Yale GLP20LX Service Manual
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Yale GLP20LX Service Manual

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GLP20LX, GLP25LX, GDP20LX, GDP25LX (B974)
SECTION
FRAME............................................................................................................................
YANMAR DIESEL ENGINES..........................................................................................
PSI 2.4L ENGINE............................................................................................................
COOLING SYSTEM........................................................................................................
FUEL SYSTEM PSI 2.4L................................................................................................
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................
STEERING AXLE REPAIR.............................................................................................
BRAKE SYSTEM............................................................................................................
HYDRAULIC CLEANLINESS PROCEDURES...............................................................
HYDRAULIC GEAR PUMPS..........................................................................................
MAIN CONTROL VALVE................................................................................................
CYLINDER REPAIR (MAST S/N A698 AND A699).......................................................
WIRE HARNESS REPAIR..............................................................................................
ELECTRICAL SYSTEM..................................................................................................
ENGINE ELECTRICAL SYSTEM, PSI 2.4L ENGINE.....................................................
MAST REPAIR (S/N A698 AND A699)...........................................................................
METRIC AND INCH (SAE) FASTENERS.......................................................................
PERIODIC MAINTENANCE............................................................................................
CAPACITIES AND SPECIFICATIONS...........................................................................
DIAGRAMS AND SCHEMATICS....................................................................................
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................
SERVICE MANUAL CONTENTS
PART NO. 550109188 (12/14)
PART
YRM
NUMBER
NUMBER
550109110
0100 YRM 1766
524240453
0600 YRM 1205
550108890
0600 YRM 1755
550109111
0700 YRM 1767
550108892
0900 YRM 1757
550108495
1300 YRM 1740
550109112
1400 YRM 1768
550109113
1600 YRM 1769
550108498
1800 YRM 1743
550073240
1900 YRM 1620
550108499
1900 YRM 1744
550108500
2000 YRM 1745
550109114
2100 YRM 1770
524223769
2200 YRM 1128
550109115
2200 YRM 1771
550109116
2200 YRM 1772
550109117
4000 YRM 1773
524150797
8000 YRM 0231
550109197
8000 YRM 1774
550109119
8000 YRM 1775
550109120
8000 YRM 1776
550022929
9000 YRM 1434
REV
DATE
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

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  • Page 1 GLP20LX, GLP25LX, GDP20LX, GDP25LX (B974) SERVICE MANUAL CONTENTS PART SECTION NUMBER NUMBER DATE FRAME..........................550109110 0100 YRM 1766 12/14 YANMAR DIESEL ENGINES..................524240453 0600 YRM 1205 12/14 PSI 2.4L ENGINE......................550108890 0600 YRM 1755 12/14 COOLING SYSTEM......................550109111 0700 YRM 1767 12/14 FUEL SYSTEM PSI 2.4L....................
  • Page 2 0100 YRM 1766 General General The surface must be solid, even, and level when WARNING the lift truck is put on blocks. Make sure that any The lift truck must be put on blocks for some blocks used to support the lift truck are solid, one-piece units.
  • Page 3 General 0100 YRM 1766 1. COWL PLATE 5. COUNTERWIEGHT SUPPORT 2. FENDER 6. FUEL TANK 3. FRAME 7. HYDRAULIC TANK 4. HOOD MOUNT Figure 2. Frame, Dual Fuel or Diesel...
  • Page 4 0100 YRM 1766 Hood, Seat, and Side Covers Replacement Hood, Seat, and Side Covers Replacement REMOVE 1. Slide the seat to the closest position to the steer- ing column. 2. Fully tilt the steering column forward. NOTE: Perform Step 3 for lift trucks equipped with LPG.
  • Page 5 Hood, Seat, and Side Covers Replacement 0100 YRM 1766 Figure 4. Side Cover, Floor Plate, and Cowl Components...
  • Page 6 0100 YRM 1766 Hood, Seat, and Side Covers Replacement Legend for Figure 4 1. DASH ASSEMBLY 13. LEFT REAR SIDE COVER 2. UPPER STEERING COLUMN COVER 14. RIGHT REAR SIDE COVER 3. LOWER STEERING COLUMN COVER 15. FLOOR MAT 4. KICK PANEL 16.
  • Page 7 Hood, Seat, and Side Covers Replacement 0100 YRM 1766 7. Remove the four capscrews and clip nuts holding 10. Remove the five Allen Head screws (see Fig- the left and right front side covers and left and ure 5) securing the dash to top of cowl. right cowl plates to the frame.
  • Page 8 0100 YRM 1766 Hood, Seat, and Side Covers Replacement 1. ALLEN HEAD SCREWS 5. KICK PANEL NOTCHES 2. COWL 6. SEAL PLATE 3. DASH PANEL 7. CAPSCREWS 4. KICK PANEL 8. CLIPS Figure 6. Dash Panel, Kick Panel, and Seal Plate Removal...
  • Page 9 Hood, Seat, and Side Covers Replacement 0100 YRM 1766 14. Remove two capscrews and washers from cover Remove the four capscrews and nuts holding the plate and remove electrical cover. Disconnect seat to the hood. Lift the seat off the hood. See seat harness from chassis harness.
  • Page 10 0100 YRM 1766 Hood, Seat, and Side Covers Replacement Legend for Figure 8 NOTE: MOUNTING HOLES FOR FULL SUSPEN- SION SEAT SHOWN. MOUNTING HOLES FOR NON-SUSPENSION SEAT ARE THE SAME. 1. CAPSCREW 2. NUT 3. HOLE FOR CHASSIS HARNESS 4. HOOD LINER Figure 8.
  • Page 11 Hood, Seat, and Side Covers Replacement 0100 YRM 1766 INSTALL ensure that the center pin strikes the hood latch properly and that the stop screw contacts the 1. Place the hood onto the lift truck frame. frame. A properly closed hood MUST click twice on the hood latch.
  • Page 12 0100 YRM 1766 Hood, Seat, and Side Covers Replacement 8. Align the holes in the seat with the holes in the hood. See Figure 8. Insert capscrews and nuts. Tighten capscrews to 18 N•m (159 lbf in). 9. Connect seat harness to chassis harness. Install cover plate to electrical cover using two cap- screws and washers.
  • Page 13 Steering Column 0100 YRM 1766 Steering Column DESCRIPTION CAUTION This section describes the repair procedures for the Disconnect the negative battery cable on internal steering column. The Steering Column Assembly combustion trucks. Disconnect the battery before mounts to the cowl inside the operator compartment removing any covers.
  • Page 14 0100 YRM 1766 Steering Column Disassemble 4. Remove steering column covers. Remove floor mats and floor plate. See section Hood, Seat, and NOTE: Remove and discard snap rings if installed. Side Covers Replacement. 1. Remove two pins and gas spring from housing. See Figure 15.
  • Page 15 NOTE: Perform Step 1 only for lift trucks manufac- tured before January, 2012. 6. Remove blocks from each side of tires. 1. Lubricate the horn contact slip rings with a small amount conductive grease Yale 582014302. See Figure 15.
  • Page 16 0100 YRM 1766 Steering Column 1. BRACKET 9. PIN 2. SPACER 10. LOWER SHAFT 3. JOINT 11. GAS SPRING 4. NUT 12. BOLT 5. WASHER 13. BUSHING 6. SCREW 14. CONNECTOR 7. UPPER SHAFT 15. FASTENER 8. HOUSING 16. HORN CONTACT Figure 15.
  • Page 17 Counterweight Replacement 0100 YRM 1766 Counterweight Replacement REMOVE NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. One M24 × 3 × 110 capscrew holds the counterweight to WARNING the lower part of the frame on lift truck models See The lift truck must be put on blocks for some Figure 16.
  • Page 18 0100 YRM 1766 Counterweight Replacement INSTALL 4. Install tow pin onto counterweight. 1. Make sure the seals are on the counterweight. If NOTE: Perform Step 5 for lift trucks equipped with lifting eyebolts were removed from counterweight, LPG. install washers, lifting eyebolts, and nuts into lift 5.
  • Page 19 See Figure 18. big or in the wrong location, can reduce the strength of the overhead guard. See your dealer for Yale lift trucks BEFORE per- forming any changes to the overhead guard. NOTE: The lifting device can be connected to any number of positions on the overhead guard depend- ing upon the lifting device available.
  • Page 20 0100 YRM 1766 Overhead Guard Replacement INSTALL NOTE: Note position of rain top on overhead guard before removal. NOTE: Make sure electrical wires are routed as no- ted during removal to ensure that wires do not get 5. Remove rain top from overhead guard. See Fig- pinched.
  • Page 21 Overhead Guard Replacement 0100 YRM 1766 1. RAIN TOP 7. RIGHT BRACKET 2. CAPSCREW 8. CENTER BRACKET 3. WHEEL NUT 9. BUSHING 4. LOCKNUT 10. SEALER 5. WASHER 11. OVERHEAD GUARD 6. LEFT BRACKET Figure 19. Overhead Guard Rain Top...
  • Page 22 0100 YRM 1766 Operator Restraint System Replacement Operator Restraint System Replacement DESCRIPTION Pull firmly on the seat belt and hold for a mo- ment to remove slack from the belt in the re- The seat belt, hip restraint brackets, seat and mount- tractor.
  • Page 23 Operator Restraint System Replacement 0100 YRM 1766 A. NON-SUSPENSION SEAT B. FULL-SUSPENSION SEAT 1. HOOD 7. WEIGHT ADJUSTMENT KNOW 2. SEAT 8. RIDE POSITION INDICATOR 3. HIP RESTRAINT 9. FORWARD/BACKWARD ADJUSTMENT LEVER 4. SEAT BELT 10. BACKREST ADJUSTMENT LEVER 5. LATCH 11.
  • Page 24 0100 YRM 1766 Engine Replacement 1. Close the shutoff valve on the LPG tank and run WARNING engine until all fuel is gone and engine stops. Always disconnect the cables at the battery be- 2. For removal of the LPG Tank, see service manual fore you make repairs to the engine.
  • Page 25 Engine Replacement 0100 YRM 1766 Figure 22. PSI Engine and Transmission Remove...
  • Page 26 0100 YRM 1766 Engine Replacement Legend for Figure 22 A. TOP VIEW B. LEFT VIEW 1. AIR FILTER AND BRACKET ASSEMBLY 12. CHASSIS HARNESS 2. AIR FILTER HOSE 13. TRANSMISSION MOUNT 3. SHROUD 14. TRANSMISSION OIL COOLER LINES 4. RADIATOR CAP 15.
  • Page 27 Engine Replacement 0100 YRM 1766 19. Remove six capscrews from flywheel housing and WARNING torque converter housing on flywheel housing All fuels are very flammable and can burn or side. cause an explosion. DO NOT use an open flame to check the fuel level or to check for leaks in the WARNING fuel system.
  • Page 28 0100 YRM 1766 Engine Replacement 1. TEMPERATURE SENSOR CONNECTOR 2. TRANSMISSION HOUSING 3. PROPORTIONAL VALVE CONNECTOR 4. TRANSDUCER CONNECTOR 1. ACCESS PORT 5. TRANSMISSION SENSOR PLUG 2. ENGINE MOUNTING BRACKET AND HARD- 6. SOLENOID VALVE CONNECTOR WARE 7. ENGINE WIRING HARNESS Figure 25.
  • Page 29 Engine Replacement 0100 YRM 1766 1. EYEBOLT BRACKET 2. TORQUE CONVERTER HOUSING 3. FLYWHEEL HOUSING 4. CAPSCREW 5. TRANSMISSION ASSEMBLY 6. ENGINE ASSEMBLY Figure 26. PSI Flywheel and Torque Converter Housings...
  • Page 30 0100 YRM 1766 Engine Replacement 1. FRAME 2. ENGINE MOUNT 3. LOCK NUT 1. CAPSCREW 2. WASHER Figure 27. PSI Engine and Frame 3. SNUBBING WASHER 4. ISOLATOR 5. LOCKNUT 6. CROSSMEMBER (OPTIONAL) 7. LEFT ENGINE MOUNT 8. RIGHT ENGINE MOUNT Figure 28.
  • Page 31 Engine Replacement 0100 YRM 1766 Diesel Engine 4. Open drain plug or disconnect bottom radiator hose to drain coolant from radiator and engine. See Figure 30. WARNING The lift truck must be put on blocks for some 5. Remove hood and seat combination and rear side types of maintenance and repairs.
  • Page 32 0100 YRM 1766 Engine Replacement NOTE: PART OF THE FRAME NOT SHOWN FOR CLARITY. LIFT TRUCK MODELS GDP25LX (GDP050LX) (B974) SHOWN. 1. TRANSMISSION ISOLATOR 5. FRAME 2. TRANSMISSION MOUNTING BRACKET 6. ENGINE WIRING HARNESS 3. ENGINE ISOLATOR 7. CHASSIS WIRING HARNESS 4.
  • Page 33 Engine Replacement 0100 YRM 1766 Figure 30. Yanmar 2.6L Diesel Engine and Transmission Removal...
  • Page 34 0100 YRM 1766 Engine Replacement Legend for Figure 30 A. TOP VIEW B. LEFT VIEW 1. AIR FILTER AND BRACKET ASSEMBLY 12. HYDRAULIC RETURN HOSE 2. AIR FILTER HOSE 13. CHASSIS HARNESS 3. SHROUD 14. TRANSMISSION MOUNT 4. RADIATOR CAP 15.
  • Page 35 Engine Replacement 0100 YRM 1766 12. Disconnect engine wiring harness connectors 16. Remove six hex head capscrews and six lock- from proportional valve connectors, transducer washers from flywheel housing and torque con- connectors, solenoid valve connector, tempera- verter housing on flywheel housing side. See Fig- ture sensor connector, and transmission.
  • Page 36 0100 YRM 1766 Engine Replacement 1. TORQUE CONVERTER HOUSING 5. LOCKWASHER 2. EYEBOLT BRACKET 6. FLANGE BOLT 3. HEX HEAD CAPSCREW 7. TRANSMISSION ASSEMBLY 4. FLYWHEEL HOUSING 8. ENGINE ASSEMBLY Figure 34. Yanmar Flywheel and Torque Converter Housings...
  • Page 37 Engine Replacement 0100 YRM 1766 3. Install isolators, bolts, washers, and flange nuts on engine mounts. See Figure 21, Figure 27, and Figure Tighten flange nuts 150 N•m (110 lbf ft). 4. Use access port on side of engine and install bolts to hold torque converter to flywheel.
  • Page 38 0100 YRM 1766 Engine Replacement 13. Connect the PDM and connect the ground strap 4. Use access port on side of engine and install four to lift truck frame and attach it to battery. bolts attached flywheel to torque converter. See Figure 33.
  • Page 39 Engine Replacement 0100 YRM 1766 c. Install battery lockdown bar on top of battery 15. Install overhead guard. See section Overhead and engage with bar on side of battery tray. Guard Replacement for procedures. See Figure 31. 16. Check all fluid levels and fill as needed. See Peri- d.
  • Page 40 0100 YRM 1766 Transmission Replacement NOTE: PSI ENGINE SHOWN FOR REFERENCE ONLY. 1. TRANSMISSION HOUSING 2. HYDRAULIC HOSE 3. SUCTION HOSE NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. 4. DRAIN FITTING 5. HYDRAULIC GEAR PUMP INLET PORT 1. MOUNTING BRACKET 6.
  • Page 41 Transmission Replacement 0100 YRM 1766 10. Remove flange head capscrew, yoke, and spacer 1. Using a lifting device, install transmission in lift from transmission housing. Make sure to not truck frame. Place a block under the transmission damage the oil seal. Remove and discard stat-o- housing to support the transmission.
  • Page 42 0100 YRM 1766 Throttle Pedal and Cable Adjustment Throttle Pedal and Cable Adjustment PSI 2.4L ENGINE YANMAR DIESEL ENGINE 1. Remove floor plate and disconnect throttle cable Throttle Pedal Stop Adjustment from bellcrank and engine. The PSI 2.4L dual fuel or LPG engines used on lift 2.
  • Page 43 Throttle Pedal and Cable Adjustment 0100 YRM 1766 NOTE: THROTTLE PEDAL NOT SHOWN IN FULLY DEPRESSED POSITION (WIDE OPEN POSITION). NOTE: MOUNTING BRACKET FOR THREE FUNCTION CONTROL VALVE SHOWN, FOUR FUNCTION CON- TROL VALVE SIMILAR. 1. COWL 7. PEDAL STOP 2.
  • Page 44 0100 YRM 1766 Hydraulic Filter Repair Hydraulic Filter Repair REMOVE 3. Inspect dipstick plug. Replace O-ring and plug as necessary. WARNING INSTALL At operating temperature, the hydraulic oil is HOT. 1. Lubricate sealing surfaces on filter housing with DO NOT permit the hot oil to touch the skin and clean hydraulic oil.
  • Page 45 Check for leaks. Stop engine and check hydraulic oil level. Add oil, if necessary. Use hydraulic oil in- Additives may damage the hydraulic system. Be- dicated in Periodic Maintenance 8000YRM1774. fore using additives, contact your local Yale dealer. Tank Repair HYDRAULIC AND DIESEL TANKS...
  • Page 46 0100 YRM 1766 Tank Repair Steam Method of Cleaning 3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank. WARNING Compressed air can move particles so that they 4.
  • Page 47 Tank Repair 0100 YRM 1766 Chemical Solution Method of Cleaning tainers That Have Held Combustibles by the Ameri- can Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be WARNING used as follows: When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or 1.
  • Page 48 0100 YRM 1766 Label Replacement Label Replacement See Figure 43 for lift truck models below with PSI en- WARNING gine Safety labels are installed on the lift truck to pro- • GLC050LX (B967) vide information about operation and possible • GLP20-25LX (GLP050LX) (B974) hazards.
  • Page 49 Label Replacement 0100 YRM 1766 Figure 43. Warning and Safety Labels for Lift Trucks with PSI Engine...
  • Page 50 0100 YRM 1766 Label Replacement Legend for Figure 43 1. TIP OVER WARNING 13. LIFT AND TILT LABEL 2. OVERHEAD GUARD LABEL 14. FLAMMABLE LP GAS 3. OPERATION WARNING 15. LPG TANK WARNING 4. NO RIDERS 16. AIR FILTER INSTALL CAUTION 5.
  • Page 51 Label Replacement 0100 YRM 1766 Figure 44. Warning and Safety Labels for Lift Trucks with Yanmar Diesel Engine...
  • Page 52 0100 YRM 1766 Label Replacement Legend for Figure 44 1. FUEL LABEL (DIESEL)* 13. PINCH POINT WARNING 2. AIR FILTER INSTALL CAUTION 14. NO ONE ON OR UNDER FORKS 3. PARKING BRAKE WARNING LABEL 15. NO RIDERS 4. ETHER WARNING LABEL 16.
  • Page 53 4TNE98-NMH - 3.3L engine (Yale Part No. 580063567), used in lift truck GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) • 4TNE92-NMH/1688273 - 2.6L engine (Yale Part No. 580090036), used in lift truck GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875, C875). • 4TNE98-BNMH - 3.3L engine (Yale Part No. 588087403), used 1.
  • Page 54 General 0600 YRM 1205 Location of Labels The typical location of the emission control information label is shown in Figure 2. The typical location of the engine nameplate is shown in Figure 2. The engine nameplate is shown in Figure 3. Figure 3.
  • Page 55 0600 YRM 1205 Engine Removal and Installation Engine Removal and Installation The procedures to remove and install the engine are See section Frame 0100YRM1423 for lift truck mod- not included in this section. • GLP/GDP20-25LX (GLP/GDP050LX) (A974) See section Frame 0100YRM1120 for lift truck mod- See section Frame 0100YRM1672 for lift truck mod- •...
  • Page 56 Cylinder Head Assembly Repair 0600 YRM 1205 Figure 4. Cylinder Head Components...
  • Page 57 0600 YRM 1205 Cylinder Head Assembly Repair Legend for Figure 4 1. VALVE COVER NUT 16. EXHAUST VALVE 2. O-RING 17. CYLINDER HEAD GASKET 3. VALVE COVER 18. CYLINDER HEAD 4. VALVE COVER GASKET 19. GLOW PLUG 5. ROCKER ARM SHAFT 20.
  • Page 58 Cylinder Head Assembly Repair 0600 YRM 1205 GLOW PLUGS Install 1. Install the glow plugs into the cylinder head. Remove 2. Connect the glow plug harness to the glow plugs. 1. Disconnect the negative battery cable at the bat- tery. 3.
  • Page 59 0600 YRM 1205 Cylinder Head Assembly Repair Clean and Inspect 5. Install and tighten the valve cover nuts. Refer to Standard Torque Specifications. WARNING ROCKER ARM ASSEMBLY Cleaning solvents can be flammable and toxic and Remove can cause skin irritation. When using cleaning solvents, always follow the recommendations of 1.
  • Page 60 Cylinder Head Assembly Repair 0600 YRM 1205 1. SUPPORT BRACKET NUT 7. SUPPORT BRACKET 2. VALVE ADJUSTING SCREW LOCK NUT 8. ROCKER ARM SHAFT SPRING 3. VALVE ADJUSTING SCREW 9. ROCKER ARM 4. ROCKER ARM SHAFT 10. SUPPORT BRACKET BOLT 5.
  • Page 61 0600 YRM 1205 Cylinder Head Assembly Repair Clean and Inspect Rocker Arm Assembly Rocker Arm and Support Bracket Inside Diameter WARNING - Use a test indicator and micrometer to determine if Cleaning solvents can be flammable and toxic and the inside diameter of all the rocker arm support can cause skin irritation.
  • Page 62 Cylinder Head Assembly Repair 0600 YRM 1205 VALVE CLEARANCE ADJUSTMENTS Assemble NOTE: The rocker arm shaft fits tightly in the rocker NOTE: Make measurements and adjustments while arm support brackets. Clamp the rocker arm shaft in a the engine is cold. padded vise and twist and push the support brackets NOTE: The cylinder to be adjusted first does not...
  • Page 63 0600 YRM 1205 Cylinder Head Assembly Repair A. NORMAL B. ABNORMAL 1. VALVE CAP Figure 13. Valve Cap Check 1. FEELER GAUGE Figure 11. Valve Clearance Measurement NOTE: There is a tendency for the clearance to de- crease slightly when the lock nut is tightened. It is 4.
  • Page 64 Cylinder Head Assembly Repair 0600 YRM 1205 CYLINDER HEAD ASSEMBLY Remove 1. Disconnect the negative battery cable at the bat- tery. 2. Remove the alternator. See Electrical Equipment Repair. 3. Remove the water pump. See Cooling System Repair. 4. Disconnect the air intake hose from the intake manifold.
  • Page 65 0600 YRM 1205 Cylinder Head Assembly Repair 11. Remove the bolts retaining the intake manifold to the cylinder head and remove the intake manifold and gasket. Discard gasket. See Figure 15. 1. GASKET 3. BOLT 2. INTAKE MANIFOLD 4. CYLINDER HEAD Figure 15.
  • Page 66 Cylinder Head Assembly Repair 0600 YRM 1205 12. Remove the nuts retaining the exhaust pipe to the 13. Remove the bolts retaining the exhaust manifold exhaust manifold and disconnect the exhaust pipe to the cylinder head and remove the exhaust from the exhaust manifold.
  • Page 67 0600 YRM 1205 Cylinder Head Assembly Repair 14. Remove the valve cover. See Valve CoverRe- move. 15. Remove the rocker arm assembly. See Rocker Arm AssemblyRemove. 16. Loosen the cylinder head bolts following the se- quence shown in Figure 17. A.
  • Page 68 Cylinder Head Assembly Repair 0600 YRM 1205 Disassemble 3. Slowly release the tension on the valve spring. 4. Remove the spring retainer, valve spring, and Valves and Valve Springs, Remove valve stem seal. 1. Using a valve spring compressor tool, compress 5.
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