Yale Forklift C909 (GDPGLP170VX, GDPGLP175VX36, GDPGLP190VX) Service Manual PDF

Yale Forklift C909 (GDPGLP170VX, GDPGLP175VX36, GDPGLP190VX) Service Manual – PDF DOWNLOAD

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Yale Forklift C909 (GDPGLP170VX, GDPGLP175VX36, GDPGLP190VX) Service Manual – PDF DOWNLOAD

Language : English
Pages : 4684
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift C909 (GDPGLP170VX, GDPGLP175VX36, GDPGLP190VX) 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) US EN 23
General 27
Threaded Fasteners 27
Nomenclature, Threads 27
Strength Identification 28
Cotter (Split) Pins 29
Fastener Torque Tables 34
Conversion Table 36
524208014 2200YRM1097 (03 2020) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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) US 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
550118420 8000YRM1904 (10 2020) US EN 3285
General Information About Diagrams and Schematics 3289
Symbol Definitions 3290
Diagrams Manual Applications 3291
Diagrams and Schematics 3293
550118555 0100YRM1892 (03 2020) US EN 3403
General 3409
Cab Replacement for 4-5 5 Ton Lift Trucks 3409
Remove 3409
Install 3420
Cab Replacement for 6-9 Ton Lift Trucks 3422
Remove 3422
Door Assemblies for 4-5 5 Ton Lift Trucks 3428
Right Side Door Assembly 3428
Remove 3428
Disassemble 3432
Door Cover With Heater Unit 3432
Door Cover With Air Conditioner/Heater Unit 3434
Heater Assembly 3436
Air Conditioner and Heater Unit Assembly 3436
Door Lock Assembly 3437
Windows 3439
Clean 3439
Inspect 3439
Assemble 3439
Windows 3439
Door Lock Assembly 3439
Heater Assembly 3439
Air Conditioner and Heater Unit Assembly 3440
Door Cover With Heater Unit 3440
Door Cover With Air Conditioner and Heater Unit 3440
Install 3440
Left Side Door Assembly 3441
Remove 3441
Disassemble 3441
Door Cover 3441
Door Lock Assembly 3441
Windows 3442
Clean 3442
Inspect 3442
Assemble 3442
Windows 3442
Door Lock Assembly 3442
Door Cover 3442
Install 3442
Door Assemblies for 6-9 Ton Lift Trucks 3443
Right and Left Side Door Assemblies 3443
Remove 3443
Disassemble 3443
Door Cover 3443
Door Lock Assembly 3444
Windows 3446
Clean 3446
Inspect 3446
Assemble 3446
Windows 3446
Door Lock Assembly 3446
Door Cover 3447
Install 3447
Window Replacement 3447
General 3447
Remove Door Windows for 4-5 5 Ton Lift Trucks 3447
Install Door Windows for 4-5 5 Ton Lift Trucks 3449
Remove Door Windows for 6-9 Ton Lift Trucks 3449
Install Door Windows for 6-9 Ton Lift Trucks 3451
Window Wipers Replacement 3451
General 3451
Front Wiper Assembly and Motor 3451
Remove 3451
Install 3453
Rear Wiper Assembly and Motor 3453
Remove, for 4-5 5 Ton Lift Trucks 3453
Install for 4-5 5 Ton Lift Trucks 3456
Remove for 6-9 Ton Lift Trucks 3456
Install for 6-9 Ton Lift Truck 3458
Heater Replacement 3459
Remove for 6-9 Ton Lift Trucks 3459
Install for 6-9 Ton Lift Trucks 3464
Heater and Air Conditioner Assembly 3465
Air Conditioner Condenser Unit 3465
Remove 3465
Install 3467
Air Conditioner Receiver/Drier Unit 3467
Remove 3467
Install 3469
Air Conditioner Compressor 3469
Light Replacement 3470
Work Lights (Front and Rear) 3470
Remove 3470
Install 3472
Strobe Light 3472
Remove 3472
Install 3473
Turn, Stop, Tail, and Backup Light 3473
Remove 3473
Install 3474
Front Marker/Turn Signal Lights 3474
Remove 3474
Install 3474
Display Switches 3475
Electrical Schematics 3477
Optional Equipment 3478
Heavy Duty Pre-Cleaner 3478
Fan 3478
Remove 3478
Install 3480
Mirror 3480
Remove 3480
Install 3480
Rear View Camera 3480
Monitor Removal 3480
Monitor Install 3482
Camera removal 3482
Camera install 3482
Label Replacement 3482
550131845 0100YRM1948 (09 2022) US EN 3485
General 3489
Description 3490
Side Covers, Seat, Dash, and Hood Replacement 3491
Side Covers 3491
Remove 3491
Install 3491
Seat and Seat Plate 3492
Remove Seat 3492
Remove Seat Plate 3492
Install Seat Plate 3492
Install Seat 3492
Operator Restraint System 3496
Emergency Locking Retractor (ELR) 3496
Seat Plate and Seat Rail Check 3496
Steering Column, Dash, Kick Panel, and Seal Plate 3496
Remove 3496
Install 3499
Hood Support and Door Assembly 3501
Remove 3501
Install 3502
Hood Door Assembly 3507
Remove 3507
Install 3508
Steering Column 3509
Description 3509
Steering Column Repair 3509
Remove 3509
Disassemble 3510
Clean 3512
Inspect 3512
Assemble 3512
Install 3512
LPG Tank and Bracket Assembly 3512
Counterweight Replacement 3513
Remove 3513
Install 3514
Tow Pin, Remove and Install 3515
Overhead Guard Replacement 3516
Remove 3516
Install 3518
Engine Replacement 3519
Remove Engine 3519
Remove Transmission 3542
Remove Engine and Transmission 3546
Install Engine 3549
Install Transmission 3553
Install Engine and Transmission 3554
Throttle Pedal and Cable Adjustment 3558
Throttle Cable Adjustment, Kubota 3 6L Diesel Tier 3 Engine with Basic Powershift Transmission 3558
Exhaust System Repair 3560
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) 3560
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 3560
Kubota 3 8L Diesel Engine w/DPF 3560
Remove 3562
Inspect 3563
Install 3563
Kubota 3 8L Diesel Engine w/DOC 3563
Remove 3565
Inspect 3566
Install 3566
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) 3567
Remove 3567
Inspect 3569
Install 3569
Diesel Particulate Filter (DPF) 3570
Diesel Particulate Filter 3570
Disassemble 3570
Clean and Inspect 3571
Differential Pressure Pipes and Hoses 3572
Assemble 3572
Diesel Exhaust Fluid System 3573
General 3573
Description and Operation 3573
Selective Catalyst Reducer (SCR) 3577
Remove 3577
Clean and Inspect 3577
Install 3578
DEF Tank 3578
Remove 3578
Clean and Inspect 3580
Install 3580
Cooling System 3581
Description 3581
Hydraulic Filter Assembly Repair 3582
Remove 3582
Install 3584
Fuel and Hydraulic Tanks Repair 3585
Inspect 3585
Clean 3585
Steam Method of Cleaning 3585
Chemical Solution Method of Cleaning 3586
Additional Preparations for Repair 3586
Small Leaks, Repair 3587
Large Leaks, Repair 3587
Preparations for Use After Repair 3587
Safety Labels 3588
550131845 0100YRM1948 (11 2019) US EN 3597
General 3601
Description 3601
Side Covers, Seat, Dash, and Hood Replacement 3602
Side Covers 3602
Remove 3602
Install 3602
Seat and Seat Plate 3603
Remove Seat 3603
Remove Seat Plate 3604
Install Seat Plate 3604
Install Seat 3604
Operator Restraint System 3608
Emergency Locking Retractor (ELR) 3608
Seat Plate and Seat Rail Check 3608
Steering Column, Dash, Kick Panel, and Seal Plate 3608
Remove 3608
Install 3611
Hood Support and Door Assembly 3613
Remove 3613
Install 3613
Hood Door Assembly 3618
Remove 3618
Install 3619
Steering Column 3620
Description 3620
Steering Column Repair 3620
Remove 3620
Disassemble 3621
Clean 3622
Inspect 3623
Assemble 3623
Install 3623
LPG Tank and Bracket Assembly 3623
Counterweight Replacement 3623
Remove 3623
Install 3625
Tow Pin, Remove and Install 3626
Overhead Guard Replacement 3626
Remove 3626
Install 3628
Engine Replacement 3628
Remove Engine 3628
Remove Transmission 3649
Remove Engine and Transmission 3652
Install Engine 3655
Install Transmission 3658
Install Engine and Transmission 3660
Throttle Pedal and Cable Adjustment 3663
Exhaust System Repair 3663
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) 3663
GM 5 7L Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (C909) 3663
Kubota 3 8L Diesel Engine w/DPF 3663
Remove 3665
Inspect 3666
Install 3666
Kubota 3 8L Diesel Engine w/DOC 3666
Remove 3668
Inspect 3669
Install 3669
Kubota 3 6L Diesel Engine for Lift Truck Models GDP60VX, GDP70VX (GDP135VX, GDP155VX) (F878) and GDP60VX, GDP70VX, GP70VXS6 GP70VXS9 (GDP135VX, GDP155VX, GP155VXS) (G878) 3670
Remove 3670
Inspect 3671
Install 3671
Diesel Particulate Filter (DPF) 3672
Diesel Particulate Filter 3672
Disassemble 3673
Clean and Inspect 3673
Differential Pressure Pipes and Hoses 3674
Assemble 3675
Diesel Exhaust Fluid System 3675
General 3675
Description and Operation 3675
Selective Catalyst Reducer (SCR) 3677
Remove 3677
Clean and Inspect 3678
Install 3678
DEF Tank 3679
Remove 3679
Clean and Inspect 3681
Install 3681
Cooling System 3682
Description 3682
Hydraulic Filter Assembly Repair 3682
Remove 3682
Install 3683
Fuel and Hydraulic Tanks Repair 3684
Inspect 3684
Clean 3684
Steam Method of Cleaning 3685
Chemical Solution Method of Cleaning 3685
Additional Preparations for Repair 3685
Small Leaks, Repair 3686
Large Leaks, Repair 3686
Preparations for Use After Repair 3686
Safety Labels 3686
550131847 0600YRM1962 (11 2019) US EN 3695
General 3701
Engine Identification 3701
Major Engine Component Identification 3701
Location of Labels 3701
Cylinder Block Description 3702
Precautions Before Beginning Repair 3703
Exhaust System, SCR, and DPF 3703
Engine Removal and Installation 3704
Cylinder Head Assembly Repair 3704
Valve Covers and Fuel Injectors 3704
Remove 3704
Clean and Inspect 3707
Install 3707
Rocker Arm Assembly 3708
Remove 3708
Disassemble 3709
Clean and Inspect 3709
Push Rods 3709
Rocker Arm Assembly 3709
Assemble 3710
Install 3710
Valve Clearance Adjustments 3710
Cylinder Head Assembly 3712
Remove 3712
Disassemble 3720
Valves and Valve Springs, Remove 3720
Valve Guides, Remove 3721
Clean and Inspect 3721
Cylinder Head 3722
Valve Guides 3722
Valves 3722
Valve Sink 3723
Valve Seat 3723
Valve Springs 3724
Assemble 3724
Valve Guides, Install 3724
Valves and Valve Springs, Install 3725
Install 3726
Timing Gear Case and Timing Gears Repair 3728
Timing Gear Case Cover 3728
Remove 3728
Clean and Inspect 3729
Install 3729
Timing Gears 3730
Crankshaft Gear 3730
Remove 3730
Install 3731
Idler Gear 1 and Idler Gear 2 3731
Remove 3731
Inspect 3732
Install 3733
Idler Gear 3 3733
Remove 3733
Inspect 3733
Install 3733
Camshaft Gear 3733
Remove 3733
Install 3733
Drive Train, Camshaft, and Cylinder Block Repair 3734
Remove 3734
Disassemble 3734
Pistons and Connecting Rods 3734
Crankshaft 3735
Camshaft 3737
Clean and Inspect 3739
Cylinder Block 3739
Honing and Boring 3741
Cylinder Correction (Oversize) 3742
Pistons 3742
Piston Pin 3743
Connecting Rod 3743
Tappets 3744
Crankshaft 3744
Camshaft 3746
Camshaft Bushing 3747
Assemble 3747
Camshaft 3747
Crankshaft 3747
Pistons and Connecting Rods 3748
Install 3750
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 3750
Lubrication System Repair 3753
Engine Oil and Oil Filter Change (Standard Oil Filter) 3753
Engine Oil and Oil Filter Change (Remote Oil Filter) 3754
Oil Pan 3754
Remove 3754
Install 3755
Oil Suction Tube 3755
Remove 3755
Clean 3756
Install 3756
Oil Pump 3756
Remove 3756
Clean and Inspect 3757
Inner Rotor and Outer Rotor Clearance 3757
Outer Rotor and Pump Body Clearance 3758
Rotor and Cover Clearance 3758
Rotor Shaft Clearance 3758
Install 3759
Remote Oil Filter 3759
Remove 3759
Clean and Inspect 3761
Install 3761
Fuel System Repair 3762
Fuel Injectors 3762
Remove 3762
Inspect 3762
Clean 3762
Replace 3762
Install 3763
Test 3763
Fuel Injection Pump 3763
Remove 3763
Clean and Inspect 3766
Install 3767
Cooling System Repair 3768
Serpentine Belt 3768
Remove 3768
Inspect 3768
Install 3768
Adjust 3768
Water Pump 3769
Remove 3769
Install 3770
Thermostat 3771
Remove 3771
Inspect 3772
Install 3772
Flywheel and Flywheel Housing 3774
Flywheel 3774
Remove 3774
Install 3774
Flywheel Housing 3774
Remove 3774
Install 3774
Electrical Equipment Repair 3775
Alternator 3775
Remove 3775
Install 3776
Starter 3777
Remove 3777
Install 3777
Engine Specifications 3779
Engine Data 3779
Engine Tuning 3780
Cylinder Head 3780
Intake/Exhaust Valve and Guide 3781
Valve Spring 3781
Rocker Arm and Shaft 3781
Push Rod 3781
Gear Train and Camshaft 3782
Camshaft 3782
Idle Gear Shaft and Bushing 3782
Backlash of Each Gear 3782
Cylinder Block 3782
Crankshaft 3783
Piston 3783
Piston Ring 3783
Connecting Rod 3784
Rod Small End 3784
Tappet 3784
Oil Pump 3784
Engine Oil Pressure 3784
Inner and Outer Rotor Clearance 3784
Outer Rotor and Pump Body 3784
Rotor and Cover 3785
Standard Torque Specifications 3785
Standard Torque Chart 3785
Special Torque Specifications 3786
Special Tools 3787
550131848 0600YRM1961 (03 2020) US EN 3801
General 3807
Engine Identification 3808
Major Engine Component Identification 3808
Location of Labels 3810
Cylinder Block Description 3811
Precautions Before Beginning Repair 3812
Exhaust System and DPF 3813
Engine Removal and Installation 3813
Cylinder Head Assembly Repair 3813
Valve Covers and Fuel Injectors 3813
Remove 3813
Clean and Inspect 3816
Install 3816
Rocker Arm Assembly 3817
Remove 3817
Disassemble 3817
Clean and Inspect 3818
Push Rods 3818
Rocker Arm Assembly 3818
Assemble 3819
Install 3819
Valve Clearance Adjustments 3819
Cylinder Head Assembly 3820
Remove 3820
Disassemble 3828
Valves and Valve Springs, Remove 3828
Valve Guides, Remove 3829
Clean and Inspect 3829
Cylinder Head 3830
Valve Guides 3830
Valves 3831
Valve Sink 3831
Valve Seat 3831
Valve Springs 3832
Assemble 3832
Valve Guides, Install 3832
Valves and Valve Springs, Install 3833
Install 3834
Timing Gear Case and Timing Gears Repair 3836
Timing Gear Case Cover 3836
Remove 3836
Clean and Inspect 3837
Install 3837
Timing Gears 3838
Crankshaft Gear 3838
Remove 3838
Install 3839
Idler Gear 1 and Idler Gear 2 3839
Remove 3839
Inspect 3840
Install 3841
Idler Gear 3 3841
Remove 3841
Inspect 3841
Install 3841
Camshaft Gear 3841
Remove 3841
Install 3841
Drive Train, Camshaft, and Cylinder Block Repair 3842
Remove 3842
Disassemble 3842
Pistons and Connecting Rods 3842
Crankshaft 3843
Camshaft 3845
Clean and Inspect 3847
Cylinder Block 3847
Honing and Boring 3849
Cylinder Correction (Oversize) 3850
Pistons 3850
Piston Pin 3851
Connecting Rod 3851
Tappets 3852
Crankshaft 3852
Camshaft 3854
Camshaft Bushing 3855
Assemble 3855
Camshaft 3855
Crankshaft 3855
Pistons and Connecting Rods 3856
Install 3858
Angular Deviation Procedure 3858
Lubrication System Repair 3861
Engine Oil and Oil Filter Change 3861
Oil Pan 3862
Remove 3862
Install 3862
Oil Suction Tube 3862
Remove 3862
Clean 3863
Install 3863
Oil Pump 3863
Remove 3863
Clean and Inspect 3864
Inner Rotor and Outer Rotor Clearance 3864
Outer Rotor and Pump Body Clearance 3865
Rotor and Cover Clearance 3865
Rotor Shaft Clearance 3865
Install 3866
Fuel System Repair 3866
Fuel Injectors 3866
Remove 3866
Inspect 3866
Clean 3867
Replace 3867
Install 3867
Test 3867
Fuel Injection Pump 3867
Remove 3867
Clean and Inspect 3870
Install 3870
Cooling System Repair 3871
Serpentine Belt 3871
Remove 3871
Inspect 3871
Install 3871
Adjust 3871
Water Pump 3872
Remove 3872
Install 3874
Thermostat 3874
Remove 3874
Inspect 3875
Install 3875
Flywheel and Flywheel Housing 3876
Flywheel 3876
Remove 3876
Install 3877
Flywheel Housing 3877
Remove 3877
Install 3877
Electrical Equipment Repair 3878
Alternator 3878
Remove 3878
Install 3879
Starter 3880
Remove 3880
Install 3880
Engine Specifications 3882
Engine Data 3882
Engine Tuning 3884
Cylinder Head 3884
Intake/Exhaust Valve and Guide 3885
Valve Spring 3885
Rocker Arm and Shaft 3885
Push Rod 3885
Gear Train and Camshaft 3886
Camshaft 3886
Idle Gear Shaft and Bushing 3886
Backlash of Each Gear 3886
Cylinder Block 3886
Crankshaft 3887
Piston 3887
Piston Ring 3887
Connecting Rod 3888
Rod Small End 3888
Tappet 3888
Oil Pump 3888
Engine Oil Pressure 3888
Inner and Outer Rotor Clearance 3888
Outer Rotor and Pump Body 3888
Rotor and Cover 3889
Standard Torque Specifications 3889
Standard Torque Chart 3889
Special Torque Specifications 3889
Special Tools 3891
550131849 0700YRM1950 (03 2020) US EN 3905
General 3909
Cooling System Checks 3910
Exhaust Leaks Into Cooling System 3910
Water Flow Restrictions in Radiator 3910
Radiator Hoses 3910
Water Pump 3910
Flushing the Cooling System 3911
Cooling System, Clean 3911
Radiator Repair 3912
Remove 3912
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 3912
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 3920
Install 3926
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 3926
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 3927
Fan Assembly Replacement 3929
Remove 3929
Inspect 3934
Install 3934
550131851 1600YRM1952 (03 2020) US EN 3937
General 3941
Steering Axle Assembly Repair 3944
Remove 3944
Disassemble 3945
Clean 3946
Inspect 3946
Assemble 3947
Install 3947
Spindles, Bearings, and Tie Rods Repair 3948
Spindles and Bearings 3948
Remove 3948
Disassemble 3948
Clean 3949
Inspect 3949
Assemble 3949
Install 3950
Tie Rods 3950
Remove 3950
Install 3951
Steering Cylinder Repair 3951
Remove and Disassemble 3951
Clean and Inspect 3951
Assemble and Install 3951
Turn Assist (Lift trucks built after February 2019) 3953
Removal 3953
Instal 3955
Adjustment 3955
Torque Specifications 3956
550131852 2100YRM1953 (03 2020) US EN 3959
General 3965
Safety Procedures When Working Near Mast 3965
Tilt Cylinder Repair 3967
Remove 3967
Disassemble 3970
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3970
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3970
Clean 3971
Inspect 3971
Assemble 3971
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3971
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3972
Install 3973
Tilt Cylinders, Adjust 3974
Tilt Cylinder Leak Check 3976
Lift Cylinder Repair 3977
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3977
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 3980
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 3984
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3989
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 3990
Clean 3991
Inspect 3991
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3991
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3992
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3992
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 3993
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 3993
Free-Lift Cylinder Repair 3994
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3994
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 3997
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 3999
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4000
Clean 4002
Inspect 4002
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4002
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4003
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4003
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4003
Sideshift Cylinder Repair 4004
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4004
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4004
Clean 4005
Inspect 4005
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4005
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4006
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4006
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4007
Clean 4008
Inspect 4008
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4008
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4008
Bolzoni Sideshift Cylinder Repair 4009
Remove 4009
Disassemble 4009
Clean 4010
Inspect 4010
Assemble 4011
Install 4011
Fork Positioner Cylinder Repair 4012
Remove 4012
Disassemble 4014
Clean 4017
Inspect 4017
Assemble 4018
Install 4019
Lift Cylinder Leak Check 4020
Seal Kit Installation 4020
External Installation (Seal and Back-Up Ring) 4020
Internal Installation (Piston Rod Assembly) 4021
Special Tools 4021
Torque Specifications 4022
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 4022
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 4022
550131853 2200YRM1954 (03 2020) US EN 4025
General 4033
Display Switch Cluster 4036
Remove 4036
Install 4038
Direction Control and Turn Signal Levers 4038
Remove 4038
Install 4039
Key Switch 4039
Remove 4039
Install 4040
Display Switch Cluster Panel Bezel and Overlay 4040
Remove 4040
Install 4041
Steering Column Repair 4041
Sensors and Switches 4044
General 4044
Dash and Kick Panel, Remove and Install 4044
Remove 4044
Install 4045
Accelerator Pedal Position Sensor 4045
Remove 4045
Install 4048
Brake Fluid Level Switch 4048
Remove 4048
Install 4049
Service Brake Pedal Position Sensor 4049
Remove 4049
Install 4050
Parking Brake Position Sensor 4050
Remove 4050
Install 4050
Service Brake Pressure Sensor 4051
Remove 4051
Install 4051
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 4052
Remove 4052
Install 4052
Sensor MicroswitchFoot Directional Control 4053
Remove 4053
Install 4055
Low Coolant Level Sensor 4055
Remove 4055
Install 4056
Fuel Level Sensor, Diesel Engines Only 4056
Remove 4056
Install 4057
Seat Sensor (Operator Presence System) 4057
Non-Suspension Seat 4057
Remove 4057
Install 4059
Full Suspension and Swivel Seats 4059
Remove 4059
Install 4059
Hood Shut Off Switch 4060
Remove 4060
Install 4060
Remote Key Switch 4061
Remove 4061
Install 4061
Hydraulic Filter Pressure Switch 4062
Remove 4062
Install 4062
Transmission Speed Sensor 4062
Remove 4062
Install 4063
Transmission Pressure Sensors 4063
Remove 4063
Install 4063
Transmission Temperature Sensor 4064
Remove 4064
Install 4064
Engine Speed Sensor 4064
Remove 4064
Install 4064
Intermediate Speed Sensor 4064
Remove 4064
Install 4064
Return To Set Tilt (Tilt Angle) Sensor 4064
Remove 4064
Install 4065
Rear Horn Button Switch 4065
Remove 4065
Install 4065
Impact Sensor 4066
Remove 4066
Install 4066
Load Weight Sensor 4067
Remove 4067
Install 4067
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 4068
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 4069
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 4069
Air Filter Restriction Switch 4069
Remove 4069
Install 4069
Engine Oil Pressure Sensor 4070
Remove 4070
Install 4070
Engine Speed Sensor 4070
Remove 4070
Install 4070
Engine Coolant Temperature (ECT) Sensor 4071
Remove 4071
Install 4071
Fuel/Water Separator Sensor 4071
Remove 4071
Install 4071
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 4072
Engine Coolant Temperature (ECT) Sensor 4072
Remove 4072
Install 4072
Throttle Position Sensor 4073
Engine Oil Pressure Sensor 4073
Remove 4073
Install 4073
Fuel Shut Off Solenoid 4073
Remove 4073
Install 4074
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) 4074
Intake Air Temperature Sensor 4075
Remove 4075
Install 4075
Boost Sensor 4075
Remove 4075
Install 4075
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 4077
Remove 4077
Install 4078
Engine Coolant Temperature (ECT) Sensor 4078
Remove 4078
Install 4078
Engine Oil Pressure Sensor 4078
Remove 4078
Install 4079
Crankshaft Position Sensor 4079
Remove 4079
Install 4079
Adjust Shim Procedure 4079
Camshaft Position Sensor 4081
Remove 4081
Install 4081
Differential Pressure Sensor 4081
Remove 4081
Install 4082
Oxygen Sensors (Inlet and Outlet) 4082
Remove 4082
Install 4083
Inlet Temperature Sensor 4084
Remove 4084
Install 4084
Mass Air Flow Sensor 4084
Remove 4084
Install 4084
Fuel/Water Separator 4084
Remove 4084
Install 4085
Air Filter Restriction Switch 4085
Remove 4085
Install 4085
Vehicle System Manager (VSM) 4086
General 4086
VSM Replacement 4086
Remove 4086
Install 4086
Programming A New VSM And/Or Display Switch Cluster 4087
Data Transferring 4088
New VSM 4088
New (Blank) Display Switch Cluster 4088
Used (Non-Blank) Display Switch Cluster 4088
PC Service Tool Software 4089
Power Distribution Module (PDM) and Component Parts 4089
Remove 4089
PDM as a Unit 4089
Install 4090
PDM as a Unit 4090
Remove and Install 4090
PDM Component Parts 4090
Transmission Control Unit (TCU) 4091
Remove 4091
Install 4093
Battery 4096
Remove 4096
Install 4096
Lights 4096
Work Lights (Front and Rear) 4096
Halogen Bulb Lights 4096
Remove 4096
Install 4096
LED Lights 4097
Remove 4097
Install 4097
Strobe Light 4097
Remove 4097
Install 4098
LED Tail, Backup, and Brake Lights 4098
Remove 4098
Install 4098
Front Marker/Turn Signal Lights 4099
Replacing Whole Front Marker/Turn Signal Light Assembly 4099
Remove 4099
Install 4099
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 4100
Remove 4100
Install 4100
Electronic-Hydraulic Controls, Before January, 2020 4101
E-Hydraulic Controls – TEST 4101
Mini-Levers 4101
Full Stroke Test 4101
Function Returns to Neutral Test 4101
Push (Override) Button Switch 4101
General 4102
Mini-levers, Remove and Install 4102
Armrest Assembly 4103
Remove 4103
Install 4106
Horn Button 4106
Remove 4106
Install 4106
Direction Control Switch 4106
Remove 4106
Install 4107
Push (Override) Button 4107
Remove 4107
Install 4108
Electronic-Hydraulic Controls, After January, 2020 4109
E-Hydraulic Controls – TEST 4109
Mini-Levers 4109
Full Stroke Test 4109
Function Returns to Neutral Test 4109
Push Button Switch 4109
General 4110
Mini-levers, Remove and Install 4110
Armrest Assembly 4111
Remove 4111
Install 4114
Horn Button 4114
Remove 4114
Install 4114
Direction Control Switch 4114
Remove 4114
Install 4115
Push (Override) Buttons 4115
Remove 4115
Install 4116
Diesel Particulate Filter (DPF) Display 4117
Remove 4117
Clean and Inspect 4118
Install 4118
Special Tools 4119
550131855 4000YRM1956 (03 2020) US EN 4123
Safety Procedures When Working Near Mast 4127
Fork Replacement 4128
General 4128
Remove 4128
Install 4130
Checks 4130
Carriage Repair 4132
Remove 4132
Clean and Inspect 4135
Install 4135
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 4136
Connecting Attachment Hydraulic Quick Disconnect Hoses 4136
Integral Sideshift Carriage And Fork Positioners Repair 4137
Integral Sideshift Carriage 4137
Remove 4137
Disassemble 4138
Clean and Inspect 4140
Assemble 4141
Install 4141
Fork Positioners 4142
Remove 4142
Disassemble 4145
Clean and Inspect 4147
Assemble 4147
Install 4147
Hang-On Sideshift Carriage Repair 4148
Remove 4148
Disassemble Carriage 4150
Clean and Inspect 4153
Assemble 4153
Install 4156
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 4158
Remove 4158
Disassemble 4162
Clean and Inspect 4166
Assemble 4168
Install 4168
Header Hose Installation 4169
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 4172
Remove 4172
Disassemble 4175
Clean and Inspect 4178
Assemble 4180
Install 4180
Header Hose Installation 4181
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 4184
Remove 4184
Disassemble 4187
Clean and Inspect 4190
Assemble 4192
Install 4192
Header Hose Installation 4193
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 4196
Remove 4196
Disassemble 4199
Clean and Inspect 4203
Assemble 4205
Install 4205
Header Hose Installation 4206
Mast Operation Check 4209
Tilt Cylinder Adjustment 4209
Main Lift Cylinder Repair 4210
Lift Chain Adjustment 4210
Mast Adjustments 4211
Load Roller Adjustment 4211
Mast Side Kicking Adjustment 4213
Carriage Adjustment 4213
550131987 8000YRM1959 (09 2020) US EN 4217
General 4223
Serial Number Data 4223
How to Move Disabled Lift Truck 4223
How to Tow Lift Truck 4223
How to Put Lift Truck on Blocks 4224
How to Raise Drive Tires 4224
How to Raise Steering Tires 4225
How to Clean a Lift Truck 4226
Safety Procedures When Working Near Mast 4227
Maintenance Schedule 4229
Maintenance Schedule 4229
Maintenance Procedures Every 8 Hours or Daily 4241
How to Make Checks With Engine Stopped 4241
Tires and Wheels 4241
Safety Labels 4241
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 4241
Operator Restraint System 4242
Emergency Locking Retractor (ELR) 4242
Adjust Seat – Full Suspension 4243
Adjust Seat – Internal Suspension 4244
Seat Plate and Seat Rails 4244
Engine Compartment 4244
Fuel, Oil, and Coolant Leaks, Check 4244
Hydraulic Hoses 4244
Coolant Hoses 4244
Steering Column Gas Cylinder 4245
Transmission 4245
Hydraulic System Oil 4245
Engine Oil 4247
Forks 4249
Inspect 4249
Remove 4250
Install 4251
Adjust 4251
Integral Sideshift Carriage 4252
How to Make Checks With Engine Running 4252
Indicator Lights, Horn, Fuses, and Relays 4252
Service Brakes 4255
Operation, Check 4255
Accumulator Pressure 4255
Parking Brake 4255
Engine Oil Pressure 4255
Cooling System 4256
Steering System 4257
Control Levers and Pedals 4257
Lift System, Operate 4257
Air Filter 4257
Fuel/Water Separator Filter, Cummins and Kubota Diesel Engines 4258
First Service After First 100 Hours of Operation 4259
Engine Oil and Oil Filter 4259
Maintenance Procedures Every 500 Hours or 6 Months 4261
Hydraulic System Oil Check 4261
Hydraulic Tank Breather 4262
Inspect 4262
Battery 4263
Engine Oil and Oil Filter 4264
Fuel/Water Separator Filter Replacement, Cummins QSB 3 3L Diesel Engine 4264
Remove 4265
Install 4265
Final Fuel Filter Replacement, Cummins QSB 3 3L Diesel Engine 4266
Priming The Fuel System, Cummins QSB 3 3L Diesel Engine 4267
Controlled Venting 4267
Manual Bleeding 4267
Fuel/Water Separator Filter Replacement, Kubota 3 8L Diesel Engine 4268
Remove 4268
Install 4268
Priming The Fuel System, Kubota 3 8L Diesel Engine 4269
Drive Belt 4270
Fan and Alternator Drive Belt Inspection 4270
Fan and Alternator Drive Belt Adjustment,Cummins QSB 3 3L Diesel Engine 4271
Clean Debris From Radiator Core 4271
Transmission and Wet Brake Axle Oil Level Check 4272
Wet Brake Center Body Oil Level Check 4273
Forks, Inspect 4275
Mast Lubrication 4276
Header Hose Checks 4279
Lift Chain Lubrication 4279
Tilt Cylinder Lubrication 4281
Brake Actuation Valve Rod End Pin 4283
Tie Rod Lubrication 4284
Low Idle Speed Check 4285
Parking Brake Adjustment 4285
Cab Heater Air Filter 4286
Maintenance Procedures Every 1000 Hours or 6 Months 4288
Lift Chain Lubrication and Wear Check 4288
Integral Sideshift Carriage, Check Sliding Surfaces 4289
Steering Axle Spindle Bearings 4290
Control Levers and Pedals 4291
Inspect Engine Electrical System, Connectors 4291
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 4292
Crankcase Breather Filter, Kubota 3 8L Diesel 4295
Remove 4295
Clean and Inspect 4296
Install 4296
DEF Injector Tip 4296
Maintenance Procedures Every 2000 Hours or Annually 4297
Hydraulic System 4297
Hydraulic Filter Assembly, Replace 4297
Remove 4297
Install 4298
Hydraulic Tank Breather, Replace 4299
Cooling System Check 4300
Air Filter 4302
Fuel Injectors and Fuel System 4303
Forks, Inspect 4303
Check Throttle Shaft for Sticking 4304
Inspect Exhaust Manifold and Piping for Leaks 4304
Transmission Automatic Clutch Calibration 4305
Brake System Accumulator 4305
Valve Clearance, Check and Adjust, Cummins QSB 3 3L Diesel Engine 4305
Oxygen Sensors 4306
Kubota 3 8L Diesel Engine 4306
Wheel Bearings 4306
Steer Wheels, Lubrication 4306
Maintenance Procedures Every 3000 Hours 4307
Diesel Particulate Filter 4307
Remove 4307
Disassemble 4309
Servicing the Diesel Particulate Filter, Pressure Tubes, and Pressure Hoses 4310
Assemble 4310
Install 4311
Diesel Exhaust Fluid (DEF) System 4311
Maintenance Procedures Every 4000 Hours or 2 Years 4313
Hydraulic Oil, Replace 4313
Fuel Filter Water Removal 4314
Lift Chain Adjustments 4316
Jump-Starting the Lift Truck 4317
Jump-Starting Using a Battery Charger 4317
Jump-Starting a Lift Truck Using Another Lift Truck 4317
Welding Repairs 4318
Overhead Guard Changes 4318
Wheel and Tire Replacement 4318
General 4318
Pneumatic Tire With Tube, Repair 4318
Remove Wheels From Lift Truck 4318
Remove Tire From Wheel 4319
Install Wheel in Tire 4322
Install Tire on Two-Piece Wheel 4324
Add Air to Pneumatic Tires With Tube 4325
Install the Wheels 4325
Dual Drive Wheels, Install 4326
Pneumatic Tubeless Tire, Repair 4326
Remove Wheels From Lift Truck 4326
Add Air to Pneumatic Tubeless Tire 4331
Wheels, Install 4331
Solid Rubber Tires on Pneumatic Wheels, Change 4332
Adhesives and Sealants 4335
550131988 8000YRM1960 (09 2020) US EN 4337
Lift Truck Lifting Capacity 4341
Capacities 4341
Counterweight Weights 4343
Electrical System 4344
Engine Specifications 4344
Front End Equipment – Mast Creep 4345
Mast Creep 4345
Hydraulic System Relief Pressures 4346
Mast Speeds 4346
Stall Speeds 4347
Steering System 4347
Tilt Angles 4348
Tire Sizes 4348
Transmission Oil Pressures 4348
Diesel Fuel Cleanliness Levels 4350
Torque Specifications 4351
Frame 4351
Mast, Carriage, and Fork Positioner 4351
Steering System 4351
Transmission 4351
Engine, Cummins QSB 3 3L 4351
Engine, GM 5 7L LPG 4351
Engine – Kubota 3 8L Diesel 4352
550136209 1800YRM1977 (03 2020) US EN 4355
General 4359
Wet Brake System 4359
Parking Brake Repair 4360
Master Cylinder Repair, For 6-8 Ton Lift Trucks 4363
Remove 4363
Disassemble 4364
Clean and Inspect 4365
Assemble 4366
Install and Adjust 4366
Accumulator; For 6-8 Ton Lift Trucks 4367
Pre-Charge Check 4367
Remove 4368
Install 4369
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For 8-9 Ton Lift Trucks 4369
Remove 4369
Modulating Brake Valve 4371
Disassemble 4371
Clean and Inspect 4372
Assemble 4373
Accumulator Charge Valve 4373
Disassemble 4373
Clean and Inspect 4375
Assemble 4375
Install 4376
Pressure Checks 4377
Accumulator Charge Valve Check 4377
Accumulator Check 4377
Brake System Air Removal; For 6-8 Ton Lift Trucks 4378
Using Pressure Bleed System 4378
Using Brake Pedal Pressure 4378
Lift Truck Models with Master Cylinder 4378
Brake System Air Removal for 8-9 Ton Lift Trucks 4379
Using Brake Pedal Pressure 4379
Lift Truck Models with Modulating Brake Valve 4379
Brake Pedal Adjustment 4379
For 6-8 Ton Lift Trucks 4379
For 8-9 Ton Lift Trucks 4380
Free Pedal Adjustment 4382
Torque Specifications 4383
550136209 1800YRM1977 (08 2022) US EN 4385
General 4391
Wet Brake System 4391
Parking Brake Repair 4392
Master Cylinder Repair, For Lift Truck Models F878/G878/H878 4396
Remove 4396
Disassemble 4396
Clean and Inspect 4398
Assemble 4398
Install and Adjust 4398
Accumulator; For Lift Truck Models F878/G878/H878 4400
Pre-Charge Check 4400
Remove 4400
Install 4401
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For Lift Truck Models C909/D909 4402
Remove 4402
Modulating Brake Valve 4403
Disassemble 4403
Clean and Inspect 4404
Assemble 4405
Accumulator Charge Valve 4405
Disassemble 4405
Clean and Inspect 4407
Assemble 4407
Install 4408
Pressure Checks 4409
Accumulator Charge Valve Check 4409
Accumulator Check 4409
Brake System Air Removal; For Lift Truck Models 4410
Using Pressure Bleed System 4410
Using Brake Pedal Pressure 4410
Lift Truck Models with Master Cylinder 4410
Brake System Air Removal for Lift Truck Models C909/D909 4412
Using Brake Pedal Pressure 4412
Lift Truck Models with Modulating Brake Valve 4412
Brake Pedal Adjustment 4412
For Lift Truck Models F878/G878/H878 4412
For Lift Truck Models C909/D909 4413
Free Pedal Adjustment 4415
Torque Specifications 4416
550136214 9000YRM1976 (12 2020) US EN 4419
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 4425
Group 05 – Operational Checkout 4427
SECTION 9020 ENGINE 4433
Group 10 – Principles of Operation 4435
Group 30 – Observed Symptoms 4459
Group 40 – Tests and Adjustments 4467
SECTION 9030 ELECTRICAL SYSTEM 4485
Group 03 – General Maintenance and Diagnostic Data 4491
Group 10 – Principles of Operation 4503
Group 20 – Diagnostic Trouble Codes 4511
SECTION 9080 SUPPLEMENTARY DATA 4667
Group 50 – Abbreviations and Acronyms 4669
Group 60 – Special Tools List 4677
Group 70 – Fault Mode Indicator Reference 4681