Yale Forklift G879 (GC135VX, GC155VX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift G879 (GC135VX, GC155VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift G879 (GC135VX, GC155VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2646
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift G879 (GC135VX, GC155VX) Service Manual – PDF DOWNLOAD

524150797-8000YRM0231-(02-2023)-US-EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797-8000YRM0231-(12-2021)-US-EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524223757-0700YRM1123-(06-2021)-US-EN 43
General 47
Cooling System Checks 47
Exhaust Leaks Into Cooling System 47
Water Flow Restrictions in Radiator 47
Radiator Hoses 47
Water Pump 47
Flushing the Cooling System 49
Cooling System, Clean 49
Radiator Replacement 51
Radiator, Remove GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX, GLC55SVX,(GC/GLC080, 100, 120VX, GC/GLC080,100VXBCS, GC/GLC120SVX,GC/GLC120VXPRS) (E818, F818) ANDGLP/GDP40VX5/VX6, GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 51
Radiator, Remove for Lift Trucks Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) AND GLP/GDP20-25LX(GLP/GDP050LX) (A974) 66
Radiator, Remove for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 69
Radiator , Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX(GP/GLP/GDP135VX, GP/GLP/GDP155VX)(C878, D878, E878) and GLP/GDP80VX,GLP/GDP80VX9, GLP/GDP90VX(GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909, B909) 72
Radiator, Install for Lift Truck Models GC/GLC030VX,GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX (GP/GLP/GDP030VX,GP/GLP/GDP035VX, GP/GLP/GDP040SVX)(C810); GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910); GLC050LX(A967); GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875);GLP/GDP20-25LX (GLP/GDP050LX)(A974); GLC40, 45, 55VX; GLC55SVX;(GC/GLC080, 100, 120VX; GC/GLC080,100VXBCS; GC/GLC120SVX;GC/GLC120VXPRS) (E818, F818) andGLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) 78
Radiator, Install for Lift Truck Models Equipped with Oil CoolerGC/GLC030VX, GC/GLC035VX,GC/GLC040SVX (C809); GLP/GDP16VX,GLP/GDP18VX, GLP/GDP20SVX(GP/GLP/GDP030VX, GP/GLP/GDP035VX,GP/GLP/GDP040SVX) (C810); GLC050LX(A967) and GLP/GDP20-25LX(GLP/GDP050LX) (A974) 82
Radiator, Install for Lift Truck Models GLC/GDC60VX,GLC/GDC60VX, (GC/GLC/GDC135VX,GC/GLC/GDC135VX) (C879, D879, E879,F879, G879) 83
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 86
Fan Assembly Replacement 97
Fan Removal 97
Inspect 111
Fan Installation 112
524223764-1600YRM1133-(07-2013)-US-EN 117
toc 117
Steering Axle 117
Safety Precautions Maintenance and Repair 118
General 121
Steering Axle Assembly Repair 123
Remove 123
Disassemble 124
Clean 132
Inspect 132
Assemble 132
Install 138
Spindles, Bearings, and Tie Rods Repair 140
Spindles and Bearings 140
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 140
Remove 140
Disassemble 142
Clean 143
Inspect 143
Assemble 143
Install 144
Spindles and Bearings 147
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 147
Remove and Disassemble 147
Assemble and Install 148
Tie Rods 148
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 148
Remove 148
Install 149
Tie Rods 150
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 150
Remove 150
Install 156
Steering Cylinder Repair 156
Remove and Disassemble 156
Clean and Inspect 157
Assemble and Install 157
Torque Specifications 158
524223766-1900YRM1136-(01-2022)-US-EN 163
General 167
Hydraulic Gear Pump Assembly 168
Variable Displacement Pump Assembly 169
Single Gear Pump Assembly Repair 170
Remove 170
Disassemble 176
Clean 178
Inspect 178
Assemble 178
Install 178
Tandem Gear Pump Assembly 183
Remove 183
Disassemble 184
Clean 187
Inspect 187
Assemble 187
Install 188
Gear Pump Specifications 189
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 195
Remove 195
Disassemble 205
Clean 208
Inspect 209
Assemble 209
Install 209
63 0 cc/rev – Variable Displacement Pump Repair 214
Remove 214
Disassemble 217
Clean 219
Inspect 219
Assemble 219
Install 219
Variable Displacement Pump Checks and Adjustments (Single Pump) 223
Margin Pressure Check 223
Flow Compensator Adjustment 224
Pressure Compensator Adjustment 224
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 226
Variable Displacement Pump Specifications 229
Torque Specifications 231
Hydraulic Gear Pump 231
Variable Displacement Pump 232
Special Tools 233
524223767-2000YRM1137-(06-2021)-US-EN 235
General 239
Electro-Hydraulic Main Control Valve 240
Description 240
Remove 248
Electro-Hydraulic Control Valve Sections 253
General 253
Outlet Control Valve Section 253
Remove 253
Disassemble 253
Clean 256
Inspect 256
Assemble 257
Install 257
Auxiliary Control Valve Sections 257
Remove 258
Disassemble 263
Clean 265
Inspect 265
Assemble 265
Install 267
Tilt Control Valve Section 268
Remove 268
Disassemble 269
Clean 273
Inspect 273
Assemble 274
Install 275
Lift/Lower Control Valve Section 275
Remove 275
Disassemble 275
Clean 281
Inspect 281
Assemble 281
Install 282
Mid-Inlet Section 282
Remove 282
Clean 283
Inspect 283
Install 283
Install 283
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 288
Lift Pilot Pin 288
Lower Pilot Pin 291
Abnormal/Erroneous EHPV Adjustment 293
Manual Main Control Valve 294
Description 294
Remove 298
OPS Solenoid Assembly 306
General 306
Remove 307
Clean and Inspect 309
Install 309
Manual Control Valve Sections 310
General 310
Outlet Control Valve Section 310
Remove 310
Disassemble 310
Clean 313
Inspect 313
Assemble 313
Install 313
Auxiliary Control Valve Sections 314
Remove 314
Disassemble 314
Clean 317
Inspect 317
Assemble 317
Install 317
Lift/Tilt Control Valve Section 318
Remove 318
Disassemble 318
Clean 324
Inspect 324
Assemble 324
Install 326
Mid-Inlet Section 326
Remove 326
Clean 327
Inspect 327
Install 327
Install 327
Pressure Relief Valve Check and Adjustment 335
Primary Relief Valve 335
Secondary Relief Valve 338
Steering Control Unit Repair 343
Steering Control Unit, Remove 343
Steering Control Unit, Disassemble 347
Steering Control Unit, Clean 349
Steering Control Unit, Inspect 349
Steering Control Unit, Assemble 349
Relief Valve, Disassemble 350
Relief Valve, Clean 350
Relief Valve, Inspect 351
Relief Valve, Assemble 351
Steering Control Unit, Install 351
524223769-2200YRM1128-(01-2023)-US-EN 355
Series Code / Model Designation Reference Table 363
General 365
Deutsch Crimping Tool 366
How to Strip a Wire for Use With Deutsch Crimping Tool 366
How to Crimp With the Deutsch Crimping Tool 367
Calibration Test for the Deutsch Crimping Tool 369
Deutsch Connectors 371
DT, DTM, and DTP Series Connectors 371
HD Series Connectors 414
Metri-Pack Connectors 436
Remove and Install 436
Micro-Pack Connectors 439
Weather-Pack Connectors 440
AMPSEAL Crimping Tools 442
AMP Hand Crimping Tool With Certi-Crimp 442
Description 442
Stripping Wire for Use with AMP Hand Crimping Tool 443
Insulation Crimp Adjustment 444
Maintenance and Inspection for AMP Hand Crimping Tool 444
AMP Hand Crimping Tool 444
Crimp Height Inspection 444
How to use AMP Hand Crimping Tool 445
AMP Pro-Crimper II Tool 445
Description 445
Remove and Install Die Set and Locator Assembly 446
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 446
Contact Support Adjustment 447
Crimp Height Adjustment 448
Maintenance and Inspection Procedures 448
PRO-CRIMPER II Tool 448
Crimp Height Inspection 448
How to Use AMP PRO-CRIMPER II Tool 449
AMPSEAL Connector Assemblies 450
Description for Plug Connector Assembly 450
Seal Plug 451
Contact Crimping 451
Description for Plug Connector and Header Assembly 456
Voltage Reading 459
Seal Plug 459
Contact Crimping 459
AMP Superseal 1 5 Crimping Tools 466
Mini Mic Receptacle and Tab Contacts 466
Description 466
Crimping Conditions and Measurements 466
Insertion of Rubber Seal on Cable 468
AMP Hand Application Tool 473
Description 473
Maintenance and Inspection 473
Crimp Height Inspection 473
Crimp Height Adjustment 474
How to Use AMP Hand Application Tool 474
AMP Pro-Crimper II Tool 475
Description 475
Remove and Install Die Set and Locator Assembly 475
Adjustments 476
Contact Support 476
Crimp Height 477
Inspections and Maintenance 478
Crimp Height Inspection 478
Visual Inspection 478
Maintenance 479
How to Use Pro-Crimper II Tool 479
AMP Superseal 1 5 Connector Assemblies 480
Description 480
Repair and Maintenance 487
Panel Mount Option 487
AMP Fastin-Faston Hand Tools 488
Description – AMP Double Action Hand Tool 488
Maintenance and Inspection Procedures 488
Daily Maintenance 488
Periodic Tool Inspection 489
Lubrication 489
Visual Inspection 489
Crimp Height Inspection 489
Certi-Crimp Ratchet Inspection 490
How to Use AMP Double Action Hand Tool 491
Description – AMP Extraction Tool 492
Maintenance and Inspection 493
How to Use AMP Extraction Tool 493
AMP Fastin-Faston Receptacles and Housings 495
Description 495
Wire Repair 503
Wire Splicing Requirements 503
Deutsch Jiffy Splice 504
Twisted/Shielded Cable and Leads Repair 510
Special Tools 512
524223769-2200YRM1128-(06-2021)-US-EN 521
Series Code / Model Designation Reference Table 527
General 530
Deutsch Crimping Tool 530
How to Strip a Wire for Use With Deutsch Crimping Tool 530
How to Crimp With the Deutsch Crimping Tool 532
Calibration Test for the Deutsch Crimping Tool 533
Deutsch Connectors 536
DT, DTM, and DTP Series Connectors 536
HD Series Connectors 579
Metri-Pack Connectors 601
Remove and Install 601
Micro-Pack Connectors 604
Weather-Pack Connectors 605
AMPSEAL Crimping Tools 607
AMP Hand Crimping Tool With Certi-Crimp 607
Description 607
Stripping Wire for Use with AMP Hand Crimping Tool 608
Insulation Crimp Adjustment 608
Maintenance and Inspection for AMP Hand Crimping Tool 608
AMP Hand Crimping Tool 608
Crimp Height Inspection 608
How to use AMP Hand Crimping Tool 610
AMP Pro-Crimper II Tool 611
Description 611
Remove and Install Die Set and Locator Assembly 611
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 612
Contact Support Adjustment 612
Crimp Height Adjustment 613
Maintenance and Inspection Procedures 613
PRO-CRIMPER II Tool 613
Crimp Height Inspection 613
How to Use AMP PRO-CRIMPER II Tool 614
AMPSEAL Connector Assemblies 615
Description for Plug Connector Assembly 615
Seal Plug 615
Contact Crimping 616
Description for Plug Connector and Header Assembly 620
Voltage Reading 622
Seal Plug 622
Contact Crimping 622
AMP Superseal 1 5 Crimping Tools 629
Mini Mic Receptacle and Tab Contacts 629
Description 629
Crimping Conditions and Measurements 629
Insertion of Rubber Seal on Cable 631
AMP Hand Application Tool 637
Description 637
Maintenance and Inspection 637
Crimp Height Inspection 637
Crimp Height Adjustment 638
How to Use AMP Hand Application Tool 638
AMP Pro-Crimper II Tool 639
Description 639
Remove and Install Die Set and Locator Assembly 640
Adjustments 640
Contact Support 640
Crimp Height 641
Inspections and Maintenance 642
Crimp Height Inspection 642
Visual Inspection 643
Maintenance 643
How to Use Pro-Crimper II Tool 643
AMP Superseal 1 5 Connector Assemblies 644
Description 644
Repair and Maintenance 651
Panel Mount Option 651
AMP Fastin-Faston Hand Tools 652
Description – AMP Double Action Hand Tool 652
Maintenance and Inspection Procedures 653
Daily Maintenance 653
Periodic Tool Inspection 653
Lubrication 653
Visual Inspection 653
Crimp Height Inspection 654
Certi-Crimp Ratchet Inspection 654
How to Use AMP Double Action Hand Tool 656
Description – AMP Extraction Tool 657
Maintenance and Inspection 658
How to Use AMP Extraction Tool 659
AMP Fastin-Faston Receptacles and Housings 660
Description 660
Wire Repair 668
Wire Splicing Requirements 668
Deutsch Jiffy Splice 669
Twisted/Shielded Cable and Leads Repair 675
Special Tools 677
524223770-2200YRM1130-(05-2021)-US-EN 685
General 689
Description 689
Dash Display Menu Access 689
Menu Navigation 690
Standard Display 690
Main Menu 690
Passwords Menu 691
Password Administration 691
Add Password 691
Delete Password 691
Edit Password 692
Other Password Functions 693
Operator Passwords – Enable/Disable 693
Password Time-Out Delay 693
Passwords – Number Wrong to Disable 693
Lockout Reset Password 694
View Password Log 694
View Versions 695
VSM Versions 695
Dash Display Versions 696
Engine Controller Version 697
Transmission (Xmsn) Controller Version 698
Truck Serial Number 699
Diagnostics 700
View Fault Log 700
Set Travel and Braking 701
Speed Limit 701
Acceleration Rate 702
Auto-Deceleration Rate 702
Set Power Reversal Rate 703
Set Inching/Brake Overlap 704
Setup Display Menu 705
Set Operator Language 705
Set Units 706
Set Time Format (12/24 Hour) 706
Set Daylight Saving Time 707
Set Time 710
Set Date Format 710
Set Date 711
Setup Hydraulics 712
Return to Set Tilt Delay/On/Off 712
Setup General Items 713
Light Shutdown Time-Out 713
Impact Sensor – Enable/Disable 714
Impact Sensor – Soft Impact Settings 715
Impact Sensor – Hard Impact Settings 715
Adjust Impact Sensor Settings 716
Initial Adjustment of Soft and Hard Impact Settings 718
Readjustment of Soft and Hard Impact Settings 718
Impact Sensor – Impact Alarm/Shutdown Reset 719
Impact Sensor – Alarm Time Duration and Deactivation 720
Impact Sensor – View Impact Event Log 721
Engine Mode Indicator 721
Generation 1 (ECO-eLo ONLY) 721
Generation 2 722
Operator Checklist 723
Operator Checklist Off-On Mode 723
Edit Operator Checklist 723
Set Operator Checklist Expiration 723
View Checklist Log 724
Clear Operator Checklist Log 725
Clear Operator Checklist Fault 725
Calibrations 726
Set Tilt Stop Point 726
Calibrate Loaded Weight 726
524223771-2200YRM1131-(05-2021)-US-EN 729
Series Code / Model Designation Reference Table 735
General 737
Description 737
Dash Display Menu Access 737
Menu Navigation 738
Main Menu 739
Passwords 739
Adding Passwords 739
Hourmeters 741
View Versions 742
VSM Versions 742
Dash Display Versions 743
Engine Controller Version 744
Transmission (Xmsn) Controller Version 745
Truck Serial Number 746
Truck Configuration 747
Diagnostics 748
Clear Fault Log 748
View Fault Log 749
No-Run Data Display 750
Engine Accelerator and Throttle Data Display 751
Engine Speeds and Governor Data Display 753
Engine Fuel and Emissions Data Display 754
Engine General Data Display 756
XMSN/Brake Data Display 757
Hydraulic Data Display 759
General Truck Data Display 762
Set Travel and Braking 764
Speed Limit 764
Acceleration Rate 765
Auto-Deceleration Rate 765
Set Power Reversal Rate 766
Set Inching/Brake Overlap 766
Setup Hydraulics 767
Lift Maximum Speed 767
Lower Maximum Speed 768
Tilt Maximum Speed 768
Auxiliary Function One, Direction A, Maximum Speed 770
Auxiliary Function One, Direction B, Maximum Speed 773
Auxiliary Function Two, Direction A, Maximum Speed 773
Auxiliary Function Two, Direction B, Maximum Speed 774
Auxiliary Function Three, Direction A, Maximum Speed 775
Auxiliary Function Three, Direction B, Maximum Speed 775
Lift/Lower Ramp Rate 776
Hydraulic Auxiliary Ramp Rate 776
Return to Set Tilt Delay/On/Off 777
Hydraulic Input Device 778
Auxiliary Solenoid 778
Dual Function 779
Setup Display 780
Set Service Language 780
Setup General Items 780
Motion Alarm Activation Type 781
Light Shutdown Time-Out 782
Restore Default Settings 782
Restore Engine Controller Default Calibration 783
Impact Sensor – Enable/Disable 783
Impact Sensor – Soft Impact Settings 784
Impact Sensor – Hard Impact Settings 784
Adjust Impact Sensor Settings 785
Initial Adjustment of Soft and Hard Impact Settings 787
Readjustment of Soft and Hard Impact Settings 787
Impact Sensor – Impact Alarm/Shutdown Reset 788
Impact Sensor – Alarm Time Duration and Deactivation 789
Impact Sensor – View Impact Event Log 790
Engine Mode Indicator 790
Generation 1 (ECO-eLo ONLY) 790
Generation 2 791
Diesel Particulate Filter (DPF) Display 792
General Description 792
Passive Regeneration Only 792
Regeneration Level 0 792
Auto/Active Regeneration Inhibited 793
Auto/Active Regeneration 793
Regeneration Level 1 793
Parked Regeneration Request 794
Regeneration Level 2 794
Warning Level 795
Regeneration Level 3 795
Service Level 795
Regeneration Level 4 795
Display, Diesel Particulate Filter (DPF), Revised 795
Operator Interface 796
Refer to Operator Manual 796
CAN Communication Lost 796
Passive Regeneration Only 796
Regeneration Level 0 796
Auto/Active Regeneration Inhibited 797
Auto/Active Regeneration 797
Regeneration Level 1 797
Idle-up Auto/Active Regeneration 797
Parked Regeneration Request 798
Regeneration Level 2 798
Warning Level 799
Regeneration Level 3 799
Service Level 799
Regeneration Level 4 799
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 800
Display, Diesel Particulate Filter (DPF), Stage V Engine 800
Operator Interface 800
Refer to Operator Manual 800
CAN Communication Lost 801
Passive Regeneration Only 801
Regeneration Level 0 801
Auto/Active Regeneration Inhibited 801
Auto/Active Regeneration 802
Regeneration Level 1 802
Idle-up Auto/Active Regeneration 802
Parked Regeneration Request 802
Regeneration Level 2 802
Warning Level 804
Regeneration Level 3 804
Service Level 804
Regeneration Level 4 804
Stage V Content 804
Emissions System Malfunction 804
Ash Load 805
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 806
Operator Interface 806
Refer to Operator Manual 806
CAN Communication Lost 807
Passive Regeneration Only 807
Regeneration Level 0 807
Auto/Active Regeneration Inhibited 807
Auto/Active Regeneration 808
Regeneration Level 1 808
Idle-up Auto/Active Regeneration 808
Parked Regeneration Request 808
Regeneration Level 2 808
Warning Level 810
Regeneration Level 3 810
Service Level 810
Regeneration Level 4 810
Calibrations 811
Calibrate Transmission Valve 813
Set Tilt Stop Point 813
Calibrate Loaded Weight 814
Calibrate Travel Speed Sensor 814
Calibrate Mazda LP and Gas Accelerator Pedal 815
524223772-2200YRM1142-(08-2021)-US-EN 817
General 827
Display Switch Cluster 831
Remove 831
Install 833
Direction Control and Turn Signal Levers 833
Remove 833
Install 834
Key Switch 835
Remove 835
Install 836
Display Switch Cluster Panel Bezel and Overlay 836
Remove 836
Install 836
Steering Column Repair 837
Remove 837
Disassemble 840
Assemble 840
Install 840
Sensors and Switches 841
General 841
Dash and Kick Panel, Remove and Install 841
Remove 841
Install 842
Accelerator Pedal Position Sensor 842
Remove 842
Install 846
Brake Fluid Level Switch 847
Remove 847
Install 848
Service Brake Pedal Position Sensor 850
Remove 850
Install 852
Parking Brake Sensor 853
Remove 853
Install 855
Service Brake Pressure Sensor 855
Remove 855
Install 857
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 859
Remove 859
Install 859
Sensor Microswitch (Foot Directional Control Pedal) 859
Remove 859
Install 862
Low Coolant Level Sensor 863
Remove 863
Install 866
Fuel Level Sensor, Gas and Diesel Engines Only 867
Remove 867
Install 868
Armrest Switch 868
Remove 868
Install 870
Seat Sensor (Operator Presence System) 870
Non-Suspension and Semi-Suspension Seats; For Lift truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-8VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (C879, D879, E879, F879) 870
Remove 870
Install 871
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 871
Remove 871
Install 871
Full Suspension Seats; All Lift Truck Models 872
Remove 872
Install 872
Hood Shut Off Switch 873
Remove 873
Install 875
Remote Key Switch 876
Remove 876
Install 876
Hydraulic Filter Pressure Switch 877
Remove 877
Install 879
Transmission Speed Sensor 879
Remove 879
Install 882
Transmission Pressure Sensors 883
Remove 883
Install 885
Transmission Temperature Sensor 886
Remove 886
Install 888
Engine Speed Sensor 890
Remove 890
Install 891
Intermediate Speed Sensor 891
Remove 891
Install 891
Return to Set Tilt (Tilt Angle) Sensor 892
Lift Truck Models GLC20-35VX (GC/GCL040-070VX, GC/GLC055SVX) (A910); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP30VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) 892
Remove 892
Install 892
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 892
Remove 893
Install 894
Rear Horn Button Switch 895
Remove 895
Install 895
Impact Sensor 896
Lift Truck Models GC/GLC030-35VX, GC/GLC040SVX (C809), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810), GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GLC40-55VX; GLC55SVX; (GC/GLC080-120VX; GC/GLC080-100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (F813, G813, H813, J813), and GLC/GDC60-70VX (GC/GLC/GDC135-155VX,) (C879, D879, E879, F879) 896
Remove 896
Install 898
Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 898
Remove 898
Install 899
Load Weight Sensor 899
Remove 899
Install 901
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 902
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 902
Crankshaft Position (CKP) Sensor 902
Camshaft Position (CMP) Sensor 902
Oil Pressure Sensor 902
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 902
Engine Coolant Temperature (ECT) Sensor 903
Air Flow Restriction Switch 903
Remove for GM 2 4L Gas and LPG Trucks 903
Install for GM 2 4L Gas and LPG Trucks 903
Oxygen Sensor 904
Remove 904
Install 907
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 908
Crankshaft Position (CKP) Sensor 908
Camshaft Position (CMP) Sensor 908
Oil Pressure Sensor 908
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 908
Engine Coolant Temperature (ECT) Sensor 908
Air Flow Restriction Switch 908
Oxygen Sensor 908
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 908
Low LPG Pressure Switch 908
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 909
Air Filter Restriction Switch 909
Remove 909
Install 909
Oil Pressure Sensor 909
Remove 909
Install 909
Engine Speed Sensor 909
Remove 909
Install 909
Engine Coolant Temperature (ECT) Sensor 909
Remove 909
Install 909
Throttle Position Sensor (TPS) 912
Remove 912
Install 913
Fuel/Water Separator Sensor 913
Remove 913
Install 913
Glow Plug Relay 914
Remove 914
Install 916
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 916
Air Filter Restriction Switch 916
Remove 916
Install 917
Engine Oil Pressure Sensor 921
Remove 921
Install 921
Engine Speed Sensor 921
Remove 921
Install 922
Engine Coolant Temperature (ECT) Sensor 922
Remove 922
Install 923
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 924
Remove 924
Install 924
Fuel/Water Separator Sensor 925
Remove 925
Install 925
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 926
Intake Air Temperature Sensor 926
Remove 926
Install 927
Intake Air Pressure Sensor 927
Remove 927
Install 927
Air Inlet Heater 927
Remove 927
Install 928
Engine Oil Pressure Sensor 928
Remove 928
Install 928
Engine Coolant Temperature (ECT) Sensor 928
Remove 928
Install 928
Crankshaft Position Sensor 929
Remove 929
Install 929
Adjust Shim Procedure 930
Camshaft Position Sensor 931
Remove 931
Install 931
Air Flow Restriction Sensor 931
Remove 931
Install 932
Fuel/Water Separator 932
Remove 932
Install 933
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 933
Intake Air Temperature Sensor 937
Remove 937
Install 938
Boost Sensor 938
Remove 938
Install 939
Throttle Valve Assembly and Air Intake Heater 939
Remove 939
Install 939
Engine Coolant Temperature (ECT) Sensor 940
Remove 940
Install 940
Engine Oil Pressure Sensor 941
Remove 941
Install 941
Crankshaft Position Sensor 941
Remove 941
Install 941
Adjust Shim Procedure 942
Camshaft Position Sensor 944
Remove 944
Install 944
Differential Pressure Sensor 944
Remove 944
Install 945
Mass Air Flow Sensor 945
Remove 945
Install 946
Fuel/Water Separator 947
Remove 947
Install 948
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 949
Engine Coolant Temperature (ECT) Sensor 950
Remove 950
Install 950
Throttle Position Sensor 950
Engine Oil Pressure Sensor 950
Remove 950
Install 950
Engine Speed Sensor 950
Remove 950
Install 950
Fuel Shut Off Solenoid 951
Remove 951
Install 951
Vehicle System Manager (VSM) 952
General 952
VSM Replacement 952
Remove 952
Install 954
Programming a New VSM and/or Display Switch Cluster 954
General 954
PC Service Tool Software 955
Data Transferring 955
New VSM 955
New (Blank) Display Switch Cluster 955
Used (Non-Blank) Display Switch Cluster 955
Power Distribution Module (PDM) and Component Parts 958
Remove 958
PDM as a Unit 958
Install 961
PDM as a Unit 961
Remove and Install 962
PDM Component Parts 962
Transmission Control Unit (TCU) 963
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 963
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 963
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 964
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 964
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped with 3-Speed Transmission and Manufactured Before December, 2018 964
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped With 3-Speed Transmission and Manufactured Before December, 2018 965
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 966
Install, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured Between December, 2018 and July, 2021 968
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) Equipped with 3-Speed Transmission and Manufactured After July, 2021 968
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Equipped With 3-Speed Transmission and Manufactured After July, 2021 968
Battery 969
Remove 969
Install 969
Lights 970
Work Lights (Front and Rear) 970
Remove 970
Install 970
Strobe Light 971
Remove 971
Install 971
LED Tail, Backup, and Brake Lights 972
Remove 972
Install 973
Front Marker/Turn Signal Lights 974
Replacing Whole Front Marker/Turn Signal Light Assembly 974
Remove 974
Install 974
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 975
Remove 975
Install 975
Diesel Particulate Filter (DPF) Display 976
Remove 976
Clean and Inspect 977
Install 977
Electronic-Hydraulic Controls – Generation 1 978
E-Hydraulic Controls – Test 978
Mini-Levers 978
Full Stroke Test 978
Function Returns to Neutral Test 978
Push Button Switch 978
General 979
Mini-Lever Replacement 979
Remove 979
Clean and Inspect 980
Install 980
Push Button Switch Replacement 981
Remove 981
Install 983
Mini-Lever Module (MLM) 983
Remove 983
Install 983
Joystick 984
Remove and Disassemble 984
Inspect 984
Assemble and Install 984
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 985
General 985
Mini-levers, Remove and Install 985
Armrest Assembly 986
Remove 986
Install 989
Horn Button 989
Remove 989
Install 989
Direction Control Switch 990
Remove 990
Install 990
push (override) buttons and Toggle Switch 990
Remove 991
Install 992
Joystick 993
Remove and Disassemble 993
Inspect 993
Assemble and Install 993
Joystick Armrest Slider Assembly 994
Remove 994
Install 995
Electronic-Hydraulic Controls, After January, 2020 996
E-Hydraulic Controls – TEST 996
Mini-Levers 996
Full Stroke Test 996
Function Returns to Neutral Test 996
Push (Override) Button 996
General 997
Mini-levers, Remove and Install 997
Armrest Assembly 998
Remove 998
Install 1001
Horn Button 1001
Remove 1001
Install 1001
Direction Control Switch 1001
Remove 1001
Install 1002
Push (Override) buttons and Toggle Switch 1002
Remove 1003
Install 1005
Special Tools 1006
524223780-8000YRM1134-(05-2021)-US-EN 1009
Series Code / Model Designation Reference Table 1015
Description 1017
Proc_Cal_001: Service Password Entry 1019
When to Perform 1019
Why Perform 1019
How to Perform 1019
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 1020
When to Perform 1020
Calibration Order 1020
Why Perform 1020
How to Perform 1021
Proc_Cal_003: Save and Exit 1022
When to Perform 1022
Why Perform 1022
How to Perform 1022
Proc_Cal_004: Lift Valve Output Threshold 1023
When to Perform 1023
Calibration Order 1023
Why Perform 1023
How to Perform 1024
Proc_Cal_005: Lower Valve Output Threshold 1026
When to Perform 1026
Calibration Order 1026
Why Perform 1026
How to Perform 1026
Proc_Cal_006: Tilt Back Valve Output Threshold 1029
When to Perform 1029
Calibration Order 1029
Why Perform 1029
How to Perform 1029
Proc_Cal_007: Tilt Forward Valve Output Threshold 1032
When to Perform 1032
Calibration Order 1032
Why Perform 1032
How to Perform 1032
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 1035
When to Perform 1035
Calibration Order 1035
Why Perform 1035
How to Perform 1035
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 1038
When to Perform 1038
Calibration Order 1038
Why Perform 1038
How to Perform 1038
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 1041
When to Perform 1041
Calibration Order 1041
Why Perform 1041
How to Perform 1041
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 1044
When to Perform 1044
Calibration Order 1044
Why Perform 1044
How to Perform 1044
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 1047
When to Perform 1047
Calibration Order 1047
Why Perform 1047
How to Perform 1047
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 1050
When to Perform 1050
Calibration Order 1050
Why Perform 1050
How to Perform 1050
Proc_Cal_014: Load Weight Zero Point 1053
When to Perform 1053
Calibration Order 1053
Why Perform 1053
How to Perform 1053
Proc_Cal_015: Loaded Weight Calibration 1055
When to Perform 1055
Calibration Order 1055
Why Perform 1055
How to Perform 1055
Proc_Cal_016: Transmission Valve Calibration 1058
Applicable System/Option 1058
When to Perform 1058
Calibration Order 1058
Why Perform 1058
How to Perform 1058
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 1060
Applicable System/Option 1060
When to Perform 1060
Calibration Order 1060
Why Perform 1060
How to Perform 1060
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 1062
Applicable System/Option 1062
When to Perform 1062
Calibration Order 1062
Why Perform 1062
How to Perform 1063
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 1064
Required Tools 1064
When to Perform 1064
Calibration Order 1064
Why Perform 1065
How to Perform 1065
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 1066
When to Perform 1066
Why Perform 1066
How to Perform 1066
Proc_Cal_026: Travel Speed Calibration 1068
When to Perform 1068
Calibration Order 1068
Why Perform 1068
How to Perform 1068
524223780-8000YRM1134-(05-2022)-US-EN 1071
Series Code / Model Designation Reference Table 1077
Description 1080
Proc_Cal_001: Service Password Entry 1082
When to Perform 1082
Why Perform 1082
How to Perform 1082
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 1083
When to Perform 1083
Calibration Order 1083
Why Perform 1083
How to Perform 1083
Proc_Cal_003: Save and Exit 1085
When to Perform 1085
Why Perform 1085
How to Perform 1085
Proc_Cal_004: Lift Valve Output Threshold 1086
When to Perform 1086
Calibration Order 1086
Why Perform 1086
How to Perform 1086
Proc_Cal_005: Lower Valve Output Threshold 1089
When to Perform 1089
Calibration Order 1089
Why Perform 1089
How to Perform 1089
Proc_Cal_006: Tilt Back Valve Output Threshold 1092
When to Perform 1092
Calibration Order 1092
Why Perform 1092
How to Perform 1092
Proc_Cal_007: Tilt Forward Valve Output Threshold 1095
When to Perform 1095
Calibration Order 1095
Why Perform 1095
How to Perform 1095
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 1098
When to Perform 1098
Calibration Order 1098
Why Perform 1098
How to Perform 1098
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 1101
When to Perform 1101
Calibration Order 1101
Why Perform 1101
How to Perform 1101
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 1104
When to Perform 1104
Calibration Order 1104
Why Perform 1104
How to Perform 1104
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 1107
When to Perform 1107
Calibration Order 1107
Why Perform 1107
How to Perform 1107
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 1110
When to Perform 1110
Calibration Order 1110
Why Perform 1110
How to Perform 1110
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 1113
When to Perform 1113
Calibration Order 1113
Why Perform 1113
How to Perform 1113
Proc_Cal_014: Load Weight Zero Point 1116
When to Perform 1116
Calibration Order 1116
Why Perform 1116
How to Perform 1116
Proc_Cal_015: Loaded Weight Calibration 1118
When to Perform 1118
Calibration Order 1118
Why Perform 1118
How to Perform 1118
Proc_Cal_016: Transmission Valve Calibration 1121
Applicable System/Option 1121
When to Perform 1121
Calibration Order 1121
Why Perform 1121
How to Perform 1121
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 1123
Applicable System/Option 1123
When to Perform 1123
Calibration Order 1123
Why Perform 1123
How to Perform 1123
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 1126
Applicable System/Option 1126
When to Perform 1126
Calibration Order 1126
Why Perform 1126
How to Perform 1126
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 1129
Required Tools 1129
When to Perform 1129
Calibration Order 1129
Why Perform 1129
How to Perform 1129
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 1131
When to Perform 1131
Why Perform 1131
How to Perform 1131
Proc_Cal_026: Travel Speed Calibration 1133
When to Perform 1133
Calibration Order 1133
Why Perform 1133
How to Perform 1133
524262279-1800YRM1247-(06-2021)-US-EN 1137
General 1141
Dry Brake System 1141
Wet Brake System 1141
Service Brakes Repair (Dry Brake) 1145
Remove and Disassemble 1145
Clean 1147
Inspect 1148
Assemble and Install 1149
Adjust 1152
Parking Brake Repair 1153
Dry Brake System 1153
Remove and Disassembly 1153
Assemble and Install 1155
Wet Brake System 1155
Remove and Install 1155
Assemble and Install 1162
Adjust 1162
Dry Brake System 1162
Wet Brake System 1163
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 1163
Master Cylinder Repair 1165
Remove 1165
Disassemble 1169
Clean and Inspect 1170
Assemble 1171
Install and Adjust 1171
Accumulator 1174
Pre-Charge Check 1174
Remove 1175
Install 1177
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 1178
Remove 1178
Modulating Brake Valve 1180
Disassemble 1180
Clean and Inspect 1181
Assemble 1181
Accumulator Charge Valve 1182
Disassemble 1182
Clean and Inspect 1184
Assemble 1184
Install 1185
Pressure Checks 1186
Accumulator Charge Valve Check 1186
Accumulator Check 1186
Service Brakes Adjustment (Dry Brake) 1187
Service Brakes Adjustment 1187
Brake System Air Removal 1189
Using Pressure Bleed System 1189
Using Brake Pedal Pressure 1189
Lift Truck Models with Master Cylinder 1189
Lift Truck Models with Modulating Brake Valve 1190
Brake Pedal Adjustment 1191
For Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813), GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1191
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1192
Free Pedal Adjustment 1194
Torque Specifications 1195
524265342-4000YRM1250-(06-2021)-US-EN 1197
Safety Procedures When Working Near Mast 1203
Fork Replacement 1206
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1206
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1207
Remove, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 1209
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1210
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1211
Install, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017 GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 1212
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1212
Checks, Lift Truck Models Equipped With Fork Positioner and Manufactured After March, 2017GLC40, 45, 55VX, GLC55SVX (GC/GLC080, 100, 120VX, GC/GLC80, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS (G818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX (K813) 1213
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1214
Fixed Carriage Replacement 1216
Remove, Carriage With Hook Forks 1216
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1224
Install, Carriage With Hook Forks 1225
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1225
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1226
Connecting Attachment Hydraulic Quick Disconnect Hoses 1226
Integral Sideshift Carriage Repair 1227
Remove, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 1227
Disassemble 1227
Clean and Inspect 1230
Assemble 1230
Install, for lift truck models ERC35-55HG (ERC70-120HH) (C839), GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 1231
Hang On Sideshift Carriage Repair 1232
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 1232
Disassemble 1244
Clean and Inspect 1253
Assemble 1254
Install 1255
Hang-On Sideshift Carriage Repair 1257
Remove 1257
Disassemble Carriage 1259
Clean and Inspect 1262
Assemble 1262
Install 1265
Fork Positioner 1268
Two-Stage Mast With Limited Free-Lift Repair 1269
Remove 1269
Disassemble 1272
Clean and Inspect 1275
Assemble 1293
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1295
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and ERC35-55HG (ERC70-120HH) (C839) 1297
Header Hose Alignment 1308
Two-Stage Mast With Full Free-Lift Repair 1319
Remove 1319
Disassemble 1321
Clean and Inspect 1332
Assemble 1333
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) 1335
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818) and ERC35-55HG (ERC70-120HH) (C839) 1338
Header Hose Installation and Adjustment 1342
Installation 1342
Adjustment 1343
Three-Stage Mast With Full Free-Lift Repair 1344
Remove 1344
Disassemble 1346
Clean and Inspect 1376
Assemble 1378
Install, Lift Truck ModelsGLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813) and GLP/GDP60VX, GLP/GDP70VX, (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1381
Install, Lift Trucks ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879), and ERC35-55HG (ERC70-120HH) (C839) 1386
Header Hose Alignment for GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818, G818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813, K813), and ERC35-55HG (ERC70-120HH) (C839) 1393
Header Hose Alignment for GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GC/GLC/GDC60VX, GC/GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 1400
Mast Operation Check 1404
Tilt Cylinder Adjustment 1405
Lift Chains Adjustment 1405
Mast Adjustments 1407
Load Roller Adjustment 1407
Mast Side Kicking Adjustment 1409
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 1410
Carriage Adjustments 1412
Series Code / Model Designation Reference Table 1413
524288189-0100YRM1316-(01-2022)-US-EN 1417
General 1421
Description 1422
Hood, Seat, Dash, and Side Covers Replacement 1424
Remove 1424
Install 1430
Steering Column 1434
Description 1434
Steering Column Repair 1434
Remove 1434
Disassemble 1435
Clean 1437
Inspect 1437
Assemble 1437
Install 1437
LPG Tank and Bracket Replacement 1437
Counterweight Replacement 1438
Remove 1438
Install 1439
Tow Pin, Remove and Install 1441
Overhead Guard Replacement 1442
Remove 1442
Install 1443
LED Tail, Backup, and Brake Lights, Replace 1444
Operator Restraint System Replacement 1445
Description 1445
Engine Replacement 1447
Remove Engine Only 1447
Install Engine only 1473
Remove Engine and Transmission 1476
Install Engine and Transmission 1478
Electronic Throttle Replacement 1482
Cummins 4 5L Diesel Engine With Electronic Throttle 1482
Remove 1482
Install 1486
Pull Actuator Linkage Adjustment 1488
Low Idle Adjustment 1488
Throttle Pedal and Cable Adjustment 1489
Cummins 4 5L Diesel Engine 1489
Exhaust System Repair 1491
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1491
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 1491
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 1491
Remove 1491
Inspect 1491
Install 1494
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 1494
Remove 1494
Inspect 1496
Install 1496
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 1496
Remove 1496
Inspect 1499
Install 1499
Kubota 3 8L Diesel Engine w/DPF for Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 1499
Remove 1499
Inspect 1502
Install 1502
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 1502
Remove 1502
Inspect 1505
Install 1505
Cooling System 1506
Description 1506
Hydraulic Filter Assembly Repair 1507
Remove 1507
Disassemble 1507
Clean 1508
Inspect 1508
Assemble 1508
Install 1508
Fuel and Hydraulic Tanks Repair 1509
Inspect 1509
Clean 1509
Steam Method of Cleaning 1509
Chemical Solution Method of Cleaning 1510
Additional Preparations for Repair 1511
Small Leaks, Repair 1511
Large Leaks, Repair 1511
Preparations for Use After Repair 1511
Safety Labels 1512
524288194-1300YRM1317-(06-2021)-US-EN 1519
Transmission Repair 1523
Remove 1523
Torque Converter, Remove 1523
Disassemble 1524
Clean and Inspect 1575
Housings 1575
Oil Seals and Gaskets 1575
Bearings 1575
Gears and Shafts 1576
Assemble 1576
Torque Converter, Install 1618
Install 1619
Control Valve Repair 1620
Remove 1620
Disassemble 1620
Clean 1622
Inspect 1622
Assemble 1622
Install 1623
Torque Specification 1624
524288199-1400YRM1318-(06-2021)-US-EN 1627
General 1631
Identification Plate 1631
Drive Axle Removal 1631
Planetary Reduction Gear Repair 1639
Clean and Inspect 1646
Brake Repair 1654
Clean and Inspect 1661
Wet Brake Noise Reduction 1672
General 1672
Adding Additive To Transmission 1672
Differential Repair 1674
Clean and Inspect 1683
Bevel Pinion 1695
Clean and Inspect 1699
Drive Axle Installation 1710
Special Tools 1718
Torque Specifications 1719
524294873-1300YRM1343-(06-2021)-US-EN 1721
Transmission Repair 1725
Remove 1725
Torque Converter, Remove 1725
Disassemble 1727
Clean and Inspect 1768
Housings 1768
Oil Seals and Gaskets 1768
Bearings 1768
Gears and Shafts 1769
Assemble 1769
Torque Converter, Install 1807
Install 1808
Control Valve Repair 1809
Remove 1809
Disassemble 1809
Control Valve Assembly 1809
Control Valve Body 1809
Clean 1812
Inspect 1812
Assemble 1812
Control Valve Body 1812
Control Valve Assembly 1813
Install 1813
Torque Specification 1815
524294878-2100YRM1328-(06-2021)-US-EN 1817
General 1821
Safety Procedures When Working Near Mast 1821
Tilt Cylinder Repair 1824
Remove 1824
Disassemble 1828
Clean 1830
Inspect 1830
Assemble 1830
Install 1832
Tilt Cylinders, Adjust 1834
Tilt Cylinder Leak Check 1836
Lift Cylinder Repair 1837
Remove 1837
Disassemble 1846
Clean 1849
Inspect 1849
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 1849
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1849
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) 1850
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1850
Free-Lift Cylinder Repair 1852
Remove 1852
Disassemble 1858
Clean 1860
Inspect 1860
Assemble, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1861
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1861
Install, Lift Truck Models and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1861
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1862
Sideshift Cylinder Repair 1863
Remove 1863
Disassemble 1864
Clean 1867
Inspect 1867
Assemble 1868
Install 1869
Bolzoni Sideshift Cylinder Repair 1870
Remove 1870
Disassemble 1870
Clean 1871
Inspect 1871
Assemble 1872
Install 1872
Fork Positioner Cylinder Repair 1873
Remove 1873
Disassemble 1876
Clean 1880
Inspect 1880
Assemble 1881
Install 1882
Lift Cylinder Leak Check 1884
Seal Kit Installation 1885
External Installation (Seal and Back-Up Ring) 1885
Internal Installation (Piston Rod Assembly) 1885
Special Tools 1886
Torque Specifications 1887
For Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879, G879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1887
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1887
550048607-0600YRM1557-(11-2021)-US-EN 1889
General 1895
Engine Identification 1895
Major Engine Component Identification 1895
Location of Labels 1896
Crankcase Description 1897
Engine Removal and Installation 1898
Cylinder Head Assembly Repair 1898
Valve Covers and Fuel Injectors 1898
Remove 1898
Clean and Inspect 1905
Install 1905
Rocker Arm Assembly 1907
Remove 1907
Disassemble 1907
Clean and Inspect 1908
Push Rods 1908
Rocker Arm Assembly 1908
Assemble 1909
Install 1909
Valve Clearance Adjustments 1909
Cylinder Head Assembly 1910
Remove 1910
Disassemble 1921
Valves and Valve Springs, Remove 1921
Valve Guides, Remove 1922
Clean and Inspect 1922
Cylinder Head 1923
Valve Guides 1923
Valves 1923
Valve Sink 1923
Valve Seat 1924
Valve Springs 1924
Assemble 1925
Valve Guides, Install 1925
Valves and Valve Springs, Install 1926
Install 1926
Timing Gear Case and Timing Gears Repair 1930
Timing Gear Case Cover 1930
Remove 1930
Clean and Inspect 1931
Install 1931
Timing Gears 1932
Crankshaft Gear 1932
Remove 1932
Install 1932
Idler Gear 1933
Remove 1933
Inspect 1933
Install 1933
Camshaft Gear 1933
Remove 1933
Install 1934
Timing Gear Case 1934
Remove 1934
Clean and Inspect 1935
Install 1935
Drive Train, Camshaft, and Cylinder Block Repair 1936
Remove 1936
Disassemble 1936
Pistons and Connecting Rods 1936
Crankshaft 1937
Camshaft 1939
Clean and Inspect 1941
Cylinder Block 1941
Honing and Boring 1943
Cylinder Correction (Oversize) 1944
Pistons 1944
Piston Pin 1945
Connecting Rod 1945
Tappets 1946
Crankshaft 1946
Camshaft 1948
Camshaft Bushing 1949
Assemble 1949
Camshaft 1949
Crankshaft 1950
Pistons and Connecting Rods 1950
Install 1952
Angular Deviation Procedure 1952
Lubrication System Repair 1956
Engine Oil and Oil Filter Change 1956
Oil Pan 1957
Remove 1957
Install 1958
Oil Suction Tube 1958
Remove 1958
Clean 1959
Install 1959
Oil Pump 1959
Remove 1959
Clean and Inspect 1960
Outer Rotor Outside Clearance 1960
Outer Rotor to Inner Rotor Tip Clearance 1960
Outer Rotor Side Clearance 1961
Rotor Shaft Clearance 1961
Install 1961
Fuel System Repair 1963
Fuel Injectors 1963
Remove 1963
Inspect 1963
Clean 1963
Replace 1963
Install 1963
Test 1963
Fuel Injection Pump 1963
Remove 1963
Clean and Inspect 1968
Install 1968
Cooling System Repair 1970
Serpentine Belt 1970
Remove 1970
Inspect 1970
Install 1970
Serpentine Belt, Adjustment 1970
Water Pump 1971
Remove 1971
Install 1974
Thermostat 1976
Remove 1976
Inspect 1976
Install 1977
Flywheel and Flywheel Housing 1979
Flywheel 1979
Remove 1979
Install 1979
Flywheel Housing 1979
Remove 1979
Install 1979
Electrical Equipment Repair 1980
Alternator 1980
Remove 1980
Install 1981
Starter 1982
Remove 1982
Install 1982
Engine Specifications 1983
Engine Data For Lift Truck Models and GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (H813)GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (E879) 1983
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 1984
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879, G879) 1985
Engine Tuning 1986
Cylinder Head 1986
Intake/Exhaust Valve and Guide 1987
Valve Spring 1987
Rocker Arm and Shaft 1987
Push Rod 1987
Gear Train and Camshaft 1988
Camshaft 1988
Idle Gear Shaft and Bushing 1988
Backlash of Each Gear 1988
Cylinder Block 1988
Crankshaft 1988
Piston 1989
Piston Ring 1989
Connecting Rod 1989
Rod Small End 1989
Tappet 1990
Oil Pump 1990
Engine Oil Pressure 1990
Outer Rotor Outside Clearance 1990
Outer Rotor Side Clearance 1990
Inner Rotor to Cover 1990
Standard Torque Specifications 1991
Standard Torque Chart 1991
Special Torque Specifications 1992
Special Tools 1993
550073240-1900YRM1620-(01-2023)-US-EN 2007
Proper Flushing after Major Hydraulic Repairs 2013
Introduction 2013
The Phases of Wear 2013
Causes of Hydraulic System Failure 2013
Progression of Contaminant Caused Hydraulic System Failure 2014
Hydraulic System Flushing Techniques 2014
Double Oil and Filter Change 2014
Mechanical Cleaning 2015
Cleaning of Components 2015
How to Clean Tubes and Hoses 2015
Filter Caddy 2015
Start-Up Procedure for Cleaned System 2016
Contaminated Oil Coolers 2016
Additional Filter Caddy Functions 2017
How to Handle Different Fluids 2017
Water Removal Filters 2017
Fluid Conditioning and System Flushing Procedures 2018
Operation of the Filter Caddy 2018
Filter Caddy operation 2018
Fluid Conditioning Procedure 2018
Filter Caddy Start-Up 2019
System Flushing Procedure 2019
Component Cleaning Procedure 2020
Reservoir Cleaning Procedure 2020
Cylinder Cleaning Procedure 2020
Hose and Tube Cleaning Procedure 2020
Valve Cleaning Procedure 2021
Front-End Attachment Cleaning Procedure 2022
System Flushing Procedure 2022
Filter Caddy Start-Up 2023
System Start-Up and Flushing 2023
Reservoir Fluid Cleaning Times 2024
Dealing With Different Fluid Types 2025
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2025
Filter Caddy Maintenance 2025
Servicing the Strainer 2025
DC Motor 2025
Hydraulic Oil Sampling Method and Procedure 2026
Hydraulic Oil Sampling Method 2026
Objective 2026
General Guidelines 2026
Synopsis 2027
Hydraulic Oil Analysis Report Guidelines 2028
Sampling Conditions 2028
Equipment 2028
Sampling Procedure 2029
Hydraulic Oil Sampling 2029
Sample Labeling 2029
Results Documentation 2029
550118410-0600YRM1893-(01-2022)-US-EN 2031
General 2039
Engine Identification 2039
Major Engine Component Identification 2039
Major Engine Component Identification 2040
Location of Labels 2041
Location of Labels 2042
Crankcase Description 2043
Engine Removal and Installation 2044
Cylinder Head Assembly Repair 2044
Valve Covers and Ignition Coils 2044
Remove 2044
Clean and Inspect 2049
Install 2049
Rocker Arm Assembly 2050
Remove 2050
Disassemble 2052
Clean and Inspect 2052
Push Rods 2052
Rocker Arm Assembly 2052
Assemble 2053
Install 2053
Valve Clearance Adjustments 2053
Cylinder Head Assembly 2054
Remove 2054
Disassemble 2060
Valves and Valve Springs, Remove 2060
Valve Guides, Remove 2061
Clean and Inspect 2061
Cylinder Head 2062
Valve Guides 2062
Valves 2063
Valve Sink 2063
Valve Seat 2063
Valve Springs 2064
Assemble 2064
Valve Guides, Install 2064
Valves and Valve Springs, Install 2065
Install 2066
Timing Gear Case and Timing Gears Repair 2069
Timing Gear Case Cover 2069
Remove 2069
Clean and Inspect 2069
Install 2069
Timing Gears 2070
Crankshaft Gear 2070
Remove 2070
Install 2071
Idler Gear 2071
Remove 2071
Inspect 2071
Install 2072
Camshaft Gear 2072
Remove 2072
Install 2072
Timing Gear Case 2073
Remove 2073
Clean and Inspect 2073
Install 2073
Drive Train, Camshaft, and Cylinder Block Repair 2074
Remove 2074
Disassemble 2074
Pistons and Connecting Rods 2074
Crankshaft 2075
Camshaft 2077
Clean and Inspect 2078
Cylinder Block 2078
Honing and Boring 2081
Cylinder Correction (Oversize) 2082
Pistons 2082
Piston Pin 2083
Connecting Rod 2083
Tappets 2084
Crankshaft 2084
Camshaft 2086
Camshaft Bushing 2087
Assemble 2087
Camshaft 2087
Crankshaft 2087
Pistons and Connecting Rods 2087
Install 2089
Lubrication System Repair 2091
Engine Oil and Oil Filter Change 2091
Oil Pan 2092
Remove 2092
Install 2092
Oil Suction Tube 2092
Remove 2092
Clean 2093
Install 2093
Oil Pump 2093
Remove 2093
Clean and Inspect 2094
Outer Rotor Outside Clearance 2094
Outer Rotor to Inner Rotor Tip Clearance 2094
Outer Rotor Side Clearance 2094
Rotor Shaft Clearance 2095
Install 2095
Fuel System Repair 2096
Cooling System Repair 2096
Serpentine Belt 2096
Remove 2096
Inspect 2096
Install 2096
Serpentine Belt, Adjustment 2096
Water Pump 2098
Remove 2098
Install 2100
Thermostat 2101
Remove 2101
Inspect 2102
Install 2102
Flywheel and Flywheel Housing 2104
Flywheel 2104
Remove 2104
Install 2104
Flywheel Housing 2104
Remove 2104
Install 2104
Electrical Equipment Repair 2105
Alternator 2105
Remove 2105
Install 2106
Starter 2107
Remove 2107
Install 2107
Engine Specifications 2108
Engine Data 2108
Engine Tuning 2113
Cylinder Head 2113
Intake/Exhaust Valve and Guide 2113
Valve Spring 2114
Rocker Arm and Shaft 2114
Push Rod 2114
Gear Train and Camshaft 2114
Camshaft 2114
Idle Gear Shaft and Bushing 2115
Backlash of Each Gear 2115
Cylinder Block 2115
Crankshaft 2115
Piston 2116
Piston Ring 2116
Connecting Rod 2116
Rod Small End 2116
Tappet 2117
Oil Pump 2117
Engine Oil Pressure 2117
Outer Rotor Outside Clearance 2117
Outer Rotor Side Clearance 2117
Inner Rotor to Cover 2117
Standard Torque Specifications 2118
Standard Torque Chart 2118
Special Torque Specifications 2119
Special Tools 2120
550118420-8000YRM1904-(05-2022)-US-EN 2129
General Information About Diagrams and Schematics 2135
Symbol Definitions 2135
Diagrams Manual Applications 2136
Diagrams and Schematics 2138
550119576-0900YRM1905-(01-2022)-US-EN 2247
General 2253
LPG Tank and Bracket Replacement 2254
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) 2254
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) 2257
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) 2258
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) 2258
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) 2259
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) 2261
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) 2262
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) 2262
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) 2263
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) 2265
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) 2265
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) 2266
LPG Fuel Filter Unit Repair 2268
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) 2268
Remove/Disassemble 2268
Clean/Inspect 2270
Assemble/Install 2270
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) 2270
Remove/Disassemble 2270
Clean/Inspect 2271
Assemble/Install 2271
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) 2271
Remove 2271
Disassemble 2277
Clean and Inspect 2278
Assemble 2278
Install 2278
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) 2279
Remove 2279
Disassemble 2280
Clean and Inspect 2281
Assemble 2281
Install 2282
Electronic Throttle Body Repair 2283
Remove 2283
Install 2285
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 2286
Remove 2286
Install 2289
Control System 2290
Engine Control Unit (ECU) 2290
Remove 2290
Install 2290
LPG Low Level Sensor 2291
Remove 2291
Remove 2293
Install 2294
Exhaust System 2295
Counterweight Exhaust 2295
Remove and Disassemble 2295
Remove and Disassemble 2297
Inspect 2299
Assemble and Install 2299
Assemble and Install 2299
Exhaust Manifold 2299
Remove 2299
Install 2300
Oxygen (HEGO) Sensor 2300
Remove 2300
Install 2300
LPG Fuel Testing 2301
General 2301
Available Fuel Tests 2301
Composition Test (ASTM D-2163) 2301
Ammonia Test (ASTM D-4490) 2301
Basic Nitrogen Test (ASTM UOP269-90) 2301
Residues Test (ASTM D-2158) 2301
Vapor Pressure Test (ASTM D-2598) 2301
Sulfur Compounds Test (ASTM D-5623) 2301
Methanol Test (ASTM D-4864) 2302
Copper Corrosion (ASTM D-1838) 2302
Where To Send LPG Fuel Samples For Testing 2302
550131848-0600YRM1961-(03-2020)-US-EN 2305
General 2311
Engine Identification 2312
Major Engine Component Identification 2312
Location of Labels 2314
Cylinder Block Description 2315
Precautions Before Beginning Repair 2316
Exhaust System and DPF 2317
Engine Removal and Installation 2317
Cylinder Head Assembly Repair 2317
Valve Covers and Fuel Injectors 2317
Remove 2317
Clean and Inspect 2320
Install 2320
Rocker Arm Assembly 2321
Remove 2321
Disassemble 2321
Clean and Inspect 2322
Push Rods 2322
Rocker Arm Assembly 2322
Assemble 2323
Install 2323
Valve Clearance Adjustments 2323
Cylinder Head Assembly 2324
Remove 2324
Disassemble 2332
Valves and Valve Springs, Remove 2332
Valve Guides, Remove 2333
Clean and Inspect 2333
Cylinder Head 2334
Valve Guides 2334
Valves 2335
Valve Sink 2335
Valve Seat 2335
Valve Springs 2336
Assemble 2336
Valve Guides, Install 2336
Valves and Valve Springs, Install 2337
Install 2338
Timing Gear Case and Timing Gears Repair 2340
Timing Gear Case Cover 2340
Remove 2340
Clean and Inspect 2341
Install 2341
Timing Gears 2342
Crankshaft Gear 2342
Remove 2342
Install 2343
Idler Gear 1 and Idler Gear 2 2343
Remove 2343
Inspect 2344
Install 2345
Idler Gear 3 2345
Remove 2345
Inspect 2345
Install 2345
Camshaft Gear 2345
Remove 2345
Install 2345
Drive Train, Camshaft, and Cylinder Block Repair 2346
Remove 2346
Disassemble 2346
Pistons and Connecting Rods 2346
Crankshaft 2347
Camshaft 2349
Clean and Inspect 2351
Cylinder Block 2351
Honing and Boring 2353
Cylinder Correction (Oversize) 2354
Pistons 2354
Piston Pin 2355
Connecting Rod 2355
Tappets 2356
Crankshaft 2356
Camshaft 2358
Camshaft Bushing 2359
Assemble 2359
Camshaft 2359
Crankshaft 2359
Pistons and Connecting Rods 2360
Install 2362
Angular Deviation Procedure 2362
Lubrication System Repair 2365
Engine Oil and Oil Filter Change 2365
Oil Pan 2366
Remove 2366
Install 2366
Oil Suction Tube 2366
Remove 2366
Clean 2367
Install 2367
Oil Pump 2367
Remove 2367
Clean and Inspect 2368
Inner Rotor and Outer Rotor Clearance 2368
Outer Rotor and Pump Body Clearance 2369
Rotor and Cover Clearance 2369
Rotor Shaft Clearance 2369
Install 2370
Fuel System Repair 2370
Fuel Injectors 2370
Remove 2370
Inspect 2370
Clean 2371
Replace 2371
Install 2371
Test 2371
Fuel Injection Pump 2371
Remove 2371
Clean and Inspect 2374
Install 2374
Cooling System Repair 2375
Serpentine Belt 2375
Remove 2375
Inspect 2375
Install 2375
Adjust 2375
Water Pump 2376
Remove 2376
Install 2378
Thermostat 2378
Remove 2378
Inspect 2379
Install 2379
Flywheel and Flywheel Housing 2380
Flywheel 2380
Remove 2380
Install 2381
Flywheel Housing 2381
Remove 2381
Install 2381
Electrical Equipment Repair 2382
Alternator 2382
Remove 2382
Install 2383
Starter 2384
Remove 2384
Install 2384
Engine Specifications 2386
Engine Data 2386
Engine Tuning 2388
Cylinder Head 2388
Intake/Exhaust Valve and Guide 2389
Valve Spring 2389
Rocker Arm and Shaft 2389
Push Rod 2389
Gear Train and Camshaft 2390
Camshaft 2390
Idle Gear Shaft and Bushing 2390
Backlash of Each Gear 2390
Cylinder Block 2390
Crankshaft 2391
Piston 2391
Piston Ring 2391
Connecting Rod 2392
Rod Small End 2392
Tappet 2392
Oil Pump 2392
Engine Oil Pressure 2392
Inner and Outer Rotor Clearance 2392
Outer Rotor and Pump Body 2392
Rotor and Cover 2393
Standard Torque Specifications 2393
Standard Torque Chart 2393
Special Torque Specifications 2393
Special Tools 2395
550256055-8000YRM2404-(06-2021)-US-EN 2409
Lift Truck Lifting Capacity 2415
Counterweight Weights 2415
Tire Sizes 2415
Capacities 2415
Electrical System 2418
Transmission Oil Pressures 2419
Hydraulic System Relief Pressures 2420
Steering System 2421
Stall Speeds (in RPM ±100 rpm) 2421
Kubota 3 8L Diesel 2421
Kubota 3 8L LPG 2421
Tilt Angles 2422
Front End Equipment – Mast Creep 2422
Mast Creep 2422
Engine Specifications 2423
Torque Specifications 2425
Frame 2425
Mast 2425
Hang On Sideshift Carriage With Fork Positioner 2425
Fuel System- Kubota 3 8L LPG 2426
Fuel System- Kubota 3 8L Diesel 2426
Steering System 2426
Transmission 2426
Engine – Kubota 3 8L LPG 2426
Engine – Kubota 3 8L Diesel 2427
550256056-8000YRM2403-(01-2023)-US-EN 2431
General 2439
Serial Number Data 2439
How to Move Disabled Lift Truck 2439
How to Tow Lift Truck 2439
How to Put Lift Truck on Blocks 2441
How to Raise Drive Tires 2441
How to Raise Steering Tires 2441
How to Clean a Lift Truck 2443
Safety Procedures When Working Near Mast 2444
Maintenance Schedule 2446
Maintenance Procedures Every 8 Hours or Daily 2459
How to Make Checks With Engine Stopped 2459
Tires and Wheels 2459
Safety Labels 2459
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2460
Operator Restraint System 2460
Emergency Locking Retractor (ELR) 2460
Adjust Seat – Full Suspension 2462
Adjust Seat – Internal Suspension 2463
Hood and Seat Latches 2464
Engine Compartment 2464
Paper Application 2464
Fuel, Oil, and Coolant Leaks, Check 2465
Hydraulic Hoses 2465
Coolant Hoses 2465
Steering Column Gas Cylinder 2465
Transmission 2465
Hydraulic System Oil 2465
Engine Oil 2467
Air Filter 2468
Forks 2468
General 2468
Inspect 2469
Remove 2470
Install 2470
Adjust 2470
Hang On Sideshift Carriage 2471
How to Make Checks With Engine Running 2472
Indicator Lights, Horn, Fuses, and Relays 2472
Service Brakes 2474
Brake Oil Level 2474
Operation, Check 2474
Parking Brake 2474
Engine Oil Pressure 2474
Cooling System 2475
Steering System 2476
Control Levers and Pedals 2476
Lift System, Operate 2476
Air Filter 2477
Fuel/Water Separator Filter, Kubota 3 8L Diesel Engine 2477
First Service After First 100 Hours of Operation 2478
Kubota 3 8L Engine Oil and Oil Filter 2478
Bolzoni Hang on Sideshift Carriage Checks 2478
Maintenance Procedures Every 250 Hours or 6 Months 2480
Kubota 3 8L LPG Engine Oil and Oil Filter 2480
Drive Belt 2480
3 8L Engine 2480
Fan and Alternator Drive Belt 2480
Drain Tar From LPG Converter 2480
Cleaning Carbon Buildup From Intake Valves – Kubota 3 8L LPG Engines 2481
Maintenance Procedures Every 500 Hours or 6 Months 2484
Hydraulic System Oil 2484
Hydraulic Tank Breather 2486
Inspect 2486
Battery 2486
Kubota Diesel Engine Oil and Oil Filter 2486
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 2487
Remove 2487
Install 2487
Priming the Fuel System (Kubota 3 8L Engine) 2488
Drive Belt 2489
Kubota 3 8L Diesel Engine 2489
Fan and Alternator Drive Belt 2489
Clean Debris From Radiator Core 2489
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 2490
Wet Brake Center Body Oil Level Check 2490
Forks 2492
Inspect 2492
Mast Lubrication 2494
Bolzoni Hang on Sideshift Carriage Checks 2500
Header Hose Checks 2501
Lift Chain Lubrication 2502
Tilt Cylinder Lubrication 2502
Master Brake Cylinder Rod End Pin Lubrication 2503
Manual Hydraulic Levers Lubrication 2503
Brake Oil 2504
Tie Rod Lubrication 2505
Parking Brake Adjustment 2506
Maintenance Procedures Every 1000 Hours or 6 Months 2507
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine and Kubota 3 8L LPG SI Engine 2507
Ignition System 2507
3 8L Engine 2507
LPG Fuel Filter Element Replace, 3 8L Engine 2507
Remove 2507
Install 2508
In-Line Strainer Replacement, Kubota Diesel Engine 2508
Remove 2508
Install 2508
Lift Chains Wear Check 2510
Lift Chain Lubrication 2510
Hang On Sideshift Carriage, Check Sliding Surfaces 2510
Steering Axle Spindle Bearings 2512
Control Levers and Pedals 2512
Inspect Engine Electrical System, Connectors 2512
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2513
Crankcase Breather Element, Kubota 3 8L Diesel 2516
Remove 2516
Clean and Inspect 2516
Install 2516
Parking Brake Lever Lubrication, Wet Brake Axle 2517
Normal Operating Environment 2517
Heavy Duty or Contaminated Environment 2518
Remove 2518
Clean and Inspect 2519
Install 2519
DEF Injector Tip 2520
Maintenance Procedures Every 2000 Hours or Annually 2521
Hydraulic System 2521
Hydraulic Filter Assembly, Replace 2521
Install 2523
Hydraulic Tank Breather, Replace 2523
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2524
Cooling System Check 2524
Air Filter 2525
Fuel Injector, Kubota 3 8L Engine 2527
Forks 2527
Brake Oil (Master Cylinder), Change 2528
Check Throttle Shaft for Sticking 2529
Inspect Exhaust Manifold and Piping for Leaks 2529
Transmission Automatic Clutch Calibration 2530
Wheel Bearings 2530
Steer Wheels, Lubrication 2530
Maintenance Procedures Every 4000 Hours or 2 Years 2531
Hydraulic Oil, Replace 2531
Overhead Guard Changes 2532
Jump-Starting the Lift Truck 2533
Jump-Starting Using a Battery Charger 2533
Jump-Starting a Lift Truck Using Another Lift Truck 2533
Wheel and Tire Replacement 2533
General 2533
Solid Rubber Tire, Change 2533
Remove and Install Tire on Wheel 2533
Fuel Filter Water Removal 2535
Kubota Diesel Engine 2535
3 8L Diesel Engine 2535
3 6L Diesel Engine 2536
Lift Chain Adjustments 2537
Welding Repairs 2538
Adhesives and Sealants 2539
550256056-8000YRM2403-(12-2021)-US-EN 2541
General 2549
Serial Number Data 2549
How to Move Disabled Lift Truck 2549
How to Tow Lift Truck 2549
How to Put Lift Truck on Blocks 2550
How to Raise Drive Tires 2550
How to Raise Steering Tires 2551
How to Clean a Lift Truck 2552
Safety Procedures When Working Near Mast 2553
Maintenance Schedule 2555
Maintenance Procedures Every 8 Hours or Daily 2568
How to Make Checks With Engine Stopped 2568
Tires and Wheels 2568
Safety Labels 2568
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2569
Operator Restraint System 2569
Emergency Locking Retractor (ELR) 2569
Adjust Seat – Full Suspension 2570
Adjust Seat – Internal Suspension 2571
Hood and Seat Latches 2572
Engine Compartment 2572
Paper Application 2572
Fuel, Oil, and Coolant Leaks, Check 2573
Hydraulic Hoses 2573
Coolant Hoses 2574
Steering Column Gas Cylinder 2574
Transmission 2574
Hydraulic System Oil 2574
Engine Oil 2575
Air Filter 2577
Forks 2577
General 2577
Inspect 2577
Remove 2579
Install 2579
Adjust 2579
Hang On Sideshift Carriage 2580
How to Make Checks With Engine Running 2581
Indicator Lights, Horn, Fuses, and Relays 2581
Service Brakes 2583
Brake Oil Level 2583
Operation, Check 2584
Parking Brake 2584
Engine Oil Pressure 2584
Cooling System 2584
Steering System 2585
Control Levers and Pedals 2585
Lift System, Operate 2585
Air Filter 2586
Fuel/Water Separator Filter, Kubota 3 8L Diesel Engine 2586
First Service After First 100 Hours of Operation 2586
Kubota 3 8L Engine Oil and Oil Filter 2586
Bolzoni Hang on Sideshift Carriage Checks 2587
Maintenance Procedures Every 250 Hours or 6 Months 2588
Kubota 3 8L LPG Engine Oil and Oil Filter 2588
Drive Belt 2589
3 8L Engine 2589
Fan and Alternator Drive Belt 2589
Drain Tar From LPG Converter 2589
Cleaning Carbon Buildup From Intake Valves – Kubota 3 8L LPG Engines 2590
Maintenance Procedures Every 500 Hours or 6 Months 2592
Hydraulic System Oil 2592
Hydraulic Tank Breather 2593
Inspect 2593
Battery 2594
Kubota Diesel Engine Oil and Oil Filter 2594
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 2595
Remove 2595
Install 2595
Priming the Fuel System (Kubota 3 8L Engine) 2596
Drive Belt 2597
Kubota 3 8L Diesel Engine 2597
Fan and Alternator Drive Belt 2597
Clean Debris From Radiator Core 2597
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 2598
Wet Brake Center Body Oil Level Check 2599
Forks 2601
Inspect 2601
Mast Lubrication 2603
Bolzoni Hang on Sideshift Carriage Checks 2608
Header Hose Checks 2609
Lift Chain Lubrication 2609
Tilt Cylinder Lubrication 2610
Master Brake Cylinder Rod End Pin Lubrication 2610
Manual Hydraulic Levers Lubrication 2611
Brake Oil 2611
Tie Rod Lubrication 2612
Parking Brake Adjustment 2613
Maintenance Procedures Every 1000 Hours or 6 Months 2614
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 2614
Ignition System 2614
3 8L Engine 2614
LPG Fuel Filter Element Replace, 3 8L Engine 2614
Remove 2614
Install 2616
In-Line Strainer Replacement, Kubota Diesel Engine 2616
Remove 2616
Install 2616
Lift Chains Wear Check 2618
Lift Chain Lubrication 2618
Hang On Sideshift Carriage, Check Sliding Surfaces 2618
Steering Axle Spindle Bearings 2619
Control Levers and Pedals 2620
Inspect Engine Electrical System, Connectors 2620
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2620
Crankcase Breather Element, Kubota 3 8L Diesel 2624
Remove 2624
Clean and Inspect 2624
Install 2624
Parking Brake Lever Lubrication, Wet Brake Axle 2624
Normal Operating Environment 2625
Heavy Duty or Contaminated Environment 2626
Remove 2626
Clean and Inspect 2627
Install 2627
DEF Injector Tip 2628
Maintenance Procedures Every 2000 Hours or Annually 2628
Hydraulic System 2628
Hydraulic Filter Assembly, Replace 2628
Install 2629
Hydraulic Tank Breather, Replace 2630
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2631
Cooling System Check 2631
Air Filter 2632
Fuel Injector, Kubota 3 8L Engine 2634
Forks 2634
Brake Oil (Master Cylinder), Change 2635
Check Throttle Shaft for Sticking 2636
Inspect Exhaust Manifold and Piping for Leaks 2636
Transmission Automatic Clutch Calibration 2637
Wheel Bearings 2637
Steer Wheels, Lubrication 2637
Maintenance Procedures Every 4000 Hours or 2 Years 2637
Hydraulic Oil, Replace 2637
Overhead Guard Changes 2638
Jump-Starting the Lift Truck 2639
Jump-Starting Using a Battery Charger 2639
Jump-Starting a Lift Truck Using Another Lift Truck 2639
Wheel and Tire Replacement 2639
General 2639
Solid Rubber Tire, Change 2639
Remove and Install Tire on Wheel 2639
Fuel Filter Water Removal 2640
Kubota Diesel Engine 2640
3 8L Diesel Engine 2640
3 6L Diesel Engine 2642
Lift Chain Adjustments 2643
Welding Repairs 2644
Adhesives and Sealants 2645

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