Yale Forklift G879 (GC60VX, GC70VX) Service Manual – PDF DOWNLOAD

Description

Yale Forklift G879 (GC60VX, GC70VX) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift G879 (GC60VX, GC70VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2792
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift G879 (GC60VX, GC70VX) 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)-UK-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)-UK-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
524223764-1600YRM1133-(07-2013)-US-EN 163
toc 163
Steering Axle 163
Safety Precautions Maintenance and Repair 164
General 167
Steering Axle Assembly Repair 169
Remove 169
Disassemble 170
Clean 178
Inspect 178
Assemble 178
Install 184
Spindles, Bearings, and Tie Rods Repair 186
Spindles and Bearings 186
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 186
Remove 186
Disassemble 188
Clean 189
Inspect 189
Assemble 189
Install 190
Spindles and Bearings 193
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 193
Remove and Disassemble 193
Assemble and Install 194
Tie Rods 194
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 194
Remove 194
Install 195
Tie Rods 196
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 196
Remove 196
Install 202
Steering Cylinder Repair 202
Remove and Disassemble 202
Clean and Inspect 203
Assemble and Install 203
Torque Specifications 204
524223766-1900YRM1136-(01-2022)-US-EN 209
General 213
Hydraulic Gear Pump Assembly 214
Variable Displacement Pump Assembly 215
Single Gear Pump Assembly Repair 216
Remove 216
Disassemble 222
Clean 224
Inspect 224
Assemble 224
Install 224
Tandem Gear Pump Assembly 229
Remove 229
Disassemble 230
Clean 233
Inspect 233
Assemble 233
Install 234
Gear Pump Specifications 235
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 241
Remove 241
Disassemble 251
Clean 254
Inspect 255
Assemble 255
Install 255
63 0 cc/rev – Variable Displacement Pump Repair 260
Remove 260
Disassemble 263
Clean 265
Inspect 265
Assemble 265
Install 265
Variable Displacement Pump Checks and Adjustments (Single Pump) 269
Margin Pressure Check 269
Flow Compensator Adjustment 270
Pressure Compensator Adjustment 270
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 272
Variable Displacement Pump Specifications 275
Torque Specifications 277
Hydraulic Gear Pump 277
Variable Displacement Pump 278
Special Tools 279
524223767-2000YRM1137-(06-2021)-US-EN 281
General 285
Electro-Hydraulic Main Control Valve 286
Description 286
Remove 294
Electro-Hydraulic Control Valve Sections 299
General 299
Outlet Control Valve Section 299
Remove 299
Disassemble 299
Clean 302
Inspect 302
Assemble 303
Install 303
Auxiliary Control Valve Sections 303
Remove 304
Disassemble 309
Clean 311
Inspect 311
Assemble 311
Install 313
Tilt Control Valve Section 314
Remove 314
Disassemble 315
Clean 319
Inspect 319
Assemble 320
Install 321
Lift/Lower Control Valve Section 321
Remove 321
Disassemble 321
Clean 327
Inspect 327
Assemble 327
Install 328
Mid-Inlet Section 328
Remove 328
Clean 329
Inspect 329
Install 329
Install 329
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 334
Lift Pilot Pin 334
Lower Pilot Pin 337
Abnormal/Erroneous EHPV Adjustment 339
Manual Main Control Valve 340
Description 340
Remove 344
OPS Solenoid Assembly 352
General 352
Remove 353
Clean and Inspect 355
Install 355
Manual Control Valve Sections 356
General 356
Outlet Control Valve Section 356
Remove 356
Disassemble 356
Clean 359
Inspect 359
Assemble 359
Install 359
Auxiliary Control Valve Sections 360
Remove 360
Disassemble 360
Clean 363
Inspect 363
Assemble 363
Install 363
Lift/Tilt Control Valve Section 364
Remove 364
Disassemble 364
Clean 370
Inspect 370
Assemble 370
Install 372
Mid-Inlet Section 372
Remove 372
Clean 373
Inspect 373
Install 373
Install 373
Pressure Relief Valve Check and Adjustment 381
Primary Relief Valve 381
Secondary Relief Valve 384
Steering Control Unit Repair 389
Steering Control Unit, Remove 389
Steering Control Unit, Disassemble 393
Steering Control Unit, Clean 395
Steering Control Unit, Inspect 395
Steering Control Unit, Assemble 395
Relief Valve, Disassemble 396
Relief Valve, Clean 396
Relief Valve, Inspect 397
Relief Valve, Assemble 397
Steering Control Unit, Install 397
524223769-2200YRM1128-(01-2023)-US-EN 401
Series Code / Model Designation Reference Table 409
General 411
Deutsch Crimping Tool 412
How to Strip a Wire for Use With Deutsch Crimping Tool 412
How to Crimp With the Deutsch Crimping Tool 413
Calibration Test for the Deutsch Crimping Tool 415
Deutsch Connectors 417
DT, DTM, and DTP Series Connectors 417
HD Series Connectors 460
Metri-Pack Connectors 482
Remove and Install 482
Micro-Pack Connectors 485
Weather-Pack Connectors 486
AMPSEAL Crimping Tools 488
AMP Hand Crimping Tool With Certi-Crimp 488
Description 488
Stripping Wire for Use with AMP Hand Crimping Tool 489
Insulation Crimp Adjustment 490
Maintenance and Inspection for AMP Hand Crimping Tool 490
AMP Hand Crimping Tool 490
Crimp Height Inspection 490
How to use AMP Hand Crimping Tool 491
AMP Pro-Crimper II Tool 491
Description 491
Remove and Install Die Set and Locator Assembly 492
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 492
Contact Support Adjustment 493
Crimp Height Adjustment 494
Maintenance and Inspection Procedures 494
PRO-CRIMPER II Tool 494
Crimp Height Inspection 494
How to Use AMP PRO-CRIMPER II Tool 495
AMPSEAL Connector Assemblies 496
Description for Plug Connector Assembly 496
Seal Plug 497
Contact Crimping 497
Description for Plug Connector and Header Assembly 502
Voltage Reading 505
Seal Plug 505
Contact Crimping 505
AMP Superseal 1 5 Crimping Tools 512
Mini Mic Receptacle and Tab Contacts 512
Description 512
Crimping Conditions and Measurements 512
Insertion of Rubber Seal on Cable 514
AMP Hand Application Tool 519
Description 519
Maintenance and Inspection 519
Crimp Height Inspection 519
Crimp Height Adjustment 520
How to Use AMP Hand Application Tool 520
AMP Pro-Crimper II Tool 521
Description 521
Remove and Install Die Set and Locator Assembly 521
Adjustments 522
Contact Support 522
Crimp Height 523
Inspections and Maintenance 524
Crimp Height Inspection 524
Visual Inspection 524
Maintenance 525
How to Use Pro-Crimper II Tool 525
AMP Superseal 1 5 Connector Assemblies 526
Description 526
Repair and Maintenance 533
Panel Mount Option 533
AMP Fastin-Faston Hand Tools 534
Description – AMP Double Action Hand Tool 534
Maintenance and Inspection Procedures 534
Daily Maintenance 534
Periodic Tool Inspection 535
Lubrication 535
Visual Inspection 535
Crimp Height Inspection 535
Certi-Crimp Ratchet Inspection 536
How to Use AMP Double Action Hand Tool 537
Description – AMP Extraction Tool 538
Maintenance and Inspection 539
How to Use AMP Extraction Tool 539
AMP Fastin-Faston Receptacles and Housings 541
Description 541
Wire Repair 549
Wire Splicing Requirements 549
Deutsch Jiffy Splice 550
Twisted/Shielded Cable and Leads Repair 556
Special Tools 558
524223769-2200YRM1128-(06-2021)-UK-EN 567
Series Code / Model Designation Reference Table 573
General 576
Deutsch Crimping Tool 576
How to Strip a Wire for Use With Deutsch Crimping Tool 576
How to Crimp With the Deutsch Crimping Tool 578
Calibration Test for the Deutsch Crimping Tool 579
Deutsch Connectors 582
DT, DTM, and DTP Series Connectors 582
HD Series Connectors 625
Metri-Pack Connectors 647
Remove and Install 647
Micro-Pack Connectors 650
Weather-Pack Connectors 651
AMPSEAL Crimping Tools 653
AMP Hand Crimping Tool With Certi-Crimp 653
Description 653
Stripping Wire for Use with AMP Hand Crimping Tool 654
Insulation Crimp Adjustment 654
Maintenance and Inspection for AMP Hand Crimping Tool 654
AMP Hand Crimping Tool 654
Crimp Height Inspection 654
How to use AMP Hand Crimping Tool 656
AMP Pro-Crimper II Tool 657
Description 657
Remove and Install Die Set and Locator Assembly 657
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 658
Contact Support Adjustment 658
Crimp Height Adjustment 659
Maintenance and Inspection Procedures 659
PRO-CRIMPER II Tool 659
Crimp Height Inspection 659
How to Use AMP PRO-CRIMPER II Tool 660
AMPSEAL Connector Assemblies 661
Description for Plug Connector Assembly 661
Seal Plug 661
Contact Crimping 662
Description for Plug Connector and Header Assembly 666
Voltage Reading 668
Seal Plug 668
Contact Crimping 668
AMP Superseal 1 5 Crimping Tools 675
Mini Mic Receptacle and Tab Contacts 675
Description 675
Crimping Conditions and Measurements 675
Insertion of Rubber Seal on Cable 677
AMP Hand Application Tool 683
Description 683
Maintenance and Inspection 683
Crimp Height Inspection 683
Crimp Height Adjustment 684
How to Use AMP Hand Application Tool 684
AMP Pro-Crimper II Tool 685
Description 685
Remove and Install Die Set and Locator Assembly 686
Adjustments 686
Contact Support 686
Crimp Height 687
Inspections and Maintenance 688
Crimp Height Inspection 688
Visual Inspection 689
Maintenance 689
How to Use Pro-Crimper II Tool 689
AMP Superseal 1 5 Connector Assemblies 690
Description 690
Repair and Maintenance 697
Panel Mount Option 697
AMP Fastin-Faston Hand Tools 698
Description – AMP Double Action Hand Tool 698
Maintenance and Inspection Procedures 699
Daily Maintenance 699
Periodic Tool Inspection 699
Lubrication 699
Visual Inspection 699
Crimp Height Inspection 700
Certi-Crimp Ratchet Inspection 700
How to Use AMP Double Action Hand Tool 702
Description – AMP Extraction Tool 703
Maintenance and Inspection 704
How to Use AMP Extraction Tool 705
AMP Fastin-Faston Receptacles and Housings 706
Description 706
Wire Repair 714
Wire Splicing Requirements 714
Deutsch Jiffy Splice 715
Twisted/Shielded Cable and Leads Repair 721
Special Tools 723
524223770-2200YRM1130-(05-2021)-US-EN 731
General 735
Description 735
Dash Display Menu Access 735
Menu Navigation 736
Standard Display 736
Main Menu 736
Passwords Menu 737
Password Administration 737
Add Password 737
Delete Password 737
Edit Password 738
Other Password Functions 739
Operator Passwords – Enable/Disable 739
Password Time-Out Delay 739
Passwords – Number Wrong to Disable 739
Lockout Reset Password 740
View Password Log 740
View Versions 741
VSM Versions 741
Dash Display Versions 742
Engine Controller Version 743
Transmission (Xmsn) Controller Version 744
Truck Serial Number 745
Diagnostics 746
View Fault Log 746
Set Travel and Braking 747
Speed Limit 747
Acceleration Rate 748
Auto-Deceleration Rate 748
Set Power Reversal Rate 749
Set Inching/Brake Overlap 750
Setup Display Menu 751
Set Operator Language 751
Set Units 752
Set Time Format (12/24 Hour) 752
Set Daylight Saving Time 753
Set Time 756
Set Date Format 756
Set Date 757
Setup Hydraulics 758
Return to Set Tilt Delay/On/Off 758
Setup General Items 759
Light Shutdown Time-Out 759
Impact Sensor – Enable/Disable 760
Impact Sensor – Soft Impact Settings 761
Impact Sensor – Hard Impact Settings 761
Adjust Impact Sensor Settings 762
Initial Adjustment of Soft and Hard Impact Settings 764
Readjustment of Soft and Hard Impact Settings 764
Impact Sensor – Impact Alarm/Shutdown Reset 765
Impact Sensor – Alarm Time Duration and Deactivation 766
Impact Sensor – View Impact Event Log 767
Engine Mode Indicator 767
Generation 1 (ECO-eLo ONLY) 767
Generation 2 768
Operator Checklist 769
Operator Checklist Off-On Mode 769
Edit Operator Checklist 769
Set Operator Checklist Expiration 769
View Checklist Log 770
Clear Operator Checklist Log 771
Clear Operator Checklist Fault 771
Calibrations 772
Set Tilt Stop Point 772
Calibrate Loaded Weight 772
524223771-2200YRM1131-(05-2021)-US-EN 775
Series Code / Model Designation Reference Table 781
General 783
Description 783
Dash Display Menu Access 783
Menu Navigation 784
Main Menu 785
Passwords 785
Adding Passwords 785
Hourmeters 787
View Versions 788
VSM Versions 788
Dash Display Versions 789
Engine Controller Version 790
Transmission (Xmsn) Controller Version 791
Truck Serial Number 792
Truck Configuration 793
Diagnostics 794
Clear Fault Log 794
View Fault Log 795
No-Run Data Display 796
Engine Accelerator and Throttle Data Display 797
Engine Speeds and Governor Data Display 799
Engine Fuel and Emissions Data Display 800
Engine General Data Display 802
XMSN/Brake Data Display 803
Hydraulic Data Display 805
General Truck Data Display 808
Set Travel and Braking 810
Speed Limit 810
Acceleration Rate 811
Auto-Deceleration Rate 811
Set Power Reversal Rate 812
Set Inching/Brake Overlap 812
Setup Hydraulics 813
Lift Maximum Speed 813
Lower Maximum Speed 814
Tilt Maximum Speed 814
Auxiliary Function One, Direction A, Maximum Speed 816
Auxiliary Function One, Direction B, Maximum Speed 819
Auxiliary Function Two, Direction A, Maximum Speed 819
Auxiliary Function Two, Direction B, Maximum Speed 820
Auxiliary Function Three, Direction A, Maximum Speed 821
Auxiliary Function Three, Direction B, Maximum Speed 821
Lift/Lower Ramp Rate 822
Hydraulic Auxiliary Ramp Rate 822
Return to Set Tilt Delay/On/Off 823
Hydraulic Input Device 824
Auxiliary Solenoid 824
Dual Function 825
Setup Display 826
Set Service Language 826
Setup General Items 826
Motion Alarm Activation Type 827
Light Shutdown Time-Out 828
Restore Default Settings 828
Restore Engine Controller Default Calibration 829
Impact Sensor – Enable/Disable 829
Impact Sensor – Soft Impact Settings 830
Impact Sensor – Hard Impact Settings 830
Adjust Impact Sensor Settings 831
Initial Adjustment of Soft and Hard Impact Settings 833
Readjustment of Soft and Hard Impact Settings 833
Impact Sensor – Impact Alarm/Shutdown Reset 834
Impact Sensor – Alarm Time Duration and Deactivation 835
Impact Sensor – View Impact Event Log 836
Engine Mode Indicator 836
Generation 1 (ECO-eLo ONLY) 836
Generation 2 837
Diesel Particulate Filter (DPF) Display 838
General Description 838
Passive Regeneration Only 838
Regeneration Level 0 838
Auto/Active Regeneration Inhibited 839
Auto/Active Regeneration 839
Regeneration Level 1 839
Parked Regeneration Request 840
Regeneration Level 2 840
Warning Level 841
Regeneration Level 3 841
Service Level 841
Regeneration Level 4 841
Display, Diesel Particulate Filter (DPF), Revised 841
Operator Interface 842
Refer to Operator Manual 842
CAN Communication Lost 842
Passive Regeneration Only 842
Regeneration Level 0 842
Auto/Active Regeneration Inhibited 843
Auto/Active Regeneration 843
Regeneration Level 1 843
Idle-up Auto/Active Regeneration 843
Parked Regeneration Request 844
Regeneration Level 2 844
Warning Level 845
Regeneration Level 3 845
Service Level 845
Regeneration Level 4 845
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 846
Display, Diesel Particulate Filter (DPF), Stage V Engine 846
Operator Interface 846
Refer to Operator Manual 846
CAN Communication Lost 847
Passive Regeneration Only 847
Regeneration Level 0 847
Auto/Active Regeneration Inhibited 847
Auto/Active Regeneration 848
Regeneration Level 1 848
Idle-up Auto/Active Regeneration 848
Parked Regeneration Request 848
Regeneration Level 2 848
Warning Level 850
Regeneration Level 3 850
Service Level 850
Regeneration Level 4 850
Stage V Content 850
Emissions System Malfunction 850
Ash Load 851
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 852
Operator Interface 852
Refer to Operator Manual 852
CAN Communication Lost 853
Passive Regeneration Only 853
Regeneration Level 0 853
Auto/Active Regeneration Inhibited 853
Auto/Active Regeneration 854
Regeneration Level 1 854
Idle-up Auto/Active Regeneration 854
Parked Regeneration Request 854
Regeneration Level 2 854
Warning Level 856
Regeneration Level 3 856
Service Level 856
Regeneration Level 4 856
Calibrations 857
Calibrate Transmission Valve 859
Set Tilt Stop Point 859
Calibrate Loaded Weight 860
Calibrate Travel Speed Sensor 860
Calibrate Mazda LP and Gas Accelerator Pedal 861
524223772-2200YRM1142-(08-2021)-US-EN 863
General 873
Display Switch Cluster 877
Remove 877
Install 879
Direction Control and Turn Signal Levers 879
Remove 879
Install 880
Key Switch 881
Remove 881
Install 882
Display Switch Cluster Panel Bezel and Overlay 882
Remove 882
Install 882
Steering Column Repair 883
Remove 883
Disassemble 886
Assemble 886
Install 886
Sensors and Switches 887
General 887
Dash and Kick Panel, Remove and Install 887
Remove 887
Install 888
Accelerator Pedal Position Sensor 888
Remove 888
Install 892
Brake Fluid Level Switch 893
Remove 893
Install 894
Service Brake Pedal Position Sensor 896
Remove 896
Install 898
Parking Brake Sensor 899
Remove 899
Install 901
Service Brake Pressure Sensor 901
Remove 901
Install 903
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 905
Remove 905
Install 905
Sensor Microswitch (Foot Directional Control Pedal) 905
Remove 905
Install 908
Low Coolant Level Sensor 909
Remove 909
Install 912
Fuel Level Sensor, Gas and Diesel Engines Only 913
Remove 913
Install 914
Armrest Switch 914
Remove 914
Install 916
Seat Sensor (Operator Presence System) 916
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) 916
Remove 916
Install 917
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 917
Remove 917
Install 917
Full Suspension Seats; All Lift Truck Models 918
Remove 918
Install 918
Hood Shut Off Switch 919
Remove 919
Install 921
Remote Key Switch 922
Remove 922
Install 922
Hydraulic Filter Pressure Switch 923
Remove 923
Install 925
Transmission Speed Sensor 925
Remove 925
Install 928
Transmission Pressure Sensors 929
Remove 929
Install 931
Transmission Temperature Sensor 932
Remove 932
Install 934
Engine Speed Sensor 936
Remove 936
Install 937
Intermediate Speed Sensor 937
Remove 937
Install 937
Return to Set Tilt (Tilt Angle) Sensor 938
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) 938
Remove 938
Install 938
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) 938
Remove 939
Install 940
Rear Horn Button Switch 941
Remove 941
Install 941
Impact Sensor 942
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) 942
Remove 942
Install 944
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) 944
Remove 944
Install 945
Load Weight Sensor 945
Remove 945
Install 947
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 948
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 948
Crankshaft Position (CKP) Sensor 948
Camshaft Position (CMP) Sensor 948
Oil Pressure Sensor 948
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 948
Engine Coolant Temperature (ECT) Sensor 949
Air Flow Restriction Switch 949
Remove for GM 2 4L Gas and LPG Trucks 949
Install for GM 2 4L Gas and LPG Trucks 949
Oxygen Sensor 950
Remove 950
Install 953
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 954
Crankshaft Position (CKP) Sensor 954
Camshaft Position (CMP) Sensor 954
Oil Pressure Sensor 954
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 954
Engine Coolant Temperature (ECT) Sensor 954
Air Flow Restriction Switch 954
Oxygen Sensor 954
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 954
Low LPG Pressure Switch 954
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 955
Air Filter Restriction Switch 955
Remove 955
Install 955
Oil Pressure Sensor 955
Remove 955
Install 955
Engine Speed Sensor 955
Remove 955
Install 955
Engine Coolant Temperature (ECT) Sensor 955
Remove 955
Install 955
Throttle Position Sensor (TPS) 958
Remove 958
Install 959
Fuel/Water Separator Sensor 959
Remove 959
Install 959
Glow Plug Relay 960
Remove 960
Install 962
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 962
Air Filter Restriction Switch 962
Remove 962
Install 963
Engine Oil Pressure Sensor 967
Remove 967
Install 967
Engine Speed Sensor 967
Remove 967
Install 968
Engine Coolant Temperature (ECT) Sensor 968
Remove 968
Install 969
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 970
Remove 970
Install 970
Fuel/Water Separator Sensor 971
Remove 971
Install 971
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 972
Intake Air Temperature Sensor 972
Remove 972
Install 973
Intake Air Pressure Sensor 973
Remove 973
Install 973
Air Inlet Heater 973
Remove 973
Install 974
Engine Oil Pressure Sensor 974
Remove 974
Install 974
Engine Coolant Temperature (ECT) Sensor 974
Remove 974
Install 974
Crankshaft Position Sensor 975
Remove 975
Install 975
Adjust Shim Procedure 976
Camshaft Position Sensor 977
Remove 977
Install 977
Air Flow Restriction Sensor 977
Remove 977
Install 978
Fuel/Water Separator 978
Remove 978
Install 979
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 979
Intake Air Temperature Sensor 983
Remove 983
Install 984
Boost Sensor 984
Remove 984
Install 985
Throttle Valve Assembly and Air Intake Heater 985
Remove 985
Install 985
Engine Coolant Temperature (ECT) Sensor 986
Remove 986
Install 986
Engine Oil Pressure Sensor 987
Remove 987
Install 987
Crankshaft Position Sensor 987
Remove 987
Install 987
Adjust Shim Procedure 988
Camshaft Position Sensor 990
Remove 990
Install 990
Differential Pressure Sensor 990
Remove 990
Install 991
Mass Air Flow Sensor 991
Remove 991
Install 992
Fuel/Water Separator 993
Remove 993
Install 994
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 995
Engine Coolant Temperature (ECT) Sensor 996
Remove 996
Install 996
Throttle Position Sensor 996
Engine Oil Pressure Sensor 996
Remove 996
Install 996
Engine Speed Sensor 996
Remove 996
Install 996
Fuel Shut Off Solenoid 997
Remove 997
Install 997
Vehicle System Manager (VSM) 998
General 998
VSM Replacement 998
Remove 998
Install 1000
Programming a New VSM and/or Display Switch Cluster 1000
General 1000
PC Service Tool Software 1001
Data Transferring 1001
New VSM 1001
New (Blank) Display Switch Cluster 1001
Used (Non-Blank) Display Switch Cluster 1001
Power Distribution Module (PDM) and Component Parts 1004
Remove 1004
PDM as a Unit 1004
Install 1007
PDM as a Unit 1007
Remove and Install 1008
PDM Component Parts 1008
Transmission Control Unit (TCU) 1009
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) 1009
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) 1009
Remove, Lift Truck Models GC/GLC/GDC60VX, GC/GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 1010
Install, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) 1010
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 1010
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 1011
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 1012
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 1014
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 1014
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 1014
Battery 1015
Remove 1015
Install 1015
Lights 1016
Work Lights (Front and Rear) 1016
Remove 1016
Install 1016
Strobe Light 1017
Remove 1017
Install 1017
LED Tail, Backup, and Brake Lights 1018
Remove 1018
Install 1019
Front Marker/Turn Signal Lights 1020
Replacing Whole Front Marker/Turn Signal Light Assembly 1020
Remove 1020
Install 1020
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 1021
Remove 1021
Install 1021
Diesel Particulate Filter (DPF) Display 1022
Remove 1022
Clean and Inspect 1023
Install 1023
Electronic-Hydraulic Controls – Generation 1 1024
E-Hydraulic Controls – Test 1024
Mini-Levers 1024
Full Stroke Test 1024
Function Returns to Neutral Test 1024
Push Button Switch 1024
General 1025
Mini-Lever Replacement 1025
Remove 1025
Clean and Inspect 1026
Install 1026
Push Button Switch Replacement 1027
Remove 1027
Install 1029
Mini-Lever Module (MLM) 1029
Remove 1029
Install 1029
Joystick 1030
Remove and Disassemble 1030
Inspect 1030
Assemble and Install 1030
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 1031
General 1031
Mini-levers, Remove and Install 1031
Armrest Assembly 1032
Remove 1032
Install 1035
Horn Button 1035
Remove 1035
Install 1035
Direction Control Switch 1036
Remove 1036
Install 1036
push (override) buttons and Toggle Switch 1036
Remove 1037
Install 1038
Joystick 1039
Remove and Disassemble 1039
Inspect 1039
Assemble and Install 1039
Joystick Armrest Slider Assembly 1040
Remove 1040
Install 1041
Electronic-Hydraulic Controls, After January, 2020 1042
E-Hydraulic Controls – TEST 1042
Mini-Levers 1042
Full Stroke Test 1042
Function Returns to Neutral Test 1042
Push (Override) Button 1042
General 1043
Mini-levers, Remove and Install 1043
Armrest Assembly 1044
Remove 1044
Install 1047
Horn Button 1047
Remove 1047
Install 1047
Direction Control Switch 1047
Remove 1047
Install 1048
Push (Override) buttons and Toggle Switch 1048
Remove 1049
Install 1051
Special Tools 1052
524223780-8000YRM1134-(05-2021)-UK-EN 1055
Series Code / Model Designation Reference Table 1061
Description 1063
Proc_Cal_001: Service Password Entry 1065
When to Perform 1065
Why Perform 1065
How to Perform 1065
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 1066
When to Perform 1066
Calibration Order 1066
Why Perform 1066
How to Perform 1067
Proc_Cal_003: Save and Exit 1068
When to Perform 1068
Why Perform 1068
How to Perform 1068
Proc_Cal_004: Lift Valve Output Threshold 1069
When to Perform 1069
Calibration Order 1069
Why Perform 1069
How to Perform 1070
Proc_Cal_005: Lower Valve Output Threshold 1072
When to Perform 1072
Calibration Order 1072
Why Perform 1072
How to Perform 1072
Proc_Cal_006: Tilt Back Valve Output Threshold 1075
When to Perform 1075
Calibration Order 1075
Why Perform 1075
How to Perform 1075
Proc_Cal_007: Tilt Forward Valve Output Threshold 1078
When to Perform 1078
Calibration Order 1078
Why Perform 1078
How to Perform 1078
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 1081
When to Perform 1081
Calibration Order 1081
Why Perform 1081
How to Perform 1081
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 1084
When to Perform 1084
Calibration Order 1084
Why Perform 1084
How to Perform 1084
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 1087
When to Perform 1087
Calibration Order 1087
Why Perform 1087
How to Perform 1087
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 1090
When to Perform 1090
Calibration Order 1090
Why Perform 1090
How to Perform 1090
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 1093
When to Perform 1093
Calibration Order 1093
Why Perform 1093
How to Perform 1093
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 1096
When to Perform 1096
Calibration Order 1096
Why Perform 1096
How to Perform 1096
Proc_Cal_014: Load Weight Zero Point 1099
When to Perform 1099
Calibration Order 1099
Why Perform 1099
How to Perform 1099
Proc_Cal_015: Loaded Weight Calibration 1101
When to Perform 1101
Calibration Order 1101
Why Perform 1101
How to Perform 1101
Proc_Cal_016: Transmission Valve Calibration 1104
Applicable System/Option 1104
When to Perform 1104
Calibration Order 1104
Why Perform 1104
How to Perform 1104
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 1106
Applicable System/Option 1106
When to Perform 1106
Calibration Order 1106
Why Perform 1106
How to Perform 1106
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 1108
Applicable System/Option 1108
When to Perform 1108
Calibration Order 1108
Why Perform 1108
How to Perform 1109
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 1110
Required Tools 1110
When to Perform 1110
Calibration Order 1110
Why Perform 1111
How to Perform 1111
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 1112
When to Perform 1112
Why Perform 1112
How to Perform 1112
Proc_Cal_026: Travel Speed Calibration 1114
When to Perform 1114
Calibration Order 1114
Why Perform 1114
How to Perform 1114
524223780-8000YRM1134-(05-2022)-US-EN 1117
Series Code / Model Designation Reference Table 1123
Description 1126
Proc_Cal_001: Service Password Entry 1128
When to Perform 1128
Why Perform 1128
How to Perform 1128
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 1129
When to Perform 1129
Calibration Order 1129
Why Perform 1129
How to Perform 1129
Proc_Cal_003: Save and Exit 1131
When to Perform 1131
Why Perform 1131
How to Perform 1131
Proc_Cal_004: Lift Valve Output Threshold 1132
When to Perform 1132
Calibration Order 1132
Why Perform 1132
How to Perform 1132
Proc_Cal_005: Lower Valve Output Threshold 1135
When to Perform 1135
Calibration Order 1135
Why Perform 1135
How to Perform 1135
Proc_Cal_006: Tilt Back Valve Output Threshold 1138
When to Perform 1138
Calibration Order 1138
Why Perform 1138
How to Perform 1138
Proc_Cal_007: Tilt Forward Valve Output Threshold 1141
When to Perform 1141
Calibration Order 1141
Why Perform 1141
How to Perform 1141
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 1144
When to Perform 1144
Calibration Order 1144
Why Perform 1144
How to Perform 1144
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 1147
When to Perform 1147
Calibration Order 1147
Why Perform 1147
How to Perform 1147
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 1150
When to Perform 1150
Calibration Order 1150
Why Perform 1150
How to Perform 1150
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 1153
When to Perform 1153
Calibration Order 1153
Why Perform 1153
How to Perform 1153
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 1156
When to Perform 1156
Calibration Order 1156
Why Perform 1156
How to Perform 1156
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 1159
When to Perform 1159
Calibration Order 1159
Why Perform 1159
How to Perform 1159
Proc_Cal_014: Load Weight Zero Point 1162
When to Perform 1162
Calibration Order 1162
Why Perform 1162
How to Perform 1162
Proc_Cal_015: Loaded Weight Calibration 1164
When to Perform 1164
Calibration Order 1164
Why Perform 1164
How to Perform 1164
Proc_Cal_016: Transmission Valve Calibration 1167
Applicable System/Option 1167
When to Perform 1167
Calibration Order 1167
Why Perform 1167
How to Perform 1167
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 1169
Applicable System/Option 1169
When to Perform 1169
Calibration Order 1169
Why Perform 1169
How to Perform 1169
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 1172
Applicable System/Option 1172
When to Perform 1172
Calibration Order 1172
Why Perform 1172
How to Perform 1172
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 1175
Required Tools 1175
When to Perform 1175
Calibration Order 1175
Why Perform 1175
How to Perform 1175
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 1177
When to Perform 1177
Why Perform 1177
How to Perform 1177
Proc_Cal_026: Travel Speed Calibration 1179
When to Perform 1179
Calibration Order 1179
Why Perform 1179
How to Perform 1179
524262279-1800YRM1247-(06-2021)-US-EN 1183
General 1187
Dry Brake System 1187
Wet Brake System 1187
Service Brakes Repair (Dry Brake) 1191
Remove and Disassemble 1191
Clean 1193
Inspect 1194
Assemble and Install 1195
Adjust 1198
Parking Brake Repair 1199
Dry Brake System 1199
Remove and Disassembly 1199
Assemble and Install 1201
Wet Brake System 1201
Remove and Install 1201
Assemble and Install 1208
Adjust 1208
Dry Brake System 1208
Wet Brake System 1209
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 1209
Master Cylinder Repair 1211
Remove 1211
Disassemble 1215
Clean and Inspect 1216
Assemble 1217
Install and Adjust 1217
Accumulator 1220
Pre-Charge Check 1220
Remove 1221
Install 1223
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 1224
Remove 1224
Modulating Brake Valve 1226
Disassemble 1226
Clean and Inspect 1227
Assemble 1227
Accumulator Charge Valve 1228
Disassemble 1228
Clean and Inspect 1230
Assemble 1230
Install 1231
Pressure Checks 1232
Accumulator Charge Valve Check 1232
Accumulator Check 1232
Service Brakes Adjustment (Dry Brake) 1233
Service Brakes Adjustment 1233
Brake System Air Removal 1235
Using Pressure Bleed System 1235
Using Brake Pedal Pressure 1235
Lift Truck Models with Master Cylinder 1235
Lift Truck Models with Modulating Brake Valve 1236
Brake Pedal Adjustment 1237
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) 1237
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1238
Free Pedal Adjustment 1240
Torque Specifications 1241
524265342-4000YRM1250-(06-2021)-US-EN 1243
Safety Procedures When Working Near Mast 1249
Fork Replacement 1252
Remove, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1252
Remove, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1253
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) 1255
Install, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1256
Install, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1257
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) 1258
Checks, Lift Trucks Not Equipped With Fork Positioner Or Equipped With Fork Positioner Before August, 2012 1258
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) 1259
Checks, Lift Trucks Manufactured After August, 2012 And Equipped With Fork Positioner 1260
Fixed Carriage Replacement 1262
Remove, Carriage With Hook Forks 1262
Remove, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1270
Install, Carriage With Hook Forks 1271
Install, Carriage With Pin Type Forks Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 1271
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1272
Connecting Attachment Hydraulic Quick Disconnect Hoses 1272
Integral Sideshift Carriage Repair 1273
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) 1273
Disassemble 1273
Clean and Inspect 1276
Assemble 1276
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) 1277
Hang On Sideshift Carriage Repair 1278
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) 1278
Disassemble 1290
Clean and Inspect 1299
Assemble 1300
Install 1301
Hang-On Sideshift Carriage Repair 1303
Remove 1303
Disassemble Carriage 1305
Clean and Inspect 1308
Assemble 1308
Install 1311
Fork Positioner 1314
Two-Stage Mast With Limited Free-Lift Repair 1315
Remove 1315
Disassemble 1318
Clean and Inspect 1321
Assemble 1339
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) 1341
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) 1343
Header Hose Alignment 1354
Two-Stage Mast With Full Free-Lift Repair 1365
Remove 1365
Disassemble 1367
Clean and Inspect 1378
Assemble 1379
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) 1381
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) 1384
Header Hose Installation and Adjustment 1388
Installation 1388
Adjustment 1389
Three-Stage Mast With Full Free-Lift Repair 1390
Remove 1390
Disassemble 1392
Clean and Inspect 1422
Assemble 1424
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) 1427
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) 1432
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) 1439
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) 1446
Mast Operation Check 1450
Tilt Cylinder Adjustment 1451
Lift Chains Adjustment 1451
Mast Adjustments 1453
Load Roller Adjustment 1453
Mast Side Kicking Adjustment 1455
Shimming The Mast Mounting Pin, Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813, H813, K813) 1456
Carriage Adjustments 1458
Series Code / Model Designation Reference Table 1459
524288189-0100YRM1316-(01-2022)-US-EN 1463
General 1467
Description 1468
Hood, Seat, Dash, and Side Covers Replacement 1470
Remove 1470
Install 1476
Steering Column 1480
Description 1480
Steering Column Repair 1480
Remove 1480
Disassemble 1481
Clean 1483
Inspect 1483
Assemble 1483
Install 1483
LPG Tank and Bracket Replacement 1483
Counterweight Replacement 1484
Remove 1484
Install 1485
Tow Pin, Remove and Install 1487
Overhead Guard Replacement 1488
Remove 1488
Install 1489
LED Tail, Backup, and Brake Lights, Replace 1490
Operator Restraint System Replacement 1491
Description 1491
Engine Replacement 1493
Remove Engine Only 1493
Install Engine only 1519
Remove Engine and Transmission 1522
Install Engine and Transmission 1524
Electronic Throttle Replacement 1528
Cummins 4 5L Diesel Engine With Electronic Throttle 1528
Remove 1528
Install 1532
Pull Actuator Linkage Adjustment 1534
Low Idle Adjustment 1534
Throttle Pedal and Cable Adjustment 1535
Cummins 4 5L Diesel Engine 1535
Exhaust System Repair 1537
GM 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1537
PSI 4 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) 1537
Cummins QSB 3 3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 1537
Remove 1537
Inspect 1537
Install 1540
Cummins 4 5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 1540
Remove 1540
Inspect 1542
Install 1542
Kubota 3 8L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) 1542
Remove 1542
Inspect 1545
Install 1545
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) 1545
Remove 1545
Inspect 1548
Install 1548
Kubota 3 8L Diesel Engine w/DOC for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879, G879) 1548
Remove 1548
Inspect 1551
Install 1551
Cooling System 1552
Description 1552
Hydraulic Filter Assembly Repair 1553
Remove 1553
Disassemble 1553
Clean 1554
Inspect 1554
Assemble 1554
Install 1554
Fuel and Hydraulic Tanks Repair 1555
Inspect 1555
Clean 1555
Steam Method of Cleaning 1555
Chemical Solution Method of Cleaning 1556
Additional Preparations for Repair 1557
Small Leaks, Repair 1557
Large Leaks, Repair 1557
Preparations for Use After Repair 1557
Safety Labels 1558
524288194-1300YRM1317-(06-2021)-US-EN 1565
Transmission Repair 1569
Remove 1569
Torque Converter, Remove 1569
Disassemble 1570
Clean and Inspect 1621
Housings 1621
Oil Seals and Gaskets 1621
Bearings 1621
Gears and Shafts 1622
Assemble 1622
Torque Converter, Install 1664
Install 1665
Control Valve Repair 1666
Remove 1666
Disassemble 1666
Clean 1668
Inspect 1668
Assemble 1668
Install 1669
Torque Specification 1670
524288199-1400YRM1318-(06-2021)-US-EN 1673
General 1677
Identification Plate 1677
Drive Axle Removal 1677
Planetary Reduction Gear Repair 1685
Clean and Inspect 1692
Brake Repair 1700
Clean and Inspect 1707
Wet Brake Noise Reduction 1718
General 1718
Adding Additive To Transmission 1718
Differential Repair 1720
Clean and Inspect 1729
Bevel Pinion 1741
Clean and Inspect 1745
Drive Axle Installation 1756
Special Tools 1764
Torque Specifications 1765
524294873-1300YRM1343-(06-2021)-US-EN 1767
Transmission Repair 1771
Remove 1771
Torque Converter, Remove 1771
Disassemble 1773
Clean and Inspect 1814
Housings 1814
Oil Seals and Gaskets 1814
Bearings 1814
Gears and Shafts 1815
Assemble 1815
Torque Converter, Install 1853
Install 1854
Control Valve Repair 1855
Remove 1855
Disassemble 1855
Control Valve Assembly 1855
Control Valve Body 1855
Clean 1858
Inspect 1858
Assemble 1858
Control Valve Body 1858
Control Valve Assembly 1859
Install 1859
Torque Specification 1861
524294878-2100YRM1328-(06-2021)-US-EN 1863
General 1867
Safety Procedures When Working Near Mast 1867
Tilt Cylinder Repair 1870
Remove 1870
Disassemble 1874
Clean 1876
Inspect 1876
Assemble 1876
Install 1878
Tilt Cylinders, Adjust 1880
Tilt Cylinder Leak Check 1882
Lift Cylinder Repair 1883
Remove 1883
Disassemble 1892
Clean 1895
Inspect 1895
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) 1895
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1895
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) 1896
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1896
Free-Lift Cylinder Repair 1898
Remove 1898
Disassemble 1904
Clean 1906
Inspect 1906
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) 1907
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1907
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) 1907
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1908
Sideshift Cylinder Repair 1909
Remove 1909
Disassemble 1910
Clean 1913
Inspect 1913
Assemble 1914
Install 1915
Bolzoni Sideshift Cylinder Repair 1916
Remove 1916
Disassemble 1916
Clean 1917
Inspect 1917
Assemble 1918
Install 1918
Fork Positioner Cylinder Repair 1919
Remove 1919
Disassemble 1922
Clean 1926
Inspect 1926
Assemble 1927
Install 1928
Lift Cylinder Leak Check 1930
Seal Kit Installation 1931
External Installation (Seal and Back-Up Ring) 1931
Internal Installation (Piston Rod Assembly) 1931
Special Tools 1932
Torque Specifications 1933
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) 1933
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 1933
550048607-0600YRM1557-(11-2021)-US-EN 1935
General 1941
Engine Identification 1941
Major Engine Component Identification 1941
Location of Labels 1942
Crankcase Description 1943
Engine Removal and Installation 1944
Cylinder Head Assembly Repair 1944
Valve Covers and Fuel Injectors 1944
Remove 1944
Clean and Inspect 1951
Install 1951
Rocker Arm Assembly 1953
Remove 1953
Disassemble 1953
Clean and Inspect 1954
Push Rods 1954
Rocker Arm Assembly 1954
Assemble 1955
Install 1955
Valve Clearance Adjustments 1955
Cylinder Head Assembly 1956
Remove 1956
Disassemble 1967
Valves and Valve Springs, Remove 1967
Valve Guides, Remove 1968
Clean and Inspect 1968
Cylinder Head 1969
Valve Guides 1969
Valves 1969
Valve Sink 1969
Valve Seat 1970
Valve Springs 1970
Assemble 1971
Valve Guides, Install 1971
Valves and Valve Springs, Install 1972
Install 1972
Timing Gear Case and Timing Gears Repair 1976
Timing Gear Case Cover 1976
Remove 1976
Clean and Inspect 1977
Install 1977
Timing Gears 1978
Crankshaft Gear 1978
Remove 1978
Install 1978
Idler Gear 1979
Remove 1979
Inspect 1979
Install 1979
Camshaft Gear 1979
Remove 1979
Install 1980
Timing Gear Case 1980
Remove 1980
Clean and Inspect 1981
Install 1981
Drive Train, Camshaft, and Cylinder Block Repair 1982
Remove 1982
Disassemble 1982
Pistons and Connecting Rods 1982
Crankshaft 1983
Camshaft 1985
Clean and Inspect 1987
Cylinder Block 1987
Honing and Boring 1989
Cylinder Correction (Oversize) 1990
Pistons 1990
Piston Pin 1991
Connecting Rod 1991
Tappets 1992
Crankshaft 1992
Camshaft 1994
Camshaft Bushing 1995
Assemble 1995
Camshaft 1995
Crankshaft 1996
Pistons and Connecting Rods 1996
Install 1998
Angular Deviation Procedure 1998
Lubrication System Repair 2002
Engine Oil and Oil Filter Change 2002
Oil Pan 2003
Remove 2003
Install 2004
Oil Suction Tube 2004
Remove 2004
Clean 2005
Install 2005
Oil Pump 2005
Remove 2005
Clean and Inspect 2006
Outer Rotor Outside Clearance 2006
Outer Rotor to Inner Rotor Tip Clearance 2006
Outer Rotor Side Clearance 2007
Rotor Shaft Clearance 2007
Install 2007
Fuel System Repair 2009
Fuel Injectors 2009
Remove 2009
Inspect 2009
Clean 2009
Replace 2009
Install 2009
Test 2009
Fuel Injection Pump 2009
Remove 2009
Clean and Inspect 2014
Install 2014
Cooling System Repair 2016
Serpentine Belt 2016
Remove 2016
Inspect 2016
Install 2016
Serpentine Belt, Adjustment 2016
Water Pump 2017
Remove 2017
Install 2020
Thermostat 2022
Remove 2022
Inspect 2022
Install 2023
Flywheel and Flywheel Housing 2025
Flywheel 2025
Remove 2025
Install 2025
Flywheel Housing 2025
Remove 2025
Install 2025
Electrical Equipment Repair 2026
Alternator 2026
Remove 2026
Install 2027
Starter 2028
Remove 2028
Install 2028
Engine Specifications 2029
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) 2029
Engine Data For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080-120VX) (J813, K813) 2030
Engine Data For Lift Truck Models GLC/GDC60-70VX (GC/GLC/GDC135-155VX) (F879, G879) 2031
Engine Tuning 2032
Cylinder Head 2032
Intake/Exhaust Valve and Guide 2033
Valve Spring 2033
Rocker Arm and Shaft 2033
Push Rod 2033
Gear Train and Camshaft 2034
Camshaft 2034
Idle Gear Shaft and Bushing 2034
Backlash of Each Gear 2034
Cylinder Block 2034
Crankshaft 2034
Piston 2035
Piston Ring 2035
Connecting Rod 2035
Rod Small End 2035
Tappet 2036
Oil Pump 2036
Engine Oil Pressure 2036
Outer Rotor Outside Clearance 2036
Outer Rotor Side Clearance 2036
Inner Rotor to Cover 2036
Standard Torque Specifications 2037
Standard Torque Chart 2037
Special Torque Specifications 2038
Special Tools 2039
550073240-1900YRM1620-(01-2023)-US-EN 2053
Proper Flushing after Major Hydraulic Repairs 2059
Introduction 2059
The Phases of Wear 2059
Causes of Hydraulic System Failure 2059
Progression of Contaminant Caused Hydraulic System Failure 2060
Hydraulic System Flushing Techniques 2060
Double Oil and Filter Change 2060
Mechanical Cleaning 2061
Cleaning of Components 2061
How to Clean Tubes and Hoses 2061
Filter Caddy 2061
Start-Up Procedure for Cleaned System 2062
Contaminated Oil Coolers 2062
Additional Filter Caddy Functions 2063
How to Handle Different Fluids 2063
Water Removal Filters 2063
Fluid Conditioning and System Flushing Procedures 2064
Operation of the Filter Caddy 2064
Filter Caddy operation 2064
Fluid Conditioning Procedure 2064
Filter Caddy Start-Up 2065
System Flushing Procedure 2065
Component Cleaning Procedure 2066
Reservoir Cleaning Procedure 2066
Cylinder Cleaning Procedure 2066
Hose and Tube Cleaning Procedure 2066
Valve Cleaning Procedure 2067
Front-End Attachment Cleaning Procedure 2068
System Flushing Procedure 2068
Filter Caddy Start-Up 2069
System Start-Up and Flushing 2069
Reservoir Fluid Cleaning Times 2070
Dealing With Different Fluid Types 2071
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 2071
Filter Caddy Maintenance 2071
Servicing the Strainer 2071
DC Motor 2071
Hydraulic Oil Sampling Method and Procedure 2072
Hydraulic Oil Sampling Method 2072
Objective 2072
General Guidelines 2072
Synopsis 2073
Hydraulic Oil Analysis Report Guidelines 2074
Sampling Conditions 2074
Equipment 2074
Sampling Procedure 2075
Hydraulic Oil Sampling 2075
Sample Labeling 2075
Results Documentation 2075
550118410-0600YRM1893-(01-2022)-US-EN 2077
General 2085
Engine Identification 2085
Major Engine Component Identification 2085
Major Engine Component Identification 2086
Location of Labels 2087
Location of Labels 2088
Crankcase Description 2089
Engine Removal and Installation 2090
Cylinder Head Assembly Repair 2090
Valve Covers and Ignition Coils 2090
Remove 2090
Clean and Inspect 2095
Install 2095
Rocker Arm Assembly 2096
Remove 2096
Disassemble 2098
Clean and Inspect 2098
Push Rods 2098
Rocker Arm Assembly 2098
Assemble 2099
Install 2099
Valve Clearance Adjustments 2099
Cylinder Head Assembly 2100
Remove 2100
Disassemble 2106
Valves and Valve Springs, Remove 2106
Valve Guides, Remove 2107
Clean and Inspect 2107
Cylinder Head 2108
Valve Guides 2108
Valves 2109
Valve Sink 2109
Valve Seat 2109
Valve Springs 2110
Assemble 2110
Valve Guides, Install 2110
Valves and Valve Springs, Install 2111
Install 2112
Timing Gear Case and Timing Gears Repair 2115
Timing Gear Case Cover 2115
Remove 2115
Clean and Inspect 2115
Install 2115
Timing Gears 2116
Crankshaft Gear 2116
Remove 2116
Install 2117
Idler Gear 2117
Remove 2117
Inspect 2117
Install 2118
Camshaft Gear 2118
Remove 2118
Install 2118
Timing Gear Case 2119
Remove 2119
Clean and Inspect 2119
Install 2119
Drive Train, Camshaft, and Cylinder Block Repair 2120
Remove 2120
Disassemble 2120
Pistons and Connecting Rods 2120
Crankshaft 2121
Camshaft 2123
Clean and Inspect 2124
Cylinder Block 2124
Honing and Boring 2127
Cylinder Correction (Oversize) 2128
Pistons 2128
Piston Pin 2129
Connecting Rod 2129
Tappets 2130
Crankshaft 2130
Camshaft 2132
Camshaft Bushing 2133
Assemble 2133
Camshaft 2133
Crankshaft 2133
Pistons and Connecting Rods 2133
Install 2135
Lubrication System Repair 2137
Engine Oil and Oil Filter Change 2137
Oil Pan 2138
Remove 2138
Install 2138
Oil Suction Tube 2138
Remove 2138
Clean 2139
Install 2139
Oil Pump 2139
Remove 2139
Clean and Inspect 2140
Outer Rotor Outside Clearance 2140
Outer Rotor to Inner Rotor Tip Clearance 2140
Outer Rotor Side Clearance 2140
Rotor Shaft Clearance 2141
Install 2141
Fuel System Repair 2142
Cooling System Repair 2142
Serpentine Belt 2142
Remove 2142
Inspect 2142
Install 2142
Serpentine Belt, Adjustment 2142
Water Pump 2144
Remove 2144
Install 2146
Thermostat 2147
Remove 2147
Inspect 2148
Install 2148
Flywheel and Flywheel Housing 2150
Flywheel 2150
Remove 2150
Install 2150
Flywheel Housing 2150
Remove 2150
Install 2150
Electrical Equipment Repair 2151
Alternator 2151
Remove 2151
Install 2152
Starter 2153
Remove 2153
Install 2153
Engine Specifications 2154
Engine Data 2154
Engine Tuning 2159
Cylinder Head 2159
Intake/Exhaust Valve and Guide 2159
Valve Spring 2160
Rocker Arm and Shaft 2160
Push Rod 2160
Gear Train and Camshaft 2160
Camshaft 2160
Idle Gear Shaft and Bushing 2161
Backlash of Each Gear 2161
Cylinder Block 2161
Crankshaft 2161
Piston 2162
Piston Ring 2162
Connecting Rod 2162
Rod Small End 2162
Tappet 2163
Oil Pump 2163
Engine Oil Pressure 2163
Outer Rotor Outside Clearance 2163
Outer Rotor Side Clearance 2163
Inner Rotor to Cover 2163
Standard Torque Specifications 2164
Standard Torque Chart 2164
Special Torque Specifications 2165
Special Tools 2166
550118420-8000YRM1904-(05-2022)-US-EN 2175
General Information About Diagrams and Schematics 2181
Symbol Definitions 2181
Diagrams Manual Applications 2182
Diagrams and Schematics 2184
550119576-0900YRM1905-(01-2022)-US-EN 2293
General 2299
LPG Tank and Bracket Replacement 2300
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) 2300
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) 2303
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) 2304
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) 2304
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) 2305
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) 2307
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) 2308
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) 2308
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) 2309
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) 2311
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) 2311
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) 2312
LPG Fuel Filter Unit Repair 2314
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) 2314
Remove/Disassemble 2314
Clean/Inspect 2316
Assemble/Install 2316
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) 2316
Remove/Disassemble 2316
Clean/Inspect 2317
Assemble/Install 2317
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) 2317
Remove 2317
Disassemble 2323
Clean and Inspect 2324
Assemble 2324
Install 2324
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) 2325
Remove 2325
Disassemble 2326
Clean and Inspect 2327
Assemble 2327
Install 2328
Electronic Throttle Body Repair 2329
Remove 2329
Install 2331
LPG Fuel Mixer With Direct Electronic Pressure Regulator (DEPR) Repair 2332
Remove 2332
Install 2335
Control System 2336
Engine Control Unit (ECU) 2336
Remove 2336
Install 2336
LPG Low Level Sensor 2337
Remove 2337
Remove 2339
Install 2340
Exhaust System 2341
Counterweight Exhaust 2341
Remove and Disassemble 2341
Remove and Disassemble 2343
Inspect 2345
Assemble and Install 2345
Assemble and Install 2345
Exhaust Manifold 2345
Remove 2345
Install 2346
Oxygen (HEGO) Sensor 2346
Remove 2346
Install 2346
LPG Fuel Testing 2347
General 2347
Available Fuel Tests 2347
Composition Test (ASTM D-2163) 2347
Ammonia Test (ASTM D-4490) 2347
Basic Nitrogen Test (ASTM UOP269-90) 2347
Residues Test (ASTM D-2158) 2347
Vapor Pressure Test (ASTM D-2598) 2347
Sulfur Compounds Test (ASTM D-5623) 2347
Methanol Test (ASTM D-4864) 2348
Copper Corrosion (ASTM D-1838) 2348
Where To Send LPG Fuel Samples For Testing 2348
550131848-0600YRM1961-(03-2020)-US-EN 2351
General 2357
Engine Identification 2358
Major Engine Component Identification 2358
Location of Labels 2360
Cylinder Block Description 2361
Precautions Before Beginning Repair 2362
Exhaust System and DPF 2363
Engine Removal and Installation 2363
Cylinder Head Assembly Repair 2363
Valve Covers and Fuel Injectors 2363
Remove 2363
Clean and Inspect 2366
Install 2366
Rocker Arm Assembly 2367
Remove 2367
Disassemble 2367
Clean and Inspect 2368
Push Rods 2368
Rocker Arm Assembly 2368
Assemble 2369
Install 2369
Valve Clearance Adjustments 2369
Cylinder Head Assembly 2370
Remove 2370
Disassemble 2378
Valves and Valve Springs, Remove 2378
Valve Guides, Remove 2379
Clean and Inspect 2379
Cylinder Head 2380
Valve Guides 2380
Valves 2381
Valve Sink 2381
Valve Seat 2381
Valve Springs 2382
Assemble 2382
Valve Guides, Install 2382
Valves and Valve Springs, Install 2383
Install 2384
Timing Gear Case and Timing Gears Repair 2386
Timing Gear Case Cover 2386
Remove 2386
Clean and Inspect 2387
Install 2387
Timing Gears 2388
Crankshaft Gear 2388
Remove 2388
Install 2389
Idler Gear 1 and Idler Gear 2 2389
Remove 2389
Inspect 2390
Install 2391
Idler Gear 3 2391
Remove 2391
Inspect 2391
Install 2391
Camshaft Gear 2391
Remove 2391
Install 2391
Drive Train, Camshaft, and Cylinder Block Repair 2392
Remove 2392
Disassemble 2392
Pistons and Connecting Rods 2392
Crankshaft 2393
Camshaft 2395
Clean and Inspect 2397
Cylinder Block 2397
Honing and Boring 2399
Cylinder Correction (Oversize) 2400
Pistons 2400
Piston Pin 2401
Connecting Rod 2401
Tappets 2402
Crankshaft 2402
Camshaft 2404
Camshaft Bushing 2405
Assemble 2405
Camshaft 2405
Crankshaft 2405
Pistons and Connecting Rods 2406
Install 2408
Angular Deviation Procedure 2408
Lubrication System Repair 2411
Engine Oil and Oil Filter Change 2411
Oil Pan 2412
Remove 2412
Install 2412
Oil Suction Tube 2412
Remove 2412
Clean 2413
Install 2413
Oil Pump 2413
Remove 2413
Clean and Inspect 2414
Inner Rotor and Outer Rotor Clearance 2414
Outer Rotor and Pump Body Clearance 2415
Rotor and Cover Clearance 2415
Rotor Shaft Clearance 2415
Install 2416
Fuel System Repair 2416
Fuel Injectors 2416
Remove 2416
Inspect 2416
Clean 2417
Replace 2417
Install 2417
Test 2417
Fuel Injection Pump 2417
Remove 2417
Clean and Inspect 2420
Install 2420
Cooling System Repair 2421
Serpentine Belt 2421
Remove 2421
Inspect 2421
Install 2421
Adjust 2421
Water Pump 2422
Remove 2422
Install 2424
Thermostat 2424
Remove 2424
Inspect 2425
Install 2425
Flywheel and Flywheel Housing 2426
Flywheel 2426
Remove 2426
Install 2427
Flywheel Housing 2427
Remove 2427
Install 2427
Electrical Equipment Repair 2428
Alternator 2428
Remove 2428
Install 2429
Starter 2430
Remove 2430
Install 2430
Engine Specifications 2432
Engine Data 2432
Engine Tuning 2434
Cylinder Head 2434
Intake/Exhaust Valve and Guide 2435
Valve Spring 2435
Rocker Arm and Shaft 2435
Push Rod 2435
Gear Train and Camshaft 2436
Camshaft 2436
Idle Gear Shaft and Bushing 2436
Backlash of Each Gear 2436
Cylinder Block 2436
Crankshaft 2437
Piston 2437
Piston Ring 2437
Connecting Rod 2438
Rod Small End 2438
Tappet 2438
Oil Pump 2438
Engine Oil Pressure 2438
Inner and Outer Rotor Clearance 2438
Outer Rotor and Pump Body 2438
Rotor and Cover 2439
Standard Torque Specifications 2439
Standard Torque Chart 2439
Special Torque Specifications 2439
Special Tools 2441
550210540-0600YRM2190-(01-2022)-UK-EN 2455
General 2461
Engine Identification 2462
Major Engine Component Identification 2462
Location of Labels 2465
Cylinder Block Description 2466
Precautions Before Beginning Repair 2467
Exhaust System and DPF 2467
Engine Removal and Installation 2468
Cylinder Head Assembly Repair 2468
Valve Covers and Fuel Injectors 2468
Remove 2468
Clean and Inspect 2471
Install 2471
Rocker Arm Assembly 2472
Remove 2472
Disassemble 2472
Clean and Inspect 2473
Push Rods 2473
Rocker Arm Assembly 2473
Assemble 2474
Install 2474
Valve Clearance Adjustments 2474
Cylinder Head Assembly 2475
Remove 2475
Disassemble 2485
Valves and Valve Springs, Remove 2485
Valve Guides, Remove 2486
Clean and Inspect 2486
Cylinder Head 2487
Valve Guides 2487
Valves 2487
Valve Sink 2487
Valve Seat 2488
Valve Springs 2488
Assemble 2489
Valve Guides, Install 2489
Valves and Valve Springs, Install 2489
Install 2490
Timing Gear Case and Timing Gears Repair 2493
Timing Gear Case Cover 2493
Remove 2493
Clean and Inspect 2494
Install 2495
Timing Gears 2495
Crankshaft Gear 2495
Remove 2495
Install 2496
Idler Gear 1 and Idler Gear 2 2496
Remove 2496
Inspect 2497
Install 2498
Idler Gear 3 2498
Remove 2498
Inspect 2498
Install 2498
Camshaft Gear 2498
Remove 2498
Install 2498
Drive Train, Camshaft, and Cylinder Block Repair 2499
Remove 2499
Disassemble 2499
Pistons and Connecting Rods 2499
Crankshaft 2500
Camshaft 2502
Clean and Inspect 2504
Cylinder Block 2504
Honing and Boring 2506
Cylinder Correction (Oversize) 2507
Pistons 2507
Piston Pin 2508
Connecting Rod 2508
Tappets 2509
Crankshaft 2509
Camshaft 2511
Camshaft Bushing 2512
Assemble 2512
Camshaft 2512
Crankshaft 2512
Pistons and Connecting Rods 2513
Install 2515
Angular Deviation Procedure 2515
Lubrication System Repair 2518
Engine Oil and Oil Filter Change 2518
Oil Pan 2519
Remove 2519
Install 2519
Oil Suction Tube 2519
Remove 2519
Clean 2520
Install 2520
Oil Pump 2520
Remove 2520
Clean and Inspect 2521
Inner Rotor and Outer Rotor Clearance 2521
Outer Rotor and Pump Body Clearance 2522
Rotor and Cover Clearance 2522
Rotor Shaft Clearance 2522
Install 2523
Fuel System Repair 2523
Fuel Injectors 2523
Remove 2523
Inspect 2523
Clean 2524
Replace 2524
Install 2524
Test 2524
Fuel Injection Pump 2524
Remove 2524
Clean and Inspect 2527
Install 2527
Cooling System Repair 2528
Serpentine Belt 2528
Remove 2528
Inspect 2528
Install 2528
Adjust 2528
Water Pump 2529
Remove 2529
Install 2531
Thermostat 2532
Remove 2532
Inspect 2533
Install 2534
Flywheel and Flywheel Housing 2534
Flywheel 2534
Remove 2534
Install 2536
Flywheel Housing 2536
Remove 2536
Install 2536
Electrical Equipment Repair 2537
Alternator 2537
Remove 2537
Install 2538
Starter 2539
Remove 2539
Install 2539
Engine Specifications 2540
Engine Data 2540
Engine Tuning 2543
Cylinder Head 2543
Intake/Exhaust Valve and Guide 2544
Valve Spring 2544
Rocker Arm and Shaft 2544
Push Rod 2544
Gear Train and Camshaft 2545
Camshaft 2545
Idle Gear Shaft and Bushing 2545
Backlash of Each Gear 2545
Cylinder Block 2545
Crankshaft 2545
Piston 2546
Piston Ring 2546
Connecting Rod 2546
Rod Small End 2546
Tappet 2547
Oil Pump 2547
Engine Oil Pressure 2547
Inner and Outer Rotor Clearance 2547
Outer Rotor and Pump Body 2547
Rotor and Cover 2547
Standard Torque Specifications 2548
Standard Torque Chart 2548
Special Torque Specifications 2548
Special Tools 2550
550256054-8000YRM2403-(12-2021)-UK-EN 2561
General 2567
Serial Number Data 2567
How to Move Disabled Lift Truck 2567
How to Tow Lift Truck 2567
How to Put Lift Truck on Blocks 2568
How to Raise Drive Tires 2568
How to Raise Steering Tires 2569
How to Clean a Lift Truck 2570
Safety Procedures When Working Near Mast 2571
Maintenance Schedule 2573
Maintenance Procedures Every 8 Hours or Daily 2587
How to Make Checks With Engine Stopped 2587
Tires and Wheels 2587
Safety Labels 2587
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2588
Operator Restraint System 2588
Emergency Locking Retractor (ELR) 2588
Adjust Seat – Full Suspension 2589
Adjust Seat – Internal Suspension 2590
Hood and Seat Latches 2591
Engine Compartment 2591
Paper Application 2591
Fuel, Oil, and Coolant Leaks, Check 2592
Hydraulic Hoses 2592
Coolant Hoses 2592
Steering Column Gas Cylinder 2592
Transmission 2592
Hydraulic System Oil 2592
Engine Oil 2593
Air Filter 2595
Forks 2595
General 2595
Inspect 2595
Remove 2597
Install 2597
Adjust 2597
Hang On Sideshift Carriage 2598
How to Make Checks With Engine Running 2599
Indicator Lights, Horn, Fuses, and Relays 2599
Service Brakes 2601
Brake Oil Level 2601
Operation, Check 2602
Parking Brake 2602
Engine Oil Pressure 2602
Cooling System 2602
Steering System 2603
Control Levers and Pedals 2603
Lift System, Operate 2603
Air Filter 2604
Fuel/Water Separator Filter, Kubota 3 8L Diesel Engine 2604
First Service After First 100 Hours of Operation 2604
Kubota 3 8L Engine Oil and Oil Filter 2604
Bolzoni Hang on Sideshift Carriage Checks 2605
Maintenance Procedures Every 500 Hours or 1 Year 2606
Hydraulic System Oil 2606
Hydraulic Tank Breather 2607
Inspect 2607
Battery 2608
Kubota 3 8L Engine Oil and Oil Filter 2608
4 3L Engine Oil and Oil Filter 2609
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 2610
Remove 2610
Install 2610
Priming the Fuel System (Kubota 3 8L Engine) 2611
Drain Tar From LPG Converter 2612
Drive Belt 2613
Kubota 3 8L Diesel Engine 2613
Fan and Alternator Drive Belt 2613
Clean Debris From Radiator Core 2613
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 2614
Wet Brake Center Body Oil Level Check 2615
Forks 2617
Inspect 2617
Bolzoni Hang on Sideshift Carriage Checks 2619
Mast Lubrication 2621
Header Hose Checks 2626
Lift Chain Lubrication 2626
Tilt Cylinder Lubrication 2626
Master Brake Cylinder Rod End Pin Lubrication 2627
Manual Hydraulic Levers Lubrication 2628
Brake Oil 2628
Tie Rod Lubrication 2629
Parking Brake Adjustment 2629
Maintenance Procedures Every 1000 Hours or 1 Year 2630
Valve Clearance, Check and Adjust 2630
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 2630
Ignition System 2630
4 3L Engine 2630
In-Line Strainer Replacement, Kubota 3 8L Engine 2630
Remove 2631
Install 2631
Lift Chains Wear Check 2632
Lift Chain Lubrication 2632
Hang On Sideshift Carriage, Check Sliding Surfaces 2632
Steering Axle Spindle Bearings 2633
Control Levers and Pedals 2634
Inspect Engine Electrical System, Connectors 2634
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2634
Parking Brake Lever Lubrication, Wet Brake Axle 2638
Normal Operating Environment 2638
Heavy Duty or Contaminated Environment 2638
Remove 2638
Clean and Inspect 2639
Install 2640
Crankcase Breather Element 2640
Remove 2640
Clean and Inspect 2641
Install 2641
Maintenance Procedures Every 2000 Hours or Annually 2641
Hydraulic System 2641
Hydraulic Filter Assembly, Replace 2641
Install 2643
Hydraulic Tank Breather, Replace 2644
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2645
Cooling System Check 2645
Air Filter 2646
Fuel Injector, Kubota 3 8L Engine 2648
Forks 2648
Brake Oil (Master Cylinder), Change 2649
Check Throttle Shaft for Sticking 2650
Inspect Exhaust Manifold and Piping for Leaks 2650
Transmission Automatic Clutch Calibration 2651
Wheel Bearings 2651
Steer Wheels, Lubrication 2651
Maintenance Procedures Every 4000 Hours or 2 Years 2651
Hydraulic Oil, Replace 2651
Overhead Guard Changes 2652
Jump-Starting the Lift Truck 2653
Jump-Starting Using a Battery Charger 2653
Jump-Starting a Lift Truck Using Another Lift Truck 2653
Wheel and Tire Replacement 2653
General 2653
Solid Rubber Tire, Change 2653
Remove and Install Tire on Wheel 2653
Fuel Filter Water Removal 2654
Kubota Diesel Engine 2654
3 8L Diesel Engine 2654
3 6L Diesel Engine 2656
Lift Chain Adjustments 2657
Welding Repairs 2658
Adhesives and Sealants 2659
550256055-8000YRM2404-(06-2021)-US-EN 2661
Lift Truck Lifting Capacity 2667
Counterweight Weights 2667
Tire Sizes 2667
Capacities 2667
Electrical System 2670
Transmission Oil Pressures 2671
Hydraulic System Relief Pressures 2672
Steering System 2673
Stall Speeds (in RPM ±100 rpm) 2673
Kubota 3 8L Diesel 2673
Kubota 3 8L LPG 2673
Tilt Angles 2674
Front End Equipment – Mast Creep 2674
Mast Creep 2674
Engine Specifications 2675
Torque Specifications 2677
Frame 2677
Mast 2677
Hang On Sideshift Carriage With Fork Positioner 2677
Fuel System- Kubota 3 8L LPG 2678
Fuel System- Kubota 3 8L Diesel 2678
Steering System 2678
Transmission 2678
Engine – Kubota 3 8L LPG 2678
Engine – Kubota 3 8L Diesel 2679
550256056-8000YRM2403-(01-2023)-US-EN 2683
General 2691
Serial Number Data 2691
How to Move Disabled Lift Truck 2691
How to Tow Lift Truck 2691
How to Put Lift Truck on Blocks 2693
How to Raise Drive Tires 2693
How to Raise Steering Tires 2693
How to Clean a Lift Truck 2695
Safety Procedures When Working Near Mast 2696
Maintenance Schedule 2698
Maintenance Procedures Every 8 Hours or Daily 2711
How to Make Checks With Engine Stopped 2711
Tires and Wheels 2711
Safety Labels 2711
Mast, Carriage, Lift Chains, Header Hoses, Attachment 2712
Operator Restraint System 2712
Emergency Locking Retractor (ELR) 2712
Adjust Seat – Full Suspension 2714
Adjust Seat – Internal Suspension 2715
Hood and Seat Latches 2716
Engine Compartment 2716
Paper Application 2716
Fuel, Oil, and Coolant Leaks, Check 2717
Hydraulic Hoses 2717
Coolant Hoses 2717
Steering Column Gas Cylinder 2717
Transmission 2717
Hydraulic System Oil 2717
Engine Oil 2719
Air Filter 2720
Forks 2720
General 2720
Inspect 2721
Remove 2722
Install 2722
Adjust 2722
Hang On Sideshift Carriage 2723
How to Make Checks With Engine Running 2724
Indicator Lights, Horn, Fuses, and Relays 2724
Service Brakes 2726
Brake Oil Level 2726
Operation, Check 2726
Parking Brake 2726
Engine Oil Pressure 2726
Cooling System 2727
Steering System 2728
Control Levers and Pedals 2728
Lift System, Operate 2728
Air Filter 2729
Fuel/Water Separator Filter, Kubota 3 8L Diesel Engine 2729
First Service After First 100 Hours of Operation 2730
Kubota 3 8L Engine Oil and Oil Filter 2730
Bolzoni Hang on Sideshift Carriage Checks 2730
Maintenance Procedures Every 250 Hours or 6 Months 2732
Kubota 3 8L LPG Engine Oil and Oil Filter 2732
Drive Belt 2732
3 8L Engine 2732
Fan and Alternator Drive Belt 2732
Drain Tar From LPG Converter 2732
Cleaning Carbon Buildup From Intake Valves – Kubota 3 8L LPG Engines 2733
Maintenance Procedures Every 500 Hours or 6 Months 2736
Hydraulic System Oil 2736
Hydraulic Tank Breather 2738
Inspect 2738
Battery 2738
Kubota Diesel Engine Oil and Oil Filter 2738
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 2739
Remove 2739
Install 2739
Priming the Fuel System (Kubota 3 8L Engine) 2740
Drive Belt 2741
Kubota 3 8L Diesel Engine 2741
Fan and Alternator Drive Belt 2741
Clean Debris From Radiator Core 2741
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check 2742
Wet Brake Center Body Oil Level Check 2742
Forks 2744
Inspect 2744
Mast Lubrication 2746
Bolzoni Hang on Sideshift Carriage Checks 2752
Header Hose Checks 2753
Lift Chain Lubrication 2754
Tilt Cylinder Lubrication 2754
Master Brake Cylinder Rod End Pin Lubrication 2755
Manual Hydraulic Levers Lubrication 2755
Brake Oil 2756
Tie Rod Lubrication 2757
Parking Brake Adjustment 2758
Maintenance Procedures Every 1000 Hours or 6 Months 2759
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine and Kubota 3 8L LPG SI Engine 2759
Ignition System 2759
3 8L Engine 2759
LPG Fuel Filter Element Replace, 3 8L Engine 2759
Remove 2759
Install 2760
In-Line Strainer Replacement, Kubota Diesel Engine 2760
Remove 2760
Install 2760
Lift Chains Wear Check 2762
Lift Chain Lubrication 2762
Hang On Sideshift Carriage, Check Sliding Surfaces 2762
Steering Axle Spindle Bearings 2764
Control Levers and Pedals 2764
Inspect Engine Electrical System, Connectors 2764
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2765
Crankcase Breather Element, Kubota 3 8L Diesel 2768
Remove 2768
Clean and Inspect 2768
Install 2768
Parking Brake Lever Lubrication, Wet Brake Axle 2769
Normal Operating Environment 2769
Heavy Duty or Contaminated Environment 2770
Remove 2770
Clean and Inspect 2771
Install 2771
DEF Injector Tip 2772
Maintenance Procedures Every 2000 Hours or Annually 2773
Hydraulic System 2773
Hydraulic Filter Assembly, Replace 2773
Install 2775
Hydraulic Tank Breather, Replace 2775
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2776
Cooling System Check 2776
Air Filter 2777
Fuel Injector, Kubota 3 8L Engine 2779
Forks 2779
Brake Oil (Master Cylinder), Change 2780
Check Throttle Shaft for Sticking 2781
Inspect Exhaust Manifold and Piping for Leaks 2781
Transmission Automatic Clutch Calibration 2782
Wheel Bearings 2782
Steer Wheels, Lubrication 2782
Maintenance Procedures Every 4000 Hours or 2 Years 2783
Hydraulic Oil, Replace 2783
Overhead Guard Changes 2784
Jump-Starting the Lift Truck 2785
Jump-Starting Using a Battery Charger 2785
Jump-Starting a Lift Truck Using Another Lift Truck 2785
Wheel and Tire Replacement 2785
General 2785
Solid Rubber Tire, Change 2785
Remove and Install Tire on Wheel 2785
Fuel Filter Water Removal 2787
Kubota Diesel Engine 2787
3 8L Diesel Engine 2787
3 6L Diesel Engine 2788
Lift Chain Adjustments 2789
Welding Repairs 2790
Adhesives and Sealants 2791

S.V 06/24