Yale G878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GLP70VX, GDP70VX, GP70VXS6, GP70VXS9, ) Service Manual

Yale Forklift G878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GLP70VX, GDP70VX, GP70VXS6, GP70VXS9, GP70SVX Europe) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift G878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GLP70VX, GDP70VX, GP70VXS6, GP70VXS9, GP70SVX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2782
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift G878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GLP70VX, GDP70VX, GP70VXS6, GP70VXS9, GP70SVX Europe) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524223769 2200YRM1128 (01 2023) US EN 23
Series Code / Model Designation Reference Table 31
General 33
Deutsch Crimping Tool 34
How to Strip a Wire for Use With Deutsch Crimping Tool 34
How to Crimp With the Deutsch Crimping Tool 35
Calibration Test for the Deutsch Crimping Tool 37
Deutsch Connectors 39
DT, DTM, and DTP Series Connectors 39
HD Series Connectors 82
Metri-Pack Connectors 104
Remove and Install 104
Micro-Pack Connectors 107
Weather-Pack Connectors 108
AMPSEAL Crimping Tools 110
AMP Hand Crimping Tool With Certi-Crimp 110
Description 110
Stripping Wire for Use with AMP Hand Crimping Tool 111
Insulation Crimp Adjustment 112
Maintenance and Inspection for AMP Hand Crimping Tool 112
AMP Hand Crimping Tool 112
Crimp Height Inspection 112
How to use AMP Hand Crimping Tool 113
AMP Pro-Crimper II Tool 113
Description 113
Remove and Install Die Set and Locator Assembly 114
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 114
Contact Support Adjustment 115
Crimp Height Adjustment 116
Maintenance and Inspection Procedures 116
PRO-CRIMPER II Tool 116
Crimp Height Inspection 116
How to Use AMP PRO-CRIMPER II Tool 117
AMPSEAL Connector Assemblies 118
Description for Plug Connector Assembly 118
Seal Plug 119
Contact Crimping 119
Description for Plug Connector and Header Assembly 124
Voltage Reading 127
Seal Plug 127
Contact Crimping 127
AMP Superseal 1 5 Crimping Tools 134
Mini Mic Receptacle and Tab Contacts 134
Description 134
Crimping Conditions and Measurements 134
Insertion of Rubber Seal on Cable 136
AMP Hand Application Tool 141
Description 141
Maintenance and Inspection 141
Crimp Height Inspection 141
Crimp Height Adjustment 142
How to Use AMP Hand Application Tool 142
AMP Pro-Crimper II Tool 143
Description 143
Remove and Install Die Set and Locator Assembly 143
Adjustments 144
Contact Support 144
Crimp Height 145
Inspections and Maintenance 146
Crimp Height Inspection 146
Visual Inspection 146
Maintenance 147
How to Use Pro-Crimper II Tool 147
AMP Superseal 1 5 Connector Assemblies 148
Description 148
Repair and Maintenance 155
Panel Mount Option 155
AMP Fastin-Faston Hand Tools 156
Description – AMP Double Action Hand Tool 156
Maintenance and Inspection Procedures 156
Daily Maintenance 156
Periodic Tool Inspection 157
Lubrication 157
Visual Inspection 157
Crimp Height Inspection 157
Certi-Crimp Ratchet Inspection 158
How to Use AMP Double Action Hand Tool 159
Description – AMP Extraction Tool 160
Maintenance and Inspection 161
How to Use AMP Extraction Tool 161
AMP Fastin-Faston Receptacles and Housings 163
Description 163
Wire Repair 171
Wire Splicing Requirements 171
Deutsch Jiffy Splice 172
Twisted/Shielded Cable and Leads Repair 178
Special Tools 180
524223769 2200YRM1128 (07 2020) UK EN 189
Series Code / Model Designation Reference Table 195
General 198
Deutsch Crimping Tool 198
How to Strip a Wire for Use With Deutsch Crimping Tool 198
How to Crimp With the Deutsch Crimping Tool 199
Calibration Test for the Deutsch Crimping Tool 201
Deutsch Connectors 203
DT, DTM, and DTP Series Connectors 203
HD Series Connectors 245
Metri-Pack Connectors 268
Remove and Install 268
Micro-Pack Connectors 270
Weather-Pack Connectors 271
AMPSEAL Crimping Tools 273
AMP Hand Crimping Tool With Certi-Crimp 273
Description 273
Stripping Wire for Use with AMP Hand Crimping Tool 273
Insulation Crimp Adjustment 274
Maintenance and Inspection for AMP Hand Crimping Tool 274
AMP Hand Crimping Tool 274
Crimp Height Inspection 274
How to use AMP Hand Crimping Tool 275
AMP Pro-Crimper II Tool 275
Description 275
Remove and Install Die Set and Locator Assembly 276
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 277
Contact Support Adjustment 277
Crimp Height Adjustment 278
Maintenance and Inspection Procedures 278
PRO-CRIMPER II Tool 278
Crimp Height Inspection 278
How to Use AMP PRO-CRIMPER II Tool 279
AMPSEAL Connector Assemblies 280
Description for Plug Connector Assembly 280
Seal Plug 281
Contact Crimping 281
Description for Plug Connector and Header Assembly 286
Voltage Reading 288
Seal Plug 288
Contact Crimping 288
AMP Superseal 1 5 Crimping Tools 295
Mini Mic Receptacle and Tab Contacts 295
Description 295
Crimping Conditions and Measurements 295
Insertion of Rubber Seal on Cable 297
AMP Hand Application Tool 302
Description 302
Maintenance and Inspection 302
Crimp Height Inspection 302
Crimp Height Adjustment 303
How to Use AMP Hand Application Tool 303
AMP Pro-Crimper II Tool 304
Description 304
Remove and Install Die Set and Locator Assembly 305
Adjustments 305
Contact Support 305
Crimp Height 306
Inspections and Maintenance 307
Crimp Height Inspection 307
Visual Inspection 307
Maintenance 308
How to Use Pro-Crimper II Tool 308
AMP Superseal 1 5 Connector Assemblies 309
Description 309
Repair and Maintenance 316
Panel Mount Option 316
AMP Fastin-Faston Hand Tools 317
Description – AMP Double Action Hand Tool 317
Maintenance and Inspection Procedures 317
Daily Maintenance 317
Periodic Tool Inspection 318
Lubrication 318
Visual Inspection 318
Crimp Height Inspection 318
Certi-Crimp Ratchet Inspection 319
How to Use AMP Double Action Hand Tool 320
Description – AMP Extraction Tool 321
Maintenance and Inspection 321
How to Use AMP Extraction Tool 322
AMP Fastin-Faston Receptacles and Housings 323
Description 323
Wire Repair 330
Wire Splicing Requirements 330
Deutsch Jiffy Splice 331
Twisted/Shielded Cable and Leads Repair 336
Special Tools 339
524223770 2200YRM1130 (03 2020) UK EN 347
General 351
Description 351
Dash Display Menu Access 351
Menu Navigation 352
Standard Display 352
Main Menu 352
Passwords Menu 353
Password Administration 353
Add Password 353
Delete Password 354
Edit Password 354
Other Password Functions 355
Operator Passwords – Enable/Disable 355
Password Time-Out Delay 355
Passwords – Number Wrong to Disable 356
Lockout Reset Password 356
View Password Log 357
View Versions 358
VSM Versions 358
Dash Display Versions 359
Engine Controller Version 360
Transmission (Xmsn) Controller Version 361
Truck Serial Number 362
Diagnostics 363
View Fault Log 363
Set Travel and Braking 364
Speed Limit 364
Acceleration Rate 365
Auto-Deceleration Rate 365
Set Power Reversal Rate 366
Set Inching/Brake Overlap 367
Setup Display Menu 368
Set Operator Language 368
Set Units 369
Set Time Format (12/24 Hour) 369
Set Daylight Saving Time 369
Set Time 372
Set Date Format 373
Set Date 373
Setup Hydraulics 374
Return to Set Tilt Delay/On/Off 374
Setup General Items 375
Light Shutdown Time-Out 375
Impact Sensor – Enable/Disable 376
Impact Sensor – Soft Impact Settings 377
Impact Sensor – Hard Impact Settings 378
Adjust Impact Sensor Settings 378
Initial Adjustment of Soft and Hard Impact Settings 380
Readjustment of Soft and Hard Impact Settings 380
Impact Sensor – Impact Alarm/Shutdown Reset 381
Impact Sensor – Alarm Time Duration and Deactivation 382
Impact Sensor – View Impact Event Log 383
Engine Mode Indicator 384
Generation 1 (ECO-eLo ONLY) 384
Generation 2 385
Operator Checklist 386
Operator Checklist Off-On Mode 386
Edit Operator Checklist 386
Set Operator Checklist Expiration 387
View Checklist Log 387
Clear Operator Checklist Log 388
Clear Operator Checklist Fault 388
Calibrations 389
Set Tilt Stop Point 389
Calibrate Loaded Weight 389
524223771 2200YRM1131 (03 2020) UK EN 391
Series Code / Model Designation Reference Table 397
General 399
Description 399
Dash Display Menu Access 399
Menu Navigation 400
Main Menu 400
Passwords 401
Adding Passwords 401
Hourmeters 403
View Versions 404
VSM Versions 404
Dash Display Versions 405
Engine Controller Version 406
Transmission (Xmsn) Controller Version 407
Truck Serial Number 408
Truck Configuration 409
Diagnostics 410
Clear Fault Log 410
View Fault Log 411
No-Run Data Display 412
Engine Accelerator and Throttle Data Display 412
Engine Speeds and Governor Data Display 413
Engine Fuel and Emissions Data Display 414
Engine General Data Display 416
XMSN/Brake Data Display 417
Hydraulic Data Display 420
General Truck Data Display 422
Set Travel and Braking 423
Speed Limit 423
Acceleration Rate 424
Auto-Deceleration Rate 425
Set Power Reversal Rate 425
Set Inching/Brake Overlap 426
Setup Hydraulics 426
Lift Maximum Speed 427
Lower Maximum Speed 427
Tilt Maximum Speed 428
Auxiliary Function One, Direction A, Maximum Speed 430
Auxiliary Function One, Direction B, Maximum Speed 432
Auxiliary Function Two, Direction A, Maximum Speed 432
Auxiliary Function Two, Direction B, Maximum Speed 433
Auxiliary Function Three, Direction A, Maximum Speed 434
Auxiliary Function Three, Direction B, Maximum Speed 434
Lift/Lower Ramp Rate 435
Hydraulic Auxiliary Ramp Rate 435
Return to Set Tilt Delay/On/Off 436
Hydraulic Input Device 437
Auxiliary Solenoid 437
Dual Function 438
Setup Display 439
Set Service Language 439
Setup General Items 439
Motion Alarm Activation Type 440
Light Shutdown Time-Out 441
Restore Default Settings 441
Restore Engine Controller Default Calibration 442
Impact Sensor – Enable/Disable 442
Impact Sensor – Soft Impact Settings 443
Impact Sensor – Hard Impact Settings 444
Adjust Impact Sensor Settings 445
Initial Adjustment of Soft and Hard Impact Settings 447
Readjustment of Soft and Hard Impact Settings 447
Impact Sensor – Impact Alarm/Shutdown Reset 448
Impact Sensor – Alarm Time Duration and Deactivation 449
Impact Sensor – View Impact Event Log 450
Engine Mode Indicator 450
Generation 1 (ECO-eLo ONLY) 450
Generation 2 451
Diesel Particulate Filter (DPF) Display 452
General Description 452
Passive Regeneration Only 452
Regeneration Level 0 452
Auto/Active Regeneration Inhibited 453
Auto/Active Regeneration 453
Regeneration Level 1 453
Parked Regeneration Request 454
Regeneration Level 2 454
Warning Level 454
Regeneration Level 3 454
Service Level 455
Regeneration Level 4 455
Display, Diesel Particulate Filter (DPF), Revised 455
Operator Interface 455
Refer to Operator Manual 455
CAN Communication Lost 456
Passive Regeneration Only 456
Regeneration Level 0 456
Auto/Active Regeneration Inhibited 456
Auto/Active Regeneration 457
Regeneration Level 1 457
Idle-up Auto/Active Regeneration 457
Parked Regeneration Request 457
Regeneration Level 2 457
Warning Level 459
Regeneration Level 3 459
Service Level 459
Regeneration Level 4 459
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 459
Display, Diesel Particulate Filter (DPF), Stage V Engine 459
Operator Interface 460
Refer to Operator Manual 460
CAN Communication Lost 460
Passive Regeneration Only 460
Regeneration Level 0 460
Auto/Active Regeneration Inhibited 461
Auto/Active Regeneration 461
Regeneration Level 1 461
Idle-up Auto/Active Regeneration 462
Parked Regeneration Request 462
Regeneration Level 2 462
Warning Level 463
Regeneration Level 3 463
Service Level 464
Regeneration Level 4 464
Stage V Content 464
Emissions System Malfunction 464
Ash Load 464
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 465
Operator Interface 465
Refer to Operator Manual 465
CAN Communication Lost 466
Passive Regeneration Only 466
Regeneration Level 0 466
Auto/Active Regeneration Inhibited 466
Auto/Active Regeneration 467
Regeneration Level 1 467
Idle-up Auto/Active Regeneration 467
Parked Regeneration Request 467
Regeneration Level 2 467
Warning Level 469
Regeneration Level 3 469
Service Level 469
Regeneration Level 4 469
Calibrations 470
Calibrate Transmission Valve 472
Set Tilt Stop Point 472
Calibrate Loaded Weight 472
Calibrate Travel Speed Sensor 473
Calibrate Mazda LP and Gas Accelerator Pedal 473
524223780 8000YRM1134 (03 2020) UK EN 475
Series Code / Model Designation Reference Table 481
Description 483
Proc_Cal_001: Service Password Entry 485
When to Perform 485
Why Perform 485
How to Perform 485
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 486
When to Perform 486
Calibration Order 486
Why Perform 486
How to Perform 487
Proc_Cal_003: Save and Exit 488
When to Perform 488
Why Perform 488
How to Perform 488
Proc_Cal_004: Lift Valve Output Threshold 489
When to Perform 489
Calibration Order 489
Why Perform 489
How to Perform 490
Proc_Cal_005: Lower Valve Output Threshold 492
When to Perform 492
Calibration Order 492
Why Perform 492
How to Perform 492
Proc_Cal_006: Tilt Back Valve Output Threshold 495
When to Perform 495
Calibration Order 495
Why Perform 495
How to Perform 495
Proc_Cal_007: Tilt Forward Valve Output Threshold 498
When to Perform 498
Calibration Order 498
Why Perform 498
How to Perform 498
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 501
When to Perform 501
Calibration Order 501
Why Perform 501
How to Perform 501
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 504
When to Perform 504
Calibration Order 504
Why Perform 504
How to Perform 504
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 507
When to Perform 507
Calibration Order 507
Why Perform 507
How to Perform 507
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 510
When to Perform 510
Calibration Order 510
Why Perform 510
How to Perform 510
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 513
When to Perform 513
Calibration Order 513
Why Perform 513
How to Perform 513
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 516
When to Perform 516
Calibration Order 516
Why Perform 516
How to Perform 516
Proc_Cal_014: Load Weight Zero Point 520
When to Perform 520
Calibration Order 520
Why Perform 520
How to Perform 520
Proc_Cal_015: Loaded Weight Calibration 522
When to Perform 522
Calibration Order 522
Why Perform 522
How to Perform 522
Proc_Cal_016: Transmission Valve Calibration 525
Applicable System/Option 525
When to Perform 525
Calibration Order 525
Why Perform 525
How to Perform 525
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 527
Applicable System/Option 527
When to Perform 527
Calibration Order 527
Why Perform 527
How to Perform 527
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 529
Applicable System/Option 529
When to Perform 529
Calibration Order 529
Why Perform 529
How to Perform 530
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 531
Required Tools 531
When to Perform 531
Calibration Order 531
Why Perform 532
How to Perform 532
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 533
When to Perform 533
Why Perform 533
How to Perform 533
Proc_Cal_026: Travel Speed Calibration 535
When to Perform 535
Calibration Order 535
Why Perform 535
How to Perform 535
524288194 1300YRM1317 (03 2020) UK EN 539
Transmission Repair 543
Remove 543
Torque Converter, Remove 543
Disassemble 544
Clean and Inspect 593
Housings 593
Oil Seals and Gaskets 593
Bearings 593
Gears and Shafts 594
Assemble 594
Torque Converter, Install 635
Install 636
Control Valve Repair 637
Remove 637
Disassemble 637
Clean 639
Inspect 639
Assemble 639
Install 640
Torque Specification 641
524294873 1300YRM1343 (11 2019) UK EN 643
Transmission Repair 647
Remove 647
Torque Converter, Remove 647
Disassemble 648
Clean and Inspect 688
Housings 688
Oil Seals and Gaskets 688
Bearings 689
Gears and Shafts 689
Assemble 689
Torque Converter, Install 727
Install 728
Control Valve Repair 729
Remove 729
Disassemble 729
Control Valve Assembly 729
Control Valve Body 729
Clean 732
Inspect 732
Assemble 732
Control Valve Body 732
Control Valve Assembly 732
Install 733
Torque Specification 735
524296605 1400YRM1344 (03 2020) UK EN 737
General 741
Identification Plate 741
Drive Axle Removal 741
Planetary Reduction Gear Repair 753
Clean and Inspect 763
Brake Repair 772
Clean and Inspect 785
Wet Brake Noise Reduction 795
General 795
Adding Additive To Transmission 796
Differential Repair 797
Clean and Inspect 808
Bevel Pinion 820
Clean and Inspect 824
Drive Axle Installation 834
Special Tools 845
Torque Specifications 846
550055279 0600YRM1579 (06 2021) US EN 849
General 855
Engine Identification 855
Major Engine Component Identification 855
Location of Labels 855
Crankcase Description 856
Engine Removal and Installation 857
Cylinder Head Assembly Repair 858
Valve Covers and Fuel Injectors 858
Remove 858
Clean and Inspect 861
Install 862
Rocker Arm Assembly 864
Remove 864
Disassemble 865
Clean and Inspect 865
Push Rods 865
Rocker Arm Assembly 866
Assemble 866
Install 866
Valve Clearance Adjustments 867
Cylinder Head Assembly 868
Remove 868
Disassemble 875
Valves and Valve Springs, Remove 875
Valve Guides, Remove 877
Clean and Inspect 877
Cylinder Head 878
Valve Guides 878
Valves 878
Valve Sink 879
Valve Seat 879
Valve Springs 879
Assemble 880
Valve Guides, Install 880
Valves and Valve Springs, Install 881
Install 881
Timing Gear Case and Timing Gears Repair 885
Timing Gear Case Cover 885
Remove 885
Clean and Inspect 885
Install 885
Timing Gears 886
Crankshaft Gear 887
Remove 887
Install 887
Idler Gear 887
Remove 887
Inspect 888
Install 888
Camshaft Gear 888
Remove 888
Install 889
Timing Gear Case 889
Remove 889
Clean and Inspect 890
Install 890
Drive Train, Camshaft, and Cylinder Block Repair 891
Remove 891
Disassemble 891
Pistons and Connecting Rods 891
Crankshaft 892
Camshaft 894
Clean and Inspect 895
Cylinder Block 896
Honing and Boring 898
Cylinder Correction (Oversize) 899
Pistons 899
Piston Pin 900
Connecting Rod 900
Tappets 900
Crankshaft 901
Camshaft 903
Camshaft Bushing 904
Assemble 904
Camshaft 904
Crankshaft 904
Pistons and Connecting Rods 904
Install 906
Lubrication System Repair 908
Engine Oil and Oil Filter Change 908
Oil Pan 909
Remove 909
Install 910
Oil Suction Tube 910
Remove 910
Clean 911
Install 911
Oil Pump 911
Remove 911
Clean and Inspect 911
Outer Rotor Outside Clearance 912
Outer Rotor to Inner Rotor Tip Clearance 912
Outer Rotor Side Clearance 912
Rotor Shaft Clearance 913
Install 913
Fuel System Repair 914
Fuel Injectors 914
Remove 914
Inspect 914
Clean 914
Replace 914
Install 914
Electronic Throttle System 915
Remove 915
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) 918
Bearing Replacement 919
Install 919
Adjustment 920
Fuel Injection Pump 921
Remove 921
Disassemble 924
Clean and Inspect 926
Assemble 926
Install 927
Cooling System Repair 929
Serpentine Belt 929
Remove 929
Inspect 929
Install 929
Serpentine Belt, Adjustment 929
Water Pump 930
Remove 930
Install 932
Thermostat 933
Remove 933
Inspect 934
Install 934
Flywheel and Flywheel Housing 936
Flywheel 936
Remove 936
Install 936
Flywheel Housing 936
Remove 936
Install 936
Electrical Equipment Repair 937
Alternator 937
Remove 937
Install 938
Starter 939
Remove 939
Install 939
Engine Specifications 940
Engine Data 940
Engine Tuning 940
Cylinder Head 941
Intake/Exhaust Valve and Guide 941
Valve Spring 942
Rocker Arm and Shaft 942
Push Rod 942
Gear Train and Camshaft 942
Camshaft 942
Idle Gear Shaft and Bushing 942
Backlash of Each Gear 943
Cylinder Block 943
Crankshaft 943
Piston 943
Piston Ring 944
Connecting Rod 944
Rod Small End 944
Tappet 944
Oil Pump 945
Engine Oil Pressure 945
Outer Rotor Outside Clearance 945
Outer Rotor Side Clearance 945
Inner Rotor to Cover 945
Standard Torque Specifications 946
Standard Torque Chart 946
Special Torque Specifications 947
Special Tools 949
550073240 1900YRM1620 (01 2023) US EN 959
Proper Flushing after Major Hydraulic Repairs 965
Introduction 965
The Phases of Wear 965
Causes of Hydraulic System Failure 965
Progression of Contaminant Caused Hydraulic System Failure 966
Hydraulic System Flushing Techniques 966
Double Oil and Filter Change 966
Mechanical Cleaning 967
Cleaning of Components 967
How to Clean Tubes and Hoses 967
Filter Caddy 967
Start-Up Procedure for Cleaned System 968
Contaminated Oil Coolers 968
Additional Filter Caddy Functions 969
How to Handle Different Fluids 969
Water Removal Filters 969
Fluid Conditioning and System Flushing Procedures 970
Operation of the Filter Caddy 970
Filter Caddy operation 970
Fluid Conditioning Procedure 970
Filter Caddy Start-Up 971
System Flushing Procedure 971
Component Cleaning Procedure 972
Reservoir Cleaning Procedure 972
Cylinder Cleaning Procedure 972
Hose and Tube Cleaning Procedure 972
Valve Cleaning Procedure 973
Front-End Attachment Cleaning Procedure 974
System Flushing Procedure 974
Filter Caddy Start-Up 975
System Start-Up and Flushing 975
Reservoir Fluid Cleaning Times 976
Dealing With Different Fluid Types 977
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 977
Filter Caddy Maintenance 977
Servicing the Strainer 977
DC Motor 977
Hydraulic Oil Sampling Method and Procedure 978
Hydraulic Oil Sampling Method 978
Objective 978
General Guidelines 978
Synopsis 979
Hydraulic Oil Analysis Report Guidelines 980
Sampling Conditions 980
Equipment 980
Sampling Procedure 981
Hydraulic Oil Sampling 981
Sample Labeling 981
Results Documentation 981
550073240 1900YRM1620 (03 2020) UK EN 983
Proper Flushing after Major Hydraulic Repairs 987
Introduction 987
The Phases of Wear 987
Causes of Hydraulic System Failure 987
Progression of Contaminant Caused Hydraulic System Failure 988
Hydraulic System Flushing Techniques 988
Double Oil and Filter Change 988
Mechanical Cleaning 989
Cleaning of Components 989
How to Clean Tubes and Hoses 989
Filter Caddy 989
Start-Up Procedure for Cleaned System 990
Contaminated Oil Coolers 990
Additional Filter Caddy Functions 990
How to Handle Different Fluids 990
Water Removal Filters 991
Fluid Conditioning and System Flushing Procedures 991
Operation of the Filter Caddy 991
Filter Caddy operation 991
Fluid Conditioning Procedure 992
Filter Caddy Start-Up 992
System Flushing Procedure 993
Component Cleaning Procedure 993
Reservoir Cleaning Procedure 993
Cylinder Cleaning Procedure 993
Hose and Tube Cleaning Procedure 994
Valve Cleaning Procedure 994
Front-End Attachment Cleaning Procedure 995
System Flushing Procedure 995
Filter Caddy Start-Up 996
System Start-Up and Flushing 996
Reservoir Fluid Cleaning Times 997
Dealing With Different Fluid Types 997
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 997
Filter Caddy Maintenance 998
Servicing the Strainer 998
DC Motor 998
Hydraulic Oil Sampling Method and Procedure 998
Hydraulic Oil Sampling Method 998
Objective 998
General Guidelines 998
Synopsis 999
Hydraulic Oil Analysis Report Guidelines 1000
Sampling Conditions 1001
Equipment 1001
Sampling Procedure 1001
Hydraulic Oil Sampling 1001
Sample Labeling 1002
Results Documentation 1002
550118414 1900YRM1897 (03 2020) UK EN 1005
Series Code / Model Designation Reference Table 1009
General 1009
Hydraulic Gear Pump Assembly Repair 1011
Remove 1011
Disassemble 1013
Clean 1015
Inspect 1015
Assemble 1015
Install 1015
Hydraulic Gear Pump Specifications 1017
Variable Displacement Pump Repair 1018
Remove 1018
Disassemble 1021
Clean 1023
Inspect 1023
Assemble 1023
Install 1023
Variable Displacement Pump Checks and Adjustments 1025
Margin Pressure Check 1025
Flow Compensator Adjustment 1026
Pressure Compensator Adjustment 1026
Variable Displacement Pump Specifications 1027
Torque Specifications 1028
Hydraulic Gear Pump 1028
Variable Displacement Pump 1028
550118415 2000YRM1898 (03 2020) UK EN 1031
Series Code / Model Designation Reference Table 1035
General 1036
Electro-Hydraulic Main Control Valve 1036
Description 1036
Remove 1042
Electro-Hydraulic Control Valve Sections 1045
General 1045
Outlet Control Valve Section 1045
Remove 1045
Disassemble 1045
Clean 1048
Inspect 1048
Assemble 1048
Install 1049
Auxiliary Control Valve Sections 1049
Remove 1049
Disassemble 1051
Clean 1051
Inspect 1052
Assemble 1052
Install 1053
Tilt Control Valve Section 1053
Remove 1053
Disassemble 1053
Clean 1054
Inspect 1054
Assemble 1055
Install 1055
Lift/Lower Control Valve Section 1055
Remove 1055
Disassemble 1055
Clean 1057
Inspect 1057
Assemble 1057
Install 1057
Transition Section 1057
Remove 1057
Disassemble 1058
Clean 1058
Inspect 1058
Assemble 1059
Install 1059
Install 1059
Manual Main Control Valve 1061
Description 1061
Remove 1063
OPS Solenoid Assembly 1067
General 1067
Remove 1068
Clean and Inspect 1070
Install 1070
Manual Control Valve Sections 1071
General 1071
Outlet Control Valve Section 1071
Remove 1071
Disassemble 1071
Clean 1073
Inspect 1073
Assemble 1073
Install 1073
Auxiliary Control Valve Sections 1074
Remove 1074
Disassemble 1074
Clean 1076
Inspect 1076
Assemble 1076
Install 1076
Lift/Tilt Control Valve Section 1077
Remove 1077
Disassemble 1077
Clean 1079
Inspect 1080
Assemble 1080
Install 1081
Install 1081
Pressure Relief Valve Check and Adjustment 1084
Primary Relief Valve 1084
Secondary Relief Valve 1085
Steering Control Unit Repair 1088
Steering Control Unit, Remove 1088
Steering Control Unit, Disassemble 1089
Steering Control Unit, Clean 1091
Steering Control Unit, Inspect 1091
Steering Control Unit, Assemble 1091
Relief Valve, Disassemble 1092
Relief Valve, Clean 1092
Relief Valve, Inspect 1093
Relief Valve, Assemble 1093
Steering Control Unit, Install 1093
550118420 8000YRM1904 (10 2020) UK EN 1097
General Information About Diagrams and Schematics 1101
Symbol Definitions 1102
Diagrams Manual Applications 1103
Diagrams and Schematics 1105
550118555 0100YRM1892 (03 2020) UK EN 1215
General 1221
Cab Replacement for 4-5 5 Ton Lift Trucks 1221
Remove 1221
Install 1232
Cab Replacement for 6-9 Ton Lift Trucks 1234
Remove 1234
Door Assemblies for 4-5 5 Ton Lift Trucks 1240
Right Side Door Assembly 1240
Remove 1240
Disassemble 1244
Door Cover With Heater Unit 1244
Door Cover With Air Conditioner/Heater Unit 1246
Heater Assembly 1248
Air Conditioner and Heater Unit Assembly 1248
Door Lock Assembly 1249
Windows 1251
Clean 1251
Inspect 1251
Assemble 1251
Windows 1251
Door Lock Assembly 1251
Heater Assembly 1251
Air Conditioner and Heater Unit Assembly 1252
Door Cover With Heater Unit 1252
Door Cover With Air Conditioner and Heater Unit 1252
Install 1252
Left Side Door Assembly 1253
Remove 1253
Disassemble 1253
Door Cover 1253
Door Lock Assembly 1253
Windows 1254
Clean 1254
Inspect 1254
Assemble 1254
Windows 1254
Door Lock Assembly 1254
Door Cover 1254
Install 1254
Door Assemblies for 6-9 Ton Lift Trucks 1255
Right and Left Side Door Assemblies 1255
Remove 1255
Disassemble 1255
Door Cover 1255
Door Lock Assembly 1256
Windows 1258
Clean 1258
Inspect 1258
Assemble 1258
Windows 1258
Door Lock Assembly 1258
Door Cover 1259
Install 1259
Window Replacement 1259
General 1259
Remove Door Windows for 4-5 5 Ton Lift Trucks 1259
Install Door Windows for 4-5 5 Ton Lift Trucks 1261
Remove Door Windows for 6-9 Ton Lift Trucks 1261
Install Door Windows for 6-9 Ton Lift Trucks 1263
Window Wipers Replacement 1263
General 1263
Front Wiper Assembly and Motor 1263
Remove 1263
Install 1265
Rear Wiper Assembly and Motor 1265
Remove, for 4-5 5 Ton Lift Trucks 1265
Install for 4-5 5 Ton Lift Trucks 1268
Remove for 6-9 Ton Lift Trucks 1268
Install for 6-9 Ton Lift Truck 1270
Heater Replacement 1271
Remove for 6-9 Ton Lift Trucks 1271
Install for 6-9 Ton Lift Trucks 1276
Heater and Air Conditioner Assembly 1277
Air Conditioner Condenser Unit 1277
Remove 1277
Install 1279
Air Conditioner Receiver/Drier Unit 1279
Remove 1279
Install 1281
Air Conditioner Compressor 1281
Light Replacement 1282
Work Lights (Front and Rear) 1282
Remove 1282
Install 1284
Strobe Light 1284
Remove 1284
Install 1285
Turn, Stop, Tail, and Backup Light 1285
Remove 1285
Install 1286
Front Marker/Turn Signal Lights 1286
Remove 1286
Install 1286
Display Switches 1287
Electrical Schematics 1289
Optional Equipment 1290
Heavy Duty Pre-Cleaner 1290
Fan 1290
Remove 1290
Install 1292
Mirror 1292
Remove 1292
Install 1292
Rear View Camera 1292
Monitor Removal 1292
Monitor Install 1294
Camera removal 1294
Camera install 1294
Label Replacement 1294
550131845 0100YRM1948 (11 2019) UK EN 1297
General 1301
Description 1301
Side Covers, Seat, Dash, and Hood Replacement 1302
Side Covers 1302
Remove 1302
Install 1302
Seat and Seat Plate 1303
Remove Seat 1303
Remove Seat Plate 1304
Install Seat Plate 1304
Install Seat 1304
Operator Restraint System 1308
Emergency Locking Retractor (ELR) 1308
Seat Plate and Seat Rail Check 1308
Steering Column, Dash, Kick Panel, and Seal Plate 1308
Remove 1308
Install 1311
Hood Support and Door Assembly 1313
Remove 1313
Install 1313
Hood Door Assembly 1318
Remove 1318
Install 1319
Steering Column 1320
Description 1320
Steering Column Repair 1320
Remove 1320
Disassemble 1321
Clean 1322
Inspect 1323
Assemble 1323
Install 1323
LPG Tank and Bracket Assembly 1323
Counterweight Replacement 1323
Remove 1323
Install 1325
Tow Pin, Remove and Install 1326
Overhead Guard Replacement 1326
Remove 1326
Install 1328
Engine Replacement 1328
Remove Engine 1328
Remove Transmission 1349
Remove Engine and Transmission 1352
Install Engine 1355
Install Transmission 1358
Install Engine and Transmission 1360
Throttle Pedal and Cable Adjustment 1363
Exhaust System Repair 1363
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) 1363
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 1363
Kubota 3 8L Diesel Engine w/DPF 1363
Remove 1365
Inspect 1366
Install 1366
Kubota 3 8L Diesel Engine w/DOC 1366
Remove 1368
Inspect 1369
Install 1369
Kubota 3 6L Diesel Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6 GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878) 1370
Remove 1370
Inspect 1371
Install 1371
Diesel Particulate Filter (DPF) 1372
Diesel Particulate Filter 1372
Disassemble 1373
Clean and Inspect 1373
Differential Pressure Pipes and Hoses 1374
Assemble 1375
Diesel Exhaust Fluid System 1375
General 1375
Description and Operation 1375
Selective Catalyst Reducer (SCR) 1377
Remove 1377
Clean and Inspect 1378
Install 1378
DEF Tank 1379
Remove 1379
Clean and Inspect 1381
Install 1381
Cooling System 1382
Description 1382
Hydraulic Filter Assembly Repair 1382
Remove 1382
Install 1383
Fuel and Hydraulic Tanks Repair 1384
Inspect 1384
Clean 1384
Steam Method of Cleaning 1385
Chemical Solution Method of Cleaning 1385
Additional Preparations for Repair 1385
Small Leaks, Repair 1386
Large Leaks, Repair 1386
Preparations for Use After Repair 1386
Safety Labels 1386
550131847 0600YRM1962 (06 2021) US EN 1395
General 1403
Engine Identification 1403
Major Engine Component Identification 1403
Location of Labels 1404
Cylinder Block Description 1404
Precautions Before Beginning Repair 1405
Exhaust System, SCR, and DPF 1406
Engine Removal and Installation 1407
Cylinder Head Assembly Repair 1407
Valve Covers and Fuel Injectors 1407
Remove 1407
Clean and Inspect 1410
Install 1410
Rocker Arm Assembly 1411
Remove 1411
Disassemble 1412
Clean and Inspect 1412
Push Rods 1412
Rocker Arm Assembly 1412
Assemble 1413
Install 1413
Valve Clearance Adjustments 1413
Cylinder Head Assembly 1414
Remove 1414
Disassemble 1423
Valves and Valve Springs, Remove 1423
Valve Guides, Remove 1424
Clean and Inspect 1424
Cylinder Head 1425
Valve Guides 1425
Valves 1425
Valve Sink 1426
Valve Seat 1426
Valve Springs 1427
Assemble 1427
Valve Guides, Install 1427
Valves and Valve Springs, Install 1428
Install 1429
Timing Gear Case and Timing Gears Repair 1432
Timing Gear Case Cover 1432
Remove 1432
Clean and Inspect 1432
Install 1433
Timing Gears 1434
Crankshaft Gear 1434
Remove 1434
Install 1435
Idler Gear 1 and Idler Gear 2 1435
Remove 1435
Inspect 1437
Install 1437
Idler Gear 3 1437
Remove 1437
Inspect 1437
Install 1437
Camshaft Gear 1438
Remove 1438
Install 1438
Drive Train, Camshaft, and Cylinder Block Repair 1439
Remove 1439
Disassemble 1439
Pistons and Connecting Rods 1439
Crankshaft 1440
Camshaft 1442
Clean and Inspect 1444
Cylinder Block 1444
Honing and Boring 1447
Cylinder Correction (Oversize) 1448
Pistons 1448
Piston Pin 1449
Connecting Rod 1449
Tappets 1450
Crankshaft 1450
Camshaft 1452
Camshaft Bushing 1453
Assemble 1453
Camshaft 1453
Crankshaft 1453
Pistons and Connecting Rods 1453
Install 1455
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 1456
Lubrication System Repair 1459
Engine Oil and Oil Filter Change (Standard Oil Filter) 1459
Engine Oil and Oil Filter Change (Remote Oil Filter) 1460
Oil Pan 1460
Remove 1460
Install 1461
Oil Suction Tube 1461
Remove 1461
Clean 1462
Install 1462
Oil Pump 1462
Remove 1462
Clean and Inspect 1463
Inner Rotor and Outer Rotor Clearance 1463
Outer Rotor and Pump Body Clearance 1464
Rotor and Cover Clearance 1464
Rotor Shaft Clearance 1464
Install 1465
Remote Oil Filter 1465
Remove 1465
Clean and Inspect 1467
Install 1468
Fuel System Repair 1469
Fuel Injectors 1469
Remove 1469
Inspect 1469
Clean 1469
Replace 1469
Install 1470
Test 1470
Fuel Injection Pump 1470
Remove 1470
Clean and Inspect 1474
Install 1474
Cooling System Repair 1475
Serpentine Belt 1475
Remove 1475
Inspect 1475
Install 1475
Adjust 1475
Water Pump 1476
Remove 1476
Install 1477
Thermostat 1478
Remove 1478
Inspect 1479
Install 1479
Flywheel and Flywheel Housing 1481
Flywheel 1481
Remove 1481
Install 1481
Flywheel Housing 1481
Remove 1481
Install 1481
Electrical Equipment Repair 1482
Alternator 1482
Remove 1482
Install 1483
Starter 1484
Remove 1484
Install 1484
Engine Specifications 1486
Engine Data 1486
Engine Tuning 1487
Cylinder Head 1487
Intake/Exhaust Valve and Guide 1488
Valve Spring 1488
Rocker Arm and Shaft 1488
Push Rod 1488
Gear Train and Camshaft 1489
Camshaft 1489
Idle Gear Shaft and Bushing 1489
Backlash of Each Gear 1489
Cylinder Block 1489
Crankshaft 1490
Piston 1490
Piston Ring 1490
Connecting Rod 1491
Rod Small End 1491
Tappet 1491
Oil Pump 1491
Engine Oil Pressure 1491
Inner and Outer Rotor Clearance 1491
Outer Rotor and Pump Body 1491
Rotor and Cover 1492
Standard Torque Specifications 1492
Standard Torque Chart 1492
Special Torque Specifications 1493
Special Tools 1494
550131847 0600YRM1962 (11 2019) UK EN 1507
General 1513
Engine Identification 1513
Major Engine Component Identification 1513
Location of Labels 1513
Cylinder Block Description 1514
Precautions Before Beginning Repair 1515
Exhaust System, SCR, and DPF 1515
Engine Removal and Installation 1516
Cylinder Head Assembly Repair 1516
Valve Covers and Fuel Injectors 1516
Remove 1516
Clean and Inspect 1519
Install 1519
Rocker Arm Assembly 1520
Remove 1520
Disassemble 1521
Clean and Inspect 1521
Push Rods 1521
Rocker Arm Assembly 1521
Assemble 1522
Install 1522
Valve Clearance Adjustments 1522
Cylinder Head Assembly 1524
Remove 1524
Disassemble 1532
Valves and Valve Springs, Remove 1532
Valve Guides, Remove 1533
Clean and Inspect 1533
Cylinder Head 1534
Valve Guides 1534
Valves 1534
Valve Sink 1535
Valve Seat 1535
Valve Springs 1536
Assemble 1536
Valve Guides, Install 1536
Valves and Valve Springs, Install 1537
Install 1538
Timing Gear Case and Timing Gears Repair 1540
Timing Gear Case Cover 1540
Remove 1540
Clean and Inspect 1541
Install 1541
Timing Gears 1542
Crankshaft Gear 1542
Remove 1542
Install 1543
Idler Gear 1 and Idler Gear 2 1543
Remove 1543
Inspect 1544
Install 1545
Idler Gear 3 1545
Remove 1545
Inspect 1545
Install 1545
Camshaft Gear 1545
Remove 1545
Install 1545
Drive Train, Camshaft, and Cylinder Block Repair 1546
Remove 1546
Disassemble 1546
Pistons and Connecting Rods 1546
Crankshaft 1547
Camshaft 1549
Clean and Inspect 1551
Cylinder Block 1551
Honing and Boring 1553
Cylinder Correction (Oversize) 1554
Pistons 1554
Piston Pin 1555
Connecting Rod 1555
Tappets 1556
Crankshaft 1556
Camshaft 1558
Camshaft Bushing 1559
Assemble 1559
Camshaft 1559
Crankshaft 1559
Pistons and Connecting Rods 1560
Install 1562
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 1562
Lubrication System Repair 1565
Engine Oil and Oil Filter Change (Standard Oil Filter) 1565
Engine Oil and Oil Filter Change (Remote Oil Filter) 1566
Oil Pan 1566
Remove 1566
Install 1567
Oil Suction Tube 1567
Remove 1567
Clean 1568
Install 1568
Oil Pump 1568
Remove 1568
Clean and Inspect 1569
Inner Rotor and Outer Rotor Clearance 1569
Outer Rotor and Pump Body Clearance 1570
Rotor and Cover Clearance 1570
Rotor Shaft Clearance 1570
Install 1571
Remote Oil Filter 1571
Remove 1571
Clean and Inspect 1573
Install 1573
Fuel System Repair 1574
Fuel Injectors 1574
Remove 1574
Inspect 1574
Clean 1574
Replace 1574
Install 1575
Test 1575
Fuel Injection Pump 1575
Remove 1575
Clean and Inspect 1578
Install 1579
Cooling System Repair 1580
Serpentine Belt 1580
Remove 1580
Inspect 1580
Install 1580
Adjust 1580
Water Pump 1581
Remove 1581
Install 1582
Thermostat 1583
Remove 1583
Inspect 1584
Install 1584
Flywheel and Flywheel Housing 1586
Flywheel 1586
Remove 1586
Install 1586
Flywheel Housing 1586
Remove 1586
Install 1586
Electrical Equipment Repair 1587
Alternator 1587
Remove 1587
Install 1588
Starter 1589
Remove 1589
Install 1589
Engine Specifications 1591
Engine Data 1591
Engine Tuning 1592
Cylinder Head 1592
Intake/Exhaust Valve and Guide 1593
Valve Spring 1593
Rocker Arm and Shaft 1593
Push Rod 1593
Gear Train and Camshaft 1594
Camshaft 1594
Idle Gear Shaft and Bushing 1594
Backlash of Each Gear 1594
Cylinder Block 1594
Crankshaft 1595
Piston 1595
Piston Ring 1595
Connecting Rod 1596
Rod Small End 1596
Tappet 1596
Oil Pump 1596
Engine Oil Pressure 1596
Inner and Outer Rotor Clearance 1596
Outer Rotor and Pump Body 1596
Rotor and Cover 1597
Standard Torque Specifications 1597
Standard Torque Chart 1597
Special Torque Specifications 1598
Special Tools 1599
550131848 0600YRM1961 (03 2020) UK EN 1613
General 1619
Engine Identification 1620
Major Engine Component Identification 1620
Location of Labels 1622
Cylinder Block Description 1623
Precautions Before Beginning Repair 1624
Exhaust System and DPF 1625
Engine Removal and Installation 1625
Cylinder Head Assembly Repair 1625
Valve Covers and Fuel Injectors 1625
Remove 1625
Clean and Inspect 1628
Install 1628
Rocker Arm Assembly 1629
Remove 1629
Disassemble 1629
Clean and Inspect 1630
Push Rods 1630
Rocker Arm Assembly 1630
Assemble 1631
Install 1631
Valve Clearance Adjustments 1631
Cylinder Head Assembly 1632
Remove 1632
Disassemble 1640
Valves and Valve Springs, Remove 1640
Valve Guides, Remove 1641
Clean and Inspect 1641
Cylinder Head 1642
Valve Guides 1642
Valves 1643
Valve Sink 1643
Valve Seat 1643
Valve Springs 1644
Assemble 1644
Valve Guides, Install 1644
Valves and Valve Springs, Install 1645
Install 1646
Timing Gear Case and Timing Gears Repair 1648
Timing Gear Case Cover 1648
Remove 1648
Clean and Inspect 1649
Install 1649
Timing Gears 1650
Crankshaft Gear 1650
Remove 1650
Install 1651
Idler Gear 1 and Idler Gear 2 1651
Remove 1651
Inspect 1652
Install 1653
Idler Gear 3 1653
Remove 1653
Inspect 1653
Install 1653
Camshaft Gear 1653
Remove 1653
Install 1653
Drive Train, Camshaft, and Cylinder Block Repair 1654
Remove 1654
Disassemble 1654
Pistons and Connecting Rods 1654
Crankshaft 1655
Camshaft 1657
Clean and Inspect 1659
Cylinder Block 1659
Honing and Boring 1661
Cylinder Correction (Oversize) 1662
Pistons 1662
Piston Pin 1663
Connecting Rod 1663
Tappets 1664
Crankshaft 1664
Camshaft 1666
Camshaft Bushing 1667
Assemble 1667
Camshaft 1667
Crankshaft 1667
Pistons and Connecting Rods 1668
Install 1670
Angular Deviation Procedure 1670
Lubrication System Repair 1673
Engine Oil and Oil Filter Change 1673
Oil Pan 1674
Remove 1674
Install 1674
Oil Suction Tube 1674
Remove 1674
Clean 1675
Install 1675
Oil Pump 1675
Remove 1675
Clean and Inspect 1676
Inner Rotor and Outer Rotor Clearance 1676
Outer Rotor and Pump Body Clearance 1677
Rotor and Cover Clearance 1677
Rotor Shaft Clearance 1677
Install 1678
Fuel System Repair 1678
Fuel Injectors 1678
Remove 1678
Inspect 1678
Clean 1679
Replace 1679
Install 1679
Test 1679
Fuel Injection Pump 1679
Remove 1679
Clean and Inspect 1682
Install 1682
Cooling System Repair 1683
Serpentine Belt 1683
Remove 1683
Inspect 1683
Install 1683
Adjust 1683
Water Pump 1684
Remove 1684
Install 1686
Thermostat 1686
Remove 1686
Inspect 1687
Install 1687
Flywheel and Flywheel Housing 1688
Flywheel 1688
Remove 1688
Install 1689
Flywheel Housing 1689
Remove 1689
Install 1689
Electrical Equipment Repair 1690
Alternator 1690
Remove 1690
Install 1691
Starter 1692
Remove 1692
Install 1692
Engine Specifications 1694
Engine Data 1694
Engine Tuning 1696
Cylinder Head 1696
Intake/Exhaust Valve and Guide 1697
Valve Spring 1697
Rocker Arm and Shaft 1697
Push Rod 1697
Gear Train and Camshaft 1698
Camshaft 1698
Idle Gear Shaft and Bushing 1698
Backlash of Each Gear 1698
Cylinder Block 1698
Crankshaft 1699
Piston 1699
Piston Ring 1699
Connecting Rod 1700
Rod Small End 1700
Tappet 1700
Oil Pump 1700
Engine Oil Pressure 1700
Inner and Outer Rotor Clearance 1700
Outer Rotor and Pump Body 1700
Rotor and Cover 1701
Standard Torque Specifications 1701
Standard Torque Chart 1701
Special Torque Specifications 1701
Special Tools 1703
550131849 0700YRM1950 (03 2020) UK EN 1717
General 1721
Cooling System Checks 1722
Exhaust Leaks Into Cooling System 1722
Water Flow Restrictions in Radiator 1722
Radiator Hoses 1722
Water Pump 1722
Flushing the Cooling System 1723
Cooling System, Clean 1723
Radiator Repair 1724
Remove 1724
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 1724
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1732
Install 1738
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 1738
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1739
Fan Assembly Replacement 1741
Remove 1741
Inspect 1746
Install 1746
550131851 1600YRM1952 (03 2020) UK EN 1749
General 1753
Steering Axle Assembly Repair 1756
Remove 1756
Disassemble 1757
Clean 1758
Inspect 1758
Assemble 1759
Install 1759
Spindles, Bearings, and Tie Rods Repair 1760
Spindles and Bearings 1760
Remove 1760
Disassemble 1760
Clean 1761
Inspect 1761
Assemble 1761
Install 1762
Tie Rods 1762
Remove 1762
Install 1763
Steering Cylinder Repair 1763
Remove and Disassemble 1763
Clean and Inspect 1763
Assemble and Install 1763
Turn Assist (Lift trucks built after February 2019) 1765
Removal 1765
Instal 1767
Adjustment 1767
Torque Specifications 1768
550131852 2100YRM1953 (03 2020) UK EN 1771
General 1777
Safety Procedures When Working Near Mast 1777
Tilt Cylinder Repair 1779
Remove 1779
Disassemble 1782
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1782
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1782
Clean 1783
Inspect 1783
Assemble 1783
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1783
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1784
Install 1785
Tilt Cylinders, Adjust 1786
Tilt Cylinder Leak Check 1788
Lift Cylinder Repair 1789
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1789
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1792
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1796
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1801
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 1802
Clean 1803
Inspect 1803
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1803
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1804
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1804
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1805
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1805
Free-Lift Cylinder Repair 1806
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1806
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1809
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1811
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1812
Clean 1814
Inspect 1814
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1814
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1815
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1815
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1815
Sideshift Cylinder Repair 1816
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1816
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1816
Clean 1817
Inspect 1817
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1817
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1818
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1818
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1819
Clean 1820
Inspect 1820
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1820
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1820
Bolzoni Sideshift Cylinder Repair 1821
Remove 1821
Disassemble 1821
Clean 1822
Inspect 1822
Assemble 1823
Install 1823
Fork Positioner Cylinder Repair 1824
Remove 1824
Disassemble 1826
Clean 1829
Inspect 1829
Assemble 1830
Install 1831
Lift Cylinder Leak Check 1832
Seal Kit Installation 1832
External Installation (Seal and Back-Up Ring) 1832
Internal Installation (Piston Rod Assembly) 1833
Special Tools 1833
Torque Specifications 1834
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1834
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1834
550131853 2200YRM1954 (03 2020) UK EN 1837
General 1845
Display Switch Cluster 1848
Remove 1848
Install 1850
Direction Control and Turn Signal Levers 1850
Remove 1850
Install 1851
Key Switch 1851
Remove 1851
Install 1852
Display Switch Cluster Panel Bezel and Overlay 1852
Remove 1852
Install 1853
Steering Column Repair 1853
Sensors and Switches 1856
General 1856
Dash and Kick Panel, Remove and Install 1856
Remove 1856
Install 1857
Accelerator Pedal Position Sensor 1857
Remove 1857
Install 1860
Brake Fluid Level Switch 1860
Remove 1860
Install 1861
Service Brake Pedal Position Sensor 1861
Remove 1861
Install 1862
Parking Brake Position Sensor 1862
Remove 1862
Install 1862
Service Brake Pressure Sensor 1863
Remove 1863
Install 1863
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 1864
Remove 1864
Install 1864
Sensor MicroswitchFoot Directional Control 1865
Remove 1865
Install 1867
Low Coolant Level Sensor 1867
Remove 1867
Install 1868
Fuel Level Sensor, Diesel Engines Only 1868
Remove 1868
Install 1869
Seat Sensor (Operator Presence System) 1869
Non-Suspension Seat 1869
Remove 1869
Install 1871
Full Suspension and Swivel Seats 1871
Remove 1871
Install 1871
Hood Shut Off Switch 1872
Remove 1872
Install 1872
Remote Key Switch 1873
Remove 1873
Install 1873
Hydraulic Filter Pressure Switch 1874
Remove 1874
Install 1874
Transmission Speed Sensor 1874
Remove 1874
Install 1875
Transmission Pressure Sensors 1875
Remove 1875
Install 1875
Transmission Temperature Sensor 1876
Remove 1876
Install 1876
Engine Speed Sensor 1876
Remove 1876
Install 1876
Intermediate Speed Sensor 1876
Remove 1876
Install 1876
Return To Set Tilt (Tilt Angle) Sensor 1876
Remove 1876
Install 1877
Rear Horn Button Switch 1877
Remove 1877
Install 1877
Impact Sensor 1878
Remove 1878
Install 1878
Load Weight Sensor 1879
Remove 1879
Install 1879
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 1880
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 1881
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 1881
Air Filter Restriction Switch 1881
Remove 1881
Install 1881
Engine Oil Pressure Sensor 1882
Remove 1882
Install 1882
Engine Speed Sensor 1882
Remove 1882
Install 1882
Engine Coolant Temperature (ECT) Sensor 1883
Remove 1883
Install 1883
Fuel/Water Separator Sensor 1883
Remove 1883
Install 1883
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 1884
Engine Coolant Temperature (ECT) Sensor 1884
Remove 1884
Install 1884
Throttle Position Sensor 1885
Engine Oil Pressure Sensor 1885
Remove 1885
Install 1885
Fuel Shut Off Solenoid 1885
Remove 1885
Install 1886
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) 1886
Intake Air Temperature Sensor 1887
Remove 1887
Install 1887
Boost Sensor 1887
Remove 1887
Install 1887
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 1889
Remove 1889
Install 1890
Engine Coolant Temperature (ECT) Sensor 1890
Remove 1890
Install 1890
Engine Oil Pressure Sensor 1890
Remove 1890
Install 1891
Crankshaft Position Sensor 1891
Remove 1891
Install 1891
Adjust Shim Procedure 1891
Camshaft Position Sensor 1893
Remove 1893
Install 1893
Differential Pressure Sensor 1893
Remove 1893
Install 1894
Oxygen Sensors (Inlet and Outlet) 1894
Remove 1894
Install 1895
Inlet Temperature Sensor 1896
Remove 1896
Install 1896
Mass Air Flow Sensor 1896
Remove 1896
Install 1896
Fuel/Water Separator 1896
Remove 1896
Install 1897
Air Filter Restriction Switch 1897
Remove 1897
Install 1897
Vehicle System Manager (VSM) 1898
General 1898
VSM Replacement 1898
Remove 1898
Install 1898
Programming A New VSM And/Or Display Switch Cluster 1899
Data Transferring 1900
New VSM 1900
New (Blank) Display Switch Cluster 1900
Used (Non-Blank) Display Switch Cluster 1900
PC Service Tool Software 1901
Power Distribution Module (PDM) and Component Parts 1901
Remove 1901
PDM as a Unit 1901
Install 1902
PDM as a Unit 1902
Remove and Install 1902
PDM Component Parts 1902
Transmission Control Unit (TCU) 1903
Remove 1903
Install 1905
Battery 1908
Remove 1908
Install 1908
Lights 1908
Work Lights (Front and Rear) 1908
Halogen Bulb Lights 1908
Remove 1908
Install 1908
LED Lights 1909
Remove 1909
Install 1909
Strobe Light 1909
Remove 1909
Install 1910
LED Tail, Backup, and Brake Lights 1910
Remove 1910
Install 1910
Front Marker/Turn Signal Lights 1911
Replacing Whole Front Marker/Turn Signal Light Assembly 1911
Remove 1911
Install 1911
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 1912
Remove 1912
Install 1912
Electronic-Hydraulic Controls, Before January, 2020 1913
E-Hydraulic Controls – TEST 1913
Mini-Levers 1913
Full Stroke Test 1913
Function Returns to Neutral Test 1913
Push (Override) Button Switch 1913
General 1914
Mini-levers, Remove and Install 1914
Armrest Assembly 1915
Remove 1915
Install 1918
Horn Button 1918
Remove 1918
Install 1918
Direction Control Switch 1918
Remove 1918
Install 1919
Push (Override) Button 1919
Remove 1919
Install 1920
Electronic-Hydraulic Controls, After January, 2020 1921
E-Hydraulic Controls – TEST 1921
Mini-Levers 1921
Full Stroke Test 1921
Function Returns to Neutral Test 1921
Push Button Switch 1921
General 1922
Mini-levers, Remove and Install 1922
Armrest Assembly 1923
Remove 1923
Install 1926
Horn Button 1926
Remove 1926
Install 1926
Direction Control Switch 1926
Remove 1926
Install 1927
Push (Override) Buttons 1927
Remove 1927
Install 1928
Diesel Particulate Filter (DPF) Display 1929
Remove 1929
Clean and Inspect 1930
Install 1930
Special Tools 1931
550131855 4000YRM1956 (03 2020) UK EN 1935
Safety Procedures When Working Near Mast 1939
Fork Replacement 1940
General 1940
Remove 1940
Install 1942
Checks 1942
Carriage Repair 1944
Remove 1944
Clean and Inspect 1947
Install 1947
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1948
Connecting Attachment Hydraulic Quick Disconnect Hoses 1948
Integral Sideshift Carriage And Fork Positioners Repair 1949
Integral Sideshift Carriage 1949
Remove 1949
Disassemble 1950
Clean and Inspect 1952
Assemble 1953
Install 1953
Fork Positioners 1954
Remove 1954
Disassemble 1957
Clean and Inspect 1959
Assemble 1959
Install 1959
Hang-On Sideshift Carriage Repair 1960
Remove 1960
Disassemble Carriage 1962
Clean and Inspect 1965
Assemble 1965
Install 1968
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 1970
Remove 1970
Disassemble 1974
Clean and Inspect 1978
Assemble 1980
Install 1980
Header Hose Installation 1981
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 1984
Remove 1984
Disassemble 1987
Clean and Inspect 1990
Assemble 1992
Install 1992
Header Hose Installation 1993
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 1996
Remove 1996
Disassemble 1999
Clean and Inspect 2002
Assemble 2004
Install 2004
Header Hose Installation 2005
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 2008
Remove 2008
Disassemble 2011
Clean and Inspect 2015
Assemble 2017
Install 2017
Header Hose Installation 2018
Mast Operation Check 2021
Tilt Cylinder Adjustment 2021
Main Lift Cylinder Repair 2022
Lift Chain Adjustment 2022
Mast Adjustments 2023
Load Roller Adjustment 2023
Mast Side Kicking Adjustment 2025
Carriage Adjustment 2025
550136209 1800YRM1977 (03 2020) UK EN 2029
General 2033
Wet Brake System 2033
Parking Brake Repair 2034
Master Cylinder Repair, For 6-8 Ton Lift Trucks 2037
Remove 2037
Disassemble 2038
Clean and Inspect 2039
Assemble 2040
Install and Adjust 2040
Accumulator; For 6-8 Ton Lift Trucks 2041
Pre-Charge Check 2041
Remove 2042
Install 2043
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For 8-9 Ton Lift Trucks 2043
Remove 2043
Modulating Brake Valve 2045
Disassemble 2045
Clean and Inspect 2046
Assemble 2047
Accumulator Charge Valve 2047
Disassemble 2047
Clean and Inspect 2049
Assemble 2049
Install 2050
Pressure Checks 2051
Accumulator Charge Valve Check 2051
Accumulator Check 2051
Brake System Air Removal; For 6-8 Ton Lift Trucks 2052
Using Pressure Bleed System 2052
Using Brake Pedal Pressure 2052
Lift Truck Models with Master Cylinder 2052
Brake System Air Removal for 8-9 Ton Lift Trucks 2053
Using Brake Pedal Pressure 2053
Lift Truck Models with Modulating Brake Valve 2053
Brake Pedal Adjustment 2053
For 6-8 Ton Lift Trucks 2053
For 8-9 Ton Lift Trucks 2054
Free Pedal Adjustment 2056
Torque Specifications 2057
550152438 0600YRM1949 (07 2023) US EN 2059
General 2065
Engine Removal and Installation 2065
Cylinder Head Repair 2065
Remove and Disassemble 2065
Clean and Inspect 2067
Valve Oil Seals 2069
Remove and Disassemble 2069
Cylinder Leak Down Test 2069
Clean and Inspect 2070
Assemble and Install 2070
Valve Guides and Seats, Repairs 2072
Valves, Repair 2073
Valve Seats, Repair 2073
Valve Springs 2074
Assemble and Install 2075
Engine Block Cleaning and Inspection 2079
Clean and Inspect 2079
Piston Bore Preparation 2081
Engine Mounts Installation 2082
Remove 2082
Clean and Inspect 2082
Install 2082
Lubrication System Repair 2083
Oil Pump, Remove and Disassemble 2083
Clean and Inspect 2084
Oil Pump, Assemble and Install 2085
Oil Pan, Install 2087
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 2089
Timing Cover 2089
Remove 2089
Install 2090
Timing Chain and Sprockets 2090
Remove 2090
Install 2091
Camshaft 2091
Remove 2091
Inspect 2092
Install 2092
Balance Shaft 2093
Remove 2093
Install 2094
Valve Lifters 2095
Remove 2095
Clean and Inspect 2095
Install 2095
Crankshaft Repair 2097
Remove 2097
Inspect and Repair 2097
How to Check Clearance Between Main Bearings and Their Journals 2098
Install 2099
Piston and Connecting Rod Assemblies Repair 2101
Connecting Rod Bearings, Replace 2101
Piston and Connecting Rod Assemblies, Remove 2102
Disassemble 2102
Piston, Clean and Inspect 2103
Cylinder Bores, Inspect and Repair 2103
Piston Rings 2104
Assemble 2105
Piston and Connecting Rod Assemblies, Install 2105
Flywheel and Flywheel Housing Repair 2106
Flywheel, Remove 2106
Clean 2106
Inspect 2106
Flywheel, Install 2107
Coolant Pump Repair 2108
Remove 2108
Clean and Inspect 2109
Install 2109
Thermostat Replacement 2110
Remove 2110
Thermostat Operation Check 2110
Install 2110
Starter Replacement 2111
Fan Assembly Replacement 2115
Remove 2115
Inspect 2117
Install 2117
Drive Belt Installation 2118
Remove 2118
Clean 2118
Inspect 2118
Installation 2118
Compression Check 2120
Engine Specifications 2121
Engine Data 2121
Cylinder Head 2121
Hydraulic Valve Lifter 2121
Camshaft 2121
Pistons 2122
Crankshaft 2122
Connecting Rods 2123
Balance Shaft 2123
Cooling System 2123
Lubrication System 2123
Torque Specifications 2124
550152439 0900YRM1951 (11 2019) UK EN 2127
General 2133
LPG Tank and Bracket 2133
LPG Tank, Lift Truck Models GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080-120VX) (K813) and GLC60-70VX (GLC135-155VX) (F879) 2133
Remove 2133
Install 2138
LPG Tank Bracket, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813), and GLC60-70VX (GLC135-155VX) (F879) 2139
Remove 2139
Install 2140
LPG Tank, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878) and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 2141
Remove 2141
Install 2143
LPG Tank Bracket, Lift Truck Models GLP60-70VX (E878), GLP60-70VX (GLP135-155VX) (F878), and GLP60-70VX, GP70VXS6, GP70VXS9 (GLP135-155VX, GP155VXS) (G878) 2143
Remove 2143
Install 2143
LPG Tank Bracket Alignment Pin, Lift Truck Models GLP040VX5/VX6, GLP45SVX5, GLP45VX6, GLP50-55VX (K813) and GLC60-70VX (GLC135-155VX) (F879) 2144
Remove 2144
Install 2145
Fuel Filter Unit 2146
Fuel Filter Element 2146
Remove 2146
Clean and Inspect 2147
Install 2147
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) 2148
Remove 2148
Disassemble 2149
Clean and Inspect 2149
Assemble 2150
Install 2150
Fuel Filter Housing, Lift Truck Models GLP60-70VX (E878) 2150
Remove 2150
Disassemble 2152
Clean and Inspect 2153
Assemble 2153
Install 2154
Throttle Body 2154
Remove 2154
Clean 2156
Install 2156
Fuel Mixer with Direct Electronic Pressure Regulator (DEPR) 2157
Remove 2157
Install 2158
Control System 2159
Engine Control Unit (ECU) 2159
Remove 2159
Install 2160
Low Pressure Switch 2160
Remove 2160
Install 2161
Low Fuel Sensor 2161
Remove 2161
Install 2162
LP Converter 2162
Remove and Disassemble 2162
Assemble and Install 2164
LPG Lock-Off 2165
Remove 2165
Install 2166
Exhaust System 2166
Counterweight Exhaust 2166
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) 2166
Inspect 2168
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) 2169
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2169
Inspect 2170
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2170
Overhead Exhaust 2171
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) 2171
Inspect 2172
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) 2173
Remove and Disassemble Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2173
Inspect 2175
Assemble and Install Lift Truck Models GLC60-70VX (GLC135-155VX) (F879) 2175
Exhaust Manifold 2175
Remove 2175
Install 2176
Oxygen (HEGO) Sensor 2177
Remove 2177
Install 2177
LPG Fuel Testing 2177
General 2177
Available Fuel Tests 2178
Composition Test (ASTM D-2163) 2178
Ammonia Test (ASTM D-4490) 2178
Basic Nitrogen Test (ASTM UOP269-90) 2178
Residues Test (ASTM D-2158) 2178
Vapor Pressure Test (ASTM D-2598) 2178
Sulfur Compounds Test (ASTM D-5623) 2178
Methanol Test (ASTM D-4864) 2178
Copper Corrosion (ASTM D-1838) 2178
Where To Send LPG Fuel Samples For Testing 2178
550152440 2200YRM1955 (11 2019) UK EN 2181
Description 2185
Distributor Ignition (DI) System 2185
Crankshaft Position (CKP) Sensor 2185
Camshaft Position (CMP) Sensor 2185
Ignition Coil and Ignition Control Module (ICM) 2185
Secondary Ignition Components 2185
Spark Plugs and Wires 2185
Spark Plug Wire Inspection 2185
Spark Plug Wire Replacement 2185
Remove 2185
Install 2186
Spark Plug Inspection 2186
Usage 2186
Inspection 2186
Visual Inspection 2188
Spark Plug Replacement 2189
Remove 2189
Install 2189
Distributor Repair 2189
Inspect 2189
Overhaul 2190
Disassemble 2190
Assemble 2192
Replace 2193
Remove 2193
Install Procedure 1 2195
Install Procedure 2 2196
Ignition Coil Replacement 2198
Remove 2198
Install 2198
Ignition Control Module Replacement 2199
Remove 2199
Install 2199
Starter Replacement 2200
Remove 2200
Install 2203
Sensors and Switches 2204
LPG Trucks 2204
Crankshaft Position (CKP) Sensor 2204
Remove 2204
Install 2204
Camshaft Position (CMP) Sensor 2205
Remove 2205
Install 2206
Oil Pressure Sensor 2207
Remove 2207
Install 2207
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 2208
Remove 2208
Install 2208
Engine Coolant Temperature (ECT) Sensor 2208
Remove 2208
Install 2209
Air Flow Restriction Switch 2209
Remove 2209
Install 2210
Specifications and Special Tools 2210
550210540 0600YRM2190 (03 2020) UK EN 2213
General 2219
Engine Identification 2219
Major Engine Component Identification 2219
Location of Labels 2223
Cylinder Block Description 2223
Precautions Before Beginning Repair 2224
Exhaust System and DPF 2225
Engine Removal and Installation 2225
Cylinder Head Assembly Repair 2225
Valve Covers and Fuel Injectors 2225
Remove 2225
Clean and Inspect 2228
Install 2228
Rocker Arm Assembly 2229
Remove 2229
Disassemble 2229
Clean and Inspect 2230
Push Rods 2230
Rocker Arm Assembly 2230
Assemble 2231
Install 2231
Valve Clearance Adjustments 2231
Cylinder Head Assembly 2232
Remove 2232
Disassemble 2242
Valves and Valve Springs, Remove 2242
Valve Guides, Remove 2243
Clean and Inspect 2243
Cylinder Head 2244
Valve Guides 2244
Valves 2244
Valve Sink 2245
Valve Seat 2245
Valve Springs 2246
Assemble 2246
Valve Guides, Install 2246
Valves and Valve Springs, Install 2247
Install 2248
Timing Gear Case and Timing Gears Repair 2250
Timing Gear Case Cover 2250
Remove 2250
Clean and Inspect 2251
Install 2252
Timing Gears 2252
Crankshaft Gear 2253
Remove 2253
Install 2253
Idler Gear 1 and Idler Gear 2 2253
Remove 2253
Inspect 2254
Install 2255
Idler Gear 3 2255
Remove 2255
Inspect 2255
Install 2255
Camshaft Gear 2255
Remove 2255
Install 2255
Drive Train, Camshaft, and Cylinder Block Repair 2256
Remove 2256
Disassemble 2256
Pistons and Connecting Rods 2256
Crankshaft 2257
Camshaft 2259
Clean and Inspect 2261
Cylinder Block 2261
Honing and Boring 2263
Cylinder Correction (Oversize) 2264
Pistons 2264
Piston Pin 2265
Connecting Rod 2265
Tappets 2266
Crankshaft 2266
Camshaft 2268
Camshaft Bushing 2269
Assemble 2269
Camshaft 2269
Crankshaft 2270
Pistons and Connecting Rods 2270
Install 2272
Angular Deviation Procedure 2272
Lubrication System Repair 2275
Engine Oil and Oil Filter Change 2275
Oil Pan 2276
Remove 2276
Install 2276
Oil Suction Tube 2276
Remove 2276
Clean 2277
Install 2277
Oil Pump 2277
Remove 2277
Clean and Inspect 2278
Inner Rotor and Outer Rotor Clearance 2278
Outer Rotor and Pump Body Clearance 2279
Rotor and Cover Clearance 2279
Rotor Shaft Clearance 2279
Install 2280
Fuel System Repair 2281
Fuel Injectors 2281
Remove 2281
Inspect 2281
Clean 2281
Replace 2281
Install 2281
Test 2281
Fuel Injection Pump 2282
Remove 2282
Clean and Inspect 2284
Install 2284
Cooling System Repair 2285
Serpentine Belt 2285
Remove 2285
Inspect 2285
Install 2285
Adjust 2285
Water Pump 2286
Remove 2286
Install 2288
Thermostat 2289
Remove 2289
Inspect 2290
Install 2291
Flywheel and Flywheel Housing 2292
Flywheel 2292
Remove 2292
Install 2293
Flywheel Housing 2293
Remove 2293
Install 2293
Electrical Equipment Repair 2294
Alternator 2294
Remove 2294
Install 2295
Starter 2295
Remove 2295
Install 2296
Engine Specifications 2297
Engine Data 2297
Engine Tuning 2299
Cylinder Head 2300
Intake/Exhaust Valve and Guide 2300
Valve Spring 2301
Rocker Arm and Shaft 2301
Push Rod 2301
Gear Train and Camshaft 2301
Camshaft 2301
Idle Gear Shaft and Bushing 2301
Backlash of Each Gear 2302
Cylinder Block 2302
Crankshaft 2302
Piston 2302
Piston Ring 2303
Connecting Rod 2303
Rod Small End 2303
Tappet 2303
Oil Pump 2304
Engine Oil Pressure 2304
Inner and Outer Rotor Clearance 2304
Outer Rotor and Pump Body 2304
Rotor and Cover 2304
Standard Torque Specifications 2305
Standard Torque Chart 2305
Special Torque Specifications 2306
Special Tools 2307
550213051 2100YRM2194 (11 2019) UK EN 2319
General 2323
Safety Procedures When Working Near Mast 2323
Tilt Cylinder Repair 2324
Remove 2324
Disassemble 2326
Clean 2326
Inspect 2327
Assemble 2327
Install 2327
Tilt Cylinders, Adjust 2328
Tilt Cylinder Leak Check 2329
Lift Cylinder Repair 2330
Remove 2330
Disassemble 2334
Clean 2335
Inspect 2335
Assemble 2335
Install 2336
Free-Lift Cylinder 2336
Remove 2336
Install 2338
Integral Sideshift Cylinder Repair 2338
Remove 2338
Disassemble 2339
Clean 2339
Inspect 2340
Assemble 2340
Install 2340
Hang On Sideshift Cylinder Repair 2340
Remove 2340
Disassemble 2340
Clean 2342
Inspect 2342
Assemble 2343
Install 2343
Fork Positioner Cylinder Repair 2343
Remove 2343
Disassemble 2347
Clean 2348
Inspect 2348
Assemble 2349
Install 2350
Lift Cylinder Leak Check 2350
Seal Kit Installation 2351
External Installation (Seal and Back-Up Ring) 2351
Internal Installation (Piston Rod Assembly) 2351
Special Tools 2352
Torque Specifications 2352
550213052 4000YRM2195 (11 2019) UK EN 2355
Safety Procedures When Working Near Mast 2359
Fork Replacement 2360
General 2360
Remove 2360
Install 2362
Checks 2362
Standard Carriage Repair 2364
Remove 2364
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 2366
Clean and Inspect 2366
Connecting Attachment Hydraulic Quick Disconnect Hoses 2367
Install 2367
Integral Sideshift Carriage Repair 2367
Integral Sideshift Carriage 2367
Remove 2367
Disassemble 2367
Clean and Inspect 2368
Assemble 2369
Install 2369
Hang-On Sideshift Carriage Repair 2369
Remove 2369
Disassemble Carriage 2371
Clean and Inspect 2374
Assemble 2374
Install 2374
Two-Stage Mast With Limited Free-Lift Repair 2377
Remove 2377
Disassemble 2379
Clean and Inspect 2382
Assemble 2384
Install 2384
Header Hose Installation 2386
Three-Stage Mast With Full Free-Lift Repair 2388
Remove 2388
Disassemble 2390
Clean and Inspect 2394
Assemble 2396
Install 2396
Header Hose Installation 2397
Mast Operation Check 2398
Tilt Cylinder Adjustment 2398
Main Lift Cylinder Repair 2399
Lift Chain Adjustment 2399
Mast Adjustments 2400
Load Roller Adjustment 2400
Mast Side Kicking Adjustment 2402
Carriage Adjustment 2402
550213053 8000YRM2196 (09 2020) UK EN 2405
General 2411
Serial Number Data 2411
How to Move Disabled Lift Truck 2411
How to Tow Lift Truck 2411
How to Put Lift Truck on Blocks 2412
How to Raise Drive Tires 2412
How to Raise Steering Tires 2413
How to Clean a Lift Truck 2414
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 2414
Connecting Attachment Hydraulic Quick Disconnect Hoses 2415
Safety Procedures When Working Near Mast 2416
Maintenance Schedule 2419
Maintenance Procedures Every 8 Hours or Daily 2437
How to Make Checks With Engine Stopped 2437
Tires and Wheels 2437
Safety Labels 2437
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2437
Operator Restraint System 2438
Emergency Locking Retractor (ELR) 2438
Adjust Seat – Full Suspension 2439
Adjust Seat – Internal Suspension 2440
Seat Plate and Seat Rails 2441
Engine Compartment 2442
Paper Application 2442
Fuel, Oil, and Coolant Leaks, Check 2443
Hydraulic Hoses 2443
Coolant Hoses 2443
Steering Column Gas Cylinder 2443
Transmission 2443
Hydraulic System Oil 2443
Engine Oil 2444
Air Filter 2450
Forks 2450
Inspect 2450
Remove 2452
Install 2452
Adjust 2452
Hang On Sideshift Carriage 2453
How to Make Checks With Engine Running 2453
Indicator Lights, Horn, Fuses, and Relays 2453
Service Brakes 2456
Brake Oil Level 2456
Operation, Check 2456
Parking Brake 2456
Engine Oil Pressure 2457
Cooling System 2457
Steering System 2458
Control Levers and Pedals 2458
Lift System, Operate 2458
Air Filter 2459
Fuel/Water Separator Filter, Kubota Diesel Engine 2459
First Service After First 100 Hours of Operation 2460
4 3L Engine Oil and Oil Filter 2460
Kubota Diesel Engine Oil and Oil Filter 2460
Hang on Sideshift Carriage Checks 2462
Maintenance Procedures Every 500 Hours or 1 Year 2463
Hydraulic System Oil 2463
Hydraulic Tank Breather 2464
Inspect 2464
Battery 2464
4 3L Engine Oil and Oil Filter Change 2464
Kubota Diesel Engine Oil and Oil Filter 2465
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 2466
Remove 2466
Install 2467
Priming the Fuel System (Kubota 3 8L Engine) 2468
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 2468
Remove 2468
Install 2468
Priming the Fuel System (Kubota 3 6L Engine) 2469
Drive Belt 2469
4 3L Engine 2469
Fan and Alternator Drive Belt 2469
Drive Belt 2470
Kubota Diesel Engine 2470
Fan and Alternator Drive Belt 2470
Drain Tar From LPG Converter 2471
Clean Debris From Radiator Core 2471
Cleaning Carbon Buildup From Intake Valves – PSI 4 3L LPG Engines 2472
Transmission Oil Breather/Dipstick 2474
Differential and Drive Axle Oil Level Check 2475
Forks, Inspect 2477
Mast Lubrication 2478
Header Hose Checks 2482
Lift Chain Lubrication 2482
Tilt Cylinder Lubrication 2482
Master Brake Cylinder Rod End Pin Lubrication 2483
Manual Hydraulic Levers Lubrication 2484
Cab Heater Air Filter 2484
Brake Oil 2485
Tie Rod Lubrication 2486
Parking Brake Adjustment 2487
Maintenance Procedures Every 1000 Hours or 1 year 2488
Valve Clearance, Check and Adjust 2488
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 2488
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 2488
Ignition System 2488
4 3L Engine 2488
LPG Fuel Filter Element Replace, 4 3L Engine 2488
Remove 2488
Install 2489
In-Line Strainer Replacement, Kubota Diesel Engine 2489
Remove 2489
Install 2489
Lift Chains Wear Check 2490
Lift Chain Lubrication 2491
Hang On Sideshift Carriage, Check Sliding Surfaces 2491
Steering Axle Spindle Bearings 2493
Control Levers and Pedals 2493
Inspect Engine Electrical System, Connectors 2493
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2494
Parking Brake Lever Lubrication, Wet Brake Axle 2497
Normal Operating Environment 2497
Heavy Duty or Contaminated Environment 2498
Remove 2498
Clean and Inspect 2499
Install 2499
Crankcase Breather Element, Kubota 3 8L Diesel 2500
Remove 2500
Clean and Inspect 2500
Install 2500
DEF Injector Tip 2500
Maintenance Procedures Every 2000 Hours or Annually 2501
Hydraulic System 2501
Hydraulic Filter Assembly, Replace 2501
Install 2502
Hydraulic Tank Breather, Replace 2503
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2504
Cooling System Check 2504
Air Filter 2505
Fuel Injector, Kubota 3 8L Engine 2507
Fuel Injector, Kubota 3 6L Engine 2507
Forks, Inspect 2507
Brake Oil (Master Cylinder), Change 2509
Check Throttle Shaft for Sticking 2510
Inspect Exhaust Manifold and Piping for Leaks 2510
Transmission Automatic Clutch Calibration 2510
Wheel Bearings 2510
Steer Wheels, Lubrication 2510
Maintenance Procedures Every 3000 Hours 2511
Diesel Particulate Filter 2511
Remove 2511
Disassemble 2513
Servicing the Diesel Particulate Filter 2514
Assemble 2514
Install 2515
Diesel Exhaust Fluid (DEF) System 2515
Maintenance Procedures Every 4000 Hours or 2 Years 2517
Hydraulic Oil, Replace 2517
Jump-Starting the Lift Truck 2518
Jump-Starting Using a Battery Charger 2518
Jump-Starting a Lift Truck Using Another Lift Truck 2519
Fuel Filter Water Removal 2519
Kubota Diesel Engine 2519
3 8L Diesel Engine 2519
Wheel and Tire Replacement 2520
General 2520
Pneumatic Tire With Tube, Repair 2521
Remove Wheels From Lift Truck 2521
Remove Tire From Wheel 2521
Install Wheel in Tire 2524
Add Air to Pneumatic Tires With Tube 2526
Install the Wheels 2527
Dual Drive Wheels, Install 2527
Pneumatic Tubeless Tire, Repair 2528
Remove Wheels From Lift Truck 2528
Add Air to Pneumatic Tubeless Tire 2533
Wheels, Install 2533
Solid Rubber Tires on Pneumatic Wheels, Change 2533
Snap-On-Tire, Change 2537
Easy Mounting Style Solid Rubber Tires on Pneumatic Wheels, Change 2539
Lift Chain Adjustments 2545
Overhead Guard Changes 2546
Welding Repairs 2546
Adhesives and Sealants 2547
550213054 8000YRM2197 (11 2019) UK EN 2549
Lift Truck Lifting Capacity 2553
Counterweight Weights 2553
Tire Sizes 2553
Capacities 2553
Electrical System 2557
Transmission Oil Pressures 2558
Hydraulic System Relief Pressures 2560
Steering System 2560
Stall Speeds (in RPM ±100 rpm) 2560
GM/PSI 4 3L LPG GLP60VX, GLP70VX, GP70VXS6, GP70VXS9 (GLP135VX GLP155VX, GP155VXS) (G878) 2560
Kubota 3 6L Diesel GDP60VX, GDP70VX, GP70VXS6, GP70VXS9 (GDP135VX GDP155VX, GP155VXS) (G878) 2561
Kubota 3 8L Diesel GDP60VX, GDP70VX, GP70VXS6, GP70VXS9 (GDP135VX GDP155VX, GP155VXS) (G878) 2561
Mast Speeds 2561
Tilt Angles 2562
Front End Equipment – Mast Creep 2563
Mast Creep 2563
Engine Specifications 2563
Diesel Fuel Cleanliness Levels 2566
Torque Specifications 2566
Frame 2566
Mast 2566
Hang On Sideshift Carriage With Fork Positioner 2566
Steering System 2567
Transmission 2567
Engine – GM/PSI 4 3L 2567
Engine – Kubota 3 6L Diesel 2568
Engine – Kubota 3 8L Diesel 2569
550229997 0600YRM2294 (06 2021) US EN 2573
General 2579
Engine Identification 2580
Major Engine Component Identification 2580
Location of Labels 2581
Crankcase Description 2582
Precautions Before Beginning Repair 2582
Exhaust System 2583
Engine Removal and Installation 2584
Cylinder Head Assembly Repair 2584
Valve Covers and Fuel Injectors 2584
Remove 2584
Clean and Inspect 2587
Install 2587
Rocker Arm Assembly 2588
Remove 2588
Disassemble 2588
Clean and Inspect 2589
Push Rods 2589
Rocker Arm Assembly 2589
Assemble 2590
Install 2590
Valve Clearance Adjustments 2590
Cylinder Head Assembly 2592
Remove 2592
Disassemble 2598
Valves and Valve Springs, Remove 2598
Valve Guides, Remove 2599
Clean and Inspect 2599
Cylinder Head 2600
Valve Guides 2600
Valves 2600
Valve Sink 2601
Valve Seat 2601
Valve Springs 2601
Assemble 2602
Valve Guides, Install 2602
Valves and Valve Springs, Install 2603
Install 2604
Timing Gear Case and Timing Gears Repair 2606
Timing Gear Case Cover 2606
Remove 2606
Clean and Inspect 2606
Install 2607
Timing Gears 2607
Crankshaft Gear 2608
Remove 2608
Install 2608
Idler Gear 2608
Remove 2608
Inspect 2609
Install 2610
Camshaft Gear 2610
Remove 2610
Install 2610
Drive Train, Camshaft, and Cylinder Block Repair 2611
Remove 2611
Disassemble 2611
Pistons and Connecting Rods 2611
Crankshaft 2612
Camshaft 2614
Clean and Inspect 2616
Cylinder Block 2616
Honing and Boring 2619
Cylinder Correction (Oversize) 2620
Pistons 2620
Piston Pin 2621
Connecting Rod 2621
Tappets 2621
Crankshaft 2622
Camshaft 2624
Camshaft Bushing 2625
Assemble 2625
Camshaft 2625
Crankshaft 2625
Pistons and Connecting Rods 2625
Install 2627
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 2628
Lubrication System Repair 2631
Engine Oil and Oil Filter Change 2631
Oil Pan 2631
Remove 2631
Install 2632
Oil Suction Tube 2632
Remove 2632
Clean 2632
Install 2633
Oil Pump 2633
Remove 2633
Clean and Inspect 2634
Outer Rotor Outside Clearance 2634
Outer Rotor to Inner Rotor Tip Clearance 2634
Outer Rotor Side Clearance 2635
Rotor Shaft Clearance 2635
Install 2635
Fuel System Repair 2636
Fuel Injectors 2636
Remove 2636
Inspect 2636
Clean 2636
Replace 2636
Install 2636
Test 2636
Fuel Injection Pump 2637
Remove 2637
Clean and Inspect 2638
Install 2638
Cooling System Repair 2640
Serpentine Belt 2640
Remove 2640
Inspect 2640
Install 2640
Adjust 2640
Water Pump 2641
Remove 2641
Install 2643
Thermostat 2643
Remove 2643
Inspect 2644
Install 2644
Flywheel and Flywheel Housing 2646
Flywheel 2646
Remove 2646
Install 2646
Flywheel Housing 2646
Remove 2646
Install 2647
Electrical Equipment Repair 2648
General 2648
Alternator 2648
Remove 2648
Install 2649
Starter 2650
Remove 2650
Install 2651
Engine Specifications 2652
Engine Data 2652
Engine Tuning 2653
Cylinder Head 2653
Intake/Exhaust Valve and Guide 2654
Valve Spring 2654
Rocker Arm and Shaft 2654
Push Rod 2654
Gear Train and Camshaft 2655
Camshaft 2655
Idle Gear Shaft and Bushing 2655
Backlash of Each Gear 2655
Cylinder Block 2655
Crankshaft 2655
Piston 2656
Piston Ring 2656
Connecting Rod 2656
Rod Small End 2656
Tappet 2657
Oil Pump 2657
Engine Oil Pressure 2657
Outer Rotor Outside Clearance 2657
Outer Rotor Side Clearance 2657
Inner Rotor to Cover 2657
Standard Torque Specifications 2658
Standard Torque Chart 2658
Special Torque Specifications 2659
Special Tools 2661
550229998 0600YRM2295 (01 2021) UK EN 2675
General 2681
Engine Identification 2681
Major Engine Component Identification 2681
Location of Labels 2682
Cylinder Block Description 2683
Precautions Before Beginning Repair 2684
Exhaust System, SCR, and DPF 2684
Engine Removal and Installation 2685
Cylinder Head Assembly Repair 2685
Valve Covers and Fuel Injectors 2685
Remove 2685
Clean and Inspect 2688
Install 2688
Rocker Arm Assembly 2689
Remove 2689
Disassemble 2690
Clean and Inspect 2690
Push Rods 2690
Rocker Arm Assembly 2690
Assemble 2691
Install 2691
Valve Clearance Adjustments 2691
Cylinder Head Assembly 2692
Remove 2692
Disassemble 2701
Valves and Valve Springs, Remove 2701
Valve Guides, Remove 2702
Clean and Inspect 2702
Cylinder Head 2703
Valve Guides 2703
Valves 2703
Valve Sink 2704
Valve Seat 2704
Valve Springs 2705
Assemble 2705
Valve Guides, Install 2705
Valves and Valve Springs, Install 2706
Install 2707
Timing Gear Case and Timing Gears Repair 2709
Timing Gear Case Cover 2709
Remove 2709
Clean and Inspect 2710
Install 2710
Timing Gears 2711
Crankshaft Gear 2711
Remove 2711
Install 2712
Idler Gear 1 and Idler Gear 2 2712
Remove 2712
Inspect 2713
Install 2714
Idler Gear 3 2714
Remove 2714
Inspect 2714
Install 2714
Camshaft Gear 2714
Remove 2714
Install 2714
Drive Train, Camshaft, and Cylinder Block Repair 2715
Remove 2715
Disassemble 2715
Pistons and Connecting Rods 2715
Crankshaft 2716
Camshaft 2718
Clean and Inspect 2720
Cylinder Block 2720
Honing and Boring 2722
Cylinder Correction (Oversize) 2723
Pistons 2723
Piston Pin 2724
Connecting Rod 2724
Tappets 2725
Crankshaft 2725
Camshaft 2727
Camshaft Bushing 2728
Assemble 2728
Camshaft 2728
Crankshaft 2728
Pistons and Connecting Rods 2729
Install 2731
Angular Deviation Procedure 2731
Lubrication System Repair 2734
Engine Oil and Oil Filter Change (Standard Oil Filter) 2734
Engine Oil and Oil Filter Change (Remote Oil Filter) 2734
Oil Pan 2735
Remove 2735
Install 2735
Oil Suction Tube 2736
Remove 2736
Clean 2736
Install 2736
Oil Pump 2736
Remove 2736
Clean and Inspect 2737
Inner Rotor and Outer Rotor Clearance 2737
Outer Rotor and Pump Body Clearance 2738
Rotor and Cover Clearance 2738
Rotor Shaft Clearance 2738
Install 2738
Remote Oil Filter 2739
Remove 2739
Clean and Inspect 2741
Install 2741
Fuel System Repair 2742
Fuel Injectors 2742
Remove 2742
Inspect 2742
Clean 2742
Replace 2742
Install 2743
Test 2743
Fuel Injection Pump 2743
Remove 2743
Clean and Inspect 2746
Install 2747
Cooling System Repair 2748
Serpentine Belt 2748
Remove 2748
Inspect 2748
Install 2748
Adjust 2748
Water Pump 2749
Remove 2749
Install 2750
Thermostat 2751
Remove 2751
Inspect 2752
Install 2752
Flywheel and Flywheel Housing 2754
Flywheel 2754
Remove 2754
Install 2754
Flywheel Housing 2754
Remove 2754
Install 2754
Electrical Equipment Repair 2755
Alternator 2755
Remove 2755
Install 2756
Starter 2757
Remove 2757
Install 2757
Engine Specifications 2759
Engine Data 2759
Engine Tuning 2761
Cylinder Head 2761
Intake/Exhaust Valve and Guide 2762
Valve Spring 2762
Rocker Arm and Shaft 2762
Push Rod 2762
Gear Train and Camshaft 2763
Camshaft 2763
Idle Gear Shaft and Bushing 2763
Backlash of Each Gear 2763
Cylinder Block 2763
Crankshaft 2764
Piston 2764
Piston Ring 2764
Connecting Rod 2765
Rod Small End 2765
Tappet 2765
Oil Pump 2765
Engine Oil Pressure 2765
Inner and Outer Rotor Clearance 2765
Outer Rotor and Pump Body 2765
Rotor and Cover 2766
Standard Torque Specifications 2766
Standard Torque Chart 2766
Special Torque Specifications 2767
Special Tools 2768