YALE (D810) GDP030VX LIFT TRUCK Service Repair Manual

GLP030VX, GDP030VX, GLP035VX, GDP035VX, GLP040SVX, GDP040SVX (D810) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................

OPERATOR'S CAB........................................................................................................

YANMAR DIESEL ENGINES..........................................................................................

PSI 2.0 LPG ENGINE......................................................................................................

COOLING SYSTEM........................................................................................................

PSI 2.0L LPG FUEL SYSTEM........................................................................................

SINGLE SPEED PS CHAIN DRIVE PTO........................................................................

DRIVE AXLE...................................................................................................................

STEERING AXLE............................................................................................................

BRAKE SYSTEM............................................................................................................

HYDRAULIC CLEANLINESS PROCEDURES...............................................................

HYDRAULIC GEAR PUMPS..........................................................................................

MAIN CONTROL VALVE................................................................................................

CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)...........................................

CYLINDER REPAIR (MAST S/N B551, B555, B559)....................................................

WIRE HARNESS REPAIR..............................................................................................

USER INTERFACE.........................................................................................................

USER INTERFACE.........................................................................................................

ELECTRICAL SYSTEM..................................................................................................

ENGINE ELECTRICAL SYSTEM, PSI 2.0L ENGINE.....................................................

MAST REPAIR (S/N B551, B555, B559)........................................................................

METRIC AND INCH (SAE) FASTENERS.......................................................................

CALIBRATION PROCEDURES......................................................................................

PERIODIC MAINTENANCE............................................................................................

CAPACITIES AND SPECIFICATIONS...........................................................................

DIAGRAMS AND SCHEMATICS....................................................................................

DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

550108490 550108590 524240453 550108491 550108492 550108494 550108495 550108496 550108497 550108498 550073240 550108499 550108500 550093750 550108501 524223769 524223770 524223771 550108502 550108503 550108504 524150797 524223780 550108505 550108506 550108507 524221866

0100 YRM 1735 0100 YRM 1752 0600 YRM 1205 0600 YRM 1736 0700 YRM 1737 0900 YRM 1739 1300 YRM 1740 1400 YRM 1741 1600 YRM 1742 1800 YRM 1743 1900 YRM 1620 1900 YRM 1744 2000 YRM 1745 2100 YRM 1668 2100 YRM 1746 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1747 2200 YRM 1748 4000 YRM 1749 8000 YRM 0231 8000 YRM 1134 8000 YRM 1750 8000 YRM 1751 8000 YRM 1753 9000 YRM 1112

12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 10/13 12/14 12/14 12/14 12/14 12/14

PART NO. 550108582 (12/14)

0100 YRM 1735

General

General WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •

Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

•

Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

NOTE: For lift trucks equipped with a PSI 2.0L LPG engine, see PSI 2.0L LPG Fuel System 0900YRM1739 for procedures to remove and install the exhaust system components. If lift truck is equipped with a Yanmar 2.6L diesel engine, see Exhaust System Repair in this manual for procedures.

This section contains the description of the frame (see Figure 1) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine and transmission, cooling system, exhaust system (see NOTE above), and other components attached to the frame are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the section Periodic Maintenance 8000YRM1750

1

Description

0100 YRM 1735

Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1.

There is a counterweight for each capacity of lift truck.

The counterweights are similar in appearance, but are different weights. See Counterweight Replacement section.

The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the frame with hinges. Two gas-controlled springs provide assistance when raising the hood and hold the hood in the open position. The floor plate and side covers can be removed for access to the engine, transmission, and other components.

The muffler is fastened to the frame inside the counterweight.

1.

2.

3.

4.

COWL PLATE FENDERS FRAME HOOD MOUNTS

5. COUNTERWEIGHT MOUNTS 6. FUEL TANK (DIESEL) 7. HYDRAULIC TANK Figure 1. Frame Components

2

0100 YRM 1735

Hood, Seat, and Side Covers Replacement

Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat all the way to the rear of the hood.

2. Use tilt lever and tilt steering column all the way forward. See Figure 2.

7. Remove capscrews, washers, and left and right rear side covers from frame.

8. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), remove eight capcrews, eight clip nuts, and left and right step covers from frame. See Figure 6.

9. For lift truck models GLC030-035VX, GLC040SVX (D809), remove six capscrews and left and right step plates from frame. See Figure 6.

For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), remove six capscrews, six clip nuts, and left and right step plates from frame.

See Figure 6.

1. TILT LEVER 2. GAS CYLINDER Figure 2. Steering Column Tilt Lever 3. If your truck is equipped with an LPG tank, swing tank off to the side. See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures.

4. Raise hood latch on the left, front corner of the hood to unlatch and lift up hood. See Figure 3.

5. Disconnect the battery.

6. Remove floor mat and floor plate.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

1. HOOD LATCH 2. HOOD Figure 3. Hood Latch

3

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLC030-035VX, GLC040SVX (D809) 4

0100 YRM 1735

Hood, Seat, and Side Covers Replacement Legend for Figure 4

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

RADIATOR COVER WASHER CAPSCREW RIGHT REAR COVER INSERT LEFT REAR COVER LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER CLIP NUT DASH PANEL SEAL

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

KICK PANEL FLOOR PLATE GROMMET SEAL PLATE LEFT STEP PLATE RIGHT STEP PLATE LEFT FRONT COVER RIGHT FRONT COVER FLOOR MAT CLIP

5

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

Figure 5. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810) 6

0100 YRM 1735

Hood, Seat, and Side Covers Replacement Legend for Figure 5

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

CAPSCREW WASHER INSERT RADIATOR COVER LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER CLIP NUT DASH PANEL KICK PANEL GROMMET SEAL PLATE SEAL

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

FUEL SHIELD (DIESEL) LEFT REAR COVER RIGHT REAR COVER FLOOR PLATE FLOOR MAT RIGHT STEP COVER LEFT STEP COVER RIGHT FRONT COVER LEFT FRONT COVER RIGHT STEP PLATE LEFT STEP PLATE CLIP

7

Hood, Seat, and Side Covers Replacement

Figure 6. Step Covers and Step Plates Remove/Install

8

0100 YRM 1735

0100 YRM 1735

Hood, Seat, and Side Covers Replacement Legend for Figure 6

NOTE: RIGHT SIDE SHOWN. PROCEDURES ARE THE SAME FOR LEFT SIDE. A. STEP PLATE FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809) B. STEP PLATE AND STEP COVER FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) 1. STEP PLATE 2. CAPSCREW 3. RIGHT REAR COVER

4. RIGHT STEP COVER 5. CLIP NUT

10. Remove capscrews, washers, and left and right front cover from frame.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

11. Use tilt lever and fully lower steering column. See Figure 2.

12. Remove upper steering column cover by pulling up on upper steering column cover to release latches (one on either side), and pulling cover away from steering column. See Figure 7.

13. Remove five fasteners securing dash to the top of cowl. See Figure 7. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash.

• •

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809) See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

14. Lift kick panel and remove from truck.

15. Remove three capscrews and clip nuts from seal plate. Remove seal plate from frame.

16. Remove two capscrews and washers from cover plate and remove seat box. Disconnect seat wire harness connector. See Figure 8.

CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews.

Damage can be caused to the threads on the screws and in the holes.

NOTE: Before removing seat from hood, tag or mark holes that mount seat to hood. This will aid in correctly installing seat to hood.

17. Remove four capscrews and washers attaching seat to hood. Lift seat up and remove from hood.

18. Remove radiator cover and seals from lift truck frame.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

19. Remove two capscrews and hood latch striker bolt from mounting bracket. See Figure 9.

20. Remove two capscrews and hood latch from hood. See Figure 9.

21. Remove capscrews and washers at the top of gas springs. Remove gas springs from hood.

22. Remove hinge screws, located in the rear of the hood. See Figure 10.

23. Remove hood from lift truck.

9

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

NOTE: TOP VIEW OF DASH SHOWN. A. INDICATES TO PULL UP TO UNLATCH 1. FASTENERS 2. COWL

3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER Figure 7. Remove Dash From Cowl

10

0100 YRM 1735

Hood, Seat, and Side Covers Replacement

A. FULL SUSPENSION SEAT B. SEMI- AND NON- SUSPENSION SEATS 1.

2.

3.

4.

5.

CAPSCREWS WASHERS SEAT BOX SEAT WIRE HARNESS CONNECTOR COVER PLATE Figure 8. Seat Wire Harness Connector

11

Hood, Seat, and Side Covers Replacement

Figure 9. Hood Latch and Hood Latch Striker Bolt Remove/Install

12

0100 YRM 1735

0100 YRM 1735

Hood, Seat, and Side Covers Replacement Legend for Figure 9

A. HOOD LATCH AND HOOD LATCH STRIKER BOLT FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809)

B. HOOD LATCH AND HOOD LATCH STRIKER BOLT FOR LIFT TRUCK MODELS GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

1.

2.

3.

4.

5. HOOD LATCH 6. BUMPER

CAPSCREW (HOOD LATCH STRIKER BOLT) CAPSCREW (HOOD LATCH) HOOD LATCH STRIKER BOLT HOOD LATCH STRIKER BOLT MOUNTING BRACKET

INSTALL

•

See Figure 11 and Table 1 for lift truck models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810)

•

See Figure 12 for lift truck models GLC030-035VX, GLC040SVX (D809)

1. Place hood onto the lift truck frame.

2. Install hinge screws, located in the rear of the hood, and tighten to 38 N•m (28 lbf ft). See Figure 10.

NOTE: LEFT SIDE SHOWN.

1. HINGE SCREWS 2. HINGE 3. HOOD Figure 10. Hood Removal/Installation 3. Align top holes in the gas springs with holes in hood. Install capscrews and washers to attach gas springs to hood. Tighten capscrews to 19 N•m (170 lbf in).

A. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT B. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT WITH CAB 1. MOUNTING POINTS FOR GAS SPRING ON HOOD Figure 11. Gas Spring Installation, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

13

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) Full or Semi-Suspension Seat Frame

Non-Suspension Seat

Hood

Frame

Hood

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Seat Without EControl

B

B

3

3

A

A

1

1

Seat With E-Control

B

B

2

2

N/A

N/A

N/A

N/A

Cab

C

C

2

2

N/A

N/A

N/A

N/A

the bolt strikes hood latch properly and that the bumpers contact the frame. A properly closed hood MUST click twice on the hood latch. If the hood latch does not close properly, loosen capscrews on the back of hood latch striker bolt and adjust bolt up or down as required for correct alignment.

6. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood latch. Open hood and tighten capscrews for latch.

7. Check operation of hood latch. Have an operator sit in seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 6.

CAUTION NOTE: LEFT SIDE SHOWN. 1. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT 2. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT Figure 12. Gas Spring Installation, Lift Truck Models GLC030-035VX, GLC040SVX (D809) 4. Install hood latch to hood using two capscrews.

See Figure 9.

5. Install latch striker bolt in highest slot position on mounting bracket. See Figure 9. Check that latch striker bolt is in center of jaws of hood latch when hood closes. Open and close hood to ensure that 14

When installing the seat to the hood, DO NOT use an impact wrench to install the capscrews. Damage can be caused to the threads on the screws and in the holes.

8. Place seat on hood. Align holes in seat with holes in hood as noted during removal. Insert washers and capscrews.

Tighten capscrews to 18 N•m (159 lbf in).

9. Install radiator cover and seals to frame.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

0100 YRM 1735 10. Connect seat wire harness. Install seat box to cover plate with two capscrews and washers.

Tighten capscrews to 1.2 N•m (10.6 lbf in). See Figure 8.

11. Install seal plate using three capscrews and clip nuts.

12. Install kick panel onto truck.

Hood, Seat, and Side Covers Replacement 16. For lift truck models GLC030-035VX, GLC040SVX (D809), install left and right step plates, and six capscrews to frame. See Figure 6.

For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), install left and right step plates, six clip nuts, and three capscrews onto frame. See Figure 6.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

17. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), install left and right step covers, eight clip nuts, and eight capscrews onto frame. See Figure 6.

13. Install dash to top of cowl. See Figure 7. Install four clips to attach the dash to kick panel.

18. Install left and right rear covers, washers and capscrew onto frame.

14. Install upper steering column cover to dash.

19. Install floor mat and floor plate.

15. Install left and right front covers, washers, and capscrews onto frame.

20. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight. See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

21. Connect the battery.

22. Adjust the steering column and seat positions.

15

Steering Column

0100 YRM 1735

Steering Column DESCRIPTION This section describes the repair procedures for the steering column. The steering column assembly mounts to the cowl inside the operator compartment and is the mechanical connection between the steering wheel and the steering control unit. The steering column includes the steering wheel, housing, bracket and lower shaft. For lift truck models GLC030-035VX, GLC040SVX (D809), capscrews and bushings attach the steering column to the cowl standoffs. For lift truck models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810), capscrews, bushings and isolators attach the steering column to the cowl standoffs. See Figure 13.

STEERING COLUMN REPAIR Remove 1. Put blocks on each side (front and back) of tires to prevent lift truck from moving.

WARNING Disconnect the battery before removing any covers to avoid injury to personnel.

2. Attach a tag on the battery connector or negative battery cable stating, DO NOT CONNECT BATTERY. Move the steering column to the most forward position.

CAUTION If a puller tool is used to remove steering wheel from steering column, be careful not to damage horn wires.

NOTE: This procedure is for the removal of all components of the steering column assembly. Not all components are removed for a repair procedure. Do only those steps of the procedure necessary to remove the required component.

NOTE: Tag wires prior to disconnecting them.

3. Remove the horn button assembly and disconnect electrical wires. Remove large hex nut and steering wheel from steering column. See Figure 14.

4. Remove steering column covers. Remove floor mats and floor plate. See Hood, Seat, and Side Covers Replacement section for procedures.

1.

2.

3.

4.

1. STEERING WHEEL 2. STEERING COLUMN 3. COWL Figure 13. Steering Column and Cowl

16

HORN BUTTON HEX NUT STEERING WHEEL STEERING COLUMN Figure 14. Steering Wheel Remove/Install

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