YALE G813 GLP100VX LIFT TRUCK Service Repair Manual

14 pages
0 views
of 14

Please download to get full document.

View again

All materials on our website are shared by users. If you have any questions about copyright issues, please report us to resolve them. We are always happy to assist you.
Share
Description
GP/GLP/GDP80VX, GP/GLP/GDP90VX, GP/GLPGDP100VX, GP/GLP/ GDP110VX, GP/GLP/GDP120VX (G813) SERVICE MANUAL CONTENTS SECTION…
Transcript
GP/GLP/GDP80VX, GP/GLP/GDP90VX, GP/GLPGDP100VX, GP/GLP/ GDP110VX, GP/GLP/GDP120VX (G813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM 4.3L)...................................................................................... GASOLINE FUEL SYSTEM (GM 4.3L).......................................................................... LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ GASOLINE FUEL SYSTEM............................................................................................ 1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... POWERSHIFT TRANSMISSION REPAIR...................................................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................PART NUMBERYRM NUMBERREV DATE524262274 524306203 524265337 524223757 524262275 524262276 550043871 550048401 524223762 550043436 524262277 524262278 524223764 524262279 524223766 550073240 5242237670100 YRM 1243 0100 YRM 1290 0600 YRM 1251 0700 YRM 1123 0900 YRM 1242 0900 YRM 1244 0900 YRM 1556 0900 YRM 1570 1300 YRM 1129 1300 YRM 1529 1400 YRM 1245 1400 YRM 1246 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 113705/14 04/14 05/14 03/13 08/12 06/12 04/14 09/13 09/09 08/13 01/12 12/13 07/13 03/13 04/14 12/14 04/14524223768 524208014 524223769 524223770 524223771 5242237722100 YRM 1139 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 114202/14 05/14 12/14 12/14 12/14 04/14524265342 524150797 524223780 524262280 524262281 524329117 550001092 5242218664000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1248 8000 YRM 1249 8000 YRM 1387 8000 YRM 1409 9000 YRM 111202/14 10/13 12/14 04/13 08/11 04/14 04/14 12/14Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 524329176 (12/14)SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.NOTE: The following symbols and words indicate safety information in this manual:WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.Cooling SystemTable of ContentsTABLE OF CONTENTS General................................................................................................................................................................ Cooling System Checks ...................................................................................................................................... Exhaust Leaks Into Cooling System ............................................................................................................... Water Flow Restrictions in Radiator ................................................................................................................ Radiator Hoses ............................................................................................................................................... Water Pump .................................................................................................................................................... Flushing the Cooling System............................................................................................................................... Cooling System, Clean.................................................................................................................................... Radiator Replacement......................................................................................................................................... Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) .............................................................................................................................. Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974) Equipped with Oil Cooler................................................................................................................................. Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) .................................................................................................................................................... Radiator, Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) ....................................................... Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) .............................................................................................................................. Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974) Equipped with Oil Cooler................................................................................................................................. Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) .................................................................................................................................................... Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) ....................................................... Fan Assembly Replacement................................................................................................................................ Fan Removal ................................................................................................................................................... Inspect............................................................................................................................................................. Fan Installation ................................................................................................................................................©2013 Yale Materials Handling Corp.1 1 1 1 1 1 2 2 3319212429333437 47 47 62 62iTable of ContentsCooling SystemTABLE OF CONTENTS (Continued) This section is for the following models: GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809]; GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810]; GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLC050LX [A967]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLP/GDP20-25LX (GLP/GDP050LX) [A974]; GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879, D879, E879, F879]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878, E878]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) [A909, B909]ii700 YRM 1123Cooling System ChecksGeneral This section contains the repair and replacement instructions for the radiator, coolant level sensor, fanassembly (pusher type), fan shroud, coolant hoses, coolant recovery bottle, and optional debris screen.Cooling System Checks EXHAUST LEAKS INTO COOLING SYSTEM WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system. Inspect all radiator hoses. If they feel spongy or have visible cracks, replace hoses.To check for exhaust leaks into the cooling system, use a Combustion Leak Test Kit for this purpose. Follow the manufacturer’s instructions when doing the test.WATER PUMPWATER FLOW RESTRICTIONS IN RADIATORDuring engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.WARNINGWARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. To check for water flow restrictions in the radiator, run engine until it is warm.WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Run engine until it is warm. Check the operation of water pump by holding the top radiator hose. If the pump is operating, there will be pressure surges in the hose. Check for leaks around the timing belt cover near the base of the oil pump. Check the weep hole where coolant that leaks past the water pump seal can be drained before reaching the water pump bearings. If there is a drip, check the pump shaft seal and water pump. Replacement of the pump shaft seal or water pump may be necessary.Shut engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will be hotter near the top radiator hose.) Cold spots on radiator indicate restrictions.For repair procedures for the GM 2.4L water pump, refer to the section GM Engine Repair, GM 2.4 Liter Engine 600 YRM 1121.If radiator has leaks, either replace the radiator or have it repaired by trained personnel.For repair procedures for the Mazda FE and F2 water pump, refer to the section Mazda Engine, FE and F2 600 YRM 1122.RADIATOR HOSES WARNINGFor replacement procedures for the Yanmar 2.6L and 3.3L water pump, refer to the section Yanmar Diesel Engines, 2.6L, 3.0L and 3.3L 600 YRM 1205.The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.1Flushing the Cooling System700 YRM 1123For replacement procedures for the GM 4.3L water pump, refer to the section GM Engines, 4.3 Liter V-6 600 YRM 1251. For replacement procedures for the GM 5.7L water pump, refer to the section GM Engines, 5.7 Liter V-8 LPG 600 YRM 1432.For replacement procedures for the Kubota water pump, refer to the section • Kubota Diesel 3.8L Engines 600 YRM 1557 • Kubota Diesel 3.6L Engine 600 YRM 1579 • Kubota Diesel 3.8L Engines, with Diesel Particulate Filter (DPF) 600 YRM 1590 For replacement procedures for the Cummins 4.5L and QSB 3.3L water pump, contact your local Yale dealer or see Yale Axcess Online.Flushing the Cooling System COOLING SYSTEM, CLEAN WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.WARNING The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while checking the radiator fins. 1. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns.WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.CAUTION Disposal of lubricants and fluids must meet local environmental regulations.22. Drain cooling system. Fill cooling system with clean water. See sections below for more information: • Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) • Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) • Radiator, Remove for Lift Truck Models GLP/GDP60VX,
Related Search
We Need Your Support
Thank you for visiting our website and your interest in our free products and services. We are nonprofit website to share and download documents. To the running of this website, we need your help to support us.

Thanks to everyone for your continued support.

No, Thanks