Yale Forklift 909 (GLPGDP80VX, GLPGDP80VX9, GLPGDP90VX Europe) Service Manual PDF

Yale Forklift 909 (GLPGDP80VX, GLPGDP80VX9, GLPGDP90VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift 909 (GLPGDP80VX, GLPGDP80VX9, GLPGDP90VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4464
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift 909 (GLPGDP80VX, GLPGDP80VX9, GLPGDP90VX Europe) Service Manual – PDF DOWNLOAD

524150797 8000YRM0231 (02 2023) US EN 1
General 7
Threaded Fasteners 7
Nomenclature, Threads 7
Strength Identification 8
Cotter (Split) Pins 9
Fastener Torque Tables 14
Conversion Table 16
524150797 8000YRM0231 (03 2020) 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
524208014 2200YRM1097 (03 2020) UK EN 43
Series Code / Model Designation Reference Table 47
Description 48
Distributor Ignition (DI) System 48
Crankshaft Position (CKP) Sensor 48
Camshaft Position (CMP) Sensor 48
Ignition Coil and Ignition Control Module (ICM) 48
Secondary Ignition Components 48
Spark Plugs and Wires 49
Spark Plug Wire Inspection 49
Spark Plug Wire Replacement 49
Remove 49
Install 50
Spark Plug Inspection 50
Usage 50
Inspection 50
Visual Inspection 52
Spark Plug Replacement 52
Remove 52
Install 52
Distributor Repair 53
Inspect 53
Overhaul 53
Disassemble 53
Assemble 56
Replace 57
Remove 57
Install Procedure 1 59
Install Procedure 2 60
Ignition Coil Replacement 61
Remove 61
Install 61
Ignition Control Module Replacement 62
Remove 62
Install 62
Starter Replacement 63
Remove 63
Install 66
Sensors and Switches 67
Gas and LPG Trucks 67
Crankshaft Position (CKP) Sensor 67
Remove 67
Install 67
Camshaft Position (CMP) Sensor 68
Remove 68
Install 70
Oil Pressure Sensor 70
Remove 70
Install 71
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 72
Remove 72
Install 72
Engine Coolant Temperature (ECT) Sensor 73
Remove 73
Install 74
Air Flow Restriction Switch 74
Remove 74
Install 75
Specifications and Special Tools 76
524211827 0600YRM1101 (11 2018) UK EN 81
Series Code / Model Designation Reference Table 85
General 85
Fault Codes 86
Normal Mode 86
Fault Log Mode 87
Access 87
Exit 87
Clear 87
Electronic Throttle Calibration 87
Electronic Throttle Calibration Procedure 88
Stationary Regeneration Procedure 88
524221866 9000YRM1112 (10 2020) UK EN 117
SECTION 9010 Operational Diagnostic Procedures 133
Group 05 – Operational Checkout 135
SECTION 9020 Engine 153
Group 10 – Principles of Operation 163
Group 30 – Observed Symptoms 361
Group 40 – Tests and Adjustments 463
SECTION 9030 Electrical System 495
Group 03 – General Maintenance and Diagnostic Data 519
Group 10 – Principles of Operation 613
Group 20 – Diagnostic Trouble Codes 637
Group 30 – Observed Symptoms 1609
SECTION 9040 Drive Train 1665
Group 10 – Principles of Operation 1669
Group 30 – Observed Symptoms 1725
Group 40 – Tests and Adjustments 1775
SECTION 9050 Hydraulic Systems 1785
Group 10 – Principles of Operation 1789
Group 30 – Observed Symptoms 1847
Group 33 – Observed Symptoms-Gear Pump 1849
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1937
Group 40 – Tests and Adjustments 1981
Group 43 – Tests and Adjustments-Gear Pump 1983
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 2007
SECTION 9060 Operators Station 2025
Group 10 – Principles of Operation 2027
SECTION 9070 Front End (Mast) and Chassis 2063
Group 10 – Principles of Operation 2065
Group 30 – Observed Symptoms 2087
SECTION 9080 Supplementary Data 2145
Group 50 – Abbreviations and Acronyms 2147
Group 60 – Special Tools List 2155
Group 70 – Fault Mode Indicator Reference 2165
Group 80 – Supplier Specification Data 2167
524223757 0700YRM1123 (06 2016) UK EN 2171
General 2175
Cooling System Checks 2175
Exhaust Leaks Into Cooling System 2175
Water Flow Restrictions in Radiator 2175
Radiator Hoses 2175
Water Pump 2176
Flushing the Cooling System 2176
Cooling System, Clean 2176
Radiator Replacement 2177
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) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2178
Radiator, Remove for Lift Trucks Models GC/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) Equipped with Oil Cooler 2193
Radiator, Remove for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2196
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) 2199
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) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) 2206
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); GLC050LX
(A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974) Equipped with Oil Cooler 2211
Radiator, Install for Lift Truck Models GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879) 2213
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) 2216
Fan Assembly Replacement 2228
Fan Removal 2228
Inspect 2243
Fan Installation 2243
524223764 1600YRM1133 (07 2013) UK EN 2249
toc 2249
Steering Axle 2249
Safety Precautions Maintenance and Repair 2250
General 2253
Steering Axle Assembly Repair 2255
Remove 2255
Disassemble 2256
Clean 2264
Inspect 2264
Assemble 2264
Install 2270
Spindles, Bearings, and Tie Rods Repair 2272
Spindles and Bearings 2272
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC40, 45, 55 2272
Remove 2272
Disassemble 2274
Clean 2275
Inspect 2275
Assemble 2275
Install 2276
Spindles and Bearings 2279
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2279
Remove and Disassemble 2279
Assemble and Install 2280
Tie Rods 2280
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), and GLC40, 45 2280
Remove 2280
Install 2281
Tie Rods 2282
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), GC/GLC030-035VX, GC 2282
Remove 2282
Install 2288
Steering Cylinder Repair 2288
Remove and Disassemble 2288
Clean and Inspect 2289
Assemble and Install 2289
Torque Specifications 2290
524223766 1900YRM1136 (11 2017) UK EN 2295
General 2299
Hydraulic Gear Pump Assembly 2300
Variable Displacement Pump Assembly 2301
Single Gear Pump Assembly Repair 2301
Remove 2301
Disassemble 2308
Clean 2308
Inspect 2310
Assemble 2310
Install 2310
Tandem Gear Pump Assembly 2314
Remove 2315
Disassemble 2317
Clean 2319
Inspect 2319
Assemble 2319
Install 2320
Gear Pump Specifications 2320
24 0 to 45 0 cc/rev – Variable Displacement Pump Repair 2326
Remove 2326
Disassemble 2336
Clean 2339
Inspect 2339
Assemble 2339
Install 2340
63 0 cc/rev – Variable Displacement Pump Repair 2343
Remove 2343
Disassemble 2346
Clean 2346
Inspect 2346
Assemble 2348
Install 2348
Variable Displacement Pump Checks and Adjustments (Single Pump) 2350
Margin Pressure Check 2350
Flow Compensator Adjustment 2351
Pressure Compensator Adjustment 2351
Variable Displacement Pump Checks and Adjustments (Tandem Pump) 2352
Variable Displacement Pump Specifications 2355
Torque Specifications 2356
Hydraulic Gear Pump 2357
Variable Displacement Pump 2358
Special Tools 2358
524223767 2000YRM1137 (01 2017) UK EN 2363
General 2369
Electro-Hydraulic Main Control Valve 2370
Description 2370
Remove 2378
Electro-Hydraulic Control Valve Sections 2383
General 2383
Outlet Control Valve Section 2383
Remove 2383
Disassemble 2384
Clean 2386
Inspect 2386
Assemble 2386
Install 2387
Auxiliary Control Valve Sections 2387
Remove 2387
Disassemble 2394
Clean 2395
Inspect 2396
Assemble 2396
Install 2398
Tilt Control Valve Section 2399
Remove 2399
Disassemble 2399
Clean 2405
Inspect 2405
Assemble 2405
Install 2406
Lift/Lower Control Valve Section 2407
Remove 2407
Disassemble 2407
Clean 2416
Inspect 2416
Assemble 2416
Install 2417
Mid-Inlet Section 2417
Remove 2417
Clean 2418
Inspect 2418
Install 2418
Install 2418
Electro Hydraulic Poppet Valve (EHPV) Pilot Pin Adjustment 2423
Lift Pilot Pin 2423
Lower Pilot Pin 2427
Abnormal/Erroneous EHPV Adjustment 2429
Manual Main Control Valve 2430
Description 2430
Remove 2434
OPS Solenoid Assembly 2442
General 2442
Remove 2443
Clean and Inspect 2446
Install 2446
Manual Control Valve Sections 2447
General 2447
Outlet Control Valve Section 2447
Remove 2447
Disassemble 2447
Clean 2450
Inspect 2450
Assemble 2450
Install 2451
Auxiliary Control Valve Sections 2451
Remove 2451
Disassemble 2451
Clean 2454
Inspect 2454
Assemble 2454
Install 2455
Lift/Tilt Control Valve Section 2455
Remove 2455
Disassemble 2455
Clean 2462
Inspect 2462
Assemble 2463
Install 2464
Mid-Inlet Section 2465
Remove 2465
Clean 2465
Inspect 2465
Install 2465
Install 2466
Pressure Relief Valve Check and Adjustment 2472
Primary Relief Valve 2473
Secondary Relief Valve 2477
Steering Control Unit Repair 2484
Steering Control Unit, Remove 2484
Steering Control Unit, Disassemble 2488
Steering Control Unit, Clean 2490
Steering Control Unit, Inspect 2490
Steering Control Unit, Assemble 2490
Relief Valve, Disassemble 2491
Relief Valve, Clean 2491
Relief Valve, Inspect 2492
Relief Valve, Assemble 2492
Steering Control Unit, Install 2492
524223769 2200YRM1128 (01 2023) US EN 2497
Series Code / Model Designation Reference Table 2505
General 2507
Deutsch Crimping Tool 2508
How to Strip a Wire for Use With Deutsch Crimping Tool 2508
How to Crimp With the Deutsch Crimping Tool 2509
Calibration Test for the Deutsch Crimping Tool 2511
Deutsch Connectors 2513
DT, DTM, and DTP Series Connectors 2513
HD Series Connectors 2556
Metri-Pack Connectors 2578
Remove and Install 2578
Micro-Pack Connectors 2581
Weather-Pack Connectors 2582
AMPSEAL Crimping Tools 2584
AMP Hand Crimping Tool With Certi-Crimp 2584
Description 2584
Stripping Wire for Use with AMP Hand Crimping Tool 2585
Insulation Crimp Adjustment 2586
Maintenance and Inspection for AMP Hand Crimping Tool 2586
AMP Hand Crimping Tool 2586
Crimp Height Inspection 2586
How to use AMP Hand Crimping Tool 2587
AMP Pro-Crimper II Tool 2587
Description 2587
Remove and Install Die Set and Locator Assembly 2588
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2588
Contact Support Adjustment 2589
Crimp Height Adjustment 2590
Maintenance and Inspection Procedures 2590
PRO-CRIMPER II Tool 2590
Crimp Height Inspection 2590
How to Use AMP PRO-CRIMPER II Tool 2591
AMPSEAL Connector Assemblies 2592
Description for Plug Connector Assembly 2592
Seal Plug 2593
Contact Crimping 2593
Description for Plug Connector and Header Assembly 2598
Voltage Reading 2601
Seal Plug 2601
Contact Crimping 2601
AMP Superseal 1 5 Crimping Tools 2608
Mini Mic Receptacle and Tab Contacts 2608
Description 2608
Crimping Conditions and Measurements 2608
Insertion of Rubber Seal on Cable 2610
AMP Hand Application Tool 2615
Description 2615
Maintenance and Inspection 2615
Crimp Height Inspection 2615
Crimp Height Adjustment 2616
How to Use AMP Hand Application Tool 2616
AMP Pro-Crimper II Tool 2617
Description 2617
Remove and Install Die Set and Locator Assembly 2617
Adjustments 2618
Contact Support 2618
Crimp Height 2619
Inspections and Maintenance 2620
Crimp Height Inspection 2620
Visual Inspection 2620
Maintenance 2621
How to Use Pro-Crimper II Tool 2621
AMP Superseal 1 5 Connector Assemblies 2622
Description 2622
Repair and Maintenance 2629
Panel Mount Option 2629
AMP Fastin-Faston Hand Tools 2630
Description – AMP Double Action Hand Tool 2630
Maintenance and Inspection Procedures 2630
Daily Maintenance 2630
Periodic Tool Inspection 2631
Lubrication 2631
Visual Inspection 2631
Crimp Height Inspection 2631
Certi-Crimp Ratchet Inspection 2632
How to Use AMP Double Action Hand Tool 2633
Description – AMP Extraction Tool 2634
Maintenance and Inspection 2635
How to Use AMP Extraction Tool 2635
AMP Fastin-Faston Receptacles and Housings 2637
Description 2637
Wire Repair 2645
Wire Splicing Requirements 2645
Deutsch Jiffy Splice 2646
Twisted/Shielded Cable and Leads Repair 2652
Special Tools 2654
524223769 2200YRM1128 (07 2020) UK EN 2663
Series Code / Model Designation Reference Table 2669
General 2672
Deutsch Crimping Tool 2672
How to Strip a Wire for Use With Deutsch Crimping Tool 2672
How to Crimp With the Deutsch Crimping Tool 2673
Calibration Test for the Deutsch Crimping Tool 2675
Deutsch Connectors 2677
DT, DTM, and DTP Series Connectors 2677
HD Series Connectors 2719
Metri-Pack Connectors 2742
Remove and Install 2742
Micro-Pack Connectors 2744
Weather-Pack Connectors 2745
AMPSEAL Crimping Tools 2747
AMP Hand Crimping Tool With Certi-Crimp 2747
Description 2747
Stripping Wire for Use with AMP Hand Crimping Tool 2747
Insulation Crimp Adjustment 2748
Maintenance and Inspection for AMP Hand Crimping Tool 2748
AMP Hand Crimping Tool 2748
Crimp Height Inspection 2748
How to use AMP Hand Crimping Tool 2749
AMP Pro-Crimper II Tool 2749
Description 2749
Remove and Install Die Set and Locator Assembly 2750
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2751
Contact Support Adjustment 2751
Crimp Height Adjustment 2752
Maintenance and Inspection Procedures 2752
PRO-CRIMPER II Tool 2752
Crimp Height Inspection 2752
How to Use AMP PRO-CRIMPER II Tool 2753
AMPSEAL Connector Assemblies 2754
Description for Plug Connector Assembly 2754
Seal Plug 2755
Contact Crimping 2755
Description for Plug Connector and Header Assembly 2760
Voltage Reading 2762
Seal Plug 2762
Contact Crimping 2762
AMP Superseal 1 5 Crimping Tools 2769
Mini Mic Receptacle and Tab Contacts 2769
Description 2769
Crimping Conditions and Measurements 2769
Insertion of Rubber Seal on Cable 2771
AMP Hand Application Tool 2776
Description 2776
Maintenance and Inspection 2776
Crimp Height Inspection 2776
Crimp Height Adjustment 2777
How to Use AMP Hand Application Tool 2777
AMP Pro-Crimper II Tool 2778
Description 2778
Remove and Install Die Set and Locator Assembly 2779
Adjustments 2779
Contact Support 2779
Crimp Height 2780
Inspections and Maintenance 2781
Crimp Height Inspection 2781
Visual Inspection 2781
Maintenance 2782
How to Use Pro-Crimper II Tool 2782
AMP Superseal 1 5 Connector Assemblies 2783
Description 2783
Repair and Maintenance 2790
Panel Mount Option 2790
AMP Fastin-Faston Hand Tools 2791
Description – AMP Double Action Hand Tool 2791
Maintenance and Inspection Procedures 2791
Daily Maintenance 2791
Periodic Tool Inspection 2792
Lubrication 2792
Visual Inspection 2792
Crimp Height Inspection 2792
Certi-Crimp Ratchet Inspection 2793
How to Use AMP Double Action Hand Tool 2794
Description – AMP Extraction Tool 2795
Maintenance and Inspection 2795
How to Use AMP Extraction Tool 2796
AMP Fastin-Faston Receptacles and Housings 2797
Description 2797
Wire Repair 2804
Wire Splicing Requirements 2804
Deutsch Jiffy Splice 2805
Twisted/Shielded Cable and Leads Repair 2810
Special Tools 2813
524223770 2200YRM1130 (03 2020) UK EN 2821
General 2825
Description 2825
Dash Display Menu Access 2825
Menu Navigation 2826
Standard Display 2826
Main Menu 2826
Passwords Menu 2827
Password Administration 2827
Add Password 2827
Delete Password 2828
Edit Password 2828
Other Password Functions 2829
Operator Passwords – Enable/Disable 2829
Password Time-Out Delay 2829
Passwords – Number Wrong to Disable 2830
Lockout Reset Password 2830
View Password Log 2831
View Versions 2832
VSM Versions 2832
Dash Display Versions 2833
Engine Controller Version 2834
Transmission (Xmsn) Controller Version 2835
Truck Serial Number 2836
Diagnostics 2837
View Fault Log 2837
Set Travel and Braking 2838
Speed Limit 2838
Acceleration Rate 2839
Auto-Deceleration Rate 2839
Set Power Reversal Rate 2840
Set Inching/Brake Overlap 2841
Setup Display Menu 2842
Set Operator Language 2842
Set Units 2843
Set Time Format (12/24 Hour) 2843
Set Daylight Saving Time 2843
Set Time 2846
Set Date Format 2847
Set Date 2847
Setup Hydraulics 2848
Return to Set Tilt Delay/On/Off 2848
Setup General Items 2849
Light Shutdown Time-Out 2849
Impact Sensor – Enable/Disable 2850
Impact Sensor – Soft Impact Settings 2851
Impact Sensor – Hard Impact Settings 2852
Adjust Impact Sensor Settings 2852
Initial Adjustment of Soft and Hard Impact Settings 2854
Readjustment of Soft and Hard Impact Settings 2854
Impact Sensor – Impact Alarm/Shutdown Reset 2855
Impact Sensor – Alarm Time Duration and Deactivation 2856
Impact Sensor – View Impact Event Log 2857
Engine Mode Indicator 2858
Generation 1 (ECO-eLo ONLY) 2858
Generation 2 2859
Operator Checklist 2860
Operator Checklist Off-On Mode 2860
Edit Operator Checklist 2860
Set Operator Checklist Expiration 2861
View Checklist Log 2861
Clear Operator Checklist Log 2862
Clear Operator Checklist Fault 2862
Calibrations 2863
Set Tilt Stop Point 2863
Calibrate Loaded Weight 2863
524223771 2200YRM1131 (03 2020) UK EN 2865
Series Code / Model Designation Reference Table 2871
General 2873
Description 2873
Dash Display Menu Access 2873
Menu Navigation 2874
Main Menu 2874
Passwords 2875
Adding Passwords 2875
Hourmeters 2877
View Versions 2878
VSM Versions 2878
Dash Display Versions 2879
Engine Controller Version 2880
Transmission (Xmsn) Controller Version 2881
Truck Serial Number 2882
Truck Configuration 2883
Diagnostics 2884
Clear Fault Log 2884
View Fault Log 2885
No-Run Data Display 2886
Engine Accelerator and Throttle Data Display 2886
Engine Speeds and Governor Data Display 2887
Engine Fuel and Emissions Data Display 2888
Engine General Data Display 2890
XMSN/Brake Data Display 2891
Hydraulic Data Display 2894
General Truck Data Display 2896
Set Travel and Braking 2897
Speed Limit 2897
Acceleration Rate 2898
Auto-Deceleration Rate 2899
Set Power Reversal Rate 2899
Set Inching/Brake Overlap 2900
Setup Hydraulics 2900
Lift Maximum Speed 2901
Lower Maximum Speed 2901
Tilt Maximum Speed 2902
Auxiliary Function One, Direction A, Maximum Speed 2904
Auxiliary Function One, Direction B, Maximum Speed 2906
Auxiliary Function Two, Direction A, Maximum Speed 2906
Auxiliary Function Two, Direction B, Maximum Speed 2907
Auxiliary Function Three, Direction A, Maximum Speed 2908
Auxiliary Function Three, Direction B, Maximum Speed 2908
Lift/Lower Ramp Rate 2909
Hydraulic Auxiliary Ramp Rate 2909
Return to Set Tilt Delay/On/Off 2910
Hydraulic Input Device 2911
Auxiliary Solenoid 2911
Dual Function 2912
Setup Display 2913
Set Service Language 2913
Setup General Items 2913
Motion Alarm Activation Type 2914
Light Shutdown Time-Out 2915
Restore Default Settings 2915
Restore Engine Controller Default Calibration 2916
Impact Sensor – Enable/Disable 2916
Impact Sensor – Soft Impact Settings 2917
Impact Sensor – Hard Impact Settings 2918
Adjust Impact Sensor Settings 2919
Initial Adjustment of Soft and Hard Impact Settings 2921
Readjustment of Soft and Hard Impact Settings 2921
Impact Sensor – Impact Alarm/Shutdown Reset 2922
Impact Sensor – Alarm Time Duration and Deactivation 2923
Impact Sensor – View Impact Event Log 2924
Engine Mode Indicator 2924
Generation 1 (ECO-eLo ONLY) 2924
Generation 2 2925
Diesel Particulate Filter (DPF) Display 2926
General Description 2926
Passive Regeneration Only 2926
Regeneration Level 0 2926
Auto/Active Regeneration Inhibited 2927
Auto/Active Regeneration 2927
Regeneration Level 1 2927
Parked Regeneration Request 2928
Regeneration Level 2 2928
Warning Level 2928
Regeneration Level 3 2928
Service Level 2929
Regeneration Level 4 2929
Display, Diesel Particulate Filter (DPF), Revised 2929
Operator Interface 2929
Refer to Operator Manual 2929
CAN Communication Lost 2930
Passive Regeneration Only 2930
Regeneration Level 0 2930
Auto/Active Regeneration Inhibited 2930
Auto/Active Regeneration 2931
Regeneration Level 1 2931
Idle-up Auto/Active Regeneration 2931
Parked Regeneration Request 2931
Regeneration Level 2 2931
Warning Level 2933
Regeneration Level 3 2933
Service Level 2933
Regeneration Level 4 2933
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2933
Display, Diesel Particulate Filter (DPF), Stage V Engine 2933
Operator Interface 2934
Refer to Operator Manual 2934
CAN Communication Lost 2934
Passive Regeneration Only 2934
Regeneration Level 0 2934
Auto/Active Regeneration Inhibited 2935
Auto/Active Regeneration 2935
Regeneration Level 1 2935
Idle-up Auto/Active Regeneration 2936
Parked Regeneration Request 2936
Regeneration Level 2 2936
Warning Level 2937
Regeneration Level 3 2937
Service Level 2938
Regeneration Level 4 2938
Stage V Content 2938
Emissions System Malfunction 2938
Ash Load 2938
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2939
Operator Interface 2939
Refer to Operator Manual 2939
CAN Communication Lost 2940
Passive Regeneration Only 2940
Regeneration Level 0 2940
Auto/Active Regeneration Inhibited 2940
Auto/Active Regeneration 2941
Regeneration Level 1 2941
Idle-up Auto/Active Regeneration 2941
Parked Regeneration Request 2941
Regeneration Level 2 2941
Warning Level 2943
Regeneration Level 3 2943
Service Level 2943
Regeneration Level 4 2943
Calibrations 2944
Calibrate Transmission Valve 2946
Set Tilt Stop Point 2946
Calibrate Loaded Weight 2946
Calibrate Travel Speed Sensor 2947
Calibrate Mazda LP and Gas Accelerator Pedal 2947
524223772 2200YRM1142 (01 2020) UK EN 2949
General 2959
Display Switch Cluster 2962
Remove 2962
Install 2965
Direction Control and Turn Signal Levers 2965
Remove 2965
Install 2967
Key Switch 2967
Remove 2967
Install 2968
Display Switch Cluster Panel Bezel and Overlay 2968
Remove 2968
Install 2968
Steering Column Repair 2968
Remove 2968
Disassemble 2971
Assemble 2971
Install 2971
Sensors and Switches 2972
General 2972
Dash and Kick Panel, Remove and Install 2972
Remove 2972
Install 2973
Accelerator Pedal Position Sensor 2974
Remove 2974
Install 2977
Brake Fluid Level Switch 2978
Remove 2978
Install 2980
Service Brake Pedal Position Sensor 2981
Remove 2981
Install 2984
Parking Brake Sensor 2985
Remove 2985
Install 2986
Service Brake Pressure Sensor 2987
Remove 2987
Install 2989
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 2990
Remove 2990
Install 2990
Sensor Microswitch (Foot Directional Control Pedal) 2991
Remove 2991
Install 2994
Low Coolant Level Sensor 2995
Remove 2995
Install 2998
Fuel Level Sensor, Gas and Diesel Engines Only 2999
Remove 2999
Install 3000
Armrest Switch 3000
Remove 3000
Install 3002
Seat Sensor (Operator Presence System) 3002
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) 3002
Remove 3002
Install 3003
Non-Suspension Seats; Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3003
Remove 3003
Install 3004
Full Suspension Seats; All Lift Truck Models 3004
Remove 3004
Install 3004
Hood Shut Off Switch 3004
Remove 3004
Install 3007
Remote Key Switch 3008
Remove 3008
Install 3008
Hydraulic Filter Pressure Switch 3009
Remove 3009
Install 3011
Transmission Speed Sensor 3011
Remove 3011
Install 3014
Transmission Pressure Sensors 3015
Remove 3015
Install 3017
Transmission Temperature Sensor 3018
Remove 3018
Install 3020
Engine Speed Sensor 3022
Remove 3022
Install 3022
Intermediate Speed Sensor 3023
Remove 3023
Install 3023
Return to Set Tilt (Tilt Angle) Sensor 3023
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) 3023
Remove 3023
Install 3024
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) 3025
Remove 3025
Install 3026
Rear Horn Button Switch 3026
Remove 3026
Install 3027
Impact Sensor 3028
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) 3028
Remove 3028
Install 3031
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) 3031
Remove 3031
Install 3032
Load Weight Sensor 3033
Remove 3033
Install 3034
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda EnginesFE and F2 3035
Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with GM Engines 3035
Crankshaft Position (CKP) Sensor 3035
Camshaft Position (CMP) Sensor 3035
Oil Pressure Sensor 3035
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3035
Engine Coolant Temperature (ECT) Sensor 3036
Air Flow Restriction Switch 3036
Remove for GM 2 4L Gas and LPG Trucks 3036
Install for GM 2 4L Gas and LPG Trucks 3036
Oxygen Sensor 3037
Remove 3037
Install 3040
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3041
Crankshaft Position (CKP) Sensor 3041
Camshaft Position (CMP) Sensor 3041
Oil Pressure Sensor 3041
Manifold Absolute Pressure (MAP)/Manifold Air Temperature (MAT) Sensor 3041
Engine Coolant Temperature (ECT) Sensor 3041
Air Flow Restriction Switch 3041
Oxygen Sensor 3041
Engine and Fuel Switches, GM 2 4L LPG Trucks Only 3041
Low LPG Pressure Switch 3041
Engine and Fuel Sensors and Switches, Yanmar Diesel Trucks 3042
Air Filter Restriction Switch 3042
Remove 3042
Install 3042
Oil Pressure Sensor 3042
Remove 3042
Install 3042
Engine Speed Sensor 3042
Remove 3042
Install 3042
Engine Coolant Temperature (ECT) Sensor 3042
Remove 3042
Install 3042
Throttle Position Sensor (TPS) 3045
Remove 3045
Install 3046
Fuel/Water Separator Sensor 3046
Remove 3046
Install 3046
Glow Plug Relay 3047
Remove 3047
Install 3049
Engine and Fuel Sensors and Switches, Cummins Diesel Engines 3049
Air Filter Restriction Switch 3049
Remove 3049
Install 3049
Engine Oil Pressure Sensor 3054
Remove 3054
Install 3054
Engine Speed Sensor 3054
Remove 3054
Install 3055
Engine Coolant Temperature (ECT) Sensor 3055
Remove 3055
Install 3056
Throttle Position Sensor (TPS) (Cummins 4 5L Only) 3057
Remove 3057
Install 3057
Fuel/Water Separator Sensor 3058
Remove 3058
Install 3058
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine Without DPF 3059
Intake Air Temperature Sensor 3059
Remove 3059
Install 3060
Intake Air Pressure Sensor 3060
Remove 3060
Install 3060
Air Inlet Heater 3060
Remove 3060
Install 3061
Engine Oil Pressure Sensor 3061
Remove 3061
Install 3061
Engine Coolant Temperature (ECT) Sensor 3061
Remove 3061
Install 3061
Crankshaft Position Sensor 3062
Remove 3062
Install 3062
Adjust Shim Procedure 3063
Camshaft Position Sensor 3064
Remove 3064
Install 3064
Air Flow Restriction Sensor 3065
Remove 3065
Install 3065
Fuel/Water Separator 3065
Remove 3065
Install 3066
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With DPF 3066
Intake Air Temperature Sensor 3070
Remove 3070
Install 3071
Boost Sensor 3071
Remove 3071
Install 3072
Throttle Valve Assembly and Air Intake Heater 3072
Remove 3072
Install 3072
Engine Coolant Temperature (ECT) Sensor 3073
Remove 3073
Install 3073
Engine Oil Pressure Sensor 3073
Remove 3073
Install 3074
Crankshaft Position Sensor 3074
Remove 3074
Install 3074
Adjust Shim Procedure 3075
Camshaft Position Sensor 3076
Remove 3076
Install 3077
Differential Pressure Sensor 3077
Remove 3077
Install 3077
Mass Air Flow Sensor 3078
Remove 3078
Install 3079
Fuel/Water Separator 3079
Remove 3079
Install 3080
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3080
Engine Coolant Temperature (ECT) Sensor 3081
Remove 3081
Install 3081
Throttle Position Sensor 3082
Engine Oil Pressure Sensor 3082
Remove 3082
Install 3082
Engine Speed Sensor 3082
Remove 3082
Install 3082
Fuel Shut Off Solenoid 3082
Remove 3082
Install 3082
Vehicle System Manager (VSM) 3083
General 3083
VSM Replacement 3083
Remove 3083
Install 3085
Programming a New VSM and/or Display Switch Cluster 3085
General 3085
PC Service Tool Software 3086
Data Transferring 3086
New VSM 3086
New (Blank) Display Switch Cluster 3086
Used (Non-Blank) Display Switch Cluster 3086
Power Distribution Module (PDM) and Component Parts 3088
Remove 3088
PDM as a Unit 3088
Install 3092
PDM as a Unit 3092
Remove and Install 3093
PDM Component Parts 3093
Transmission Control Unit 3093
Remove 3093
Install 3097
Battery 3099
Remove 3099
Install 3099
Lights 3100
Work Lights (Front and Rear) 3100
Remove 3100
Install 3100
Strobe Light 3101
Remove 3101
Install 3101
LED Tail, Backup, and Brake Lights 3102
Remove 3102
Install 3103
Front Marker/Turn Signal Lights 3104
Replacing Whole Front Marker/Turn Signal Light Assembly 3104
Remove 3104
Install 3104
Replacing Just the Front Marker/Turn Signal Light LED Light Lens 3105
Remove 3105
Install 3105
Diesel Particulate Filter (DPF) Display 3105
Remove 3105
Clean and Inspect 3106
Install 3106
Electronic-Hydraulic Controls – Generation 1 3107
E-Hydraulic Controls – Test 3107
Mini-Levers 3107
Full Stroke Test 3107
Function Returns to Neutral Test 3107
Push Button Switch 3107
General 3108
Mini-Lever Replacement 3108
Remove 3108
Clean and Inspect 3109
Install 3109
Push Button Switch Replacement 3110
Remove 3110
Install 3112
Mini-Lever Module (MLM) 3112
Remove 3112
Install 3112
Joystick 3113
Remove and Disassemble 3113
Inspect 3113
Assemble and Install 3113
Electronic-Hydraulic Controls – Generation 2, Before January, 2020 3114
General 3114
Mini-levers, Remove and Install 3114
Armrest Assembly 3115
Remove 3115
Install 3118
Horn Button 3118
Remove 3118
Install 3118
Direction Control Switch 3119
Remove 3119
Install 3119
push (override) buttons and Toggle Switch 3119
Remove 3120
Install 3121
Joystick 3122
Remove and Disassemble 3122
Inspect 3122
Assemble and Install 3122
Joystick Armrest Slider Assembly 3123
Remove 3123
Install 3124
Electronic-Hydraulic Controls, After January, 2020 3124
E-Hydraulic Controls – TEST 3124
Mini-Levers 3124
Full Stroke Test 3124
Function Returns to Neutral Test 3124
Push (Override) Button 3125
General 3125
Mini-levers, Remove and Install 3125
Armrest Assembly 3126
Remove 3126
Install 3129
Horn Button 3129
Remove 3129
Install 3129
Direction Control Switch 3129
Remove 3129
Install 3130
Push (Override) buttons and Toggle Switch 3130
Remove 3131
Install 3133
Special Tools 3134
524223780 8000YRM1134 (03 2020) UK EN 3137
Series Code / Model Designation Reference Table 3143
Description 3145
Proc_Cal_001: Service Password Entry 3147
When to Perform 3147
Why Perform 3147
How to Perform 3147
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3148
When to Perform 3148
Calibration Order 3148
Why Perform 3148
How to Perform 3149
Proc_Cal_003: Save and Exit 3150
When to Perform 3150
Why Perform 3150
How to Perform 3150
Proc_Cal_004: Lift Valve Output Threshold 3151
When to Perform 3151
Calibration Order 3151
Why Perform 3151
How to Perform 3152
Proc_Cal_005: Lower Valve Output Threshold 3154
When to Perform 3154
Calibration Order 3154
Why Perform 3154
How to Perform 3154
Proc_Cal_006: Tilt Back Valve Output Threshold 3157
When to Perform 3157
Calibration Order 3157
Why Perform 3157
How to Perform 3157
Proc_Cal_007: Tilt Forward Valve Output Threshold 3160
When to Perform 3160
Calibration Order 3160
Why Perform 3160
How to Perform 3160
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3163
When to Perform 3163
Calibration Order 3163
Why Perform 3163
How to Perform 3163
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3166
When to Perform 3166
Calibration Order 3166
Why Perform 3166
How to Perform 3166
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3169
When to Perform 3169
Calibration Order 3169
Why Perform 3169
How to Perform 3169
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3172
When to Perform 3172
Calibration Order 3172
Why Perform 3172
How to Perform 3172
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3175
When to Perform 3175
Calibration Order 3175
Why Perform 3175
How to Perform 3175
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3178
When to Perform 3178
Calibration Order 3178
Why Perform 3178
How to Perform 3178
Proc_Cal_014: Load Weight Zero Point 3182
When to Perform 3182
Calibration Order 3182
Why Perform 3182
How to Perform 3182
Proc_Cal_015: Loaded Weight Calibration 3184
When to Perform 3184
Calibration Order 3184
Why Perform 3184
How to Perform 3184
Proc_Cal_016: Transmission Valve Calibration 3187
Applicable System/Option 3187
When to Perform 3187
Calibration Order 3187
Why Perform 3187
How to Perform 3187
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3189
Applicable System/Option 3189
When to Perform 3189
Calibration Order 3189
Why Perform 3189
How to Perform 3189
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3191
Applicable System/Option 3191
When to Perform 3191
Calibration Order 3191
Why Perform 3191
How to Perform 3192
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3193
Required Tools 3193
When to Perform 3193
Calibration Order 3193
Why Perform 3194
How to Perform 3194
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3195
When to Perform 3195
Why Perform 3195
How to Perform 3195
Proc_Cal_026: Travel Speed Calibration 3197
When to Perform 3197
Calibration Order 3197
Why Perform 3197
How to Perform 3197
524223780 8000YRM1134 (05 2022) US EN 3201
Series Code / Model Designation Reference Table 3207
Description 3210
Proc_Cal_001: Service Password Entry 3212
When to Perform 3212
Why Perform 3212
How to Perform 3212
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 3213
When to Perform 3213
Calibration Order 3213
Why Perform 3213
How to Perform 3213
Proc_Cal_003: Save and Exit 3215
When to Perform 3215
Why Perform 3215
How to Perform 3215
Proc_Cal_004: Lift Valve Output Threshold 3216
When to Perform 3216
Calibration Order 3216
Why Perform 3216
How to Perform 3216
Proc_Cal_005: Lower Valve Output Threshold 3219
When to Perform 3219
Calibration Order 3219
Why Perform 3219
How to Perform 3219
Proc_Cal_006: Tilt Back Valve Output Threshold 3222
When to Perform 3222
Calibration Order 3222
Why Perform 3222
How to Perform 3222
Proc_Cal_007: Tilt Forward Valve Output Threshold 3225
When to Perform 3225
Calibration Order 3225
Why Perform 3225
How to Perform 3225
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 3228
When to Perform 3228
Calibration Order 3228
Why Perform 3228
How to Perform 3228
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 3231
When to Perform 3231
Calibration Order 3231
Why Perform 3231
How to Perform 3231
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 3234
When to Perform 3234
Calibration Order 3234
Why Perform 3234
How to Perform 3234
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 3237
When to Perform 3237
Calibration Order 3237
Why Perform 3237
How to Perform 3237
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 3240
When to Perform 3240
Calibration Order 3240
Why Perform 3240
How to Perform 3240
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 3243
When to Perform 3243
Calibration Order 3243
Why Perform 3243
How to Perform 3243
Proc_Cal_014: Load Weight Zero Point 3246
When to Perform 3246
Calibration Order 3246
Why Perform 3246
How to Perform 3246
Proc_Cal_015: Loaded Weight Calibration 3248
When to Perform 3248
Calibration Order 3248
Why Perform 3248
How to Perform 3248
Proc_Cal_016: Transmission Valve Calibration 3251
Applicable System/Option 3251
When to Perform 3251
Calibration Order 3251
Why Perform 3251
How to Perform 3251
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 3253
Applicable System/Option 3253
When to Perform 3253
Calibration Order 3253
Why Perform 3253
How to Perform 3253
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 3256
Applicable System/Option 3256
When to Perform 3256
Calibration Order 3256
Why Perform 3256
How to Perform 3256
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 3259
Required Tools 3259
When to Perform 3259
Calibration Order 3259
Why Perform 3259
How to Perform 3259
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 3261
When to Perform 3261
Why Perform 3261
How to Perform 3261
Proc_Cal_026: Travel Speed Calibration 3263
When to Perform 3263
Calibration Order 3263
Why Perform 3263
How to Perform 3263
524262279 1800YRM1247 (09 2018) UK EN 3267
General 3271
Dry Brake System 3271
Wet Brake System 3272
Service Brakes Repair (Dry Brake) 3276
Remove and Disassemble 3276
Clean 3278
Inspect 3279
Assemble and Install 3279
Adjust 3283
Parking Brake Repair 3283
Dry Brake System 3284
Remove and Disassembly 3284
Assemble and Install 3286
Wet Brake System 3286
Remove and Install 3287
Assemble and Install 3293
Adjust 3293
Dry Brake System 3293
Wet Brake System 3294
Lift Trucks With a Pedal or Forward Reverse LeverFoot Directional Control 3294
Master Cylinder Repair 3295
Remove 3295
Disassemble 3300
Clean and Inspect 3301
Assemble 3302
Install and Adjust 3302
Accumulator 3304
Pre-Charge Check 3305
Remove 3306
Install 3308
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator 3308
Remove 3309
Modulating Brake Valve 3310
Disassemble 3310
Clean and Inspect 3312
Assemble 3312
Accumulator Charge Valve 3313
Disassemble 3313
Clean and Inspect 3315
Assemble 3315
Install 3316
Pressure Checks 3317
Accumulator Charge Valve Check 3317
Accumulator Check 3317
Service Brakes Adjustment (Dry Brake) 3318
Service Brakes Adjustment 3318
Brake System Air Removal 3319
Using Pressure Bleed System 3319
Using Brake Pedal Pressure 3320
Lift Truck Models with Master Cylinder 3320
Lift Truck Models with Modulating Brake Valve 3320
Brake Pedal Adjustment 3321
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), GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879), and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3321
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3322
Free Pedal Adjustment 3324
Torque Specifications 3325
524288194 1300YRM1317 (03 2020) UK EN 3329
Transmission Repair 3333
Remove 3333
Torque Converter, Remove 3333
Disassemble 3334
Clean and Inspect 3383
Housings 3383
Oil Seals and Gaskets 3383
Bearings 3383
Gears and Shafts 3384
Assemble 3384
Torque Converter, Install 3425
Install 3426
Control Valve Repair 3427
Remove 3427
Disassemble 3427
Clean 3429
Inspect 3429
Assemble 3429
Install 3430
Torque Specification 3431
524294878 2100YRM1328 (09 2018) UK EN 3433
General 3437
Safety Procedures When Working Near Mast 3437
Tilt Cylinder Repair 3439
Remove 3439
Disassemble 3444
Clean 3446
Inspect 3446
Assemble 3446
Install 3448
Tilt Cylinders, Adjust 3450
Tilt Cylinder Leak Check 3451
Lift Cylinder Repair 3452
Remove 3452
Disassemble 3462
Clean 3465
Inspect 3465
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) 3465
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3465
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) 3466
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3466
Free-Lift Cylinder Repair 3467
Remove 3467
Disassemble 3473
Clean 3475
Inspect 3475
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) 3476
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3476
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) 3476
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3477
Sideshift Cylinder Repair 3478
Remove 3478
Disassemble 3479
Clean 3482
Inspect 3482
Assemble 3483
Install 3484
Bolzoni Sideshift Cylinder Repair 3485
Remove 3485
Disassemble 3485
Clean 3486
Inspect 3486
Assemble 3487
Install 3487
Fork Positioner Cylinder Repair 3487
Remove 3488
Disassemble 3491
Clean 3495
Inspect 3495
Assemble 3496
Install 3497
Lift Cylinder Leak Check 3498
Seal Kit Installation 3498
External Installation (Seal and Back-Up Ring) 3498
Internal Installation (Piston Rod Assembly) 3499
Special Tools 3500
Torque Specifications 3501
For Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) 3501
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3501
524296605 1400YRM1344 (03 2020) UK EN 3505
General 3509
Identification Plate 3509
Drive Axle Removal 3509
Planetary Reduction Gear Repair 3521
Clean and Inspect 3531
Brake Repair 3540
Clean and Inspect 3553
Wet Brake Noise Reduction 3563
General 3563
Adding Additive To Transmission 3564
Differential Repair 3565
Clean and Inspect 3576
Bevel Pinion 3588
Clean and Inspect 3592
Drive Axle Installation 3602
Special Tools 3613
Torque Specifications 3614
524306203 0100YRM1290 (04 2014) UK EN 3617
550000873 4000YRM1406 (10 2017) UK EN 3721
Safety Procedures When Working Near Mast 3725
Fork Replacement 3727
Remove 3727
Install 3728
Checks 3728
Carriage Repair 3729
Remove 3729
Clean and Inspect 3732
Install 3732
Integral Sideshift Carriage And Fork Positioners Repair 3732
Integral Sideshift Carriage 3733
Remove 3733
Disassemble 3734
Clean and Inspect 3736
Assemble 3736
Install 3737
Fork Positioners 3737
Remove 3737
Disassemble 3740
Clean and Inspect 3742
Assemble 3742
Install 3742
Two-Stage Mast With Limited Free-Lift Repair 3743
Remove 3743
Disassemble 3746
Clean and Inspect 3749
Assemble 3751
Install 3751
Header Hose Installation 3752
Three-Stage Mast With Full Free-Lift Repair 3755
Remove 3755
Disassemble 3759
Clean and Inspect 3762
Assemble 3764
Install 3764
Header Hose Installation 3766
Mast Operation Check 3768
Tilt Cylinder Adjustment 3768
Main Lift Cylinder Repair 3768
Lift Chain Adjustment 3769
Mast Adjustments 3770
Load Roller Adjustment 3770
Mast Side Kicking Adjustment 3772
Carriage Adjustment 3772
550021072 0600YRM1432 (03 2020) UK EN 3777
General 3783
Engine Removal and Installation 3783
Cylinder Head Repair 3783
Intake Manifold 3783
Remove 3783
Clean and Inspect 3784
Install 3784
Cylinder Head 3785
Remove and Disassemble 3785
Clean and Inspect 3787
Valve Guides and Seats Repairs 3789
Valves Repair 3789
Valve Seats Repair 3790
Valve Springs 3791
Assemble and Install 3791
Engine Block Cleaning and Inspection 3793
Piston Bore Preparation 3795
Lubrication System Repair 3795
Oil Pan Removal 3795
Oil Pump Assembly 3796
Oil Pump, Removal 3796
Oil Pump, Disassemble 3796
Oil Pump, Assemble 3796
Oil Pump, Install 3797
Clean and Inspect 3798
Oil Pan, Install 3798
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 3800
Timing Cover 3800
Remove 3800
Install 3801
Timing Sprockets 3801
Remove 3801
Install 3802
Camshaft 3802
Remove 3802
Inspect 3803
Install 3803
Clean and Inspect 3804
Valve Lifters 3804
Remove 3804
Clean and Inspect 3805
Install 3806
Crankshaft Repair 3807
Crankshaft 3807
Remove 3807
Inspect and Repair 3808
Main Bearings and Journals Clearance Check 3809
Install 3809
Piston and Connecting Rod Assembles 3810
Connecting Rod Bearings, Replace 3810
Piston and Connecting Rod Assemblies, Remove 3811
Disassemble 3812
Piston, Clean and Inspect 3812
Cylinder Bores, Inspect and Repair 3812
Piston Rings 3813
Assemble 3814
Piston and Connecting Rod Assemblies, Install 3815
Flywheel and Flywheel Housing Repair 3816
Flywheel, Remove 3816
Clean 3816
Inspect 3816
Flywheel, Install 3817
Coolant System Repair 3817
Water Pump 3817
Remove 3817
Clean and Inspect 3818
Install 3818
Serpentine Belt 3819
Remove 3819
Inspect 3819
Install 3820
Thermostat 3820
Remove 3820
Thermostat Operation Check 3820
Install 3821
Fan Assembly Replacement 3821
Remove 3821
Inspect 3823
Install 3823
Ignition System 3823
Spark Plug Wire Inspection 3823
Spark Plug Wire Replacement 3823
Remove 3823
Install 3824
Spark Plug Replacement 3825
Remove 3825
Install 3825
Spark Plug Inspection 3826
Usage 3826
Inspect 3826
Visual Inspection 3827
Alternator Repair 3828
Remove 3828
Install 3828
Starter Repair 3828
Remove 3828
Install 3829
Compression Check 3829
Valve Clearance Adjustments 3829
Engine Specifications 3831
Engine Data 3831
Cylinder Head 3831
Camshaft 3831
Cylinder Bore 3831
Piston 3832
Piston Pin 3832
Crankshaft 3832
Connecting Rods 3832
Balance Shaft 3832
Cooling System 3833
Lubrication System 3833
Torque Specifications for Capscrews and Bolts 3833
550021077 0900YRM1433 (03 2020) UK EN 3837
General 3841
LPG Tank and Bracket 3841
LPG Tank 3841
Remove 3841
Install 3844
LPG Tank Bracket 3844
Remove 3844
Install 3844
LPG Tank Bracket Alignment Pin 3845
Remove 3845
Install 3845
Fuel Filter Unit 3846
Fuel Filter Element 3846
Remove 3846
Clean and Inspect 3846
Install 3846
Fuel Filter Housing 3847
Remove 3847
Disassemble 3849
Clean and Inspect 3849
Assemble 3850
Install 3850
Electronic Throttle Body 3851
Remove 3851
Install 3852
Fuel Mixer/Electronic Pressure Regulator (EPR) 3853
Remove 3853
Install 3854
Control System 3855
Engine Control Unit (ECU) 3855
Remove 3855
Install 3856
Low Pressure Switch 3856
Remove 3856
Install 3856
Low Fuel Sensor 3857
Remove 3857
Install 3857
LP Converter 3858
Remove 3858
Disassemble 3859
Assemble 3860
Install 3861
Lock-Off Valve 3862
Remove 3862
Install 3862
Exhaust System 3863
Counterweight Exhaust 3863
Remove and Disassemble 3863
Inspect 3864
Assemble and Install 3865
Exhaust Manifold 3865
Remove 3865
Install 3867
Positive Crankcase Ventilation (PCV) Valve 3867
Remove 3867
Inspect 3868
Install 3869
Oxygen Sensors 3869
Remove 3869
Install 3869
LPG Fuel Testing 3870
General 3870
Available Fuel Tests 3870
Composition Test (ASTM D-2163) 3870
Ammonia Test (ASTM D-4490) 3870
Basic Nitrogen Test (ASTM UOP269-90) 3870
Residues Test (ASTM D-2158) 3870
Vapor Pressure Test (ASTM D-2598) 3870
Sulfur Compounds Test (ASTM D-5623) 3870
Methanol Test (ASTM D-4864) 3871
Copper Corrosion (ASTM D-1838) 3871
Where To Send LPG Fuel Samples For Testing 3871
550055278 0100YRM1581 (05 2017) UK EN 3873
General 3877
Description 3878
Side Covers, Seat, Dash, and Hood Replacement 3879
Side Covers 3879
Remove 3879
Install 3879
Seat and Seat Plate 3879
Remove Seat 3879
Remove Seat Plate 3879
Install Seat Plate 3883
Install Seat 3883
Operator Restraint System 3884
Emergency Locking Retractor (ELR) 3884
Seat Plate and Seat Rail Check 3884
Steering Column, Dash, Kick Panel, and Seal Plate 3884
Remove 3884
Install 3884
Hood Support and Door Assembly 3889
Remove 3889
Install 3889
Hood Door Assembly 3894
Remove 3894
Install 3894
Steering Column 3894
Description 3895
Steering Column Repair 3895
Remove 3895
Disassemble 3897
Clean 3898
Inspect 3898
Assemble 3898
Install 3898
LPG Tank and Bracket Assembly 3898
Counterweight Replacement 3898
Remove 3899
Install 3902
Tow Pin, Remove and Install 3902
Overhead Guard Replacement 3903
Remove 3903
Install 3903
Engine Replacement 3904
Remove Engine 3905
Remove Transmission 3927
Remove Engine and Transmission 3931
Install Engine 3934
Install Transmission 3938
Install Engine and Transmission 3940
Throttle Pedal and Cable Adjustment 3943
Exhaust System Repair 3944
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 3944
GM 5 7L Engine for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 3944
Kubota 3 8L Diesel Engine for Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878, B909) 3944
Remove 3944
Inspect 3946
Install 3946
Kubota 3 6L Diesel Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878) 3947
Remove 3947
Inspect 3947
Install 3947
Cummins QSB 3 3L Engine for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 3949
Remove 3949
Inspect 3949
Install 3949
3951
Diesel Particulate Filter 3951
Disassemble 3951
Clean and Inspect 3952
Differential Pressure Pipes and Hoses 3953
Assemble 3953
Cooling System 3954
Description 3954
Hydraulic Filter Assembly Repair 3954
Remove 3954
Install 3954
Fuel and Hydraulic Tanks Repair 3956
Inspect 3956
Clean 3956
Steam Method of Cleaning 3957
Chemical Solution Method of Cleaning 3957
Additional Preparations for Repair 3957
Small Leaks, Repair 3958
Large Leaks, Repair 3958
Preparations for Use After Repair 3958
Safety Labels 3958
550055283 8000YRM1585 (07 2020) UK EN 3967
General Information About Diagrams and Schematics 3971
Symbol Definitions 3971
Diagrams Manual Applications 3972
Diagrams and Schematics 3974
550055777 8000YRM1586 (07 2019) UK EN 4063
General 4069
Serial Number Data 4069
How to Move Disabled Lift Truck 4069
How to Tow Lift Truck 4069
How to Put Lift Truck on Blocks 4070
How to Raise Drive Tires 4070
How to Raise Steering Tires 4071
How to Clean a Lift Truck 4072
Maintenance Schedule 4072
Maintenance Procedures Every 8 Hours or Daily 4085
How to Make Checks With Engine Stopped 4085
Tires and Wheels 4085
Safety Labels 4085
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 4085
Operator Restraint System 4086
Emergency Locking Retractor (ELR) 4086
Adjust Seat – Full Suspension 4087
Adjust Seat – Internal Suspension 4088
Seat Plate and Seat Rails 4088
Engine Compartment 4088
Fuel, Oil, and Coolant Leaks, Check 4088
Hydraulic Hoses 4089
Coolant Hoses 4089
Steering Column Gas Cylinder 4089
Transmission 4089
Hydraulic System Oil 4089
Engine Oil 4091
Forks 4094
Remove 4094
Inspect 4095
Install 4095
Adjust 4096
Integral Sideshift Carriage 4096
How to Make Checks With Engine Running 4097
Indicator Lights, Horn, Fuses, and Relays 4097
Service Brakes 4100
Operation, Check 4100
Accumulator Pressure 4100
Parking Brake 4100
Engine Oil Pressure 4100
Cooling System 4101
Steering System 4102
Control Levers and Pedals 4102
Lift System, Operate 4102
Air Filter 4102
Fuel/Water Separator Filter, Cummins and Kubota Diesel Engines 4103
First Service After First 100 Hours of Operation 4104
Engine Oil and Oil Filter 4104
Maintenance Procedures Every 500 Hours or 6 Months 4106
Hydraulic System Oil Check 4106
Hydraulic Tank Breather 4107
Inspect 4107
Battery 4109
Engine Oil and Oil Filter 4109
Fuel/Water Separator Filter Replacement, Cummins QSB 3 3L Diesel Engine 4110
Remove 4110
Install 4110
Final Fuel Filter Replacement, Cummins QSB 3 3L Diesel Engine 4111
Priming The Fuel System, Cummins QSB 3 3L Diesel Engine 4112
Controlled Venting 4112
Manual Bleeding 4112
Fuel/Water Separator Filter Replacement, Kubota 3 8L Engine 4113
Remove 4113
Install 4113
Priming the Fuel System (Kubota 3 8L Engine) 4115
Drive Belt 4115
Fan and Alternator Drive Belt 4115
Fan and Alternator Drive Belt Adjustment, Cummins QSB 3 3L Diesel Engine 4117
Clean Debris From Radiator Core 4117
Transmission and Wet Brake Axle Oil Level Check 4118
Wet Brake Center Body Oil Level Check 4119
Forks 4121
Mast Lubrication 4122
Header Hose Checks 4125
Lift Chain Lubrication 4125
Tilt Cylinder Lubrication 4127
Brake Actuation Valve Rod End Pin 4129
Tie Rod Lubrication 4130
Low Idle Speed Check 4131
Drain Tar From LPG Converter 4131
GM 5 7L LPG Engine 4131
Parking Brake Adjustment 4132
Maintenance Procedures Every 1000 Hours or 6 Months 4133
Lift Chain Lubrication and Wear Check 4133
Integral Sideshift Carriage, Check Sliding Surfaces 4134
Steering Axle Spindle Bearings 4135
Control Levers and Pedals 4136
Inspect Engine Electrical System, Connectors 4136
Spark Plugs 4137
GM 5 7L LPG Engine 4137
PCV Valve 4137
GM 5 7L LPG Engine 4137
LPG Fuel Filter 4137
GM 5 7L LPG Engine 4137
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4137
Crankcase Breather Element, Kubota 3 8L Diesel 4140
Remove 4140
Clean and Inspect 4141
Install 4141
Valve Clearance, Check and Adjust for Kubota 3 8L Diesel Engine 4141
In-Line Strainer Replacement, Kubota 3 8L Diesel Engine 4141
Remove 4141
Install 4142
Maintenance Procedures Every 2000 Hours or Annually 4143
Hydraulic System 4143
Hydraulic Filter Assembly, Replace 4143
Remove 4143
Install 4144
Hydraulic Tank Breather, Replace 4145
Cooling System Check 4146
Air Filter 4148
Forks 4149
Brake Oil (Master Cylinder), Change 4149
Check Throttle Shaft for Sticking 4150
Inspect Exhaust Manifold and Piping for Leaks 4150
Transmission Automatic Clutch Calibration 4151
Brake System Accumulator 4151
Valve Clearance, Check and Adjust, Cummins QSB 3 3L Diesel Engine 4151
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4152
GM 5 7L LPG Engine 4152
PCV Valve 4153
GM 5 7L LPG Engine 4153
LPG Electronic Pressure Regulator (EPR)/Fuel Mixer, Inspect 4153
GM 5 7L LPG Engine 4153
LPG Lock-Off Valve 4154
GM 5 7L LPG Engine 4154
Oxygen Sensors 4155
GM 5 7L LPG Engine 4155
Diesel Particulate Filter 4155
Wheel Bearings 4155
Steer Wheels, Lubrication 4155
Maintenance Procedures Every 4000 Hours or 2 Years 4155
Hydraulic Oil, Replace 4155
Safety Procedures When Working Near Mast 4156
Fuel Filter Water Removal 4158
Lift Chain Adjustments 4160
Jump-Starting the Lift Truck 4161
Jump-Starting Using a Battery Charger 4161
Jump-Starting a Lift Truck Using Another Lift Truck 4161
Welding Repairs 4162
Overhead Guard Changes 4162
Wheel and Tire Replacement 4162
General 4162
Pneumatic Tire With Tube, Repair 4162
Remove Wheels From Lift Truck 4162
Remove Tire From Wheel 4163
Install Wheel in Tire 4166
Install Tire on Two-Piece Wheel 4168
Add Air to Pneumatic Tires With Tube 4169
Install the Wheels 4169
Dual Drive Wheels, Install 4170
Pneumatic Tubeless Tire, Repair 4170
Remove Wheels From Lift Truck 4170
Add Air to Pneumatic Tubeless Tire 4176
Wheels, Install 4176
Solid Rubber Tires on Pneumatic Wheels, Change 4176
Snap-On-Tire, Change 4180
Adhesives and Sealants 4183
550055782 8000YRM1587 (04 2018) UK EN 4185
Lift Truck Lifting Capacity 4189
Tire Sizes 4189
Capacities 4189
Electrical System 4192
Transmission Oil Pressures 4193
Hydraulic System Relief Pressures 4193
Steering System 4193
Stall Speeds 4194
Mast Speeds 4194
Tilt Angles 4195
Front End Equipment – Mast Creep 4196
Mast Creep 4196
Engine Specifications 4196
Diesel Fuel Cleanliness Levels 4197
Torque Specifications 4198
Frame 4198
Mast, Carriage, and Fork Positioner 4198
Steering System 4198
Transmission 4198
Engine, Cummins QSB 3 3L 4198
Engine, GM 5 7L LPG 4198
Engine – Kubota 3 8L Diesel 4199
550059479 0600YRM1590 (07 2019) UK EN 4203
General 4209
Engine Identification 4209
Major Engine Component Identification 4209
Location of Labels 4210
Crankcase Description 4210
Precautions Before Beginning Repair 4211
Exhaust System and DPF 4212
Engine Removal and Installation 4212
Cylinder Head Assembly Repair 4213
Valve Covers and Fuel Injectors 4213
Remove 4213
Clean and Inspect 4216
Install 4216
Rocker Arm Assembly 4217
Remove 4217
Disassemble 4218
Clean and Inspect 4218
Push Rods 4218
Rocker Arm Assembly 4218
Assemble 4219
Install 4219
Valve Clearance Adjustments 4219
Cylinder Head Assembly 4220
Remove 4220
Disassemble 4229
Valves and Valve Springs, Remove 4229
Valve Guides, Remove 4230
Clean and Inspect 4230
Cylinder Head 4231
Valve Guides 4231
Valves 4231
Valve Sink 4232
Valve Seat 4232
Valve Springs 4233
Assemble 4233
Valve Guides, Install 4233
Valves and Valve Springs, Install 4234
Install 4235
Timing Gear Case and Timing Gears Repair 4237
Timing Gear Case Cover 4237
Remove 4237
Clean and Inspect 4238
Install 4238
Timing Gears 4239
Crankshaft Gear 4240
Remove 4240
Install 4240
Idler Gear 4240
Remove 4240
Inspect 4241
Install 4242
Camshaft Gear 4242
Remove 4242
Install 4242
Drive Train, Camshaft, and Cylinder Block Repair 4242
Remove 4242
Disassemble 4243
Pistons and Connecting Rods 4243
Crankshaft 4244
Camshaft 4246
Clean and Inspect 4248
Cylinder Block 4248
Honing and Boring 4250
Cylinder Correction (Oversize) 4251
Pistons 4251
Piston Pin 4252
Connecting Rod 4252
Tappets 4253
Crankshaft 4253
Camshaft 4255
Camshaft Bushing 4256
Assemble 4256
Camshaft 4256
Crankshaft 4256
Pistons and Connecting Rods 4257
Install 4259
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 4259
Lubrication System Repair 4262
Engine Oil and Oil Filter Change 4262
Oil Pan 4263
Remove 4263
Install 4264
Oil Suction Tube 4265
Remove 4265
Clean 4265
Install 4265
Oil Pump 4265
Remove 4265
Clean and Inspect 4266
Outer Rotor Outside Clearance 4267
Outer Rotor to Inner Rotor Tip Clearance 4267
Outer Rotor Side Clearance 4267
Rotor Shaft Clearance 4268
Install 4268
Fuel System Repair 4269
Fuel Injectors 4269
Remove 4269
Inspect 4269
Clean 4269
Replace 4269
Install 4269
Test 4269
Fuel Injection Pump 4270
Remove 4270
Clean and Inspect 4271
Install 4271
Cooling System Repair 4272
Serpentine Belt 4272
Remove 4272
Inspect 4273
Install 4273
Adjust 4273
Water Pump 4274
Remove 4274
Install 4275
Thermostat 4276
Remove 4276
Inspect 4277
Install 4277
Flywheel and Flywheel Housing 4278
Flywheel 4278
Remove 4278
Install 4279
Flywheel Housing 4279
Remove 4279
Install 4279
Electrical Equipment Repair 4280
Alternator 4280
Remove 4280
Install 4281
Starter 4282
Remove 4282
Install 4282
Engine Specifications 4284
Engine Data 4284
Engine Tuning 4288
Cylinder Head 4288
Intake/Exhaust Valve and Guide 4288
Valve Spring 4289
Rocker Arm and Shaft 4289
Push Rod 4289
Gear Train and Camshaft 4289
Camshaft 4289
Idle Gear Shaft and Bushing 4289
Backlash of Each Gear 4290
Cylinder Block 4290
Crankshaft 4290
Piston 4290
Piston Ring 4291
Connecting Rod 4291
Rod Small End 4291
Tappet 4291
Oil Pump 4292
Engine Oil Pressure 4292
Outer Rotor Outside Clearance 4292
Outer Rotor Side Clearance 4292
Inner Rotor to Cover 4292
Standard Torque Specifications 4293
Standard Torque Chart 4293
Special Torque Specifications 4293
Special Tools 4295
550073240 1900YRM1620 (01 2023) US EN 4309
Proper Flushing after Major Hydraulic Repairs 4315
Introduction 4315
The Phases of Wear 4315
Causes of Hydraulic System Failure 4315
Progression of Contaminant Caused Hydraulic System Failure 4316
Hydraulic System Flushing Techniques 4316
Double Oil and Filter Change 4316
Mechanical Cleaning 4317
Cleaning of Components 4317
How to Clean Tubes and Hoses 4317
Filter Caddy 4317
Start-Up Procedure for Cleaned System 4318
Contaminated Oil Coolers 4318
Additional Filter Caddy Functions 4319
How to Handle Different Fluids 4319
Water Removal Filters 4319
Fluid Conditioning and System Flushing Procedures 4320
Operation of the Filter Caddy 4320
Filter Caddy operation 4320
Fluid Conditioning Procedure 4320
Filter Caddy Start-Up 4321
System Flushing Procedure 4321
Component Cleaning Procedure 4322
Reservoir Cleaning Procedure 4322
Cylinder Cleaning Procedure 4322
Hose and Tube Cleaning Procedure 4322
Valve Cleaning Procedure 4323
Front-End Attachment Cleaning Procedure 4324
System Flushing Procedure 4324
Filter Caddy Start-Up 4325
System Start-Up and Flushing 4325
Reservoir Fluid Cleaning Times 4326
Dealing With Different Fluid Types 4327
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4327
Filter Caddy Maintenance 4327
Servicing the Strainer 4327
DC Motor 4327
Hydraulic Oil Sampling Method and Procedure 4328
Hydraulic Oil Sampling Method 4328
Objective 4328
General Guidelines 4328
Synopsis 4329
Hydraulic Oil Analysis Report Guidelines 4330
Sampling Conditions 4330
Equipment 4330
Sampling Procedure 4331
Hydraulic Oil Sampling 4331
Sample Labeling 4331
Results Documentation 4331
550073240 1900YRM1620 (03 2020) UK EN 4333
Proper Flushing after Major Hydraulic Repairs 4337
Introduction 4337
The Phases of Wear 4337
Causes of Hydraulic System Failure 4337
Progression of Contaminant Caused Hydraulic System Failure 4338
Hydraulic System Flushing Techniques 4338
Double Oil and Filter Change 4338
Mechanical Cleaning 4339
Cleaning of Components 4339
How to Clean Tubes and Hoses 4339
Filter Caddy 4339
Start-Up Procedure for Cleaned System 4340
Contaminated Oil Coolers 4340
Additional Filter Caddy Functions 4340
How to Handle Different Fluids 4340
Water Removal Filters 4341
Fluid Conditioning and System Flushing Procedures 4341
Operation of the Filter Caddy 4341
Filter Caddy operation 4341
Fluid Conditioning Procedure 4342
Filter Caddy Start-Up 4342
System Flushing Procedure 4343
Component Cleaning Procedure 4343
Reservoir Cleaning Procedure 4343
Cylinder Cleaning Procedure 4343
Hose and Tube Cleaning Procedure 4344
Valve Cleaning Procedure 4344
Front-End Attachment Cleaning Procedure 4345
System Flushing Procedure 4345
Filter Caddy Start-Up 4346
System Start-Up and Flushing 4346
Reservoir Fluid Cleaning Times 4347
Dealing With Different Fluid Types 4347
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 4347
Filter Caddy Maintenance 4348
Servicing the Strainer 4348
DC Motor 4348
Hydraulic Oil Sampling Method and Procedure 4348
Hydraulic Oil Sampling Method 4348
Objective 4348
General Guidelines 4348
Synopsis 4349
Hydraulic Oil Analysis Report Guidelines 4350
Sampling Conditions 4351
Equipment 4351
Sampling Procedure 4351
Hydraulic Oil Sampling 4351
Sample Labeling 4352
Results Documentation 4352
550096331 8000YRM1689 (03 2020) UK EN 4355
General Information About Diagrams and Schematics 4359
Symbol Definitions 4359
Diagrams Manual Applications 4360
Diagrams and Schematics 4362