head Assembly 4147
Remove 4147
Disassemble 4159
Valves and Valve Springs, Remove 4159
Valve Guides, Remove 4160
Clean and Inspect 4160
Cylinder Head 4161
Valve Guides 4161
Valves 4161
Valve Sink 4161
Valve Seat 4162
Valve Springs 4162
Assemble 4163
Valve Guides, Install 4163
Valves and Valve Springs, Install 4164
Install 4165
Timing Gear Case and Timing Gears Repair 4169
Timing Gear Case Cover 4169
Remove 4169
Clean and Inspect 4170
Install 4170
Timing Gears 4171
Crankshaft Gear 4172
Remove 4172
Install 4172
Idler Gear 4172
Remove 4172
Inspect 4173
Install 4173
Camshaft Gear 4173
Remove 4173
Install 4174
Timing Gear Case 4174
Remove 4174
Clean and Inspect 4175
Install 4175
Drive Train, Camshaft, and Cylinder Block Repair 4176
Remove 4176
Disassemble 4176
Pistons and Connecting Rods 4176
Crankshaft 4177
Camshaft 4179
Clean and Inspect 4181
Cylinder Block 4181
Honing and Boring 4183
Cylinder Correction (Oversize) 4184
Pistons 4184
Piston Pin 4185
Connecting Rod 4185
Tappets 4186
Crankshaft 4186
Camshaft 4188
Camshaft Bushing 4189
Assemble 4189
Camshaft 4189
Crankshaft 4189
Pistons and Connecting Rods 4190
Install 4192
Angular Deviation Procedure 4192
Lubrication System Repair 4195
Engine Oil and Oil Filter Change 4195
Oil Pan 4196
Remove 4196
Install 4197
Oil Suction Tube 4197
Remove 4197
Clean 4198
Install 4198
Oil Pump 4198
Remove 4198
Clean and Inspect 4199
Outer Rotor Outside Clearance 4199
Outer Rotor to Inner Rotor Tip Clearance 4199
Outer Rotor Side Clearance 4200
Rotor Shaft Clearance 4200
Install 4200
Fuel System Repair 4201
Fuel Injectors 4201
Remove 4201
Inspect 4201
Clean 4201
Replace 4201
Install 4202
Test 4202
Fuel Injection Pump 4202
Remove 4202
Clean and Inspect 4207
Install 4207
Cooling System Repair 4208
Serpentine Belt 4208
Remove 4208
Inspect 4208
Install 4208
Serpentine Belt, Adjustment 4209
Water Pump 4209
Remove 4209
Install 4212
Thermostat 4214
Remove 4214
Inspect 4214
Install 4215
Flywheel and Flywheel Housing 4216
Flywheel 4216
Remove 4216
Install 4216
Flywheel Housing 4216
Remove 4216
Install 4216
Electrical Equipment Repair 4217
Alternator 4217
Remove 4217
Install 4218
Starter 4219
Remove 4219
Install 4219
Engine Specifications 4220
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) 4220
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 4221
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879) 4222
Engine Tuning 4223
Cylinder Head 4223
Intake/Exhaust Valve and Guide 4224
Valve Spring 4224
Rocker Arm and Shaft 4224
Push Rod 4224
Gear Train and Camshaft 4225
Camshaft 4225
Idle Gear Shaft and Bushing 4225
Backlash of Each Gear 4225
Cylinder Block 4225
Crankshaft 4225
Piston 4226
Piston Ring 4226
Connecting Rod 4226
Rod Small End 4226
Tappet 4227
Oil Pump 4227
Engine Oil Pressure 4227
Outer Rotor Outside Clearance 4227
Outer Rotor Side Clearance 4227
Inner Rotor to Cover 4227
Standard Torque Specifications 4228
Standard Torque Chart 4228
Special Torque Specifications 4228
Special Tools 4230
550048681 1300YRM1569 (11 2018) US EN 4243
General 4247
Serial Number 4247
Charge Pump Repair 4247
Lift Trucks Manufactured Before July, 2013 4247
Remove 4247
Inspect 4248
Install 4248
Lift Trucks Manufactured After July, 2013 4248
Remove 4248
Inspect 4249
Install 4249
Torque Converter Replace 4249
Remove 4249
Install 4255
Housings and Chain Drive Repair 4260
Remove 4261
Clean 4269
Inspect 4269
Install 4269
Clutch Packs Repair- 1 Speed Transmission 4275
Remove and Disassemble 4275
Transmission, Remove and Disassemble 4275
Clean 4287
Inspect 4287
Assemble and Install 4288
Transmission, Assemble and Install 4296
Clutch Packs Repair- 2 Speed Transmission 4299
Remove and Disassemble 4300
Transmission, Remove and Disassemble 4300
Clean 4314
Inspect 4314
Assemble and Install 4315
Transmission, Assemble and Install 4324
Control Valve Repair 4326
Remove and Disassemble 4327
Clean 4330
Inspect 4330
Assemble and Install 4330
Foot Directional Control Pedal Repair 4331
Remove and Disassemble 4331
Assemble and Install 4335
Direction Control Lever 4336
Remove 4336
Install 4336
550048682 8000YRM1558 (12 2018) US EN 4341
General 4347
Serial Number Data 4347
How to Move Disabled Lift Truck 4347
How to Tow Lift Truck 4347
How to Put Lift Truck on Blocks 4348
How to Raise Drive Tires 4348
How to Raise Steering Tires 4349
How to Clean a Lift Truck 4350
Maintenance Schedule 4350
Maintenance Procedures Every 8 Hours or Daily 4364
How to Make Checks With Engine Stopped 4365
Tires and Wheels 4365
Safety Labels 4365
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4365
Operator Restraint System 4366
Emergency Locking Retractor (ELR) 4366
Adjust Seat – Full Suspension 4368
Adjust Seat – Internal Suspension 4369
Hood and Seat Latches 4369
Engine Compartment 4370
Paper Application 4370
Fuel, Oil, and Coolant Leaks, Check 4370
Hydraulic Hoses 4371
Coolant Hoses 4371
Steering Column Gas Cylinder 4371
Transmission 4371
Hydraulic System Oil 4371
Engine Oil 4372
Air Filter 4375
Forks 4375
Remove 4375
Inspect 4376
Install 4376
Adjust 4377
Integral Sideshift Carriage 4377
How to Make Checks With Engine Running 4377
Indicator Lights, Horn, Fuses, and Relays 4378
Service Brakes 4380
Brake Oil Level 4380
Operation, Check 4381
Parking Brake 4381
Engine Oil Pressure 4381
Cooling System 4381
Steering System 4382
Control Levers and Pedals 4382
Fuel/Water Separator Filter, Kubota Diesel Engine 4382
Lift System, Operate 4382
First Service After First 100 Hours of Operation 4383
GM 4 3L Engine Oil and Oil Filter 4383
Kubota Diesel Engine Oil and Oil Filter 4384
Maintenance Procedures Every 250 Hours or 6 Months 4384
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 4387
Maintenance Procedures Every 500 Hours or 6 Months 4389
Hydraulic System Oil 4389
Hydraulic Tank Breather 4390
Inspect 4390
Battery 4390
Kubota 3 8L Diesel Engine Oil and Oil Filter 4391
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4391
Remove 4391
Install 4391
Priming the Fuel System (Kubota 3 8L Engine) 4392
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4393
Remove 4393
Install 4393
Priming the Fuel System (Kubota 3 6L Engine) 4394
Drive Belt 4394
Kubota Diesel Engine 4394
Fan and Alternator Drive Belt 4394
Clean Debris From Radiator Core 4395
Transmission Oil Level 4395
Wet Brake Center Body Oil Level Check (Dana Drive Axle) 4396
Wet Brake Oil Level Check (NMHG Drive Axle) 4397
Forks 4398
Mast Lubrication 4398
Header Hose Checks 4401
Lift Chain Lubrication 4402
Tilt Cylinder Lubrication 4402
Master Brake Cylinder Rod End Pin Lubrication 4402
Manual Hydraulic Levers Lubrication 4403
Brake Oil 4404
Tie Rod Lubrication 4404
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes 4405
Parking Brake Adjustment 4405
Maintenance Procedures Every 1000 Hours or 6 Months 4406
Valve Clearance, Check and Adjust, GM 4 3L Engine 4406
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 4406
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4406
Ignition System 4406
GM 4 3L Engine 4406
Gasoline Fuel Filter, GM 4 3L Engine 4407
Remove and Replace 4407
In-Line Strainer Replacement, Kubota Diesel Engine 4407
Remove 4407
Install 4407
Lift Chains Wear Check 4409
Lift Chain Lubrication 4409
Integral Sideshift Carriage, Check Sliding Surfaces 4409
Steering Axle (Spindle Bearings) 4410
Control Levers and Pedals 4410
Parking Brake Lever Lubrication, Dana Wet Brake Axle 4410
Normal Operating Environment 4410
Heavy Duty or Contaminated Environment 4411
Remove 4411
Clean and Inspect 4412
Install 4413
Inspect Engine Electrical System, Connectors 4413
Crankcase Breather Element, Kubota 3 8L Diesel 4413
Remove 4413
Clean and Inspect 4414
Install 4414
Maintenance Procedures Every 2000 Hours or Annually 4414
Hydraulic System 4414
Hydraulic Filter, Replace 4414
Hydraulic Tank Breather, Replace 4415
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4416
Cooling System, GM 4 3L and Kubota Diesel Engines 4416
Air Filter 4416
LPG Fuel Filter Element Replace, GM 4 3L Engine 4418
Remove 4418
Install 4419
Fuel Injector, Kubota 3 8L Engine 4419
Fuel Injector, Kubota 3 6L Engine 4419
Forks 4419
Transmission Oil and Filter (Dry Brake), Replace 4419
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 4422
Wet Brake Center Section Oil Change (Dana Drive Axle) 4424
Remove 4424
Install 4424
Wet Brake Oil Change (NMHG Drive Axle) 4425
Brake Oil (Master Cylinder), Change 4426
Brake Oil (Dry Brake), Remove 4427
Service Brakes (Dry Brake) 4427
Differential (Dry Brake) 4428
Check Throttle Shaft for Sticking 4428
Inspect Exhaust Manifold and Piping for Leaks 4428
Wheel Bearings 4429
Steer Wheels, Lubrication 4429
Maintenance Procedures Every 4000 Hours or 2 Years 4429
Hydraulic Oil, Replace 4429
Safety Procedures When Working Near Mast 4430
Fuel Filter Water Removal 4433
Kubota Diesel Engine 4433
3 8L Diesel Engine 4433
3 6L Diesel Engine 4434
Hood Latch Check 4435
Lift Chain Adjustments 4436
Jump-Starting the Lift Truck 4437
Jump-Starting Using a Battery Charger 4438
Jump-Starting a Lift Truck Using Another Lift Truck 4438
Welding Repairs 4438
Overhead Guard Changes 4439
Wheel and Tire Replacement 4439
General 4439
Pneumatic Tire With Tube, Repair 4439
Remove Wheels From Lift Truck 4439
Remove Tire From Wheel 4440
Install Wheel in Tire 4442
Install Tire on Two-Piece Wheel 4444
Add Air to Pneumatic Tires With Tube 4445
Install the Wheels 4446
Dual Drive Wheels, Install 4446
Pneumatic Tubeless Tire, Repair 4447
Remove Wheels From Lift Truck 4447
Add Air to Pneumatic Tubeless Tire 4452
Wheels, Install 4452
Solid Rubber Tires on Pneumatic Wheels, Change 4452
Adhesives and Sealants 4456
550048683 8000YRM1559 (04 2018) US EN 4459
Lift Truck Lifting Capacity 4463
Counterweight Weights 4463
Tire Sizes 4463
Capacities 4463
Electrical System 4468
Transmission Oil Pressures 4469
Hydraulic System Relief Pressures 4470
Steering System 4471
Stall Speeds (in RPM ±100 rpm) 4472
PSI (GM) 4 3L Gas 4472
PSI (GM) 4 3L LPG 4472
Kubota 3 6L Diesel 4472
Kubota 3 8L Diesel 4472
Mast Speeds 4473
Tilt Angles 4476
Front End Equipment – Mast Creep 4477
Mast Creep 4477
Engine Specifications 4477
Diesel Fuel Cleanliness Levels 4479
Torque Specifications 4480
Frame 4480
Mast 4480
Steering System 4480
Steer Axle 4480
Drive Axle, Wet Brake
(Dana Spicer Axle) 4480
Drive Axle, Wet Brake
(NMHG Axle) 4480
Drive Axle (Dry Brake) 4480
Transmission 4481
Engine – PSI (GM) 4 3L 4481
Engine – Kubota 3 6L Diesel 4482
Engine – Kubota 3 8L Diesel 4483
550055279 0600YRM1579 (11 2019) US EN 4487
General 4493
Engine Identification 4493
Major Engine Component Identification 4493
Location of Labels 4493
Crankcase Description 4494
Engine Removal and Installation 4495
Cylinder Head Assembly Repair 4495
Valve Covers and Fuel Injectors 4495
Remove 4495
Clean and Inspect 4499
Install 4500
Rocker Arm Assembly 4501
Remove 4501
Disassemble 4503
Clean and Inspect 4503
Push Rods 4503
Rocker Arm Assembly 4503
Assemble 4504
Install 4504
Valve Clearance Adjustments 4504
Cylinder Head Assembly 4505
Remove 4505
Disassemble 4513
Valves and Valve Springs, Remove 4513
Valve Guides, Remove 4515
Clean and Inspect 4515
Cylinder Head 4516
Valve Guides 4516
Valves 4516
Valve Sink 4517
Valve Seat 4517
Valve Springs 4517
Assemble 4518
Valve Guides, Install 4518
Valves and Valve Springs, Install 4518
Install 4519
Timing Gear Case and Timing Gears Repair 4524
Timing Gear Case Cover 4524
Remove 4524
Clean and Inspect 4524
Install 4525
Timing Gears 4526
Crankshaft Gear 4526
Remove 4526
Install 4526
Idler Gear 4526
Remove 4526
Inspect 4527
Install 4527
Camshaft Gear 4527
Remove 4527
Install 4528
Timing Gear Case 4528
Remove 4528
Clean and Inspect 4529
Install 4529
Drive Train, Camshaft, and Cylinder Block Repair 4529
Remove 4529
Disassemble 4530
Pistons and Connecting Rods 4530
Crankshaft 4531
Camshaft 4533
Clean and Inspect 4534
Cylinder Block 4535
Honing and Boring 4537
Cylinder Correction (Oversize) 4538
Pistons 4538
Piston Pin 4539
Connecting Rod 4539
Tappets 4539
Crankshaft 4540
Camshaft 4542
Camshaft Bushing 4543
Assemble 4543
Camshaft 4543
Crankshaft 4543
Pistons and Connecting Rods 4543
Install 4545
Lubrication System Repair 4546
Engine Oil and Oil Filter Change 4546
Oil Pan 4547
Remove 4547
Install 4548
Oil Suction Tube 4548
Remove 4548
Clean 4549
Install 4549
Oil Pump 4549
Remove 4549
Clean and Inspect 4549
Outer Rotor Outside Clearance 4550
Outer Rotor to Inner Rotor Tip Clearance 4550
Outer Rotor Side Clearance 4550
Rotor Shaft Clearance 4551
Install 4551
Fuel System Repair 4552
Fuel Injectors 4552
Remove 4552
Inspect 4552
Clean 4552
Replace 4552
Install 4552
Electronic Throttle System 4552
Remove 4552
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) 4556
Bearing Replacement 4556
Install 4557
Adjustment 4558
Fuel Injection Pump 4558
Remove 4558
Disassemble 4562
Clean and Inspect 4564
Assemble 4564
Install 4565
Cooling System Repair 4566
Serpentine Belt 4566
Remove 4566
Inspect 4566
Install 4566
Serpentine Belt, Adjustment 4566
Water Pump 4567
Remove 4567
Install 4569
Thermostat 4570
Remove 4570
Inspect 4571
Install 4571
Flywheel and Flywheel Housing 4572
Flywheel 4572
Remove 4572
Install 4573
Flywheel Housing 4573
Remove 4573
Install 4573
Electrical Equipment Repair 4573
Alternator 4573
Remove 4573
Install 4574
Starter 4575
Remove 4575
Install 4575
Engine Specifications 4577
Engine Data 4577
Engine Tuning 4578
Cylinder Head 4578
Intake/Exhaust Valve and Guide 4579
Valve Spring 4579
Rocker Arm and Shaft 4579
Push Rod 4579
Gear Train and Camshaft 4580
Camshaft 4580
Idle Gear Shaft and Bushing 4580
Backlash of Each Gear 4580
Cylinder Block 4580
Crankshaft 4580
Piston 4581
Piston Ring 4581
Connecting Rod 4581
Rod Small End 4581
Tappet 4582
Oil Pump 4582
Engine Oil Pressure 4582
Outer Rotor Outside Clearance 4582
Outer Rotor Side Clearance 4582
Inner Rotor to Cover 4582
Standard Torque Specifications 4583
Standard Torque Chart 4583
Special Torque Specifications 4583
Special Tools 4585
550055280 1400YRM1582 (01 2019) US EN 4595
General 4599
Identification Plate 4599
Drive Axle Removal 4600
Reduction Gear Assembly 4605
Remove 4605
Disassemble 4608
Clean and Inspect 4612
Assemble 4612
Install 4621
Wet Disc Brake Repair 4624
General 4624
Remove 4625
Clean and Inspect 4628
Install 4629
Initial Steps For Install 4629
Final Steps For Install 4636
Wet Brake Noise Reduction 4639
General 4639
Adding Additive To Transmission 4639
Piston Housing 4641
Remove 4641
Disassemble 4642
Clean and Inspect 4643
Assemble 4643
Install 4644
Parking Brake Control Lever 4645
Remove 4645
Clean and Inspect 4646
Install 4646
Differential Repair 4648
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 4648
Input Pinion Carrier 4648
Remove 4649
Disassemble 4649
Clean and Inspect 4650
Assemble 4650
Preload Pinion Bearings 4652
Differential Housing and Drive Axle Trumpet Arm (Right Side) 4652
Remove 4654
Disassemble 4654
Clean and Inspect 4655
Assemble 4655
Install 4657
Ring Gear Backlash 4657
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 4658
Pinion and Motor Carrier 4659
Install 4659
Drive Axle Installation 4662
Special Tools 4667
Special Tools 4667
Torque specifications 4669
550055283 8000YRM1585 (07 2020) US EN 4673
General Information About Diagrams and Schematics 4677
Symbol Definitions 4677
Diagrams Manual Applications 4678
Diagrams and Schematics 4680
550064329 1800YRM1597 (03 2017) US EN 4769
Wet Brake System 4773
Service Brake Repair 4774
Parking Brake Repair 4774
Remove and Disassemble 4774
Assemble and Install 4775
Adjust 4776
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 4776
Master Cylinder and Booster 4776
Remove 4776
Disassemble 4778
Clean and Inspect 4779
Assemble 4779
Install and Adjust 4779
Brake System Air Removal 4781
Using Pressure Bleed System 4781
Using Brake Pedal Pressure 4782
Lift Truck Models with Master Cylinder 4782
Brake Pedal Adjustment 4783
Free Pedal Adjustment 4784
Torque Specifications 4784
550073240 1900YRM1620 (01 2023) US EN 4787
Proper Flushing after Major Hydraulic Repairs 4793
Introduction 4793
The Phases of Wear 4793
Causes of Hydraulic System Failure 4793
Progression of Contaminant Caused Hydraulic System Failure 4794
Hydraulic System Flushing Techniques 4794
Double Oil and Filter Change 4794
Mechanical Cleaning 4795
Cleaning of Components 4795
How to Clean Tubes and Hoses 4795
Filter Caddy 4795
Start-Up Procedure for Cleaned System 4796
Contaminated Oil Coolers 4796
Additional Filter Caddy Functions 4797
How to Handle Different Fluids 4797
Water Removal Filters 4797
Fluid Conditioning and System Flushing Procedures 4798
Operation of the Filter Caddy 4798
Filter Caddy operation 4798
Fluid Conditioning Procedure 4798
Filter Caddy Start-Up 4799
System Flushing Procedure 4799
Component Cleaning Procedure 4800
Reservoir Cleaning Procedure 4800
Cylinder Cleaning Procedure 4800
Hose and Tube Cleaning Procedure 4800
Valve Cleaning Procedure 4801
Front-End Attachment Cleaning Procedure 4802
System Flushing Procedure 4802
Filter Caddy Start-Up 4803
System Start-Up and Flushing 4803
Reservoir Fluid Cleaning Times 4804
Dealing With Different Fluid Types 4805
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4805
Filter Caddy Maintenance 4805
Servicing the Strainer 4805
DC Motor 4805
Hydraulic Oil Sampling Method and Procedure 4806
Hydraulic Oil Sampling Method 4806
Objective 4806
General Guidelines 4806
Synopsis 4807
Hydraulic Oil Analysis Report Guidelines 4808
Sampling Conditions 4808
Equipment 4808
Sampling Procedure 4809
Hydraulic Oil Sampling 4809
Sample Labeling 4809
Results Documentation 4809
550073240 1900YRM1620 (03 2020) US EN 4811
Proper Flushing after Major Hydraulic Repairs 4815
Introduction 4815
The Phases of Wear 4815
Causes of Hydraulic System Failure 4815
Progression of Contaminant Caused Hydraulic System Failure 4816
Hydraulic System Flushing Techniques 4816
Double Oil and Filter Change 4816
Mechanical Cleaning 4817
Cleaning of Components 4817
How to Clean Tubes and Hoses 4817
Filter Caddy 4817
Start-Up Procedure for Cleaned System 4818
Contaminated Oil Coolers 4818
Additional Filter Caddy Functions 4818
How to Handle Different Fluids 4818
Water Removal Filters 4819
Fluid Conditioning and System Flushing Procedures 4819
Operation of the Filter Caddy 4819
Filter Caddy operation 4819
Fluid Conditioning Procedure 4820
Filter Caddy Start-Up 4820
System Flushing Procedure 4821
Component Cleaning Procedure 4821
Reservoir Cleaning Procedure 4821
Cylinder Cleaning Procedure 4821
Hose and Tube Cleaning Procedure 4822
Valve Cleaning Procedure 4822
Front-End Attachment Cleaning Procedure 4823
System Flushing Procedure 4823
Filter Caddy Start-Up 4824
System Start-Up and Flushing 4824
Reservoir Fluid Cleaning Times 4825
Dealing With Different Fluid Types 4825
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4825
Filter Caddy Maintenance 4826
Servicing the Strainer 4826
DC Motor 4826
Hydraulic Oil Sampling Method and Procedure 4826
Hydraulic Oil Sampling Method 4826
Objective 4826
General Guidelines 4826
Synopsis 4827
Hydraulic Oil Analysis Report Guidelines 4828
Sampling Conditions 4829
Equipment 4829
Sampling Procedure 4829
Hydraulic Oil Sampling 4829
Sample Labeling 4830
Results Documentation 4830