YALE C875 GLP20VX LIFT TRUCK Service Repair Manual

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Text of YALE C875 GLP20VX LIFT TRUCK Service Repair Manual

  • GLP/GP/GTP20VX, GLP/GDP/GTP25VXP, GLP/GDP/GTP30VX, GLP/GDP/GTP35VX (C875)

    SERVICE MANUAL CONTENTS

    SECTIONPART

    NUMBERYRM

    NUMBERREV

    DATEOPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14FRAME............................................................................................................................ 550096314 0100 YRM 1672 04/14YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14KUBOTA SPARK IGNITED 2.5L LPG............................................................................ 550096316 0600 YRM 1670 12/14MAZDA 2.2L ENGINE..................................................................................................... 550096315 0600 YRM 1673 04/14COOLING SYSTEM........................................................................................................ 550096317 0700 YRM 1674 03/14LPG FUEL SYSTEM, MAZDA 2.2L ENGINE................................................................. 550096318 0900 YRM 1675 03/14LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550096321 1300 YRM 1678 04/142-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... 550096632 1300 YRM 1690 04/14DRIVE AXLE REPAIR (WET BRAKE)........................................................................... 550096322 1400 YRM 1679 12/14DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 550096323 1400 YRM 1680 04/14STEERING AXLE............................................................................................................ 550096324 1600 YRM 1681 04/14BRAKE SYSTEM............................................................................................................ 550096325 1800 YRM 1682 04/14HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14HYDRAULIC GEAR PUMPS.......................................................................................... 550096326 1900 YRM 1683 04/14MAIN CONTROL VALVE................................................................................................ 550096327 2000 YRM 1684 04/14MAIN CONTROL VALVE WITH VARIABLE DISPLACEMENT PUMP......................... 550096637 2000 YRM 1691 04/14CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 12/14CYLINDER REPAIR (MAST S/N D515, E509, E564)..................................................... 550100651 2100 YRM 1692 12/14WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14ELECTRICAL SYSTEM.................................................................................................. 550096328 2200 YRM 1685 04/14ELECTRICAL SYSTEM, MAZDA 2.2L ENGINE............................................................ 550096329 2200 YRM 1686 04/14MAST REPAIR (S/N F507, F508, F562, F563)............................................................... 550093755 4000 YRM 1669 12/14MAST REPAIR (S/N D515, E509, E564)........................................................................ 550100656 4000 YRM 1693 12/14METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14PERIODIC MAINTENANCE............................................................................................ 550096309 8000 YRM 1687 05/14CAPACITIES AND SPECIFICATIONS........................................................................... 550096330 8000 YRM 1688 04/14DIAGRAMS AND SCHEMATICS.................................................................................... 550096331 8000 YRM 1689 04/14DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

    9000 YRM 1112 ON CDPART NO. 550096627 (12/14)

  • GeneralThe overhead guard is an integral part of operatorcab. The operator cab is installed on a platform abovemain frame members. Step plates on both sides of lifttruck provide access to operator cab. The operator

    cab is a separate unit and can be removed as acomplete unit from module and frame of the lift truck.See Figure 1.

    Figure 1. Operator Cab

    0100 YRM 1290 General

    1

  • Cab ReplacementREMOVE, FOR LIFT TRUCK MODELSGLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX)(B875, C875); AND GLP/GDP40VX5/VX6,GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,110, 120VX) (F813, G813, H813, J813)NOTE: The EZ Tank Bracket used on these trucks tomount LPG tank onto counterweight come in twostyles. One style of bracket swings out to side of truckand other swings out to side and drops down.

    NOTE: On lift trucks equipped with LPG, make sureto release EZ Tank Bracket before opening hood.

    1. For lift truck models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX(C810), tilt steering column to UP position, slideseat assembly forward, open rear door, and openhood to disconnect battery. See Figure 2.

    2. Tilt steering column to UP position, slide seat as-sembly forward, open rear sliding window, andopen hood to disconnect battery.

    See Figure 3 for lift truck models GLP/GDP20-35VX (GP/GLP/

    GDP040-070VX) (B875, C875) GLP/GDP40VX5/VX6; GLP/GDP45SVX5,

    GLP/GDP45VX6; GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813)

    3. Disconnect air filter hose from rear left corner legof cab frame. See Figure 4.

    WARNING DO NOT disconnect the heater hoses from the en-gine when the engine is hot or when the coolingsystem is under pressure, to do so could causeserious injury.

    WARNING DO NOT remove the radiator cap from the radiatorwhen the engine is hot. When the radiator is hotand the cap is removed, the pressure is releasedfrom the system and the steam and boiling cool-ant can cause burns. Wait 30 minutes for the en-gine to cool. Do a touch test by touching the radi-ator with your hand. If the radiator is still hot tothe touch, wait another 30 minutes before at-tempting to remove, check, or fix any part of thecooling system.

    NOTE: Removing radiator cap will help depressurizecooling system.

    4. Remove radiator cover to access radiator cap.Remove radiator cap. See Figure 5.

    1. LATCH2. HINGE

    3. REAR DOOR

    Figure 2. Rear Door and Latch for Lift TruckModels GLP/GDP16VX, GLP/GDP18VX, GLP/

    GDP20SVX, GLP/GDP030VX (C810)

    Cab Replacement 0100 YRM 1290

    2

  • A. LIFT TRUCKS MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) AND GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813) WITHOUT AIR CONDITIONING.

    B. LIFT TRUCKS MODELS GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) WITH AIR CONDITIONING.

    1. REAR BOTTOM WINDOW2. RELEASE LATCH

    3. AC HOSE

    Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875,C875) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,

    090, 100, 110, 120VX) (F813, G813, H813, J813)

    Figure 4. Air Filter Hose Removal

    Legend for Figure 4

    NOTE: AIR FILTER HOSE FOR GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,120VX) (F813) SHOWN. AIR FILTER HOSE FOROTHER LIFT TRUCK MODELS ARE SIMILAR.

    1. CAPSCREW2. AIR FILTER HOSE

    0100 YRM 1290 Cab Replacement

    3

  • A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810)B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)C. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,

    110, 120VX) (F813, G813, H813)D. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,

    110, 120VX) (J813)

    1. RADIATOR COVER 2. RADIATOR CAP

    Figure 5. Radiator Cover and Cap Location

    Cab Replacement 0100 YRM 1290

    4

  • CAUTIONDO NOT allow any fluid to drain when disconnect-ing the heater hose from the engine. The methodwill help when purging the system during installa-tion.

    5. Disconnect and cap heater hoses from engine.See Figure 6.

    WARNING Replacement, installation and repairs to air condi-tioning units that require discharging and/or refill-ing of the refrigeration fluid must be performed bya certified technician.

    6. Contact a certified air conditioning specialist tohave the refrigerant extracted from the air condi-tioning system.

    NOTE: Step 7 is for lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,090, 100, 110, 120VX) (G813, H813, J813) with aCummins QSB 3.3L or a Kubota diesel engine.

    7. If lift truck cab is equipped with an air conditioner/heater unit, disconnect AC refrigerant hoses fromrefrigerant compressor.

    See Figure 7 for lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,