524223772-2200YRM1142-(08-2021)-UK-EN

Maintenance
ELECTRICAL SYSTEM
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];GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) [B875];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];GLC/GDC60VX, GLC/
GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879, D879,
E879, F879];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]
PART NO. 524223772 2200 YRM 1142

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs
repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
WARNING
California Proposition 65 - Operating, servicing and maintaining a powered industrial truck can expose you to
chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other reproductive harm. For more information, go to
www.P65Warnings.ca.gov.
Table of Contents
TABLE OF CONTENTS
General....................................................................................................................................................................1
Display Switch Cluster.............................................................................................................................................5
Remove................................................................................................................................................................ 5
Install.................................................................................................................................................................... 7
Direction Control and Turn Signal Levers.............................................................................................................7
Remove..............................................................................................................................................................7
Install..................................................................................................................................................................8
Key Switch............................................................................................................................................................9
Remove..............................................................................................................................................................9
Install................................................................................................................................................................10
Display Switch Cluster Panel Bezel and Overlay............................................................................................... 10
Remove............................................................................................................................................................10
Install................................................................................................................................................................10
Steering Column Repair........................................................................................................................................ 11
Remove...............................................................................................................................................................11
Disassemble....................................................................................................................................................... 14
Assemble............................................................................................................................................................14
Install.................................................................................................................................................................. 14
Sensors and Switches...........................................................................................................................................15
General...............................................................................................................................................................15
Dash and Kick Panel, Remove and Install.......................................................................................................15
Remove......................................................................................................................................................... 15
Install............................................................................................................................................................. 16
Accelerator Pedal Position Sensor..................................................................................................................... 16
Remove............................................................................................................................................................16
Install................................................................................................................................................................20
Brake Fluid Level Switch.................................................................................................................................... 21
Remove............................................................................................................................................................21
Install................................................................................................................................................................22
Service Brake Pedal Position Sensor.................................................................................................................24
Remove............................................................................................................................................................24
Install................................................................................................................................................................26
Parking Brake Sensor.........................................................................................................................................27
Remove............................................................................................................................................................27
Install................................................................................................................................................................29
Service Brake Pressure Sensor..........................................................................................................................29
Remove............................................................................................................................................................29
Install................................................................................................................................................................31
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).................................................................... 33
Remove............................................................................................................................................................33
Install................................................................................................................................................................33
Sensor Microswitch (Foot Directional Control Pedal)......................................................................................... 33
Remove............................................................................................................................................................33
Install................................................................................................................................................................36
Low Coolant Level Sensor..................................................................................................................................37
Remove............................................................................................................................................................37
Install................................................................................................................................................................40
Fuel Level Sensor, Gas and Diesel Engines Only..............................................................................................41
Remove............................................................................................................................................................41
Install................................................................................................................................................................42
Armrest Switch....................................................................................................................................................42
©2021 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Remove............................................................................................................................................................42
Install................................................................................................................................................................44
Seat Sensor (Operator Presence System)......................................................................................................... 44
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)...................................................................................................44
Remove......................................................................................................................................................... 44
Install............................................................................................................................................................. 45
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878).................................................................................................................... 45
Remove......................................................................................................................................................... 45
Install............................................................................................................................................................. 45
Full Suspension Seats; All Lift Truck Models................................................................................................... 46
Remove......................................................................................................................................................... 46
Install............................................................................................................................................................. 46
Hood Shut Off Switch......................................................................................................................................... 47
Remove............................................................................................................................................................47
Install................................................................................................................................................................49
Remote Key Switch............................................................................................................................................ 50
Remove............................................................................................................................................................50
Install................................................................................................................................................................50
Hydraulic Filter Pressure Switch.........................................................................................................................51
Remove............................................................................................................................................................51
Install................................................................................................................................................................53
Transmission Speed Sensor...............................................................................................................................53
Remove............................................................................................................................................................53
Install................................................................................................................................................................56
Transmission Pressure Sensors.........................................................................................................................57
Remove............................................................................................................................................................57
Install................................................................................................................................................................59
Transmission Temperature Sensor.....................................................................................................................60
Remove............................................................................................................................................................60
Install................................................................................................................................................................62
Engine Speed Sensor.........................................................................................................................................64
Remove............................................................................................................................................................64
Install................................................................................................................................................................65
Intermediate Speed Sensor................................................................................................................................65
Remove............................................................................................................................................................65
Install................................................................................................................................................................65
Return to Set Tilt (Tilt Angle) Sensor.................................................................................................................. 66
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).......................................................................................................................................66
Remove......................................................................................................................................................... 66
Install............................................................................................................................................................. 66
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,
ii
Table of Contents

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)....................................................................................................................................................66
Remove......................................................................................................................................................... 67
Install............................................................................................................................................................. 68
Rear Horn Button Switch.................................................................................................................................... 69
Remove............................................................................................................................................................69
Install................................................................................................................................................................69
Impact Sensor.....................................................................................................................................................70
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)........... 70
Remove......................................................................................................................................................... 70
Install............................................................................................................................................................. 72
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).......................................................................................................................72
Remove......................................................................................................................................................... 72
Install............................................................................................................................................................. 73
Load Weight Sensor........................................................................................................................................... 73
Remove............................................................................................................................................................73
Install................................................................................................................................................................75
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2....... 76
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines............................. 76
Crankshaft Position (CKP) Sensor ..................................................................................................................76
Camshaft Position (CMP) Sensor.................................................................................................................... 76
Oil Pressure Sensor.........................................................................................................................................76
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor..................................................76
Engine Coolant Temperature (ECT) Sensor.................................................................................................... 77
Air Flow Restriction Switch...............................................................................................................................77
Remove for GM 2.4L Gas and LPG Trucks...................................................................................................77
Install for GM 2.4L Gas and LPG Trucks.......................................................................................................77
Oxygen Sensor................................................................................................................................................ 78
Remove......................................................................................................................................................... 78
Install............................................................................................................................................................. 81
Engine and Fuel Sensors and Switches, PSI 4.3L LPG Engine.........................................................................82
Crankshaft Position (CKP) Sensor ..................................................................................................................82
Camshaft Position (CMP) Sensor.................................................................................................................... 82
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor..................................................82
Air Flow Restriction Switch...............................................................................................................................82
Oxygen Sensor................................................................................................................................................ 82
Engine and Fuel Switches, GM 2.4L LPG Trucks Only...................................................................................... 82
Low LPG Pressure Switch............................................................................................................................... 82
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks........................................................................83
Air Filter Restriction Switch.............................................................................................................................. 83
iii
Table of Contents

Remove......................................................................................................................................................... 83
Install............................................................................................................................................................. 83
Remove......................................................................................................................................................... 83
Install............................................................................................................................................................. 83
Engine Speed Sensor...................................................................................................................................... 83
Remove......................................................................................................................................................... 83
Install............................................................................................................................................................. 83
Remove......................................................................................................................................................... 83
Install............................................................................................................................................................. 83
Throttle Position Sensor (TPS)........................................................................................................................ 86
Remove......................................................................................................................................................... 86
Install............................................................................................................................................................. 87
Fuel/Water Separator Sensor.......................................................................................................................... 87
Remove......................................................................................................................................................... 87
Install............................................................................................................................................................. 87
Glow Plug Relay...............................................................................................................................................88
Remove......................................................................................................................................................... 88
Install............................................................................................................................................................. 90
Engine and Fuel Sensors and Switches, Cummins Diesel Engines...................................................................90
Air Filter Restriction Switch.............................................................................................................................. 90
Remove......................................................................................................................................................... 90
Install............................................................................................................................................................. 91
Engine Oil Pressure Sensor.............................................................................................................................95
Remove......................................................................................................................................................... 95
Install............................................................................................................................................................. 95
Engine Speed Sensor...................................................................................................................................... 95
Remove......................................................................................................................................................... 95
Install............................................................................................................................................................. 96
Remove......................................................................................................................................................... 96
Install............................................................................................................................................................. 97
Throttle Position Sensor (TPS) (Cummins 4.5L Only)..................................................................................... 98
Remove......................................................................................................................................................... 98
Install............................................................................................................................................................. 98
Fuel/Water Separator Sensor.......................................................................................................................... 99
Remove......................................................................................................................................................... 99
Install............................................................................................................................................................. 99
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine Without DPF.........................................100
Intake Air Temperature Sensor...................................................................................................................... 100
Remove....................................................................................................................................................... 100
Install........................................................................................................................................................... 101
Intake Air Pressure Sensor............................................................................................................................ 101
Remove....................................................................................................................................................... 101
Install........................................................................................................................................................... 101
Air Inlet Heater............................................................................................................................................... 101
Remove....................................................................................................................................................... 101
Install........................................................................................................................................................... 102
Engine Oil Pressure Sensor...........................................................................................................................102
Remove....................................................................................................................................................... 102
Install........................................................................................................................................................... 102
iv
Table of Contents

Engine Coolant Temperature (ECT) Sensor.................................................................................................. 102
Remove....................................................................................................................................................... 102
Install........................................................................................................................................................... 102
Crankshaft Position Sensor............................................................................................................................103
Remove....................................................................................................................................................... 103
Install........................................................................................................................................................... 103
Adjust Shim Procedure................................................................................................................................104
Camshaft Position Sensor..............................................................................................................................105
Remove....................................................................................................................................................... 105
Install........................................................................................................................................................... 105
Air Flow Restriction Sensor............................................................................................................................105
Remove....................................................................................................................................................... 105
Install........................................................................................................................................................... 106
Fuel/Water Separator.....................................................................................................................................106
Remove....................................................................................................................................................... 106
Install........................................................................................................................................................... 107
Engine and Fuel Sensors and Switches, Kubota 3.8L Diesel Engine With DPF..............................................107
Intake Air Temperature Sensor.......................................................................................................................111
Remove........................................................................................................................................................111
Install........................................................................................................................................................... 112
Boost Sensor..................................................................................................................................................112
Remove....................................................................................................................................................... 112
Install........................................................................................................................................................... 113
Throttle Valve Assembly and Air Intake Heater..............................................................................................113
Remove....................................................................................................................................................... 113
Install........................................................................................................................................................... 113
Engine Coolant Temperature (ECT) Sensor...................................................................................................114
Remove....................................................................................................................................................... 114
Install........................................................................................................................................................... 114
Engine Oil Pressure Sensor........................................................................................................................... 115
Remove....................................................................................................................................................... 115
Install........................................................................................................................................................... 115
Crankshaft Position Sensor............................................................................................................................115
Remove....................................................................................................................................................... 115
Install........................................................................................................................................................... 115
Adjust Shim Procedure................................................................................................................................ 116
Camshaft Position Sensor..............................................................................................................................118
Remove....................................................................................................................................................... 118
Install........................................................................................................................................................... 118
Differential Pressure Sensor.......................................................................................................................... 118
Remove....................................................................................................................................................... 118
Install........................................................................................................................................................... 119
Mass Air Flow Sensor.................................................................................................................................... 119
Remove....................................................................................................................................................... 119
Install........................................................................................................................................................... 120
Fuel/Water Separator.....................................................................................................................................121
Remove....................................................................................................................................................... 121
Install........................................................................................................................................................... 122
Engine and Fuel Sensors and Switches, Kubota 3.6L Diesel Engine.............................................................. 123
Engine Coolant Temperature (ECT) Sensor.................................................................................................. 124
Remove....................................................................................................................................................... 124
Install........................................................................................................................................................... 124
v
Table of Contents

Throttle Position Sensor.................................................................................................................................124
Engine Oil Pressure Sensor...........................................................................................................................124
Remove....................................................................................................................................................... 124
Install........................................................................................................................................................... 124
Engine Speed Sensor.................................................................................................................................... 124
Remove....................................................................................................................................................... 124
Install........................................................................................................................................................... 124
Fuel Shut Off Solenoid................................................................................................................................... 125
Remove....................................................................................................................................................... 125
Install........................................................................................................................................................... 125
Vehicle System Manager (VSM)......................................................................................................................... 126
General.............................................................................................................................................................126
VSM Replacement............................................................................................................................................126
Remove..........................................................................................................................................................126
Install..............................................................................................................................................................128
Programming a New VSM and/or Display Switch Cluster................................................................................ 128
General.......................................................................................................................................................... 128
PC Service Tool Software.............................................................................................................................. 129
Data Transferring........................................................................................................................................... 129
New VSM.....................................................................................................................................................129
New (Blank) Display Switch Cluster............................................................................................................ 129
Used (Non-Blank) Display Switch Cluster................................................................................................... 129
Power Distribution Module (PDM) and Component Parts...................................................................................132
Remove............................................................................................................................................................ 132
PDM as a Unit................................................................................................................................................132
Install................................................................................................................................................................ 135
PDM as a Unit................................................................................................................................................135
Remove and Install...........................................................................................................................................136
PDM Component Parts.................................................................................................................................. 136
Transmission Control Unit (TCU)........................................................................................................................ 137
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909)...............................................................................................137
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909)........................................................................................................................137
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (C879, D879, E879).....................................................................................................................138
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879)..........................................................................................................................................138
GDC155VX) (F879) Equipped with 3-Speed Transmission and Manufactured Before December, 2018.........138
(F879) Equipped With 3-Speed Transmission and Manufactured Before December, 2018.............................139
GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018
and July, 2021...................................................................................................................................................140
Install, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018
and July, 2021...................................................................................................................................................142
GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured After July, 2021........... 142
vi
Table of Contents

(F879) Equipped With 3-Speed Transmission and Manufactured After July, 2021.......................................... 142
Battery.................................................................................................................................................................143
Remove............................................................................................................................................................ 143
Install................................................................................................................................................................ 143
Lights...................................................................................................................................................................144
Work Lights (Front and Rear)........................................................................................................................... 144
Remove..........................................................................................................................................................144
Install..............................................................................................................................................................144
Strobe Light...................................................................................................................................................... 145
Remove..........................................................................................................................................................145
Install..............................................................................................................................................................145
LED Tail, Backup, and Brake Lights................................................................................................................. 146
Remove..........................................................................................................................................................146
Install..............................................................................................................................................................147
Front Marker/Turn Signal Lights....................................................................................................................... 148
Replacing Whole Front Marker/Turn Signal Light Assembly..........................................................................148
Remove....................................................................................................................................................... 148
Install........................................................................................................................................................... 148
Replacing Just the Front Marker/Turn Signal Light LED Light Lens.............................................................. 149
Remove....................................................................................................................................................... 149
Install........................................................................................................................................................... 149
Diesel Particulate Filter (DPF) Display................................................................................................................150
Remove............................................................................................................................................................ 150
Clean and Inspect.............................................................................................................................................151
Install................................................................................................................................................................ 151
Electronic-Hydraulic Controls - Generation 1......................................................................................................152
E-Hydraulic Controls - Test...............................................................................................................................152
Mini-Levers.....................................................................................................................................................152
Full Stroke Test.............................................................................................................................................. 152
Function Returns to Neutral Test....................................................................................................................152
Push Button Switch........................................................................................................................................152
General.............................................................................................................................................................153
Mini-Lever Replacement...................................................................................................................................153
Remove..........................................................................................................................................................153
Clean and Inspect.......................................................................................................................................... 154
Install..............................................................................................................................................................154
Push Button Switch Replacement.................................................................................................................... 155
Remove..........................................................................................................................................................155
Install..............................................................................................................................................................157
Mini-Lever Module (MLM).................................................................................................................................157
Remove..........................................................................................................................................................157
Install..............................................................................................................................................................157
Joystick.............................................................................................................................................................158
Remove and Disassemble............................................................................................................................. 158
Inspect............................................................................................................................................................158
Assemble and Install......................................................................................................................................158
Electronic-Hydraulic Controls - Generation 2, Before January, 2020..................................................................159
General.............................................................................................................................................................159
Mini-levers, Remove and Install........................................................................................................................159
Armrest Assembly.............................................................................................................................................160
Remove..........................................................................................................................................................160
vii
Table of Contents

Install..............................................................................................................................................................163
Horn Button.......................................................................................................................................................163
Remove..........................................................................................................................................................163
Install..............................................................................................................................................................163
Direction Control Switch................................................................................................................................... 164
Remove..........................................................................................................................................................164
Install..............................................................................................................................................................164
push (override) buttons and Toggle Switch...................................................................................................... 164
Remove..........................................................................................................................................................165
Install..............................................................................................................................................................166
Joystick.............................................................................................................................................................167
Remove and Disassemble............................................................................................................................. 167
Inspect............................................................................................................................................................167
Assemble and Install......................................................................................................................................167
Joystick Armrest Slider Assembly.....................................................................................................................168
Remove..........................................................................................................................................................168
Install..............................................................................................................................................................169
Electronic-Hydraulic Controls, After January, 2020.............................................................................................170
E-Hydraulic Controls - TEST............................................................................................................................ 170
Mini-Levers.....................................................................................................................................................170
Full Stroke Test.............................................................................................................................................. 170
Function Returns to Neutral Test....................................................................................................................170
Push (Override) Button.................................................................................................................................. 170
General.............................................................................................................................................................171
Mini-levers, Remove and Install........................................................................................................................171
Armrest Assembly.............................................................................................................................................172
Remove..........................................................................................................................................................172
Install..............................................................................................................................................................175
Horn Button.......................................................................................................................................................175
Remove..........................................................................................................................................................175
Install..............................................................................................................................................................175
Direction Control Switch................................................................................................................................... 175
Remove..........................................................................................................................................................175
Install..............................................................................................................................................................176
Push (Override) buttons and Toggle Switch...................................................................................................176
Remove....................................................................................................................................................... 177
Install........................................................................................................................................................... 179
Special Tools....................................................................................................................................................... 180
viii
2200 YRM 1142 General
General
NOTE: The joystick option identified in this manual is
not available for lift truck models CAUTION
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ When welding, always disconnect the negative
GDP135VX, GP/GLP/GDP155VX) (C878, battery cable from battery and disconnect the
D878, E878) ground wire from the ground stud on the frame.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ See Figure 1. To prevent damage to the Electronic
GDP90VX (GLP/GDP170VX, GLP/ Control Unit (ECU), remove it from the lift truck.
GDP175VX36, GLP/GDP190VX) (A909, B909)
The removal and replacement procedures for the See one of the following sections for procedures to
following electrical components are covered in this remove ECU from your lift truck
manual: Gasoline Fuel System 0900YRM1126 for lift truck
• Display Switch Cluster models
• Vehicle System Manager (VSM) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
• Power Distribution Module (PDM)
• GLC20-35VX (GC/GLC040-070VX, GC/
• Joystick and mini-lever electronic-hydraulic GLC055SVX) (A910)
controls
Lights LPG Fuel System 0900YRM1124 for lift truck models
•
• Sensors and switches • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
• Battery
• Transmission Control Unit (TCU) for lift truck GLC055SVX) (A910)
models
Gasoline Fuel System 0900YRM1244 for lift truck
• GC/GLC/GDC60VX, GC/GLC/GDC70VX, models
(GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (C879, D879, E879, F879, • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
G879) GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
D878, E878) 100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/ • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP175VX36, GLP/GDP190VX) (A909, GDP135VX, GP/GLP/GDP155VX) (C878,
B909) D878)
Some of the components used are made of plastic. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
When using screws to replace and install plastic GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
components, the screws should be rotated
counterclockwise until the screw thread turns over the Gasoline Fuel System PSI GM 4.3L 0900YRM1570
last thread in the plastic part. The screw can then be for lift truck models
turned clockwise to make a connection. This prevents • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
"cutting" new threads and damaging the existing GDC135VX, GC/GLC/GDC155VX) (E879,
thread in the plastic part. F879)
If any welding must be done, obtain proper • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
authorization from a Resident Service Engineer. If GDP45VX6; GLP/GDP50-55VX (GP/GLP/
authorization is given, be sure to follow the procedures GDP080, 090, 100, 110, 120VX) (H813, J813)
in the CAUTION below. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
1
General 2200 YRM 1142
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ LPG Fuel System, Kubota 3.8L SI Engine

GDP135VX, GP/GLP/GDP155VX) (D878, 0900YRM1905 for lift truck models
E878)
•
LPG Fuel System, GM 4.3L Engine with GFI
0900YRM1242 for lift trucks LPG Fuel System, GM 5.7L Engine 0900YRM1433
for lift truck models
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, • GLP/GDP80VX, GLP/GDP80VX9, GLP/
D879) GDP90VX (GLP/GDP170VX, GLP/
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/ Gasoline Fuel System 0900YRM1127 for lift truck
GLC120SVX; GC/GLC120VXPRS) (E818) models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GDP135VX, GP/GLP/GDP155VX) (C878, (B875)
D878)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GLC055SVX) (A910)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813) LPG Fuel System 0900YRM1125 for lift truck models
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GC/GLC030VX, GC/GLC035VX, GC/
GDP90VX (GDP170VX, GDP175VX36, GLC040SVX (C809)
GDP190VX) (A909) • GLP/GDP16VX, GLP/GDP18VX, GLP/
LPG Fuel System, GM 4.3L Engine With PSI GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
0900YRM1556 for lift truck models GDP035VX, GP/GLP/GDP040SVX) (C810)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GLC055SVX) (A910)
100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
F818) (B875)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ Gasoline Fuel System 0900YRM1325 for lift truck
GDP135VX, GP/GLP/GDP155VX) (D878, models
E878)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ (B875)
GDP080, 090, 100, 110, 120VX) (G813, H813,
GLC055SVX) (A910)
J813)
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ LPG Fuel System 0900YRM1326 for lift truck models
GDC135VX, GC/GLC/GDC155VX) (D879, • GC/GLC030VX, GC/GLC035VX, GC/
E879, F879) GLC040SVX (C809)
LPG Fuel System, PSI 4.3L Engine 0900YRM1951 • GLP/GDP16VX, GLP/GDP18VX, GLP/
for lift truck models GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GDP035VX, GP/GLP/GDP040SVX) (C810)
GDC135VX, GC/GLC/GDC155VX) (F879) • GLC20-35VX (GC/GLC040-070VX, GC/
GLC055SVX) (A910)
(B875)
2
2200 YRM 1142 General
Periodic Maintenance 8000YRM1248 for lift truck

models
100, 120VX; GC/GLC080, 100VXBCS; GC/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
models
GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
models
GDP135VX, GP/GLP/GDP155VX) (C878,
D878)
model
NOTE: VIEW SHOWN IS FROM LEFT SIDE. MAJOR
COMPONENTS AND ELECTRICAL CONNECTIONS • GLP/GDP80VX, GLP/GDP80VX9, GLP/
NOT SHOWN FOR CLARITY. GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909)
1. GROUND STUD Periodic Maintenance 8000YRM1558 for lift truck
2. TANK OPENING FOR HYDRAULIC FILTER models
3. POWER DISTRIBUTION MODULE (PDM)
4. BATTERY • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/
Figure 1. Welding Preparation GDP080, 090, 100, 110, 120VX) (H813)
For more information on how to perform welding
models
repairs to lift truck and overhead guard, refer to one of
the following sections: • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (E879)
models Periodic Maintenance 8000YRM1583 for lift truck
models
GLC055SVX) (A910) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (E878)
(B875) Periodic Maintenance 8000YRM1586 for lift truck
Periodic Maintenance 8000YRM1207 for lift truck models
models • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/
• GC/GLC030VX, GC/GLC035VX, GC/
GDP175VX36, GLP/GDP190VX) (B909)
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ Periodic Maintenance 8000YRM1598 for lift truck
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ models
GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (F818)
3
General 2200 YRM 1142
Periodic Maintenance 8000YRM1604 for lift truck Periodic Maintenance 8000YRM2403 for lift truck
models models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ •
GDP080, 090, 100, 110, 120VX) (J813) See the following manual for information on
troubleshooting and viewing parameters for the E-
Periodic Maintenance 8000YRM1606 for lift truck Hydraulic control mini-levers:
models
• User Interface - Service Technician
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ 2200YRM1131 for all lift truck models covered
GDC135VX, GC/GLC/GDC155VX) (F879) in this manual
4
2200 YRM 1142 Display Switch Cluster
Display Switch Cluster

REMOVE 3. Remove upper steering column cover by pulling
up on upper steering column cover to release
NOTE: The Display Switch Cluster is a nonrepairable latches (one on either side), and pulling cover
part. See Parts Manual for replacement part number. away from steering column. See Figure 2.
1. Disconnect ground wire.
2. Lift up on steering wheel slightly and pull up on tilt

lever. Fully lower steering column.
NOTE: TOP VIEW OF DASH SHOWN.
A. INDICATES TO PULL UP TO UNLATCH
1. UPPER STEERING COLUMN COVER 3. LOWER STEERING COLUMN COVER

2. STEERING COLUMN TILT LEVER
Figure 2. Upper Steering Column Cover Removal
4. Remove horn button and disconnect horn wires.
NOTE: A puller tool may be required to remove

steering wheel.
5. Remove lock nut securing steering wheel and
remove steering wheel from steering column.
Take care to not damage horn wires. See
Figure 3.
5
Display Switch Cluster 2200 YRM 1142
Legend for Figure 3.
1. HORN BUTTON
2. LOCK NUT
6. Disconnect Display Switch Cluster harness from

Display Switch Cluster. Remove four bolts
securing Display Switch Cluster. Slide display
panel off of steering column. See Figure 4.
Figure 3. Steering Wheel Removal
NOTE: TOP DOWN VIEW SHOWN.
1. BOLTS 3. STEERING COLUMN

2. DISPLAY SWITCH CLUSTER HARNESS 4. HORN WIRES (CONTACT PADS)
Figure 4. Display Switch Cluster Removal
6
INSTALL 5. Install upper steering column cover by aligning

two latches and pushing down until latched. See
NOTE: When a new Display Switch Cluster is Figure 2.
installed on a lift truck, the data that controls all
functions and features unique to that lift truck, needs to
DIRECTION CONTROL AND TURN
be transferred to new Display Switch Cluster. See
section Vehicle System Manager (VSM), located in the SIGNAL LEVERS
back of this manual, for procedures to transfer data to Direction control lever and turn signal lever are similar
a new Display Switch Cluster. in design, but perform different functions. Turn signal
lever is located on right side of the Display Switch
1. Install Display Switch Cluster onto steering Cluster. Direction control lever is located on left side of
column. Install four bolts to secure panel to Display Switch Cluster.
steering column and tighten bolts to
19 N•m (168 lbf in). See Figure 4. Remove
2. Connect Display Switch Cluster to display NOTE: There are no repairs for direction control lever
harness. and turn signal lever. If a lever malfunctions, replace
with new lever. See Parts Manual for replacement
3. Install steering wheel onto steering shaft and part numbers.
tighten lock nut until steering wheel is fully 1. Insert two small flat-blade or Phillips screwdrivers,
seated. Final torque for lock nut is with a 3.175 mm (0.125 in.) or less, wide blade or
40 to 54 N•m (30 to 40 lbf ft). See Figure 3. die end, into opening on Display Switch Cluster
on an outward angle enough to compress spring
4. Connect horn wires to horn button. Install horn
tab on direction control lever or turn signal lever.
lock nut and horn button into steering wheel.
See A, Figure 5.
7
NOTE: DISPLAY SWITCH CLUSTER SHOWN OUTSIDE OF LIFT TRUCK FOR CLARITY. FLAT-BLADE
SCREWDRIVERS SHOWN.
A. STEP 1 B. STEP 2
1. DIRECTION CONTROL AND TURN SIGNAL 3. DISPLAY SWITCH CLUSTER

LEVERS
2. FLAT-BLADE SCREWDRIVER
Figure 5. Direction Control and Turn Signal Removal
2. Pry spring tab toward body of direction control Install

lever or turn signal lever and, at the same time,
pull on handle of lever enough to free the tab of Install direction control lever or turn signal lever into
interior lock of Display Switch Cluster. See B, opening of Display Switch Cluster until locking tabs are
Figure 5. engaged in Display Switch Cluster.
3. Repeat previous steps on opposite side of

direction control lever or turn signal lever.
Remove direction control lever or turn signal lever
from Display Switch Cluster.
8
KEY SWITCH • GLP/GDP80VX, GLP/GDP80VX9, GLP/

Remove GDP175VX36, GLP/GDP190VX) (A909, B909)
NOTE: Lift truck models covered in this section can 1. Fully lower steering column and remove upper
be equipped with an optional key switch or Power steering column cover by pushing in on both
ON/OFF button. The Power ON/OFF button is a sides of cover to release latches (one on either
nonrepairable part. See Parts Manual for replacement side), and pulling cover away from steering
parts. If truck is equipped with a key switch, follow column. See Figure 2.
steps below to remove and replace key switch.
NOTE: Lift truck models below may be equipped with 2. Remove torx head capscrews. Slide key switch
an optional remote key switch in engine compartment. assembly out of Display Switch Cluster. See
See Sensors and Switches section in this service Figure 6.
manual for replacement procedures.
D878, E878)
1. BEZEL 4. TORX HEAD SCREW

2. OVERLAY 5. INSERT SCREWDRIVER IN SLOT AT THIS
3. KEY SWITCH LOCATION
Figure 6. Display Switch Cluster Panel Bezel, Grid, and Key Switch Removal
9
Install careful to not damage bezel and overlay when

removing bezel. Lift bezel off of Display Switch
1. Install new key switch assembly into Display Cluster. See Figure 6.
Switch Cluster. Install torx head capscrews (T-15)
to secure key switch to Display Switch Cluster. 2. Remove overlay from Display Switch Cluster.
Tighten torx head capscrews to
1.1 N•m (9.7 lbf in). See Figure 6. Install
2. Install upper steering cover on steering column. Place new overlay on display panel and install a new
Align latches on upper steering cover to holes on bezel by inserting outer edge in display and then
steering column and push upper steering cover pressing down inner edge.
into place on steering column.
DISPLAY SWITCH CLUSTER PANEL

BEZEL AND OVERLAY
Remove
1. Insert a small, flat-bladed screwdriver into top slot
on inner edge of bezel and pry outward. Repeat
procedure at the lower slot on the bezel. Be
10
2200 YRM 1142 Steering Column Repair
Steering Column Repair

REMOVE 3. Remove steering wheel and instrument display
panel. See section Display Switch Cluster for
1. On lift truck models below, to access battery, removal procedures.
remove floor mat and floor plate. Disconnect
battery. 4. Remove two screws and remove lower steering
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ column cover. See Figure 7.
D878, E878) 5. Disconnect Display Switch Cluster harness from
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ display panel. Remove harness from steering
GDP90VX (GLP/GDP170VX, GLP/ column.
6. Remove four bolts (1, Figure 8) holding steering
On lift truck models below, to access battery,
column to cowl.
raise the hood. Disconnect battery.
• GC/GLC030VX, GC/GLC035VX, GC/ NOTE: Step 7 only applies to lift truck models
GLC040SVX (C809) GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/
• GLP/GDP16VX, GLP/GDP18VX, GLP/ GDC135VX, GC/GLC/GDC155VX) (C879, D879,
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ E879, F879, G879) .
GDP035VX, GP/GLP/GDP040SVX) (C810) 7. Remove two washers from two lower bolts
• GLC20-35VX (GC/GLC040-070VX, GC/ holding steering column to cowl.
GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 8. Raise steering column to disengage steering
(B875) shaft from the steering control unit.
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879)
2. Remove upper steering column cover by pulling

up on upper steering column cover to release
latches (one on either side), and pulling cover
away from steering column. See Figure 2.
11
Steering Column Repair 2200 YRM 1142
1. SCREWS
2. LOWER STEERING COLUMN COVER
Figure 7. Lower Steering Column Cover Removal
12
2200 YRM 1142 Steering Column Repair
1. BOLTS 8. COWL
2. PIVOT BOLTS 9. LOWER STRUT PIVOT PIN
3. HORN WIRES 10. HYDRAULIC CONTROL VALVE
4. STEERING SHAFT RETENTION CLIP 11. STEERING CONTROL UNIT (SCU)
5. HORN HARNESS 12. STEERING SHAFT
6. STEERING COLUMN 13. HORN CONTACT PADS
7. GAS CYLINDER
Figure 8. Steering Column Disassembly
13
Steering Column Repair 2200 YRM 1142
DISASSEMBLE 5. Install upper steering column cover by aligning

the two latches and pushing down until latched.
1. Remove steering shaft retention clip (4, Figure 8). See Figure 7.
2. Remove horn contact pads. 6. Install steering wheel and instrument display
panel. See section Display Switch Cluster.
3. Remove lower strut pivot pin from the gas
cylinder. 7. Move steering column to its lowest position and
install upper steering column cover. See Figure 2.
4. Remove steering column pivot bolts and steering
shaft. 8. For lift truck models below, connect battery and
close hood.
ASSEMBLE
1. Install steering column pivot bolts and install GLC040SVX (C809)
steering shaft. • GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
2. Install lower strut pivot pin in the gas cylinder. See GDP035VX, GP/GLP/GDP040SVX) (C810)
Figure 8.
GLC055SVX) (A910)
3. Install horn contact pads.
4. Install steering shaft retention clip. (B875)
INSTALL 100, 120VX; GC/GLC080, 100VXBCS; GC/
1. Lubricate end of steering shaft with multipurpose F818)
grease. Install end of steering shaft into steering
control unit. GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
NOTE: Step 2 only applies to lift truck models H813, J813)
GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879,
E879, F879, G879) . (C879, D879, E879, F879, G879)
2. Install two washers onto two lower bolts holding For lift truck models below, connect battery, install
steering column to cowl. floor plate and floor mat.
3. Install steering column to cowl using four bolts. • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
Tighten bolts to 38 N•m (28 lbf ft). See Figure 8. GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878)
4. Connect Display Switch Cluster harness to • GLP/GDP80VX, GLP/GDP80VX9, GLP/
Display Switch Cluster panel. Install Display GDP90VX (GLP/GDP170VX, GLP/
Switch Cluster harness on steering column. GDP175VX36, GLP/GDP190VX) (A909, B909)
14
2200 YRM 1142 Sensors and Switches
Sensors and Switches

GENERAL The dash and kick panel need to be removed and
installed on lift truck after a sensor or switch has been
replaced.
CAUTION • Accelerator pedal position sensor
Before removing and replacing any sensors or
switches, ALWAYS disconnect the battery. Failure • Brake fluid level switch
to disconnect the battery can cause damage to the • Service brake pedal position sensor
sensor or switch and other electrical components. • Park brake sensor
Always cover or protect the sensor or switch
connector from contamination after disconnecting Remove
the harness mating part.
1. Lower steering column to its lowest position and
DO NOT use solvent-based cleaners to clean area remove upper steering column cover by pulling up
around sensors or switches. on upper steering column cover to release latches
(one on either side), and pulling cover away from
All sensors and switches used on these trucks are
steering column. See Figure 2.
non-repairable parts. Replace with new sensors or
switches whenever a sensor or switch malfunctions 2. Remove Allen screws securing dash to top of
and is not operating correctly. See Parts Manual for cowl. Remove dash from clips, located
replacement part numbers. Before installing new underneath dash, that attach dash to kick panel.
sensors or switches, use a clean cloth and make sure Lift to remove the dash. See Figure 9.
the area around the sensor or switch is clean and free
of oils and contaminates. 3. Lift kick panel from seal plate and remove from lift
When removing and replacing sensors or switches, be truck. See Figure 9.
sure to tag connectors to aid in correct reconnecting.
Dash and Kick Panel, Remove and Install

Before removing and replacing the following sensors
and switches:
15
Sensors and Switches 2200 YRM 1142
NOTE: KICK PANEL AND DASH PANEL FOR GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)
AND GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) MODELS SHOWN.
1. KICK PANEL 3. FASTENERS

2. COWL 4. DASH
Figure 9. Dash and Kick Panel Removal
Install ACCELERATOR PEDAL POSITION

1. Install kick panel onto seal plate. SENSOR
Remove
2. Install dash into clips, located underneath dash,
that attach dash to kick panel. Install Allen screws 1. For lift truck models below, to access battery,
securing dash to top of cowl. remove floor mat and floor plate. Disconnect
battery.
3. Install upper steering column cover by aligning GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
•
two latches and pushing down until latched. See GDC135VX, GC/GLC/GDC155VX) (C878,
Figure 2. D878, E878)
16

For lift truck models below, to access battery,
raise hood. Disconnect battery.
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879)
•
2. Remove upper steering column cover and dash

and kick panel. See Dash and Kick Panel,
Remove and Install for procedures.
NOTE: Lift truck model shown below is equipped only

with an electronic hydraulic control valve.
NOTE: MANUAL HYDRAULIC CONTROL VALVE
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ WITHOUT OPS SHOWN. REMOVAL OF MANUAL
HYDRAULIC CONTROL VALVE WITH OPS IS THE
SAME.
3. If lift truck is equipped with:
Manual hydraulic control valve (with or 1. LEVER BRACKET CAPSCREWS
2. COWL
without Operator Presence System [OPS]).
• Remove lever bracket capscrews and move Figure 10. Manual Hydraulic Control Valve
hydraulic lever assembly toward operator's seat. Removal
See Figure 10.
Electronic hydraulic control valve. 4. Disconnect accelerator pedal position sensor.
• Disconnect valve harness from Vehicle System 5. Remove three bolts, throttle base plate, and pedal
Manager (VSM). Remove two bolts and remove assembly from cowl. See Figure 11.
valve harness bracket. See Figure 12.
17
1. BOLTS
2. PEDAL ASSEMBLY
3. COWL
6. Remove two pan head screws, lockwashers, and

accelerator pedal position sensor from throttle
base plate. See Figure 12.
Figure 11. Accelerator Pedal and Throttle Base

Plate Removal
18
NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN.
1. ACCELERATOR PEDAL POSITION SENSOR 6. BOLTS (THROTTLE BASE PLATE)

2. BOLTS (THROTTLE BASE PLATE) 7. COWL
3. VALVE HARNESS MOUNTING BRACKET 8. VEHICLE SYSTEMS MANAGER (VSM)
(ELECTRONIC VALVE) 9. CONTROL VALVE HARNESS
4. BOLTS (VALVE HARNESS MOUNTING 10. SENSOR COVER
BRACKET)
5. THROTTLE BASE PLATE
Figure 12. Accelerator Pedal Position Sensor
19
Install • GLP/GDP16VX, GLP/GDP18VX, GLP/

1. Insert new accelerator pedal position sensor into GDP035VX, GP/GLP/GDP040SVX) (C810)
opening on throttle base plate. See Figure 12. GLC20-35VX (GC/GLC040-070VX, GC/
•
GLC055SVX) (A910)
2. Rotate sensor so that the D shaped throttle shaft
end slides into accelerator pedal position sensor. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
Rotate sensor counterclockwise until locating pin
on sensor lines up with hole in throttle base plate. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
3. Insert two pan head screws and lockwasher and GLC120SVX; GC/GLC120VXPRS) (E818,
install accelerator pedal position sensor to throttle F818)
base plate. Tighten screws to 2.25 N•m (20 lbf in). • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
4. Install throttle base plate and pedal assembly to GDP080, 090, 100, 110, 120VX) (F813, G813,
cowl using three bolts. Tighten capscrews to H813, J813)
19 to 25 N•m (168 to 221 lbf in). See Figure 11. • GC/GLC/GDC60VX, GC/GLC/GDC70VX
5. Connect accelerator pedal position sensor. (C879, D879, E879, F879)
•
NOTE: Lift truck model shown below is equipped only
with an electronic hydraulic control valve. 9. If throttle pedal needs to be adjusted, see one of
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ the following sections for procedures:
GDP90VX (GLP/GDP170VX, GLP/ Frame 0100YRM1120 for lift truck models
6. If lift truck is equipped with GLC040SVX (C809)
Manual hydraulic control valve (with or • GLP/GDP16VX, GLP/GDP18VX, GLP/
without Operator Presence System [OPS]). GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• Install lever bracket to cowl. Install clevis and
retention pins and connect manual levers to • GLC20-35VX (GC/GLC040-070VX, GC/
control valve. See Figure 10. GLC055SVX) (A910)
Electronic hydraulic control valve. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
• Insert two bolts into valve harness bracket and
install valve harness bracket. Connect valve Frame 0100YRM1243 for lift truck models
harness to VSM. See Figure 12. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
7. Install kick panel and dash. Install upper steering GLC120SVX; GC/GLC120VXPRS) (E818,
column cover. See Dash and Kick Panel, Remove F818)
and Install for procedures. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
8. Connect battery. For lift truck models below, GDP080, 090, 100, 110, 120VX) (F813, G813,
install floor plate and floor mat. H813, J813)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ Frame 0100YRM1316 for lift truck models
D878, E878) • GC/GLC/GDC60VX, GC/GLC/GDC70VX
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ (C879, D879, E879, F879)
GDP175VX36, GLP/GDP190VX) (A909, B909) •
Connect battery. For lift truck models below, lower Frame 0100YRM1321 for lift truck models
hood. • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GC/GLC030VX, GC/GLC035VX, GC/ GDP135VX, GP/GLP/GDP155VX) (C878,
GLC040SVX (C809) D878)
20
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ •

GDP175VX36, GLP/GDP190VX) (A909) 2. Remove upper steering column cover and dash
Frame 0100YRM1581 for lift ruck model and kick panel. See Dash and Kick Panel,
GDP135VX, GP/GLP/GDP155VX) (E878) 3. Disconnect brake fluid level switch from cowl
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ harness.
CAUTION
BRAKE FLUID LEVEL SWITCH Disposal of lubricants and fluids must meet local
Remove environmental regulations.
NOTE: Brake fluid level switch is a component of 4. Remove reservoir from bracket and drain fluid
master brake cylinder reservoir and is located inside from reservoir. Disconnect master cylinder supply
reservoir. When switch is replaced, reservoir must be hose from reservoir. Make sure air does not get
replaced as well. into hose.
NOTE: Lift truck model shown below DOES NOT See Figure 13 for lift truck models
have a brake fluid level switch.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ GLC040SVX (C809)
GDP175VX36, GLP/GDP190VX) (A909, B909) • GLP/GDP16VX, GLP/GDP18VX, GLP/
1. For lift truck models below, to access battery, GDP035VX, GP/GLP/GDP040SVX) (C810)
remove floor mat and floor plate. Disconnect • GLC20-35VX (GC/GLC040-070VX, GC/
battery. GLC055SVX) (A910)
GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
•
GDC135VX, GC/GLC/GDC155VX) (C878, (B875)
D878, E878) See Figure 14 for lift truck models
For lift truck models below, to access battery, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
raise hood. Disconnect battery. 100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GLC040SVX (C809)
GDP080, 090, 100, 110, 120VX ) (F813, G813,
H813, J813)
GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C879, D879, E879, F879)
(B875)
•
100, 120VX; GC/GLC080, 100VXBCS; GC/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
GLC120SVX; GC/GLC120VXPRS) (E818, GDC135VX, GC/GLC/GDC155VX) (C878,
F818) D878, E878)

GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879)
21
1. SERVICE BRAKE PRESSURE SENSOR

2. MASTER CYLINDER (BOOSTED)
3. SERVICE BRAKE PEDAL POSITION SENSOR
4. BRAKE FLUID LEVEL SWITCH (INSIDE
RESERVOIR)
5. BRAKE FLUID RESERVOIR MOUNTING
BRACKET
6. COWL
7. BRAKE FLUID RESERVOIR
Figure 14. Brake Fluid Level Switch, Service Brake

1. RESERVOIR SUPPLY HOSE Pedal Position Sensor, and Service Brake Pressure
2. BRAKE FLUID RESERVOIR
3. COWL Sensor For Lift Truck Models GLC40, 45, 55VX;
4. BRAKE FLUID LEVEL SWITCH (INSIDE GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080,
RESERVOIR) 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS)
5. BRAKE FLUID RESERVOIR MOUNTING (E818, F818); GLP/GDP40VX5/VX6; GLP/
BRACKET GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110 120VX) (F813,
Figure 13. Brake Fluid Level Switch, Lift Truck
G813, H813, J813); GLC/GDC60VX, GLC/GDC70VX
Models GC/GLC030VX, GC/GLC035VX, GC/
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,
GLC040SVX (C809); GLP/GDP16VX, GLP/
D879, E879, F879); and GLP/GDP60VX, GLP/
GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810);
GDP155VX) (C878, D878, E878)
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX)
(A910); and GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875) Install
1. Connect the master cylinder supply hose to a new
reservoir.
See Figure 13 for lift truck models
22
• GC/GLC030VX, GC/GLC035VX, GC/ Periodic Maintenance 8000YRM1319 for lift

GLC040SVX (C809) truck models
• GLP/GDP16VX, GLP/GDP18VX, GLP/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GDP035VX, GP/GLP/GDP040SVX) (C810) (C879, D879, E879, F879)
Periodic Maintenance 8000YRM1322 for lift
GLC055SVX) (A910)
truck models
(B875) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
See Figure 14 for lift truck models D878)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, Periodic Maintenance 8000YRM1558 for lift
100, 120VX; GC/GLC080, 100VXBCS; GC/ truck models
F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP080, 090, 100, 110, 120VX) (H813)
GDP080, 090, 100, 110, 120VX ) (F813, G813, Periodic Maintenance 8000YRM1571 for lift
H813, J813) truck models
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) GDC135VX, GC/GLC/GDC155VX) (E879)
(C879, D879, E879, F879)
•
truck models
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C878, • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
D878, E878) GDP135VX, GP/GLP/GDP155VX) (E878)
2. Install new reservoir onto bracket and fill with new truck models
brake fluid. See one of the following sections for
brake fluid specifications:
100, 120VX; GC/GLC080, 100VXBCS; GC/
Periodic Maintenance 8000YRM1150 for lift GLC120SVX; GC/GLC120VXPRS) (F818)
truck models Periodic Maintenance 8000YRM1604 for lift
• GLC20-35VX (GC/GLC040-070VX, GC/ truck models
GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GDP45VX6; GLP/GDP50-55VX (GP/GLP/
(B875) GDP080, 090, 100, 110, 120VX) (J813)
Periodic Maintenance 8000YRM1207 for lift Periodic Maintenance 8000YRM1606
truck models
• GC/GLC030VX, GC/GLC035VX, GC/ GDC135VX, GC/GLC/GDC155VX) (F879)
GLC040SVX (C809) •
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ 3. Connect brake fluid level switch to cowl harness.
Periodic Maintenance 8000YRM1248 for lift 4. Install kick panel and dash. Install upper steering
truck models column cover. See Dash and Kick Panel, Remove
and Install for procedures.
100, 120VX; GC/GLC080, 100VXBCS; GC/ 5. Connect battery. For lift truck models below,
install floor plate and floor mat.
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
GDP080, 090, 100, 110, 120VX) (F813, G813) GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878)
23
Connect battery. For lift truck models below, lower • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
hood. 100, 120VX; GC/GLC080, 100VXBCS; GC/
• GC/GLC030VX, GC/GLC035VX, GC/ F818)
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813,
GDP035VX, GP/GLP/GDP040SVX) (C810) H813, J813)
• GLC20-35VX (GC/GLC040-070VX, GC/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GLC055SVX) (A910) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(B875) •
100, 120VX; GC/GLC080, 100VXBCS; GC/ 2. Remove upper steering column cover and dash
GLC120SVX; GC/GLC120VXPRS) (E818, and kick panel. See Dash and Kick Panel,
F818) Remove and Install for procedures.
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 3. Disconnect brake pedal position sensor from cowl
GDP080, 090, 100, 110, 120VX) (F813, G813, harness.
H813, J813)
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
(C879, D879, E879, F879) 100, 120VX; GC/GLC080, 100VXBCS; GC/
•
F818)
SERVICE BRAKE PEDAL POSITION • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
SENSOR GDP080, 090, 100, 110, 120VX ) (F813, G813,
H813, J813)
Remove
1. For lift truck models below, to access battery, (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
remove floor mat and floor plate. Disconnect (C879, D879, E879, F879)
battery. •
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C878, GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878) D878, E878)
GDP175VX36, GLP/GDP190VX) (A909, B909) • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
raise hood. Disconnect battery. • GLP/GDP16VX, GLP/GDP18VX, GLP/
• GC/GLC030VX, GC/GLC035VX, GC/ GDP035VX, GP/GLP/GDP040SVX) (C810)
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ GLC055SVX) (A910)
GDP035VX, GP/GLP/GDP040SVX) (C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
GLC055SVX) (A910) See Figure 16 for lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
(B875) GDP90VX (GLP/GDP170VX, GLP/
24
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ Legend for Figure 15.

GDP080, 090, 100, 110, 120VX) (H813, J813) 1. MOUNTING BRACKET CAPSCREW
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ 2. BRAKE PEDAL POSITION SENSOR
GDC135VX, GC/GLC/GDC155VX) (E879, 3. MASTER CYLINDER
4. SERVICE BRAKE PRESSURE SENSOR
F879) 5. PARKING BRAKE SENSOR CONNECTOR (TO
COWL HARNESS)
NOTE: SERVICE BRAKE PEDAL POSITION SEN-

SOR FOR LIFT TRUCK MODELS GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)
SHOWN. SERVICE BRAKE PEDAL POSITION SEN-
SORS FOR ALL LIFT TRUCKS COVERED IN THIS
MANUAL ARE MOUNTED THE SAME WAY.
1. MOUNTING BRACKET CAPSCREW

2. MOUNTING BRACKET
3. CAPSCREWS AND NUTS
Figure 15. Service Brake Pedal Position Sensor 4. SERVICE BRAKE PEDAL POSITION SENSOR
and Service Brake Pressure Sensor For Lift Truck 5. SERVICE BRAKE PEDAL POSITION SENSOR
Models GLC20-35VX (GC/GCL040-070VX, GC/ CONNECTOR
GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/ 6. BRAKE PEDAL
7. PARKING BRAKE
GDP040-070VX) (B875), GC/GLC030VX, GC/
GLC035VX, GC/GLC040SVX (C809); GLP/ Figure 16. Service Brake Pedal Position Sensor
GDP16VX, GLP/GDP18VX, GLP/GDP20SVX Location, Prior to December, 2009
(GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/
GDP040SVX) (C810)
25
1. NUTS
1. MOUNTING BRACKET CAPSCREW 2. MOUNTING BRACKET
2. MOUNTING BRACKET 3. SERVICE BRAKE PEDAL POSITION SENSOR
3. CAPSCREWS AND NUTS CONNECTOR
4. SERVICE BRAKE PEDAL POSITION SENSOR 4. SERVICE BRAKE PEDAL POSITION SENSOR
5. SERVICE BRAKE PEDAL POSITION SENSOR 5. CAPSCREWS
CONNECTOR
6. BRAKE PEDAL Figure 18. Brake Pedal Position Sensor
7. PARKING BRAKE
Disassembly, Prior to December, 2009
Figure 17. Service Brake Pedal Position Sensor
Location, After December, 2009
4. Remove mounting bracket capscrew, mounting

bracket, and brake pedal position sensor from lift
truck.
See Figure 16 for lift trucks built prior to
December, 2009.
See Figure 17.for lift trucks built after December,
2009.
1. NUTS
5. Remove two capscrews, two nuts, and brake 2. MOUNTING BRACKET
pedal position sensor from mounting bracket. 3. SERVICE BRAKE PEDAL POSITION SENSOR
CONNECTOR
See Figure 18 for lift trucks built prior to 4. SERVICE BRAKE PEDAL POSITION SENSOR
December, 2009. 5. CAPSCREWS
See Figure 19 for lift trucks built after December, Figure 19. Brake Pedal Position Sensor
2009. Disassembly, After December, 2009
Install
1. Install new service brake pedal position sensor to
mounting bracket using two capscrews and two
nuts.
26
See Figure 18 for lift trucks built prior to • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
December, 2009. 100, 120VX; GC/GLC080, 100VXBCS; GC/
See Figure 19, for lift trucks built after December,
2009. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)
2. Install mounting bracket and service brake pedal
position sensor to lift truck using mounting 4. Install kick panel and dash. Install upper steering
bracket capscrew. Connect service brake pedal column cover. See Dash and Kick Panel, Remove
position sensor to cowl harness. and Install for procedures.
See Figure 16 for lift trucks built prior to
December, 2009. 5. Connect battery. For lift truck models below,
See Figure 17 for lift trucks built after December,
2009. • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
3. After new service brake pedal position sensor has D878, E878)
been installed, check the gap between the sensor • GLP/GDP80VX, GLP/GDP80VX9, GLP/
arm and tab. See one of the following sections for GDP90VX (GLP/GDP170VX, GLP/
procedures: GDP175VX36, GLP/GDP190VX) (A909, B909)
Brake System 1800YRM1135 for lift truck Connect battery. For lift truck models below lower
models hood.
• GC/GLC030VX, GC/GLC035VX, GC/ • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809) GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ • GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GDP035VX, GP/GLP/GDP040SVX) (C810) GDP035VX, GP/GLP/GDP040SVX) (C810)
• GLC20-35VX (GC/GLC040-070VX, GC/ • GLC20-35VX (GC/GLC040-070VX, GC/
GLC055SVX) (A910) GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875) (B875)
Brake System - DANA 1800YRM1247 for lift • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
truck models
• GC/GLC/GDC60VX, GC/GLC/GDC70VX F818)
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
(C879, D879, E879, F879) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
• GDP080, 090, 100, 110, 120VX) (F813, G813,
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, H813, J813)
•
100, 120VX; GC/GLC080, 100VXBCS; GC/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GLC120SVX; GC/GLC120VXPRS) (E818) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ (C879, D879, E879, F879)
•
GDC135VX, GC/GLC/GDC155VX) (C878, •
D878, E878)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ PARKING BRAKE SENSOR
GDP080, 090, 100, 110, 120VX) (F813, G813, Remove
H813) 1. For lift truck models below, to access battery,
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ remove floor mat and floor plate. Disconnect
GDP90VX (GLP/GDP170VX, GLP/ battery.
Wet Brakes - NMHG/HYG 1800YRM1597 for lift GDC135VX, GC/GLC/GDC155VX) (C878,
truck models D878, E878)
27

GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879)
•
2. Remove upper steering column cover and dash

and kick panel. See Dash and Kick Panel,
3. Disconnect parking brake sensor from cowl

harness. Remove torx capscrews from sensor
and remove sensor from parking brake handle
assembly. See Figure 20 or Figure 21.
1. PARKING BRAKE SENSOR

2. PARKING BRAKE HANDLE ASSEMBLY
3. PARKING BRAKE SENSOR CONNECTOR (TO
COWL HARNESS)
4. TORX CAPSCREWS
Figure 20. Parking Brake Sensor (Early Design)
28
Connect battery. For lift truck models below, lower

hood.
GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
1. PARKING BRAKE SENSOR (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
2. PARKING BRAKE HANDLE ASSEMBLY
3. PARKING BRAKE SENSOR CONNECTOR (TO (C879, D879, E879, F879)
COWL HARNESS) •
4. TORX CAPSCREWS
SERVICE BRAKE PRESSURE SENSOR
Figure 21. Parking Brake Sensor, Lift Truck Model
(Late Design) Remove
1. For lift truck models below, to access battery,
Install remove floor mat and floor plate. Disconnect
1. Install new sensor by using torx capscrews to battery.
secure sensor to parking brake handle assembly. • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
2. Visually inspect sensor to ensure sensor arm and D878, E878)
parking brake lever maintain continuous contact
throughout full range of lever operation.
3. Connect sensor to cowl harness. See Figure 20
or Figure 21. For lift truck models below, to access battery,
4. Install kick panel and dash. Install upper steering • GC/GLC030VX, GC/GLC035VX, GC/
column cover. See Dash and Kick Panel, Remove GLC040SVX (C809)
and Install for procedures.
5. Connect battery. For lift truck models below, GDP035VX, GP/GLP/GDP040SVX) (C810)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ GLC055SVX) (A910)
D878, E878)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
29
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 3. Disconnect the sensor from the cowl harness and
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ remove it from the master cylinder.
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813) See Figure 14 for lift truck models
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) 100, 120VX; GC/GLC080, 100VXBCS; GC/
(C879, D879, E879, F879) GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
•
2. Remove floor mat and floor plate to access GDP45VX6, GLP/GDP50-55VX (GP/GLP/
service brake pressure sensor for lift truck models GDP080, 090, 100, 110, 120VX ) (F813, G813,
H813, J813)
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ (C879, D879, E879, F879)
•
GLC20-35VX (GC/GLC040-070VX, GC/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
•
GLC055SVX) (A910) GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878)
(B875) See Figure 15 for lift truck models
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GC/GLC030VX, GC/GLC035VX, GC/
100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC040SVX (C809)
GLC120SVX; GC/GLC120VXPRS) (E818, • GLP/GDP16VX, GLP/GDP18VX, GLP/
F818) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ • GLC20-35VX (GC/GLC040-070VX, GC/
GDP080, 090, 100, 110, 120VX) (F813, G813, GLC055SVX) (A910)
H813, J813)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX (B875)
(C879, D879, E879, F879) NOTE: Perform Step 4 for lift truck models GLP/
• GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909, B909) .
4. Disconnect the sensor from the cowl harness and
remove it from the modulating brake valve. See
Figure 22.
30
1. PARKING BRAKE SENSOR

2. ACCUMULATOR PRESSURE SWITCH
3. BRAKE PRESSURE SENSOR
4. MODULATING BRAKE VALVE
5. ACCUMULATOR
6. ACCUMULATOR CHARGE VALVE
7. PARKING BRAKE
8. BRAKE PEDAL
Install
1. Install a new sensor on master cylinder. Tighten
sensor to 23 to 28 N•m (204 to 248 lbf in) for lift
truck models
GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879)
•
D878, E878)
NOTE: Perform Step 2 for lift truck models GLP/

GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909, B909) .
2. Install a new sensor on modulating brake valve.
Tighten sensor to 23 to 28 N•m (204 to 248 lbf in).
See Figure 22.
Figure 22. Brake Pressure Sensor and
Accumulator Pressure Switch, Lift Truck Models 3. Connect new sensor to cowl harness.
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX See Figure 14 for lift truck models
(GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
31
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/ 100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818, GLC120SVX; GC/GLC120VXPRS) (E818)
F818) • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDC135VX, GC/GLC/GDC155VX) (C878,
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ D878, E878)
GDP080, 090, 100, 110, 120VX ) (F813, G813, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
H813, J813) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDP080, 090, 100, 110, 120VX) (F813, G813,
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) H813)
(C879, D879, E879, F879) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
• GDP90VX (GLP/GDP170VX, GLP/
GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ GDP175VX36, GLP/GDP190VX) (A909, B909)
•
GDC135VX, GC/GLC/GDC155VX) (C878, Wet Brakes - NMHG/HYG 1800YRM1597 for lift
D878, E878) truck models
See Figure 15 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• GC/GLC030VX, GC/GLC035VX, GC/ 100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC040SVX (C809) GLC120SVX; GC/GLC120VXPRS) (F818)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP035VX, GP/GLP/GDP040SVX) (C810) GDP080, 090, 100, 110, 120VX) (H813, J813)
• GLC20-35VX (GC/GLC040-070VX, GC/ 5. Connect battery. For lift truck models below,
GLC055SVX) (A910)
(B875) • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
See Figure 16 for lift truck models D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/ GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909) GDP175VX36, GLP/GDP190VX) (A909, B909)
Connect battery. For lift truck models below lower
4. Bleed the brake system as described in the
hood.
section:
Brake System 1800YRM1135 for lift truck GLC040SVX (C809)
models
• GC/GLC030VX, GC/GLC035VX, GC/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GLC040SVX (C809) GDP035VX, GP/GLP/GDP040SVX) (C810)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ • GLC20-35VX (GC/GLC040-070VX, GC/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GLC055SVX) (A910)
GDP035VX, GP/GLP/GDP040SVX) (C810) GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
•
• GLC20-35VX (GC/GLC040-070VX, GC/ (B875)
GLC055SVX) (A910) GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
•
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 100, 120VX; GC/GLC080, 100VXBCS; GC/
(B875) GLC120SVX; GC/GLC120VXPRS) (E818,
Brake System - DANA 1800YRM1247 for lift F818)
truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDP080, 090, 100, 110, 120VX) (F813, G813,
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) H813, J813)
(C879, D879, E879, F879)
• (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
32
• • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/

ACCUMULATOR PRESSURE SWITCH FOR D878, E878)
LIFT TRUCK MODELS GLP/GDP80VX, • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)
GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909) raise hood. Disconnect battery.
WARNING GLC040SVX (C809)
DO NOT continue to operate the lift truck if the • GLP/GDP16VX, GLP/GDP18VX, GLP/
light and audible alarm are on during operation. GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
Low accumulator pressure will prevent the service GDP035VX, GP/GLP/GDP040SVX) (C810)
brakes from stopping the lift truck. Serious injury • GLC20-35VX (GC/GLC040-070VX, GC/
to personnel can result. GLC055SVX) (A910)
During operation of lift truck, if the red, low (B875)
accumulator pressure light illuminates and an audible • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
alarm sounds (see Operating Manual), accumulator 100, 120VX; GC/GLC080, 100VXBCS; GC/
pressure switch has detected that hydraulic pressure GLC120SVX; GC/GLC120VXPRS) (E818,
is below 7240 kPa (1050 psi). Move lift truck to level F818)
ground and/or apply the parking brake. Turn lift truck • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
power OFF immediately and DO NOT restart engine GDP45VX6, GLP/GDP50-55VX (GP/GLP/
until low pressure condition has been corrected. GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
Remove • GC/GLC/GDC60VX, GC/GLC/GDC70VX
1. Remove floor mat and floor plate and disconnect (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
battery. (C879, D879, E879, F879)
•
2. Disconnect accumulator pressure switch from the
cowl harness and remove it from the accumulator 2. Remove Foot Directional Control pedal assembly
charge valve. See Figure 22. from throttle base plate and cowl. Follow removal
procedures in one of the following sections:
Install One And Two Speed Powershift
1. Install new accumulator pressure switch into Transmissions 1300YRM1129 for lift truck
accumulator charge valve. Connect cowl harness models
to accumulator pressure switch. See Figure 16. • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
2. Connect battery and install floor plate and floor • GLP/GDP16VX, GLP/GDP18VX, GLP/
mat. GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
3. Bleed brake system as described in service
manual Brake System - DANA 1800YRM1247 .
GLC055SVX) (A910)
SENSOR MICROSWITCH (FOOT • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
DIRECTIONAL CONTROL PEDAL)
Remove 100, 120VX; GC/GLC080, 100VXBCS; GC/
remove floor mat and floor plate. Disconnect GDP45VX6, GLP/GDP50-55VX (GP/GLP/
battery. GDP080, 090, 100, 110, 120VX) (F813, G813)
33
One and Two Speed Transmissions • GLP/GDP16VX, GLP/GDP18VX, GLP/

1300YRM1569 for lift truck models GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ • GLC20-35VX (GC/GLC040-070VX, GC/
GDP080, 090, 100, 110, 120VX) (H813, J813) GLC055SVX) (A910)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
100, 120VX; GC/GLC080, 100VXBCS; GC/ (B875)
GLC120SVX; GC/GLC120VXPRS) (F818) Single Speed Powershift 1300YRM1447 for lift
Three-Speed Powershift Transmission Repair truck models
1300YRM1317 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ GLC040SVX (C809)
GDC135VX, GC/GLC/GDC155VX) (C878, • GLP/GDP16VX, GLP/GDP18VX, GLP/
D878, E878) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDP035VX, GP/GLP/GDP040SVX) (C810)
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) • GLC20-35VX (GC/GLC040-070VX, GC/
(C879, D879, E879, F879) GLC055SVX) (A910)
• • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ (B875)
GDP175VX36, GLP/GDP190VX) (A909, B909) 3. Remove u-clip, foam lock seal, and wiring
harness from the pedal frame. Remove four pan
Two-Speed Powershift Transmission Repair head screws, lockwashers, washers, pedal pad,
1300YRM1343 for lift truck models and springs from pedal frame. If any metal inserts
• GC/GLC/GDC60VX, GC/GLC/GDC70VX in pedal pad are damaged, replace as necessary.
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) See Figure 23.
(F879)
Single Speed PowerShift, Aluminum Gear 4. Remove two hex head screws 19 mm (3/4 in.),
Drive Transmission 1300YRM1421 for lift truck lockwashers, nuts, and microswitch from pedal
models pad. Repeat for remaining microswitch and
remove wiring harness from pedal frame.
GLC040SVX (C809)
34
1. WIRING HARNESS 9. METAL INSERT

2. FOAM LOCK SEAL 10. NUT
3. U-CLIP 11. LOCKWASHER
4. PAN HEAD SCREW 12. MICROSWITCH
5. LOCKWASHER 13. HEX HEAD SCREW
6. WASHER 14. SPRING
7. STOP SCREW 15. PEDAL PAD
8. NUT 16. PEDAL FRAME
Figure 23. Microswitch Removal
35
Install screws with Loctite 222 (Yale P/N 501702901) .

Install pan head screws, lockwashers, and
1. Install microswitch and two hex head screws in washers in pedal pad. Tighten pan head screws
pedal pad. Coat exposed threads of hex head to 2.25 to 2.50 N•m (19 to 22 lbf in).
screws with Loctite™ 222 (Yale P/N 501702901) .
Install two lockwashers and nuts on hex head 4. Install Foot Directional Control pedal assembly
screws. DO NOT tighten nuts at this time. Repeat onto the truck. Follow installation procedures in
for the other microswitch. one of the following sections:
2. Put wires through hole in pedal frame. The white One And Two Speed Powershift
banded wire is for the reverse microswitch, and Transmissions 1300YRM1129 for lift truck
the blue banded wire is for the forward models
microswitch. Adjust each microswitch in its mount • GC/GLC030VX, GC/GLC035VX, GC/
so that the measurement between the edge of the GLC040SVX (C809)
mount and the base of the microswitch equals • GLP/GDP16VX, GLP/GDP18VX, GLP/
0.0 to 0.5 mm (0.0 to 0.02 in.). Tighten mounting GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
nuts of each microswitch as adjustment is GDP035VX, GP/GLP/GDP040SVX) (C810)
completed. See Figure 24. • GLC20-35VX (GC/GLC040-070VX, GC/
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
GDP080, 090, 100, 110, 120VX) (F813, G813)
One and Two Speed Transmissions
1300YRM1569 for lift truck models
GDP080, 090, 100, 110, 120VX) (H813, J813)
100, 120VX; GC/GLC080, 100VXBCS; GC/
Three-Speed Powershift Transmission Repair
D878, E878)
(C879, D879, E879, F879)
•
1. MICROSWITCH MOUNT GDP90VX (GLP/GDP170VX, GLP/
2. MICROSWITCH BASE GDP175VX36, GLP/GDP190VX) (A909, B909)
Figure 24. Microswitch Adjustment Two-Speed Powershift Transmission Repair
3. Install wiring harness in pedal frame. Install foam
lock seal and u-clip. Install pedal pad and springs
in pedal frame. Coat threads of four pan head
36
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

(GC/GLC/GDC135VX, GC/GLC/GDC155VX) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
(F879, G879) GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
Single Speed PowerShift, Aluminum Gear
Drive Transmission 1300YRM1421 for lift truck • GC/GLC/GDC60VX, GC/GLC/GDC70VX
models (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
•
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ LOW COOLANT LEVEL SENSOR
GDP035VX, GP/GLP/GDP040SVX) (C810) NOTE: The low coolant level sensor is an optional
• GLC20-35VX (GC/GLC040-070VX, GC/ feature on these lift trucks and is a part of the
GLC055SVX) (A910) Electronic Monitoring package option. If the lift truck
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) does not have a low coolant sensor, a plug will be in
(B875) place of where the sensor goes. See Figure 25.
Single Speed Powershift 1300YRM1447 for lift
Remove
truck models
GLC040SVX (C809) remove floor mat and floor plate. Disconnect
battery.
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
GDP035VX, GP/GLP/GDP040SVX) (C810) GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878)
GLC055SVX) (A910) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
(B875)
5. Connect battery. For lift truck models below, raise hood. Disconnect battery.
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ GLC040SVX (C809)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
GDP90VX (GLP/GDP170VX, GLP/ • GLC20-35VX (GC/GLC040-070VX, GC/
GDP175VX36, GLP/GDP190VX) (A909, B909) GLC055SVX) (A910)
Connect battery. For lift truck models below lower • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
hood. (B875)
• GC/GLC030VX, GC/GLC035VX, GC/ • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GLC040SVX (C809) 100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP035VX, GP/GLP/GDP040SVX) (C810) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
GLC055SVX) (A910)
H813, J813)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, (C879, D879, E879, F879)
100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818, •
F818)
37
CAUTION (B875)
Disposal of lubricants and fluids must meet local • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
environmental regulations. 100, 120VX; GC/GLC080, 100VXBCS; GC/
2. Drain coolant from radiator and disconnect F818)
electrical connector from low coolant level sensor. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
3. Remove low coolant level sensor from radiator. GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GDC135VX, GC/GLC/GDC155VX) (C878, (C879, D879, E879, F879)
D878, E878)
•
GLC040SVX (C809) See Figure 26 for lift truck models
• GLP/GDP16VX, GLP/GDP18VX, GLP/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP90VX (GLP/GDP170VX, GLP/
GDP035VX, GP/GLP/GDP040SVX) (C810) GDP175VX36, GLP/GDP190VX) (A909, B909)
GLC055SVX) (A910)
38
Figure 25. Low Level Coolant Sensor
39
A. GM 2.4L ENGINES, RADIATOR WITH D. CUMMINS 4.5L AND YANMAR DIESEL ENGINES
EXTERNAL COOLER SHOWN AND GM 4.3L AND 5.7L ENGINES AND PSI 4.3L
B. MAZDA FE AND F2 ENGINES EXCEPT 2007 ENGINES AND KUBOTA 3.8L DIESEL ENGINES
EMISSION COMPLIANT ENGINES (MODINE WITH EXTERNAL COOLER SHOWN
SHOWN), RADIATOR WITH INTERNAL E. MAZDA 2007 EMISSION COMPLIANT FE AND F2
COOLER SHOWN ENGINES (MODINE SHOWN), RADIATOR WITH
C. CUMMINS 4.5L AND YANMAR DIESEL INTERNAL COOLER SHOWN
ENGINES AND GM 4.3L AND PSI 4.3L F. CUMMINS QSB 3.3L DIESEL ENGINE WITH
ENGINES WITH INTERNAL COOLER SHOWN INTERNAL COOLER SHOWN, LIFT TRUCK
MODELS GLP/GDP60VX, GLP/GDP70VX
D878)
1. RADIATOR 2. LOW LEVEL COOLANT SENSOR

GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879)
NOTE: CUMMINS QSB 3.3L DIESEL ENGINE WITH •
CHARGE AIR INTERCOOLER SHOWN.
1. RADIATOR • GLP/GDP80VX, GLP/GDP80VX9, GLP/
2. LOW LEVEL COOLANT SENSOR GDP90VX (GLP/GDP170VX, GLP/
Figure 26. Low Coolant Level Sensor, Lift Truck
Models GLP/GDP80VX, GLP/GDP80VX9, GLP/ 2. Connect the electrical connector to the low
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, coolant level sensor. Refill radiator with correct
GLP/GDP190VX) (A909, B909) coolant of 50% water and 50% Ethylene Glycol
Boron-Free Antifreeze.
Install
1. Install new low coolant level sensor into radiator. 3. Seal threads with Loctite PST 567 (Yale P/N
518795676) thread sealant and torque to
See Figure 25 for lift truck models 7 N•m (62 lbf in).
GDC135VX, GC/GLC/GDC155VX) (C878, 4. Connect battery. For lift truck models below,
D878, E878) install floor plate and floor mat.
40
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ 3. Unscrew the sensor and remove sensor and
GDC135VX, GC/GLC/GDC155VX) (C878, sender unit from fuel pump assembly. See
D878, E878) Figure 27.
Connect battery. For lift truck models below lower
hood.
GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879)
•
FUEL LEVEL SENSOR, GAS AND DIESEL

ENGINES ONLY
NOTE: If lift truck is equipped with a Mazda 2007
emissions compliant FE or F2 gas engine, or if lift
truck was built after January, 2010 and equipped with
Mazda gas engine, see the following service manual to
replace fuel level sensor.
•
Gasoline Fuel System 0900YRM1325
NOTE: GAS FUEL PUMP SHOWN. FUEL LEVEL
Remove SENSOR LOCATED IN SAME POSITION FOR DIE-
SEL FUEL PUMP.
1. To access the battery, raise the hood, on lift truck
models below. Disconnect the battery. 1. BRACKET
• GLC20-35VX (GC/GLC040-070VX, GC/ 2. FUEL SENDER UNIT
GLC055SVX) (A910) 3. FUEL LEVEL SENSOR
4. FUEL PUMP COVER
(B875) Figure 27. Fuel Pump and Sensor
2. Disconnect the electrical connector from the
sensor on the fuel pump cover.
41
Install ARMREST SWITCH

1. Install new fuel level sensor and sender unit NOTE: Lift truck models shown below are NOT
through hole in fuel pump cover. Be sure that the equipped with an armrest switch
bracket in the fuel pump engages the plastic • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
piece on the bottom of the fuel sender unit. GDC135VX, GC/GLC/GDC155VX) (C878,
Tighten fuel level sensor and sender unit onto fuel D878, E878)
pump cover. See Figure 27. • GLP/GDP80VX, GLP/GDP80VX9, GLP/
2. Connect the fuel level sensor electrical connector. GDP175VX36, GLP/GDP190VX) (A909, B909)
3. Connect the battery and lower the hood, on lift Remove
truck models
1. Raise the hood and disconnect the battery.
GLC055SVX) (A910)
2. Unlatch and raise armrest.
(B875) 3. Remove arm pad by removing four screws from
underside of armrest. Disconnect armrest switch
from seat harness. See Figure 28. Remove
screws securing armrest switch to armrest
bracket and remove switch.
42
Figure 28. Armrest Switch
43

NOTE: NON-SWIVEL SEAT SHOWN.
A. FRONT VIEW B. BOTTOM VIEW
1. ARMREST SWITCH 4. ARMREST SCREWS

2. SWITCH ACTUATOR 5. SEAT HARNESS
3. ARMREST PAD
Install
1. Install new armrest switch on bracket. Connect
switch to seat harness. See Figure 28.
2. Install arm pad by inserting four screws into

underside of armrest.
3. Close and latch armrest.
4. Connect the battery and lower the hood.
SEAT SENSOR (OPERATOR PRESENCE

SYSTEM)
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/ NOTE: BOTTOM VIEW OF HOOD SHOWN.
GLC040-070VX, GC/GLC055SVX) (A910),
1. CAPSCREWS
GLP/GDP20-35VX (GP/GLP/ 2. SEAT HARNESS BRACKET
GDP040-070VX) (B875), GLC40-55VX; 3. SEAT HARNESS
GLC55SVX; (GC/GLC080-120VX; GC/ Figure 29. Seat Removal, Non-Suspension and
GLC080-100VXBCS; GC/GLC120SVX; GC/ Semi-Suspension Seats
GLC120VXPRS) (E818, F818), GLP/
GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 3. Remove four capscrews and washers holding
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ seat to hood. Remove seat from hood.
GDP080-120VX) (F813, G813, H813, J813), 4. Disconnect seat sensor. See Figure 30.
and GLC/GDC60-70VX (GC/GLC/
GDC135-155VX) (C879, D879, E879, F879) 5. Remove two capscrews and seat sensor from
seat.
Remove
1. Raise hood for access to battery and disconnect
battery.
2. Disconnect seat harness from chassis harness.

Remove seat harness from brackets that are
attached to hood. See Figure 29.
44

Remove
1. For access to battery, remove floor plate and floor
mat. Disconnect battery.
2. Disconnect seat harness from chassis harness.

Remove the seat harness from the bracket that is
attached to the seat surround plate. See
Figure 31.
1. CAPSCREWS
2. SEAT SENSOR
3. SEAT SENSOR ELECTRICAL CONNECTOR
4. SEAT GROUND WIRE
5. SEAT HARNESS
Figure 30. Seat Sensor, Non-Suspension and Semi-

Suspension Seats
NOTE: BOTTOM VIEW SHOWN.
Install 1. HARNESS BRACKET
1. Insert two capscrews and install sensor to seat. 2. SEAT HARNESS
See Figure 30. 3. SEAT SURROUND PLATE
4. FLANGE NUTS
5. SEAT PLATE
2. Connect new seat sensor to seat harness.
Figure 31. Seat Removal, Non-Suspension Seat,
3. Install seat onto hood using four capscrews and Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
washers. Tighten capscrews to (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
18 N•m (156 lbf in). See Figure 29. D878, E878)
4. Install seat harness to brackets on hood. 3. Remove the four flange nuts holding the seat to
the seat plate. Remove seat from seat plate.
5. Connect seat harness to chassis harness.
4. Disconnect the seat sensor. See Figure 30.
6. Connect the battery and close hood.
5. Remove two capscrews and seat sensor from the
Non-Suspension Seats; Lift Truck Models seat.
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, Install
D878, E878) 1. Insert two capscrews and install new sensor to
NOTE: Lift truck model shown below is NOT equipped seat. See Figure 30.
with a non-suspension seat.
45
2. Connect new seat sensor to seat harness.
3. Install seat onto seat plate using four flange nuts.

Tighten flange nuts to 18 N•m (156 lbf in) See
Figure 31.
4. Install seat harness to bracket on seat surround

plate.
5. Connect seat harness to chassis harness.
6. Connect the battery and install the floor plate and

floor mat.
Full Suspension Seats; All Lift Truck

Models
Remove
1. Remove two clips that secure the bottom seat
cushion to seat base. See Figure 32.
2. Lift bottom seat cushion up and disconnect the

1. SEAT SENSOR
seat sensor from harness. 2. SEAT HARNESS
3. TO CHASSIS HARNESS
3. Use a small, flat-bladed screwdriver and remove 4. CLIPS
the seat sensor from bottom seat cushion. 5. BOTTOM SEAT CUSHION
6. SEAT BASE
Figure 32. Seat Sensor, Full-Suspension Seat
Install
1. Install new seat sensor into bottom seat cushion.
2. Connect seat sensor to seat harness. See

Figure 32.
3. Place bottom seat cushion onto seat base and

secure cushion to base with two clips.
46
HOOD SHUT OFF SWITCH •

NOTE: The hood shut off switch is found on certain lift 2. Raise the hood and disconnect switch from rear
truck models manufactured for use in Europe only. harness to chassis harness connector and
remove capscrews to remove switch from
Remove bracket.
1. To access the battery, remove the floor mat and See Figure 33 for lift truck models
floor plate, on lift truck models below. Disconnect
• GLC40, 45, 55VX; GLC55SVX (E818, F818)
the battery.
• GLP/GDP60VX, GLP/GDP70VX (C878, D878) GDP45VX6, GLP/GDP50-55VX (F813, G813)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GDP90VX (A909) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
To access the battery, raise the hood, on lift truck (C879, D879, E879, F879)
models below. Disconnect the battery. •
• GLP/GDP16VX, GLP/GDP18VX, GLP/ • GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX (C810) GDP20SVX (C810)
• GLC20-35VX (A910) • GLC20-35VX (A910)
• GLP/GDP20-35VX (B875) • GLP/GDP20-35VX (B875)
• GLC40, 45, 55VX; GLC55SVX (E818) See Figure 34 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GLP/GDP60VX, GLP/GDP70VX (C878, D878)
GDP45VX6, GLP/GDP50-55VX (F813, G813)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDP90VX (A909)
(C879, D879, E879, F879)
47
NOTE: BOTTOM VIEW OF HOOD SHOWN.
1. REAR HARNESS TO CHASSIS HARNESS 3. BRACKET CAPSCREW

CONNECTOR 4. ACTUATOR MAGNET SWITCH
2. HOOD SHUT OFF SWITCH
Figure 33. Hood Shut Off Switch, Lift Truck Models GLC40, 45, 55VX; GLC55SVX (E818), GLP/GDP40VX5/
VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (F813, G813), GLC/GDC60VX, GLC/GDC70VX
(C879, D879, E879, F879), GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (C810), GLC20-35VX (A910),
and GLP/GDP20-35VX (B875)
48
NOTE: BOTTOM VIEW OF HOOD SHOWN. KEY AND HOOD SWITCHES ARE OPTIONAL FEATURES.
1. HINGE BRACKET 4. REAR HARNESS TO CHASSIS HARNESS

2. ACTUATOR MAGNET CONNECTOR
3. HOOD SHUT OFF SWITCH 5. KEY SWITCH
Figure 34. Hood Shut Off Switch, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (C878, D878) and GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (A909)
Install • GLP/GDP16VX, GLP/GDP18VX, GLP/

GDP20SVX (C810)
1. Install new switch on bracket using the capscrews
• GLC20-35VX (A910)
and connect switch to rear harness to chassis
harness connector. • GLP/GDP20-35VX (B875)
See Figure 33 for lift truck models See Figure 34 for lift truck models
• GLC40, 45, 55VX; GLC55SVX (E818, F818) • GLP/GDP60VX, GLP/GDP70VX (C878, D878)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP45VX6, GLP/GDP50-55VX (F813, G813) GDP90VX (A909)
2. Connect the battery, install the floor plate and
(C879, D879, E879, F879) floor mat, on lift truck models
• • GLP/GDP60VX, GLP/GDP70VX (C878, D878)
49

GDP90VX (A909)
Connect the battery and lower the hood, on lift
truck models
GDP20SVX (C810)
• GLC20-35VX (A910)
• GLP/GDP20-35VX (B875)
• GLC40, 45, 55VX; GLC55SVX (E818)
GDP45VX6, GLP/GDP50-55VX (F813, G813)
(C879, D879, E879, F879)
•
REMOTE KEY SWITCH

NOTE: Lift truck models shown below may be
equipped with an optional remote key switch on the 1. BOOT PROTECTOR
right side of the engine compartment. 2. MOUNTING BRACKET
• GLP/GDP60VX, GLP/GDP70VX (C878, D878,) 3. REMOTE KEY SWITCH ASSEMBLY
4. NUT
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ 5. KEY
GDP90VX (A909)
Figure 35. Remote Key Switch Replacement, Lift
Remove Truck Models GLP/GDP60VX, GLP/GDP70VX
(C878, D878), GLP/GDP80VX, GLP/GDP80VX9,
1. Remove the floor mat and floor plate for access to
GLP/GDP90VX (A909)
the battery. Disconnect the battery.
3. Loosen the nut and remove remote key switch
2. Raise the hood and pull back the boot protector
assembly from mounting bracket.
and disconnect boot protector from the remote
key switch assembly. See Figure 35.
Install
1. Install new remote key switch assembly into
mounting bracket. Tighten nut to secure the
assembly to mounting bracket.
2. Connect boot protector to remote key switch

assembly. See Figure 35.
3. Close the hood. Connect the battery and install

floor plate and floor mat.
50
HYDRAULIC FILTER PRESSURE SWITCH • GLC20-35VX (GC/GLC040-070VX, GC/

GLC055SVX) (A910)
NOTE: The hydraulic filter pressure switch is an
optional feature on the lift trucks covered in this (B875)
service manual and is a part of the Electronic
Monitoring package option. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
Remove F818)
1. To access the battery, remove the floor mat and • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
floor plate, on lift truck models below. Disconnect GDP45VX6, GLP/GDP50-55VX (GP/GLP/
the battery. GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
GDC135VX, GC/GLC/GDC155VX) (C878, • GC/GLC/GDC60VX, GC/GLC/GDC70VX
D878, E878) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
GDP90VX (GLP/GDP170VX, GLP/ •
2. Disconnect the hydraulic filter pressure switch
To access the battery, raise the hood, on lift truck from the chassis harness. Remove switch from
models below. Disconnect the battery. hydraulic filter head assembly and discard switch
• GC/GLC030VX, GC/GLC035VX, GC/ and O-ring. See Figure 36.
GLC040SVX (C809)
51
Figure 36. Hydraulic Filter Pressure Switch
52
A. HYDRAULIC FILTER USED ON LIFT TRUCK B. HYDRAULIC FILTER USED ON LIFT TRUCK
MODELS GC/GLC030-035VX, GC/GLC040SVX MODELS GLC40, 45, 55VX; GLC55SVX; (GC/
(C809), GLP/GDP16-18VX, GLP/GDP20SVX GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
(C810), GLC20-35VX (GC/GLC040-070VX, GC/ GC/GLC120SVX; GC/GLC120VXPRS) (E818,
GLC055SVX) (A910), AND GLP/GDP20-35VX F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
(GP/GLP/GDP040-070VX) (B875) GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813), GLC/GDC60VX, GLC/GDC70VX
D879, E879, F879), GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878), GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX, GLP/
1. HYDRAULIC FILTER PRESSURE SWITCH 3. FILTER HEAD ASSEMBLY

2. O-RING (NOT SHOWN)
Install • GC/GLC/GDC60VX, GC/GLC/GDC70VX

1. Insert new switch, with new O-ring, into hydraulic (C879, D879, E879, F879)
filter head assembly. Torque switch to
•
20 N•m (177 lbf in). Connect hydraulic filter
pressure switch to chassis harness. See
TRANSMISSION SPEED SENSOR
Figure 36.
Remove
floor mat, on lift truck models 1. To access the battery, remove the floor mat and
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ the battery.
D878, E878) • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
D878, E878)
GDP175VX36, GLP/GDP190VX) (A909, B909) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
Connect the battery and lower the hood, on lift GDP175VX36, GLP/GDP190VX) (A909, B909)
truck models
To access the battery, raise the hood, on lift truck
• GC/GLC030VX, GC/GLC035VX, GC/ models below. Disconnect the battery.
GLC040SVX (C809)
GLC040SVX (C809)
GDP035VX, GP/GLP/GDP040SVX) (C810) • GLP/GDP16VX, GLP/GDP18VX, GLP/
GLC055SVX) (A910)
GLC055SVX) (A910)
(B875)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
F818) 100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
53

GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879)
•
NOTE: Perform Step 2 for lift trucks equipped with an

iron transmission housing.
2. Disconnect sensor from transmission harness
and remove bolt securing sensor to transmission
housing. Discard the O-rings.
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX ) (F813, G813,
H813, J813)
• GC/GLC030VX, GC/GLC035VX, GC/ NOTE: TWO-SPEED TRANSMISSION SHOWN FOR
GLC040SVX (C809) LIFT TRUCK MODELS
• GLP/GDP16VX, GLP/GDP18VX, GLP/ GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
•
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ 100, 120VX; GC/GLC080, 100VXBCS; GC/
GDP035VX, GP/GLP/GDP040SVX) (C810) GLC120SVX; GC/GLC120VXPRS) (E818,
• GLC20-35VX (GC/GLC040-070VX, GC/ F818)
GLC055SVX) (A910) GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
•
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
(B875) GDP080, 090, 100, 110, 120VX ) (F813, G813,
See Figure 38 for lift truck models H813, J813)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GLC040SVX (C809)
(C879, D879, E879, F879) • GLP/GDP16VX, GLP/GDP18VX, GLP/
• GDP035VX, GP/GLP/GDP040SVX) (C810)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ • GLC20-35VX (GC/GLC040-070VX, GC/
GDC135VX, GC/GLC/GDC155VX) (C878, GLC055SVX) (A910)
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ (B875)
GDP175VX36, GLP/GDP190VX) (A909, B909) 1. PRESSURE SENSORS
2. PRESSURE SENSOR (TWO-SPEED ONLY)
3. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)
4. TRANSMISSION INPUT SPEED SENSOR (TISS)
5. BOLTS
6. TEMPERATURE SENSOR
Figure 37. Transmission Sensors - Iron Housing
54
NOTE: THREE-SPEED TRANSMISSION SHOWN.
A. FRONT VIEW OF TRANSMISSION B. REAR VIEW OF TRANSMISSION
1. TEMPERATURE SENSOR 5. TRANSMISSION OUTPUT SPEED SENSOR

2. ENGINE SPEED SENSOR (THREE-SPEED (TOSS)**
TRANSMISSION ONLY) 6. PRESSURE SENSORS
3. INTERMEDIATE SPEED SENSOR (THREE- 7. TRANSMISSION INPUT SENSOR (TISS)
SPEED TRANSMISSION ONLY)
4. TRANSMISSION OUTPUT SPEED SENSOR
(TOSS)*
*TOSS sensor location, three-speed transmission only.
**TOSS sensor location, two-speed transmission only.
Figure 38. Transmission Sensors, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879, D879, E879, F879), 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)
NOTE: Perform Step 3 for lift trucks built prior to • GC/GLC030VX, GC/GLC035VX, GC/
January, 2011 equipped with an aluminum GLC040SVX (C809)
transmission housing. • GLP/GDP16VX, GLP/GDP18VX, GLP/
3. Remove capscrew, washer, and shield from the GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
top of the transmission housing. See Figure 39.
NOTE: Perform Step 4 and Step 5 for lift truck GLC055SVX) (A910)
equipped with an aluminum housing. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
4. Disconnect sensor from transmission harness.
5. Remove capscrew, washer, and sensor from • GC/GLC030VX, GC/GLC035VX, GC/
transmission housing. Remove and discard O- GLC040SVX (C809)
ring from sensor.
See Figure 39 for lift truck models GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
55

GLC055SVX) (A910)
(B875)
NOTE: ALUMINUM TRANSMISSION SHOWN FOR

LIFT TRUCKS 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)
NOTE: ALUMINUM TRANSMISSION SHOWN FOR (A910) , AND GLP/GDP20-35VX (GP/GLP/
LIFT TRUCKS GC/GLC030VX, GC/GLC035VX, GC/ GDP040-070VX) (B875) .
GLC040SVX (C809) , GLP/GDP16VX, GLP/
1. CAPSCREW
GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, 2. WASHER
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) , 3. TRANSMISSION SENSOR
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) 4. TRANSMISSION SPEED SENSOR
(A910) , AND GLP/GDP20-35VX (GP/GLP/ 5. PRESSURE SENSOR
GDP040-070VX) (B875) . 6. TEMPERATURE SENSOR
1. CAPSCREW Figure 40. Transmission Sensors - Aluminum

2. WASHER Housing Built After January, 2011
3. SHIELD
4. TRANSMISSION SENSOR Install
5. TRANSMISSION SPEED SENSOR
6. PRESSURE SENSOR NOTE: Perform Step 1 for lift trucks equipped with an
7. TEMPERATURE SENSOR iron transmission housing.
Figure 39. Transmission Sensors - Aluminum 1. Install new O-rings on sensor and install sensor
Housing Built Prior to January, 2011 into transmission housing with the bolt. Tighten
bolt to 6.9 N•m (61 lbf in). Connect sensor to
transmission harness.
56
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLC20-35VX (GC/GLC040-070VX, GC/

100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC055SVX) (A910)
F818) (B875)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 3. Connect sensor to transmission harness.
GDP080, 090, 100, 110, 120VX ) (F813, G813,
H813, J813) NOTE: Perform Step 4 for lift trucks built prior to
• GC/GLC030VX, GC/GLC035VX, GC/ January, 2011 equipped with an aluminum
GLC040SVX (C809) transmission housing.
• GLP/GDP16VX, GLP/GDP18VX, GLP/ 4. Install shield, washer, and capscrew onto top of
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ transmission housing. See Figure 39.
• GLC20-35VX (GC/GLC040-070VX, GC/ 5. Connect the battery, install the floor plate and
GLC055SVX) (A910) floor mat, on lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
(B875) GDC135VX, GC/GLC/GDC155VX) (C878,
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLP/GDP80VX, GLP/GDP80VX9, GLP/
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) GDP90VX (GLP/GDP170VX, GLP/
(C879, D879, E879, F879) GDP175VX36, GLP/GDP190VX) (A909, B909)
• Connect the battery and lower the hood, on lift
truck models
GDC135VX, GC/GLC/GDC155VX) (C878, • GC/GLC030VX, GC/GLC035VX, GC/
D878, E878) GLC040SVX (C809)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP90VX (GLP/GDP170VX, GLP/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909) GDP035VX, GP/GLP/GDP040SVX) (C810)
NOTE: Perform Step 2 and Step 3 for lift trucks GLC055SVX) (A910)
equipped with an aluminum transmission housing.
2. Install new O-ring on sensor. Install sensor, (B875)
washer, and capscrew on transmission housing. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
See Figure 39 for lift truck models 100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC040SVX (C809) GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
•
GDP035VX, GP/GLP/GDP040SVX) (C810) H813, J813)
(B875) •
TRANSMISSION PRESSURE SENSORS
GLC040SVX (C809) Remove
• GLP/GDP16VX, GLP/GDP18VX, GLP/ 1. To access the battery, remove the floor mat and
the battery.
57
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

GDC135VX, GC/GLC/GDC155VX) (C878, (B875)
D878, E878)
GDP90VX (GLP/GDP170VX, GLP/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GDP175VX36, GLP/GDP190VX) (A909, B909) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
•
models below. Disconnect the battery.
• GC/GLC030VX, GC/GLC035VX, GC/ GDC135VX, GC/GLC/GDC155VX) (C878,
GLC040SVX (C809) D878, E878)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP90VX (GLP/GDP170VX, GLP/
GDP035VX, GP/GLP/GDP040SVX) (C810) GDP175VX36, GLP/GDP190VX) (A909, B909)
GLC055SVX) (A910) NOTE: Perform Step 3 for lift trucks shown below,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) built prior to January, 2011, equipped with an
(B875) aluminum transmission housing.
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 3. Remove capscrew, washer, and shield from the
100, 120VX; GC/GLC080, 100VXBCS; GC/ top of the transmission housing.
F818) See Figure 39 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GC/GLC030VX, GC/GLC035VX, GC/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GLC040SVX (C809)
GDP080, 090, 100, 110, 120VX) (F813, G813, • GLP/GDP16VX, GLP/GDP18VX, GLP/
H813, J813) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDP035VX, GP/GLP/GDP040SVX) (C810)
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) • GLC20-35VX (GC/GLC040-070VX, GC/
(C879, D879, E879, F879) GLC055SVX) (A910)
• • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
NOTE: Perform Step 2 for lift truck equipped with an
iron transmission housing. NOTE: Perform Step 4 and Step 5 for lift trucks built
2. Disconnect the pressure sensors from the after January, 2011, equipped with an aluminum
transmission harness. Remove sensors from transmission housing.
fitting on the control valve. 4. Disconnect pressure sensor from transmission
See Figure 37 for lift truck models harness.
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 5. Remove pressure sensor from transmission
100, 120VX; GC/GLC080, 100VXBCS; GC/ housing.
F818) See Figure 39 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GC/GLC030VX, GC/GLC035VX, GC/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GLC040SVX (C809)
GDP080, 090, 100, 110, 120VX ) (F813, G813, • GLP/GDP16VX, GLP/GDP18VX, GLP/
H813, J813) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• GC/GLC030VX, GC/GLC035VX, GC/ GDP035VX, GP/GLP/GDP040SVX) (C810)
GLC040SVX (C809) • GLC20-35VX (GC/GLC040-070VX, GC/
• GLP/GDP16VX, GLP/GDP18VX, GLP/ GLC055SVX) (A910)
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GDP035VX, GP/GLP/GDP040SVX) (C810) (B875)
GLC055SVX) (A910)
58
• GC/GLC030VX, GC/GLC035VX, GC/ NOTE: Perform Step 2 and Step 3 for lift trucks built
GLC040SVX (C809) after January, 2011, equipped with an aluminum
• GLP/GDP16VX, GLP/GDP18VX, GLP/ transmission housing.
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ 2. Install pressure sensor on transmission housing.
• GLC20-35VX (GC/GLC040-070VX, GC/ See Figure 39 for lift truck models
GLC055SVX) (A910) • GC/GLC030VX, GC/GLC035VX, GC/
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GLC040SVX (C809)
(B875) • GLP/GDP16VX, GLP/GDP18VX, GLP/
Install GDP035VX, GP/GLP/GDP040SVX) (C810)
NOTE: When new transmission pressure sensors are • GLC20-35VX (GC/GLC040-070VX, GC/
installed, calibration is required for transmissions with GLC055SVX) (A910)
an iron housing. See the section Calibration • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
Procedures 8000YRM1134 for calibration procedures. (B875)
NOTE: Perform Step 1 for lift trucks equipped with an
iron transmission housing. • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
1. Install new sensors on control valve. Connect • GLP/GDP16VX, GLP/GDP18VX, GLP/
sensors to transmission harness. GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
See Figure 37 for lift truck models GDP035VX, GP/GLP/GDP040SVX) (C810)
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLC20-35VX (GC/GLC040-070VX, GC/
•
100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC055SVX) (A910)
F818) (B875)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 3. Connect pressure sensor to transmission
GDP080, 090, 100, 110, 120VX ) (F813, G813, harness.
H813, J813)
NOTE: Perform Step 4 for lift trucks built prior to
January, 2011 equipped with an aluminum
GLC040SVX (C809)
transmission housing.
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ 4. Install shield, washer, and capscrew onto top of
GDP035VX, GP/GLP/GDP040SVX) (C810) transmission housing. See Figure 39.
GLC055SVX) (A910) 5. Connect the battery, install the floor plate and
floor mat, on lift truck models
(B875) • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLP/GDP80VX, GLP/GDP80VX9, GLP/
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) GDP90VX (GLP/GDP170VX, GLP/
(C879, D879, E879, F879) GDP175VX36, GLP/GDP190VX) (A909, B909)
• Connect the battery and lower the hood, on lift
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ truck models
D878, E878) • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
GDP90VX (GLP/GDP170VX, GLP/ • GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
59
• GLC20-35VX (GC/GLC040-070VX, GC/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

GLC055SVX) (A910) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GDP080, 090, 100, 110, 120VX) (F813, G813,
(B875) H813, J813)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GC/GLC/GDC60VX, GC/GLC/GDC70VX
100, 120VX; GC/GLC080, 100VXBCS; GC/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GLC120SVX; GC/GLC120VXPRS) (E818, (C879, D879, E879, F879)
F818) •
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 2. Put the lift truck on blocks. See the Operating
GDP080, 090, 100, 110, 120VX) (F813, G813, Manual or one of the following sections for the
H813, J813) procedures:
• GC/GLC/GDC60VX, GC/GLC/GDC70VX Periodic Maintenance 8000YRM1150 for lift
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) truck models
(C879, D879, E879, F879)
• GLC055SVX) (A910)
TRANSMISSION TEMPERATURE SENSOR (B875)GLP/GDP20-35VX (GP/GLP/
Remove GDP040-070VX) (B875)
1. To access the battery, remove the floor mat and Periodic Maintenance 8000YRM1207 for lift
floor plate, on lift truck models below. Disconnect truck models
the battery. • GC/GLC030VX, GC/GLC035VX, GC/
GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ GLC040SVX (C809)
•
GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
•
GDP90VX (GLP/GDP170VX, GLP/ Periodic Maintenance 8000YRM1248 for lift
GDP175VX36, GLP/GDP190VX) (A909, B909) truck models
To access the battery, raise the hood, on lift truck • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
models below. Disconnect the battery. 100, 120VX; GC/GLC080, 100VXBCS; GC/
GC/GLC030VX, GC/GLC035VX, GC/ GLC120SVX; GC/GLC120VXPRS) (E818)
•
GLC040SVX (C809) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/
•
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)
GDP035VX, GP/GLP/GDP040SVX) (C810) Periodic Maintenance 8000YRM1558 for lift
• GLC20-35VX (GC/GLC040-070VX, GC/ truck models
GLC055SVX) (A910) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GDP45VX6; GLP/GDP50-55VX (GP/GLP/
(B875) GDP080, 090, 100, 110, 120VX) (H813)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
60

truck models WARNING
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ At operating temperature, the transmission oil is
GDC135VX, GC/GLC/GDC155VX) (C879, HOT. DO NOT permit the hot oil to touch the skin
D879) and cause a burn. Make sure oil is cool before
Periodic Maintenance 8000YRM1571 for lift draining.
truck models
3. Drain the transmission oil. See one of the
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ following sections for the procedures:
Periodic Maintenance 8000YRM1322 for lift truck models
truck models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GLC055SVX) (A910)
D878) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)GLP/GDP20-35VX (GP/GLP/
Periodic Maintenance 8000YRM1407 for lift GDP040-070VX) (B875)
truck models
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ truck models
GDP175VX36, GLP/GDP190VX) (A909) • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
Periodic Maintenance 8000YRM1586 for lift • GLP/GDP16VX, GLP/GDP18VX, GLP/
truck models GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
GDP90VX (GLP/GDP170VX, GLP/ Periodic Maintenance 8000YRM1248 for lift
GDP175VX36, GLP/GDP190VX) (B909) truck models
Periodic Maintenance 8000YRM1583 for lift • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
truck models 100, 120VX; GC/GLC080, 100VXBCS; GC/
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GLC120SVX; GC/GLC120VXPRS) (E818)
GDP135VX, GP/GLP/GDP155VX) (E878) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
Periodic Maintenance 8000YRM1598 for lift GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
truck models
GLC120SVX; GC/GLC120VXPRS) (F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
Periodic Maintenance 8000YRM1604 for lift GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813)
truck models
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ truck models
GDP080, 090, 100, 110, 120VX) (J813) • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
Periodic Maintenance 8000YRM1606 for lift GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
truck models
GDC135VX, GC/GLC/GDC155VX) (F879) truck models
• • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
truck models
61
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GC/GLC030VX, GC/GLC035VX, GC/

GDP135VX, GP/GLP/GDP155VX) (C878, GLC040SVX (C809)
D878) • GLP/GDP16VX, GLP/GDP18VX, GLP/
Periodic Maintenance 8000YRM1407 for lift GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
truck models GDP035VX, GP/GLP/GDP040SVX) (C810)
GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GLC20-35VX (GC/GLC040-070VX, GC/
•
GDP90VX (GLP/GDP170VX, GLP/ GLC055SVX) (A910)
GDP175VX36, GLP/GDP190VX) (A909) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
truck models See Figure 38 for lift truck models
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GDP90VX (GLP/GDP170VX, GLP/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GDP175VX36, GLP/GDP190VX) (B909) (C879, D879, E879, F879)
Periodic Maintenance 8000YRM1583 for lift •
truck models • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ D878, E878)
Periodic Maintenance 8000YRM1598 GDP90VX (GLP/GDP170VX, GLP/
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GDP175VX36, GLP/GDP190VX) (A909, B909)
100, 120VX; GC/GLC080, 100VXBCS; GC/ See Figure 39 for lift truck models
Periodic Maintenance 8000YRM1604 for lift GLC040SVX (C809)
truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
GDP080, 090, 100, 110, 120VX) (J813) • GLC20-35VX (GC/GLC040-070VX, GC/
Periodic Maintenance 8000YRM1606 for lift GLC055SVX) (A910)
truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ (B875)
•
GDC135VX, GC/GLC/GDC155VX) (F879) See Figure 40 for lift truck models
• • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
NOTE: Perform Step 4 for lift trucks built prior to GLP/GDP16VX, GLP/GDP18VX, GLP/
•
January, 2011 equipped with an aluminum GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
transmission housing. GDP035VX, GP/GLP/GDP040SVX) (C810)
4. Remove capscrew, washer, and shield from the • GLC20-35VX (GC/GLC040-070VX, GC/
top of the transmission housing. See Figure 39. GLC055SVX) (A910)
5. Disconnect temperature sensor from transmission (B875)
harness and remove sensor from transmission.
See Figure 37 for lift truck models Install
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 1. Install new temperature sensor and connect
100, 120VX; GC/GLC080, 100VXBCS; GC/ sensor to transmission harness.
F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 100, 120VX; GC/GLC080, 100VXBCS; GC/
GDP080, 090, 100, 110, 120VX ) (F813, G813, GLC120SVX; GC/GLC120VXPRS) (E818,
H813, J813) F818)
62
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 3. Remove lift truck from blocks.

GDP080, 090, 100, 110, 120VX ) (F813, G813, 4. Connect the battery, install the floor plate and
H813, J813) floor mat, on lift truck models
• GC/GLC030VX, GC/GLC035VX, GC/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
GLC040SVX (C809) GDC135VX, GC/GLC/GDC155VX) (C878,
• GLP/GDP16VX, GLP/GDP18VX, GLP/ D878, E878)
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP035VX, GP/GLP/GDP040SVX) (C810) GDP90VX (GLP/GDP170VX, GLP/
• GLC20-35VX (GC/GLC040-070VX, GC/ GDP175VX36, GLP/GDP190VX) (A909, B909)
GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) truck models
(B875)
See Figure 38 for lift truck models GLC040SVX (C809)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLP/GDP16VX, GLP/GDP18VX, GLP/
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
(C879, D879, E879, F879) GDP035VX, GP/GLP/GDP040SVX) (C810)
• • GLC20-35VX (GC/GLC040-070VX, GC/
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ GLC055SVX) (A910)
GDC135VX, GC/GLC/GDC155VX) (C878, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
D878, E878) (B875)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GDP90VX (GLP/GDP170VX, GLP/ 100, 120VX; GC/GLC080, 100VXBCS; GC/
GDP175VX36, GLP/GDP190VX) (A909, B909) GLC120SVX; GC/GLC120VXPRS) (E818,
See Figure 39 for lift truck models F818)
• GC/GLC030VX, GC/GLC035VX, GC/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GLC040SVX (C809) GDP080, 090, 100, 110, 120VX) (F813, G813,
• GLP/GDP16VX, GLP/GDP18VX, GLP/ H813, J813)
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GDP035VX, GP/GLP/GDP040SVX) (C810) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
• GLC20-35VX (GC/GLC040-070VX, GC/ (C879, D879, E879, F879)
GLC055SVX) (A910) •
(B875) 5. Fill transmission with oil. Run the lift truck and
See Figure 40 for lift truck models check oil level. See one of the following sections
for transmission oil specifications and for the
• GC/GLC030VX, GC/GLC035VX, GC/ procedures to check the transmission oil level:
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ Periodic Maintenance 8000YRM1150 for lift
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ truck models
GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/
• GLC20-35VX (GC/GLC040-070VX, GC/ GLC055SVX) (A910)
GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)GLP/GDP20-35VX (GP/GLP/
(B875) GDP040-070VX) (B875)
NOTE: Perform Step 2 for lift trucks built prior to
truck models
January, 2011 equipped with an aluminum
transmission housing. • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
2. Install shield, washer, and capscrew onto top of
transmission housing. See Figure 39.
63
• GLP/GDP16VX, GLP/GDP18VX, GLP/ Periodic Maintenance 8000YRM1604 for lift

GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ truck models
Periodic Maintenance 8000YRM1248 for lift GDP45VX6; GLP/GDP50-55VX (GP/GLP/
truck models GDP080, 090, 100, 110, 120VX) (J813)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, Periodic Maintenance 8000YRM1606 for lift
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDC135VX, GC/GLC/GDC155VX) (F879)
GDP080, 090, 100, 110, 120VX) (F813, G813) •
Periodic Maintenance 8000YRM1558 for lift ENGINE SPEED SENSOR
truck models
NOTE: The engine speed sensor is used only on lift
truck models shown below, equipped with three-speed
GDP080, 090, 100, 110, 120VX) (H813) transmission.
Periodic Maintenance 8000YRM1319 for lift See Figure 38 for lift truck models
truck models • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
•
D879) •
Periodic Maintenance 8000YRM1571 for lift • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
truck models GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878)
Periodic Maintenance 8000YRM1322 for lift GDP175VX36, GLP/GDP190VX) (A909, B909)
truck models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ Remove
GDP135VX, GP/GLP/GDP155VX) (C878, 1. Remove the floor plate and mat from frame and
D878) disconnect the battery for lift truck models
truck models • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ D878, E878)
GDP175VX36, GLP/GDP190VX) (A909) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
Periodic Maintenance 8000YRM1586 for lift GDP90VX (GLP/GDP170VX, GLP/
truck models
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ 2. To access the battery, raise the hood, on lift truck
GDP90VX (GLP/GDP170VX, GLP/ models below. Disconnect the battery.
Periodic Maintenance 8000YRM1583 for lift • GC/GLC/GDC60VX, GC/GLC/GDC70VX
truck models
(C879, D879, E879, F879)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ •
Periodic Maintenance 8000YRM1598 3. Disconnect engine speed sensor from
transmission harness and remove bolt securing
100, 120VX; GC/GLC080, 100VXBCS; GC/ sensor to transmission housing. Discard the O-
GLC120SVX; GC/GLC120VXPRS) (F818) ring. See Figure 38.
64
Install • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/

1. Install new O-ring on sensor and install sensor D878, E878)
into transmission housing with the bolt. Tighten GLP/GDP80VX, GLP/GDP80VX9, GLP/
•
bolt to 6.9 N•m (61 lbf in). Connect sensor to GDP90VX (GLP/GDP170VX, GLP/
transmission harness. See Figure 38. GDP175VX36, GLP/GDP190VX) (A909, B909)
2. Connect the battery and place floor plate and mat To access the battery, raise the hood, on lift truck
onto frame for lift truck models models below. Disconnect the battery.
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
D878, E878)
•
GDP90VX (GLP/GDP170VX, GLP/ 2. Disconnect intermediate speed sensor from
GDP175VX36, GLP/GDP190VX) (A909, B909) transmission harness and remove bolt securing
sensor to transmission housing. Discard the O-
3. Connect battery and lower hood, on lift truck ring. See Figure 38.
models
Install
GDC135VX, GC/GLC/GDC155VX) (C878, 1. Install new O-ring on intermediate speed sensor
D878, E878) and install intermediate speed sensor into
transmission housing with the bolt. Tighten bolt to
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ 6.9 N•m (61 lbf in). Connect intermediate speed
GDP90VX (GLP/GDP170VX, GLP/ sensor to transmission harness. See Figure 38.
INTERMEDIATE SPEED SENSOR floor mat, on lift truck models
NOTE: The intermediate speed sensor is used only • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
on lift truck models shown below, equipped with three- GDC135VX, GC/GLC/GDC155VX) (C878,
speed transmission. D878, E878)
See Figure 38 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDP175VX36, GLP/GDP190VX) (A909, B909)
(C879, D879, E879, F879) Connect the battery and lower the hood, on lift
truck models
•
(C879, D879, E879, F879)
D878, E878)
GLP/GDP80VX, GLP/GDP80VX9, GLP/ •
•
Remove
1. To access the battery, remove the floor mat and
the battery.
65
RETURN TO SET TILT (TILT ANGLE)

SENSOR
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/
NOTE: Before working on or near the mast, see the
section Safety Procedures When Working Near Mast
in the section:
models
GLC055SVX) (A910)
(B875)GLP/GDP20-35VX (GP/GLP/ NOTE: MAST SHOWN MAY BE DIFFERENT, BUT
GDP040-070VX) (B875) LOCATION OF TILT SENSOR IS THE SAME FOR
ALL LIFT TRUCKS COVERED IN THIS SECTION.
models 1. TORX CAPSCREWS
• GC/GLC030VX, GC/GLC035VX, GC/ 2. RETURN TO SET TILT (TILT ANGLE) SENSOR
GLC040SVX (C809) 3. SENSOR BRACKET
4. COWL
• GLP/GDP16VX, GLP/GDP18VX, GLP/ 5. MAST HARNESS (TO COWL HARNESS)
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ 6. HARNESS BRACKET
Figure 41. Return to Set Tilt (Tilt Angle) Sensor
Remove
1. Raise hood and disconnect the battery. Install
1. Install new sensor onto sensor bracket and insert
2. Disconnect mast harness from cowl harness. two torx capscrews and nuts to secure sensor to
bracket. Secure mast harness to harness bracket.
3. Remove two torx capscrews and nuts holding the See Figure 41.
tilt sensor to the sensor bracket on the mast and
remove sensor and mast harness from sensor 2. Connect mast harness to cowl harness.
and harness brackets. See Figure 41.
3. Connect battery and close hood.
4. Tilt mast completely forward and backward to

ensure that tilt sensor is correctly installed and
connected.
Lift Truck Models GLP/GDP60VX, GLP/

GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878), GLC/
GDC60VX, GLC/GDC70VX (GC/GLC/
66
D879, E879, F879), GLC40, 45, 55VX; Periodic Maintenance 8000YRM1586 for lift truck
GLC55SVX; (GC/GLC080, 100, 120VX; GC/ models
GLC080, 100VXBCS; GC/GLC120SVX; GC/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GLC120VXPRS) (E818, F818), GLP/ GDP175VX36, GLP/GDP190VX) (B909)
GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ models
GDP080, 090, 100, 110, 120VX) (F813,
G813, H813, J813), GLP/GDP80VX, GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)
GDP80VX9, GLP/GDP90VX (GLP/
Periodic Maintenance 8000YRM1598
GDP190VX) (A909, B909) 100, 120VX; GC/GLC080, 100VXBCS; GC/
NOTE: Before working on or near the mast, see the GLC120SVX; GC/GLC120VXPRS) (F818)
section Safety Procedures When Working Near Mast Periodic Maintenance 8000YRM1604 for lift truck
in the section: models
Periodic Maintenance 8000YRM1248 for lift truck • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
models GDP45VX6; GLP/GDP50-55VX (GP/GLP/
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GDP080, 090, 100, 110, 120VX) (J813)
100, 120VX; GC/GLC080, 100VXBCS; GC/ Periodic Maintenance 8000YRM1606 for lift truck
GLC120SVX; GC/GLC120VXPRS) (E818) models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDC135VX, GC/GLC/GDC155VX) (F879)
GDP080, 090, 100, 110, 120VX) (F813, G813)
Periodic Maintenance 8000YRM1558 for lift truck Remove
models
1. To access the battery, remove floor mat and floor
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ plate, on lift truck models below. Disconnect the
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ battery.
GDP080, 090, 100, 110, 120VX) (H813)
Periodic Maintenance 8000YRM1319 for lift truck GDC135VX, GC/GLC/GDC155VX) (C878,
models D878, E878)
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ • GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDC135VX, GC/GLC/GDC155VX) (C879, GDP90VX (GLP/GDP170VX, GLP/
D879) GDP175VX36, GLP/GDP190VX) (A909, B909)
Periodic Maintenance 8000YRM1571 for lift truck To access the battery, raise hood, on lift truck
models models below. Disconnect the battery.
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GDC135VX, GC/GLC/GDC155VX) (E879) 100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, GDP080, 090, 100, 110, 120VX) (F813, G813,
D878) H813, J813)
Periodic Maintenance 8000YRM1407 for lift truck • GC/GLC/GDC60VX, GC/GLC/GDC70VX
models (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
GDP175VX36, GLP/GDP190VX) (A909)
67
2. Disconnect sensor harness from cowl harness. Install

See Figure 42.
1. Install new tilt sensor onto sensor bracket using
3. Remove harness bracket from cowl and remove two torx capscrews and nuts.
harness from bracket.
2. Secure sensor bracket and tilt sensor to mast
4. Remove capscrew that attaches tilt sensor using capscrew. Tighten capscrew to
bracket to mast. See Figure 42. 90 to 99 N•m (66 to 73 lbf ft). See Figure 42.
5. Remove sensor bracket and tilt sensor from mast. 3. Place sensor harness in harness bracket and
install bracket onto cowl. Tighten capscrew to
6. Remove two torx capscrews and nuts holding tilt 38 N•m (28 lbf ft).
sensor to sensor bracket. Remove sensor from
bracket. 4. Connect sensor harness connector to cowl
harness.
5. Connect the battery, install floor plate and floor

mat, on lift truck models
D878, E878)
truck models
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
NOTE: GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ (C879, D879, E879, F879)
GDC135VX, GC/GLC/GDC155VX) (E879) SHOWN. •
1. TILT SENSOR 6. Tilt the mast completely forward and backward to

2. TILT SENSOR BRACKET ensure that the tilt sensor is correctly installed
3. CAPSCREW
4. SENSOR HARNESS BRACKET and connected.
5. SENSOR CONNECTOR TO COWL HARNESS
6. COWL
7. TILT CYLINDERS
Figure 42. Return to Set Tilt (Tilt Angle) Sensor
68
REAR HORN BUTTON SWITCH

Remove
the battery.
D878, E878)
GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/ 1. CAPSCREW
GLC120SVX; GC/GLC120VXPRS) (E818, 2. INSERT
F818) 3. HANDLE AND SWITCH ASSEMBLY
4. HOLE
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 5. HANDLE
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 6. REAR HORN BUTTON SWITCH
GDP080, 090, 100, 110, 120VX) (F813, G813, 7. ELECTRICAL CONNECTOR
H813, J813) 8. OVERHEAD GUARD LEG
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) Figure 43. Rear Horn Button Switch
(C879, D879, E879, F879)
Install
•
1. Insert wire and connector in the hole in overhead
2. Disconnect rear horn button switch electrical guard leg and thread wire until connector can be
connector from chassis harness. See Figure 43. pulled through bottom hole in the overhead guard
leg.
3. Remove two capscrews and inserts that attach
rear horn button switch and handle to the right 2. Attach handle and switch assembly to overhead
rear overhead guard leg. guard leg with two capscrews and inserts. See
Figure 43.
4. Remove switch and handle assembly from
overhead guard leg, pulling the wire and 3. Connect rear horn switch electrical connector to
connector through the holes in the overhead chassis harness.
guard leg.
D878, E878)
69
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ and GLC/GDC60-70VX (GC/GLC/

GDC135-155VX,) (C879, D879, E879, F879)
Connect the battery and lower the hood, on lift Remove
truck models 1. Raise the hood and disconnect the battery.
GLC040SVX (C809) 2. Remove floor mat and floor plate. Remove right
• GLP/GDP16VX, GLP/GDP18VX, GLP/ rear panel, right panel, right fender cover, and
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ right step plate. See one of the following sections
GDP035VX, GP/GLP/GDP040SVX) (C810) for removal procedures:
• GLC20-35VX (GC/GLC040-070VX, GC/ Frame 0100YRM1120 for lift truck models
GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GLC040SVX (C809)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
100, 120VX; GC/GLC080, 100VXBCS; GC/ GDP035VX, GP/GLP/GDP040SVX) (C810)
F818)
GLC055SVX) (A910)
(B875)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813) Frame 0100YRM1243 for lift truck models
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) 100, 120VX; GC/GLC080, 100VXBCS; GC/
(C879, D879, E879, F879) GLC120SVX; GC/GLC120VXPRS) (E818,
• F818)
IMPACT SENSOR GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
The impact sensor is located under the right step H813, J813)
plate.
Frame 0100YRM1316 for lift truck models
Lift Truck Models GC/GLC030-35VX, GC/ • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GLC040SVX (C809), GLP/GDP16-18VX, GDC135VX, GC/GLC/GDC155VX) (C879,
D879, E879, F879)
GLP/GDP20SVX (GP/GLP/GDP030-35VX,
GP/GLP/GDP040SVX) (C810), GLC20-35VX Frame 0100YRM1321 for lift truck models
(GC/GLC040-070VX, GC/GLC055SVX) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
(A910), GLP/GDP20-35VX (GP/GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)
GDP040-070VX) (B875), GLC40-55VX;
GLC55SVX; (GC/GLC080-120VX; GC/ 3. Disconnect impact sensor from right chassis
GLC080-100VXBCS; GC/GLC120SVX; GC/ harness. See Figure 44.
GLC120VXPRS) (E818, F818), GLP/ 4. Remove two capscrews that attach the impact
GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ sensor to mounting bracket. Remove sensor from
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ lift truck.
GDP080-120VX) (F813, G813, H813, J813),
70
NOTE: THE FRAME SHOWN IN FIGURE 44 MAY BE DIFFERENT, BUT LOCATION OF IMPACT SENSOR IS
THE SAME. ON LIFT TRUCK MODEL GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/
GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (F818) , SINGLE HYDRAULIC TANK SHOWN, DU-
AL HYDRAULIC TANK SIMILAR.
A. SIDE VIEW B. VIEW UNDERNEATH RIGHT STEP PLATE.
1. RIGHT STEP PLATE 4. RIGHT CHASSIS HARNESS CONNECTOR

2. SENSOR MOUNTING BRACKET 5. IMPACT SENSOR
3. ELECTRICAL CONNECTOR 6. CAPSCREW
Figure 44. Impact Sensor Replacement, Lift Truck Models GC/GLC030-035VX, GC/GLC040SVX (C809),
GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-035VX, 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)
71
Install Frame 0100YRM1316 for lift truck models

1. Install new impact sensor to mounting bracket. • GC/GLC/GDC60VX, GC/GLC/GDC70VX
Tighten capscrews to 26 N•m (19 lbf ft). (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
2. Connect impact sensor to right chassis harness. •
See Figure 44. Frame 0100YRM1321 for lift truck models
3. Install floor mat and floor plate. Install right rear • GLP/GDP80VX, GLP/GDP80VX9, GLP/
panel, right panel, right fender cover, and right GDP90VX (GLP/GDP170VX, GLP/
step plate. See one of the following sections for GDP175VX36, GLP/GDP190VX) (A909, B909)
installation procedures:
Frame 0100YRM1120 for lift truck models
• GC/GLC030VX, GC/GLC035VX, GC/ Lift Truck Models GLP/GDP60VX, GLP/
GLC040SVX (C809) GDP70VX (GP/GLP/GDP135VX, GP/GLP/
• GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP155VX) (C878, D878, E878), GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/
GLC055SVX) (A910) GDP190VX) (A909, B909)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) Remove
(B875)
1. Remove floor mat and floor plate and disconnect
Frame 0100YRM1243 for lift truck models the battery.
100, 120VX; GC/GLC080, 100VXBCS; GC/ 2. Disconnect impact sensor connector from right
GLC120SVX; GC/GLC120VXPRS) (E818, chassis harness connector. See Figure 45.
F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 3. Remove two capscrews that secure impact
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ sensor to bracket and remove sensor from lift
GDP080, 090, 100, 110, 120VX) (F813, G813, truck. See Figure 45.
H813, J813)
72
1. IMPACT SENSOR 5. CAPSCREW

2. SENSOR BRACKET 6. SENSOR CONNECTOR
3. FLOOR PLATE 7. PUSH-IN FASTENER
4. FLOOR MAT 8. RIGHT CHASSIS HARNESS CONNECTOR
Figure 45. Impact Sensor Replacement, 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)
Install 3. Connect the battery and install the floor plate and
floor mat.
1. Install new impact sensor to sensor bracket using
two capscrews. Tighten capscrews to
LOAD WEIGHT SENSOR
26 N•m (230 lbf in).
Remove
2. Insert the push-in fastener into the connector clip,
then connect the right chassis harness connector 1. To access the battery, remove the floor mat and
to the impact sensor connector. See Figure 45. floor plate, on lift truck models below. Disconnect
the battery.
73
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,

GDC135VX, GC/GLC/GDC155VX) (C878, 100, 120VX; GC/GLC080, 100VXBCS; GC/
D878, E878) GLC120SVX; GC/GLC120VXPRS) (E818,
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ F818)
GDP90VX (GLP/GDP170VX, GLP/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
• GC/GLC030VX, GC/GLC035VX, GC/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GLC040SVX (C809) (C879, D879, E879, F879)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ •
GDP035VX, GP/GLP/GDP040SVX) (C810) 2. Disconnect the harness connector from the load
• GLC20-35VX (GC/GLC040-070VX, GC/ weight sensor. See Figure 46.
GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 3. Remove the load weight sensor from the special
(B875) fitting on hydraulic control valve.
74
NOTE: THE POSITION OF THE VEHICLE SYSTEM MANAGER SHOWN IN FIGURE 46 MAY BE DIFFERENT,
BUT LOCATION OF LOAD WEIGHT SENSOR IS THE SAME FOR ALL LIFT TRUCKS COVERED IN THIS
YRM .
NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN. LOAD WEIGHT SENSOR IS IN SAME POSI-
TION ON MANUAL HYDRAULIC CONTROL VALVE.
NOTE: COWL COMPONENTS OMITTED FOR CLARITY. COWL SHOWN MAY BE DIFFERENT FOR SOME
LIFT TRUCKS COVERED IN THIS YRM , BUT THE LOCATION FOR THE COMPONENTS OF THE LOAD
WEIGHT SENSOR IS THE SAME.
1. SPECIAL FITTING 4. VEHICLE SYSTEM MANAGER (VSM)

2. LOAD WEIGHT SENSOR 5. COWL
3. HARNESS CONNECTOR 6. MAIN CONTROL VALVE
Figure 46. Load Weight Sensor
Install 3. Connect the battery, install the floor plate and

1. Insert new load weight sensor into special fitting.
Tighten sensor by hand, and then torque sensor • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
to 37 N•m (27 lbf ft). GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878)
2. Connect the harness connector to the load weight • GLP/GDP80VX, GLP/GDP80VX9, GLP/
sensor. See Figure 46. GDP90VX (GLP/GDP170VX, GLP/
75
Connect the battery and lower the hood, on lift ENGINE AND FUEL SENSORS AND
truck models SWITCHES, GAS AND LPG TRUCKS
• GC/GLC030VX, GC/GLC035VX, GC/ EQUIPPED WITH GM ENGINES
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ Crankshaft Position (CKP) Sensor
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ NOTE: To replace crankshaft position sensor on GM
GDP035VX, GP/GLP/GDP040SVX) (C810) 4.3L engine, see section High Voltage Switch (HVS)
• GLC20-35VX (GC/GLC040-070VX, GC/ Ignition, GM4.3L EPA Compliant Engines and
GLC055SVX) (A910) GM5.7L LPG EPA Compliant Engine 2200YRM1097.
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) NOTE: To replace the crankshaft position sensor on
(B875)
GM 2.4L engine, see section GM Engine Repair
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 0600YRM1121.
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
Camshaft Position (CMP) Sensor
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ NOTE: On the GM 4.3L engine, the camshaft position
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ sensor cannot be replaced separately from the
GDP080, 090, 100, 110, 120VX) (F813, G813, distributor. If the CMP sensor fails, the whole
H813, J813) distributor must be replaced. See the section High
• GC/GLC/GDC60VX, GC/GLC/GDC70VX Voltage Switch (HVS) Ignition, GM4.3L EPA
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) Compliant Engines and GM5.7L LPG EPA
(C879, D879, E879, F879) Compliant Engine 2200YRM1097 for procedures to
• replace the distributor.
NOTE: To replace the camshaft position sensor on
ENGINE AND FUEL SENSORS AND the GM 2.4L engine, see section GM Engine Repair
SWITCHES, GAS AND LPG TRUCKS 0600YRM1121.
EQUIPPED WITH MAZDA ENGINESFE
AND F2 Oil Pressure Sensor
NOTE: To replace oil pressure sensor on GM 4.3L
For lift trucks equipped with a Mazda engine, see the
engine, see section High Voltage Switch (HVS)
following service manuals for procedures to replace
Ignition, GM4.3L EPA Compliant Engines and
the engine and fuel sensors and switches. The list
GM5.7L LPG EPA Compliant Engine 2200YRM1097.
below is for Mazda engines built prior to 2007:
NOTE: To replace oil pressure sensor on GM 2.4L
•
engine, see section GM Engine Repair
Electrical System 2200YRM1143 0600YRM1121.
•
Gasoline Fuel System 0900YRM1127 Manifold Absolute Pressure (MAP)/
• Manifold Air Temperature (MAT) Sensor
LPG Fuel System 0900YRM1125 NOTE: To replace manifold absolute pressure (MAP)/
The list of service manuals below are for Mazda manifold air temperature (MAT) sensor on GM 4.3L
engines that are 2007 emissions compliant and for lift engine, see section High Voltage Switch (HVS)
trucks built after January, 2010: Ignition, GM4.3L EPA Compliant Engines and
GM5.7L LPG EPA Compliant Engine 2200YRM1097.
•
NOTE: To replace manifold absolute pressure (AMP)/
Electrical System 2200YRM1327 manifold air temperature (MAT) sensor on GM 2.4L
• engine, see sections LPG Fuel System
Gasoline Fuel System 0900YRM1325 0900YRM1124 for LPG or Gasoline Fuel System
0900YRM1126 for gas.
•
LPG Fuel System 0900YRM1326
76
Engine Coolant Temperature (ECT) Sensor

NOTE: To replace engine coolant temperature (ECT)
sensor on GM 4.3L engine, see section High Voltage
Switch (HVS) Ignition, GM4.3L EPA Compliant
Engines and GM5.7L LPG EPA Compliant Engine
2200YRM1097.
NOTE: To replace engine coolant temperature (ECT)
sensor on GM 2.4L engine, see sections LPG Fuel
System 0900YRM1124 for LPG or Gasoline Fuel
System 0900YRM1126 for gas.
Air Flow Restriction Switch

NOTE: To replace engine air flow restriction switch on
GM 4.3L or GM 5.7L engine, see section High
Voltage Switch (HVS) Ignition, GM4.3L EPA
Compliant Engines and GM5.7L LPG EPA
Compliant Engine 2200YRM1097. NOTE: AIR CLEANER HOSE NOT SHOWN FOR
NOTE: The air flow restriction switch is an optional CLARITY. SWITCH NOT SHOWN, BUT ITEM #4
feature on these lift trucks and is a part of the POINTS TO ITS LOCATION.
Electronic Monitoring package option.
1. ECT SENSOR
2. AIR FLOW RESTRICTION ELECTRICAL
Remove for GM 2.4L Gas and LPG Trucks CONNECTOR
1. Raise hood and disconnect the battery. 3. AIR CLEANER
4. AIR FLOW RESTRICTION SWITCH
2. Disconnect the air flow restriction switch electrical Figure 47. Air Flow Restriction Switch
connection. See Figure 47.
3. Remove air filter restriction switch from air

Install for GM 2.4L Gas and LPG Trucks
cleaner. 1. Install new air flow restriction switch into air
cleaner.
2. Connect the air flow restriction switch electrical

connection. See Figure 47.
3. Connect the battery and lower the hood.
77
Oxygen Sensor • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/

NOTE: The procedures below cover GM 4.3L engine, D878, E878)
for lift trucks built before January, 2010. For
procedures to replace oxygen sensor on GM 4.3L
engine on lift trucks built after January, 2010, see one
of the following service manuals: • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
•
LPG Fuel System, GM 4.3L Engine with GFI F818)
0900YRM1242
• GDP45VX6, GLP/GDP50-55VX (GP/GLP/
LPG Fuel System, GM 4.3L Engine With PSI GDP080, 090, 100, 110, 120VX) (F813, G813,
0900YRM1556 H813, J813)
• • GC/GLC/GDC60VX, GC/GLC/GDC70VX
Gasoline Fuel System 0900YRM1244 (C879, D879, E879, F879)
• Gasoline Fuel System PSI GM 4.3L •
• GLC/GDC60VX, GLC/GDC70VX NOTE: The GM 4.3L engine has two oxygen sensors
(GC/GLC/GDC135VX, GC/GLC/ and two electrical connectors.
GDC155VX) (E879, F879)
2. Disconnect the oxygen sensor electrical
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, connector.
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) See Figure 48 for lift truck models
(H813, J813)
• GLC40, 45, 55VX; GLC55SVX; (GC/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GLC080, 100, 120VX; GC/GLC080, GDP080, 090, 100, 110, 120VX ) (F813, G813,
100VXBCS; GC/GLC120SVX; GC/ H813, J813)
GLC120VXPRS) (E818, F818)
GDP135VX, GP/GLP/GDP155VX) (D878, • GC/GLC/GDC60VX, GC/GLC/GDC70VX
E878) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
NOTE: For procedures to replace oxygen sensors on
GM 2.4L engine, see sections •
• LPG Fuel System 0900YRM1124 • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
• Gasoline Fuel System 0900YRM1126 D878, E878)
Remove
1. To access the battery, remove the floor mat and 100, 120VX; GC/GLC080, 100VXBCS; GC/
floor plate, on lift truck models below. Disconnect GLC120SVX; GC/GLC120VXPRS) (E818,
the battery. F818)
78
NOTE: EXHAUST SYSTEM FOR LIFT TRUCK MODELS GLC40, 45, 55VX, (GC/GLC080, 100, 120VX) (E818,
F818) IS SIMILAR.
NOTE: SEE FIGURE 50 FOR OXYGEN SENSOR LOCATION ON LIFT TRUCK MODEL GLC55SVX (GC/
GLC080, 100VXBCS, GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818).
1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD

2. ELECTRICAL CONNECTOR
Figure 48. Oxygen Sensor, GM 4.3L Engine, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)
79
NOTE: OVERHEAD EXHAUST IS AN OPTIONAL FEATURE.
1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD

Figure 49. Oxygen Sensor, GM 4.3L Engine, Lift Truck Models 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)
80
NOTE: Perform Step 3 for lift truck models GLC40, • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GDC135VX, GC/GLC/GDC155VX) (C878,
GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ D878, E878)
GLC120VXPRS) (E818, F818) , equipped with the GM See Figure 50 for lift truck models
4.3L engine.
3. Remove the clip connector retaining each wire 100, 120VX; GC/GLC080, 100VXBCS; GC/
harness to the oxygen sensor brackets. See GLC120SVX; GC/GLC120VXPRS) (E818,
Figure 50. F818)
Figure 51. Oxygen Sensor Socket
Install
1. Before installing the sensor, coat sensor sparingly
1. OXYGEN SENSOR (POST-CATALYTIC) with an antiseize compound, then install oxygen
2. MUFFLER sensor into the exhaust pipes to the exhaust
3. OXYGEN SENSOR (PRE-CATALYTIC)
4. SENSOR ELECTRICAL CONNECTORS manifold for GM 4.3L engines. Using a special
5. CLIP CONNECTOR tool, oxygen sensor socket (see Figure 51),
6. BRACKET tighten oxygen sensors to
40 to 60 N•m (30 to 44 lbf ft).
Figure 50. Oxygen Sensor, GM 4.3L Engine for Lift
Truck Models (BCS/PRS Only) GLC55SVX (GC/ See Figure 48 for lift truck models
GLC080, 100VXBCS; GC/GLC120SVX; GC/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GLC120VXPRS) (E818, F818) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX ) (F813, G813,
4. Using a special tool, oxygen sensor socket (see H813, J813)
Figure 51), remove the oxygen sensor. See Figure 49 for lift truck models
See Figure 48 for lift truck models • GC/GLC/GDC60VX, GC/GLC/GDC70VX
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ (C879, D879, E879, F879)
GDP080, 090, 100, 110, 120VX ) (F813, G813, •
H813, J813) GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
•
Figure 49 for lift truck models GDC135VX, GC/GLC/GDC155VX) (C878,
D878, E878)
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) Figure 50 for lift truck models
(C879, D879, E879, F879)
•
81
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, Ignition, PSI 4.3L EPA Compliant Engine
100, 120VX; GC/GLC080, 100VXBCS; GC/ 2200YRM1955.
F818) Camshaft Position (CMP) Sensor
NOTE: Perform Step 2 for lift truck models NOTE: On the PSI 4.3L engine, the camshaft position
GLC55SVX (GC/GLC080, 100VXBCS; GC/ sensor cannot be replaced separately from the
GLC120SVX; GC/GLC120VXPRS) (E818, F818) distributor. If the CMP sensor fails, the whole
equipped with the GM 4.3L engine. distributor must be replaced. See the section High
Voltage Switch (HVS) Ignition, PSI 4.3L EPA
2. Install the clip connector to attach oxygen sensor
Compliant Engine 2200YRM1955 for procedures to
wiring harness to oxygen sensor brackets.
replace the distributor.
3. Connect the electrical connectors. Verify that the
connectors click/lock into place. Oil Pressure Sensor
NOTE: To replace oil pressure sensor on PSI 4.3L
4. Verify that the wire is pulled up toward the engine, see section High Voltage Switch (HVS)
thermostat and away from any hot exhaust Ignition, PSI 4.3L EPA Compliant Engine
components. 2200YRM1955
5. Connect the battery, install the floor plate and Manifold Absolute Pressure (MAP)/
Manifold Air Temperature (MAT) Sensor
GDC135VX, GC/GLC/GDC155VX) (C878, NOTE: To replace manifold absolute pressure (MAP)/
D878, E878) manifold air temperature (MAT) sensor on PSI 4.3L
engine, see section High Voltage Switch (HVS)
Ignition, PSI 4.3L EPA Compliant Engine
truck models
2200YRM1955
100, 120VX; GC/GLC080, 100VXBCS; GC/ Engine Coolant Temperature (ECT) Sensor
F818) NOTE: To replace engine coolant temperature (ECT)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ sensor on PSI 4.3L engine, see High Voltage Switch
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ (HVS) Ignition, PSI 4.3L EPA Compliant Engine
GDP080, 090, 100, 110, 120VX) (F813, G813, 2200YRM1955
H813, J813)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX Air Flow Restriction Switch
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) NOTE: To replace engine air flow restriction switch on
(C879, D879, E879, F879) PSI 4.3L engine, see High Voltage Switch (HVS)
• Ignition, PSI 4.3L EPA Compliant Engine
2200YRM1955.
6. Connect the battery; install the floor plate and
floor mat for lift truck model Oxygen Sensor
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ NOTE: See LPG Fuel System, PSI 4.3L Engine
0900YRM1951 for procedures to replace oxygen
D878, E878)
sensor on PSI 4.3L engine.
ENGINE AND FUEL SENSORS AND
ENGINE AND FUEL SWITCHES, GM 2.4L
SWITCHES, PSI 4.3L LPG ENGINE
LPG TRUCKS ONLY
Crankshaft Position (CKP) Sensor
Low LPG Pressure Switch
NOTE: To replace crankshaft position sensor on PSI
NOTE: For procedures to replace Low LPG pressure
4.3L engine, see section High Voltage Switch (HVS)
switch on GM 2.4L LPG engine, see section LPG Fuel
System 0900YRM1124.
82
ENGINE AND FUEL SENSORS AND 3. Remove capscrew from engine speed sensor
SWITCHES, YANMAR DIESEL TRUCKS bracket and remove bracket and engine speed
sensor. See Figure 52.
Air Filter Restriction Switch
NOTE: The air filter restriction switch is an optional Install
feature on these lift trucks and is a part of the 1. Install engine speed sensor bracket and install
Electronic Monitoring package option. new engine speed sensor.
Remove 2. Connect electrical connector to engine speed

sensor.
1. Raise hood and disconnect the battery.
2. Disconnect the electrical connector from air filter
restriction switch.
Engine Coolant Temperature (ECT) Sensor
3. Remove air filter restriction switch from air Remove
cleaner. See Figure 52.
Install
2. Drain the engine coolant from radiator before
1. Install new air filter restriction switch into air removing the ECT sensor. Refer to the section
cleaner. Cooling System 0700YRM1123.
2. Connect air filter electrical connector. 3. Disconnect the ECT sensor connector. See
Figure 52.
4. Remove the ECT sensor and packing from the
Oil Pressure Sensor intake manifold. Discard the copper washer. See
Figure 52.
Remove
1. Raise hood and disconnect the battery. Install
1. Install new copper washer onto ECT sensor.
2. Disconnect the electrical connector for the oil
Install new ECT sensor and new packing and
pressure sensor.
tighten the ECT sensor to
3. Remove the oil pressure sensor. See Figure 52. 25 to 34 N•m (18 to 25 lbf ft).
2. Connect the ECT sensor connector.

Install
1. Install new oil pressure sensor onto engine. 3. Refill the radiator with engine coolant after
Tighten sensor to 9 N•m (80 lbf in). replacing the ECT sensor. See one of the
following sections for coolant specifications and
2. Connect the electrical connector for the oil procedures:
pressure sensor. See Figure 52.
truck models
Engine Speed Sensor GLC055SVX) (A910)
Remove (B875)
1. Raise the hood and disconnect the battery. Periodic Maintenance 8000YRM1207 for lift
truck models
2. Disconnect the electrical connection from engine
speed sensor. • GC/GLC030VX, GC/GLC035VX, GC/
GLC040SVX (C809)
83
• GLP/GDP16VX, GLP/GDP18VX, GLP/ Periodic Maintenance 8000YRM1598

GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
Periodic Maintenance 8000YRM1248 for lift GLC120SVX; GC/GLC120VXPRS) (F818)
truck models
100, 120VX; GC/GLC080, 100VXBCS; GC/
GDP080, 090, 100, 110, 120VX) (F813, G813)
84
Figure 52. Yanmar Diesel Engine Sensors and Switches
85
A. FRONT VIEW B. SIDE VIEW
1. AIR FILTER RESTRICTION SWITCH 6. ENGINE COOLANT TEMPERATURE SENSOR

ELECTRICAL CONNECTOR 7. THROTTLE POSITION SENSOR
2. AIR CLEANER 8. ENGINE OIL PRESSURE SENSOR
3. AIR FILTER RESTRICTION SWITCH 9. FUEL/WATER SEPARATOR SENSOR
4. AIR CLEANER BRACKET
5. ENGINE SPEED SENSOR
Throttle Position Sensor (TPS)

Remove
1. Open hood and disconnect the battery.

throttle position sensor (TPS).
3. Remove Torx-head screws securing the TPS to

TPS bracket. See Figure 53. Remove TPS sensor
from TPS bracket.
1. LOCKWASHER
2. TORX-HEAD SCREW (BRACKET)
3. TPS BRACKET
4. WASHER
5. TORX-HEAD SCREW (SENSOR)
6. THROTTLE POSITION SENSOR (TPS)
7. TPS ROTOR
8. THROTTLE LEVER
9. FUEL PUMP
Figure 53. Throttle Position Sensor (TPS)

Assembly
86
Install
NOTE: When installing the TPS, rotate the sensor
rotor clockwise to match D-shape on the TPS rotor.
See Figure 54.
1. Install new TPS sensor on TPS bracket and
secure with Torx-head screws. Tighten Torx-head
screws to 2.25 N•m (20 lbf in).
2. Connect the throttle position sensor (TPS)

electrical connector.
1. SENSOR ROTOR
2. TPS
3. TPS ROTOR
4. D-SHAPE
Figure 54. TPS and Rotor
Fuel/Water Separator Sensor

Remove 1. DRAIN PLUG
2. O-RING
1. Open hood and disconnect the battery. 3. FUEL/WATER SEPARATOR SENSOR
4. FUEL FILTER ELEMENT BODY
2. Remove drain plug from bottom of fuel/water 5. FUEL FILTER
6. FUEL FILTER COVER
separator sensor and drain water from fuel filter.
See Figure 55. Figure 55. Fuel/Water Separator Sensor
3. Disconnect sensor from harness.
Install
4. Remove sensor from bottom of fuel filter element 1. Install new sensor into bottom of fuel filter
body. element body. See Figure 55.
2. Connect sensor to harness.
87
3. Install drain plug and O-ring into bottom of fuel/ Legend for Figure 56.
water separator sensor.
1. M TERMINAL
4. Connect the battery and close hood. 2. E TERMINAL
3. B TERMINAL
4. S TERMINAL
Glow Plug Relay
Remove 3. Slide the protective boots back on the wires for
terminals B and M. See Figure 56 and Figure 57.
WARNING
Always disconnect the cables at the battery before
you make repairs to the engine. Disconnect the
cable at the negative terminal first. Install a tag on
the battery terminals so that no one connects the
cables on the terminals.
1. Open hood and disconnect the battery.
2. Tag and disconnect the wiring connectors at

terminals E and S. See Figure 56.
Figure 56. Glow Plug Relay Terminals
88
1. B TERMINAL 5. NUT
2. M TERMINAL 6. S TERMINAL WIRING
3. M TERMINAL WIRING 7. E TERMINAL WIRING
4. WASHER 8. B TERMINAL WIRING
Figure 57. Glow Plug Relay and Wiring
4. Place tags on the wires for terminals B and M to

properly identify them for reinstallation.
5. Remove the nuts and washers retaining the wires

to terminals B and M. See Figure 57.
6. Remove the nuts retaining the glow plug relay to

the mounting bracket and remove the glow plug
relay. See Figure 58.
89
5. Connect the battery and close the hood.

SWITCHES, CUMMINS DIESEL ENGINES
Air Filter Restriction Switch
NOTE: The air filter restriction switch is an optional
feature on these lift trucks and is a part of the
Electronic Monitoring package option.
Remove
the battery.
D878)
NOTE: ENGINE NOT SHOWN FOR CLARITY. • GLP/GDP80VX, GLP/GDP80VX9, GLP/
1. MOUNTING BRACKET GDP175VX36, GLP/GDP190VX) (A909, B909)
2. GLOW PLUG RELAY To access the battery, raise the hood, on lift truck
3. NUT
Figure 58. Glow Plug Relay and Mounting Bracket • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
Install GDP080, 090, 100, 110, 120VX) (F813, G813)
1. Place the glow plug relay in position on the • GC/GLC/GDC60VX, GC/GLC/GDC70VX
mounting bracket and install retaining nuts.
(C879, D879, E879, F879)
Tighten retaining nuts to
2.50 to 2.75 N•m (22.13 to 24.34 lbf in). See •
Figure 58.
2. Disconnect the electrical connector from air filter
2. Connect the wiring connections to terminals B restriction switch.
and M. Install the nuts and washers. Tighten the
nuts to 2.9 to 4.0 N•m (25.67 to 35.40 lbf in). See 3. Remove air filter restriction switch from air
Figure 56 and Figure 57. cleaner.
See Figure 59 for lift trucks equipped with
3. Install the protective boots over the terminals B Cummins 4.5L diesel engine.
and M. See Figure 57.
4. Connect the electrical connectors at terminals E Cummins QSB 3.3L diesel engine.
and S. See Figure 56.
90
Install Connect the battery and lower the hood, on lift

truck models
1. Install new air filter restriction switch onto air
cleaner. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
2. Connect air filter electrical connector. GDP080, 090, 100, 110, 120VX) (F813, G813)
3. Connect the battery, install the floor plate and (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
floor mat, on lift truck models (C879, D879, E879, F879)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ •
D878)
91
Figure 59. Cummins 4.5L Diesel Engine Sensors and Switches
92
A. LEFT SIDE OF ENGINE B. RIGHT SIDE OF ENGINE
1. ENGINE SPEED SENSOR 5. FUEL/WATER SEPARATOR SENSOR

2. AIR FILTER RESTRICTION SWITCH 6. ENGINE OIL PRESSURE SENSOR
3. AIR CLEANER 7. THROTTLE POSITION SENSOR (TPS)
4. WATER (COOLANT) TEMPERATURE SENSOR
93
Figure 60. Cummins QSB 3.3L Diesel Engine Sensors and Switches
94
A. CUMMINS QSB 3.3L DIESEL ENGINE USED ON B. CUMMINS QSB 3.3L DIESEL ENGINE USED ON
LIFT TRUCK MODELS GDP40VX5/VX6; LIFT TRUCK MODELS GDP60VX, GDP70VX
GDP45SVX5, GDP45VX6; GDP50-55VX (GDP135VX, GDP155VX) (C878, D878), GDP80VX,
(GDP080, 090, 100, 110, 120VX) (F813, G813) GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909, B909)
1. AIR FILTER RESTRICTION SWITCH 5. FUEL/WATER SEPARATOR DRAIN PLUG

2. ENGINE COOLANT TEMPERATURE SENSOR 6. ENGINE SPEED SENSOR
3. AIR CLEANER 7. ENGINE OIL PRESSURE SWITCH
4. FUEL/WATER SEPARATOR ELECTRICAL
CONNECTOR AND SENSOR
Engine Oil Pressure Sensor 2. Connect the electrical connector for the oil
pressure sensor.
Remove
1. To access the battery, remove the floor mat and Cummins 4.5L diesel engine.
the battery. See Figure 60 for lift trucks equipped with
Cummins QSB 3.3L diesel engine.
GDC135VX, GC/GLC/GDC155VX) (C878, 3. Connect the battery, install the floor plate and
D878) floor mat, on lift truck models
GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909, B909).
D878)
To access the battery, raise the hood, on lift truck • GLP/GDP80VX, GLP/GDP80VX9, GLP/
models below. Disconnect the battery. GDP90VX (GDP170VX, GDP175VX36,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP190VX) (A909, B909).
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ Connect the battery and lower the hood, on lift
GDP080, 090, 100, 110, 120VX) (F813, G813) truck models
(C879, D879, E879, F879)
GDP080, 090, 100, 110, 120VX) (F813, G813)
•
2. Disconnect the electrical connector from the oil (C879, D879, E879, F879)
pressure sensor.
•
3. Unscrew and remove the oil pressure sensor from
adapter. Adapter does not need to be removed Engine Speed Sensor
from engine. Discard O-ring. Remove
Cummins 4.5L diesel engine.
See Figure 60 for lift trucks equipped with the battery.
Cummins QSB 3.3L diesel engine. GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
•
Install D878)
1. Apply 50 ml (1.7 oz) of Loctite 592™ thread • GLP/GDP80VX, GLP/GDP80VX9, GLP/
sealant on O-ring. Install new oil pressure sensor GDP90VX (GDP170VX, GDP175VX36,
into adapter. Tighten sensor two to three turns GDP190VX) (A909, B909).
past finger tight.
95
To access the battery, raise the hood, on lift truck Engine Coolant Temperature (ECT) Sensor
Remove
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 1. To access the battery, remove the floor mat and
GDP080, 090, 100, 110, 120VX) (F813, G813) floor plate, on lift truck models below. Disconnect
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ the battery.
GDC135VX, GC/GLC/GDC155VX) (C879, • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
D879) GDC135VX, GC/GLC/GDC155VX) (C878,
D878)
2. Disconnect the electrical connection from engine
speed sensor.
See Figure 59 for lift trucks equipped with GDP190VX) (A909, B909).
Cummins 4.5L diesel engine. To access the battery, raise the hood, on lift truck
See Figure 60 for lift trucks equipped with models below. Disconnect the battery.
Cummins QSB 3.3L diesel engine. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
3. Remove capscrew from engine speed sensor GDP080, 090, 100, 110, 120VX) (F813, G813)
bracket and remove bracket and engine speed
sensor. GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
Install
1. Install engine speed sensor bracket to engine. 2. Drain the engine coolant from radiator before
Tighten capscrew to 7 N•m (62 lbf in). Install new removing the ECT sensor. Refer to the section
engine speed sensor onto bracket. Cooling System 0700YRM1123.
2. Connect electrical connector to engine speed 3. Disconnect the ECT sensor connector.
sensor. See Figure 60 for lift trucks equipped with
See Figure 59 for lift trucks equipped with Cummins QSB 3.3L diesel engine.
Cummins 4.5L diesel engine. See Figure 61 for lift trucks equipped with
See Figure 60 for lift trucks equipped with Cummins 4.5L diesel engine.
Cummins QSB 3.3L diesel engine.
4. Remove the ECT sensor and packing from the
3. Connect the battery, install the floor plate and intake manifold. Discard the O-ring.
D878)
GDP190VX) (A909, B909).
truck models
GDP080, 090, 100, 110, 120VX) (F813, G813)
D879)
96
3. Refill the radiator with engine coolant after

replacing the ECT sensor. See one of the
following sections for coolant specification and
procedures:
truck models
100, 120VX; GC/GLC080, 100VXBCS; GC/
GDP080, 090, 100, 110, 120VX) (F813, G813)
truck models
D879)
truck models
D878)
NOTE: TOP VIEW SHOWN. Periodic Maintenance 8000YRM1407 for lift
truck models
1. ENGINE COOLANT TEMPERATURE SENSOR • GLP/GDP80VX, GLP/GDP80VX9, GLP/
(ECT)
2. ECT ELECTRICAL CONNECTOR GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909)
Figure 61. Engine Coolant Temperature Sensor, Periodic Maintenance 8000YRM1586 for lift
Cummins 4.5L Diesel Engine truck models
Install GDP90VX (GLP/GDP170VX, GLP/
1. Install new O-ring onto ECT sensor. Install new GDP175VX36, GLP/GDP190VX) (B909)
ECT sensor and new packing and tighten the
ECT sensor to 20 N•m (177 lbf in). 4. Connect the battery, install the floor plate and
2. Connect the ECT sensor connector. • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
See Figure 60, Cummins QSB 3.3L Diesel Engine GDC135VX, GC/GLC/GDC155VX) (C878,
D878)
Sensors and Switches for Cummins QSB 3.3L
diesel engine. • GLP/GDP80VX, GLP/GDP80VX9, GLP/
See Figure 61, Engine Coolant Temperature GDP190VX) (A909, B909).
Sensor, Cummins 4.5L Diesel Engine for
Cummins 4.5L diesel engine.
truck models
GDP080, 090, 100, 110, 120VX) (F813, G813)
D879)
97
Throttle Position Sensor (TPS) (Cummins

4.5L Only)
Remove
the battery.
• GDP60VX, GDP70VX (GDC135VX,
GDC155VX) (C878, D878)
• GDP80VX, GDP80VX9, GDP90VX
(GDP170VX, GDP175VX36, GDP190VX)
(A909)
GDP080, 090, 100, 110, 120VX) (F813, G813)
D879)

throttle position sensor (TPS).
3. Remove Torx-head screws and washers securing

the TPS to TPS bracket. See Figure 62. Remove
TPS sensor from TPS bracket.
1. TORX-HEAD SCREW
2. WASHER
3. TPS ELECTRICAL CONNECTOR
4. TPS COVER
5. THROTTLE POSITION SENSOR (TPS)
6. TPS BRACKET
7. FUEL PUMP
Figure 62. Throttle Position Sensor (TPS)

Assembly, Cummins 4.5L Diesel Engine
Install
NOTE: The TPS mounting screws are non-magnetic
stainless steel to avoid interference with the sensor
magnet and must be reused if the TPS is replaced.
1. Install new TPS sensor on TPS bracket and
secure with Torx-head screws and washers.
Tighten Torx-head screws to 2.25 N•m (20 lbf in).
2. Connect the throttle position sensor (TPS)

electrical connector. See Figure 62.
98

GDC155VX) (C878, D878)
• GDP80VX, GDP80VX9, GDP90VX
(GDP170VX, GDP175VX36, GDP190VX)
(A909)
truck models
GDP080, 090, 100, 110, 120VX) (F813, G813)
D879)
Fuel/Water Separator Sensor

Remove
the battery.
GDC155VX) (C878, D878)
1. FUEL FILTER ELEMENT BODY
To access the battery, raise the hood, on lift truck 2. DRAIN PLUG
models below. Disconnect the battery. 3. ELECTRICAL CONNECTOR
4. FUEL/WATER SEPARATOR SENSOR
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6, 5. FUEL FILTER
GDP50-55VX (GDP080, 090, 100, 110, 120VX)
(F813, G813) Figure 63. Fuel/Water Separator Sensor
• GDC60VX, GDC70VX (GDC135VX,
GDC155VX) (C879, D879) Install
2. Remove drain plug from bottom of fuel filter 1. Install new sensor into bottom of fuel filter
element body and drain water from fuel filter. See element body. See Figure 63.
Figure 63.
2. Connect sensor to harness.
3. Disconnect sensor from harness.
3. Install drain plug and new O-ring into bottom of
4. Remove sensor from bottom of fuel filter element fuel filter element body.
body.
GDC155VX) (C878, D878)
99
Connect the battery and lower the hood, on lift ENGINE AND FUEL SENSORS AND
truck models SWITCHES, KUBOTA 3.8L DIESEL
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6, ENGINE WITHOUT DPF
GDP50-55VX (GDP080, 090, 100, 110, 120VX)
(F813, G813) Refer to Figure 64 for location of engine sensors and
GDC60VX, GDC70VX (GDC135VX, switches.
•
GDC155VX) (C879, D879)
1. INTAKE AIR TEMPERATURE SENSOR 5. EGR VALVE LIFT SENSOR

2. INTAKE AIR PRESSURE SENSOR 6. CRANKSHAFT POSITION SENSOR
3. RAIL PRESSURE SENSOR 7. CAMSHAFT POSITION SENSOR
4. COOLANT TEMPERATURE SENSOR 8. OIL PRESSURE SENSOR
Figure 64. Kubota 3.8L Diesel Engine without DPF Sensors and Switches
Intake Air Temperature Sensor • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

Remove GDP080, 090, 100, 110, 120VX) (H813)
1. To access battery, raise hood, on lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
below. Disconnect the battery. GDC135VX, GC/GLC/GDC155VX) (E879)
100
2. Disconnect electrical connector from intake air • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

temperature sensor. GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813)
3. Remove intake air temperature sensor from • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
intake air inlet elbow. See Figure 65. GDC135VX, GC/GLC/GDC155VX) (E879)
2. Disconnect electrical connector from intake

pressure sensor.
3. Remove two capscrews and intake air pressure

Install
NOTE: If intake air pressure sensor has been
identified as faulty, replace sensor with new one.
1. Install two capscrews and intake air pressure
sensor. Tighten capscrews to
30 to 39 N•m (22 to 29 lbf ft).
2. Connect intake air pressure sensor electrical

connector.
3. Connect battery and lower the hood on lift truck

1. AIR INLET ELBOW models
2. INTAKE AIR TEMPERATURE SENSOR
3. AIR HEATER TERMINAL NUTS • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
4. AIR INLET HEATER GDP45VX6; GLP/GDP50-55VX (GP/GLP/
5. INTAKE AIR PRESSURE SENSOR GDP080, 090, 100, 110, 120VX) (H813)
Figure 65. Intake Air Inlet Elbow GDC135VX, GC/GLC/GDC155VX) (E879)
Install Air Inlet Heater

NOTE: If intake air temperature sensor has been
Remove
identified as faulty, replace sensor with new one.
1. To access battery, raise hood, on lift truck models
1. Install intake air temperature sensor. Tighten to
below. Disconnect the battery.
16 to 23 N•m (12 to 17 lbf ft).
2. Connect intake air temperature sensor electrical GDP45VX6; GLP/GDP50-55VX (GP/GLP/
sensor. GDP080, 090, 100, 110, 120VX) (H813)
3. Connect battery and lower the hood on lift truck GDC135VX, GC/GLC/GDC155VX) (E879)
models
2. Disconnect electrical connections from air inlet
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ heater terminal nuts. See Figure 65.
GDP080, 090, 100, 110, 120VX) (H813)
3. Remove four capscrews from intake air inlet
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ elbow.
4. Remove intake air inlet elbow and set aside for
Intake Air Pressure Sensor later installation.
Remove
5. Remove air intake heater from air intake manifold.
101
Install 3. Connect electrical connector for oil pressure

NOTE: If intake air heater has been identified as
faulty, replace air intake heater with new one. 4. Connect battery and lower the hood on lift truck
1. Install air inlet heater into air intake manifold. models
2. Using four capscrews, install intake air inlet elbow GDP45VX6; GLP/GDP50-55VX (GP/GLP/
to air intake manifold, cover the air intake heater. GDP080, 090, 100, 110, 120VX) (H813)
See Figure 65. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
•
3. Connect electrical connections for air intake
heater to terminal nuts. Engine Coolant Temperature (ECT) Sensor
4. Tighten terminal nuts to Remove
3.5 to 5.3 N•m (31 to 44 lbf in). See Figure 65.
5. Connect battery and lower the hood on lift truck below. Disconnect the battery.
models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/
•
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813)
GDP080, 090, 100, 110, 120VX) (H813) • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879)
•
2. Drain engine coolant from radiator before
removing ECT sensor. Refer to the section
Engine Oil Pressure Sensor
Cooling System 0700YRM1123.
Remove
3. Disconnect the ECT sensor electrical connector
1. To access battery, raise hood, on lift truck models from the ECT sensor. See Figure 64.
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 4. Remove the ECT sensor and O-ring. Discard O-
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ ring.
GDP080, 090, 100, 110, 120VX) (H813)
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ Install
NOTE: If ECT sensor has been identified as faulty,
replace ECT sensor with new one.
2. Disconnect electrical connector from oil pressure
sensor. 1. Install new O-ring onto ECT sensor.
3. Unscrew and remove oil pressure sensor and O- 2. Install ECT sensor. Tighten sensor to
ring from adapter. See Figure 64. 16 to 23 N•m (12 to 17 lbf ft).
4. Discard O-ring. 3. Connect ECT sensor connector. See Figure 64.
Install 4. Refill the radiator with engine coolant. See one of

the following sections for coolant specification
NOTE: If oil pressure sensor has been identified as and procedures
faulty, replace oil pressure sensor with new one.
1. Lubricate new O-ring with multipurpose grease, truck models
and install on oil pressure sensor.
2. Apply thread locker to threads of oil pressure GDP45VX6; GLP/GDP50-55VX (GP/GLP/
sensor. Install oil pressure sensor into adapter. GDP080, 090, 100, 110, 120VX) (H813)
Tighten to 15 to 19 N•m (11 to 14 lbf ft). Periodic Maintenance 8000YRM1571 for lift
truck models
102


models
GDP080, 090, 100, 110, 120VX) (H813)
Crankshaft Position Sensor

Remove
1. To access battery, raise hood, on lift truck models 1. PULSAR GEAR
below. Disconnect the battery. 2. AIR GAP
3. SHIM
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 4. CRANKSHAFT POSITION SENSOR
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ 5. GEAR CASE
GDP080, 090, 100, 110, 120VX) (H813) 6. SHIM 0.25 mm (0.0098 in.)
7. SHIM 0.50 mm (0.020 in.)
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ 8. SHIM 1.00 mm (0.0394 in.)
Figure 66. Crankshaft Position Sensor Air Gap
2. Disconnect crankshaft position sensor electrical
connector from the crankshaft position sensor. NOTE: An air gap of
See Figure 64. 0.25 to 1.4 mm (0.0098 to 0.055 in.) is needed
between the crankshaft position sensor and the pulsar
3. Remove crankshaft position sensor mounting
gear. The air gap is achieved by using shims shown in
capscrew.
Figure 66 and procedure outlined in Adjust Shim
Procedure.
4. Remove crankshaft position sensor and O-ring.
Discard O-ring. 2. Add the appropriate amount of air gap by adding
shims to the crankshaft position sensor. See
Install Figure 66.
NOTE: If crankshaft position sensor has been 3. Install crankshaft position sensor.
identified as faulty, replace crankshaft position sensor
with new one. 4. Install crankshaft position sensor mounting
1. Lubricate new O-ring with multipurpose grease. capscrew. Tighten to 4 to 5 N•m (35 to 45 lbf in).
Install O-ring on crankshaft position sensor. See
Figure 66. 5. Connect crankshaft position sensor electrical
connector to crankshaft position sensor.

models
GDP080, 090, 100, 110, 120VX) (H813)
103
Adjust Shim Procedure

NOTE: This procedure uses special tools JIG 1 and
JIG 2 or a combination tool Yale P/N 582020863 .
Where JIG 1 or JIG 2 is specified the combination tool
may be used instead. See section Special Tools in this
manual for additional tool information.
1. Align TC mark of flywheel with flywheel housing
timing window. See procedure in Fuel System
Repair section of Kubota Diesel 3.8L Engines
with Diesel Particulate Filter (DPF)
0600YRM1590.
2. Install measurement JIG 1 into sensor mounting

position. See Figure 67. 1. MEASUREMENT JIG 2
2. DIAL GAUGE
Figure 68. Measurement JIG 2
1. MEASUREMENT JIG 1

1. JIG 1
3. Set dial gauge at measurement JIG 2, then 2. PROTRUSION
measure protrusion of JIG 1. See Figure 68 and 3. GEAR CASE
Figure 69. 4. PULSE GEAR
Figure 69. Protrusion Measurement
4. Using the protrusion measurement, see Table 1

for the proper shim combination required to set
the air gap.
104
Table 1. Adjustment Shim Combinations

Thickness and Number of Shims
Protrusion
0.25 mm (0.0098 in.) 0.50 mm (0.020 in.) 1.00 mm (0.0394 in.)
2.25 to 2.50 mm
1 2
(0.0886 to 0.0984 in.)
2.00 to 2.25 mm
2
(0.0788 to 0.0885 in.)
1.75 to 2.00 mm
1 1 1
(0.0689 to 0.0787 in.)
1.50 to 1.75 mm
1 1
(0.0591 to 0.0688 in.)
1.25 to 1.50 mm
1 1
(0.0493 to 0.0590 in.)
1.00 to 1.25 mm
1
(0.0394 to 0.0492 in.)
0.750 to 1.00 mm
1 1
(0.0296 to 0.0393 in.)
0.500 to 0.750 mm
1
(0.0197 to 0.0295 in.)
0.250 to 0.500 mm
1
(0.00985 to 0.0196 in.)
Camshaft Position Sensor 1. Lubricate new O-ring with multipurpose grease.

Install O-ring on camshaft position sensor. See
Remove Figure 64.
below. Disconnect the battery. 2. Install camshaft position sensor.
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 3. Install camshaft position sensor mounting

GDP45VX6; GLP/GDP50-55VX (GP/GLP/ capscrew. Tighten to 4 to 5 N•m (35 to 45 lbf in).
GDP080, 090, 100, 110, 120VX) (H813)
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ 4. Connect camshaft position sensor electrical
GDC135VX, GC/GLC/GDC155VX) (E879) connector to camshaft position sensor.
2. Disconnect camshaft position sensor electrical 5. Connect battery and lower the hood on lift truck
connector from camshaft position sensor. See models
Figure 64.
3. Remove camshaft position sensor mounting
GDP080, 090, 100, 110, 120VX) (H813)
capscrew.
4. Remove camshaft position sensor and O-ring. GDC135VX, GC/GLC/GDC155VX) (E879)
Discard O-ring.
Air Flow Restriction Sensor
Install Remove
NOTE: If camshaft position sensor has been identified 1. To access battery, raise hood, on lift truck models
as faulty, replace camshaft position sensor with new below. Disconnect the battery.
one.
105
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ Fuel/Water Separator

GDP080, 090, 100, 110, 120VX) (H813) Remove
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ 1. To access battery, raise hood, on lift truck models
GDC135VX, GC/GLC/GDC155VX) (E879) below. Disconnect the battery.
2. Disconnect air flow restriction sensor electrical • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
connector. See Figure 70. GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813)
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
2. Attach a small hose to hose barb on drain valve

at bottom of fuel filter element and route hose into
a suitable container to collect fuel and
contaminants. See Figure 71.
1. AIR FLOW RESTRICTION SENSOR

Figure 70. Air Flow Restriction Sensor
3. Remove the air flow restriction sensor. See

Figure 70.
Install
NOTE: If air flow restriction sensor has been identified
as faulty, replace air flow restriction sensor with new
one.
1. Install air flow restriction sensor. Tighten sensor
two to three turns past finger tight. 1. FUEL FILTER ELEMENT HOUSING
2. FUEL/WATER SENSOR ASSEMBLY
2. Connect electrical connector for air flow restriction 3. DRAIN
Figure 71. Fuel/Water Separator
models 3. Open drain valve. See Figure 71.
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ 4. Disconnect electrical connector.
GDP080, 090, 100, 110, 120VX) (H813)
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ 5. Once all fuel and contaminants have been
GDC135VX, GC/GLC/GDC155VX) (E879) drained from fuel filter element housing, remove
drain hose.
106
6. Remove fuel filter element housing. See 5. Tighten housing one quarter turn past hand tight.
Figure 71.
6. Connect electrical connector. See Figure 71.
CAUTION 7. Connect battery and lower the hood on lift truck

DO NOT over tighten the vice. If over tightening of models
the vice occurs, the fuel filter element housing will • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
become misshapen and not seal correctly. GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813)
7. Place fuel filter element housing in soft jawed • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
vice. GDC135VX, GC/GLC/GDC155VX) (E879)
NOTE: The fuel/water sensor, drain, and electrical ENGINE AND FUEL SENSORS AND
connection are one piece and will be removed as an
SWITCHES, KUBOTA 3.8L DIESEL
assembly.
ENGINE WITH DPF
8. Remove fuel/water sensor, drain, and electrical
connection from fuel filter housing. See Figure 72 for location of engine sensors and
switches on lift truck models.
Install • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
NOTE: If fuel/water sensor has been identified as
faulty, replace fuel/water sensor with new one. • GLP/GDP80VX, GLP/GDP80VX9, GLP/
1. Apply Loctite 567 or equivalent to threads on fuel/ GDP175VX36,GLP/GDP190VX) (B909)
water sensor assembly.
See Figure 73 for location of engine sensors and
switches on lift truck models
2. Install fuel/water sensor assembly into fuel filter
element housing and tighten one half turn past • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
hand tight. GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (J813)
3. Apply Loctite 567 or equivalent to threads on fuel • GC/GLC/GDC60VX, GC/GLC/GDC70VX
filter element housing. (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879)
4. Install fuel filter element housing to casting
mounted on engine. See Figure 71.
107
Figure 72. Kubota 3.8L Diesel Engine with DPF Sensors and Switches for Lift Truck Models And GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (B909)
108
1. INTAKE AIR TEMPERATURE SENSOR 7. CRANKSHAFT POSITION SENSOR

2. THROTTLE VALVE ASSEMBLY 8. CAMSHAFT POSITION SENSOR
3. FUEL RAIL PRESSURE SENSOR 9. OIL PRESSURE SENSOR
4. COOLANT TEMPERATURE SENSOR 10. DIFFERENTIAL PRESSURE SENSOR
5. EGR VALVE LIFT SENSOR 11. DIESEL PARTICULATE FILTER
6. BOOST SENSOR
109
Figure 73. Kubota 3.8L Diesel Engine with DPF Sensors and Switches for Lift Truck Models And GLP/
GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (J813) GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879,
G879)
110
1. INTAKE AIR TEMPERATURE SENSOR 7. DIESEL PARTICULATE FILTER (DPF)

2. BOOST SENSOR 8. CAMSHAFT POSITION SENSOR
3. THROTTLE VALVE ASSEMBLY 9. OIL PRESSURE SENSOR
4. EGR VALVE LIFT SENSOR 10. CRANKSHAFT POSITION SENSOR
5. FUEL RAIL PRESSURE SENSOR 11. COOLANT TEMPERATURE SENSOR
6. DIFFERENTIAL PRESSURE SENSOR
Intake Air Temperature Sensor • GC/GLC/GDC60VX, GC/GLC/GDC70VX

Remove (F879, G879)
1. To access battery, raise hood, on lift truck models 2. Disconnect electrical connector from intake air
below. Disconnect the battery. temperature sensor.
GDC135VX, GC/GLC/GDC155VX) (E878) 3. Remove intake air temperature sensor and
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ gasket from intake air intake housing. See
GDP90VX (GLP/GDP170VX, GLP/ Figure 74. Discard gasket.
GDP080, 090, 100, 110, 120VX) (J813)
111
1. BOOST SENSOR 8. FLANGE NUTS

2. CAPSCREW 9. FLANGE BOLTS
3. CLAMP 10. THROTTLE VALVE ASSEMBLY
4. HOSE 11. STUD
5. INTAKE AIR TEMPERATURE SENSOR 12. AIR INTAKE HEATER
6. GASKET 13. INTAKE MANIFOLD
7. AIR INTAKE HOUSING 14. AIR HEATER TERMINAL NUTS
Figure 74. Air Intake Housing and Throttle Valve
Install • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

NOTE: If intake air temperature sensor has been GDP080, 090, 100, 110, 120VX) (J813)
identified as faulty, replace sensor with new one. GC/GLC/GDC60VX, GC/GLC/GDC70VX
•
1. Install new gasket and intake air temperature (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
sensor. Tighten to 16 to 23 N•m (12 to 17 lbf ft). (C879, D879, E879, F879, G879)
2. Connect intake air temperature sensor electrical Boost Sensor

sensor.
Remove
3. Connect battery and lower the hood on lift truck 1. To access battery, raise hood, on lift truck models
GDC135VX, GC/GLC/GDC155VX) (E878) GDC135VX, GC/GLC/GDC155VX) (E878)
GDP175VX36, GLP/GDP190VX) (B909) GDP175VX36, GLP/GDP190VX) (B909)
112
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/

GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDC135VX, GC/GLC/GDC155VX) (E878)
GDP080, 090, 100, 110, 120VX) (J813) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDP90VX (GLP/GDP170VX, GLP/
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) GDP175VX36, GLP/GDP190VX) (B909)
(C879, D879, E879, F879, G879) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
2. Disconnect electrical connector from boost GDP080, 090, 100, 110, 120VX) (J813)
sensor.
3. Remove two hose clamps and hose from boost
(C879, D879, E879, F879, G879)
sensor and air intake housing. See Figure 74.
2. Disconnect electrical connector from air intake
4. Remove two capscrews from boost sensor. See sensor and boost sensor.
Figure 74.
3. Disconnect electrical connections from air intake
5. Remove boost sensor from air intake housing. heater terminal nuts.
See Figure 74.
4. Remove two flange nuts and two flange bolts
Install from air intake housing. See Figure 74.
NOTE: If boost sensor has been identified as faulty,
replace boost sensor with new one. 5. Remove air intake housing and gasket from
throttle valve assembly. Discard gasket. See
1. Install boost sensor onto air intake housing. See Figure 74.
Figure 74.
6. Remove throttle valve assembly and gasket from
2. Install two capscrews to boost sensor. Torque to air intake heater. Discard gasket. See Figure 74.
30 to 39 N•m (22 to 28 lbf ft). See Figure 74.
7. Remove air intake heater and gasket from intake
3. Install hose and two hose clamps to boost sensor manifold. Discard gasket. See Figure 74.
and air intake housing. See Figure 74.
8. Remove two studs from intake manifold. See
4. Connect electrical connector to boost sensor. Figure 74.
5. Connect battery and lower the hood on lift truck Install
models
NOTE: If throttle valve assembly or air intake heater
have been identified as faulty, replace with new one.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ 1. Install two studs into intake manifold. See
GDP90VX (GLP/GDP170VX, GLP/ Figure 74.
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 2. Install new gasket and air intake heater onto
•
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ studs and intake manifold. See Figure 74.
GDP080, 090, 100, 110, 120VX) (J813)
3. Install new gasket and throttle valve assembly
onto two studs and air intake heater. See
(C879, D879, E879, F879, G879) Figure 74.
4. Install new gasket and air intake housing onto two

Throttle Valve Assembly and Air Intake
studs and throttle valve assembly. See Figure 74.
Heater
Remove 5. Install two flange bolts through air intake housing,
throttle valve assembly and air intake heater into
1. To access battery, raise hood, on lift truck models intake manifold. See Figure 74.
113
6. Install two flange nuts onto two studs at air intake Install
housing. See Figure 74.
7. Connect electrical connectors to air intake heater replace ECT sensor with new one.
terminal nuts. Torque nuts to 1. Install new O-ring onto ECT sensor.
3.5 to 5.3 N•m (30.9 to 46.9 lbf in).
2. Install ECT sensor. Tighten sensor to
8. Connect electrical connectors to boost sensor 16 to 23 N•m (12 to 17 lbf ft).
and air temperature sensor.
3. Connect ECT sensor connector. See Figure 72.
models 4. Refill the radiator with engine coolant. See one of
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ the following sections for coolant specification
GDC135VX, GC/GLC/GDC155VX) (E878) and procedures
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ Periodic Maintenance 8000YRM1583 for lift
GDP90VX (GLP/GDP170VX, GLP/ truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)
GDP080, 090, 100, 110, 120VX) (J813) Periodic Maintenance 8000YRM1586 for lift
truck model
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) • GLP/GDP80VX, GLP/GDP80VX9, GLP/
(C879, D879, E879, F879, G879) GDP90VX (GLP/GDP170VX, GLP/
Engine Coolant Temperature (ECT) Sensor Periodic Maintenance 8000YRM1604 for lift
Remove truck models
below. Disconnect the battery. GDP080, 090, 100, 110, 120VX) (J813)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ Periodic Maintenance 8000YRM1606
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ •
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 5. Connect battery and lower the hood on lift truck
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ models
GDP080, 090, 100, 110, 120VX) (J813) • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GDC135VX, GC/GLC/GDC155VX) (E878)
2. Drain engine coolant from radiator before
removing ECT sensor. Refer to the section • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP080, 090, 100, 110, 120VX) (J813)
3. Disconnect the ECT sensor electrical connector • GC/GLC/GDC60VX, GC/GLC/GDC70VX
from the ECT sensor. See Figure 72. (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879)
4. Remove the ECT sensor and O-ring. Discard O-
ring.
114
Engine Oil Pressure Sensor Crankshaft Position Sensor

Remove Remove
1. To access battery, raise hood, on lift truck models 1. To access battery, raise hood, on lift truck models
below. Disconnect the battery. below. Disconnect the battery.
GDC135VX, GC/GLC/GDC155VX) (E878) GDC135VX, GC/GLC/GDC155VX) (E878)
GDP175VX36, GLP/GDP190VX) (B909) GDP175VX36, GLP/GDP190VX) (B909)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (J813) GDP080, 090, 100, 110, 120VX) (J813)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GC/GLC/GDC60VX, GC/GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879) (C879, D879, E879, F879, G879)
2. Disconnect electrical connector from oil pressure 2. Disconnect crankshaft position sensor electrical
sensor. connector from the crankshaft position sensor.
See Figure 72.
3. Unscrew and remove oil pressure sensor and O-
ring from adapter. See Figure 72. 3. Remove crankshaft position sensor mounting
capscrew.
4. Discard O-ring.
4. Remove crankshaft position sensor and O-ring.
Install Discard O-ring.
NOTE: If oil pressure sensor has been identified as
faulty, replace oil pressure sensor with new one.
Install
NOTE: If crankshaft position sensor has been
1. Lubricate new O-ring with multipurpose grease,
identified as faulty, replace crankshaft position sensor
with new one.
2. Apply thread locker to threads of oil pressure 1. Lubricate new O-ring with multipurpose grease.
sensor. Install oil pressure sensor into adapter. Install O-ring on crankshaft position sensor. See
Tighten to 15 to 19 N•m (11 to 14 lbf ft). Figure 75.
3. Connect electrical connector for oil pressure


models
GDP080, 090, 100, 110, 120VX) (J813)
(C879, D879, E879, F879, G879)
115
(C879, D879, E879, F879, G879)
Adjust Shim Procedure

NOTE: This procedure uses spcial tools JIG 1 and
JIG 2 or a combination tool Yale P/N 582020863 .
Where JIG 1 or JIG 2 is specified the combination tool
may be used instead. See section Special Tools in this
manual for additional tool information.
1. Align TC mark of flywheel with flywheel housing
timing window. See procedure in Fuel System
Repair section of Kubota Diesel 3.8L Engines
with Diesel Particulate Filter (DPF)
1. PULSAR GEAR
2. AIR GAP 0600YRM1590.
3. SHIM
4. CRANKSHAFT POSITION SENSOR 2. Install measurement JIG 1 into sensor mounting
5. GEAR CASE position. See Figure 76.
6. SHIM 0.25 mm (0.0098 in.)
7. SHIM 0.50 mm (0.020 in.)
8. SHIM 1.00 mm (0.0394 in.)
Figure 75. Crankshaft Position Sensor Air Gap
NOTE: An air gap of

0.25 to 1.4 mm (0.0098 to 0.055 in.) is needed
between the crankshaft position sensor and the pulsar
gear. The air gap is achieved by using shims shown in
Figure 75 and procedure outlined in Adjust Shim
Procedure.
2. Add the appropriate amount of air gap by adding
shims to the crankshaft position sensor. See
Figure 75.
1. MEASUREMENT JIG 1
3. Install crankshaft position sensor.
4. Install crankshaft position sensor mounting
capscrew. Tighten to 4 to 5 N•m (35 to 45 lbf in). 3. Set dial gauge at measurement JIG 2, then
measure protrusion of JIG 1. See Figure 77 and
5. Connect crankshaft position sensor electrical Figure 78.
connector to crankshaft position sensor.

models
GDP080, 090, 100, 110, 120VX) (J813)
116
1. MEASUREMENT JIG 2 1. JIG 1

2. DIAL GAUGE 2. PROTRUSION
3. GEAR CASE
4. PULSE GEAR
Figure 78. Protrusion Measurement
4. Using the protrusion measurement, see Table 2

for the proper shim combination required to set
the air gap.
Table 2. Adjustment Shim Combinations

Thickness and Number of Shims
Protrusion
0.25 mm (0.0098 in.) 0.50 mm (0.020 in.) 1.00 mm (0.0394 in.)
2.25 to 2.50 mm (0.0886
1 2
to 0.0984 in.)
2.00 to 2.25 mm (0.0788
2
to 0.0885 in.)
1.75 to 2.00 mm (0.0689
1 1 1
to 0.0787 in.)
1.50 to 1.75 mm (0.0591
1 1
to 0.0688 in.)
1.25 to 1.50 mm (0.0493
1 1
to 0.0590 in.)
1.00 to 1.25 mm (0.0394
1
to 0.0492 in.)
0.750 to 1.00 mm (0.0296
1 1
to 0.0393 in.)
0.500 to 0.750 mm
1
(0.0197 to 0.0295 in.)
0.250 to 0.500 mm
1
(0.00985 to 0.0196 in.)
117
Camshaft Position Sensor • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

Remove GDP080, 090, 100, 110, 120VX) (J813)
1. To access battery, raise hood, on lift truck models • GC/GLC/GDC60VX, GC/GLC/GDC70VX
below. Disconnect the battery. (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879)
GDC135VX, GC/GLC/GDC155VX) (E878) Differential Pressure Sensor
GDP90VX (GLP/GDP170VX, GLP/ Remove
GDP175VX36, GLP/GDP190VX) (B909) 1. To access battery, raise hood, on lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ below. Disconnect the battery.
GDP080, 090, 100, 110, 120VX) (J813) • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
2. Disconnect camshaft position sensor electrical • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
connector from camshaft position sensor. See GDP45VX6; GLP/GDP50-55VX (GP/GLP/
Figure 72. GDP080, 090, 100, 110, 120VX) (J813)
3. Remove camshaft position sensor mounting (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
capscrew. (C879, D879, E879, F879, G879)
4. Remove camshaft position sensor and O-ring. 2. Disconnect electrical connector from differential
Discard O-ring. pressure sensor.
Install 3. Remove two clamps and two hoses from bottom

of differential pressure sensor. See Figure 79.
NOTE: If camshaft position sensor has been identified
as faulty, replace camshaft position sensor with new 4. Remove two capscrews and differential pressure
one. sensor from bracket. See Figure 79.
1. Lubricate new O-ring with multipurpose grease.
Install O-ring on camshaft position sensor. See
Figure 72.
2. Install camshaft position sensor.
3. Install camshaft position sensor mounting

capscrew. Tighten to 4 to 5 N•m (35 to 45 lbf in).
4. Connect camshaft position sensor electrical

connector to camshaft position sensor.

models
118
Mass Air Flow Sensor

Remove
GDP080, 090, 100, 110, 120VX) (J813)
(C879, D879, E879, F879, G879)
1. DIFFERENTIAL PRESSURE SENSOR
2. BRACKET 2. Disconnect mass air flow sensor electrical
3. CAPSCREW
4. CLAMP connector.
5. HOSE See Figure 80 for lift truck models
Figure 79. Differential Pressure Sensor • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
Install • GLP/GDP80VX, GLP/GDP80VX9, GLP/
NOTE: If differential pressure sensor has been GDP175VX36,GLP/GDP190VX) (B909)
identified as faulty, replace differential pressure sensor
with new one. See Figure 81 for lift truck models
1. Using two capscrews, install differential pressure • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

sensor onto bracket. See Figure 79.
GDP080, 090, 100, 110, 120VX) (J813)
2. Connect electrical connector to differential • GC/GLC/GDC60VX, GC/GLC/GDC70VX
pressure sensor. (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879)
3. Install two hoses and two clamps onto bottom of

models
GDP080, 090, 100, 110, 120VX) (J813)
(C879, D879, E879, F879, G879)
119
1. MASS AIR FLOW SENSOR

1. MASS AIR FLOW SENSOR 2. CAPSCREW
2. CAPSCREW
Figure 81. Mass Air Flow Sensor for Lift Truck
Figure 80. Mass Air Flow Sensor for Lift Truck
Models And GLP/GDP40VX5/VX6; GLP/
Models And GLP/GDP60VX, GLP/GDP70VX
GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(E878) GLP/GDP80VX, GLP/GDP80VX9, GLP/
(J813) GC/GLC/GDC60VX, GC/GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879,
GDP175VX36,GLP/GDP190VX) (B909)
G879)
3. Remove two capscrews and mass air flow sensor.

GDP080, 090, 100, 110, 120VX) (J813)
(C879, D879, E879, F879, G879)
Install
NOTE: If mass air flow sensor has been identified as
faulty, replace mass air flow sensor with new one.
1. Install mass air flow restriction sensor and two
capscrews.
120
2. Connect electrical connector for mass air flow 2. Attach a small hose to hose barb on drain valve
sensor. at bottom of fuel filter element and route hose into
a suitable container to collect fuel and
contaminants. See Figure 82.
GDP080, 090, 100, 110, 120VX) (J813)
(C879, D879, E879, F879, G879)

models
GDP90VX (GLP/GDP170VX, GLP/ 1. FUEL FILTER ELEMENT HOUSING
GDP175VX36, GLP/GDP190VX) (B909) 2. FUEL/WATER SENSOR ASSEMBLY
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 3. DRAIN
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ 4. ELECTRICAL CONNECTOR
GDP080, 090, 100, 110, 120VX) (J813)
Figure 82. Fuel/Water Separator
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) 3. Open drain valve. See Figure 82.
(C879, D879, E879, F879, G879)
4. Disconnect electrical connector.
Fuel/Water Separator
Remove 5. Once all fuel and contaminants have been
drained from fuel filter element housing, remove
1. To access battery, raise hood, on lift truck models drain hose.
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ 6. Remove fuel filter element housing. See
GDC135VX, GC/GLC/GDC155VX) (E878) Figure 82.
GDP175VX36, GLP/GDP190VX) (B909) CAUTION
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ DO NOT over tighten the vice. If over tightening of
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ the vice occurs, the fuel filter element housing will
GDP080, 090, 100, 110, 120VX) (J813) become misshapen and not seal correctly.
7. Place fuel filter element housing in soft jawed
(F879, G879) vice.
NOTE: The fuel/water sensor, drain, and electrical

connection are one piece and will be removed as an
CAUTION
assembly.
Disposal of lubricants and fluids must meet local
environmental regulations.
121
8. Remove fuel/water sensor, drain, and electrical 4. Connect electrical connector. See Figure 82.
connection from fuel filter housing.
Install models
NOTE: If fuel/water sensor has been identified as • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
faulty, replace fuel/water sensor with new one. GDC135VX, GC/GLC/GDC155VX) (E878)
1. Install fuel/water sensor assembly into fuel filter GDP90VX (GLP/GDP170VX, GLP/
element housing and tighten one half turn past GDP175VX36, GLP/GDP190VX) (B909)
hand tight.
2. Install fuel filter element housing to casting
GDP080, 090, 100, 110, 120VX) (J813)
mounted on engine. See Figure 82.
3. Tighten housing one quarter turn past hand tight. (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(F879, G879)
122

SWITCHES, KUBOTA 3.6L DIESEL
ENGINE
Refer to Figure 83 for location of engine sensors and
switches.
NOTE: GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090,

100, 110, 120VX) (H813) ENGINE SHOWN, GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E878) AND GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) SIMILAR.
A. RIGHT SIDE OF ENGINE B. LEFT SIDE OF ENGINE
1. COOLANT TEMPERATURE SENSOR 3. ENGINE SPEED SENSOR (GLP/GDP40VX5/VX6;

2. OIL PRESSURE SENSOR GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (H813, J813) ONLY
4. FUEL SHUT OFF SOLENOID
Figure 83. Kubota 3.6L Diesel Engine Sensors and Switches
123
Engine Coolant Temperature (ECT) Sensor Engine Oil Pressure Sensor

Remove Remove
1. Raise hood and disconnect the battery. 1. Raise hood and disconnect the battery.
2. Drain engine coolant from radiator before 2. Disconnect electrical connector from oil pressure
removing ECT sensor. Refer to the section sensor.
3. Unscrew and remove oil pressure sensor and O-
3. Disconnect the ECT sensor electrical connector ring from adapter. See Figure 83.
from the ECT sensor. See Figure 83.
4. Discard O-ring.
4. Remove the ECT sensor and O-ring. Discard O-
ring. Install
NOTE: If oil pressure sensor has been identified as
Install faulty, replace oil pressure sensor with new one.
1. Lubricate new O-ring with multipurpose grease,
replace ECT sensor with new one.
1. Install new O-ring onto ECT sensor.
2. Apply thread locker to threads of oil pressure
2. Install ECT sensor. sensor. Install oil pressure sensor into adapter.
Tighten two to three turns past finger tight.
3. Connect ECT sensor connector. See Figure 83.
3. Connect electrical connector for oil pressure
4. Refill the radiator with engine coolant. For coolant sensor. See Figure 83.
specification and procedure
4. Connect battery and lower the hood.
See Periodic Maintenance 8000YRM1558 for lift
truck model
Engine Speed Sensor
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ Remove
GDP080, 090, 100, 110, 120VX) (H813)
See Periodic Maintenance 8000YRM1583 for lift
truck model 2. Disconnect electrical connector from engine
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ speed sensor. See Figure 83.
3. Remove engine speed sensor mounting
See Periodic Maintenance 8000YRM1604 for lift capscrew.
truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ 4. Remove engine speed sensor and O-ring.
GDP45VX6; GLP/GDP50-55VX (GP/GLP/ Discard O-ring.
GDP080, 090, 100, 110, 120VX) (J813)
Install
5. Connect battery and lower the hood.
NOTE: If engine speed sensor has been identified as
faulty, replace camshaft position sensor with new one.
Throttle Position Sensor
1. Lubricate new O-ring with multipurpose grease.
See section Kubota Diesel 3.6L Engine
Install O-ring on engine speed sensor.
0600YRM1579, Electronic Throttle System for
procedures to remove and install throttle position 2. Install engine speed sensor. See Figure 83.
sensor.
3. Install engine speed sensor mounting capscrew.
124
4. Connect engine speed sensor electrical 4. Remove fuel shut off solenoid and O-ring. Discard
connector. O-ring.
5. Connect battery and lower hood on lift truck. Install

NOTE: If fuel shut off solenoid has been identified as
Fuel Shut Off Solenoid
defective, replace fuel shut off solenoid with new one.
Remove 1. Lubricate new O-ring with multipurpose grease
1. Raise hood and disconnect battery. and install onto fuel shut off solenoid.
2. Disconnect electrical connector from fuel shut off 2. Install fuel shut off solenoid. See Figure 83.
solenoid. See Figure 83.
3. Install two socket head bolts into fuel shut off
3. Remove two socket head bolts from fuel shut off solenoid.
solenoid.
125
Vehicle System Manager (VSM) 2200 YRM 1142
Vehicle System Manager (VSM)

GENERAL • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
The Vehicle System Manager (VSM) is a
microprocessor-powered controller which controls or 100, 120VX; GC/GLC080, 100VXBCS; GC/
monitors, directly or indirectly, every electrical device GLC120SVX; GC/GLC120VXPRS) (E818,
on the lift truck, except for the Electronic Control Unit F818)
(ECU) and the Governor Control Unit (GCU). These
devices are controlled by the engine. GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
VSM REPLACEMENT H813, J813)
NOTE: The VSM is not a serviceable part. If the VSM • GC/GLC/GDC60VX, GC/GLC/GDC70VX
malfunctions, replace with a new VSM. See the Parts (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
Manual for replacement part number. (C879, D879, E879, F879, G879)
2. Fully lower the steering column and remove the

Remove
upper steering column cover. See the section
1. To access the battery, remove the floor mat and Steering Column Repair for the removal
floor plate, on lift truck models below. Disconnect procedures.
the battery.
3. Remove the dash and kick panel. See the section
GDC135VX, GC/GLC/GDC155VX) (C878, Dash and Kick Panel, Remove and Install for
D878, E878) removal procedures.
4. Disconnect all electrical connections from the
GDP175VX36, GLP/GDP190VX) (A909, B909) VSM. These connections include the chassis
harness, cowl harness, transmission harness,
To access the battery, raise the hood, on lift truck and electronic hydraulic (e-hydraulic) controls, if
models below. Disconnect the battery. lift truck is equipped with this feature. See
• GC/GLC030VX, GC/GLC035VX, GC/ Figure 84.
GLC040SVX (C809)
GLP/GDP16VX, GLP/GDP18VX, GLP/ 5. Remove the three bolts securing the VSM and
•
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ harness bracket to the cowl. Remove VSM from
GDP035VX, GP/GLP/GDP040SVX) (C810) lift truck cowl.
GLC055SVX) (A910)
126
2200 YRM 1142 Vehicle System Manager (VSM)
Figure 84. Vehicle System Manager
127
A. VSM ARRANGEMENT FOR ALL LIFT TRUCK C. VSM ARRANGEMENT FOR LIFT TRUCK MODELS
MODELS EXCEPT FOR GC/GLC/GDC60VX, GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
GC/GLC/GDC70VX (GC/GLC/GDC135VX, (GLP/GDP170VX, GLP/GDP175VX36, GLP/
GC/GLC/GDC155VX) (C879, D879, E879, F879, GDP190VX) (A909, B909)
G879) AND GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX, GLP/
B. VSM ARRANGEMENT FOR LIFT TRUCK
MODELS GC/GLC/GDC60VX, GC/GLC/
GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (C879, D879, E879, F879, G879)
1. BOLTS 4. E-HYDRAULIC CONTROLS HARNESS

2. COWL HARNESS 5. COWL
3. VSM
Install • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,

100, 120VX; GC/GLC080, 100VXBCS; GC/
1. Install VSM and harness bracket onto lift truck GLC120SVX; GC/GLC120VXPRS) (E818,
cowl. Tighten bolts to 19.2 N•m (14 lbf ft). F818)
2. Connect all electrical connections to the VSM. GDP45VX6, GLP/GDP50-55VX (GP/GLP/
The connectors are color coded for easy GDP080, 090, 100, 110, 120VX) (F813, G813,
connection. H813, J813)
3. Install the dash panel and kick panel. See the (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
section Dash and Kick Panel, Remove and Install (C879, D879, E879, F879, G879)
for installation procedures.
PROGRAMMING A NEW VSM AND/OR
4. Install the upper steering column cover. See the
section Steering Column Repair for the DISPLAY SWITCH CLUSTER
installation procedures. NOTE: See the section Diagnostic Troubleshooting
Manual 9000YRM1112 for information on how delete
5. Connect the battery, install the floor plate and and reset fault codes to the VSM, how to use the PC
floor mat, on lift truck models Service Tool software, and for the procedures to
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ troubleshoot the VSM, Display Switch Cluster, and
GDC135VX, GC/GLC/GDC155VX) (C878, other electrical components used on these trucks.
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ General
GDP90VX (GLP/GDP170VX, GLP/ Whenever a new VSM or Display Switch Cluster is
installed (see Display Switch Cluster for procedures to
Connect the battery and lower the hood, on lift remove and install the Display Switch Cluster) on a lift
truck models truck, the data that controls all the functions and
• GC/GLC030VX, GC/GLC035VX, GC/ features unique to that lift truck needs to be transferred
GLC040SVX (C809) to the new VSM or Display Switch Cluster.
• GLP/GDP16VX, GLP/GDP18VX, GLP/ There are two types of data files that may be required
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ to be transferred when a new VSM or Display Switch
GDP035VX, GP/GLP/GDP040SVX) (C810) Cluster is installed:
• GLC20-35VX (GC/GLC040-070VX, GC/ • Configuration Data File (CDF).
GLC055SVX) (A910)
(B875)
128
This data file has the configuration and optional transferred to the new display from the VSM (see
details specific to a given truck. For example, Table 3).
configuration information may include data that
shows the truck's lifting capacity and base type To connect the PC Service Tool, remove the plug that
(e.g., 2-3 Ton Cushion tire truck). Optional covers the PC service tool diagnostic connector on the
information may include data defining the type right side of the steering column and connect the
of engine the truck has and whether any interface cable (Yale P/N 580039670) to the PC
Software Enabled Options (SEO) have been service tool diagnostic connector. See Figure 85. For
installed (e.g., operator passwords). Adding new minimum PC requirements to run the software, refer to
SEO will require that new CDF be downloaded the PC Service Tool Installation and Use Guide,
and transferred into the VSM and Display Systems Requirements section.
Switch Cluster. This data information is directly
linked to the truck's serial number. An example
of a lift truck serial number is Data Transferring
A910V12345A001 . The first 11 characters New VSM
(A910V12345A001) represent the truck's serial
number and the last 3 digits (001) represent the NOTE: Data transfer to a used VSM is not possible.
CDF revision loaded on the truck. The serial Only a new VSM can be used.
number of a lift truck is stored in the Display
Switch Cluster. See the section User Interface - If the VSM is being replaced, the lift truck's CDF and
Service Technician 2200YRM1131 for the Operating Data files must be retrieved from the
procedures to find the serial number. A lift Display Switch Cluster using the PC Service Tool
truck's serial number can be found online at software or the data will be overwritten. This also
Axcess Online . The CDF revision will change includes the truck hourmeters. See Table 3. Detailed
every time a new version is loaded and instructions can be found in the PC Service Tool
transferred to either the VSM or Display Switch (PCST) Truck Reprogramming Guide.
Cluster.
The CDF for a particular truck cannot be New (Blank) Display Switch Cluster
modified by a service technician. However, a If the Display Switch Cluster is being replaced with a
replacement file (with alternate options [SEO]) new (blank) display, the PC Service Tool software will
can be loaded into a truck's controller by a
match the VSM to the display. If the PC Service Tool is
service technician. The operational copy of the
CDF is stored in the VSM and a backup copy is not used there will be a mismatch. See Table 3.
stored in the Display Switch Cluster.
Operating Data
Used (Non-Blank) Display Switch Cluster
•
This includes periodically updated and truck If the replacement Display Switch Cluster has been
specific information such as component serial used on another truck, the PC Service Tool software
numbers and hourmeters. It also includes the must be used to perform the data copying sequence
specific adjustments that can be made by the discussed in New (Blank) Display Switch Cluster. See
service technician for various parameters on a Table 3.
given lift truck. Examples are: auto-deceleration,
which may be set on a scale from (1to10); and Depending on the part being replaced and the tools
certain features which can be activated or available, different methods of transferring the needed
deactivated. data exist. Refer to Table 3 for the best method to use
to transfer data based on the tools available.
PC Service Tool Software
The PC Service Tool software (Yale P/N 580056634)
is required to perform any CDF data file transfers from
the Display Switch Cluster to a new VSM or from the
VSM to a nonblank Display Switch Cluster. A nonblank
Display Switch Cluster is one that has been used on
several trucks. If the Display Switch Cluster is brand
new (blank display), the PC Service Tool software is
not used. The CDF data will automatically be
129
1. STEERING COLUMN
2. PC SERVICE TOOL DIAGNOSTIC CONNECTOR
Figure 85. Connecting PC Service Tool
130
Table 3. VSM and Display Switch Cluster Replacement

Repair Location Conditions
PC Not Available PC Available, No PC and Internet
Internet Available
VSM Replaced, Not allowed - PC Read back up CDF Read back up
Original Display required from Display, Display, download
Intact download into new into new VSM
VSM
VSM and Display Not allowed - PC and Not allowed - PC and Read back up CDF
Replaced Internet required Internet required from Axcess Online ,
download into new
VSM, new blank
Field Repair display auto updated
after installation
Display Replaced New blank display New blank display New blank display
With New Blank auto updated after auto updated after auto updated after
Display installation installation installation
Display Replaced Not allowed - PC PC Service Tool PC Service Tool
With Previously required enables over write of enables over write of
Used Display old CDF in display old CDF in display
131
Power Distribution Module (PDM) and Component Parts 2200 YRM 1142
Power Distribution Module (PDM) and Component Parts

REMOVE • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
PDM as a Unit GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
NOTE: The PDM as a unit, is not a serviceable part.
The component parts of the PDM (relays, fuses, and • GC/GLC/GDC60VX, GC/GLC/GDC70VX
resistors), can be replaced without replacing the PDM. (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879)
If the PDM malfunctions, replace with a new PDM. See
the Parts Manual for replacement part number. 2. Disconnect the chassis harness from the main
1. To access the PDM and battery, remove the floor power connection terminals on the PDM.
mat and floor plate, on lift truck models below.
Disconnect the battery. 3. Remove bolts and PDM from battery tray for lift
truck models below.
GDC135VX, GC/GLC/GDC155VX) (C878, See Figure 86 for lift truck models
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ GLC040SVX (C809)
To access the PDM and battery, raise the steering GDP035VX, GP/GLP/GDP040SVX) (C810)
column to its highest position, move the seat all • GLC20-35VX (GC/GLC040-070VX, GC/
the way forward, and raise the hood on lift truck GLC055SVX) (A910)
models below. Disconnect the battery. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GC/GLC030VX, GC/GLC035VX, GC/ (B875)
GLC040SVX (C809) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• GLP/GDP16VX, GLP/GDP18VX, GLP/ 100, 120VX; GC/GLC080, 100VXBCS; GC/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GLC120SVX; GC/GLC120VXPRS) (E818,
GDP035VX, GP/GLP/GDP040SVX) (C810) F818)
• GLC20-35VX (GC/GLC040-070VX, GC/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GLC055SVX) (A910) GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
(C879, D879, E879, F879, G879)
F818)
132
2200 YRM 1142 Power Distribution Module (PDM) and Component Parts
Figure 86. PDM Removal, For Lift Truck Models GC/GLC030-035VX, 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), GC/GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879,
E879, F879, G879)
133

NOTE: FRAME FOR YOUR MODEL LIFT TRUCK MAY VARY FROM IMAGE SHOWN.
1. BATTERY 5. MAIN POWER CONNECTIONS

2. BATTERY TRAY 6. BOLTS (SECURE PDM TO BATTERY TRAY)
3. PDM 7. BATTERY LOCKDOWN BAR
4. FUSE CLIP
4. Remove bolts and PDM from PDM mounting • GLP/GDP80VX, GLP/GDP80VX9, GLP/
bracket, for lift truck models below. GDP90VX (GLP/GDP170VX, GLP/
D878, E878)
1. BATTERY 4. CHASSIS HARNESS

2. BATTERY CONNECTIONS 5. BOLTS
3. MAIN POWER TERMINALS 6. PDM
Figure 87. PDM Removal, Lift Truck Models GLP/GDP60-70VX (GP/GLP/GDP135-155VX) (C878, D878,
E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
134
2200 YRM 1142 Power Distribution Module (PDM) and Component Parts
INSTALL • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/

PDM as a Unit D878, E878)
1. For lift truck models below, install PDM and bolts • GLP/GDP80VX, GLP/GDP80VX9, GLP/
onto battery tray. Tighten bolts to GDP90VX (GLP/GDP170VX, GLP/
8 N•m (71 lbf in). GDP175VX36, GLP/GDP190VX) (A909, B909)
See Figure 86 for lift truck models 4. Connect the lift truck battery.
GLC040SVX (C809) 5. Close the hood and move the seat and steering
column into position, for lift truck models shown
below see section indicated for procedures:
GDP035VX, GP/GLP/GDP040SVX) (C810) Frame 0100YRM1120 for lift truck models
• GLC20-35VX (GC/GLC040-070VX, GC/ • GC/GLC030VX, GC/GLC035VX, GC/
GLC055SVX) (A910) GLC040SVX (C809)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLP/GDP16VX, GLP/GDP18VX, GLP/
(B875) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GDP035VX, GP/GLP/GDP040SVX) (C810)
100, 120VX; GC/GLC080, 100VXBCS; GC/ • GLC20-35VX (GC/GLC040-070VX, GC/
GLC120SVX; GC/GLC120VXPRS) (E818, GLC055SVX) (A910)
F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ (B875)
GDP080, 090, 100, 110, 120VX) (F813, G813, Frame 0100YRM1243 for lift truck models
H813, J813) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
• GC/GLC/GDC60VX, GC/GLC/GDC70VX 100, 120VX; GC/GLC080, 100VXBCS; GC/
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) GLC120SVX; GC/GLC120VXPRS) (E818,
(C879, D879, E879, F879, G879) F818)
2. For lift truck models below, install PDM and bolts GDP45VX6, GLP/GDP50-55VX (GP/GLP/
onto PDM mounting bracket. Tighten bolts to GDP080, 090, 100, 110, 120VX) (F813, G813,
8 N•m (71 lbf in). H813, J813)
See Figure 87 for lift truck models Frame 0100YRM1316 for lift truck models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GDP135VX, GP/GLP/GDP155VX) (C878, (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
D878, E878) (C879, D879, E879, F879, G879)
GDP90VX (GLP/GDP170VX, GLP/ 6. Install the floor plate and floor mat for lift truck
GDP175VX36, GLP/GDP190VX) (A909, B909) models shown below, see section indicated for
procedures:
3. Connect the chassis harness to the main power Frame 0100YRM1321 for lift truck models
connection terminals on the PDM.
See Figure 86 for lift truck models GDP135VX, GP/GLP/GDP155VX) (C878,
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ D878)
GDP135VX, GP/GLP/GDP155VX) (C878, • GLP/GDP80VX, GLP/GDP80VX9, GLP/
D878, E878) GDP90VX (GLP/GDP170VX, GLP/
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP175VX36, GLP/GDP190VX) (A909)
GDP90VX (GLP/GDP170VX, GLP/ Frame 0100YRM1581 for lift ruck model
See Figure 87 for lift truck models GDP135VX, GP/GLP/GDP155VX) (E878)
135

REMOVE AND INSTALL

PDM Component Parts
If lift truck is equipped with a key switch, turn key to
ON position. If lift truck is equipped with a Power
ON/OFF button, press button to turn system power on.
Check all indicator lights for correct operation as
described in the Operating Manual. Check the
operation of the horn. Start the engine by turning the
key switch to the Start position, if truck is equipped
with a key switch, or press the Power ON/OFF button,
if lift truck is equipped with this button. If any indicator
lights do not operate correctly, check the fuses. The
fuses are located in the Power Distribution Module 1. RESISTOR (68 OHM)
2. START RELAY
(PDM) which is under the hood next to the battery on 3. STARTER (30 AMP)
the right side. See Figure 88. 4. IGNITION 3 RELAY
5. BACKUP RELAY
6. BACKUP (20 AMP)
7. IGNITION (30 AMP)
8. SPARE FUEL PUMP (20 AMP)
9. SPARE FUEL PUMP RELAY
10. BATTERY (25 AMP)
11. FRONT WORK LIGHT (20 AMP)
12. FRONT/REAR WORK LIGHT RELAYS
14. REAR WORK LIGHT (20 AMP)
15. IGNITION 1 (20 AMP)
16. IGNITION 1 RELAY
Figure 88. PDM Component Parts
136
2200 YRM 1142 Transmission Control Unit (TCU)
Transmission Control Unit (TCU)

NOTE: The transmission control unit (TCU) is used
only on lift truck models:
D878, E878)
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879, E879, F879, G879)
REMOVE, LIFT TRUCK MODELS GLP/

GDP60VX, GLP/GDP70VX (GC/GLC/
D878, E878) AND GLP/GDP80VX, GLP/
GDP190VX) (A909, B909) 1. FLANGE CAPSCREW
2. TRANSMISSION CONTROL UNIT (TCU)
1. Remove front and rear floor mat and floor plates 3. TRANSMISSION HARNESS CONNECTOR
and disconnect battery. (CPS129)
4. TRANSMISSION HARNESS CONNECTOR
2. Disconnect transmission harness connectors from (CPS128)
5. MOUNTING BRACKET
TCU. See Figure 89.
Figure 89. Transmission Control Unit (TCU)
3. Remove four flange capscrews from mounting
Location
bracket and TCU. See Figure 89.
4. Remove TCU form mounting bracket. See INSTALL, LIFT TRUCK MODELS GLP/
Figure 89. GDP60VX, GLP/GDP70VX (GC/GLC/
D878, E878) AND GLP/GDP80VX, GLP/
GDP190VX) (A909, B909)
1. Install TCU into bracket using four flange
capscrews. See Figure 89.
2. Connect transmission harness connectors to TCU

as tagged during removal. See Figure 89.
3. Connect battery and install front and rear floor

plate and floor mats. See Figure 89.
5. Calibrate the transmission by referring to

Calibration Procedures 8000YRM1134.
137
Transmission Control Unit (TCU) 2200 YRM 1142
REMOVE, LIFT TRUCK MODELS GC/GLC/ INSTALL, LIFT TRUCK MODELS GLC/
GDC60VX, GC/GLC/GDC70VX (GC/GLC/ GDC60VX, GLC/GDC70VX, (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, GDC135VX, GC/GLC/GDC155VX) (C879,
D879, E879) D879, E879)
1. Open hood and discount battery. 1. Install TCU into mounting bracket using four
flange capscrews. See Figure 90.
2. Disconnect transmission harness connectors from
TCU. See Figure 90. 2. Connect transmission harness connectors to TCU
bracket and TCU. See Figure 90. 3. Connect battery and install front and rear floor
plate and floor mats.
4. Remove TCU from mounting bracket. See
Figure 90. 4. Calibrate the transmission by referring to
REMOVE, LIFT TRUCK MODELS GC/GLC/

GDC60VX, GC/GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (F879)
EQUIPPED WITH 3-SPEED
TRANSMISSION AND MANUFACTURED
BEFORE DECEMBER, 2018
1. Open hood and discount battery.
2. Disconnect transmission harness connectors from

TCU. See Figure 91.

4. Remove TCU from mounting bracket. See

Figure 91.
1. FLANGE CAPSCREW
2. TRANMISSION CONTROL UNIT (TCU)
3. TRANMSISION HARNESS CONNECTOR
(CPS129)
(CPS128)
5. MOUNTING BRACKET

Location
138
1. FLANGE CAPSCREW 1. FLANGE CAPSCREW

2. TRANMISSION CONTROL UNIT (TCU) 2. MOUNTING BRACKET
3. TRANMSISION HARNESS CONNECTOR 3. FRONT SIDE PLATE
(CPS129) 4. PLATE
4. TRANSMISSION HARNESS CONNECTOR 5. FOLDOVER NUT
(CPS128) 6. TCU COVER
5. MOUNTING BRACKET
Figure 91. Transmission Control Unit (TCU) Mounting Brackets
Location
INSTALL, LIFT TRUCK MODELS GLC/
5. If replacing TCU, remove old mounting bracket
and TCU cover from front side plate by removing
GDC60VX, GLC/GDC70VX, (GC/GLC/
flange capscrew and foldover nut from plate. See GDC135VX, GC/GLC/GDC155VX) (F879)
Figure 92. EQUIPPED WITH 3-SPEED
BEFORE DECEMBER, 2018
NOTE: On lift truck models GC/GLC/GDC60VX,
GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879, G879) , equipped with a 3-speed
transmission and manufactured before December,
2018, if the TCU needs to be replaced the TCU shown
in Figure 92 will be sent with Yale kit P/N 550202623 .
1. If replacing TCU, install TCU cover and new

mounting bracket on front side plate using flange
capscrews and foldover nuts. See Figure 92.
2. Install TCU into mounting bracket. See Figure 91.


plate and floor mats.
139
5. On lift truck models GLC/GDC60VX, GLC/ December, 2018, if the TCU was replaced with
GDC70VX, (GC/GLC/GDC135VX, GC/GLC/ TCU shown in (Yale kit P/N 550202623), replace
GDC155VX) (F879) equipped with 3-speed two 5.0 amp fuses with two 7.5 amp fuses and
transmission and manufactured before replace label on fuse covers. See Figure 93.
1. FUSE COVER (7.5 AMP) 4. TRANSMISSION WIRE HARNESS

2. FUSE LABEL 5. TRANSMISSION OIL FILTER
3. RIGHT CHASSIS WIRE HARNESS
Figure 93. TCU Fuse and Label Replacement
6. Calibrate the transmission by referring to 2. Disconnect transmission harness connectors from

Calibration Procedures 8000YRM1134. TCU. See Figure 94.
REMOVE, LIFT TRUCK MODELS GC/GLC/ 3. Remove three flange capscrews and foldover
GDC60VX, GC/GLC/GDC70VX (GC/GLC/ nuts from mounting bracket and TCU. See
Figure 94.
GDC135VX, GC/GLC/GDC155VX) (F879,
G879) EQUIPPED WITH 3-SPEED 4. Remove TCU from mounting bracket. See
TRANSMISSION AND MANUFACTURED Figure 94.
BETWEEN DECEMBER, 2018 AND JULY,
2021
1. Open hood and disconnect battery.
140
1. FLANGE CAPSCREWS/FOLDOVER NUTS 4. TRANSMISSION WIRE HARNESS

2. MOUNTING BRACKET 5. TRANSMISSION HARNESS CONNECTOR
3. TRANSMISSION CONTROL UNIT (CPS128)
(CPS129)
Figure 94. Transmission Control Unit (TCU) Location
5. If replacing TCU, remove mounting bracket and

TCU cover from front side plate by removing
flange capscrew and foldover nut from plate. See
Figure 95.

Mounting Brackets
141
1. FLANGE CAPSCREW
2. MOUNTING BRACKET
3. FRONT SIDE PLATE
4. PLATE
5. FOLDOVER NUT
INSTALL, LIFT TRUCK MODELS GC/GLC/

GDC60VX, GC/GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (F879,
G879) EQUIPPED WITH 3-SPEED
BETWEEN DECEMBER, 2018 AND JULY,
2021
1. If replacing TCU, install TCU cover and mounting
bracket on front side plate using foldover nut and
flange capscrew. See Figure 95.
1. FLANGE CAPSCREW
2. Install TCU on mounting bracket. See Figure 94. 3. TRANMSISION HARNESS CONNECTOR
(CPS129)
3. Connect transmission harness connectors to TCU 4. TRANSMISSION HARNESS CONNECTOR
as tagged during removal. See Figure 94. (CPS128)
5. MOUNTING BRACKET
5. Calibrate the transmission by referring to Location
INSTALL, LIFT TRUCK MODELS GLC/
REMOVE, LIFT TRUCK MODELS GC/GLC/ GDC60VX, GLC/GDC70VX, (GC/GLC/
GDC60VX, GC/GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (F879)
GDC135VX, GC/GLC/GDC155VX) (F879, EQUIPPED WITH 3-SPEED
G879) EQUIPPED WITH 3-SPEED TRANSMISSION AND MANUFACTURED
TRANSMISSION AND MANUFACTURED AFTER JULY, 2021
AFTER JULY, 2021 1. Install TCU into mounting bracket. See Figure 91.
1. Open hood and discount battery.
2. Disconnect transmission harness connectors from as tagged during removal. See Figure 91.
TCU. See Figure 96.
3. Remove four flange capscrews from mounting plate and floor mats.
4. Calibrate the transmission by referring to
4. Remove TCU from mounting bracket. See Calibration Procedures 8000YRM1134.
Figure 96.
142
2200 YRM 1142 Battery
Battery
REMOVE See Figure 87 for lift truck models
1. To access the battery, remove the floor mat and • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
floor plate, on lift truck models below. Disconnect GDP135VX, GP/GLP/GDP155VX) (C878,
the battery. D878, E878)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ GDP90VX (GLP/GDP170VX, GLP/
GDC135VX, GC/GLC/GDC155VX) (C878, GDP175VX36, GLP/GDP190VX) (A909, B909)
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ INSTALL
GDP175VX36, GLP/GDP190VX) (A909, B909) 1. Install new battery onto battery tray. Secure
battery to battery tray with battery lockdown bar.
models below. Disconnect the battery. 2. Connect the battery, install the floor plate and
• GC/GLC030VX, GC/GLC035VX, GC/ floor mat, on lift truck models:
GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/ GDC135VX, GC/GLC/GDC155VX) (C878,
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ D878, E878)
• GLC20-35VX (GC/GLC040-070VX, GC/ GDP90VX (GLP/GDP170VX, GLP/
GLC055SVX) (A910) GDP175VX36, GLP/GDP190VX) (A909, B909)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) Connect the battery and lower the hood, on lift
(B875) truck models:
100, 120VX; GC/GLC080, 100VXBCS; GC/ • GC/GLC030VX, GC/GLC035VX, GC/
GLC120SVX; GC/GLC120VXPRS) (E818, GLC040SVX (C809)
F818) • GLP/GDP16VX, GLP/GDP18VX, GLP/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)
GDP080, 090, 100, 110, 120VX) (F813, G813, • GLC20-35VX (GC/GLC040-070VX, GC/
H813, J813) GLC055SVX) (A910)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (B875)
(C879, D879, E879, F879, G879) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
2. Remove the battery lockdown bar securing GLC120SVX; GC/GLC120VXPRS) (E818,
battery to battery tray. Remove battery from lift F818)
truck. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
See Figure 86 for lift truck models GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ H813, J813)
D878) • GC/GLC/GDC60VX, GC/GLC/GDC70VX
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ (C879, D879, E879, F879, G879)
143
Lights 2200 YRM 1142
Lights
WORK LIGHTS (FRONT AND REAR) 2. To replace the bulb, remove the lens assembly by
removing the four capscrews. See Figure 97.
Remove Replace the bulb and reinstall the lens assembly.
floor plate on lift truck models below. Disconnect 3. To replace the work light assembly, disconnect
the battery. the light from the overhead guard harness and
remove the capscrew, washer, and nut attaching
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ the work light to the overhead guard.
D878, E878)
To access the battery, raise the hood on lift truck
GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818, NOTE: REAR WORK LIGHT SHOWN, FRONT
F818)
WORK LIGHT IS SIMILAR.
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 1. CAPSCREWS (LENS ASSEMBLY)
GDP080, 090, 100, 110, 120VX) (F813, G813, 2. LENS ASSEMBLY
H813, J813) 3. NUT (ATTACHES LIGHT TO OVERHEAD
• GC/GLC/GDC60VX, GC/GLC/GDC70VX GUARD)
(C879, D879, E879, F879, G879) Figure 97. Work Lights
Install
CAUTION 1. Install work light to overhead guard using the
DO NOT touch the Halogen bulb surface or inside capscrew, washer, and nut. See Figure 97.
reflectors with your bare hands. Oils from skin can Connect work light to overhead guard harness.
lead to breakage or shorten the life of the lamp.
Use clean gloves or lint free cloth for installation 2. Connect the battery, install the floor plate and
and removal. floor mat, on lift truck models
Clean any dirt or oil, from the lamp surface with • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
alcohol and a lint free cloth or tissue. Any foreign GDC135VX, GC/GLC/GDC155VX) (C878,
particles or materials on the bulb surface can D878, E878)
cause hot spots on the bulb and result in lamp • GLP/GDP80VX, GLP/GDP80VX9, GLP/
failure. GDP90VX (GLP/GDP170VX, GLP/
144
2200 YRM 1142 Lights
Connect the battery and lower the hood, on lift • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
truck models 100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC040SVX (C809)
GDP035VX, GP/GLP/GDP040SVX) (C810) H813, j813)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C879, D879, E879, F879, G879)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 2. Disconnect the strobe light electrical connector
100, 120VX; GC/GLC080, 100VXBCS; GC/ from the overhead guard harness. See Figure 98.
F818) 3. Remove the capscrews, washers, lockwasher,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ and nuts securing the strobe light and light guard
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ to strobe light mounting bracket. Remove strobe
GDP080, 090, 100, 110, 120VX) (F813, G813, light and guard from lift truck.
H813, J813)
GC/GLC/GDC60VX, GC/GLC/GDC70VX 4. If the strobe light bulb needs to be replaced,
•
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) remove the strobe light lens from base and
(C879, D879, E879, F879, G879) remove bulb.
STROBE LIGHT Install

NOTE: The strobe light may either be mounted above 1. If bulb is being replaced, install new bulb into
the top of the overhead guard (high-mounted) or below strobe light base. Install strobe light lens onto
the top of the overhead guard (low-mounted). The base.
removal and installation procedures are the same for
both options. 2. Place strobe light assembly and strobe light guard
onto mounting bracket. Secure the assembly to
Remove mounting bracket with capscrews, washers,
lockwasher, and nuts. See Figure 98.
floor plate on lift truck models below. Disconnect 3. Connect strobe light electrical connector to
the battery. overhead guard harness.
GDC135VX, GC/GLC/GDC155VX) (C878, 4. Connect the battery, install the floor plate and
D878, E878) floor mat, on lift truck models
• GLP/GDP80VX, GLP/GDP80VX9, GLP/ • GLP/GDP60VX, GLP/GDP70VX (GC/GLC/
GDP90VX (GLP/GDP170VX, GLP/ GDC135VX, GC/GLC/GDC155VX) (C878,
GDP175VX36, GLP/GDP190VX) (A909, B909) D878, E878)
To access the battery, raise the hood, on lift truck • GLP/GDP80VX, GLP/GDP80VX9, GLP/
models below. Disconnect the battery. GDP90VX (GLP/GDP170VX, GLP/
GLC040SVX (C809) Connect the battery and lower the hood, on lift
truck models
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ • GC/GLC030VX, GC/GLC035VX, GC/
GDP035VX, GP/GLP/GDP040SVX) (C810) GLC040SVX (C809)
• GLC20-35VX (GC/GLC040-070VX, GC/ • GLP/GDP16VX, GLP/GDP18VX, GLP/
GLC055SVX) (A910) GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GDP035VX, GP/GLP/GDP040SVX) (C810)
(B875)
145
• GLC20-35VX (GC/GLC040-070VX, GC/ LED TAIL, BACKUP, AND BRAKE LIGHTS

GLC055SVX) (A910)
NOTE: These light assemblies are nonrepairable and
(B875) must be replaced as an assembly. See the Parts
Manual for replacement LED lights.
100, 120VX; GC/GLC080, 100VXBCS; GC/
GLC120SVX; GC/GLC120VXPRS) (E818, Remove
F818) 1. To access the battery, remove the floor mat and
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ floor plate on lift truck models below. Disconnect
GDP45VX6, GLP/GDP50-55VX (GP/GLP/ the battery.
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
• GC/GLC/GDC60VX, GC/GLC/GDC70VX D878, E878)
(C879, D879, E879, F879, G879)
GLC040SVX (C809)
GLC055SVX) (A910)
(B875)
100, 120VX; GC/GLC080, 100VXBCS; GC/
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
(C879, D879, E879, F879, G879)
2. If lift truck is equipped with an optional key switch,

1. STROBE LIGHT GUARD remove the key.
2. STROBE LIGHT LENS
3. STROBE LIGHT BULB 3. Remove screw and clip nut securing the LED light
4. LIGHT BASE
5. NUT to mounting bracket. Pull LED light downward to
6. LOCKWASHER remove it from the mounting bracket.
7. WASHER
8. MOUNTING BRACKET 4. Disconnect the LED light from the chassis light
9. CAPSCREW harness. See Figure 99.
10. LOCK NUT
5. If the mounting bracket must be removed from the
Figure 98. Strobe Light Assembly overhead guard leg, remove rear crossmember
cover and remove the mounting bracket from the
overhead guard leg. See Figure 99.
146
Install • GC/GLC030VX, GC/GLC035VX, GC/

GLC040SVX (C809)
1. If the mounting bracket was removed, install the
rear crossmember cover. Install mounting bracket GDP20SVX (GP/GLP/GDP030VX, GP/GLP/
to overhead guard leg. GDP035VX, GP/GLP/GDP040SVX) (C810)
2. Connect the LED light to the chassis light • GLC20-35VX (GC/GLC040-070VX, GC/
GLC055SVX) (A910)
harness. See Figure 99.
3. Insert the screw and install the LED light to the (B875)
mounting bracket. See Figure 99. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS; GC/
4. Connect the battery, install the floor plate and GLC120SVX; GC/GLC120VXPRS) (E818,
floor mat, on lift truck models F818)
• GLP/GDP60VX, GLP/GDP70VX (GC/GLC/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDC135VX, GC/GLC/GDC155VX) (C878, GDP45VX6, GLP/GDP50-55VX (GP/GLP/
D878, E878) GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
GDP90VX (GLP/GDP170VX, GLP/ • GC/GLC/GDC60VX, GC/GLC/GDC70VX
GDP175VX36, GLP/GDP190VX) (A909, B909) (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879, G879)
truck models
147
1. CHASSIS LIGHT HARNESS 6. SCREW

2. VEHICLE SYSTEM MANAGER 7. CLIP NUT
3. MOUNTING BRACKET 8. CROSSMEMBER
4. REFLEX LENS 9. LED LIGHT HOUSING
5. LED LIGHT LENS 10. INSERT
Figure 99. LED Tail, Backup, and Brake Lights Replacement
FRONT MARKER/TURN SIGNAL LIGHTS Install

Replacing Whole Front Marker/Turn Signal 1. Install new front marker/turn signal light assembly
Light Assembly to overhead guard and trim using two bolts. See
Figure 100.
Remove
2. Connect light wire harness to front marker/turn
1. Disconnect light wire harness from front marker/
signal light connector.
turn signal light connector. See Figure 100.
3. Connect the battery.
2. Remove two bolts located at the top of the front
marker/turn signal light assembly and inside the
corner of the overhead guard. See Figure 100.
3. Remove front marker/turn signal light assembly

from overhead guard and trim.
148
NOTE: RIGHT FRONT MARKER/TURN SIGNAL

LIGHT ASSEMBLY SHOWN. PROCEDURES TO RE-
MOVE AND REPLACE LEFT FRONT MARKER/
TURNS SIGNAL LIGHT ASSEMBLY ARE THE SAME.
1. FRONT MARKER/TURN SIGNAL LIGHT

ASSEMBLY NOTE: RIGHT LED LENS SHOWN. PROCEDURES
2. LIGHT WIRE HARNESS TO REMOVE AND REPLACE LEFT LED LENS ARE
3. BOLT
4. TRIM THE SAME.
5. OVERHEAD GUARD
Figure 100. Front Marker/Turn Signal Light ASSEMBLY
2. CAPS
Assembly Removal 3. CAPSCREWS
Replacing Just the Front Marker/Turn ASSEMBLY CONNECTOR
Signal Light LED Light Lens 5. LED LIGHT
Remove Figure 101. LED Lens Replace

1. Use a flat head tool and remove the two caps
Install
located on each side of the LED lens. See
Figure 101. 1. Install new LED light into front marker/turn signal
light assembly using four capscrews. See
2. Remove the four capscrews securing the LED Figure 101.
lens in the front marker/turn signal light assembly.
Remove LED lens from assembly. See 2. Install two caps on each side of LED lens. Push
Figure 101. caps until they snap into place.
149
Diesel Particulate Filter (DPF) Display 2200 YRM 1142
Diesel Particulate Filter (DPF) Display

REMOVE
NOTE: Use a flat head screwdriver to help separate
the cover from base, where the bracket enters the
cover pry point. See Figure 102.
1. Remove cover from base and DPF display. See
Figure 102.
NOTE: Note position of lock ring during removal to

help in installation.
2. Unscrew lock ring from back of DPF display and
base. See Figure 102.
3. Disconnect electrical connector from back of DPF

display. See Figure 102.
4. Remove DPF display from lift truck
NOTE: Note position of lock ring and base in relation 1. DPF DISPLAY
to wiring harness and mounting bracket prior to 2. COVER
removal to help in installation. 3. BASE
4. LOCK RING
5. Slide base and lock ring down wiring harness and 5. ELECTRICAL CONNECTOR
remove from lift truck. 6. WIRING HARNESS
7. HOOK TABS
6. Remove two capscrews and mounting bracket 8. MOUNTING BRACKET
from overhead guard. See Figure 102. 9. COVER PRY POINT
10. CAPSCREW
11. OVERHEAD GUARD
Figure 102. DPF Display
150
2200 YRM 1142 Diesel Particulate Filter (DPF) Display
CLEAN AND INSPECT 3. Connect electrical connector into back of DPF

display. See Figure 102.
Using a lint free cloth, wipe down components and
inspect for damage or defects. NOTE: DO NOT overtighten lock ring.
If any components are found to have damage or defect 4. Secure DPF display to base and mounting
replace them. See Parts Manual for part information. bracket using lock ring as noted during removal.
See Figure 102.
INSTALL
1. Install mounting bracket and two capscrews onto NOTE: Align two hook tabs into openings of base at
overhead guard. See Figure 102. top of cover and snap bottom of cover into position.
5. Snap cover onto base and DPF display. See
2. Slide lock ring and base over wiring harness and Figure 102.
into position on mounting bracket as noted during
removal.
151
Electronic-Hydraulic Controls - Generation 1 2200 YRM 1142
Electronic-Hydraulic Controls - Generation 1

E-HYDRAULIC CONTROLS - TEST 2. (DO NOT start.) Turn key switch to ON position.
Mini-Levers 3. Display the electro-hydraulic diagnostics menu on

Perform all of the following test procedures to be sure the dash display panel.
mini-levers operate properly. • Is each lever output = 0%?
See the User Interface - Service Technician manual, • YES: Go to Step 4.
listed in the General section, for instructions to view • NO: Mini-lever is not working properly. See
Lever output Value. With Service Password, view procedures for each generation of MLM for
Diagnostics – Hydraulic Data Display – Hydraulic repair or replacement. Upon completion, rerun
Input. the test.
Full Stroke Test 4. Operate each lever to full stroke forward and
slowly release (1-2 seconds from full stroke).
Check for full stroke of mini-lever. Use DSC or install Read output when fully released.
the Service Tool to monitor functions.
• Is each lever output = 0%?
1. Stroke each lever to full stroke, forward and • YES: Go to Step 5.
backward, and allow lever to snap back to center. NO: Mini-lever is not working properly. See
•
procedures for each generation of MLM for
2. (DO NOT start.) Turn key switch to ON position. repair or replacement. Upon completion, rerun
the test.
3. Display the electro-hydraulic diagnostics menu on
the dash display panel. Operate each lever to full 5. Operate each lever to full stroke back and slowly
stroke forward and read input. release (1-2 seconds from full stroke). Read
• Is lever output = -92%? output when fully released.
• YES: Go to Step 4. • Is each lever output = 0%?
• NO: Mini-lever not working properly. See • YES: Mini-lever function is returning to neutral.
procedures for each generation of MLM for • NO: Mini-lever is not working properly. See
repair or replacement. Upon completion, rerun procedures for each generation of MLM for
the test. repair or replacement. Upon completion, rerun
the test.
4. Operate each lever to full stroke backward and
read input. 6. If mini-lever continues to not function, contact
• Is lever output = +92%? your local YALE dealer or see Yale Axcess
Online .
• YES: Mini-lever is supplying full stroke.
• NO: Mini-lever not working properly. See Push Button Switch
procedures for each generation of MLM for
repair or replacement. Upon completion, rerun 1. Validate push button switch operates properly by
the test. operating applicable function.
5. If mini-lever continues to not function properly, 2. If system does not function; see procedures for
contact your local YALE dealer or see Yale each generation of MLM for repair or
Axcess Online . replacement. Upon completion, rerun the test.
Function Returns to Neutral Test 3. If push button switch continues to not function
properly, contact your local YALE dealer or see
Check to confirm function returns to neutral (0%). Use Yale Axcess Online .
DSC or install the Service Tool to monitor functions.
1. Stroke each lever to full stroke, forward and

backward, and allow lever to snap back to center.
152
2200 YRM 1142 Electronic-Hydraulic Controls - Generation 1
GENERAL and on an electrically grounded surface. Do not

touch any printed circuit board (PCB) surface to
prevent damage from electrostatic voltage.
WARNING
Before replacing any part of the electronic NOTE: Warranty seal will be broken when the MLM
hydraulic control assembly, fully lower all parts of housing is opened.
the mast and tilt it forward until the tips of forks 2. Remove lower MLM housing screws using a No.
touch the ground. This action will prevent mast 25 torx driver. See Figure 103.
from lowering suddenly if the control lever is
accidently moved. 3. Remove lower MLM housing bottom. See
Figure 103.
WARNING 4. Unplug the mini-lever connector from the main

PCB. See Figure 104.
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidently make an
electrical connection and cause an injury.
CAUTION
DO NOT TRY TO REMOVE CONNECTOR BY
PULLING ON THE WIRES.
CAUTION
A short circuit and damage can occur if wires are 5. If push button switch connector is attached to the
not installed correctly. Make sure wire connectors mini-lever PCB then unplug this connector.
do not touch other metal terminals or wire Carefully grip plug with flush cutting wire cutters.
connectors, metal brackets, or bracket mounting Gently work the plug out of the socket. See
nuts. Make sure wires are not pulled tight and are Figure 105.
not touching other parts to damage the insulation.
6. Locate the mini-lever mounting screws. See
NOTE: The information in this section covers lift Figure 106.
trucks equipped with Electronic-Hydraulic Controls and
built before January, 2010.
NOTE: The mini-levers and joystick do not need to be
calibrated.
The line of trucks covered in this manual come
standard with manual hydraulic levers, but have the
option of using electronic-hydraulic controls. If the
joystick, Mini-Levers Module (MLM), or mini-levers
malfunction, replace with new part. See the Parts
Manual for replacement parts.
MINI-LEVER REPLACEMENT
Remove
1. Remove MLM from lift truck. See Mini-Lever
Module (MLM), Remove.
CAUTION
The following procedure should only be performed
by Yale trained and certified technicians. The
removal and replacement of the mini-levers should 1. LOWER MLM HOUSING
be done in a clean environment whenever possible 2. TORX HOUSING SCREWS
Figure 103. MLM Housing Screws
153
7. Remove screws using a No. 10 torx driver.

Carefully slide lever out of the top of the MLM. Be
sure wires do no catch on any sharp edges.
Clean and Inspect

Remove any grease or dirt from MLM housing exterior.
Install
1. Install seal (supplied in mini-lever kit) onto base of
new mini-lever.
NOTE: Mini-lever will only insert in one direction.

2. Carefully position mini-lever over mounting hole.
Use index pins to align with matching hole
pattern.
3. Insert one mounting screw and hand tighten to

hold mini-lever in place. See Figure 106.
4. Insert the remaining three screws but do not

tighten.
1. MAIN PCB BOARD
2. MINI-LEVER CONNECTOR 5. Tighten all screws per the tightening sequence
3. SCREWS using a No. 10 torx driver. See Figure 106. Torque
4. METAL BACKING PLATE to 0.62 N•m (5.5 lbf in). If a torque measurement
device is not available, tightened firmly, but DO
Figure 104. MLM Connector
NOT over tighten.
NOTE: NUMBERS IN PARENTHESES REPRESENT

MINI-LEVER TIGHTENING SEQUENCE.
1. MOUNTING SCREWS
2. MINI-LEVER PCB BOARD
Figure 106. MLM
Figure 105. MLM Push Button Switch Connector

CAUTION
Part can be damaged. Use caution when installing.
154
6. Apply Nye 760G grease (supplied in lever kit) to

the push button switch connector.
7. Connect push button switch connector (if fitted) to

mini-lever connection using long nosed pliers.
See Figure 107.

the mini-lever connector.
9. Connect the mini-lever harness to the main PCB.

See Figure 104.
10. Confirm mini-lever functions properly. See E-

Hydraulic Controls - Test procedures in this
section.
1. LOWER MLM HOUSING

2. TORX HOUSING SCREWS
Figure 108. MLM Housing
PUSH BUTTON SWITCH REPLACEMENT

NOTE: The yellow, rectangular button is a toggle
switch and the round, green button(s) is a momentary
switch. See Figure 109.
Remove
1. While in the seat, power truck ON. Check to
confirm there is no Hydraulic Interlock or fault
code display messages. If codes exist, clear
codes using procedures in Diagnostic
Troubleshooting Manual 9000YRM1112. Repeat
power ON to confirm codes are cleared.
Figure 107. MLM Push Connector
If Hydraulic Interlock appears, perform Operator
11. Install lower MLM housing and lower housing Presence System Check, Hydraulic Interlock
screws. Tighten screws to 2.8 N•m (25 lbf in) Check, and Armrest Hydraulic Interlock
using No. 25 torx driver. See Figure 108. Check. See Diagnostic Troubleshooting
Manual 9000YRM1112, Operational Checkout.
12. Install MLM on lift truck. See Mini-Lever
Replacement, Install. 2. Remove MLM from lift truck. See Mini-Lever
Module (MLM), Remove.
155
12. If replacing yellow, rectangular toggle switch, go

CAUTION to Step 13. Remove lock nut from back of green,
The following procedure should only be performed round momentary switch. See Figure 110.
by Yale trained and certified technicians. The Remove push button switch from housing.
removal and replacement of the mini-levers and
push button switch should be done in a clean
environment whenever possible and on an
electrically grounded surface. Do not touch any
printed circuit board (PCB) surface to prevent
damage from electrostatic voltage.
NOTE: Warranty seal will be broken when the MLM

housing is opened.
3. Remove the MLM lower housing screws using a
No. 25 torx driver. See Figure 108.
4. Remove the MLM housing bottom.
5. Disconnect all mini-levers from main PCB

connectors. See Figure 104.
6. Disconnect the main PCB to MLM wire harness

connector. 1. TOGGLE SWITCH
2. MOMENTARY SWITCH
7. Remove the screws from the metal MLM backing
plate using a No. 20 torx driver. See Figure 104. Figure 109. Push Button Switches
8. Remove metal backing plate. Make sure wires

are clear and not pinched.
CAUTION
DO NOT touch any printed circuit board (PCB)
surface to prevent damage from electrostatic
voltage. Handle only by edges of the PCB.
9. Remove the screws securing the main PCB using

a No. 10 Torx driver.
10. Remove the main PCB.
CAUTION
DO NOT TRY TO REMOVE THE CONNECTOR BY
PULLING ON THE WIRES.
1. LOCKNUT
11. Disconnect push button switch connector from 2. KNURL NUT
3. BLACK CYLINDER
mini-lever connection. Carefully grip plug with 4. BLUE CONNECTOR
flush cutting wire cutters. Gently work the plug out 5. RED SCREW
of the socket. See Figure 105.
Figure 110. Push Button Switch Housing
156
NOTE: Note the position of the yellow rectangular 14. Remove lower MLM housing screws.
toggle switch before removal to aid in installation. See
Figure 110. 15. Apply Nye 760G grease (supplied in kit) to the
main MLM wire harness connector.
13. Remove knurl nut. See Figure 109.
16. Connect the main MLM wire harness to the main
14. Rotate red screw to left stop. See Figure 109.
PCB connector.
15. Remove blue connector by sliding from black
cylinder.
the mini-lever connector.
16. Remove push button switch from front of housing.
18. Connect all of the mini-lever to main PCB
connectors.
Install
1. If installing yellow rectangular toggle switch, insert 19. Install lower MLM housing with the lower housing
black cylinder portion of switch through the screws. Tighten screws to 2.8 N•m (25 lbf in)
housing. using No. 25 torx driver. See Figure 108.
2. Slide blue connector onto cylinder. 20. Confirm push button switch operates properly.
See E-Hydraulic Controls - TestPush Button
3. Rotate red screw to right stop. See Figure 109. Switch.
4. Adjust position of yellow rectangular toggle switch 21. Install MLM on lift truck. See Mini-Lever Module
and tighten knurl nut. Go to Step 7. (MLM), Install.
5. Install a new green round momentary switch MINI-LEVER MODULE (MLM)

assembly.
Remove
6. Tighten lock nut. 1. If equipped, pull up on armrest lever and put
armrest cover in the up position see Figure 116.
7. Apply Nye 760G grease (supplied in kit) to the Disconnect the electrical connector. See
push button switch connector. Figure 111.
8. Connect push button switch connector to mini- 2. Remove flange nuts that secure MLM to armrest
lever connection using long nosed pliers. See and remove MLM from armrest.
Figure 107.
9. Replace the main PCB without touching the

Install
surface and secure with screws using a No. 10 1. Install MLM onto armrest and secure with flange
torx driver. Torque to 0.62 N•m (5.5 lbf in). If no nuts.
torque measurement device is available, tighten
firmly. DO NOT over tighten. NOTE: When closing the armrest cover, make sure
the wires for the electrical connection are inside the
10. Replace metal backing plate. Make sure push armrest. If they are hanging out, they can be cut when
button switch wires are routed into channel. Be closing the armrest cover.
sure all wires are clear and not pinched.
2. Connect the electrical connection and if equipped,
put armrest cover in the down position.
11. Install the two mounting screws loosely.
12. Temporarily insert lower MLM housing screws to

align metal backing plate.
13. Tighten the metal backing plate screws using a

No. 25 torx driver.
157
1. BOTTOM COVER
1. MINI-LEVER ASSEMBLY 2. SCREW
2. FLANGE NUTS 3. ELECTRICAL CONNECTOR
3. ELECTRICAL CONNECTOR 4. MOUNTING BRACKET
4. MINI-LEVER 5. WASHER
6. LOCKWASHER
Figure 111. Mini-Lever Module Removal 7. NUT
8. SCREW
JOYSTICK 9. JOYSTICK
10. LOCK NUT
NOTE: Joystick control used on lift trucks 11. UPPER HOUSING
manufactured prior to 4/7/2014. 12. BRACKET
Remove and Disassemble Figure 112. Joystick
1. Remove four nuts that attach joystick to mounting Inspect

bracket.
Inspect the components of the joystick to ensure that
2. Disconnect the joystick electrical connector. See there is no damage. If any component is damaged,
Figure 112. other than the wiring harness, replace that component.
Inspect the pins of the wiring harness. If any are
3. Remove four nuts, lockwashers, washers, damaged, see the section Wire Harness Repair
screws, and upper housing from the bracket. 2200YRM1128 for the proper repair procedures.
Assemble and Install

1. Install upper housing, four screws, washers,
lockwashers, and nuts to the bracket. See
Figure 112.
2. Install the bottom cover to the bracket using four

screws.
3. Connect the joystick connector.
4. Using four nuts, attach joystick to mounting

bracket.
158
2200 YRM 1142 Electronic-Hydraulic Controls - Generation 2, Before January, 2020
Electronic-Hydraulic Controls - Generation 2, Before January,

2020
NOTE: The information in this section, on repairing,
replacing, and servicing the Mini-Levers (MLM),
armrest, and mounting bracket, applies to lift truck
models manufactured before January, 2020.
GENERAL
WARNING
Before replacing any part of the electronic
hydraulic control assembly, fully lower all parts of
the mast and tilt it forward until the tips of forks
touch the ground. This action will prevent mast
accidently moved.
WARNING 1. ARMREST
Never wear any metallic items on your fingers, 2. TO WIRE HARNESS
3. HORN BUTTON
arms, or neck. Metal items can accidently make an 4. DIRECTION CONTROL SWITCH
electrical connection and cause an injury. 5. MINI-LEVERS
6. PUSH (OVERRIDE) BUTTONS
7. TOGGLE SWITCH
CAUTION Figure 113. E-Hydraulic Controls Arrangement
A short circuit and damage can occur if wires are
not installed correctly. Make sure wire connectors
MINI-LEVERS, REMOVE AND INSTALL
do not touch other metal terminals or wire
connectors, metal brackets, or bracket mounting
nuts. Make sure wires are not pulled tight and are CAUTION
not touching other parts to damage the insulation. The following procedure should only be performed
by Yale trained certified technicians. The removal
NOTE: Prior to performing the following procedures and replacement of the mini-levers should be done
the E-Hydraulic Controls - Test must be performed. in a clean environment whenever possible and on
NOTE: The information in this section covers lift an electrically grounded surface. Do not touch any
trucks equipped with Electronic-Hydraulic Controls and printed circuit board (PCB) surface to prevent
built before January, 2010. damage from electrostatic voltage.
NOTE: The mini-levers and joystick do not need to be 1. Remove the two capscrews that secure the mini-
calibrated. lever to the armrest. Remove mini-lever from
NOTE: The Direction Control Switch (DCS) is an armrest. See Figure 114.
optional feature on lift trucks equipped with Electronic-
Hydraulic Controls. See Figure 113.
standard with manual hydraulic levers, but have the
option of using electronic-hydraulic controls. See
Figure 113. If the joystick, Mini-Levers Module (MLM),
or mini-levers malfunction, replace with new part. See
the Parts Manual for replacement parts.
159
Electronic-Hydraulic Controls - Generation 2, Before January, 2020 2200 YRM 1142
1. CAPSCREWS
2. MINI-LEVER
3. ARMREST
4. PUSH (OVERRIDE) BUTTON
NOTE: Before installing new mini-lever, check the

Parts Manual for the correct part number to be sure
the correct mini-lever is being installed.
2. Install new mini-lever onto armrest using two
capscrews.
ARMREST ASSEMBLY
Remove
1. Disconnect the battery.
2. Remove two capscrews and washers from cover

plate and remove seat box. Disconnect the main
E-Hydraulic control wire harness from E-Hydraulic
armrest harness. See Figure 115.
Figure 114. Mini-Lever Removal
160
NOTE: SOME COMPONENT PARTS AND ELECTRICAL CONNECTIONS OMITTED OR MOVED FOR CLARI-
TY.
A. FULL SUSPENSION SEATS B. SEMI SUSPENSION SEATS
1. CAPSCREWS 4. E-HYDRAULIC ARMREST HARNESS

2. WASHERS CONNECTOR
3. SEAT BOX 5. COVER PLATE
Figure 115. Seat Box Cover Removal
3. Pull up on handle (see Figure 116) and slide

armrest all the way forward and remove the
flange capscrew from under the armrest mounting
bracket that attaches the armrest to the mounting
bracket. Pull up on handle and slide armrest all
the way back and remove the other flange
capscrew. See Figure 117.
Figure 116. Armrest Adjustment Handles
161
A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN
4. Remove armrest from armrest mounting bracket.
1. SOCKET HEAD SCREWS

2. BOTTOM ARMREST COVER
Figure 118. Bottom Armrest Cover Removal
NOTE: The push (override) buttons and toggle switch

are optional features. If lift truck is not equipped with
1. E-HYDRAULIC CONTROL WIRE HARNESS these features, there will be a plug covering the
2. FLANGE CAPSCREWS electrical connector on the PCB cassette.
3. ARMREST
4. ARMREST MOUNTING BRACKET 6. Disconnect the push (override) buttons/toggle
5. HOLES FOR FLANGE CAPSCREWS switch connector from PCB cassette. See
Figure 119.
Figure 117. E-Hydraulic Armrest and Mounting
Bracket 7. Remove the three socket screws from PCB
cassette and remove PCB cassette from the
5. Remove six socket head screws that fasten the armrest. See Figure 119.
bottom and top armrest covers together. See
Figure 118. Remove the bottom armrest cover
from armrest.
162
2. Remove two Phillips head screws that attach horn

button to armrest. See Figure 120. Remove horn
button from armrest.
1. TO E-HYDRAULIC CONTROL WIRE HARNESS

3. PCB CASSETTE
4. PUSH (OVERRIDE) BUTTONS/TOGGLE
SWITCH CONNECTOR
Figure 119. PCB Cassette Removal
Install
1. Install PCB cassette to armrest with three socket
head screws. See Figure 119.
2. If lift truck is equipped, connect the push

(override) buttons/toggle switch connector to PCB
cassette. See Figure 119. NOTE: PUSH (OVERRIDE) BUTTONS AND TOG-
GLE SWITCH CONNECTIONS NOT SHOWN FOR
3. Install bottom armrest cover to armrest with six CLARITY.
socket head screws. See Figure 118.
1. PHILLIPS HEAD SCREWS
4. Install new armrest onto mounting bracket with 2. DIRECTION CONTROL SWITCH ADAPTER*
flange capscrews. Tighten flange capscrews to 3. HORN BUTTON ADAPTER
13 to 15 N•m (115 to 132 lbf in). 4. PLUG
5. HORN SWITCH
5. Connect the E-hydraulic wire harness to armrest. 6. DIRECTION CONTROL SWITCH CONNECTOR
7. ARMREST
See Figure 117. Install seat box to cover plate *Direction Control Switch is an optional feature.
with two capscrews and washers. See
Figure 115. Tighten capscrews to Figure 120. Switch Arrangement and Connections,
1.2 N•m (10.6 lbf in). E-Hydraulic Mini-Levers
6. Connect the battery. Install

HORN BUTTON 1. Insert new horn switch into armrest and secure
switch to armrest with two Phillips head screws.
Remove See Figure 120.
1. Remove the armrest from armrest mounting
2. Install armrest and PCB cassette to armrest and
bracket. Remove bottom armrest and PCB
install armrest to armrest mounting bracket. See
cassette. See the section Armrest Assembly for
the section Armrest Assembly for installation
removal procedures.
procedures.
163
DIRECTION CONTROL SWITCH Install

NOTE: The Direction Control Switch (DCS) is an 1. Insert new Direction Control Switch into bezel.
optional feature on lift trucks covered in this manual See Figure 121.
that are equipped with electro-hydraulic controls and
built after January 2010. 2. Connect the E-Hydraulic control valve wiring
harness to the Direction Control Switch. Install the
Remove Direction Control Switch assembly into the
armrest by compressing the clips on either side of
1. Remove armrest from armrest mounting bracket. the bezel and pushing the assembly into the
Remove bottom armrest cover. See section armrest until the clips latch. See Figure 121.
Armrest Assembly for removal procedures.
3. Install armrest cover to armrest, and install
2. Remove Direction Control Switch assembly from armrest to armrest mounting bracket. See the
armrest by compressing the clips on either side of section Armrest Assembly for installation
the bezel and carefully pulling the assembly out. procedures.
Disconnect the E-Hydraulic control wiring harness
from the Direction Control Switch. See
PUSH (OVERRIDE) BUTTONS AND
Figure 121.
TOGGLE SWITCH
On lift trucks equipped with E-Hydraulic controls, there
may be two optional push (override) buttons (green
buttons) and a toggle switch (yellow button) located
behind the second, third, or fourth mini-lever. See
Figure 122. The push (override) button located behind
the second mini-lever is used to override the Return To
Set Tilt (RTST) function. By pressing this button, the
RTST parameters are overridden and the mast is
allowed to tilt unrestricted.
If the lift truck is equipped with three mini-levers and a
four function control valve, there will be a toggle switch
behind the third mini-lever. Pressing this switch allows
the third mini-lever to switch between the third and
fourth functions. If the lift truck is equipped with four
mini-levers and a five function control valve, the toggle
switch will be located behind the fourth mini-lever.
Pressing the switch allows the fourth mini-lever to
switch between the fourth and fifth functions.
If the lift truck is equipped with a clamp attachment,
1. DIRECTION CONTROL SWITCH the last mini-lever on the right controls the clamp
2. BEZEL
3. ARMREST function. Behind this lever will be a push (override)
4. E-HYDRAULIC CONTROL VALVE WIRING button. To engage the clamp, move the mini-lever
HARNESS backward. To disengage the clamp, push the push
(override) button behind the mini-lever and move mini-
Figure 121. Direction Control Switch Replacement lever forward.
3. Remove the Direction Control Switch from the The different configurations of switches and buttons
bezel. See Figure 121. discussed in this section may not be found on your lift
truck.
164
NOTE: Tag wires prior to disconnecting them to aid in

reconnecting.
2. Pull the push (override) buttons or toggle switch
connectors apart to disconnect them from wire
3. If push (override) button is being replaced,

remove lock nut from back of green, round, push
button. Remove push button switch from armrest.
See Figure 123.
NOTE: Note the position of the yellow, rectangular,

Figure 122.
4. If function selection button is being replaced:
NOTE: NOT ALL LIFT TRUCK MAY HAVE ALL
SWITCHES AND BUTTONS SHOWN. a. Remove knurl nut. See Figure 123.
1. MINI-LEVERS b. Rotate red screw to left stop. Remove blue
2. PUSH (OVERRIDE) BUTTON (RTST) connector by sliding it from black cylinder. See
3. TOGGLE SWITCH
4. PUSH (OVERRIDE) BUTTON (CLAMP) Figure 123.
5. ARMREST HOUSING
c. Remove toggle switch from armrest.
Figure 122. Push (Override) Buttons and Toggle
Switch Location
Remove
cassette. See procedures in Armrest Assembly
section above.
165
1. CLAMP BUTTON CONNECTION 5. LOCK NUT

2. RTST CONNECTION 6. BLUE CONNECTOR
3. TOGGLE SWITCH CONNECTION 7. KNURL NUT
4. RED SCREW 8. BLACK CYLINDER
Figure 123. Push (Override) Buttons and Toggle Switch Replacement
Install c. Rotate red screw to right stop.

1. If installing a new toggle switch: d. Adjust position of yellow, rectangular toggle
switch. See Figure 122. Install and tighten
a. Insert black cylinder portion of toggle switch knurl nut to secure toggle switch to armrest.
through armrest housing.
e. Apply Nye 760G grease (supplied in kit) to
b. Slide blue connector onto cylinder. See toggle switch connector. Push toggle switch
Figure 123. connector to wire harness. See Figure 123.
166
2. If installing a push (override) button:
a. Install new green, round push (override) button

assembly through armrest housing.
b. Install and tighten lock nut to secure push

(override) button to armrest. See Figure 123.
c. Push the push (override) button connector to

wire harness. See Figure 123.

procedures.
4. Connect the E-hydraulic wire harness to armrest.

See Figure 117.
JOYSTICK
1. BOTTOM COVER
NOTE: Joystick control used on lift trucks 2. SCREW
manufactured prior to 4/7/2014. 3. ELECTRICAL CONNECTOR
4. MOUNTING BRACKET
5. WASHER
Remove and Disassemble 6. LOCKWASHER
1. Remove four nuts that attach joystick to mounting 7. NUT
8. SCREW
bracket. 9. JOYSTICK
10. LOCK NUT
2. Disconnect the joystick electrical connector. See 11. UPPER HOUSING
Figure 124. 12. BRACKET
3. Remove four nuts, lockwashers, washers, Figure 124. Joystick

screws, and upper housing from the bracket.
Inspect
Inspect the components of the joystick to ensure that
there is no damage. If any component is damaged,
other than the wiring harness, replace that component.
Inspect the pins of the wiring harness. If any are
damaged, see the section Wire Harness Repair
2200YRM1128 for the proper repair procedures.
Assemble and Install

1. Install upper housing, four screws, washers,
lockwashers, and nuts to the bracket. See
Figure 124.
2. Install the bottom cover to the bracket using four

screws.
3. Connect the joystick connector.
4. Using four nuts, attach joystick to mounting

bracket.
167
JOYSTICK ARMREST SLIDER ASSEMBLY The joystick armrest slider assembly covers and arm
pad can be replaced if damaged.
NOTE: Joystick control used on lift trucks
manufactured prior to 4/7/2014.
Remove
1. Remove three screws from inner cover that attach
inner and outer covers to joystick armrest slider
assembly. See Figure 125.
1. ARM PAD 6. STRAP CLAMP

2. ARM PAD FRAME 7. SCREW
3. JOYSTICK ELECTRICAL CONNECTOR 8. CAPSCREW
4. INNER COVER 9. NUT
5. OUTER COVER 10. JOYSTICK ARMREST SLIDER ASSEMBLY FRAME
Figure 125. Joystick Armrest Slider Assembly
168
2. Remove inner and outer covers from joystick 2. Install inner and outer covers onto joystick
armrest slider assembly. armrest assembly frame using three screws. See
Figure 125.
3. Remove capscrew and nut from rear of arm pad
frame. Remove arm pad from arm pad frame.
See Figure 125.
Install
1. Install arm pad to arm pad frame with nut and
capscrew. See Figure 125.
169
Electronic-Hydraulic Controls, After January, 2020 2200 YRM 1142
Electronic-Hydraulic Controls, After January, 2020

NOTE: The information in this section applies to the Function Returns to Neutral Test
electronic-hydraulic controls used on lift truck models
GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/ Check to confirm function returns to neutral (0%). Use
GDC135VX, GC/GLC/GDC155VX) (F879), (G879) DSC or install the Service Tool to monitor functions.
manufactured after January, 2020.
1. Stroke each lever to full stroke, forward and
backward, and allow lever to snap back to center.
E-HYDRAULIC CONTROLS - TEST
Mini-Levers 2. (DO NOT start). Turn key switch to ON position.
Perform all of the following test procedures to be sure 3. Display the electro-hydraulic diagnostics menu on
mini-levers operate properly. the dash display panel.
See the User Interface - Service Technician manual, • Is each lever output = 0%?
located in the General section of this manual, for
• YES: Go to Step 4.
instructions to view Lever output Value, With Service
Password, view Diagnostics – Hydraulic Data Display • NO: Mini-lever is not working properly. See
– Hydraulic Input. procedures below for repair or replacement.
Upon completion, rerun the test.
Full Stroke Test 4. Operate each lever to full stroke forward and
Check for full stroke of mini-lever. Use the Display slowly release (1-2 seconds from full stroke).
Switch Cluster (DSC) or install the Service Tool to Read output when fully released.
monitor functions. • Is each lever output = 0%?
1. Stroke each lever to full stroke, forward and • YES: Go to Step 5.
backward, and allow lever to snap back to center. • NO: Mini-lever is not working properly. See
procedures below for repair or replacement.
2. (DO NOT start). Turn key switch to ON position. Upon completion, rerun the test.
3. Display the electro-hydraulic diagnostics menu on 5. Operate each lever to full stroke back and slowly
the dash display panel. Operate each lever to full release (1-2 seconds from full stroke). Read
stroke forward and read input. output when fully released.
• Is lever output ≥ -92%? • Is each lever output = 0%?
• YES: Go to Step 4. • YES: Mini-lever function is returning to neutral.
• NO: Mini-lever is not working properly. See • NO: Mini-lever is not working properly. See
procedures below for repair or replacement. procedures below for repair or replacement.
Upon completion, rerun the test. Upon completion, rerun the test.
4. Operate each lever to full stroke backward and 6. If mini-lever continues to not function properly,
read input. contact your local Yale dealer or see Yale
Axcess Online.
• Is lever output ≥ +92%?
• YES: Mini-lever is supplying full stroke. Push (Override) Button
• NO: Mini-lever is not working properly. See
1. Validate that push (override) button operates
procedures below for repair or replacement.
Upon completion, rerun the test. properly by operating applicable function.
5. If mini-lever continues to not function properly, 2. If system does not function, see procedures
contact your local Yale dealer or see Yale below for repair or replacement. Upon
Axcess Online. completion, rerun the test.
170
2200 YRM 1142 Electronic-Hydraulic Controls, After January, 2020
3. If push (override) button continues to not function

properly, contact your local Yale dealer or see
Yale Axcess Online.
GENERAL
WARNING
Before replacing any part of the electronic
hydraulic control assembly, fully lower all parts of
the mast and tilt it forward until the tips of forks
touch the ground. This action will prevent mast
accidently moved.
WARNING
Never wear any metallic items on your fingers,
arms, or neck. Metal items can accidently make an
electrical connection and cause an injury. 1. ARMREST
2. TO WIRE HARNESS
3. HORN BUTTON
4. DIRECTION CONTROL SWITCH
CAUTION 5. MINI-LEVERS
A short circuit and damage can occur if wires are 6. PUSH (OVERRIDE) BUTTONS
not installed correctly. Make sure wire connectors
Figure 126. E-Hydraulic Controls Arrangement
do not touch other metal terminals or wire
connectors, metal brackets, or bracket mounting
nuts. Make sure wires are not pulled tight and are MINI-LEVERS, REMOVE AND INSTALL
not touching other parts to damage the insulation.
CAUTION
NOTE: Prior to performing the following procedures,
The following procedure should only be performed
the E-Hydraulic Controls - TEST must be performed.
by Yale trained certified technicians. The removal
NOTE: The mini-levers do not need to be calibrated. and replacement of the mini-levers should be done
NOTE: The Direction Control Switch (DCS) is an in a clean environment whenever possible and on
optional feature on lift trucks equipped with electronic- an electrically grounded surface. Do not touch any
hydraulic controls. See Figure 126. printed circuit board (PCB) surface to prevent
damage from electrostatic voltage.
standard with manual hydraulic levers, but have the 1. Remove two capscrews and mini-lever from
option of using electronic-hydraulic controls. See armrest. See Figure 127.
Figure 126. If the Mini-Levers Module (MLM), or mini-
levers malfunction, replace with new part. See the
Parts Manual for replacement parts.
171
1. CAPSCREWS
2. MINI-LEVER
3. ARMREST
4. PUSH (OVERRIDE) BUTTON
NOTE: Before installing new mini-lever, check Parts

Manual for correct part number to be sure correct
mini-lever is being installed.
2. Install new mini-lever onto armrest using two
capscrews. See Figure 127.
ARMREST ASSEMBLY
Remove
1. Disconnect the battery.
2. Remove two capscrews and washers from cover

plate and remove seat box. Disconnect the main
Figure 127. Mini-Lever Removal
E-Hydraulic control wire harness from E-Hydraulic
armrest harness. See Figure 128.
172
NOTE: SOME COMPONENT PARTS AND ELECTRICAL CONNECTIONS OMITTED FOR CLARITY.
A. FULL SUSPENSION AND SWIVEL SEATS B. NON SUSPENSION SEATS
1. CAPSCREWS 4. E-HYDRAULIC ARMREST HARNESS

2. WASHERS CONNECTOR
3. SEAT BOX 5. COVER PLATE
Figure 128. Seat Box Cover Removal
3. Pull up on handle (see Figure 129) and slide

armrest all the way forward and remove flange
capscrew from under armrest mounting bracket
that attaches armrest to mounting bracket. Pull up
on handle and slide armrest all the way back and
remove the other flange capscrew. See
Figure 130.
Figure 129. Armrest Adjustment Handles
173
A. HANDLE MOVES ARMREST FORWARD OR

BACKWARD
B. HANDLE MOVES ARMREST UP OR DOWN

2. BOTTOM ARMREST COVER
Figure 131. Bottom Armrest Cover Removal
NOTE: The push (override) button is optional features

and lift truck may be equipped with more than one
1. E-HYDRAULIC CONTROL WIRE HARNESS push (override) button depending of the number of
2. FLANGE CAPSCREWS hydraulic functions on the lift truck. If lift truck is not
3. ARMREST equipped with this feature, there will be a plug
4. ARMREST MOUNTING BRACKET
5. HOLES FOR FLANGE CAPSCREWS covering the electrical connector on the PCB cassette.
6. Disconnect the push (override) button connector
Figure 130. E-Hydraulic Armrest and Mounting from PCB cassette. See Figure 132.
Bracket
7. Remove three socket screws from PCB cassette
5. Remove six socket head screws that fasten the and remove PCB cassette from armrest. See
bottom and top armrest covers together. See Figure 132.
Figure 131. Remove the bottom armrest cover
from armrest.
174
1. TO E-HYDRAULIC CONTROL WIRE HARNESS

3. PCB CASSETTE
4. PUSH (OVERRIDE) BUTTON CONNECTOR
Figure 132. PCB Cassette Removal NOTE: PUSH (OVERRIDE) BUTTON CONNEC-
TIONS NOT SHOWN FOR CLARITY.
Install 1. PHILLIPS HEAD SCREWS
1. Install PCB cassette to armrest with three socket 2. DIRECTION CONTROL SWITCH ADAPTER*
head screws. See Figure 132. 3. HORN BUTTON ADAPTER
4. PLUG
5. HORN SWITCH
2. If lift truck is equipped, connect the push 6. DIRECTION CONTROL SWITCH CONNECTOR
(override) button connector to PCB cassette. See 7. ARMREST
Figure 132. *Direction Control Switch is an optional feature.
3. Install bottom armrest cover to armrest with six Figure 133. Switch Arrangement and Connections,
socket head screws. See Figure 132. E-Hydraulic Mini-Levers
4. Install new armrest onto mounting bracket with Install

flange capscrews. Tighten flange capscrews to
1. Install new horn switch and two Phillips head
13 to 15 N•m (115 to 132 lbf in).
screws onto armrest. See Figure 133.
5. Connect E-hydraulic wire harness to armrest. See
Figure 130. Install seat box to cover plate with
two capscrews and washers. See Figure 128.
Tighten capscrews to 1.2 N•m (10.6 lbf in).
procedures.
DIRECTION CONTROL SWITCH
HORN BUTTON NOTE: The Direction Control Switch (DCS) is an
optional feature on lift trucks covered in this manual
Remove that are equipped with electro-hydraulic controls.
bracket. Remove bottom armrest and PCB Remove
cassette. See section Armrest Assembly for
removal procedures.
Remove bottom armrest cover. See section
Armrest Assembly for removal procedures.
2. Remove two Phillips head screws that attach horn
button to armrest. See Figure 133. Remove horn
button from armrest.
175
2. Remove Direction Control Switch (DCS) Push (Override) buttons and Toggle
assembly from armrest by compressing the clips Switch
on either side of the bezel and carefully pulling
the assembly out. Disconnect E-Hydraulic control On lift trucks equipped with E-Hydraulic controls, there
wiring harness from the Direction Control Switch. may be two optional push (override) buttons (green
See Figure 134. buttons) and a toggle switch (yellow button) located
behind the second, third, or fourth mini-lever. See
Figure 135. The push (override) button located behind
the second mini-lever is used to override the Return To
Set Tilt (RTST) function. By pressing this button, the
RTST parameters are overridden and the mast is
allowed to tilt unrestricted.
If the lift truck is equipped with three mini-levers and a
four function control valve, there will be a toggle switch
behind the third mini-lever. Pressing this switch allows
the third mini-lever to switch between the third and
fourth functions. If the lift truck is equipped with four
mini-levers and a five function control valve, the toggle
switch will be located behind the fourth mini-lever.
Pressing the switch allows the fourth mini-lever to
switch between the fourth and fifth functions.
If the lift truck is equipped with a clamp attachment,
the last mini-lever on the right controls the clamp
function. Behind this lever will be a push (override)
button. To engage the clamp, move the mini-lever
backward. To disengage the clamp, push the push
1. DIRECTION CONTROL SWITCH (override) button behind the mini-lever and move mini-
2. BEZEL lever forward.
3. ARMREST
4. E-HYDRAULIC CONTROL VALVE WIRING The different configurations of switches and buttons
HARNESS discussed in this section may not be found on your lift
truck.
Figure 134. Direction Control Switch Replacement
3. Remove DCS from bezel. See Figure 134.
Install
1. Insert new Direction Control Switch into bezel.
See Figure 134.
2. Connect E-Hydraulic control valve wiring harness

to the DCS. Install DCS assembly into armrest by
compressing clips on either side of the bezel and
pushing assembly into armrest until the clips
latch. See Figure 134.
3. Install armrest cover to armrest, and install

armrest to armrest mounting bracket. See section
Armrest Assembly for installation procedures.
176
NOTE: Tag wires prior to disconnecting them to aid in

reconnecting.
2. Pull the push (override) buttons or toggle switch
connectors apart to disconnect them from wire
3. If push (override) button is being replaced,

remove lock nut from back of green, round, push
button. Remove push (override) button from
armrest. See Figure 136.
NOTE: Note the position of the yellow, rectangular,

Figure 135.
4. If function selection button is being replaced:
NOTE: NOT ALL LIFT TRUCKS WILL HAVE ALL
a. Remove knurl nut. See Figure 136.
SWITCHES AND BUTTONS SHOWN.
b. Rotate red screw to left stop. Remove blue
1. MINI-LEVERS
2. PUSH (OVERRIDE) BUTTON (RTST) connector by sliding it from black cylinder. See
3. TOGGLE SWITCH Figure 136.
4. PUSH (OVERRIDE) BUTTON (CLAMP)
5. ARMREST HOUSING c. Remove toggle switch from armrest.
Figure 135. Push (Override) Buttons And Toggle

Switch Locations
Remove
cassette. See procedures in Armrest Assembly
section above.
177
1. CLAMP BUTTON CONNECTION 5. LOCK NUT

2. RTST CONNECTION 6. BLUE CONNECTOR
3. TOGGLE SWITCH CONNECTION 7. KNURL NUT
4. RED SCREW 8. BLACK CYLINDER
Figure 136. Push (Override) Buttons and Toggle Switch Replacement
178
Install 2. If installing a push (override) button:

1. If installing a new toggle switch: a. Install new green, round push (override) button
assembly through armrest housing.
a. Insert black cylinder portion of toggle switch
through armrest housing. b. Install and tighten lock nut to secure push
(override) button to armrest. See Figure 136.
b. Slide blue connector onto cylinder. See
Figure 136. c. Push the push (override) button connector to
wire harness. See Figure 136.
c. Rotate red screw to right stop.
d. Adjust position of yellow, rectangular toggle install armrest to armrest mounting bracket. See
switch. See Figure 135. Install and tighten the section Armrest Assembly for installation
knurl nut to secure toggle switch to armrest. procedures.
e. Apply Nye 760G grease (supplied in kit) to 4. Connect the E-hydraulic wire harness to armrest.
toggle switch connector. Push toggle switch See Figure 117.
connector to wire harness. See Figure 136.
179
Special Tools 2200 YRM 1142
Special Tools
Tool Name Applicable Model and Tool Size Illustration

Crankshaft A 92 mm (3.6 in.) radius
Position B 13.0 to 13.1 mm (0.0512 to 0.51 in.) dia.
Sensor
Measuring C 10.000 to 10.015 mm (0.39370 to 0.39429 in.) dia.
JIG 1 D 18 mm (0.71 in.) dia.
E 16 mm (0.63 in.)
F Chamfer 0.3 mm (0.01 in.)
G Chamfer 0.5 mm (0.02 in.)
H Chamfer 0.5 mm (0.02 in.)
I Chamfer 0.5 mm (0.02 in.)
J 5.0 to 5.05 mm (0.197 to 0.198 in.)
K 7.0 mm (0.28 in.)
L 39.990 to 40.010 mm (1.5744 to 1.5751 in.)
M 50 mm (2.0 in.)
N 5.0 mm (0.20 in.) radius
O 0.35 rad (20°)
P 0.35 rad (20°)
Q 2.0 mm (0.079 in.)
R 18.380 to 18.393 mm (0.72363 to 0.72413 in.) dia.
S 92 mm (3.6 in.) radius
T Chamfer 0.5 mm (0.02 in.)
U 11 mm (0.43 in.)
V 13 mm (0.51 in.) radius
W 80.0 mm (3.1 in.) dia.
X 8.0 mm (0.31 in.) radius
Y 6.5 mm (0.26 in.) dia.
Z 19.5 mm (0.768 in.)
a 12.8 to 12.9 mm (0.504 to 0.507 in.) dia.
b Chamfer 0.3 mm (0.01 in.)
c Chamfer 0.5 mm (0.02 in.)
d 0.4 mm (0.02 in.) radius
e 12.8 to 12.9 mm (0.504 to 0.507 in.) dia.
f 4.95 to 5.00 mm (0.195 to 0.196 in.) dia.
g 2.0 mm (0.079 in.)
h 0.35 rad (20°)
i 9.978 to 9.987 mm (0.3929 to 0.3931 in.)
Locally Manufactured
180
2200 YRM 1142 Special Tools
Tool Name Applicable Model and Tool Size Illustration

Crankshaft A 8.0 mm (0.31 in.) dia. reamer
Position B 22 mm (0.866 in.)
Sensor
Measuring C M4 X Pitch 0.7
JIG 2 D 6.5 mm (0.26 in.)
E 34.0 mm (1.34 in.)
F 35 mm (1.14 in.) radius
G 20 mm (0.79 in.) radius
H 68.0 mm (2.68 in.)
Locally Manufactured
Crankshaft
Position
Sensor Air
Gap Tool -
JIG 1 and
JIG 2 Yale P/N 582020863
181
2200 YRM 1142 8/21 (6/21)(1/20)(7/19)(12/18)(11/16)

524223772-2200YRM1142-(08-2021)-UK-EN

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Maintenance

PART NO. 524223772 2200 YRM 1142

©2021 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ LPG Fuel System, Kubota 3.8L SI Engine

Periodic Maintenance 8000YRM1248 for lift truck

Display Switch Cluster

2. Lift up on steering wheel slightly and pull up on tilt

NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH

1. UPPER STEERING COLUMN COVER 3. LOWER STEERING COLUMN COVER

Figure 2. Upper Steering Column Cover Removal

4. Remove horn button and disconnect horn wires.

NOTE: A puller tool may be required to remove

Legend for Figure 3.

6. Disconnect Display Switch Cluster harness from

Figure 3. Steering Wheel Removal

NOTE: TOP DOWN VIEW SHOWN.

1. BOLTS 3. STEERING COLUMN

Figure 4. Display Switch Cluster Removal

INSTALL 5. Install upper steering column cover by aligning

1. DIRECTION CONTROL AND TURN SIGNAL 3. DISPLAY SWITCH CLUSTER

Figure 5. Direction Control and Turn Signal Removal

2. Pry spring tab toward body of direction control Install

3. Repeat previous steps on opposite side of

KEY SWITCH • GLP/GDP80VX, GLP/GDP80VX9, GLP/

1. BEZEL 4. TORX HEAD SCREW

Install careful to not damage bezel and overlay when

DISPLAY SWITCH CLUSTER PANEL

Steering Column Repair

2. Remove upper steering column cover by pulling

Figure 7. Lower Steering Column Cover Removal

Figure 8. Steering Column Disassembly

DISASSEMBLE 5. Install upper steering column cover by aligning

Sensors and Switches

Dash and Kick Panel, Remove and Install

1. KICK PANEL 3. FASTENERS

Figure 9. Dash and Kick Panel Removal

Install ACCELERATOR PEDAL POSITION

• GLP/GDP80VX, GLP/GDP80VX9, GLP/

2. Remove upper steering column cover and dash

NOTE: Lift truck model shown below is equipped only

Legend for Figure 11.

6. Remove two pan head screws, lockwashers, and

Figure 11. Accelerator Pedal and Throttle Base

NOTE: ELECTRONIC HYDRAULIC CONTROL VALVE SHOWN.

1. ACCELERATOR PEDAL POSITION SENSOR 6. BOLTS (THROTTLE BASE PLATE)

Figure 12. Accelerator Pedal Position Sensor

Install • GLP/GDP16VX, GLP/GDP18VX, GLP/

• GLP/GDP80VX, GLP/GDP80VX9, GLP/ •

• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

1. SERVICE BRAKE PRESSURE SENSOR

Figure 14. Brake Fluid Level Switch, Service Brake

• GC/GLC030VX, GC/GLC035VX, GC/ Periodic Maintenance 8000YRM1319 for lift

• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ Legend for Figure 15.

NOTE: SERVICE BRAKE PEDAL POSITION SEN-

1. MOUNTING BRACKET CAPSCREW

4. Remove mounting bracket capscrew, mounting