Yale Forklift D909 (GDP80VX, GDP80VX9, GDP90VX, GLP80VX, GLP80VX9, GLP90VX Europe) Service Manual

Yale Forklift D909 (GDP80VX, GDP80VX9, GDP90VX, GLP80VX, GLP80VX9, GLP90VX Europe) Service Manual – PDF DOWNLOAD

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Yale Forklift D909 (GDP80VX, GDP80VX9, GDP90VX, GLP80VX, GLP80VX9, GLP90VX Europe) Service Manual – PDF DOWNLOAD

Language : English
Pages : 2714
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift D909 (GDP80VX, GDP80VX9, GDP90VX, GLP80VX, GLP80VX9, GLP90VX 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
524223769 2200YRM1128 (01 2023) US EN 81
Series Code / Model Designation Reference Table 89
General 91
Deutsch Crimping Tool 92
How to Strip a Wire for Use With Deutsch Crimping Tool 92
How to Crimp With the Deutsch Crimping Tool 93
Calibration Test for the Deutsch Crimping Tool 95
Deutsch Connectors 97
DT, DTM, and DTP Series Connectors 97
HD Series Connectors 140
Metri-Pack Connectors 162
Remove and Install 162
Micro-Pack Connectors 165
Weather-Pack Connectors 166
AMPSEAL Crimping Tools 168
AMP Hand Crimping Tool With Certi-Crimp 168
Description 168
Stripping Wire for Use with AMP Hand Crimping Tool 169
Insulation Crimp Adjustment 170
Maintenance and Inspection for AMP Hand Crimping Tool 170
AMP Hand Crimping Tool 170
Crimp Height Inspection 170
How to use AMP Hand Crimping Tool 171
AMP Pro-Crimper II Tool 171
Description 171
Remove and Install Die Set and Locator Assembly 172
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 172
Contact Support Adjustment 173
Crimp Height Adjustment 174
Maintenance and Inspection Procedures 174
PRO-CRIMPER II Tool 174
Crimp Height Inspection 174
How to Use AMP PRO-CRIMPER II Tool 175
AMPSEAL Connector Assemblies 176
Description for Plug Connector Assembly 176
Seal Plug 177
Contact Crimping 177
Description for Plug Connector and Header Assembly 182
Voltage Reading 185
Seal Plug 185
Contact Crimping 185
AMP Superseal 1 5 Crimping Tools 192
Mini Mic Receptacle and Tab Contacts 192
Description 192
Crimping Conditions and Measurements 192
Insertion of Rubber Seal on Cable 194
AMP Hand Application Tool 199
Description 199
Maintenance and Inspection 199
Crimp Height Inspection 199
Crimp Height Adjustment 200
How to Use AMP Hand Application Tool 200
AMP Pro-Crimper II Tool 201
Description 201
Remove and Install Die Set and Locator Assembly 201
Adjustments 202
Contact Support 202
Crimp Height 203
Inspections and Maintenance 204
Crimp Height Inspection 204
Visual Inspection 204
Maintenance 205
How to Use Pro-Crimper II Tool 205
AMP Superseal 1 5 Connector Assemblies 206
Description 206
Repair and Maintenance 213
Panel Mount Option 213
AMP Fastin-Faston Hand Tools 214
Description – AMP Double Action Hand Tool 214
Maintenance and Inspection Procedures 214
Daily Maintenance 214
Periodic Tool Inspection 215
Lubrication 215
Visual Inspection 215
Crimp Height Inspection 215
Certi-Crimp Ratchet Inspection 216
How to Use AMP Double Action Hand Tool 217
Description – AMP Extraction Tool 218
Maintenance and Inspection 219
How to Use AMP Extraction Tool 219
AMP Fastin-Faston Receptacles and Housings 221
Description 221
Wire Repair 229
Wire Splicing Requirements 229
Deutsch Jiffy Splice 230
Twisted/Shielded Cable and Leads Repair 236
Special Tools 238
524223769 2200YRM1128 (07 2020) UK EN 247
Series Code / Model Designation Reference Table 253
General 256
Deutsch Crimping Tool 256
How to Strip a Wire for Use With Deutsch Crimping Tool 256
How to Crimp With the Deutsch Crimping Tool 257
Calibration Test for the Deutsch Crimping Tool 259
Deutsch Connectors 261
DT, DTM, and DTP Series Connectors 261
HD Series Connectors 303
Metri-Pack Connectors 326
Remove and Install 326
Micro-Pack Connectors 328
Weather-Pack Connectors 329
AMPSEAL Crimping Tools 331
AMP Hand Crimping Tool With Certi-Crimp 331
Description 331
Stripping Wire for Use with AMP Hand Crimping Tool 331
Insulation Crimp Adjustment 332
Maintenance and Inspection for AMP Hand Crimping Tool 332
AMP Hand Crimping Tool 332
Crimp Height Inspection 332
How to use AMP Hand Crimping Tool 333
AMP Pro-Crimper II Tool 333
Description 333
Remove and Install Die Set and Locator Assembly 334
Stripping Wire for Use With AMP PRO-CRIMPER II Tool 335
Contact Support Adjustment 335
Crimp Height Adjustment 336
Maintenance and Inspection Procedures 336
PRO-CRIMPER II Tool 336
Crimp Height Inspection 336
How to Use AMP PRO-CRIMPER II Tool 337
AMPSEAL Connector Assemblies 338
Description for Plug Connector Assembly 338
Seal Plug 339
Contact Crimping 339
Description for Plug Connector and Header Assembly 344
Voltage Reading 346
Seal Plug 346
Contact Crimping 346
AMP Superseal 1 5 Crimping Tools 353
Mini Mic Receptacle and Tab Contacts 353
Description 353
Crimping Conditions and Measurements 353
Insertion of Rubber Seal on Cable 355
AMP Hand Application Tool 360
Description 360
Maintenance and Inspection 360
Crimp Height Inspection 360
Crimp Height Adjustment 361
How to Use AMP Hand Application Tool 361
AMP Pro-Crimper II Tool 362
Description 362
Remove and Install Die Set and Locator Assembly 363
Adjustments 363
Contact Support 363
Crimp Height 364
Inspections and Maintenance 365
Crimp Height Inspection 365
Visual Inspection 365
Maintenance 366
How to Use Pro-Crimper II Tool 366
AMP Superseal 1 5 Connector Assemblies 367
Description 367
Repair and Maintenance 374
Panel Mount Option 374
AMP Fastin-Faston Hand Tools 375
Description – AMP Double Action Hand Tool 375
Maintenance and Inspection Procedures 375
Daily Maintenance 375
Periodic Tool Inspection 376
Lubrication 376
Visual Inspection 376
Crimp Height Inspection 376
Certi-Crimp Ratchet Inspection 377
How to Use AMP Double Action Hand Tool 378
Description – AMP Extraction Tool 379
Maintenance and Inspection 379
How to Use AMP Extraction Tool 380
AMP Fastin-Faston Receptacles and Housings 381
Description 381
Wire Repair 388
Wire Splicing Requirements 388
Deutsch Jiffy Splice 389
Twisted/Shielded Cable and Leads Repair 394
Special Tools 397
524223770 2200YRM1130 (03 2020) UK EN 405
General 409
Description 409
Dash Display Menu Access 409
Menu Navigation 410
Standard Display 410
Main Menu 410
Passwords Menu 411
Password Administration 411
Add Password 411
Delete Password 412
Edit Password 412
Other Password Functions 413
Operator Passwords – Enable/Disable 413
Password Time-Out Delay 413
Passwords – Number Wrong to Disable 414
Lockout Reset Password 414
View Password Log 415
View Versions 416
VSM Versions 416
Dash Display Versions 417
Engine Controller Version 418
Transmission (Xmsn) Controller Version 419
Truck Serial Number 420
Diagnostics 421
View Fault Log 421
Set Travel and Braking 422
Speed Limit 422
Acceleration Rate 423
Auto-Deceleration Rate 423
Set Power Reversal Rate 424
Set Inching/Brake Overlap 425
Setup Display Menu 426
Set Operator Language 426
Set Units 427
Set Time Format (12/24 Hour) 427
Set Daylight Saving Time 427
Set Time 430
Set Date Format 431
Set Date 431
Setup Hydraulics 432
Return to Set Tilt Delay/On/Off 432
Setup General Items 433
Light Shutdown Time-Out 433
Impact Sensor – Enable/Disable 434
Impact Sensor – Soft Impact Settings 435
Impact Sensor – Hard Impact Settings 436
Adjust Impact Sensor Settings 436
Initial Adjustment of Soft and Hard Impact Settings 438
Readjustment of Soft and Hard Impact Settings 438
Impact Sensor – Impact Alarm/Shutdown Reset 439
Impact Sensor – Alarm Time Duration and Deactivation 440
Impact Sensor – View Impact Event Log 441
Engine Mode Indicator 442
Generation 1 (ECO-eLo ONLY) 442
Generation 2 443
Operator Checklist 444
Operator Checklist Off-On Mode 444
Edit Operator Checklist 444
Set Operator Checklist Expiration 445
View Checklist Log 445
Clear Operator Checklist Log 446
Clear Operator Checklist Fault 446
Calibrations 447
Set Tilt Stop Point 447
Calibrate Loaded Weight 447
524223771 2200YRM1131 (03 2020) UK EN 449
Series Code / Model Designation Reference Table 455
General 457
Description 457
Dash Display Menu Access 457
Menu Navigation 458
Main Menu 458
Passwords 459
Adding Passwords 459
Hourmeters 461
View Versions 462
VSM Versions 462
Dash Display Versions 463
Engine Controller Version 464
Transmission (Xmsn) Controller Version 465
Truck Serial Number 466
Truck Configuration 467
Diagnostics 468
Clear Fault Log 468
View Fault Log 469
No-Run Data Display 470
Engine Accelerator and Throttle Data Display 470
Engine Speeds and Governor Data Display 471
Engine Fuel and Emissions Data Display 472
Engine General Data Display 474
XMSN/Brake Data Display 475
Hydraulic Data Display 478
General Truck Data Display 480
Set Travel and Braking 481
Speed Limit 481
Acceleration Rate 482
Auto-Deceleration Rate 483
Set Power Reversal Rate 483
Set Inching/Brake Overlap 484
Setup Hydraulics 484
Lift Maximum Speed 485
Lower Maximum Speed 485
Tilt Maximum Speed 486
Auxiliary Function One, Direction A, Maximum Speed 488
Auxiliary Function One, Direction B, Maximum Speed 490
Auxiliary Function Two, Direction A, Maximum Speed 490
Auxiliary Function Two, Direction B, Maximum Speed 491
Auxiliary Function Three, Direction A, Maximum Speed 492
Auxiliary Function Three, Direction B, Maximum Speed 492
Lift/Lower Ramp Rate 493
Hydraulic Auxiliary Ramp Rate 493
Return to Set Tilt Delay/On/Off 494
Hydraulic Input Device 495
Auxiliary Solenoid 495
Dual Function 496
Setup Display 497
Set Service Language 497
Setup General Items 497
Motion Alarm Activation Type 498
Light Shutdown Time-Out 499
Restore Default Settings 499
Restore Engine Controller Default Calibration 500
Impact Sensor – Enable/Disable 500
Impact Sensor – Soft Impact Settings 501
Impact Sensor – Hard Impact Settings 502
Adjust Impact Sensor Settings 503
Initial Adjustment of Soft and Hard Impact Settings 505
Readjustment of Soft and Hard Impact Settings 505
Impact Sensor – Impact Alarm/Shutdown Reset 506
Impact Sensor – Alarm Time Duration and Deactivation 507
Impact Sensor – View Impact Event Log 508
Engine Mode Indicator 508
Generation 1 (ECO-eLo ONLY) 508
Generation 2 509
Diesel Particulate Filter (DPF) Display 510
General Description 510
Passive Regeneration Only 510
Regeneration Level 0 510
Auto/Active Regeneration Inhibited 511
Auto/Active Regeneration 511
Regeneration Level 1 511
Parked Regeneration Request 512
Regeneration Level 2 512
Warning Level 512
Regeneration Level 3 512
Service Level 513
Regeneration Level 4 513
Display, Diesel Particulate Filter (DPF), Revised 513
Operator Interface 513
Refer to Operator Manual 513
CAN Communication Lost 514
Passive Regeneration Only 514
Regeneration Level 0 514
Auto/Active Regeneration Inhibited 514
Auto/Active Regeneration 515
Regeneration Level 1 515
Idle-up Auto/Active Regeneration 515
Parked Regeneration Request 515
Regeneration Level 2 515
Warning Level 517
Regeneration Level 3 517
Service Level 517
Regeneration Level 4 517
Diesel Particulate Filter (DPF) Display 2-3 5T ICE Stage V 517
Display, Diesel Particulate Filter (DPF), Stage V Engine 517
Operator Interface 518
Refer to Operator Manual 518
CAN Communication Lost 518
Passive Regeneration Only 518
Regeneration Level 0 518
Auto/Active Regeneration Inhibited 519
Auto/Active Regeneration 519
Regeneration Level 1 519
Idle-up Auto/Active Regeneration 520
Parked Regeneration Request 520
Regeneration Level 2 520
Warning Level 521
Regeneration Level 3 521
Service Level 522
Regeneration Level 4 522
Stage V Content 522
Emissions System Malfunction 522
Ash Load 522
Diesel Particulate Filter (DPF) Display with Diesel Exhaust Fluid (DEF) 523
Operator Interface 523
Refer to Operator Manual 523
CAN Communication Lost 524
Passive Regeneration Only 524
Regeneration Level 0 524
Auto/Active Regeneration Inhibited 524
Auto/Active Regeneration 525
Regeneration Level 1 525
Idle-up Auto/Active Regeneration 525
Parked Regeneration Request 525
Regeneration Level 2 525
Warning Level 527
Regeneration Level 3 527
Service Level 527
Regeneration Level 4 527
Calibrations 528
Calibrate Transmission Valve 530
Set Tilt Stop Point 530
Calibrate Loaded Weight 530
Calibrate Travel Speed Sensor 531
Calibrate Mazda LP and Gas Accelerator Pedal 531
524223780 8000YRM1134 (03 2020) UK EN 533
Series Code / Model Designation Reference Table 539
Description 541
Proc_Cal_001: Service Password Entry 543
When to Perform 543
Why Perform 543
How to Perform 543
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 544
When to Perform 544
Calibration Order 544
Why Perform 544
How to Perform 545
Proc_Cal_003: Save and Exit 546
When to Perform 546
Why Perform 546
How to Perform 546
Proc_Cal_004: Lift Valve Output Threshold 547
When to Perform 547
Calibration Order 547
Why Perform 547
How to Perform 548
Proc_Cal_005: Lower Valve Output Threshold 550
When to Perform 550
Calibration Order 550
Why Perform 550
How to Perform 550
Proc_Cal_006: Tilt Back Valve Output Threshold 553
When to Perform 553
Calibration Order 553
Why Perform 553
How to Perform 553
Proc_Cal_007: Tilt Forward Valve Output Threshold 556
When to Perform 556
Calibration Order 556
Why Perform 556
How to Perform 556
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 559
When to Perform 559
Calibration Order 559
Why Perform 559
How to Perform 559
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 562
When to Perform 562
Calibration Order 562
Why Perform 562
How to Perform 562
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 565
When to Perform 565
Calibration Order 565
Why Perform 565
How to Perform 565
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 568
When to Perform 568
Calibration Order 568
Why Perform 568
How to Perform 568
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 571
When to Perform 571
Calibration Order 571
Why Perform 571
How to Perform 571
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 574
When to Perform 574
Calibration Order 574
Why Perform 574
How to Perform 574
Proc_Cal_014: Load Weight Zero Point 578
When to Perform 578
Calibration Order 578
Why Perform 578
How to Perform 578
Proc_Cal_015: Loaded Weight Calibration 580
When to Perform 580
Calibration Order 580
Why Perform 580
How to Perform 580
Proc_Cal_016: Transmission Valve Calibration 583
Applicable System/Option 583
When to Perform 583
Calibration Order 583
Why Perform 583
How to Perform 583
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 585
Applicable System/Option 585
When to Perform 585
Calibration Order 585
Why Perform 585
How to Perform 585
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 587
Applicable System/Option 587
When to Perform 587
Calibration Order 587
Why Perform 587
How to Perform 588
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 589
Required Tools 589
When to Perform 589
Calibration Order 589
Why Perform 590
How to Perform 590
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 591
When to Perform 591
Why Perform 591
How to Perform 591
Proc_Cal_026: Travel Speed Calibration 593
When to Perform 593
Calibration Order 593
Why Perform 593
How to Perform 593
524223780 8000YRM1134 (05 2022) US EN 597
Series Code / Model Designation Reference Table 603
Description 606
Proc_Cal_001: Service Password Entry 608
When to Perform 608
Why Perform 608
How to Perform 608
Proc_Cal_002: Hydraulic Valve Calibration Warm Up and Air Bleed 609
When to Perform 609
Calibration Order 609
Why Perform 609
How to Perform 609
Proc_Cal_003: Save and Exit 611
When to Perform 611
Why Perform 611
How to Perform 611
Proc_Cal_004: Lift Valve Output Threshold 612
When to Perform 612
Calibration Order 612
Why Perform 612
How to Perform 612
Proc_Cal_005: Lower Valve Output Threshold 615
When to Perform 615
Calibration Order 615
Why Perform 615
How to Perform 615
Proc_Cal_006: Tilt Back Valve Output Threshold 618
When to Perform 618
Calibration Order 618
Why Perform 618
How to Perform 618
Proc_Cal_007: Tilt Forward Valve Output Threshold 621
When to Perform 621
Calibration Order 621
Why Perform 621
How to Perform 621
Proc_Cal_008: Aux 1 Dir A Valve Output Threshold 624
When to Perform 624
Calibration Order 624
Why Perform 624
How to Perform 624
Proc_Cal_009: Aux 1 Dir B Valve Output Threshold 627
When to Perform 627
Calibration Order 627
Why Perform 627
How to Perform 627
Proc_Cal_010: Aux 2 Dir A Valve Output Threshold 630
When to Perform 630
Calibration Order 630
Why Perform 630
How to Perform 630
Proc_Cal_011: Aux 2 Dir B Valve Output Threshold 633
When to Perform 633
Calibration Order 633
Why Perform 633
How to Perform 633
Proc_Cal_012: Aux 3 Dir A Valve Output Threshold 636
When to Perform 636
Calibration Order 636
Why Perform 636
How to Perform 636
Proc_Cal_013: Aux 3 Dir B Valve Output Threshold 639
When to Perform 639
Calibration Order 639
Why Perform 639
How to Perform 639
Proc_Cal_014: Load Weight Zero Point 642
When to Perform 642
Calibration Order 642
Why Perform 642
How to Perform 642
Proc_Cal_015: Loaded Weight Calibration 644
When to Perform 644
Calibration Order 644
Why Perform 644
How to Perform 644
Proc_Cal_016: Transmission Valve Calibration 647
Applicable System/Option 647
When to Perform 647
Calibration Order 647
Why Perform 647
How to Perform 647
Proc_Cal_016A: Transmission Valve Calibration-Electronic Extended Function 649
Applicable System/Option 649
When to Perform 649
Calibration Order 649
Why Perform 649
How to Perform 649
Proc_Cal_016B: Trans Valve Calibration-Electronic and Electronic Extended Function 652
Applicable System/Option 652
When to Perform 652
Calibration Order 652
Why Perform 652
How to Perform 652
Proc_Cal_019: Mazda LP and Gas Accelerator Pedal Adjustment 655
Required Tools 655
When to Perform 655
Calibration Order 655
Why Perform 655
How to Perform 655
Proc_Cal_025: Hydraulic Valve Pressure Gage Installation 657
When to Perform 657
Why Perform 657
How to Perform 657
Proc_Cal_026: Travel Speed Calibration 659
When to Perform 659
Calibration Order 659
Why Perform 659
How to Perform 659
524288194 1300YRM1317 (03 2020) UK EN 663
Transmission Repair 667
Remove 667
Torque Converter, Remove 667
Disassemble 668
Clean and Inspect 717
Housings 717
Oil Seals and Gaskets 717
Bearings 717
Gears and Shafts 718
Assemble 718
Torque Converter, Install 759
Install 760
Control Valve Repair 761
Remove 761
Disassemble 761
Clean 763
Inspect 763
Assemble 763
Install 764
Torque Specification 765
524296605 1400YRM1344 (03 2020) UK EN 767
General 771
Identification Plate 771
Drive Axle Removal 771
Planetary Reduction Gear Repair 783
Clean and Inspect 793
Brake Repair 802
Clean and Inspect 815
Wet Brake Noise Reduction 825
General 825
Adding Additive To Transmission 826
Differential Repair 827
Clean and Inspect 838
Bevel Pinion 850
Clean and Inspect 854
Drive Axle Installation 864
Special Tools 875
Torque Specifications 876
550021072 0600YRM1432 (03 2020) UK EN 879
General 885
Engine Removal and Installation 885
Cylinder Head Repair 885
Intake Manifold 885
Remove 885
Clean and Inspect 886
Install 886
Cylinder Head 887
Remove and Disassemble 887
Clean and Inspect 889
Valve Guides and Seats Repairs 891
Valves Repair 891
Valve Seats Repair 892
Valve Springs 893
Assemble and Install 893
Engine Block Cleaning and Inspection 895
Piston Bore Preparation 897
Lubrication System Repair 897
Oil Pan Removal 897
Oil Pump Assembly 898
Oil Pump, Removal 898
Oil Pump, Disassemble 898
Oil Pump, Assemble 898
Oil Pump, Install 899
Clean and Inspect 900
Oil Pan, Install 900
Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters 902
Timing Cover 902
Remove 902
Install 903
Timing Sprockets 903
Remove 903
Install 904
Camshaft 904
Remove 904
Inspect 905
Install 905
Clean and Inspect 906
Valve Lifters 906
Remove 906
Clean and Inspect 907
Install 908
Crankshaft Repair 909
Crankshaft 909
Remove 909
Inspect and Repair 910
Main Bearings and Journals Clearance Check 911
Install 911
Piston and Connecting Rod Assembles 912
Connecting Rod Bearings, Replace 912
Piston and Connecting Rod Assemblies, Remove 913
Disassemble 914
Piston, Clean and Inspect 914
Cylinder Bores, Inspect and Repair 914
Piston Rings 915
Assemble 916
Piston and Connecting Rod Assemblies, Install 917
Flywheel and Flywheel Housing Repair 918
Flywheel, Remove 918
Clean 918
Inspect 918
Flywheel, Install 919
Coolant System Repair 919
Water Pump 919
Remove 919
Clean and Inspect 920
Install 920
Serpentine Belt 921
Remove 921
Inspect 921
Install 922
Thermostat 922
Remove 922
Thermostat Operation Check 922
Install 923
Fan Assembly Replacement 923
Remove 923
Inspect 925
Install 925
Ignition System 925
Spark Plug Wire Inspection 925
Spark Plug Wire Replacement 925
Remove 925
Install 926
Spark Plug Replacement 927
Remove 927
Install 927
Spark Plug Inspection 928
Usage 928
Inspect 928
Visual Inspection 929
Alternator Repair 930
Remove 930
Install 930
Starter Repair 930
Remove 930
Install 931
Compression Check 931
Valve Clearance Adjustments 931
Engine Specifications 933
Engine Data 933
Cylinder Head 933
Camshaft 933
Cylinder Bore 933
Piston 934
Piston Pin 934
Crankshaft 934
Connecting Rods 934
Balance Shaft 934
Cooling System 935
Lubrication System 935
Torque Specifications for Capscrews and Bolts 935
550021077 0900YRM1433 (03 2020) UK EN 939
General 943
LPG Tank and Bracket 943
LPG Tank 943
Remove 943
Install 946
LPG Tank Bracket 946
Remove 946
Install 946
LPG Tank Bracket Alignment Pin 947
Remove 947
Install 947
Fuel Filter Unit 948
Fuel Filter Element 948
Remove 948
Clean and Inspect 948
Install 948
Fuel Filter Housing 949
Remove 949
Disassemble 951
Clean and Inspect 951
Assemble 952
Install 952
Electronic Throttle Body 953
Remove 953
Install 954
Fuel Mixer/Electronic Pressure Regulator (EPR) 955
Remove 955
Install 956
Control System 957
Engine Control Unit (ECU) 957
Remove 957
Install 958
Low Pressure Switch 958
Remove 958
Install 958
Low Fuel Sensor 959
Remove 959
Install 959
LP Converter 960
Remove 960
Disassemble 961
Assemble 962
Install 963
Lock-Off Valve 964
Remove 964
Install 964
Exhaust System 965
Counterweight Exhaust 965
Remove and Disassemble 965
Inspect 966
Assemble and Install 967
Exhaust Manifold 967
Remove 967
Install 969
Positive Crankcase Ventilation (PCV) Valve 969
Remove 969
Inspect 970
Install 971
Oxygen Sensors 971
Remove 971
Install 971
LPG Fuel Testing 972
General 972
Available Fuel Tests 972
Composition Test (ASTM D-2163) 972
Ammonia Test (ASTM D-4490) 972
Basic Nitrogen Test (ASTM UOP269-90) 972
Residues Test (ASTM D-2158) 972
Vapor Pressure Test (ASTM D-2598) 972
Sulfur Compounds Test (ASTM D-5623) 972
Methanol Test (ASTM D-4864) 973
Copper Corrosion (ASTM D-1838) 973
Where To Send LPG Fuel Samples For Testing 973
550073240 1900YRM1620 (01 2023) US EN 975
Proper Flushing after Major Hydraulic Repairs 981
Introduction 981
The Phases of Wear 981
Causes of Hydraulic System Failure 981
Progression of Contaminant Caused Hydraulic System Failure 982
Hydraulic System Flushing Techniques 982
Double Oil and Filter Change 982
Mechanical Cleaning 983
Cleaning of Components 983
How to Clean Tubes and Hoses 983
Filter Caddy 983
Start-Up Procedure for Cleaned System 984
Contaminated Oil Coolers 984
Additional Filter Caddy Functions 985
How to Handle Different Fluids 985
Water Removal Filters 985
Fluid Conditioning and System Flushing Procedures 986
Operation of the Filter Caddy 986
Filter Caddy operation 986
Fluid Conditioning Procedure 986
Filter Caddy Start-Up 987
System Flushing Procedure 987
Component Cleaning Procedure 988
Reservoir Cleaning Procedure 988
Cylinder Cleaning Procedure 988
Hose and Tube Cleaning Procedure 988
Valve Cleaning Procedure 989
Front-End Attachment Cleaning Procedure 990
System Flushing Procedure 990
Filter Caddy Start-Up 991
System Start-Up and Flushing 991
Reservoir Fluid Cleaning Times 992
Dealing With Different Fluid Types 993
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 993
Filter Caddy Maintenance 993
Servicing the Strainer 993
DC Motor 993
Hydraulic Oil Sampling Method and Procedure 994
Hydraulic Oil Sampling Method 994
Objective 994
General Guidelines 994
Synopsis 995
Hydraulic Oil Analysis Report Guidelines 996
Sampling Conditions 996
Equipment 996
Sampling Procedure 997
Hydraulic Oil Sampling 997
Sample Labeling 997
Results Documentation 997
550073240 1900YRM1620 (03 2020) UK EN 999
Proper Flushing after Major Hydraulic Repairs 1003
Introduction 1003
The Phases of Wear 1003
Causes of Hydraulic System Failure 1003
Progression of Contaminant Caused Hydraulic System Failure 1004
Hydraulic System Flushing Techniques 1004
Double Oil and Filter Change 1004
Mechanical Cleaning 1005
Cleaning of Components 1005
How to Clean Tubes and Hoses 1005
Filter Caddy 1005
Start-Up Procedure for Cleaned System 1006
Contaminated Oil Coolers 1006
Additional Filter Caddy Functions 1006
How to Handle Different Fluids 1006
Water Removal Filters 1007
Fluid Conditioning and System Flushing Procedures 1007
Operation of the Filter Caddy 1007
Filter Caddy operation 1007
Fluid Conditioning Procedure 1008
Filter Caddy Start-Up 1008
System Flushing Procedure 1009
Component Cleaning Procedure 1009
Reservoir Cleaning Procedure 1009
Cylinder Cleaning Procedure 1009
Hose and Tube Cleaning Procedure 1010
Valve Cleaning Procedure 1010
Front-End Attachment Cleaning Procedure 1011
System Flushing Procedure 1011
Filter Caddy Start-Up 1012
System Start-Up and Flushing 1012
Reservoir Fluid Cleaning Times 1013
Dealing With Different Fluid Types 1013
Cleaning Procedure After Switching Fluids (Cross Contamination Flushing) 1013
Filter Caddy Maintenance 1014
Servicing the Strainer 1014
DC Motor 1014
Hydraulic Oil Sampling Method and Procedure 1014
Hydraulic Oil Sampling Method 1014
Objective 1014
General Guidelines 1014
Synopsis 1015
Hydraulic Oil Analysis Report Guidelines 1016
Sampling Conditions 1017
Equipment 1017
Sampling Procedure 1017
Hydraulic Oil Sampling 1017
Sample Labeling 1018
Results Documentation 1018
550118414 1900YRM1897 (03 2020) UK EN 1021
Series Code / Model Designation Reference Table 1025
General 1025
Hydraulic Gear Pump Assembly Repair 1027
Remove 1027
Disassemble 1029
Clean 1031
Inspect 1031
Assemble 1031
Install 1031
Hydraulic Gear Pump Specifications 1033
Variable Displacement Pump Repair 1034
Remove 1034
Disassemble 1037
Clean 1039
Inspect 1039
Assemble 1039
Install 1039
Variable Displacement Pump Checks and Adjustments 1041
Margin Pressure Check 1041
Flow Compensator Adjustment 1042
Pressure Compensator Adjustment 1042
Variable Displacement Pump Specifications 1043
Torque Specifications 1044
Hydraulic Gear Pump 1044
Variable Displacement Pump 1044
550118415 2000YRM1898 (03 2020) UK EN 1047
Series Code / Model Designation Reference Table 1051
General 1052
Electro-Hydraulic Main Control Valve 1052
Description 1052
Remove 1058
Electro-Hydraulic Control Valve Sections 1061
General 1061
Outlet Control Valve Section 1061
Remove 1061
Disassemble 1061
Clean 1064
Inspect 1064
Assemble 1064
Install 1065
Auxiliary Control Valve Sections 1065
Remove 1065
Disassemble 1067
Clean 1067
Inspect 1068
Assemble 1068
Install 1069
Tilt Control Valve Section 1069
Remove 1069
Disassemble 1069
Clean 1070
Inspect 1070
Assemble 1071
Install 1071
Lift/Lower Control Valve Section 1071
Remove 1071
Disassemble 1071
Clean 1073
Inspect 1073
Assemble 1073
Install 1073
Transition Section 1073
Remove 1073
Disassemble 1074
Clean 1074
Inspect 1074
Assemble 1075
Install 1075
Install 1075
Manual Main Control Valve 1077
Description 1077
Remove 1079
OPS Solenoid Assembly 1083
General 1083
Remove 1084
Clean and Inspect 1086
Install 1086
Manual Control Valve Sections 1087
General 1087
Outlet Control Valve Section 1087
Remove 1087
Disassemble 1087
Clean 1089
Inspect 1089
Assemble 1089
Install 1089
Auxiliary Control Valve Sections 1090
Remove 1090
Disassemble 1090
Clean 1092
Inspect 1092
Assemble 1092
Install 1092
Lift/Tilt Control Valve Section 1093
Remove 1093
Disassemble 1093
Clean 1095
Inspect 1096
Assemble 1096
Install 1097
Install 1097
Pressure Relief Valve Check and Adjustment 1100
Primary Relief Valve 1100
Secondary Relief Valve 1101
Steering Control Unit Repair 1104
Steering Control Unit, Remove 1104
Steering Control Unit, Disassemble 1105
Steering Control Unit, Clean 1107
Steering Control Unit, Inspect 1107
Steering Control Unit, Assemble 1107
Relief Valve, Disassemble 1108
Relief Valve, Clean 1108
Relief Valve, Inspect 1109
Relief Valve, Assemble 1109
Steering Control Unit, Install 1109
550118420 8000YRM1904 (05 2022) US EN 1113
General Information About Diagrams and Schematics 1119
Symbol Definitions 1119
Diagrams Manual Applications 1120
Diagrams and Schematics 1122
550118420 8000YRM1904 (10 2020) UK EN 1231
General Information About Diagrams and Schematics 1235
Symbol Definitions 1236
Diagrams Manual Applications 1237
Diagrams and Schematics 1239
550118555 0100YRM1892 (03 2020) UK EN 1349
General 1355
Cab Replacement for 4-5 5 Ton Lift Trucks 1355
Remove 1355
Install 1366
Cab Replacement for 6-9 Ton Lift Trucks 1368
Remove 1368
Door Assemblies for 4-5 5 Ton Lift Trucks 1374
Right Side Door Assembly 1374
Remove 1374
Disassemble 1378
Door Cover With Heater Unit 1378
Door Cover With Air Conditioner/Heater Unit 1380
Heater Assembly 1382
Air Conditioner and Heater Unit Assembly 1382
Door Lock Assembly 1383
Windows 1385
Clean 1385
Inspect 1385
Assemble 1385
Windows 1385
Door Lock Assembly 1385
Heater Assembly 1385
Air Conditioner and Heater Unit Assembly 1386
Door Cover With Heater Unit 1386
Door Cover With Air Conditioner and Heater Unit 1386
Install 1386
Left Side Door Assembly 1387
Remove 1387
Disassemble 1387
Door Cover 1387
Door Lock Assembly 1387
Windows 1388
Clean 1388
Inspect 1388
Assemble 1388
Windows 1388
Door Lock Assembly 1388
Door Cover 1388
Install 1388
Door Assemblies for 6-9 Ton Lift Trucks 1389
Right and Left Side Door Assemblies 1389
Remove 1389
Disassemble 1389
Door Cover 1389
Door Lock Assembly 1390
Windows 1392
Clean 1392
Inspect 1392
Assemble 1392
Windows 1392
Door Lock Assembly 1392
Door Cover 1393
Install 1393
Window Replacement 1393
General 1393
Remove Door Windows for 4-5 5 Ton Lift Trucks 1393
Install Door Windows for 4-5 5 Ton Lift Trucks 1395
Remove Door Windows for 6-9 Ton Lift Trucks 1395
Install Door Windows for 6-9 Ton Lift Trucks 1397
Window Wipers Replacement 1397
General 1397
Front Wiper Assembly and Motor 1397
Remove 1397
Install 1399
Rear Wiper Assembly and Motor 1399
Remove, for 4-5 5 Ton Lift Trucks 1399
Install for 4-5 5 Ton Lift Trucks 1402
Remove for 6-9 Ton Lift Trucks 1402
Install for 6-9 Ton Lift Truck 1404
Heater Replacement 1405
Remove for 6-9 Ton Lift Trucks 1405
Install for 6-9 Ton Lift Trucks 1410
Heater and Air Conditioner Assembly 1411
Air Conditioner Condenser Unit 1411
Remove 1411
Install 1413
Air Conditioner Receiver/Drier Unit 1413
Remove 1413
Install 1415
Air Conditioner Compressor 1415
Light Replacement 1416
Work Lights (Front and Rear) 1416
Remove 1416
Install 1418
Strobe Light 1418
Remove 1418
Install 1419
Turn, Stop, Tail, and Backup Light 1419
Remove 1419
Install 1420
Front Marker/Turn Signal Lights 1420
Remove 1420
Install 1420
Display Switches 1421
Electrical Schematics 1423
Optional Equipment 1424
Heavy Duty Pre-Cleaner 1424
Fan 1424
Remove 1424
Install 1426
Mirror 1426
Remove 1426
Install 1426
Rear View Camera 1426
Monitor Removal 1426
Monitor Install 1428
Camera removal 1428
Camera install 1428
Label Replacement 1428
550131848 0600YRM1961 (03 2020) UK EN 1431
General 1437
Engine Identification 1438
Major Engine Component Identification 1438
Location of Labels 1440
Cylinder Block Description 1441
Precautions Before Beginning Repair 1442
Exhaust System and DPF 1443
Engine Removal and Installation 1443
Cylinder Head Assembly Repair 1443
Valve Covers and Fuel Injectors 1443
Remove 1443
Clean and Inspect 1446
Install 1446
Rocker Arm Assembly 1447
Remove 1447
Disassemble 1447
Clean and Inspect 1448
Push Rods 1448
Rocker Arm Assembly 1448
Assemble 1449
Install 1449
Valve Clearance Adjustments 1449
Cylinder Head Assembly 1450
Remove 1450
Disassemble 1458
Valves and Valve Springs, Remove 1458
Valve Guides, Remove 1459
Clean and Inspect 1459
Cylinder Head 1460
Valve Guides 1460
Valves 1461
Valve Sink 1461
Valve Seat 1461
Valve Springs 1462
Assemble 1462
Valve Guides, Install 1462
Valves and Valve Springs, Install 1463
Install 1464
Timing Gear Case and Timing Gears Repair 1466
Timing Gear Case Cover 1466
Remove 1466
Clean and Inspect 1467
Install 1467
Timing Gears 1468
Crankshaft Gear 1468
Remove 1468
Install 1469
Idler Gear 1 and Idler Gear 2 1469
Remove 1469
Inspect 1470
Install 1471
Idler Gear 3 1471
Remove 1471
Inspect 1471
Install 1471
Camshaft Gear 1471
Remove 1471
Install 1471
Drive Train, Camshaft, and Cylinder Block Repair 1472
Remove 1472
Disassemble 1472
Pistons and Connecting Rods 1472
Crankshaft 1473
Camshaft 1475
Clean and Inspect 1477
Cylinder Block 1477
Honing and Boring 1479
Cylinder Correction (Oversize) 1480
Pistons 1480
Piston Pin 1481
Connecting Rod 1481
Tappets 1482
Crankshaft 1482
Camshaft 1484
Camshaft Bushing 1485
Assemble 1485
Camshaft 1485
Crankshaft 1485
Pistons and Connecting Rods 1486
Install 1488
Angular Deviation Procedure 1488
Lubrication System Repair 1491
Engine Oil and Oil Filter Change 1491
Oil Pan 1492
Remove 1492
Install 1492
Oil Suction Tube 1492
Remove 1492
Clean 1493
Install 1493
Oil Pump 1493
Remove 1493
Clean and Inspect 1494
Inner Rotor and Outer Rotor Clearance 1494
Outer Rotor and Pump Body Clearance 1495
Rotor and Cover Clearance 1495
Rotor Shaft Clearance 1495
Install 1496
Fuel System Repair 1496
Fuel Injectors 1496
Remove 1496
Inspect 1496
Clean 1497
Replace 1497
Install 1497
Test 1497
Fuel Injection Pump 1497
Remove 1497
Clean and Inspect 1500
Install 1500
Cooling System Repair 1501
Serpentine Belt 1501
Remove 1501
Inspect 1501
Install 1501
Adjust 1501
Water Pump 1502
Remove 1502
Install 1504
Thermostat 1504
Remove 1504
Inspect 1505
Install 1505
Flywheel and Flywheel Housing 1506
Flywheel 1506
Remove 1506
Install 1507
Flywheel Housing 1507
Remove 1507
Install 1507
Electrical Equipment Repair 1508
Alternator 1508
Remove 1508
Install 1509
Starter 1510
Remove 1510
Install 1510
Engine Specifications 1512
Engine Data 1512
Engine Tuning 1514
Cylinder Head 1514
Intake/Exhaust Valve and Guide 1515
Valve Spring 1515
Rocker Arm and Shaft 1515
Push Rod 1515
Gear Train and Camshaft 1516
Camshaft 1516
Idle Gear Shaft and Bushing 1516
Backlash of Each Gear 1516
Cylinder Block 1516
Crankshaft 1517
Piston 1517
Piston Ring 1517
Connecting Rod 1518
Rod Small End 1518
Tappet 1518
Oil Pump 1518
Engine Oil Pressure 1518
Inner and Outer Rotor Clearance 1518
Outer Rotor and Pump Body 1518
Rotor and Cover 1519
Standard Torque Specifications 1519
Standard Torque Chart 1519
Special Torque Specifications 1519
Special Tools 1521
550131849 0700YRM1950 (03 2020) UK EN 1535
General 1539
Cooling System Checks 1540
Exhaust Leaks Into Cooling System 1540
Water Flow Restrictions in Radiator 1540
Radiator Hoses 1540
Water Pump 1540
Flushing the Cooling System 1541
Cooling System, Clean 1541
Radiator Repair 1542
Remove 1542
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 1542
Lift Truck Model GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1550
Install 1556
Lift Truck Models GDP60-70VX(GDP135-155VX) (F878) and GDP60VX, GDP70VX,GP70VXS6, GP70VXS9 (GDP135VX GDP155VX,GP155VXS) (G878) 1556
Lift Truck Models GLC/GDP80VX,GLP/GDP80VX9, GLC/GDP90VX (GLC/GDP170VX,GLP/GDP175VX36, GLC/GDP190VX) (C909, D909) 1557
Fan Assembly Replacement 1559
Remove 1559
Inspect 1564
Install 1564
550131851 1600YRM1952 (03 2020) UK EN 1567
General 1571
Steering Axle Assembly Repair 1574
Remove 1574
Disassemble 1575
Clean 1576
Inspect 1576
Assemble 1577
Install 1577
Spindles, Bearings, and Tie Rods Repair 1578
Spindles and Bearings 1578
Remove 1578
Disassemble 1578
Clean 1579
Inspect 1579
Assemble 1579
Install 1580
Tie Rods 1580
Remove 1580
Install 1581
Steering Cylinder Repair 1581
Remove and Disassemble 1581
Clean and Inspect 1581
Assemble and Install 1581
Turn Assist (Lift trucks built after February 2019) 1583
Removal 1583
Instal 1585
Adjustment 1585
Torque Specifications 1586
550131852 2100YRM1953 (03 2020) UK EN 1589
General 1595
Safety Procedures When Working Near Mast 1595
Tilt Cylinder Repair 1597
Remove 1597
Disassemble 1600
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1600
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1600
Clean 1601
Inspect 1601
Assemble 1601
Cylinders for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1601
Cylinders for Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1602
Install 1603
Tilt Cylinders, Adjust 1604
Tilt Cylinder Leak Check 1606
Lift Cylinder Repair 1607
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1607
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1610
Remove, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1614
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1619
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909)) 1620
Clean 1621
Inspect 1621
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1621
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1622
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1622
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) 1623
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (D909) 1623
Free-Lift Cylinder Repair 1624
Remove, Lift Truck Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1624
Remove, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1627
Disassemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878); GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1629
Disassemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1630
Clean 1632
Inspect 1632
Assemble, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1632
Assemble, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1633
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1633
Install, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1633
Sideshift Cylinder Repair 1634
Remove, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1634
Disassemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1634
Clean 1635
Inspect 1635
Assemble, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1635
Install, Lift Truck Models GLC/GDP60VX, GLC/GDP70VX (GP/GLC/GDP135VX, GP/GLC/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1636
Remove, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1636
Disassemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1637
Clean 1638
Inspect 1638
Assemble, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1638
Install, Lift Truck Models GLC/GDP80VX, GLC/GDP80VX9, GLC/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1638
Bolzoni Sideshift Cylinder Repair 1639
Remove 1639
Disassemble 1639
Clean 1640
Inspect 1640
Assemble 1641
Install 1641
Fork Positioner Cylinder Repair 1642
Remove 1642
Disassemble 1644
Clean 1647
Inspect 1647
Assemble 1648
Install 1649
Lift Cylinder Leak Check 1650
Seal Kit Installation 1650
External Installation (Seal and Back-Up Ring) 1650
Internal Installation (Piston Rod Assembly) 1651
Special Tools 1651
Torque Specifications 1652
For Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (F878) and GLP60VX, GLP70VX, GP70VXS6 (GP135VX GP155VX, GP155VXS) (G878) 1652
For Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909, D909) 1652
550131853 2200YRM1954 (03 2020) UK EN 1655
General 1663
Display Switch Cluster 1666
Remove 1666
Install 1668
Direction Control and Turn Signal Levers 1668
Remove 1668
Install 1669
Key Switch 1669
Remove 1669
Install 1670
Display Switch Cluster Panel Bezel and Overlay 1670
Remove 1670
Install 1671
Steering Column Repair 1671
Sensors and Switches 1674
General 1674
Dash and Kick Panel, Remove and Install 1674
Remove 1674
Install 1675
Accelerator Pedal Position Sensor 1675
Remove 1675
Install 1678
Brake Fluid Level Switch 1678
Remove 1678
Install 1679
Service Brake Pedal Position Sensor 1679
Remove 1679
Install 1680
Parking Brake Position Sensor 1680
Remove 1680
Install 1680
Service Brake Pressure Sensor 1681
Remove 1681
Install 1681
Accumulator Pressure Switch For Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (C909) and GLP/GDP170-190VX, GLP/GDP175VX36 (D909) 1682
Remove 1682
Install 1682
Sensor MicroswitchFoot Directional Control 1683
Remove 1683
Install 1685
Low Coolant Level Sensor 1685
Remove 1685
Install 1686
Fuel Level Sensor, Diesel Engines Only 1686
Remove 1686
Install 1687
Seat Sensor (Operator Presence System) 1687
Non-Suspension Seat 1687
Remove 1687
Install 1689
Full Suspension and Swivel Seats 1689
Remove 1689
Install 1689
Hood Shut Off Switch 1690
Remove 1690
Install 1690
Remote Key Switch 1691
Remove 1691
Install 1691
Hydraulic Filter Pressure Switch 1692
Remove 1692
Install 1692
Transmission Speed Sensor 1692
Remove 1692
Install 1693
Transmission Pressure Sensors 1693
Remove 1693
Install 1693
Transmission Temperature Sensor 1694
Remove 1694
Install 1694
Engine Speed Sensor 1694
Remove 1694
Install 1694
Intermediate Speed Sensor 1694
Remove 1694
Install 1694
Return To Set Tilt (Tilt Angle) Sensor 1694
Remove 1694
Install 1695
Rear Horn Button Switch 1695
Remove 1695
Install 1695
Impact Sensor 1696
Remove 1696
Install 1696
Load Weight Sensor 1697
Remove 1697
Install 1697
Engine and Fuel Sensors and Switches, GM 4 3L and 5 7L LPG Engines 1698
Engine and Fuel Sensors and Switches, PSI 4 3L LPG Engine 1699
Engine and Fuel Sensors and Switches, Cummins QSB 3 3L Diesel Engine 1699
Air Filter Restriction Switch 1699
Remove 1699
Install 1699
Engine Oil Pressure Sensor 1700
Remove 1700
Install 1700
Engine Speed Sensor 1700
Remove 1700
Install 1700
Engine Coolant Temperature (ECT) Sensor 1701
Remove 1701
Install 1701
Fuel/Water Separator Sensor 1701
Remove 1701
Install 1701
Engine and Fuel Sensors and Switches, Kubota 3 6L Diesel Engine 1702
Engine Coolant Temperature (ECT) Sensor 1702
Remove 1702
Install 1702
Throttle Position Sensor 1703
Engine Oil Pressure Sensor 1703
Remove 1703
Install 1703
Fuel Shut Off Solenoid 1703
Remove 1703
Install 1704
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) 1704
Intake Air Temperature Sensor 1705
Remove 1705
Install 1705
Boost Sensor 1705
Remove 1705
Install 1705
Throttle Valve Assembly, Air Intake Adapterand Air Intake Heater 1707
Remove 1707
Install 1708
Engine Coolant Temperature (ECT) Sensor 1708
Remove 1708
Install 1708
Engine Oil Pressure Sensor 1708
Remove 1708
Install 1709
Crankshaft Position Sensor 1709
Remove 1709
Install 1709
Adjust Shim Procedure 1709
Camshaft Position Sensor 1711
Remove 1711
Install 1711
Differential Pressure Sensor 1711
Remove 1711
Install 1712
Oxygen Sensors (Inlet and Outlet) 1712
Remove 1712
Install 1713
Inlet Temperature Sensor 1714
Remove 1714
Install 1714
Mass Air Flow Sensor 1714
Remove 1714
Install 1714
Fuel/Water Separator 1714
Remove 1714
Install 1715
Air Filter Restriction Switch 1715
Remove 1715
Install 1715
Vehicle System Manager (VSM) 1716
General 1716
VSM Replacement 1716
Remove 1716
Install 1716
Programming A New VSM And/Or Display Switch Cluster 1717
Data Transferring 1718
New VSM 1718
New (Blank) Display Switch Cluster 1718
Used (Non-Blank) Display Switch Cluster 1718
PC Service Tool Software 1719
Power Distribution Module (PDM) and Component Parts 1719
Remove 1719
PDM as a Unit 1719
Install 1720
PDM as a Unit 1720
Remove and Install 1720
PDM Component Parts 1720
Transmission Control Unit (TCU) 1721
Remove 1721
Install 1723
Battery 1726
Remove 1726
Install 1726
Lights 1726
Work Lights (Front and Rear) 1726
Halogen Bulb Lights 1726
Remove 1726
Install 1726
LED Lights 1727
Remove 1727
Install 1727
Strobe Light 1727
Remove 1727
Install 1728
LED Tail, Backup, and Brake Lights 1728
Remove 1728
Install 1728
Front Marker/Turn Signal Lights 1729
Replacing Whole Front Marker/Turn Signal Light Assembly 1729
Remove 1729
Install 1729
Replacing Just the Front Marker/Turn Signal
Light LED Light Lens 1730
Remove 1730
Install 1730
Electronic-Hydraulic Controls, Before January, 2020 1731
E-Hydraulic Controls – TEST 1731
Mini-Levers 1731
Full Stroke Test 1731
Function Returns to Neutral Test 1731
Push (Override) Button Switch 1731
General 1732
Mini-levers, Remove and Install 1732
Armrest Assembly 1733
Remove 1733
Install 1736
Horn Button 1736
Remove 1736
Install 1736
Direction Control Switch 1736
Remove 1736
Install 1737
Push (Override) Button 1737
Remove 1737
Install 1738
Electronic-Hydraulic Controls, After January, 2020 1739
E-Hydraulic Controls – TEST 1739
Mini-Levers 1739
Full Stroke Test 1739
Function Returns to Neutral Test 1739
Push Button Switch 1739
General 1740
Mini-levers, Remove and Install 1740
Armrest Assembly 1741
Remove 1741
Install 1744
Horn Button 1744
Remove 1744
Install 1744
Direction Control Switch 1744
Remove 1744
Install 1745
Push (Override) Buttons 1745
Remove 1745
Install 1746
Diesel Particulate Filter (DPF) Display 1747
Remove 1747
Clean and Inspect 1748
Install 1748
Special Tools 1749
550131855 4000YRM1956 (03 2020) UK EN 1753
Safety Procedures When Working Near Mast 1757
Fork Replacement 1758
General 1758
Remove 1758
Install 1760
Checks 1760
Carriage Repair 1762
Remove 1762
Clean and Inspect 1765
Install 1765
Disconnecting Attachment Hydraulic Quick Disconnect Hoses 1766
Connecting Attachment Hydraulic Quick Disconnect Hoses 1766
Integral Sideshift Carriage And Fork Positioners Repair 1767
Integral Sideshift Carriage 1767
Remove 1767
Disassemble 1768
Clean and Inspect 1770
Assemble 1771
Install 1771
Fork Positioners 1772
Remove 1772
Disassemble 1775
Clean and Inspect 1777
Assemble 1777
Install 1777
Hang-On Sideshift Carriage Repair 1778
Remove 1778
Disassemble Carriage 1780
Clean and Inspect 1783
Assemble 1783
Install 1786
Two-Stage Mast With Limited Free-Lift Repair for 6-8 Ton Lift Trucks 1788
Remove 1788
Disassemble 1792
Clean and Inspect 1796
Assemble 1798
Install 1798
Header Hose Installation 1799
Two-Stage Mast With Limited Free-Lift Repair for 8-9 Ton Lift Trucks 1802
Remove 1802
Disassemble 1805
Clean and Inspect 1808
Assemble 1810
Install 1810
Header Hose Installation 1811
Three-Stage Mast With Full Free-Lift Repair for 6-8 Ton Lift Trucks 1814
Remove 1814
Disassemble 1817
Clean and Inspect 1820
Assemble 1822
Install 1822
Header Hose Installation 1823
Three-Stage Mast With Full Free-Lift Repair for 8-9 Ton Lift Trucks 1826
Remove 1826
Disassemble 1829
Clean and Inspect 1833
Assemble 1835
Install 1835
Header Hose Installation 1836
Mast Operation Check 1839
Tilt Cylinder Adjustment 1839
Main Lift Cylinder Repair 1840
Lift Chain Adjustment 1840
Mast Adjustments 1841
Load Roller Adjustment 1841
Mast Side Kicking Adjustment 1843
Carriage Adjustment 1843
550136209 1800YRM1977 (03 2020) UK EN 1847
General 1851
Wet Brake System 1851
Parking Brake Repair 1852
Master Cylinder Repair, For 6-8 Ton Lift Trucks 1855
Remove 1855
Disassemble 1856
Clean and Inspect 1857
Assemble 1858
Install and Adjust 1858
Accumulator; For 6-8 Ton Lift Trucks 1859
Pre-Charge Check 1859
Remove 1860
Install 1861
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For 8-9 Ton Lift Trucks 1861
Remove 1861
Modulating Brake Valve 1863
Disassemble 1863
Clean and Inspect 1864
Assemble 1865
Accumulator Charge Valve 1865
Disassemble 1865
Clean and Inspect 1867
Assemble 1867
Install 1868
Pressure Checks 1869
Accumulator Charge Valve Check 1869
Accumulator Check 1869
Brake System Air Removal; For 6-8 Ton Lift Trucks 1870
Using Pressure Bleed System 1870
Using Brake Pedal Pressure 1870
Lift Truck Models with Master Cylinder 1870
Brake System Air Removal for 8-9 Ton Lift Trucks 1871
Using Brake Pedal Pressure 1871
Lift Truck Models with Modulating Brake Valve 1871
Brake Pedal Adjustment 1871
For 6-8 Ton Lift Trucks 1871
For 8-9 Ton Lift Trucks 1872
Free Pedal Adjustment 1874
Torque Specifications 1875
550136209 1800YRM1977 (08 2022) US EN 1877
General 1883
Wet Brake System 1883
Parking Brake Repair 1884
Master Cylinder Repair, For Lift Truck Models F878/G878/H878 1888
Remove 1888
Disassemble 1888
Clean and Inspect 1890
Assemble 1890
Install and Adjust 1890
Accumulator; For Lift Truck Models F878/G878/H878 1892
Pre-Charge Check 1892
Remove 1892
Install 1893
Modulating Brake Valve, Accumulator Charge Valve, and Accumulator, For Lift Truck Models C909/D909 1894
Remove 1894
Modulating Brake Valve 1895
Disassemble 1895
Clean and Inspect 1896
Assemble 1897
Accumulator Charge Valve 1897
Disassemble 1897
Clean and Inspect 1899
Assemble 1899
Install 1900
Pressure Checks 1901
Accumulator Charge Valve Check 1901
Accumulator Check 1901
Brake System Air Removal; For Lift Truck Models 1902
Using Pressure Bleed System 1902
Using Brake Pedal Pressure 1902
Lift Truck Models with Master Cylinder 1902
Brake System Air Removal for Lift Truck Models C909/D909 1904
Using Brake Pedal Pressure 1904
Lift Truck Models with Modulating Brake Valve 1904
Brake Pedal Adjustment 1904
For Lift Truck Models F878/G878/H878 1904
For Lift Truck Models C909/D909 1905
Free Pedal Adjustment 1907
Torque Specifications 1908
550136214 9000YRM1976 (12 2020) UK EN 1911
SECTION 9010 OPERATIONAL DIAGNOSTIC PROCEDURES 1917
Group 05 – Operational Checkout 1919
SECTION 9020 ENGINE 1925
Group 10 – Principles of Operation 1927
Group 30 – Observed Symptoms 1951
Group 40 – Tests and Adjustments 1959
SECTION 9030 ELECTRICAL SYSTEM 1977
Group 03 – General Maintenance and Diagnostic Data 1983
Group 10 – Principles of Operation 1995
Group 20 – Diagnostic Trouble Codes 2003
SECTION 9080 SUPPLEMENTARY DATA 2159
Group 50 – Abbreviations and Acronyms 2161
Group 60 – Special Tools List 2169
Group 70 – Fault Mode Indicator Reference 2173
550210540 0600YRM2190 (03 2020) UK EN 2177
General 2183
Engine Identification 2183
Major Engine Component Identification 2183
Location of Labels 2187
Cylinder Block Description 2187
Precautions Before Beginning Repair 2188
Exhaust System and DPF 2189
Engine Removal and Installation 2189
Cylinder Head Assembly Repair 2189
Valve Covers and Fuel Injectors 2189
Remove 2189
Clean and Inspect 2192
Install 2192
Rocker Arm Assembly 2193
Remove 2193
Disassemble 2193
Clean and Inspect 2194
Push Rods 2194
Rocker Arm Assembly 2194
Assemble 2195
Install 2195
Valve Clearance Adjustments 2195
Cylinder Head Assembly 2196
Remove 2196
Disassemble 2206
Valves and Valve Springs, Remove 2206
Valve Guides, Remove 2207
Clean and Inspect 2207
Cylinder Head 2208
Valve Guides 2208
Valves 2208
Valve Sink 2209
Valve Seat 2209
Valve Springs 2210
Assemble 2210
Valve Guides, Install 2210
Valves and Valve Springs, Install 2211
Install 2212
Timing Gear Case and Timing Gears Repair 2214
Timing Gear Case Cover 2214
Remove 2214
Clean and Inspect 2215
Install 2216
Timing Gears 2216
Crankshaft Gear 2217
Remove 2217
Install 2217
Idler Gear 1 and Idler Gear 2 2217
Remove 2217
Inspect 2218
Install 2219
Idler Gear 3 2219
Remove 2219
Inspect 2219
Install 2219
Camshaft Gear 2219
Remove 2219
Install 2219
Drive Train, Camshaft, and Cylinder Block Repair 2220
Remove 2220
Disassemble 2220
Pistons and Connecting Rods 2220
Crankshaft 2221
Camshaft 2223
Clean and Inspect 2225
Cylinder Block 2225
Honing and Boring 2227
Cylinder Correction (Oversize) 2228
Pistons 2228
Piston Pin 2229
Connecting Rod 2229
Tappets 2230
Crankshaft 2230
Camshaft 2232
Camshaft Bushing 2233
Assemble 2233
Camshaft 2233
Crankshaft 2234
Pistons and Connecting Rods 2234
Install 2236
Angular Deviation Procedure 2236
Lubrication System Repair 2239
Engine Oil and Oil Filter Change 2239
Oil Pan 2240
Remove 2240
Install 2240
Oil Suction Tube 2240
Remove 2240
Clean 2241
Install 2241
Oil Pump 2241
Remove 2241
Clean and Inspect 2242
Inner Rotor and Outer Rotor Clearance 2242
Outer Rotor and Pump Body Clearance 2243
Rotor and Cover Clearance 2243
Rotor Shaft Clearance 2243
Install 2244
Fuel System Repair 2245
Fuel Injectors 2245
Remove 2245
Inspect 2245
Clean 2245
Replace 2245
Install 2245
Test 2245
Fuel Injection Pump 2246
Remove 2246
Clean and Inspect 2248
Install 2248
Cooling System Repair 2249
Serpentine Belt 2249
Remove 2249
Inspect 2249
Install 2249
Adjust 2249
Water Pump 2250
Remove 2250
Install 2252
Thermostat 2253
Remove 2253
Inspect 2254
Install 2255
Flywheel and Flywheel Housing 2256
Flywheel 2256
Remove 2256
Install 2257
Flywheel Housing 2257
Remove 2257
Install 2257
Electrical Equipment Repair 2258
Alternator 2258
Remove 2258
Install 2259
Starter 2259
Remove 2259
Install 2260
Engine Specifications 2261
Engine Data 2261
Engine Tuning 2263
Cylinder Head 2264
Intake/Exhaust Valve and Guide 2264
Valve Spring 2265
Rocker Arm and Shaft 2265
Push Rod 2265
Gear Train and Camshaft 2265
Camshaft 2265
Idle Gear Shaft and Bushing 2265
Backlash of Each Gear 2266
Cylinder Block 2266
Crankshaft 2266
Piston 2266
Piston Ring 2267
Connecting Rod 2267
Rod Small End 2267
Tappet 2267
Oil Pump 2268
Engine Oil Pressure 2268
Inner and Outer Rotor Clearance 2268
Outer Rotor and Pump Body 2268
Rotor and Cover 2268
Standard Torque Specifications 2269
Standard Torque Chart 2269
Special Torque Specifications 2270
Special Tools 2271
550229996 0100YRM2293 (03 2020) UK EN 2283
General 2287
Description 2287
Side Covers, Seat, Dash, and Hood Replacement 2288
Side Covers 2288
Remove 2288
Install 2288
Seat and Seat Plate 2289
Remove Seat 2289
Remove Seat Plate 2290
Install Seat Plate 2290
Install Seat 2290
Operator Restraint System 2293
Emergency Locking Retractor (ELR) 2293
Seat Plate and Seat Rail Check 2293
Steering Column, Dash, Kick Panel, and Seal Plate 2293
Remove 2293
Install 2296
Hood Support and Door Assembly 2298
Remove 2298
Install 2299
Hood Door Assembly 2301
Remove 2301
Install 2302
Steering Column 2302
Description 2302
Steering Column Repair 2303
Remove 2303
Disassemble 2304
Clean 2305
Inspect 2306
Assemble 2306
Install 2306
LPG Tank and Bracket Assembly 2306
Counterweight Replacement 2306
Remove 2306
Install 2308
Tow Pin, Remove and Install 2309
Overhead Guard Replacement 2309
Remove 2309
Install 2311
Engine Replacement 2311
Remove Engine 2311
Remove Transmission 2325
Remove Engine and Transmission 2329
Install Engine 2331
Install Transmission 2333
Install Engine and Transmission 2335
Throttle Pedal and Cable Adjustment 2337
Exhaust System Repair 2337
General 2337
GM 5 7L LPG Engine 2337
Kubota 3 8L Diesel Engine w/DPF 2337
Remove 2339
Inspect 2340
Install 2340
Kubota 3 8L Diesel Engine w/DOC 2340
Remove 2342
Inspect 2343
Install 2343
Kubota 3 8L, 82kW, Non-Compliant Emissions Diesel Engine 2343
Remove 2343
Inspect 2345
Install 2346
Diesel Particulate Filter (DPF) 2346
Diesel Particulate Filter 2346
Disassemble 2347
Clean and Inspect 2348
Differential Pressure Pipes and Hoses 2349
Assemble 2349
Diesel Exhaust Fluid System 2350
General 2350
Description and Operation 2350
Selective Catalyst Reducer (SCR) 2352
Remove 2352
Clean and Inspect 2353
Install 2354
DEF Tank 2354
Remove 2354
Clean and Inspect 2356
Install 2356
Cooling System 2357
Description 2357
Hydraulic Filter Assembly Repair 2357
Remove 2357
Install 2358
Fuel and Hydraulic Tanks Repair 2359
Inspect 2359
Clean 2359
Steam Method of Cleaning 2360
Chemical Solution Method of Cleaning 2360
Additional Preparations for Repair 2360
Small Leaks, Repair 2361
Large Leaks, Repair 2361
Preparations for Use After Repair 2361
Safety Labels 2361
550229997 0600YRM2294 (01 2021) UK EN 2367
General 2373
Engine Identification 2373
Major Engine Component Identification 2373
Location of Labels 2374
Crankcase Description 2375
Precautions Before Beginning Repair 2376
Exhaust System 2377
Engine Removal and Installation 2377
Cylinder Head Assembly Repair 2377
Valve Covers and Fuel Injectors 2377
Remove 2377
Clean and Inspect 2380
Install 2380
Rocker Arm Assembly 2380
Remove 2380
Disassemble 2381
Clean and Inspect 2382
Push Rods 2382
Rocker Arm Assembly 2382
Assemble 2382
Install 2383
Valve Clearance Adjustments 2383
Cylinder Head Assembly 2384
Remove 2384
Disassemble 2390
Valves and Valve Springs, Remove 2390
Valve Guides, Remove 2391
Clean and Inspect 2391
Cylinder Head 2392
Valve Guides 2392
Valves 2392
Valve Sink 2392
Valve Seat 2393
Valve Springs 2393
Assemble 2394
Valve Guides, Install 2394
Valves and Valve Springs, Install 2394
Install 2395
Timing Gear Case and Timing Gears Repair 2397
Timing Gear Case Cover 2397
Remove 2397
Clean and Inspect 2398
Install 2398
Timing Gears 2399
Crankshaft Gear 2399
Remove 2399
Install 2400
Idler Gear 2400
Remove 2400
Inspect 2401
Install 2402
Camshaft Gear 2402
Remove 2402
Install 2402
Drive Train, Camshaft, and Cylinder Block Repair 2402
Remove 2402
Disassemble 2402
Pistons and Connecting Rods 2402
Crankshaft 2404
Camshaft 2406
Clean and Inspect 2408
Cylinder Block 2408
Honing and Boring 2410
Cylinder Correction (Oversize) 2411
Pistons 2411
Piston Pin 2412
Connecting Rod 2412
Tappets 2413
Crankshaft 2413
Camshaft 2415
Camshaft Bushing 2416
Assemble 2416
Camshaft 2416
Crankshaft 2416
Pistons and Connecting Rods 2417
Install 2419
Angular Deviation Procedure – Kubota 3 8L Diesel Engine 2419
Lubrication System Repair 2422
Engine Oil and Oil Filter Change 2422
Oil Pan 2423
Remove 2423
Install 2423
Oil Suction Tube 2423
Remove 2423
Clean 2424
Install 2424
Oil Pump 2424
Remove 2424
Clean and Inspect 2425
Outer Rotor Outside Clearance 2425
Outer Rotor to Inner Rotor Tip Clearance 2426
Outer Rotor Side Clearance 2426
Rotor Shaft Clearance 2426
Install 2426
Fuel System Repair 2427
Fuel Injectors 2427
Remove 2427
Inspect 2427
Clean 2427
Replace 2428
Install 2428
Test 2428
Fuel Injection Pump 2428
Remove 2428
Clean and Inspect 2430
Install 2430
Cooling System Repair 2431
Serpentine Belt 2431
Remove 2431
Inspect 2431
Install 2431
Adjust 2432
Water Pump 2432
Remove 2432
Install 2434
Thermostat 2435
Remove 2435
Inspect 2435
Install 2436
Flywheel and Flywheel Housing 2437
Flywheel 2437
Remove 2437
Install 2437
Flywheel Housing 2437
Remove 2437
Install 2438
Electrical Equipment Repair 2438
General 2438
Alternator 2438
Remove 2438
Install 2439
Starter 2440
Remove 2440
Install 2440
Engine Specifications 2442
Engine Data 2442
Engine Tuning 2443
Cylinder Head 2443
Intake/Exhaust Valve and Guide 2443
Valve Spring 2444
Rocker Arm and Shaft 2444
Push Rod 2444
Gear Train and Camshaft 2444
Camshaft 2444
Idle Gear Shaft and Bushing 2444
Backlash of Each Gear 2445
Cylinder Block 2445
Crankshaft 2445
Piston 2445
Piston Ring 2446
Connecting Rod 2446
Rod Small End 2446
Tappet 2446
Oil Pump 2447
Engine Oil Pressure 2447
Outer Rotor Outside Clearance 2447
Outer Rotor Side Clearance 2447
Inner Rotor to Cover 2447
Standard Torque Specifications 2448
Standard Torque Chart 2448
Special Torque Specifications 2448
Special Tools 2450
550229998 0600YRM2295 (01 2021) UK EN 2463
General 2469
Engine Identification 2469
Major Engine Component Identification 2469
Location of Labels 2470
Cylinder Block Description 2471
Precautions Before Beginning Repair 2472
Exhaust System, SCR, and DPF 2472
Engine Removal and Installation 2473
Cylinder Head Assembly Repair 2473
Valve Covers and Fuel Injectors 2473
Remove 2473
Clean and Inspect 2476
Install 2476
Rocker Arm Assembly 2477
Remove 2477
Disassemble 2478
Clean and Inspect 2478
Push Rods 2478
Rocker Arm Assembly 2478
Assemble 2479
Install 2479
Valve Clearance Adjustments 2479
Cylinder Head Assembly 2480
Remove 2480
Disassemble 2489
Valves and Valve Springs, Remove 2489
Valve Guides, Remove 2490
Clean and Inspect 2490
Cylinder Head 2491
Valve Guides 2491
Valves 2491
Valve Sink 2492
Valve Seat 2492
Valve Springs 2493
Assemble 2493
Valve Guides, Install 2493
Valves and Valve Springs, Install 2494
Install 2495
Timing Gear Case and Timing Gears Repair 2497
Timing Gear Case Cover 2497
Remove 2497
Clean and Inspect 2498
Install 2498
Timing Gears 2499
Crankshaft Gear 2499
Remove 2499
Install 2500
Idler Gear 1 and Idler Gear 2 2500
Remove 2500
Inspect 2501
Install 2502
Idler Gear 3 2502
Remove 2502
Inspect 2502
Install 2502
Camshaft Gear 2502
Remove 2502
Install 2502
Drive Train, Camshaft, and Cylinder Block Repair 2503
Remove 2503
Disassemble 2503
Pistons and Connecting Rods 2503
Crankshaft 2504
Camshaft 2506
Clean and Inspect 2508
Cylinder Block 2508
Honing and Boring 2510
Cylinder Correction (Oversize) 2511
Pistons 2511
Piston Pin 2512
Connecting Rod 2512
Tappets 2513
Crankshaft 2513
Camshaft 2515
Camshaft Bushing 2516
Assemble 2516
Camshaft 2516
Crankshaft 2516
Pistons and Connecting Rods 2517
Install 2519
Angular Deviation Procedure 2519
Lubrication System Repair 2522
Engine Oil and Oil Filter Change (Standard Oil Filter) 2522
Engine Oil and Oil Filter Change (Remote Oil Filter) 2522
Oil Pan 2523
Remove 2523
Install 2523
Oil Suction Tube 2524
Remove 2524
Clean 2524
Install 2524
Oil Pump 2524
Remove 2524
Clean and Inspect 2525
Inner Rotor and Outer Rotor Clearance 2525
Outer Rotor and Pump Body Clearance 2526
Rotor and Cover Clearance 2526
Rotor Shaft Clearance 2526
Install 2526
Remote Oil Filter 2527
Remove 2527
Clean and Inspect 2529
Install 2529
Fuel System Repair 2530
Fuel Injectors 2530
Remove 2530
Inspect 2530
Clean 2530
Replace 2530
Install 2531
Test 2531
Fuel Injection Pump 2531
Remove 2531
Clean and Inspect 2534
Install 2535
Cooling System Repair 2536
Serpentine Belt 2536
Remove 2536
Inspect 2536
Install 2536
Adjust 2536
Water Pump 2537
Remove 2537
Install 2538
Thermostat 2539
Remove 2539
Inspect 2540
Install 2540
Flywheel and Flywheel Housing 2542
Flywheel 2542
Remove 2542
Install 2542
Flywheel Housing 2542
Remove 2542
Install 2542
Electrical Equipment Repair 2543
Alternator 2543
Remove 2543
Install 2544
Starter 2545
Remove 2545
Install 2545
Engine Specifications 2547
Engine Data 2547
Engine Tuning 2549
Cylinder Head 2549
Intake/Exhaust Valve and Guide 2550
Valve Spring 2550
Rocker Arm and Shaft 2550
Push Rod 2550
Gear Train and Camshaft 2551
Camshaft 2551
Idle Gear Shaft and Bushing 2551
Backlash of Each Gear 2551
Cylinder Block 2551
Crankshaft 2552
Piston 2552
Piston Ring 2552
Connecting Rod 2553
Rod Small End 2553
Tappet 2553
Oil Pump 2553
Engine Oil Pressure 2553
Inner and Outer Rotor Clearance 2553
Outer Rotor and Pump Body 2553
Rotor and Cover 2554
Standard Torque Specifications 2554
Standard Torque Chart 2554
Special Torque Specifications 2555
Special Tools 2556
550230000 8000YRM2297 (03 2020) UK EN 2571
Lift Truck Lifting Capacity 2575
Counterweight Weights 2575
Tire Sizes 2575
Capacities 2576
Electrical System 2578
Transmission Oil Pressures 2579
Hydraulic System Relief Pressures 2580
Steering System 2580
Stall Speeds 2580
Mast Speeds 2581
Tilt Angles 2581
Front End Equipment – Mast Creep 2582
Mast Creep 2582
Engine Specifications 2583
Diesel Fuel Cleanliness Levels 2584
Torque Specifications 2584
Frame 2584
Mast, Carriage, and Fork Positioner 2584
Steering System 2584
Transmission 2585
Engine, GM 5 7L LPG 2585
Engine – Kubota 3 8L Diesel 2586
550230001 8000YRM2296 (04 2020) UK EN 2589
General 2595
Serial Number Data 2595
How to Move Disabled Lift Truck 2595
How to Tow Lift Truck 2595
How to Put Lift Truck on Blocks 2596
How to Raise Drive Tires 2596
How to Raise Steering Tires 2597
How to Clean a Lift Truck 2598
Safety Procedures When Working Near Mast 2599
Maintenance Schedule 2600
Maintenance Schedule 2600
Maintenance Procedures Every 8 Hours or Daily 2615
How to Make Checks With Engine Stopped 2615
Tires and Wheels 2615
Safety Labels 2615
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 2615
Operator Restraint System 2616
Emergency Locking Retractor (ELR) 2616
Adjust Seat – Full Suspension 2617
Adjust Seat – Internal Suspension 2618
Seat Plate and Seat Rails 2618
Engine Compartment 2618
Fuel, Oil, and Coolant Leaks, Check 2618
Hydraulic Hoses 2619
Coolant Hoses 2619
Steering Column Gas Cylinder 2619
Transmission 2619
Hydraulic System Oil 2619
Engine Oil 2621
Forks 2624
Inspect 2624
Remove 2626
Install 2626
Adjust 2626
Integral Sideshift Carriage 2628
How to Make Checks With Engine Running 2628
Indicator Lights, Horn, Fuses, and Relays 2628
Service Brakes 2631
Operation, Check 2631
Accumulator Pressure 2631
Parking Brake 2631
Engine Oil Pressure 2631
Cooling System 2632
Steering System 2633
Control Levers and Pedals 2633
Lift System, Operate 2633
Air Filter 2633
Fuel/Water Separator Filter, Kubota Diesel Engines 2634
First Service After First 100 Hours of Operation 2635
Engine Oil and Oil Filter 2635
Maintenance Procedures Every 500 Hours or 6 Months 2637
Hydraulic System Oil Check 2637
Hydraulic Tank Breather 2638
Inspect 2638
Battery 2640
Engine Oil and Oil Filter 2640
Fuel/Water Separator Filter Replacement, Kubota 3 8L Diesel Engine 2641
Remove 2641
Install 2641
Priming The Fuel System, Kubota 3 8L Diesel Engine 2642
Drive Belt 2643
Fan and Alternator Drive Belt Inspection 2643
Clean Debris From Radiator Core 2644
Transmission and Wet Brake Axle Oil Level Check 2644
Wet Brake Center Body Oil Level Check 2645
Cab Heater Air Filter 2647
Forks, Inspect 2648
Mast Lubrication 2650
Header Hose Checks 2652
Lift Chain Lubrication 2652
Tilt Cylinder Lubrication 2654
Brake Actuation Valve Rod End Pin 2656
Tie Rod Lubrication 2657
Low Idle Speed Check 2658
Drain Tar From LPG Converter 2658
GM 5 7L LPG Engine 2658
Parking Brake Adjustment 2659
Maintenance Procedures Every 1000 Hours or 6 Months 2660
Lift Chain Lubrication and Wear Check 2660
Integral Sideshift Carriage, Check Sliding Surfaces 2662
Steering Axle Spindle Bearings 2662
Control Levers and Pedals 2663
Inspect Engine Electrical System, Connectors 2663
Spark Plugs 2664
GM 5 7L LPG Engine 2664
PCV Valve 2664
GM 5 7L LPG Engine 2664
LPG Fuel Filter 2665
GM 5 7L LPG Engine 2665
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change 2665
Crankcase Breather Filter, Kubota 3 8L Diesel Engine 2668
Remove 2668
Clean and Inspect 2669
Install 2669
DEF Injector Tip 2669
Maintenance Procedures Every 2000 Hours or Annually 2670
Hydraulic System 2670
Hydraulic Filter Assembly, Replace 2670
Remove 2670
Install 2671
Hydraulic Tank Breather, Replace 2672
Cooling System Check 2673
Air Filter 2675
Fuel Injectors and Fuel System 2676
Forks, Inspect 2676
Check Throttle Shaft for Sticking 2678
Inspect Exhaust Manifold and Piping for Leaks 2678
Transmission Automatic Clutch Calibration 2678
Brake System Accumulator 2678
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires 2678
GM 5 7L LPG Engine 2678
PCV Valve 2679
GM 5 7L LPG Engine 2679
LPG Electronic Pressure Regulator (EPR)/Fuel Mixer, Inspect 2679
GM 5 7L LPG Engine 2679
LPG Lock-Off Valve 2680
GM 5 7L LPG Engine 2680
Oxygen Sensors 2680
GM 5 7L LPG Engine 2680
Kubota 3 8L Diesel Engine 2680
Wheel Bearings 2680
Steer Wheels, Lubrication 2680
Maintenance Procedures Every 3000 Hours 2681
Diesel Particulate Filter 2681
Remove 2681
Disassemble 2683
Servicing the Diesel Particulate Filter, Pressure Tubes, and Pressure Hoses 2684
Assemble 2684
Install 2685
Diesel Exhaust Fluid (DEF) System 2685
Maintenance Procedures Every 4000 Hours or 2 Years 2688
Hydraulic Oil, Replace 2688
Fuel Filter Water Removal 2690
Lift Chain Adjustments 2691
Jump-Starting the Lift Truck 2692
Jump-Starting Using a Battery Charger 2692
Jump-Starting a Lift Truck Using Another Lift Truck 2692
Welding Repairs 2693
Overhead Guard Changes 2693
Wheel and Tire Replacement 2693
General 2693
Pneumatic Tire With Tube, Repair 2693
Remove Wheels From Lift Truck 2693
Remove Tire From Wheel 2694
Install Wheel in Tire 2697
Install Tire on Two-Piece Wheel 2699
Add Air to Pneumatic Tires With Tube 2700
Install the Wheels 2700
Dual Drive Wheels, Install 2701
Pneumatic Tubeless Tire, Repair 2701
Remove Wheels From Lift Truck 2701
Add Air to Pneumatic Tubeless Tire 2706
Wheels, Install 2707
Solid Rubber Tires on Pneumatic Wheels, Change 2707
Snap-On-Tire, Change 2710
Adhesives and Sealants 2713