YALE (D875) GTP050VX LIFT TRUCK Service Repair Manual

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Text of YALE (D875) GTP050VX LIFT TRUCK Service Repair Manual

  • GP/GLPO/GDP/GTP040VX, GP/GLPO/GDP/GTP050VX, GP/GLPO/GDP/GTP060VX, GP/GLPO/GDP/GTP070VX (D875)

    SERVICE MANUAL CONTENTS

    SECTIONPART

    NUMBERYRM

    NUMBERREV

    DATEOPERATOR'S CAB........................................................................................................ 550108590 0100 YRM 1752 12/14FRAME............................................................................................................................ 550108889 0100 YRM 1754 12/14YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14KUBOTA SPARK IGNITED 2.5L LPG............................................................................ 550096316 0600 YRM 1670 12/14PSI 2.4L ENGINE............................................................................................................ 550108890 0600 YRM 1755 12/14COOLING SYSTEM........................................................................................................ 550108891 0700 YRM 1756 12/14LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14FUEL SYSTEM PSI 2.4L................................................................................................ 550108892 0900 YRM 1757 12/14SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550108495 1300 YRM 1740 12/142-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... 550109083 1300 YRM 1764 12/14DRIVE AXLE REPAIR (WET BRAKE)........................................................................... 550096322 1400 YRM 1679 12/14DRIVE AXLE REPAIR - DRY BRAKE............................................................................ 550108893 1400 YRM 1758 12/14STEERING AXLE............................................................................................................ 550108894 1600 YRM 1759 12/14BRAKE SYSTEM............................................................................................................ 550108498 1800 YRM 1743 12/14HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14HYDRAULIC GEAR PUMPS.......................................................................................... 550108499 1900 YRM 1744 12/14MAIN CONTROL VALVE................................................................................................ 550108500 2000 YRM 1745 12/14CYLINDER 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.................................................................................................. 550108895 2200 YRM 1760 12/14ENGINE ELECTRICAL SYSTEM, PSI 2.4L ENGINE..................................................... 550108896 2200 YRM 1761 12/14MAST 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 12/14DIAGRAMS AND SCHEMATICS.................................................................................... 550108507 8000 YRM 1753 12/14PERIODIC MAINTENANCE............................................................................................ 550108897 8000 YRM 1762 12/14CAPACITIES AND SPECIFICATIONS........................................................................... 550108898 8000 YRM 1763 12/14DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

    PART NO. 550109093 (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 beremoved as a complete unit from module and frameof the lift truck. See Figure 1.

    Figure 1. Operator Cab

    Cab ReplacementREMOVENOTE: The LPG tank bracket used to mount the LPGtank (if equipped) onto the counterweight comes intwo styles. One style of bracket swings out to side oftruck and other swings out to side and drops down.

    NOTE: On lift trucks equipped with a LPG fuel sys-tem, move the LPG tank and bracket to side of truckbefore opening the hood.

    See PSI 2.0L LPG Fuel System 0900YRM1739 forlift truck models

    GLP/GDP16-18VX, GLP/GDP20SVX (D810)

    See for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

    (D875) equipped with a PSI 2.4L LPG engine

    See for lift truck models

    0100 YRM 1752 General

    1

  • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)(D875) equipped with a Kubota 2.5L LPG en-gine

    1. For lift truck models GLP/GDP16-18VX, GLP/GDP20SVX (D810), tilt steering column to UP po-sition, slide seat assembly forward, open reardoor, and open hood to disconnect battery. SeeFigure 2.

    For lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875), tilt steering column to UPposition, slide seat assembly forward, open rearsliding window, and open hood to disconnect bat-tery. See Figure 3.

    1. LATCH2. HINGE

    3. REAR DOOR

    Figure 2. Rear Door and Latch, Lift Truck ModelsGLP/GDP16-18VX, GLP/GDP20SVX (D810)

    A. LIFT TRUCKS WITHOUT AIR CONDITIONINGB. LIFT TRUCKS WITH AIR CONDITIONING

    1. REAR BOTTOM WINDOW2. RELEASE LATCH3. AC HOSE

    Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)

    Cab Replacement 0100 YRM 1752

    2

  • 2. Loosen clamp and disconnect air filter hose fromelbow. Remove bolts, elbow, retainer, and grom-met from rear left corner leg of cab frame. SeeFigure 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.

    3. Turn knobs counterclockwise and remove radiatorcover to access radiator cap. Remove radiatorcap. See Figure 5.

    NOTE: AIR FILTER HOSE FOR LIFT TRUCK MOD-ELS GLP/GDP16-18VX, GLP/GDP20SVX (D810)SHOWN. AIR FILTER HOSE FOR LIFT TRUCKMODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) IS SIMILAR.

    1. CLAMP2. AIR FILTER HOSE3. BOLTS4. ELBOW5. RETAINER6. GROMMET

    Figure 4. Air Filter Hose Removal

    0100 YRM 1752 Cab Replacement

    3

  • 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.

    4. Disconnect and cap heater hoses from engine.See Figure 7.

    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.

    NOTE: Perform Step 5 and Step 6 for lift truck mod-els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)(D875).

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

    6. If lift truck cab is equipped with an air conditioner/heater unit, disconnect AC refrigerant hoses fromrefrigerant compressor. See Figure 6.

    NOTE: Removing door assemblies requires two peo-ple.

    7. Open left side door, remove lock nut and discon-nect gas spring from cab mounting bracket. SeeFigure 8.

    8. Lift left side door up and over hinge pin and setaside. See Figure 9 .

    NOTE: RADIATOR COVER FOR LIFT TRUCKS EQUIPPED WITH STEEL DOORS SHOWN. RADIATORCOVER FOR LIFT TRUCKS EQUIPPED WITH PVC DOORS IS SIMILAR.

    A. GLP/GDP16-18VX, GLP/GDP20SVX (D810) LIFTTRUCKS

    B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX)(D875) LIFT TRUCKS

    1. RADIATOR COVER2. RADIATOR CAP

    Figure 5. Radiator Cover and Cap Location

    Cab Replacement 0100 YRM 1752

    4

  • NOTE: KUBOTA 2.5L LPG ENGINE SHOWN. OTHER ENGINES ARE SIMILAR.

    1. AC REFRIGERANT HOSES2. REFRIGERANT COMPRESSOR3. AC/HEATER UNIT

    4. ENGINE5. HOSE WRAP6. AC WIRE HARNESS

    Figure 6. AC Refrigerant Hose and Wire Harness Connections

    WARNING DO NOT disconnect the heater hoses from thequick disconnect fittings (inside operator cab) orengine when the engine is hot or under pressure,to do so could cause serious injury.

    9. Disconnect heater hose quick disconnect fittings.

    a. For lift truck mo