Yale Forklift K813 (GPGLPGDP80-120VX) Service Manual – PDF DOWNLOAD

Yale Forklift K813 (GPGLPGDP80-120VX) Service Manual – PDF DOWNLOAD

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Yale Forklift K813 (GPGLPGDP80-120VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 5162
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift K813 (GPGLPGDP80-120VX) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
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
550059479 0600YRM1590 (07 2019) US EN 3393
General 3399
Engine Identification 3399
Major Engine Component Identification 3399
Location of Labels 3400
Crankcase Description 3400
Precautions Before Beginning Repair 3401
Exhaust System and DPF 3402
Engine Removal and Installation 3402
Cylinder Head Assembly Repair 3403
Valve Covers and Fuel Injectors 3403
Remove 3403
Clean and Inspect 3406
Install 3406
Rocker Arm Assembly 3407
Remove 3407
Disassemble 3408
Clean and Inspect 3408
Push Rods 3408
Rocker Arm Assembly 3408
Assemble 3409
Install 3409
Valve Clearance Adjustments 3409
Cylinder Head Assembly 3410
Remove 3410
Disassemble 3419
Valves and Valve Springs, Remove 3419
Valve Guides, Remove 3420
Clean and Inspect 3420
Cylinder Head 3421
Valve Guides 3421
Valves 3421
Valve Sink 3422
Valve Seat 3422
Valve Springs 3423
Assemble 3423
Valve Guides, Install 3423
Valves and Valve Springs, Install 3424
Install 3425
Timing Gear Case and Timing Gears Repair 3427
Timing Gear Case Cover 3427
Remove 3427
Clean and Inspect 3428
Install 3428
Timing Gears 3429
Crankshaft Gear 3430
Remove 3430
Install 3430
Idler Gear 3430
Remove 3430
Inspect 3431
Install 3432
Camshaft Gear 3432
Remove 3432
Install 3432
Drive Train, Camshaft, and Cylinder Block Repair 3432
Remove 3432
Disassemble 3433
Pistons and Connecting Rods 3433
Crankshaft 3434
Camshaft 3436
Clean and Inspect 3438
Cylinder Block 3438
Honing and Boring 3440
Cylinder Correction (Oversize) 3441
Pistons 3441
Piston Pin 3442
Connecting Rod 3442
Tappets 3443
Crankshaft 3443
Camshaft 3445
Camshaft Bushing 3446
Assemble 3446
Camshaft 3446
Crankshaft 3446
Pistons and Connecting Rods 3447
Install 3449
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 3449
Lubrication System Repair 3452
Engine Oil and Oil Filter Change 3452
Oil Pan 3453
Remove 3453
Install 3454
Oil Suction Tube 3455
Remove 3455
Clean 3455
Install 3455
Oil Pump 3455
Remove 3455
Clean and Inspect 3456
Outer Rotor Outside Clearance 3457
Outer Rotor to Inner Rotor Tip Clearance 3457
Outer Rotor Side Clearance 3457
Rotor Shaft Clearance 3458
Install 3458
Fuel System Repair 3459
Fuel Injectors 3459
Remove 3459
Inspect 3459
Clean 3459
Replace 3459
Install 3459
Test 3459
Fuel Injection Pump 3460
Remove 3460
Clean and Inspect 3461
Install 3461
Cooling System Repair 3462
Serpentine Belt 3462
Remove 3462
Inspect 3463
Install 3463
Adjust 3463
Water Pump 3464
Remove 3464
Install 3465
Thermostat 3466
Remove 3466
Inspect 3467
Install 3467
Flywheel and Flywheel Housing 3468
Flywheel 3468
Remove 3468
Install 3469
Flywheel Housing 3469
Remove 3469
Install 3469
Electrical Equipment Repair 3470
Alternator 3470
Remove 3470
Install 3471
Starter 3472
Remove 3472
Install 3472
Engine Specifications 3474
Engine Data 3474
Engine Tuning 3478
Cylinder Head 3478
Intake/Exhaust Valve and Guide 3478
Valve Spring 3479
Rocker Arm and Shaft 3479
Push Rod 3479
Gear Train and Camshaft 3479
Camshaft 3479
Idle Gear Shaft and Bushing 3479
Backlash of Each Gear 3480
Cylinder Block 3480
Crankshaft 3480
Piston 3480
Piston Ring 3481
Connecting Rod 3481
Rod Small End 3481
Tappet 3481
Oil Pump 3482
Engine Oil Pressure 3482
Outer Rotor Outside Clearance 3482
Outer Rotor Side Clearance 3482
Inner Rotor to Cover 3482
Standard Torque Specifications 3483
Standard Torque Chart 3483
Special Torque Specifications 3483
Special Tools 3485
550064329 1800YRM1597 (03 2017) US EN 3499
Wet Brake System 3503
Service Brake Repair 3504
Parking Brake Repair 3504
Remove and Disassemble 3504
Assemble and Install 3505
Adjust 3506
Lift Trucks With a Foot Directional Control Pedal or Forward Reverse Lever 3506
Master Cylinder and Booster 3506
Remove 3506
Disassemble 3508
Clean and Inspect 3509
Assemble 3509
Install and Adjust 3509
Brake System Air Removal 3511
Using Pressure Bleed System 3511
Using Brake Pedal Pressure 3512
Lift Truck Models with Master Cylinder 3512
Brake Pedal Adjustment 3513
Free Pedal Adjustment 3514
Torque Specifications 3514
550073240 1900YRM1620 (01 2023) US EN 3517
Proper Flushing after Major Hydraulic Repairs 3523
Introduction 3523
The Phases of Wear 3523
Causes of Hydraulic System Failure 3523
Progression of Contaminant Caused Hydraulic System Failure 3524
Hydraulic System Flushing Techniques 3524
Double Oil and Filter Change 3524
Mechanical Cleaning 3525
Cleaning of Components 3525
How to Clean Tubes and Hoses 3525
Filter Caddy 3525
Start-Up Procedure for Cleaned System 3526
Contaminated Oil Coolers 3526
Additional Filter Caddy Functions 3527
How to Handle Different Fluids 3527
Water Removal Filters 3527
Fluid Conditioning and System Flushing Procedures 3528
Operation of the Filter Caddy 3528
Filter Caddy operation 3528
Fluid Conditioning Procedure 3528
Filter Caddy Start-Up 3529
System Flushing Procedure 3529
Component Cleaning Procedure 3530
Reservoir Cleaning Procedure 3530
Cylinder Cleaning Procedure 3530
Hose and Tube Cleaning Procedure 3530
Valve Cleaning Procedure 3531
Front-End Attachment Cleaning Procedure 3532
System Flushing Procedure 3532
Filter Caddy Start-Up 3533
System Start-Up and Flushing 3533
Reservoir Fluid Cleaning Times 3534
Dealing With Different Fluid Types 3535
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3535
Filter Caddy Maintenance 3535
Servicing the Strainer 3535
DC Motor 3535
Hydraulic Oil Sampling Method and Procedure 3536
Hydraulic Oil Sampling Method 3536
Objective 3536
General Guidelines 3536
Synopsis 3537
Hydraulic Oil Analysis Report Guidelines 3538
Sampling Conditions 3538
Equipment 3538
Sampling Procedure 3539
Hydraulic Oil Sampling 3539
Sample Labeling 3539
Results Documentation 3539
550118409 0100YRM1891 (05 2017) US EN 3541
General 3545
Description 3546
Hood, Seat, and Side Covers Replacement 3549
Remove 3549
Install 3556
Hood Latch and Striker Bolt Adjustment 3562
Steering Column 3562
Description 3562
Steering Column Repair 3563
Remove 3563
Disassemble 3564
Clean 3566
Inspect 3566
Assemble 3566
Install 3566
LPG Tank and Bracket Replacement 3567
Counterweight Replacement 3567
Remove 3567
Install 3570
Tow Pin 3574
Operator Restraint System Replacement 3575
Description 3575
Emergency Locking Retractor (ELR) 3576
Overhead Guard Replacement 3577
Remove 3578
Install 3579
LED Tail, Backup, and Brake Lights, Replace 3579
Engine Replacement 3580
Remove Engine Only 3580
Install Engine only 3605
Remove Engine and Transmission 3608
Install Engine and Transmission 3612
Throttle Pedal and Cable Adjustment 3615
Kubota 3 6L Diesel Engine 3615
Exhaust System Repair 3617
4 3L Engine for Lift Truck Models GP/GLP080, 090, 100, 110, 120VX (K813) 3617
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) 3617
Kubota 3 6L Diesel Engine for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3617
Remove 3617
Inspect 3619
Install 3619
Kubota 3 8L Diesel Engine W/DOC for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3619
Remove 3619
Inspect 3624
Install 3624
Kubota 3 8L Diesel Engine W/DPF for Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (K813) 3625
Remove 3625
Inspect 3630
Diesel Particulate Filter (DPF) 3630
Disassemble 3630
Clean and Inspect 3631
Differential Pressure Pipes and Hoses 3632
Assembly 3632
Install 3632
Heavy Duty Pre-Cleaner, Kubota 3 6L and 3 8L Diesel Engines 3634
Remove 3634
Clean 3634
Inspect 3634
Install 3634
Cooling System 3634
Description 3634
Hydraulic Fan Drive 3635
Description 3635
Hydraulic Filter Assembly Repair 3635
Remove 3636
Disassemble 3636
Clean 3637
Inspect 3637
Assemble 3637
Install 3637
Fuel and Hydraulic Tanks Repair 3637
Inspect 3637
Clean 3638
Steam Method of Cleaning 3638
Chemical Solution Method of Cleaning 3639
Additional Preparations for Repair 3639
Small Leaks, Repair 3639
Large Leaks, Repair 3639
Preparations for Use After Repair 3639
Safety Labels 3639
550118411 1900YRM1894 (06 2016) US EN 3647
General 3651
Description 3653
Hydraulic Fan Drive Replacement 3660
Lift Truck Models GC/GLC60VX, GC/GLC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 3661
Remove 3661
Disassemble 3663
Clean and Inspect 3664
Assemble 3664
Install 3664
Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) 3665
Remove 3665
Disassemble 3666
Clean and Inspect 3668
Assemble 3668
Install 3668
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) 3669
Remove 3669
Disassemble 3670
Clean and Inspect 3672
Assemble 3672
Install 3672
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 3672
Remove 3672
Disassemble 3674
Clean and Inspect 3675
Assemble 3675
Install 3675
Hydraulic Fan Drive Manifold 3675
Remove 3675
Install 3677
550118412 0700YRM1895 (08 2016) US EN 3681
General 3685
Cooling System Checks 3686
Exhaust Leaks Into Cooling System 3686
Water Flow Restrictions in Radiator 3686
Radiator Hoses 3686
Water Pump 3686
Flushing the Cooling System 3686
Cooling System, Clean 3687
Radiator Replacement 3688
Lift Truck Models GLC40, 45, 55VX; GLC55SVX (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (G818) 3688
Remove 3688
Install 3694
Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (K813) 3695
Remove 3695
Install 3702
Fan Assembly Replacement 3703
Fan Removal 3703
Inspect 3708
Fan Installation 3708
550118413 1600YRM1896 (03 2015) US EN 3711
550118414 1900YRM1897 (06 2021) US EN 3733
Series Code / Model Designation Reference Table 3739
General 3740
Hydraulic Gear Pump Assembly Repair 3742
Remove 3742
Disassemble 3745
Clean 3747
Inspect 3747
Assemble 3747
Install 3747
Hydraulic Gear Pump Specifications 3749
Variable Displacement Pump Repair 3751
Remove 3751
Disassemble 3754
Clean 3756
Inspect 3756
Assemble 3756
Install 3756
Variable Displacement Pump Checks and Adjustments 3759
Margin Pressure Check 3759
Flow Compensator Adjustment 3759
Pressure Compensator Adjustment 3760
Variable Displacement Pump Specifications 3762
Torque Specifications 3763
Hydraulic Gear Pump 3763
Variable Displacement Pump 3763
550118415 2000YRM1898 (06 2021) US EN 3765
Series Code / Model Designation Reference Table 3771
General 3772
Electro-Hydraulic Main Control Valve 3773
Description 3773
Remove 3779
Electro-Hydraulic Control Valve Sections 3783
General 3783
Outlet Control Valve Section 3783
Remove 3783
Disassemble 3783
Clean 3785
Inspect 3785
Assemble 3785
Install 3786
Auxiliary Control Valve Sections 3786
Remove 3786
Disassemble 3788
Clean 3788
Inspect 3789
Assemble 3789
Install 3790
Tilt Control Valve Section 3790
Remove 3790
Disassemble 3790
Clean 3792
Inspect 3792
Assemble 3792
Install 3792
Lift/Lower Control Valve Section 3792
Remove 3792
Disassemble 3792
Clean 3794
Inspect 3794
Assemble 3794
Install 3794
Transition Section 3794
Remove 3794
Disassemble 3795
Clean 3795
Inspect 3795
Assemble 3796
Install 3796
Install 3796
Manual Main Control Valve 3799
Description 3799
Remove 3801
OPS Solenoid Assembly 3805
General 3805
Remove 3806
Clean and Inspect 3808
Install 3808
Manual Control Valve Sections 3809
General 3809
Outlet Control Valve Section 3809
Remove 3809
Disassemble 3809
Clean 3811
Inspect 3811
Assemble 3811
Install 3811
Auxiliary Control Valve Sections 3812
Remove 3812
Disassemble 3812
Clean 3814
Inspect 3814
Assemble 3814
Install 3814
Lift/Tilt Control Valve Section 3815
Remove 3815
Disassemble 3815
Clean 3817
Inspect 3818
Assemble 3818
Install 3819
Install 3819
Pressure Relief Valve Check and Adjustment 3822
Primary Relief Valve 3822
Secondary Relief Valve 3823
Steering Control Unit Repair 3827
Steering Control Unit, Remove 3827
Steering Control Unit, Disassemble 3828
Steering Control Unit, Clean 3830
Steering Control Unit, Inspect 3830
Steering Control Unit, Assemble 3830
Relief Valve, Disassemble 3831
Relief Valve, Clean 3831
Relief Valve, Inspect 3832
Relief Valve, Assemble 3832
Steering Control Unit, Install 3832
550118417 2200YRM1901 (01 2020) US EN 3835
General 3843
Display Switch Cluster 3845
Remove 3845
Install 3847
Direction Control and Turn Signal Levers 3847
Remove 3847
Install 3848
Key Switch 3849
Remove 3849
Install 3850
Display Switch Cluster Panel Bezel and Overlay 3850
Remove 3850
Install 3850
Steering Column Repair 3850
Remove 3850
Disassemble 3852
Assemble 3852
Install 3853
Sensors and Switches 3853
General 3853
Dash Panel, Kick Panel, and Seal Plate, Remove and Install 3853
Remove 3853
Install 3854
Accelerator (Throttle) Pedal Position Sensor 3854
Remove 3854
Install 3855
Brake Fluid Level Switch 3856
Remove 3856
Install 3857
Service Brake Pedal Position Sensor 3858
Remove 3858
Install 3859
Service Brake Pressure Sensor 3860
Remove 3860
Install 3860
Parking Brake Position Sensor 3860
Remove 3860
Install 3860
Sensor MicroswitchFoot Directional Control 3861
Remove 3861
Install 3863
Low Coolant Level Sensor 3863
Remove 3863
Install 3864
Fuel Level Sensor, Gas and Diesel Engines Only 3865
Remove 3865
Install 3865
Seat Sensor (Operator Presence System) 3866
Non-Suspension and Semi-Suspension Seats 3866
Remove 3866
Install 3867
Full Suspension Seats 3868
Remove 3868
Install 3869
Hood Shut Off Switch 3869
Remove 3869
Install 3869
Remote Key Switch 3869
Remove 3869
Install 3870
Hydraulic Filter Pressure Switch 3870
Remove 3870
Install 3870
Transmission Speed Sensors 3871
Remove 3871
Install 3871
Transmission Pressure Sensors 3871
Remove 3871
Install 3872
Transmission Temperature Sensor 3872
Remove 3872
Install 3872
Return To Set Tilt (Tilt Angle) Sensor 3872
Remove 3872
Install 3873
Rear Horn Button Switch 3873
Remove 3873
Install 3874
Impact Sensor 3874
Remove 3874
Install 3875
Load Weight Sensor 3876
Remove 3876
Install 3876
Hydraulic Fan Drive Push Button Switch 3877
Remove 3877
Install 3877
Engine and Fuel Sensors and Switches – GM 4 3L Gas and LPG Engines 3878
Engine and Fuel Sensors and Switches – PSI 4 3L LPG Engine 3878
Engine and Fuel Sensors and Switches – Kubota 3 8L LPG and Bi-Fuel Engine 3878
Crankshaft Position Sensor 3879
Remove 3879
Install 3879
Camshaft Position Sensor 3879
Remove 3879
Install 3879
Oil Pressure Sensor 3880
Remove 3880
Install 3880
Engine Coolant Temperature (ECT) Sensor 3880
Remove 3880
Install 3880
Temperature And Manifold Absolute Pressure (TMAP) Sensor 3880
Remove 3880
Install 3881
Knock Sensor 3881
Remove 3881
Install 3881
Oxygen Sensors 3882
Air Flow Restriction Switch 3882
Remove 3882
Install 3882
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without Diesel Particulate Filter (DPF) 3883
Intake Air Temperature Sensor 3883
Remove 3883
Install 3884
Intake Air Pressure Sensor 3884
Remove 3884
Install 3884
Air Inlet Heater 3884
Remove 3884
Install 3884
Engine Oil Pressure Sensor 3884
Remove 3884
Install 3885
Engine Coolant Temperature (ECT) Sensor 3885
Remove 3885
Install 3885
Crankshaft Position Sensor 3885
Remove 3885
Install 3885
Adjust Shim Procedure 3886
Camshaft Position Sensor 3887
Remove 3887
Install 3887
Air Flow Restriction Sensor 3888
Remove 3888
Install 3888
Fuel/Water Separator 3888
Remove 3888
Install 3889
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) 3889
Intake Air Temperature Sensor 3891
Remove 3891
Install 3891
Boost Sensor 3892
Remove 3892
Install 3892
Throttle Valve Assembly, Air Intake Adapter and Air Intake Heater 3894
Remove 3894
Install 3895
Engine Coolant Temperature (ECT) Sensor 3895
Remove 3895
Install 3895
Engine Oil Pressure Sensor 3896
Remove 3896
Install 3896
Crankshaft Position Sensor 3896
Remove 3896
Install 3896
Adjust Shim Procedure 3897
Camshaft Position Sensor 3898
Remove 3898
Install 3898
Differential Pressure Sensor 3898
Remove 3898
Install 3899
Mass Air flow Sensor 3899
Remove 3899
Install 3899
Fuel/Water Separator 3899
Remove 3899
Install 3900
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3901
Engine Coolant Temperature (ECT) Sensor 3901
Remove 3901
Install 3901
Engine Oil Pressure Sensor 3902
Remove 3902
Install 3902
Throttle Position Sensor 3902
Engine Speed Sensor 3902
Remove 3902
Install 3902
Fuel Shut Off Solenoid 3902
Remove 3902
Install 3902
Vehicle System Manager (VSM) 3903
General 3903
VSM Replacement 3903
Remove 3903
Install 3903
Programming a New VSM and/or Display Switch Cluster (DSC) 3904
Data Transferring 3905
New VSM 3905
New (Blank) Display Switch Cluster 3905
Used (Non-Blank) Display Switch Cluster 3905
PC Service Tool Software 3906
Power Distribution Module (PDM) and Component Parts 3907
Remove 3907
PDM as a Unit 3907
Install 3909
PDM as a Unit 3909
Remove and Install 3909
PDM Component Parts 3909
Battery 3909
Remove 3909
Install 3909
Lights 3910
Work Lights (Front and Rear) 3910
Halogen Bulb Lights 3910
Remove 3910
Install 3910
LED Lights 3910
Remove 3910
Install 3911
Strobe Light 3911
Remove 3911
Install 3911
LED Tail, Backup, and Brake Lights 3912
Remove 3912
Install 3912
Front Marker/Turn Signal Lights 3913
Replacing Whole Front Marker/Turn Signal Light Assembly 3913
Remove 3913
Install 3913
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3914
Remove 3914
Install 3914
Diesel Particulate Filter (DPF) Display 3915
Remove 3915
Clean and Inspect 3915
Install 3915
Electronic-Hydraulic Controls, Before January, 2020 3916
E-Hydraulic Controls – Test 3916
Mini-Levers 3916
Full Stroke Test 3916
Function Returns to Neutral Test 3916
Push (Override) Button 3917
General 3917
Mini-levers, Remove and Install 3917
Armrest Assembly 3918
Remove 3918
Install 3921
Horn Button 3921
Remove 3921
Install 3921
Direction Control Switch 3921
Remove 3921
Install 3922
Push (Override) Buttons 3922
Remove 3923
Install 3923
Electronic-Hydraulic Controls, After January, 2020 3924
E-Hydraulic Controls – TEST 3924
Mini-Levers 3924
Full Stroke Test 3924
Function Returns to Neutral Test 3924
Push (Override) Button 3924
General 3925
Mini-levers, Remove and Install 3925
Armrest Assembly 3926
Remove 3926
Install 3929
Horn Button 3929
Remove 3929
Install 3929
Direction Control Switch 3929
Remove 3929
Install 3930
Push (Override) Buttons 3930
Remove 3931
Install 3931
Push (Override) Buttons and Toggle Switch 3932
Remove 3932
Install 3934
Special Tools 3935
550118418 8000YRM1902 (12 2020) US EN 3939
General 3947
Serial Number Data 3947
How to Move Disabled Lift Truck 3948
How to Tow Lift Truck 3948
How to Put Lift Truck on Blocks 3949
How to Raise Drive Tires 3949
How to Raise Steering Tires 3950
How to Clean a Lift Truck 3951
Maintenance Schedule 3951
Maintenance Procedures Every 8 Hours or Daily 3984
How to Make Checks With Engine Stopped 3984
Tires and Wheels 3984
Safety Labels 3985
Mast, Carriage, Lift Chains, Header Hoses, Attachment 3985
Operator Restraint System 3986
Emergency Locking Retractor (ELR) 3986
Hood and Seat Latches 3987
Engine Compartment 3987
Paper Application 3987
Fuel, Oil, and Coolant Leaks, Check 3988
Hydraulic Hoses 3988
Coolant Hoses 3988
Steering Column Gas Cylinder 3988
Transmission 3989
Hydraulic System Oil 3989
Engine Oil 3989
Air Filter 3997
Forks 3997
Forks, Inspect 3998
Forks, Remove 3999
Forks, Install 3999
Forks, Adjust 3999
Integral Sideshift Carriage 4000
Fork Positioner 4000
Forks, Inspect 4000
Forks, Remove 4001
Forks, Install 4002
Forks, Adjustments 4003
How to Make Checks With Engine Running 4003
Indicator Lights, Horn, Fuses, and Relays 4003
Service Brakes 4005
Brake Oil Level 4005
Operation, Check 4006
Parking Brake 4006
Engine Oil Pressure 4006
Cooling System 4006
Steering System 4007
Control Levers and Pedals 4007
Fuel/Water Separator Filter, Kubota Diesel Engine 4007
Lift System, Operate 4008
Air Filter 4008
First Service After First 100 Hours of Operation 4009
4 3L Engine Oil and Oil Filter 4009
Kubota Diesel Engine Oil and Oil Filter 4009
Kubota 3 8L LPG or Bi-Fuel Engine Oil and Oil Filter 4010
Maintenance Procedures Every 250 Hours or 6 Months 4010
4 3L Engine Oil and Oil Filter 4010
Kubota 3 6L Diesel Engine Oil and Oil Filter 4011
Drive Belt 4012
4 3L Engine 4012
Fan and Alternator Drive Belt 4012
Drain Tar From LPG Converter 4013
Cleaning Carbon Buildup From Intake Valves – GM 4 3L and Kubota 3 8L LPG Engines 4014
Maintenance Procedures Every 500 Hours or 6 Months 4016
Hydraulic System Oil 4016
Hydraulic Tank Breather 4017
Inspect 4017
Battery 4018
Kubota 3 8L Diesel Engine Oil and Oil Filter 4018
Kubota 3 8L LPG and Bi-Fuel Engine Oil and Oil Filter 4019
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4019
Remove 4019
Install 4019
Priming the Fuel System (Kubota 3 8L Engine) 4020
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 4021
Remove 4021
Install 4021
Priming the Fuel System (Kubota 3 6L Engine) 4022
Drive Belt 4022
Kubota Diesel Engine 4022
Fan and Alternator Drive Belt 4022
Kubota LPG and Bi-Fuel Engine 4023
Fan and Alternator Drive Belt 4023
Clean Debris From Radiator Core 4024
Transmission Oil Level 4024
Wet Brake Center Body Oil Level Check (Dana Drive Axle) 4026
Wet Brake Oil Level Check (NMHG/HYG Drive Axle) 4027
Forks, Inspect 4028
Mast Lubrication 4030
Fork Positioner Lubrication 4032
Header Hose Checks 4033
Lift Chain Lubrication 4033
Tilt Cylinder Lubrication 4033
Master Brake Cylinder Rod End Pin Lubrication 4034
Manual Hydraulic Levers Lubrication 4035
Brake Oil 4035
Tie Rod Lubrication 4036
Parking Brake Adjustment 4036
Maintenance Procedures Every 1000 Hours or 6 Months 4037
Valve Clearance, Check and Adjust, 4 3L Engine 4037
Valve Clearance, Check and Adjust, Kubota 3 6L Diesel Engine 4037
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4037
Valve Clearance, Check and Adjust for Kubota 3 8L LPG and Bi-Fuel Engine 4038
Ignition System 4038
4 3L Engine 4038
Kubota 3 8L LPG and Bi-Fuel Engine, Standard Spark Plugs 4038
Gasoline Fuel Filter, GM 4 3L Engine 4038
Remove and Replace 4038
LPG Fuel Filter Element Replace, 4 3L Engine 4038
Remove 4038
Install 4039
LPG Fuel Filter Element Replace, Kubota 3 8L LPG and Bi-Fuel Engine 4039
Remove 4039
Install 4040
In-Line Strainer Replacement, Kubota Diesel Engine 4042
Remove 4042
Install 4042
Lift Chains Wear Check 4044
Lift Chain Lubrication 4044
Integral Sideshift Carriage, Check Sliding Surfaces 4044
Steering Axle (Spindle Bearings) 4045
Control Levers and Pedals 4046
Parking Brake Lever Lubrication, Dana Wet Brake Axle 4046
Normal Operating Environment 4046
Heavy Duty or Contaminated Environment – Parking Brake Lever on Top of Drive Axle 4049
Remove 4049
Clean and Inspect 4050
Install 4051
Heavy Duty or Contaminated Environment – Parking Brake Lever on Right Side of Drive Axle 4051
Remove 4051
Clean and Inspect 4053
Install 4053
Inspect Engine Electrical System, Connectors 4055
Crankcase Breather Element, Kubota 3 8L Diesel 4056
Remove 4056
Clean and Inspect 4056
Install 4056
Maintenance Procedures Every 2000 Hours or Annually 4057
Hydraulic System 4057
Hydraulic Filter, Replace 4057
Hydraulic Tank Breather, Replace 4058
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires 4059
Spark Plugs, 4 3L Engine 4059
Remove 4059
Install 4059
Long-Life Spark Plugs, Kubota 3 8L LPG and Bi-Fuel Engine 4060
Cooling System 4060
Air Filter 4060
4 3L Gasoline Fuel Filter 4062
Remove and Replace 4062
Kubota 3 8L Bi-Fuel Gasoline Fuel Filter 4063
Remove and Replace 4063
Fuel Injector, Kubota 3 8L Engine 4064
Fuel Injector, Kubota 3 6L Engine 4064
Forks, Inspect 4064
Transmission Oil and Filter, Replace 4065
Transmission and Wet Brake Planetary Carrier Housing Oil Change (Dana Drive Axle) 4066
Wet Brake Center Section Oil Change (Dana Drive Axle) 4069
Remove 4069
Install 4069
Wet Brake Oil Change (NMHG/HYG Drive Axle) 4070
Brake Oil (Master Cylinder), Change 4071
Check Throttle Shaft for Sticking 4072
Inspect Exhaust Manifold and Piping for Leaks 4072
Wheel Bearings 4072
Steer Wheels, Lubrication 4072
Maintenance Procedures Every 3000 Hours 4073
Diesel Particulate Filter 4073
Remove 4073
Inspect 4077
Disassemble 4077
Servicing the Diesel Particulate Filter,Pressure Tubes and Pressure Hoses 4078
Assemble 4078
Install 4079
Maintenance Procedures Every 4000 Hours or 2 Years 4080
Hydraulic Oil, Replace 4080
Weld Inspection 4082
Safety Procedures When Working Near Mast 4085
Fuel Filter Water Removal 4086
Kubota Diesel Engine 4086
3 8L Diesel Engine 4086
3 6L Diesel Engine 4087
Hood Latch Check 4088
Lift Chain Adjustments 4089
Jump-Starting the Lift Truck 4091
Jump-Starting Using a Battery Charger 4091
Jump-Starting a Lift Truck Using Another Lift Truck 4091
Welding Repairs 4091
Overhead Guard Changes 4092
Wheel and Tire Replacement 4092
General 4092
Pneumatic Tire With Tube, Repair ( Series)GP/GLP/GDP 4092
Remove Wheels From Lift Truck 4092
Remove Tire From Wheel 4093
Install Wheel in Tire 4095
Install Tire on Two-Piece Wheel 4097
Add Air to Pneumatic Tires With Tube 4098
Install the Wheels 4099
Dual Drive Wheels, Install 4099
Pneumatic Tubeless Tire, Repair ( Series)GP/GLP/GDP 4100
Remove Wheels From Lift Truck 4100
Add Air to Pneumatic Tubeless Tire 4105
Install the Wheels 4105
Dual Drive Wheels, Install 4106
Solid Rubber Tire , Change ( Series)GLC 4106
Remove and Install Tire on Wheel 4107
Dual Drive Wheels, Install 4107
Adhesives and Sealants 4108
550118419 8000YRM1903 (08 2019) US EN 4111
Lift Truck Lifting Capacity 4115
Counterweight Weights 4115
Tire Sizes 4116
Capacities 4116
Electrical System 4122
Transmission Oil Pressures 4124
Hydraulic System Relief Pressures 4126
Steering System 4127
Stall Speeds (in RPM ±100 rpm) 4128
GM/PSI 4 3L 4128
Kubota 3 6L Diesel 4128
Kubota 3 8L Diesel 4128
Kubota 3 8L LPG/Bi-Fuel 4129
Mast Speeds 4129
Tilt Angles 4133
Front End Equipment – Mast Creep 4133
Mast Creep 4133
Engine Specifications 4134
Diesel Fuel Cleanliness Levels 4136
Torque Specifications 4137
Frame 4137
Mast 4137
Steering System 4137
Steer Axle 4137
Drive Axle, Wet Brake
(Dana Spicer Axle) 4137
Drive Axle, Wet Brake
(NMHG/HYG Axle) 4137
Transmission 4138
Engine – GM/PSI 4 3L 4138
Engine – Kubota 3 6L Diesel 4139
Engine – Kubota 3 8L 4140
550118420 8000YRM1904 (05 2022) US EN 4143
General Information About Diagrams and Schematics 4149
Symbol Definitions 4149
Diagrams Manual Applications 4150
Diagrams and Schematics 4152
550118555 0100YRM1892 (06 2021) US EN 4261
General 4269
Cab Replacement for 4-5 5 Ton Lift Trucks 4270
Remove 4270
Install 4280
Cab Replacement for 6-9 Ton Lift Trucks 4282
Remove 4282
Door Assemblies for 4-5 5 Ton Lift Trucks 4288
Right Side Door Assembly 4288
Remove 4288
Disassemble 4292
Door Cover With Heater Unit 4292
Door Cover With Air Conditioner/Heater Unit 4294
Heater Assembly 4296
Air Conditioner and Heater Unit Assembly 4296
Door Lock Assembly 4298
Windows 4299
Clean 4299
Inspect 4299
Assemble 4299
Windows 4299
Door Lock Assembly 4299
Heater Assembly 4299
Air Conditioner and Heater Unit Assembly 4300
Door Cover With Heater Unit 4300
Door Cover With Air Conditioner and Heater Unit 4300
Install 4300
Left Side Door Assembly 4301
Remove 4301
Disassemble 4301
Door Cover 4301
Door Lock Assembly 4301
Windows 4302
Clean 4302
Inspect 4302
Assemble 4302
Windows 4302
Door Lock Assembly 4302
Door Cover 4302
Install 4302
Door Assemblies for 6-9 Ton Lift Trucks 4303
Right and Left Side Door Assemblies 4303
Remove 4303
Disassemble 4304
Door Cover 4304
Door Lock Assembly 4305
Windows 4306
Clean 4306
Inspect 4306
Assemble 4306
Windows 4306
Door Lock Assembly 4307
Door Cover 4307
Install 4307
Window Replacement 4308
General 4308
Remove Door Windows for 4-5 5 Ton Lift Trucks 4308
Install Door Windows for 4-5 5 Ton Lift Trucks 4309
Remove Door Windows for 6-9 Ton Lift Trucks 4309
Install Door Windows for 6-9 Ton Lift Trucks 4311
Window Wipers Replacement 4312
General 4312
Front Wiper Assembly and Motor 4312
Remove 4312
Install 4314
Rear Wiper Assembly and Motor 4314
Remove, for 4-5 5 Ton Lift Trucks 4314
Install for 4-5 5 Ton Lift Trucks 4317
Remove for 6-9 Ton Lift Trucks 4317
Install for 6-9 Ton Lift Truck 4319
Heater Replacement 4320
Remove for 6-9 Ton Lift Trucks 4320
Install for 6-9 Ton Lift Trucks 4326
Heater and Air Conditioner Assembly 4327
Air Conditioner Condenser Unit 4327
Remove 4327
Install 4328
Air Conditioner Receiver/Drier Unit 4328
Remove 4328
Install 4330
Air Conditioner Compressor 4330
Light Replacement 4331
Work Lights (Front and Rear) 4331
Remove 4331
Install 4333
Strobe Light 4333
Remove 4333
Install 4334
Turn, Stop, Tail, and Backup Light 4334
Remove 4334
Install 4335
Front Marker/Turn Signal Lights 4335
Remove 4335
Install 4335
Display Switches 4336
Electrical Schematics 4339
Optional Equipment 4339
Heavy Duty Pre-Cleaner 4339
Fan 4339
Remove 4339
Install 4341
Mirror 4341
Remove 4341
Install 4341
Rear View Camera 4341
Monitor Removal 4341
Monitor Install 4343
Camera removal 4343
Camera install 4343
Label Replacement 4344
550118556 2000YRM1899 (03 2015) US EN 4347
550119576 0900YRM1905 (01 2022) US EN 4383
General 4389
LPG Tank and Bracket Replacement 4390
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) 4390
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) 4393
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) 4394
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) 4394
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) 4395
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) 4397
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) 4398
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) 4398
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) 4399
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) 4401
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) 4401
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) 4402
LPG Fuel Filter Unit Repair 4404
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) 4404
Remove/Disassemble 4404
Clean/Inspect 4406
Assemble/Install 4406
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) 4406
Remove/Disassemble 4406
Clean/Inspect 4407
Assemble/Install 4407
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) 4407
Remove 4407
Disassemble 4413
Clean and Inspect 4414
Assemble 4414
Install 4414
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) 4415
Remove 4415
Disassemble 4416
Clean and Inspect 4417
Assemble 4417
Install 4418
Electronic Throttle Body Repair 4419
Remove 4419
Install 4421
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4422
Remove 4422
Install 4425
Control System 4426
Engine Control Unit (ECU) 4426
Remove 4426
Install 4426
LPG Low Level Sensor 4427
Remove 4427
Remove 4429
Install 4430
Exhaust System 4431
Counterweight Exhaust 4431
Remove and Disassemble 4431
Remove and Disassemble 4433
Inspect 4435
Assemble and Install 4435
Assemble and Install 4435
Exhaust Manifold 4435
Remove 4435
Install 4436
Oxygen (HEGO) Sensor 4436
Remove 4436
Install 4436
LPG Fuel Testing 4437
General 4437
Available Fuel Tests 4437
Composition Test (ASTM D-2163) 4437
Ammonia Test (ASTM D-4490) 4437
Basic Nitrogen Test (ASTM UOP269-90) 4437
Residues Test (ASTM D-2158) 4437
Vapor Pressure Test (ASTM D-2598) 4437
Sulfur Compounds Test (ASTM D-5623) 4437
Methanol Test (ASTM D-4864) 4438
Copper Corrosion (ASTM D-1838) 4438
Where To Send LPG Fuel Samples For Testing 4438
550125043 2100YRM1947 (03 2015) US EN 4441
550131848 0600YRM1961 (03 2020) US EN 4483
General 4489
Engine Identification 4490
Major Engine Component Identification 4490
Location of Labels 4492
Cylinder Block Description 4493
Precautions Before Beginning Repair 4494
Exhaust System and DPF 4495
Engine Removal and Installation 4495
Cylinder Head Assembly Repair 4495
Valve Covers and Fuel Injectors 4495
Remove 4495
Clean and Inspect 4498
Install 4498
Rocker Arm Assembly 4499
Remove 4499
Disassemble 4499
Clean and Inspect 4500
Push Rods 4500
Rocker Arm Assembly 4500
Assemble 4501
Install 4501
Valve Clearance Adjustments 4501
Cylinder Head Assembly 4502
Remove 4502
Disassemble 4510
Valves and Valve Springs, Remove 4510
Valve Guides, Remove 4511
Clean and Inspect 4511
Cylinder Head 4512
Valve Guides 4512
Valves 4513
Valve Sink 4513
Valve Seat 4513
Valve Springs 4514
Assemble 4514
Valve Guides, Install 4514
Valves and Valve Springs, Install 4515
Install 4516
Timing Gear Case and Timing Gears Repair 4518
Timing Gear Case Cover 4518
Remove 4518
Clean and Inspect 4519
Install 4519
Timing Gears 4520
Crankshaft Gear 4520
Remove 4520
Install 4521
Idler Gear 1 and Idler Gear 2 4521
Remove 4521
Inspect 4522
Install 4523
Idler Gear 3 4523
Remove 4523
Inspect 4523
Install 4523
Camshaft Gear 4523
Remove 4523
Install 4523
Drive Train, Camshaft, and Cylinder Block Repair 4524
Remove 4524
Disassemble 4524
Pistons and Connecting Rods 4524
Crankshaft 4525
Camshaft 4527
Clean and Inspect 4529
Cylinder Block 4529
Honing and Boring 4531
Cylinder Correction (Oversize) 4532
Pistons 4532
Piston Pin 4533
Connecting Rod 4533
Tappets 4534
Crankshaft 4534
Camshaft 4536
Camshaft Bushing 4537
Assemble 4537
Camshaft 4537
Crankshaft 4537
Pistons and Connecting Rods 4538
Install 4540
Angular Deviation Procedure 4540
Lubrication System Repair 4543
Engine Oil and Oil Filter Change 4543
Oil Pan 4544
Remove 4544
Install 4544
Oil Suction Tube 4544
Remove 4544
Clean 4545
Install 4545
Oil Pump 4545
Remove 4545
Clean and Inspect 4546
Inner Rotor and Outer Rotor Clearance 4546
Outer Rotor and Pump Body Clearance 4547
Rotor and Cover Clearance 4547
Rotor Shaft Clearance 4547
Install 4548
Fuel System Repair 4548
Fuel Injectors 4548
Remove 4548
Inspect 4548
Clean 4549
Replace 4549
Install 4549
Test 4549
Fuel Injection Pump 4549
Remove 4549
Clean and Inspect 4552
Install 4552
Cooling System Repair 4553
Serpentine Belt 4553
Remove 4553
Inspect 4553
Install 4553
Adjust 4553
Water Pump 4554
Remove 4554
Install 4556
Thermostat 4556
Remove 4556
Inspect 4557
Install 4557
Flywheel and Flywheel Housing 4558
Flywheel 4558
Remove 4558
Install 4559
Flywheel Housing 4559
Remove 4559
Install 4559
Electrical Equipment Repair 4560
Alternator 4560
Remove 4560
Install 4561
Starter 4562
Remove 4562
Install 4562
Engine Specifications 4564
Engine Data 4564
Engine Tuning 4566
Cylinder Head 4566
Intake/Exhaust Valve and Guide 4567
Valve Spring 4567
Rocker Arm and Shaft 4567
Push Rod 4567
Gear Train and Camshaft 4568
Camshaft 4568
Idle Gear Shaft and Bushing 4568
Backlash of Each Gear 4568
Cylinder Block 4568
Crankshaft 4569
Piston 4569
Piston Ring 4569
Connecting Rod 4570
Rod Small End 4570
Tappet 4570
Oil Pump 4570
Engine Oil Pressure 4570
Inner and Outer Rotor Clearance 4570
Outer Rotor and Pump Body 4570
Rotor and Cover 4571
Standard Torque Specifications 4571
Standard Torque Chart 4571
Special Torque Specifications 4571
Special Tools 4573
550148125 9000YRM2010 (05 2016) US EN 4587
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 4593
Group 05 – Operational Checkout 4595
SECTION 9020 ENGINE 4601
Group 10 – Principles of Operation 4603
Group 03 – General Maintenance and Diagnostic Data 4613
Group 30 – Observed Symptoms 4617
SECTION 9030 ELECTRICAL SYSTEM 4623
Group 03 – General Maintenance and Diagnostic Data 4627
Group 10 – Principles of Operation 4633
Group 20 – Diagnostic Trouble Codes 4641
SECTION 9080 SUPPLEMENTARY DATA 4703
Group 50 – Abbreviations and Acronyms 4705
Group 60 – Special Tools List 4713
Group 70 – Fault Mode Indicator Reference 4715
550152439 0900YRM1951 (11 2019) US EN 4719
General 4725
LPG Tank and Bracket 4725
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 4725
Remove 4725
Install 4730
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 4731
Remove 4731
Install 4732
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 4733
Remove 4733
Install 4735
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 4735
Remove 4735
Install 4735
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 4736
Remove 4736
Install 4737
Fuel Filter Unit 4738
Fuel Filter Element 4738
Remove 4738
Clean and Inspect 4739
Install 4739
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) 4740
Remove 4740
Disassemble 4741
Clean and Inspect 4741
Assemble 4742
Install 4742
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 4742
Remove 4742
Disassemble 4744
Clean and Inspect 4745
Assemble 4745
Install 4746
Throttle Body 4746
Remove 4746
Clean 4748
Install 4748
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 4749
Remove 4749
Install 4750
Control System 4751
Engine Control Unit (ECU) 4751
Remove 4751
Install 4752
Low Pressure Switch 4752
Remove 4752
Install 4753
Low Fuel Sensor 4753
Remove 4753
Install 4754
LP Converter 4754
Remove and Disassemble 4754
Assemble and Install 4756
LPG Lock-Off 4757
Remove 4757
Install 4758
Exhaust System 4758
Counterweight Exhaust 4758
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) 4758
Inspect 4760
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) 4761
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4761
Inspect 4762
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4762
Overhead Exhaust 4763
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) 4763
Inspect 4764
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) 4765
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4765
Inspect 4767
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 4767
Exhaust Manifold 4767
Remove 4767
Install 4768
Oxygen (HEGO) Sensor 4769
Remove 4769
Install 4769
LPG Fuel Testing 4769
General 4769
Available Fuel Tests 4770
Composition Test (ASTM D-2163) 4770
Ammonia Test (ASTM D-4490) 4770
Basic Nitrogen Test (ASTM UOP269-90) 4770
Residues Test (ASTM D-2158) 4770
Vapor Pressure Test (ASTM D-2598) 4770
Sulfur Compounds Test (ASTM D-5623) 4770
Methanol Test (ASTM D-4864) 4770
Copper Corrosion (ASTM D-1838) 4770
Where To Send LPG Fuel Samples For Testing 4770
550152440 2200YRM1955 (11 2019) US EN 4773
Description 4777
Distributor Ignition (DI) System 4777
Crankshaft Position (CKP) Sensor 4777
Camshaft Position (CMP) Sensor 4777
Ignition Coil and Ignition Control Module (ICM) 4777
Secondary Ignition Components 4777
Spark Plugs and Wires 4777
Spark Plug Wire Inspection 4777
Spark Plug Wire Replacement 4777
Remove 4777
Install 4778
Spark Plug Inspection 4778
Usage 4778
Inspection 4778
Visual Inspection 4780
Spark Plug Replacement 4781
Remove 4781
Install 4781
Distributor Repair 4781
Inspect 4781
Overhaul 4782
Disassemble 4782
Assemble 4784
Replace 4785
Remove 4785
Install Procedure 1 4787
Install Procedure 2 4788
Ignition Coil Replacement 4790
Remove 4790
Install 4790
Ignition Control Module Replacement 4791
Remove 4791
Install 4791
Starter Replacement 4792
Remove 4792
Install 4795
Sensors and Switches 4796
LPG Trucks 4796
Crankshaft Position (CKP) Sensor 4796
Remove 4796
Install 4796
Camshaft Position (CMP) Sensor 4797
Remove 4797
Install 4798
Oil Pressure Sensor 4799
Remove 4799
Install 4799
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 4800
Remove 4800
Install 4800
Engine Coolant Temperature (ECT) Sensor 4800
Remove 4800
Install 4801
Air Flow Restriction Switch 4801
Remove 4801
Install 4802
Specifications and Special Tools 4802
550156616 0600YRM2011 (07 2019) US EN 4805
General 4811
Engine Identification 4811
Major Engine Component Identification 4811
Location of Labels 4812
Crankcase Description 4812
Engine Removal and Installation 4813
Cylinder Head Assembly Repair 4814
Valve Covers and Ignition Coils 4814
Remove 4814
Clean and Inspect 4818
Install 4819
Rocker Arm Assembly 4819
Remove 4819
Disassemble 4820
Clean and Inspect 4821
Push Rods 4821
Rocker Arm Assembly 4821
Assemble 4822
Install 4822
Valve Clearance Adjustments 4822
Cylinder Head Assembly 4823
Remove 4823
Disassemble 4829
Valves and Valve Springs, Remove 4829
Valve Guides, Remove 4829
Clean and Inspect 4830
Cylinder Head 4830
Valve Guides 4831
Valves 4831
Valve Sink 4831
Valve Seat 4831
Valve Springs 4832
Assemble 4832
Valve Guides, Install 4832
Valves and Valve Springs, Install 4833
Install 4834
Timing Gear Case and Timing Gears Repair 4836
Timing Gear Case Cover 4836
Remove 4836
Clean and Inspect 4836
Install 4836
Timing Gears 4837
Crankshaft Gear 4837
Remove 4837
Install 4837
Idler Gear 4837
Remove 4837
Inspect 4838
Install 4838
Camshaft Gear 4838
Remove 4838
Install 4839
Timing Gear Case 4839
Remove 4839
Clean and Inspect 4839
Install 4839
Drive Train, Camshaft, and Cylinder Block Repair 4840
Remove 4840
Disassemble 4840
Pistons and Connecting Rods 4840
Crankshaft 4841
Camshaft 4843
Clean and Inspect 4844
Cylinder Block 4844
Honing and Boring 4847
Cylinder Correction (Oversize) 4848
Pistons 4848
Piston Pin 4849
Connecting Rod 4849
Tappets 4849
Crankshaft 4850
Camshaft 4852
Camshaft Bushing 4853
Assemble 4853
Camshaft 4853
Crankshaft 4853
Pistons and Connecting Rods 4853
Install 4855
Lubrication System Repair 4856
Engine Oil and Oil Filter Change 4856
Oil Pan 4856
Remove 4856
Install 4857
Oil Suction Tube 4857
Remove 4857
Clean 4857
Install 4858
Oil Pump 4858
Remove 4858
Clean and Inspect 4858
Outer Rotor Outside Clearance 4859
Outer Rotor to Inner Rotor Tip Clearance 4859
Outer Rotor Side Clearance 4859
Rotor Shaft Clearance 4860
Install 4860
Fuel System Repair 4861
Cooling System Repair 4861
Serpentine Belt 4861
Remove 4861
Inspect 4861
Install 4861
Serpentine Belt, Adjustment 4861
Water Pump 4863
Remove 4863
Install 4865
Thermostat 4866
Remove 4866
Inspect 4867
Install 4867
Flywheel and Flywheel Housing 4868
Flywheel 4868
Remove 4868
Install 4869
Flywheel Housing 4869
Remove 4869
Install 4869
Electrical Equipment Repair 4869
Alternator 4869
Remove 4869
Install 4870
Starter 4871
Remove 4871
Install 4871
Engine Specifications 4872
Engine Data 4872
Engine Tuning 4873
Cylinder Head 4873
Intake/Exhaust Valve and Guide 4874
Valve Spring 4874
Rocker Arm and Shaft 4874
Push Rod 4874
Gear Train and Camshaft 4875
Camshaft 4875
Idle Gear Shaft and Bushing 4875
Backlash of Each Gear 4875
Cylinder Block 4875
Crankshaft 4875
Piston 4876
Piston Ring 4876
Connecting Rod 4876
Rod Small End 4876
Tappet 4877
Oil Pump 4877
Engine Oil Pressure 4877
Outer Rotor Outside Clearance 4877
Outer Rotor Side Clearance 4877
Inner Rotor to Cover 4877
Standard Torque Specifications 4878
Standard Torque Chart 4878
Special Torque Specifications 4878
Special Tools 4879
550156617 0900YRM2012 (08 2016) US EN 4889
General 4893
Intake-Air System 4893
Intake-Air System Manifold Vacuum Check 4893
Throttle Body 4894
Remove 4895
Install 4895
Intake Manifold 4895
LPG Tank and Bracket Replacement 4896
Remove LPG Tank 4896
Install LPG Tank 4899
Remove LPG Bracket 4900
Install LPG Bracket 4902
Remove LPG Tank Bracket Alignment Pin 4902
Install LPG Tank Bracket Alignment Pin 4904
LPG Fuel Filter Unit Repair 4904
LPG Fuel Filter Element 4904
Remove/Disassemble 4904
Clean/Inspect 4905
Assemble/Install 4905
Fuel Filter Housing 4905
Remove 4905
Disassemble 4907
Clean and Inspect 4908
Assemble 4908
Install 4908
Electronic Throttle Body Repair 4909
Remove 4909
Install 4912
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 4912
Remove 4912
Install 4914
Gasoline Fuel System 4914
Before Repair Procedure 4916
Fuel Line Safety Procedure 4916
After Repair Procedure 4916
Fuel Hose, Install 4916
Fuel Leakage Check 4917
Fuel Line Pressure Check 4917
Fuel Injectors 4917
Remove 4917
Install 4918
Pressure Regulator 4918
Remove 4918
Install 4919
Control System 4919
Engine Control Module (ECM) 4919
Remove 4919
Install 4921
Fuel Level Sensor 4921
Remove 4921
Install 4922
LPG Low Level Sensor 4922
Remove 4922
Install 4923
LPG Converter 4924
4924
Remove 4924
Install 4926
LPG Lock-Off Valve 4928
Remove 4928
Install 4930
Exhaust System 4931
Counterweight Exhaust 4931
Remove and Disassemble 4931
Inspect 4932
Assemble and Install 4933
Exhaust Manifold 4933
Remove 4933
Install 4933
Oxygen (HEGO) Sensor 4934
Remove 4934
Install 4934
550156618 9000YRM2013 (08 2016) US EN 4937
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 4943
Group 05 – Operational Checkout 4945
Group 30 – Observed Symptoms 4951
SECTION 9020 ENGINE 4955
Group 10 – Principles of Operation 4957
SECTION 9030 ELECTRICAL SYSTEM 4975
Group 03 – General Maintenance and Diagnostic Data 4979
Group 10 – Principles of Operation 4991
Group 20 – Diagnostic Trouble Codes 4999
SECTION 9080 REFERENCE 5077
Group 50 – Abbreviations and Acronyms 5079
Group 60 – Special Tools List 5087
Group 70 – Fault Mode Indicator Reference 5091
550158688 2040YRM2075 (06 2017) US EN 5095
General 5099
Description 5099
Precautions 5099
Clamp Assembly Installation 5099
Hydraulic Hose Flush 5100
Clamp Installation (With Lifting Device) 5100
Clamp Installation (Without Lifting Device) 5102
Hose Connections 5102
Clamp Series 5102
Connecting The Hoses 5103
Operating Checks 5103
Clamping Force Test 5103
Troubleshooting 5105
General 5105
Hydraulic Schematics 5107
550166584 2040YRM2041 (06 2017) US EN 5111
General 5115
Description 5115
Precautions 5115
5116
Center of Gravity and Lift Truck Capacity 5121
Net Capacity Rating 5121
The Effects of Loading 5121
Choosing The Right Equipment 5122
Choosing the Right Clamp 5122
Choosing the Right Truck 5122
Choosing the Right Contact Pads 5123
Clamping Force 5123
Description 5124
CLAMPING FORCE 5124
Clamping Force Too High 5124
Clamping Force Too Low 5124
Clamping Operation 5125
Lever Functions 5125
Two-Motion Controls 5125
Bilge Position 5125
Damage Prevention 5126
Description 5126
ROLL DAMAGE 5126
Edge Damage 5126
End Damage 5127
Belly Damage 5127
Out-of-Roundness 5128
Inspection and Maintenance 5128
Daily Checks 5128
Pad Inspection 5128
Inspection and Service (6 Months / 300 hours) 5129
Rotation Bearing 5129
Rack and Pinion 5129
Arm Pivots (Pins/Bushings/Seats) 5129
Rotation Mechanism (Rack and Pinion) 5129
550166585 2040YRM2040 (12 2016) US EN 5133
General 5137
Description 5137
Precautions 5137
Clamp Assembly Installation 5139
Hydraulic Hose Flush 5139
Clamp Installation (With Lifting Device) 5140
Clamp Installation (Without Lifting Device) 5141
Hose Connections 5141
AR Series Clamp 5141
ARC Series Clamp 5142
Connecting The Hoses 5142
Two-Motion Controls 5143
Operating Checks 5143
Set Flow Rate 5144
Hydraulic Adjustments 5145
E-Hydraulics 5145
Clamping Pressure 5145
Clamping Force Test 5146
5146
Clamping Force 5146
Testing Clamping Force with the Test Pad 5147
Test Procedures 5148
Testing Clamping force with the Test Stand 5148
Test Procedures 5149
Testing Clamping Force with the Test Cylinder 5149
Test Procedures 5149
Hydraulic Adjustments 5150
E-Hydraulics 5150
Bolzoni Force-Matic 5151
General Description 5151
Installation 5151
Operation 5154
Troubleshooting 5154
General 5154
Hydraulic Schematics 5157