Yale H878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GP70VXS9, GP70SVX, GP80SVX Europe) Service Manual PDF

Yale Forklift H878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GP70VXS9, GP70SVX, GP80SVX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift H878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GP70VXS9, GP70SVX, GP80SVX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2196
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift H878 (GP60VX, GLP60VX, GDP60VX, GP70VX, GP70VXS9, GP70SVX, GP80SVX 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
524223770 2200YRM1130 (05 2021) US EN 189
General 193
Description 193
Dash Display Menu Access 193
Menu Navigation 194
Standard Display 194
Main Menu 194
Passwords Menu 195
Password Administration 195
Add Password 195
Delete Password 195
Edit Password 196
Other Password Functions 197
Operator Passwords – Enable/Disable 197
Password Time-Out Delay 197
Passwords – Number Wrong to Disable 197
Lockout Reset Password 198
View Password Log 198
View Versions 199
VSM Versions 199
Dash Display Versions 200
Engine Controller Version 201
Transmission (Xmsn) Controller Version 202
Truck Serial Number 203
Diagnostics 204
View Fault Log 204
Set Travel and Braking 205
Speed Limit 205
Acceleration Rate 206
Auto-Deceleration Rate 206
Set Power Reversal Rate 207
Set Inching/Brake Overlap 208
Setup Display Menu 209
Set Operator Language 209
Set Units 210
Set Time Format (12/24 Hour) 210
Set Daylight Saving Time 211
Set Time 214
Set Date Format 214
Set Date 215
Setup Hydraulics 216
Return to Set Tilt Delay/On/Off 216
Setup General Items 217
Light Shutdown Time-Out 217
Impact Sensor – Enable/Disable 218
Impact Sensor – Soft Impact Settings 219
Impact Sensor – Hard Impact Settings 219
Adjust Impact Sensor Settings 220
Initial Adjustment of Soft and Hard Impact Settings 222
Readjustment of Soft and Hard Impact Settings 222
Impact Sensor – Impact Alarm/Shutdown Reset 223
Impact Sensor – Alarm Time Duration and Deactivation 224
Impact Sensor – View Impact Event Log 225
Engine Mode Indicator 225
Generation 1 (ECO-eLo ONLY) 225
Generation 2 226
Operator Checklist 227
Operator Checklist Off-On Mode 227
Edit Operator Checklist 227
Set Operator Checklist Expiration 227
View Checklist Log 228
Clear Operator Checklist Log 229
Clear Operator Checklist Fault 229
Calibrations 230
Set Tilt Stop Point 230
Calibrate Loaded Weight 230
524223771 2200YRM1131 (05 2021) US EN 233
Series Code / Model Designation Reference Table 239
General 241
Description 241
Dash Display Menu Access 241
Menu Navigation 242
Main Menu 243
Passwords 243
Adding Passwords 243
Hourmeters 245
View Versions 246
VSM Versions 246
Dash Display Versions 247
Engine Controller Version 248
Transmission (Xmsn) Controller Version 249
Truck Serial Number 250
Truck Configuration 251
Diagnostics 252
Clear Fault Log 252
View Fault Log 253
No-Run Data Display 254
Engine Accelerator and Throttle Data Display 255
Engine Speeds and Governor Data Display 257
Engine Fuel and Emissions Data Display 258
Engine General Data Display 260
XMSN/Brake Data Display 261
Hydraulic Data Display 263
General Truck Data Display 266
Set Travel and Braking 268
Speed Limit 268
Acceleration Rate 269
Auto-Deceleration Rate 269
Set Power Reversal Rate 270
Set Inching/Brake Overlap 270
Setup Hydraulics 271
Lift Maximum Speed 271
Lower Maximum Speed 272
Tilt Maximum Speed 272
Auxiliary Function One, Direction A, Maximum Speed 274
Auxiliary Function One, Direction B, Maximum Speed 277
Auxiliary Function Two, Direction A, Maximum Speed 277
Auxiliary Function Two, Direction B, Maximum Speed 278
Auxiliary Function Three, Direction A, Maximum Speed 279
Auxiliary Function Three, Direction B, Maximum Speed 279
Lift/Lower Ramp Rate 280
Hydraulic Auxiliary Ramp Rate 280
Return to Set Tilt Delay/On/Off 281
Hydraulic Input Device 282
Auxiliary Solenoid 282
Dual Function 283
Setup Display 284
Set Service Language 284
Setup General Items 284
Motion Alarm Activation Type 285
Light Shutdown Time-Out 286
Restore Default Settings 286
Restore Engine Controller Default Calibration 287
Impact Sensor – Enable/Disable 287
Impact Sensor – Soft Impact Settings 288
Impact Sensor – Hard Impact Settings 288
Adjust Impact Sensor Settings 289
Initial Adjustment of Soft and Hard Impact Settings 291
Readjustment of Soft and Hard Impact Settings 291
Impact Sensor – Impact Alarm/Shutdown Reset 292
Impact Sensor – Alarm Time Duration and Deactivation 293
Impact Sensor – View Impact Event Log 294
Engine Mode Indicator 294
Generation 1 (ECO-eLo ONLY) 294
Generation 2 295
Diesel Particulate Filter (DPF) Display 296
General Description 296
Passive Regeneration Only 296
Regeneration Level 0 296
Auto/Active Regeneration Inhibited 297
Auto/Active Regeneration 297
Regeneration Level 1 297
Parked Regeneration Request 298
Regeneration Level 2 298
Warning Level 299
Regeneration Level 3 299
Service Level 299
Regeneration Level 4 299
Display, Diesel Particulate Filter (DPF), Revised 299
Operator Interface 300
Refer to Operator Manual 300
CAN Communication Lost 300
Passive Regeneration Only 300
Regeneration Level 0 300
Auto/Active Regeneration Inhibited 301
Auto/Active Regeneration 301
Regeneration Level 1 301
Idle-up Auto/Active Regeneration 301
Parked Regeneration Request 302
Regeneration Level 2 302
Warning Level 303
Regeneration Level 3 303
Service Level 303
Regeneration Level 4 303
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 304
Display, Diesel Particulate Filter (DPF), Stage V Engine 304
Operator Interface 304
Refer to Operator Manual 304
CAN Communication Lost 305
Passive Regeneration Only 305
Regeneration Level 0 305
Auto/Active Regeneration Inhibited 305
Auto/Active Regeneration 306
Regeneration Level 1 306
Idle-up Auto/Active Regeneration 306
Parked Regeneration Request 306
Regeneration Level 2 306
Warning Level 308
Regeneration Level 3 308
Service Level 308
Regeneration Level 4 308
Stage V Content 308
Emissions System Malfunction 308
Ash Load 309
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 310
Operator Interface 310
Refer to Operator Manual 310
CAN Communication Lost 311
Passive Regeneration Only 311
Regeneration Level 0 311
Auto/Active Regeneration Inhibited 311
Auto/Active Regeneration 312
Regeneration Level 1 312
Idle-up Auto/Active Regeneration 312
Parked Regeneration Request 312
Regeneration Level 2 312
Warning Level 314
Regeneration Level 3 314
Service Level 314
Regeneration Level 4 314
Calibrations 315
Calibrate Transmission Valve 317
Set Tilt Stop Point 317
Calibrate Loaded Weight 318
Calibrate Travel Speed Sensor 318
Calibrate Mazda LP and Gas Accelerator Pedal 319
524223780 8000YRM1134 (05 2022) US EN 321
Series Code / Model Designation Reference Table 327
Description 330
Proc_Cal_001: Service Password Entry 332
When to Perform 332
Why Perform 332
How to Perform 332
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 333
When to Perform 333
Calibration Order 333
Why Perform 333
How to Perform 333
Proc_Cal_003: Save and Exit 335
When to Perform 335
Why Perform 335
How to Perform 335
Proc_Cal_004: Lift Valve Output Threshold 336
When to Perform 336
Calibration Order 336
Why Perform 336
How to Perform 336
Proc_Cal_005: Lower Valve Output Threshold 339
When to Perform 339
Calibration Order 339
Why Perform 339
How to Perform 339
Proc_Cal_006: Tilt Back Valve Output Threshold 342
When to Perform 342
Calibration Order 342
Why Perform 342
How to Perform 342
Proc_Cal_007: Tilt Forward Valve Output Threshold 345
When to Perform 345
Calibration Order 345
Why Perform 345
How to Perform 345
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 348
When to Perform 348
Calibration Order 348
Why Perform 348
How to Perform 348
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 351
When to Perform 351
Calibration Order 351
Why Perform 351
How to Perform 351
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 354
When to Perform 354
Calibration Order 354
Why Perform 354
How to Perform 354
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 357
When to Perform 357
Calibration Order 357
Why Perform 357
How to Perform 357
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 360
When to Perform 360
Calibration Order 360
Why Perform 360
How to Perform 360
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 363
When to Perform 363
Calibration Order 363
Why Perform 363
How to Perform 363
Proc_Cal_014: Load Weight Zero Point 366
When to Perform 366
Calibration Order 366
Why Perform 366
How to Perform 366
Proc_Cal_015: Loaded Weight Calibration 368
When to Perform 368
Calibration Order 368
Why Perform 368
How to Perform 368
Proc_Cal_016: Transmission Valve Calibration 371
Applicable System/Option 371
When to Perform 371
Calibration Order 371
Why Perform 371
How to Perform 371
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 373
Applicable System/Option 373
When to Perform 373
Calibration Order 373
Why Perform 373
How to Perform 373
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 376
Applicable System/Option 376
When to Perform 376
Calibration Order 376
Why Perform 376
How to Perform 376
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 379
Required Tools 379
When to Perform 379
Calibration Order 379
Why Perform 379
How to Perform 379
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 381
When to Perform 381
Why Perform 381
How to Perform 381
Proc_Cal_026: Travel Speed Calibration 383
When to Perform 383
Calibration Order 383
Why Perform 383
How to Perform 383
524288194 1300YRM1317 (06 2021) US EN 387
Transmission Repair 391
Remove 391
Torque Converter, Remove 391
Disassemble 392
Clean and Inspect 443
Housings 443
Oil Seals and Gaskets 443
Bearings 443
Gears and Shafts 444
Assemble 444
Torque Converter, Install 486
Install 487
Control Valve Repair 488
Remove 488
Disassemble 488
Clean 490
Inspect 490
Assemble 490
Install 491
Torque Specification 492
524294873 1300YRM1343 (06 2021) US EN 495
Transmission Repair 499
Remove 499
Torque Converter, Remove 499
Disassemble 501
Clean and Inspect 542
Housings 542
Oil Seals and Gaskets 542
Bearings 542
Gears and Shafts 543
Assemble 543
Torque Converter, Install 581
Install 582
Control Valve Repair 583
Remove 583
Disassemble 583
Control Valve Assembly 583
Control Valve Body 583
Clean 586
Inspect 586
Assemble 586
Control Valve Body 586
Control Valve Assembly 587
Install 587
Torque Specification 589
524296605 1400YRM1344 (06 2021) US EN 591
General 595
Identification Plate 595
Drive Axle Removal 596
Planetary Reduction Gear Repair 608
Clean and Inspect 617
Brake Repair 627
Clean and Inspect 639
Wet Brake Noise Reduction 650
General 650
Adding Additive To Transmission 650
Differential Repair 652
Clean and Inspect 662
Bevel Pinion 674
Clean and Inspect 678
Drive Axle Installation 689
Special Tools 701
Torque Specifications 702
550055279 0600YRM1579 (06 2021) US EN 705
General 711
Engine Identification 711
Major Engine Component Identification 711
Location of Labels 711
Crankcase Description 712
Engine Removal and Installation 713
Cylinder Head Assembly Repair 714
Valve Covers and Fuel Injectors 714
Remove 714
Clean and Inspect 717
Install 718
Rocker Arm Assembly 720
Remove 720
Disassemble 721
Clean and Inspect 721
Push Rods 721
Rocker Arm Assembly 722
Assemble 722
Install 722
Valve Clearance Adjustments 723
Cylinder Head Assembly 724
Remove 724
Disassemble 731
Valves and Valve Springs, Remove 731
Valve Guides, Remove 733
Clean and Inspect 733
Cylinder Head 734
Valve Guides 734
Valves 734
Valve Sink 735
Valve Seat 735
Valve Springs 735
Assemble 736
Valve Guides, Install 736
Valves and Valve Springs, Install 737
Install 737
Timing Gear Case and Timing Gears Repair 741
Timing Gear Case Cover 741
Remove 741
Clean and Inspect 741
Install 741
Timing Gears 742
Crankshaft Gear 743
Remove 743
Install 743
Idler Gear 743
Remove 743
Inspect 744
Install 744
Camshaft Gear 744
Remove 744
Install 745
Timing Gear Case 745
Remove 745
Clean and Inspect 746
Install 746
Drive Train, Camshaft, and Cylinder Block Repair 747
Remove 747
Disassemble 747
Pistons and Connecting Rods 747
Crankshaft 748
Camshaft 750
Clean and Inspect 751
Cylinder Block 752
Honing and Boring 754
Cylinder Correction (Oversize) 755
Pistons 755
Piston Pin 756
Connecting Rod 756
Tappets 756
Crankshaft 757
Camshaft 759
Camshaft Bushing 760
Assemble 760
Camshaft 760
Crankshaft 760
Pistons and Connecting Rods 760
Install 762
Lubrication System Repair 764
Engine Oil and Oil Filter Change 764
Oil Pan 765
Remove 765
Install 766
Oil Suction Tube 766
Remove 766
Clean 767
Install 767
Oil Pump 767
Remove 767
Clean and Inspect 767
Outer Rotor Outside Clearance 768
Outer Rotor to Inner Rotor Tip Clearance 768
Outer Rotor Side Clearance 768
Rotor Shaft Clearance 769
Install 769
Fuel System Repair 770
Fuel Injectors 770
Remove 770
Inspect 770
Clean 770
Replace 770
Install 770
Electronic Throttle System 771
Remove 771
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) 774
Bearing Replacement 775
Install 775
Adjustment 776
Fuel Injection Pump 777
Remove 777
Disassemble 780
Clean and Inspect 782
Assemble 782
Install 783
Cooling System Repair 785
Serpentine Belt 785
Remove 785
Inspect 785
Install 785
Serpentine Belt, Adjustment 785
Water Pump 786
Remove 786
Install 788
Thermostat 789
Remove 789
Inspect 790
Install 790
Flywheel and Flywheel Housing 792
Flywheel 792
Remove 792
Install 792
Flywheel Housing 792
Remove 792
Install 792
Electrical Equipment Repair 793
Alternator 793
Remove 793
Install 794
Starter 795
Remove 795
Install 795
Engine Specifications 796
Engine Data 796
Engine Tuning 796
Cylinder Head 797
Intake/Exhaust Valve and Guide 797
Valve Spring 798
Rocker Arm and Shaft 798
Push Rod 798
Gear Train and Camshaft 798
Camshaft 798
Idle Gear Shaft and Bushing 798
Backlash of Each Gear 799
Cylinder Block 799
Crankshaft 799
Piston 799
Piston Ring 800
Connecting Rod 800
Rod Small End 800
Tappet 800
Oil Pump 801
Engine Oil Pressure 801
Outer Rotor Outside Clearance 801
Outer Rotor Side Clearance 801
Inner Rotor to Cover 801
Standard Torque Specifications 802
Standard Torque Chart 802
Special Torque Specifications 803
Special Tools 805
550073240 1900YRM1620 (01 2023) US EN 815
Proper Flushing after Major Hydraulic Repairs 821
Introduction 821
The Phases of Wear 821
Causes of Hydraulic System Failure 821
Progression of Contaminant Caused Hydraulic System Failure 822
Hydraulic System Flushing Techniques 822
Double Oil and Filter Change 822
Mechanical Cleaning 823
Cleaning of Components 823
How to Clean Tubes and Hoses 823
Filter Caddy 823
Start-Up Procedure for Cleaned System 824
Contaminated Oil Coolers 824
Additional Filter Caddy Functions 825
How to Handle Different Fluids 825
Water Removal Filters 825
Fluid Conditioning and System Flushing Procedures 826
Operation of the Filter Caddy 826
Filter Caddy operation 826
Fluid Conditioning Procedure 826
Filter Caddy Start-Up 827
System Flushing Procedure 827
Component Cleaning Procedure 828
Reservoir Cleaning Procedure 828
Cylinder Cleaning Procedure 828
Hose and Tube Cleaning Procedure 828
Valve Cleaning Procedure 829
Front-End Attachment Cleaning Procedure 830
System Flushing Procedure 830
Filter Caddy Start-Up 831
System Start-Up and Flushing 831
Reservoir Fluid Cleaning Times 832
Dealing With Different Fluid Types 833
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 833
Filter Caddy Maintenance 833
Servicing the Strainer 833
DC Motor 833
Hydraulic Oil Sampling Method and Procedure 834
Hydraulic Oil Sampling Method 834
Objective 834
General Guidelines 834
Synopsis 835
Hydraulic Oil Analysis Report Guidelines 836
Sampling Conditions 836
Equipment 836
Sampling Procedure 837
Hydraulic Oil Sampling 837
Sample Labeling 837
Results Documentation 837
550118410 0600YRM1893 (01 2022) US EN 839
General 847
Engine Identification 847
Major Engine Component Identification 847
Major Engine Component Identification 848
Location of Labels 849
Location of Labels 850
Crankcase Description 851
Engine Removal and Installation 852
Cylinder Head Assembly Repair 852
Valve Covers and Ignition Coils 852
Remove 852
Clean and Inspect 857
Install 857
Rocker Arm Assembly 858
Remove 858
Disassemble 860
Clean and Inspect 860
Push Rods 860
Rocker Arm Assembly 860
Assemble 861
Install 861
Valve Clearance Adjustments 861
Cylinder Head Assembly 862
Remove 862
Disassemble 868
Valves and Valve Springs, Remove 868
Valve Guides, Remove 869
Clean and Inspect 869
Cylinder Head 870
Valve Guides 870
Valves 871
Valve Sink 871
Valve Seat 871
Valve Springs 872
Assemble 872
Valve Guides, Install 872
Valves and Valve Springs, Install 873
Install 874
Timing Gear Case and Timing Gears Repair 877
Timing Gear Case Cover 877
Remove 877
Clean and Inspect 877
Install 877
Timing Gears 878
Crankshaft Gear 878
Remove 878
Install 879
Idler Gear 879
Remove 879
Inspect 879
Install 880
Camshaft Gear 880
Remove 880
Install 880
Timing Gear Case 881
Remove 881
Clean and Inspect 881
Install 881
Drive Train, Camshaft, and Cylinder Block Repair 882
Remove 882
Disassemble 882
Pistons and Connecting Rods 882
Crankshaft 883
Camshaft 885
Clean and Inspect 886
Cylinder Block 886
Honing and Boring 889
Cylinder Correction (Oversize) 890
Pistons 890
Piston Pin 891
Connecting Rod 891
Tappets 892
Crankshaft 892
Camshaft 894
Camshaft Bushing 895
Assemble 895
Camshaft 895
Crankshaft 895
Pistons and Connecting Rods 895
Install 897
Lubrication System Repair 899
Engine Oil and Oil Filter Change 899
Oil Pan 900
Remove 900
Install 900
Oil Suction Tube 900
Remove 900
Clean 901
Install 901
Oil Pump 901
Remove 901
Clean and Inspect 902
Outer Rotor Outside Clearance 902
Outer Rotor to Inner Rotor Tip Clearance 902
Outer Rotor Side Clearance 902
Rotor Shaft Clearance 903
Install 903
Fuel System Repair 904
Cooling System Repair 904
Serpentine Belt 904
Remove 904
Inspect 904
Install 904
Serpentine Belt, Adjustment 904
Water Pump 906
Remove 906
Install 908
Thermostat 909
Remove 909
Inspect 910
Install 910
Flywheel and Flywheel Housing 912
Flywheel 912
Remove 912
Install 912
Flywheel Housing 912
Remove 912
Install 912
Electrical Equipment Repair 913
Alternator 913
Remove 913
Install 914
Starter 915
Remove 915
Install 915
Engine Specifications 916
Engine Data 916
Engine Tuning 921
Cylinder Head 921
Intake/Exhaust Valve and Guide 921
Valve Spring 922
Rocker Arm and Shaft 922
Push Rod 922
Gear Train and Camshaft 922
Camshaft 922
Idle Gear Shaft and Bushing 923
Backlash of Each Gear 923
Cylinder Block 923
Crankshaft 923
Piston 924
Piston Ring 924
Connecting Rod 924
Rod Small End 924
Tappet 925
Oil Pump 925
Engine Oil Pressure 925
Outer Rotor Outside Clearance 925
Outer Rotor Side Clearance 925
Inner Rotor to Cover 925
Standard Torque Specifications 926
Standard Torque Chart 926
Special Torque Specifications 927
Special Tools 928
550118414 1900YRM1897 (06 2021) US EN 937
Series Code / Model Designation Reference Table 943
General 944
Hydraulic Gear Pump Assembly Repair 946
Remove 946
Disassemble 949
Clean 951
Inspect 951
Assemble 951
Install 951
Hydraulic Gear Pump Specifications 953
Variable Displacement Pump Repair 955
Remove 955
Disassemble 958
Clean 960
Inspect 960
Assemble 960
Install 960
Variable Displacement Pump Checks and Adjustments 963
Margin Pressure Check 963
Flow Compensator Adjustment 963
Pressure Compensator Adjustment 964
Variable Displacement Pump Specifications 966
Torque Specifications 967
Hydraulic Gear Pump 967
Variable Displacement Pump 967
550118415 2000YRM1898 (06 2021) US EN 969
Series Code / Model Designation Reference Table 975
General 976
Electro-Hydraulic Main Control Valve 977
Description 977
Remove 983
Electro-Hydraulic Control Valve Sections 987
General 987
Outlet Control Valve Section 987
Remove 987
Disassemble 987
Clean 989
Inspect 989
Assemble 989
Install 990
Auxiliary Control Valve Sections 990
Remove 990
Disassemble 992
Clean 992
Inspect 993
Assemble 993
Install 994
Tilt Control Valve Section 994
Remove 994
Disassemble 994
Clean 996
Inspect 996
Assemble 996
Install 996
Lift/Lower Control Valve Section 996
Remove 996
Disassemble 996
Clean 998
Inspect 998
Assemble 998
Install 998
Transition Section 998
Remove 998
Disassemble 999
Clean 999
Inspect 999
Assemble 1000
Install 1000
Install 1000
Manual Main Control Valve 1003
Description 1003
Remove 1005
OPS Solenoid Assembly 1009
General 1009
Remove 1010
Clean and Inspect 1012
Install 1012
Manual Control Valve Sections 1013
General 1013
Outlet Control Valve Section 1013
Remove 1013
Disassemble 1013
Clean 1015
Inspect 1015
Assemble 1015
Install 1015
Auxiliary Control Valve Sections 1016
Remove 1016
Disassemble 1016
Clean 1018
Inspect 1018
Assemble 1018
Install 1018
Lift/Tilt Control Valve Section 1019
Remove 1019
Disassemble 1019
Clean 1021
Inspect 1022
Assemble 1022
Install 1023
Install 1023
Pressure Relief Valve Check and Adjustment 1026
Primary Relief Valve 1026
Secondary Relief Valve 1027
Steering Control Unit Repair 1031
Steering Control Unit, Remove 1031
Steering Control Unit, Disassemble 1032
Steering Control Unit, Clean 1034
Steering Control Unit, Inspect 1034
Steering Control Unit, Assemble 1034
Relief Valve, Disassemble 1035
Relief Valve, Clean 1035
Relief Valve, Inspect 1036
Relief Valve, Assemble 1036
Steering Control Unit, Install 1036
550119576 0900YRM1905 (01 2022) US EN 1039
General 1045
LPG Tank and Bracket Replacement 1046
Remove LPG Tank, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1046
Remove LPG Tank, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1049
Install LPG Tank, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1050
Install LPG Tank, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1050
Remove LPG Bracket, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1051
Remove LPG Bracket, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1053
Install LPG Bracket, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1054
Install LPG Bracket, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1054
Remove LPG Tank Bracket Alignment Pin, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1055
Remove LPG Tank Bracket Alignment Pin, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1057
Install LPG Tank Bracket Alignment Pin, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1057
Install LPG Tank Bracket Alignment Pin, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1058
LPG Fuel Filter Unit Repair 1060
LPG Fuel Filter Element, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1060
Remove/Disassemble 1060
Clean/Inspect 1062
Assemble/Install 1062
LPG Fuel Filter Element, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1062
Remove/Disassemble 1062
Clean/Inspect 1063
Assemble/Install 1063
Fuel Filter Housing, for Lift Truck Models GLC40VX, GLC45VX, GLC55VX, GLC55SVX (GLC080-120VX, GLC080-100VXBCS, GLC120SVX, GLC120VXPRS) (G818) and GLP/GDP40VX, GLP/GDP45VX, GLP/GDP50VX, GLP/GDP55VX (GP/GLP/GDP80-120VX) (K813) 1063
Remove 1063
Disassemble 1069
Clean and Inspect 1070
Assemble 1070
Install 1070
Fuel Filter Housing, for Lift Truck Models GC60-70VX (GC135-155VX) (G879) and GLP/GDP60VX, GLP/GDP70VX, GP70VXS9 (GP/GLP/GDP135VX, GP/GLP/GDP155VX, GP155SVX) (G878) 1071
Remove 1071
Disassemble 1072
Clean and Inspect 1073
Assemble 1073
Install 1074
Electronic Throttle Body Repair 1075
Remove 1075
Install 1077
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 1078
Remove 1078
Install 1081
Control System 1082
Engine Control Unit (ECU) 1082
Remove 1082
Install 1082
LPG Low Level Sensor 1083
Remove 1083
Remove 1085
Install 1086
Exhaust System 1087
Counterweight Exhaust 1087
Remove and Disassemble 1087
Remove and Disassemble 1089
Inspect 1091
Assemble and Install 1091
Assemble and Install 1091
Exhaust Manifold 1091
Remove 1091
Install 1092
Oxygen (HEGO) Sensor 1092
Remove 1092
Install 1092
LPG Fuel Testing 1093
General 1093
Available Fuel Tests 1093
Composition Test (ASTM D-2163) 1093
Ammonia Test (ASTM D-4490) 1093
Basic Nitrogen Test (ASTM UOP269-90) 1093
Residues Test (ASTM D-2158) 1093
Vapor Pressure Test (ASTM D-2598) 1093
Sulfur Compounds Test (ASTM D-5623) 1093
Methanol Test (ASTM D-4864) 1094
Copper Corrosion (ASTM D-1838) 1094
Where To Send LPG Fuel Samples For Testing 1094
550131845 0100YRM1948 (09 2022) US EN 1097
General 1101
Description 1102
Side Covers, Seat, Dash, and Hood Replacement 1103
Side Covers 1103
Remove 1103
Install 1103
Seat and Seat Plate 1104
Remove Seat 1104
Remove Seat Plate 1104
Install Seat Plate 1104
Install Seat 1104
Operator Restraint System 1108
Emergency Locking Retractor (ELR) 1108
Seat Plate and Seat Rail Check 1108
Steering Column, Dash, Kick Panel, and Seal Plate 1108
Remove 1108
Install 1111
Hood Support and Door Assembly 1113
Remove 1113
Install 1114
Hood Door Assembly 1119
Remove 1119
Install 1120
Steering Column 1121
Description 1121
Steering Column Repair 1121
Remove 1121
Disassemble 1122
Clean 1124
Inspect 1124
Assemble 1124
Install 1124
LPG Tank and Bracket Assembly 1124
Counterweight Replacement 1125
Remove 1125
Install 1126
Tow Pin, Remove and Install 1127
Overhead Guard Replacement 1128
Remove 1128
Install 1130
Engine Replacement 1131
Remove Engine 1131
Remove Transmission 1154
Remove Engine and Transmission 1158
Install Engine 1161
Install Transmission 1165
Install Engine and Transmission 1166
Throttle Pedal and Cable Adjustment 1170
Throttle Cable Adjustment, Kubota 3 6L Diesel Tier 3 Engine with Basic Powershift Transmission 1170
Exhaust System Repair 1172
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), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1172
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 1172
Kubota 3 8L Diesel Engine w/DPF 1172
Remove 1174
Inspect 1175
Install 1175
Kubota 3 8L Diesel Engine w/DOC 1175
Remove 1177
Inspect 1178
Install 1178
Kubota 3 6L Diesel Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6 GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1179
Remove 1179
Inspect 1181
Install 1181
Diesel Particulate Filter (DPF) 1182
Diesel Particulate Filter 1182
Disassemble 1182
Clean and Inspect 1183
Differential Pressure Pipes and Hoses 1184
Assemble 1184
Diesel Exhaust Fluid System 1185
General 1185
Description and Operation 1185
Selective Catalyst Reducer (SCR) 1189
Remove 1189
Clean and Inspect 1189
Install 1190
DEF Tank 1190
Remove 1190
Clean and Inspect 1192
Install 1192
Cooling System 1193
Description 1193
Hydraulic Filter Assembly Repair 1194
Remove 1194
Install 1196
Fuel and Hydraulic Tanks Repair 1197
Inspect 1197
Clean 1197
Steam Method of Cleaning 1197
Chemical Solution Method of Cleaning 1198
Additional Preparations for Repair 1198
Small Leaks, Repair 1199
Large Leaks, Repair 1199
Preparations for Use After Repair 1199
Safety Labels 1200
550131847 0600YRM1962 (06 2021) US EN 1209
General 1217
Engine Identification 1217
Major Engine Component Identification 1217
Location of Labels 1218
Cylinder Block Description 1218
Precautions Before Beginning Repair 1219
Exhaust System, SCR, and DPF 1220
Engine Removal and Installation 1221
Cylinder Head Assembly Repair 1221
Valve Covers and Fuel Injectors 1221
Remove 1221
Clean and Inspect 1224
Install 1224
Rocker Arm Assembly 1225
Remove 1225
Disassemble 1226
Clean and Inspect 1226
Push Rods 1226
Rocker Arm Assembly 1226
Assemble 1227
Install 1227
Valve Clearance Adjustments 1227
Cylinder Head Assembly 1228
Remove 1228
Disassemble 1237
Valves and Valve Springs, Remove 1237
Valve Guides, Remove 1238
Clean and Inspect 1238
Cylinder Head 1239
Valve Guides 1239
Valves 1239
Valve Sink 1240
Valve Seat 1240
Valve Springs 1241
Assemble 1241
Valve Guides, Install 1241
Valves and Valve Springs, Install 1242
Install 1243
Timing Gear Case and Timing Gears Repair 1246
Timing Gear Case Cover 1246
Remove 1246
Clean and Inspect 1246
Install 1247
Timing Gears 1248
Crankshaft Gear 1248
Remove 1248
Install 1249
Idler Gear 1 and Idler Gear 2 1249
Remove 1249
Inspect 1251
Install 1251
Idler Gear 3 1251
Remove 1251
Inspect 1251
Install 1251
Camshaft Gear 1252
Remove 1252
Install 1252
Drive Train, Camshaft, and Cylinder Block Repair 1253
Remove 1253
Disassemble 1253
Pistons and Connecting Rods 1253
Crankshaft 1254
Camshaft 1256
Clean and Inspect 1258
Cylinder Block 1258
Honing and Boring 1261
Cylinder Correction (Oversize) 1262
Pistons 1262
Piston Pin 1263
Connecting Rod 1263
Tappets 1264
Crankshaft 1264
Camshaft 1266
Camshaft Bushing 1267
Assemble 1267
Camshaft 1267
Crankshaft 1267
Pistons and Connecting Rods 1267
Install 1269
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 1270
Lubrication System Repair 1273
Engine Oil and Oil Filter Change (Standard Oil Filter) 1273
Engine Oil and Oil Filter Change (Remote Oil Filter) 1274
Oil Pan 1274
Remove 1274
Install 1275
Oil Suction Tube 1275
Remove 1275
Clean 1276
Install 1276
Oil Pump 1276
Remove 1276
Clean and Inspect 1277
Inner Rotor and Outer Rotor Clearance 1277
Outer Rotor and Pump Body Clearance 1278
Rotor and Cover Clearance 1278
Rotor Shaft Clearance 1278
Install 1279
Remote Oil Filter 1279
Remove 1279
Clean and Inspect 1281
Install 1282
Fuel System Repair 1283
Fuel Injectors 1283
Remove 1283
Inspect 1283
Clean 1283
Replace 1283
Install 1284
Test 1284
Fuel Injection Pump 1284
Remove 1284
Clean and Inspect 1288
Install 1288
Cooling System Repair 1289
Serpentine Belt 1289
Remove 1289
Inspect 1289
Install 1289
Adjust 1289
Water Pump 1290
Remove 1290
Install 1291
Thermostat 1292
Remove 1292
Inspect 1293
Install 1293
Flywheel and Flywheel Housing 1295
Flywheel 1295
Remove 1295
Install 1295
Flywheel Housing 1295
Remove 1295
Install 1295
Electrical Equipment Repair 1296
Alternator 1296
Remove 1296
Install 1297
Starter 1298
Remove 1298
Install 1298
Engine Specifications 1300
Engine Data 1300
Engine Tuning 1301
Cylinder Head 1301
Intake/Exhaust Valve and Guide 1302
Valve Spring 1302
Rocker Arm and Shaft 1302
Push Rod 1302
Gear Train and Camshaft 1303
Camshaft 1303
Idle Gear Shaft and Bushing 1303
Backlash of Each Gear 1303
Cylinder Block 1303
Crankshaft 1304
Piston 1304
Piston Ring 1304
Connecting Rod 1305
Rod Small End 1305
Tappet 1305
Oil Pump 1305
Engine Oil Pressure 1305
Inner and Outer Rotor Clearance 1305
Outer Rotor and Pump Body 1305
Rotor and Cover 1306
Standard Torque Specifications 1306
Standard Torque Chart 1306
Special Torque Specifications 1307
Special Tools 1308
550131848 0600YRM1961 (03 2020) US EN 1321
General 1327
Engine Identification 1328
Major Engine Component Identification 1328
Location of Labels 1330
Cylinder Block Description 1331
Precautions Before Beginning Repair 1332
Exhaust System and DPF 1333
Engine Removal and Installation 1333
Cylinder Head Assembly Repair 1333
Valve Covers and Fuel Injectors 1333
Remove 1333
Clean and Inspect 1336
Install 1336
Rocker Arm Assembly 1337
Remove 1337
Disassemble 1337
Clean and Inspect 1338
Push Rods 1338
Rocker Arm Assembly 1338
Assemble 1339
Install 1339
Valve Clearance Adjustments 1339
Cylinder Head Assembly 1340
Remove 1340
Disassemble 1348
Valves and Valve Springs, Remove 1348
Valve Guides, Remove 1349
Clean and Inspect 1349
Cylinder Head 1350
Valve Guides 1350
Valves 1351
Valve Sink 1351
Valve Seat 1351
Valve Springs 1352
Assemble 1352
Valve Guides, Install 1352
Valves and Valve Springs, Install 1353
Install 1354
Timing Gear Case and Timing Gears Repair 1356
Timing Gear Case Cover 1356
Remove 1356
Clean and Inspect 1357
Install 1357
Timing Gears 1358
Crankshaft Gear 1358
Remove 1358
Install 1359
Idler Gear 1 and Idler Gear 2 1359
Remove 1359
Inspect 1360
Install 1361
Idler Gear 3 1361
Remove 1361
Inspect 1361
Install 1361
Camshaft Gear 1361
Remove 1361
Install 1361
Drive Train, Camshaft, and Cylinder Block Repair 1362
Remove 1362
Disassemble 1362
Pistons and Connecting Rods 1362
Crankshaft 1363
Camshaft 1365
Clean and Inspect 1367
Cylinder Block 1367
Honing and Boring 1369
Cylinder Correction (Oversize) 1370
Pistons 1370
Piston Pin 1371
Connecting Rod 1371
Tappets 1372
Crankshaft 1372
Camshaft 1374
Camshaft Bushing 1375
Assemble 1375
Camshaft 1375
Crankshaft 1375
Pistons and Connecting Rods 1376
Install 1378
Angular Deviation Procedure 1378
Lubrication System Repair 1381
Engine Oil and Oil Filter Change 1381
Oil Pan 1382
Remove 1382
Install 1382
Oil Suction Tube 1382
Remove 1382
Clean 1383
Install 1383
Oil Pump 1383
Remove 1383
Clean and Inspect 1384
Inner Rotor and Outer Rotor Clearance 1384
Outer Rotor and Pump Body Clearance 1385
Rotor and Cover Clearance 1385
Rotor Shaft Clearance 1385
Install 1386
Fuel System Repair 1386
Fuel Injectors 1386
Remove 1386
Inspect 1386
Clean 1387
Replace 1387
Install 1387
Test 1387
Fuel Injection Pump 1387
Remove 1387
Clean and Inspect 1390
Install 1390
Cooling System Repair 1391
Serpentine Belt 1391
Remove 1391
Inspect 1391
Install 1391
Adjust 1391
Water Pump 1392
Remove 1392
Install 1394
Thermostat 1394
Remove 1394
Inspect 1395
Install 1395
Flywheel and Flywheel Housing 1396
Flywheel 1396
Remove 1396
Install 1397
Flywheel Housing 1397
Remove 1397
Install 1397
Electrical Equipment Repair 1398
Alternator 1398
Remove 1398
Install 1399
Starter 1400
Remove 1400
Install 1400
Engine Specifications 1402
Engine Data 1402
Engine Tuning 1404
Cylinder Head 1404
Intake/Exhaust Valve and Guide 1405
Valve Spring 1405
Rocker Arm and Shaft 1405
Push Rod 1405
Gear Train and Camshaft 1406
Camshaft 1406
Idle Gear Shaft and Bushing 1406
Backlash of Each Gear 1406
Cylinder Block 1406
Crankshaft 1407
Piston 1407
Piston Ring 1407
Connecting Rod 1408
Rod Small End 1408
Tappet 1408
Oil Pump 1408
Engine Oil Pressure 1408
Inner and Outer Rotor Clearance 1408
Outer Rotor and Pump Body 1408
Rotor and Cover 1409
Standard Torque Specifications 1409
Standard Torque Chart 1409
Special Torque Specifications 1409
Special Tools 1411
550131849 0700YRM1950 (06 2021) US EN 1425
General 1431
Cooling System Checks 1433
Exhaust Leaks Into Cooling System 1433
Water Flow Restrictions in Radiator 1433
Radiator Hoses 1433
Water Pump 1433
Flushing the Cooling System 1434
Cooling System, Clean 1434
Radiator Repair 1435
Remove 1435
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6, GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1435
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1443
Install 1449
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1449
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1451
Fan Assembly Replacement 1453
Remove 1453
Inspect 1458
Install 1458
550131851 1600YRM1952 (06 2021) US EN 1461
General 1467
Steering Axle Assembly Repair 1470
Remove 1470
Disassemble 1471
Clean 1473
Inspect 1473
Assemble 1473
Install 1474
Spindles, Bearings, and Tie Rods Repair 1475
Spindles and Bearings 1475
Remove 1475
Disassemble 1475
Clean 1476
Inspect 1476
Assemble 1476
Install 1477
Tie Rods 1477
Remove 1477
Install 1478
Steering Cylinder Repair 1479
Remove and Disassemble 1479
Clean and Inspect 1479
Assemble and Install 1479
Turn Assist (Lift trucks built after February 2019) 1481
Removal 1481
Install 1484
Adjustment 1484
Torque Specifications 1485
550131852 2100YRM1953 (06 2021) US EN 1487
General 1495
Safety Procedures When Working Near Mast 1495
Tilt Cylinder Repair 1497
Remove 1497
Disassemble 1500
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878); GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1500
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1500
Clean 1501
Inspect 1501
Assemble 1501
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1501
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1502
Install 1503
Tilt Cylinders, Adjust 1505
Tilt Cylinder Leak Check 1507
Lift Cylinder Repair 1508
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1508
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1511
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1516
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878),GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1522
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 1523
Clean 1524
Inspect 1524
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878),GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1524
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1524
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878),GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1525
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1525
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1526
Free-Lift Cylinder Repair 1527
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1527
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1530
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1532
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1533
Clean 1534
Inspect 1534
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1535
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1535
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878)GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1535
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1536
Sideshift Cylinder Repair 1537
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1537
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1537
Clean 1538
Inspect 1538
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1538
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1538
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1538
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1539
Clean 1541
Inspect 1541
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1541
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1541
Bolzoni Sideshift Cylinder Repair 1542
Remove 1542
Disassemble 1542
Clean 1543
Inspect 1543
Assemble 1544
Install 1544
Fork Positioner Cylinder Repair 1545
Remove 1545
Disassemble 1547
Clean 1550
Inspect 1550
Assemble 1551
Install 1552
Lift Cylinder Leak Check 1553
Seal Kit Installation 1554
External Installation (Seal and Back-Up Ring) 1554
Internal Installation (Piston Rod Assembly) 1554
Special Tools 1555
Torque Specifications 1556
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878);GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1556
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1556
550131853 2200YRM1954 (08 2021) US EN 1559
General 1569
Display Switch Cluster 1573
Remove 1573
Install 1575
Direction Control and Turn Signal Levers 1575
Remove 1575
Install 1576
Key Switch 1577
Remove 1577
Install 1577
Display Switch Cluster Panel Bezel and Overlay 1578
Remove 1578
Install 1578
Steering Column Repair 1579
Sensors and Switches 1582
General 1582
Dash and Kick Panel, Remove and Install 1582
Remove 1582
Install 1582
Accelerator Pedal Position Sensor 1583
Remove 1583
Install 1586
Brake Fluid Level Switch 1586
Remove 1586
Install 1587
Service Brake Pedal Position Sensor 1587
Remove 1587
Install 1588
Parking Brake Position Sensor 1588
Remove 1588
Install 1588
Service Brake Pressure Sensor 1589
Remove 1589
Install 1589
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 1590
Remove 1590
Install 1590
Sensor MicroswitchFoot Directional Control 1591
Remove 1591
Install 1593
Low Coolant Level Sensor 1593
Remove 1593
Install 1594
Fuel Level Sensor, Diesel Engines Only 1594
Remove 1594
Install 1595
Seat Sensor (Operator Presence System) 1595
Non-Suspension Seat 1595
Remove 1595
Install 1597
Full Suspension and Swivel Seats 1597
Remove 1597
Install 1597
Hood Shut Off Switch 1598
Remove 1598
Install 1598
Remote Key Switch 1599
Remove 1599
Install 1599
Hydraulic Filter Pressure Switch 1600
Remove 1600
Install 1600
Transmission Speed Sensor 1600
Remove 1600
Install 1601
Transmission Pressure Sensors 1601
Remove 1601
Install 1601
Transmission Temperature Sensor 1602
Remove 1602
Install 1602
Engine Speed Sensor 1602
Remove 1602
Install 1602
Intermediate Speed Sensor 1602
Remove 1602
Install 1602
Return To Set Tilt (Tilt Angle) Sensor 1602
Remove 1602
Install 1603
Rear Horn Button Switch 1603
Remove 1603
Install 1603
Impact Sensor 1604
Remove 1604
Install 1604
Load Weight Sensor 1605
Remove 1605
Install 1605
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 1606
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 1607
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 1607
Air Filter Restriction Switch 1607
Remove 1607
Install 1607
Engine Oil Pressure Sensor 1608
Remove 1608
Install 1608
Engine Speed Sensor 1608
Remove 1608
Install 1608
Engine Coolant Temperature (ECT) Sensor 1609
Remove 1609
Install 1609
Fuel/Water Separator Sensor 1609
Remove 1609
Install 1609
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 1610
Engine Coolant Temperature (ECT) Sensor 1610
Remove 1610
Install 1610
Throttle Position Sensor 1611
Engine Oil Pressure Sensor 1611
Remove 1611
Install 1611
Fuel Shut Off Solenoid 1611
Remove 1611
Install 1612
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) 1612
Intake Air Temperature Sensor 1613
Remove 1613
Install 1613
Boost Sensor 1613
Remove 1613
Install 1613
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 1615
Remove 1615
Install 1616
Engine Coolant Temperature (ECT) Sensor 1616
Remove 1616
Install 1616
Engine Oil Pressure Sensor 1616
Remove 1616
Install 1617
Crankshaft Position Sensor 1617
Remove 1617
Install 1617
Adjust Shim Procedure 1617
Camshaft Position Sensor 1619
Remove 1619
Install 1619
Differential Pressure Sensor 1619
Remove 1619
Install 1620
Oxygen Sensors (Inlet and Outlet) 1620
Remove 1620
Install 1621
Inlet Temperature Sensor 1621
Remove 1622
Install 1622
Mass Air Flow Sensor 1622
Remove 1622
Install 1622
Fuel/Water Separator 1622
Remove 1622
Install 1623
Air Filter Restriction Switch 1623
Remove 1623
Install 1623
Vehicle System Manager (VSM) 1624
General 1624
VSM Replacement 1624
Remove 1624
Install 1624
Programming A New VSM And/Or Display Switch Cluster 1625
Data Transferring 1626
New VSM 1626
New (Blank) Display Switch Cluster 1626
Used (Non-Blank) Display Switch Cluster 1626
PC Service Tool Software 1627
Power Distribution Module (PDM) and Component Parts 1628
Remove 1628
PDM as a Unit 1628
Install 1629
PDM as a Unit 1629
Remove and Install 1629
PDM Component Parts 1629
Transmission Control Unit (TCU) 1630
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured Before December, 2018 1630
Remove 1630
Install 1631
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 1632
Remove 1632
Install 1633
Lift Trucks Equipped with a 3-Speed Transmission and Manufactured After July, 2021 1633
Remove 1633
Install 1635
Battery 1637
Remove 1637
Install 1637
Lights 1638
Work Lights (Front and Rear) 1638
Halogen Bulb Lights 1638
Remove 1638
Install 1638
LED Lights 1638
Remove 1638
Install 1638
Strobe Light 1639
Remove 1639
Install 1639
LED Tail, Backup, and Brake Lights 1640
Remove 1640
Install 1640
Front Marker/Turn Signal Lights 1641
Replacing Whole Front Marker/Turn Signal Light Assembly 1641
Remove 1641
Install 1641
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 1642
Remove 1642
Install 1642
Electronic-Hydraulic Controls, Before January, 2020 1643
E-Hydraulic Controls – TEST 1643
Mini-Levers 1643
Full Stroke Test 1643
Function Returns to Neutral Test 1643
Push (Override) Button Switch 1643
General 1644
Mini-levers, Remove and Install 1644
Armrest Assembly 1645
Remove 1645
Install 1648
Horn Button 1648
Remove 1648
Install 1648
Direction Control Switch 1648
Remove 1648
Install 1649
Push (Override) Button 1649
Remove 1649
Install 1650
Electronic-Hydraulic Controls, After January, 2020 1651
E-Hydraulic Controls – TEST 1651
Mini-Levers 1651
Full Stroke Test 1651
Function Returns to Neutral Test 1651
Push Button Switch 1651
General 1652
Mini-levers, Remove and Install 1652
Armrest Assembly 1653
Remove 1653
Install 1656
Horn Button 1656
Remove 1656
Install 1656
Direction Control Switch 1656
Remove 1656
Install 1657
Push (Override) Buttons 1657
Remove 1657
Install 1658
Diesel Particulate Filter (DPF) Display 1659
Remove 1659
Clean and Inspect 1660
Install 1660
Special Tools 1661
550131855 4000YRM1956 (06 2021) US EN 1665
Safety Procedures When Working Near Mast 1671
Fork Replacement 1673
General 1673
Remove 1673
Install 1674
Checks 1674
Carriage Repair 1676
Remove 1676
Clean and Inspect 1679
Install 1679
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1680
Connecting Attachment Hydraulic Quick Disconnect Hoses 1681
Integral Sideshift Carriage And Fork Positioners Repair 1682
Integral Sideshift Carriage 1682
Remove 1682
Disassemble 1683
Clean and Inspect 1686
Assemble 1686
Install 1686
Fork Positioners 1687
Remove 1687
Disassemble 1690
Clean and Inspect 1692
Assemble 1692
Install 1692
Hang-On Sideshift Carriage Repair 1693
Remove 1693
Disassemble Carriage 1696
Clean and Inspect 1698
Assemble 1698
Install 1701
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 1704
Remove 1704
Disassemble 1708
Clean and Inspect 1711
Assemble 1713
Install 1713
Header Hose Installation 1714
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 1718
Remove 1718
Disassemble 1721
Clean and Inspect 1724
Assemble 1726
Install 1726
Header Hose Installation 1727
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 1731
Remove 1731
Disassemble 1734
Clean and Inspect 1737
Assemble 1739
Install 1739
Header Hose Installation 1740
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 1744
Remove 1744
Disassemble 1748
Clean and Inspect 1751
Assemble 1753
Install 1753
Header Hose Installation 1754
Mast Operation Check 1758
Tilt Cylinder Adjustment 1758
Main Lift Cylinder Repair 1758
Lift Chain Adjustment 1759
Mast Adjustments 1761
Load Roller Adjustment 1761
Mast Side Kicking Adjustment 1762
Carriage Adjustment 1763
550136209 1800YRM1977 (08 2022) US EN 1767
General 1773
Wet Brake System 1773
Parking Brake Repair 1774
Master Cylinder Repair, For Lift Truck Models F878/G878/H878 1778
Remove 1778
Disassemble 1778
Clean and Inspect 1780
Assemble 1780
Install and Adjust 1780
Accumulator; For Lift Truck Models F878/G878/H878 1782
Pre-Charge Check 1782
Remove 1782
Install 1783
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For Lift Truck Models C909/D909 1784
Remove 1784
Modulating Brake Valve 1785
Disassemble 1785
Clean and Inspect 1786
Assemble 1787
Accumulator Charge Valve 1787
Disassemble 1787
Clean and Inspect 1789
Assemble 1789
Install 1790
Pressure Checks 1791
Accumulator Charge Valve Check 1791
Accumulator Check 1791
Brake System Air Removal; For Lift Truck Models 1792
Using Pressure Bleed System 1792
Using Brake Pedal Pressure 1792
Lift Truck Models with Master Cylinder 1792
Brake System Air Removal for Lift Truck Models C909/D909 1794
Using Brake Pedal Pressure 1794
Lift Truck Models with Modulating Brake Valve 1794
Brake Pedal Adjustment 1794
For Lift Truck Models F878/G878/H878 1794
For Lift Truck Models C909/D909 1795
Free Pedal Adjustment 1797
Torque Specifications 1798
550229998 0600YRM2295 (06 2021) US EN 1801
General 1809
Engine Identification 1810
Major Engine Component Identification 1810
Location of Labels 1811
Cylinder Block Description 1812
Precautions Before Beginning Repair 1813
Exhaust System, SCR, and DPF 1814
Engine Removal and Installation 1815
Cylinder Head Assembly Repair 1815
Valve Covers and Fuel Injectors 1815
Remove 1815
Clean and Inspect 1818
Install 1818
Rocker Arm Assembly 1819
Remove 1819
Disassemble 1820
Clean and Inspect 1820
Push Rods 1820
Rocker Arm Assembly 1820
Assemble 1821
Install 1821
Valve Clearance Adjustments 1821
Cylinder Head Assembly 1823
Remove 1823
Disassemble 1831
Valves and Valve Springs, Remove 1831
Valve Guides, Remove 1832
Clean and Inspect 1832
Cylinder Head 1833
Valve Guides 1833
Valves 1833
Valve Sink 1834
Valve Seat 1834
Valve Springs 1835
Assemble 1835
Valve Guides, Install 1835
Valves and Valve Springs, Install 1836
Install 1837
Timing Gear Case and Timing Gears Repair 1840
Timing Gear Case Cover 1840
Remove 1840
Clean and Inspect 1840
Install 1841
Timing Gears 1841
Crankshaft Gear 1842
Remove 1842
Install 1842
Idler Gear 1 and Idler Gear 2 1842
Remove 1842
Inspect 1843
Install 1844
Idler Gear 3 1844
Remove 1844
Inspect 1844
Install 1844
Camshaft Gear 1844
Remove 1844
Install 1844
Drive Train, Camshaft, and Cylinder Block Repair 1845
Remove 1845
Disassemble 1845
Pistons and Connecting Rods 1845
Crankshaft 1846
Camshaft 1848
Clean and Inspect 1850
Cylinder Block 1850
Honing and Boring 1853
Cylinder Correction (Oversize) 1854
Pistons 1854
Piston Pin 1855
Connecting Rod 1855
Tappets 1856
Crankshaft 1856
Camshaft 1858
Camshaft Bushing 1859
Assemble 1859
Camshaft 1859
Crankshaft 1859
Pistons and Connecting Rods 1859
Install 1861
Angular Deviation Procedure 1862
Lubrication System Repair 1865
Engine Oil and Oil Filter Change (Standard Oil Filter) 1865
Engine Oil and Oil Filter Change (Remote Oil Filter) 1865
Oil Pan 1866
Remove 1866
Install 1866
Oil Suction Tube 1867
Remove 1867
Clean 1867
Install 1867
Oil Pump 1867
Remove 1867
Clean and Inspect 1868
Inner Rotor and Outer Rotor Clearance 1868
Outer Rotor and Pump Body Clearance 1869
Rotor and Cover Clearance 1869
Rotor Shaft Clearance 1869
Install 1869
Remote Oil Filter 1870
Remove 1870
Clean and Inspect 1872
Install 1873
Fuel System Repair 1874
Fuel Injectors 1874
Remove 1874
Inspect 1874
Clean 1874
Replace 1874
Install 1875
Test 1875
Fuel Injection Pump 1875
Remove 1875
Clean and Inspect 1879
Install 1879
Cooling System Repair 1880
Serpentine Belt 1880
Remove 1880
Inspect 1880
Install 1880
Adjust 1880
Water Pump 1881
Remove 1881
Install 1882
Thermostat 1884
Remove 1884
Inspect 1884
Install 1885
Flywheel and Flywheel Housing 1886
Flywheel 1886
Remove 1886
Install 1886
Flywheel Housing 1886
Remove 1886
Install 1886
Electrical Equipment Repair 1887
Alternator 1887
Remove 1887
Install 1888
Starter 1889
Remove 1889
Install 1889
Engine Specifications 1891
Engine Data 1891
Engine Tuning 1892
Cylinder Head 1893
Intake/Exhaust Valve and Guide 1893
Valve Spring 1894
Rocker Arm and Shaft 1894
Push Rod 1894
Gear Train and Camshaft 1894
Camshaft 1894
Idle Gear Shaft and Bushing 1894
Backlash of Each Gear 1895
Cylinder Block 1895
Crankshaft 1895
Piston 1896
Piston Ring 1896
Connecting Rod 1896
Rod Small End 1896
Tappet 1897
Oil Pump 1897
Engine Oil Pressure 1897
Inner and Outer Rotor Clearance 1897
Outer Rotor and Pump Body 1897
Rotor and Cover 1897
Standard Torque Specifications 1898
Standard Torque Chart 1898
Special Torque Specifications 1899
Special Tools 1900
550255917 8000YRM2402 (06 2021) US EN 1915
Lift Truck Lifting Capacity 1921
Counterweight Weights 1921
Tire Sizes 1921
Capacities 1921
Electrical System 1925
Transmission Oil Pressures 1926
Hydraulic System Relief Pressures 1927
Steering System 1928
Stall Speeds 1928
Kubota 3 8L LPG GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1928
Kubota 3 6L Diesel GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1928
Kubota 3 8L Diesel GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 1928
Mast Speeds 1929
Tilt Angles 1930
Front End Equipment – Mast Creep 1930
Mast Creep 1930
Engine Specifications 1931
Torque Specifications 1935
Frame 1935
Mast 1935
Hang On Sideshift Carriage With Fork Positioner 1935
Steering System 1935
Transmission 1936
Fuel System- Kubota 3 8L Diesel 1936
Fuel System- Kubota 3 8L LPG 1936
Engine – Kubota 3 6L Diesel 1936
Engine – Kubota 3 8L Diesel 1937
Engine – Kubota 3 8L LPG 1938
550255918 8000YRM2400 (10 2021) US EN 1941
General Information About Diagrams and Schematics 1947
Symbol Definitions 1947
Diagrams Manual Applications 1948
Schematics/Diagrams 1950
Schematics and Diagrams 1950
550256065 8000YRM2401 (12 2021) US EN 2049
General 2057
Serial Number Data 2057
How to Move Disabled Lift Truck 2057
How to Tow Lift Truck 2057
How to Put Lift Truck on Blocks 2058
How to Raise Drive Tires 2058
How to Raise Steering Tires 2059
How to Clean a Lift Truck 2060
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 2060
Connecting Attachment Hydraulic Quick Disconnect Hoses 2061
Safety Procedures When Working Near Mast 2062
Maintenance Schedule 2064
Maintenance Procedures Every 8 Hours or Daily 2084
How to Make Checks With Engine Stopped 2084
Tires and Wheels 2084
Safety Labels 2084
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2084
Operator Restraint System 2085
Emergency Locking Retractor (ELR) 2085
Seat Plate and Seat Rails 2086
Engine Compartment 2086
Paper Application 2086
Fuel, Oil, and Coolant Leaks, Check 2087
Hydraulic Hoses 2087
Coolant Hoses 2087
Steering Column Gas Cylinder 2088
Transmission 2088
Hydraulic System Oil 2088
Engine Oil 2089
Air Filter 2094
Forks 2094
Inspect 2095
Remove 2096
Install 2096
Adjust 2096
Hang On Sideshift Carriage 2097
How to Make Checks With Engine Running 2098
Indicator Lights, Horn, Fuses, and Relays 2098
Service Brakes 2101
Brake Oil Level 2101
Operation, Check 2101
Parking Brake 2101
Engine Oil Pressure 2102
Cooling System 2102
Steering System 2103
Control Levers and Pedals 2103
Lift System, Operate 2103
Air Filter 2104
Fuel/Water Separator Filter, Kubota Diesel Engine 2104
First Service After First 100 Hours of Operation 2105
4 3L Engine Oil and Oil Filter 2105
Kubota Diesel Engine Oil and Oil Filter 2105
Hang on Sideshift Carriage Checks 2106
Maintenance Procedures Every 250 Hours or 6 Months 2108
Kubota Diesel Engine Oil and Oil Filter 2108
Drive Belt 2110
4 3L Engine 2110
Fan and Alternator Drive Belt 2110
Drain Tar From LPG Converter 2111
Cleaning Carbon Buildup From Intake Valves – Kubota 3 8L LPG Engines 2111
Maintenance Procedures Every 500 Hours or 6 Months 2114
Hydraulic System Oil 2114
Hydraulic Tank Breather 2115
Inspect 2115
Battery 2115
Kubota Diesel Engine Oil and Oil Filter 2116
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engines 2117
Remove 2117
Install 2118
Priming the Fuel System (Kubota 3 8L Engine) 2119
Fuel/Water Separator Filter Replacement, Kubota 3 6L Engine 2119
Remove 2119
Install 2119
Priming the Fuel System (Kubota 3 6L Engine) 2120
Drive Belt 2120
Kubota Diesel Engine 2120
Fan and Alternator Drive Belt 2120
Clean Debris From Radiator Core 2121
Transmission Oil Breather/Dipstick 2121
Differential and Drive Axle Oil Level Check 2122
Forks, Inspect 2124
Mast Lubrication 2125
Tilt Cylinder Lubrication 2130
Header Hose Checks 2130
Lift Chain Lubrication 2131
Master Brake Cylinder Rod End Pin Lubrication 2131
Manual Hydraulic Levers Lubrication 2131
Cab Heater Air Filter 2131
Brake Oil 2133
Tie Rod Lubrication 2134
Parking Brake Adjustment 2135
Maintenance Procedures Every 1000 Hours or 6 Months 2136
Valve Clearance, Check and Adjust, Kubota 3 6L Engine 2136
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 2136
Ignition System 2136
3 8L Engine 2136
LPG Fuel Filter Element Replace, 3 8L Engine 2136
Remove 2136
Install 2136
In-Line Strainer Replacement, Kubota Diesel Engine 2137
Remove 2137
Install 2137
Lift Chains Wear Check 2139
Lift Chain Lubrication 2139
Hang On Sideshift Carriage, Check Sliding Surfaces 2139
Steering Axle Spindle Bearings 2141
Control Levers and Pedals 2141
Inspect Engine Electrical System, Connectors 2141
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2142
Parking Brake Lever Lubrication, Wet Brake Axle 2145
Normal Operating Environment 2145
Heavy Duty or Contaminated Environment 2146
Remove 2146
Clean and Inspect 2147
Install 2147
Crankcase Breather Element, Kubota 3 8L Diesel 2148
Remove 2148
Clean and Inspect 2148
Install 2149
DEF Injector Tip 2149
Maintenance Procedures Every 2000 Hours or Annually 2150
Hydraulic System 2150
Hydraulic Filter Assembly, Replace 2150
Install 2152
Hydraulic Tank Breather, Replace 2152
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2154
Cooling System Check 2154
Air Filter 2155
Fuel Injector, Kubota 3 8L Engine 2157
Fuel Injector, Kubota 3 6L Engine 2157
Forks 2157
Brake Oil (Master Cylinder), Change 2159
Check Throttle Shaft for Sticking 2159
Inspect Exhaust Manifold and Piping for Leaks 2160
Transmission Automatic Clutch Calibration 2160
Wheel Bearings 2160
Steer Wheels, Lubrication 2160
Maintenance Procedures Every 3000 Hours 2161
Diesel Particulate Filter 2161
Remove 2161
Disassemble 2163
Servicing the Diesel Particulate Filter, Pressure Tubes and Pressure Hoses 2164
Assemble 2164
Install 2165
Diesel Exhaust Fluid (DEF) System 2165
Maintenance Procedures Every 4000 Hours or 2 Years 2168
Hydraulic Oil, Replace 2168
Overhead Guard Changes 2169
Jump-Starting the Lift Truck 2170
Jump-Starting Using a Battery Charger 2170
Jump-Starting a Lift Truck Using Another Lift Truck 2170
Wheel and Tire Replacement 2170
General 2170
Pneumatic Tire With Tube, Repair 2170
Remove Wheels From Lift Truck 2170
Remove Tire From Wheel 2171
Install Wheel in Tire 2174
Install Tire on Two-Piece Wheel 2176
Add Air to Pneumatic Tires With Tube 2177
Install the Wheels 2177
Dual Drive Wheels, Install 2177
Pneumatic Tubeless Tire, Repair 2179
Remove Wheels From Lift Truck 2179
Add Air to Pneumatic Tubeless Tire 2184
Wheels, Install 2184
Solid Rubber Tires on Pneumatic Wheels, Change 2184
Wheels, Install 2188
Fuel Filter Water Removal 2189
Kubota Diesel Engine 2189
3 8L Diesel Engine 2189
3 6L Diesel Engine 2190
Lift Chain Adjustments 2192
Welding Repairs 2194
Adhesives and Sealants 2194