Yale Forklift J813 (GLPGDP40VX5, 40VX6, 45VX6, 45SVX5, 50VX, 55VX Europe) Service Manual PDF

Yale Forklift J813 (GLPGDP40VX5, 40VX6, 45VX6, 45SVX5, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift J813 (GLPGDP40VX5, 40VX6, 45VX6, 45SVX5, 50VX, 55VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2920
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift J813 (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
524223757 0700YRM1123 (06 2016) UK EN 81
General 85
Cooling System Checks 85
Exhaust Leaks Into Cooling System 85
Water Flow Restrictions in Radiator 85
Radiator Hoses 85
Water Pump 86
Flushing the Cooling System 86
Cooling System, Clean 86
Radiator Replacement 87
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) 88
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 103
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 106
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) 109
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) 116
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 121
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 123
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) 126
Fan Assembly Replacement 138
Fan Removal 138
Inspect 153
Fan Installation 153
524223764 1600YRM1133 (07 2013) UK EN 159
toc 159
Steering Axle 159
Safety Precautions Maintenance and Repair 160
General 163
Steering Axle Assembly Repair 165
Remove 165
Disassemble 166
Clean 174
Inspect 174
Assemble 174
Install 180
Spindles, Bearings, and Tie Rods Repair 182
Spindles and Bearings 182
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 182
Remove 182
Disassemble 184
Clean 185
Inspect 185
Assemble 185
Install 186
Spindles and Bearings 189
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 189
Remove and Disassemble 189
Assemble and Install 190
Tie Rods 190
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 190
Remove 190
Install 191
Tie Rods 192
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 192
Remove 192
Install 198
Steering Cylinder Repair 198
Remove and Disassemble 198
Clean and Inspect 199
Assemble and Install 199
Torque Specifications 200
524223764 1600YRM1133 (07 2013) US EN 205
toc 205
Steering Axle 205
Safety Precautions Maintenance and Repair 206
General 209
Steering Axle Assembly Repair 211
Remove 211
Disassemble 212
Clean 220
Inspect 220
Assemble 220
Install 226
Spindles, Bearings, and Tie Rods Repair 228
Spindles and Bearings 228
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 228
Remove 228
Disassemble 230
Clean 231
Inspect 231
Assemble 231
Install 232
Spindles and Bearings 235
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 235
Remove and Disassemble 235
Assemble and Install 236
Tie Rods 236
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 236
Remove 236
Install 237
Tie Rods 238
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 238
Remove 238
Install 244
Steering Cylinder Repair 244
Remove and Disassemble 244
Clean and Inspect 245
Assemble and Install 245
Torque Specifications 246
524223766 1900YRM1136 (11 2017) UK EN 251
General 255
Hydraulic Gear Pump Assembly 256
Variable Displacement Pump Assembly 257
Single Gear Pump Assembly Repair 257
Remove 257
Disassemble 264
Clean 264
Inspect 266
Assemble 266
Install 266
Tandem Gear Pump Assembly 270
Remove 271
Disassemble 273
Clean 275
Inspect 275
Assemble 275
Install 276
Gear Pump Specifications 276
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 282
Remove 282
Disassemble 292
Clean 295
Inspect 295
Assemble 295
Install 296
63 0 cc/rev – Variable Displacement Pump Repair 299
Remove 299
Disassemble 302
Clean 302
Inspect 302
Assemble 304
Install 304
Variable Displacement Pump Checks and Adjustments (Single Pump) 306
Margin Pressure Check 306
Flow Compensator Adjustment 307
Pressure Compensator Adjustment 307
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 308
Variable Displacement Pump Specifications 311
Torque Specifications 312
Hydraulic Gear Pump 313
Variable Displacement Pump 314
Special Tools 314
524223767 2000YRM1137 (01 2017) UK EN 319
General 325
Electro-Hydraulic Main Control Valve 326
Description 326
Remove 334
Electro-Hydraulic Control Valve Sections 339
General 339
Outlet Control Valve Section 339
Remove 339
Disassemble 340
Clean 342
Inspect 342
Assemble 342
Install 343
Auxiliary Control Valve Sections 343
Remove 343
Disassemble 350
Clean 351
Inspect 352
Assemble 352
Install 354
Tilt Control Valve Section 355
Remove 355
Disassemble 355
Clean 361
Inspect 361
Assemble 361
Install 362
Lift/Lower Control Valve Section 363
Remove 363
Disassemble 363
Clean 372
Inspect 372
Assemble 372
Install 373
Mid-Inlet Section 373
Remove 373
Clean 374
Inspect 374
Install 374
Install 374
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 379
Lift Pilot Pin 379
Lower Pilot Pin 383
Abnormal/Erroneous EHPV Adjustment 385
Manual Main Control Valve 386
Description 386
Remove 390
OPS Solenoid Assembly 398
General 398
Remove 399
Clean and Inspect 402
Install 402
Manual Control Valve Sections 403
General 403
Outlet Control Valve Section 403
Remove 403
Disassemble 403
Clean 406
Inspect 406
Assemble 406
Install 407
Auxiliary Control Valve Sections 407
Remove 407
Disassemble 407
Clean 410
Inspect 410
Assemble 410
Install 411
Lift/Tilt Control Valve Section 411
Remove 411
Disassemble 411
Clean 418
Inspect 418
Assemble 419
Install 420
Mid-Inlet Section 421
Remove 421
Clean 421
Inspect 421
Install 421
Install 422
Pressure Relief Valve Check and Adjustment 428
Primary Relief Valve 429
Secondary Relief Valve 433
Steering Control Unit Repair 440
Steering Control Unit, Remove 440
Steering Control Unit, Disassemble 444
Steering Control Unit, Clean 446
Steering Control Unit, Inspect 446
Steering Control Unit, Assemble 446
Relief Valve, Disassemble 447
Relief Valve, Clean 447
Relief Valve, Inspect 448
Relief Valve, Assemble 448
Steering Control Unit, Install 448
524223768 2100YRM1139 (02 2014) UK EN 453
524223769 2200YRM1128 (01 2023) US EN 501
Series Code / Model Designation Reference Table 509
General 511
Deutsch Crimping Tool 512
How to Strip a Wire for Use With Deutsch Crimping Tool 512
How to Crimp With the Deutsch Crimping Tool 513
Calibration Test for the Deutsch Crimping Tool 515
Deutsch Connectors 517
DT, DTM, and DTP Series Connectors 517
HD Series Connectors 560
Metri-Pack Connectors 582
Remove and Install 582
Micro-Pack Connectors 585
Weather-Pack Connectors 586
AMPSEAL Crimping Tools 588
AMP Hand Crimping Tool With Certi-Crimp 588
Description 588
Stripping Wire for Use with AMP Hand Crimping Tool 589
Insulation Crimp Adjustment 590
Maintenance and Inspection for AMP Hand Crimping Tool 590
AMP Hand Crimping Tool 590
Crimp Height Inspection 590
How to use AMP Hand Crimping Tool 591
AMP Pro-Crimper II Tool 591
Description 591
Remove and Install Die Set and Locator Assembly 592
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 592
Contact Support Adjustment 593
Crimp Height Adjustment 594
Maintenance and Inspection Procedures 594
PRO-CRIMPER II Tool 594
Crimp Height Inspection 594
How to Use AMP PRO-CRIMPER II Tool 595
AMPSEAL Connector Assemblies 596
Description for Plug Connector Assembly 596
Seal Plug 597
Contact Crimping 597
Description for Plug Connector and Header Assembly 602
Voltage Reading 605
Seal Plug 605
Contact Crimping 605
AMP Superseal 1 5 Crimping Tools 612
Mini Mic Receptacle and Tab Contacts 612
Description 612
Crimping Conditions and Measurements 612
Insertion of Rubber Seal on Cable 614
AMP Hand Application Tool 619
Description 619
Maintenance and Inspection 619
Crimp Height Inspection 619
Crimp Height Adjustment 620
How to Use AMP Hand Application Tool 620
AMP Pro-Crimper II Tool 621
Description 621
Remove and Install Die Set and Locator Assembly 621
Adjustments 622
Contact Support 622
Crimp Height 623
Inspections and Maintenance 624
Crimp Height Inspection 624
Visual Inspection 624
Maintenance 625
How to Use Pro-Crimper II Tool 625
AMP Superseal 1 5 Connector Assemblies 626
Description 626
Repair and Maintenance 633
Panel Mount Option 633
AMP Fastin-Faston Hand Tools 634
Description – AMP Double Action Hand Tool 634
Maintenance and Inspection Procedures 634
Daily Maintenance 634
Periodic Tool Inspection 635
Lubrication 635
Visual Inspection 635
Crimp Height Inspection 635
Certi-Crimp Ratchet Inspection 636
How to Use AMP Double Action Hand Tool 637
Description – AMP Extraction Tool 638
Maintenance and Inspection 639
How to Use AMP Extraction Tool 639
AMP Fastin-Faston Receptacles and Housings 641
Description 641
Wire Repair 649
Wire Splicing Requirements 649
Deutsch Jiffy Splice 650
Twisted/Shielded Cable and Leads Repair 656
Special Tools 658
524223769 2200YRM1128 (07 2020) UK EN 667
Series Code / Model Designation Reference Table 673
General 676
Deutsch Crimping Tool 676
How to Strip a Wire for Use With Deutsch Crimping Tool 676
How to Crimp With the Deutsch Crimping Tool 677
Calibration Test for the Deutsch Crimping Tool 679
Deutsch Connectors 681
DT, DTM, and DTP Series Connectors 681
HD Series Connectors 723
Metri-Pack Connectors 746
Remove and Install 746
Micro-Pack Connectors 748
Weather-Pack Connectors 749
AMPSEAL Crimping Tools 751
AMP Hand Crimping Tool With Certi-Crimp 751
Description 751
Stripping Wire for Use with AMP Hand Crimping Tool 751
Insulation Crimp Adjustment 752
Maintenance and Inspection for AMP Hand Crimping Tool 752
AMP Hand Crimping Tool 752
Crimp Height Inspection 752
How to use AMP Hand Crimping Tool 753
AMP Pro-Crimper II Tool 753
Description 753
Remove and Install Die Set and Locator Assembly 754
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 755
Contact Support Adjustment 755
Crimp Height Adjustment 756
Maintenance and Inspection Procedures 756
PRO-CRIMPER II Tool 756
Crimp Height Inspection 756
How to Use AMP PRO-CRIMPER II Tool 757
AMPSEAL Connector Assemblies 758
Description for Plug Connector Assembly 758
Seal Plug 759
Contact Crimping 759
Description for Plug Connector and Header Assembly 764
Voltage Reading 766
Seal Plug 766
Contact Crimping 766
AMP Superseal 1 5 Crimping Tools 773
Mini Mic Receptacle and Tab Contacts 773
Description 773
Crimping Conditions and Measurements 773
Insertion of Rubber Seal on Cable 775
AMP Hand Application Tool 780
Description 780
Maintenance and Inspection 780
Crimp Height Inspection 780
Crimp Height Adjustment 781
How to Use AMP Hand Application Tool 781
AMP Pro-Crimper II Tool 782
Description 782
Remove and Install Die Set and Locator Assembly 783
Adjustments 783
Contact Support 783
Crimp Height 784
Inspections and Maintenance 785
Crimp Height Inspection 785
Visual Inspection 785
Maintenance 786
How to Use Pro-Crimper II Tool 786
AMP Superseal 1 5 Connector Assemblies 787
Description 787
Repair and Maintenance 794
Panel Mount Option 794
AMP Fastin-Faston Hand Tools 795
Description – AMP Double Action Hand Tool 795
Maintenance and Inspection Procedures 795
Daily Maintenance 795
Periodic Tool Inspection 796
Lubrication 796
Visual Inspection 796
Crimp Height Inspection 796
Certi-Crimp Ratchet Inspection 797
How to Use AMP Double Action Hand Tool 798
Description – AMP Extraction Tool 799
Maintenance and Inspection 799
How to Use AMP Extraction Tool 800
AMP Fastin-Faston Receptacles and Housings 801
Description 801
Wire Repair 808
Wire Splicing Requirements 808
Deutsch Jiffy Splice 809
Twisted/Shielded Cable and Leads Repair 814
Special Tools 817
524223770 2200YRM1130 (03 2020) UK EN 825
General 829
Description 829
Dash Display Menu Access 829
Menu Navigation 830
Standard Display 830
Main Menu 830
Passwords Menu 831
Password Administration 831
Add Password 831
Delete Password 832
Edit Password 832
Other Password Functions 833
Operator Passwords – Enable/Disable 833
Password Time-Out Delay 833
Passwords – Number Wrong to Disable 834
Lockout Reset Password 834
View Password Log 835
View Versions 836
VSM Versions 836
Dash Display Versions 837
Engine Controller Version 838
Transmission (Xmsn) Controller Version 839
Truck Serial Number 840
Diagnostics 841
View Fault Log 841
Set Travel and Braking 842
Speed Limit 842
Acceleration Rate 843
Auto-Deceleration Rate 843
Set Power Reversal Rate 844
Set Inching/Brake Overlap 845
Setup Display Menu 846
Set Operator Language 846
Set Units 847
Set Time Format (12/24 Hour) 847
Set Daylight Saving Time 847
Set Time 850
Set Date Format 851
Set Date 851
Setup Hydraulics 852
Return to Set Tilt Delay/On/Off 852
Setup General Items 853
Light Shutdown Time-Out 853
Impact Sensor – Enable/Disable 854
Impact Sensor – Soft Impact Settings 855
Impact Sensor – Hard Impact Settings 856
Adjust Impact Sensor Settings 856
Initial Adjustment of Soft and Hard Impact Settings 858
Readjustment of Soft and Hard Impact Settings 858
Impact Sensor – Impact Alarm/Shutdown Reset 859
Impact Sensor – Alarm Time Duration and Deactivation 860
Impact Sensor – View Impact Event Log 861
Engine Mode Indicator 862
Generation 1 (ECO-eLo ONLY) 862
Generation 2 863
Operator Checklist 864
Operator Checklist Off-On Mode 864
Edit Operator Checklist 864
Set Operator Checklist Expiration 865
View Checklist Log 865
Clear Operator Checklist Log 866
Clear Operator Checklist Fault 866
Calibrations 867
Set Tilt Stop Point 867
Calibrate Loaded Weight 867
524223771 2200YRM1131 (03 2020) UK EN 869
Series Code / Model Designation Reference Table 875
General 877
Description 877
Dash Display Menu Access 877
Menu Navigation 878
Main Menu 878
Passwords 879
Adding Passwords 879
Hourmeters 881
View Versions 882
VSM Versions 882
Dash Display Versions 883
Engine Controller Version 884
Transmission (Xmsn) Controller Version 885
Truck Serial Number 886
Truck Configuration 887
Diagnostics 888
Clear Fault Log 888
View Fault Log 889
No-Run Data Display 890
Engine Accelerator and Throttle Data Display 890
Engine Speeds and Governor Data Display 891
Engine Fuel and Emissions Data Display 892
Engine General Data Display 894
XMSN/Brake Data Display 895
Hydraulic Data Display 898
General Truck Data Display 900
Set Travel and Braking 901
Speed Limit 901
Acceleration Rate 902
Auto-Deceleration Rate 903
Set Power Reversal Rate 903
Set Inching/Brake Overlap 904
Setup Hydraulics 904
Lift Maximum Speed 905
Lower Maximum Speed 905
Tilt Maximum Speed 906
Auxiliary Function One, Direction A, Maximum Speed 908
Auxiliary Function One, Direction B, Maximum Speed 910
Auxiliary Function Two, Direction A, Maximum Speed 910
Auxiliary Function Two, Direction B, Maximum Speed 911
Auxiliary Function Three, Direction A, Maximum Speed 912
Auxiliary Function Three, Direction B, Maximum Speed 912
Lift/Lower Ramp Rate 913
Hydraulic Auxiliary Ramp Rate 913
Return to Set Tilt Delay/On/Off 914
Hydraulic Input Device 915
Auxiliary Solenoid 915
Dual Function 916
Setup Display 917
Set Service Language 917
Setup General Items 917
Motion Alarm Activation Type 918
Light Shutdown Time-Out 919
Restore Default Settings 919
Restore Engine Controller Default Calibration 920
Impact Sensor – Enable/Disable 920
Impact Sensor – Soft Impact Settings 921
Impact Sensor – Hard Impact Settings 922
Adjust Impact Sensor Settings 923
Initial Adjustment of Soft and Hard Impact Settings 925
Readjustment of Soft and Hard Impact Settings 925
Impact Sensor – Impact Alarm/Shutdown Reset 926
Impact Sensor – Alarm Time Duration and Deactivation 927
Impact Sensor – View Impact Event Log 928
Engine Mode Indicator 928
Generation 1 (ECO-eLo ONLY) 928
Generation 2 929
Diesel Particulate Filter (DPF) Display 930
General Description 930
Passive Regeneration Only 930
Regeneration Level 0 930
Auto/Active Regeneration Inhibited 931
Auto/Active Regeneration 931
Regeneration Level 1 931
Parked Regeneration Request 932
Regeneration Level 2 932
Warning Level 932
Regeneration Level 3 932
Service Level 933
Regeneration Level 4 933
Display, Diesel Particulate Filter (DPF), Revised 933
Operator Interface 933
Refer to Operator Manual 933
CAN Communication Lost 934
Passive Regeneration Only 934
Regeneration Level 0 934
Auto/Active Regeneration Inhibited 934
Auto/Active Regeneration 935
Regeneration Level 1 935
Idle-up Auto/Active Regeneration 935
Parked Regeneration Request 935
Regeneration Level 2 935
Warning Level 937
Regeneration Level 3 937
Service Level 937
Regeneration Level 4 937
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 937
Display, Diesel Particulate Filter (DPF), Stage V Engine 937
Operator Interface 938
Refer to Operator Manual 938
CAN Communication Lost 938
Passive Regeneration Only 938
Regeneration Level 0 938
Auto/Active Regeneration Inhibited 939
Auto/Active Regeneration 939
Regeneration Level 1 939
Idle-up Auto/Active Regeneration 940
Parked Regeneration Request 940
Regeneration Level 2 940
Warning Level 941
Regeneration Level 3 941
Service Level 942
Regeneration Level 4 942
Stage V Content 942
Emissions System Malfunction 942
Ash Load 942
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 943
Operator Interface 943
Refer to Operator Manual 943
CAN Communication Lost 944
Passive Regeneration Only 944
Regeneration Level 0 944
Auto/Active Regeneration Inhibited 944
Auto/Active Regeneration 945
Regeneration Level 1 945
Idle-up Auto/Active Regeneration 945
Parked Regeneration Request 945
Regeneration Level 2 945
Warning Level 947
Regeneration Level 3 947
Service Level 947
Regeneration Level 4 947
Calibrations 948
Calibrate Transmission Valve 950
Set Tilt Stop Point 950
Calibrate Loaded Weight 950
Calibrate Travel Speed Sensor 951
Calibrate Mazda LP and Gas Accelerator Pedal 951
524223772 2200YRM1142 (01 2020) UK EN 953
General 963
Display Switch Cluster 966
Remove 966
Install 969
Direction Control and Turn Signal Levers 969
Remove 969
Install 971
Key Switch 971
Remove 971
Install 972
Display Switch Cluster Panel Bezel and Overlay 972
Remove 972
Install 972
Steering Column Repair 972
Remove 972
Disassemble 975
Assemble 975
Install 975
Sensors and Switches 976
General 976
Dash and Kick Panel, Remove and Install 976
Remove 976
Install 977
Accelerator Pedal Position Sensor 978
Remove 978
Install 981
Brake Fluid Level Switch 982
Remove 982
Install 984
Service Brake Pedal Position Sensor 985
Remove 985
Install 988
Parking Brake Sensor 989
Remove 989
Install 990
Service Brake Pressure Sensor 991
Remove 991
Install 993
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 994
Remove 994
Install 994
Sensor Microswitch (Foot Directional Control Pedal) 995
Remove 995
Install 998
Low Coolant Level Sensor 999
Remove 999
Install 1002
Fuel Level Sensor, Gas and Diesel Engines Only 1003
Remove 1003
Install 1004
Armrest Switch 1004
Remove 1004
Install 1006
Seat Sensor (Operator Presence System) 1006
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) 1006
Remove 1006
Install 1007
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1007
Remove 1007
Install 1008
Full Suspension Seats; All Lift Truck Models 1008
Remove 1008
Install 1008
Hood Shut Off Switch 1008
Remove 1008
Install 1011
Remote Key Switch 1012
Remove 1012
Install 1012
Hydraulic Filter Pressure Switch 1013
Remove 1013
Install 1015
Transmission Speed Sensor 1015
Remove 1015
Install 1018
Transmission Pressure Sensors 1019
Remove 1019
Install 1021
Transmission Temperature Sensor 1022
Remove 1022
Install 1024
Engine Speed Sensor 1026
Remove 1026
Install 1026
Intermediate Speed Sensor 1027
Remove 1027
Install 1027
Return to Set Tilt (Tilt Angle) Sensor 1027
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) 1027
Remove 1027
Install 1028
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) 1029
Remove 1029
Install 1030
Rear Horn Button Switch 1030
Remove 1030
Install 1031
Impact Sensor 1032
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) 1032
Remove 1032
Install 1035
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) 1035
Remove 1035
Install 1036
Load Weight Sensor 1037
Remove 1037
Install 1038
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 1039
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 1039
Crankshaft Position (CKP) Sensor 1039
Camshaft Position (CMP) Sensor 1039
Oil Pressure Sensor 1039
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 1039
Engine Coolant Temperature (ECT) Sensor 1040
Air Flow Restriction Switch 1040
Remove for GM 2 4L Gas and LPG Trucks 1040
Install for GM 2 4L Gas and LPG Trucks 1040
Oxygen Sensor 1041
Remove 1041
Install 1044
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 1045
Crankshaft Position (CKP) Sensor 1045
Camshaft Position (CMP) Sensor 1045
Oil Pressure Sensor 1045
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 1045
Engine Coolant Temperature (ECT) Sensor 1045
Air Flow Restriction Switch 1045
Oxygen Sensor 1045
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 1045
Low LPG Pressure Switch 1045
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 1046
Air Filter Restriction Switch 1046
Remove 1046
Install 1046
Oil Pressure Sensor 1046
Remove 1046
Install 1046
Engine Speed Sensor 1046
Remove 1046
Install 1046
Engine Coolant Temperature (ECT) Sensor 1046
Remove 1046
Install 1046
Throttle Position Sensor (TPS) 1049
Remove 1049
Install 1050
Fuel/Water Separator Sensor 1050
Remove 1050
Install 1050
Glow Plug Relay 1051
Remove 1051
Install 1053
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 1053
Air Filter Restriction Switch 1053
Remove 1053
Install 1053
Engine Oil Pressure Sensor 1058
Remove 1058
Install 1058
Engine Speed Sensor 1058
Remove 1058
Install 1059
Engine Coolant Temperature (ECT) Sensor 1059
Remove 1059
Install 1060
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 1061
Remove 1061
Install 1061
Fuel/Water Separator Sensor 1062
Remove 1062
Install 1062
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 1063
Intake Air Temperature Sensor 1063
Remove 1063
Install 1064
Intake Air Pressure Sensor 1064
Remove 1064
Install 1064
Air Inlet Heater 1064
Remove 1064
Install 1065
Engine Oil Pressure Sensor 1065
Remove 1065
Install 1065
Engine Coolant Temperature (ECT) Sensor 1065
Remove 1065
Install 1065
Crankshaft Position Sensor 1066
Remove 1066
Install 1066
Adjust Shim Procedure 1067
Camshaft Position Sensor 1068
Remove 1068
Install 1068
Air Flow Restriction Sensor 1069
Remove 1069
Install 1069
Fuel/Water Separator 1069
Remove 1069
Install 1070
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 1070
Intake Air Temperature Sensor 1074
Remove 1074
Install 1075
Boost Sensor 1075
Remove 1075
Install 1076
Throttle Valve Assembly and Air Intake Heater 1076
Remove 1076
Install 1076
Engine Coolant Temperature (ECT) Sensor 1077
Remove 1077
Install 1077
Engine Oil Pressure Sensor 1077
Remove 1077
Install 1078
Crankshaft Position Sensor 1078
Remove 1078
Install 1078
Adjust Shim Procedure 1079
Camshaft Position Sensor 1080
Remove 1080
Install 1081
Differential Pressure Sensor 1081
Remove 1081
Install 1081
Mass Air Flow Sensor 1082
Remove 1082
Install 1083
Fuel/Water Separator 1083
Remove 1083
Install 1084
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 1084
Engine Coolant Temperature (ECT) Sensor 1085
Remove 1085
Install 1085
Throttle Position Sensor 1086
Engine Oil Pressure Sensor 1086
Remove 1086
Install 1086
Engine Speed Sensor 1086
Remove 1086
Install 1086
Fuel Shut Off Solenoid 1086
Remove 1086
Install 1086
Vehicle System Manager (VSM) 1087
General 1087
VSM Replacement 1087
Remove 1087
Install 1089
Programming a New VSM and/or Display Switch Cluster 1089
General 1089
PC Service Tool Software 1090
Data Transferring 1090
New VSM 1090
New (Blank) Display Switch Cluster 1090
Used (Non-Blank) Display Switch Cluster 1090
Power Distribution Module (PDM) and Component Parts 1092
Remove 1092
PDM as a Unit 1092
Install 1096
PDM as a Unit 1096
Remove and Install 1097
PDM Component Parts 1097
Transmission Control Unit 1097
Remove 1097
Install 1101
Battery 1103
Remove 1103
Install 1103
Lights 1104
Work Lights (Front and Rear) 1104
Remove 1104
Install 1104
Strobe Light 1105
Remove 1105
Install 1105
LED Tail, Backup, and Brake Lights 1106
Remove 1106
Install 1107
Front Marker/Turn Signal Lights 1108
Replacing Whole Front Marker/Turn Signal Light Assembly 1108
Remove 1108
Install 1108
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 1109
Remove 1109
Install 1109
Diesel Particulate Filter (DPF) Display 1109
Remove 1109
Clean and Inspect 1110
Install 1110
Electronic-Hydraulic Controls – Generation 1 1111
E-Hydraulic Controls – Test 1111
Mini-Levers 1111
Full Stroke Test 1111
Function Returns to Neutral Test 1111
Push Button Switch 1111
General 1112
Mini-Lever Replacement 1112
Remove 1112
Clean and Inspect 1113
Install 1113
Push Button Switch Replacement 1114
Remove 1114
Install 1116
Mini-Lever Module (MLM) 1116
Remove 1116
Install 1116
Joystick 1117
Remove and Disassemble 1117
Inspect 1117
Assemble and Install 1117
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 1118
General 1118
Mini-levers, Remove and Install 1118
Armrest Assembly 1119
Remove 1119
Install 1122
Horn Button 1122
Remove 1122
Install 1122
Direction Control Switch 1123
Remove 1123
Install 1123
push (override) buttons and Toggle Switch 1123
Remove 1124
Install 1125
Joystick 1126
Remove and Disassemble 1126
Inspect 1126
Assemble and Install 1126
Joystick Armrest Slider Assembly 1127
Remove 1127
Install 1128
Electronic-Hydraulic Controls, After January, 2020 1128
E-Hydraulic Controls – TEST 1128
Mini-Levers 1128
Full Stroke Test 1128
Function Returns to Neutral Test 1128
Push (Override) Button 1129
General 1129
Mini-levers, Remove and Install 1129
Armrest Assembly 1130
Remove 1130
Install 1133
Horn Button 1133
Remove 1133
Install 1133
Direction Control Switch 1133
Remove 1133
Install 1134
Push (Override) buttons and Toggle Switch 1134
Remove 1135
Install 1137
Special Tools 1138
524223780 8000YRM1134 (03 2020) UK EN 1141
Series Code / Model Designation Reference Table 1147
Description 1149
Proc_Cal_001: Service Password Entry 1151
When to Perform 1151
Why Perform 1151
How to Perform 1151
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 1152
When to Perform 1152
Calibration Order 1152
Why Perform 1152
How to Perform 1153
Proc_Cal_003: Save and Exit 1154
When to Perform 1154
Why Perform 1154
How to Perform 1154
Proc_Cal_004: Lift Valve Output Threshold 1155
When to Perform 1155
Calibration Order 1155
Why Perform 1155
How to Perform 1156
Proc_Cal_005: Lower Valve Output Threshold 1158
When to Perform 1158
Calibration Order 1158
Why Perform 1158
How to Perform 1158
Proc_Cal_006: Tilt Back Valve Output Threshold 1161
When to Perform 1161
Calibration Order 1161
Why Perform 1161
How to Perform 1161
Proc_Cal_007: Tilt Forward Valve Output Threshold 1164
When to Perform 1164
Calibration Order 1164
Why Perform 1164
How to Perform 1164
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 1167
When to Perform 1167
Calibration Order 1167
Why Perform 1167
How to Perform 1167
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 1170
When to Perform 1170
Calibration Order 1170
Why Perform 1170
How to Perform 1170
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 1173
When to Perform 1173
Calibration Order 1173
Why Perform 1173
How to Perform 1173
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 1176
When to Perform 1176
Calibration Order 1176
Why Perform 1176
How to Perform 1176
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 1179
When to Perform 1179
Calibration Order 1179
Why Perform 1179
How to Perform 1179
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 1182
When to Perform 1182
Calibration Order 1182
Why Perform 1182
How to Perform 1182
Proc_Cal_014: Load Weight Zero Point 1186
When to Perform 1186
Calibration Order 1186
Why Perform 1186
How to Perform 1186
Proc_Cal_015: Loaded Weight Calibration 1188
When to Perform 1188
Calibration Order 1188
Why Perform 1188
How to Perform 1188
Proc_Cal_016: Transmission Valve Calibration 1191
Applicable System/Option 1191
When to Perform 1191
Calibration Order 1191
Why Perform 1191
How to Perform 1191
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 1193
Applicable System/Option 1193
When to Perform 1193
Calibration Order 1193
Why Perform 1193
How to Perform 1193
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 1195
Applicable System/Option 1195
When to Perform 1195
Calibration Order 1195
Why Perform 1195
How to Perform 1196
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 1197
Required Tools 1197
When to Perform 1197
Calibration Order 1197
Why Perform 1198
How to Perform 1198
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 1199
When to Perform 1199
Why Perform 1199
How to Perform 1199
Proc_Cal_026: Travel Speed Calibration 1201
When to Perform 1201
Calibration Order 1201
Why Perform 1201
How to Perform 1201
524262274 0100YRM1243 (11 2016) UK EN 1205
General 1209
Description 1210
Hood, Seat, and Side Covers Replacement 1212
Remove 1212
Install 1212
Steering Column 1219
Description 1220
Steering Column Repair 1220
Remove 1220
Disassemble 1222
Clean 1225
Inspect 1225
Assemble 1225
Install 1225
LPG Tank and Bracket Replacement 1226
Counterweight Replacement 1226
Remove 1226
Install 1229
Tow Pin 1233
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) 1233
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) 1233
Overhead Guard Replacement 1234
Remove 1234
Install 1235
LED Tail, Backup, and Brake Lights, Replace 1235
Operator Restraint System Replacement 1236
Description 1236
Engine Replacement 1237
Remove Engine Only 1237
Install Engine only 1264
Remove Engine and Transmission 1267
Install Engine and Transmission 1271
Electronic Throttle Replacement 1275
Cummins 4 5L Diesel Engine With Electronic Throttle 1275
Remove 1275
Install 1278
Pull Actuator Linkage Adjustment 1280
Low Idle Adjustment 1280
Throttle Pedal and Cable Adjustment 1281
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 1281
Kubota 3 6L Diesel Engine 1281
Exhaust System Repair 1284
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) 1284
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) 1284
Remove 1284
Inspect 1284
Install 1286
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) 1286
Remove 1286
Inspect 1288
Install 1288
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 1288
Remove 1288
Inspect 1290
Install 1290
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) 1290
Remove 1290
Inspect 1293
Diesel Particulate Filter 1295
Disassemble 1295
CLEAN AND INSPECT 1296
Assembly 1296
Install 1297
Cooling System 1298
Description 1298
Hydraulic Filter Assembly Repair 1299
Remove 1299
Disassemble 1299
Clean 1300
Inspect 1300
Assemble 1300
Install 1300
Fuel and Hydraulic Tanks Repair 1300
Inspect 1300
Clean 1301
Steam Method of Cleaning 1301
Chemical Solution Method of Cleaning 1302
Additional Preparations for Repair 1302
Small Leaks, Repair 1302
Large Leaks, Repair 1302
Preparations for Use After Repair 1302
Safety Labels 1302
524262278 1400YRM1246 (02 2018) UK EN 1313
General 1317
Identification Plate 1318
Drive Axle Removal 1318
Hub Seal Replacement 1330
Planetary Reduction Repair 1339
Clean and Inspect 1348
Brake Repair 1361
Clean and Inspect 1377
Wet Brake Noise Reduction 1393
General 1393
Adding Additive To Transmission 1394
Bevel Pinion 1395
Clean and Inspect 1400
Differential Unit 1412
Disassemble 1423
Clean and Inspect 1429
Assemble 1430
Drive Axle Installation 1453
Special Tools 1463
Torque Specifications 1463
524262279 1800YRM1247 (09 2018) UK EN 1467
General 1471
Dry Brake System 1471
Wet Brake System 1472
Service Brakes Repair (Dry Brake) 1476
Remove and Disassemble 1476
Clean 1478
Inspect 1479
Assemble and Install 1479
Adjust 1483
Parking Brake Repair 1483
Dry Brake System 1484
Remove and Disassembly 1484
Assemble and Install 1486
Wet Brake System 1486
Remove and Install 1487
Assemble and Install 1493
Adjust 1493
Dry Brake System 1493
Wet Brake System 1494
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 1494
Master Cylinder Repair 1495
Remove 1495
Disassemble 1500
Clean and Inspect 1501
Assemble 1502
Install and Adjust 1502
Accumulator 1504
Pre-Charge Check 1505
Remove 1506
Install 1508
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 1508
Remove 1509
Modulating Brake Valve 1510
Disassemble 1510
Clean and Inspect 1512
Assemble 1512
Accumulator Charge Valve 1513
Disassemble 1513
Clean and Inspect 1515
Assemble 1515
Install 1516
Pressure Checks 1517
Accumulator Charge Valve Check 1517
Accumulator Check 1517
Service Brakes Adjustment (Dry Brake) 1518
Service Brakes Adjustment 1518
Brake System Air Removal 1519
Using Pressure Bleed System 1519
Using Brake Pedal Pressure 1520
Lift Truck Models with Master Cylinder 1520
Lift Truck Models with Modulating Brake Valve 1520
Brake Pedal Adjustment 1521
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) 1521
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1522
Free Pedal Adjustment 1524
Torque Specifications 1525
524265337 0600YRM1251 (09 2015) UK EN 1529
General 1535
Engine Removal and Installation 1535
Cylinder Head Repair 1535
Remove and Disassemble 1535
Clean and Inspect 1537
Valve Oil Seals 1540
Remove and Disassemble 1540
Cylinder Leak Down Test 1540
Clean and Inspect 1541
Assemble and Install 1541
Valve Guides and Seats, Repairs 1543
Valves, Repair 1543
Valve Seats, Repair 1544
Valve Springs 1545
Assemble and Install 1546
Engine Block Cleaning and Inspection 1549
Clean and Inspect 1550
Piston Bore Preparation 1552
Engine Mounts Installation 1552
Remove 1552
Clean and Inspect 1553
Install 1553
Lubrication System Repair 1554
Oil Pump, Remove and Disassemble 1554
Clean and Inspect 1555
Oil Pump, Assemble and Install 1556
Oil Pan, Install 1558
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 1560
Timing Cover 1560
Remove 1560
Install 1562
Timing Sprockets 1562
Remove 1562
Install 1562
Camshaft 1562
Remove 1562
Inspect 1563
Install 1563
Balance Shaft 1564
Remove 1564
Install 1565
Valve Lifters 1566
Remove 1566
Clean and Inspect 1566
Install 1567
Crankshaft Repair 1567
Remove 1568
Inspect and Repair 1568
How to Check Clearance Between Main Bearings and Their Journals 1569
Install 1570
Piston and Connecting Rod Assemblies Repair 1572
Connecting Rod Bearings, Replace 1572
Piston and Connecting Rod Assemblies, Remove 1573
Disassemble 1573
Piston, Clean and Inspect 1574
Cylinder Bores, Inspect and Repair 1574
Piston Rings 1575
Assemble 1576
Piston and Connecting Rod Assemblies, Install 1576
Flywheel and Flywheel Housing Repair 1576
Flywheel, Remove 1577
Clean 1577
Inspect 1577
Flywheel, Install 1578
Coolant Pump Repair 1578
Remove 1578
Clean and Inspect 1579
Install 1579
Thermostat Replacement 1579
Remove 1580
Thermostat Operation Check 1580
Install 1580
Starter Replacement 1581
1581
Remove 1581
Install 1584
Fan Assembly Replacement 1585
Remove 1585
Inspect 1587
Install 1587
Drive Belt Installation 1588
Remove 1588
Clean 1588
Inspect 1588
Installation 1589
Compression Check 1590
Engine Specifications 1590
Engine Data 1590
Cylinder Head 1590
Hydraulic Valve Lifter 1591
Camshaft 1591
Pistons 1591
Crankshaft 1592
Connecting Rods 1592
Balance Shaft 1593
Cooling System 1593
Lubrication System 1593
Torque Specifications 1594
524265342 4000YRM1250 (09 2018) UK EN 1599
Safety Procedures When Working Near Mast 1605
Fork Replacement 1607
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1607
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1609
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) 1610
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1611
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1612
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) 1613
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1613
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) 1615
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1615
Fixed Carriage Replacement 1617
Remove, Carriage With Hook Forks 1617
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1626
Install, Carriage With Hook Forks 1627
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1627
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1628
Connecting Attachment Hydraulic Quick Disconnect Hoses 1628
Integral Sideshift Carriage Repair 1629
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) 1629
Disassemble 1629
Clean and Inspect 1632
Assemble 1632
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) 1633
Hang On Sideshift Carriage Repair 1633
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) 1633
Disassemble 1645
Clean and Inspect 1654
Assemble 1655
Install 1656
Bolzoni Hang-On Sideshift Carriage Repair 1658
Remove 1658
Disassemble Carriage 1660
Clean and Inspect 1663
Assemble 1663
Install 1666
Fork Positioner 1668
Two-Stage Mast With Limited Free-Lift Repair 1669
Remove 1669
Disassemble 1673
Clean and Inspect 1676
Assemble 1693
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) 1695
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) 1696
Header Hose Alignment 1708
Two-Stage Mast With Full Free-Lift Repair 1718
Remove 1718
Disassemble 1720
Clean and Inspect 1732
Assemble 1733
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) 1735
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) 1738
Header Hose Installation and Adjustment 1742
Installation 1742
Adjustment 1742
Three-Stage Mast With Full Free-Lift Repair 1743
Remove 1743
Disassemble 1745
Clean and Inspect 1775
Assemble 1776
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) 1780
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) 1785
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) 1792
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) 1798
Mast Operation Check 1802
Tilt Cylinder Adjustment 1802
Lift Chains Adjustment 1803
Mast Adjustments 1804
Load Roller Adjustment 1804
Mast Side Kicking Adjustment 1806
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 1807
Carriage Adjustments 1810
524306203 0100YRM1290 (04 2014) UK EN 1813
550031265 2000YRM1457 (10 2015) UK EN 1917
General 1921
Main Control Valve Repair 1923
Remove 1923
Main Control Valve Sections 1926
General 1926
Outlet Control Valve Section 1926
Remove 1926
Disassemble 1926
Clean 1926
Inspect 1926
Assemble 1928
Install 1928
Auxiliary Control Valve Section 1928
Remove 1928
Disassemble 1928
Clean 1930
Inspect 1930
Assemble 1930
Install 1930
Tilt Control Valve Section 1931
Remove 1931
Disassemble 1931
Clean 1931
Inspect 1931
Assemble 1932
Install 1933
Lift/Lower Control Valve Section 1933
Remove 1933
Disassemble 1933
Clean 1933
Inspect 1933
Assemble 1934
Install 1935
Transition Section 1935
Remove 1935
Disassemble 1935
Clean 1935
Inspect 1935
Assemble 1936
Install 1936
Install 1937
Pressure Relief Valve Check and Adjustment 1941
General 1941
Secondary Relief Valve 1941
Steering Control Unit Repair 1942
Remove 1943
Disassemble 1943
Clean 1947
Inspect 1947
Assemble 1947
Install 1948
System Relief Valve 1949
Disassemble 1949
Clean 1949
Inspect 1949
Assemble 1949
Accumulator Replacement 1950
Remove 1950
Install 1950
550043871 0900YRM1556 (04 2018) UK EN 1955
General 1959
LPG Tank and Bracket 1959
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) 1959
Remove 1959
Install 1967
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) 1968
Remove 1968
Install 1970
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 1970
Remove 1970
Install 1972
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 1972
Remove 1972
Install 1972
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) 1973
Remove 1973
Install 1975
Fuel Filter Unit 1975
Fuel Filter Element 1976
Remove 1976
Clean and Inspect 1976
Install 1977
Fuel Filter Housing with LP Vapor Sensor 1977
Remove 1977
Disassemble 1979
Clean and Inspect 1980
Assemble 1980
Install 1981
Throttle Body 1982
Remove 1982
Clean 1986
Install 1986
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 1987
Remove 1987
Install 1988
Control System 1988
Engine Control Unit (ECU) 1989
Remove 1989
Install 1990
Low Pressure Switch 1990
Remove 1990
Install 1990
Low Fuel Sensor 1991
Remove 1991
Install 1991
LP Converter 1992
Remove and Disassemble 1992
Assemble and Install 1993
LPG Lock-Off 1993
Remove 1994
Install 1995
Exhaust System 1996
Counterweight Exhaust 1996
Remove and Disassemble 1996
Inspect 1998
Assemble and Install 1998
Overhead Exhaust 1999
Remove and Disassemble 1999
Inspect 2001
Assemble and Install 2001
Exhaust Manifold 2001
Remove 2001
Install 2003
Oxygen (HEGO) Sensor 2003
Remove 2003
Install 2003
LPG Fuel Testing 2004
General 2004
Available Fuel Tests 2004
Composition Test (ASTM D-2163) 2004
Ammonia Test (ASTM D-4490) 2004
Basic Nitrogen Test (ASTM UOP269-90) 2004
Residues Test (ASTM D-2158) 2004
Vapor Pressure Test (ASTM D-2598) 2004
Sulfur Compounds Test (ASTM D-5623) 2004
Methanol Test (ASTM D-4864) 2005
Copper Corrosion (ASTM D-1838) 2005
Where To Send LPG Fuel Samples For Testing 2005
550048607 0600YRM1557 (07 2019) UK EN 2009
General 2015
Engine Identification 2015
Major Engine Component Identification 2015
Location of Labels 2015
Crankcase Description 2016
Engine Removal and Installation 2017
Cylinder Head Assembly Repair 2018
Valve Covers and Fuel Injectors 2018
Remove 2018
Clean and Inspect 2024
Install 2024
Rocker Arm Assembly 2025
Remove 2025
Disassemble 2026
Clean and Inspect 2027
Push Rods 2027
Rocker Arm Assembly 2027
Assemble 2027
Install 2028
Valve Clearance Adjustments 2028
Cylinder Head Assembly 2029
Remove 2029
Disassemble 2041
Valves and Valve Springs, Remove 2041
Valve Guides, Remove 2042
Clean and Inspect 2042
Cylinder Head 2043
Valve Guides 2043
Valves 2043
Valve Sink 2043
Valve Seat 2044
Valve Springs 2044
Assemble 2045
Valve Guides, Install 2045
Valves and Valve Springs, Install 2046
Install 2047
Timing Gear Case and Timing Gears Repair 2051
Timing Gear Case Cover 2051
Remove 2051
Clean and Inspect 2052
Install 2052
Timing Gears 2053
Crankshaft Gear 2054
Remove 2054
Install 2054
Idler Gear 2054
Remove 2054
Inspect 2055
Install 2055
Camshaft Gear 2055
Remove 2055
Install 2056
Timing Gear Case 2056
Remove 2056
Clean and Inspect 2057
Install 2057
Drive Train, Camshaft, and Cylinder Block Repair 2058
Remove 2058
Disassemble 2058
Pistons and Connecting Rods 2058
Crankshaft 2059
Camshaft 2061
Clean and Inspect 2063
Cylinder Block 2063
Honing and Boring 2065
Cylinder Correction (Oversize) 2066
Pistons 2066
Piston Pin 2067
Connecting Rod 2067
Tappets 2068
Crankshaft 2068
Camshaft 2070
Camshaft Bushing 2071
Assemble 2071
Camshaft 2071
Crankshaft 2071
Pistons and Connecting Rods 2072
Install 2074
Angular Deviation Procedure 2074
Lubrication System Repair 2077
Engine Oil and Oil Filter Change 2077
Oil Pan 2078
Remove 2078
Install 2079
Oil Suction Tube 2079
Remove 2079
Clean 2080
Install 2080
Oil Pump 2080
Remove 2080
Clean and Inspect 2081
Outer Rotor Outside Clearance 2081
Outer Rotor to Inner Rotor Tip Clearance 2081
Outer Rotor Side Clearance 2082
Rotor Shaft Clearance 2082
Install 2082
Fuel System Repair 2083
Fuel Injectors 2083
Remove 2083
Inspect 2083
Clean 2083
Replace 2083
Install 2084
Test 2084
Fuel Injection Pump 2084
Remove 2084
Clean and Inspect 2089
Install 2089
Cooling System Repair 2090
Serpentine Belt 2090
Remove 2090
Inspect 2090
Install 2090
Serpentine Belt, Adjustment 2091
Water Pump 2091
Remove 2091
Install 2094
Thermostat 2096
Remove 2096
Inspect 2096
Install 2097
Flywheel and Flywheel Housing 2098
Flywheel 2098
Remove 2098
Install 2098
Flywheel Housing 2098
Remove 2098
Install 2098
Electrical Equipment Repair 2099
Alternator 2099
Remove 2099
Install 2100
Starter 2101
Remove 2101
Install 2101
Engine Specifications 2102
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) 2102
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 2103
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879) 2104
Engine Tuning 2105
Cylinder Head 2105
Intake/Exhaust Valve and Guide 2106
Valve Spring 2106
Rocker Arm and Shaft 2106
Push Rod 2106
Gear Train and Camshaft 2107
Camshaft 2107
Idle Gear Shaft and Bushing 2107
Backlash of Each Gear 2107
Cylinder Block 2107
Crankshaft 2107
Piston 2108
Piston Ring 2108
Connecting Rod 2108
Rod Small End 2108
Tappet 2109
Oil Pump 2109
Engine Oil Pressure 2109
Outer Rotor Outside Clearance 2109
Outer Rotor Side Clearance 2109
Inner Rotor to Cover 2109
Standard Torque Specifications 2110
Standard Torque Chart 2110
Special Torque Specifications 2110
Special Tools 2112
550048681 1300YRM1569 (11 2018) UK EN 2125
General 2129
Serial Number 2129
Charge Pump Repair 2129
Lift Trucks Manufactured Before July, 2013 2129
Remove 2129
Inspect 2130
Install 2130
Lift Trucks Manufactured After July, 2013 2130
Remove 2130
Inspect 2131
Install 2131
Torque Converter Replace 2131
Remove 2131
Install 2137
Housings and Chain Drive Repair 2142
Remove 2143
Clean 2151
Inspect 2151
Install 2151
Clutch Packs Repair- 1 Speed Transmission 2157
Remove and Disassemble 2157
Transmission, Remove and Disassemble 2157
Clean 2169
Inspect 2169
Assemble and Install 2170
Transmission, Assemble and Install 2178
Clutch Packs Repair- 2 Speed Transmission 2181
Remove and Disassemble 2182
Transmission, Remove and Disassemble 2182
Clean 2196
Inspect 2196
Assemble and Install 2197
Transmission, Assemble and Install 2206
Control Valve Repair 2208
Remove and Disassemble 2209
Clean 2212
Inspect 2212
Assemble and Install 2212
Foot Directional Control Pedal Repair 2213
Remove and Disassemble 2213
Assemble and Install 2217
Direction Control Lever 2218
Remove 2218
Install 2218
550055279 0600YRM1579 (11 2019) UK EN 2223
General 2229
Engine Identification 2229
Major Engine Component Identification 2229
Location of Labels 2229
Crankcase Description 2230
Engine Removal and Installation 2231
Cylinder Head Assembly Repair 2231
Valve Covers and Fuel Injectors 2231
Remove 2231
Clean and Inspect 2235
Install 2236
Rocker Arm Assembly 2237
Remove 2237
Disassemble 2239
Clean and Inspect 2239
Push Rods 2239
Rocker Arm Assembly 2239
Assemble 2240
Install 2240
Valve Clearance Adjustments 2240
Cylinder Head Assembly 2241
Remove 2241
Disassemble 2249
Valves and Valve Springs, Remove 2249
Valve Guides, Remove 2251
Clean and Inspect 2251
Cylinder Head 2252
Valve Guides 2252
Valves 2252
Valve Sink 2253
Valve Seat 2253
Valve Springs 2253
Assemble 2254
Valve Guides, Install 2254
Valves and Valve Springs, Install 2254
Install 2255
Timing Gear Case and Timing Gears Repair 2260
Timing Gear Case Cover 2260
Remove 2260
Clean and Inspect 2260
Install 2261
Timing Gears 2262
Crankshaft Gear 2262
Remove 2262
Install 2262
Idler Gear 2262
Remove 2262
Inspect 2263
Install 2263
Camshaft Gear 2263
Remove 2263
Install 2264
Timing Gear Case 2264
Remove 2264
Clean and Inspect 2265
Install 2265
Drive Train, Camshaft, and Cylinder Block Repair 2265
Remove 2265
Disassemble 2266
Pistons and Connecting Rods 2266
Crankshaft 2267
Camshaft 2269
Clean and Inspect 2270
Cylinder Block 2271
Honing and Boring 2273
Cylinder Correction (Oversize) 2274
Pistons 2274
Piston Pin 2275
Connecting Rod 2275
Tappets 2275
Crankshaft 2276
Camshaft 2278
Camshaft Bushing 2279
Assemble 2279
Camshaft 2279
Crankshaft 2279
Pistons and Connecting Rods 2279
Install 2281
Lubrication System Repair 2282
Engine Oil and Oil Filter Change 2282
Oil Pan 2283
Remove 2283
Install 2284
Oil Suction Tube 2284
Remove 2284
Clean 2285
Install 2285
Oil Pump 2285
Remove 2285
Clean and Inspect 2285
Outer Rotor Outside Clearance 2286
Outer Rotor to Inner Rotor Tip Clearance 2286
Outer Rotor Side Clearance 2286
Rotor Shaft Clearance 2287
Install 2287
Fuel System Repair 2288
Fuel Injectors 2288
Remove 2288
Inspect 2288
Clean 2288
Replace 2288
Install 2288
Electronic Throttle System 2288
Remove 2288
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) 2292
Bearing Replacement 2292
Install 2293
Adjustment 2294
Fuel Injection Pump 2294
Remove 2294
Disassemble 2298
Clean and Inspect 2300
Assemble 2300
Install 2301
Cooling System Repair 2302
Serpentine Belt 2302
Remove 2302
Inspect 2302
Install 2302
Serpentine Belt, Adjustment 2302
Water Pump 2303
Remove 2303
Install 2305
Thermostat 2306
Remove 2306
Inspect 2307
Install 2307
Flywheel and Flywheel Housing 2308
Flywheel 2308
Remove 2308
Install 2309
Flywheel Housing 2309
Remove 2309
Install 2309
Electrical Equipment Repair 2309
Alternator 2309
Remove 2309
Install 2310
Starter 2311
Remove 2311
Install 2311
Engine Specifications 2313
Engine Data 2313
Engine Tuning 2314
Cylinder Head 2314
Intake/Exhaust Valve and Guide 2315
Valve Spring 2315
Rocker Arm and Shaft 2315
Push Rod 2315
Gear Train and Camshaft 2316
Camshaft 2316
Idle Gear Shaft and Bushing 2316
Backlash of Each Gear 2316
Cylinder Block 2316
Crankshaft 2316
Piston 2317
Piston Ring 2317
Connecting Rod 2317
Rod Small End 2317
Tappet 2318
Oil Pump 2318
Engine Oil Pressure 2318
Outer Rotor Outside Clearance 2318
Outer Rotor Side Clearance 2318
Inner Rotor to Cover 2318
Standard Torque Specifications 2319
Standard Torque Chart 2319
Special Torque Specifications 2319
Special Tools 2321
550055280 1400YRM1582 (01 2019) UK EN 2331
General 2335
Identification Plate 2335
Drive Axle Removal 2336
Reduction Gear Assembly 2341
Remove 2341
Disassemble 2344
Clean and Inspect 2348
Assemble 2348
Install 2357
Wet Disc Brake Repair 2360
General 2360
Remove 2361
Clean and Inspect 2364
Install 2365
Initial Steps For Install 2365
Final Steps For Install 2372
Wet Brake Noise Reduction 2375
General 2375
Adding Additive To Transmission 2375
Piston Housing 2377
Remove 2377
Disassemble 2378
Clean and Inspect 2379
Assemble 2379
Install 2380
Parking Brake Control Lever 2381
Remove 2381
Clean and Inspect 2382
Install 2382
Differential Repair 2384
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 2384
Input Pinion Carrier 2384
Remove 2385
Disassemble 2385
Clean and Inspect 2386
Assemble 2386
Preload Pinion Bearings 2388
Differential Housing and Drive Axle Trumpet Arm (Right Side) 2388
Remove 2390
Disassemble 2390
Clean and Inspect 2391
Assemble 2391
Install 2393
Ring Gear Backlash 2393
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 2394
Pinion and Motor Carrier 2395
Install 2395
Drive Axle Installation 2398
Special Tools 2403
Special Tools 2403
Torque specifications 2405
550055283 8000YRM1585 (07 2020) UK EN 2409
General Information About Diagrams and Schematics 2413
Symbol Definitions 2413
Diagrams Manual Applications 2414
Diagrams and Schematics 2416
550059479 0600YRM1590 (07 2019) UK EN 2505
General 2511
Engine Identification 2511
Major Engine Component Identification 2511
Location of Labels 2512
Crankcase Description 2512
Precautions Before Beginning Repair 2513
Exhaust System and DPF 2514
Engine Removal and Installation 2514
Cylinder Head Assembly Repair 2515
Valve Covers and Fuel Injectors 2515
Remove 2515
Clean and Inspect 2518
Install 2518
Rocker Arm Assembly 2519
Remove 2519
Disassemble 2520
Clean and Inspect 2520
Push Rods 2520
Rocker Arm Assembly 2520
Assemble 2521
Install 2521
Valve Clearance Adjustments 2521
Cylinder Head Assembly 2522
Remove 2522
Disassemble 2531
Valves and Valve Springs, Remove 2531
Valve Guides, Remove 2532
Clean and Inspect 2532
Cylinder Head 2533
Valve Guides 2533
Valves 2533
Valve Sink 2534
Valve Seat 2534
Valve Springs 2535
Assemble 2535
Valve Guides, Install 2535
Valves and Valve Springs, Install 2536
Install 2537
Timing Gear Case and Timing Gears Repair 2539
Timing Gear Case Cover 2539
Remove 2539
Clean and Inspect 2540
Install 2540
Timing Gears 2541
Crankshaft Gear 2542
Remove 2542
Install 2542
Idler Gear 2542
Remove 2542
Inspect 2543
Install 2544
Camshaft Gear 2544
Remove 2544
Install 2544
Drive Train, Camshaft, and Cylinder Block Repair 2544
Remove 2544
Disassemble 2545
Pistons and Connecting Rods 2545
Crankshaft 2546
Camshaft 2548
Clean and Inspect 2550
Cylinder Block 2550
Honing and Boring 2552
Cylinder Correction (Oversize) 2553
Pistons 2553
Piston Pin 2554
Connecting Rod 2554
Tappets 2555
Crankshaft 2555
Camshaft 2557
Camshaft Bushing 2558
Assemble 2558
Camshaft 2558
Crankshaft 2558
Pistons and Connecting Rods 2559
Install 2561
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 2561
Lubrication System Repair 2564
Engine Oil and Oil Filter Change 2564
Oil Pan 2565
Remove 2565
Install 2566
Oil Suction Tube 2567
Remove 2567
Clean 2567
Install 2567
Oil Pump 2567
Remove 2567
Clean and Inspect 2568
Outer Rotor Outside Clearance 2569
Outer Rotor to Inner Rotor Tip Clearance 2569
Outer Rotor Side Clearance 2569
Rotor Shaft Clearance 2570
Install 2570
Fuel System Repair 2571
Fuel Injectors 2571
Remove 2571
Inspect 2571
Clean 2571
Replace 2571
Install 2571
Test 2571
Fuel Injection Pump 2572
Remove 2572
Clean and Inspect 2573
Install 2573
Cooling System Repair 2574
Serpentine Belt 2574
Remove 2574
Inspect 2575
Install 2575
Adjust 2575
Water Pump 2576
Remove 2576
Install 2577
Thermostat 2578
Remove 2578
Inspect 2579
Install 2579
Flywheel and Flywheel Housing 2580
Flywheel 2580
Remove 2580
Install 2581
Flywheel Housing 2581
Remove 2581
Install 2581
Electrical Equipment Repair 2582
Alternator 2582
Remove 2582
Install 2583
Starter 2584
Remove 2584
Install 2584
Engine Specifications 2586
Engine Data 2586
Engine Tuning 2590
Cylinder Head 2590
Intake/Exhaust Valve and Guide 2590
Valve Spring 2591
Rocker Arm and Shaft 2591
Push Rod 2591
Gear Train and Camshaft 2591
Camshaft 2591
Idle Gear Shaft and Bushing 2591
Backlash of Each Gear 2592
Cylinder Block 2592
Crankshaft 2592
Piston 2592
Piston Ring 2593
Connecting Rod 2593
Rod Small End 2593
Tappet 2593
Oil Pump 2594
Engine Oil Pressure 2594
Outer Rotor Outside Clearance 2594
Outer Rotor Side Clearance 2594
Inner Rotor to Cover 2594
Standard Torque Specifications 2595
Standard Torque Chart 2595
Special Torque Specifications 2595
Special Tools 2597
550064329 1800YRM1597 (03 2017) UK EN 2611
Wet Brake System 2615
Service Brake Repair 2616
Parking Brake Repair 2616
Remove and Disassemble 2616
Assemble and Install 2617
Adjust 2618
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 2618
Master Cylinder and Booster 2618
Remove 2618
Disassemble 2620
Clean and Inspect 2621
Assemble 2621
Install and Adjust 2621
Brake System Air Removal 2623
Using Pressure Bleed System 2623
Using Brake Pedal Pressure 2624
Lift Truck Models with Master Cylinder 2624
Brake Pedal Adjustment 2625
Free Pedal Adjustment 2626
Torque Specifications 2626
550068688 8000YRM1604 (05 2019) UK EN 2629
General 2635
Serial Number Data 2635
How to Move Disabled Lift Truck 2635
How to Tow Lift Truck 2635
How to Put Lift Truck on Blocks 2636
How to Raise Drive Tires 2636
How to Raise Steering Tires 2637
How to Clean a Lift Truck 2638
Maintenance Schedule 2638
Maintenance Procedures Every 8 Hours or Daily 2651
How to Make Checks With Engine Stopped 2652
Tires and Wheels 2652
Safety Labels 2652
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2652
Operator Restraint System 2653
Emergency Locking Retractor (ELR) 2653
Adjust Seat – Full Suspension 2654
Adjust Seat – Internal Suspension 2655
Hood and Seat Latches 2655
Engine Compartment 2656
Paper Application 2656
Fuel, Oil, and Coolant Leaks, Check 2656
Hydraulic Hoses 2657
Coolant Hoses 2657
Steering Column Gas Cylinder 2657
Transmission 2657
Hydraulic System Oil 2657
Engine Oil 2657
Air Filter 2661
Forks 2661
Remove 2661
Inspect 2662
Install 2662
Adjust 2663
Integral Sideshift Carriage 2663
How to Make Checks With Engine Running 2664
Indicator Lights, Horn, Fuses, and Relays 2664
Service Brakes 2666
Brake Oil Level 2666
Operation, Check 2667
Parking Brake 2667
Engine Oil Pressure 2667
Cooling System 2667
Steering System 2668
Control Levers and Pedals 2668
Fuel/Water Separator Filter, Kubota Diesel Engine 2668
Lift System, Operate 2668
Air Filter 2669
First Service After First 100 Hours of Operation 2670
GM 4 3L Engine Oil and Oil Filter 2670
Kubota Diesel Engine Oil and Oil Filter 2670
Maintenance Procedures Every 500 Hours or 1 Year 2671
Hydraulic System Oil 2671
Hydraulic Tank Breather 2671
Inspect 2671
Battery 2672
Kubota Diesel Engine Oil and Oil Filter 2672
GM 4 3L Engine Oil and Oil Filter 2672
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 2673
Remove 2673
Install 2673
Priming the Fuel System (Kubota 3 8L Engine) 2674
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 2675
Remove 2675
Install 2675
Priming the Fuel System (Kubota 3 6L Engine) 2676
Drain Tar From LPG Converter 2676
Drive Belt 2677
GM 4 3L Engine 2677
Fan and Alternator Drive Belt 2677
Kubota Diesel Engine 2678
Fan and Alternator Drive Belt 2678
Clean Debris From Radiator Core 2678
Transmission Oil Level 2679
Wet Brake Center Body Oil Level Check (Dana Drive Axle) 2679
Wet Brake Oil Level Check (NMHG Drive Axle) 2680
Forks 2681
Mast Lubrication 2681
Header Hose Checks 2683
Lift Chain Lubrication 2683
Tilt Cylinder Lubrication 2684
Master Brake Cylinder Rod End Pin Lubrication 2684
Manual Hydraulic Levers Lubrication 2685
Brake Oil 2685
Tie Rod Lubrication 2686
Parking Brake Adjustment 2686
Maintenance Procedures Every 1000 Hours or 1 Year 2687
Valve Clearance, Check and Adjust, GM 4 3L Engine 2687
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 2687
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 2687
Ignition System 2688
GM 4 3L Engine 2688
LPG Fuel Filter Element Replace, GM 4 3L Engine 2688
Remove 2688
Install 2688
In-Line Strainer Replacement, Kubota Diesel Engine 2689
Remove 2689
Install 2689
Lift Chains Wear Check 2690
Lift Chain Lubrication 2691
Integral Sideshift Carriage, Check Sliding Surfaces 2691
Steering Axle (Spindle Bearings) 2692
Control Levers and Pedals 2692
Parking Brake Lever Lubrication, Dana Wet Brake Axle 2692
Normal Operating Environment 2692
Heavy Duty or Contaminated Environment 2693
Remove 2693
Clean and Inspect 2694
Install 2695
Inspect Engine Electrical System, Connectors 2695
Crankcase Breather Element, Kubota 3 8L Diesel Engine 2695
Remove 2695
Clean and Inspect 2696
Install 2696
Maintenance Procedures Every 2000 Hours or Annually 2696
Hydraulic System 2696
Hydraulic Filter, Replace 2696
Hydraulic Tank Breather, Replace 2697
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 2698
Cooling System, GM 4 3L and Kubota Diesel Engines 2698
Air Filter 2698
Fuel Injector, Kubota 3 8L Engine 2700
Fuel Injector, Kubota 3 6L Engine 2700
Forks 2700
Transmission Oil and Filter, Replace 2700
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 2702
Wet Brake Center Section Oil Change (Dana Drive Axle) 2705
Remove 2705
Install 2705
Wet Brake Oil Change (NMHG Drive Axle) 2705
Brake Oil (Master Cylinder), Change 2707
Check Throttle Shaft for Sticking 2708
Inspect Exhaust Manifold and Piping for Leaks 2708
Wheel Bearings 2708
Steer Wheels, Lubrication 2708
Maintenance Procedures Every 4000 Hours or 2 Years 2708
Hydraulic Oil, Replace 2708
Safety Procedures When Working Near Mast 2709
Fuel Filter Water Removal 2712
Kubota Diesel Engine 2712
3 8L Diesel Engine 2712
3 6L Diesel Engine 2713
Hood Latch Check 2714
Lift Chain Adjustments 2715
Jump-Starting the Lift Truck 2716
Jump-Starting Using a Battery Charger 2717
Jump-Starting a Lift Truck Using Another Lift Truck 2717
Welding Repairs 2717
Overhead Guard Changes 2718
Wheel and Tire Replacement 2718
General 2718
Pneumatic Tire With Tube, Repair 2718
Remove Wheels From Lift Truck 2718
Remove Tire From Wheel 2718
Install Wheel in Tire 2721
Install Tire on Two-Piece Wheel 2723
Add Air to Pneumatic Tires With Tube 2724
Install the Wheels 2724
Dual Drive Wheels, Install 2725
Pneumatic Tubeless Tire, Repair 2726
Remove Wheels From Lift Truck 2726
Add Air to Pneumatic Tubeless Tire 2731
Wheels, Install 2731
Solid Rubber Tires on Pneumatic Wheels, Change 2731
Adhesives and Sealants 2735
550068693 8000YRM1605 (04 2018) UK EN 2739
Counterweight Weights 2743
Tire Sizes 2743
Capacities 2743
Electrical System 2747
Transmission Oil Pressures 2748
Hydraulic System Relief Pressures 2750
Steering System 2750
Stall Speeds (in RPM ±100 rpm) 2750
PSI (GM) 4 3L 2751
Kubota 3 6L Diesel 2751
Kubota 3 8L Diesel 2751
Mast Speeds 2751
Tilt Angles 2755
Front End Equipment – Mast Creep 2755
Mast Creep 2755
Engine Specifications 2755
Diesel Fuel Cleanliness Levels 2758
Torque Specifications 2758
Frame 2758
Mast 2758
Steering System 2758
Steer Axle 2758
Drive Axle, Wet Brake
(Dana Spicer Axle) 2758
Drive Axle, Wet Brake
(NMHG Axle) 2759
Transmission 2759
Engine – PSI (GM) 4 3L 2759
Engine – Kubota 3 6L Diesel 2760
Engine – Kubota 3 8L Diesel 2761
550073240 1900YRM1620 (01 2023) US EN 2765
Proper Flushing after Major Hydraulic Repairs 2771
Introduction 2771
The Phases of Wear 2771
Causes of Hydraulic System Failure 2771
Progression of Contaminant Caused Hydraulic System Failure 2772
Hydraulic System Flushing Techniques 2772
Double Oil and Filter Change 2772
Mechanical Cleaning 2773
Cleaning of Components 2773
How to Clean Tubes and Hoses 2773
Filter Caddy 2773
Start-Up Procedure for Cleaned System 2774
Contaminated Oil Coolers 2774
Additional Filter Caddy Functions 2775
How to Handle Different Fluids 2775
Water Removal Filters 2775
Fluid Conditioning and System Flushing Procedures 2776
Operation of the Filter Caddy 2776
Filter Caddy operation 2776
Fluid Conditioning Procedure 2776
Filter Caddy Start-Up 2777
System Flushing Procedure 2777
Component Cleaning Procedure 2778
Reservoir Cleaning Procedure 2778
Cylinder Cleaning Procedure 2778
Hose and Tube Cleaning Procedure 2778
Valve Cleaning Procedure 2779
Front-End Attachment Cleaning Procedure 2780
System Flushing Procedure 2780
Filter Caddy Start-Up 2781
System Start-Up and Flushing 2781
Reservoir Fluid Cleaning Times 2782
Dealing With Different Fluid Types 2783
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2783
Filter Caddy Maintenance 2783
Servicing the Strainer 2783
DC Motor 2783
Hydraulic Oil Sampling Method and Procedure 2784
Hydraulic Oil Sampling Method 2784
Objective 2784
General Guidelines 2784
Synopsis 2785
Hydraulic Oil Analysis Report Guidelines 2786
Sampling Conditions 2786
Equipment 2786
Sampling Procedure 2787
Hydraulic Oil Sampling 2787
Sample Labeling 2787
Results Documentation 2787
550073240 1900YRM1620 (03 2020) UK EN 2789
Proper Flushing after Major Hydraulic Repairs 2793
Introduction 2793
The Phases of Wear 2793
Causes of Hydraulic System Failure 2793
Progression of Contaminant Caused Hydraulic System Failure 2794
Hydraulic System Flushing Techniques 2794
Double Oil and Filter Change 2794
Mechanical Cleaning 2795
Cleaning of Components 2795
How to Clean Tubes and Hoses 2795
Filter Caddy 2795
Start-Up Procedure for Cleaned System 2796
Contaminated Oil Coolers 2796
Additional Filter Caddy Functions 2796
How to Handle Different Fluids 2796
Water Removal Filters 2797
Fluid Conditioning and System Flushing Procedures 2797
Operation of the Filter Caddy 2797
Filter Caddy operation 2797
Fluid Conditioning Procedure 2798
Filter Caddy Start-Up 2798
System Flushing Procedure 2799
Component Cleaning Procedure 2799
Reservoir Cleaning Procedure 2799
Cylinder Cleaning Procedure 2799
Hose and Tube Cleaning Procedure 2800
Valve Cleaning Procedure 2800
Front-End Attachment Cleaning Procedure 2801
System Flushing Procedure 2801
Filter Caddy Start-Up 2802
System Start-Up and Flushing 2802
Reservoir Fluid Cleaning Times 2803
Dealing With Different Fluid Types 2803
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2803
Filter Caddy Maintenance 2804
Servicing the Strainer 2804
DC Motor 2804
Hydraulic Oil Sampling Method and Procedure 2804
Hydraulic Oil Sampling Method 2804
Objective 2804
General Guidelines 2804
Synopsis 2805
Hydraulic Oil Analysis Report Guidelines 2806
Sampling Conditions 2807
Equipment 2807
Sampling Procedure 2807
Hydraulic Oil Sampling 2807
Sample Labeling 2808
Results Documentation 2808
550096331 8000YRM1689 (03 2020) UK EN 2811
General Information About Diagrams and Schematics 2815
Symbol Definitions 2815
Diagrams Manual Applications 2816
Diagrams and Schematics 2818