Yale Forklift J813 (GP GLPGDP80VX, 90VX, 100VX, 110VX, 120VX) Service Manual PDF

Yale Forklift J813 (GP GLPGDP80VX, 90VX, 100VX, 110VX, 120VX) Service Manual – PDF DOWNLOAD

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Yale Forklift J813 (GP GLPGDP80VX, 90VX, 100VX, 110VX, 120VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4926
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift J813 (GP GLPGDP80VX, 90VX, 100VX, 110VX, 120VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) US EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014 2200YRM1097 (03 2020) US EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524221866 9000YRM1112 (10 2020) US EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223757 0700YRM1123 (06 2016) US EN 2135
General 2139
Cooling System Checks 2139
Exhaust Leaks Into Cooling System 2139
Water Flow Restrictions in Radiator 2139
Radiator Hoses 2139
Water Pump 2140
Flushing the Cooling System 2140
Cooling System, Clean 2140
Radiator Replacement 2141
Radiator, Remove GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2142
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2157
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2160
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) and GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 2163
Radiator, Install for Lift Truck Models GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2170
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2175
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2177
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2180
Fan Assembly Replacement 2192
Fan Removal 2192
Inspect 2207
Fan Installation 2207
524223764 1600YRM1133 (07 2013) US EN 2213
toc 2213
Steering Axle 2213
Safety Precautions Maintenance and Repair 2214
General 2217
Steering Axle Assembly Repair 2219
Remove 2219
Disassemble 2220
Clean 2228
Inspect 2228
Assemble 2228
Install 2234
Spindles, Bearings, and Tie Rods Repair 2236
Spindles and Bearings 2236
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2236
Remove 2236
Disassemble 2238
Clean 2239
Inspect 2239
Assemble 2239
Install 2240
Spindles and Bearings 2243
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2243
Remove and Disassemble 2243
Assemble and Install 2244
Tie Rods 2244
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2244
Remove 2244
Install 2245
Tie Rods 2246
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2246
Remove 2246
Install 2252
Steering Cylinder Repair 2252
Remove and Disassemble 2252
Clean and Inspect 2253
Assemble and Install 2253
Torque Specifications 2254
524223766 1900YRM1136 (11 2017) US EN 2259
General 2263
Hydraulic Gear Pump Assembly 2264
Variable Displacement Pump Assembly 2265
Single Gear Pump Assembly Repair 2265
Remove 2265
Disassemble 2272
Clean 2272
Inspect 2274
Assemble 2274
Install 2274
Tandem Gear Pump Assembly 2278
Remove 2279
Disassemble 2281
Clean 2283
Inspect 2283
Assemble 2283
Install 2284
Gear Pump Specifications 2284
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2290
Remove 2290
Disassemble 2300
Clean 2303
Inspect 2303
Assemble 2303
Install 2304
63 0 cc/rev – Variable Displacement Pump Repair 2307
Remove 2307
Disassemble 2310
Clean 2310
Inspect 2310
Assemble 2312
Install 2312
Variable Displacement Pump Checks and Adjustments (Single Pump) 2314
Margin Pressure Check 2314
Flow Compensator Adjustment 2315
Pressure Compensator Adjustment 2315
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2316
Variable Displacement Pump Specifications 2319
Torque Specifications 2320
Hydraulic Gear Pump 2321
Variable Displacement Pump 2322
Special Tools 2322
524223767 2000YRM1137 (01 2017) US EN 2327
General 2333
Electro-Hydraulic Main Control Valve 2334
Description 2334
Remove 2342
Electro-Hydraulic Control Valve Sections 2347
General 2347
Outlet Control Valve Section 2347
Remove 2347
Disassemble 2348
Clean 2350
Inspect 2350
Assemble 2350
Install 2351
Auxiliary Control Valve Sections 2351
Remove 2351
Disassemble 2358
Clean 2359
Inspect 2360
Assemble 2360
Install 2362
Tilt Control Valve Section 2363
Remove 2363
Disassemble 2363
Clean 2369
Inspect 2369
Assemble 2369
Install 2370
Lift/Lower Control Valve Section 2371
Remove 2371
Disassemble 2371
Clean 2380
Inspect 2380
Assemble 2380
Install 2381
Mid-Inlet Section 2381
Remove 2381
Clean 2382
Inspect 2382
Install 2382
Install 2382
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2387
Lift Pilot Pin 2387
Lower Pilot Pin 2391
Abnormal/Erroneous EHPV Adjustment 2393
Manual Main Control Valve 2394
Description 2394
Remove 2398
OPS Solenoid Assembly 2406
General 2406
Remove 2407
Clean and Inspect 2410
Install 2410
Manual Control Valve Sections 2411
General 2411
Outlet Control Valve Section 2411
Remove 2411
Disassemble 2411
Clean 2414
Inspect 2414
Assemble 2414
Install 2415
Auxiliary Control Valve Sections 2415
Remove 2415
Disassemble 2415
Clean 2418
Inspect 2418
Assemble 2418
Install 2419
Lift/Tilt Control Valve Section 2419
Remove 2419
Disassemble 2419
Clean 2426
Inspect 2426
Assemble 2427
Install 2428
Mid-Inlet Section 2429
Remove 2429
Clean 2429
Inspect 2429
Install 2429
Install 2430
Pressure Relief Valve Check and Adjustment 2436
Primary Relief Valve 2437
Secondary Relief Valve 2441
Steering Control Unit Repair 2448
Steering Control Unit, Remove 2448
Steering Control Unit, Disassemble 2452
Steering Control Unit, Clean 2454
Steering Control Unit, Inspect 2454
Steering Control Unit, Assemble 2454
Relief Valve, Disassemble 2455
Relief Valve, Clean 2455
Relief Valve, Inspect 2456
Relief Valve, Assemble 2456
Steering Control Unit, Install 2456
524223768 2100YRM1139 (02 2014) US EN 2461
524223769 2200YRM1128 (01 2023) US EN 2509
Series Code / Model Designation Reference Table 2517
General 2519
Deutsch Crimping Tool 2520
How to Strip a Wire for Use With Deutsch Crimping Tool 2520
How to Crimp With the Deutsch Crimping Tool 2521
Calibration Test for the Deutsch Crimping Tool 2523
Deutsch Connectors 2525
DT, DTM, and DTP Series Connectors 2525
HD Series Connectors 2568
Metri-Pack Connectors 2590
Remove and Install 2590
Micro-Pack Connectors 2593
Weather-Pack Connectors 2594
AMPSEAL Crimping Tools 2596
AMP Hand Crimping Tool With Certi-Crimp 2596
Description 2596
Stripping Wire for Use with AMP Hand Crimping Tool 2597
Insulation Crimp Adjustment 2598
Maintenance and Inspection for AMP Hand Crimping Tool 2598
AMP Hand Crimping Tool 2598
Crimp Height Inspection 2598
How to use AMP Hand Crimping Tool 2599
AMP Pro-Crimper II Tool 2599
Description 2599
Remove and Install Die Set and Locator Assembly 2600
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2600
Contact Support Adjustment 2601
Crimp Height Adjustment 2602
Maintenance and Inspection Procedures 2602
PRO-CRIMPER II Tool 2602
Crimp Height Inspection 2602
How to Use AMP PRO-CRIMPER II Tool 2603
AMPSEAL Connector Assemblies 2604
Description for Plug Connector Assembly 2604
Seal Plug 2605
Contact Crimping 2605
Description for Plug Connector and Header Assembly 2610
Voltage Reading 2613
Seal Plug 2613
Contact Crimping 2613
AMP Superseal 1 5 Crimping Tools 2620
Mini Mic Receptacle and Tab Contacts 2620
Description 2620
Crimping Conditions and Measurements 2620
Insertion of Rubber Seal on Cable 2622
AMP Hand Application Tool 2627
Description 2627
Maintenance and Inspection 2627
Crimp Height Inspection 2627
Crimp Height Adjustment 2628
How to Use AMP Hand Application Tool 2628
AMP Pro-Crimper II Tool 2629
Description 2629
Remove and Install Die Set and Locator Assembly 2629
Adjustments 2630
Contact Support 2630
Crimp Height 2631
Inspections and Maintenance 2632
Crimp Height Inspection 2632
Visual Inspection 2632
Maintenance 2633
How to Use Pro-Crimper II Tool 2633
AMP Superseal 1 5 Connector Assemblies 2634
Description 2634
Repair and Maintenance 2641
Panel Mount Option 2641
AMP Fastin-Faston Hand Tools 2642
Description – AMP Double Action Hand Tool 2642
Maintenance and Inspection Procedures 2642
Daily Maintenance 2642
Periodic Tool Inspection 2643
Lubrication 2643
Visual Inspection 2643
Crimp Height Inspection 2643
Certi-Crimp Ratchet Inspection 2644
How to Use AMP Double Action Hand Tool 2645
Description – AMP Extraction Tool 2646
Maintenance and Inspection 2647
How to Use AMP Extraction Tool 2647
AMP Fastin-Faston Receptacles and Housings 2649
Description 2649
Wire Repair 2657
Wire Splicing Requirements 2657
Deutsch Jiffy Splice 2658
Twisted/Shielded Cable and Leads Repair 2664
Special Tools 2666
524223769 2200YRM1128 (07 2020) US EN 2675
Series Code / Model Designation Reference Table 2681
General 2684
Deutsch Crimping Tool 2684
How to Strip a Wire for Use With Deutsch Crimping Tool 2684
How to Crimp With the Deutsch Crimping Tool 2685
Calibration Test for the Deutsch Crimping Tool 2687
Deutsch Connectors 2689
DT, DTM, and DTP Series Connectors 2689
HD Series Connectors 2731
Metri-Pack Connectors 2754
Remove and Install 2754
Micro-Pack Connectors 2756
Weather-Pack Connectors 2757
AMPSEAL Crimping Tools 2759
AMP Hand Crimping Tool With Certi-Crimp 2759
Description 2759
Stripping Wire for Use with AMP Hand Crimping Tool 2759
Insulation Crimp Adjustment 2760
Maintenance and Inspection for AMP Hand Crimping Tool 2760
AMP Hand Crimping Tool 2760
Crimp Height Inspection 2760
How to use AMP Hand Crimping Tool 2761
AMP Pro-Crimper II Tool 2761
Description 2761
Remove and Install Die Set and Locator Assembly 2762
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2763
Contact Support Adjustment 2763
Crimp Height Adjustment 2764
Maintenance and Inspection Procedures 2764
PRO-CRIMPER II Tool 2764
Crimp Height Inspection 2764
How to Use AMP PRO-CRIMPER II Tool 2765
AMPSEAL Connector Assemblies 2766
Description for Plug Connector Assembly 2766
Seal Plug 2767
Contact Crimping 2767
Description for Plug Connector and Header Assembly 2772
Voltage Reading 2774
Seal Plug 2774
Contact Crimping 2774
AMP Superseal 1 5 Crimping Tools 2781
Mini Mic Receptacle and Tab Contacts 2781
Description 2781
Crimping Conditions and Measurements 2781
Insertion of Rubber Seal on Cable 2783
AMP Hand Application Tool 2788
Description 2788
Maintenance and Inspection 2788
Crimp Height Inspection 2788
Crimp Height Adjustment 2789
How to Use AMP Hand Application Tool 2789
AMP Pro-Crimper II Tool 2790
Description 2790
Remove and Install Die Set and Locator Assembly 2791
Adjustments 2791
Contact Support 2791
Crimp Height 2792
Inspections and Maintenance 2793
Crimp Height Inspection 2793
Visual Inspection 2793
Maintenance 2794
How to Use Pro-Crimper II Tool 2794
AMP Superseal 1 5 Connector Assemblies 2795
Description 2795
Repair and Maintenance 2802
Panel Mount Option 2802
AMP Fastin-Faston Hand Tools 2803
Description – AMP Double Action Hand Tool 2803
Maintenance and Inspection Procedures 2803
Daily Maintenance 2803
Periodic Tool Inspection 2804
Lubrication 2804
Visual Inspection 2804
Crimp Height Inspection 2804
Certi-Crimp Ratchet Inspection 2805
How to Use AMP Double Action Hand Tool 2806
Description – AMP Extraction Tool 2807
Maintenance and Inspection 2807
How to Use AMP Extraction Tool 2808
AMP Fastin-Faston Receptacles and Housings 2809
Description 2809
Wire Repair 2816
Wire Splicing Requirements 2816
Deutsch Jiffy Splice 2817
Twisted/Shielded Cable and Leads Repair 2822
Special Tools 2825
524223770 2200YRM1130 (03 2020) US EN 2833
General 2837
Description 2837
Dash Display Menu Access 2837
Menu Navigation 2838
Standard Display 2838
Main Menu 2838
Passwords Menu 2839
Password Administration 2839
Add Password 2839
Delete Password 2840
Edit Password 2840
Other Password Functions 2841
Operator Passwords – Enable/Disable 2841
Password Time-Out Delay 2841
Passwords – Number Wrong to Disable 2842
Lockout Reset Password 2842
View Password Log 2843
View Versions 2844
VSM Versions 2844
Dash Display Versions 2845
Engine Controller Version 2846
Transmission (Xmsn) Controller Version 2847
Truck Serial Number 2848
Diagnostics 2849
View Fault Log 2849
Set Travel and Braking 2850
Speed Limit 2850
Acceleration Rate 2851
Auto-Deceleration Rate 2851
Set Power Reversal Rate 2852
Set Inching/Brake Overlap 2853
Setup Display Menu 2854
Set Operator Language 2854
Set Units 2855
Set Time Format (12/24 Hour) 2855
Set Daylight Saving Time 2855
Set Time 2858
Set Date Format 2859
Set Date 2859
Setup Hydraulics 2860
Return to Set Tilt Delay/On/Off 2860
Setup General Items 2861
Light Shutdown Time-Out 2861
Impact Sensor – Enable/Disable 2862
Impact Sensor – Soft Impact Settings 2863
Impact Sensor – Hard Impact Settings 2864
Adjust Impact Sensor Settings 2864
Initial Adjustment of Soft and Hard Impact Settings 2866
Readjustment of Soft and Hard Impact Settings 2866
Impact Sensor – Impact Alarm/Shutdown Reset 2867
Impact Sensor – Alarm Time Duration and Deactivation 2868
Impact Sensor – View Impact Event Log 2869
Engine Mode Indicator 2870
Generation 1 (ECO-eLo ONLY) 2870
Generation 2 2871
Operator Checklist 2872
Operator Checklist Off-On Mode 2872
Edit Operator Checklist 2872
Set Operator Checklist Expiration 2873
View Checklist Log 2873
Clear Operator Checklist Log 2874
Clear Operator Checklist Fault 2874
Calibrations 2875
Set Tilt Stop Point 2875
Calibrate Loaded Weight 2875
524223771 2200YRM1131 (03 2020) US EN 2877
Series Code / Model Designation Reference Table 2883
General 2885
Description 2885
Dash Display Menu Access 2885
Menu Navigation 2886
Main Menu 2886
Passwords 2887
Adding Passwords 2887
Hourmeters 2889
View Versions 2890
VSM Versions 2890
Dash Display Versions 2891
Engine Controller Version 2892
Transmission (Xmsn) Controller Version 2893
Truck Serial Number 2894
Truck Configuration 2895
Diagnostics 2896
Clear Fault Log 2896
View Fault Log 2897
No-Run Data Display 2898
Engine Accelerator and Throttle Data Display 2898
Engine Speeds and Governor Data Display 2899
Engine Fuel and Emissions Data Display 2900
Engine General Data Display 2902
XMSN/Brake Data Display 2903
Hydraulic Data Display 2906
General Truck Data Display 2908
Set Travel and Braking 2909
Speed Limit 2909
Acceleration Rate 2910
Auto-Deceleration Rate 2911
Set Power Reversal Rate 2911
Set Inching/Brake Overlap 2912
Setup Hydraulics 2912
Lift Maximum Speed 2913
Lower Maximum Speed 2913
Tilt Maximum Speed 2914
Auxiliary Function One, Direction A, Maximum Speed 2916
Auxiliary Function One, Direction B, Maximum Speed 2918
Auxiliary Function Two, Direction A, Maximum Speed 2918
Auxiliary Function Two, Direction B, Maximum Speed 2919
Auxiliary Function Three, Direction A, Maximum Speed 2920
Auxiliary Function Three, Direction B, Maximum Speed 2920
Lift/Lower Ramp Rate 2921
Hydraulic Auxiliary Ramp Rate 2921
Return to Set Tilt Delay/On/Off 2922
Hydraulic Input Device 2923
Auxiliary Solenoid 2923
Dual Function 2924
Setup Display 2925
Set Service Language 2925
Setup General Items 2925
Motion Alarm Activation Type 2926
Light Shutdown Time-Out 2927
Restore Default Settings 2927
Restore Engine Controller Default Calibration 2928
Impact Sensor – Enable/Disable 2928
Impact Sensor – Soft Impact Settings 2929
Impact Sensor – Hard Impact Settings 2930
Adjust Impact Sensor Settings 2931
Initial Adjustment of Soft and Hard Impact Settings 2933
Readjustment of Soft and Hard Impact Settings 2933
Impact Sensor – Impact Alarm/Shutdown Reset 2934
Impact Sensor – Alarm Time Duration and Deactivation 2935
Impact Sensor – View Impact Event Log 2936
Engine Mode Indicator 2936
Generation 1 (ECO-eLo ONLY) 2936
Generation 2 2937
Diesel Particulate Filter (DPF) Display 2938
General Description 2938
Passive Regeneration Only 2938
Regeneration Level 0 2938
Auto/Active Regeneration Inhibited 2939
Auto/Active Regeneration 2939
Regeneration Level 1 2939
Parked Regeneration Request 2940
Regeneration Level 2 2940
Warning Level 2940
Regeneration Level 3 2940
Service Level 2941
Regeneration Level 4 2941
Display, Diesel Particulate Filter (DPF), Revised 2941
Operator Interface 2941
Refer to Operator Manual 2941
CAN Communication Lost 2942
Passive Regeneration Only 2942
Regeneration Level 0 2942
Auto/Active Regeneration Inhibited 2942
Auto/Active Regeneration 2943
Regeneration Level 1 2943
Idle-up Auto/Active Regeneration 2943
Parked Regeneration Request 2943
Regeneration Level 2 2943
Warning Level 2945
Regeneration Level 3 2945
Service Level 2945
Regeneration Level 4 2945
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2945
Display, Diesel Particulate Filter (DPF), Stage V Engine 2945
Operator Interface 2946
Refer to Operator Manual 2946
CAN Communication Lost 2946
Passive Regeneration Only 2946
Regeneration Level 0 2946
Auto/Active Regeneration Inhibited 2947
Auto/Active Regeneration 2947
Regeneration Level 1 2947
Idle-up Auto/Active Regeneration 2948
Parked Regeneration Request 2948
Regeneration Level 2 2948
Warning Level 2949
Regeneration Level 3 2949
Service Level 2950
Regeneration Level 4 2950
Stage V Content 2950
Emissions System Malfunction 2950
Ash Load 2950
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2951
Operator Interface 2951
Refer to Operator Manual 2951
CAN Communication Lost 2952
Passive Regeneration Only 2952
Regeneration Level 0 2952
Auto/Active Regeneration Inhibited 2952
Auto/Active Regeneration 2953
Regeneration Level 1 2953
Idle-up Auto/Active Regeneration 2953
Parked Regeneration Request 2953
Regeneration Level 2 2953
Warning Level 2955
Regeneration Level 3 2955
Service Level 2955
Regeneration Level 4 2955
Calibrations 2956
Calibrate Transmission Valve 2958
Set Tilt Stop Point 2958
Calibrate Loaded Weight 2958
Calibrate Travel Speed Sensor 2959
Calibrate Mazda LP and Gas Accelerator Pedal 2959
524223772 2200YRM1142 (01 2020) US EN 2961
General 2971
Display Switch Cluster 2974
Remove 2974
Install 2977
Direction Control and Turn Signal Levers 2977
Remove 2977
Install 2979
Key Switch 2979
Remove 2979
Install 2980
Display Switch Cluster Panel Bezel and Overlay 2980
Remove 2980
Install 2980
Steering Column Repair 2980
Remove 2980
Disassemble 2983
Assemble 2983
Install 2983
Sensors and Switches 2984
General 2984
Dash and Kick Panel, Remove and Install 2984
Remove 2984
Install 2985
Accelerator Pedal Position Sensor 2986
Remove 2986
Install 2989
Brake Fluid Level Switch 2990
Remove 2990
Install 2992
Service Brake Pedal Position Sensor 2993
Remove 2993
Install 2996
Parking Brake Sensor 2997
Remove 2997
Install 2998
Service Brake Pressure Sensor 2999
Remove 2999
Install 3001
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3002
Remove 3002
Install 3002
Sensor Microswitch (Foot Directional Control Pedal) 3003
Remove 3003
Install 3006
Low Coolant Level Sensor 3007
Remove 3007
Install 3010
Fuel Level Sensor, Gas and Diesel Engines Only 3011
Remove 3011
Install 3012
Armrest Switch 3012
Remove 3012
Install 3014
Seat Sensor (Operator Presence System) 3014
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 3014
Remove 3014
Install 3015
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3015
Remove 3015
Install 3016
Full Suspension Seats; All Lift Truck Models 3016
Remove 3016
Install 3016
Hood Shut Off Switch 3016
Remove 3016
Install 3019
Remote Key Switch 3020
Remove 3020
Install 3020
Hydraulic Filter Pressure Switch 3021
Remove 3021
Install 3023
Transmission Speed Sensor 3023
Remove 3023
Install 3026
Transmission Pressure Sensors 3027
Remove 3027
Install 3029
Transmission Temperature Sensor 3030
Remove 3030
Install 3032
Engine Speed Sensor 3034
Remove 3034
Install 3034
Intermediate Speed Sensor 3035
Remove 3035
Install 3035
Return to Set Tilt (Tilt Angle) Sensor 3035
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 3035
Remove 3035
Install 3036
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3037
Remove 3037
Install 3038
Rear Horn Button Switch 3038
Remove 3038
Install 3039
Impact Sensor 3040
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 3040
Remove 3040
Install 3043
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3043
Remove 3043
Install 3044
Load Weight Sensor 3045
Remove 3045
Install 3046
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3047
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3047
Crankshaft Position (CKP) Sensor 3047
Camshaft Position (CMP) Sensor 3047
Oil Pressure Sensor 3047
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3047
Engine Coolant Temperature (ECT) Sensor 3048
Air Flow Restriction Switch 3048
Remove for GM 2 4L Gas and LPG Trucks 3048
Install for GM 2 4L Gas and LPG Trucks 3048
Oxygen Sensor 3049
Remove 3049
Install 3052
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3053
Crankshaft Position (CKP) Sensor 3053
Camshaft Position (CMP) Sensor 3053
Oil Pressure Sensor 3053
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3053
Engine Coolant Temperature (ECT) Sensor 3053
Air Flow Restriction Switch 3053
Oxygen Sensor 3053
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3053
Low LPG Pressure Switch 3053
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3054
Air Filter Restriction Switch 3054
Remove 3054
Install 3054
Oil Pressure Sensor 3054
Remove 3054
Install 3054
Engine Speed Sensor 3054
Remove 3054
Install 3054
Engine Coolant Temperature (ECT) Sensor 3054
Remove 3054
Install 3054
Throttle Position Sensor (TPS) 3057
Remove 3057
Install 3058
Fuel/Water Separator Sensor 3058
Remove 3058
Install 3058
Glow Plug Relay 3059
Remove 3059
Install 3061
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3061
Air Filter Restriction Switch 3061
Remove 3061
Install 3061
Engine Oil Pressure Sensor 3066
Remove 3066
Install 3066
Engine Speed Sensor 3066
Remove 3066
Install 3067
Engine Coolant Temperature (ECT) Sensor 3067
Remove 3067
Install 3068
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3069
Remove 3069
Install 3069
Fuel/Water Separator Sensor 3070
Remove 3070
Install 3070
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3071
Intake Air Temperature Sensor 3071
Remove 3071
Install 3072
Intake Air Pressure Sensor 3072
Remove 3072
Install 3072
Air Inlet Heater 3072
Remove 3072
Install 3073
Engine Oil Pressure Sensor 3073
Remove 3073
Install 3073
Engine Coolant Temperature (ECT) Sensor 3073
Remove 3073
Install 3073
Crankshaft Position Sensor 3074
Remove 3074
Install 3074
Adjust Shim Procedure 3075
Camshaft Position Sensor 3076
Remove 3076
Install 3076
Air Flow Restriction Sensor 3077
Remove 3077
Install 3077
Fuel/Water Separator 3077
Remove 3077
Install 3078
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3078
Intake Air Temperature Sensor 3082
Remove 3082
Install 3083
Boost Sensor 3083
Remove 3083
Install 3084
Throttle Valve Assembly and Air Intake Heater 3084
Remove 3084
Install 3084
Engine Coolant Temperature (ECT) Sensor 3085
Remove 3085
Install 3085
Engine Oil Pressure Sensor 3085
Remove 3085
Install 3086
Crankshaft Position Sensor 3086
Remove 3086
Install 3086
Adjust Shim Procedure 3087
Camshaft Position Sensor 3088
Remove 3088
Install 3089
Differential Pressure Sensor 3089
Remove 3089
Install 3089
Mass Air Flow Sensor 3090
Remove 3090
Install 3091
Fuel/Water Separator 3091
Remove 3091
Install 3092
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3092
Engine Coolant Temperature (ECT) Sensor 3093
Remove 3093
Install 3093
Throttle Position Sensor 3094
Engine Oil Pressure Sensor 3094
Remove 3094
Install 3094
Engine Speed Sensor 3094
Remove 3094
Install 3094
Fuel Shut Off Solenoid 3094
Remove 3094
Install 3094
Vehicle System Manager (VSM) 3095
General 3095
VSM Replacement 3095
Remove 3095
Install 3097
Programming a New VSM and/or Display Switch Cluster 3097
General 3097
PC Service Tool Software 3098
Data Transferring 3098
New VSM 3098
New (Blank) Display Switch Cluster 3098
Used (Non-Blank) Display Switch Cluster 3098
Power Distribution Module (PDM) and Component Parts 3100
Remove 3100
PDM as a Unit 3100
Install 3104
PDM as a Unit 3104
Remove and Install 3105
PDM Component Parts 3105
Transmission Control Unit 3105
Remove 3105
Install 3109
Battery 3111
Remove 3111
Install 3111
Lights 3112
Work Lights (Front and Rear) 3112
Remove 3112
Install 3112
Strobe Light 3113
Remove 3113
Install 3113
LED Tail, Backup, and Brake Lights 3114
Remove 3114
Install 3115
Front Marker/Turn Signal Lights 3116
Replacing Whole Front Marker/Turn Signal Light Assembly 3116
Remove 3116
Install 3116
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3117
Remove 3117
Install 3117
Diesel Particulate Filter (DPF) Display 3117
Remove 3117
Clean and Inspect 3118
Install 3118
Electronic-Hydraulic Controls – Generation 1 3119
E-Hydraulic Controls – Test 3119
Mini-Levers 3119
Full Stroke Test 3119
Function Returns to Neutral Test 3119
Push Button Switch 3119
General 3120
Mini-Lever Replacement 3120
Remove 3120
Clean and Inspect 3121
Install 3121
Push Button Switch Replacement 3122
Remove 3122
Install 3124
Mini-Lever Module (MLM) 3124
Remove 3124
Install 3124
Joystick 3125
Remove and Disassemble 3125
Inspect 3125
Assemble and Install 3125
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3126
General 3126
Mini-levers, Remove and Install 3126
Armrest Assembly 3127
Remove 3127
Install 3130
Horn Button 3130
Remove 3130
Install 3130
Direction Control Switch 3131
Remove 3131
Install 3131
push (override) buttons and Toggle Switch 3131
Remove 3132
Install 3133
Joystick 3134
Remove and Disassemble 3134
Inspect 3134
Assemble and Install 3134
Joystick Armrest Slider Assembly 3135
Remove 3135
Install 3136
Electronic-Hydraulic Controls, After January, 2020 3136
E-Hydraulic Controls – TEST 3136
Mini-Levers 3136
Full Stroke Test 3136
Function Returns to Neutral Test 3136
Push (Override) Button 3137
General 3137
Mini-levers, Remove and Install 3137
Armrest Assembly 3138
Remove 3138
Install 3141
Horn Button 3141
Remove 3141
Install 3141
Direction Control Switch 3141
Remove 3141
Install 3142
Push (Override) buttons and Toggle Switch 3142
Remove 3143
Install 3145
Special Tools 3146
524223780 8000YRM1134 (03 2020) US EN 3149
Series Code / Model Designation Reference Table 3155
Description 3157
Proc_Cal_001: Service Password Entry 3159
When to Perform 3159
Why Perform 3159
How to Perform 3159
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3160
When to Perform 3160
Calibration Order 3160
Why Perform 3160
How to Perform 3161
Proc_Cal_003: Save and Exit 3162
When to Perform 3162
Why Perform 3162
How to Perform 3162
Proc_Cal_004: Lift Valve Output Threshold 3163
When to Perform 3163
Calibration Order 3163
Why Perform 3163
How to Perform 3164
Proc_Cal_005: Lower Valve Output Threshold 3166
When to Perform 3166
Calibration Order 3166
Why Perform 3166
How to Perform 3166
Proc_Cal_006: Tilt Back Valve Output Threshold 3169
When to Perform 3169
Calibration Order 3169
Why Perform 3169
How to Perform 3169
Proc_Cal_007: Tilt Forward Valve Output Threshold 3172
When to Perform 3172
Calibration Order 3172
Why Perform 3172
How to Perform 3172
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3175
When to Perform 3175
Calibration Order 3175
Why Perform 3175
How to Perform 3175
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3178
When to Perform 3178
Calibration Order 3178
Why Perform 3178
How to Perform 3178
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3181
When to Perform 3181
Calibration Order 3181
Why Perform 3181
How to Perform 3181
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3184
When to Perform 3184
Calibration Order 3184
Why Perform 3184
How to Perform 3184
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3187
When to Perform 3187
Calibration Order 3187
Why Perform 3187
How to Perform 3187
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3190
When to Perform 3190
Calibration Order 3190
Why Perform 3190
How to Perform 3190
Proc_Cal_014: Load Weight Zero Point 3194
When to Perform 3194
Calibration Order 3194
Why Perform 3194
How to Perform 3194
Proc_Cal_015: Loaded Weight Calibration 3196
When to Perform 3196
Calibration Order 3196
Why Perform 3196
How to Perform 3196
Proc_Cal_016: Transmission Valve Calibration 3199
Applicable System/Option 3199
When to Perform 3199
Calibration Order 3199
Why Perform 3199
How to Perform 3199
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3201
Applicable System/Option 3201
When to Perform 3201
Calibration Order 3201
Why Perform 3201
How to Perform 3201
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3203
Applicable System/Option 3203
When to Perform 3203
Calibration Order 3203
Why Perform 3203
How to Perform 3204
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3205
Required Tools 3205
When to Perform 3205
Calibration Order 3205
Why Perform 3206
How to Perform 3206
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3207
When to Perform 3207
Why Perform 3207
How to Perform 3207
Proc_Cal_026: Travel Speed Calibration 3209
When to Perform 3209
Calibration Order 3209
Why Perform 3209
How to Perform 3209
524262274 0100YRM1243 (11 2016) US EN 3213
General 3217
Description 3218
Hood, Seat, and Side Covers Replacement 3220
Remove 3220
Install 3220
Steering Column 3227
Description 3228
Steering Column Repair 3228
Remove 3228
Disassemble 3230
Clean 3233
Inspect 3233
Assemble 3233
Install 3233
LPG Tank and Bracket Replacement 3234
Counterweight Replacement 3234
Remove 3234
Install 3237
Tow Pin 3241
Remove and Install For Lift Truck
Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813) 3241
Remove and Install For Lift Truck
Models GLC55SVX (GC/GLC80XVBCS,
GC/GLC100VXBCS; GC/GLC120SVX; and
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(J813) 3241
Overhead Guard Replacement 3242
Remove 3242
Install 3243
LED Tail, Backup, and Brake Lights, Replace 3243
Operator Restraint System Replacement 3244
Description 3244
Engine Replacement 3245
Remove Engine Only 3245
Install Engine only 3272
Remove Engine and Transmission 3275
Install Engine and Transmission 3279
Electronic Throttle Replacement 3283
Cummins 4 5L Diesel Engine With Electronic Throttle 3283
Remove 3283
Install 3286
Pull Actuator Linkage Adjustment 3288
Low Idle Adjustment 3288
Throttle Pedal and Cable Adjustment 3289
Cummins 4 5L Diesel Engine with Basic Power Shift Transmission 3289
Kubota 3 6L Diesel Engine 3289
Exhaust System Repair 3292
GM 4 3L Engine for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) 3292
Cummins 4 5L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813) 3292
Remove 3292
Inspect 3292
Install 3294
Cummins QSB 3 3L Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) 3294
Remove 3294
Inspect 3296
Install 3296
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Equipped with Kubota 3 6L Diesel Engine 3296
Remove 3296
Inspect 3298
Install 3298
Kubota Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 3298
Remove 3298
Inspect 3301
Diesel Particulate Filter 3303
Disassemble 3303
CLEAN AND INSPECT 3304
Assembly 3304
Install 3305
Cooling System 3306
Description 3306
Hydraulic Filter Assembly Repair 3307
Remove 3307
Disassemble 3307
Clean 3308
Inspect 3308
Assemble 3308
Install 3308
Fuel and Hydraulic Tanks Repair 3308
Inspect 3308
Clean 3309
Steam Method of Cleaning 3309
Chemical Solution Method of Cleaning 3310
Additional Preparations for Repair 3310
Small Leaks, Repair 3310
Large Leaks, Repair 3310
Preparations for Use After Repair 3310
Safety Labels 3310
524262278 1400YRM1246 (02 2018) US EN 3321
General 3325
Identification Plate 3326
Drive Axle Removal 3326
Hub Seal Replacement 3338
Planetary Reduction Repair 3347
Clean and Inspect 3356
Brake Repair 3369
Clean and Inspect 3385
Wet Brake Noise Reduction 3401
General 3401
Adding Additive To Transmission 3402
Bevel Pinion 3403
Clean and Inspect 3408
Differential Unit 3420
Disassemble 3431
Clean and Inspect 3437
Assemble 3438
Drive Axle Installation 3461
Special Tools 3471
Torque Specifications 3471
524262279 1800YRM1247 (09 2018) US EN 3475
General 3479
Dry Brake System 3479
Wet Brake System 3480
Service Brakes Repair (Dry Brake) 3484
Remove and Disassemble 3484
Clean 3486
Inspect 3487
Assemble and Install 3487
Adjust 3491
Parking Brake Repair 3491
Dry Brake System 3492
Remove and Disassembly 3492
Assemble and Install 3494
Wet Brake System 3494
Remove and Install 3495
Assemble and Install 3501
Adjust 3501
Dry Brake System 3501
Wet Brake System 3502
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3502
Master Cylinder Repair 3503
Remove 3503
Disassemble 3508
Clean and Inspect 3509
Assemble 3510
Install and Adjust 3510
Accumulator 3512
Pre-Charge Check 3513
Remove 3514
Install 3516
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3516
Remove 3517
Modulating Brake Valve 3518
Disassemble 3518
Clean and Inspect 3520
Assemble 3520
Accumulator Charge Valve 3521
Disassemble 3521
Clean and Inspect 3523
Assemble 3523
Install 3524
Pressure Checks 3525
Accumulator Charge Valve Check 3525
Accumulator Check 3525
Service Brakes Adjustment (Dry Brake) 3526
Service Brakes Adjustment 3526
Brake System Air Removal 3527
Using Pressure Bleed System 3527
Using Brake Pedal Pressure 3528
Lift Truck Models with Master Cylinder 3528
Lift Truck Models with Modulating Brake Valve 3528
Brake Pedal Adjustment 3529
For Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3529
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3530
Free Pedal Adjustment 3532
Torque Specifications 3533
524265337 0600YRM1251 (09 2015) US EN 3537
General 3543
Engine Removal and Installation 3543
Cylinder Head Repair 3543
Remove and Disassemble 3543
Clean and Inspect 3545
Valve Oil Seals 3548
Remove and Disassemble 3548
Cylinder Leak Down Test 3548
Clean and Inspect 3549
Assemble and Install 3549
Valve Guides and Seats, Repairs 3551
Valves, Repair 3551
Valve Seats, Repair 3552
Valve Springs 3553
Assemble and Install 3554
Engine Block Cleaning and Inspection 3557
Clean and Inspect 3558
Piston Bore Preparation 3560
Engine Mounts Installation 3560
Remove 3560
Clean and Inspect 3561
Install 3561
Lubrication System Repair 3562
Oil Pump, Remove and Disassemble 3562
Clean and Inspect 3563
Oil Pump, Assemble and Install 3564
Oil Pan, Install 3566
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3568
Timing Cover 3568
Remove 3568
Install 3570
Timing Sprockets 3570
Remove 3570
Install 3570
Camshaft 3570
Remove 3570
Inspect 3571
Install 3571
Balance Shaft 3572
Remove 3572
Install 3573
Valve Lifters 3574
Remove 3574
Clean and Inspect 3574
Install 3575
Crankshaft Repair 3575
Remove 3576
Inspect and Repair 3576
How to Check Clearance Between Main Bearings and Their Journals 3577
Install 3578
Piston and Connecting Rod Assemblies Repair 3580
Connecting Rod Bearings, Replace 3580
Piston and Connecting Rod Assemblies, Remove 3581
Disassemble 3581
Piston, Clean and Inspect 3582
Cylinder Bores, Inspect and Repair 3582
Piston Rings 3583
Assemble 3584
Piston and Connecting Rod Assemblies, Install 3584
Flywheel and Flywheel Housing Repair 3584
Flywheel, Remove 3585
Clean 3585
Inspect 3585
Flywheel, Install 3586
Coolant Pump Repair 3586
Remove 3586
Clean and Inspect 3587
Install 3587
Thermostat Replacement 3587
Remove 3588
Thermostat Operation Check 3588
Install 3588
Starter Replacement 3589
3589
Remove 3589
Install 3592
Fan Assembly Replacement 3593
Remove 3593
Inspect 3595
Install 3595
Drive Belt Installation 3596
Remove 3596
Clean 3596
Inspect 3596
Installation 3597
Compression Check 3598
Engine Specifications 3598
Engine Data 3598
Cylinder Head 3598
Hydraulic Valve Lifter 3599
Camshaft 3599
Pistons 3599
Crankshaft 3600
Connecting Rods 3600
Balance Shaft 3601
Cooling System 3601
Lubrication System 3601
Torque Specifications 3602
524265342 4000YRM1250 (09 2018) US EN 3607
Safety Procedures When Working Near Mast 3613
Fork Replacement 3615
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3615
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3617
Remove, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 3618
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3619
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3620
Install, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017 GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 3621
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 3621
Checks, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 3623
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 3623
Fixed Carriage Replacement 3625
Remove, Carriage With Hook Forks 3625
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3634
Install, Carriage With Hook Forks 3635
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3635
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 3636
Connecting Attachment Hydraulic Quick Disconnect Hoses 3636
Integral Sideshift Carriage Repair 3637
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 3637
Disassemble 3637
Clean and Inspect 3640
Assemble 3640
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 3641
Hang On Sideshift Carriage Repair 3641
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 3641
Disassemble 3653
Clean and Inspect 3662
Assemble 3663
Install 3664
Bolzoni Hang-On Sideshift Carriage Repair 3666
Remove 3666
Disassemble Carriage 3668
Clean and Inspect 3671
Assemble 3671
Install 3674
Fork Positioner 3676
Two-Stage Mast With Limited Free-Lift Repair 3677
Remove 3677
Disassemble 3681
Clean and Inspect 3684
Assemble 3701
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3703
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 3704
Header Hose Alignment 3716
Two-Stage Mast With Full Free-Lift Repair 3726
Remove 3726
Disassemble 3728
Clean and Inspect 3740
Assemble 3741
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 3743
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and ERC35-55HG (ERC70-120HH) (C839) 3746
Header Hose Installation and Adjustment 3750
Installation 3750
Adjustment 3750
Three-Stage Mast With Full Free-Lift Repair 3751
Remove 3751
Disassemble 3753
Clean and Inspect 3783
Assemble 3784
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX, (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3788
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and ERC35-55HG (ERC70-120HH) (C839) 3793
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813), and ERC35-55HG (ERC70-120HH) (C839) 3800
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 3806
Mast Operation Check 3810
Tilt Cylinder Adjustment 3810
Lift Chains Adjustment 3811
Mast Adjustments 3812
Load Roller Adjustment 3812
Mast Side Kicking Adjustment 3814
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 3815
Carriage Adjustments 3818
524306203 0100YRM1290 (04 2014) US EN 3821
550043871 0900YRM1556 (04 2018) US EN 3925
General 3929
LPG Tank and Bracket 3929
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) 3929
Remove 3929
Install 3937
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) 3938
Remove 3938
Install 3940
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 3940
Remove 3940
Install 3942
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 3942
Remove 3942
Install 3942
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) 3943
Remove 3943
Install 3945
Fuel Filter Unit 3945
Fuel Filter Element 3946
Remove 3946
Clean and Inspect 3946
Install 3947
Fuel Filter Housing with LP Vapor Sensor 3947
Remove 3947
Disassemble 3949
Clean and Inspect 3950
Assemble 3950
Install 3951
Throttle Body 3952
Remove 3952
Clean 3956
Install 3956
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 3957
Remove 3957
Install 3958
Control System 3958
Engine Control Unit (ECU) 3959
Remove 3959
Install 3960
Low Pressure Switch 3960
Remove 3960
Install 3960
Low Fuel Sensor 3961
Remove 3961
Install 3961
LP Converter 3962
Remove and Disassemble 3962
Assemble and Install 3963
LPG Lock-Off 3963
Remove 3964
Install 3965
Exhaust System 3966
Counterweight Exhaust 3966
Remove and Disassemble 3966
Inspect 3968
Assemble and Install 3968
Overhead Exhaust 3969
Remove and Disassemble 3969
Inspect 3971
Assemble and Install 3971
Exhaust Manifold 3971
Remove 3971
Install 3973
Oxygen (HEGO) Sensor 3973
Remove 3973
Install 3973
LPG Fuel Testing 3974
General 3974
Available Fuel Tests 3974
Composition Test (ASTM D-2163) 3974
Ammonia Test (ASTM D-4490) 3974
Basic Nitrogen Test (ASTM UOP269-90) 3974
Residues Test (ASTM D-2158) 3974
Vapor Pressure Test (ASTM D-2598) 3974
Sulfur Compounds Test (ASTM D-5623) 3974
Methanol Test (ASTM D-4864) 3975
Copper Corrosion (ASTM D-1838) 3975
Where To Send LPG Fuel Samples For Testing 3975
550048401 0900YRM1570 (03 2015) US EN 3979
550048607 0600YRM1557 (07 2019) US EN 4009
General 4015
Engine Identification 4015
Major Engine Component Identification 4015
Location of Labels 4015
Crankcase Description 4016
Engine Removal and Installation 4017
Cylinder Head Assembly Repair 4018
Valve Covers and Fuel Injectors 4018
Remove 4018
Clean and Inspect 4024
Install 4024
Rocker Arm Assembly 4025
Remove 4025
Disassemble 4026
Clean and Inspect 4027
Push Rods 4027
Rocker Arm Assembly 4027
Assemble 4027
Install 4028
Valve Clearance Adjustments 4028
Cylinder Head Assembly 4029
Remove 4029
Disassemble 4041
Valves and Valve Springs, Remove 4041
Valve Guides, Remove 4042
Clean and Inspect 4042
Cylinder Head 4043
Valve Guides 4043
Valves 4043
Valve Sink 4043
Valve Seat 4044
Valve Springs 4044
Assemble 4045
Valve Guides, Install 4045
Valves and Valve Springs, Install 4046
Install 4047
Timing Gear Case and Timing Gears Repair 4051
Timing Gear Case Cover 4051
Remove 4051
Clean and Inspect 4052
Install 4052
Timing Gears 4053
Crankshaft Gear 4054
Remove 4054
Install 4054
Idler Gear 4054
Remove 4054
Inspect 4055
Install 4055
Camshaft Gear 4055
Remove 4055
Install 4056
Timing Gear Case 4056
Remove 4056
Clean and Inspect 4057
Install 4057
Drive Train, Camshaft, and Cylinder Block Repair 4058
Remove 4058
Disassemble 4058
Pistons and Connecting Rods 4058
Crankshaft 4059
Camshaft 4061
Clean and Inspect 4063
Cylinder Block 4063
Honing and Boring 4065
Cylinder Correction (Oversize) 4066
Pistons 4066
Piston Pin 4067
Connecting Rod 4067
Tappets 4068
Crankshaft 4068
Camshaft 4070
Camshaft Bushing 4071
Assemble 4071
Camshaft 4071
Crankshaft 4071
Pistons and Connecting Rods 4072
Install 4074
Angular Deviation Procedure 4074
Lubrication System Repair 4077
Engine Oil and Oil Filter Change 4077
Oil Pan 4078
Remove 4078
Install 4079
Oil Suction Tube 4079
Remove 4079
Clean 4080
Install 4080
Oil Pump 4080
Remove 4080
Clean and Inspect 4081
Outer Rotor Outside Clearance 4081
Outer Rotor to Inner Rotor Tip Clearance 4081
Outer Rotor Side Clearance 4082
Rotor Shaft Clearance 4082
Install 4082
Fuel System Repair 4083
Fuel Injectors 4083
Remove 4083
Inspect 4083
Clean 4083
Replace 4083
Install 4084
Test 4084
Fuel Injection Pump 4084
Remove 4084
Clean and Inspect 4089
Install 4089
Cooling System Repair 4090
Serpentine Belt 4090
Remove 4090
Inspect 4090
Install 4090
Serpentine Belt, Adjustment 4091
Water Pump 4091
Remove 4091
Install 4094
Thermostat 4096
Remove 4096
Inspect 4096
Install 4097
Flywheel and Flywheel Housing 4098
Flywheel 4098
Remove 4098
Install 4098
Flywheel Housing 4098
Remove 4098
Install 4098
Electrical Equipment Repair 4099
Alternator 4099
Remove 4099
Install 4100
Starter 4101
Remove 4101
Install 4101
Engine Specifications 4102
Engine Data For Lift Truck Models and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (H813)GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (E879) 4102
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 4103
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879) 4104
Engine Tuning 4105
Cylinder Head 4105
Intake/Exhaust Valve and Guide 4106
Valve Spring 4106
Rocker Arm and Shaft 4106
Push Rod 4106
Gear Train and Camshaft 4107
Camshaft 4107
Idle Gear Shaft and Bushing 4107
Backlash of Each Gear 4107
Cylinder Block 4107
Crankshaft 4107
Piston 4108
Piston Ring 4108
Connecting Rod 4108
Rod Small End 4108
Tappet 4109
Oil Pump 4109
Engine Oil Pressure 4109
Outer Rotor Outside Clearance 4109
Outer Rotor Side Clearance 4109
Inner Rotor to Cover 4109
Standard Torque Specifications 4110
Standard Torque Chart 4110
Special Torque Specifications 4110
Special Tools 4112
550048681 1300YRM1569 (11 2018) US EN 4125
General 4129
Serial Number 4129
Charge Pump Repair 4129
Lift Trucks Manufactured Before July, 2013 4129
Remove 4129
Inspect 4130
Install 4130
Lift Trucks Manufactured After July, 2013 4130
Remove 4130
Inspect 4131
Install 4131
Torque Converter Replace 4131
Remove 4131
Install 4137
Housings and Chain Drive Repair 4142
Remove 4143
Clean 4151
Inspect 4151
Install 4151
Clutch Packs Repair- 1 Speed Transmission 4157
Remove and Disassemble 4157
Transmission, Remove and Disassemble 4157
Clean 4169
Inspect 4169
Assemble and Install 4170
Transmission, Assemble and Install 4178
Clutch Packs Repair- 2 Speed Transmission 4181
Remove and Disassemble 4182
Transmission, Remove and Disassemble 4182
Clean 4196
Inspect 4196
Assemble and Install 4197
Transmission, Assemble and Install 4206
Control Valve Repair 4208
Remove and Disassemble 4209
Clean 4212
Inspect 4212
Assemble and Install 4212
Foot Directional Control Pedal Repair 4213
Remove and Disassemble 4213
Assemble and Install 4217
Direction Control Lever 4218
Remove 4218
Install 4218
550055279 0600YRM1579 (11 2019) US EN 4223
General 4229
Engine Identification 4229
Major Engine Component Identification 4229
Location of Labels 4229
Crankcase Description 4230
Engine Removal and Installation 4231
Cylinder Head Assembly Repair 4231
Valve Covers and Fuel Injectors 4231
Remove 4231
Clean and Inspect 4235
Install 4236
Rocker Arm Assembly 4237
Remove 4237
Disassemble 4239
Clean and Inspect 4239
Push Rods 4239
Rocker Arm Assembly 4239
Assemble 4240
Install 4240
Valve Clearance Adjustments 4240
Cylinder Head Assembly 4241
Remove 4241
Disassemble 4249
Valves and Valve Springs, Remove 4249
Valve Guides, Remove 4251
Clean and Inspect 4251
Cylinder Head 4252
Valve Guides 4252
Valves 4252
Valve Sink 4253
Valve Seat 4253
Valve Springs 4253
Assemble 4254
Valve Guides, Install 4254
Valves and Valve Springs, Install 4254
Install 4255
Timing Gear Case and Timing Gears Repair 4260
Timing Gear Case Cover 4260
Remove 4260
Clean and Inspect 4260
Install 4261
Timing Gears 4262
Crankshaft Gear 4262
Remove 4262
Install 4262
Idler Gear 4262
Remove 4262
Inspect 4263
Install 4263
Camshaft Gear 4263
Remove 4263
Install 4264
Timing Gear Case 4264
Remove 4264
Clean and Inspect 4265
Install 4265
Drive Train, Camshaft, and Cylinder Block Repair 4265
Remove 4265
Disassemble 4266
Pistons and Connecting Rods 4266
Crankshaft 4267
Camshaft 4269
Clean and Inspect 4270
Cylinder Block 4271
Honing and Boring 4273
Cylinder Correction (Oversize) 4274
Pistons 4274
Piston Pin 4275
Connecting Rod 4275
Tappets 4275
Crankshaft 4276
Camshaft 4278
Camshaft Bushing 4279
Assemble 4279
Camshaft 4279
Crankshaft 4279
Pistons and Connecting Rods 4279
Install 4281
Lubrication System Repair 4282
Engine Oil and Oil Filter Change 4282
Oil Pan 4283
Remove 4283
Install 4284
Oil Suction Tube 4284
Remove 4284
Clean 4285
Install 4285
Oil Pump 4285
Remove 4285
Clean and Inspect 4285
Outer Rotor Outside Clearance 4286
Outer Rotor to Inner Rotor Tip Clearance 4286
Outer Rotor Side Clearance 4286
Rotor Shaft Clearance 4287
Install 4287
Fuel System Repair 4288
Fuel Injectors 4288
Remove 4288
Inspect 4288
Clean 4288
Replace 4288
Install 4288
Electronic Throttle System 4288
Remove 4288
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) 4292
Bearing Replacement 4292
Install 4293
Adjustment 4294
Fuel Injection Pump 4294
Remove 4294
Disassemble 4298
Clean and Inspect 4300
Assemble 4300
Install 4301
Cooling System Repair 4302
Serpentine Belt 4302
Remove 4302
Inspect 4302
Install 4302
Serpentine Belt, Adjustment 4302
Water Pump 4303
Remove 4303
Install 4305
Thermostat 4306
Remove 4306
Inspect 4307
Install 4307
Flywheel and Flywheel Housing 4308
Flywheel 4308
Remove 4308
Install 4309
Flywheel Housing 4309
Remove 4309
Install 4309
Electrical Equipment Repair 4309
Alternator 4309
Remove 4309
Install 4310
Starter 4311
Remove 4311
Install 4311
Engine Specifications 4313
Engine Data 4313
Engine Tuning 4314
Cylinder Head 4314
Intake/Exhaust Valve and Guide 4315
Valve Spring 4315
Rocker Arm and Shaft 4315
Push Rod 4315
Gear Train and Camshaft 4316
Camshaft 4316
Idle Gear Shaft and Bushing 4316
Backlash of Each Gear 4316
Cylinder Block 4316
Crankshaft 4316
Piston 4317
Piston Ring 4317
Connecting Rod 4317
Rod Small End 4317
Tappet 4318
Oil Pump 4318
Engine Oil Pressure 4318
Outer Rotor Outside Clearance 4318
Outer Rotor Side Clearance 4318
Inner Rotor to Cover 4318
Standard Torque Specifications 4319
Standard Torque Chart 4319
Special Torque Specifications 4319
Special Tools 4321
550055280 1400YRM1582 (01 2019) US EN 4331
General 4335
Identification Plate 4335
Drive Axle Removal 4336
Reduction Gear Assembly 4341
Remove 4341
Disassemble 4344
Clean and Inspect 4348
Assemble 4348
Install 4357
Wet Disc Brake Repair 4360
General 4360
Remove 4361
Clean and Inspect 4364
Install 4365
Initial Steps For Install 4365
Final Steps For Install 4372
Wet Brake Noise Reduction 4375
General 4375
Adding Additive To Transmission 4375
Piston Housing 4377
Remove 4377
Disassemble 4378
Clean and Inspect 4379
Assemble 4379
Install 4380
Parking Brake Control Lever 4381
Remove 4381
Clean and Inspect 4382
Install 4382
Differential Repair 4384
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 4384
Input Pinion Carrier 4384
Remove 4385
Disassemble 4385
Clean and Inspect 4386
Assemble 4386
Preload Pinion Bearings 4388
Differential Housing and Drive Axle Trumpet Arm (Right Side) 4388
Remove 4390
Disassemble 4390
Clean and Inspect 4391
Assemble 4391
Install 4393
Ring Gear Backlash 4393
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 4394
Pinion and Motor Carrier 4395
Install 4395
Drive Axle Installation 4398
Special Tools 4403
Special Tools 4403
Torque specifications 4405
550055283 8000YRM1585 (07 2020) US EN 4409
General Information About Diagrams and Schematics 4413
Symbol Definitions 4413
Diagrams Manual Applications 4414
Diagrams and Schematics 4416
550059479 0600YRM1590 (07 2019) US EN 4505
General 4511
Engine Identification 4511
Major Engine Component Identification 4511
Location of Labels 4512
Crankcase Description 4512
Precautions Before Beginning Repair 4513
Exhaust System and DPF 4514
Engine Removal and Installation 4514
Cylinder Head Assembly Repair 4515
Valve Covers and Fuel Injectors 4515
Remove 4515
Clean and Inspect 4518
Install 4518
Rocker Arm Assembly 4519
Remove 4519
Disassemble 4520
Clean and Inspect 4520
Push Rods 4520
Rocker Arm Assembly 4520
Assemble 4521
Install 4521
Valve Clearance Adjustments 4521
Cylinder Head Assembly 4522
Remove 4522
Disassemble 4531
Valves and Valve Springs, Remove 4531
Valve Guides, Remove 4532
Clean and Inspect 4532
Cylinder Head 4533
Valve Guides 4533
Valves 4533
Valve Sink 4534
Valve Seat 4534
Valve Springs 4535
Assemble 4535
Valve Guides, Install 4535
Valves and Valve Springs, Install 4536
Install 4537
Timing Gear Case and Timing Gears Repair 4539
Timing Gear Case Cover 4539
Remove 4539
Clean and Inspect 4540
Install 4540
Timing Gears 4541
Crankshaft Gear 4542
Remove 4542
Install 4542
Idler Gear 4542
Remove 4542
Inspect 4543
Install 4544
Camshaft Gear 4544
Remove 4544
Install 4544
Drive Train, Camshaft, and Cylinder Block Repair 4544
Remove 4544
Disassemble 4545
Pistons and Connecting Rods 4545
Crankshaft 4546
Camshaft 4548
Clean and Inspect 4550
Cylinder Block 4550
Honing and Boring 4552
Cylinder Correction (Oversize) 4553
Pistons 4553
Piston Pin 4554
Connecting Rod 4554
Tappets 4555
Crankshaft 4555
Camshaft 4557
Camshaft Bushing 4558
Assemble 4558
Camshaft 4558
Crankshaft 4558
Pistons and Connecting Rods 4559
Install 4561
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 4561
Lubrication System Repair 4564
Engine Oil and Oil Filter Change 4564
Oil Pan 4565
Remove 4565
Install 4566
Oil Suction Tube 4567
Remove 4567
Clean 4567
Install 4567
Oil Pump 4567
Remove 4567
Clean and Inspect 4568
Outer Rotor Outside Clearance 4569
Outer Rotor to Inner Rotor Tip Clearance 4569
Outer Rotor Side Clearance 4569
Rotor Shaft Clearance 4570
Install 4570
Fuel System Repair 4571
Fuel Injectors 4571
Remove 4571
Inspect 4571
Clean 4571
Replace 4571
Install 4571
Test 4571
Fuel Injection Pump 4572
Remove 4572
Clean and Inspect 4573
Install 4573
Cooling System Repair 4574
Serpentine Belt 4574
Remove 4574
Inspect 4575
Install 4575
Adjust 4575
Water Pump 4576
Remove 4576
Install 4577
Thermostat 4578
Remove 4578
Inspect 4579
Install 4579
Flywheel and Flywheel Housing 4580
Flywheel 4580
Remove 4580
Install 4581
Flywheel Housing 4581
Remove 4581
Install 4581
Electrical Equipment Repair 4582
Alternator 4582
Remove 4582
Install 4583
Starter 4584
Remove 4584
Install 4584
Engine Specifications 4586
Engine Data 4586
Engine Tuning 4590
Cylinder Head 4590
Intake/Exhaust Valve and Guide 4590
Valve Spring 4591
Rocker Arm and Shaft 4591
Push Rod 4591
Gear Train and Camshaft 4591
Camshaft 4591
Idle Gear Shaft and Bushing 4591
Backlash of Each Gear 4592
Cylinder Block 4592
Crankshaft 4592
Piston 4592
Piston Ring 4593
Connecting Rod 4593
Rod Small End 4593
Tappet 4593
Oil Pump 4594
Engine Oil Pressure 4594
Outer Rotor Outside Clearance 4594
Outer Rotor Side Clearance 4594
Inner Rotor to Cover 4594
Standard Torque Specifications 4595
Standard Torque Chart 4595
Special Torque Specifications 4595
Special Tools 4597
550064329 1800YRM1597 (03 2017) US EN 4611
Wet Brake System 4615
Service Brake Repair 4616
Parking Brake Repair 4616
Remove and Disassemble 4616
Assemble and Install 4617
Adjust 4618
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 4618
Master Cylinder and Booster 4618
Remove 4618
Disassemble 4620
Clean and Inspect 4621
Assemble 4621
Install and Adjust 4621
Brake System Air Removal 4623
Using Pressure Bleed System 4623
Using Brake Pedal Pressure 4624
Lift Truck Models with Master Cylinder 4624
Brake Pedal Adjustment 4625
Free Pedal Adjustment 4626
Torque Specifications 4626
550068685 8000YRM1604 (12 2018) US EN 4629
General 4635
Serial Number Data 4635
How to Move Disabled Lift Truck 4635
How to Tow Lift Truck 4635
How to Put Lift Truck on Blocks 4636
How to Raise Drive Tires 4636
How to Raise Steering Tires 4637
How to Clean a Lift Truck 4638
Maintenance Schedule 4638
Maintenance Procedures Every 8 Hours or Daily 4653
How to Make Checks With Engine Stopped 4653
Tires and Wheels 4653
Safety Labels 4653
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4654
Operator Restraint System 4654
Emergency Locking Retractor (ELR) 4654
Adjust Seat – Full Suspension 4656
Adjust Seat – Internal Suspension 4657
Hood and Seat Latches 4657
Engine Compartment 4658
Paper Application 4658
Fuel, Oil, and Coolant Leaks, Check 4658
Hydraulic Hoses 4659
Coolant Hoses 4659
Steering Column Gas Cylinder 4659
Transmission 4659
Hydraulic System Oil 4659
Engine Oil 4660
Air Filter 4664
Forks 4664
Remove 4664
Inspect 4664
Install 4665
Adjust 4665
Integral Sideshift Carriage 4665
How to Make Checks With Engine Running 4666
Indicator Lights, Horn, Fuses, and Relays 4666
Service Brakes 4668
Brake Oil Level 4668
Operation, Check 4669
Parking Brake 4669
Engine Oil Pressure 4669
Cooling System 4669
Steering System 4670
Control Levers and Pedals 4670
Fuel/Water Separator Filter, Kubota Diesel Engine 4670
Lift System, Operate 4670
Air Filter 4671
First Service After First 100 Hours of Operation 4671
GM 4 3L Engine Oil and Oil Filter 4671
Kubota Diesel Engine Oil and Oil Filter 4672
Maintenance Procedures Every 250 Hours or 6 Months 4672
GM 4 3L Engine Oil and Oil Filter 4672
Kubota 3 6L Diesel Engine Oil and Oil Filter 4673
Drive Belt 4673
GM 4 3L Engine 4673
Fan and Alternator Drive Belt 4673
Drain Tar From LPG Converter 4674
Cleaning Carbon Buildup From Intake Valves – GM 4 3L LPG Engine 4675
Maintenance Procedures Every 500 Hours or 6 Months 4677
Hydraulic System Oil 4677
Hydraulic Tank Breather 4678
Inspect 4678
Battery 4678
Kubota 3 8L Diesel Engine Oil and Oil Filter 4679
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4679
Remove 4679
Install 4679
Priming the Fuel System (Kubota 3 8L Engine) 4680
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4681
Remove 4681
Install 4681
Priming the Fuel System (Kubota 3 6L Engine) 4682
Drive Belt 4682
Kubota Diesel Engine 4682
Fan and Alternator Drive Belt 4682
Clean Debris From Radiator Core 4683
Transmission Oil Level 4683
Wet Brake Center Body Oil Level Check (Dana Drive Axle) 4684
Wet Brake Oil Level Check (NMHG Drive Axle) 4684
Forks 4685
Mast Lubrication 4686
Header Hose Checks 4687
Lift Chain Lubrication 4688
Tilt Cylinder Lubrication 4688
Master Brake Cylinder Rod End Pin Lubrication 4688
Manual Hydraulic Levers Lubrication 4689
Brake Oil 4689
Tie Rod Lubrication 4690
Parking Brake Adjustment 4690
Maintenance Procedures Every 1000 Hours or 6 Months 4692
Valve Clearance, Check and Adjust, GM 4 3L Engine 4692
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 4692
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4692
Ignition System 4692
GM 4 3L Engine 4692
Gasoline Fuel Filter, GM 4 3L Engine 4692
Remove and Replace 4692
In-Line Strainer Replacement, Kubota Diesel Engine 4692
Remove 4692
Install 4693
Lift Chains Wear Check 4693
Lift Chain Lubrication 4694
Integral Sideshift Carriage, Check Sliding Surfaces 4694
Steering Axle (Spindle Bearings) 4695
Control Levers and Pedals 4695
Parking Brake Lever Lubrication, Dana Wet Brake Axle 4695
Normal Operating Environment 4695
Heavy Duty or Contaminated Environment 4696
Remove 4696
Clean and Inspect 4697
Install 4698
Inspect Engine Electrical System, Connectors 4698
Crankcase Breather Element, Kubota 3 8L Diesel 4698
Remove 4698
Clean and Inspect 4699
Install 4699
Maintenance Procedures Every 2000 Hours or Annually 4700
Hydraulic System 4700
Hydraulic Filter, Replace 4700
Hydraulic Tank Breather, Replace 4701
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4701
Cooling System, GM 4 3L and Kubota Diesel Engines 4701
Air Filter 4702
LPG Fuel Filter Element Replace, GM 4 3L Engine 4704
Remove 4704
Install 4705
Fuel Injector, Kubota 3 8L Engine 4705
Fuel Injector, Kubota 3 6L Engine 4705
Forks 4705
Transmission Oil and Filter, Replace 4706
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 4708
Wet Brake Center Section Oil Change (Dana Drive Axle) 4710
Remove 4710
Install 4710
Wet Brake Oil Change (NMHG Drive Axle) 4711
Brake Oil (Master Cylinder), Change 4712
Check Throttle Shaft for Sticking 4713
Inspect Exhaust Manifold and Piping for Leaks 4713
Wheel Bearings 4713
Steer Wheels, Lubrication 4713
Maintenance Procedures Every 4000 Hours or 2 Years 4713
Hydraulic Oil, Replace 4714
Safety Procedures When Working Near Mast 4716
Fuel Filter Water Removal 4718
Kubota Diesel Engine 4718
3 8L Diesel Engine 4718
3 6L Diesel Engine 4719
Hood Latch Check 4720
Lift Chain Adjustments 4722
Jump-Starting the Lift Truck 4723
Jump-Starting Using a Battery Charger 4723
Jump-Starting a Lift Truck Using Another Lift Truck 4723
Welding Repairs 4724
Overhead Guard Changes 4724
Wheel and Tire Replacement 4724
General 4724
Pneumatic Tire With Tube, Repair 4724
Remove Wheels From Lift Truck 4724
Remove Tire From Wheel 4725
Install Wheel in Tire 4728
Install Tire on Two-Piece Wheel 4730
Add Air to Pneumatic Tires With Tube 4731
Install the Wheels 4731
Dual Drive Wheels, Install 4732
Pneumatic Tubeless Tire, Repair 4733
Remove Wheels From Lift Truck 4733
Add Air to Pneumatic Tubeless Tire 4738
Wheels, Install 4738
Solid Rubber Tires on Pneumatic Wheels, Change 4738
Adhesives and Sealants 4742
550068693 8000YRM1605 (04 2018) US EN 4745
Counterweight Weights 4749
Tire Sizes 4749
Capacities 4749
Electrical System 4753
Transmission Oil Pressures 4754
Hydraulic System Relief Pressures 4756
Steering System 4756
Stall Speeds (in RPM ±100 rpm) 4756
PSI (GM) 4 3L 4757
Kubota 3 6L Diesel 4757
Kubota 3 8L Diesel 4757
Mast Speeds 4757
Tilt Angles 4761
Front End Equipment – Mast Creep 4761
Mast Creep 4761
Engine Specifications 4761
Diesel Fuel Cleanliness Levels 4764
Torque Specifications 4764
Frame 4764
Mast 4764
Steering System 4764
Steer Axle 4764
Drive Axle, Wet Brake
(Dana Spicer Axle) 4764
Drive Axle, Wet Brake
(NMHG Axle) 4765
Transmission 4765
Engine – PSI (GM) 4 3L 4765
Engine – Kubota 3 6L Diesel 4766
Engine – Kubota 3 8L Diesel 4767
550073240 1900YRM1620 (01 2023) US EN 4771
Proper Flushing after Major Hydraulic Repairs 4777
Introduction 4777
The Phases of Wear 4777
Causes of Hydraulic System Failure 4777
Progression of Contaminant Caused Hydraulic System Failure 4778
Hydraulic System Flushing Techniques 4778
Double Oil and Filter Change 4778
Mechanical Cleaning 4779
Cleaning of Components 4779
How to Clean Tubes and Hoses 4779
Filter Caddy 4779
Start-Up Procedure for Cleaned System 4780
Contaminated Oil Coolers 4780
Additional Filter Caddy Functions 4781
How to Handle Different Fluids 4781
Water Removal Filters 4781
Fluid Conditioning and System Flushing Procedures 4782
Operation of the Filter Caddy 4782
Filter Caddy operation 4782
Fluid Conditioning Procedure 4782
Filter Caddy Start-Up 4783
System Flushing Procedure 4783
Component Cleaning Procedure 4784
Reservoir Cleaning Procedure 4784
Cylinder Cleaning Procedure 4784
Hose and Tube Cleaning Procedure 4784
Valve Cleaning Procedure 4785
Front-End Attachment Cleaning Procedure 4786
System Flushing Procedure 4786
Filter Caddy Start-Up 4787
System Start-Up and Flushing 4787
Reservoir Fluid Cleaning Times 4788
Dealing With Different Fluid Types 4789
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4789
Filter Caddy Maintenance 4789
Servicing the Strainer 4789
DC Motor 4789
Hydraulic Oil Sampling Method and Procedure 4790
Hydraulic Oil Sampling Method 4790
Objective 4790
General Guidelines 4790
Synopsis 4791
Hydraulic Oil Analysis Report Guidelines 4792
Sampling Conditions 4792
Equipment 4792
Sampling Procedure 4793
Hydraulic Oil Sampling 4793
Sample Labeling 4793
Results Documentation 4793
550073240 1900YRM1620 (03 2020) US EN 4795
Proper Flushing after Major Hydraulic Repairs 4799
Introduction 4799
The Phases of Wear 4799
Causes of Hydraulic System Failure 4799
Progression of Contaminant Caused Hydraulic System Failure 4800
Hydraulic System Flushing Techniques 4800
Double Oil and Filter Change 4800
Mechanical Cleaning 4801
Cleaning of Components 4801
How to Clean Tubes and Hoses 4801
Filter Caddy 4801
Start-Up Procedure for Cleaned System 4802
Contaminated Oil Coolers 4802
Additional Filter Caddy Functions 4802
How to Handle Different Fluids 4802
Water Removal Filters 4803
Fluid Conditioning and System Flushing Procedures 4803
Operation of the Filter Caddy 4803
Filter Caddy operation 4803
Fluid Conditioning Procedure 4804
Filter Caddy Start-Up 4804
System Flushing Procedure 4805
Component Cleaning Procedure 4805
Reservoir Cleaning Procedure 4805
Cylinder Cleaning Procedure 4805
Hose and Tube Cleaning Procedure 4806
Valve Cleaning Procedure 4806
Front-End Attachment Cleaning Procedure 4807
System Flushing Procedure 4807
Filter Caddy Start-Up 4808
System Start-Up and Flushing 4808
Reservoir Fluid Cleaning Times 4809
Dealing With Different Fluid Types 4809
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4809
Filter Caddy Maintenance 4810
Servicing the Strainer 4810
DC Motor 4810
Hydraulic Oil Sampling Method and Procedure 4810
Hydraulic Oil Sampling Method 4810
Objective 4810
General Guidelines 4810
Synopsis 4811
Hydraulic Oil Analysis Report Guidelines 4812
Sampling Conditions 4813
Equipment 4813
Sampling Procedure 4813
Hydraulic Oil Sampling 4813
Sample Labeling 4814
Results Documentation 4814
550096331 8000YRM1689 (03 2020) US EN 4817
General Information About Diagrams and Schematics 4821
Symbol Definitions 4821
Diagrams Manual Applications 4822
Diagrams and Schematics 4824