YALE (D810) GLP040SVX LIFT TRUCK Service Repair Manual PDF
YALE (D810) GLP040SVX LIFT TRUCK Service Repair Manual PDF
YALE (D810) GLP040SVX LIFT TRUCK Service Repair Manual PDF
(D810)
SERVICE MANUAL CONTENTS
PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 550108490 0100 YRM 1735 12/14
OPERATOR'S CAB........................................................................................................ 550108590 0100 YRM 1752 12/14
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
PSI 2.0 LPG ENGINE...................................................................................................... 550108491 0600 YRM 1736 12/14
COOLING SYSTEM........................................................................................................ 550108492 0700 YRM 1737 12/14
PSI 2.0L LPG FUEL SYSTEM........................................................................................ 550108494 0900 YRM 1739 12/14
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550108495 1300 YRM 1740 12/14
DRIVE AXLE................................................................................................................... 550108496 1400 YRM 1741 12/14
STEERING AXLE............................................................................................................ 550108497 1600 YRM 1742 12/14
BRAKE SYSTEM............................................................................................................ 550108498 1800 YRM 1743 12/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
HYDRAULIC GEAR PUMPS.......................................................................................... 550108499 1900 YRM 1744 12/14
MAIN CONTROL VALVE................................................................................................ 550108500 2000 YRM 1745 12/14
CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 12/14
CYLINDER REPAIR (MAST S/N B551, B555, B559).................................................... 550108501 2100 YRM 1746 12/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 550108502 2200 YRM 1747 12/14
ENGINE ELECTRICAL SYSTEM, PSI 2.0L ENGINE..................................................... 550108503 2200 YRM 1748 12/14
MAST REPAIR (S/N B551, B555, B559)........................................................................ 550108504 4000 YRM 1749 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 550108505 8000 YRM 1750 12/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550108506 8000 YRM 1751 12/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550108507 8000 YRM 1753 12/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
General
NOTE: For lift trucks equipped with a PSI 2.0L LPG
WARNING engine, see PSI 2.0L LPG Fuel System
The lift truck must be put on blocks for some 0900YRM1739 for procedures to remove and install
types of maintenance and repairs. The removal of the exhaust system components. If lift truck is
the following assemblies will cause large changes equipped with a Yanmar 2.6L diesel engine, see
in the center of gravity: mast, drive axle, engine Exhaust System Repair in this manual for procedures.
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in This section contains the description of the frame (see
the following positions to maintain stability: Figure 1) and connected parts. Procedures for
• Before removing the mast and drive axle, removing and installing the counterweight, hood,
put blocks under the counterweight so the overhead guard, engine and transmission, cooling
lift truck cannot fall backward. system, exhaust system (see NOTE above), and
other components attached to the frame are found in
• Before removing the counterweight, put this section. Checks for the operator restraint system
blocks under the mast assembly so the lift and procedures for the repair of tanks and installation
truck cannot fall forward. 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 The overhead guard, cowl, and hood are installed on
tank and fuel tank for gasoline or diesel fuel. See Fig- the frame. The hood is connected to the frame with
ure 1. hinges. Two gas-controlled springs provide assis-
tance when raising the hood and hold the hood in the
There is a counterweight for each capacity of lift truck. open position. The floor plate and side covers can be
The counterweights are similar in appearance, but are removed for access to the engine, transmission, and
different weights. See Counterweight Replacement other components.
section.
2
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
1. TILT LEVER
2. GAS CYLINDER
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
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
7
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
8
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
13. Remove five fasteners securing dash to the top of • See Figure 4 for lift truck models
cowl. See Figure 7. Remove four clips, located GLC030-035VX, GLC040SVX (D809)
underneath dash, that attach dash to the kick • See Figure 5 for lift truck models GLP/
panel. Lift to remove dash. GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809) 19. Remove two capscrews and hood latch striker
• See Figure 5 for lift truck models GLP/ bolt from mounting bracket. See Figure 9.
GDP16-18VX, GLP/GDP20SVX (GLP/
20. Remove two capscrews and hood latch from
GDP030-035VX, GLP/GDP040SVX) (D810)
hood. See Figure 9.
14. Lift kick panel and remove from truck.
21. Remove capscrews and washers at the top of gas
15. Remove three capscrews and clip nuts from seal springs. Remove gas springs from hood.
plate. Remove seal plate from frame.
22. Remove hinge screws, located in the rear of the
16. Remove two capscrews and washers from cover hood. See Figure 10.
plate and remove seat box. Disconnect seat wire
23. Remove hood from lift truck.
harness connector. See Figure 8.
9
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
10
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
11
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
12
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
A. HOOD LATCH AND HOOD LATCH STRIKER B. HOOD LATCH AND HOOD LATCH STRIKER
BOLT FOR LIFT TRUCK MODELS BOLT FOR LIFT TRUCK MODELS GLP/
GLC030-035VX, GLC040SVX (D809) GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
1. CAPSCREW (HOOD LATCH STRIKER BOLT) 5. HOOD LATCH
2. CAPSCREW (HOOD LATCH) 6. BUMPER
3. HOOD LATCH STRIKER BOLT
4. HOOD LATCH STRIKER BOLT MOUNTING
BRACKET
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)
CAUTION
When installing the seat to the hood, DO NOT use
an impact wrench to install the capscrews. Dam-
NOTE: LEFT SIDE SHOWN. age can be caused to the threads on the screws
and in the holes.
1. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION
SEAT 8. Place seat on hood. Align holes in seat with holes
2. MOUNTING LOCATION FOR CYLINDER END in hood as noted during removal. Insert washers
OF GAS SPRING FOR SEMI OR FULL SUS- and capscrews. Tighten capscrews to
PENSION SEAT 18 N•m (159 lbf in).
Figure 12. Gas Spring Installation, Lift Truck
9. Install radiator cover and seals to frame.
Models GLC030-035VX, GLC040SVX (D809)
• See Figure 4 for lift truck models
4. Install hood latch to hood using two capscrews. GLC030-035VX, GLC040SVX (D809)
See Figure 9. • See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
5. Install latch striker bolt in highest slot position on GDP030-035VX, GLP/GDP040SVX) (D810)
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
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
10. Connect seat wire harness. Install seat box to 16. For lift truck models GLC030-035VX,
cover plate with two capscrews and washers. GLC040SVX (D809), install left and right step
Tighten capscrews to 1.2 N•m (10.6 lbf in). See plates, and six capscrews to frame. See Figure 6.
Figure 8.
For lift truck models GLP/GDP16-18VX, GLP/
11. Install seal plate using three capscrews and clip GDP20SVX (GLP/GDP030-035VX, GLP/
nuts. GDP040SVX) (D810), install left and right step
plates, six clip nuts, and three capscrews onto
12. Install kick panel onto truck. frame. See Figure 6.
• See Figure 4 for lift truck models 17. For lift truck models GLP/GDP16-18VX, GLP/
GLC030-035VX, GLC040SVX (D809) GDP20SVX (GLP/GDP030-035VX, GLP/
• See Figure 5 for lift truck models GLP/ GDP040SVX) (D810), install left and right step
GDP16-18VX, GLP/GDP20SVX (GLP/ covers, eight clip nuts, and eight capscrews onto
GDP030-035VX, GLP/GDP040SVX) (D810) frame. See Figure 6.
13. Install dash to top of cowl. See Figure 7. Install 18. Install left and right rear covers, washers and cap-
four clips to attach the dash to kick panel. screw 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 20. If truck is equipped with an LPG tank, swing LPG
capscrews onto frame. tank into position on back of counterweight. See
PSI 2.0L LPG Fuel System 0900YRM1739 for
• See Figure 4 for lift truck models procedures.
GLC030-035VX, GLC040SVX (D809)
21. Connect the battery.
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/ 22. Adjust the steering column and seat positions.
GDP030-035VX, GLP/GDP040SVX) (D810)
15
Steering Column 0100 YRM 1735
Steering Column
DESCRIPTION 2. Attach a tag on the battery connector or negative
battery cable stating, DO NOT CONNECT BAT-
This section describes the repair procedures for the TERY. Move the steering column to the most for-
steering column. The steering column assembly ward position.
mounts to the cowl inside the operator compartment
and is the mechanical connection between the steer-
ing wheel and the steering control unit. The steering CAUTION
column includes the steering wheel, housing, bracket If a puller tool is used to remove steering wheel
and lower shaft. For lift truck models GLC030-035VX, from steering column, be careful not to damage
GLC040SVX (D809), capscrews and bushings attach horn wires.
the steering column to the cowl standoffs. For lift truck
models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ NOTE: This procedure is for the removal of all com-
GDP030-035VX, GLP/GDP040SVX) (D810), cap- ponents of the steering column assembly. Not all
screws, bushings and isolators attach the steering components are removed for a repair procedure. Do
column to the cowl standoffs. See Figure 13. only those steps of the procedure necessary to re-
move the required component.
STEERING COLUMN REPAIR NOTE: Tag wires prior to disconnecting them.
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
1. STEERING WHEEL
2. STEERING COLUMN Figure 14. Steering Wheel Remove/Install
3. COWL
Figure 13. Steering Column and Cowl
16
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