Yale Forklift F878 (GPGLPGDP135-155VX) Service Manual – PDF DOWNLOAD

Yale Forklift F878 (GPGLPGDP135-155VX) Service Manual – PDF DOWNLOAD

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Yale Forklift F878 (GPGLPGDP135-155VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5198
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift F878 (GPGLPGDP135-155VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524208014 2200YRM1097 (03 2020) US EN 23
Series Code / Model Designation Reference Table 27
Description 28
Distributor Ignition (DI) System 28
Crankshaft Position (CKP) Sensor 28
Camshaft Position (CMP) Sensor 28
Ignition Coil and Ignition Control Module (ICM) 28
Secondary Ignition Components 28
Spark Plugs and Wires 29
Spark Plug Wire Inspection 29
Spark Plug Wire Replacement 29
Remove 29
Install 30
Spark Plug Inspection 30
Usage 30
Inspection 30
Visual Inspection 32
Spark Plug Replacement 32
Remove 32
Install 32
Distributor Repair 33
Inspect 33
Overhaul 33
Disassemble 33
Assemble 36
Replace 37
Remove 37
Install Procedure 1 39
Install Procedure 2 40
Ignition Coil Replacement 41
Remove 41
Install 41
Ignition Control Module Replacement 42
Remove 42
Install 42
Starter Replacement 43
Remove 43
Install 46
Sensors and Switches 47
Gas and LPG Trucks 47
Crankshaft Position (CKP) Sensor 47
Remove 47
Install 47
Camshaft Position (CMP) Sensor 48
Remove 48
Install 50
Oil Pressure Sensor 50
Remove 50
Install 51
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 52
Remove 52
Install 52
Engine Coolant Temperature (ECT) Sensor 53
Remove 53
Install 54
Air Flow Restriction Switch 54
Remove 54
Install 55
Specifications and Special Tools 56
524221866 9000YRM1112 (10 2020) US EN 61
SECTION 9010 Operational Diagnostic Procedures 77
Group 05 – Operational Checkout 79
SECTION 9020 Engine 97
Group 10 – Principles of Operation 107
Group 30 – Observed Symptoms 305
Group 40 – Tests and Adjustments 407
SECTION 9030 Electrical System 439
Group 03 – General Maintenance and Diagnostic Data 463
Group 10 – Principles of Operation 557
Group 20 – Diagnostic Trouble Codes 581
Group 30 – Observed Symptoms 1553
SECTION 9040 Drive Train 1609
Group 10 – Principles of Operation 1613
Group 30 – Observed Symptoms 1669
Group 40 – Tests and Adjustments 1719
SECTION 9050 Hydraulic Systems 1729
Group 10 – Principles of Operation 1733
Group 30 – Observed Symptoms 1791
Group 33 – Observed Symptoms-Gear Pump 1793
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1881
Group 40 – Tests and Adjustments 1925
Group 43 – Tests and Adjustments-Gear Pump 1927
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1951
SECTION 9060 Operators Station 1969
Group 10 – Principles of Operation 1971
SECTION 9070 Front End (Mast) and Chassis 2007
Group 10 – Principles of Operation 2009
Group 30 – Observed Symptoms 2031
SECTION 9080 Supplementary Data 2089
Group 50 – Abbreviations and Acronyms 2091
Group 60 – Special Tools List 2099
Group 70 – Fault Mode Indicator Reference 2109
Group 80 – Supplier Specification Data 2111
524223769 2200YRM1128 (01 2023) US EN 2115
Series Code / Model Designation Reference Table 2123
General 2125
Deutsch Crimping Tool 2126
How to Strip a Wire for Use With Deutsch Crimping Tool 2126
How to Crimp With the Deutsch Crimping Tool 2127
Calibration Test for the Deutsch Crimping Tool 2129
Deutsch Connectors 2131
DT, DTM, and DTP Series Connectors 2131
HD Series Connectors 2174
Metri-Pack Connectors 2196
Remove and Install 2196
Micro-Pack Connectors 2199
Weather-Pack Connectors 2200
AMPSEAL Crimping Tools 2202
AMP Hand Crimping Tool With Certi-Crimp 2202
Description 2202
Stripping Wire for Use with AMP Hand Crimping Tool 2203
Insulation Crimp Adjustment 2204
Maintenance and Inspection for AMP Hand Crimping Tool 2204
AMP Hand Crimping Tool 2204
Crimp Height Inspection 2204
How to use AMP Hand Crimping Tool 2205
AMP Pro-Crimper II Tool 2205
Description 2205
Remove and Install Die Set and Locator Assembly 2206
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2206
Contact Support Adjustment 2207
Crimp Height Adjustment 2208
Maintenance and Inspection Procedures 2208
PRO-CRIMPER II Tool 2208
Crimp Height Inspection 2208
How to Use AMP PRO-CRIMPER II Tool 2209
AMPSEAL Connector Assemblies 2210
Description for Plug Connector Assembly 2210
Seal Plug 2211
Contact Crimping 2211
Description for Plug Connector and Header Assembly 2216
Voltage Reading 2219
Seal Plug 2219
Contact Crimping 2219
AMP Superseal 1 5 Crimping Tools 2226
Mini Mic Receptacle and Tab Contacts 2226
Description 2226
Crimping Conditions and Measurements 2226
Insertion of Rubber Seal on Cable 2228
AMP Hand Application Tool 2233
Description 2233
Maintenance and Inspection 2233
Crimp Height Inspection 2233
Crimp Height Adjustment 2234
How to Use AMP Hand Application Tool 2234
AMP Pro-Crimper II Tool 2235
Description 2235
Remove and Install Die Set and Locator Assembly 2235
Adjustments 2236
Contact Support 2236
Crimp Height 2237
Inspections and Maintenance 2238
Crimp Height Inspection 2238
Visual Inspection 2238
Maintenance 2239
How to Use Pro-Crimper II Tool 2239
AMP Superseal 1 5 Connector Assemblies 2240
Description 2240
Repair and Maintenance 2247
Panel Mount Option 2247
AMP Fastin-Faston Hand Tools 2248
Description – AMP Double Action Hand Tool 2248
Maintenance and Inspection Procedures 2248
Daily Maintenance 2248
Periodic Tool Inspection 2249
Lubrication 2249
Visual Inspection 2249
Crimp Height Inspection 2249
Certi-Crimp Ratchet Inspection 2250
How to Use AMP Double Action Hand Tool 2251
Description – AMP Extraction Tool 2252
Maintenance and Inspection 2253
How to Use AMP Extraction Tool 2253
AMP Fastin-Faston Receptacles and Housings 2255
Description 2255
Wire Repair 2263
Wire Splicing Requirements 2263
Deutsch Jiffy Splice 2264
Twisted/Shielded Cable and Leads Repair 2270
Special Tools 2272
524223769 2200YRM1128 (07 2020) US EN 2281
Series Code / Model Designation Reference Table 2287
General 2290
Deutsch Crimping Tool 2290
How to Strip a Wire for Use With Deutsch Crimping Tool 2290
How to Crimp With the Deutsch Crimping Tool 2291
Calibration Test for the Deutsch Crimping Tool 2293
Deutsch Connectors 2295
DT, DTM, and DTP Series Connectors 2295
HD Series Connectors 2337
Metri-Pack Connectors 2360
Remove and Install 2360
Micro-Pack Connectors 2362
Weather-Pack Connectors 2363
AMPSEAL Crimping Tools 2365
AMP Hand Crimping Tool With Certi-Crimp 2365
Description 2365
Stripping Wire for Use with AMP Hand Crimping Tool 2365
Insulation Crimp Adjustment 2366
Maintenance and Inspection for AMP Hand Crimping Tool 2366
AMP Hand Crimping Tool 2366
Crimp Height Inspection 2366
How to use AMP Hand Crimping Tool 2367
AMP Pro-Crimper II Tool 2367
Description 2367
Remove and Install Die Set and Locator Assembly 2368
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2369
Contact Support Adjustment 2369
Crimp Height Adjustment 2370
Maintenance and Inspection Procedures 2370
PRO-CRIMPER II Tool 2370
Crimp Height Inspection 2370
How to Use AMP PRO-CRIMPER II Tool 2371
AMPSEAL Connector Assemblies 2372
Description for Plug Connector Assembly 2372
Seal Plug 2373
Contact Crimping 2373
Description for Plug Connector and Header Assembly 2378
Voltage Reading 2380
Seal Plug 2380
Contact Crimping 2380
AMP Superseal 1 5 Crimping Tools 2387
Mini Mic Receptacle and Tab Contacts 2387
Description 2387
Crimping Conditions and Measurements 2387
Insertion of Rubber Seal on Cable 2389
AMP Hand Application Tool 2394
Description 2394
Maintenance and Inspection 2394
Crimp Height Inspection 2394
Crimp Height Adjustment 2395
How to Use AMP Hand Application Tool 2395
AMP Pro-Crimper II Tool 2396
Description 2396
Remove and Install Die Set and Locator Assembly 2397
Adjustments 2397
Contact Support 2397
Crimp Height 2398
Inspections and Maintenance 2399
Crimp Height Inspection 2399
Visual Inspection 2399
Maintenance 2400
How to Use Pro-Crimper II Tool 2400
AMP Superseal 1 5 Connector Assemblies 2401
Description 2401
Repair and Maintenance 2408
Panel Mount Option 2408
AMP Fastin-Faston Hand Tools 2409
Description – AMP Double Action Hand Tool 2409
Maintenance and Inspection Procedures 2409
Daily Maintenance 2409
Periodic Tool Inspection 2410
Lubrication 2410
Visual Inspection 2410
Crimp Height Inspection 2410
Certi-Crimp Ratchet Inspection 2411
How to Use AMP Double Action Hand Tool 2412
Description – AMP Extraction Tool 2413
Maintenance and Inspection 2413
How to Use AMP Extraction Tool 2414
AMP Fastin-Faston Receptacles and Housings 2415
Description 2415
Wire Repair 2422
Wire Splicing Requirements 2422
Deutsch Jiffy Splice 2423
Twisted/Shielded Cable and Leads Repair 2428
Special Tools 2431
524223770 2200YRM1130 (03 2020) US EN 2439
General 2443
Description 2443
Dash Display Menu Access 2443
Menu Navigation 2444
Standard Display 2444
Main Menu 2444
Passwords Menu 2445
Password Administration 2445
Add Password 2445
Delete Password 2446
Edit Password 2446
Other Password Functions 2447
Operator Passwords – Enable/Disable 2447
Password Time-Out Delay 2447
Passwords – Number Wrong to Disable 2448
Lockout Reset Password 2448
View Password Log 2449
View Versions 2450
VSM Versions 2450
Dash Display Versions 2451
Engine Controller Version 2452
Transmission (Xmsn) Controller Version 2453
Truck Serial Number 2454
Diagnostics 2455
View Fault Log 2455
Set Travel and Braking 2456
Speed Limit 2456
Acceleration Rate 2457
Auto-Deceleration Rate 2457
Set Power Reversal Rate 2458
Set Inching/Brake Overlap 2459
Setup Display Menu 2460
Set Operator Language 2460
Set Units 2461
Set Time Format (12/24 Hour) 2461
Set Daylight Saving Time 2461
Set Time 2464
Set Date Format 2465
Set Date 2465
Setup Hydraulics 2466
Return to Set Tilt Delay/On/Off 2466
Setup General Items 2467
Light Shutdown Time-Out 2467
Impact Sensor – Enable/Disable 2468
Impact Sensor – Soft Impact Settings 2469
Impact Sensor – Hard Impact Settings 2470
Adjust Impact Sensor Settings 2470
Initial Adjustment of Soft and Hard Impact Settings 2472
Readjustment of Soft and Hard Impact Settings 2472
Impact Sensor – Impact Alarm/Shutdown Reset 2473
Impact Sensor – Alarm Time Duration and Deactivation 2474
Impact Sensor – View Impact Event Log 2475
Engine Mode Indicator 2476
Generation 1 (ECO-eLo ONLY) 2476
Generation 2 2477
Operator Checklist 2478
Operator Checklist Off-On Mode 2478
Edit Operator Checklist 2478
Set Operator Checklist Expiration 2479
View Checklist Log 2479
Clear Operator Checklist Log 2480
Clear Operator Checklist Fault 2480
Calibrations 2481
Set Tilt Stop Point 2481
Calibrate Loaded Weight 2481
524223771 2200YRM1131 (03 2020) US EN 2483
Series Code / Model Designation Reference Table 2489
General 2491
Description 2491
Dash Display Menu Access 2491
Menu Navigation 2492
Main Menu 2492
Passwords 2493
Adding Passwords 2493
Hourmeters 2495
View Versions 2496
VSM Versions 2496
Dash Display Versions 2497
Engine Controller Version 2498
Transmission (Xmsn) Controller Version 2499
Truck Serial Number 2500
Truck Configuration 2501
Diagnostics 2502
Clear Fault Log 2502
View Fault Log 2503
No-Run Data Display 2504
Engine Accelerator and Throttle Data Display 2504
Engine Speeds and Governor Data Display 2505
Engine Fuel and Emissions Data Display 2506
Engine General Data Display 2508
XMSN/Brake Data Display 2509
Hydraulic Data Display 2512
General Truck Data Display 2514
Set Travel and Braking 2515
Speed Limit 2515
Acceleration Rate 2516
Auto-Deceleration Rate 2517
Set Power Reversal Rate 2517
Set Inching/Brake Overlap 2518
Setup Hydraulics 2518
Lift Maximum Speed 2519
Lower Maximum Speed 2519
Tilt Maximum Speed 2520
Auxiliary Function One, Direction A, Maximum Speed 2522
Auxiliary Function One, Direction B, Maximum Speed 2524
Auxiliary Function Two, Direction A, Maximum Speed 2524
Auxiliary Function Two, Direction B, Maximum Speed 2525
Auxiliary Function Three, Direction A, Maximum Speed 2526
Auxiliary Function Three, Direction B, Maximum Speed 2526
Lift/Lower Ramp Rate 2527
Hydraulic Auxiliary Ramp Rate 2527
Return to Set Tilt Delay/On/Off 2528
Hydraulic Input Device 2529
Auxiliary Solenoid 2529
Dual Function 2530
Setup Display 2531
Set Service Language 2531
Setup General Items 2531
Motion Alarm Activation Type 2532
Light Shutdown Time-Out 2533
Restore Default Settings 2533
Restore Engine Controller Default Calibration 2534
Impact Sensor – Enable/Disable 2534
Impact Sensor – Soft Impact Settings 2535
Impact Sensor – Hard Impact Settings 2536
Adjust Impact Sensor Settings 2537
Initial Adjustment of Soft and Hard Impact Settings 2539
Readjustment of Soft and Hard Impact Settings 2539
Impact Sensor – Impact Alarm/Shutdown Reset 2540
Impact Sensor – Alarm Time Duration and Deactivation 2541
Impact Sensor – View Impact Event Log 2542
Engine Mode Indicator 2542
Generation 1 (ECO-eLo ONLY) 2542
Generation 2 2543
Diesel Particulate Filter (DPF) Display 2544
General Description 2544
Passive Regeneration Only 2544
Regeneration Level 0 2544
Auto/Active Regeneration Inhibited 2545
Auto/Active Regeneration 2545
Regeneration Level 1 2545
Parked Regeneration Request 2546
Regeneration Level 2 2546
Warning Level 2546
Regeneration Level 3 2546
Service Level 2547
Regeneration Level 4 2547
Display, Diesel Particulate Filter (DPF), Revised 2547
Operator Interface 2547
Refer to Operator Manual 2547
CAN Communication Lost 2548
Passive Regeneration Only 2548
Regeneration Level 0 2548
Auto/Active Regeneration Inhibited 2548
Auto/Active Regeneration 2549
Regeneration Level 1 2549
Idle-up Auto/Active Regeneration 2549
Parked Regeneration Request 2549
Regeneration Level 2 2549
Warning Level 2551
Regeneration Level 3 2551
Service Level 2551
Regeneration Level 4 2551
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2551
Display, Diesel Particulate Filter (DPF), Stage V Engine 2551
Operator Interface 2552
Refer to Operator Manual 2552
CAN Communication Lost 2552
Passive Regeneration Only 2552
Regeneration Level 0 2552
Auto/Active Regeneration Inhibited 2553
Auto/Active Regeneration 2553
Regeneration Level 1 2553
Idle-up Auto/Active Regeneration 2554
Parked Regeneration Request 2554
Regeneration Level 2 2554
Warning Level 2555
Regeneration Level 3 2555
Service Level 2556
Regeneration Level 4 2556
Stage V Content 2556
Emissions System Malfunction 2556
Ash Load 2556
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2557
Operator Interface 2557
Refer to Operator Manual 2557
CAN Communication Lost 2558
Passive Regeneration Only 2558
Regeneration Level 0 2558
Auto/Active Regeneration Inhibited 2558
Auto/Active Regeneration 2559
Regeneration Level 1 2559
Idle-up Auto/Active Regeneration 2559
Parked Regeneration Request 2559
Regeneration Level 2 2559
Warning Level 2561
Regeneration Level 3 2561
Service Level 2561
Regeneration Level 4 2561
Calibrations 2562
Calibrate Transmission Valve 2564
Set Tilt Stop Point 2564
Calibrate Loaded Weight 2564
Calibrate Travel Speed Sensor 2565
Calibrate Mazda LP and Gas Accelerator Pedal 2565
524223780 8000YRM1134 (05 2022) US EN 2567
Series Code / Model Designation Reference Table 2573
Description 2576
Proc_Cal_001: Service Password Entry 2578
When to Perform 2578
Why Perform 2578
How to Perform 2578
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2579
When to Perform 2579
Calibration Order 2579
Why Perform 2579
How to Perform 2579
Proc_Cal_003: Save and Exit 2581
When to Perform 2581
Why Perform 2581
How to Perform 2581
Proc_Cal_004: Lift Valve Output Threshold 2582
When to Perform 2582
Calibration Order 2582
Why Perform 2582
How to Perform 2582
Proc_Cal_005: Lower Valve Output Threshold 2585
When to Perform 2585
Calibration Order 2585
Why Perform 2585
How to Perform 2585
Proc_Cal_006: Tilt Back Valve Output Threshold 2588
When to Perform 2588
Calibration Order 2588
Why Perform 2588
How to Perform 2588
Proc_Cal_007: Tilt Forward Valve Output Threshold 2591
When to Perform 2591
Calibration Order 2591
Why Perform 2591
How to Perform 2591
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2594
When to Perform 2594
Calibration Order 2594
Why Perform 2594
How to Perform 2594
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2597
When to Perform 2597
Calibration Order 2597
Why Perform 2597
How to Perform 2597
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2600
When to Perform 2600
Calibration Order 2600
Why Perform 2600
How to Perform 2600
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2603
When to Perform 2603
Calibration Order 2603
Why Perform 2603
How to Perform 2603
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2606
When to Perform 2606
Calibration Order 2606
Why Perform 2606
How to Perform 2606
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2609
When to Perform 2609
Calibration Order 2609
Why Perform 2609
How to Perform 2609
Proc_Cal_014: Load Weight Zero Point 2612
When to Perform 2612
Calibration Order 2612
Why Perform 2612
How to Perform 2612
Proc_Cal_015: Loaded Weight Calibration 2614
When to Perform 2614
Calibration Order 2614
Why Perform 2614
How to Perform 2614
Proc_Cal_016: Transmission Valve Calibration 2617
Applicable System/Option 2617
When to Perform 2617
Calibration Order 2617
Why Perform 2617
How to Perform 2617
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2619
Applicable System/Option 2619
When to Perform 2619
Calibration Order 2619
Why Perform 2619
How to Perform 2619
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2622
Applicable System/Option 2622
When to Perform 2622
Calibration Order 2622
Why Perform 2622
How to Perform 2622
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2625
Required Tools 2625
When to Perform 2625
Calibration Order 2625
Why Perform 2625
How to Perform 2625
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2627
When to Perform 2627
Why Perform 2627
How to Perform 2627
Proc_Cal_026: Travel Speed Calibration 2629
When to Perform 2629
Calibration Order 2629
Why Perform 2629
How to Perform 2629
524265337 0600YRM1251 (09 2015) US EN 2633
General 2639
Engine Removal and Installation 2639
Cylinder Head Repair 2639
Remove and Disassemble 2639
Clean and Inspect 2641
Valve Oil Seals 2644
Remove and Disassemble 2644
Cylinder Leak Down Test 2644
Clean and Inspect 2645
Assemble and Install 2645
Valve Guides and Seats, Repairs 2647
Valves, Repair 2647
Valve Seats, Repair 2648
Valve Springs 2649
Assemble and Install 2650
Engine Block Cleaning and Inspection 2653
Clean and Inspect 2654
Piston Bore Preparation 2656
Engine Mounts Installation 2656
Remove 2656
Clean and Inspect 2657
Install 2657
Lubrication System Repair 2658
Oil Pump, Remove and Disassemble 2658
Clean and Inspect 2659
Oil Pump, Assemble and Install 2660
Oil Pan, Install 2662
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 2664
Timing Cover 2664
Remove 2664
Install 2666
Timing Sprockets 2666
Remove 2666
Install 2666
Camshaft 2666
Remove 2666
Inspect 2667
Install 2667
Balance Shaft 2668
Remove 2668
Install 2669
Valve Lifters 2670
Remove 2670
Clean and Inspect 2670
Install 2671
Crankshaft Repair 2671
Remove 2672
Inspect and Repair 2672
How to Check Clearance Between Main Bearings and Their Journals 2673
Install 2674
Piston and Connecting Rod Assemblies Repair 2676
Connecting Rod Bearings, Replace 2676
Piston and Connecting Rod Assemblies, Remove 2677
Disassemble 2677
Piston, Clean and Inspect 2678
Cylinder Bores, Inspect and Repair 2678
Piston Rings 2679
Assemble 2680
Piston and Connecting Rod Assemblies, Install 2680
Flywheel and Flywheel Housing Repair 2680
Flywheel, Remove 2681
Clean 2681
Inspect 2681
Flywheel, Install 2682
Coolant Pump Repair 2682
Remove 2682
Clean and Inspect 2683
Install 2683
Thermostat Replacement 2683
Remove 2684
Thermostat Operation Check 2684
Install 2684
Starter Replacement 2685
2685
Remove 2685
Install 2688
Fan Assembly Replacement 2689
Remove 2689
Inspect 2691
Install 2691
Drive Belt Installation 2692
Remove 2692
Clean 2692
Inspect 2692
Installation 2693
Compression Check 2694
Engine Specifications 2694
Engine Data 2694
Cylinder Head 2694
Hydraulic Valve Lifter 2695
Camshaft 2695
Pistons 2695
Crankshaft 2696
Connecting Rods 2696
Balance Shaft 2697
Cooling System 2697
Lubrication System 2697
Torque Specifications 2698
524288194 1300YRM1317 (03 2020) US EN 2703
Transmission Repair 2707
Remove 2707
Torque Converter, Remove 2707
Disassemble 2708
Clean and Inspect 2757
Housings 2757
Oil Seals and Gaskets 2757
Bearings 2757
Gears and Shafts 2758
Assemble 2758
Torque Converter, Install 2799
Install 2800
Control Valve Repair 2801
Remove 2801
Disassemble 2801
Clean 2803
Inspect 2803
Assemble 2803
Install 2804
Torque Specification 2805
524294873 1300YRM1343 (11 2019) US EN 2807
Transmission Repair 2811
Remove 2811
Torque Converter, Remove 2811
Disassemble 2812
Clean and Inspect 2852
Housings 2852
Oil Seals and Gaskets 2852
Bearings 2853
Gears and Shafts 2853
Assemble 2853
Torque Converter, Install 2891
Install 2892
Control Valve Repair 2893
Remove 2893
Disassemble 2893
Control Valve Assembly 2893
Control Valve Body 2893
Clean 2896
Inspect 2896
Assemble 2896
Control Valve Body 2896
Control Valve Assembly 2896
Install 2897
Torque Specification 2899
524296605 1400YRM1344 (03 2020) US EN 2901
General 2905
Identification Plate 2905
Drive Axle Removal 2905
Planetary Reduction Gear Repair 2917
Clean and Inspect 2927
Brake Repair 2936
Clean and Inspect 2949
Wet Brake Noise Reduction 2959
General 2959
Adding Additive To Transmission 2960
Differential Repair 2961
Clean and Inspect 2972
Bevel Pinion 2984
Clean and Inspect 2988
Drive Axle Installation 2998
Special Tools 3009
Torque Specifications 3010
550043871 0900YRM1556 (04 2018) US EN 3013
General 3017
LPG Tank and Bracket 3017
LPG Tank, Lift Truck Models GLC40-55VX; GLC55SVX; GLC080-120VX; GLC080-100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818), GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 3017
Remove 3017
Install 3025
LPG Tank Bracket, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 3026
Remove 3026
Install 3028
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 3028
Remove 3028
Install 3030
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 3030
Remove 3030
Install 3030
LPG Tank Bracket Alignment Pin, Lift Truck Models GLC40-55VX; GLC55SVX (GLC080-120VX; GLC080-100VXBCS, GLC120SVX; GLC120VXPRS) (E818, F818), GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (F813, G813, H813, J813, K813), and GLC60-70VX (GLC135-155VX) (D879, E879, F879) 3031
Remove 3031
Install 3033
Fuel Filter Unit 3033
Fuel Filter Element 3034
Remove 3034
Clean and Inspect 3034
Install 3035
Fuel Filter Housing with LP Vapor Sensor 3035
Remove 3035
Disassemble 3037
Clean and Inspect 3038
Assemble 3038
Install 3039
Throttle Body 3040
Remove 3040
Clean 3044
Install 3044
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 3045
Remove 3045
Install 3046
Control System 3046
Engine Control Unit (ECU) 3047
Remove 3047
Install 3048
Low Pressure Switch 3048
Remove 3048
Install 3048
Low Fuel Sensor 3049
Remove 3049
Install 3049
LP Converter 3050
Remove and Disassemble 3050
Assemble and Install 3051
LPG Lock-Off 3051
Remove 3052
Install 3053
Exhaust System 3054
Counterweight Exhaust 3054
Remove and Disassemble 3054
Inspect 3056
Assemble and Install 3056
Overhead Exhaust 3057
Remove and Disassemble 3057
Inspect 3059
Assemble and Install 3059
Exhaust Manifold 3059
Remove 3059
Install 3061
Oxygen (HEGO) Sensor 3061
Remove 3061
Install 3061
LPG Fuel Testing 3062
General 3062
Available Fuel Tests 3062
Composition Test (ASTM D-2163) 3062
Ammonia Test (ASTM D-4490) 3062
Basic Nitrogen Test (ASTM UOP269-90) 3062
Residues Test (ASTM D-2158) 3062
Vapor Pressure Test (ASTM D-2598) 3062
Sulfur Compounds Test (ASTM D-5623) 3062
Methanol Test (ASTM D-4864) 3063
Copper Corrosion (ASTM D-1838) 3063
Where To Send LPG Fuel Samples For Testing 3063
550055279 0600YRM1579 (11 2019) US EN 3067
General 3073
Engine Identification 3073
Major Engine Component Identification 3073
Location of Labels 3073
Crankcase Description 3074
Engine Removal and Installation 3075
Cylinder Head Assembly Repair 3075
Valve Covers and Fuel Injectors 3075
Remove 3075
Clean and Inspect 3079
Install 3080
Rocker Arm Assembly 3081
Remove 3081
Disassemble 3083
Clean and Inspect 3083
Push Rods 3083
Rocker Arm Assembly 3083
Assemble 3084
Install 3084
Valve Clearance Adjustments 3084
Cylinder Head Assembly 3085
Remove 3085
Disassemble 3093
Valves and Valve Springs, Remove 3093
Valve Guides, Remove 3095
Clean and Inspect 3095
Cylinder Head 3096
Valve Guides 3096
Valves 3096
Valve Sink 3097
Valve Seat 3097
Valve Springs 3097
Assemble 3098
Valve Guides, Install 3098
Valves and Valve Springs, Install 3098
Install 3099
Timing Gear Case and Timing Gears Repair 3104
Timing Gear Case Cover 3104
Remove 3104
Clean and Inspect 3104
Install 3105
Timing Gears 3106
Crankshaft Gear 3106
Remove 3106
Install 3106
Idler Gear 3106
Remove 3106
Inspect 3107
Install 3107
Camshaft Gear 3107
Remove 3107
Install 3108
Timing Gear Case 3108
Remove 3108
Clean and Inspect 3109
Install 3109
Drive Train, Camshaft, and Cylinder Block Repair 3109
Remove 3109
Disassemble 3110
Pistons and Connecting Rods 3110
Crankshaft 3111
Camshaft 3113
Clean and Inspect 3114
Cylinder Block 3115
Honing and Boring 3117
Cylinder Correction (Oversize) 3118
Pistons 3118
Piston Pin 3119
Connecting Rod 3119
Tappets 3119
Crankshaft 3120
Camshaft 3122
Camshaft Bushing 3123
Assemble 3123
Camshaft 3123
Crankshaft 3123
Pistons and Connecting Rods 3123
Install 3125
Lubrication System Repair 3126
Engine Oil and Oil Filter Change 3126
Oil Pan 3127
Remove 3127
Install 3128
Oil Suction Tube 3128
Remove 3128
Clean 3129
Install 3129
Oil Pump 3129
Remove 3129
Clean and Inspect 3129
Outer Rotor Outside Clearance 3130
Outer Rotor to Inner Rotor Tip Clearance 3130
Outer Rotor Side Clearance 3130
Rotor Shaft Clearance 3131
Install 3131
Fuel System Repair 3132
Fuel Injectors 3132
Remove 3132
Inspect 3132
Clean 3132
Replace 3132
Install 3132
Electronic Throttle System 3132
Remove 3132
Throttle Position Sensor Proceedures After September 2018 GDP60-70VX (GDP135-155VX) (F878), GDP60VX, GDP70VX, GP70VXS6 (GDP135VX GDP155VX, GP155VXS) (G878), and GP080VX, GP090VX, GP100VX, GP100VX, GP120VX, (GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5, GDP50VX, GDP55VX) (K813) 3136
Bearing Replacement 3136
Install 3137
Adjustment 3138
Fuel Injection Pump 3138
Remove 3138
Disassemble 3142
Clean and Inspect 3144
Assemble 3144
Install 3145
Cooling System Repair 3146
Serpentine Belt 3146
Remove 3146
Inspect 3146
Install 3146
Serpentine Belt, Adjustment 3146
Water Pump 3147
Remove 3147
Install 3149
Thermostat 3150
Remove 3150
Inspect 3151
Install 3151
Flywheel and Flywheel Housing 3152
Flywheel 3152
Remove 3152
Install 3153
Flywheel Housing 3153
Remove 3153
Install 3153
Electrical Equipment Repair 3153
Alternator 3153
Remove 3153
Install 3154
Starter 3155
Remove 3155
Install 3155
Engine Specifications 3157
Engine Data 3157
Engine Tuning 3158
Cylinder Head 3158
Intake/Exhaust Valve and Guide 3159
Valve Spring 3159
Rocker Arm and Shaft 3159
Push Rod 3159
Gear Train and Camshaft 3160
Camshaft 3160
Idle Gear Shaft and Bushing 3160
Backlash of Each Gear 3160
Cylinder Block 3160
Crankshaft 3160
Piston 3161
Piston Ring 3161
Connecting Rod 3161
Rod Small End 3161
Tappet 3162
Oil Pump 3162
Engine Oil Pressure 3162
Outer Rotor Outside Clearance 3162
Outer Rotor Side Clearance 3162
Inner Rotor to Cover 3162
Standard Torque Specifications 3163
Standard Torque Chart 3163
Special Torque Specifications 3163
Special Tools 3165
550073240 1900YRM1620 (01 2023) US EN 3175
Proper Flushing after Major Hydraulic Repairs 3181
Introduction 3181
The Phases of Wear 3181
Causes of Hydraulic System Failure 3181
Progression of Contaminant Caused Hydraulic System Failure 3182
Hydraulic System Flushing Techniques 3182
Double Oil and Filter Change 3182
Mechanical Cleaning 3183
Cleaning of Components 3183
How to Clean Tubes and Hoses 3183
Filter Caddy 3183
Start-Up Procedure for Cleaned System 3184
Contaminated Oil Coolers 3184
Additional Filter Caddy Functions 3185
How to Handle Different Fluids 3185
Water Removal Filters 3185
Fluid Conditioning and System Flushing Procedures 3186
Operation of the Filter Caddy 3186
Filter Caddy operation 3186
Fluid Conditioning Procedure 3186
Filter Caddy Start-Up 3187
System Flushing Procedure 3187
Component Cleaning Procedure 3188
Reservoir Cleaning Procedure 3188
Cylinder Cleaning Procedure 3188
Hose and Tube Cleaning Procedure 3188
Valve Cleaning Procedure 3189
Front-End Attachment Cleaning Procedure 3190
System Flushing Procedure 3190
Filter Caddy Start-Up 3191
System Start-Up and Flushing 3191
Reservoir Fluid Cleaning Times 3192
Dealing With Different Fluid Types 3193
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3193
Filter Caddy Maintenance 3193
Servicing the Strainer 3193
DC Motor 3193
Hydraulic Oil Sampling Method and Procedure 3194
Hydraulic Oil Sampling Method 3194
Objective 3194
General Guidelines 3194
Synopsis 3195
Hydraulic Oil Analysis Report Guidelines 3196
Sampling Conditions 3196
Equipment 3196
Sampling Procedure 3197
Hydraulic Oil Sampling 3197
Sample Labeling 3197
Results Documentation 3197
550118414 1900YRM1897 (03 2020) US EN 3199
Series Code / Model Designation Reference Table 3203
General 3203
Hydraulic Gear Pump Assembly Repair 3205
Remove 3205
Disassemble 3207
Clean 3209
Inspect 3209
Assemble 3209
Install 3209
Hydraulic Gear Pump Specifications 3211
Variable Displacement Pump Repair 3212
Remove 3212
Disassemble 3215
Clean 3217
Inspect 3217
Assemble 3217
Install 3217
Variable Displacement Pump Checks and Adjustments 3219
Margin Pressure Check 3219
Flow Compensator Adjustment 3220
Pressure Compensator Adjustment 3220
Variable Displacement Pump Specifications 3221
Torque Specifications 3222
Hydraulic Gear Pump 3222
Variable Displacement Pump 3222
550118415 2000YRM1898 (03 2020) US EN 3225
Series Code / Model Designation Reference Table 3229
General 3230
Electro-Hydraulic Main Control Valve 3230
Description 3230
Remove 3236
Electro-Hydraulic Control Valve Sections 3239
General 3239
Outlet Control Valve Section 3239
Remove 3239
Disassemble 3239
Clean 3242
Inspect 3242
Assemble 3242
Install 3243
Auxiliary Control Valve Sections 3243
Remove 3243
Disassemble 3245
Clean 3245
Inspect 3246
Assemble 3246
Install 3247
Tilt Control Valve Section 3247
Remove 3247
Disassemble 3247
Clean 3248
Inspect 3248
Assemble 3249
Install 3249
Lift/Lower Control Valve Section 3249
Remove 3249
Disassemble 3249
Clean 3251
Inspect 3251
Assemble 3251
Install 3251
Transition Section 3251
Remove 3251
Disassemble 3252
Clean 3252
Inspect 3252
Assemble 3253
Install 3253
Install 3253
Manual Main Control Valve 3255
Description 3255
Remove 3257
OPS Solenoid Assembly 3261
General 3261
Remove 3262
Clean and Inspect 3264
Install 3264
Manual Control Valve Sections 3265
General 3265
Outlet Control Valve Section 3265
Remove 3265
Disassemble 3265
Clean 3267
Inspect 3267
Assemble 3267
Install 3267
Auxiliary Control Valve Sections 3268
Remove 3268
Disassemble 3268
Clean 3270
Inspect 3270
Assemble 3270
Install 3270
Lift/Tilt Control Valve Section 3271
Remove 3271
Disassemble 3271
Clean 3273
Inspect 3274
Assemble 3274
Install 3275
Install 3275
Pressure Relief Valve Check and Adjustment 3278
Primary Relief Valve 3278
Secondary Relief Valve 3279
Steering Control Unit Repair 3282
Steering Control Unit, Remove 3282
Steering Control Unit, Disassemble 3283
Steering Control Unit, Clean 3285
Steering Control Unit, Inspect 3285
Steering Control Unit, Assemble 3285
Relief Valve, Disassemble 3286
Relief Valve, Clean 3286
Relief Valve, Inspect 3287
Relief Valve, Assemble 3287
Steering Control Unit, Install 3287
550118420 8000YRM1904 (05 2022) US EN 3291
General Information About Diagrams and Schematics 3297
Symbol Definitions 3297
Diagrams Manual Applications 3298
Diagrams and Schematics 3300
550118420 8000YRM1904 (10 2020) US EN 3409
General Information About Diagrams and Schematics 3413
Symbol Definitions 3414
Diagrams Manual Applications 3415
Diagrams and Schematics 3417
550118555 0100YRM1892 (03 2020) US EN 3527
General 3533
Cab Replacement for 4-5 5 Ton Lift Trucks 3533
Remove 3533
Install 3544
Cab Replacement for 6-9 Ton Lift Trucks 3546
Remove 3546
Door Assemblies for 4-5 5 Ton Lift Trucks 3552
Right Side Door Assembly 3552
Remove 3552
Disassemble 3556
Door Cover With Heater Unit 3556
Door Cover With Air Conditioner/Heater Unit 3558
Heater Assembly 3560
Air Conditioner and Heater Unit Assembly 3560
Door Lock Assembly 3561
Windows 3563
Clean 3563
Inspect 3563
Assemble 3563
Windows 3563
Door Lock Assembly 3563
Heater Assembly 3563
Air Conditioner and Heater Unit Assembly 3564
Door Cover With Heater Unit 3564
Door Cover With Air Conditioner and Heater Unit 3564
Install 3564
Left Side Door Assembly 3565
Remove 3565
Disassemble 3565
Door Cover 3565
Door Lock Assembly 3565
Windows 3566
Clean 3566
Inspect 3566
Assemble 3566
Windows 3566
Door Lock Assembly 3566
Door Cover 3566
Install 3566
Door Assemblies for 6-9 Ton Lift Trucks 3567
Right and Left Side Door Assemblies 3567
Remove 3567
Disassemble 3567
Door Cover 3567
Door Lock Assembly 3568
Windows 3570
Clean 3570
Inspect 3570
Assemble 3570
Windows 3570
Door Lock Assembly 3570
Door Cover 3571
Install 3571
Window Replacement 3571
General 3571
Remove Door Windows for 4-5 5 Ton Lift Trucks 3571
Install Door Windows for 4-5 5 Ton Lift Trucks 3573
Remove Door Windows for 6-9 Ton Lift Trucks 3573
Install Door Windows for 6-9 Ton Lift Trucks 3575
Window Wipers Replacement 3575
General 3575
Front Wiper Assembly and Motor 3575
Remove 3575
Install 3577
Rear Wiper Assembly and Motor 3577
Remove, for 4-5 5 Ton Lift Trucks 3577
Install for 4-5 5 Ton Lift Trucks 3580
Remove for 6-9 Ton Lift Trucks 3580
Install for 6-9 Ton Lift Truck 3582
Heater Replacement 3583
Remove for 6-9 Ton Lift Trucks 3583
Install for 6-9 Ton Lift Trucks 3588
Heater and Air Conditioner Assembly 3589
Air Conditioner Condenser Unit 3589
Remove 3589
Install 3591
Air Conditioner Receiver/Drier Unit 3591
Remove 3591
Install 3593
Air Conditioner Compressor 3593
Light Replacement 3594
Work Lights (Front and Rear) 3594
Remove 3594
Install 3596
Strobe Light 3596
Remove 3596
Install 3597
Turn, Stop, Tail, and Backup Light 3597
Remove 3597
Install 3598
Front Marker/Turn Signal Lights 3598
Remove 3598
Install 3598
Display Switches 3599
Electrical Schematics 3601
Optional Equipment 3602
Heavy Duty Pre-Cleaner 3602
Fan 3602
Remove 3602
Install 3604
Mirror 3604
Remove 3604
Install 3604
Rear View Camera 3604
Monitor Removal 3604
Monitor Install 3606
Camera removal 3606
Camera install 3606
Label Replacement 3606
550131845 0100YRM1948 (09 2022) US EN 3609
General 3613
Description 3614
Side Covers, Seat, Dash, and Hood Replacement 3615
Side Covers 3615
Remove 3615
Install 3615
Seat and Seat Plate 3616
Remove Seat 3616
Remove Seat Plate 3616
Install Seat Plate 3616
Install Seat 3616
Operator Restraint System 3620
Emergency Locking Retractor (ELR) 3620
Seat Plate and Seat Rail Check 3620
Steering Column, Dash, Kick Panel, and Seal Plate 3620
Remove 3620
Install 3623
Hood Support and Door Assembly 3625
Remove 3625
Install 3626
Hood Door Assembly 3631
Remove 3631
Install 3632
Steering Column 3633
Description 3633
Steering Column Repair 3633
Remove 3633
Disassemble 3634
Clean 3636
Inspect 3636
Assemble 3636
Install 3636
LPG Tank and Bracket Assembly 3636
Counterweight Replacement 3637
Remove 3637
Install 3638
Tow Pin, Remove and Install 3639
Overhead Guard Replacement 3640
Remove 3640
Install 3642
Engine Replacement 3643
Remove Engine 3643
Remove Transmission 3666
Remove Engine and Transmission 3670
Install Engine 3673
Install Transmission 3677
Install Engine and Transmission 3678
Throttle Pedal and Cable Adjustment 3682
Throttle Cable Adjustment, Kubota 3 6L Diesel Tier 3 Engine with Basic Powershift Transmission 3682
Exhaust System Repair 3684
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP135VX, GP/GLP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 (GLP135VX, GLP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 3684
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 3684
Kubota 3 8L Diesel Engine w/DPF 3684
Remove 3686
Inspect 3687
Install 3687
Kubota 3 8L Diesel Engine w/DOC 3687
Remove 3689
Inspect 3690
Install 3690
Kubota 3 6L Diesel Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6 GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 3691
Remove 3691
Inspect 3693
Install 3693
Diesel Particulate Filter (DPF) 3694
Diesel Particulate Filter 3694
Disassemble 3694
Clean and Inspect 3695
Differential Pressure Pipes and Hoses 3696
Assemble 3696
Diesel Exhaust Fluid System 3697
General 3697
Description and Operation 3697
Selective Catalyst Reducer (SCR) 3701
Remove 3701
Clean and Inspect 3701
Install 3702
DEF Tank 3702
Remove 3702
Clean and Inspect 3704
Install 3704
Cooling System 3705
Description 3705
Hydraulic Filter Assembly Repair 3706
Remove 3706
Install 3708
Fuel and Hydraulic Tanks Repair 3709
Inspect 3709
Clean 3709
Steam Method of Cleaning 3709
Chemical Solution Method of Cleaning 3710
Additional Preparations for Repair 3710
Small Leaks, Repair 3711
Large Leaks, Repair 3711
Preparations for Use After Repair 3711
Safety Labels 3712
550131847 0600YRM1962 (11 2019) US EN 3721
General 3727
Engine Identification 3727
Major Engine Component Identification 3727
Location of Labels 3727
Cylinder Block Description 3728
Precautions Before Beginning Repair 3729
Exhaust System, SCR, and DPF 3729
Engine Removal and Installation 3730
Cylinder Head Assembly Repair 3730
Valve Covers and Fuel Injectors 3730
Remove 3730
Clean and Inspect 3733
Install 3733
Rocker Arm Assembly 3734
Remove 3734
Disassemble 3735
Clean and Inspect 3735
Push Rods 3735
Rocker Arm Assembly 3735
Assemble 3736
Install 3736
Valve Clearance Adjustments 3736
Cylinder Head Assembly 3738
Remove 3738
Disassemble 3746
Valves and Valve Springs, Remove 3746
Valve Guides, Remove 3747
Clean and Inspect 3747
Cylinder Head 3748
Valve Guides 3748
Valves 3748
Valve Sink 3749
Valve Seat 3749
Valve Springs 3750
Assemble 3750
Valve Guides, Install 3750
Valves and Valve Springs, Install 3751
Install 3752
Timing Gear Case and Timing Gears Repair 3754
Timing Gear Case Cover 3754
Remove 3754
Clean and Inspect 3755
Install 3755
Timing Gears 3756
Crankshaft Gear 3756
Remove 3756
Install 3757
Idler Gear 1 and Idler Gear 2 3757
Remove 3757
Inspect 3758
Install 3759
Idler Gear 3 3759
Remove 3759
Inspect 3759
Install 3759
Camshaft Gear 3759
Remove 3759
Install 3759
Drive Train, Camshaft, and Cylinder Block Repair 3760
Remove 3760
Disassemble 3760
Pistons and Connecting Rods 3760
Crankshaft 3761
Camshaft 3763
Clean and Inspect 3765
Cylinder Block 3765
Honing and Boring 3767
Cylinder Correction (Oversize) 3768
Pistons 3768
Piston Pin 3769
Connecting Rod 3769
Tappets 3770
Crankshaft 3770
Camshaft 3772
Camshaft Bushing 3773
Assemble 3773
Camshaft 3773
Crankshaft 3773
Pistons and Connecting Rods 3774
Install 3776
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 3776
Lubrication System Repair 3779
Engine Oil and Oil Filter Change (Standard Oil Filter) 3779
Engine Oil and Oil Filter Change (Remote Oil Filter) 3780
Oil Pan 3780
Remove 3780
Install 3781
Oil Suction Tube 3781
Remove 3781
Clean 3782
Install 3782
Oil Pump 3782
Remove 3782
Clean and Inspect 3783
Inner Rotor and Outer Rotor Clearance 3783
Outer Rotor and Pump Body Clearance 3784
Rotor and Cover Clearance 3784
Rotor Shaft Clearance 3784
Install 3785
Remote Oil Filter 3785
Remove 3785
Clean and Inspect 3787
Install 3787
Fuel System Repair 3788
Fuel Injectors 3788
Remove 3788
Inspect 3788
Clean 3788
Replace 3788
Install 3789
Test 3789
Fuel Injection Pump 3789
Remove 3789
Clean and Inspect 3792
Install 3793
Cooling System Repair 3794
Serpentine Belt 3794
Remove 3794
Inspect 3794
Install 3794
Adjust 3794
Water Pump 3795
Remove 3795
Install 3796
Thermostat 3797
Remove 3797
Inspect 3798
Install 3798
Flywheel and Flywheel Housing 3800
Flywheel 3800
Remove 3800
Install 3800
Flywheel Housing 3800
Remove 3800
Install 3800
Electrical Equipment Repair 3801
Alternator 3801
Remove 3801
Install 3802
Starter 3803
Remove 3803
Install 3803
Engine Specifications 3805
Engine Data 3805
Engine Tuning 3806
Cylinder Head 3806
Intake/Exhaust Valve and Guide 3807
Valve Spring 3807
Rocker Arm and Shaft 3807
Push Rod 3807
Gear Train and Camshaft 3808
Camshaft 3808
Idle Gear Shaft and Bushing 3808
Backlash of Each Gear 3808
Cylinder Block 3808
Crankshaft 3809
Piston 3809
Piston Ring 3809
Connecting Rod 3810
Rod Small End 3810
Tappet 3810
Oil Pump 3810
Engine Oil Pressure 3810
Inner and Outer Rotor Clearance 3810
Outer Rotor and Pump Body 3810
Rotor and Cover 3811
Standard Torque Specifications 3811
Standard Torque Chart 3811
Special Torque Specifications 3812
Special Tools 3813
550131848 0600YRM1961 (03 2020) US EN 3827
General 3833
Engine Identification 3834
Major Engine Component Identification 3834
Location of Labels 3836
Cylinder Block Description 3837
Precautions Before Beginning Repair 3838
Exhaust System and DPF 3839
Engine Removal and Installation 3839
Cylinder Head Assembly Repair 3839
Valve Covers and Fuel Injectors 3839
Remove 3839
Clean and Inspect 3842
Install 3842
Rocker Arm Assembly 3843
Remove 3843
Disassemble 3843
Clean and Inspect 3844
Push Rods 3844
Rocker Arm Assembly 3844
Assemble 3845
Install 3845
Valve Clearance Adjustments 3845
Cylinder Head Assembly 3846
Remove 3846
Disassemble 3854
Valves and Valve Springs, Remove 3854
Valve Guides, Remove 3855
Clean and Inspect 3855
Cylinder Head 3856
Valve Guides 3856
Valves 3857
Valve Sink 3857
Valve Seat 3857
Valve Springs 3858
Assemble 3858
Valve Guides, Install 3858
Valves and Valve Springs, Install 3859
Install 3860
Timing Gear Case and Timing Gears Repair 3862
Timing Gear Case Cover 3862
Remove 3862
Clean and Inspect 3863
Install 3863
Timing Gears 3864
Crankshaft Gear 3864
Remove 3864
Install 3865
Idler Gear 1 and Idler Gear 2 3865
Remove 3865
Inspect 3866
Install 3867
Idler Gear 3 3867
Remove 3867
Inspect 3867
Install 3867
Camshaft Gear 3867
Remove 3867
Install 3867
Drive Train, Camshaft, and Cylinder Block Repair 3868
Remove 3868
Disassemble 3868
Pistons and Connecting Rods 3868
Crankshaft 3869
Camshaft 3871
Clean and Inspect 3873
Cylinder Block 3873
Honing and Boring 3875
Cylinder Correction (Oversize) 3876
Pistons 3876
Piston Pin 3877
Connecting Rod 3877
Tappets 3878
Crankshaft 3878
Camshaft 3880
Camshaft Bushing 3881
Assemble 3881
Camshaft 3881
Crankshaft 3881
Pistons and Connecting Rods 3882
Install 3884
Angular Deviation Procedure 3884
Lubrication System Repair 3887
Engine Oil and Oil Filter Change 3887
Oil Pan 3888
Remove 3888
Install 3888
Oil Suction Tube 3888
Remove 3888
Clean 3889
Install 3889
Oil Pump 3889
Remove 3889
Clean and Inspect 3890
Inner Rotor and Outer Rotor Clearance 3890
Outer Rotor and Pump Body Clearance 3891
Rotor and Cover Clearance 3891
Rotor Shaft Clearance 3891
Install 3892
Fuel System Repair 3892
Fuel Injectors 3892
Remove 3892
Inspect 3892
Clean 3893
Replace 3893
Install 3893
Test 3893
Fuel Injection Pump 3893
Remove 3893
Clean and Inspect 3896
Install 3896
Cooling System Repair 3897
Serpentine Belt 3897
Remove 3897
Inspect 3897
Install 3897
Adjust 3897
Water Pump 3898
Remove 3898
Install 3900
Thermostat 3900
Remove 3900
Inspect 3901
Install 3901
Flywheel and Flywheel Housing 3902
Flywheel 3902
Remove 3902
Install 3903
Flywheel Housing 3903
Remove 3903
Install 3903
Electrical Equipment Repair 3904
Alternator 3904
Remove 3904
Install 3905
Starter 3906
Remove 3906
Install 3906
Engine Specifications 3908
Engine Data 3908
Engine Tuning 3910
Cylinder Head 3910
Intake/Exhaust Valve and Guide 3911
Valve Spring 3911
Rocker Arm and Shaft 3911
Push Rod 3911
Gear Train and Camshaft 3912
Camshaft 3912
Idle Gear Shaft and Bushing 3912
Backlash of Each Gear 3912
Cylinder Block 3912
Crankshaft 3913
Piston 3913
Piston Ring 3913
Connecting Rod 3914
Rod Small End 3914
Tappet 3914
Oil Pump 3914
Engine Oil Pressure 3914
Inner and Outer Rotor Clearance 3914
Outer Rotor and Pump Body 3914
Rotor and Cover 3915
Standard Torque Specifications 3915
Standard Torque Chart 3915
Special Torque Specifications 3915
Special Tools 3917
550131849 0700YRM1950 (03 2020) US EN 3931
General 3935
Cooling System Checks 3936
Exhaust Leaks Into Cooling System 3936
Water Flow Restrictions in Radiator 3936
Radiator Hoses 3936
Water Pump 3936
Flushing the Cooling System 3937
Cooling System, Clean 3937
Radiator Repair 3938
Remove 3938
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 3938
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 3946
Install 3952
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 3952
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 3953
Fan Assembly Replacement 3955
Remove 3955
Inspect 3960
Install 3960
550131851 1600YRM1952 (03 2020) US EN 3963
General 3967
Steering Axle Assembly Repair 3970
Remove 3970
Disassemble 3971
Clean 3972
Inspect 3972
Assemble 3973
Install 3973
Spindles, Bearings, and Tie Rods Repair 3974
Spindles and Bearings 3974
Remove 3974
Disassemble 3974
Clean 3975
Inspect 3975
Assemble 3975
Install 3976
Tie Rods 3976
Remove 3976
Install 3977
Steering Cylinder Repair 3977
Remove and Disassemble 3977
Clean and Inspect 3977
Assemble and Install 3977
Turn Assist (Lift trucks built after February 2019) 3979
Removal 3979
Instal 3981
Adjustment 3981
Torque Specifications 3982
550131852 2100YRM1953 (03 2020) US EN 3985
General 3991
Safety Procedures When Working Near Mast 3991
Tilt Cylinder Repair 3993
Remove 3993
Disassemble 3996
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3996
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3996
Clean 3997
Inspect 3997
Assemble 3997
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3997
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3998
Install 3999
Tilt Cylinders, Adjust 4000
Tilt Cylinder Leak Check 4002
Lift Cylinder Repair 4003
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4003
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 4006
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 4010
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4015
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 4016
Clean 4017
Inspect 4017
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4017
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4018
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4018
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 4019
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 4019
Free-Lift Cylinder Repair 4020
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4020
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4023
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4025
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4026
Clean 4028
Inspect 4028
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4028
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4029
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4029
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4029
Sideshift Cylinder Repair 4030
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4030
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4030
Clean 4031
Inspect 4031
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4031
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4032
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4032
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4033
Clean 4034
Inspect 4034
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4034
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4034
Bolzoni Sideshift Cylinder Repair 4035
Remove 4035
Disassemble 4035
Clean 4036
Inspect 4036
Assemble 4037
Install 4037
Fork Positioner Cylinder Repair 4038
Remove 4038
Disassemble 4040
Clean 4043
Inspect 4043
Assemble 4044
Install 4045
Lift Cylinder Leak Check 4046
Seal Kit Installation 4046
External Installation (Seal and Back-Up Ring) 4046
Internal Installation (Piston Rod Assembly) 4047
Special Tools 4047
Torque Specifications 4048
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4048
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4048
550131853 2200YRM1954 (03 2020) US EN 4051
General 4059
Display Switch Cluster 4062
Remove 4062
Install 4064
Direction Control and Turn Signal Levers 4064
Remove 4064
Install 4065
Key Switch 4065
Remove 4065
Install 4066
Display Switch Cluster Panel Bezel and Overlay 4066
Remove 4066
Install 4067
Steering Column Repair 4067
Sensors and Switches 4070
General 4070
Dash and Kick Panel, Remove and Install 4070
Remove 4070
Install 4071
Accelerator Pedal Position Sensor 4071
Remove 4071
Install 4074
Brake Fluid Level Switch 4074
Remove 4074
Install 4075
Service Brake Pedal Position Sensor 4075
Remove 4075
Install 4076
Parking Brake Position Sensor 4076
Remove 4076
Install 4076
Service Brake Pressure Sensor 4077
Remove 4077
Install 4077
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 4078
Remove 4078
Install 4078
Sensor MicroswitchFoot Directional Control 4079
Remove 4079
Install 4081
Low Coolant Level Sensor 4081
Remove 4081
Install 4082
Fuel Level Sensor, Diesel Engines Only 4082
Remove 4082
Install 4083
Seat Sensor (Operator Presence System) 4083
Non-Suspension Seat 4083
Remove 4083
Install 4085
Full Suspension and Swivel Seats 4085
Remove 4085
Install 4085
Hood Shut Off Switch 4086
Remove 4086
Install 4086
Remote Key Switch 4087
Remove 4087
Install 4087
Hydraulic Filter Pressure Switch 4088
Remove 4088
Install 4088
Transmission Speed Sensor 4088
Remove 4088
Install 4089
Transmission Pressure Sensors 4089
Remove 4089
Install 4089
Transmission Temperature Sensor 4090
Remove 4090
Install 4090
Engine Speed Sensor 4090
Remove 4090
Install 4090
Intermediate Speed Sensor 4090
Remove 4090
Install 4090
Return To Set Tilt (Tilt Angle) Sensor 4090
Remove 4090
Install 4091
Rear Horn Button Switch 4091
Remove 4091
Install 4091
Impact Sensor 4092
Remove 4092
Install 4092
Load Weight Sensor 4093
Remove 4093
Install 4093
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 4094
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 4095
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 4095
Air Filter Restriction Switch 4095
Remove 4095
Install 4095
Engine Oil Pressure Sensor 4096
Remove 4096
Install 4096
Engine Speed Sensor 4096
Remove 4096
Install 4096
Engine Coolant Temperature (ECT) Sensor 4097
Remove 4097
Install 4097
Fuel/Water Separator Sensor 4097
Remove 4097
Install 4097
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 4098
Engine Coolant Temperature (ECT) Sensor 4098
Remove 4098
Install 4098
Throttle Position Sensor 4099
Engine Oil Pressure Sensor 4099
Remove 4099
Install 4099
Fuel Shut Off Solenoid 4099
Remove 4099
Install 4100
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With Diesel Particulate Filter (DPF) And Kubota 3 8L (Tier 4) 55kW Diesel Engine, With Diesel Oxidation Catalyst (DOC) 4100
Intake Air Temperature Sensor 4101
Remove 4101
Install 4101
Boost Sensor 4101
Remove 4101
Install 4101
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 4103
Remove 4103
Install 4104
Engine Coolant Temperature (ECT) Sensor 4104
Remove 4104
Install 4104
Engine Oil Pressure Sensor 4104
Remove 4104
Install 4105
Crankshaft Position Sensor 4105
Remove 4105
Install 4105
Adjust Shim Procedure 4105
Camshaft Position Sensor 4107
Remove 4107
Install 4107
Differential Pressure Sensor 4107
Remove 4107
Install 4108
Oxygen Sensors (Inlet and Outlet) 4108
Remove 4108
Install 4109
Inlet Temperature Sensor 4110
Remove 4110
Install 4110
Mass Air Flow Sensor 4110
Remove 4110
Install 4110
Fuel/Water Separator 4110
Remove 4110
Install 4111
Air Filter Restriction Switch 4111
Remove 4111
Install 4111
Vehicle System Manager (VSM) 4112
General 4112
VSM Replacement 4112
Remove 4112
Install 4112
Programming A New VSM And/Or Display Switch Cluster 4113
Data Transferring 4114
New VSM 4114
New (Blank) Display Switch Cluster 4114
Used (Non-Blank) Display Switch Cluster 4114
PC Service Tool Software 4115
Power Distribution Module (PDM) and Component Parts 4115
Remove 4115
PDM as a Unit 4115
Install 4116
PDM as a Unit 4116
Remove and Install 4116
PDM Component Parts 4116
Transmission Control Unit (TCU) 4117
Remove 4117
Install 4119
Battery 4122
Remove 4122
Install 4122
Lights 4122
Work Lights (Front and Rear) 4122
Halogen Bulb Lights 4122
Remove 4122
Install 4122
LED Lights 4123
Remove 4123
Install 4123
Strobe Light 4123
Remove 4123
Install 4124
LED Tail, Backup, and Brake Lights 4124
Remove 4124
Install 4124
Front Marker/Turn Signal Lights 4125
Replacing Whole Front Marker/Turn Signal Light Assembly 4125
Remove 4125
Install 4125
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 4126
Remove 4126
Install 4126
Electronic-Hydraulic Controls, Before January, 2020 4127
E-Hydraulic Controls – TEST 4127
Mini-Levers 4127
Full Stroke Test 4127
Function Returns to Neutral Test 4127
Push (Override) Button Switch 4127
General 4128
Mini-levers, Remove and Install 4128
Armrest Assembly 4129
Remove 4129
Install 4132
Horn Button 4132
Remove 4132
Install 4132
Direction Control Switch 4132
Remove 4132
Install 4133
Push (Override) Button 4133
Remove 4133
Install 4134
Electronic-Hydraulic Controls, After January, 2020 4135
E-Hydraulic Controls – TEST 4135
Mini-Levers 4135
Full Stroke Test 4135
Function Returns to Neutral Test 4135
Push Button Switch 4135
General 4136
Mini-levers, Remove and Install 4136
Armrest Assembly 4137
Remove 4137
Install 4140
Horn Button 4140
Remove 4140
Install 4140
Direction Control Switch 4140
Remove 4140
Install 4141
Push (Override) Buttons 4141
Remove 4141
Install 4142
Diesel Particulate Filter (DPF) Display 4143
Remove 4143
Clean and Inspect 4144
Install 4144
Special Tools 4145
550131855 4000YRM1956 (03 2020) US EN 4149
Safety Procedures When Working Near Mast 4153
Fork Replacement 4154
General 4154
Remove 4154
Install 4156
Checks 4156
Carriage Repair 4158
Remove 4158
Clean and Inspect 4161
Install 4161
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4162
Connecting Attachment Hydraulic Quick Disconnect Hoses 4162
Integral Sideshift Carriage And Fork Positioners Repair 4163
Integral Sideshift Carriage 4163
Remove 4163
Disassemble 4164
Clean and Inspect 4166
Assemble 4167
Install 4167
Fork Positioners 4168
Remove 4168
Disassemble 4171
Clean and Inspect 4173
Assemble 4173
Install 4173
Hang-On Sideshift Carriage Repair 4174
Remove 4174
Disassemble Carriage 4176
Clean and Inspect 4179
Assemble 4179
Install 4182
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 4184
Remove 4184
Disassemble 4188
Clean and Inspect 4192
Assemble 4194
Install 4194
Header Hose Installation 4195
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 4198
Remove 4198
Disassemble 4201
Clean and Inspect 4204
Assemble 4206
Install 4206
Header Hose Installation 4207
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 4210
Remove 4210
Disassemble 4213
Clean and Inspect 4216
Assemble 4218
Install 4218
Header Hose Installation 4219
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 4222
Remove 4222
Disassemble 4225
Clean and Inspect 4229
Assemble 4231
Install 4231
Header Hose Installation 4232
Mast Operation Check 4235
Tilt Cylinder Adjustment 4235
Main Lift Cylinder Repair 4236
Lift Chain Adjustment 4236
Mast Adjustments 4237
Load Roller Adjustment 4237
Mast Side Kicking Adjustment 4239
Carriage Adjustment 4239
550131856 8000YRM1957 (08 2019) US EN 4243
General 4249
Serial Number Data 4249
How to Move Disabled Lift Truck 4249
How to Tow Lift Truck 4249
How to Put Lift Truck on Blocks 4250
How to Raise Drive Tires 4250
How to Raise Steering Tires 4251
How to Clean a Lift Truck 4252
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4252
Connecting Attachment Hydraulic Quick Disconnect Hoses 4253
Maintenance Schedule 4253
Maintenance Procedures Every 8 Hours or Daily 4269
How to Make Checks With Engine Stopped 4269
Tires and Wheels 4269
Safety Labels 4270
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4270
Operator Restraint System 4271
Emergency Locking Retractor (ELR) 4271
Adjust Seat – Full Suspension 4271
Adjust Seat – Internal Suspension 4272
Seat Plate and Seat Rails 4273
Engine Compartment 4274
Paper Application 4274
Fuel, Oil, and Coolant Leaks, Check 4275
Hydraulic Hoses 4275
Coolant Hoses 4275
Steering Column Gas Cylinder 4275
Transmission 4275
Hydraulic System Oil 4275
Engine Oil 4276
Air Filter 4281
Forks 4281
Inspect 4281
Remove 4283
Install 4283
Adjust 4283
Hang On Sideshift Carriage 4284
How to Make Checks With Engine Running 4285
Indicator Lights, Horn, Fuses, and Relays 4285
Service Brakes 4288
Brake Oil Level 4288
Operation, Check 4288
Parking Brake 4288
Engine Oil Pressure 4289
Cooling System 4289
Steering System 4290
Control Levers and Pedals 4290
Lift System, Operate 4290
Air Filter 4291
Fuel/Water Separator Filter, Kubota Diesel Engine 4291
First Service After First 100 Hours of Operation 4291
4 3L Engine Oil and Oil Filter 4291
Kubota Diesel Engine Oil and Oil Filter 4292
Bolzoni Hang on Sideshift Carriage Checks 4293
Maintenance Procedures Every 250 Hours or 6 Months 4294
4 3L Engine Oil and Oil Filter Change 4294
Kubota Diesel Engine Oil and Oil Filter 4295
Drive Belt 4296
4 3L Engine 4296
Fan and Alternator Drive Belt 4296
Drain Tar From LPG Converter 4297
Cleaning Carbon Buildup From Intake Valves – GM and PSI 4 3L LPG Engines 4298
Maintenance Procedures Every 500 Hours or 6 Months 4300
Hydraulic System Oil 4300
Hydraulic Tank Breather 4301
Inspect 4301
Battery 4302
Kubota Diesel Engine Oil and Oil Filter 4302
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engines 4303
Remove 4303
Install 4304
Priming the Fuel System (Kubota 3 8L Engine) 4305
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4305
Remove 4305
Install 4306
Priming the Fuel System (Kubota 3 6L Engine) 4306
Drive Belt 4307
Kubota Diesel Engine 4307
Fan and Alternator Drive Belt 4307
Clean Debris From Radiator Core 4307
Transmission Oil Breather/Dipstick 4308
Differential and Drive Axle Oil Level Check 4309
Forks, Inspect 4311
Mast Lubrication 4312
Bolzoni Hang On Sideshift Carraige Checks 4317
Tilt Cylinder Lubrication 4318
Header Hose Checks 4319
Lift Chain Lubrication 4319
Master Brake Cylinder Rod End Pin Lubrication 4319
Manual Hydraulic Levers Lubrication 4320
Brake Oil 4320
Tie Rod Lubrication 4321
Parking Brake Adjustment 4322
Maintenance Procedures Every 1000 Hours or 6 Months 4323
Valve Clearance, Check and Adjust 4323
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 4323
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4323
Ignition System 4323
4 3L Engine 4323
LPG Fuel Filter Element Replace, 4 3L Engine 4324
Remove 4324
Install 4324
In-Line Strainer Replacement, Kubota Diesel Engine 4325
Remove 4325
Install 4325
Lift Chains Wear Check 4327
Lift Chain Lubrication 4327
Hang On Sideshift Carriage, Check Sliding Surfaces 4327
Bolzoni Hang On Sideshift Carriage Checks 4328
Steering Axle Spindle Bearings 4331
Control Levers and Pedals 4332
Inspect Engine Electrical System, Connectors 4332
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4332
Parking Brake Lever Lubrication, Wet Brake Axle 4336
Normal Operating Environment 4336
Heavy Duty or Contaminated Environment 4337
Remove 4337
Clean and Inspect 4338
Install 4338
Crankcase Breather Element, Kubota 3 8L Diesel 4339
Remove 4339
Clean and Inspect 4339
Install 4339
DEF Injector Tip 4340
Maintenance Procedures Every 2000 Hours or Annually 4340
Hydraulic System 4340
Hydraulic Filter Assembly, Replace 4340
Install 4341
Hydraulic Tank Breather, Replace 4342
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4343
Cooling System Check 4343
Air Filter 4344
Fuel Injector, Kubota 3 8L Engine 4346
Fuel Injector, Kubota 3 6L Engine 4346
Forks 4346
Bolzoni Hang On Sideshift Carriage Checks 4348
Brake Oil (Master Cylinder), Change 4350
Check Throttle Shaft for Sticking 4351
Inspect Exhaust Manifold and Piping for Leaks 4351
Transmission Automatic Clutch Calibration 4351
Wheel Bearings 4351
Steer Wheels, Lubrication 4351
Maintenance Procedures Every 3000 Hours 4352
Diesel Particulate Filter 4352
Remove 4352
Disassemble 4354
Servicing the Diesel Particulate Filter, Pressure Tubes and Pressure Hoses 4355
Assemble 4355
Install 4356
Diesel Exhaust Fluid (DEF) System 4356
Maintenance Procedures Every 4000 Hours or 2 Years 4358
Hydraulic Oil, Replace 4358
Safety Procedures When Working Near Mast 4359
Fuel Filter Water Removal 4360
Kubota Diesel Engine 4360
3 8L Diesel Engine 4360
3 6L Diesel Engine 4361
Lift Chain Adjustments 4362
Jump-Starting the Lift Truck 4363
Jump-Starting Using a Battery Charger 4363
Jump-Starting a Lift Truck Using Another Lift Truck 4364
Welding Repairs 4364
Overhead Guard Changes 4365
Wheel and Tire Replacement 4365
General 4365
Pneumatic Tire With Tube, Repair 4365
Remove Wheels From Lift Truck 4365
Remove Tire From Wheel 4365
Install Wheel in Tire 4368
Install Tire on Two-Piece Wheel 4370
Add Air to Pneumatic Tires With Tube 4371
Install the Wheels 4371
Dual Drive Wheels, Install 4372
Pneumatic Tubeless Tire, Repair 4373
Remove Wheels From Lift Truck 4373
Add Air to Pneumatic Tubeless Tire 4378
Wheels, Install 4378
Solid Rubber Tires on Pneumatic Wheels, Change 4378
Wheels, Install 4382
Adhesives and Sealants 4382
550131857 8000YRM1958 (08 2019) US EN 4385
Lift Truck Lifting Capacity 4389
Counterweight Weights 4389
Tire Sizes 4389
Capacities 4389
Electrical System 4393
Transmission Oil Pressures 4394
Hydraulic System Relief Pressures 4395
Steering System 4396
Stall Speeds (in RPM ±100 rpm) 4396
GM/PSI 4 3L LPG GLP60VX, GLP70VX (GLP135VX, GLP155VX) (F878) 4396
Kubota 3 6L Diesel GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) 4396
Kubota 3 8L Diesel GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) 4396
Mast Speeds 4397
Tilt Angles 4398
Front End Equipment – Mast Creep 4398
Mast Creep 4398
Engine Specifications 4399
Diesel Fuel Cleanliness Levels 4401
Torque Specifications 4402
Frame 4402
Mast 4402
Hang On Sideshift Carriage With Fork Positioner 4402
Steering System 4402
Transmission 4403
Engine – GM/PSI 4 3L 4403
Engine – Kubota 3 6L Diesel 4404
Engine – Kubota 3 8L Diesel 4405
550136209 1800YRM1977 (08 2022) US EN 4409
General 4415
Wet Brake System 4415
Parking Brake Repair 4416
Master Cylinder Repair, For Lift Truck Models F878/G878/H878 4420
Remove 4420
Disassemble 4420
Clean and Inspect 4422
Assemble 4422
Install and Adjust 4422
Accumulator; For Lift Truck Models F878/G878/H878 4424
Pre-Charge Check 4424
Remove 4424
Install 4425
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For Lift Truck Models C909/D909 4426
Remove 4426
Modulating Brake Valve 4427
Disassemble 4427
Clean and Inspect 4428
Assemble 4429
Accumulator Charge Valve 4429
Disassemble 4429
Clean and Inspect 4431
Assemble 4431
Install 4432
Pressure Checks 4433
Accumulator Charge Valve Check 4433
Accumulator Check 4433
Brake System Air Removal; For Lift Truck Models 4434
Using Pressure Bleed System 4434
Using Brake Pedal Pressure 4434
Lift Truck Models with Master Cylinder 4434
Brake System Air Removal for Lift Truck Models C909/D909 4436
Using Brake Pedal Pressure 4436
Lift Truck Models with Modulating Brake Valve 4436
Brake Pedal Adjustment 4436
For Lift Truck Models F878/G878/H878 4436
For Lift Truck Models C909/D909 4437
Free Pedal Adjustment 4439
Torque Specifications 4440
550136214 9000YRM1976 (12 2020) US EN 4443
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 4449
Group 05 – Operational Checkout 4451
SECTION 9020 ENGINE 4457
Group 10 – Principles of Operation 4459
Group 30 – Observed Symptoms 4483
Group 40 – Tests and Adjustments 4491
SECTION 9030 ELECTRICAL SYSTEM 4509
Group 03 – General Maintenance and Diagnostic Data 4515
Group 10 – Principles of Operation 4527
Group 20 – Diagnostic Trouble Codes 4535
SECTION 9080 SUPPLEMENTARY DATA 4691
Group 50 – Abbreviations and Acronyms 4693
Group 60 – Special Tools List 4701
Group 70 – Fault Mode Indicator Reference 4705
550148125 9000YRM2010 (05 2016) US EN 4709
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 4715
Group 05 – Operational Checkout 4717
SECTION 9020 ENGINE 4723
Group 10 – Principles of Operation 4725
Group 03 – General Maintenance and Diagnostic Data 4735
Group 30 – Observed Symptoms 4739
SECTION 9030 ELECTRICAL SYSTEM 4745
Group 03 – General Maintenance and Diagnostic Data 4749
Group 10 – Principles of Operation 4755
Group 20 – Diagnostic Trouble Codes 4763
SECTION 9080 SUPPLEMENTARY DATA 4825
Group 50 – Abbreviations and Acronyms 4827
Group 60 – Special Tools List 4835
Group 70 – Fault Mode Indicator Reference 4837
550152438 0600YRM1949 (07 2023) US EN 4841
General 4847
Engine Removal and Installation 4847
Cylinder Head Repair 4847
Remove and Disassemble 4847
Clean and Inspect 4849
Valve Oil Seals 4851
Remove and Disassemble 4851
Cylinder Leak Down Test 4851
Clean and Inspect 4852
Assemble and Install 4852
Valve Guides and Seats, Repairs 4854
Valves, Repair 4855
Valve Seats, Repair 4855
Valve Springs 4856
Assemble and Install 4857
Engine Block Cleaning and Inspection 4861
Clean and Inspect 4861
Piston Bore Preparation 4863
Engine Mounts Installation 4864
Remove 4864
Clean and Inspect 4864
Install 4864
Lubrication System Repair 4865
Oil Pump, Remove and Disassemble 4865
Clean and Inspect 4866
Oil Pump, Assemble and Install 4867
Oil Pan, Install 4869
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4871
Timing Cover 4871
Remove 4871
Install 4872
Timing Chain and Sprockets 4872
Remove 4872
Install 4873
Camshaft 4873
Remove 4873
Inspect 4874
Install 4874
Balance Shaft 4875
Remove 4875
Install 4876
Valve Lifters 4877
Remove 4877
Clean and Inspect 4877
Install 4877
Crankshaft Repair 4879
Remove 4879
Inspect and Repair 4879
How to Check Clearance Between Main Bearings and Their Journals 4880
Install 4881
Piston and Connecting Rod Assemblies Repair 4883
Connecting Rod Bearings, Replace 4883
Piston and Connecting Rod Assemblies, Remove 4884
Disassemble 4884
Piston, Clean and Inspect 4885
Cylinder Bores, Inspect and Repair 4885
Piston Rings 4886
Assemble 4887
Piston and Connecting Rod Assemblies, Install 4887
Flywheel and Flywheel Housing Repair 4888
Flywheel, Remove 4888
Clean 4888
Inspect 4888
Flywheel, Install 4889
Coolant Pump Repair 4890
Remove 4890
Clean and Inspect 4891
Install 4891
Thermostat Replacement 4892
Remove 4892
Thermostat Operation Check 4892
Install 4892
Starter Replacement 4893
Fan Assembly Replacement 4897
Remove 4897
Inspect 4899
Install 4899
Drive Belt Installation 4900
Remove 4900
Clean 4900
Inspect 4900
Installation 4900
Compression Check 4902
Engine Specifications 4903
Engine Data 4903
Cylinder Head 4903
Hydraulic Valve Lifter 4903
Camshaft 4903
Pistons 4904
Crankshaft 4904
Connecting Rods 4905
Balance Shaft 4905
Cooling System 4905
Lubrication System 4905
Torque Specifications 4906
550152439 0900YRM1951 (11 2019) US EN 4909
General 4915
LPG Tank and Bracket 4915
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 4915
Remove 4915
Install 4920
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 4921
Remove 4921
Install 4922
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 4923
Remove 4923
Install 4925
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 4925
Remove 4925
Install 4925
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 4926
Remove 4926
Install 4927
Fuel Filter Unit 4928
Fuel Filter Element 4928
Remove 4928
Clean and Inspect 4929
Install 4929
Fuel Filter Housing, Lift Truck Models GLP60-70VX (GLP135-155VX) (F878), GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878), GLC60-70VX (GLC135-155VX) (F879), and GLP40VX5, GLP40-45VX6, GLP45SVX5, GLP50-55VX (GLP80-120VX) (K813) 4930
Remove 4930
Disassemble 4931
Clean and Inspect 4931
Assemble 4932
Install 4932
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 4932
Remove 4932
Disassemble 4934
Clean and Inspect 4935
Assemble 4935
Install 4936
Throttle Body 4936
Remove 4936
Clean 4938
Install 4938
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4939
Remove 4939
Install 4940
Control System 4941
Engine Control Unit (ECU) 4941
Remove 4941
Install 4942
Low Pressure Switch 4942
Remove 4942
Install 4943
Low Fuel Sensor 4943
Remove 4943
Install 4944
LP Converter 4944
Remove and Disassemble 4944
Assemble and Install 4946
LPG Lock-Off 4947
Remove 4947
Install 4948
Exhaust System 4948
Counterweight Exhaust 4948
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 4948
Inspect 4950
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 4951
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4951
Inspect 4952
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4952
Overhead Exhaust 4953
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 4953
Inspect 4954
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 4955
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4955
Inspect 4957
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4957
Exhaust Manifold 4957
Remove 4957
Install 4958
Oxygen (HEGO) Sensor 4959
Remove 4959
Install 4959
LPG Fuel Testing 4959
General 4959
Available Fuel Tests 4960
Composition Test (ASTM D-2163) 4960
Ammonia Test (ASTM D-4490) 4960
Basic Nitrogen Test (ASTM UOP269-90) 4960
Residues Test (ASTM D-2158) 4960
Vapor Pressure Test (ASTM D-2598) 4960
Sulfur Compounds Test (ASTM D-5623) 4960
Methanol Test (ASTM D-4864) 4960
Copper Corrosion (ASTM D-1838) 4960
Where To Send LPG Fuel Samples For Testing 4960
550152440 2200YRM1955 (11 2019) US EN 4963
Description 4967
Distributor Ignition (DI) System 4967
Crankshaft Position (CKP) Sensor 4967
Camshaft Position (CMP) Sensor 4967
Ignition Coil and Ignition Control Module (ICM) 4967
Secondary Ignition Components 4967
Spark Plugs and Wires 4967
Spark Plug Wire Inspection 4967
Spark Plug Wire Replacement 4967
Remove 4967
Install 4968
Spark Plug Inspection 4968
Usage 4968
Inspection 4968
Visual Inspection 4970
Spark Plug Replacement 4971
Remove 4971
Install 4971
Distributor Repair 4971
Inspect 4971
Overhaul 4972
Disassemble 4972
Assemble 4974
Replace 4975
Remove 4975
Install Procedure 1 4977
Install Procedure 2 4978
Ignition Coil Replacement 4980
Remove 4980
Install 4980
Ignition Control Module Replacement 4981
Remove 4981
Install 4981
Starter Replacement 4982
Remove 4982
Install 4985
Sensors and Switches 4986
LPG Trucks 4986
Crankshaft Position (CKP) Sensor 4986
Remove 4986
Install 4986
Camshaft Position (CMP) Sensor 4987
Remove 4987
Install 4988
Oil Pressure Sensor 4989
Remove 4989
Install 4989
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4990
Remove 4990
Install 4990
Engine Coolant Temperature (ECT) Sensor 4990
Remove 4990
Install 4991
Air Flow Restriction Switch 4991
Remove 4991
Install 4992
Specifications and Special Tools 4992
550229997 0600YRM2294 (01 2021) US EN 4995
General 5001
Engine Identification 5001
Major Engine Component Identification 5001
Location of Labels 5002
Crankcase Description 5003
Precautions Before Beginning Repair 5004
Exhaust System 5005
Engine Removal and Installation 5005
Cylinder Head Assembly Repair 5005
Valve Covers and Fuel Injectors 5005
Remove 5005
Clean and Inspect 5008
Install 5008
Rocker Arm Assembly 5008
Remove 5008
Disassemble 5009
Clean and Inspect 5010
Push Rods 5010
Rocker Arm Assembly 5010
Assemble 5010
Install 5011
Valve Clearance Adjustments 5011
Cylinder Head Assembly 5012
Remove 5012
Disassemble 5018
Valves and Valve Springs, Remove 5018
Valve Guides, Remove 5019
Clean and Inspect 5019
Cylinder Head 5020
Valve Guides 5020
Valves 5020
Valve Sink 5020
Valve Seat 5021
Valve Springs 5021
Assemble 5022
Valve Guides, Install 5022
Valves and Valve Springs, Install 5022
Install 5023
Timing Gear Case and Timing Gears Repair 5025
Timing Gear Case Cover 5025
Remove 5025
Clean and Inspect 5026
Install 5026
Timing Gears 5027
Crankshaft Gear 5027
Remove 5027
Install 5028
Idler Gear 5028
Remove 5028
Inspect 5029
Install 5030
Camshaft Gear 5030
Remove 5030
Install 5030
Drive Train, Camshaft, and Cylinder Block Repair 5030
Remove 5030
Disassemble 5030
Pistons and Connecting Rods 5030
Crankshaft 5032
Camshaft 5034
Clean and Inspect 5036
Cylinder Block 5036
Honing and Boring 5038
Cylinder Correction (Oversize) 5039
Pistons 5039
Piston Pin 5040
Connecting Rod 5040
Tappets 5041
Crankshaft 5041
Camshaft 5043
Camshaft Bushing 5044
Assemble 5044
Camshaft 5044
Crankshaft 5044
Pistons and Connecting Rods 5045
Install 5047
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 5047
Lubrication System Repair 5050
Engine Oil and Oil Filter Change 5050
Oil Pan 5051
Remove 5051
Install 5051
Oil Suction Tube 5051
Remove 5051
Clean 5052
Install 5052
Oil Pump 5052
Remove 5052
Clean and Inspect 5053
Outer Rotor Outside Clearance 5053
Outer Rotor to Inner Rotor Tip Clearance 5054
Outer Rotor Side Clearance 5054
Rotor Shaft Clearance 5054
Install 5054
Fuel System Repair 5055
Fuel Injectors 5055
Remove 5055
Inspect 5055
Clean 5055
Replace 5056
Install 5056
Test 5056
Fuel Injection Pump 5056
Remove 5056
Clean and Inspect 5058
Install 5058
Cooling System Repair 5059
Serpentine Belt 5059
Remove 5059
Inspect 5059
Install 5059
Adjust 5060
Water Pump 5060
Remove 5060
Install 5062
Thermostat 5063
Remove 5063
Inspect 5063
Install 5064
Flywheel and Flywheel Housing 5065
Flywheel 5065
Remove 5065
Install 5065
Flywheel Housing 5065
Remove 5065
Install 5066
Electrical Equipment Repair 5066
General 5066
Alternator 5066
Remove 5066
Install 5067
Starter 5068
Remove 5068
Install 5068
Engine Specifications 5070
Engine Data 5070
Engine Tuning 5071
Cylinder Head 5071
Intake/Exhaust Valve and Guide 5071
Valve Spring 5072
Rocker Arm and Shaft 5072
Push Rod 5072
Gear Train and Camshaft 5072
Camshaft 5072
Idle Gear Shaft and Bushing 5072
Backlash of Each Gear 5073
Cylinder Block 5073
Crankshaft 5073
Piston 5073
Piston Ring 5074
Connecting Rod 5074
Rod Small End 5074
Tappet 5074
Oil Pump 5075
Engine Oil Pressure 5075
Outer Rotor Outside Clearance 5075
Outer Rotor Side Clearance 5075
Inner Rotor to Cover 5075
Standard Torque Specifications 5076
Standard Torque Chart 5076
Special Torque Specifications 5076
Special Tools 5078
550229998 0600YRM2295 (01 2021) US EN 5091
General 5097
Engine Identification 5097
Major Engine Component Identification 5097
Location of Labels 5098
Cylinder Block Description 5099
Precautions Before Beginning Repair 5100
Exhaust System, SCR, and DPF 5100
Engine Removal and Installation 5101
Cylinder Head Assembly Repair 5101
Valve Covers and Fuel Injectors 5101
Remove 5101
Clean and Inspect 5104
Install 5104
Rocker Arm Assembly 5105
Remove 5105
Disassemble 5106
Clean and Inspect 5106
Push Rods 5106
Rocker Arm Assembly 5106
Assemble 5107
Install 5107
Valve Clearance Adjustments 5107
Cylinder Head Assembly 5108
Remove 5108
Disassemble 5117
Valves and Valve Springs, Remove 5117
Valve Guides, Remove 5118
Clean and Inspect 5118
Cylinder Head 5119
Valve Guides 5119
Valves 5119
Valve Sink 5120
Valve Seat 5120
Valve Springs 5121
Assemble 5121
Valve Guides, Install 5121
Valves and Valve Springs, Install 5122
Install 5123
Timing Gear Case and Timing Gears Repair 5125
Timing Gear Case Cover 5125
Remove 5125
Clean and Inspect 5126
Install 5126
Timing Gears 5127
Crankshaft Gear 5127
Remove 5127
Install 5128
Idler Gear 1 and Idler Gear 2 5128
Remove 5128
Inspect 5129
Install 5130
Idler Gear 3 5130
Remove 5130
Inspect 5130
Install 5130
Camshaft Gear 5130
Remove 5130
Install 5130
Drive Train, Camshaft, and Cylinder Block Repair 5131
Remove 5131
Disassemble 5131
Pistons and Connecting Rods 5131
Crankshaft 5132
Camshaft 5134
Clean and Inspect 5136
Cylinder Block 5136
Honing and Boring 5138
Cylinder Correction (Oversize) 5139
Pistons 5139
Piston Pin 5140
Connecting Rod 5140
Tappets 5141
Crankshaft 5141
Camshaft 5143
Camshaft Bushing 5144
Assemble 5144
Camshaft 5144
Crankshaft 5144
Pistons and Connecting Rods 5145
Install 5147
Angular Deviation Procedure 5147
Lubrication System Repair 5150
Engine Oil and Oil Filter Change (Standard Oil Filter) 5150
Engine Oil and Oil Filter Change (Remote Oil Filter) 5150
Oil Pan 5151
Remove 5151
Install 5151
Oil Suction Tube 5152
Remove 5152
Clean 5152
Install 5152
Oil Pump 5152
Remove 5152
Clean and Inspect 5153
Inner Rotor and Outer Rotor Clearance 5153
Outer Rotor and Pump Body Clearance 5154
Rotor and Cover Clearance 5154
Rotor Shaft Clearance 5154
Install 5154
Remote Oil Filter 5155
Remove 5155
Clean and Inspect 5157
Install 5157
Fuel System Repair 5158
Fuel Injectors 5158
Remove 5158
Inspect 5158
Clean 5158
Replace 5158
Install 5159
Test 5159
Fuel Injection Pump 5159
Remove 5159
Clean and Inspect 5162
Install 5163
Cooling System Repair 5164
Serpentine Belt 5164
Remove 5164
Inspect 5164
Install 5164
Adjust 5164
Water Pump 5165
Remove 5165
Install 5166
Thermostat 5167
Remove 5167
Inspect 5168
Install 5168
Flywheel and Flywheel Housing 5170
Flywheel 5170
Remove 5170
Install 5170
Flywheel Housing 5170
Remove 5170
Install 5170
Electrical Equipment Repair 5171
Alternator 5171
Remove 5171
Install 5172
Starter 5173
Remove 5173
Install 5173
Engine Specifications 5175
Engine Data 5175
Engine Tuning 5177
Cylinder Head 5177
Intake/Exhaust Valve and Guide 5178
Valve Spring 5178
Rocker Arm and Shaft 5178
Push Rod 5178
Gear Train and Camshaft 5179
Camshaft 5179
Idle Gear Shaft and Bushing 5179
Backlash of Each Gear 5179
Cylinder Block 5179
Crankshaft 5180
Piston 5180
Piston Ring 5180
Connecting Rod 5181
Rod Small End 5181
Tappet 5181
Oil Pump 5181
Engine Oil Pressure 5181
Inner and Outer Rotor Clearance 5181
Outer Rotor and Pump Body 5181
Rotor and Cover 5182
Standard Torque Specifications 5182
Standard Torque Chart 5182
Special Torque Specifications 5183
Special Tools 5184