Yale Forklift H878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GP155SVX, GP170SVX) Service Manual

Yale Forklift H878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GP155SVX, GP170SVX) Service Manual – PDF DOWNLOAD

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Yale Forklift H878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GP155SVX, GP170SVX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2428
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift H878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GP155SVX, GP170SVX) 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
524223769 2200YRM1128 (01 2023) US EN 23
Series Code / Model Designation Reference Table 31
General 33
Deutsch Crimping Tool 34
How to Strip a Wire for Use With Deutsch Crimping Tool 34
How to Crimp With the Deutsch Crimping Tool 35
Calibration Test for the Deutsch Crimping Tool 37
Deutsch Connectors 39
DT, DTM, and DTP Series Connectors 39
HD Series Connectors 82
Metri-Pack Connectors 104
Remove and Install 104
Micro-Pack Connectors 107
Weather-Pack Connectors 108
AMPSEAL Crimping Tools 110
AMP Hand Crimping Tool With Certi-Crimp 110
Description 110
Stripping Wire for Use with AMP Hand Crimping Tool 111
Insulation Crimp Adjustment 112
Maintenance and Inspection for AMP Hand Crimping Tool 112
AMP Hand Crimping Tool 112
Crimp Height Inspection 112
How to use AMP Hand Crimping Tool 113
AMP Pro-Crimper II Tool 113
Description 113
Remove and Install Die Set and Locator Assembly 114
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 114
Contact Support Adjustment 115
Crimp Height Adjustment 116
Maintenance and Inspection Procedures 116
PRO-CRIMPER II Tool 116
Crimp Height Inspection 116
How to Use AMP PRO-CRIMPER II Tool 117
AMPSEAL Connector Assemblies 118
Description for Plug Connector Assembly 118
Seal Plug 119
Contact Crimping 119
Description for Plug Connector and Header Assembly 124
Voltage Reading 127
Seal Plug 127
Contact Crimping 127
AMP Superseal 1 5 Crimping Tools 134
Mini Mic Receptacle and Tab Contacts 134
Description 134
Crimping Conditions and Measurements 134
Insertion of Rubber Seal on Cable 136
AMP Hand Application Tool 141
Description 141
Maintenance and Inspection 141
Crimp Height Inspection 141
Crimp Height Adjustment 142
How to Use AMP Hand Application Tool 142
AMP Pro-Crimper II Tool 143
Description 143
Remove and Install Die Set and Locator Assembly 143
Adjustments 144
Contact Support 144
Crimp Height 145
Inspections and Maintenance 146
Crimp Height Inspection 146
Visual Inspection 146
Maintenance 147
How to Use Pro-Crimper II Tool 147
AMP Superseal 1 5 Connector Assemblies 148
Description 148
Repair and Maintenance 155
Panel Mount Option 155
AMP Fastin-Faston Hand Tools 156
Description – AMP Double Action Hand Tool 156
Maintenance and Inspection Procedures 156
Daily Maintenance 156
Periodic Tool Inspection 157
Lubrication 157
Visual Inspection 157
Crimp Height Inspection 157
Certi-Crimp Ratchet Inspection 158
How to Use AMP Double Action Hand Tool 159
Description – AMP Extraction Tool 160
Maintenance and Inspection 161
How to Use AMP Extraction Tool 161
AMP Fastin-Faston Receptacles and Housings 163
Description 163
Wire Repair 171
Wire Splicing Requirements 171
Deutsch Jiffy Splice 172
Twisted/Shielded Cable and Leads Repair 178
Special Tools 180
524223770 2200YRM1130 (05 2021) US EN – Copy 189
General 193
Description 193
Dash Display Menu Access 193
Menu Navigation 194
Standard Display 194
Main Menu 194
Passwords Menu 195
Password Administration 195
Add Password 195
Delete Password 195
Edit Password 196
Other Password Functions 197
Operator Passwords – Enable/Disable 197
Password Time-Out Delay 197
Passwords – Number Wrong to Disable 197
Lockout Reset Password 198
View Password Log 198
View Versions 199
VSM Versions 199
Dash Display Versions 200
Engine Controller Version 201
Transmission (Xmsn) Controller Version 202
Truck Serial Number 203
Diagnostics 204
View Fault Log 204
Set Travel and Braking 205
Speed Limit 205
Acceleration Rate 206
Auto-Deceleration Rate 206
Set Power Reversal Rate 207
Set Inching/Brake Overlap 208
Setup Display Menu 209
Set Operator Language 209
Set Units 210
Set Time Format (12/24 Hour) 210
Set Daylight Saving Time 211
Set Time 214
Set Date Format 214
Set Date 215
Setup Hydraulics 216
Return to Set Tilt Delay/On/Off 216
Setup General Items 217
Light Shutdown Time-Out 217
Impact Sensor – Enable/Disable 218
Impact Sensor – Soft Impact Settings 219
Impact Sensor – Hard Impact Settings 219
Adjust Impact Sensor Settings 220
Initial Adjustment of Soft and Hard Impact Settings 222
Readjustment of Soft and Hard Impact Settings 222
Impact Sensor – Impact Alarm/Shutdown Reset 223
Impact Sensor – Alarm Time Duration and Deactivation 224
Impact Sensor – View Impact Event Log 225
Engine Mode Indicator 225
Generation 1 (ECO-eLo ONLY) 225
Generation 2 226
Operator Checklist 227
Operator Checklist Off-On Mode 227
Edit Operator Checklist 227
Set Operator Checklist Expiration 227
View Checklist Log 228
Clear Operator Checklist Log 229
Clear Operator Checklist Fault 229
Calibrations 230
Set Tilt Stop Point 230
Calibrate Loaded Weight 230
524223770 2200YRM1130 (05 2021) US EN 233
General 237
Description 237
Dash Display Menu Access 237
Menu Navigation 238
Standard Display 238
Main Menu 238
Passwords Menu 239
Password Administration 239
Add Password 239
Delete Password 239
Edit Password 240
Other Password Functions 241
Operator Passwords – Enable/Disable 241
Password Time-Out Delay 241
Passwords – Number Wrong to Disable 241
Lockout Reset Password 242
View Password Log 242
View Versions 243
VSM Versions 243
Dash Display Versions 244
Engine Controller Version 245
Transmission (Xmsn) Controller Version 246
Truck Serial Number 247
Diagnostics 248
View Fault Log 248
Set Travel and Braking 249
Speed Limit 249
Acceleration Rate 250
Auto-Deceleration Rate 250
Set Power Reversal Rate 251
Set Inching/Brake Overlap 252
Setup Display Menu 253
Set Operator Language 253
Set Units 254
Set Time Format (12/24 Hour) 254
Set Daylight Saving Time 255
Set Time 258
Set Date Format 258
Set Date 259
Setup Hydraulics 260
Return to Set Tilt Delay/On/Off 260
Setup General Items 261
Light Shutdown Time-Out 261
Impact Sensor – Enable/Disable 262
Impact Sensor – Soft Impact Settings 263
Impact Sensor – Hard Impact Settings 263
Adjust Impact Sensor Settings 264
Initial Adjustment of Soft and Hard Impact Settings 266
Readjustment of Soft and Hard Impact Settings 266
Impact Sensor – Impact Alarm/Shutdown Reset 267
Impact Sensor – Alarm Time Duration and Deactivation 268
Impact Sensor – View Impact Event Log 269
Engine Mode Indicator 269
Generation 1 (ECO-eLo ONLY) 269
Generation 2 270
Operator Checklist 271
Operator Checklist Off-On Mode 271
Edit Operator Checklist 271
Set Operator Checklist Expiration 271
View Checklist Log 272
Clear Operator Checklist Log 273
Clear Operator Checklist Fault 273
Calibrations 274
Set Tilt Stop Point 274
Calibrate Loaded Weight 274
524223771 2200YRM1131 (05 2021) US EN 277
Series Code / Model Designation Reference Table 283
General 285
Description 285
Dash Display Menu Access 285
Menu Navigation 286
Main Menu 287
Passwords 287
Adding Passwords 287
Hourmeters 289
View Versions 290
VSM Versions 290
Dash Display Versions 291
Engine Controller Version 292
Transmission (Xmsn) Controller Version 293
Truck Serial Number 294
Truck Configuration 295
Diagnostics 296
Clear Fault Log 296
View Fault Log 297
No-Run Data Display 298
Engine Accelerator and Throttle Data Display 299
Engine Speeds and Governor Data Display 301
Engine Fuel and Emissions Data Display 302
Engine General Data Display 304
XMSN/Brake Data Display 305
Hydraulic Data Display 307
General Truck Data Display 310
Set Travel and Braking 312
Speed Limit 312
Acceleration Rate 313
Auto-Deceleration Rate 313
Set Power Reversal Rate 314
Set Inching/Brake Overlap 314
Setup Hydraulics 315
Lift Maximum Speed 315
Lower Maximum Speed 316
Tilt Maximum Speed 316
Auxiliary Function One, Direction A, Maximum Speed 318
Auxiliary Function One, Direction B, Maximum Speed 321
Auxiliary Function Two, Direction A, Maximum Speed 321
Auxiliary Function Two, Direction B, Maximum Speed 322
Auxiliary Function Three, Direction A, Maximum Speed 323
Auxiliary Function Three, Direction B, Maximum Speed 323
Lift/Lower Ramp Rate 324
Hydraulic Auxiliary Ramp Rate 324
Return to Set Tilt Delay/On/Off 325
Hydraulic Input Device 326
Auxiliary Solenoid 326
Dual Function 327
Setup Display 328
Set Service Language 328
Setup General Items 328
Motion Alarm Activation Type 329
Light Shutdown Time-Out 330
Restore Default Settings 330
Restore Engine Controller Default Calibration 331
Impact Sensor – Enable/Disable 331
Impact Sensor – Soft Impact Settings 332
Impact Sensor – Hard Impact Settings 332
Adjust Impact Sensor Settings 333
Initial Adjustment of Soft and Hard Impact Settings 335
Readjustment of Soft and Hard Impact Settings 335
Impact Sensor – Impact Alarm/Shutdown Reset 336
Impact Sensor – Alarm Time Duration and Deactivation 337
Impact Sensor – View Impact Event Log 338
Engine Mode Indicator 338
Generation 1 (ECO-eLo ONLY) 338
Generation 2 339
Diesel Particulate Filter (DPF) Display 340
General Description 340
Passive Regeneration Only 340
Regeneration Level 0 340
Auto/Active Regeneration Inhibited 341
Auto/Active Regeneration 341
Regeneration Level 1 341
Parked Regeneration Request 342
Regeneration Level 2 342
Warning Level 343
Regeneration Level 3 343
Service Level 343
Regeneration Level 4 343
Display, Diesel Particulate Filter (DPF), Revised 343
Operator Interface 344
Refer to Operator Manual 344
CAN Communication Lost 344
Passive Regeneration Only 344
Regeneration Level 0 344
Auto/Active Regeneration Inhibited 345
Auto/Active Regeneration 345
Regeneration Level 1 345
Idle-up Auto/Active Regeneration 345
Parked Regeneration Request 346
Regeneration Level 2 346
Warning Level 347
Regeneration Level 3 347
Service Level 347
Regeneration Level 4 347
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 348
Display, Diesel Particulate Filter (DPF), Stage V Engine 348
Operator Interface 348
Refer to Operator Manual 348
CAN Communication Lost 349
Passive Regeneration Only 349
Regeneration Level 0 349
Auto/Active Regeneration Inhibited 349
Auto/Active Regeneration 350
Regeneration Level 1 350
Idle-up Auto/Active Regeneration 350
Parked Regeneration Request 350
Regeneration Level 2 350
Warning Level 352
Regeneration Level 3 352
Service Level 352
Regeneration Level 4 352
Stage V Content 352
Emissions System Malfunction 352
Ash Load 353
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 354
Operator Interface 354
Refer to Operator Manual 354
CAN Communication Lost 355
Passive Regeneration Only 355
Regeneration Level 0 355
Auto/Active Regeneration Inhibited 355
Auto/Active Regeneration 356
Regeneration Level 1 356
Idle-up Auto/Active Regeneration 356
Parked Regeneration Request 356
Regeneration Level 2 356
Warning Level 358
Regeneration Level 3 358
Service Level 358
Regeneration Level 4 358
Calibrations 359
Calibrate Transmission Valve 361
Set Tilt Stop Point 361
Calibrate Loaded Weight 362
Calibrate Travel Speed Sensor 362
Calibrate Mazda LP and Gas Accelerator Pedal 363
524223780 8000YRM1134 (05 2022) US EN 365
Series Code / Model Designation Reference Table 371
Description 374
Proc_Cal_001: Service Password Entry 376
When to Perform 376
Why Perform 376
How to Perform 376
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 377
When to Perform 377
Calibration Order 377
Why Perform 377
How to Perform 377
Proc_Cal_003: Save and Exit 379
When to Perform 379
Why Perform 379
How to Perform 379
Proc_Cal_004: Lift Valve Output Threshold 380
When to Perform 380
Calibration Order 380
Why Perform 380
How to Perform 380
Proc_Cal_005: Lower Valve Output Threshold 383
When to Perform 383
Calibration Order 383
Why Perform 383
How to Perform 383
Proc_Cal_006: Tilt Back Valve Output Threshold 386
When to Perform 386
Calibration Order 386
Why Perform 386
How to Perform 386
Proc_Cal_007: Tilt Forward Valve Output Threshold 389
When to Perform 389
Calibration Order 389
Why Perform 389
How to Perform 389
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 392
When to Perform 392
Calibration Order 392
Why Perform 392
How to Perform 392
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 395
When to Perform 395
Calibration Order 395
Why Perform 395
How to Perform 395
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 398
When to Perform 398
Calibration Order 398
Why Perform 398
How to Perform 398
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 401
When to Perform 401
Calibration Order 401
Why Perform 401
How to Perform 401
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 404
When to Perform 404
Calibration Order 404
Why Perform 404
How to Perform 404
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 407
When to Perform 407
Calibration Order 407
Why Perform 407
How to Perform 407
Proc_Cal_014: Load Weight Zero Point 410
When to Perform 410
Calibration Order 410
Why Perform 410
How to Perform 410
Proc_Cal_015: Loaded Weight Calibration 412
When to Perform 412
Calibration Order 412
Why Perform 412
How to Perform 412
Proc_Cal_016: Transmission Valve Calibration 415
Applicable System/Option 415
When to Perform 415
Calibration Order 415
Why Perform 415
How to Perform 415
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 417
Applicable System/Option 417
When to Perform 417
Calibration Order 417
Why Perform 417
How to Perform 417
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 420
Applicable System/Option 420
When to Perform 420
Calibration Order 420
Why Perform 420
How to Perform 420
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 423
Required Tools 423
When to Perform 423
Calibration Order 423
Why Perform 423
How to Perform 423
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 425
When to Perform 425
Why Perform 425
How to Perform 425
Proc_Cal_026: Travel Speed Calibration 427
When to Perform 427
Calibration Order 427
Why Perform 427
How to Perform 427
524288194 1300YRM1317 (06 2021) US EN 431
Transmission Repair 435
Remove 435
Torque Converter, Remove 435
Disassemble 436
Clean and Inspect 487
Housings 487
Oil Seals and Gaskets 487
Bearings 487
Gears and Shafts 488
Assemble 488
Torque Converter, Install 530
Install 531
Control Valve Repair 532
Remove 532
Disassemble 532
Clean 534
Inspect 534
Assemble 534
Install 535
Torque Specification 536
524294873 1300YRM1343 (06 2021) US EN 539
Transmission Repair 543
Remove 543
Torque Converter, Remove 543
Disassemble 545
Clean and Inspect 586
Housings 586
Oil Seals and Gaskets 586
Bearings 586
Gears and Shafts 587
Assemble 587
Torque Converter, Install 625
Install 626
Control Valve Repair 627
Remove 627
Disassemble 627
Control Valve Assembly 627
Control Valve Body 627
Clean 630
Inspect 630
Assemble 630
Control Valve Body 630
Control Valve Assembly 631
Install 631
Torque Specification 633
524296605 1400YRM1344 (06 2021) US EN 635
General 639
Identification Plate 639
Drive Axle Removal 640
Planetary Reduction Gear Repair 652
Clean and Inspect 661
Brake Repair 671
Clean and Inspect 683
Wet Brake Noise Reduction 694
General 694
Adding Additive To Transmission 694
Differential Repair 696
Clean and Inspect 706
Bevel Pinion 718
Clean and Inspect 722
Drive Axle Installation 733
Special Tools 745
Torque Specifications 746
550055279 0600YRM1579 (06 2021) US EN 749
General 755
Engine Identification 755
Major Engine Component Identification 755
Location of Labels 755
Crankcase Description 756
Engine Removal and Installation 757
Cylinder Head Assembly Repair 758
Valve Covers and Fuel Injectors 758
Remove 758
Clean and Inspect 761
Install 762
Rocker Arm Assembly 764
Remove 764
Disassemble 765
Clean and Inspect 765
Push Rods 765
Rocker Arm Assembly 766
Assemble 766
Install 766
Valve Clearance Adjustments 767
Cylinder Head Assembly 768
Remove 768
Disassemble 775
Valves and Valve Springs, Remove 775
Valve Guides, Remove 777
Clean and Inspect 777
Cylinder Head 778
Valve Guides 778
Valves 778
Valve Sink 779
Valve Seat 779
Valve Springs 779
Assemble 780
Valve Guides, Install 780
Valves and Valve Springs, Install 781
Install 781
Timing Gear Case and Timing Gears Repair 785
Timing Gear Case Cover 785
Remove 785
Clean and Inspect 785
Install 785
Timing Gears 786
Crankshaft Gear 787
Remove 787
Install 787
Idler Gear 787
Remove 787
Inspect 788
Install 788
Camshaft Gear 788
Remove 788
Install 789
Timing Gear Case 789
Remove 789
Clean and Inspect 790
Install 790
Drive Train, Camshaft, and Cylinder Block Repair 791
Remove 791
Disassemble 791
Pistons and Connecting Rods 791
Crankshaft 792
Camshaft 794
Clean and Inspect 795
Cylinder Block 796
Honing and Boring 798
Cylinder Correction (Oversize) 799
Pistons 799
Piston Pin 800
Connecting Rod 800
Tappets 800
Crankshaft 801
Camshaft 803
Camshaft Bushing 804
Assemble 804
Camshaft 804
Crankshaft 804
Pistons and Connecting Rods 804
Install 806
Lubrication System Repair 808
Engine Oil and Oil Filter Change 808
Oil Pan 809
Remove 809
Install 810
Oil Suction Tube 810
Remove 810
Clean 811
Install 811
Oil Pump 811
Remove 811
Clean and Inspect 811
Outer Rotor Outside Clearance 812
Outer Rotor to Inner Rotor Tip Clearance 812
Outer Rotor Side Clearance 812
Rotor Shaft Clearance 813
Install 813
Fuel System Repair 814
Fuel Injectors 814
Remove 814
Inspect 814
Clean 814
Replace 814
Install 814
Electronic Throttle System 815
Remove 815
Throttle Position Sensor Proceedures After September 2018 GDP60-70VX (GDP135-155VX) (F878), GDP60VX, GDP70VX, GP70VXS6 (GDP135VX GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) and GP080VX, GP090VX, GP100VX, GP100VX, GP120VX (GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5, GDP50VX, GDP55VX) (K813) 818
Bearing Replacement 819
Install 819
Adjustment 820
Fuel Injection Pump 821
Remove 821
Disassemble 824
Clean and Inspect 826
Assemble 826
Install 827
Cooling System Repair 829
Serpentine Belt 829
Remove 829
Inspect 829
Install 829
Serpentine Belt, Adjustment 829
Water Pump 830
Remove 830
Install 832
Thermostat 833
Remove 833
Inspect 834
Install 834
Flywheel and Flywheel Housing 836
Flywheel 836
Remove 836
Install 836
Flywheel Housing 836
Remove 836
Install 836
Electrical Equipment Repair 837
Alternator 837
Remove 837
Install 838
Starter 839
Remove 839
Install 839
Engine Specifications 840
Engine Data 840
Engine Tuning 840
Cylinder Head 841
Intake/Exhaust Valve and Guide 841
Valve Spring 842
Rocker Arm and Shaft 842
Push Rod 842
Gear Train and Camshaft 842
Camshaft 842
Idle Gear Shaft and Bushing 842
Backlash of Each Gear 843
Cylinder Block 843
Crankshaft 843
Piston 843
Piston Ring 844
Connecting Rod 844
Rod Small End 844
Tappet 844
Oil Pump 845
Engine Oil Pressure 845
Outer Rotor Outside Clearance 845
Outer Rotor Side Clearance 845
Inner Rotor to Cover 845
Standard Torque Specifications 846
Standard Torque Chart 846
Special Torque Specifications 847
Special Tools 849
550073240 1900YRM1620 (01 2023) US EN 859
Proper Flushing after Major Hydraulic Repairs 865
Introduction 865
The Phases of Wear 865
Causes of Hydraulic System Failure 865
Progression of Contaminant Caused Hydraulic System Failure 866
Hydraulic System Flushing Techniques 866
Double Oil and Filter Change 866
Mechanical Cleaning 867
Cleaning of Components 867
How to Clean Tubes and Hoses 867
Filter Caddy 867
Start-Up Procedure for Cleaned System 868
Contaminated Oil Coolers 868
Additional Filter Caddy Functions 869
How to Handle Different Fluids 869
Water Removal Filters 869
Fluid Conditioning and System Flushing Procedures 870
Operation of the Filter Caddy 870
Filter Caddy operation 870
Fluid Conditioning Procedure 870
Filter Caddy Start-Up 871
System Flushing Procedure 871
Component Cleaning Procedure 872
Reservoir Cleaning Procedure 872
Cylinder Cleaning Procedure 872
Hose and Tube Cleaning Procedure 872
Valve Cleaning Procedure 873
Front-End Attachment Cleaning Procedure 874
System Flushing Procedure 874
Filter Caddy Start-Up 875
System Start-Up and Flushing 875
Reservoir Fluid Cleaning Times 876
Dealing With Different Fluid Types 877
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 877
Filter Caddy Maintenance 877
Servicing the Strainer 877
DC Motor 877
Hydraulic Oil Sampling Method and Procedure 878
Hydraulic Oil Sampling Method 878
Objective 878
General Guidelines 878
Synopsis 879
Hydraulic Oil Analysis Report Guidelines 880
Sampling Conditions 880
Equipment 880
Sampling Procedure 881
Hydraulic Oil Sampling 881
Sample Labeling 881
Results Documentation 881
550118410 0600YRM1893 (01 2022) US EN 883
General 891
Engine Identification 891
Major Engine Component Identification 891
Major Engine Component Identification 892
Location of Labels 893
Location of Labels 894
Crankcase Description 895
Engine Removal and Installation 896
Cylinder Head Assembly Repair 896
Valve Covers and Ignition Coils 896
Remove 896
Clean and Inspect 901
Install 901
Rocker Arm Assembly 902
Remove 902
Disassemble 904
Clean and Inspect 904
Push Rods 904
Rocker Arm Assembly 904
Assemble 905
Install 905
Valve Clearance Adjustments 905
Cylinder Head Assembly 906
Remove 906
Disassemble 912
Valves and Valve Springs, Remove 912
Valve Guides, Remove 913
Clean and Inspect 913
Cylinder Head 914
Valve Guides 914
Valves 915
Valve Sink 915
Valve Seat 915
Valve Springs 916
Assemble 916
Valve Guides, Install 916
Valves and Valve Springs, Install 917
Install 918
Timing Gear Case and Timing Gears Repair 921
Timing Gear Case Cover 921
Remove 921
Clean and Inspect 921
Install 921
Timing Gears 922
Crankshaft Gear 922
Remove 922
Install 923
Idler Gear 923
Remove 923
Inspect 923
Install 924
Camshaft Gear 924
Remove 924
Install 924
Timing Gear Case 925
Remove 925
Clean and Inspect 925
Install 925
Drive Train, Camshaft, and Cylinder Block Repair 926
Remove 926
Disassemble 926
Pistons and Connecting Rods 926
Crankshaft 927
Camshaft 929
Clean and Inspect 930
Cylinder Block 930
Honing and Boring 933
Cylinder Correction (Oversize) 934
Pistons 934
Piston Pin 935
Connecting Rod 935
Tappets 936
Crankshaft 936
Camshaft 938
Camshaft Bushing 939
Assemble 939
Camshaft 939
Crankshaft 939
Pistons and Connecting Rods 939
Install 941
Lubrication System Repair 943
Engine Oil and Oil Filter Change 943
Oil Pan 944
Remove 944
Install 944
Oil Suction Tube 944
Remove 944
Clean 945
Install 945
Oil Pump 945
Remove 945
Clean and Inspect 946
Outer Rotor Outside Clearance 946
Outer Rotor to Inner Rotor Tip Clearance 946
Outer Rotor Side Clearance 946
Rotor Shaft Clearance 947
Install 947
Fuel System Repair 948
Cooling System Repair 948
Serpentine Belt 948
Remove 948
Inspect 948
Install 948
Serpentine Belt, Adjustment 948
Water Pump 950
Remove 950
Install 952
Thermostat 953
Remove 953
Inspect 954
Install 954
Flywheel and Flywheel Housing 956
Flywheel 956
Remove 956
Install 956
Flywheel Housing 956
Remove 956
Install 956
Electrical Equipment Repair 957
Alternator 957
Remove 957
Install 958
Starter 959
Remove 959
Install 959
Engine Specifications 960
Engine Data 960
Engine Tuning 965
Cylinder Head 965
Intake/Exhaust Valve and Guide 965
Valve Spring 966
Rocker Arm and Shaft 966
Push Rod 966
Gear Train and Camshaft 966
Camshaft 966
Idle Gear Shaft and Bushing 967
Backlash of Each Gear 967
Cylinder Block 967
Crankshaft 967
Piston 968
Piston Ring 968
Connecting Rod 968
Rod Small End 968
Tappet 969
Oil Pump 969
Engine Oil Pressure 969
Outer Rotor Outside Clearance 969
Outer Rotor Side Clearance 969
Inner Rotor to Cover 969
Standard Torque Specifications 970
Standard Torque Chart 970
Special Torque Specifications 971
Special Tools 972
550118414 1900YRM1897 (06 2021) US EN 981
Series Code / Model Designation Reference Table 987
General 988
Hydraulic Gear Pump Assembly Repair 990
Remove 990
Disassemble 993
Clean 995
Inspect 995
Assemble 995
Install 995
Hydraulic Gear Pump Specifications 997
Variable Displacement Pump Repair 999
Remove 999
Disassemble 1002
Clean 1004
Inspect 1004
Assemble 1004
Install 1004
Variable Displacement Pump Checks and Adjustments 1007
Margin Pressure Check 1007
Flow Compensator Adjustment 1007
Pressure Compensator Adjustment 1008
Variable Displacement Pump Specifications 1010
Torque Specifications 1011
Hydraulic Gear Pump 1011
Variable Displacement Pump 1011
550118415 2000YRM1898 (06 2021) US EN 1013
Series Code / Model Designation Reference Table 1019
General 1020
Electro-Hydraulic Main Control Valve 1021
Description 1021
Remove 1027
Electro-Hydraulic Control Valve Sections 1031
General 1031
Outlet Control Valve Section 1031
Remove 1031
Disassemble 1031
Clean 1033
Inspect 1033
Assemble 1033
Install 1034
Auxiliary Control Valve Sections 1034
Remove 1034
Disassemble 1036
Clean 1036
Inspect 1037
Assemble 1037
Install 1038
Tilt Control Valve Section 1038
Remove 1038
Disassemble 1038
Clean 1040
Inspect 1040
Assemble 1040
Install 1040
Lift/Lower Control Valve Section 1040
Remove 1040
Disassemble 1040
Clean 1042
Inspect 1042
Assemble 1042
Install 1042
Transition Section 1042
Remove 1042
Disassemble 1043
Clean 1043
Inspect 1043
Assemble 1044
Install 1044
Install 1044
Manual Main Control Valve 1047
Description 1047
Remove 1049
OPS Solenoid Assembly 1053
General 1053
Remove 1054
Clean and Inspect 1056
Install 1056
Manual Control Valve Sections 1057
General 1057
Outlet Control Valve Section 1057
Remove 1057
Disassemble 1057
Clean 1059
Inspect 1059
Assemble 1059
Install 1059
Auxiliary Control Valve Sections 1060
Remove 1060
Disassemble 1060
Clean 1062
Inspect 1062
Assemble 1062
Install 1062
Lift/Tilt Control Valve Section 1063
Remove 1063
Disassemble 1063
Clean 1065
Inspect 1066
Assemble 1066
Install 1067
Install 1067
Pressure Relief Valve Check and Adjustment 1070
Primary Relief Valve 1070
Secondary Relief Valve 1071
Steering Control Unit Repair 1075
Steering Control Unit, Remove 1075
Steering Control Unit, Disassemble 1076
Steering Control Unit, Clean 1078
Steering Control Unit, Inspect 1078
Steering Control Unit, Assemble 1078
Relief Valve, Disassemble 1079
Relief Valve, Clean 1079
Relief Valve, Inspect 1080
Relief Valve, Assemble 1080
Steering Control Unit, Install 1080
550118555 0100YRM1892 (06 2021) US EN 1083
General 1091
Cab Replacement for 4-5 5 Ton Lift Trucks 1092
Remove 1092
Install 1102
Cab Replacement for 6-9 Ton Lift Trucks 1104
Remove 1104
Door Assemblies for 4-5 5 Ton Lift Trucks 1110
Right Side Door Assembly 1110
Remove 1110
Disassemble 1114
Door Cover With Heater Unit 1114
Door Cover With Air Conditioner/Heater Unit 1116
Heater Assembly 1118
Air Conditioner and Heater Unit Assembly 1118
Door Lock Assembly 1120
Windows 1121
Clean 1121
Inspect 1121
Assemble 1121
Windows 1121
Door Lock Assembly 1121
Heater Assembly 1121
Air Conditioner and Heater Unit Assembly 1122
Door Cover With Heater Unit 1122
Door Cover With Air Conditioner and Heater Unit 1122
Install 1122
Left Side Door Assembly 1123
Remove 1123
Disassemble 1123
Door Cover 1123
Door Lock Assembly 1123
Windows 1124
Clean 1124
Inspect 1124
Assemble 1124
Windows 1124
Door Lock Assembly 1124
Door Cover 1124
Install 1124
Door Assemblies for 6-9 Ton Lift Trucks 1125
Right and Left Side Door Assemblies 1125
Remove 1125
Disassemble 1126
Door Cover 1126
Door Lock Assembly 1127
Windows 1128
Clean 1128
Inspect 1128
Assemble 1128
Windows 1128
Door Lock Assembly 1129
Door Cover 1129
Install 1129
Window Replacement 1130
General 1130
Remove Door Windows for 4-5 5 Ton Lift Trucks 1130
Install Door Windows for 4-5 5 Ton Lift Trucks 1131
Remove Door Windows for 6-9 Ton Lift Trucks 1131
Install Door Windows for 6-9 Ton Lift Trucks 1133
Window Wipers Replacement 1134
General 1134
Front Wiper Assembly and Motor 1134
Remove 1134
Install 1136
Rear Wiper Assembly and Motor 1136
Remove, for 4-5 5 Ton Lift Trucks 1136
Install for 4-5 5 Ton Lift Trucks 1139
Remove for 6-9 Ton Lift Trucks 1139
Install for 6-9 Ton Lift Truck 1141
Heater Replacement 1142
Remove for 6-9 Ton Lift Trucks 1142
Install for 6-9 Ton Lift Trucks 1148
Heater and Air Conditioner Assembly 1149
Air Conditioner Condenser Unit 1149
Remove 1149
Install 1150
Air Conditioner Receiver/Drier Unit 1150
Remove 1150
Install 1152
Air Conditioner Compressor 1152
Light Replacement 1153
Work Lights (Front and Rear) 1153
Remove 1153
Install 1155
Strobe Light 1155
Remove 1155
Install 1156
Turn, Stop, Tail, and Backup Light 1156
Remove 1156
Install 1157
Front Marker/Turn Signal Lights 1157
Remove 1157
Install 1157
Display Switches 1158
Electrical Schematics 1161
Optional Equipment 1161
Heavy Duty Pre-Cleaner 1161
Fan 1161
Remove 1161
Install 1163
Mirror 1163
Remove 1163
Install 1163
Rear View Camera 1163
Monitor Removal 1163
Monitor Install 1165
Camera removal 1165
Camera install 1165
Label Replacement 1166
550119576 0900YRM1905 (01 2022) US EN 1169
General 1175
LPG Tank and Bracket Replacement 1176
Remove LPG Tank, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1176
Remove LPG Tank, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1179
Install LPG Tank, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1180
Install LPG Tank, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1180
Remove LPG Bracket, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1181
Remove LPG Bracket, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1183
Install LPG Bracket, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1184
Install LPG Bracket, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1184
Remove LPG Tank Bracket Alignment Pin, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1185
Remove LPG Tank Bracket Alignment Pin, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1187
Install LPG Tank Bracket Alignment Pin, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1187
Install LPG Tank Bracket Alignment Pin, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1188
LPG Fuel Filter Unit Repair 1190
LPG Fuel Filter Element, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1190
Remove/Disassemble 1190
Clean/Inspect 1192
Assemble/Install 1192
LPG Fuel Filter Element, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1192
Remove/Disassemble 1192
Clean/Inspect 1193
Assemble/Install 1193
Fuel Filter Housing, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1193
Remove 1193
Disassemble 1199
Clean and Inspect 1200
Assemble 1200
Install 1200
Fuel Filter Housing, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1201
Remove 1201
Disassemble 1202
Clean and Inspect 1203
Assemble 1203
Install 1204
Electronic Throttle Body Repair 1205
Remove 1205
Install 1207
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 1208
Remove 1208
Install 1211
Control System 1212
Engine Control Unit (ECU) 1212
Remove 1212
Install 1212
LPG Low Level Sensor 1213
Remove 1213
Remove 1215
Install 1216
Exhaust System 1217
Counterweight Exhaust 1217
Remove and Disassemble 1217
Remove and Disassemble 1219
Inspect 1221
Assemble and Install 1221
Assemble and Install 1221
Exhaust Manifold 1221
Remove 1221
Install 1222
Oxygen (HEGO) Sensor 1222
Remove 1222
Install 1222
LPG Fuel Testing 1223
General 1223
Available Fuel Tests 1223
Composition Test (ASTM D-2163) 1223
Ammonia Test (ASTM D-4490) 1223
Basic Nitrogen Test (ASTM UOP269-90) 1223
Residues Test (ASTM D-2158) 1223
Vapor Pressure Test (ASTM D-2598) 1223
Sulfur Compounds Test (ASTM D-5623) 1223
Methanol Test (ASTM D-4864) 1224
Copper Corrosion (ASTM D-1838) 1224
Where To Send LPG Fuel Samples For Testing 1224
550131845 0100YRM1948 (09 2022) US EN 1227
General 1231
Description 1232
Side Covers, Seat, Dash, and Hood Replacement 1233
Side Covers 1233
Remove 1233
Install 1233
Seat and Seat Plate 1234
Remove Seat 1234
Remove Seat Plate 1234
Install Seat Plate 1234
Install Seat 1234
Operator Restraint System 1238
Emergency Locking Retractor (ELR) 1238
Seat Plate and Seat Rail Check 1238
Steering Column, Dash, Kick Panel, and Seal Plate 1238
Remove 1238
Install 1241
Hood Support and Door Assembly 1243
Remove 1243
Install 1244
Hood Door Assembly 1249
Remove 1249
Install 1250
Steering Column 1251
Description 1251
Steering Column Repair 1251
Remove 1251
Disassemble 1252
Clean 1254
Inspect 1254
Assemble 1254
Install 1254
LPG Tank and Bracket Assembly 1254
Counterweight Replacement 1255
Remove 1255
Install 1256
Tow Pin, Remove and Install 1257
Overhead Guard Replacement 1258
Remove 1258
Install 1260
Engine Replacement 1261
Remove Engine 1261
Remove Transmission 1284
Remove Engine and Transmission 1288
Install Engine 1291
Install Transmission 1295
Install Engine and Transmission 1296
Throttle Pedal and Cable Adjustment 1300
Throttle Cable Adjustment, Kubota 3 6L Diesel Tier 3 Engine with Basic Powershift Transmission 1300
Exhaust System Repair 1302
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) 1302
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 1302
Kubota 3 8L Diesel Engine w/DPF 1302
Remove 1304
Inspect 1305
Install 1305
Kubota 3 8L Diesel Engine w/DOC 1305
Remove 1307
Inspect 1308
Install 1308
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) 1309
Remove 1309
Inspect 1311
Install 1311
Diesel Particulate Filter (DPF) 1312
Diesel Particulate Filter 1312
Disassemble 1312
Clean and Inspect 1313
Differential Pressure Pipes and Hoses 1314
Assemble 1314
Diesel Exhaust Fluid System 1315
General 1315
Description and Operation 1315
Selective Catalyst Reducer (SCR) 1319
Remove 1319
Clean and Inspect 1319
Install 1320
DEF Tank 1320
Remove 1320
Clean and Inspect 1322
Install 1322
Cooling System 1323
Description 1323
Hydraulic Filter Assembly Repair 1324
Remove 1324
Install 1326
Fuel and Hydraulic Tanks Repair 1327
Inspect 1327
Clean 1327
Steam Method of Cleaning 1327
Chemical Solution Method of Cleaning 1328
Additional Preparations for Repair 1328
Small Leaks, Repair 1329
Large Leaks, Repair 1329
Preparations for Use After Repair 1329
Safety Labels 1330
550131847 0600YRM1962 (06 2021) US EN 1339
General 1347
Engine Identification 1347
Major Engine Component Identification 1347
Location of Labels 1348
Cylinder Block Description 1348
Precautions Before Beginning Repair 1349
Exhaust System, SCR, and DPF 1350
Engine Removal and Installation 1351
Cylinder Head Assembly Repair 1351
Valve Covers and Fuel Injectors 1351
Remove 1351
Clean and Inspect 1354
Install 1354
Rocker Arm Assembly 1355
Remove 1355
Disassemble 1356
Clean and Inspect 1356
Push Rods 1356
Rocker Arm Assembly 1356
Assemble 1357
Install 1357
Valve Clearance Adjustments 1357
Cylinder Head Assembly 1358
Remove 1358
Disassemble 1367
Valves and Valve Springs, Remove 1367
Valve Guides, Remove 1368
Clean and Inspect 1368
Cylinder Head 1369
Valve Guides 1369
Valves 1369
Valve Sink 1370
Valve Seat 1370
Valve Springs 1371
Assemble 1371
Valve Guides, Install 1371
Valves and Valve Springs, Install 1372
Install 1373
Timing Gear Case and Timing Gears Repair 1376
Timing Gear Case Cover 1376
Remove 1376
Clean and Inspect 1376
Install 1377
Timing Gears 1378
Crankshaft Gear 1378
Remove 1378
Install 1379
Idler Gear 1 and Idler Gear 2 1379
Remove 1379
Inspect 1381
Install 1381
Idler Gear 3 1381
Remove 1381
Inspect 1381
Install 1381
Camshaft Gear 1382
Remove 1382
Install 1382
Drive Train, Camshaft, and Cylinder Block Repair 1383
Remove 1383
Disassemble 1383
Pistons and Connecting Rods 1383
Crankshaft 1384
Camshaft 1386
Clean and Inspect 1388
Cylinder Block 1388
Honing and Boring 1391
Cylinder Correction (Oversize) 1392
Pistons 1392
Piston Pin 1393
Connecting Rod 1393
Tappets 1394
Crankshaft 1394
Camshaft 1396
Camshaft Bushing 1397
Assemble 1397
Camshaft 1397
Crankshaft 1397
Pistons and Connecting Rods 1397
Install 1399
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 1400
Lubrication System Repair 1403
Engine Oil and Oil Filter Change (Standard Oil Filter) 1403
Engine Oil and Oil Filter Change (Remote Oil Filter) 1404
Oil Pan 1404
Remove 1404
Install 1405
Oil Suction Tube 1405
Remove 1405
Clean 1406
Install 1406
Oil Pump 1406
Remove 1406
Clean and Inspect 1407
Inner Rotor and Outer Rotor Clearance 1407
Outer Rotor and Pump Body Clearance 1408
Rotor and Cover Clearance 1408
Rotor Shaft Clearance 1408
Install 1409
Remote Oil Filter 1409
Remove 1409
Clean and Inspect 1411
Install 1412
Fuel System Repair 1413
Fuel Injectors 1413
Remove 1413
Inspect 1413
Clean 1413
Replace 1413
Install 1414
Test 1414
Fuel Injection Pump 1414
Remove 1414
Clean and Inspect 1418
Install 1418
Cooling System Repair 1419
Serpentine Belt 1419
Remove 1419
Inspect 1419
Install 1419
Adjust 1419
Water Pump 1420
Remove 1420
Install 1421
Thermostat 1422
Remove 1422
Inspect 1423
Install 1423
Flywheel and Flywheel Housing 1425
Flywheel 1425
Remove 1425
Install 1425
Flywheel Housing 1425
Remove 1425
Install 1425
Electrical Equipment Repair 1426
Alternator 1426
Remove 1426
Install 1427
Starter 1428
Remove 1428
Install 1428
Engine Specifications 1430
Engine Data 1430
Engine Tuning 1431
Cylinder Head 1431
Intake/Exhaust Valve and Guide 1432
Valve Spring 1432
Rocker Arm and Shaft 1432
Push Rod 1432
Gear Train and Camshaft 1433
Camshaft 1433
Idle Gear Shaft and Bushing 1433
Backlash of Each Gear 1433
Cylinder Block 1433
Crankshaft 1434
Piston 1434
Piston Ring 1434
Connecting Rod 1435
Rod Small End 1435
Tappet 1435
Oil Pump 1435
Engine Oil Pressure 1435
Inner and Outer Rotor Clearance 1435
Outer Rotor and Pump Body 1435
Rotor and Cover 1436
Standard Torque Specifications 1436
Standard Torque Chart 1436
Special Torque Specifications 1437
Special Tools 1438
550131848 0600YRM1961 (03 2020) US EN 1451
General 1457
Engine Identification 1458
Major Engine Component Identification 1458
Location of Labels 1460
Cylinder Block Description 1461
Precautions Before Beginning Repair 1462
Exhaust System and DPF 1463
Engine Removal and Installation 1463
Cylinder Head Assembly Repair 1463
Valve Covers and Fuel Injectors 1463
Remove 1463
Clean and Inspect 1466
Install 1466
Rocker Arm Assembly 1467
Remove 1467
Disassemble 1467
Clean and Inspect 1468
Push Rods 1468
Rocker Arm Assembly 1468
Assemble 1469
Install 1469
Valve Clearance Adjustments 1469
Cylinder Head Assembly 1470
Remove 1470
Disassemble 1478
Valves and Valve Springs, Remove 1478
Valve Guides, Remove 1479
Clean and Inspect 1479
Cylinder Head 1480
Valve Guides 1480
Valves 1481
Valve Sink 1481
Valve Seat 1481
Valve Springs 1482
Assemble 1482
Valve Guides, Install 1482
Valves and Valve Springs, Install 1483
Install 1484
Timing Gear Case and Timing Gears Repair 1486
Timing Gear Case Cover 1486
Remove 1486
Clean and Inspect 1487
Install 1487
Timing Gears 1488
Crankshaft Gear 1488
Remove 1488
Install 1489
Idler Gear 1 and Idler Gear 2 1489
Remove 1489
Inspect 1490
Install 1491
Idler Gear 3 1491
Remove 1491
Inspect 1491
Install 1491
Camshaft Gear 1491
Remove 1491
Install 1491
Drive Train, Camshaft, and Cylinder Block Repair 1492
Remove 1492
Disassemble 1492
Pistons and Connecting Rods 1492
Crankshaft 1493
Camshaft 1495
Clean and Inspect 1497
Cylinder Block 1497
Honing and Boring 1499
Cylinder Correction (Oversize) 1500
Pistons 1500
Piston Pin 1501
Connecting Rod 1501
Tappets 1502
Crankshaft 1502
Camshaft 1504
Camshaft Bushing 1505
Assemble 1505
Camshaft 1505
Crankshaft 1505
Pistons and Connecting Rods 1506
Install 1508
Angular Deviation Procedure 1508
Lubrication System Repair 1511
Engine Oil and Oil Filter Change 1511
Oil Pan 1512
Remove 1512
Install 1512
Oil Suction Tube 1512
Remove 1512
Clean 1513
Install 1513
Oil Pump 1513
Remove 1513
Clean and Inspect 1514
Inner Rotor and Outer Rotor Clearance 1514
Outer Rotor and Pump Body Clearance 1515
Rotor and Cover Clearance 1515
Rotor Shaft Clearance 1515
Install 1516
Fuel System Repair 1516
Fuel Injectors 1516
Remove 1516
Inspect 1516
Clean 1517
Replace 1517
Install 1517
Test 1517
Fuel Injection Pump 1517
Remove 1517
Clean and Inspect 1520
Install 1520
Cooling System Repair 1521
Serpentine Belt 1521
Remove 1521
Inspect 1521
Install 1521
Adjust 1521
Water Pump 1522
Remove 1522
Install 1524
Thermostat 1524
Remove 1524
Inspect 1525
Install 1525
Flywheel and Flywheel Housing 1526
Flywheel 1526
Remove 1526
Install 1527
Flywheel Housing 1527
Remove 1527
Install 1527
Electrical Equipment Repair 1528
Alternator 1528
Remove 1528
Install 1529
Starter 1530
Remove 1530
Install 1530
Engine Specifications 1532
Engine Data 1532
Engine Tuning 1534
Cylinder Head 1534
Intake/Exhaust Valve and Guide 1535
Valve Spring 1535
Rocker Arm and Shaft 1535
Push Rod 1535
Gear Train and Camshaft 1536
Camshaft 1536
Idle Gear Shaft and Bushing 1536
Backlash of Each Gear 1536
Cylinder Block 1536
Crankshaft 1537
Piston 1537
Piston Ring 1537
Connecting Rod 1538
Rod Small End 1538
Tappet 1538
Oil Pump 1538
Engine Oil Pressure 1538
Inner and Outer Rotor Clearance 1538
Outer Rotor and Pump Body 1538
Rotor and Cover 1539
Standard Torque Specifications 1539
Standard Torque Chart 1539
Special Torque Specifications 1539
Special Tools 1541
550131849 0700YRM1950 (06 2021) US EN 1555
General 1561
Cooling System Checks 1563
Exhaust Leaks Into Cooling System 1563
Water Flow Restrictions in Radiator 1563
Radiator Hoses 1563
Water Pump 1563
Flushing the Cooling System 1564
Cooling System, Clean 1564
Radiator Repair 1565
Remove 1565
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6, GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1565
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1573
Install 1579
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1579
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1581
Fan Assembly Replacement 1583
Remove 1583
Inspect 1588
Install 1588
550131851 1600YRM1952 (06 2021) US EN 1591
General 1597
Steering Axle Assembly Repair 1600
Remove 1600
Disassemble 1601
Clean 1603
Inspect 1603
Assemble 1603
Install 1604
Spindles, Bearings, and Tie Rods Repair 1605
Spindles and Bearings 1605
Remove 1605
Disassemble 1605
Clean 1606
Inspect 1606
Assemble 1606
Install 1607
Tie Rods 1607
Remove 1607
Install 1608
Steering Cylinder Repair 1609
Remove and Disassemble 1609
Clean and Inspect 1609
Assemble and Install 1609
Turn Assist (Lift trucks built after February 2019) 1611
Removal 1611
Install 1614
Adjustment 1614
Torque Specifications 1615
550131852 2100YRM1953 (06 2021) US EN 1617
General 1625
Safety Procedures When Working Near Mast 1625
Tilt Cylinder Repair 1627
Remove 1627
Disassemble 1630
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878); GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1630
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1630
Clean 1631
Inspect 1631
Assemble 1631
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1631
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1632
Install 1633
Tilt Cylinders, Adjust 1635
Tilt Cylinder Leak Check 1637
Lift Cylinder Repair 1638
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1638
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1641
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1646
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878),GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1652
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 1653
Clean 1654
Inspect 1654
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878),GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1654
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1654
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878),GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1655
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1655
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1656
Free-Lift Cylinder Repair 1657
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1657
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1660
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1662
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1663
Clean 1664
Inspect 1664
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1665
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1665
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878)GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1665
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1666
Sideshift Cylinder Repair 1667
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1667
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1667
Clean 1668
Inspect 1668
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1668
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1668
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1668
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1669
Clean 1671
Inspect 1671
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1671
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1671
Bolzoni Sideshift Cylinder Repair 1672
Remove 1672
Disassemble 1672
Clean 1673
Inspect 1673
Assemble 1674
Install 1674
Fork Positioner Cylinder Repair 1675
Remove 1675
Disassemble 1677
Clean 1680
Inspect 1680
Assemble 1681
Install 1682
Lift Cylinder Leak Check 1683
Seal Kit Installation 1684
External Installation (Seal and Back-Up Ring) 1684
Internal Installation (Piston Rod Assembly) 1684
Special Tools 1685
Torque Specifications 1686
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1686
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1686
550131853 2200YRM1954 (08 2021) US EN 1689
General 1699
Display Switch Cluster 1703
Remove 1703
Install 1705
Direction Control and Turn Signal Levers 1705
Remove 1705
Install 1706
Key Switch 1707
Remove 1707
Install 1707
Display Switch Cluster Panel Bezel and Overlay 1708
Remove 1708
Install 1708
Steering Column Repair 1709
Sensors and Switches 1712
General 1712
Dash and Kick Panel, Remove and Install 1712
Remove 1712
Install 1712
Accelerator Pedal Position Sensor 1713
Remove 1713
Install 1716
Brake Fluid Level Switch 1716
Remove 1716
Install 1717
Service Brake Pedal Position Sensor 1717
Remove 1717
Install 1718
Parking Brake Position Sensor 1718
Remove 1718
Install 1718
Service Brake Pressure Sensor 1719
Remove 1719
Install 1719
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 1720
Remove 1720
Install 1720
Sensor MicroswitchFoot Directional Control 1721
Remove 1721
Install 1723
Low Coolant Level Sensor 1723
Remove 1723
Install 1724
Fuel Level Sensor, Diesel Engines Only 1724
Remove 1724
Install 1725
Seat Sensor (Operator Presence System) 1725
Non-Suspension Seat 1725
Remove 1725
Install 1727
Full Suspension and Swivel Seats 1727
Remove 1727
Install 1727
Hood Shut Off Switch 1728
Remove 1728
Install 1728
Remote Key Switch 1729
Remove 1729
Install 1729
Hydraulic Filter Pressure Switch 1730
Remove 1730
Install 1730
Transmission Speed Sensor 1730
Remove 1730
Install 1731
Transmission Pressure Sensors 1731
Remove 1731
Install 1731
Transmission Temperature Sensor 1732
Remove 1732
Install 1732
Engine Speed Sensor 1732
Remove 1732
Install 1732
Intermediate Speed Sensor 1732
Remove 1732
Install 1732
Return To Set Tilt (Tilt Angle) Sensor 1732
Remove 1732
Install 1733
Rear Horn Button Switch 1733
Remove 1733
Install 1733
Impact Sensor 1734
Remove 1734
Install 1734
Load Weight Sensor 1735
Remove 1735
Install 1735
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 1736
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 1737
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 1737
Air Filter Restriction Switch 1737
Remove 1737
Install 1737
Engine Oil Pressure Sensor 1738
Remove 1738
Install 1738
Engine Speed Sensor 1738
Remove 1738
Install 1738
Engine Coolant Temperature (ECT) Sensor 1739
Remove 1739
Install 1739
Fuel/Water Separator Sensor 1739
Remove 1739
Install 1739
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 1740
Engine Coolant Temperature (ECT) Sensor 1740
Remove 1740
Install 1740
Throttle Position Sensor 1741
Engine Oil Pressure Sensor 1741
Remove 1741
Install 1741
Fuel Shut Off Solenoid 1741
Remove 1741
Install 1742
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) 1742
Intake Air Temperature Sensor 1743
Remove 1743
Install 1743
Boost Sensor 1743
Remove 1743
Install 1743
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 1745
Remove 1745
Install 1746
Engine Coolant Temperature (ECT) Sensor 1746
Remove 1746
Install 1746
Engine Oil Pressure Sensor 1746
Remove 1746
Install 1747
Crankshaft Position Sensor 1747
Remove 1747
Install 1747
Adjust Shim Procedure 1747
Camshaft Position Sensor 1749
Remove 1749
Install 1749
Differential Pressure Sensor 1749
Remove 1749
Install 1750
Oxygen Sensors (Inlet and Outlet) 1750
Remove 1750
Install 1751
Inlet Temperature Sensor 1751
Remove 1752
Install 1752
Mass Air Flow Sensor 1752
Remove 1752
Install 1752
Fuel/Water Separator 1752
Remove 1752
Install 1753
Air Filter Restriction Switch 1753
Remove 1753
Install 1753
Vehicle System Manager (VSM) 1754
General 1754
VSM Replacement 1754
Remove 1754
Install 1754
Programming A New VSM And/Or Display Switch Cluster 1755
Data Transferring 1756
New VSM 1756
New (Blank) Display Switch Cluster 1756
Used (Non-Blank) Display Switch Cluster 1756
PC Service Tool Software 1757
Power Distribution Module (PDM) and Component Parts 1758
Remove 1758
PDM as a Unit 1758
Install 1759
PDM as a Unit 1759
Remove and Install 1759
PDM Component Parts 1759
Transmission Control Unit (TCU) 1760
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured Before December, 2018 1760
Remove 1760
Install 1761
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 1762
Remove 1762
Install 1763
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured After July, 2021 1763
Remove 1763
Install 1765
Battery 1767
Remove 1767
Install 1767
Lights 1768
Work Lights (Front and Rear) 1768
Halogen Bulb Lights 1768
Remove 1768
Install 1768
LED Lights 1768
Remove 1768
Install 1768
Strobe Light 1769
Remove 1769
Install 1769
LED Tail, Backup, and Brake Lights 1770
Remove 1770
Install 1770
Front Marker/Turn Signal Lights 1771
Replacing Whole Front Marker/Turn Signal Light Assembly 1771
Remove 1771
Install 1771
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 1772
Remove 1772
Install 1772
Electronic-Hydraulic Controls, Before January, 2020 1773
E-Hydraulic Controls – TEST 1773
Mini-Levers 1773
Full Stroke Test 1773
Function Returns to Neutral Test 1773
Push (Override) Button Switch 1773
General 1774
Mini-levers, Remove and Install 1774
Armrest Assembly 1775
Remove 1775
Install 1778
Horn Button 1778
Remove 1778
Install 1778
Direction Control Switch 1778
Remove 1778
Install 1779
Push (Override) Button 1779
Remove 1779
Install 1780
Electronic-Hydraulic Controls, After January, 2020 1781
E-Hydraulic Controls – TEST 1781
Mini-Levers 1781
Full Stroke Test 1781
Function Returns to Neutral Test 1781
Push Button Switch 1781
General 1782
Mini-levers, Remove and Install 1782
Armrest Assembly 1783
Remove 1783
Install 1786
Horn Button 1786
Remove 1786
Install 1786
Direction Control Switch 1786
Remove 1786
Install 1787
Push (Override) Buttons 1787
Remove 1787
Install 1788
Diesel Particulate Filter (DPF) Display 1789
Remove 1789
Clean and Inspect 1790
Install 1790
Special Tools 1791
550131855 4000YRM1956 (06 2021) US EN 1795
Safety Procedures When Working Near Mast 1801
Fork Replacement 1803
General 1803
Remove 1803
Install 1804
Checks 1804
Carriage Repair 1806
Remove 1806
Clean and Inspect 1809
Install 1809
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1810
Connecting Attachment Hydraulic Quick Disconnect Hoses 1811
Integral Sideshift Carriage And Fork Positioners Repair 1812
Integral Sideshift Carriage 1812
Remove 1812
Disassemble 1813
Clean and Inspect 1816
Assemble 1816
Install 1816
Fork Positioners 1817
Remove 1817
Disassemble 1820
Clean and Inspect 1822
Assemble 1822
Install 1822
Hang-On Sideshift Carriage Repair 1823
Remove 1823
Disassemble Carriage 1826
Clean and Inspect 1828
Assemble 1828
Install 1831
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 1834
Remove 1834
Disassemble 1838
Clean and Inspect 1841
Assemble 1843
Install 1843
Header Hose Installation 1844
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 1848
Remove 1848
Disassemble 1851
Clean and Inspect 1854
Assemble 1856
Install 1856
Header Hose Installation 1857
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 1861
Remove 1861
Disassemble 1864
Clean and Inspect 1867
Assemble 1869
Install 1869
Header Hose Installation 1870
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 1874
Remove 1874
Disassemble 1878
Clean and Inspect 1881
Assemble 1883
Install 1883
Header Hose Installation 1884
Mast Operation Check 1888
Tilt Cylinder Adjustment 1888
Main Lift Cylinder Repair 1888
Lift Chain Adjustment 1889
Mast Adjustments 1891
Load Roller Adjustment 1891
Mast Side Kicking Adjustment 1892
Carriage Adjustment 1893
550136209 1800YRM1977 (08 2022) US EN 1897
General 1903
Wet Brake System 1903
Parking Brake Repair 1904
Master Cylinder Repair, For Lift Truck Models F878/G878/H878 1908
Remove 1908
Disassemble 1908
Clean and Inspect 1910
Assemble 1910
Install and Adjust 1910
Accumulator; For Lift Truck Models F878/G878/H878 1912
Pre-Charge Check 1912
Remove 1912
Install 1913
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For Lift Truck Models C909/D909 1914
Remove 1914
Modulating Brake Valve 1915
Disassemble 1915
Clean and Inspect 1916
Assemble 1917
Accumulator Charge Valve 1917
Disassemble 1917
Clean and Inspect 1919
Assemble 1919
Install 1920
Pressure Checks 1921
Accumulator Charge Valve Check 1921
Accumulator Check 1921
Brake System Air Removal; For Lift Truck Models 1922
Using Pressure Bleed System 1922
Using Brake Pedal Pressure 1922
Lift Truck Models with Master Cylinder 1922
Brake System Air Removal for Lift Truck Models C909/D909 1924
Using Brake Pedal Pressure 1924
Lift Truck Models with Modulating Brake Valve 1924
Brake Pedal Adjustment 1924
For Lift Truck Models F878/G878/H878 1924
For Lift Truck Models C909/D909 1925
Free Pedal Adjustment 1927
Torque Specifications 1928
550229997 0600YRM2294 (06 2021) US EN 1931
General 1937
Engine Identification 1938
Major Engine Component Identification 1938
Location of Labels 1939
Crankcase Description 1940
Precautions Before Beginning Repair 1940
Exhaust System 1941
Engine Removal and Installation 1942
Cylinder Head Assembly Repair 1942
Valve Covers and Fuel Injectors 1942
Remove 1942
Clean and Inspect 1945
Install 1945
Rocker Arm Assembly 1946
Remove 1946
Disassemble 1946
Clean and Inspect 1947
Push Rods 1947
Rocker Arm Assembly 1947
Assemble 1948
Install 1948
Valve Clearance Adjustments 1948
Cylinder Head Assembly 1950
Remove 1950
Disassemble 1956
Valves and Valve Springs, Remove 1956
Valve Guides, Remove 1957
Clean and Inspect 1957
Cylinder Head 1958
Valve Guides 1958
Valves 1958
Valve Sink 1959
Valve Seat 1959
Valve Springs 1959
Assemble 1960
Valve Guides, Install 1960
Valves and Valve Springs, Install 1961
Install 1962
Timing Gear Case and Timing Gears Repair 1964
Timing Gear Case Cover 1964
Remove 1964
Clean and Inspect 1964
Install 1965
Timing Gears 1965
Crankshaft Gear 1966
Remove 1966
Install 1966
Idler Gear 1966
Remove 1966
Inspect 1967
Install 1968
Camshaft Gear 1968
Remove 1968
Install 1968
Drive Train, Camshaft, and Cylinder Block Repair 1969
Remove 1969
Disassemble 1969
Pistons and Connecting Rods 1969
Crankshaft 1970
Camshaft 1972
Clean and Inspect 1974
Cylinder Block 1974
Honing and Boring 1977
Cylinder Correction (Oversize) 1978
Pistons 1978
Piston Pin 1979
Connecting Rod 1979
Tappets 1979
Crankshaft 1980
Camshaft 1982
Camshaft Bushing 1983
Assemble 1983
Camshaft 1983
Crankshaft 1983
Pistons and Connecting Rods 1983
Install 1985
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 1986
Lubrication System Repair 1989
Engine Oil and Oil Filter Change 1989
Oil Pan 1989
Remove 1989
Install 1990
Oil Suction Tube 1990
Remove 1990
Clean 1990
Install 1991
Oil Pump 1991
Remove 1991
Clean and Inspect 1992
Outer Rotor Outside Clearance 1992
Outer Rotor to Inner Rotor Tip Clearance 1992
Outer Rotor Side Clearance 1993
Rotor Shaft Clearance 1993
Install 1993
Fuel System Repair 1994
Fuel Injectors 1994
Remove 1994
Inspect 1994
Clean 1994
Replace 1994
Install 1994
Test 1994
Fuel Injection Pump 1995
Remove 1995
Clean and Inspect 1996
Install 1996
Cooling System Repair 1998
Serpentine Belt 1998
Remove 1998
Inspect 1998
Install 1998
Adjust 1998
Water Pump 1999
Remove 1999
Install 2001
Thermostat 2001
Remove 2001
Inspect 2002
Install 2002
Flywheel and Flywheel Housing 2004
Flywheel 2004
Remove 2004
Install 2004
Flywheel Housing 2004
Remove 2004
Install 2005
Electrical Equipment Repair 2006
General 2006
Alternator 2006
Remove 2006
Install 2007
Starter 2008
Remove 2008
Install 2009
Engine Specifications 2010
Engine Data 2010
Engine Tuning 2011
Cylinder Head 2011
Intake/Exhaust Valve and Guide 2012
Valve Spring 2012
Rocker Arm and Shaft 2012
Push Rod 2012
Gear Train and Camshaft 2013
Camshaft 2013
Idle Gear Shaft and Bushing 2013
Backlash of Each Gear 2013
Cylinder Block 2013
Crankshaft 2013
Piston 2014
Piston Ring 2014
Connecting Rod 2014
Rod Small End 2014
Tappet 2015
Oil Pump 2015
Engine Oil Pressure 2015
Outer Rotor Outside Clearance 2015
Outer Rotor Side Clearance 2015
Inner Rotor to Cover 2015
Standard Torque Specifications 2016
Standard Torque Chart 2016
Special Torque Specifications 2017
Special Tools 2019
550229998 0600YRM2295 (06 2021) US EN 2033
General 2041
Engine Identification 2042
Major Engine Component Identification 2042
Location of Labels 2043
Cylinder Block Description 2044
Precautions Before Beginning Repair 2045
Exhaust System, SCR, and DPF 2046
Engine Removal and Installation 2047
Cylinder Head Assembly Repair 2047
Valve Covers and Fuel Injectors 2047
Remove 2047
Clean and Inspect 2050
Install 2050
Rocker Arm Assembly 2051
Remove 2051
Disassemble 2052
Clean and Inspect 2052
Push Rods 2052
Rocker Arm Assembly 2052
Assemble 2053
Install 2053
Valve Clearance Adjustments 2053
Cylinder Head Assembly 2055
Remove 2055
Disassemble 2063
Valves and Valve Springs, Remove 2063
Valve Guides, Remove 2064
Clean and Inspect 2064
Cylinder Head 2065
Valve Guides 2065
Valves 2065
Valve Sink 2066
Valve Seat 2066
Valve Springs 2067
Assemble 2067
Valve Guides, Install 2067
Valves and Valve Springs, Install 2068
Install 2069
Timing Gear Case and Timing Gears Repair 2072
Timing Gear Case Cover 2072
Remove 2072
Clean and Inspect 2072
Install 2073
Timing Gears 2073
Crankshaft Gear 2074
Remove 2074
Install 2074
Idler Gear 1 and Idler Gear 2 2074
Remove 2074
Inspect 2075
Install 2076
Idler Gear 3 2076
Remove 2076
Inspect 2076
Install 2076
Camshaft Gear 2076
Remove 2076
Install 2076
Drive Train, Camshaft, and Cylinder Block Repair 2077
Remove 2077
Disassemble 2077
Pistons and Connecting Rods 2077
Crankshaft 2078
Camshaft 2080
Clean and Inspect 2082
Cylinder Block 2082
Honing and Boring 2085
Cylinder Correction (Oversize) 2086
Pistons 2086
Piston Pin 2087
Connecting Rod 2087
Tappets 2088
Crankshaft 2088
Camshaft 2090
Camshaft Bushing 2091
Assemble 2091
Camshaft 2091
Crankshaft 2091
Pistons and Connecting Rods 2091
Install 2093
Angular Deviation Procedure 2094
Lubrication System Repair 2097
Engine Oil and Oil Filter Change (Standard Oil Filter) 2097
Engine Oil and Oil Filter Change (Remote Oil Filter) 2097
Oil Pan 2098
Remove 2098
Install 2098
Oil Suction Tube 2099
Remove 2099
Clean 2099
Install 2099
Oil Pump 2099
Remove 2099
Clean and Inspect 2100
Inner Rotor and Outer Rotor Clearance 2100
Outer Rotor and Pump Body Clearance 2101
Rotor and Cover Clearance 2101
Rotor Shaft Clearance 2101
Install 2101
Remote Oil Filter 2102
Remove 2102
Clean and Inspect 2104
Install 2105
Fuel System Repair 2106
Fuel Injectors 2106
Remove 2106
Inspect 2106
Clean 2106
Replace 2106
Install 2107
Test 2107
Fuel Injection Pump 2107
Remove 2107
Clean and Inspect 2111
Install 2111
Cooling System Repair 2112
Serpentine Belt 2112
Remove 2112
Inspect 2112
Install 2112
Adjust 2112
Water Pump 2113
Remove 2113
Install 2114
Thermostat 2116
Remove 2116
Inspect 2116
Install 2117
Flywheel and Flywheel Housing 2118
Flywheel 2118
Remove 2118
Install 2118
Flywheel Housing 2118
Remove 2118
Install 2118
Electrical Equipment Repair 2119
Alternator 2119
Remove 2119
Install 2120
Starter 2121
Remove 2121
Install 2121
Engine Specifications 2123
Engine Data 2123
Engine Tuning 2124
Cylinder Head 2125
Intake/Exhaust Valve and Guide 2125
Valve Spring 2126
Rocker Arm and Shaft 2126
Push Rod 2126
Gear Train and Camshaft 2126
Camshaft 2126
Idle Gear Shaft and Bushing 2126
Backlash of Each Gear 2127
Cylinder Block 2127
Crankshaft 2127
Piston 2128
Piston Ring 2128
Connecting Rod 2128
Rod Small End 2128
Tappet 2129
Oil Pump 2129
Engine Oil Pressure 2129
Inner and Outer Rotor Clearance 2129
Outer Rotor and Pump Body 2129
Rotor and Cover 2129
Standard Torque Specifications 2130
Standard Torque Chart 2130
Special Torque Specifications 2131
Special Tools 2132
550255917 8000YRM2402 (06 2021) US EN 2147
Lift Truck Lifting Capacity 2153
Counterweight Weights 2153
Tire Sizes 2153
Capacities 2153
Electrical System 2157
Transmission Oil Pressures 2158
Hydraulic System Relief Pressures 2159
Steering System 2160
Stall Speeds 2160
Kubota 3 8L LPG GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 2160
Kubota 3 6L Diesel GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 2160
Kubota 3 8L Diesel GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 2160
Mast Speeds 2161
Tilt Angles 2162
Front End Equipment – Mast Creep 2162
Mast Creep 2162
Engine Specifications 2163
Torque Specifications 2167
Frame 2167
Mast 2167
Hang On Sideshift Carriage With Fork Positioner 2167
Steering System 2167
Transmission 2168
Fuel System- Kubota 3 8L Diesel 2168
Fuel System- Kubota 3 8L LPG 2168
Engine – Kubota 3 6L Diesel 2168
Engine – Kubota 3 8L Diesel 2169
Engine – Kubota 3 8L LPG 2170
550255918 8000YRM2400 (10 2021) US EN 2173
General Information About Diagrams and Schematics 2179
Symbol Definitions 2179
Diagrams Manual Applications 2180
Schematics/Diagrams 2182
Schematics and Diagrams 2182
550256065 8000YRM2401 (12 2021) US EN 2281
General 2289
Serial Number Data 2289
How to Move Disabled Lift Truck 2289
How to Tow Lift Truck 2289
How to Put Lift Truck on Blocks 2290
How to Raise Drive Tires 2290
How to Raise Steering Tires 2291
How to Clean a Lift Truck 2292
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 2292
Connecting Attachment Hydraulic Quick Disconnect Hoses 2293
Safety Procedures When Working Near Mast 2294
Maintenance Schedule 2296
Maintenance Procedures Every 8 Hours or Daily 2316
How to Make Checks With Engine Stopped 2316
Tires and Wheels 2316
Safety Labels 2316
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2316
Operator Restraint System 2317
Emergency Locking Retractor (ELR) 2317
Seat Plate and Seat Rails 2318
Engine Compartment 2318
Paper Application 2318
Fuel, Oil, and Coolant Leaks, Check 2319
Hydraulic Hoses 2319
Coolant Hoses 2319
Steering Column Gas Cylinder 2320
Transmission 2320
Hydraulic System Oil 2320
Engine Oil 2321
Air Filter 2326
Forks 2326
Inspect 2327
Remove 2328
Install 2328
Adjust 2328
Hang On Sideshift Carriage 2329
How to Make Checks With Engine Running 2330
Indicator Lights, Horn, Fuses, and Relays 2330
Service Brakes 2333
Brake Oil Level 2333
Operation, Check 2333
Parking Brake 2333
Engine Oil Pressure 2334
Cooling System 2334
Steering System 2335
Control Levers and Pedals 2335
Lift System, Operate 2335
Air Filter 2336
Fuel/Water Separator Filter, Kubota Diesel Engine 2336
First Service After First 100 Hours of Operation 2337
4 3L Engine Oil and Oil Filter 2337
Kubota Diesel Engine Oil and Oil Filter 2337
Hang on Sideshift Carriage Checks 2338
Maintenance Procedures Every 250 Hours or 6 Months 2340
Kubota Diesel Engine Oil and Oil Filter 2340
Drive Belt 2342
4 3L Engine 2342
Fan and Alternator Drive Belt 2342
Drain Tar From LPG Converter 2343
Cleaning Carbon Buildup From Intake Valves – Kubota 3 8L LPG Engines 2343
Maintenance Procedures Every 500 Hours or 6 Months 2346
Hydraulic System Oil 2346
Hydraulic Tank Breather 2347
Inspect 2347
Battery 2347
Kubota Diesel Engine Oil and Oil Filter 2348
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engines 2349
Remove 2349
Install 2350
Priming the Fuel System (Kubota 3 8L Engine) 2351
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 2351
Remove 2351
Install 2351
Priming the Fuel System (Kubota 3 6L Engine) 2352
Drive Belt 2352
Kubota Diesel Engine 2352
Fan and Alternator Drive Belt 2352
Clean Debris From Radiator Core 2353
Transmission Oil Breather/Dipstick 2353
Differential and Drive Axle Oil Level Check 2354
Forks, Inspect 2356
Mast Lubrication 2357
Tilt Cylinder Lubrication 2362
Header Hose Checks 2362
Lift Chain Lubrication 2363
Master Brake Cylinder Rod End Pin Lubrication 2363
Manual Hydraulic Levers Lubrication 2363
Cab Heater Air Filter 2363
Brake Oil 2365
Tie Rod Lubrication 2366
Parking Brake Adjustment 2367
Maintenance Procedures Every 1000 Hours or 6 Months 2368
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 2368
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 2368
Ignition System 2368
3 8L Engine 2368
LPG Fuel Filter Element Replace, 3 8L Engine 2368
Remove 2368
Install 2368
In-Line Strainer Replacement, Kubota Diesel Engine 2369
Remove 2369
Install 2369
Lift Chains Wear Check 2371
Lift Chain Lubrication 2371
Hang On Sideshift Carriage, Check Sliding Surfaces 2371
Steering Axle Spindle Bearings 2373
Control Levers and Pedals 2373
Inspect Engine Electrical System, Connectors 2373
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2374
Parking Brake Lever Lubrication, Wet Brake Axle 2377
Normal Operating Environment 2377
Heavy Duty or Contaminated Environment 2378
Remove 2378
Clean and Inspect 2379
Install 2379
Crankcase Breather Element, Kubota 3 8L Diesel 2380
Remove 2380
Clean and Inspect 2380
Install 2381
DEF Injector Tip 2381
Maintenance Procedures Every 2000 Hours or Annually 2382
Hydraulic System 2382
Hydraulic Filter Assembly, Replace 2382
Install 2384
Hydraulic Tank Breather, Replace 2384
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2386
Cooling System Check 2386
Air Filter 2387
Fuel Injector, Kubota 3 8L Engine 2389
Fuel Injector, Kubota 3 6L Engine 2389
Forks 2389
Brake Oil (Master Cylinder), Change 2391
Check Throttle Shaft for Sticking 2391
Inspect Exhaust Manifold and Piping for Leaks 2392
Transmission Automatic Clutch Calibration 2392
Wheel Bearings 2392
Steer Wheels, Lubrication 2392
Maintenance Procedures Every 3000 Hours 2393
Diesel Particulate Filter 2393
Remove 2393
Disassemble 2395
Servicing the Diesel Particulate Filter, Pressure Tubes and Pressure Hoses 2396
Assemble 2396
Install 2397
Diesel Exhaust Fluid (DEF) System 2397
Maintenance Procedures Every 4000 Hours or 2 Years 2400
Hydraulic Oil, Replace 2400
Overhead Guard Changes 2401
Jump-Starting the Lift Truck 2402
Jump-Starting Using a Battery Charger 2402
Jump-Starting a Lift Truck Using Another Lift Truck 2402
Wheel and Tire Replacement 2402
General 2402
Pneumatic Tire With Tube, Repair 2402
Remove Wheels From Lift Truck 2402
Remove Tire From Wheel 2403
Install Wheel in Tire 2406
Install Tire on Two-Piece Wheel 2408
Add Air to Pneumatic Tires With Tube 2409
Install the Wheels 2409
Dual Drive Wheels, Install 2409
Pneumatic Tubeless Tire, Repair 2411
Remove Wheels From Lift Truck 2411
Add Air to Pneumatic Tubeless Tire 2416
Wheels, Install 2416
Solid Rubber Tires on Pneumatic Wheels, Change 2416
Wheels, Install 2420
Fuel Filter Water Removal 2421
Kubota Diesel Engine 2421
3 8L Diesel Engine 2421
3 6L Diesel Engine 2422
Lift Chain Adjustments 2424
Welding Repairs 2426
Adhesives and Sealants 2426