Yale Forklift K813 (GLPGDP40VX, GLPGDP45VX, GLPGDP50VX, GLPGDP55VX) Service Manual - pdf

Yale Forklift K813 (GLPGDP40VX, GLPGDP45VX, GLPGDP50VX, GLPGDP55VX) Service Manual – PDF DOWNLOAD

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Yale Forklift K813 (GLPGDP40VX, GLPGDP45VX, GLPGDP50VX, GLPGDP55VX) Service Manual – PDF DOWNLOAD

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Pages : 5406
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Yale Forklift K813 (GLPGDP40VX, GLPGDP45VX, GLPGDP50VX, GLPGDP55VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524208014 2200YRM1097 (03 2020) US EN 23
Series Code / Model Designation Reference Table 27
Description 28
Distributor Ignition (DI) System 28
Crankshaft Position (CKP) Sensor 28
Camshaft Position (CMP) Sensor 28
Ignition Coil and Ignition Control Module (ICM) 28
Secondary Ignition Components 28
Spark Plugs and Wires 29
Spark Plug Wire Inspection 29
Spark Plug Wire Replacement 29
Remove 29
Install 30
Spark Plug Inspection 30
Usage 30
Inspection 30
Visual Inspection 32
Spark Plug Replacement 32
Remove 32
Install 32
Distributor Repair 33
Inspect 33
Overhaul 33
Disassemble 33
Assemble 36
Replace 37
Remove 37
Install Procedure 1 39
Install Procedure 2 40
Ignition Coil Replacement 41
Remove 41
Install 41
Ignition Control Module Replacement 42
Remove 42
Install 42
Starter Replacement 43
Remove 43
Install 46
Sensors and Switches 47
Gas and LPG Trucks 47
Crankshaft Position (CKP) Sensor 47
Remove 47
Install 47
Camshaft Position (CMP) Sensor 48
Remove 48
Install 50
Oil Pressure Sensor 50
Remove 50
Install 51
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 52
Remove 52
Install 52
Engine Coolant Temperature (ECT) Sensor 53
Remove 53
Install 54
Air Flow Restriction Switch 54
Remove 54
Install 55
Specifications and Special Tools 56
524221866 9000YRM1112 (10 2020) US EN 61
SECTION 9010 Operational Diagnostic Procedures 77
Group 05 – Operational Checkout 79
SECTION 9020 Engine 97
Group 10 – Principles of Operation 107
Group 30 – Observed Symptoms 305
Group 40 – Tests and Adjustments 407
SECTION 9030 Electrical System 439
Group 03 – General Maintenance and Diagnostic Data 463
Group 10 – Principles of Operation 557
Group 20 – Diagnostic Trouble Codes 581
Group 30 – Observed Symptoms 1553
SECTION 9040 Drive Train 1609
Group 10 – Principles of Operation 1613
Group 30 – Observed Symptoms 1669
Group 40 – Tests and Adjustments 1719
SECTION 9050 Hydraulic Systems 1729
Group 10 – Principles of Operation 1733
Group 30 – Observed Symptoms 1791
Group 33 – Observed Symptoms-Gear Pump 1793
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1881
Group 40 – Tests and Adjustments 1925
Group 43 – Tests and Adjustments-Gear Pump 1927
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1951
SECTION 9060 Operators Station 1969
Group 10 – Principles of Operation 1971
SECTION 9070 Front End (Mast) and Chassis 2007
Group 10 – Principles of Operation 2009
Group 30 – Observed Symptoms 2031
SECTION 9080 Supplementary Data 2089
Group 50 – Abbreviations and Acronyms 2091
Group 60 – Special Tools List 2099
Group 70 – Fault Mode Indicator Reference 2109
Group 80 – Supplier Specification Data 2111
524223769 2200YRM1128 (01 2023) US EN 2115
Series Code / Model Designation Reference Table 2123
General 2125
Deutsch Crimping Tool 2126
How to Strip a Wire for Use With Deutsch Crimping Tool 2126
How to Crimp With the Deutsch Crimping Tool 2127
Calibration Test for the Deutsch Crimping Tool 2129
Deutsch Connectors 2131
DT, DTM, and DTP Series Connectors 2131
HD Series Connectors 2174
Metri-Pack Connectors 2196
Remove and Install 2196
Micro-Pack Connectors 2199
Weather-Pack Connectors 2200
AMPSEAL Crimping Tools 2202
AMP Hand Crimping Tool With Certi-Crimp 2202
Description 2202
Stripping Wire for Use with AMP Hand Crimping Tool 2203
Insulation Crimp Adjustment 2204
Maintenance and Inspection for AMP Hand Crimping Tool 2204
AMP Hand Crimping Tool 2204
Crimp Height Inspection 2204
How to use AMP Hand Crimping Tool 2205
AMP Pro-Crimper II Tool 2205
Description 2205
Remove and Install Die Set and Locator Assembly 2206
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2206
Contact Support Adjustment 2207
Crimp Height Adjustment 2208
Maintenance and Inspection Procedures 2208
PRO-CRIMPER II Tool 2208
Crimp Height Inspection 2208
How to Use AMP PRO-CRIMPER II Tool 2209
AMPSEAL Connector Assemblies 2210
Description for Plug Connector Assembly 2210
Seal Plug 2211
Contact Crimping 2211
Description for Plug Connector and Header Assembly 2216
Voltage Reading 2219
Seal Plug 2219
Contact Crimping 2219
AMP Superseal 1 5 Crimping Tools 2226
Mini Mic Receptacle and Tab Contacts 2226
Description 2226
Crimping Conditions and Measurements 2226
Insertion of Rubber Seal on Cable 2228
AMP Hand Application Tool 2233
Description 2233
Maintenance and Inspection 2233
Crimp Height Inspection 2233
Crimp Height Adjustment 2234
How to Use AMP Hand Application Tool 2234
AMP Pro-Crimper II Tool 2235
Description 2235
Remove and Install Die Set and Locator Assembly 2235
Adjustments 2236
Contact Support 2236
Crimp Height 2237
Inspections and Maintenance 2238
Crimp Height Inspection 2238
Visual Inspection 2238
Maintenance 2239
How to Use Pro-Crimper II Tool 2239
AMP Superseal 1 5 Connector Assemblies 2240
Description 2240
Repair and Maintenance 2247
Panel Mount Option 2247
AMP Fastin-Faston Hand Tools 2248
Description – AMP Double Action Hand Tool 2248
Maintenance and Inspection Procedures 2248
Daily Maintenance 2248
Periodic Tool Inspection 2249
Lubrication 2249
Visual Inspection 2249
Crimp Height Inspection 2249
Certi-Crimp Ratchet Inspection 2250
How to Use AMP Double Action Hand Tool 2251
Description – AMP Extraction Tool 2252
Maintenance and Inspection 2253
How to Use AMP Extraction Tool 2253
AMP Fastin-Faston Receptacles and Housings 2255
Description 2255
Wire Repair 2263
Wire Splicing Requirements 2263
Deutsch Jiffy Splice 2264
Twisted/Shielded Cable and Leads Repair 2270
Special Tools 2272
524223770 2200YRM1130 (05 2021) US EN 2281
General 2285
Description 2285
Dash Display Menu Access 2285
Menu Navigation 2286
Standard Display 2286
Main Menu 2286
Passwords Menu 2287
Password Administration 2287
Add Password 2287
Delete Password 2287
Edit Password 2288
Other Password Functions 2289
Operator Passwords – Enable/Disable 2289
Password Time-Out Delay 2289
Passwords – Number Wrong to Disable 2289
Lockout Reset Password 2290
View Password Log 2290
View Versions 2291
VSM Versions 2291
Dash Display Versions 2292
Engine Controller Version 2293
Transmission (Xmsn) Controller Version 2294
Truck Serial Number 2295
Diagnostics 2296
View Fault Log 2296
Set Travel and Braking 2297
Speed Limit 2297
Acceleration Rate 2298
Auto-Deceleration Rate 2298
Set Power Reversal Rate 2299
Set Inching/Brake Overlap 2300
Setup Display Menu 2301
Set Operator Language 2301
Set Units 2302
Set Time Format (12/24 Hour) 2302
Set Daylight Saving Time 2303
Set Time 2306
Set Date Format 2306
Set Date 2307
Setup Hydraulics 2308
Return to Set Tilt Delay/On/Off 2308
Setup General Items 2309
Light Shutdown Time-Out 2309
Impact Sensor – Enable/Disable 2310
Impact Sensor – Soft Impact Settings 2311
Impact Sensor – Hard Impact Settings 2311
Adjust Impact Sensor Settings 2312
Initial Adjustment of Soft and Hard Impact Settings 2314
Readjustment of Soft and Hard Impact Settings 2314
Impact Sensor – Impact Alarm/Shutdown Reset 2315
Impact Sensor – Alarm Time Duration and Deactivation 2316
Impact Sensor – View Impact Event Log 2317
Engine Mode Indicator 2317
Generation 1 (ECO-eLo ONLY) 2317
Generation 2 2318
Operator Checklist 2319
Operator Checklist Off-On Mode 2319
Edit Operator Checklist 2319
Set Operator Checklist Expiration 2319
View Checklist Log 2320
Clear Operator Checklist Log 2321
Clear Operator Checklist Fault 2321
Calibrations 2322
Set Tilt Stop Point 2322
Calibrate Loaded Weight 2322
524223771 2200YRM1131 (05 2021) US EN 2325
Series Code / Model Designation Reference Table 2331
General 2333
Description 2333
Dash Display Menu Access 2333
Menu Navigation 2334
Main Menu 2335
Passwords 2335
Adding Passwords 2335
Hourmeters 2337
View Versions 2338
VSM Versions 2338
Dash Display Versions 2339
Engine Controller Version 2340
Transmission (Xmsn) Controller Version 2341
Truck Serial Number 2342
Truck Configuration 2343
Diagnostics 2344
Clear Fault Log 2344
View Fault Log 2345
No-Run Data Display 2346
Engine Accelerator and Throttle Data Display 2347
Engine Speeds and Governor Data Display 2349
Engine Fuel and Emissions Data Display 2350
Engine General Data Display 2352
XMSN/Brake Data Display 2353
Hydraulic Data Display 2355
General Truck Data Display 2358
Set Travel and Braking 2360
Speed Limit 2360
Acceleration Rate 2361
Auto-Deceleration Rate 2361
Set Power Reversal Rate 2362
Set Inching/Brake Overlap 2362
Setup Hydraulics 2363
Lift Maximum Speed 2363
Lower Maximum Speed 2364
Tilt Maximum Speed 2364
Auxiliary Function One, Direction A, Maximum Speed 2366
Auxiliary Function One, Direction B, Maximum Speed 2369
Auxiliary Function Two, Direction A, Maximum Speed 2369
Auxiliary Function Two, Direction B, Maximum Speed 2370
Auxiliary Function Three, Direction A, Maximum Speed 2371
Auxiliary Function Three, Direction B, Maximum Speed 2371
Lift/Lower Ramp Rate 2372
Hydraulic Auxiliary Ramp Rate 2372
Return to Set Tilt Delay/On/Off 2373
Hydraulic Input Device 2374
Auxiliary Solenoid 2374
Dual Function 2375
Setup Display 2376
Set Service Language 2376
Setup General Items 2376
Motion Alarm Activation Type 2377
Light Shutdown Time-Out 2378
Restore Default Settings 2378
Restore Engine Controller Default Calibration 2379
Impact Sensor – Enable/Disable 2379
Impact Sensor – Soft Impact Settings 2380
Impact Sensor – Hard Impact Settings 2380
Adjust Impact Sensor Settings 2381
Initial Adjustment of Soft and Hard Impact Settings 2383
Readjustment of Soft and Hard Impact Settings 2383
Impact Sensor – Impact Alarm/Shutdown Reset 2384
Impact Sensor – Alarm Time Duration and Deactivation 2385
Impact Sensor – View Impact Event Log 2386
Engine Mode Indicator 2386
Generation 1 (ECO-eLo ONLY) 2386
Generation 2 2387
Diesel Particulate Filter (DPF) Display 2388
General Description 2388
Passive Regeneration Only 2388
Regeneration Level 0 2388
Auto/Active Regeneration Inhibited 2389
Auto/Active Regeneration 2389
Regeneration Level 1 2389
Parked Regeneration Request 2390
Regeneration Level 2 2390
Warning Level 2391
Regeneration Level 3 2391
Service Level 2391
Regeneration Level 4 2391
Display, Diesel Particulate Filter (DPF), Revised 2391
Operator Interface 2392
Refer to Operator Manual 2392
CAN Communication Lost 2392
Passive Regeneration Only 2392
Regeneration Level 0 2392
Auto/Active Regeneration Inhibited 2393
Auto/Active Regeneration 2393
Regeneration Level 1 2393
Idle-up Auto/Active Regeneration 2393
Parked Regeneration Request 2394
Regeneration Level 2 2394
Warning Level 2395
Regeneration Level 3 2395
Service Level 2395
Regeneration Level 4 2395
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2396
Display, Diesel Particulate Filter (DPF), Stage V Engine 2396
Operator Interface 2396
Refer to Operator Manual 2396
CAN Communication Lost 2397
Passive Regeneration Only 2397
Regeneration Level 0 2397
Auto/Active Regeneration Inhibited 2397
Auto/Active Regeneration 2398
Regeneration Level 1 2398
Idle-up Auto/Active Regeneration 2398
Parked Regeneration Request 2398
Regeneration Level 2 2398
Warning Level 2400
Regeneration Level 3 2400
Service Level 2400
Regeneration Level 4 2400
Stage V Content 2400
Emissions System Malfunction 2400
Ash Load 2401
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2402
Operator Interface 2402
Refer to Operator Manual 2402
CAN Communication Lost 2403
Passive Regeneration Only 2403
Regeneration Level 0 2403
Auto/Active Regeneration Inhibited 2403
Auto/Active Regeneration 2404
Regeneration Level 1 2404
Idle-up Auto/Active Regeneration 2404
Parked Regeneration Request 2404
Regeneration Level 2 2404
Warning Level 2406
Regeneration Level 3 2406
Service Level 2406
Regeneration Level 4 2406
Calibrations 2407
Calibrate Transmission Valve 2409
Set Tilt Stop Point 2409
Calibrate Loaded Weight 2410
Calibrate Travel Speed Sensor 2410
Calibrate Mazda LP and Gas Accelerator Pedal 2411
524223780 8000YRM1134 (05 2022) US EN 2413
Series Code / Model Designation Reference Table 2419
Description 2422
Proc_Cal_001: Service Password Entry 2424
When to Perform 2424
Why Perform 2424
How to Perform 2424
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2425
When to Perform 2425
Calibration Order 2425
Why Perform 2425
How to Perform 2425
Proc_Cal_003: Save and Exit 2427
When to Perform 2427
Why Perform 2427
How to Perform 2427
Proc_Cal_004: Lift Valve Output Threshold 2428
When to Perform 2428
Calibration Order 2428
Why Perform 2428
How to Perform 2428
Proc_Cal_005: Lower Valve Output Threshold 2431
When to Perform 2431
Calibration Order 2431
Why Perform 2431
How to Perform 2431
Proc_Cal_006: Tilt Back Valve Output Threshold 2434
When to Perform 2434
Calibration Order 2434
Why Perform 2434
How to Perform 2434
Proc_Cal_007: Tilt Forward Valve Output Threshold 2437
When to Perform 2437
Calibration Order 2437
Why Perform 2437
How to Perform 2437
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2440
When to Perform 2440
Calibration Order 2440
Why Perform 2440
How to Perform 2440
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2443
When to Perform 2443
Calibration Order 2443
Why Perform 2443
How to Perform 2443
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2446
When to Perform 2446
Calibration Order 2446
Why Perform 2446
How to Perform 2446
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2449
When to Perform 2449
Calibration Order 2449
Why Perform 2449
How to Perform 2449
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2452
When to Perform 2452
Calibration Order 2452
Why Perform 2452
How to Perform 2452
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2455
When to Perform 2455
Calibration Order 2455
Why Perform 2455
How to Perform 2455
Proc_Cal_014: Load Weight Zero Point 2458
When to Perform 2458
Calibration Order 2458
Why Perform 2458
How to Perform 2458
Proc_Cal_015: Loaded Weight Calibration 2460
When to Perform 2460
Calibration Order 2460
Why Perform 2460
How to Perform 2460
Proc_Cal_016: Transmission Valve Calibration 2463
Applicable System/Option 2463
When to Perform 2463
Calibration Order 2463
Why Perform 2463
How to Perform 2463
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2465
Applicable System/Option 2465
When to Perform 2465
Calibration Order 2465
Why Perform 2465
How to Perform 2465
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2468
Applicable System/Option 2468
When to Perform 2468
Calibration Order 2468
Why Perform 2468
How to Perform 2468
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2471
Required Tools 2471
When to Perform 2471
Calibration Order 2471
Why Perform 2471
How to Perform 2471
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2473
When to Perform 2473
Why Perform 2473
How to Perform 2473
Proc_Cal_026: Travel Speed Calibration 2475
When to Perform 2475
Calibration Order 2475
Why Perform 2475
How to Perform 2475
524262278 1400YRM1246 (02 2018) US EN 2479
General 2483
Identification Plate 2484
Drive Axle Removal 2484
Hub Seal Replacement 2496
Planetary Reduction Repair 2505
Clean and Inspect 2514
Brake Repair 2527
Clean and Inspect 2543
Wet Brake Noise Reduction 2559
General 2559
Adding Additive To Transmission 2560
Bevel Pinion 2561
Clean and Inspect 2566
Differential Unit 2578
Disassemble 2589
Clean and Inspect 2595
Assemble 2596
Drive Axle Installation 2619
Special Tools 2629
Torque Specifications 2629
524262279 1800YRM1247 (06 2021) US EN 2633
General 2637
Dry Brake System 2637
Wet Brake System 2637
Service Brakes Repair (Dry Brake) 2641
Remove and Disassemble 2641
Clean 2643
Inspect 2644
Assemble and Install 2645
Adjust 2648
Parking Brake Repair 2649
Dry Brake System 2649
Remove and Disassembly 2649
Assemble and Install 2651
Wet Brake System 2651
Remove and Install 2651
Assemble and Install 2658
Adjust 2658
Dry Brake System 2658
Wet Brake System 2659
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 2659
Master Cylinder Repair 2661
Remove 2661
Disassemble 2665
Clean and Inspect 2666
Assemble 2667
Install and Adjust 2667
Accumulator 2670
Pre-Charge Check 2670
Remove 2671
Install 2673
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 2674
Remove 2674
Modulating Brake Valve 2676
Disassemble 2676
Clean and Inspect 2677
Assemble 2677
Accumulator Charge Valve 2678
Disassemble 2678
Clean and Inspect 2680
Assemble 2680
Install 2681
Pressure Checks 2682
Accumulator Charge Valve Check 2682
Accumulator Check 2682
Service Brakes Adjustment (Dry Brake) 2683
Service Brakes Adjustment 2683
Brake System Air Removal 2685
Using Pressure Bleed System 2685
Using Brake Pedal Pressure 2685
Lift Truck Models with Master Cylinder 2685
Lift Truck Models with Modulating Brake Valve 2686
Brake Pedal Adjustment 2687
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), GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2687
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2688
Free Pedal Adjustment 2690
Torque Specifications 2691
524265337 0600YRM1251 (09 2015) US EN 2693
General 2699
Engine Removal and Installation 2699
Cylinder Head Repair 2699
Remove and Disassemble 2699
Clean and Inspect 2701
Valve Oil Seals 2704
Remove and Disassemble 2704
Cylinder Leak Down Test 2704
Clean and Inspect 2705
Assemble and Install 2705
Valve Guides and Seats, Repairs 2707
Valves, Repair 2707
Valve Seats, Repair 2708
Valve Springs 2709
Assemble and Install 2710
Engine Block Cleaning and Inspection 2713
Clean and Inspect 2714
Piston Bore Preparation 2716
Engine Mounts Installation 2716
Remove 2716
Clean and Inspect 2717
Install 2717
Lubrication System Repair 2718
Oil Pump, Remove and Disassemble 2718
Clean and Inspect 2719
Oil Pump, Assemble and Install 2720
Oil Pan, Install 2722
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 2724
Timing Cover 2724
Remove 2724
Install 2726
Timing Sprockets 2726
Remove 2726
Install 2726
Camshaft 2726
Remove 2726
Inspect 2727
Install 2727
Balance Shaft 2728
Remove 2728
Install 2729
Valve Lifters 2730
Remove 2730
Clean and Inspect 2730
Install 2731
Crankshaft Repair 2731
Remove 2732
Inspect and Repair 2732
How to Check Clearance Between Main Bearings and Their Journals 2733
Install 2734
Piston and Connecting Rod Assemblies Repair 2736
Connecting Rod Bearings, Replace 2736
Piston and Connecting Rod Assemblies, Remove 2737
Disassemble 2737
Piston, Clean and Inspect 2738
Cylinder Bores, Inspect and Repair 2738
Piston Rings 2739
Assemble 2740
Piston and Connecting Rod Assemblies, Install 2740
Flywheel and Flywheel Housing Repair 2740
Flywheel, Remove 2741
Clean 2741
Inspect 2741
Flywheel, Install 2742
Coolant Pump Repair 2742
Remove 2742
Clean and Inspect 2743
Install 2743
Thermostat Replacement 2743
Remove 2744
Thermostat Operation Check 2744
Install 2744
Starter Replacement 2745
2745
Remove 2745
Install 2748
Fan Assembly Replacement 2749
Remove 2749
Inspect 2751
Install 2751
Drive Belt Installation 2752
Remove 2752
Clean 2752
Inspect 2752
Installation 2753
Compression Check 2754
Engine Specifications 2754
Engine Data 2754
Cylinder Head 2754
Hydraulic Valve Lifter 2755
Camshaft 2755
Pistons 2755
Crankshaft 2756
Connecting Rods 2756
Balance Shaft 2757
Cooling System 2757
Lubrication System 2757
Torque Specifications 2758
524265342 4000YRM1250 (06 2021) US EN 2763
Safety Procedures When Working Near Mast 2769
Fork Replacement 2772
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 2772
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 2773
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) 2775
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 2776
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 2777
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) 2778
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 2778
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) 2779
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 2780
Fixed Carriage Replacement 2782
Remove, Carriage With Hook Forks 2782
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2790
Install, Carriage With Hook Forks 2791
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 2791
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 2792
Connecting Attachment Hydraulic Quick Disconnect Hoses 2792
Integral Sideshift Carriage Repair 2793
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) 2793
Disassemble 2793
Clean and Inspect 2796
Assemble 2796
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) 2797
Hang On Sideshift Carriage Repair 2798
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 2798
Disassemble 2810
Clean and Inspect 2819
Assemble 2820
Install 2821
Hang-On Sideshift Carriage Repair 2823
Remove 2823
Disassemble Carriage 2825
Clean and Inspect 2828
Assemble 2828
Install 2831
Fork Positioner 2834
Two-Stage Mast With Limited Free-Lift Repair 2835
Remove 2835
Disassemble 2838
Clean and Inspect 2841
Assemble 2859
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) 2861
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, G879), and ERC35-55HG (ERC70-120HH) (C839) 2863
Header Hose Alignment 2874
Two-Stage Mast With Full Free-Lift Repair 2885
Remove 2885
Disassemble 2887
Clean and Inspect 2898
Assemble 2899
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) 2901
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) 2904
Header Hose Installation and Adjustment 2908
Installation 2908
Adjustment 2909
Three-Stage Mast With Full Free-Lift Repair 2910
Remove 2910
Disassemble 2912
Clean and Inspect 2942
Assemble 2944
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) 2947
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and ERC35-55HG (ERC70-120HH) (C839) 2952
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) 2959
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 2966
Mast Operation Check 2970
Tilt Cylinder Adjustment 2971
Lift Chains Adjustment 2971
Mast Adjustments 2973
Load Roller Adjustment 2973
Mast Side Kicking Adjustment 2975
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 2976
Carriage Adjustments 2978
Series Code / Model Designation Reference Table 2979
550043871 0900YRM1556 (04 2018) US EN 2983
General 2987
LPG Tank and Bracket 2987
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) 2987
Remove 2987
Install 2995
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) 2996
Remove 2996
Install 2998
LPG Tank, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 2998
Remove 2998
Install 3000
LPG Tank Bracket, Lift Truck Models GLP60-70VX (GLP135-155VX) (D878, E878, F878) 3000
Remove 3000
Install 3000
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) 3001
Remove 3001
Install 3003
Fuel Filter Unit 3003
Fuel Filter Element 3004
Remove 3004
Clean and Inspect 3004
Install 3005
Fuel Filter Housing with LP Vapor Sensor 3005
Remove 3005
Disassemble 3007
Clean and Inspect 3008
Assemble 3008
Install 3009
Throttle Body 3010
Remove 3010
Clean 3014
Install 3014
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 3015
Remove 3015
Install 3016
Control System 3016
Engine Control Unit (ECU) 3017
Remove 3017
Install 3018
Low Pressure Switch 3018
Remove 3018
Install 3018
Low Fuel Sensor 3019
Remove 3019
Install 3019
LP Converter 3020
Remove and Disassemble 3020
Assemble and Install 3021
LPG Lock-Off 3021
Remove 3022
Install 3023
Exhaust System 3024
Counterweight Exhaust 3024
Remove and Disassemble 3024
Inspect 3026
Assemble and Install 3026
Overhead Exhaust 3027
Remove and Disassemble 3027
Inspect 3029
Assemble and Install 3029
Exhaust Manifold 3029
Remove 3029
Install 3031
Oxygen (HEGO) Sensor 3031
Remove 3031
Install 3031
LPG Fuel Testing 3032
General 3032
Available Fuel Tests 3032
Composition Test (ASTM D-2163) 3032
Ammonia Test (ASTM D-4490) 3032
Basic Nitrogen Test (ASTM UOP269-90) 3032
Residues Test (ASTM D-2158) 3032
Vapor Pressure Test (ASTM D-2598) 3032
Sulfur Compounds Test (ASTM D-5623) 3032
Methanol Test (ASTM D-4864) 3033
Copper Corrosion (ASTM D-1838) 3033
Where To Send LPG Fuel Samples For Testing 3033
550048401 0900YRM1570 (03 2015) US EN 3037
550048607 0600YRM1557 (11 2021) US EN 3067
General 3073
Engine Identification 3073
Major Engine Component Identification 3073
Location of Labels 3074
Crankcase Description 3075
Engine Removal and Installation 3076
Cylinder Head Assembly Repair 3076
Valve Covers and Fuel Injectors 3076
Remove 3076
Clean and Inspect 3083
Install 3083
Rocker Arm Assembly 3085
Remove 3085
Disassemble 3085
Clean and Inspect 3086
Push Rods 3086
Rocker Arm Assembly 3086
Assemble 3087
Install 3087
Valve Clearance Adjustments 3087
Cylinder Head Assembly 3088
Remove 3088
Disassemble 3099
Valves and Valve Springs, Remove 3099
Valve Guides, Remove 3100
Clean and Inspect 3100
Cylinder Head 3101
Valve Guides 3101
Valves 3101
Valve Sink 3101
Valve Seat 3102
Valve Springs 3102
Assemble 3103
Valve Guides, Install 3103
Valves and Valve Springs, Install 3104
Install 3104
Timing Gear Case and Timing Gears Repair 3108
Timing Gear Case Cover 3108
Remove 3108
Clean and Inspect 3109
Install 3109
Timing Gears 3110
Crankshaft Gear 3110
Remove 3110
Install 3110
Idler Gear 3111
Remove 3111
Inspect 3111
Install 3111
Camshaft Gear 3111
Remove 3111
Install 3112
Timing Gear Case 3112
Remove 3112
Clean and Inspect 3113
Install 3113
Drive Train, Camshaft, and Cylinder Block Repair 3114
Remove 3114
Disassemble 3114
Pistons and Connecting Rods 3114
Crankshaft 3115
Camshaft 3117
Clean and Inspect 3119
Cylinder Block 3119
Honing and Boring 3121
Cylinder Correction (Oversize) 3122
Pistons 3122
Piston Pin 3123
Connecting Rod 3123
Tappets 3124
Crankshaft 3124
Camshaft 3126
Camshaft Bushing 3127
Assemble 3127
Camshaft 3127
Crankshaft 3128
Pistons and Connecting Rods 3128
Install 3130
Angular Deviation Procedure 3130
Lubrication System Repair 3134
Engine Oil and Oil Filter Change 3134
Oil Pan 3135
Remove 3135
Install 3136
Oil Suction Tube 3136
Remove 3136
Clean 3137
Install 3137
Oil Pump 3137
Remove 3137
Clean and Inspect 3138
Outer Rotor Outside Clearance 3138
Outer Rotor to Inner Rotor Tip Clearance 3138
Outer Rotor Side Clearance 3139
Rotor Shaft Clearance 3139
Install 3139
Fuel System Repair 3141
Fuel Injectors 3141
Remove 3141
Inspect 3141
Clean 3141
Replace 3141
Install 3141
Test 3141
Fuel Injection Pump 3141
Remove 3141
Clean and Inspect 3146
Install 3146
Cooling System Repair 3148
Serpentine Belt 3148
Remove 3148
Inspect 3148
Install 3148
Serpentine Belt, Adjustment 3148
Water Pump 3149
Remove 3149
Install 3152
Thermostat 3154
Remove 3154
Inspect 3154
Install 3155
Flywheel and Flywheel Housing 3157
Flywheel 3157
Remove 3157
Install 3157
Flywheel Housing 3157
Remove 3157
Install 3157
Electrical Equipment Repair 3158
Alternator 3158
Remove 3158
Install 3159
Starter 3160
Remove 3160
Install 3160
Engine Specifications 3161
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) 3161
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 3162
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879, G879) 3163
Engine Tuning 3164
Cylinder Head 3164
Intake/Exhaust Valve and Guide 3165
Valve Spring 3165
Rocker Arm and Shaft 3165
Push Rod 3165
Gear Train and Camshaft 3166
Camshaft 3166
Idle Gear Shaft and Bushing 3166
Backlash of Each Gear 3166
Cylinder Block 3166
Crankshaft 3166
Piston 3167
Piston Ring 3167
Connecting Rod 3167
Rod Small End 3167
Tappet 3168
Oil Pump 3168
Engine Oil Pressure 3168
Outer Rotor Outside Clearance 3168
Outer Rotor Side Clearance 3168
Inner Rotor to Cover 3168
Standard Torque Specifications 3169
Standard Torque Chart 3169
Special Torque Specifications 3170
Special Tools 3171
550048681 1300YRM1569 (11 2018) US EN 3185
General 3189
Serial Number 3189
Charge Pump Repair 3189
Lift Trucks Manufactured Before July, 2013 3189
Remove 3189
Inspect 3190
Install 3190
Lift Trucks Manufactured After July, 2013 3190
Remove 3190
Inspect 3191
Install 3191
Torque Converter Replace 3191
Remove 3191
Install 3197
Housings and Chain Drive Repair 3202
Remove 3203
Clean 3211
Inspect 3211
Install 3211
Clutch Packs Repair- 1 Speed Transmission 3217
Remove and Disassemble 3217
Transmission, Remove and Disassemble 3217
Clean 3229
Inspect 3229
Assemble and Install 3230
Transmission, Assemble and Install 3238
Clutch Packs Repair- 2 Speed Transmission 3241
Remove and Disassemble 3242
Transmission, Remove and Disassemble 3242
Clean 3256
Inspect 3256
Assemble and Install 3257
Transmission, Assemble and Install 3266
Control Valve Repair 3268
Remove and Disassemble 3269
Clean 3272
Inspect 3272
Assemble and Install 3272
Foot Directional Control Pedal Repair 3273
Remove and Disassemble 3273
Assemble and Install 3277
Direction Control Lever 3278
Remove 3278
Install 3278
550055279 0600YRM1579 (06 2021) US EN 3283
General 3289
Engine Identification 3289
Major Engine Component Identification 3289
Location of Labels 3289
Crankcase Description 3290
Engine Removal and Installation 3291
Cylinder Head Assembly Repair 3292
Valve Covers and Fuel Injectors 3292
Remove 3292
Clean and Inspect 3295
Install 3296
Rocker Arm Assembly 3298
Remove 3298
Disassemble 3299
Clean and Inspect 3299
Push Rods 3299
Rocker Arm Assembly 3300
Assemble 3300
Install 3300
Valve Clearance Adjustments 3301
Cylinder Head Assembly 3302
Remove 3302
Disassemble 3309
Valves and Valve Springs, Remove 3309
Valve Guides, Remove 3311
Clean and Inspect 3311
Cylinder Head 3312
Valve Guides 3312
Valves 3312
Valve Sink 3313
Valve Seat 3313
Valve Springs 3313
Assemble 3314
Valve Guides, Install 3314
Valves and Valve Springs, Install 3315
Install 3315
Timing Gear Case and Timing Gears Repair 3319
Timing Gear Case Cover 3319
Remove 3319
Clean and Inspect 3319
Install 3319
Timing Gears 3320
Crankshaft Gear 3321
Remove 3321
Install 3321
Idler Gear 3321
Remove 3321
Inspect 3322
Install 3322
Camshaft Gear 3322
Remove 3322
Install 3323
Timing Gear Case 3323
Remove 3323
Clean and Inspect 3324
Install 3324
Drive Train, Camshaft, and Cylinder Block Repair 3325
Remove 3325
Disassemble 3325
Pistons and Connecting Rods 3325
Crankshaft 3326
Camshaft 3328
Clean and Inspect 3329
Cylinder Block 3330
Honing and Boring 3332
Cylinder Correction (Oversize) 3333
Pistons 3333
Piston Pin 3334
Connecting Rod 3334
Tappets 3334
Crankshaft 3335
Camshaft 3337
Camshaft Bushing 3338
Assemble 3338
Camshaft 3338
Crankshaft 3338
Pistons and Connecting Rods 3338
Install 3340
Lubrication System Repair 3342
Engine Oil and Oil Filter Change 3342
Oil Pan 3343
Remove 3343
Install 3344
Oil Suction Tube 3344
Remove 3344
Clean 3345
Install 3345
Oil Pump 3345
Remove 3345
Clean and Inspect 3345
Outer Rotor Outside Clearance 3346
Outer Rotor to Inner Rotor Tip Clearance 3346
Outer Rotor Side Clearance 3346
Rotor Shaft Clearance 3347
Install 3347
Fuel System Repair 3348
Fuel Injectors 3348
Remove 3348
Inspect 3348
Clean 3348
Replace 3348
Install 3348
Electronic Throttle System 3349
Remove 3349
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) 3352
Bearing Replacement 3353
Install 3353
Adjustment 3354
Fuel Injection Pump 3355
Remove 3355
Disassemble 3358
Clean and Inspect 3360
Assemble 3360
Install 3361
Cooling System Repair 3363
Serpentine Belt 3363
Remove 3363
Inspect 3363
Install 3363
Serpentine Belt, Adjustment 3363
Water Pump 3364
Remove 3364
Install 3366
Thermostat 3367
Remove 3367
Inspect 3368
Install 3368
Flywheel and Flywheel Housing 3370
Flywheel 3370
Remove 3370
Install 3370
Flywheel Housing 3370
Remove 3370
Install 3370
Electrical Equipment Repair 3371
Alternator 3371
Remove 3371
Install 3372
Starter 3373
Remove 3373
Install 3373
Engine Specifications 3374
Engine Data 3374
Engine Tuning 3374
Cylinder Head 3375
Intake/Exhaust Valve and Guide 3375
Valve Spring 3376
Rocker Arm and Shaft 3376
Push Rod 3376
Gear Train and Camshaft 3376
Camshaft 3376
Idle Gear Shaft and Bushing 3376
Backlash of Each Gear 3377
Cylinder Block 3377
Crankshaft 3377
Piston 3377
Piston Ring 3378
Connecting Rod 3378
Rod Small End 3378
Tappet 3378
Oil Pump 3379
Engine Oil Pressure 3379
Outer Rotor Outside Clearance 3379
Outer Rotor Side Clearance 3379
Inner Rotor to Cover 3379
Standard Torque Specifications 3380
Standard Torque Chart 3380
Special Torque Specifications 3381
Special Tools 3383
550055280 1400YRM1582 (01 2019) US EN 3393
General 3397
Identification Plate 3397
Drive Axle Removal 3398
Reduction Gear Assembly 3403
Remove 3403
Disassemble 3406
Clean and Inspect 3410
Assemble 3410
Install 3419
Wet Disc Brake Repair 3422
General 3422
Remove 3423
Clean and Inspect 3426
Install 3427
Initial Steps For Install 3427
Final Steps For Install 3434
Wet Brake Noise Reduction 3437
General 3437
Adding Additive To Transmission 3437
Piston Housing 3439
Remove 3439
Disassemble 3440
Clean and Inspect 3441
Assemble 3441
Install 3442
Parking Brake Control Lever 3443
Remove 3443
Clean and Inspect 3444
Install 3444
Differential Repair 3446
Initial Removal Steps for Differential Housing and drive axle trumpet arm (right side) 3446
Input Pinion Carrier 3446
Remove 3447
Disassemble 3447
Clean and Inspect 3448
Assemble 3448
Preload Pinion Bearings 3450
Differential Housing and Drive Axle Trumpet Arm (Right Side) 3450
Remove 3452
Disassemble 3452
Clean and Inspect 3453
Assemble 3453
Install 3455
Ring Gear Backlash 3455
Final Installation Steps for Differential Housing and drive axle trumpet arm (right side) 3456
Pinion and Motor Carrier 3457
Install 3457
Drive Axle Installation 3460
Special Tools 3465
Special Tools 3465
Torque specifications 3467
550059479 0600YRM1590 (07 2019) US EN 3471
General 3477
Engine Identification 3477
Major Engine Component Identification 3477
Location of Labels 3478
Crankcase Description 3478
Precautions Before Beginning Repair 3479
Exhaust System and DPF 3480
Engine Removal and Installation 3480
Cylinder Head Assembly Repair 3481
Valve Covers and Fuel Injectors 3481
Remove 3481
Clean and Inspect 3484
Install 3484
Rocker Arm Assembly 3485
Remove 3485
Disassemble 3486
Clean and Inspect 3486
Push Rods 3486
Rocker Arm Assembly 3486
Assemble 3487
Install 3487
Valve Clearance Adjustments 3487
Cylinder Head Assembly 3488
Remove 3488
Disassemble 3497
Valves and Valve Springs, Remove 3497
Valve Guides, Remove 3498
Clean and Inspect 3498
Cylinder Head 3499
Valve Guides 3499
Valves 3499
Valve Sink 3500
Valve Seat 3500
Valve Springs 3501
Assemble 3501
Valve Guides, Install 3501
Valves and Valve Springs, Install 3502
Install 3503
Timing Gear Case and Timing Gears Repair 3505
Timing Gear Case Cover 3505
Remove 3505
Clean and Inspect 3506
Install 3506
Timing Gears 3507
Crankshaft Gear 3508
Remove 3508
Install 3508
Idler Gear 3508
Remove 3508
Inspect 3509
Install 3510
Camshaft Gear 3510
Remove 3510
Install 3510
Drive Train, Camshaft, and Cylinder Block Repair 3510
Remove 3510
Disassemble 3511
Pistons and Connecting Rods 3511
Crankshaft 3512
Camshaft 3514
Clean and Inspect 3516
Cylinder Block 3516
Honing and Boring 3518
Cylinder Correction (Oversize) 3519
Pistons 3519
Piston Pin 3520
Connecting Rod 3520
Tappets 3521
Crankshaft 3521
Camshaft 3523
Camshaft Bushing 3524
Assemble 3524
Camshaft 3524
Crankshaft 3524
Pistons and Connecting Rods 3525
Install 3527
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 3527
Lubrication System Repair 3530
Engine Oil and Oil Filter Change 3530
Oil Pan 3531
Remove 3531
Install 3532
Oil Suction Tube 3533
Remove 3533
Clean 3533
Install 3533
Oil Pump 3533
Remove 3533
Clean and Inspect 3534
Outer Rotor Outside Clearance 3535
Outer Rotor to Inner Rotor Tip Clearance 3535
Outer Rotor Side Clearance 3535
Rotor Shaft Clearance 3536
Install 3536
Fuel System Repair 3537
Fuel Injectors 3537
Remove 3537
Inspect 3537
Clean 3537
Replace 3537
Install 3537
Test 3537
Fuel Injection Pump 3538
Remove 3538
Clean and Inspect 3539
Install 3539
Cooling System Repair 3540
Serpentine Belt 3540
Remove 3540
Inspect 3541
Install 3541
Adjust 3541
Water Pump 3542
Remove 3542
Install 3543
Thermostat 3544
Remove 3544
Inspect 3545
Install 3545
Flywheel and Flywheel Housing 3546
Flywheel 3546
Remove 3546
Install 3547
Flywheel Housing 3547
Remove 3547
Install 3547
Electrical Equipment Repair 3548
Alternator 3548
Remove 3548
Install 3549
Starter 3550
Remove 3550
Install 3550
Engine Specifications 3552
Engine Data 3552
Engine Tuning 3556
Cylinder Head 3556
Intake/Exhaust Valve and Guide 3556
Valve Spring 3557
Rocker Arm and Shaft 3557
Push Rod 3557
Gear Train and Camshaft 3557
Camshaft 3557
Idle Gear Shaft and Bushing 3557
Backlash of Each Gear 3558
Cylinder Block 3558
Crankshaft 3558
Piston 3558
Piston Ring 3559
Connecting Rod 3559
Rod Small End 3559
Tappet 3559
Oil Pump 3560
Engine Oil Pressure 3560
Outer Rotor Outside Clearance 3560
Outer Rotor Side Clearance 3560
Inner Rotor to Cover 3560
Standard Torque Specifications 3561
Standard Torque Chart 3561
Special Torque Specifications 3561
Special Tools 3563
550064329 1800YRM1597 (03 2017) US EN 3577
Wet Brake System 3581
Service Brake Repair 3582
Parking Brake Repair 3582
Remove and Disassemble 3582
Assemble and Install 3583
Adjust 3584
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 3584
Master Cylinder and Booster 3584
Remove 3584
Disassemble 3586
Clean and Inspect 3587
Assemble 3587
Install and Adjust 3587
Brake System Air Removal 3589
Using Pressure Bleed System 3589
Using Brake Pedal Pressure 3590
Lift Truck Models with Master Cylinder 3590
Brake Pedal Adjustment 3591
Free Pedal Adjustment 3592
Torque Specifications 3592
550073240 1900YRM1620 (01 2023) US EN 3595
Proper Flushing after Major Hydraulic Repairs 3601
Introduction 3601
The Phases of Wear 3601
Causes of Hydraulic System Failure 3601
Progression of Contaminant Caused Hydraulic System Failure 3602
Hydraulic System Flushing Techniques 3602
Double Oil and Filter Change 3602
Mechanical Cleaning 3603
Cleaning of Components 3603
How to Clean Tubes and Hoses 3603
Filter Caddy 3603
Start-Up Procedure for Cleaned System 3604
Contaminated Oil Coolers 3604
Additional Filter Caddy Functions 3605
How to Handle Different Fluids 3605
Water Removal Filters 3605
Fluid Conditioning and System Flushing Procedures 3606
Operation of the Filter Caddy 3606
Filter Caddy operation 3606
Fluid Conditioning Procedure 3606
Filter Caddy Start-Up 3607
System Flushing Procedure 3607
Component Cleaning Procedure 3608
Reservoir Cleaning Procedure 3608
Cylinder Cleaning Procedure 3608
Hose and Tube Cleaning Procedure 3608
Valve Cleaning Procedure 3609
Front-End Attachment Cleaning Procedure 3610
System Flushing Procedure 3610
Filter Caddy Start-Up 3611
System Start-Up and Flushing 3611
Reservoir Fluid Cleaning Times 3612
Dealing With Different Fluid Types 3613
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3613
Filter Caddy Maintenance 3613
Servicing the Strainer 3613
DC Motor 3613
Hydraulic Oil Sampling Method and Procedure 3614
Hydraulic Oil Sampling Method 3614
Objective 3614
General Guidelines 3614
Synopsis 3615
Hydraulic Oil Analysis Report Guidelines 3616
Sampling Conditions 3616
Equipment 3616
Sampling Procedure 3617
Hydraulic Oil Sampling 3617
Sample Labeling 3617
Results Documentation 3617
550118409 0100YRM1891 (05 2017) US EN 3619
General 3623
Description 3624
Hood, Seat, and Side Covers Replacement 3627
Remove 3627
Install 3634
Hood Latch and Striker Bolt Adjustment 3640
Steering Column 3640
Description 3640
Steering Column Repair 3641
Remove 3641
Disassemble 3642
Clean 3644
Inspect 3644
Assemble 3644
Install 3644
LPG Tank and Bracket Replacement 3645
Counterweight Replacement 3645
Remove 3645
Install 3648
Tow Pin 3652
Operator Restraint System Replacement 3653
Description 3653
Emergency Locking Retractor (ELR) 3654
Overhead Guard Replacement 3655
Remove 3656
Install 3657
LED Tail, Backup, and Brake Lights, Replace 3657
Engine Replacement 3658
Remove Engine Only 3658
Install Engine only 3683
Remove Engine and Transmission 3686
Install Engine and Transmission 3690
Throttle Pedal and Cable Adjustment 3693
Kubota 3 6L Diesel Engine 3693
Exhaust System Repair 3695
4 3L Engine for Lift Truck Models GP/GLP080, 090, 100, 110, 120VX (K813) 3695
Kubota 3 8L LPG Engine for Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) and GLP40VX5/VX6; GLP45SVX5, GLP/45VX6; GLP50-55VX (GLP080, 090, 100, 110, 120VX) (K813) 3695
Kubota 3 6L Diesel Engine for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3695
Remove 3695
Inspect 3697
Install 3697
Kubota 3 8L Diesel Engine W/DOC for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3697
Remove 3697
Inspect 3702
Install 3702
Kubota 3 8L Diesel Engine W/DPF for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3703
Remove 3703
Inspect 3708
Diesel Particulate Filter (DPF) 3708
Disassemble 3708
Clean and Inspect 3709
Differential Pressure Pipes and Hoses 3710
Assembly 3710
Install 3710
Heavy Duty Pre-Cleaner, Kubota 3 6L and 3 8L Diesel Engines 3712
Remove 3712
Clean 3712
Inspect 3712
Install 3712
Cooling System 3712
Description 3712
Hydraulic Fan Drive 3713
Description 3713
Hydraulic Filter Assembly Repair 3713
Remove 3714
Disassemble 3714
Clean 3715
Inspect 3715
Assemble 3715
Install 3715
Fuel and Hydraulic Tanks Repair 3715
Inspect 3715
Clean 3716
Steam Method of Cleaning 3716
Chemical Solution Method of Cleaning 3717
Additional Preparations for Repair 3717
Small Leaks, Repair 3717
Large Leaks, Repair 3717
Preparations for Use After Repair 3717
Safety Labels 3717
550118410 0600YRM1893 (01 2022) US EN 3725
General 3733
Engine Identification 3733
Major Engine Component Identification 3733
Major Engine Component Identification 3734
Location of Labels 3735
Location of Labels 3736
Crankcase Description 3737
Engine Removal and Installation 3738
Cylinder Head Assembly Repair 3738
Valve Covers and Ignition Coils 3738
Remove 3738
Clean and Inspect 3743
Install 3743
Rocker Arm Assembly 3744
Remove 3744
Disassemble 3746
Clean and Inspect 3746
Push Rods 3746
Rocker Arm Assembly 3746
Assemble 3747
Install 3747
Valve Clearance Adjustments 3747
Cylinder Head Assembly 3748
Remove 3748
Disassemble 3754
Valves and Valve Springs, Remove 3754
Valve Guides, Remove 3755
Clean and Inspect 3755
Cylinder Head 3756
Valve Guides 3756
Valves 3757
Valve Sink 3757
Valve Seat 3757
Valve Springs 3758
Assemble 3758
Valve Guides, Install 3758
Valves and Valve Springs, Install 3759
Install 3760
Timing Gear Case and Timing Gears Repair 3763
Timing Gear Case Cover 3763
Remove 3763
Clean and Inspect 3763
Install 3763
Timing Gears 3764
Crankshaft Gear 3764
Remove 3764
Install 3765
Idler Gear 3765
Remove 3765
Inspect 3765
Install 3766
Camshaft Gear 3766
Remove 3766
Install 3766
Timing Gear Case 3767
Remove 3767
Clean and Inspect 3767
Install 3767
Drive Train, Camshaft, and Cylinder Block Repair 3768
Remove 3768
Disassemble 3768
Pistons and Connecting Rods 3768
Crankshaft 3769
Camshaft 3771
Clean and Inspect 3772
Cylinder Block 3772
Honing and Boring 3775
Cylinder Correction (Oversize) 3776
Pistons 3776
Piston Pin 3777
Connecting Rod 3777
Tappets 3778
Crankshaft 3778
Camshaft 3780
Camshaft Bushing 3781
Assemble 3781
Camshaft 3781
Crankshaft 3781
Pistons and Connecting Rods 3781
Install 3783
Lubrication System Repair 3785
Engine Oil and Oil Filter Change 3785
Oil Pan 3786
Remove 3786
Install 3786
Oil Suction Tube 3786
Remove 3786
Clean 3787
Install 3787
Oil Pump 3787
Remove 3787
Clean and Inspect 3788
Outer Rotor Outside Clearance 3788
Outer Rotor to Inner Rotor Tip Clearance 3788
Outer Rotor Side Clearance 3788
Rotor Shaft Clearance 3789
Install 3789
Fuel System Repair 3790
Cooling System Repair 3790
Serpentine Belt 3790
Remove 3790
Inspect 3790
Install 3790
Serpentine Belt, Adjustment 3790
Water Pump 3792
Remove 3792
Install 3794
Thermostat 3795
Remove 3795
Inspect 3796
Install 3796
Flywheel and Flywheel Housing 3798
Flywheel 3798
Remove 3798
Install 3798
Flywheel Housing 3798
Remove 3798
Install 3798
Electrical Equipment Repair 3799
Alternator 3799
Remove 3799
Install 3800
Starter 3801
Remove 3801
Install 3801
Engine Specifications 3802
Engine Data 3802
Engine Tuning 3807
Cylinder Head 3807
Intake/Exhaust Valve and Guide 3807
Valve Spring 3808
Rocker Arm and Shaft 3808
Push Rod 3808
Gear Train and Camshaft 3808
Camshaft 3808
Idle Gear Shaft and Bushing 3809
Backlash of Each Gear 3809
Cylinder Block 3809
Crankshaft 3809
Piston 3810
Piston Ring 3810
Connecting Rod 3810
Rod Small End 3810
Tappet 3811
Oil Pump 3811
Engine Oil Pressure 3811
Outer Rotor Outside Clearance 3811
Outer Rotor Side Clearance 3811
Inner Rotor to Cover 3811
Standard Torque Specifications 3812
Standard Torque Chart 3812
Special Torque Specifications 3813
Special Tools 3814
550118411 1900YRM1894 (06 2016) US EN 3823
General 3827
Description 3829
Hydraulic Fan Drive Replacement 3836
Lift Truck Models GC/GLC60VX, GC/GLC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 3837
Remove 3837
Disassemble 3839
Clean and Inspect 3840
Assemble 3840
Install 3840
Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) 3841
Remove 3841
Disassemble 3842
Clean and Inspect 3844
Assemble 3844
Install 3844
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) 3845
Remove 3845
Disassemble 3846
Clean and Inspect 3848
Assemble 3848
Install 3848
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) with Kubota 3 8L Diesel Engine (Tier 4), 55kw with DOC 3848
Remove 3848
Disassemble 3850
Clean and Inspect 3851
Assemble 3851
Install 3851
Hydraulic Fan Drive Manifold 3851
Remove 3851
Install 3853
550118412 0700YRM1895 (08 2016) US EN 3857
General 3861
Cooling System Checks 3862
Exhaust Leaks Into Cooling System 3862
Water Flow Restrictions in Radiator 3862
Radiator Hoses 3862
Water Pump 3862
Flushing the Cooling System 3862
Cooling System, Clean 3863
Radiator Replacement 3864
Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) 3864
Remove 3864
Install 3870
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) 3871
Remove 3871
Install 3878
Fan Assembly Replacement 3879
Fan Removal 3879
Inspect 3884
Fan Installation 3884
550118413 1600YRM1896 (03 2015) US EN 3887
550118414 1900YRM1897 (06 2021) US EN 3909
Series Code / Model Designation Reference Table 3915
General 3916
Hydraulic Gear Pump Assembly Repair 3918
Remove 3918
Disassemble 3921
Clean 3923
Inspect 3923
Assemble 3923
Install 3923
Hydraulic Gear Pump Specifications 3925
Variable Displacement Pump Repair 3927
Remove 3927
Disassemble 3930
Clean 3932
Inspect 3932
Assemble 3932
Install 3932
Variable Displacement Pump Checks and Adjustments 3935
Margin Pressure Check 3935
Flow Compensator Adjustment 3935
Pressure Compensator Adjustment 3936
Variable Displacement Pump Specifications 3938
Torque Specifications 3939
Hydraulic Gear Pump 3939
Variable Displacement Pump 3939
550118415 2000YRM1898 (06 2021) US EN 3941
Series Code / Model Designation Reference Table 3947
General 3948
Electro-Hydraulic Main Control Valve 3949
Description 3949
Remove 3955
Electro-Hydraulic Control Valve Sections 3959
General 3959
Outlet Control Valve Section 3959
Remove 3959
Disassemble 3959
Clean 3961
Inspect 3961
Assemble 3961
Install 3962
Auxiliary Control Valve Sections 3962
Remove 3962
Disassemble 3964
Clean 3964
Inspect 3965
Assemble 3965
Install 3966
Tilt Control Valve Section 3966
Remove 3966
Disassemble 3966
Clean 3968
Inspect 3968
Assemble 3968
Install 3968
Lift/Lower Control Valve Section 3968
Remove 3968
Disassemble 3968
Clean 3970
Inspect 3970
Assemble 3970
Install 3970
Transition Section 3970
Remove 3970
Disassemble 3971
Clean 3971
Inspect 3971
Assemble 3972
Install 3972
Install 3972
Manual Main Control Valve 3975
Description 3975
Remove 3977
OPS Solenoid Assembly 3981
General 3981
Remove 3982
Clean and Inspect 3984
Install 3984
Manual Control Valve Sections 3985
General 3985
Outlet Control Valve Section 3985
Remove 3985
Disassemble 3985
Clean 3987
Inspect 3987
Assemble 3987
Install 3987
Auxiliary Control Valve Sections 3988
Remove 3988
Disassemble 3988
Clean 3990
Inspect 3990
Assemble 3990
Install 3990
Lift/Tilt Control Valve Section 3991
Remove 3991
Disassemble 3991
Clean 3993
Inspect 3994
Assemble 3994
Install 3995
Install 3995
Pressure Relief Valve Check and Adjustment 3998
Primary Relief Valve 3998
Secondary Relief Valve 3999
Steering Control Unit Repair 4003
Steering Control Unit, Remove 4003
Steering Control Unit, Disassemble 4004
Steering Control Unit, Clean 4006
Steering Control Unit, Inspect 4006
Steering Control Unit, Assemble 4006
Relief Valve, Disassemble 4007
Relief Valve, Clean 4007
Relief Valve, Inspect 4008
Relief Valve, Assemble 4008
Steering Control Unit, Install 4008
550118417 2200YRM1901 (01 2020) US EN 4011
General 4019
Display Switch Cluster 4021
Remove 4021
Install 4023
Direction Control and Turn Signal Levers 4023
Remove 4023
Install 4024
Key Switch 4025
Remove 4025
Install 4026
Display Switch Cluster Panel Bezel and Overlay 4026
Remove 4026
Install 4026
Steering Column Repair 4026
Remove 4026
Disassemble 4028
Assemble 4028
Install 4029
Sensors and Switches 4029
General 4029
Dash Panel, Kick Panel, and Seal Plate, Remove and Install 4029
Remove 4029
Install 4030
Accelerator (Throttle) Pedal Position Sensor 4030
Remove 4030
Install 4031
Brake Fluid Level Switch 4032
Remove 4032
Install 4033
Service Brake Pedal Position Sensor 4034
Remove 4034
Install 4035
Service Brake Pressure Sensor 4036
Remove 4036
Install 4036
Parking Brake Position Sensor 4036
Remove 4036
Install 4036
Sensor MicroswitchFoot Directional Control 4037
Remove 4037
Install 4039
Low Coolant Level Sensor 4039
Remove 4039
Install 4040
Fuel Level Sensor, Gas and Diesel Engines Only 4041
Remove 4041
Install 4041
Seat Sensor (Operator Presence System) 4042
Non-Suspension and Semi-Suspension Seats 4042
Remove 4042
Install 4043
Full Suspension Seats 4044
Remove 4044
Install 4045
Hood Shut Off Switch 4045
Remove 4045
Install 4045
Remote Key Switch 4045
Remove 4045
Install 4046
Hydraulic Filter Pressure Switch 4046
Remove 4046
Install 4046
Transmission Speed Sensors 4047
Remove 4047
Install 4047
Transmission Pressure Sensors 4047
Remove 4047
Install 4048
Transmission Temperature Sensor 4048
Remove 4048
Install 4048
Return To Set Tilt (Tilt Angle) Sensor 4048
Remove 4048
Install 4049
Rear Horn Button Switch 4049
Remove 4049
Install 4050
Impact Sensor 4050
Remove 4050
Install 4051
Load Weight Sensor 4052
Remove 4052
Install 4052
Hydraulic Fan Drive Push Button Switch 4053
Remove 4053
Install 4053
Engine and Fuel Sensors and Switches – GM 4 3L Gas and LPG Engines 4054
Engine and Fuel Sensors and Switches – PSI 4 3L LPG Engine 4054
Engine and Fuel Sensors and Switches – Kubota 3 8L LPG and Bi-Fuel Engine 4054
Crankshaft Position Sensor 4055
Remove 4055
Install 4055
Camshaft Position Sensor 4055
Remove 4055
Install 4055
Oil Pressure Sensor 4056
Remove 4056
Install 4056
Engine Coolant Temperature (ECT) Sensor 4056
Remove 4056
Install 4056
Temperature And Manifold Absolute Pressure (TMAP) Sensor 4056
Remove 4056
Install 4057
Knock Sensor 4057
Remove 4057
Install 4057
Oxygen Sensors 4058
Air Flow Restriction Switch 4058
Remove 4058
Install 4058
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without Diesel Particulate Filter (DPF) 4059
Intake Air Temperature Sensor 4059
Remove 4059
Install 4060
Intake Air Pressure Sensor 4060
Remove 4060
Install 4060
Air Inlet Heater 4060
Remove 4060
Install 4060
Engine Oil Pressure Sensor 4060
Remove 4060
Install 4061
Engine Coolant Temperature (ECT) Sensor 4061
Remove 4061
Install 4061
Crankshaft Position Sensor 4061
Remove 4061
Install 4061
Adjust Shim Procedure 4062
Camshaft Position Sensor 4063
Remove 4063
Install 4063
Air Flow Restriction Sensor 4064
Remove 4064
Install 4064
Fuel/Water Separator 4064
Remove 4064
Install 4065
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With Diesel Particulate Filter (DPF) And Kubota 3 8L Diesel Engine (Tier 4), 55kW With Diesel Oxidation Catalyst (DOC) 4065
Intake Air Temperature Sensor 4067
Remove 4067
Install 4067
Boost Sensor 4068
Remove 4068
Install 4068
Throttle Valve Assembly, Air Intake Adapter and Air Intake Heater 4070
Remove 4070
Install 4071
Engine Coolant Temperature (ECT) Sensor 4071
Remove 4071
Install 4071
Engine Oil Pressure Sensor 4072
Remove 4072
Install 4072
Crankshaft Position Sensor 4072
Remove 4072
Install 4072
Adjust Shim Procedure 4073
Camshaft Position Sensor 4074
Remove 4074
Install 4074
Differential Pressure Sensor 4074
Remove 4074
Install 4075
Mass Air flow Sensor 4075
Remove 4075
Install 4075
Fuel/Water Separator 4075
Remove 4075
Install 4076
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 4077
Engine Coolant Temperature (ECT) Sensor 4077
Remove 4077
Install 4077
Engine Oil Pressure Sensor 4078
Remove 4078
Install 4078
Throttle Position Sensor 4078
Engine Speed Sensor 4078
Remove 4078
Install 4078
Fuel Shut Off Solenoid 4078
Remove 4078
Install 4078
Vehicle System Manager (VSM) 4079
General 4079
VSM Replacement 4079
Remove 4079
Install 4079
Programming a New VSM and/or Display Switch Cluster (DSC) 4080
Data Transferring 4081
New VSM 4081
New (Blank) Display Switch Cluster 4081
Used (Non-Blank) Display Switch Cluster 4081
PC Service Tool Software 4082
Power Distribution Module (PDM) and Component Parts 4083
Remove 4083
PDM as a Unit 4083
Install 4085
PDM as a Unit 4085
Remove and Install 4085
PDM Component Parts 4085
Battery 4085
Remove 4085
Install 4085
Lights 4086
Work Lights (Front and Rear) 4086
Halogen Bulb Lights 4086
Remove 4086
Install 4086
LED Lights 4086
Remove 4086
Install 4087
Strobe Light 4087
Remove 4087
Install 4087
LED Tail, Backup, and Brake Lights 4088
Remove 4088
Install 4088
Front Marker/Turn Signal Lights 4089
Replacing Whole Front Marker/Turn Signal Light Assembly 4089
Remove 4089
Install 4089
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 4090
Remove 4090
Install 4090
Diesel Particulate Filter (DPF) Display 4091
Remove 4091
Clean and Inspect 4091
Install 4091
Electronic-Hydraulic Controls, Before January, 2020 4092
E-Hydraulic Controls – Test 4092
Mini-Levers 4092
Full Stroke Test 4092
Function Returns to Neutral Test 4092
Push (Override) Button 4093
General 4093
Mini-levers, Remove and Install 4093
Armrest Assembly 4094
Remove 4094
Install 4097
Horn Button 4097
Remove 4097
Install 4097
Direction Control Switch 4097
Remove 4097
Install 4098
Push (Override) Buttons 4098
Remove 4099
Install 4099
Electronic-Hydraulic Controls, After January, 2020 4100
E-Hydraulic Controls – TEST 4100
Mini-Levers 4100
Full Stroke Test 4100
Function Returns to Neutral Test 4100
Push (Override) Button 4100
General 4101
Mini-levers, Remove and Install 4101
Armrest Assembly 4102
Remove 4102
Install 4105
Horn Button 4105
Remove 4105
Install 4105
Direction Control Switch 4105
Remove 4105
Install 4106
Push (Override) Buttons 4106
Remove 4107
Install 4107
Push (Override) Buttons and Toggle Switch 4108
Remove 4108
Install 4110
Special Tools 4111
550118418 8000YRM1902 (12 2020) US EN 4115
General 4123
Serial Number Data 4123
How to Move Disabled Lift Truck 4124
How to Tow Lift Truck 4124
How to Put Lift Truck on Blocks 4125
How to Raise Drive Tires 4125
How to Raise Steering Tires 4126
How to Clean a Lift Truck 4127
Maintenance Schedule 4127
Maintenance Procedures Every 8 Hours or Daily 4160
How to Make Checks With Engine Stopped 4160
Tires and Wheels 4160
Safety Labels 4161
Mast, Carriage, Lift Chains, Header Hoses, Attachment 4161
Operator Restraint System 4162
Emergency Locking Retractor (ELR) 4162
Hood and Seat Latches 4163
Engine Compartment 4163
Paper Application 4163
Fuel, Oil, and Coolant Leaks, Check 4164
Hydraulic Hoses 4164
Coolant Hoses 4164
Steering Column Gas Cylinder 4164
Transmission 4165
Hydraulic System Oil 4165
Engine Oil 4165
Air Filter 4173
Forks 4173
Forks, Inspect 4174
Forks, Remove 4175
Forks, Install 4175
Forks, Adjust 4175
Integral Sideshift Carriage 4176
Fork Positioner 4176
Forks, Inspect 4176
Forks, Remove 4177
Forks, Install 4178
Forks, Adjustments 4179
How to Make Checks With Engine Running 4179
Indicator Lights, Horn, Fuses, and Relays 4179
Service Brakes 4181
Brake Oil Level 4181
Operation, Check 4182
Parking Brake 4182
Engine Oil Pressure 4182
Cooling System 4182
Steering System 4183
Control Levers and Pedals 4183
Fuel/Water Separator Filter, Kubota Diesel Engine 4183
Lift System, Operate 4184
Air Filter 4184
First Service After First 100 Hours of Operation 4185
4 3L Engine Oil and Oil Filter 4185
Kubota Diesel Engine Oil and Oil Filter 4185
Kubota 3 8L LPG or Bi-Fuel Engine Oil and Oil Filter 4186
Maintenance Procedures Every 250 Hours or 6 Months 4186
4 3L Engine Oil and Oil Filter 4186
Kubota 3 6L Diesel Engine Oil and Oil Filter 4187
Drive Belt 4188
4 3L Engine 4188
Fan and Alternator Drive Belt 4188
Drain Tar From LPG Converter 4189
Cleaning Carbon Buildup From Intake Valves – GM 4 3L and Kubota 3 8L LPG Engines 4190
Maintenance Procedures Every 500 Hours or 6 Months 4192
Hydraulic System Oil 4192
Hydraulic Tank Breather 4193
Inspect 4193
Battery 4194
Kubota 3 8L Diesel Engine Oil and Oil Filter 4194
Kubota 3 8L LPG and Bi-Fuel Engine Oil and Oil Filter 4195
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4195
Remove 4195
Install 4195
Priming the Fuel System (Kubota 3 8L Engine) 4196
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4197
Remove 4197
Install 4197
Priming the Fuel System (Kubota 3 6L Engine) 4198
Drive Belt 4198
Kubota Diesel Engine 4198
Fan and Alternator Drive Belt 4198
Kubota LPG and Bi-Fuel Engine 4199
Fan and Alternator Drive Belt 4199
Clean Debris From Radiator Core 4200
Transmission Oil Level 4200
Wet Brake Center Body Oil Level Check (Dana Drive Axle) 4202
Wet Brake Oil Level Check (NMHG/HYG Drive Axle) 4203
Forks, Inspect 4204
Mast Lubrication 4206
Fork Positioner Lubrication 4208
Header Hose Checks 4209
Lift Chain Lubrication 4209
Tilt Cylinder Lubrication 4209
Master Brake Cylinder Rod End Pin Lubrication 4210
Manual Hydraulic Levers Lubrication 4211
Brake Oil 4211
Tie Rod Lubrication 4212
Parking Brake Adjustment 4212
Maintenance Procedures Every 1000 Hours or 6 Months 4213
Valve Clearance, Check and Adjust, 4 3L Engine 4213
Valve Clearance, Check and Adjust, Kubota 3 6L Diesel Engine 4213
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4213
Valve Clearance, Check and Adjust for Kubota 3 8L LPG and Bi-Fuel Engine 4214
Ignition System 4214
4 3L Engine 4214
Kubota 3 8L LPG and Bi-Fuel Engine, Standard Spark Plugs 4214
Gasoline Fuel Filter, GM 4 3L Engine 4214
Remove and Replace 4214
LPG Fuel Filter Element Replace, 4 3L Engine 4214
Remove 4214
Install 4215
LPG Fuel Filter Element Replace, Kubota 3 8L LPG and Bi-Fuel Engine 4215
Remove 4215
Install 4216
In-Line Strainer Replacement, Kubota Diesel Engine 4218
Remove 4218
Install 4218
Lift Chains Wear Check 4220
Lift Chain Lubrication 4220
Integral Sideshift Carriage, Check Sliding Surfaces 4220
Steering Axle (Spindle Bearings) 4221
Control Levers and Pedals 4222
Parking Brake Lever Lubrication, Dana Wet Brake Axle 4222
Normal Operating Environment 4222
Heavy Duty or Contaminated Environment – Parking Brake Lever on Top of Drive Axle 4225
Remove 4225
Clean and Inspect 4226
Install 4227
Heavy Duty or Contaminated Environment – Parking Brake Lever on Right Side of Drive Axle 4227
Remove 4227
Clean and Inspect 4229
Install 4229
Inspect Engine Electrical System, Connectors 4231
Crankcase Breather Element, Kubota 3 8L Diesel 4232
Remove 4232
Clean and Inspect 4232
Install 4232
Maintenance Procedures Every 2000 Hours or Annually 4233
Hydraulic System 4233
Hydraulic Filter, Replace 4233
Hydraulic Tank Breather, Replace 4234
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4235
Spark Plugs, 4 3L Engine 4235
Remove 4235
Install 4235
Long-Life Spark Plugs, Kubota 3 8L LPG and Bi-Fuel Engine 4236
Cooling System 4236
Air Filter 4236
4 3L Gasoline Fuel Filter 4238
Remove and Replace 4238
Kubota 3 8L Bi-Fuel Gasoline Fuel Filter 4239
Remove and Replace 4239
Fuel Injector, Kubota 3 8L Engine 4240
Fuel Injector, Kubota 3 6L Engine 4240
Forks, Inspect 4240
Transmission Oil and Filter, Replace 4241
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 4242
Wet Brake Center Section Oil Change (Dana Drive Axle) 4245
Remove 4245
Install 4245
Wet Brake Oil Change (NMHG/HYG Drive Axle) 4246
Brake Oil (Master Cylinder), Change 4247
Check Throttle Shaft for Sticking 4248
Inspect Exhaust Manifold and Piping for Leaks 4248
Wheel Bearings 4248
Steer Wheels, Lubrication 4248
Maintenance Procedures Every 3000 Hours 4249
Diesel Particulate Filter 4249
Remove 4249
Inspect 4253
Disassemble 4253
Servicing the Diesel Particulate Filter,Pressure Tubes and Pressure Hoses 4254
Assemble 4254
Install 4255
Maintenance Procedures Every 4000 Hours or 2 Years 4256
Hydraulic Oil, Replace 4256
Weld Inspection 4258
Safety Procedures When Working Near Mast 4261
Fuel Filter Water Removal 4262
Kubota Diesel Engine 4262
3 8L Diesel Engine 4262
3 6L Diesel Engine 4263
Hood Latch Check 4264
Lift Chain Adjustments 4265
Jump-Starting the Lift Truck 4267
Jump-Starting Using a Battery Charger 4267
Jump-Starting a Lift Truck Using Another Lift Truck 4267
Welding Repairs 4267
Overhead Guard Changes 4268
Wheel and Tire Replacement 4268
General 4268
Pneumatic Tire With Tube, Repair ( Series)GP/GLP/GDP 4268
Remove Wheels From Lift Truck 4268
Remove Tire From Wheel 4269
Install Wheel in Tire 4271
Install Tire on Two-Piece Wheel 4273
Add Air to Pneumatic Tires With Tube 4274
Install the Wheels 4275
Dual Drive Wheels, Install 4275
Pneumatic Tubeless Tire, Repair ( Series)GP/GLP/GDP 4276
Remove Wheels From Lift Truck 4276
Add Air to Pneumatic Tubeless Tire 4281
Install the Wheels 4281
Dual Drive Wheels, Install 4282
Solid Rubber Tire , Change ( Series)GLC 4282
Remove and Install Tire on Wheel 4283
Dual Drive Wheels, Install 4283
Adhesives and Sealants 4284
550118419 8000YRM1903 (08 2019) US EN 4287
Lift Truck Lifting Capacity 4291
Counterweight Weights 4291
Tire Sizes 4292
Capacities 4292
Electrical System 4298
Transmission Oil Pressures 4300
Hydraulic System Relief Pressures 4302
Steering System 4303
Stall Speeds (in RPM ±100 rpm) 4304
GM/PSI 4 3L 4304
Kubota 3 6L Diesel 4304
Kubota 3 8L Diesel 4304
Kubota 3 8L LPG/Bi-Fuel 4305
Mast Speeds 4305
Tilt Angles 4309
Front End Equipment – Mast Creep 4309
Mast Creep 4309
Engine Specifications 4310
Diesel Fuel Cleanliness Levels 4312
Torque Specifications 4313
Frame 4313
Mast 4313
Steering System 4313
Steer Axle 4313
Drive Axle, Wet Brake
(Dana Spicer Axle) 4313
Drive Axle, Wet Brake
(NMHG/HYG Axle) 4313
Transmission 4314
Engine – GM/PSI 4 3L 4314
Engine – Kubota 3 6L Diesel 4315
Engine – Kubota 3 8L 4316
550118420 8000YRM1904 (05 2022) US EN 4319
General Information About Diagrams and Schematics 4325
Symbol Definitions 4325
Diagrams Manual Applications 4326
Diagrams and Schematics 4328
550118555 0100YRM1892 (06 2021) US EN 4437
General 4445
Cab Replacement for 4-5 5 Ton Lift Trucks 4446
Remove 4446
Install 4456
Cab Replacement for 6-9 Ton Lift Trucks 4458
Remove 4458
Door Assemblies for 4-5 5 Ton Lift Trucks 4464
Right Side Door Assembly 4464
Remove 4464
Disassemble 4468
Door Cover With Heater Unit 4468
Door Cover With Air Conditioner/Heater Unit 4470
Heater Assembly 4472
Air Conditioner and Heater Unit Assembly 4472
Door Lock Assembly 4474
Windows 4475
Clean 4475
Inspect 4475
Assemble 4475
Windows 4475
Door Lock Assembly 4475
Heater Assembly 4475
Air Conditioner and Heater Unit Assembly 4476
Door Cover With Heater Unit 4476
Door Cover With Air Conditioner and Heater Unit 4476
Install 4476
Left Side Door Assembly 4477
Remove 4477
Disassemble 4477
Door Cover 4477
Door Lock Assembly 4477
Windows 4478
Clean 4478
Inspect 4478
Assemble 4478
Windows 4478
Door Lock Assembly 4478
Door Cover 4478
Install 4478
Door Assemblies for 6-9 Ton Lift Trucks 4479
Right and Left Side Door Assemblies 4479
Remove 4479
Disassemble 4480
Door Cover 4480
Door Lock Assembly 4481
Windows 4482
Clean 4482
Inspect 4482
Assemble 4482
Windows 4482
Door Lock Assembly 4483
Door Cover 4483
Install 4483
Window Replacement 4484
General 4484
Remove Door Windows for 4-5 5 Ton Lift Trucks 4484
Install Door Windows for 4-5 5 Ton Lift Trucks 4485
Remove Door Windows for 6-9 Ton Lift Trucks 4485
Install Door Windows for 6-9 Ton Lift Trucks 4487
Window Wipers Replacement 4488
General 4488
Front Wiper Assembly and Motor 4488
Remove 4488
Install 4490
Rear Wiper Assembly and Motor 4490
Remove, for 4-5 5 Ton Lift Trucks 4490
Install for 4-5 5 Ton Lift Trucks 4493
Remove for 6-9 Ton Lift Trucks 4493
Install for 6-9 Ton Lift Truck 4495
Heater Replacement 4496
Remove for 6-9 Ton Lift Trucks 4496
Install for 6-9 Ton Lift Trucks 4502
Heater and Air Conditioner Assembly 4503
Air Conditioner Condenser Unit 4503
Remove 4503
Install 4504
Air Conditioner Receiver/Drier Unit 4504
Remove 4504
Install 4506
Air Conditioner Compressor 4506
Light Replacement 4507
Work Lights (Front and Rear) 4507
Remove 4507
Install 4509
Strobe Light 4509
Remove 4509
Install 4510
Turn, Stop, Tail, and Backup Light 4510
Remove 4510
Install 4511
Front Marker/Turn Signal Lights 4511
Remove 4511
Install 4511
Display Switches 4512
Electrical Schematics 4515
Optional Equipment 4515
Heavy Duty Pre-Cleaner 4515
Fan 4515
Remove 4515
Install 4517
Mirror 4517
Remove 4517
Install 4517
Rear View Camera 4517
Monitor Removal 4517
Monitor Install 4519
Camera removal 4519
Camera install 4519
Label Replacement 4520
550118556 2000YRM1899 (03 2015) US EN 4523
550119576 0900YRM1905 (01 2022) US EN 4559
General 4565
LPG Tank and Bracket Replacement 4566
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) 4566
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) 4569
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) 4570
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) 4570
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) 4571
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) 4573
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) 4574
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) 4574
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) 4575
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) 4577
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) 4577
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) 4578
LPG Fuel Filter Unit Repair 4580
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) 4580
Remove/Disassemble 4580
Clean/Inspect 4582
Assemble/Install 4582
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) 4582
Remove/Disassemble 4582
Clean/Inspect 4583
Assemble/Install 4583
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) 4583
Remove 4583
Disassemble 4589
Clean and Inspect 4590
Assemble 4590
Install 4590
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) 4591
Remove 4591
Disassemble 4592
Clean and Inspect 4593
Assemble 4593
Install 4594
Electronic Throttle Body Repair 4595
Remove 4595
Install 4597
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4598
Remove 4598
Install 4601
Control System 4602
Engine Control Unit (ECU) 4602
Remove 4602
Install 4602
LPG Low Level Sensor 4603
Remove 4603
Remove 4605
Install 4606
Exhaust System 4607
Counterweight Exhaust 4607
Remove and Disassemble 4607
Remove and Disassemble 4609
Inspect 4611
Assemble and Install 4611
Assemble and Install 4611
Exhaust Manifold 4611
Remove 4611
Install 4612
Oxygen (HEGO) Sensor 4612
Remove 4612
Install 4612
LPG Fuel Testing 4613
General 4613
Available Fuel Tests 4613
Composition Test (ASTM D-2163) 4613
Ammonia Test (ASTM D-4490) 4613
Basic Nitrogen Test (ASTM UOP269-90) 4613
Residues Test (ASTM D-2158) 4613
Vapor Pressure Test (ASTM D-2598) 4613
Sulfur Compounds Test (ASTM D-5623) 4613
Methanol Test (ASTM D-4864) 4614
Copper Corrosion (ASTM D-1838) 4614
Where To Send LPG Fuel Samples For Testing 4614
550125043 2100YRM1947 (03 2015) US EN 4617
550131848 0600YRM1961 (03 2020) US EN 4659
General 4665
Engine Identification 4666
Major Engine Component Identification 4666
Location of Labels 4668
Cylinder Block Description 4669
Precautions Before Beginning Repair 4670
Exhaust System and DPF 4671
Engine Removal and Installation 4671
Cylinder Head Assembly Repair 4671
Valve Covers and Fuel Injectors 4671
Remove 4671
Clean and Inspect 4674
Install 4674
Rocker Arm Assembly 4675
Remove 4675
Disassemble 4675
Clean and Inspect 4676
Push Rods 4676
Rocker Arm Assembly 4676
Assemble 4677
Install 4677
Valve Clearance Adjustments 4677
Cylinder Head Assembly 4678
Remove 4678
Disassemble 4686
Valves and Valve Springs, Remove 4686
Valve Guides, Remove 4687
Clean and Inspect 4687
Cylinder Head 4688
Valve Guides 4688
Valves 4689
Valve Sink 4689
Valve Seat 4689
Valve Springs 4690
Assemble 4690
Valve Guides, Install 4690
Valves and Valve Springs, Install 4691
Install 4692
Timing Gear Case and Timing Gears Repair 4694
Timing Gear Case Cover 4694
Remove 4694
Clean and Inspect 4695
Install 4695
Timing Gears 4696
Crankshaft Gear 4696
Remove 4696
Install 4697
Idler Gear 1 and Idler Gear 2 4697
Remove 4697
Inspect 4698
Install 4699
Idler Gear 3 4699
Remove 4699
Inspect 4699
Install 4699
Camshaft Gear 4699
Remove 4699
Install 4699
Drive Train, Camshaft, and Cylinder Block Repair 4700
Remove 4700
Disassemble 4700
Pistons and Connecting Rods 4700
Crankshaft 4701
Camshaft 4703
Clean and Inspect 4705
Cylinder Block 4705
Honing and Boring 4707
Cylinder Correction (Oversize) 4708
Pistons 4708
Piston Pin 4709
Connecting Rod 4709
Tappets 4710
Crankshaft 4710
Camshaft 4712
Camshaft Bushing 4713
Assemble 4713
Camshaft 4713
Crankshaft 4713
Pistons and Connecting Rods 4714
Install 4716
Angular Deviation Procedure 4716
Lubrication System Repair 4719
Engine Oil and Oil Filter Change 4719
Oil Pan 4720
Remove 4720
Install 4720
Oil Suction Tube 4720
Remove 4720
Clean 4721
Install 4721
Oil Pump 4721
Remove 4721
Clean and Inspect 4722
Inner Rotor and Outer Rotor Clearance 4722
Outer Rotor and Pump Body Clearance 4723
Rotor and Cover Clearance 4723
Rotor Shaft Clearance 4723
Install 4724
Fuel System Repair 4724
Fuel Injectors 4724
Remove 4724
Inspect 4724
Clean 4725
Replace 4725
Install 4725
Test 4725
Fuel Injection Pump 4725
Remove 4725
Clean and Inspect 4728
Install 4728
Cooling System Repair 4729
Serpentine Belt 4729
Remove 4729
Inspect 4729
Install 4729
Adjust 4729
Water Pump 4730
Remove 4730
Install 4732
Thermostat 4732
Remove 4732
Inspect 4733
Install 4733
Flywheel and Flywheel Housing 4734
Flywheel 4734
Remove 4734
Install 4735
Flywheel Housing 4735
Remove 4735
Install 4735
Electrical Equipment Repair 4736
Alternator 4736
Remove 4736
Install 4737
Starter 4738
Remove 4738
Install 4738
Engine Specifications 4740
Engine Data 4740
Engine Tuning 4742
Cylinder Head 4742
Intake/Exhaust Valve and Guide 4743
Valve Spring 4743
Rocker Arm and Shaft 4743
Push Rod 4743
Gear Train and Camshaft 4744
Camshaft 4744
Idle Gear Shaft and Bushing 4744
Backlash of Each Gear 4744
Cylinder Block 4744
Crankshaft 4745
Piston 4745
Piston Ring 4745
Connecting Rod 4746
Rod Small End 4746
Tappet 4746
Oil Pump 4746
Engine Oil Pressure 4746
Inner and Outer Rotor Clearance 4746
Outer Rotor and Pump Body 4746
Rotor and Cover 4747
Standard Torque Specifications 4747
Standard Torque Chart 4747
Special Torque Specifications 4747
Special Tools 4749
550148125 9000YRM2010 (05 2016) US EN 4763
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 4769
Group 05 – Operational Checkout 4771
SECTION 9020 ENGINE 4777
Group 10 – Principles of Operation 4779
Group 03 – General Maintenance and Diagnostic Data 4789
Group 30 – Observed Symptoms 4793
SECTION 9030 ELECTRICAL SYSTEM 4799
Group 03 – General Maintenance and Diagnostic Data 4803
Group 10 – Principles of Operation 4809
Group 20 – Diagnostic Trouble Codes 4817
SECTION 9080 SUPPLEMENTARY DATA 4879
Group 50 – Abbreviations and Acronyms 4881
Group 60 – Special Tools List 4889
Group 70 – Fault Mode Indicator Reference 4891
550152438 0600YRM1949 (07 2023) US EN 4895
General 4901
Engine Removal and Installation 4901
Cylinder Head Repair 4901
Remove and Disassemble 4901
Clean and Inspect 4903
Valve Oil Seals 4905
Remove and Disassemble 4905
Cylinder Leak Down Test 4905
Clean and Inspect 4906
Assemble and Install 4906
Valve Guides and Seats, Repairs 4908
Valves, Repair 4909
Valve Seats, Repair 4909
Valve Springs 4910
Assemble and Install 4911
Engine Block Cleaning and Inspection 4915
Clean and Inspect 4915
Piston Bore Preparation 4917
Engine Mounts Installation 4918
Remove 4918
Clean and Inspect 4918
Install 4918
Lubrication System Repair 4919
Oil Pump, Remove and Disassemble 4919
Clean and Inspect 4920
Oil Pump, Assemble and Install 4921
Oil Pan, Install 4923
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 4925
Timing Cover 4925
Remove 4925
Install 4926
Timing Chain and Sprockets 4926
Remove 4926
Install 4927
Camshaft 4927
Remove 4927
Inspect 4928
Install 4928
Balance Shaft 4929
Remove 4929
Install 4930
Valve Lifters 4931
Remove 4931
Clean and Inspect 4931
Install 4931
Crankshaft Repair 4933
Remove 4933
Inspect and Repair 4933
How to Check Clearance Between Main Bearings and Their Journals 4934
Install 4935
Piston and Connecting Rod Assemblies Repair 4937
Connecting Rod Bearings, Replace 4937
Piston and Connecting Rod Assemblies, Remove 4938
Disassemble 4938
Piston, Clean and Inspect 4939
Cylinder Bores, Inspect and Repair 4939
Piston Rings 4940
Assemble 4941
Piston and Connecting Rod Assemblies, Install 4941
Flywheel and Flywheel Housing Repair 4942
Flywheel, Remove 4942
Clean 4942
Inspect 4942
Flywheel, Install 4943
Coolant Pump Repair 4944
Remove 4944
Clean and Inspect 4945
Install 4945
Thermostat Replacement 4946
Remove 4946
Thermostat Operation Check 4946
Install 4946
Starter Replacement 4947
Fan Assembly Replacement 4951
Remove 4951
Inspect 4953
Install 4953
Drive Belt Installation 4954
Remove 4954
Clean 4954
Inspect 4954
Installation 4954
Compression Check 4956
Engine Specifications 4957
Engine Data 4957
Cylinder Head 4957
Hydraulic Valve Lifter 4957
Camshaft 4957
Pistons 4958
Crankshaft 4958
Connecting Rods 4959
Balance Shaft 4959
Cooling System 4959
Lubrication System 4959
Torque Specifications 4960
550152439 0900YRM1951 (11 2019) US EN 4963
General 4969
LPG Tank and Bracket 4969
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 4969
Remove 4969
Install 4974
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 4975
Remove 4975
Install 4976
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 4977
Remove 4977
Install 4979
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 4979
Remove 4979
Install 4979
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 4980
Remove 4980
Install 4981
Fuel Filter Unit 4982
Fuel Filter Element 4982
Remove 4982
Clean and Inspect 4983
Install 4983
Fuel Filter Housing, Lift Truck Models GLP60-70VX (GLP135-155VX) (F878), GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878), GLC60-70VX (GLC135-155VX) (F879), and GLP40VX5, GLP40-45VX6, GLP45SVX5, GLP50-55VX (GLP80-120VX) (K813) 4984
Remove 4984
Disassemble 4985
Clean and Inspect 4985
Assemble 4986
Install 4986
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 4986
Remove 4986
Disassemble 4988
Clean and Inspect 4989
Assemble 4989
Install 4990
Throttle Body 4990
Remove 4990
Clean 4992
Install 4992
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4993
Remove 4993
Install 4994
Control System 4995
Engine Control Unit (ECU) 4995
Remove 4995
Install 4996
Low Pressure Switch 4996
Remove 4996
Install 4997
Low Fuel Sensor 4997
Remove 4997
Install 4998
LP Converter 4998
Remove and Disassemble 4998
Assemble and Install 5000
LPG Lock-Off 5001
Remove 5001
Install 5002
Exhaust System 5002
Counterweight Exhaust 5002
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5002
Inspect 5004
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5005
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5005
Inspect 5006
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5006
Overhead Exhaust 5007
Remove and Disassemble Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5007
Inspect 5008
Assemble and Install Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6, GLP50-55VX (GLP080-120VX) (K813), GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 5009
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5009
Inspect 5011
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 5011
Exhaust Manifold 5011
Remove 5011
Install 5012
Oxygen (HEGO) Sensor 5013
Remove 5013
Install 5013
LPG Fuel Testing 5013
General 5013
Available Fuel Tests 5014
Composition Test (ASTM D-2163) 5014
Ammonia Test (ASTM D-4490) 5014
Basic Nitrogen Test (ASTM UOP269-90) 5014
Residues Test (ASTM D-2158) 5014
Vapor Pressure Test (ASTM D-2598) 5014
Sulfur Compounds Test (ASTM D-5623) 5014
Methanol Test (ASTM D-4864) 5014
Copper Corrosion (ASTM D-1838) 5014
Where To Send LPG Fuel Samples For Testing 5014
550152440 2200YRM1955 (11 2019) US EN 5017
Description 5021
Distributor Ignition (DI) System 5021
Crankshaft Position (CKP) Sensor 5021
Camshaft Position (CMP) Sensor 5021
Ignition Coil and Ignition Control Module (ICM) 5021
Secondary Ignition Components 5021
Spark Plugs and Wires 5021
Spark Plug Wire Inspection 5021
Spark Plug Wire Replacement 5021
Remove 5021
Install 5022
Spark Plug Inspection 5022
Usage 5022
Inspection 5022
Visual Inspection 5024
Spark Plug Replacement 5025
Remove 5025
Install 5025
Distributor Repair 5025
Inspect 5025
Overhaul 5026
Disassemble 5026
Assemble 5028
Replace 5029
Remove 5029
Install Procedure 1 5031
Install Procedure 2 5032
Ignition Coil Replacement 5034
Remove 5034
Install 5034
Ignition Control Module Replacement 5035
Remove 5035
Install 5035
Starter Replacement 5036
Remove 5036
Install 5039
Sensors and Switches 5040
LPG Trucks 5040
Crankshaft Position (CKP) Sensor 5040
Remove 5040
Install 5040
Camshaft Position (CMP) Sensor 5041
Remove 5041
Install 5042
Oil Pressure Sensor 5043
Remove 5043
Install 5043
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 5044
Remove 5044
Install 5044
Engine Coolant Temperature (ECT) Sensor 5044
Remove 5044
Install 5045
Air Flow Restriction Switch 5045
Remove 5045
Install 5046
Specifications and Special Tools 5046
550156616 0600YRM2011 (07 2019) US EN 5049
General 5055
Engine Identification 5055
Major Engine Component Identification 5055
Location of Labels 5056
Crankcase Description 5056
Engine Removal and Installation 5057
Cylinder Head Assembly Repair 5058
Valve Covers and Ignition Coils 5058
Remove 5058
Clean and Inspect 5062
Install 5063
Rocker Arm Assembly 5063
Remove 5063
Disassemble 5064
Clean and Inspect 5065
Push Rods 5065
Rocker Arm Assembly 5065
Assemble 5066
Install 5066
Valve Clearance Adjustments 5066
Cylinder Head Assembly 5067
Remove 5067
Disassemble 5073
Valves and Valve Springs, Remove 5073
Valve Guides, Remove 5073
Clean and Inspect 5074
Cylinder Head 5074
Valve Guides 5075
Valves 5075
Valve Sink 5075
Valve Seat 5075
Valve Springs 5076
Assemble 5076
Valve Guides, Install 5076
Valves and Valve Springs, Install 5077
Install 5078
Timing Gear Case and Timing Gears Repair 5080
Timing Gear Case Cover 5080
Remove 5080
Clean and Inspect 5080
Install 5080
Timing Gears 5081
Crankshaft Gear 5081
Remove 5081
Install 5081
Idler Gear 5081
Remove 5081
Inspect 5082
Install 5082
Camshaft Gear 5082
Remove 5082
Install 5083
Timing Gear Case 5083
Remove 5083
Clean and Inspect 5083
Install 5083
Drive Train, Camshaft, and Cylinder Block Repair 5084
Remove 5084
Disassemble 5084
Pistons and Connecting Rods 5084
Crankshaft 5085
Camshaft 5087
Clean and Inspect 5088
Cylinder Block 5088
Honing and Boring 5091
Cylinder Correction (Oversize) 5092
Pistons 5092
Piston Pin 5093
Connecting Rod 5093
Tappets 5093
Crankshaft 5094
Camshaft 5096
Camshaft Bushing 5097
Assemble 5097
Camshaft 5097
Crankshaft 5097
Pistons and Connecting Rods 5097
Install 5099
Lubrication System Repair 5100
Engine Oil and Oil Filter Change 5100
Oil Pan 5100
Remove 5100
Install 5101
Oil Suction Tube 5101
Remove 5101
Clean 5101
Install 5102
Oil Pump 5102
Remove 5102
Clean and Inspect 5102
Outer Rotor Outside Clearance 5103
Outer Rotor to Inner Rotor Tip Clearance 5103
Outer Rotor Side Clearance 5103
Rotor Shaft Clearance 5104
Install 5104
Fuel System Repair 5105
Cooling System Repair 5105
Serpentine Belt 5105
Remove 5105
Inspect 5105
Install 5105
Serpentine Belt, Adjustment 5105
Water Pump 5107
Remove 5107
Install 5109
Thermostat 5110
Remove 5110
Inspect 5111
Install 5111
Flywheel and Flywheel Housing 5112
Flywheel 5112
Remove 5112
Install 5113
Flywheel Housing 5113
Remove 5113
Install 5113
Electrical Equipment Repair 5113
Alternator 5113
Remove 5113
Install 5114
Starter 5115
Remove 5115
Install 5115
Engine Specifications 5116
Engine Data 5116
Engine Tuning 5117
Cylinder Head 5117
Intake/Exhaust Valve and Guide 5118
Valve Spring 5118
Rocker Arm and Shaft 5118
Push Rod 5118
Gear Train and Camshaft 5119
Camshaft 5119
Idle Gear Shaft and Bushing 5119
Backlash of Each Gear 5119
Cylinder Block 5119
Crankshaft 5119
Piston 5120
Piston Ring 5120
Connecting Rod 5120
Rod Small End 5120
Tappet 5121
Oil Pump 5121
Engine Oil Pressure 5121
Outer Rotor Outside Clearance 5121
Outer Rotor Side Clearance 5121
Inner Rotor to Cover 5121
Standard Torque Specifications 5122
Standard Torque Chart 5122
Special Torque Specifications 5122
Special Tools 5123
550156617 0900YRM2012 (08 2016) US EN 5133
General 5137
Intake-Air System 5137
Intake-Air System Manifold Vacuum Check 5137
Throttle Body 5138
Remove 5139
Install 5139
Intake Manifold 5139
LPG Tank and Bracket Replacement 5140
Remove LPG Tank 5140
Install LPG Tank 5143
Remove LPG Bracket 5144
Install LPG Bracket 5146
Remove LPG Tank Bracket Alignment Pin 5146
Install LPG Tank Bracket Alignment Pin 5148
LPG Fuel Filter Unit Repair 5148
LPG Fuel Filter Element 5148
Remove/Disassemble 5148
Clean/Inspect 5149
Assemble/Install 5149
Fuel Filter Housing 5149
Remove 5149
Disassemble 5151
Clean and Inspect 5152
Assemble 5152
Install 5152
Electronic Throttle Body Repair 5153
Remove 5153
Install 5156
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 5156
Remove 5156
Install 5158
Gasoline Fuel System 5158
Before Repair Procedure 5160
Fuel Line Safety Procedure 5160
After Repair Procedure 5160
Fuel Hose, Install 5160
Fuel Leakage Check 5161
Fuel Line Pressure Check 5161
Fuel Injectors 5161
Remove 5161
Install 5162
Pressure Regulator 5162
Remove 5162
Install 5163
Control System 5163
Engine Control Module (ECM) 5163
Remove 5163
Install 5165
Fuel Level Sensor 5165
Remove 5165
Install 5166
LPG Low Level Sensor 5166
Remove 5166
Install 5167
LPG Converter 5168
5168
Remove 5168
Install 5170
LPG Lock-Off Valve 5172
Remove 5172
Install 5174
Exhaust System 5175
Counterweight Exhaust 5175
Remove and Disassemble 5175
Inspect 5176
Assemble and Install 5177
Exhaust Manifold 5177
Remove 5177
Install 5177
Oxygen (HEGO) Sensor 5178
Remove 5178
Install 5178
550156618 9000YRM2013 (08 2016) US EN 5181
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 5187
Group 05 – Operational Checkout 5189
Group 30 – Observed Symptoms 5195
SECTION 9020 ENGINE 5199
Group 10 – Principles of Operation 5201
SECTION 9030 ELECTRICAL SYSTEM 5219
Group 03 – General Maintenance and Diagnostic Data 5223
Group 10 – Principles of Operation 5235
Group 20 – Diagnostic Trouble Codes 5243
SECTION 9080 REFERENCE 5321
Group 50 – Abbreviations and Acronyms 5323
Group 60 – Special Tools List 5331
Group 70 – Fault Mode Indicator Reference 5335
550158688 2040YRM2075 (06 2017) US EN 5339
General 5343
Description 5343
Precautions 5343
Clamp Assembly Installation 5343
Hydraulic Hose Flush 5344
Clamp Installation (With Lifting Device) 5344
Clamp Installation (Without Lifting Device) 5346
Hose Connections 5346
Clamp Series 5346
Connecting The Hoses 5347
Operating Checks 5347
Clamping Force Test 5347
Troubleshooting 5349
General 5349
Hydraulic Schematics 5351
550166584 2040YRM2041 (06 2017) US EN 5355
General 5359
Description 5359
Precautions 5359
5360
Center of Gravity and Lift Truck Capacity 5365
Net Capacity Rating 5365
The Effects of Loading 5365
Choosing The Right Equipment 5366
Choosing the Right Clamp 5366
Choosing the Right Truck 5366
Choosing the Right Contact Pads 5367
Clamping Force 5367
Description 5368
CLAMPING FORCE 5368
Clamping Force Too High 5368
Clamping Force Too Low 5368
Clamping Operation 5369
Lever Functions 5369
Two-Motion Controls 5369
Bilge Position 5369
Damage Prevention 5370
Description 5370
ROLL DAMAGE 5370
Edge Damage 5370
End Damage 5371
Belly Damage 5371
Out-of-Roundness 5372
Inspection and Maintenance 5372
Daily Checks 5372
Pad Inspection 5372
Inspection and Service (6 Months / 300 hours) 5373
Rotation Bearing 5373
Rack and Pinion 5373
Arm Pivots (Pins/Bushings/Seats) 5373
Rotation Mechanism (Rack and Pinion) 5373
550166585 2040YRM2040 (12 2016) US EN 5377
General 5381
Description 5381
Precautions 5381
Clamp Assembly Installation 5383
Hydraulic Hose Flush 5383
Clamp Installation (With Lifting Device) 5384
Clamp Installation (Without Lifting Device) 5385
Hose Connections 5385
AR Series Clamp 5385
ARC Series Clamp 5386
Connecting The Hoses 5386
Two-Motion Controls 5387
Operating Checks 5387
Set Flow Rate 5388
Hydraulic Adjustments 5389
E-Hydraulics 5389
Clamping Pressure 5389
Clamping Force Test 5390
5390
Clamping Force 5390
Testing Clamping Force with the Test Pad 5391
Test Procedures 5392
Testing Clamping force with the Test Stand 5392
Test Procedures 5393
Testing Clamping Force with the Test Cylinder 5393
Test Procedures 5393
Hydraulic Adjustments 5394
E-Hydraulics 5394
Bolzoni Force-Matic 5395
General Description 5395
Installation 5395
Operation 5398
Troubleshooting 5398
General 5398
Hydraulic Schematics 5401