Yale G878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GLP155VX, GDP155VX, GP155VXS) Service Manual PDF

Yale Forklift G878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GLP155VX, GDP155VX, GP155VXS) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift G878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GLP155VX, GDP155VX, GP155VXS) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2546
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift G878 (GP135VX, GLP135VX, GDP135VX, GP155VX, GLP155VX, GDP155VX, GP155VXS) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) US EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524223769 2200YRM1128 (01 2023) US EN 43
Series Code / Model Designation Reference Table 51
General 53
Deutsch Crimping Tool 54
How to Strip a Wire for Use With Deutsch Crimping Tool 54
How to Crimp With the Deutsch Crimping Tool 55
Calibration Test for the Deutsch Crimping Tool 57
Deutsch Connectors 59
DT, DTM, and DTP Series Connectors 59
HD Series Connectors 102
Metri-Pack Connectors 124
Remove and Install 124
Micro-Pack Connectors 127
Weather-Pack Connectors 128
AMPSEAL Crimping Tools 130
AMP Hand Crimping Tool With Certi-Crimp 130
Description 130
Stripping Wire for Use with AMP Hand Crimping Tool 131
Insulation Crimp Adjustment 132
Maintenance and Inspection for AMP Hand Crimping Tool 132
AMP Hand Crimping Tool 132
Crimp Height Inspection 132
How to use AMP Hand Crimping Tool 133
AMP Pro-Crimper II Tool 133
Description 133
Remove and Install Die Set and Locator Assembly 134
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 134
Contact Support Adjustment 135
Crimp Height Adjustment 136
Maintenance and Inspection Procedures 136
PRO-CRIMPER II Tool 136
Crimp Height Inspection 136
How to Use AMP PRO-CRIMPER II Tool 137
AMPSEAL Connector Assemblies 138
Description for Plug Connector Assembly 138
Seal Plug 139
Contact Crimping 139
Description for Plug Connector and Header Assembly 144
Voltage Reading 147
Seal Plug 147
Contact Crimping 147
AMP Superseal 1 5 Crimping Tools 154
Mini Mic Receptacle and Tab Contacts 154
Description 154
Crimping Conditions and Measurements 154
Insertion of Rubber Seal on Cable 156
AMP Hand Application Tool 161
Description 161
Maintenance and Inspection 161
Crimp Height Inspection 161
Crimp Height Adjustment 162
How to Use AMP Hand Application Tool 162
AMP Pro-Crimper II Tool 163
Description 163
Remove and Install Die Set and Locator Assembly 163
Adjustments 164
Contact Support 164
Crimp Height 165
Inspections and Maintenance 166
Crimp Height Inspection 166
Visual Inspection 166
Maintenance 167
How to Use Pro-Crimper II Tool 167
AMP Superseal 1 5 Connector Assemblies 168
Description 168
Repair and Maintenance 175
Panel Mount Option 175
AMP Fastin-Faston Hand Tools 176
Description – AMP Double Action Hand Tool 176
Maintenance and Inspection Procedures 176
Daily Maintenance 176
Periodic Tool Inspection 177
Lubrication 177
Visual Inspection 177
Crimp Height Inspection 177
Certi-Crimp Ratchet Inspection 178
How to Use AMP Double Action Hand Tool 179
Description – AMP Extraction Tool 180
Maintenance and Inspection 181
How to Use AMP Extraction Tool 181
AMP Fastin-Faston Receptacles and Housings 183
Description 183
Wire Repair 191
Wire Splicing Requirements 191
Deutsch Jiffy Splice 192
Twisted/Shielded Cable and Leads Repair 198
Special Tools 200
524223769 2200YRM1128 (07 2020) US EN 209
Series Code / Model Designation Reference Table 215
General 218
Deutsch Crimping Tool 218
How to Strip a Wire for Use With Deutsch Crimping Tool 218
How to Crimp With the Deutsch Crimping Tool 219
Calibration Test for the Deutsch Crimping Tool 221
Deutsch Connectors 223
DT, DTM, and DTP Series Connectors 223
HD Series Connectors 265
Metri-Pack Connectors 288
Remove and Install 288
Micro-Pack Connectors 290
Weather-Pack Connectors 291
AMPSEAL Crimping Tools 293
AMP Hand Crimping Tool With Certi-Crimp 293
Description 293
Stripping Wire for Use with AMP Hand Crimping Tool 293
Insulation Crimp Adjustment 294
Maintenance and Inspection for AMP Hand Crimping Tool 294
AMP Hand Crimping Tool 294
Crimp Height Inspection 294
How to use AMP Hand Crimping Tool 295
AMP Pro-Crimper II Tool 295
Description 295
Remove and Install Die Set and Locator Assembly 296
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 297
Contact Support Adjustment 297
Crimp Height Adjustment 298
Maintenance and Inspection Procedures 298
PRO-CRIMPER II Tool 298
Crimp Height Inspection 298
How to Use AMP PRO-CRIMPER II Tool 299
AMPSEAL Connector Assemblies 300
Description for Plug Connector Assembly 300
Seal Plug 301
Contact Crimping 301
Description for Plug Connector and Header Assembly 306
Voltage Reading 308
Seal Plug 308
Contact Crimping 308
AMP Superseal 1 5 Crimping Tools 315
Mini Mic Receptacle and Tab Contacts 315
Description 315
Crimping Conditions and Measurements 315
Insertion of Rubber Seal on Cable 317
AMP Hand Application Tool 322
Description 322
Maintenance and Inspection 322
Crimp Height Inspection 322
Crimp Height Adjustment 323
How to Use AMP Hand Application Tool 323
AMP Pro-Crimper II Tool 324
Description 324
Remove and Install Die Set and Locator Assembly 325
Adjustments 325
Contact Support 325
Crimp Height 326
Inspections and Maintenance 327
Crimp Height Inspection 327
Visual Inspection 327
Maintenance 328
How to Use Pro-Crimper II Tool 328
AMP Superseal 1 5 Connector Assemblies 329
Description 329
Repair and Maintenance 336
Panel Mount Option 336
AMP Fastin-Faston Hand Tools 337
Description – AMP Double Action Hand Tool 337
Maintenance and Inspection Procedures 337
Daily Maintenance 337
Periodic Tool Inspection 338
Lubrication 338
Visual Inspection 338
Crimp Height Inspection 338
Certi-Crimp Ratchet Inspection 339
How to Use AMP Double Action Hand Tool 340
Description – AMP Extraction Tool 341
Maintenance and Inspection 341
How to Use AMP Extraction Tool 342
AMP Fastin-Faston Receptacles and Housings 343
Description 343
Wire Repair 350
Wire Splicing Requirements 350
Deutsch Jiffy Splice 351
Twisted/Shielded Cable and Leads Repair 356
Special Tools 359
524223770 2200YRM1130 (03 2020) US EN 367
General 371
Description 371
Dash Display Menu Access 371
Menu Navigation 372
Standard Display 372
Main Menu 372
Passwords Menu 373
Password Administration 373
Add Password 373
Delete Password 374
Edit Password 374
Other Password Functions 375
Operator Passwords – Enable/Disable 375
Password Time-Out Delay 375
Passwords – Number Wrong to Disable 376
Lockout Reset Password 376
View Password Log 377
View Versions 378
VSM Versions 378
Dash Display Versions 379
Engine Controller Version 380
Transmission (Xmsn) Controller Version 381
Truck Serial Number 382
Diagnostics 383
View Fault Log 383
Set Travel and Braking 384
Speed Limit 384
Acceleration Rate 385
Auto-Deceleration Rate 385
Set Power Reversal Rate 386
Set Inching/Brake Overlap 387
Setup Display Menu 388
Set Operator Language 388
Set Units 389
Set Time Format (12/24 Hour) 389
Set Daylight Saving Time 389
Set Time 392
Set Date Format 393
Set Date 393
Setup Hydraulics 394
Return to Set Tilt Delay/On/Off 394
Setup General Items 395
Light Shutdown Time-Out 395
Impact Sensor – Enable/Disable 396
Impact Sensor – Soft Impact Settings 397
Impact Sensor – Hard Impact Settings 398
Adjust Impact Sensor Settings 398
Initial Adjustment of Soft and Hard Impact Settings 400
Readjustment of Soft and Hard Impact Settings 400
Impact Sensor – Impact Alarm/Shutdown Reset 401
Impact Sensor – Alarm Time Duration and Deactivation 402
Impact Sensor – View Impact Event Log 403
Engine Mode Indicator 404
Generation 1 (ECO-eLo ONLY) 404
Generation 2 405
Operator Checklist 406
Operator Checklist Off-On Mode 406
Edit Operator Checklist 406
Set Operator Checklist Expiration 407
View Checklist Log 407
Clear Operator Checklist Log 408
Clear Operator Checklist Fault 408
Calibrations 409
Set Tilt Stop Point 409
Calibrate Loaded Weight 409
524223771 2200YRM1131 (03 2020) US EN 411
Series Code / Model Designation Reference Table 417
General 419
Description 419
Dash Display Menu Access 419
Menu Navigation 420
Main Menu 420
Passwords 421
Adding Passwords 421
Hourmeters 423
View Versions 424
VSM Versions 424
Dash Display Versions 425
Engine Controller Version 426
Transmission (Xmsn) Controller Version 427
Truck Serial Number 428
Truck Configuration 429
Diagnostics 430
Clear Fault Log 430
View Fault Log 431
No-Run Data Display 432
Engine Accelerator and Throttle Data Display 432
Engine Speeds and Governor Data Display 433
Engine Fuel and Emissions Data Display 434
Engine General Data Display 436
XMSN/Brake Data Display 437
Hydraulic Data Display 440
General Truck Data Display 442
Set Travel and Braking 443
Speed Limit 443
Acceleration Rate 444
Auto-Deceleration Rate 445
Set Power Reversal Rate 445
Set Inching/Brake Overlap 446
Setup Hydraulics 446
Lift Maximum Speed 447
Lower Maximum Speed 447
Tilt Maximum Speed 448
Auxiliary Function One, Direction A, Maximum Speed 450
Auxiliary Function One, Direction B, Maximum Speed 452
Auxiliary Function Two, Direction A, Maximum Speed 452
Auxiliary Function Two, Direction B, Maximum Speed 453
Auxiliary Function Three, Direction A, Maximum Speed 454
Auxiliary Function Three, Direction B, Maximum Speed 454
Lift/Lower Ramp Rate 455
Hydraulic Auxiliary Ramp Rate 455
Return to Set Tilt Delay/On/Off 456
Hydraulic Input Device 457
Auxiliary Solenoid 457
Dual Function 458
Setup Display 459
Set Service Language 459
Setup General Items 459
Motion Alarm Activation Type 460
Light Shutdown Time-Out 461
Restore Default Settings 461
Restore Engine Controller Default Calibration 462
Impact Sensor – Enable/Disable 462
Impact Sensor – Soft Impact Settings 463
Impact Sensor – Hard Impact Settings 464
Adjust Impact Sensor Settings 465
Initial Adjustment of Soft and Hard Impact Settings 467
Readjustment of Soft and Hard Impact Settings 467
Impact Sensor – Impact Alarm/Shutdown Reset 468
Impact Sensor – Alarm Time Duration and Deactivation 469
Impact Sensor – View Impact Event Log 470
Engine Mode Indicator 470
Generation 1 (ECO-eLo ONLY) 470
Generation 2 471
Diesel Particulate Filter (DPF) Display 472
General Description 472
Passive Regeneration Only 472
Regeneration Level 0 472
Auto/Active Regeneration Inhibited 473
Auto/Active Regeneration 473
Regeneration Level 1 473
Parked Regeneration Request 474
Regeneration Level 2 474
Warning Level 474
Regeneration Level 3 474
Service Level 475
Regeneration Level 4 475
Display, Diesel Particulate Filter (DPF), Revised 475
Operator Interface 475
Refer to Operator Manual 475
CAN Communication Lost 476
Passive Regeneration Only 476
Regeneration Level 0 476
Auto/Active Regeneration Inhibited 476
Auto/Active Regeneration 477
Regeneration Level 1 477
Idle-up Auto/Active Regeneration 477
Parked Regeneration Request 477
Regeneration Level 2 477
Warning Level 479
Regeneration Level 3 479
Service Level 479
Regeneration Level 4 479
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 479
Display, Diesel Particulate Filter (DPF), Stage V Engine 479
Operator Interface 480
Refer to Operator Manual 480
CAN Communication Lost 480
Passive Regeneration Only 480
Regeneration Level 0 480
Auto/Active Regeneration Inhibited 481
Auto/Active Regeneration 481
Regeneration Level 1 481
Idle-up Auto/Active Regeneration 482
Parked Regeneration Request 482
Regeneration Level 2 482
Warning Level 483
Regeneration Level 3 483
Service Level 484
Regeneration Level 4 484
Stage V Content 484
Emissions System Malfunction 484
Ash Load 484
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 485
Operator Interface 485
Refer to Operator Manual 485
CAN Communication Lost 486
Passive Regeneration Only 486
Regeneration Level 0 486
Auto/Active Regeneration Inhibited 486
Auto/Active Regeneration 487
Regeneration Level 1 487
Idle-up Auto/Active Regeneration 487
Parked Regeneration Request 487
Regeneration Level 2 487
Warning Level 489
Regeneration Level 3 489
Service Level 489
Regeneration Level 4 489
Calibrations 490
Calibrate Transmission Valve 492
Set Tilt Stop Point 492
Calibrate Loaded Weight 492
Calibrate Travel Speed Sensor 493
Calibrate Mazda LP and Gas Accelerator Pedal 493
524223780 8000YRM1134 (03 2020) US EN 495
Series Code / Model Designation Reference Table 501
Description 503
Proc_Cal_001: Service Password Entry 505
When to Perform 505
Why Perform 505
How to Perform 505
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 506
When to Perform 506
Calibration Order 506
Why Perform 506
How to Perform 507
Proc_Cal_003: Save and Exit 508
When to Perform 508
Why Perform 508
How to Perform 508
Proc_Cal_004: Lift Valve Output Threshold 509
When to Perform 509
Calibration Order 509
Why Perform 509
How to Perform 510
Proc_Cal_005: Lower Valve Output Threshold 512
When to Perform 512
Calibration Order 512
Why Perform 512
How to Perform 512
Proc_Cal_006: Tilt Back Valve Output Threshold 515
When to Perform 515
Calibration Order 515
Why Perform 515
How to Perform 515
Proc_Cal_007: Tilt Forward Valve Output Threshold 518
When to Perform 518
Calibration Order 518
Why Perform 518
How to Perform 518
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 521
When to Perform 521
Calibration Order 521
Why Perform 521
How to Perform 521
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 524
When to Perform 524
Calibration Order 524
Why Perform 524
How to Perform 524
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 527
When to Perform 527
Calibration Order 527
Why Perform 527
How to Perform 527
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 530
When to Perform 530
Calibration Order 530
Why Perform 530
How to Perform 530
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 533
When to Perform 533
Calibration Order 533
Why Perform 533
How to Perform 533
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 536
When to Perform 536
Calibration Order 536
Why Perform 536
How to Perform 536
Proc_Cal_014: Load Weight Zero Point 540
When to Perform 540
Calibration Order 540
Why Perform 540
How to Perform 540
Proc_Cal_015: Loaded Weight Calibration 542
When to Perform 542
Calibration Order 542
Why Perform 542
How to Perform 542
Proc_Cal_016: Transmission Valve Calibration 545
Applicable System/Option 545
When to Perform 545
Calibration Order 545
Why Perform 545
How to Perform 545
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 547
Applicable System/Option 547
When to Perform 547
Calibration Order 547
Why Perform 547
How to Perform 547
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 549
Applicable System/Option 549
When to Perform 549
Calibration Order 549
Why Perform 549
How to Perform 550
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 551
Required Tools 551
When to Perform 551
Calibration Order 551
Why Perform 552
How to Perform 552
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 553
When to Perform 553
Why Perform 553
How to Perform 553
Proc_Cal_026: Travel Speed Calibration 555
When to Perform 555
Calibration Order 555
Why Perform 555
How to Perform 555
524288194 1300YRM1317 (03 2020) US EN 559
Transmission Repair 563
Remove 563
Torque Converter, Remove 563
Disassemble 564
Clean and Inspect 613
Housings 613
Oil Seals and Gaskets 613
Bearings 613
Gears and Shafts 614
Assemble 614
Torque Converter, Install 655
Install 656
Control Valve Repair 657
Remove 657
Disassemble 657
Clean 659
Inspect 659
Assemble 659
Install 660
Torque Specification 661
524294873 1300YRM1343 (11 2019) US EN 663
Transmission Repair 667
Remove 667
Torque Converter, Remove 667
Disassemble 668
Clean and Inspect 708
Housings 708
Oil Seals and Gaskets 708
Bearings 709
Gears and Shafts 709
Assemble 709
Torque Converter, Install 747
Install 748
Control Valve Repair 749
Remove 749
Disassemble 749
Control Valve Assembly 749
Control Valve Body 749
Clean 752
Inspect 752
Assemble 752
Control Valve Body 752
Control Valve Assembly 752
Install 753
Torque Specification 755
524296605 1400YRM1344 (03 2020) US EN 757
General 761
Identification Plate 761
Drive Axle Removal 761
Planetary Reduction Gear Repair 773
Clean and Inspect 783
Brake Repair 792
Clean and Inspect 805
Wet Brake Noise Reduction 815
General 815
Adding Additive To Transmission 816
Differential Repair 817
Clean and Inspect 828
Bevel Pinion 840
Clean and Inspect 844
Drive Axle Installation 854
Special Tools 865
Torque Specifications 866
550055279 0600YRM1579 (11 2019) US EN 869
General 875
Engine Identification 875
Major Engine Component Identification 875
Location of Labels 875
Crankcase Description 876
Engine Removal and Installation 877
Cylinder Head Assembly Repair 877
Valve Covers and Fuel Injectors 877
Remove 877
Clean and Inspect 881
Install 882
Rocker Arm Assembly 883
Remove 883
Disassemble 885
Clean and Inspect 885
Push Rods 885
Rocker Arm Assembly 885
Assemble 886
Install 886
Valve Clearance Adjustments 886
Cylinder Head Assembly 887
Remove 887
Disassemble 895
Valves and Valve Springs, Remove 895
Valve Guides, Remove 897
Clean and Inspect 897
Cylinder Head 898
Valve Guides 898
Valves 898
Valve Sink 899
Valve Seat 899
Valve Springs 899
Assemble 900
Valve Guides, Install 900
Valves and Valve Springs, Install 900
Install 901
Timing Gear Case and Timing Gears Repair 906
Timing Gear Case Cover 906
Remove 906
Clean and Inspect 906
Install 907
Timing Gears 908
Crankshaft Gear 908
Remove 908
Install 908
Idler Gear 908
Remove 908
Inspect 909
Install 909
Camshaft Gear 909
Remove 909
Install 910
Timing Gear Case 910
Remove 910
Clean and Inspect 911
Install 911
Drive Train, Camshaft, and Cylinder Block Repair 911
Remove 911
Disassemble 912
Pistons and Connecting Rods 912
Crankshaft 913
Camshaft 915
Clean and Inspect 916
Cylinder Block 917
Honing and Boring 919
Cylinder Correction (Oversize) 920
Pistons 920
Piston Pin 921
Connecting Rod 921
Tappets 921
Crankshaft 922
Camshaft 924
Camshaft Bushing 925
Assemble 925
Camshaft 925
Crankshaft 925
Pistons and Connecting Rods 925
Install 927
Lubrication System Repair 928
Engine Oil and Oil Filter Change 928
Oil Pan 929
Remove 929
Install 930
Oil Suction Tube 930
Remove 930
Clean 931
Install 931
Oil Pump 931
Remove 931
Clean and Inspect 931
Outer Rotor Outside Clearance 932
Outer Rotor to Inner Rotor Tip Clearance 932
Outer Rotor Side Clearance 932
Rotor Shaft Clearance 933
Install 933
Fuel System Repair 934
Fuel Injectors 934
Remove 934
Inspect 934
Clean 934
Replace 934
Install 934
Electronic Throttle System 934
Remove 934
Throttle Position Sensor Proceedures After September 2018 GDP60-70VX (GDP135-155VX) (F878), GDP60VX, GDP70VX, GP70VXS6 (GDP135VX GDP155VX, GP155VXS) (G878), and GP080VX, GP090VX, GP100VX, GP100VX, GP120VX, (GDP40VX5, GDP40VX6, GDP45VX6, GDP45SVX5, GDP50VX, GDP55VX) (K813) 938
Bearing Replacement 938
Install 939
Adjustment 940
Fuel Injection Pump 940
Remove 940
Disassemble 944
Clean and Inspect 946
Assemble 946
Install 947
Cooling System Repair 948
Serpentine Belt 948
Remove 948
Inspect 948
Install 948
Serpentine Belt, Adjustment 948
Water Pump 949
Remove 949
Install 951
Thermostat 952
Remove 952
Inspect 953
Install 953
Flywheel and Flywheel Housing 954
Flywheel 954
Remove 954
Install 955
Flywheel Housing 955
Remove 955
Install 955
Electrical Equipment Repair 955
Alternator 955
Remove 955
Install 956
Starter 957
Remove 957
Install 957
Engine Specifications 959
Engine Data 959
Engine Tuning 960
Cylinder Head 960
Intake/Exhaust Valve and Guide 961
Valve Spring 961
Rocker Arm and Shaft 961
Push Rod 961
Gear Train and Camshaft 962
Camshaft 962
Idle Gear Shaft and Bushing 962
Backlash of Each Gear 962
Cylinder Block 962
Crankshaft 962
Piston 963
Piston Ring 963
Connecting Rod 963
Rod Small End 963
Tappet 964
Oil Pump 964
Engine Oil Pressure 964
Outer Rotor Outside Clearance 964
Outer Rotor Side Clearance 964
Inner Rotor to Cover 964
Standard Torque Specifications 965
Standard Torque Chart 965
Special Torque Specifications 965
Special Tools 967
550073240 1900YRM1620 (01 2023) US EN 977
Proper Flushing after Major Hydraulic Repairs 983
Introduction 983
The Phases of Wear 983
Causes of Hydraulic System Failure 983
Progression of Contaminant Caused Hydraulic System Failure 984
Hydraulic System Flushing Techniques 984
Double Oil and Filter Change 984
Mechanical Cleaning 985
Cleaning of Components 985
How to Clean Tubes and Hoses 985
Filter Caddy 985
Start-Up Procedure for Cleaned System 986
Contaminated Oil Coolers 986
Additional Filter Caddy Functions 987
How to Handle Different Fluids 987
Water Removal Filters 987
Fluid Conditioning and System Flushing Procedures 988
Operation of the Filter Caddy 988
Filter Caddy operation 988
Fluid Conditioning Procedure 988
Filter Caddy Start-Up 989
System Flushing Procedure 989
Component Cleaning Procedure 990
Reservoir Cleaning Procedure 990
Cylinder Cleaning Procedure 990
Hose and Tube Cleaning Procedure 990
Valve Cleaning Procedure 991
Front-End Attachment Cleaning Procedure 992
System Flushing Procedure 992
Filter Caddy Start-Up 993
System Start-Up and Flushing 993
Reservoir Fluid Cleaning Times 994
Dealing With Different Fluid Types 995
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 995
Filter Caddy Maintenance 995
Servicing the Strainer 995
DC Motor 995
Hydraulic Oil Sampling Method and Procedure 996
Hydraulic Oil Sampling Method 996
Objective 996
General Guidelines 996
Synopsis 997
Hydraulic Oil Analysis Report Guidelines 998
Sampling Conditions 998
Equipment 998
Sampling Procedure 999
Hydraulic Oil Sampling 999
Sample Labeling 999
Results Documentation 999
550073240 1900YRM1620 (03 2020) US EN 1001
Proper Flushing after Major Hydraulic Repairs 1005
Introduction 1005
The Phases of Wear 1005
Causes of Hydraulic System Failure 1005
Progression of Contaminant Caused Hydraulic System Failure 1006
Hydraulic System Flushing Techniques 1006
Double Oil and Filter Change 1006
Mechanical Cleaning 1007
Cleaning of Components 1007
How to Clean Tubes and Hoses 1007
Filter Caddy 1007
Start-Up Procedure for Cleaned System 1008
Contaminated Oil Coolers 1008
Additional Filter Caddy Functions 1008
How to Handle Different Fluids 1008
Water Removal Filters 1009
Fluid Conditioning and System Flushing Procedures 1009
Operation of the Filter Caddy 1009
Filter Caddy operation 1009
Fluid Conditioning Procedure 1010
Filter Caddy Start-Up 1010
System Flushing Procedure 1011
Component Cleaning Procedure 1011
Reservoir Cleaning Procedure 1011
Cylinder Cleaning Procedure 1011
Hose and Tube Cleaning Procedure 1012
Valve Cleaning Procedure 1012
Front-End Attachment Cleaning Procedure 1013
System Flushing Procedure 1013
Filter Caddy Start-Up 1014
System Start-Up and Flushing 1014
Reservoir Fluid Cleaning Times 1015
Dealing With Different Fluid Types 1015
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 1015
Filter Caddy Maintenance 1016
Servicing the Strainer 1016
DC Motor 1016
Hydraulic Oil Sampling Method and Procedure 1016
Hydraulic Oil Sampling Method 1016
Objective 1016
General Guidelines 1016
Synopsis 1017
Hydraulic Oil Analysis Report Guidelines 1018
Sampling Conditions 1019
Equipment 1019
Sampling Procedure 1019
Hydraulic Oil Sampling 1019
Sample Labeling 1020
Results Documentation 1020
550118414 1900YRM1897 (03 2020) US EN 1023
Series Code / Model Designation Reference Table 1027
General 1027
Hydraulic Gear Pump Assembly Repair 1029
Remove 1029
Disassemble 1031
Clean 1033
Inspect 1033
Assemble 1033
Install 1033
Hydraulic Gear Pump Specifications 1035
Variable Displacement Pump Repair 1036
Remove 1036
Disassemble 1039
Clean 1041
Inspect 1041
Assemble 1041
Install 1041
Variable Displacement Pump Checks and Adjustments 1043
Margin Pressure Check 1043
Flow Compensator Adjustment 1044
Pressure Compensator Adjustment 1044
Variable Displacement Pump Specifications 1045
Torque Specifications 1046
Hydraulic Gear Pump 1046
Variable Displacement Pump 1046
550118415 2000YRM1898 (03 2020) US EN 1049
Series Code / Model Designation Reference Table 1053
General 1054
Electro-Hydraulic Main Control Valve 1054
Description 1054
Remove 1060
Electro-Hydraulic Control Valve Sections 1063
General 1063
Outlet Control Valve Section 1063
Remove 1063
Disassemble 1063
Clean 1066
Inspect 1066
Assemble 1066
Install 1067
Auxiliary Control Valve Sections 1067
Remove 1067
Disassemble 1069
Clean 1069
Inspect 1070
Assemble 1070
Install 1071
Tilt Control Valve Section 1071
Remove 1071
Disassemble 1071
Clean 1072
Inspect 1072
Assemble 1073
Install 1073
Lift/Lower Control Valve Section 1073
Remove 1073
Disassemble 1073
Clean 1075
Inspect 1075
Assemble 1075
Install 1075
Transition Section 1075
Remove 1075
Disassemble 1076
Clean 1076
Inspect 1076
Assemble 1077
Install 1077
Install 1077
Manual Main Control Valve 1079
Description 1079
Remove 1081
OPS Solenoid Assembly 1085
General 1085
Remove 1086
Clean and Inspect 1088
Install 1088
Manual Control Valve Sections 1089
General 1089
Outlet Control Valve Section 1089
Remove 1089
Disassemble 1089
Clean 1091
Inspect 1091
Assemble 1091
Install 1091
Auxiliary Control Valve Sections 1092
Remove 1092
Disassemble 1092
Clean 1094
Inspect 1094
Assemble 1094
Install 1094
Lift/Tilt Control Valve Section 1095
Remove 1095
Disassemble 1095
Clean 1097
Inspect 1098
Assemble 1098
Install 1099
Install 1099
Pressure Relief Valve Check and Adjustment 1102
Primary Relief Valve 1102
Secondary Relief Valve 1103
Steering Control Unit Repair 1106
Steering Control Unit, Remove 1106
Steering Control Unit, Disassemble 1107
Steering Control Unit, Clean 1109
Steering Control Unit, Inspect 1109
Steering Control Unit, Assemble 1109
Relief Valve, Disassemble 1110
Relief Valve, Clean 1110
Relief Valve, Inspect 1111
Relief Valve, Assemble 1111
Steering Control Unit, Install 1111
550118420 8000YRM1904 (10 2020) US EN 1115
General Information About Diagrams and Schematics 1119
Symbol Definitions 1120
Diagrams Manual Applications 1121
Diagrams and Schematics 1123
550118555 0100YRM1892 (03 2020) US EN 1233
General 1239
Cab Replacement for 4-5 5 Ton Lift Trucks 1239
Remove 1239
Install 1250
Cab Replacement for 6-9 Ton Lift Trucks 1252
Remove 1252
Door Assemblies for 4-5 5 Ton Lift Trucks 1258
Right Side Door Assembly 1258
Remove 1258
Disassemble 1262
Door Cover With Heater Unit 1262
Door Cover With Air Conditioner/Heater Unit 1264
Heater Assembly 1266
Air Conditioner and Heater Unit Assembly 1266
Door Lock Assembly 1267
Windows 1269
Clean 1269
Inspect 1269
Assemble 1269
Windows 1269
Door Lock Assembly 1269
Heater Assembly 1269
Air Conditioner and Heater Unit Assembly 1270
Door Cover With Heater Unit 1270
Door Cover With Air Conditioner and Heater Unit 1270
Install 1270
Left Side Door Assembly 1271
Remove 1271
Disassemble 1271
Door Cover 1271
Door Lock Assembly 1271
Windows 1272
Clean 1272
Inspect 1272
Assemble 1272
Windows 1272
Door Lock Assembly 1272
Door Cover 1272
Install 1272
Door Assemblies for 6-9 Ton Lift Trucks 1273
Right and Left Side Door Assemblies 1273
Remove 1273
Disassemble 1273
Door Cover 1273
Door Lock Assembly 1274
Windows 1276
Clean 1276
Inspect 1276
Assemble 1276
Windows 1276
Door Lock Assembly 1276
Door Cover 1277
Install 1277
Window Replacement 1277
General 1277
Remove Door Windows for 4-5 5 Ton Lift Trucks 1277
Install Door Windows for 4-5 5 Ton Lift Trucks 1279
Remove Door Windows for 6-9 Ton Lift Trucks 1279
Install Door Windows for 6-9 Ton Lift Trucks 1281
Window Wipers Replacement 1281
General 1281
Front Wiper Assembly and Motor 1281
Remove 1281
Install 1283
Rear Wiper Assembly and Motor 1283
Remove, for 4-5 5 Ton Lift Trucks 1283
Install for 4-5 5 Ton Lift Trucks 1286
Remove for 6-9 Ton Lift Trucks 1286
Install for 6-9 Ton Lift Truck 1288
Heater Replacement 1289
Remove for 6-9 Ton Lift Trucks 1289
Install for 6-9 Ton Lift Trucks 1294
Heater and Air Conditioner Assembly 1295
Air Conditioner Condenser Unit 1295
Remove 1295
Install 1297
Air Conditioner Receiver/Drier Unit 1297
Remove 1297
Install 1299
Air Conditioner Compressor 1299
Light Replacement 1300
Work Lights (Front and Rear) 1300
Remove 1300
Install 1302
Strobe Light 1302
Remove 1302
Install 1303
Turn, Stop, Tail, and Backup Light 1303
Remove 1303
Install 1304
Front Marker/Turn Signal Lights 1304
Remove 1304
Install 1304
Display Switches 1305
Electrical Schematics 1307
Optional Equipment 1308
Heavy Duty Pre-Cleaner 1308
Fan 1308
Remove 1308
Install 1310
Mirror 1310
Remove 1310
Install 1310
Rear View Camera 1310
Monitor Removal 1310
Monitor Install 1312
Camera removal 1312
Camera install 1312
Label Replacement 1312
550131845 0100YRM1948 (11 2019) US EN 1315
General 1319
Description 1319
Side Covers, Seat, Dash, and Hood Replacement 1320
Side Covers 1320
Remove 1320
Install 1320
Seat and Seat Plate 1321
Remove Seat 1321
Remove Seat Plate 1322
Install Seat Plate 1322
Install Seat 1322
Operator Restraint System 1326
Emergency Locking Retractor (ELR) 1326
Seat Plate and Seat Rail Check 1326
Steering Column, Dash, Kick Panel, and Seal Plate 1326
Remove 1326
Install 1329
Hood Support and Door Assembly 1331
Remove 1331
Install 1331
Hood Door Assembly 1336
Remove 1336
Install 1337
Steering Column 1338
Description 1338
Steering Column Repair 1338
Remove 1338
Disassemble 1339
Clean 1340
Inspect 1341
Assemble 1341
Install 1341
LPG Tank and Bracket Assembly 1341
Counterweight Replacement 1341
Remove 1341
Install 1343
Tow Pin, Remove and Install 1344
Overhead Guard Replacement 1344
Remove 1344
Install 1346
Engine Replacement 1346
Remove Engine 1346
Remove Transmission 1367
Remove Engine and Transmission 1370
Install Engine 1373
Install Transmission 1376
Install Engine and Transmission 1378
Throttle Pedal and Cable Adjustment 1381
Exhaust System Repair 1381
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP135VX, GP/GLP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 (GLP135VX, GLP155VX, GP155VXS) (G878) 1381
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 1381
Kubota 3 8L Diesel Engine w/DPF 1381
Remove 1383
Inspect 1384
Install 1384
Kubota 3 8L Diesel Engine w/DOC 1384
Remove 1386
Inspect 1387
Install 1387
Kubota 3 6L Diesel Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6 GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878) 1388
Remove 1388
Inspect 1389
Install 1389
Diesel Particulate Filter (DPF) 1390
Diesel Particulate Filter 1390
Disassemble 1391
Clean and Inspect 1391
Differential Pressure Pipes and Hoses 1392
Assemble 1393
Diesel Exhaust Fluid System 1393
General 1393
Description and Operation 1393
Selective Catalyst Reducer (SCR) 1395
Remove 1395
Clean and Inspect 1396
Install 1396
DEF Tank 1397
Remove 1397
Clean and Inspect 1399
Install 1399
Cooling System 1400
Description 1400
Hydraulic Filter Assembly Repair 1400
Remove 1400
Install 1401
Fuel and Hydraulic Tanks Repair 1402
Inspect 1402
Clean 1402
Steam Method of Cleaning 1403
Chemical Solution Method of Cleaning 1403
Additional Preparations for Repair 1403
Small Leaks, Repair 1404
Large Leaks, Repair 1404
Preparations for Use After Repair 1404
Safety Labels 1404
550131847 0600YRM1962 (11 2019) US EN 1413
General 1419
Engine Identification 1419
Major Engine Component Identification 1419
Location of Labels 1419
Cylinder Block Description 1420
Precautions Before Beginning Repair 1421
Exhaust System, SCR, and DPF 1421
Engine Removal and Installation 1422
Cylinder Head Assembly Repair 1422
Valve Covers and Fuel Injectors 1422
Remove 1422
Clean and Inspect 1425
Install 1425
Rocker Arm Assembly 1426
Remove 1426
Disassemble 1427
Clean and Inspect 1427
Push Rods 1427
Rocker Arm Assembly 1427
Assemble 1428
Install 1428
Valve Clearance Adjustments 1428
Cylinder Head Assembly 1430
Remove 1430
Disassemble 1438
Valves and Valve Springs, Remove 1438
Valve Guides, Remove 1439
Clean and Inspect 1439
Cylinder Head 1440
Valve Guides 1440
Valves 1440
Valve Sink 1441
Valve Seat 1441
Valve Springs 1442
Assemble 1442
Valve Guides, Install 1442
Valves and Valve Springs, Install 1443
Install 1444
Timing Gear Case and Timing Gears Repair 1446
Timing Gear Case Cover 1446
Remove 1446
Clean and Inspect 1447
Install 1447
Timing Gears 1448
Crankshaft Gear 1448
Remove 1448
Install 1449
Idler Gear 1 and Idler Gear 2 1449
Remove 1449
Inspect 1450
Install 1451
Idler Gear 3 1451
Remove 1451
Inspect 1451
Install 1451
Camshaft Gear 1451
Remove 1451
Install 1451
Drive Train, Camshaft, and Cylinder Block Repair 1452
Remove 1452
Disassemble 1452
Pistons and Connecting Rods 1452
Crankshaft 1453
Camshaft 1455
Clean and Inspect 1457
Cylinder Block 1457
Honing and Boring 1459
Cylinder Correction (Oversize) 1460
Pistons 1460
Piston Pin 1461
Connecting Rod 1461
Tappets 1462
Crankshaft 1462
Camshaft 1464
Camshaft Bushing 1465
Assemble 1465
Camshaft 1465
Crankshaft 1465
Pistons and Connecting Rods 1466
Install 1468
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 1468
Lubrication System Repair 1471
Engine Oil and Oil Filter Change (Standard Oil Filter) 1471
Engine Oil and Oil Filter Change (Remote Oil Filter) 1472
Oil Pan 1472
Remove 1472
Install 1473
Oil Suction Tube 1473
Remove 1473
Clean 1474
Install 1474
Oil Pump 1474
Remove 1474
Clean and Inspect 1475
Inner Rotor and Outer Rotor Clearance 1475
Outer Rotor and Pump Body Clearance 1476
Rotor and Cover Clearance 1476
Rotor Shaft Clearance 1476
Install 1477
Remote Oil Filter 1477
Remove 1477
Clean and Inspect 1479
Install 1479
Fuel System Repair 1480
Fuel Injectors 1480
Remove 1480
Inspect 1480
Clean 1480
Replace 1480
Install 1481
Test 1481
Fuel Injection Pump 1481
Remove 1481
Clean and Inspect 1484
Install 1485
Cooling System Repair 1486
Serpentine Belt 1486
Remove 1486
Inspect 1486
Install 1486
Adjust 1486
Water Pump 1487
Remove 1487
Install 1488
Thermostat 1489
Remove 1489
Inspect 1490
Install 1490
Flywheel and Flywheel Housing 1492
Flywheel 1492
Remove 1492
Install 1492
Flywheel Housing 1492
Remove 1492
Install 1492
Electrical Equipment Repair 1493
Alternator 1493
Remove 1493
Install 1494
Starter 1495
Remove 1495
Install 1495
Engine Specifications 1497
Engine Data 1497
Engine Tuning 1498
Cylinder Head 1498
Intake/Exhaust Valve and Guide 1499
Valve Spring 1499
Rocker Arm and Shaft 1499
Push Rod 1499
Gear Train and Camshaft 1500
Camshaft 1500
Idle Gear Shaft and Bushing 1500
Backlash of Each Gear 1500
Cylinder Block 1500
Crankshaft 1501
Piston 1501
Piston Ring 1501
Connecting Rod 1502
Rod Small End 1502
Tappet 1502
Oil Pump 1502
Engine Oil Pressure 1502
Inner and Outer Rotor Clearance 1502
Outer Rotor and Pump Body 1502
Rotor and Cover 1503
Standard Torque Specifications 1503
Standard Torque Chart 1503
Special Torque Specifications 1504
Special Tools 1505
550131848 0600YRM1961 (03 2020) US EN 1519
General 1525
Engine Identification 1526
Major Engine Component Identification 1526
Location of Labels 1528
Cylinder Block Description 1529
Precautions Before Beginning Repair 1530
Exhaust System and DPF 1531
Engine Removal and Installation 1531
Cylinder Head Assembly Repair 1531
Valve Covers and Fuel Injectors 1531
Remove 1531
Clean and Inspect 1534
Install 1534
Rocker Arm Assembly 1535
Remove 1535
Disassemble 1535
Clean and Inspect 1536
Push Rods 1536
Rocker Arm Assembly 1536
Assemble 1537
Install 1537
Valve Clearance Adjustments 1537
Cylinder Head Assembly 1538
Remove 1538
Disassemble 1546
Valves and Valve Springs, Remove 1546
Valve Guides, Remove 1547
Clean and Inspect 1547
Cylinder Head 1548
Valve Guides 1548
Valves 1549
Valve Sink 1549
Valve Seat 1549
Valve Springs 1550
Assemble 1550
Valve Guides, Install 1550
Valves and Valve Springs, Install 1551
Install 1552
Timing Gear Case and Timing Gears Repair 1554
Timing Gear Case Cover 1554
Remove 1554
Clean and Inspect 1555
Install 1555
Timing Gears 1556
Crankshaft Gear 1556
Remove 1556
Install 1557
Idler Gear 1 and Idler Gear 2 1557
Remove 1557
Inspect 1558
Install 1559
Idler Gear 3 1559
Remove 1559
Inspect 1559
Install 1559
Camshaft Gear 1559
Remove 1559
Install 1559
Drive Train, Camshaft, and Cylinder Block Repair 1560
Remove 1560
Disassemble 1560
Pistons and Connecting Rods 1560
Crankshaft 1561
Camshaft 1563
Clean and Inspect 1565
Cylinder Block 1565
Honing and Boring 1567
Cylinder Correction (Oversize) 1568
Pistons 1568
Piston Pin 1569
Connecting Rod 1569
Tappets 1570
Crankshaft 1570
Camshaft 1572
Camshaft Bushing 1573
Assemble 1573
Camshaft 1573
Crankshaft 1573
Pistons and Connecting Rods 1574
Install 1576
Angular Deviation Procedure 1576
Lubrication System Repair 1579
Engine Oil and Oil Filter Change 1579
Oil Pan 1580
Remove 1580
Install 1580
Oil Suction Tube 1580
Remove 1580
Clean 1581
Install 1581
Oil Pump 1581
Remove 1581
Clean and Inspect 1582
Inner Rotor and Outer Rotor Clearance 1582
Outer Rotor and Pump Body Clearance 1583
Rotor and Cover Clearance 1583
Rotor Shaft Clearance 1583
Install 1584
Fuel System Repair 1584
Fuel Injectors 1584
Remove 1584
Inspect 1584
Clean 1585
Replace 1585
Install 1585
Test 1585
Fuel Injection Pump 1585
Remove 1585
Clean and Inspect 1588
Install 1588
Cooling System Repair 1589
Serpentine Belt 1589
Remove 1589
Inspect 1589
Install 1589
Adjust 1589
Water Pump 1590
Remove 1590
Install 1592
Thermostat 1592
Remove 1592
Inspect 1593
Install 1593
Flywheel and Flywheel Housing 1594
Flywheel 1594
Remove 1594
Install 1595
Flywheel Housing 1595
Remove 1595
Install 1595
Electrical Equipment Repair 1596
Alternator 1596
Remove 1596
Install 1597
Starter 1598
Remove 1598
Install 1598
Engine Specifications 1600
Engine Data 1600
Engine Tuning 1602
Cylinder Head 1602
Intake/Exhaust Valve and Guide 1603
Valve Spring 1603
Rocker Arm and Shaft 1603
Push Rod 1603
Gear Train and Camshaft 1604
Camshaft 1604
Idle Gear Shaft and Bushing 1604
Backlash of Each Gear 1604
Cylinder Block 1604
Crankshaft 1605
Piston 1605
Piston Ring 1605
Connecting Rod 1606
Rod Small End 1606
Tappet 1606
Oil Pump 1606
Engine Oil Pressure 1606
Inner and Outer Rotor Clearance 1606
Outer Rotor and Pump Body 1606
Rotor and Cover 1607
Standard Torque Specifications 1607
Standard Torque Chart 1607
Special Torque Specifications 1607
Special Tools 1609
550131849 0700YRM1950 (03 2020) US EN 1623
General 1627
Cooling System Checks 1628
Exhaust Leaks Into Cooling System 1628
Water Flow Restrictions in Radiator 1628
Radiator Hoses 1628
Water Pump 1628
Flushing the Cooling System 1629
Cooling System, Clean 1629
Radiator Repair 1630
Remove 1630
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 1630
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1638
Install 1644
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 1644
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1645
Fan Assembly Replacement 1647
Remove 1647
Inspect 1652
Install 1652
550131851 1600YRM1952 (03 2020) US EN 1655
General 1659
Steering Axle Assembly Repair 1662
Remove 1662
Disassemble 1663
Clean 1664
Inspect 1664
Assemble 1665
Install 1665
Spindles, Bearings, and Tie Rods Repair 1666
Spindles and Bearings 1666
Remove 1666
Disassemble 1666
Clean 1667
Inspect 1667
Assemble 1667
Install 1668
Tie Rods 1668
Remove 1668
Install 1669
Steering Cylinder Repair 1669
Remove and Disassemble 1669
Clean and Inspect 1669
Assemble and Install 1669
Turn Assist (Lift trucks built after February 2019) 1671
Removal 1671
Instal 1673
Adjustment 1673
Torque Specifications 1674
550131852 2100YRM1953 (03 2020) US EN 1677
General 1683
Safety Procedures When Working Near Mast 1683
Tilt Cylinder Repair 1685
Remove 1685
Disassemble 1688
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1688
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1688
Clean 1689
Inspect 1689
Assemble 1689
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1689
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1690
Install 1691
Tilt Cylinders, Adjust 1692
Tilt Cylinder Leak Check 1694
Lift Cylinder Repair 1695
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1695
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1698
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1702
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1707
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 1708
Clean 1709
Inspect 1709
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1709
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1710
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1710
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1711
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1711
Free-Lift Cylinder Repair 1712
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1712
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1715
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1717
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1718
Clean 1720
Inspect 1720
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1720
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1721
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1721
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1721
Sideshift Cylinder Repair 1722
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1722
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1722
Clean 1723
Inspect 1723
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1723
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1724
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1724
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1725
Clean 1726
Inspect 1726
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1726
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1726
Bolzoni Sideshift Cylinder Repair 1727
Remove 1727
Disassemble 1727
Clean 1728
Inspect 1728
Assemble 1729
Install 1729
Fork Positioner Cylinder Repair 1730
Remove 1730
Disassemble 1732
Clean 1735
Inspect 1735
Assemble 1736
Install 1737
Lift Cylinder Leak Check 1738
Seal Kit Installation 1738
External Installation (Seal and Back-Up Ring) 1738
Internal Installation (Piston Rod Assembly) 1739
Special Tools 1739
Torque Specifications 1740
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1740
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1740
550131853 2200YRM1954 (03 2020) US EN 1743
General 1751
Display Switch Cluster 1754
Remove 1754
Install 1756
Direction Control and Turn Signal Levers 1756
Remove 1756
Install 1757
Key Switch 1757
Remove 1757
Install 1758
Display Switch Cluster Panel Bezel and Overlay 1758
Remove 1758
Install 1759
Steering Column Repair 1759
Sensors and Switches 1762
General 1762
Dash and Kick Panel, Remove and Install 1762
Remove 1762
Install 1763
Accelerator Pedal Position Sensor 1763
Remove 1763
Install 1766
Brake Fluid Level Switch 1766
Remove 1766
Install 1767
Service Brake Pedal Position Sensor 1767
Remove 1767
Install 1768
Parking Brake Position Sensor 1768
Remove 1768
Install 1768
Service Brake Pressure Sensor 1769
Remove 1769
Install 1769
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 1770
Remove 1770
Install 1770
Sensor MicroswitchFoot Directional Control 1771
Remove 1771
Install 1773
Low Coolant Level Sensor 1773
Remove 1773
Install 1774
Fuel Level Sensor, Diesel Engines Only 1774
Remove 1774
Install 1775
Seat Sensor (Operator Presence System) 1775
Non-Suspension Seat 1775
Remove 1775
Install 1777
Full Suspension and Swivel Seats 1777
Remove 1777
Install 1777
Hood Shut Off Switch 1778
Remove 1778
Install 1778
Remote Key Switch 1779
Remove 1779
Install 1779
Hydraulic Filter Pressure Switch 1780
Remove 1780
Install 1780
Transmission Speed Sensor 1780
Remove 1780
Install 1781
Transmission Pressure Sensors 1781
Remove 1781
Install 1781
Transmission Temperature Sensor 1782
Remove 1782
Install 1782
Engine Speed Sensor 1782
Remove 1782
Install 1782
Intermediate Speed Sensor 1782
Remove 1782
Install 1782
Return To Set Tilt (Tilt Angle) Sensor 1782
Remove 1782
Install 1783
Rear Horn Button Switch 1783
Remove 1783
Install 1783
Impact Sensor 1784
Remove 1784
Install 1784
Load Weight Sensor 1785
Remove 1785
Install 1785
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 1786
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 1787
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 1787
Air Filter Restriction Switch 1787
Remove 1787
Install 1787
Engine Oil Pressure Sensor 1788
Remove 1788
Install 1788
Engine Speed Sensor 1788
Remove 1788
Install 1788
Engine Coolant Temperature (ECT) Sensor 1789
Remove 1789
Install 1789
Fuel/Water Separator Sensor 1789
Remove 1789
Install 1789
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 1790
Engine Coolant Temperature (ECT) Sensor 1790
Remove 1790
Install 1790
Throttle Position Sensor 1791
Engine Oil Pressure Sensor 1791
Remove 1791
Install 1791
Fuel Shut Off Solenoid 1791
Remove 1791
Install 1792
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With Diesel Particulate Filter (DPF) And Kubota 3 8L (Tier 4) 55kW Diesel Engine, With Diesel Oxidation Catalyst (DOC) 1792
Intake Air Temperature Sensor 1793
Remove 1793
Install 1793
Boost Sensor 1793
Remove 1793
Install 1793
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 1795
Remove 1795
Install 1796
Engine Coolant Temperature (ECT) Sensor 1796
Remove 1796
Install 1796
Engine Oil Pressure Sensor 1796
Remove 1796
Install 1797
Crankshaft Position Sensor 1797
Remove 1797
Install 1797
Adjust Shim Procedure 1797
Camshaft Position Sensor 1799
Remove 1799
Install 1799
Differential Pressure Sensor 1799
Remove 1799
Install 1800
Oxygen Sensors (Inlet and Outlet) 1800
Remove 1800
Install 1801
Inlet Temperature Sensor 1802
Remove 1802
Install 1802
Mass Air Flow Sensor 1802
Remove 1802
Install 1802
Fuel/Water Separator 1802
Remove 1802
Install 1803
Air Filter Restriction Switch 1803
Remove 1803
Install 1803
Vehicle System Manager (VSM) 1804
General 1804
VSM Replacement 1804
Remove 1804
Install 1804
Programming A New VSM And/Or Display Switch Cluster 1805
Data Transferring 1806
New VSM 1806
New (Blank) Display Switch Cluster 1806
Used (Non-Blank) Display Switch Cluster 1806
PC Service Tool Software 1807
Power Distribution Module (PDM) and Component Parts 1807
Remove 1807
PDM as a Unit 1807
Install 1808
PDM as a Unit 1808
Remove and Install 1808
PDM Component Parts 1808
Transmission Control Unit (TCU) 1809
Remove 1809
Install 1811
Battery 1814
Remove 1814
Install 1814
Lights 1814
Work Lights (Front and Rear) 1814
Halogen Bulb Lights 1814
Remove 1814
Install 1814
LED Lights 1815
Remove 1815
Install 1815
Strobe Light 1815
Remove 1815
Install 1816
LED Tail, Backup, and Brake Lights 1816
Remove 1816
Install 1816
Front Marker/Turn Signal Lights 1817
Replacing Whole Front Marker/Turn Signal Light Assembly 1817
Remove 1817
Install 1817
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 1818
Remove 1818
Install 1818
Electronic-Hydraulic Controls, Before January, 2020 1819
E-Hydraulic Controls – TEST 1819
Mini-Levers 1819
Full Stroke Test 1819
Function Returns to Neutral Test 1819
Push (Override) Button Switch 1819
General 1820
Mini-levers, Remove and Install 1820
Armrest Assembly 1821
Remove 1821
Install 1824
Horn Button 1824
Remove 1824
Install 1824
Direction Control Switch 1824
Remove 1824
Install 1825
Push (Override) Button 1825
Remove 1825
Install 1826
Electronic-Hydraulic Controls, After January, 2020 1827
E-Hydraulic Controls – TEST 1827
Mini-Levers 1827
Full Stroke Test 1827
Function Returns to Neutral Test 1827
Push Button Switch 1827
General 1828
Mini-levers, Remove and Install 1828
Armrest Assembly 1829
Remove 1829
Install 1832
Horn Button 1832
Remove 1832
Install 1832
Direction Control Switch 1832
Remove 1832
Install 1833
Push (Override) Buttons 1833
Remove 1833
Install 1834
Diesel Particulate Filter (DPF) Display 1835
Remove 1835
Clean and Inspect 1836
Install 1836
Special Tools 1837
550131855 4000YRM1956 (03 2020) US EN 1841
Safety Procedures When Working Near Mast 1845
Fork Replacement 1846
General 1846
Remove 1846
Install 1848
Checks 1848
Carriage Repair 1850
Remove 1850
Clean and Inspect 1853
Install 1853
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1854
Connecting Attachment Hydraulic Quick Disconnect Hoses 1854
Integral Sideshift Carriage And Fork Positioners Repair 1855
Integral Sideshift Carriage 1855
Remove 1855
Disassemble 1856
Clean and Inspect 1858
Assemble 1859
Install 1859
Fork Positioners 1860
Remove 1860
Disassemble 1863
Clean and Inspect 1865
Assemble 1865
Install 1865
Hang-On Sideshift Carriage Repair 1866
Remove 1866
Disassemble Carriage 1868
Clean and Inspect 1871
Assemble 1871
Install 1874
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 1876
Remove 1876
Disassemble 1880
Clean and Inspect 1884
Assemble 1886
Install 1886
Header Hose Installation 1887
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 1890
Remove 1890
Disassemble 1893
Clean and Inspect 1896
Assemble 1898
Install 1898
Header Hose Installation 1899
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 1902
Remove 1902
Disassemble 1905
Clean and Inspect 1908
Assemble 1910
Install 1910
Header Hose Installation 1911
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 1914
Remove 1914
Disassemble 1917
Clean and Inspect 1921
Assemble 1923
Install 1923
Header Hose Installation 1924
Mast Operation Check 1927
Tilt Cylinder Adjustment 1927
Main Lift Cylinder Repair 1928
Lift Chain Adjustment 1928
Mast Adjustments 1929
Load Roller Adjustment 1929
Mast Side Kicking Adjustment 1931
Carriage Adjustment 1931
550136209 1800YRM1977 (03 2020) US EN 1935
General 1939
Wet Brake System 1939
Parking Brake Repair 1940
Master Cylinder Repair, For 6-8 Ton Lift Trucks 1943
Remove 1943
Disassemble 1944
Clean and Inspect 1945
Assemble 1946
Install and Adjust 1946
Accumulator; For 6-8 Ton Lift Trucks 1947
Pre-Charge Check 1947
Remove 1948
Install 1949
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For 8-9 Ton Lift Trucks 1949
Remove 1949
Modulating Brake Valve 1951
Disassemble 1951
Clean and Inspect 1952
Assemble 1953
Accumulator Charge Valve 1953
Disassemble 1953
Clean and Inspect 1955
Assemble 1955
Install 1956
Pressure Checks 1957
Accumulator Charge Valve Check 1957
Accumulator Check 1957
Brake System Air Removal; For 6-8 Ton Lift Trucks 1958
Using Pressure Bleed System 1958
Using Brake Pedal Pressure 1958
Lift Truck Models with Master Cylinder 1958
Brake System Air Removal for 8-9 Ton Lift Trucks 1959
Using Brake Pedal Pressure 1959
Lift Truck Models with Modulating Brake Valve 1959
Brake Pedal Adjustment 1959
For 6-8 Ton Lift Trucks 1959
For 8-9 Ton Lift Trucks 1960
Free Pedal Adjustment 1962
Torque Specifications 1963
550152438 0600YRM1949 (07 2023) US EN 1965
General 1971
Engine Removal and Installation 1971
Cylinder Head Repair 1971
Remove and Disassemble 1971
Clean and Inspect 1973
Valve Oil Seals 1975
Remove and Disassemble 1975
Cylinder Leak Down Test 1975
Clean and Inspect 1976
Assemble and Install 1976
Valve Guides and Seats, Repairs 1978
Valves, Repair 1979
Valve Seats, Repair 1979
Valve Springs 1980
Assemble and Install 1981
Engine Block Cleaning and Inspection 1985
Clean and Inspect 1985
Piston Bore Preparation 1987
Engine Mounts Installation 1988
Remove 1988
Clean and Inspect 1988
Install 1988
Lubrication System Repair 1989
Oil Pump, Remove and Disassemble 1989
Clean and Inspect 1990
Oil Pump, Assemble and Install 1991
Oil Pan, Install 1993
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 1995
Timing Cover 1995
Remove 1995
Install 1996
Timing Chain and Sprockets 1996
Remove 1996
Install 1997
Camshaft 1997
Remove 1997
Inspect 1998
Install 1998
Balance Shaft 1999
Remove 1999
Install 2000
Valve Lifters 2001
Remove 2001
Clean and Inspect 2001
Install 2001
Crankshaft Repair 2003
Remove 2003
Inspect and Repair 2003
How to Check Clearance Between Main Bearings and Their Journals 2004
Install 2005
Piston and Connecting Rod Assemblies Repair 2007
Connecting Rod Bearings, Replace 2007
Piston and Connecting Rod Assemblies, Remove 2008
Disassemble 2008
Piston, Clean and Inspect 2009
Cylinder Bores, Inspect and Repair 2009
Piston Rings 2010
Assemble 2011
Piston and Connecting Rod Assemblies, Install 2011
Flywheel and Flywheel Housing Repair 2012
Flywheel, Remove 2012
Clean 2012
Inspect 2012
Flywheel, Install 2013
Coolant Pump Repair 2014
Remove 2014
Clean and Inspect 2015
Install 2015
Thermostat Replacement 2016
Remove 2016
Thermostat Operation Check 2016
Install 2016
Starter Replacement 2017
Fan Assembly Replacement 2021
Remove 2021
Inspect 2023
Install 2023
Drive Belt Installation 2024
Remove 2024
Clean 2024
Inspect 2024
Installation 2024
Compression Check 2026
Engine Specifications 2027
Engine Data 2027
Cylinder Head 2027
Hydraulic Valve Lifter 2027
Camshaft 2027
Pistons 2028
Crankshaft 2028
Connecting Rods 2029
Balance Shaft 2029
Cooling System 2029
Lubrication System 2029
Torque Specifications 2030
550152438 0600YRM1949 (11 2019) US EN 2033
General 2037
Engine Removal and Installation 2037
Cylinder Head Repair 2037
Remove and Disassemble 2037
Clean and Inspect 2039
Valve Oil Seals 2041
Remove and Disassemble 2041
Cylinder Leak Down Test 2041
Clean and Inspect 2042
Assemble and Install 2042
Valve Guides and Seats, Repairs 2044
Valves, Repair 2045
Valve Seats, Repair 2045
Valve Springs 2046
Assemble and Install 2047
Engine Block Cleaning and Inspection 2050
Clean and Inspect 2050
Piston Bore Preparation 2052
Engine Mounts Installation 2053
Remove 2053
Clean and Inspect 2053
Install 2053
Lubrication System Repair 2053
Oil Pump, Remove and Disassemble 2053
Clean and Inspect 2055
Oil Pump, Assemble and Install 2056
Oil Pan, Install 2057
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 2059
Timing Cover 2059
Remove 2059
Install 2060
Timing Chain and Sprockets 2060
Remove 2060
Install 2061
Camshaft 2062
Remove 2062
Inspect 2062
Install 2062
Balance Shaft 2063
Remove 2063
Install 2064
Valve Lifters 2065
Remove 2065
Clean and Inspect 2065
Install 2066
Crankshaft Repair 2066
Remove 2066
Inspect and Repair 2067
How to Check Clearance Between Main Bearings and Their Journals 2068
Install 2069
Piston and Connecting Rod Assemblies Repair 2070
Connecting Rod Bearings, Replace 2070
Piston and Connecting Rod Assemblies, Remove 2071
Disassemble 2072
Piston, Clean and Inspect 2072
Cylinder Bores, Inspect and Repair 2073
Piston Rings 2073
Assemble 2074
Piston and Connecting Rod Assemblies, Install 2075
Flywheel and Flywheel Housing Repair 2076
Flywheel, Remove 2076
Clean 2076
Inspect 2076
Flywheel, Install 2077
Coolant Pump Repair 2078
Remove 2078
Clean and Inspect 2078
Install 2079
Thermostat Replacement 2080
Remove 2080
Thermostat Operation Check 2080
Install 2080
Starter Replacement 2081
Fan Assembly Replacement 2084
Remove 2084
Inspect 2086
Install 2086
Drive Belt Installation 2087
Remove 2087
Clean 2087
Inspect 2087
Installation 2087
Compression Check 2088
Engine Specifications 2089
Engine Data 2089
Cylinder Head 2089
Hydraulic Valve Lifter 2089
Camshaft 2089
Pistons 2090
Crankshaft 2090
Connecting Rods 2091
Balance Shaft 2091
Cooling System 2091
Lubrication System 2091
Torque Specifications 2091
550152439 0900YRM1951 (11 2019) US EN 2095
General 2101
LPG Tank and Bracket 2101
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 2101
Remove 2101
Install 2106
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 2107
Remove 2107
Install 2108
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 2109
Remove 2109
Install 2111
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 2111
Remove 2111
Install 2111
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 2112
Remove 2112
Install 2113
Fuel Filter Unit 2114
Fuel Filter Element 2114
Remove 2114
Clean and Inspect 2115
Install 2115
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) 2116
Remove 2116
Disassemble 2117
Clean and Inspect 2117
Assemble 2118
Install 2118
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 2118
Remove 2118
Disassemble 2120
Clean and Inspect 2121
Assemble 2121
Install 2122
Throttle Body 2122
Remove 2122
Clean 2124
Install 2124
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 2125
Remove 2125
Install 2126
Control System 2127
Engine Control Unit (ECU) 2127
Remove 2127
Install 2128
Low Pressure Switch 2128
Remove 2128
Install 2129
Low Fuel Sensor 2129
Remove 2129
Install 2130
LP Converter 2130
Remove and Disassemble 2130
Assemble and Install 2132
LPG Lock-Off 2133
Remove 2133
Install 2134
Exhaust System 2134
Counterweight Exhaust 2134
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) 2134
Inspect 2136
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) 2137
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2137
Inspect 2138
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2138
Overhead Exhaust 2139
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) 2139
Inspect 2140
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) 2141
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2141
Inspect 2143
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2143
Exhaust Manifold 2143
Remove 2143
Install 2144
Oxygen (HEGO) Sensor 2145
Remove 2145
Install 2145
LPG Fuel Testing 2145
General 2145
Available Fuel Tests 2146
Composition Test (ASTM D-2163) 2146
Ammonia Test (ASTM D-4490) 2146
Basic Nitrogen Test (ASTM UOP269-90) 2146
Residues Test (ASTM D-2158) 2146
Vapor Pressure Test (ASTM D-2598) 2146
Sulfur Compounds Test (ASTM D-5623) 2146
Methanol Test (ASTM D-4864) 2146
Copper Corrosion (ASTM D-1838) 2146
Where To Send LPG Fuel Samples For Testing 2146
550152440 2200YRM1955 (11 2019) US EN 2149
Description 2153
Distributor Ignition (DI) System 2153
Crankshaft Position (CKP) Sensor 2153
Camshaft Position (CMP) Sensor 2153
Ignition Coil and Ignition Control Module (ICM) 2153
Secondary Ignition Components 2153
Spark Plugs and Wires 2153
Spark Plug Wire Inspection 2153
Spark Plug Wire Replacement 2153
Remove 2153
Install 2154
Spark Plug Inspection 2154
Usage 2154
Inspection 2154
Visual Inspection 2156
Spark Plug Replacement 2157
Remove 2157
Install 2157
Distributor Repair 2157
Inspect 2157
Overhaul 2158
Disassemble 2158
Assemble 2160
Replace 2161
Remove 2161
Install Procedure 1 2163
Install Procedure 2 2164
Ignition Coil Replacement 2166
Remove 2166
Install 2166
Ignition Control Module Replacement 2167
Remove 2167
Install 2167
Starter Replacement 2168
Remove 2168
Install 2171
Sensors and Switches 2172
LPG Trucks 2172
Crankshaft Position (CKP) Sensor 2172
Remove 2172
Install 2172
Camshaft Position (CMP) Sensor 2173
Remove 2173
Install 2174
Oil Pressure Sensor 2175
Remove 2175
Install 2175
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2176
Remove 2176
Install 2176
Engine Coolant Temperature (ECT) Sensor 2176
Remove 2176
Install 2177
Air Flow Restriction Switch 2177
Remove 2177
Install 2178
Specifications and Special Tools 2178
550213054 8000YRM2197 (11 2019) US EN 2181
Lift Truck Lifting Capacity 2185
Counterweight Weights 2185
Tire Sizes 2185
Capacities 2185
Electrical System 2189
Transmission Oil Pressures 2190
Hydraulic System Relief Pressures 2192
Steering System 2192
Stall Speeds (in RPM ±100 rpm) 2192
GM/PSI 4 3L LPG GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 2192
Kubota 3 6L Diesel GDP60VX, GDP70VX, GP70VXS6, GP70VXS9 (GDP135VX GDP155VX, GP155VXS) (G878) 2193
Kubota 3 8L Diesel GDP60VX, GDP70VX, GP70VXS6, GP70VXS9 (GDP135VX GDP155VX, GP155VXS) (G878) 2193
Mast Speeds 2193
Tilt Angles 2194
Front End Equipment – Mast Creep 2195
Mast Creep 2195
Engine Specifications 2195
Diesel Fuel Cleanliness Levels 2198
Torque Specifications 2198
Frame 2198
Mast 2198
Hang On Sideshift Carriage With Fork Positioner 2198
Steering System 2199
Transmission 2199
Engine – GM/PSI 4 3L 2199
Engine – Kubota 3 6L Diesel 2200
Engine – Kubota 3 8L Diesel 2201
550213055 8000YRM2196 (09 2020) US EN 2205
General 2211
Serial Number Data 2211
How to Move Disabled Lift Truck 2211
How to Tow Lift Truck 2211
How to Put Lift Truck on Blocks 2212
How to Raise Drive Tires 2212
How to Raise Steering Tires 2213
How to Clean a Lift Truck 2214
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 2214
Connecting Attachment Hydraulic Quick Disconnect Hoses 2215
Safety Procedures When Working Near Mast 2216
Maintenance Schedule 2217
Maintenance Procedures Every 8 Hours or Daily 2235
How to Make Checks With Engine Stopped 2235
Tires and Wheels 2235
Safety Labels 2235
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2235
Operator Restraint System 2236
Emergency Locking Retractor (ELR) 2236
Adjust Seat – Full Suspension 2237
Adjust Seat – Internal Suspension 2238
Seat Plate and Seat Rails 2239
Engine Compartment 2240
Paper Application 2240
Fuel, Oil, and Coolant Leaks, Check 2241
Hydraulic Hoses 2241
Coolant Hoses 2241
Steering Column Gas Cylinder 2241
Transmission 2241
Hydraulic System Oil 2241
Engine Oil 2242
Air Filter 2248
Forks 2248
Inspect 2248
Remove 2250
Install 2250
Adjust 2250
Hang On Sideshift Carriage 2251
How to Make Checks With Engine Running 2251
Indicator Lights, Horn, Fuses, and Relays 2251
Service Brakes 2254
Brake Oil Level 2254
Operation, Check 2254
Parking Brake 2254
Engine Oil Pressure 2255
Cooling System 2255
Steering System 2256
Control Levers and Pedals 2256
Lift System, Operate 2256
Air Filter 2257
Fuel/Water Separator Filter, Kubota Diesel Engine 2257
First Service After First 100 Hours of Operation 2258
4 3L Engine Oil and Oil Filter 2258
Kubota Diesel Engine Oil and Oil Filter 2258
Hang on Sideshift Carriage Checks 2260
Maintenance Procedures Every 250 Hours or 6 Months 2262
4 3L Engine Oil and Oil Filter Change 2262
Kubota Diesel Engine Oil and Oil Filter 2262
Drive Belt 2264
4 3L Engine 2264
Fan and Alternator Drive Belt 2264
Drain Tar From LPG Converter 2265
Cleaning Carbon Buildup From Intake Valves – PSI 4 3L LPG Engines 2266
Maintenance Procedures Every 500 Hours or 6 Months 2268
Hydraulic System Oil 2268
Hydraulic Tank Breather 2269
Inspect 2269
Battery 2269
Kubota Diesel Engine Oil and Oil Filter 2270
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engines 2271
Remove 2271
Install 2271
Priming the Fuel System (Kubota 3 8L Engine) 2272
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 2273
Remove 2273
Install 2273
Priming the Fuel System (Kubota 3 6L Engine) 2274
Drive Belt 2274
Kubota Diesel Engine 2274
Fan and Alternator Drive Belt 2274
Clean Debris From Radiator Core 2275
Transmission Oil Breather/Dipstick 2275
Differential and Drive Axle Oil Level Check 2276
Forks, Inspect 2278
Mast Lubrication 2279
Tilt Cylinder Lubrication 2283
Header Hose Checks 2283
Lift Chain Lubrication 2284
Master Brake Cylinder Rod End Pin Lubrication 2284
Manual Hydraulic Levers Lubrication 2284
Cab Heater Air Filter 2284
Brake Oil 2285
Tie Rod Lubrication 2286
Parking Brake Adjustment 2287
Maintenance Procedures Every 1000 Hours or 6 Months 2288
Valve Clearance, Check and Adjust 2288
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 2288
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 2288
Ignition System 2288
4 3L Engine 2288
LPG Fuel Filter Element Replace, 4 3L Engine 2288
Remove 2288
Install 2289
In-Line Strainer Replacement, Kubota Diesel Engine 2289
Remove 2289
Install 2289
Lift Chains Wear Check 2290
Lift Chain Lubrication 2291
Hang On Sideshift Carriage, Check Sliding Surfaces 2291
Steering Axle Spindle Bearings 2292
Control Levers and Pedals 2293
Inspect Engine Electrical System, Connectors 2293
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2293
Parking Brake Lever Lubrication, Wet Brake Axle 2297
Normal Operating Environment 2297
Heavy Duty or Contaminated Environment 2298
Remove 2298
Clean and Inspect 2299
Install 2299
Crankcase Breather Element, Kubota 3 8L Diesel 2300
Remove 2300
Clean and Inspect 2300
Install 2300
DEF Injector Tip 2300
Maintenance Procedures Every 2000 Hours or Annually 2301
Hydraulic System 2301
Hydraulic Filter Assembly, Replace 2301
Install 2302
Hydraulic Tank Breather, Replace 2303
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2304
Cooling System Check 2304
Air Filter 2305
Fuel Injector, Kubota 3 8L Engine 2307
Fuel Injector, Kubota 3 6L Engine 2307
Forks 2307
Brake Oil (Master Cylinder), Change 2308
Check Throttle Shaft for Sticking 2309
Inspect Exhaust Manifold and Piping for Leaks 2309
Transmission Automatic Clutch Calibration 2309
Wheel Bearings 2309
Steer Wheels, Lubrication 2309
Maintenance Procedures Every 3000 Hours 2310
Diesel Particulate Filter 2310
Remove 2310
Disassemble 2312
Servicing the Diesel Particulate Filter, Pressure Tubes and Pressure Hoses 2313
Assemble 2313
Install 2314
Diesel Exhaust Fluid (DEF) System 2314
Maintenance Procedures Every 4000 Hours or 2 Years 2316
Hydraulic Oil, Replace 2316
Overhead Guard Changes 2317
Jump-Starting the Lift Truck 2318
Jump-Starting Using a Battery Charger 2318
Jump-Starting a Lift Truck Using Another Lift Truck 2318
Wheel and Tire Replacement 2318
General 2318
Pneumatic Tire With Tube, Repair 2318
Remove Wheels From Lift Truck 2318
Remove Tire From Wheel 2319
Install Wheel in Tire 2322
Install Tire on Two-Piece Wheel 2324
Add Air to Pneumatic Tires With Tube 2325
Install the Wheels 2325
Dual Drive Wheels, Install 2325
Pneumatic Tubeless Tire, Repair 2327
Remove Wheels From Lift Truck 2327
Add Air to Pneumatic Tubeless Tire 2332
Wheels, Install 2332
Solid Rubber Tires on Pneumatic Wheels, Change 2332
Wheels, Install 2336
Fuel Filter Water Removal 2336
Kubota Diesel Engine 2336
3 8L Diesel Engine 2336
3 6L Diesel Engine 2337
Lift Chain Adjustments 2338
Welding Repairs 2339
Adhesives and Sealants 2340
550229997 0600YRM2294 (01 2021) US EN 2343
General 2349
Engine Identification 2349
Major Engine Component Identification 2349
Location of Labels 2350
Crankcase Description 2351
Precautions Before Beginning Repair 2352
Exhaust System 2353
Engine Removal and Installation 2353
Cylinder Head Assembly Repair 2353
Valve Covers and Fuel Injectors 2353
Remove 2353
Clean and Inspect 2356
Install 2356
Rocker Arm Assembly 2356
Remove 2356
Disassemble 2357
Clean and Inspect 2358
Push Rods 2358
Rocker Arm Assembly 2358
Assemble 2358
Install 2359
Valve Clearance Adjustments 2359
Cylinder Head Assembly 2360
Remove 2360
Disassemble 2366
Valves and Valve Springs, Remove 2366
Valve Guides, Remove 2367
Clean and Inspect 2367
Cylinder Head 2368
Valve Guides 2368
Valves 2368
Valve Sink 2368
Valve Seat 2369
Valve Springs 2369
Assemble 2370
Valve Guides, Install 2370
Valves and Valve Springs, Install 2370
Install 2371
Timing Gear Case and Timing Gears Repair 2373
Timing Gear Case Cover 2373
Remove 2373
Clean and Inspect 2374
Install 2374
Timing Gears 2375
Crankshaft Gear 2375
Remove 2375
Install 2376
Idler Gear 2376
Remove 2376
Inspect 2377
Install 2378
Camshaft Gear 2378
Remove 2378
Install 2378
Drive Train, Camshaft, and Cylinder Block Repair 2378
Remove 2378
Disassemble 2378
Pistons and Connecting Rods 2378
Crankshaft 2380
Camshaft 2382
Clean and Inspect 2384
Cylinder Block 2384
Honing and Boring 2386
Cylinder Correction (Oversize) 2387
Pistons 2387
Piston Pin 2388
Connecting Rod 2388
Tappets 2389
Crankshaft 2389
Camshaft 2391
Camshaft Bushing 2392
Assemble 2392
Camshaft 2392
Crankshaft 2392
Pistons and Connecting Rods 2393
Install 2395
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 2395
Lubrication System Repair 2398
Engine Oil and Oil Filter Change 2398
Oil Pan 2399
Remove 2399
Install 2399
Oil Suction Tube 2399
Remove 2399
Clean 2400
Install 2400
Oil Pump 2400
Remove 2400
Clean and Inspect 2401
Outer Rotor Outside Clearance 2401
Outer Rotor to Inner Rotor Tip Clearance 2402
Outer Rotor Side Clearance 2402
Rotor Shaft Clearance 2402
Install 2402
Fuel System Repair 2403
Fuel Injectors 2403
Remove 2403
Inspect 2403
Clean 2403
Replace 2404
Install 2404
Test 2404
Fuel Injection Pump 2404
Remove 2404
Clean and Inspect 2406
Install 2406
Cooling System Repair 2407
Serpentine Belt 2407
Remove 2407
Inspect 2407
Install 2407
Adjust 2408
Water Pump 2408
Remove 2408
Install 2410
Thermostat 2411
Remove 2411
Inspect 2411
Install 2412
Flywheel and Flywheel Housing 2413
Flywheel 2413
Remove 2413
Install 2413
Flywheel Housing 2413
Remove 2413
Install 2414
Electrical Equipment Repair 2414
General 2414
Alternator 2414
Remove 2414
Install 2415
Starter 2416
Remove 2416
Install 2416
Engine Specifications 2418
Engine Data 2418
Engine Tuning 2419
Cylinder Head 2419
Intake/Exhaust Valve and Guide 2419
Valve Spring 2420
Rocker Arm and Shaft 2420
Push Rod 2420
Gear Train and Camshaft 2420
Camshaft 2420
Idle Gear Shaft and Bushing 2420
Backlash of Each Gear 2421
Cylinder Block 2421
Crankshaft 2421
Piston 2421
Piston Ring 2422
Connecting Rod 2422
Rod Small End 2422
Tappet 2422
Oil Pump 2423
Engine Oil Pressure 2423
Outer Rotor Outside Clearance 2423
Outer Rotor Side Clearance 2423
Inner Rotor to Cover 2423
Standard Torque Specifications 2424
Standard Torque Chart 2424
Special Torque Specifications 2424
Special Tools 2426
550229998 0600YRM2295 (01 2021) US EN 2439
General 2445
Engine Identification 2445
Major Engine Component Identification 2445
Location of Labels 2446
Cylinder Block Description 2447
Precautions Before Beginning Repair 2448
Exhaust System, SCR, and DPF 2448
Engine Removal and Installation 2449
Cylinder Head Assembly Repair 2449
Valve Covers and Fuel Injectors 2449
Remove 2449
Clean and Inspect 2452
Install 2452
Rocker Arm Assembly 2453
Remove 2453
Disassemble 2454
Clean and Inspect 2454
Push Rods 2454
Rocker Arm Assembly 2454
Assemble 2455
Install 2455
Valve Clearance Adjustments 2455
Cylinder Head Assembly 2456
Remove 2456
Disassemble 2465
Valves and Valve Springs, Remove 2465
Valve Guides, Remove 2466
Clean and Inspect 2466
Cylinder Head 2467
Valve Guides 2467
Valves 2467
Valve Sink 2468
Valve Seat 2468
Valve Springs 2469
Assemble 2469
Valve Guides, Install 2469
Valves and Valve Springs, Install 2470
Install 2471
Timing Gear Case and Timing Gears Repair 2473
Timing Gear Case Cover 2473
Remove 2473
Clean and Inspect 2474
Install 2474
Timing Gears 2475
Crankshaft Gear 2475
Remove 2475
Install 2476
Idler Gear 1 and Idler Gear 2 2476
Remove 2476
Inspect 2477
Install 2478
Idler Gear 3 2478
Remove 2478
Inspect 2478
Install 2478
Camshaft Gear 2478
Remove 2478
Install 2478
Drive Train, Camshaft, and Cylinder Block Repair 2479
Remove 2479
Disassemble 2479
Pistons and Connecting Rods 2479
Crankshaft 2480
Camshaft 2482
Clean and Inspect 2484
Cylinder Block 2484
Honing and Boring 2486
Cylinder Correction (Oversize) 2487
Pistons 2487
Piston Pin 2488
Connecting Rod 2488
Tappets 2489
Crankshaft 2489
Camshaft 2491
Camshaft Bushing 2492
Assemble 2492
Camshaft 2492
Crankshaft 2492
Pistons and Connecting Rods 2493
Install 2495
Angular Deviation Procedure 2495
Lubrication System Repair 2498
Engine Oil and Oil Filter Change (Standard Oil Filter) 2498
Engine Oil and Oil Filter Change (Remote Oil Filter) 2498
Oil Pan 2499
Remove 2499
Install 2499
Oil Suction Tube 2500
Remove 2500
Clean 2500
Install 2500
Oil Pump 2500
Remove 2500
Clean and Inspect 2501
Inner Rotor and Outer Rotor Clearance 2501
Outer Rotor and Pump Body Clearance 2502
Rotor and Cover Clearance 2502
Rotor Shaft Clearance 2502
Install 2502
Remote Oil Filter 2503
Remove 2503
Clean and Inspect 2505
Install 2505
Fuel System Repair 2506
Fuel Injectors 2506
Remove 2506
Inspect 2506
Clean 2506
Replace 2506
Install 2507
Test 2507
Fuel Injection Pump 2507
Remove 2507
Clean and Inspect 2510
Install 2511
Cooling System Repair 2512
Serpentine Belt 2512
Remove 2512
Inspect 2512
Install 2512
Adjust 2512
Water Pump 2513
Remove 2513
Install 2514
Thermostat 2515
Remove 2515
Inspect 2516
Install 2516
Flywheel and Flywheel Housing 2518
Flywheel 2518
Remove 2518
Install 2518
Flywheel Housing 2518
Remove 2518
Install 2518
Electrical Equipment Repair 2519
Alternator 2519
Remove 2519
Install 2520
Starter 2521
Remove 2521
Install 2521
Engine Specifications 2523
Engine Data 2523
Engine Tuning 2525
Cylinder Head 2525
Intake/Exhaust Valve and Guide 2526
Valve Spring 2526
Rocker Arm and Shaft 2526
Push Rod 2526
Gear Train and Camshaft 2527
Camshaft 2527
Idle Gear Shaft and Bushing 2527
Backlash of Each Gear 2527
Cylinder Block 2527
Crankshaft 2528
Piston 2528
Piston Ring 2528
Connecting Rod 2529
Rod Small End 2529
Tappet 2529
Oil Pump 2529
Engine Oil Pressure 2529
Inner and Outer Rotor Clearance 2529
Outer Rotor and Pump Body 2529
Rotor and Cover 2530
Standard Torque Specifications 2530
Standard Torque Chart 2530
Special Torque Specifications 2531
Special Tools 2532