Yale Forklift (C909) GDPGLP (80VX, 80VX9, 90VX, GP80VX-6 Europe) Service Manual PDF

Yale Forklift C909 (GDPGLP80VX, GDPGLP80VX9, GDPGLP90VX, GP80VX-6 Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift C909 (GDPGLP80VX, GDPGLP80VX9, GDPGLP90VX, GP80VX-6 Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4688
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C909 (GDPGLP80VX, GDPGLP80VX9, GDPGLP90VX, GP80VX-6 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
524221866 9000YRM1112 (10 2020) UK EN 81
SECTION 9010 Operational Diagnostic Procedures 97
Group 05 – Operational Checkout 99
SECTION 9020 Engine 117
Group 10 – Principles of Operation 127
Group 30 – Observed Symptoms 325
Group 40 – Tests and Adjustments 427
SECTION 9030 Electrical System 459
Group 03 – General Maintenance and Diagnostic Data 483
Group 10 – Principles of Operation 577
Group 20 – Diagnostic Trouble Codes 601
Group 30 – Observed Symptoms 1573
SECTION 9040 Drive Train 1629
Group 10 – Principles of Operation 1633
Group 30 – Observed Symptoms 1689
Group 40 – Tests and Adjustments 1739
SECTION 9050 Hydraulic Systems 1749
Group 10 – Principles of Operation 1753
Group 30 – Observed Symptoms 1811
Group 33 – Observed Symptoms-Gear Pump 1813
Group 35 – Observed Symptoms-Variable Displacement Pump (VDP) 1901
Group 40 – Tests and Adjustments 1945
Group 43 – Tests and Adjustments-Gear Pump 1947
Group 45 – Tests and Adjustments-Variable Displacement Pump (VDP) 1971
SECTION 9060 Operators Station 1989
Group 10 – Principles of Operation 1991
SECTION 9070 Front End (Mast) and Chassis 2027
Group 10 – Principles of Operation 2029
Group 30 – Observed Symptoms 2051
SECTION 9080 Supplementary Data 2109
Group 50 – Abbreviations and Acronyms 2111
Group 60 – Special Tools List 2119
Group 70 – Fault Mode Indicator Reference 2129
Group 80 – Supplier Specification Data 2131
524223769 2200YRM1128 (01 2023) US EN 2135
Series Code / Model Designation Reference Table 2143
General 2145
Deutsch Crimping Tool 2146
How to Strip a Wire for Use With Deutsch Crimping Tool 2146
How to Crimp With the Deutsch Crimping Tool 2147
Calibration Test for the Deutsch Crimping Tool 2149
Deutsch Connectors 2151
DT, DTM, and DTP Series Connectors 2151
HD Series Connectors 2194
Metri-Pack Connectors 2216
Remove and Install 2216
Micro-Pack Connectors 2219
Weather-Pack Connectors 2220
AMPSEAL Crimping Tools 2222
AMP Hand Crimping Tool With Certi-Crimp 2222
Description 2222
Stripping Wire for Use with AMP Hand Crimping Tool 2223
Insulation Crimp Adjustment 2224
Maintenance and Inspection for AMP Hand Crimping Tool 2224
AMP Hand Crimping Tool 2224
Crimp Height Inspection 2224
How to use AMP Hand Crimping Tool 2225
AMP Pro-Crimper II Tool 2225
Description 2225
Remove and Install Die Set and Locator Assembly 2226
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2226
Contact Support Adjustment 2227
Crimp Height Adjustment 2228
Maintenance and Inspection Procedures 2228
PRO-CRIMPER II Tool 2228
Crimp Height Inspection 2228
How to Use AMP PRO-CRIMPER II Tool 2229
AMPSEAL Connector Assemblies 2230
Description for Plug Connector Assembly 2230
Seal Plug 2231
Contact Crimping 2231
Description for Plug Connector and Header Assembly 2236
Voltage Reading 2239
Seal Plug 2239
Contact Crimping 2239
AMP Superseal 1 5 Crimping Tools 2246
Mini Mic Receptacle and Tab Contacts 2246
Description 2246
Crimping Conditions and Measurements 2246
Insertion of Rubber Seal on Cable 2248
AMP Hand Application Tool 2253
Description 2253
Maintenance and Inspection 2253
Crimp Height Inspection 2253
Crimp Height Adjustment 2254
How to Use AMP Hand Application Tool 2254
AMP Pro-Crimper II Tool 2255
Description 2255
Remove and Install Die Set and Locator Assembly 2255
Adjustments 2256
Contact Support 2256
Crimp Height 2257
Inspections and Maintenance 2258
Crimp Height Inspection 2258
Visual Inspection 2258
Maintenance 2259
How to Use Pro-Crimper II Tool 2259
AMP Superseal 1 5 Connector Assemblies 2260
Description 2260
Repair and Maintenance 2267
Panel Mount Option 2267
AMP Fastin-Faston Hand Tools 2268
Description – AMP Double Action Hand Tool 2268
Maintenance and Inspection Procedures 2268
Daily Maintenance 2268
Periodic Tool Inspection 2269
Lubrication 2269
Visual Inspection 2269
Crimp Height Inspection 2269
Certi-Crimp Ratchet Inspection 2270
How to Use AMP Double Action Hand Tool 2271
Description – AMP Extraction Tool 2272
Maintenance and Inspection 2273
How to Use AMP Extraction Tool 2273
AMP Fastin-Faston Receptacles and Housings 2275
Description 2275
Wire Repair 2283
Wire Splicing Requirements 2283
Deutsch Jiffy Splice 2284
Twisted/Shielded Cable and Leads Repair 2290
Special Tools 2292
524223769 2200YRM1128 (07 2020) UK EN 2301
Series Code / Model Designation Reference Table 2307
General 2310
Deutsch Crimping Tool 2310
How to Strip a Wire for Use With Deutsch Crimping Tool 2310
How to Crimp With the Deutsch Crimping Tool 2311
Calibration Test for the Deutsch Crimping Tool 2313
Deutsch Connectors 2315
DT, DTM, and DTP Series Connectors 2315
HD Series Connectors 2357
Metri-Pack Connectors 2380
Remove and Install 2380
Micro-Pack Connectors 2382
Weather-Pack Connectors 2383
AMPSEAL Crimping Tools 2385
AMP Hand Crimping Tool With Certi-Crimp 2385
Description 2385
Stripping Wire for Use with AMP Hand Crimping Tool 2385
Insulation Crimp Adjustment 2386
Maintenance and Inspection for AMP Hand Crimping Tool 2386
AMP Hand Crimping Tool 2386
Crimp Height Inspection 2386
How to use AMP Hand Crimping Tool 2387
AMP Pro-Crimper II Tool 2387
Description 2387
Remove and Install Die Set and Locator Assembly 2388
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 2389
Contact Support Adjustment 2389
Crimp Height Adjustment 2390
Maintenance and Inspection Procedures 2390
PRO-CRIMPER II Tool 2390
Crimp Height Inspection 2390
How to Use AMP PRO-CRIMPER II Tool 2391
AMPSEAL Connector Assemblies 2392
Description for Plug Connector Assembly 2392
Seal Plug 2393
Contact Crimping 2393
Description for Plug Connector and Header Assembly 2398
Voltage Reading 2400
Seal Plug 2400
Contact Crimping 2400
AMP Superseal 1 5 Crimping Tools 2407
Mini Mic Receptacle and Tab Contacts 2407
Description 2407
Crimping Conditions and Measurements 2407
Insertion of Rubber Seal on Cable 2409
AMP Hand Application Tool 2414
Description 2414
Maintenance and Inspection 2414
Crimp Height Inspection 2414
Crimp Height Adjustment 2415
How to Use AMP Hand Application Tool 2415
AMP Pro-Crimper II Tool 2416
Description 2416
Remove and Install Die Set and Locator Assembly 2417
Adjustments 2417
Contact Support 2417
Crimp Height 2418
Inspections and Maintenance 2419
Crimp Height Inspection 2419
Visual Inspection 2419
Maintenance 2420
How to Use Pro-Crimper II Tool 2420
AMP Superseal 1 5 Connector Assemblies 2421
Description 2421
Repair and Maintenance 2428
Panel Mount Option 2428
AMP Fastin-Faston Hand Tools 2429
Description – AMP Double Action Hand Tool 2429
Maintenance and Inspection Procedures 2429
Daily Maintenance 2429
Periodic Tool Inspection 2430
Lubrication 2430
Visual Inspection 2430
Crimp Height Inspection 2430
Certi-Crimp Ratchet Inspection 2431
How to Use AMP Double Action Hand Tool 2432
Description – AMP Extraction Tool 2433
Maintenance and Inspection 2433
How to Use AMP Extraction Tool 2434
AMP Fastin-Faston Receptacles and Housings 2435
Description 2435
Wire Repair 2442
Wire Splicing Requirements 2442
Deutsch Jiffy Splice 2443
Twisted/Shielded Cable and Leads Repair 2448
Special Tools 2451
524223770 2200YRM1130 (03 2020) UK EN 2459
General 2463
Description 2463
Dash Display Menu Access 2463
Menu Navigation 2464
Standard Display 2464
Main Menu 2464
Passwords Menu 2465
Password Administration 2465
Add Password 2465
Delete Password 2466
Edit Password 2466
Other Password Functions 2467
Operator Passwords – Enable/Disable 2467
Password Time-Out Delay 2467
Passwords – Number Wrong to Disable 2468
Lockout Reset Password 2468
View Password Log 2469
View Versions 2470
VSM Versions 2470
Dash Display Versions 2471
Engine Controller Version 2472
Transmission (Xmsn) Controller Version 2473
Truck Serial Number 2474
Diagnostics 2475
View Fault Log 2475
Set Travel and Braking 2476
Speed Limit 2476
Acceleration Rate 2477
Auto-Deceleration Rate 2477
Set Power Reversal Rate 2478
Set Inching/Brake Overlap 2479
Setup Display Menu 2480
Set Operator Language 2480
Set Units 2481
Set Time Format (12/24 Hour) 2481
Set Daylight Saving Time 2481
Set Time 2484
Set Date Format 2485
Set Date 2485
Setup Hydraulics 2486
Return to Set Tilt Delay/On/Off 2486
Setup General Items 2487
Light Shutdown Time-Out 2487
Impact Sensor – Enable/Disable 2488
Impact Sensor – Soft Impact Settings 2489
Impact Sensor – Hard Impact Settings 2490
Adjust Impact Sensor Settings 2490
Initial Adjustment of Soft and Hard Impact Settings 2492
Readjustment of Soft and Hard Impact Settings 2492
Impact Sensor – Impact Alarm/Shutdown Reset 2493
Impact Sensor – Alarm Time Duration and Deactivation 2494
Impact Sensor – View Impact Event Log 2495
Engine Mode Indicator 2496
Generation 1 (ECO-eLo ONLY) 2496
Generation 2 2497
Operator Checklist 2498
Operator Checklist Off-On Mode 2498
Edit Operator Checklist 2498
Set Operator Checklist Expiration 2499
View Checklist Log 2499
Clear Operator Checklist Log 2500
Clear Operator Checklist Fault 2500
Calibrations 2501
Set Tilt Stop Point 2501
Calibrate Loaded Weight 2501
524223771 2200YRM1131 (03 2020) UK EN 2503
Series Code / Model Designation Reference Table 2509
General 2511
Description 2511
Dash Display Menu Access 2511
Menu Navigation 2512
Main Menu 2512
Passwords 2513
Adding Passwords 2513
Hourmeters 2515
View Versions 2516
VSM Versions 2516
Dash Display Versions 2517
Engine Controller Version 2518
Transmission (Xmsn) Controller Version 2519
Truck Serial Number 2520
Truck Configuration 2521
Diagnostics 2522
Clear Fault Log 2522
View Fault Log 2523
No-Run Data Display 2524
Engine Accelerator and Throttle Data Display 2524
Engine Speeds and Governor Data Display 2525
Engine Fuel and Emissions Data Display 2526
Engine General Data Display 2528
XMSN/Brake Data Display 2529
Hydraulic Data Display 2532
General Truck Data Display 2534
Set Travel and Braking 2535
Speed Limit 2535
Acceleration Rate 2536
Auto-Deceleration Rate 2537
Set Power Reversal Rate 2537
Set Inching/Brake Overlap 2538
Setup Hydraulics 2538
Lift Maximum Speed 2539
Lower Maximum Speed 2539
Tilt Maximum Speed 2540
Auxiliary Function One, Direction A, Maximum Speed 2542
Auxiliary Function One, Direction B, Maximum Speed 2544
Auxiliary Function Two, Direction A, Maximum Speed 2544
Auxiliary Function Two, Direction B, Maximum Speed 2545
Auxiliary Function Three, Direction A, Maximum Speed 2546
Auxiliary Function Three, Direction B, Maximum Speed 2546
Lift/Lower Ramp Rate 2547
Hydraulic Auxiliary Ramp Rate 2547
Return to Set Tilt Delay/On/Off 2548
Hydraulic Input Device 2549
Auxiliary Solenoid 2549
Dual Function 2550
Setup Display 2551
Set Service Language 2551
Setup General Items 2551
Motion Alarm Activation Type 2552
Light Shutdown Time-Out 2553
Restore Default Settings 2553
Restore Engine Controller Default Calibration 2554
Impact Sensor – Enable/Disable 2554
Impact Sensor – Soft Impact Settings 2555
Impact Sensor – Hard Impact Settings 2556
Adjust Impact Sensor Settings 2557
Initial Adjustment of Soft and Hard Impact Settings 2559
Readjustment of Soft and Hard Impact Settings 2559
Impact Sensor – Impact Alarm/Shutdown Reset 2560
Impact Sensor – Alarm Time Duration and Deactivation 2561
Impact Sensor – View Impact Event Log 2562
Engine Mode Indicator 2562
Generation 1 (ECO-eLo ONLY) 2562
Generation 2 2563
Diesel Particulate Filter (DPF) Display 2564
General Description 2564
Passive Regeneration Only 2564
Regeneration Level 0 2564
Auto/Active Regeneration Inhibited 2565
Auto/Active Regeneration 2565
Regeneration Level 1 2565
Parked Regeneration Request 2566
Regeneration Level 2 2566
Warning Level 2566
Regeneration Level 3 2566
Service Level 2567
Regeneration Level 4 2567
Display, Diesel Particulate Filter (DPF), Revised 2567
Operator Interface 2567
Refer to Operator Manual 2567
CAN Communication Lost 2568
Passive Regeneration Only 2568
Regeneration Level 0 2568
Auto/Active Regeneration Inhibited 2568
Auto/Active Regeneration 2569
Regeneration Level 1 2569
Idle-up Auto/Active Regeneration 2569
Parked Regeneration Request 2569
Regeneration Level 2 2569
Warning Level 2571
Regeneration Level 3 2571
Service Level 2571
Regeneration Level 4 2571
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 2571
Display, Diesel Particulate Filter (DPF), Stage V Engine 2571
Operator Interface 2572
Refer to Operator Manual 2572
CAN Communication Lost 2572
Passive Regeneration Only 2572
Regeneration Level 0 2572
Auto/Active Regeneration Inhibited 2573
Auto/Active Regeneration 2573
Regeneration Level 1 2573
Idle-up Auto/Active Regeneration 2574
Parked Regeneration Request 2574
Regeneration Level 2 2574
Warning Level 2575
Regeneration Level 3 2575
Service Level 2576
Regeneration Level 4 2576
Stage V Content 2576
Emissions System Malfunction 2576
Ash Load 2576
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 2577
Operator Interface 2577
Refer to Operator Manual 2577
CAN Communication Lost 2578
Passive Regeneration Only 2578
Regeneration Level 0 2578
Auto/Active Regeneration Inhibited 2578
Auto/Active Regeneration 2579
Regeneration Level 1 2579
Idle-up Auto/Active Regeneration 2579
Parked Regeneration Request 2579
Regeneration Level 2 2579
Warning Level 2581
Regeneration Level 3 2581
Service Level 2581
Regeneration Level 4 2581
Calibrations 2582
Calibrate Transmission Valve 2584
Set Tilt Stop Point 2584
Calibrate Loaded Weight 2584
Calibrate Travel Speed Sensor 2585
Calibrate Mazda LP and Gas Accelerator Pedal 2585
524223780 8000YRM1134 (03 2020) UK EN 2587
Series Code / Model Designation Reference Table 2593
Description 2595
Proc_Cal_001: Service Password Entry 2597
When to Perform 2597
Why Perform 2597
How to Perform 2597
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2598
When to Perform 2598
Calibration Order 2598
Why Perform 2598
How to Perform 2599
Proc_Cal_003: Save and Exit 2600
When to Perform 2600
Why Perform 2600
How to Perform 2600
Proc_Cal_004: Lift Valve Output Threshold 2601
When to Perform 2601
Calibration Order 2601
Why Perform 2601
How to Perform 2602
Proc_Cal_005: Lower Valve Output Threshold 2604
When to Perform 2604
Calibration Order 2604
Why Perform 2604
How to Perform 2604
Proc_Cal_006: Tilt Back Valve Output Threshold 2607
When to Perform 2607
Calibration Order 2607
Why Perform 2607
How to Perform 2607
Proc_Cal_007: Tilt Forward Valve Output Threshold 2610
When to Perform 2610
Calibration Order 2610
Why Perform 2610
How to Perform 2610
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2613
When to Perform 2613
Calibration Order 2613
Why Perform 2613
How to Perform 2613
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2616
When to Perform 2616
Calibration Order 2616
Why Perform 2616
How to Perform 2616
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2619
When to Perform 2619
Calibration Order 2619
Why Perform 2619
How to Perform 2619
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2622
When to Perform 2622
Calibration Order 2622
Why Perform 2622
How to Perform 2622
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2625
When to Perform 2625
Calibration Order 2625
Why Perform 2625
How to Perform 2625
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2628
When to Perform 2628
Calibration Order 2628
Why Perform 2628
How to Perform 2628
Proc_Cal_014: Load Weight Zero Point 2632
When to Perform 2632
Calibration Order 2632
Why Perform 2632
How to Perform 2632
Proc_Cal_015: Loaded Weight Calibration 2634
When to Perform 2634
Calibration Order 2634
Why Perform 2634
How to Perform 2634
Proc_Cal_016: Transmission Valve Calibration 2637
Applicable System/Option 2637
When to Perform 2637
Calibration Order 2637
Why Perform 2637
How to Perform 2637
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2639
Applicable System/Option 2639
When to Perform 2639
Calibration Order 2639
Why Perform 2639
How to Perform 2639
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2641
Applicable System/Option 2641
When to Perform 2641
Calibration Order 2641
Why Perform 2641
How to Perform 2642
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2643
Required Tools 2643
When to Perform 2643
Calibration Order 2643
Why Perform 2644
How to Perform 2644
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2645
When to Perform 2645
Why Perform 2645
How to Perform 2645
Proc_Cal_026: Travel Speed Calibration 2647
When to Perform 2647
Calibration Order 2647
Why Perform 2647
How to Perform 2647
524223780 8000YRM1134 (05 2022) US EN 2651
Series Code / Model Designation Reference Table 2657
Description 2660
Proc_Cal_001: Service Password Entry 2662
When to Perform 2662
Why Perform 2662
How to Perform 2662
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 2663
When to Perform 2663
Calibration Order 2663
Why Perform 2663
How to Perform 2663
Proc_Cal_003: Save and Exit 2665
When to Perform 2665
Why Perform 2665
How to Perform 2665
Proc_Cal_004: Lift Valve Output Threshold 2666
When to Perform 2666
Calibration Order 2666
Why Perform 2666
How to Perform 2666
Proc_Cal_005: Lower Valve Output Threshold 2669
When to Perform 2669
Calibration Order 2669
Why Perform 2669
How to Perform 2669
Proc_Cal_006: Tilt Back Valve Output Threshold 2672
When to Perform 2672
Calibration Order 2672
Why Perform 2672
How to Perform 2672
Proc_Cal_007: Tilt Forward Valve Output Threshold 2675
When to Perform 2675
Calibration Order 2675
Why Perform 2675
How to Perform 2675
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 2678
When to Perform 2678
Calibration Order 2678
Why Perform 2678
How to Perform 2678
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 2681
When to Perform 2681
Calibration Order 2681
Why Perform 2681
How to Perform 2681
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 2684
When to Perform 2684
Calibration Order 2684
Why Perform 2684
How to Perform 2684
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 2687
When to Perform 2687
Calibration Order 2687
Why Perform 2687
How to Perform 2687
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 2690
When to Perform 2690
Calibration Order 2690
Why Perform 2690
How to Perform 2690
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 2693
When to Perform 2693
Calibration Order 2693
Why Perform 2693
How to Perform 2693
Proc_Cal_014: Load Weight Zero Point 2696
When to Perform 2696
Calibration Order 2696
Why Perform 2696
How to Perform 2696
Proc_Cal_015: Loaded Weight Calibration 2698
When to Perform 2698
Calibration Order 2698
Why Perform 2698
How to Perform 2698
Proc_Cal_016: Transmission Valve Calibration 2701
Applicable System/Option 2701
When to Perform 2701
Calibration Order 2701
Why Perform 2701
How to Perform 2701
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 2703
Applicable System/Option 2703
When to Perform 2703
Calibration Order 2703
Why Perform 2703
How to Perform 2703
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 2706
Applicable System/Option 2706
When to Perform 2706
Calibration Order 2706
Why Perform 2706
How to Perform 2706
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 2709
Required Tools 2709
When to Perform 2709
Calibration Order 2709
Why Perform 2709
How to Perform 2709
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 2711
When to Perform 2711
Why Perform 2711
How to Perform 2711
Proc_Cal_026: Travel Speed Calibration 2713
When to Perform 2713
Calibration Order 2713
Why Perform 2713
How to Perform 2713
524288194 1300YRM1317 (03 2020) UK EN 2717
Transmission Repair 2721
Remove 2721
Torque Converter, Remove 2721
Disassemble 2722
Clean and Inspect 2771
Housings 2771
Oil Seals and Gaskets 2771
Bearings 2771
Gears and Shafts 2772
Assemble 2772
Torque Converter, Install 2813
Install 2814
Control Valve Repair 2815
Remove 2815
Disassemble 2815
Clean 2817
Inspect 2817
Assemble 2817
Install 2818
Torque Specification 2819
524296605 1400YRM1344 (03 2020) UK EN 2821
General 2825
Identification Plate 2825
Drive Axle Removal 2825
Planetary Reduction Gear Repair 2837
Clean and Inspect 2847
Brake Repair 2856
Clean and Inspect 2869
Wet Brake Noise Reduction 2879
General 2879
Adding Additive To Transmission 2880
Differential Repair 2881
Clean and Inspect 2892
Bevel Pinion 2904
Clean and Inspect 2908
Drive Axle Installation 2918
Special Tools 2929
Torque Specifications 2930
550021072 0600YRM1432 (03 2020) UK EN 2933
General 2939
Engine Removal and Installation 2939
Cylinder Head Repair 2939
Intake Manifold 2939
Remove 2939
Clean and Inspect 2940
Install 2940
Cylinder Head 2941
Remove and Disassemble 2941
Clean and Inspect 2943
Valve Guides and Seats Repairs 2945
Valves Repair 2945
Valve Seats Repair 2946
Valve Springs 2947
Assemble and Install 2947
Engine Block Cleaning and Inspection 2949
Piston Bore Preparation 2951
Lubrication System Repair 2951
Oil Pan Removal 2951
Oil Pump Assembly 2952
Oil Pump, Removal 2952
Oil Pump, Disassemble 2952
Oil Pump, Assemble 2952
Oil Pump, Install 2953
Clean and Inspect 2954
Oil Pan, Install 2954
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 2956
Timing Cover 2956
Remove 2956
Install 2957
Timing Sprockets 2957
Remove 2957
Install 2958
Camshaft 2958
Remove 2958
Inspect 2959
Install 2959
Clean and Inspect 2960
Valve Lifters 2960
Remove 2960
Clean and Inspect 2961
Install 2962
Crankshaft Repair 2963
Crankshaft 2963
Remove 2963
Inspect and Repair 2964
Main Bearings and Journals Clearance Check 2965
Install 2965
Piston and Connecting Rod Assembles 2966
Connecting Rod Bearings, Replace 2966
Piston and Connecting Rod Assemblies, Remove 2967
Disassemble 2968
Piston, Clean and Inspect 2968
Cylinder Bores, Inspect and Repair 2968
Piston Rings 2969
Assemble 2970
Piston and Connecting Rod Assemblies, Install 2971
Flywheel and Flywheel Housing Repair 2972
Flywheel, Remove 2972
Clean 2972
Inspect 2972
Flywheel, Install 2973
Coolant System Repair 2973
Water Pump 2973
Remove 2973
Clean and Inspect 2974
Install 2974
Serpentine Belt 2975
Remove 2975
Inspect 2975
Install 2976
Thermostat 2976
Remove 2976
Thermostat Operation Check 2976
Install 2977
Fan Assembly Replacement 2977
Remove 2977
Inspect 2979
Install 2979
Ignition System 2979
Spark Plug Wire Inspection 2979
Spark Plug Wire Replacement 2979
Remove 2979
Install 2980
Spark Plug Replacement 2981
Remove 2981
Install 2981
Spark Plug Inspection 2982
Usage 2982
Inspect 2982
Visual Inspection 2983
Alternator Repair 2984
Remove 2984
Install 2984
Starter Repair 2984
Remove 2984
Install 2985
Compression Check 2985
Valve Clearance Adjustments 2985
Engine Specifications 2987
Engine Data 2987
Cylinder Head 2987
Camshaft 2987
Cylinder Bore 2987
Piston 2988
Piston Pin 2988
Crankshaft 2988
Connecting Rods 2988
Balance Shaft 2988
Cooling System 2989
Lubrication System 2989
Torque Specifications for Capscrews and Bolts 2989
550021077 0900YRM1433 (03 2020) UK EN 2993
General 2997
LPG Tank and Bracket 2997
LPG Tank 2997
Remove 2997
Install 3000
LPG Tank Bracket 3000
Remove 3000
Install 3000
LPG Tank Bracket Alignment Pin 3001
Remove 3001
Install 3001
Fuel Filter Unit 3002
Fuel Filter Element 3002
Remove 3002
Clean and Inspect 3002
Install 3002
Fuel Filter Housing 3003
Remove 3003
Disassemble 3005
Clean and Inspect 3005
Assemble 3006
Install 3006
Electronic Throttle Body 3007
Remove 3007
Install 3008
Fuel Mixer/Electronic Pressure Regulator (EPR) 3009
Remove 3009
Install 3010
Control System 3011
Engine Control Unit (ECU) 3011
Remove 3011
Install 3012
Low Pressure Switch 3012
Remove 3012
Install 3012
Low Fuel Sensor 3013
Remove 3013
Install 3013
LP Converter 3014
Remove 3014
Disassemble 3015
Assemble 3016
Install 3017
Lock-Off Valve 3018
Remove 3018
Install 3018
Exhaust System 3019
Counterweight Exhaust 3019
Remove and Disassemble 3019
Inspect 3020
Assemble and Install 3021
Exhaust Manifold 3021
Remove 3021
Install 3023
Positive Crankcase Ventilation (PCV) Valve 3023
Remove 3023
Inspect 3024
Install 3025
Oxygen Sensors 3025
Remove 3025
Install 3025
LPG Fuel Testing 3026
General 3026
Available Fuel Tests 3026
Composition Test (ASTM D-2163) 3026
Ammonia Test (ASTM D-4490) 3026
Basic Nitrogen Test (ASTM UOP269-90) 3026
Residues Test (ASTM D-2158) 3026
Vapor Pressure Test (ASTM D-2598) 3026
Sulfur Compounds Test (ASTM D-5623) 3026
Methanol Test (ASTM D-4864) 3027
Copper Corrosion (ASTM D-1838) 3027
Where To Send LPG Fuel Samples For Testing 3027
550073240 1900YRM1620 (01 2023) US EN 3029
Proper Flushing after Major Hydraulic Repairs 3035
Introduction 3035
The Phases of Wear 3035
Causes of Hydraulic System Failure 3035
Progression of Contaminant Caused Hydraulic System Failure 3036
Hydraulic System Flushing Techniques 3036
Double Oil and Filter Change 3036
Mechanical Cleaning 3037
Cleaning of Components 3037
How to Clean Tubes and Hoses 3037
Filter Caddy 3037
Start-Up Procedure for Cleaned System 3038
Contaminated Oil Coolers 3038
Additional Filter Caddy Functions 3039
How to Handle Different Fluids 3039
Water Removal Filters 3039
Fluid Conditioning and System Flushing Procedures 3040
Operation of the Filter Caddy 3040
Filter Caddy operation 3040
Fluid Conditioning Procedure 3040
Filter Caddy Start-Up 3041
System Flushing Procedure 3041
Component Cleaning Procedure 3042
Reservoir Cleaning Procedure 3042
Cylinder Cleaning Procedure 3042
Hose and Tube Cleaning Procedure 3042
Valve Cleaning Procedure 3043
Front-End Attachment Cleaning Procedure 3044
System Flushing Procedure 3044
Filter Caddy Start-Up 3045
System Start-Up and Flushing 3045
Reservoir Fluid Cleaning Times 3046
Dealing With Different Fluid Types 3047
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3047
Filter Caddy Maintenance 3047
Servicing the Strainer 3047
DC Motor 3047
Hydraulic Oil Sampling Method and Procedure 3048
Hydraulic Oil Sampling Method 3048
Objective 3048
General Guidelines 3048
Synopsis 3049
Hydraulic Oil Analysis Report Guidelines 3050
Sampling Conditions 3050
Equipment 3050
Sampling Procedure 3051
Hydraulic Oil Sampling 3051
Sample Labeling 3051
Results Documentation 3051
550073240 1900YRM1620 (03 2020) UK EN 3053
Proper Flushing after Major Hydraulic Repairs 3057
Introduction 3057
The Phases of Wear 3057
Causes of Hydraulic System Failure 3057
Progression of Contaminant Caused Hydraulic System Failure 3058
Hydraulic System Flushing Techniques 3058
Double Oil and Filter Change 3058
Mechanical Cleaning 3059
Cleaning of Components 3059
How to Clean Tubes and Hoses 3059
Filter Caddy 3059
Start-Up Procedure for Cleaned System 3060
Contaminated Oil Coolers 3060
Additional Filter Caddy Functions 3060
How to Handle Different Fluids 3060
Water Removal Filters 3061
Fluid Conditioning and System Flushing Procedures 3061
Operation of the Filter Caddy 3061
Filter Caddy operation 3061
Fluid Conditioning Procedure 3062
Filter Caddy Start-Up 3062
System Flushing Procedure 3063
Component Cleaning Procedure 3063
Reservoir Cleaning Procedure 3063
Cylinder Cleaning Procedure 3063
Hose and Tube Cleaning Procedure 3064
Valve Cleaning Procedure 3064
Front-End Attachment Cleaning Procedure 3065
System Flushing Procedure 3065
Filter Caddy Start-Up 3066
System Start-Up and Flushing 3066
Reservoir Fluid Cleaning Times 3067
Dealing With Different Fluid Types 3067
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 3067
Filter Caddy Maintenance 3068
Servicing the Strainer 3068
DC Motor 3068
Hydraulic Oil Sampling Method and Procedure 3068
Hydraulic Oil Sampling Method 3068
Objective 3068
General Guidelines 3068
Synopsis 3069
Hydraulic Oil Analysis Report Guidelines 3070
Sampling Conditions 3071
Equipment 3071
Sampling Procedure 3071
Hydraulic Oil Sampling 3071
Sample Labeling 3072
Results Documentation 3072
550118414 1900YRM1897 (03 2020) UK EN 3075
Series Code / Model Designation Reference Table 3079
General 3079
Hydraulic Gear Pump Assembly Repair 3081
Remove 3081
Disassemble 3083
Clean 3085
Inspect 3085
Assemble 3085
Install 3085
Hydraulic Gear Pump Specifications 3087
Variable Displacement Pump Repair 3088
Remove 3088
Disassemble 3091
Clean 3093
Inspect 3093
Assemble 3093
Install 3093
Variable Displacement Pump Checks and Adjustments 3095
Margin Pressure Check 3095
Flow Compensator Adjustment 3096
Pressure Compensator Adjustment 3096
Variable Displacement Pump Specifications 3097
Torque Specifications 3098
Hydraulic Gear Pump 3098
Variable Displacement Pump 3098
550118415 2000YRM1898 (03 2020) UK EN 3101
Series Code / Model Designation Reference Table 3105
General 3106
Electro-Hydraulic Main Control Valve 3106
Description 3106
Remove 3112
Electro-Hydraulic Control Valve Sections 3115
General 3115
Outlet Control Valve Section 3115
Remove 3115
Disassemble 3115
Clean 3118
Inspect 3118
Assemble 3118
Install 3119
Auxiliary Control Valve Sections 3119
Remove 3119
Disassemble 3121
Clean 3121
Inspect 3122
Assemble 3122
Install 3123
Tilt Control Valve Section 3123
Remove 3123
Disassemble 3123
Clean 3124
Inspect 3124
Assemble 3125
Install 3125
Lift/Lower Control Valve Section 3125
Remove 3125
Disassemble 3125
Clean 3127
Inspect 3127
Assemble 3127
Install 3127
Transition Section 3127
Remove 3127
Disassemble 3128
Clean 3128
Inspect 3128
Assemble 3129
Install 3129
Install 3129
Manual Main Control Valve 3131
Description 3131
Remove 3133
OPS Solenoid Assembly 3137
General 3137
Remove 3138
Clean and Inspect 3140
Install 3140
Manual Control Valve Sections 3141
General 3141
Outlet Control Valve Section 3141
Remove 3141
Disassemble 3141
Clean 3143
Inspect 3143
Assemble 3143
Install 3143
Auxiliary Control Valve Sections 3144
Remove 3144
Disassemble 3144
Clean 3146
Inspect 3146
Assemble 3146
Install 3146
Lift/Tilt Control Valve Section 3147
Remove 3147
Disassemble 3147
Clean 3149
Inspect 3150
Assemble 3150
Install 3151
Install 3151
Pressure Relief Valve Check and Adjustment 3154
Primary Relief Valve 3154
Secondary Relief Valve 3155
Steering Control Unit Repair 3158
Steering Control Unit, Remove 3158
Steering Control Unit, Disassemble 3159
Steering Control Unit, Clean 3161
Steering Control Unit, Inspect 3161
Steering Control Unit, Assemble 3161
Relief Valve, Disassemble 3162
Relief Valve, Clean 3162
Relief Valve, Inspect 3163
Relief Valve, Assemble 3163
Steering Control Unit, Install 3163
550118420 8000YRM1904 (05 2022) US EN 3167
General Information About Diagrams and Schematics 3173
Symbol Definitions 3173
Diagrams Manual Applications 3174
Diagrams and Schematics 3176
550118555 0100YRM1892 (03 2020) UK EN 3285
General 3291
Cab Replacement for 4-5 5 Ton Lift Trucks 3291
Remove 3291
Install 3302
Cab Replacement for 6-9 Ton Lift Trucks 3304
Remove 3304
Door Assemblies for 4-5 5 Ton Lift Trucks 3310
Right Side Door Assembly 3310
Remove 3310
Disassemble 3314
Door Cover With Heater Unit 3314
Door Cover With Air Conditioner/Heater Unit 3316
Heater Assembly 3318
Air Conditioner and Heater Unit Assembly 3318
Door Lock Assembly 3319
Windows 3321
Clean 3321
Inspect 3321
Assemble 3321
Windows 3321
Door Lock Assembly 3321
Heater Assembly 3321
Air Conditioner and Heater Unit Assembly 3322
Door Cover With Heater Unit 3322
Door Cover With Air Conditioner and Heater Unit 3322
Install 3322
Left Side Door Assembly 3323
Remove 3323
Disassemble 3323
Door Cover 3323
Door Lock Assembly 3323
Windows 3324
Clean 3324
Inspect 3324
Assemble 3324
Windows 3324
Door Lock Assembly 3324
Door Cover 3324
Install 3324
Door Assemblies for 6-9 Ton Lift Trucks 3325
Right and Left Side Door Assemblies 3325
Remove 3325
Disassemble 3325
Door Cover 3325
Door Lock Assembly 3326
Windows 3328
Clean 3328
Inspect 3328
Assemble 3328
Windows 3328
Door Lock Assembly 3328
Door Cover 3329
Install 3329
Window Replacement 3329
General 3329
Remove Door Windows for 4-5 5 Ton Lift Trucks 3329
Install Door Windows for 4-5 5 Ton Lift Trucks 3331
Remove Door Windows for 6-9 Ton Lift Trucks 3331
Install Door Windows for 6-9 Ton Lift Trucks 3333
Window Wipers Replacement 3333
General 3333
Front Wiper Assembly and Motor 3333
Remove 3333
Install 3335
Rear Wiper Assembly and Motor 3335
Remove, for 4-5 5 Ton Lift Trucks 3335
Install for 4-5 5 Ton Lift Trucks 3338
Remove for 6-9 Ton Lift Trucks 3338
Install for 6-9 Ton Lift Truck 3340
Heater Replacement 3341
Remove for 6-9 Ton Lift Trucks 3341
Install for 6-9 Ton Lift Trucks 3346
Heater and Air Conditioner Assembly 3347
Air Conditioner Condenser Unit 3347
Remove 3347
Install 3349
Air Conditioner Receiver/Drier Unit 3349
Remove 3349
Install 3351
Air Conditioner Compressor 3351
Light Replacement 3352
Work Lights (Front and Rear) 3352
Remove 3352
Install 3354
Strobe Light 3354
Remove 3354
Install 3355
Turn, Stop, Tail, and Backup Light 3355
Remove 3355
Install 3356
Front Marker/Turn Signal Lights 3356
Remove 3356
Install 3356
Display Switches 3357
Electrical Schematics 3359
Optional Equipment 3360
Heavy Duty Pre-Cleaner 3360
Fan 3360
Remove 3360
Install 3362
Mirror 3362
Remove 3362
Install 3362
Rear View Camera 3362
Monitor Removal 3362
Monitor Install 3364
Camera removal 3364
Camera install 3364
Label Replacement 3364
550131845 0100YRM1948 (09 2022) US EN 3367
General 3371
Description 3372
Side Covers, Seat, Dash, and Hood Replacement 3373
Side Covers 3373
Remove 3373
Install 3373
Seat and Seat Plate 3374
Remove Seat 3374
Remove Seat Plate 3374
Install Seat Plate 3374
Install Seat 3374
Operator Restraint System 3378
Emergency Locking Retractor (ELR) 3378
Seat Plate and Seat Rail Check 3378
Steering Column, Dash, Kick Panel, and Seal Plate 3378
Remove 3378
Install 3381
Hood Support and Door Assembly 3383
Remove 3383
Install 3384
Hood Door Assembly 3389
Remove 3389
Install 3390
Steering Column 3391
Description 3391
Steering Column Repair 3391
Remove 3391
Disassemble 3392
Clean 3394
Inspect 3394
Assemble 3394
Install 3394
LPG Tank and Bracket Assembly 3394
Counterweight Replacement 3395
Remove 3395
Install 3396
Tow Pin, Remove and Install 3397
Overhead Guard Replacement 3398
Remove 3398
Install 3400
Engine Replacement 3401
Remove Engine 3401
Remove Transmission 3424
Remove Engine and Transmission 3428
Install Engine 3431
Install Transmission 3435
Install Engine and Transmission 3436
Throttle Pedal and Cable Adjustment 3440
Throttle Cable Adjustment, Kubota 3 6L Diesel Tier 3 Engine with Basic Powershift Transmission 3440
Exhaust System Repair 3442
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP135VX, GP/GLP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 (GLP135VX, GLP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 3442
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 3442
Kubota 3 8L Diesel Engine w/DPF 3442
Remove 3444
Inspect 3445
Install 3445
Kubota 3 8L Diesel Engine w/DOC 3445
Remove 3447
Inspect 3448
Install 3448
Kubota 3 6L Diesel Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6 GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878), GP60VX, GP70VX, GP70SVX, GP70SVX9, GP80SVX (GP135VX, GP155VX, GP155SVX, GP170SVX) (H878) 3449
Remove 3449
Inspect 3451
Install 3451
Diesel Particulate Filter (DPF) 3452
Diesel Particulate Filter 3452
Disassemble 3452
Clean and Inspect 3453
Differential Pressure Pipes and Hoses 3454
Assemble 3454
Diesel Exhaust Fluid System 3455
General 3455
Description and Operation 3455
Selective Catalyst Reducer (SCR) 3459
Remove 3459
Clean and Inspect 3459
Install 3460
DEF Tank 3460
Remove 3460
Clean and Inspect 3462
Install 3462
Cooling System 3463
Description 3463
Hydraulic Filter Assembly Repair 3464
Remove 3464
Install 3466
Fuel and Hydraulic Tanks Repair 3467
Inspect 3467
Clean 3467
Steam Method of Cleaning 3467
Chemical Solution Method of Cleaning 3468
Additional Preparations for Repair 3468
Small Leaks, Repair 3469
Large Leaks, Repair 3469
Preparations for Use After Repair 3469
Safety Labels 3470
550131845 0100YRM1948 (11 2019) UK EN 3479
General 3483
Description 3483
Side Covers, Seat, Dash, and Hood Replacement 3484
Side Covers 3484
Remove 3484
Install 3484
Seat and Seat Plate 3485
Remove Seat 3485
Remove Seat Plate 3486
Install Seat Plate 3486
Install Seat 3486
Operator Restraint System 3490
Emergency Locking Retractor (ELR) 3490
Seat Plate and Seat Rail Check 3490
Steering Column, Dash, Kick Panel, and Seal Plate 3490
Remove 3490
Install 3493
Hood Support and Door Assembly 3495
Remove 3495
Install 3495
Hood Door Assembly 3500
Remove 3500
Install 3501
Steering Column 3502
Description 3502
Steering Column Repair 3502
Remove 3502
Disassemble 3503
Clean 3504
Inspect 3505
Assemble 3505
Install 3505
LPG Tank and Bracket Assembly 3505
Counterweight Replacement 3505
Remove 3505
Install 3507
Tow Pin, Remove and Install 3508
Overhead Guard Replacement 3508
Remove 3508
Install 3510
Engine Replacement 3510
Remove Engine 3510
Remove Transmission 3531
Remove Engine and Transmission 3534
Install Engine 3537
Install Transmission 3540
Install Engine and Transmission 3542
Throttle Pedal and Cable Adjustment 3545
Exhaust System Repair 3545
GM 4 3L Engine for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP135VX, GP/GLP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 GP70VXS9 (GLP135VX, GLP155VX, GP155VXS) (G878) 3545
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 3545
Kubota 3 8L Diesel Engine w/DPF 3545
Remove 3547
Inspect 3548
Install 3548
Kubota 3 8L Diesel Engine w/DOC 3548
Remove 3550
Inspect 3551
Install 3551
Kubota 3 6L Diesel Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6 GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878) 3552
Remove 3552
Inspect 3553
Install 3553
Diesel Particulate Filter (DPF) 3554
Diesel Particulate Filter 3554
Disassemble 3555
Clean and Inspect 3555
Differential Pressure Pipes and Hoses 3556
Assemble 3557
Diesel Exhaust Fluid System 3557
General 3557
Description and Operation 3557
Selective Catalyst Reducer (SCR) 3559
Remove 3559
Clean and Inspect 3560
Install 3560
DEF Tank 3561
Remove 3561
Clean and Inspect 3563
Install 3563
Cooling System 3564
Description 3564
Hydraulic Filter Assembly Repair 3564
Remove 3564
Install 3565
Fuel and Hydraulic Tanks Repair 3566
Inspect 3566
Clean 3566
Steam Method of Cleaning 3567
Chemical Solution Method of Cleaning 3567
Additional Preparations for Repair 3567
Small Leaks, Repair 3568
Large Leaks, Repair 3568
Preparations for Use After Repair 3568
Safety Labels 3568
550131847 0600YRM1962 (11 2019) UK EN 3577
General 3583
Engine Identification 3583
Major Engine Component Identification 3583
Location of Labels 3583
Cylinder Block Description 3584
Precautions Before Beginning Repair 3585
Exhaust System, SCR, and DPF 3585
Engine Removal and Installation 3586
Cylinder Head Assembly Repair 3586
Valve Covers and Fuel Injectors 3586
Remove 3586
Clean and Inspect 3589
Install 3589
Rocker Arm Assembly 3590
Remove 3590
Disassemble 3591
Clean and Inspect 3591
Push Rods 3591
Rocker Arm Assembly 3591
Assemble 3592
Install 3592
Valve Clearance Adjustments 3592
Cylinder Head Assembly 3594
Remove 3594
Disassemble 3602
Valves and Valve Springs, Remove 3602
Valve Guides, Remove 3603
Clean and Inspect 3603
Cylinder Head 3604
Valve Guides 3604
Valves 3604
Valve Sink 3605
Valve Seat 3605
Valve Springs 3606
Assemble 3606
Valve Guides, Install 3606
Valves and Valve Springs, Install 3607
Install 3608
Timing Gear Case and Timing Gears Repair 3610
Timing Gear Case Cover 3610
Remove 3610
Clean and Inspect 3611
Install 3611
Timing Gears 3612
Crankshaft Gear 3612
Remove 3612
Install 3613
Idler Gear 1 and Idler Gear 2 3613
Remove 3613
Inspect 3614
Install 3615
Idler Gear 3 3615
Remove 3615
Inspect 3615
Install 3615
Camshaft Gear 3615
Remove 3615
Install 3615
Drive Train, Camshaft, and Cylinder Block Repair 3616
Remove 3616
Disassemble 3616
Pistons and Connecting Rods 3616
Crankshaft 3617
Camshaft 3619
Clean and Inspect 3621
Cylinder Block 3621
Honing and Boring 3623
Cylinder Correction (Oversize) 3624
Pistons 3624
Piston Pin 3625
Connecting Rod 3625
Tappets 3626
Crankshaft 3626
Camshaft 3628
Camshaft Bushing 3629
Assemble 3629
Camshaft 3629
Crankshaft 3629
Pistons and Connecting Rods 3630
Install 3632
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 3632
Lubrication System Repair 3635
Engine Oil and Oil Filter Change (Standard Oil Filter) 3635
Engine Oil and Oil Filter Change (Remote Oil Filter) 3636
Oil Pan 3636
Remove 3636
Install 3637
Oil Suction Tube 3637
Remove 3637
Clean 3638
Install 3638
Oil Pump 3638
Remove 3638
Clean and Inspect 3639
Inner Rotor and Outer Rotor Clearance 3639
Outer Rotor and Pump Body Clearance 3640
Rotor and Cover Clearance 3640
Rotor Shaft Clearance 3640
Install 3641
Remote Oil Filter 3641
Remove 3641
Clean and Inspect 3643
Install 3643
Fuel System Repair 3644
Fuel Injectors 3644
Remove 3644
Inspect 3644
Clean 3644
Replace 3644
Install 3645
Test 3645
Fuel Injection Pump 3645
Remove 3645
Clean and Inspect 3648
Install 3649
Cooling System Repair 3650
Serpentine Belt 3650
Remove 3650
Inspect 3650
Install 3650
Adjust 3650
Water Pump 3651
Remove 3651
Install 3652
Thermostat 3653
Remove 3653
Inspect 3654
Install 3654
Flywheel and Flywheel Housing 3656
Flywheel 3656
Remove 3656
Install 3656
Flywheel Housing 3656
Remove 3656
Install 3656
Electrical Equipment Repair 3657
Alternator 3657
Remove 3657
Install 3658
Starter 3659
Remove 3659
Install 3659
Engine Specifications 3661
Engine Data 3661
Engine Tuning 3662
Cylinder Head 3662
Intake/Exhaust Valve and Guide 3663
Valve Spring 3663
Rocker Arm and Shaft 3663
Push Rod 3663
Gear Train and Camshaft 3664
Camshaft 3664
Idle Gear Shaft and Bushing 3664
Backlash of Each Gear 3664
Cylinder Block 3664
Crankshaft 3665
Piston 3665
Piston Ring 3665
Connecting Rod 3666
Rod Small End 3666
Tappet 3666
Oil Pump 3666
Engine Oil Pressure 3666
Inner and Outer Rotor Clearance 3666
Outer Rotor and Pump Body 3666
Rotor and Cover 3667
Standard Torque Specifications 3667
Standard Torque Chart 3667
Special Torque Specifications 3668
Special Tools 3669
550131848 0600YRM1961 (03 2020) UK EN 3683
General 3689
Engine Identification 3690
Major Engine Component Identification 3690
Location of Labels 3692
Cylinder Block Description 3693
Precautions Before Beginning Repair 3694
Exhaust System and DPF 3695
Engine Removal and Installation 3695
Cylinder Head Assembly Repair 3695
Valve Covers and Fuel Injectors 3695
Remove 3695
Clean and Inspect 3698
Install 3698
Rocker Arm Assembly 3699
Remove 3699
Disassemble 3699
Clean and Inspect 3700
Push Rods 3700
Rocker Arm Assembly 3700
Assemble 3701
Install 3701
Valve Clearance Adjustments 3701
Cylinder Head Assembly 3702
Remove 3702
Disassemble 3710
Valves and Valve Springs, Remove 3710
Valve Guides, Remove 3711
Clean and Inspect 3711
Cylinder Head 3712
Valve Guides 3712
Valves 3713
Valve Sink 3713
Valve Seat 3713
Valve Springs 3714
Assemble 3714
Valve Guides, Install 3714
Valves and Valve Springs, Install 3715
Install 3716
Timing Gear Case and Timing Gears Repair 3718
Timing Gear Case Cover 3718
Remove 3718
Clean and Inspect 3719
Install 3719
Timing Gears 3720
Crankshaft Gear 3720
Remove 3720
Install 3721
Idler Gear 1 and Idler Gear 2 3721
Remove 3721
Inspect 3722
Install 3723
Idler Gear 3 3723
Remove 3723
Inspect 3723
Install 3723
Camshaft Gear 3723
Remove 3723
Install 3723
Drive Train, Camshaft, and Cylinder Block Repair 3724
Remove 3724
Disassemble 3724
Pistons and Connecting Rods 3724
Crankshaft 3725
Camshaft 3727
Clean and Inspect 3729
Cylinder Block 3729
Honing and Boring 3731
Cylinder Correction (Oversize) 3732
Pistons 3732
Piston Pin 3733
Connecting Rod 3733
Tappets 3734
Crankshaft 3734
Camshaft 3736
Camshaft Bushing 3737
Assemble 3737
Camshaft 3737
Crankshaft 3737
Pistons and Connecting Rods 3738
Install 3740
Angular Deviation Procedure 3740
Lubrication System Repair 3743
Engine Oil and Oil Filter Change 3743
Oil Pan 3744
Remove 3744
Install 3744
Oil Suction Tube 3744
Remove 3744
Clean 3745
Install 3745
Oil Pump 3745
Remove 3745
Clean and Inspect 3746
Inner Rotor and Outer Rotor Clearance 3746
Outer Rotor and Pump Body Clearance 3747
Rotor and Cover Clearance 3747
Rotor Shaft Clearance 3747
Install 3748
Fuel System Repair 3748
Fuel Injectors 3748
Remove 3748
Inspect 3748
Clean 3749
Replace 3749
Install 3749
Test 3749
Fuel Injection Pump 3749
Remove 3749
Clean and Inspect 3752
Install 3752
Cooling System Repair 3753
Serpentine Belt 3753
Remove 3753
Inspect 3753
Install 3753
Adjust 3753
Water Pump 3754
Remove 3754
Install 3756
Thermostat 3756
Remove 3756
Inspect 3757
Install 3757
Flywheel and Flywheel Housing 3758
Flywheel 3758
Remove 3758
Install 3759
Flywheel Housing 3759
Remove 3759
Install 3759
Electrical Equipment Repair 3760
Alternator 3760
Remove 3760
Install 3761
Starter 3762
Remove 3762
Install 3762
Engine Specifications 3764
Engine Data 3764
Engine Tuning 3766
Cylinder Head 3766
Intake/Exhaust Valve and Guide 3767
Valve Spring 3767
Rocker Arm and Shaft 3767
Push Rod 3767
Gear Train and Camshaft 3768
Camshaft 3768
Idle Gear Shaft and Bushing 3768
Backlash of Each Gear 3768
Cylinder Block 3768
Crankshaft 3769
Piston 3769
Piston Ring 3769
Connecting Rod 3770
Rod Small End 3770
Tappet 3770
Oil Pump 3770
Engine Oil Pressure 3770
Inner and Outer Rotor Clearance 3770
Outer Rotor and Pump Body 3770
Rotor and Cover 3771
Standard Torque Specifications 3771
Standard Torque Chart 3771
Special Torque Specifications 3771
Special Tools 3773
550131849 0700YRM1950 (03 2020) UK EN 3787
General 3791
Cooling System Checks 3792
Exhaust Leaks Into Cooling System 3792
Water Flow Restrictions in Radiator 3792
Radiator Hoses 3792
Water Pump 3792
Flushing the Cooling System 3793
Cooling System, Clean 3793
Radiator Repair 3794
Remove 3794
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 3794
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 3802
Install 3808
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 3808
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 3809
Fan Assembly Replacement 3811
Remove 3811
Inspect 3816
Install 3816
550131851 1600YRM1952 (03 2020) UK EN 3819
General 3823
Steering Axle Assembly Repair 3826
Remove 3826
Disassemble 3827
Clean 3828
Inspect 3828
Assemble 3829
Install 3829
Spindles, Bearings, and Tie Rods Repair 3830
Spindles and Bearings 3830
Remove 3830
Disassemble 3830
Clean 3831
Inspect 3831
Assemble 3831
Install 3832
Tie Rods 3832
Remove 3832
Install 3833
Steering Cylinder Repair 3833
Remove and Disassemble 3833
Clean and Inspect 3833
Assemble and Install 3833
Turn Assist (Lift trucks built after February 2019) 3835
Removal 3835
Instal 3837
Adjustment 3837
Torque Specifications 3838
550131852 2100YRM1953 (03 2020) UK EN 3841
General 3847
Safety Procedures When Working Near Mast 3847
Tilt Cylinder Repair 3849
Remove 3849
Disassemble 3852
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3852
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3852
Clean 3853
Inspect 3853
Assemble 3853
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3853
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3854
Install 3855
Tilt Cylinders, Adjust 3856
Tilt Cylinder Leak Check 3858
Lift Cylinder Repair 3859
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3859
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 3862
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 3866
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3871
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 3872
Clean 3873
Inspect 3873
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3873
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3874
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3874
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 3875
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 3875
Free-Lift Cylinder Repair 3876
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3876
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3879
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3881
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3882
Clean 3884
Inspect 3884
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3884
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3885
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3885
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3885
Sideshift Cylinder Repair 3886
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3886
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3886
Clean 3887
Inspect 3887
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3887
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3888
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3888
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3889
Clean 3890
Inspect 3890
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3890
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3890
Bolzoni Sideshift Cylinder Repair 3891
Remove 3891
Disassemble 3891
Clean 3892
Inspect 3892
Assemble 3893
Install 3893
Fork Positioner Cylinder Repair 3894
Remove 3894
Disassemble 3896
Clean 3899
Inspect 3899
Assemble 3900
Install 3901
Lift Cylinder Leak Check 3902
Seal Kit Installation 3902
External Installation (Seal and Back-Up Ring) 3902
Internal Installation (Piston Rod Assembly) 3903
Special Tools 3903
Torque Specifications 3904
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3904
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3904
550131853 2200YRM1954 (03 2020) UK EN 3907
General 3915
Display Switch Cluster 3918
Remove 3918
Install 3920
Direction Control and Turn Signal Levers 3920
Remove 3920
Install 3921
Key Switch 3921
Remove 3921
Install 3922
Display Switch Cluster Panel Bezel and Overlay 3922
Remove 3922
Install 3923
Steering Column Repair 3923
Sensors and Switches 3926
General 3926
Dash and Kick Panel, Remove and Install 3926
Remove 3926
Install 3927
Accelerator Pedal Position Sensor 3927
Remove 3927
Install 3930
Brake Fluid Level Switch 3930
Remove 3930
Install 3931
Service Brake Pedal Position Sensor 3931
Remove 3931
Install 3932
Parking Brake Position Sensor 3932
Remove 3932
Install 3932
Service Brake Pressure Sensor 3933
Remove 3933
Install 3933
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 3934
Remove 3934
Install 3934
Sensor MicroswitchFoot Directional Control 3935
Remove 3935
Install 3937
Low Coolant Level Sensor 3937
Remove 3937
Install 3938
Fuel Level Sensor, Diesel Engines Only 3938
Remove 3938
Install 3939
Seat Sensor (Operator Presence System) 3939
Non-Suspension Seat 3939
Remove 3939
Install 3941
Full Suspension and Swivel Seats 3941
Remove 3941
Install 3941
Hood Shut Off Switch 3942
Remove 3942
Install 3942
Remote Key Switch 3943
Remove 3943
Install 3943
Hydraulic Filter Pressure Switch 3944
Remove 3944
Install 3944
Transmission Speed Sensor 3944
Remove 3944
Install 3945
Transmission Pressure Sensors 3945
Remove 3945
Install 3945
Transmission Temperature Sensor 3946
Remove 3946
Install 3946
Engine Speed Sensor 3946
Remove 3946
Install 3946
Intermediate Speed Sensor 3946
Remove 3946
Install 3946
Return To Set Tilt (Tilt Angle) Sensor 3946
Remove 3946
Install 3947
Rear Horn Button Switch 3947
Remove 3947
Install 3947
Impact Sensor 3948
Remove 3948
Install 3948
Load Weight Sensor 3949
Remove 3949
Install 3949
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 3950
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 3951
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 3951
Air Filter Restriction Switch 3951
Remove 3951
Install 3951
Engine Oil Pressure Sensor 3952
Remove 3952
Install 3952
Engine Speed Sensor 3952
Remove 3952
Install 3952
Engine Coolant Temperature (ECT) Sensor 3953
Remove 3953
Install 3953
Fuel/Water Separator Sensor 3953
Remove 3953
Install 3953
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 3954
Engine Coolant Temperature (ECT) Sensor 3954
Remove 3954
Install 3954
Throttle Position Sensor 3955
Engine Oil Pressure Sensor 3955
Remove 3955
Install 3955
Fuel Shut Off Solenoid 3955
Remove 3955
Install 3956
Engine and Fuel Sensors and Switches, Kubota 3 8L Diesel Engine With Diesel Particulate Filter (DPF) And Kubota 3 8L (Tier 4) 55kW Diesel Engine, With Diesel Oxidation Catalyst (DOC) 3956
Intake Air Temperature Sensor 3957
Remove 3957
Install 3957
Boost Sensor 3957
Remove 3957
Install 3957
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 3959
Remove 3959
Install 3960
Engine Coolant Temperature (ECT) Sensor 3960
Remove 3960
Install 3960
Engine Oil Pressure Sensor 3960
Remove 3960
Install 3961
Crankshaft Position Sensor 3961
Remove 3961
Install 3961
Adjust Shim Procedure 3961
Camshaft Position Sensor 3963
Remove 3963
Install 3963
Differential Pressure Sensor 3963
Remove 3963
Install 3964
Oxygen Sensors (Inlet and Outlet) 3964
Remove 3964
Install 3965
Inlet Temperature Sensor 3966
Remove 3966
Install 3966
Mass Air Flow Sensor 3966
Remove 3966
Install 3966
Fuel/Water Separator 3966
Remove 3966
Install 3967
Air Filter Restriction Switch 3967
Remove 3967
Install 3967
Vehicle System Manager (VSM) 3968
General 3968
VSM Replacement 3968
Remove 3968
Install 3968
Programming A New VSM And/Or Display Switch Cluster 3969
Data Transferring 3970
New VSM 3970
New (Blank) Display Switch Cluster 3970
Used (Non-Blank) Display Switch Cluster 3970
PC Service Tool Software 3971
Power Distribution Module (PDM) and Component Parts 3971
Remove 3971
PDM as a Unit 3971
Install 3972
PDM as a Unit 3972
Remove and Install 3972
PDM Component Parts 3972
Transmission Control Unit (TCU) 3973
Remove 3973
Install 3975
Battery 3978
Remove 3978
Install 3978
Lights 3978
Work Lights (Front and Rear) 3978
Halogen Bulb Lights 3978
Remove 3978
Install 3978
LED Lights 3979
Remove 3979
Install 3979
Strobe Light 3979
Remove 3979
Install 3980
LED Tail, Backup, and Brake Lights 3980
Remove 3980
Install 3980
Front Marker/Turn Signal Lights 3981
Replacing Whole Front Marker/Turn Signal Light Assembly 3981
Remove 3981
Install 3981
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 3982
Remove 3982
Install 3982
Electronic-Hydraulic Controls, Before January, 2020 3983
E-Hydraulic Controls – TEST 3983
Mini-Levers 3983
Full Stroke Test 3983
Function Returns to Neutral Test 3983
Push (Override) Button Switch 3983
General 3984
Mini-levers, Remove and Install 3984
Armrest Assembly 3985
Remove 3985
Install 3988
Horn Button 3988
Remove 3988
Install 3988
Direction Control Switch 3988
Remove 3988
Install 3989
Push (Override) Button 3989
Remove 3989
Install 3990
Electronic-Hydraulic Controls, After January, 2020 3991
E-Hydraulic Controls – TEST 3991
Mini-Levers 3991
Full Stroke Test 3991
Function Returns to Neutral Test 3991
Push Button Switch 3991
General 3992
Mini-levers, Remove and Install 3992
Armrest Assembly 3993
Remove 3993
Install 3996
Horn Button 3996
Remove 3996
Install 3996
Direction Control Switch 3996
Remove 3996
Install 3997
Push (Override) Buttons 3997
Remove 3997
Install 3998
Diesel Particulate Filter (DPF) Display 3999
Remove 3999
Clean and Inspect 4000
Install 4000
Special Tools 4001
550131855 4000YRM1956 (03 2020) UK EN 4005
Safety Procedures When Working Near Mast 4009
Fork Replacement 4010
General 4010
Remove 4010
Install 4012
Checks 4012
Carriage Repair 4014
Remove 4014
Clean and Inspect 4017
Install 4017
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4018
Connecting Attachment Hydraulic Quick Disconnect Hoses 4018
Integral Sideshift Carriage And Fork Positioners Repair 4019
Integral Sideshift Carriage 4019
Remove 4019
Disassemble 4020
Clean and Inspect 4022
Assemble 4023
Install 4023
Fork Positioners 4024
Remove 4024
Disassemble 4027
Clean and Inspect 4029
Assemble 4029
Install 4029
Hang-On Sideshift Carriage Repair 4030
Remove 4030
Disassemble Carriage 4032
Clean and Inspect 4035
Assemble 4035
Install 4038
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 4040
Remove 4040
Disassemble 4044
Clean and Inspect 4048
Assemble 4050
Install 4050
Header Hose Installation 4051
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 4054
Remove 4054
Disassemble 4057
Clean and Inspect 4060
Assemble 4062
Install 4062
Header Hose Installation 4063
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 4066
Remove 4066
Disassemble 4069
Clean and Inspect 4072
Assemble 4074
Install 4074
Header Hose Installation 4075
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 4078
Remove 4078
Disassemble 4081
Clean and Inspect 4085
Assemble 4087
Install 4087
Header Hose Installation 4088
Mast Operation Check 4091
Tilt Cylinder Adjustment 4091
Main Lift Cylinder Repair 4092
Lift Chain Adjustment 4092
Mast Adjustments 4093
Load Roller Adjustment 4093
Mast Side Kicking Adjustment 4095
Carriage Adjustment 4095
550131988 8000YRM1960 (09 2020) UK EN 4099
Lift Truck Lifting Capacity 4103
Capacities 4103
Counterweight Weights 4105
Electrical System 4106
Engine Specifications 4106
Front End Equipment – Mast Creep 4107
Mast Creep 4107
Hydraulic System Relief Pressures 4108
Mast Speeds 4108
Stall Speeds 4109
Steering System 4109
Tilt Angles 4110
Tire Sizes 4110
Transmission Oil Pressures 4110
Diesel Fuel Cleanliness Levels 4112
Torque Specifications 4113
Frame 4113
Mast, Carriage, and Fork Positioner 4113
Steering System 4113
Transmission 4113
Engine, Cummins QSB 3 3L 4113
Engine, GM 5 7L LPG 4113
Engine – Kubota 3 8L Diesel 4114
550131989 8000YRM1959 (09 2020) UK EN 4117
General 4123
Serial Number Data 4123
How to Move Disabled Lift Truck 4123
How to Tow Lift Truck 4123
How to Put Lift Truck on Blocks 4124
How to Raise Drive Tires 4124
How to Raise Steering Tires 4125
How to Clean a Lift Truck 4126
Safety Procedures When Working Near Mast 4127
Maintenance Schedule 4129
Maintenance Schedule 4129
Maintenance Procedures Every 8 Hours or Daily 4145
How to Make Checks With Engine Stopped 4145
Tires and Wheels 4145
Safety Labels 4145
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 4145
Operator Restraint System 4146
Emergency Locking Retractor (ELR) 4146
Adjust Seat – Full Suspension 4147
Adjust Seat – Internal Suspension 4148
Seat Plate and Seat Rails 4148
Engine Compartment 4148
Fuel, Oil, and Coolant Leaks, Check 4149
Hydraulic Hoses 4149
Coolant Hoses 4149
Steering Column Gas Cylinder 4149
Transmission 4149
Hydraulic System Oil 4149
Engine Oil 4151
Forks 4153
Inspect 4153
Remove 4155
Install 4155
Adjust 4155
Integral Sideshift Carriage 4156
How to Make Checks With Engine Running 4157
Indicator Lights, Horn, Fuses, and Relays 4157
Service Brakes 4160
Operation, Check 4160
Accumulator Pressure 4160
Parking Brake 4160
Engine Oil Pressure 4160
Cooling System 4161
Steering System 4162
Control Levers and Pedals 4162
Lift System, Operate 4162
Air Filter 4163
Fuel/Water Separator Filter, Cummins and Kubota Diesel Engines 4163
First Service After First 100 Hours of Operation 4164
Engine Oil and Oil Filter 4164
Maintenance Procedures Every 500 Hours or 6 Months 4167
Hydraulic System Oil Check 4167
Hydraulic Tank Breather 4168
Inspect 4168
Battery 4169
Engine Oil and Oil Filter 4170
Fuel/Water Separator Filter Replacement, Cummins QSB 3 3L Diesel Engine 4171
Remove 4171
Install 4171
Final Fuel Filter Replacement, Cummins QSB 3 3L Diesel Engine 4173
Priming The Fuel System, Cummins QSB 3 3L Diesel Engine 4173
Controlled Venting 4173
Manual Bleeding 4173
Fuel/Water Separator Filter Replacement, Kubota 3 8L Diesel Engine 4174
Remove 4174
Install 4175
Priming The Fuel System, Kubota 3 8L Diesel Engine 4176
Drive Belt 4176
Fan and Alternator Drive Belt Inspection 4176
Fan and Alternator Drive Belt Adjustment,Cummins QSB 3 3L Diesel Engine 4178
Clean Debris From Radiator Core 4178
Transmission and Wet Brake Axle Oil Level Check 4179
Wet Brake Center Body Oil Level Check 4180
Forks, Inspect 4182
Mast Lubrication 4183
Header Hose Checks 4186
Lift Chain Lubrication 4186
Tilt Cylinder Lubrication 4188
Brake Actuation Valve Rod End Pin 4190
Tie Rod Lubrication 4191
Low Idle Speed Check 4192
Drain Tar From LPG Converter 4192
GM 5 7L LPG Engine 4192
Parking Brake Adjustment 4193
Cab Heater Air Filter 4193
Maintenance Procedures Every 1000 Hours or 6 Months 4195
Lift Chain Lubrication and Wear Check 4195
Integral Sideshift Carriage, Check Sliding Surfaces 4196
Steering Axle Spindle Bearings 4197
Control Levers and Pedals 4198
Inspect Engine Electrical System, Connectors 4198
Spark Plugs 4199
GM 5 7L LPG Engine 4199
PCV Valve 4199
GM 5 7L LPG Engine 4199
LPG Fuel Filter 4199
GM 5 7L LPG Engine 4199
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4199
Crankcase Breather Filter, Kubota 3 8L Diesel 4203
Remove 4203
Clean and Inspect 4204
Install 4204
DEF Injector Tip 4204
Maintenance Procedures Every 2000 Hours or Annually 4205
Hydraulic System 4205
Hydraulic Filter Assembly, Replace 4205
Remove 4205
Install 4206
Hydraulic Tank Breather, Replace 4207
Cooling System Check 4208
Air Filter 4210
Fuel Injectors and Fuel System 4211
Forks, Inspect 4212
Check Throttle Shaft for Sticking 4213
Inspect Exhaust Manifold and Piping for Leaks 4213
Transmission Automatic Clutch Calibration 4213
Brake System Accumulator 4213
Valve Clearance, Check and Adjust, Cummins QSB 3 3L Diesel Engine 4213
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 4214
GM 5 7L LPG Engine 4214
PCV Valve 4215
GM 5 7L LPG Engine 4215
LPG Electronic Pressure Regulator (EPR)/Fuel Mixer, Inspect 4215
GM 5 7L LPG Engine 4215
LPG Lock-Off Valve 4216
GM 5 7L LPG Engine 4216
Oxygen Sensors 4217
GM 5 7L LPG Engine 4217
Kubota 3 8L Diesel Engine 4217
Wheel Bearings 4217
Steer Wheels, Lubrication 4217
Maintenance Procedures Every 3000 Hours 4218
Diesel Particulate Filter 4218
Remove 4218
Disassemble 4220
Servicing the Diesel Particulate Filter, Pressure Tubes, and Pressure Hoses 4221
Assemble 4221
Install 4222
Diesel Exhaust Fluid (DEF) System 4222
Maintenance Procedures Every 4000 Hours or 2 Years 4224
Hydraulic Oil, Replace 4224
Fuel Filter Water Removal 4225
Lift Chain Adjustments 4227
Jump-Starting the Lift Truck 4228
Jump-Starting Using a Battery Charger 4228
Jump-Starting a Lift Truck Using Another Lift Truck 4228
Welding Repairs 4229
Overhead Guard Changes 4229
Wheel and Tire Replacement 4229
General 4229
Pneumatic Tire With Tube, Repair 4229
Remove Wheels From Lift Truck 4229
Remove Tire From Wheel 4230
Install Wheel in Tire 4233
Install Tire on Two-Piece Wheel 4235
Add Air to Pneumatic Tires With Tube 4236
Install the Wheels 4236
Dual Drive Wheels, Install 4237
Pneumatic Tubeless Tire, Repair 4237
Remove Wheels From Lift Truck 4237
Add Air to Pneumatic Tubeless Tire 4243
Wheels, Install 4243
Solid Rubber Tires on Pneumatic Wheels, Change 4243
Snap-On-Tire, Change 4247
Adhesives and Sealants 4250
550136209 1800YRM1977 (03 2020) UK EN 4253
General 4257
Wet Brake System 4257
Parking Brake Repair 4258
Master Cylinder Repair, For 6-8 Ton Lift Trucks 4261
Remove 4261
Disassemble 4262
Clean and Inspect 4263
Assemble 4264
Install and Adjust 4264
Accumulator; For 6-8 Ton Lift Trucks 4265
Pre-Charge Check 4265
Remove 4266
Install 4267
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For 8-9 Ton Lift Trucks 4267
Remove 4267
Modulating Brake Valve 4269
Disassemble 4269
Clean and Inspect 4270
Assemble 4271
Accumulator Charge Valve 4271
Disassemble 4271
Clean and Inspect 4273
Assemble 4273
Install 4274
Pressure Checks 4275
Accumulator Charge Valve Check 4275
Accumulator Check 4275
Brake System Air Removal; For 6-8 Ton Lift Trucks 4276
Using Pressure Bleed System 4276
Using Brake Pedal Pressure 4276
Lift Truck Models with Master Cylinder 4276
Brake System Air Removal for 8-9 Ton Lift Trucks 4277
Using Brake Pedal Pressure 4277
Lift Truck Models with Modulating Brake Valve 4277
Brake Pedal Adjustment 4277
For 6-8 Ton Lift Trucks 4277
For 8-9 Ton Lift Trucks 4278
Free Pedal Adjustment 4280
Torque Specifications 4281
550136209 1800YRM1977 (08 2022) US EN 4283
General 4289
Wet Brake System 4289
Parking Brake Repair 4290
Master Cylinder Repair, For Lift Truck Models F878/G878/H878 4294
Remove 4294
Disassemble 4294
Clean and Inspect 4296
Assemble 4296
Install and Adjust 4296
Accumulator; For Lift Truck Models F878/G878/H878 4298
Pre-Charge Check 4298
Remove 4298
Install 4299
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For Lift Truck Models C909/D909 4300
Remove 4300
Modulating Brake Valve 4301
Disassemble 4301
Clean and Inspect 4302
Assemble 4303
Accumulator Charge Valve 4303
Disassemble 4303
Clean and Inspect 4305
Assemble 4305
Install 4306
Pressure Checks 4307
Accumulator Charge Valve Check 4307
Accumulator Check 4307
Brake System Air Removal; For Lift Truck Models 4308
Using Pressure Bleed System 4308
Using Brake Pedal Pressure 4308
Lift Truck Models with Master Cylinder 4308
Brake System Air Removal for Lift Truck Models C909/D909 4310
Using Brake Pedal Pressure 4310
Lift Truck Models with Modulating Brake Valve 4310
Brake Pedal Adjustment 4310
For Lift Truck Models F878/G878/H878 4310
For Lift Truck Models C909/D909 4311
Free Pedal Adjustment 4313
Torque Specifications 4314
550136214 9000YRM1976 (12 2020) UK EN 4317
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 4323
Group 05 – Operational Checkout 4325
SECTION 9020 ENGINE 4331
Group 10 – Principles of Operation 4333
Group 30 – Observed Symptoms 4357
Group 40 – Tests and Adjustments 4365
SECTION 9030 ELECTRICAL SYSTEM 4383
Group 03 – General Maintenance and Diagnostic Data 4389
Group 10 – Principles of Operation 4401
Group 20 – Diagnostic Trouble Codes 4409
SECTION 9080 SUPPLEMENTARY DATA 4565
Group 50 – Abbreviations and Acronyms 4567
Group 60 – Special Tools List 4575
Group 70 – Fault Mode Indicator Reference 4579
550210540 0600YRM2190 (03 2020) UK EN 4583
General 4589
Engine Identification 4589
Major Engine Component Identification 4589
Location of Labels 4593
Cylinder Block Description 4593
Precautions Before Beginning Repair 4594
Exhaust System and DPF 4595
Engine Removal and Installation 4595
Cylinder Head Assembly Repair 4595
Valve Covers and Fuel Injectors 4595
Remove 4595
Clean and Inspect 4598
Install 4598
Rocker Arm Assembly 4599
Remove 4599
Disassemble 4599
Clean and Inspect 4600
Push Rods 4600
Rocker Arm Assembly 4600
Assemble 4601
Install 4601
Valve Clearance Adjustments 4601
Cylinder Head Assembly 4602
Remove 4602
Disassemble 4612
Valves and Valve Springs, Remove 4612
Valve Guides, Remove 4613
Clean and Inspect 4613
Cylinder Head 4614
Valve Guides 4614
Valves 4614
Valve Sink 4615
Valve Seat 4615
Valve Springs 4616
Assemble 4616
Valve Guides, Install 4616
Valves and Valve Springs, Install 4617
Install 4618
Timing Gear Case and Timing Gears Repair 4620
Timing Gear Case Cover 4620
Remove 4620
Clean and Inspect 4621
Install 4622
Timing Gears 4622
Crankshaft Gear 4623
Remove 4623
Install 4623
Idler Gear 1 and Idler Gear 2 4623
Remove 4623
Inspect 4624
Install 4625
Idler Gear 3 4625
Remove 4625
Inspect 4625
Install 4625
Camshaft Gear 4625
Remove 4625
Install 4625
Drive Train, Camshaft, and Cylinder Block Repair 4626
Remove 4626
Disassemble 4626
Pistons and Connecting Rods 4626
Crankshaft 4627
Camshaft 4629
Clean and Inspect 4631
Cylinder Block 4631
Honing and Boring 4633
Cylinder Correction (Oversize) 4634
Pistons 4634
Piston Pin 4635
Connecting Rod 4635
Tappets 4636
Crankshaft 4636
Camshaft 4638
Camshaft Bushing 4639
Assemble 4639
Camshaft 4639
Crankshaft 4640
Pistons and Connecting Rods 4640
Install 4642
Angular Deviation Procedure 4642
Lubrication System Repair 4645
Engine Oil and Oil Filter Change 4645
Oil Pan 4646
Remove 4646
Install 4646
Oil Suction Tube 4646
Remove 4646
Clean 4647
Install 4647
Oil Pump 4647
Remove 4647
Clean and Inspect 4648
Inner Rotor and Outer Rotor Clearance 4648
Outer Rotor and Pump Body Clearance 4649
Rotor and Cover Clearance 4649
Rotor Shaft Clearance 4649
Install 4650
Fuel System Repair 4651
Fuel Injectors 4651
Remove 4651
Inspect 4651
Clean 4651
Replace 4651
Install 4651
Test 4651
Fuel Injection Pump 4652
Remove 4652
Clean and Inspect 4654
Install 4654
Cooling System Repair 4655
Serpentine Belt 4655
Remove 4655
Inspect 4655
Install 4655
Adjust 4655
Water Pump 4656
Remove 4656
Install 4658
Thermostat 4659
Remove 4659
Inspect 4660
Install 4661
Flywheel and Flywheel Housing 4662
Flywheel 4662
Remove 4662
Install 4663
Flywheel Housing 4663
Remove 4663
Install 4663
Electrical Equipment Repair 4664
Alternator 4664
Remove 4664
Install 4665
Starter 4665
Remove 4665
Install 4666
Engine Specifications 4667
Engine Data 4667
Engine Tuning 4669
Cylinder Head 4670
Intake/Exhaust Valve and Guide 4670
Valve Spring 4671
Rocker Arm and Shaft 4671
Push Rod 4671
Gear Train and Camshaft 4671
Camshaft 4671
Idle Gear Shaft and Bushing 4671
Backlash of Each Gear 4672
Cylinder Block 4672
Crankshaft 4672
Piston 4672
Piston Ring 4673
Connecting Rod 4673
Rod Small End 4673
Tappet 4673
Oil Pump 4674
Engine Oil Pressure 4674
Inner and Outer Rotor Clearance 4674
Outer Rotor and Pump Body 4674
Rotor and Cover 4674
Standard Torque Specifications 4675
Standard Torque Chart 4675
Special Torque Specifications 4676
Special Tools 4677