GP/GLPO/GDP/GTP040VX, GP/GLPO/GDP/GTP050VX, GP/GLPO/GDP/ GTP060VX, GP/GLPO/GDP/GTP070VX (D875) SERVICE MANUAL CONTENTS SECTION
PART NUMBER
YRM NUMBER
REV DATE
OPERATOR'S CAB........................................................................................................ FRAME............................................................................................................................ YANMAR DIESEL ENGINES.......................................................................................... KUBOTA SPARK IGNITED 2.5L LPG............................................................................ PSI 2.4L ENGINE............................................................................................................ COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... FUEL SYSTEM PSI 2.4L................................................................................................ SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... DRIVE AXLE REPAIR (WET BRAKE)........................................................................... DRIVE AXLE REPAIR - DRY BRAKE............................................................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC CLEANLINESS PROCEDURES............................................................... HYDRAULIC GEAR PUMPS.......................................................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... CYLINDER REPAIR (MAST S/N D515, E509, E564)..................................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. ENGINE ELECTRICAL SYSTEM, PSI 2.4L ENGINE..................................................... MAST REPAIR (S/N F507, F508, F562, F563)............................................................... MAST REPAIR (S/N D515, E509, E564)........................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................
550108590 550108889 524240453 550096316 550108890 550108891 550096320 550108892 550108495 550109083 550096322 550108893 550108894 550108498 550073240 550108499 550108500 550093750 550100651 524223769 524223770 524223771 550108895 550108896 550093755 550100656 524150797 524223780 550108507 550108897 550108898 524221866
0100 YRM 1752 0100 YRM 1754 0600 YRM 1205 0600 YRM 1670 0600 YRM 1755 0700 YRM 1756 0900 YRM 1677 0900 YRM 1757 1300 YRM 1740 1300 YRM 1764 1400 YRM 1679 1400 YRM 1758 1600 YRM 1759 1800 YRM 1743 1900 YRM 1620 1900 YRM 1744 2000 YRM 1745 2100 YRM 1668 2100 YRM 1692 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1760 2200 YRM 1761 4000 YRM 1669 4000 YRM 1693 8000 YRM 0231 8000 YRM 1134 8000 YRM 1753 8000 YRM 1762 8000 YRM 1763 9000 YRM 1112
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 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 12/14
PART NO. 550109093 (12/14)
0100 YRM 1752
General
General The overhead guard is an integral part of operator cab. The operator cab is installed on a platform above main frame members. Step plates on both sides of lift truck provide access to operator cab.
The operator cab is a separate unit and can be removed as a complete unit from module and frame of the lift truck. See Figure 1.
Figure 1. Operator Cab
Cab Replacement REMOVE NOTE: The LPG tank bracket used to mount the LPG tank (if equipped) onto the counterweight comes in two styles. One style of bracket swings out to side of truck and other swings out to side and drops down.
NOTE: On lift trucks equipped with a LPG fuel system, move the LPG tank and bracket to side of truck before opening the hood. See PSI 2.0L LPG Fuel System 0900YRM1739 for lift 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
1
Cab Replacement •
0100 YRM 1752
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) equipped with a Kubota 2.5L LPG engine
1. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (D810), tilt steering column to UP position, slide seat assembly forward, open rear door, and open hood to disconnect battery. See Figure 2. For lift truck models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (D875), tilt steering column to UP position, slide seat assembly forward, open rear sliding window, and open hood to disconnect battery. See Figure 3.
1. LATCH 2. HINGE
3. REAR DOOR
Figure 2. Rear Door and Latch, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (D810)
A. LIFT TRUCKS WITHOUT AIR CONDITIONING B. LIFT TRUCKS WITH AIR CONDITIONING 1. REAR BOTTOM WINDOW 2. RELEASE LATCH 3. AC HOSE Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
2
0100 YRM 1752
Cab Replacement
2. Loosen clamp and disconnect air filter hose from elbow. Remove bolts, elbow, retainer, and grommet from rear left corner leg of cab frame. See Figure 4.
WARNING DO NOT disconnect the heater hoses from the engine when the engine is hot or when the cooling system is under pressure, to do so could cause serious injury.
WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator is hot and the cap is removed, the pressure is released from the system and the steam and boiling coolant can cause burns. Wait 30 minutes for the engine 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 remove, check, or fix any part of the cooling system. NOTE: Removing radiator cap will help depressurize cooling system. 3. Turn knobs counterclockwise and remove radiator cover to access radiator cap. Remove radiator cap. See Figure 5.
NOTE: AIR FILTER HOSE FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) SHOWN. AIR FILTER HOSE FOR LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (D875) IS SIMILAR. 1. 2. 3. 4. 5. 6.
CLAMP AIR FILTER HOSE BOLTS ELBOW RETAINER GROMMET Figure 4. Air Filter Hose Removal
3
Cab Replacement
0100 YRM 1752
CAUTION
5. Contact a certified air conditioning specialist to have the refrigerant extracted from the air conditioning system.
DO NOT allow any fluid to drain when disconnecting the heater hose from the engine. The method will help when purging the system during installation. 4. Disconnect and cap heater hoses from engine. See Figure 7.
WARNING Replacement, installation and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid must be performed by a certified technician.
6. If lift truck cab is equipped with an air conditioner/ heater unit, disconnect AC refrigerant hoses from refrigerant compressor. See Figure 6. NOTE: Removing door assemblies requires two people. 7. Open left side door, remove lock nut and disconnect gas spring from cab mounting bracket. See Figure 8. 8. Lift left side door up and over hinge pin and set aside. See Figure 9 .
NOTE: Perform Step 5 and Step 6 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875).
NOTE: RADIATOR COVER FOR LIFT TRUCKS EQUIPPED WITH STEEL DOORS SHOWN. RADIATOR COVER FOR LIFT TRUCKS EQUIPPED WITH PVC DOORS IS SIMILAR. A. GLP/GDP16-18VX, GLP/GDP20SVX (D810) LIFT TRUCKS
B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) LIFT TRUCKS
1. RADIATOR COVER 2. RADIATOR CAP Figure 5. Radiator Cover and Cap Location
4
0100 YRM 1752
Cab Replacement
NOTE: KUBOTA 2.5L LPG ENGINE SHOWN. OTHER ENGINES ARE SIMILAR. 1. AC REFRIGERANT HOSES 2. REFRIGERANT COMPRESSOR 3. AC/HEATER UNIT
4. ENGINE 5. HOSE WRAP 6. AC WIRE HARNESS
Figure 6. AC Refrigerant Hose and Wire Harness Connections
WARNING DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator cab) or engine 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 models GLP/GDP16-18VX, GLP/ GDP20SVX (D810), open right side door and push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly hoses. Disconnect heater wire harness connectors. See Figure 7. b. For lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875), open right side door and remove radiator cover to access quick disconnect fittings. Push buttons on quick
disconnect fittings to disconnect heater hoses from heater assembly (see Figure 7). Disconnect heater wire harness connections. See Figure 10. NOTE: Removing door assemblies requires two people. 10. Open right side door, remove lock nut, and disconnect gas spring from cab mounting bracket. See Figure 8. 11. Lift right side door up and over hinge pin and set aside. See Figure 9 . NOTE: Wiper motor cover must be removed before dash assembly can be removed. 12. Unclip and remove front wiper motor cover. See Figure 11.
5
Cab Replacement
0100 YRM 1752
NOTE: HOSE SLEEVE REMOVED FOR CLARITY A. OUTSIDE OF LIFT TRUCK, LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) B. INSIDE OF LIFT TRUCK, LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (D810)
C. LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
1. QUICK DISCONNECT FITTING 2. HEATER HOSES
3. INNER REAR COVER Figure 7. Heater Hose Connection
6
0100 YRM 1752
Cab Replacement
NOTE: RIGHT SIDE DOOR SHOWN.
NOTE: MAJOR COMPONENTS OF CAB OMITTED FOR CLARITY.
1. GAS SPRING 3. LOCK NUT 2. CAB MOUNTING BRACKET Figure 8. Gas Spring Mounting Removal
1. HEATER WIRE HARNESS CONNECTOR 2. REAR GRAB HANDLE HORN BUTTON CONNECTOR (TO RIGHT CHASSIS HARNESS) Figure 10. Heater Wire Harness and Rear Grab Handle Horn Button Connections, Lift Truck Models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (D875) 13. Remove five fasteners securing dash panel to top of cowl panel. Remove four clips, located underneath dash panel, that attach dash panel to the kick panel. See Figure 11. 14. Remove two capscrews securing cowl panel to front operator cab legs. See Figure 11. 15. Remove dash assembly from lift truck. 16. Remove floor mat and floor plate. 17. Remove kick panel from seal plate assembly. See Figure 11. 18. Remove capscrews, clip nuts, and seal plate assembly from lift truck frame. See Figure 11.
NOTE: RIGHT SIDE DOOR HINGE SHOWN. 1. HINGE PIN 2. DOOR HINGE Figure 9. Door Removal
19. Disconnect rear grab handle horn button connector from right-hand chassis harness, located in right rear corner leg of cab frame. See Figure 12.
7
Cab Replacement
0100 YRM 1752
20. Disconnect light harness connector from Vehicle Systems Manager (VSM) and right-hand chassis harness connector. See Figure 12.
22. Remove front and rear cab capscrews and flange nuts from lift truck frame. See Figure 14.
21. Remove rear panels, front panels, and fender covers to access cab mounting capscrews and flange nuts. See Figure 13.
NOTE: DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) SHOWN. DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) IS SIMILAR. 1. 2. 3. 4. 5.
FASTENER CAPSCREW CLIP CLIP NUT FRONT WIPER MOTOR COVER
6. 7. 8. 9.
KICK PANEL DASH PANEL SEAL PLATE COWL PANEL
Figure 11. Dash Assembly, Remove/Install
8
0100 YRM 1752
Cab Replacement
NOTE: KICK AND DASH PANELS REMOVED FOR CLARITY. 1. VSM 2. LIGHT HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT CHASSIS HARNESS) 4. REAR GRAB HANDLE HORN BUTTON CONNECTOR
Figure 12. Cab Electrical Connections
WARNING Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb) 23. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 15.
CAUTION Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected and are not damaged. 24. Carefully lift operator cab away from lift truck. Set operator cab in a storage area and place blocks under operator cab to make it stable and prevent damage to parts still attached.
9
Cab Replacement
0100 YRM 1752
NOTE: LEFT DOOR REMOVED FOR CLARITY 1. 2. 3. 4. 5. 6.
REAR PANEL (LPG) REAR PANEL (DIESEL) FRONT PANEL FENDER COVER SCREWS CAPSCREW Figure 13. Front and Rear Panels and Fender Cover Removal
A. FRONT VIEW B. REAR VIEW 1. CAPSCREWS 2. FLANGE NUTS Figure 14. Front and Rear Cab Mounting
10
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING
NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
0100 YRM 1752
Cab Replacement 5. Install fender covers, front and rear panels to frame. Tighten capscrews to 11 N•m (8 lbf in). See Figure 13. 6. Connect light harness connector to Vehicle Systems Manager (VSM) and right-hand chassis harness. See Figure 12. 7. Connect right-hand chassis harness to rear grab handle horn button connector. See Figure 12. 8. Install seal plate assembly to lift truck frame and tighten capscrews and clip nuts. 9. Install kick panel onto seal plate assembly. See Figure 11. 10. Install floor plate and floor mat. 11. Install dash assembly onto kick panel and install five capscrews to secure dash assembly to cowl panel. See Figure 11. 12. Install and clip front wiper motor cover. 13. Install right side door onto cab by lifting door up and over top and bottom hinge pins. See Figure 9.
NOTE: ILLUSTRATION FOR REFERENCE PURPOSES ONLY. ACTUAL CAB MAY BE SLIGHTLY DIFFERENT. Figure 15. Lift Strap Connection
INSTALL 1. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 15. 2. Carefully lift operator cab onto lift truck frame making sure that front and rear leg mounting holes are aligned with frame mounting holes. 3. Install capscrews and flange nuts to rear operator cab legs. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 14. 4. Install capscrews and lock nuts to front operator's cab legs. Tighten capscrews to 66 N•m (49 lbf ft).
14. Connect gas spring and lock nut to cab mounting bracket. See Figure 8 . 15. If lift truck cab is equipped with an air conditioner/ heater unit, connect AC refrigerant hoses to refrigerant compressor. See Figure 6. 16. Connect heater hoses to heater assembly and connect heater wire harness connection. See Figure 7. 17. Install left side door onto cab by lifting door up and over top and bottom hinge pins. See Figure 9. 18. Connect gas spring and lock nut to cab mounting bracket. See Figure 8. 19. Uncap and connect heater hoses at engine. See Figure 7. 20. Check coolant level, fill if necessary. For procedures, see Cooling System 0700YRM1737 for lift truck models •
GLP/GDP16-18VX, GLP/GDP20SVX (D810)
11
Cab Replacement
0100 YRM 1752
Cooling System 0700YRM1756 for lift truck models •
GLP/GDP20-35VX GDP040-070VX) (D875)
(GP/GLP/
21. Install radiator cap and radiator cover. See Figure 5. 22. Connect air filter hose onto rear left corner leg of cab frame. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 4. 23. Connect battery and close hood.
26. On lift trucks equipped with an air conditioner/ heater unit, start engine and turn on heater to ON position, run engine approximately one to two minutes or until heater supply hose is fully purged. 27. If lift truck is equipped with a LPG engine, swing the LPG tank and bracket back to its original position on counterweight and make sure it locks in position. See PSI 2.0L LPG Fuel System 0900YRM1739 for lift truck models •
24. For lift trucks NOT equipped with an AC/Heater unit, start engine and turn on heater to ON position, run engine approximately one to two minutes or until heater supply hose is fully purged.
WARNING Replacement, installation and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid must be performed by a certified technician. NOTE: Step 25 and Step 26 apply only to lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) equipped with an air conditioner/heater unit.
GLP/GDP16-18VX, GLP/GDP20SVX (D810)
See Fuel System PSI 2.4L 0900YRM1757 for lift truck models •
GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (D875) equipped with a PSI 2.4L LPG engine
See LPG Fuel System, Kubota 2.5L Engine 0900YRM1677 for lift truck models •
GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (D875) equipped with a Kubota 2.5L LPG engine
25. Contact a certified air conditioning specialist to have the refrigerant refilled into air conditioning system.
Door Assemblies RIGHT DOOR ASSEMBLY Remove
WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When radiator cap is removed, the pressure is released from cooling system. If cooling system is hot, the steam and boiling coolant can cause burns. Wait 30 minutes for the engine 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 remove the radiator cap.
12
NOTE: Removing radiator cap will help depressurize cooling system. 1. Remove radiator cover to access radiator cap. Remove radiator cap. See Radiator Cover and Cap Location.
WARNING DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator cab) or engine when the engine is hot or under pressure. Serious injury can occur. NOTE: Removing right door assembly requires two people. 2. Disconnect heater hose quick disconnect fittings. See Figure 7.
0100 YRM 1752
Door Assemblies
a. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (D810), open right door and push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly hoses. Disconnect heater wire harness connection. See Figure 7 and Figure 12.
7. Disconnect gas spring. See Figure 8.
b. For lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875), open right side door and remove radiator cover to access quick disconnect fittings. Push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly hoses. Disconnect heater wire harness connection. See Figure 7 and Figure 12.
Door Cover With Heater Unit
WARNING Replacement, installation and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid must be performed by a certified technician. NOTE: Step 3 through Step 6 apply to lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) equipped with a air conditioner/heater unit. 3. Contact a certified air conditioning specialist to have the refrigerant extracted from the air conditioning system. 4. Remove fasteners and rear cover. See Figure 5.
8. Remove right door from cab frame by lifting door up and over hinge pin. See Figure 9.
Disassemble
NOTE: This section removes the right door cover. To remove the heater unit from right door, see section Heater and Air Conditioner Replacement. 1. Remove four screws and washers that attach handle to door cover. Remove handle and two handle plates. See Figure 16. 2. Remove fan and heater knobs from knob plate. Remove four screws that fasten knob plate to heater valve and switch plate. Remove knob plate from door cover. 3. Remove two fasteners from top of door cover. See Figure 16. 4. Remove five plugs, washers, and star nuts along sides and front of door cover. Remove two capscrews and washers from bottom of door cover. Remove door cover from door frame. See Figure 16. 5. Remove pre-filter, located on bottom of door frame. See Figure 16.
5. Disconnect air conditioner hoses at bulkhead bracket. See Figure 6. 6. Disconnect air conditioner wire harness. See Figure 6.
13
Door Assemblies
0100 YRM 1752
Figure 16. Right Door Cover With Heater Unit
14