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1. GP170-280DB (B876), GP300-360EB (B877)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524150772 0100 YRM 0927 01/11
OPERATOR'S CAB........................................................................................................ 550033400 0100 YRM 1390 11/13
CAB HEATER (PRIOR TO OCT. 2008).......................................................................... 550033397 0100 YRM 1458 04/11
PERKINS DIESEL ENGINE............................................................................................ 524150774 0600 YRM 0705 03/06
PERKINS TIER 2 DIESEL ENGINE................................................................................ 524192855 0600 YRM 1068 05/04
PERKINS TIER 2 DIESEL ENGINE ELECTRONIC TROUBLESHOOTING GUIDE..... 524203841 0600 YRM 1072 06/05
COOLING SYSTEM........................................................................................................ 524150775 0700 YRM 0626 03/03
THREE-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION. 524150776 1300 YRM 0930 08/01
THREE-SPEED POWERSHIFT TRANSMISSION-REPAIR........................................... 524150777 1300 YRM 0931 08/01
AUTOSHIFT TRANSMISSION CONTROLLER.............................................................. 524150778 1300 YRM 0932 12/04
DIFFERENTIAL............................................................................................................... 524150779 1400 YRM 0046 08/12
PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. 524150780 1400 YRM 0944 08/12
PLANETARY DRIVE AXLE (DRY SYSTEM)................................................................. 524150781 1400 YRM 0945 08/11
STEERING AXLE............................................................................................................ 524150783 1600 YRM 0326 03/07
STEERING SYSTEM...................................................................................................... 524150782 1600 YRM 0936 03/07
BRAKE SYSTEM (DRY)................................................................................................. 524150784 1800 YRM 0937 04/10
BRAKE SYSTEM (WET)................................................................................................. 524150785 1800 YRM 0951 03/11
HYDRAULIC SYSTEM.................................................................................................... 524150787 1900 YRM 0938 03/07
MAIN CONTROL VALVE................................................................................................ 524150788 2000 YRM 0943 03/07
TILT CYLINDERS........................................................................................................... 524150790 2100 YRM 0103 03/07
ALTERNATOR................................................................................................................ 524150791 2200 YRM 0002 12/04
STARTER........................................................................................................................ 524150792 2200 YRM 0106 12/04
INSTRUMENT PANEL INDICATORS AND SENDERS................................................. 524150793 2200 YRM 0939 12/04
LIFT CYLINDERS........................................................................................................... 524150794 4000 YRM 0135 03/11
MASTS (BEFORE JANUARY 2003).............................................................................. 524150795 4000 YRM 0445 08/01
MAST AND CARRIAGES............................................................................................... 524203754 4000 YRM 1062 08/12
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 524149351 8000 YRM 0934 04/03
CAPACITIES AND SPECIFICATIONS........................................................................... 524150798 8000 YRM 0940 07/13
DIAGRAMS..................................................................................................................... 524150799 8000 YRM 0941 01/06
PERIODIC MAINTENANCE PERKINS TIER 2 EMISSION ENGINE............................. 524192598 8000 YRM 1066 09/05
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524150771 (11/13)

2. 8000 YRM 940 Lift Truck Weights
Lift Truck Weights
Unit kg lb
GP170DB 11,735 25,872
GDP80DB (GP190DB) 11,928 26,296
GDP90DB (GP210DB) 12,508 27,572
GDP100DB (GP230DB) 14,144 31,178
GP250DB 14,343 31,621
GDP120DB (GP280DB) 15,787 34,800
GDP130EB (GP300EB) 16,669 36,753
GDP140EB (GP330EB) 17,826 39,303
GDP160EB (GP360EB) 18,710 41,253
GDP80-120DB (GP170-280DB) models: 5335 mm (210 in.) mast, 2350 mm (92.5 in.) standard carriage,
65 [70] × 200 × 1220 mm (2.6 [2.76] × 8 × 48 in.) forks.
GDP130-160EB (GP300-360EB) models: 5310 mm (209 in.) mast, 2502 mm (98.5 in.) standard carriage, 90 ×
200 × 1375 mm (3.5 × 8 × 54 in.) forks.
1

3. Capacities 8000 YRM 940
Capacities
Item Quantity
Engine Oil, Perkins Diesel 1006-60, With Oil Filter 13.2 liter (13.9 qt)
Engine Oil, Perkins 1006-60T, With Oil Filter 14.2 liter (15 qt)
Engine Oil, Perkins 1106C-E60 TA Tier 2, With Oil Filter 14.2 liter (15 qt)
Engine Oil, Cummins QSB5.9-30 and B LPG Plus,
With Oil Filter
16.3 liter (17.2 qt)
Cooling System, Perkins 1006-60 26 liter (27.5 qt)
Cooling System, Perkins 1006-60T 31 liter (32.8 qt)
Cooling System, Perkins 1106C-E60 TA Tier 2 25.5 liter (27 qt)
Cooling System, Cummins 25.5 liter (27 qt)
Hydraulic Tank (FULL mark)
GDP80-120DB (GP170-280DB) 109 liter (28.8 gal)
GDP130-160EB (GP300-360EB) 109 liter (28.8 gal)
Hydraulic System (Total Capacity)
GDP80-120DB (GP170-280DB) 139 liter (36.7 gal)
GDP130-160EB (GP300-360EB) 139 liter (36.7 gal)
Transmission 16.5 liter (17.4 qt)
Drive Axle and Differential
Dry Brake System
GDP80-120DB (GP170-280DB) 19 liter (20 qt)
GDP130-160EB (GP300-360EB) 21 liter (21.1 qt)
Wet Brake System
GDP80-120DB (GP170-280DB) 19 liter (20 qt)
GDP130-160EB (GP300-360EB) 21 liter (21.1 qt)
Planetary Gears
GDP80-120DB (GP170-280DB) 2.8 liter (3.0 qt) each
GDP130-160EB (GP300-360EB) 2.4 liter (2.5 qt) each
Fuel Tank (Diesel Engines) 128 liter (33.8 gal)
LPG Tank LPG HD-10 77 liter (20.3 gal)
2

4. 8000 YRM 940 Engine Specifications
Engine Specifications
PERKINS DIESEL
Item Specification
Type Perkins 1006-60, 1006-60T and 1106C-E60 TA, Tier 2
Numbers of Cylinders 6
Firing Order 1-5-3-6-2-4
Bore 100 mm (3.937 in.)
Stroke 127 mm (5.000 in.)
Displacement 6 liter (366 in.3
)
Compression Ratio 17.25:1
Oil Pressure (Minimum, at 2200 rpm and normal
operating temperature)
280 kPa (40 psi)
Governed Speed (Full power and normal operating temperature)
1006-60 2200 rpm with load, 2310 ±50 no load
1006-60T 2300 rpm with load, 2415 ±50 no load
Governed Speed (To high idle)
1106C-E60 TA, Tier 2 2415 ±10
Idle Speed
1006-60 725 to 775 rpm
1006-60T 725 to 775 rpm
1106C-E60 TA, Tier 2 740 to 760 rpm
Stall Speed (Broken-in Engine)
1006-60 1925 ±50 rpm
1006-60T/1106C-E60 TA, Tier 2 2095 ±50 rpm
Fuel Injection Timing 23° BTDC (Static)
Thermostat
Begin to open 80 to 84°C (176 to 183°F)
Fully open 96°C (205°F)
Valve Clearance (Cold)
Intake 0.20 mm (0.008 in.)
Exhaust 0.45 mm (0.018 in.)
3

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6. Engine Specifications 8000 YRM 940
CUMMINS DIESEL/LPG
Item Specification
Type Cummins B LPG Plus Cummins QSB5.9-30
Number of Cylinders 6 6
Firing Order 1-5-3-6-2-4 1-5-3-6-2-4
Bore 102 mm (4.02 in.) 102 mm (4.02 in.)
Stroke 120 mm (4.62 in.) 120 mm (4.62 in.)
Displacement 5.88 liter (359 in.3
) 5.88 liter (359 in.3
)
Compression Ratio 9.25:1 18:1
Oil Pressure (Minimum, at 2500 rpm
and normal operating temperature)
345 kPa (50 psi) 345 kPa (50 psi)
Oil Pressure (At low idle) 69 kPa (10 psi) 69 kPa (10 psi)
Governed Speed (Full power at Normal Operating Temperature)
GDP80-120DB, GDP130-160EB 2500 rpm with load
2600 ±50 no load
2300 rpm with load
2450±30 no load
GP170-280DB, GP300-360EB 2500 rpm with load
2600 ±50 no load
2500 rpm with load
2600±50 no load
Idle Speed 850 rpm±2% 725 ±2%
Stall Speed (Broken-in Engine) 1950 to 2100 rpm 1950 to 2100 rpm
Thermostat
Begin to open 83°C (181°F) 83°C (181°F)
Fully open 91°C (196°F) 91°C (196°F)
Valve Clearance (Cold)
Intake 0.305 mm (0.012 in.) 0.25 mm (0.01 in.)
Exhaust 0.61 mm (0.024 in.) 0.51 mm (0.02 in.)
4

7. 8000 YRM 940 Hydraulic System
Hydraulic System
Item Quantity
Perkins Hydraulic Pump Capacity @ 2300 rpm for turbo, 2200 rpm for nonturbo
Main Section @ 21 MPa (3045 psi)
1006-60T/1106C-E60 TA 192 liter/min (51 gal/min)
1006-60 160 liter/min (42.3 gal/min)
Steering/Aux Section @ 19.3 MPa (2800 psi)
1006-60T/1106C-E60 TA 93 liter/min (24.6 gal/min)
1006-60 78 liter/min (20.6 gal/min)
Cummins Diesel Hydraulic Pump Capacity @ 2300 rpm
Main Section @ 21 MPa (3045 psi) 192 liter/min (51 gal/min)
Steering/Aux Section @ 19.3 MPa (2800 psi) 93 liter/min (24.6 gal/min)
Cummins LPG Hydraulic Pump Capacity @ 2500 rpm
Main Section @ 21 MPa (3045 psi) 183 liter/min (48.3 gal/min)
Steering/Aux Section @ 19.3 MPa (2800 psi) 89 liter/min (23.5 gal/min)
Relief Pressures *
Main Control Valve
Lift Circuit 21.0 MPa (3045 psi)
Tilt and Auxiliary Circuits 19.3 MPa (2800 psi)
Steering Circuit 16.5 MPa (2400 psi)
ECH Functions 14.0 MPa (2030 psi)
*Oil temperature 60°C (140°F)
5

8. Tire Sizes 8000 YRM 940
Electrical System
All Models 24 Volt, Negative Ground
Alternator Output at 24°C (75°F)
21 amps at 750 rpm
All Engines
76 amps at 2200 rpm
Tire Sizes
NOTE: Refer to Truck Nameplate for correct tire pres-
sure.
Model Tire Size Tire Pressure
GDP80-90DB (GP170-210DB) 9.00 × 20-12 ply 690 kPa (100 psi)
GDP80-90DB (GP170-210DB) 9.00 × 20-14 ply 900 kPa (130 psi)
GDP100-120DB (GP230-280DB) 10.00 × 20-12 ply 690 kPa (100 psi)
GDP100-120DB (GP230-280DB) 10.00 × 20-16 ply 900 kPa (130 psi)
GDP130EB (GP300EB) 11.00 × 20-14 ply 690 kPa (100 psi)
GDP130-160EB (GP300-360EB) 12.00 × 20-16 ply 1000 kPa (145 psi)
All Michelin XZM Radial Tires 1000 kPa (145 psi)
6

9. 8000 YRM 940 Mast Speeds
Mast Speeds
PERKINS DIESEL
Lifting Lifting Lifting Lowering
1006.60 1006.60T 1106C-E60 TA 1006.60, 1006.60T and
1106C-E60 TA
No Load
Rated
Load
No Load
Rated
Load
No Load
Rated
Load
No Load
Rated
Load
Unit
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
GP170DB 0.63 124 0.41 80 0.73 143 0.48 96 0.73 143 0.48 96 0.48 95 0.50 98
GDP80DB
(GP190DB)
0.63 124 0.41 80 0.73 143 0.48 96 0.73 143 0.48 96 0.48 95 0.50 98
GDP90DB
(GP210DB)
0.63 124 0.41 80 0.73 143 0.48 96 0.73 143 0.48 96 0.48 95 0.50 98
GDP100DB
(GP230DB)
0.53 104 0.36 70 0.56 110 0.38 74 0.53 104 0.34 67 0.46 91 0.49 97
GP250DB 0.53 104 0.36 70 0.56 110 0.38 74 0.53 104 0.34 67 0.46 91 0.49 97
GDP120DB
(GP280DB)
0.53 104 0.36 70 0.56 110 0.38 74 0.53 104 0.34 67 0.46 91 0.49 97
GDP130EB
(GP300EB)
- - - - 0.46 91 0.30 59 0.44 87 0.29 57 0.44 87 0.48 95
GDP140EB
(GP330EB)
- - - - 0.46 91 0.30 59 0.44 87 0.29 57 0.44 87 0.48 95
GDP160EB
(GP360EB)
- - - - 0.46 91 0.30 59 0.44 87 0.29 57 0.44 87 0.48 95
7

10. Mast Speeds 8000 YRM 940
CUMMINS DIESEL/LPG
Lifting Lifting Lowering
B LPG Plus QSB5.9-30 B LPG Plus/QSB5.9-30
No Load Rated Load No Load Rated Load No Load Rated Load
Unit
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
m/
sec
ft/
min
GP170DB 0.69 136 0.37 73 0.73 143 0.48 95 0.48 95 0.50 98
GDP80DB
(GP190DB)
0.69 136 0.37 73 0.73 143 0.48 95 0.48 95 0.50 98
GDP90D
(GP210DB)
0.69 136 0.37 73 0.73 143 0.48 95 0.48 95 0.50 98
GDP100DB
(GP230DB)
0.50 98 0.26 51 0.53 104 0.46 91 0.46 91 0.49 97
GP250DB 0.50 98 0.26 51 0.53 104 0.46 91 0.46 91 0.49 97
GDP120DB
(GP280DB)
0.50 98 0.26 51 0.53 104 0.46 91 0.46 91 0.49 97
GDP130EB
(GP300EB)
0.41 81 0.22 43 0.44 87 0.29 57 0.44 87 0.48 95
GDP140EB
(GP330EB)
0.41 81 0.22 43 0.44 87 0.29 57 0.44 87 0.48 95
GDP160EB
(GP360EB)
0.41 81 0.22 43 0.44 87 0.29 57 0.44 87 0.48 95
8

11. 8000 YRM 940 Torque Specifications, Perkins Diesel
Torque Specifications, Cummins Diesel
LUBRICATION SYSTEM
Plug, Oil Sump, Aluminum Oil Pan
60 N•m (44 lbf ft)
Plug, Oil Sump, Steel Oil Pan
80 N•m (59 lbf ft)
All other Torque Specifications are found in Cummins Engine Manual. Contact Cummins Engine for any torque
specifications not listed for this engine.
Torque Specifications, Perkins Diesel
ENGINE
Cylinder Head Assembly
Capscrews, Cylinder Head Special Procedure (See
the section Perkins Diesel Engines, 1004-42 (AR),
1006-60 (YG), 1006-60T (YH) 600 YRM 705)
Fasteners, Rocker Arm Brackets
Aluminum 40 N•m (30 lbf ft)
Cast Iron 75 N•m (55 lbf ft)
Cap Nuts, Valve Cover
20 N•m (15 lbf ft)
Capscrews, Inlet Manifold to Cylinder Head
44 N•m (32 lbf ft)
Nuts (cadmium plated) Exhaust Manifold
to Cylinder Head
44 N•m (32 lbf ft)
Capscrews, Engine Lift Brackets
44 N•m (32 lbf ft)
Piston and Connecting Rod Assemblies
Nuts, Connecting Rods
125 N•m (92 lbf ft)
Capscrews, Connecting Rods
155 N•m (114 lbf ft)
Banjo Bolts, Piston Cooling Jets
27 N•m (20 lbf ft)
Crankshaft Assembly
Capscrews, Main Bearings
265 N•m (195 lbf ft)
Capscrews, Crankshaft Pulley
115 N•m (85 lbf ft)
Capscrews, Viscous Damper to Crankshaft Pulley
75 N•m (55 lbf ft)
Capscrews, Damper to Crankshaft Pulley
35 N•m (26 lbf ft)
Capscrews, Rear Oil Seal Housing to Engine Block
22 N•m (16 lbf ft)
Capscrews, Bridge Piece to Cylinder Block
16 N•m (12 lbf ft)
Capscrews, Rear Oil Seal Housing to Bridge Piece
13 N•m (10 lbf ft)
Torx-head screw, Rear Oil Seal Housing
to Engine Block
18 N•m (13 lbf ft)
Timing Case and Drive Assembly
Capscrews, Timing Case to Engine Block
M8 22 N•m (16 lbf ft)
M10 44 N•m (32 lbf ft)
Capscrews, Hub of Idler Gear
44 N•m (32 lbf ft)
Capscrew, Camshaft Gear
95 N•m (70 lbf ft)
Capscrews, Timing Case Cover to Timing Case
22 N•m (16 lbf ft)
Nuts, Timing Case Cover to Timing Case
22 N•m (16 lbf ft)
Turbocharger
Nuts, Turbocharger to Manifold
44 N•m (32 lbf ft)
9

12. Torque Specifications, Perkins Diesel 8000 YRM 940
Lubrication System
Plug, Oil Sump
34 N•m (25 lbf ft)
Capscrews, Oil Pump to Front Bearing Cap
22 N•m (16 lbf ft)
Capscrews, Cover for Oil Pump
28 N•m (21 lbf ft)
Fasteners, Oil Sump
22 N•m (16 lbf ft)
Fuel System
Nuts, High-pressure Fuel Lines
22 N•m (16 lbf ft)
Bolt Leak-off Connection
9 N•m (7 lbf ft)
Capscrews, Fuel Lift Pump
22 N•m (16 lbf ft)
Nut for Fuel Injector Body
40 N•m (30 lbf ft)
Capscrews for Gear of Fuel Injection Pump
28 N•m (21 lbf ft)
Special (Torx-head) Screws for the Gear of
the Fuel Injection Pump
22 N•m (16 lbf ft)
Nuts for Flange of Fuel Injection Pump
22 N•m (16 lbf ft)
Locking Screw of Lucas DP 200 Fuel Injection Pump
10 N•m (7 lbf ft)
Cooling System
Capscrews for Fan Drive Housing to Timing Case
44 N•m (32 lbf ft)
Capscrews, Fan Drive Pulley to Hub M8
22 N•m (16 lbf ft)
Capscrews, Fan Drive Pulley to Hub M10
44 N•m (32 lbf ft)
Capscrews, Fan
22 N•m (16 lbf ft)
Flywheel and Housing
Capscrews, Flywheel to Crankshaft
105 N•m (77 lbf ft)
Capscrews, Cast Iron Flywheel Housing
to Cylinder Block:
Head Stamped 8.8 (M10) 44 N•m (32 lbf ft)
Head Stamped 8.8 (M12) 75 N•m (55 lbf ft)
Head Stamped 10.9 (M10) 63 N•m (46 lbf ft)
Head Stamped 10.9 (M12) 115 N•m (85 lbf ft)
Capscrews, Aluminum Flywheel Housing
to Cylinder Block
70 N•m (52 lbf ft)
Capscrews, Flywheel Housing to Cylinder
Block (Paper Joint)
70 N•m (52 lbf ft)
Aspiration System
Nuts, Turbocharger to Manifold
44 N•m (32 lbf ft)
Electrical Equipment
Nut, Alternator Pulley:
Lucas CAV AC5RA and AC4RS 55 N•m (41 lbf ft)
Thin nut A127 and Motorola pulley 22 mm
A/F 60 N•m (44 lbf ft)
Thick nut A127 and Motorola pulley 22 mm
A/F 80 N•m (59 lbf ft)
Fueled Start Aid to Induction Manifold
31 N•m (23 lbf ft)
Nut/screw, Starter Motor
31 N•m (23 lbf ft)
Auxiliary Equipment
Nut, Air Compressor Drive Gear to Com-
pressor Drive Shaft
120 N•m (89 lbf ft)
Nut, (30mm A/F) Air Compressor Gears
130 N•m (96 lbf ft)
Capscrew, Bracket to Idler Hub
60 N•m (44 lbf ft)
Capscrew, Bracket to Timing Case
35 N•m (26 lbf ft)
10

13. 8000 YRM 940 Torque Specifications, General
Torque Specifications, General
TRANSMISSION
Nuts, Mount Bolts for Isolator
155 N•m (114 lbf ft)
Capscrews, Mount Bracket to Transmission
270 N•m (200 lbf ft)
Capscrews, Transmission to Flywheel Housing
Perkins 31 N•m (23 lbf ft)
Cummins 25 N•m (19 lbf ft)
Capscrews, Drive Plate to Flywheel
36 N•m (26.5 lbf ft)
Nut, Output Yoke
270 to 339 N•m (200 to 250 lbf ft)
Capscrews, Drive Plate to Torque Convertor
50 N•m (37 lbf ft)
Oil Screen Assembly
14 to 20 N•m (10 to 15 lbf ft)
Oil Filter
27 to 34 N•m (20 to 25 lbf ft)
See the sections Three-Speed Powershift
Transmission, Repairs 1300 YRM 931 and
Transmission 1300 YRM 1082 for other torque values.
DRIVELINE AND AXLE
Capscrews, Universal Yoke
50 N•m (37 lbf ft)
Bolts, Axle to Frame
920 N•m (679 lbf ft)
Nuts, Wheel (Front and Rear)
640 to 680 N•m (472 to 502 lbf ft)
DIFFERENTIAL
See the section Differential 1400 YRM 46.
BRAKES - WET
See the sections Planetary Drive Axle, (Wet System)
1400 YRM 944 and Wet Brake System 1800 YRM 951.
BRAKES - DRY
Air Fittings in Air Chambers
34 N•m (25 lbf ft)
Nuts Air Chamber Ring Clamps
GDP80-120DB (GP170-280DB) 27 to
34 N•m (20 to 25 lbf ft)
GDP130-160EB (GP300-360EB) 34 to
47 N•m (25 to 35 lbf ft)
Jam Nut, Clevis
47 to 68 N•m (35 to 50 lbf ft)
Lock Nuts, Air Chamber Studs
135 to 156 N•m (100 to 115 lbf ft)
Capscrew, Brake Anchor Pin
14 N•m (10 lbf ft)
Capscrew, Spider See the section Dry Brake
System 1800 YRM 937.
STEERING
Nut, Steering Wheel
68 N•m (50 lbf ft)
Capscrews, Steer Cylinder Mount
435 N•m (321 lbf ft)
Capscrews, Bearing Cap
75 N•m (55 lbf ft)
Nut, Wheel Bearing
Initial 203 N•m (150 lbf ft)
Final 34 N•m (25 lbf ft)
Note: Torque lock nut to Initial torque while rotating
wheel hub. Back off lock nut until wheel hub turns
freely with no end play. (Torque at this point should
be less than 27 N•m (20 lbf ft)). Retorque to Final
torque and lock in place at first alignment position
which occurs at or above final torque spec.
Nuts, Wheel (Front and Rear)
640 to 680 N•m (472 to 502 lbf ft)
Capscrews, Steer Axle Mount
270 N•m (199 lbf ft)
HYDRAULIC SYSTEM
Nuts, Hydraulic Pump Assembly
271 N•m (200 lbf ft)
Capscrews, High-pressure Hose Flange
71 N•m (52 lbf ft)
11

14. Torque Specifications, General 8000 YRM 940
Capscrews, Suction Hose Flange
110 N•m (81 lbf ft)
Nuts, Control Valve Assembly
7/16 in. 65 N•m (48 lbf ft)
1/2 in. 100 N•m (74 lbf ft)
Jam Nut, Relief Valve Adjustment
55 to 67 N•m (41 to 49 lbf ft)
Capscrews, Pump Mount
110 N•m (81 lbf ft)
MAST
Capscrews, Pivot Pin
435 N•m (321 lbf ft)
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nuts, Wear Plate
53 N•m (39 lbf ft)
Retainer, Lift Cylinder
GDP80-90DB (GP170-210DB) 400 to 475 N•m
(295 to 350 lbf ft)
GDP100-120DB (GP230-280DB) 475 to
550 N•m (350 to 406 lbf ft)
GDP130-160EB (GP300-360EB) 550 to
625 N•m (406 to 461 lbf ft)
CARRIAGE
Capscrew, Bearing Block
9 N•m (7 lbf ft)
Capscrews, Bearing Block Bracket
44 N•m (32 lbf ft)
Nut, Sideshift Cylinder Rod
675 N•m (498 lbf ft)
TILT CYLINDERS
Nut, Cylinder Rod
GDP80-120DB (GP170-280DB) 950 to
983 N•m (701 to 725 lbf ft)
GDP130-160EB (GP300-360EB) 1105 to
1140 N•m (815 to 841 lbf ft)
Retainer
GDP80-120DB (GP170-280DB) 542 to
610 N•m (400 to 450 lbf ft)
GDP130-160EB (GP300-360EB) 610 to
675 N•m (450 to 498 lbf ft)
Lock Nut, Rod End
66 N•m (49 lbf ft)
Capscrew, Pin Anchor
165 N•m (122 lbf ft)
FRAME
Capscrew, Rear Counterweight, Lubricated
1900 N•m (1401 lbf ft)
Nuts, Fender Counterweight, Lubricated
320 N•m (236 lbf ft)
Capscrews, Frame Counterweight, Lubricated
640 N•m (472 lbf ft)
WIPER ARMS, FRONT
Capscrews, Bracket to Cab
20 to 25 N•m (14.7 to 18.4 lbf ft)
Capscrews, Arm to Bracket
22 to 27 N•m (16.2 to 19.9 lbf ft)
Capscrews, Blade to Arm
8 to 10 N•m (6 to 7.4 lbf ft)
Capscrew, Arm Set
35 to 45 N•m (25.8 to 33.2 lbf ft)
12

15. 8000 YRM 940 Transmission Pressures (Powershift and Automatic)
Transmission Pressures (Powershift and Automatic)
A System Pressure 1100 to 1310 kPa
(160 to 190 psi)
H Torque Converter
Supply (Port H is on
the right-hand side
of the transmission
pump)
827 to 1034 kPa
(120 to 150 psi)
G Lubrication System
Pressure
55 to 103 kPa
(8 to 15 psi)
C Reverse Clutch
Pressure*
1100 to 1310 kPa
(160 to 190 psi)**
E Forward Clutch
Pressure*
1100 to 1310 kPa
(160 to 190 psi)**
F 1st Speed Clutch
Pressure
1100 to 1310 kPa
(160 to 190 psi)**
D 2nd Speed Clutch
Pressure
1100 to 1310 kPa
(160 to 190 psi)**
B 3rd Speed Clutch
Pressure
1100 to 1310 kPa
(160 to 190 psi)**
J Forward Pilot Pressure 1100 to 1310 kPa
(160 to 190 psi)
*Inching pressures 0 to 310 ±34 kPa (0 to 45 ±5 psi)
Modulator pressure increases 414 to 758 kPa (60 to 110 psi) in 1.2 to 1.6 seconds.
**The difference in clutch pressures for all clutches cannot be greater than 70 kPa (10 psi).
13

16. TE-10 Transmission Specifications 8000 YRM 940
TE-10 Transmission Specifications
ELECTRICAL
Electronic-controlled modulation solenoids
VFS 2nd - VFS 1st/3rd - VFS Fwd - VFS Rev
Coil resistance - 4.35 ±0.35 at 25°C (77°F)
On/Off solenoids
Total neutral and selector solenoids
Coil resistance - 12V - 28 ±2 at 20°C (68°F)
Coil resistance - 24V - 28 ±2 at 20°C (68°F)
Speed sensor
Type - Magneto resistive sensor.
Sensing distance - 0 to 1.8 mm (0 to 0.07 in.)
Sensor signal - Generates a square current with a
fixed amplitude changing between 7 and 14 mA.
Table 1. Temperature Sensor (In Speed Sensor)
Resistance vs Temperature
Ambient Temperature Resistance
55°C ( 67°F) 980
50°C ( 58°F) 1030
40°C ( 40°F) 1135
30°C ( 22°F) 1247
20°C ( 4°F) 1367
10°C (14°F) 1496
0°C (32°F) 1630
10°C (50°F) 1772
20°C (68°F) 1922
25°C (77°F) 2000
30°C (86°F) 2080
40°C (104°F) 2245
Table 1. Temperature Sensor (In Speed Sensor)
Resistance vs Temperature (Continued)
Ambient Temperature Resistance
50°C (122°F) 2417
60°C (140°F) 2597
70°C (158°F) 2785
80°C (176°F) 2980
90°C (194°F) 3182
100°C (212°F) 3392
110°C (230°F) 3607
120°C (248°F) 3817
125°C (257°F) 3915
130°C (266°F) 4008
140°C (284°F) 4166
150°C (302°F) 4280
HYDRAULIC COOLER LINES
There is a minimum 19 mm (0.75 in.) internal diameter
for lines and fittings. They must be suitable for operation
from ambient temperature to 120°C (248°F) continu-
ous operating temperature. They must withstand 30 bar
(435 psi) continuous pressure and 45 bar (652 psi) in-
termittent surges. Conform SAE J1019 and SAE J517,
100RI.
TORQUE SPECIFICATIONS FOR
LUBRICATED OR PLATED SCREW
THREADS
14

17. 8000 YRM 940 TE-10 Transmission Specifications
Table 2. Grade 5
Nom.
Size
Fine Thread Coarse Thread
0.2500 12.2 to 14.9 N•m (9 to 11 lbf ft) 10.8 to 13.6 N•m (8 to 10 lbf ft)
0.3125 21.7 to 27.1 N•m (16 to 20 lbf ft) 16.3 to 21.7 N•m (12 to 16 lbf ft)
0.3750 35.2 to 39.3 N•m (26 to 29 lbf ft) 31.2 to 33.9 N•m (23 to 25 lbf ft)
0.4375 55.6 to 61 N•m (41 to 45 lbf ft) 50.2 to 55.6 N•m (37 to 41 lbf ft)
0.5000 86.8 to 94.9 N•m (64 to 70 lbf ft) 77.3 to 85.4 N•m (57 to 63 lbf ft)
0.5625 123.4 to 135.6 N•m (91 to 100 lbf ft) 111.2 to 122 N•m (82 to 90 lbf ft)
0.6250 173.5 to 191.1 N•m (128 to 141 lbf ft) 153.2 to 168.1 N•m (113 to 124 lbf ft)
0.7500 302.3 to 332.1 N•m (223 to 245 lbf ft) 271.1 to 298.2 N•m (200 to 220 lbf ft)
Table 3. Grade 8
Nom.
Size
Fine Thread Coarse Thread
0.2500 14.9 to 17.6 N•m (11 to 13 lbf ft) 12.2 to 14.9 N•m (9 to 11 lbf ft)
0.3125 38 to 43.4 N•m (28 to 32 lbf ft) 35.2 to 40.7 N•m (26 to 30 lbf ft)
0.3750 50.2 to 55.6 N•m (37 to 41 lbf ft) 44.7 to 48.8 N•m (33 to 36 lbf ft)
0.4375 78.6 to 86.8 N•m (58 to 64 lbf ft) 70.5 to 77.3 N•m (52 to 57 lbf ft)
0.5000 122 to 134.2 N•m (90 to 99 lbf ft) 108.4 to 119.3 N•m (80 to 88 lbf ft)
0.5625 173.5 to 191.1 N•m (128 to 141 lbf ft) 155.9 to 172.2 N•m (115 to 127 lbf ft)
0.6250 244 to 268.4 N•m (180 to 198 lbf ft) 215.5 to 237.2 N•m (159 to 175 lbf ft)
0.7500 427 to 470.4 N•m (315 to 347 lbf ft) 382.3 to 420.2 N•m (282 to 310 lbf ft)
15

18. TE-10 Transmission Specifications 8000 YRM 940
Table 4. Grades 8.8, 10.9, and 12.9
Grade 8.8 Grade 10.9 Grade 12.9
Nom. Size
Coarse Thread Coarse Thread Coarse Thread
M5 5 to 6 N•m
(3.7 to 4.4 lbf ft)
7 to 8 N•m
(5.2 to 5.9 lbf ft)
8 to 10 N•m
(5.9 to 7.4 lbf ft)
M6 8 to 10 N•m
(5.9 to 7.4 lbf ft)
12 to 15 N•m
(8.9 to 11.1 lbf ft)
13 to 16 N•m
(9.6 to 11.8 lbf ft)
M8 20 to 25 N•m
(14.8 to 18.4 lbf ft)
30 to 35 N•m
(22.1 to 25.8 lbf ft)
35 to 40 N•m
(25.8 to 29.5 lbf ft)
M10 40 to 50 N•m
(29.5 to 36.9 lbf ft)
60 to 65 N•m
(44.3 to 47.9 lbf ft)
65 to 75 N•m
(47.9 to 55.3 lbf ft)
M12 68 to 75 N•m
(50.2 to 55.3 lbf ft)
100 to 110 N•m
(73.8 to 81.1 lbf ft)
115 to 130 N•m
(84.8 to 95.9 lbf ft)
M14 110 to 125 N•m
(81.1 to 92.2 lbf ft)
150 to 175 N•m
(110.6 to 129.1 lbf ft)
180 to 210 N•m
(132.8 to 154.9 lbf ft)
M16 170 to 190 N•m
(125.4 to 140.1 lbf ft)
240 to 275 N•m
(177 to 202.8 lbf ft)
280 to 320 N•m
(206.5 to 236 lbf ft)
M20 320 to 360 N•m
(236 to 265.5 lbf ft)
450 to 500 N•m
(331.9 to 368.8 lbf ft)
525 to 600 N•m
(387.2 to 442.5 lbf ft)
M24 570 to 650 N•m
(420.4 to 479.4 lbf ft)
800 to 900 N•m
(590.1 to 663.8 lbf ft)
900 to 1050 N•m
(663.8 to 774.4 lbf ft)
M30 1150 to 1300 N•m
(848.2 to 958.8 lbf ft)
1600 to 1800 N•m
(1180.1 to 1327.6 lbf ft)
1850 to 2100 N•m
(1364.5 to 1548.9 lbf ft)
M36 2000 to 2250 N•m
(1475.1 to 1659.5 lbf ft)
2749 to 3149 N•m
(2027.6 to 2322.6 lbf ft)
3249 to 3699 N•m
(2396.3 to 2728.2 lbf ft)
16

19. 8000 YRM 940 TE-10 Transmission Specifications
Table 5. O-ring Port Plug Torque Chart
Thread Size
NPTF
Torque
1/16 × 27 7 to 9 N•m (5 to 7 lbf ft)
1/8 × 27 9 to 14 N•m (7 to 10 lbf ft)
1/4 × 18 20 to 27 N•m (15 to 20 lbf ft)
3/8 × 18 34 to 41 N•m (25 to 30 lbf ft)
1/2 × 14 41 to 47 N•m (30 to 35 lbf ft)
3/4 × 10 or 14 54 to 61 N•m (40 to 45 lbf ft)
1 × 11 1/2 68 to 75 N•m (50 to 55 lbf ft)
1 1/4 × 11 1/2 81 to 88 N•m (60 to 65 lbf ft)
M10 × 1 8 to 10 N•m (6 to 7 lbf ft)
M14 × 1.5 10 to 12 N•m (7 to 9 lbf ft)
M18 × 1.5 34 to 41 N•m (25 to 30 lbf ft)
Table 5. O-ring Port Plug Torque Chart (Continued)
Thread Size
NPTF
Torque
M22 × 1.5 48 to 60 N•m (35 to 44 lbf ft)
M33 × 2 112 to 140 N•m (83 to 103 lbf ft)
Table 6. Pipe Plug Torque Chart
Plugs
(Permanent Plugs)
Nom. Size
Torque
M18 × 1.5
6H
34 to 41 N•m (25 to 30 lbf ft)
M26 × 1.5
6H
61 to 68 N•m (45 to 50 lbf ft)
17

20. 100 YRM 927 Description
General
This section has the description and repair procedures
for the frame and connected parts. Included in this sec-
tion are the frame, counterweight, fenders, hood, hy-
draulic and fuel tanks, radiator/cooling section, opera-
tor compartment, and cab. The instructions for removal
and installation of the engine are included in this sec-
tion.
If the lift truck is fitted with a battery disconnect switch,
open the switch if welding on the engine and remove
the ECM (Engine Control Module). If welding on the
lift truck chassis, verify the ground clamp is placed as
close to the welding point as possible and NOT near the
ECM. If it is necessary to weld near the ECM, remove
the ECM from the engine to avoid damage from welding
arc radiation.
Description
The frame is a one-piece weldment and has mounts
for the counterweight, fenders, engine, transmission,
axles, hydraulic and fuel tanks, operator’s compart-
ment, and other parts. See Figure 1.
1. MAIN MOUNT
2. COUNTERWEIGHT MOUNT
3. STEERING MOUNT
4. DRIVE AXLE MOUNT
5. TILT CYLINDERS MOUNT
6. CAB CYLINDER MOUNT
7. CAB HINGE
8. MAST MOUNT
9. SIDE COUNTERWEIGHT MOUNT
10. FENDERS
11. CAB LATCH MOUNT
Figure 1. Frame
1

21. Counterweight Repair 100 YRM 927
Counterweight Repair
REMOVE
WARNING
The counterweight is heavy. Make sure that the
crane and lifting devices have the capacity to lift
4600 kg (10,141 lb).
1. Remove the hood spine assembly. See Hood and
Air Cleaner Repair.
2. GDP80-120DB (GP170-280DB) units only. Re-
move the counterweight by placing an eyebolt
through the hole in the top of the counterweight.
See Figure 2. The eyebolt must be able to support
the weight of the counterweight. Attach a lifting
device to eyebolt.
GDP130-160EB (GP300-360EB) units only. Re-
move the fenders, noting shims used and location
of shims. Remove the radiator fan, shroud, and
hardware. Tilt the radiator away from the coun-
terweight so there is clearance when removing the
counterweight. See Figure 2. Install eyebolt into
the top of the counterweight. The eyebolt must be
able to support the weight of the counterweight. At-
tach lifting device.
3. Remove the single capscrew from the rear of the
counterweight. Remove the counterweight from the
frame.
INSTALL
WARNING
The counterweight is heavy. Make sure that the
crane and lifting devices have the capacity to lift
4600 kg (10,141 lb).
1. Put a chain into top opening of the counterweight
and attach chain to a lifting device. See Figure 2.
2. GDP130-160EB (GP300-360EB) units only. In-
stall the radiator hardware. Tilt the radiator ahead
so there is clearance for the chain that is installed
through the counterweight.
3. Install the counterweight on the frame. Install the
capscrew, lockwasher, and flat washer to fasten the
counterweight to the frame. Tighten the capscrew
to 1140 N•m (841 lbf ft).
FENDERS
Remove
WARNING
The fenders are part of the lift truck counterweight
and are very heavy. Make sure any lifting devices
have the capacity to lift 1750 kg (3858 lb). Make sure
the fender is balanced and supported by the chain.
The fenders are not of a regular shape and can be
difficult to handle.
1. Remove the capscrews, washers, and nuts that fas-
ten the fender to the frame mount. Install eyebolts
in the mount holes. Use mount holes to pick up
fender from frame.
2. Fasten a lifting device to the eyebolts. Operate the
lifting device and lift the fender away from the frame.
Install
1. Install eyebolts in the fenders as described in Re-
move, Step 1. Fasten a lifting device to the eye-
bolts.
2. Raise the fender to the lift truck. Align the eyebolts
in the fender with the holes in the fender mount on
the frame. Shim fenders to correct height. Lower
the fender to the fender mount and remove the lift-
ing device and the eyebolts.
3. Install the capscrews, washers, and nuts that hold
the fender to the frame. Tighten the nuts to 320 N•m
(236 lbf ft).
2

22. 100 YRM 927 Counterweight Repair
1. LH FENDER
COUNTERWEIGHT
2. RH FENDER
COUNTERWEIGHT
3. CAPSCREW
4. WASHER
5. NUT
6. WASHER
7. TOW PIN
8. GRIP
9. PIN
10. PIN
11. SHIM
12. WASHER
13. LOCKWASHER
14. WASHER
15. SHIM
16. SHIM
17. SHIM
18. COUNTERWEIGHT
19. CAPSCREW
20. SLAB COUNTERWEIGHT
21. PLATE
22. LOCKWASHER
23. CAPSCREW
24. RH SLAB COUNTERWEIGHT
25. LH SLAB COUNTERWEIGHT
26. CAPSCREW
27. WASHER
28. WASHER
29. NUT
30. ISOLATOR
31. LOCKWASHER
32. NUT
33. RUBBER STOP
Figure 2. Counterweight Mounts
3

23. Hood and Air Cleaner Repair 100 YRM 927
SIDE COUNTERWEIGHTS GDP130-160EB
(GP300-360EB)
The counterweights located on either side of the lift
truck are fastened to the frame by large capscrews.
Normally these counterweights will never have to be re-
moved or replaced on the lift truck.
SIDE COUNTERWEIGHT, REPLACE
If replacement of the side counterweight is required, do
the following procedure:
WARNING
The side counterweights are heavy. Each side
counterweight weighs approximately 560 kg
(1235 lb). Make sure that the crane and lifting
devices have the capacity to lift 908 kg (2433 lb).
1. Remove the extension covers from both side tanks.
2. Remove each counterweight capscrew and replace
it in turn with a long stud. The studs must protrude
about 152 mm (6 in.) beyond the counterweight.
3. Use a pry bar and carefully move the counterweight
away from the frame about 50 mm (2 in.). Install
a nylon lifting sling securely around the counter-
weight and attach it to a lifting device.
WARNING
Make sure the counterweight is balanced and can-
not fall from the sling when the sling is raised.
4. Carefully lift the counterweight away from the lift
truck frame and lower the counterweight to the floor.
5. For installation of the side counterweights, follow
the above procedure in reverse order. Tighten the
counterweight capscrews to 655 N•m (483 lbf ft).
Hood and Air Cleaner Repair
The hood and air cleaner assembly, which includes the
rain cap or optional precleaner and inlet pipe, can be
removed from the frame as a single unit, or pivoted out
of the way for access.
REMOVE
NOTE: The hood and air cleaner assembly can be piv-
oted out of the way to gain access to many components.
In order to pivot hood and air cleaner assembly, remove
2 bolts, nuts, and washers at one side connecting hood
to hood spine support and loosen the 2 bolts at oppo-
site side.
1. Unlock hood with an allen wrench.
2. Open hood panel until gas spring locks hood panel
in open position.
3. Attach a lifting device and sling to support hood
spine and attaching components. See Figure 3 and
Figure 4.
4. Loosen air intake hose to turbocharger at inlet side
of turbocharger.
5. Loosen clamps at upper exhaust stack.
6. Remove bolts, nuts, washers, and bar washers that
fasten hood spine to counterweight and hood sup-
port.
7. Disconnect washer hoses from washer container
and mark for reconnecting.
8. Disconnect the washer hoses from hood and air
cleaner assembly.
9. Using lifting device, lift hood assembly from frame.
Air filter assembly and exhaust stack will remain
attached to hood and spine assembly.
INSTALL
Install the hood and air cleaner assembly in the reverse
procedure of removal and align the hood as necessary
during installation. Make sure the hood side panels
close completely and that the cushioned screw stops
(bumpers) are located correctly.
4

24. 100 YRM 927 Hood and Air Cleaner Repair
1. HOOD SPINE HARDWARE
2. HOOD SPINE
3. COUNTERWEIGHT
4. HOOD SPINE SUPPORT
5. AIR INTAKE HOSE
6. EXHAUST STACK CLAMP
7. RAIN CAP
8. GAS SPRING
9. HOOD PANEL
10. EXHAUST STACK
Figure 3. Hood and Air Cleaner Assembly (B876 and B877)
5

25. Hood and Air Cleaner Repair 100 YRM 927
1. HOOD SPINE HARDWARE
2. HOOD SPINE
3. COUNTERWEIGHT
4. HOOD SPINE SUPPORT
5. AIR INTAKE HOSE
6. EXHAUST STACK CLAMP
7. RAINCAP
8. HOOD PANEL
9. EXHAUST STACK
Figure 4. Hood and Air Cleaner (C876 and C877)
6

26. 100 YRM 927 Hydraulic Tank Repair
Hydraulic Tank Repair
The hydraulic tank is installed on the right side of the
frame between the front and rear fenders.
REMOVE
1. Remove the side cover between the bottom of the
operator compartment and the top of the hydraulic
tank. See Figure 5. If necessary, remove the drain
plug at the bottom of the tank to drain the oil. See
Figure 6 and Figure 7.
2. Remove the extension panel.
NOTE: Do not remove items 14, 15, 16, and 17 from
the tank.
3. Disconnect the hoses at the top elbow connection
and at the side connection to the tank located on
the inside of the frame. Use a pan to catch the oil
that is in the hydraulic lines. Put tags on the lines
for identification. Put caps on the open lines and
the fittings.
WARNING
Make sure that the tank is supported by blocks be-
fore removing the nuts and washers from the top of
the tank.
4. Support the fuel tank with blocks from beneath.
First, remove the three capscrews that fasten the
bottom of the tank to the running board. Remove
the three nuts and washers that hold the top of the
tank to the frame. Install two lifting eyes at the outer
holes. Attach a lifting device and support the tank.
Lift the tank from the frame.
1. HYDRAULIC TANK
2. BATTERY BOX
3. FRAME
4. SIDE COVER
5. NUT AND WASHER
6. EXTENSION PANEL
Figure 5. Hydraulic Tank and Battery Box
7

27. Hydraulic Tank Repair 100 YRM 927
1. WASHER (3)
2. LOCKWASHER (3)
3. BREATHER
4. FILTER HEAD
5. O-RING
6. DIPSTICK
7. O-RING
8. SEAL
9. SPRING
10. WASHER
11. FILTER
12. DRAIN PLUG
13. NUT (3)
14. ADAPTER
15. ADAPTER
16. HYDRAULIC TANK
17. O-RING
18. RETAINING RING
19. FITTING
20. FITTING
21. PLUG
Figure 6. Hydraulic Tank (B876 and B877)
1. SIGHT GLASS
2. FILTER
3. FILTER HEAD
4. SPRING
5. O-RING
6. CAPSCREW
7. PLUG
8. BREATHER
9. WASHER
10. NUT
11. DRAIN PLUG
12. O-RING
13. HYDRAULIC TANK
14. COVER
15. SEAL
16. WASHER
17. CAPSCREW
Figure 7. Hydraulic Tank (C876 and C877)
8

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