GDP60-70CA (A878) (GP135CA, GP155CA) (A878) SERVICE MANUAL CONTENTS SECTION
PART NUMBER
YRM NUMBER
REV DATE
FRAME............................................................................................................................ GM ENGINES.................................................................................................................. PERKINS DIESEL ENGINE............................................................................................ COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM....................................................................................................... 2-SPEED POWERSHIFT TRANSMISSION DESCRIPTION AND OPERATION........... 2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... SPEED REDUCER.......................................................................................................... DIFFERENTIAL............................................................................................................... DRIVE AXLE................................................................................................................... STEERING CONTROL UNIT.......................................................................................... STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ TILT CYLINDERS........................................................................................................... ALTERNATOR................................................................................................................ STARTER........................................................................................................................ HIGH ENERGY IGNITION (HEI) SYSTEM..................................................................... INSTRUMENT PANEL INDICATORS AND SENDERS................................................. MICROPROCESSOR SPARK TIMING SYSTEM (GM 3.0L/4.3L) (LATER MODELS). EEC-DESCRIPTION AND OPERATION (GM 3.0L/4.3L)............................................... EEC-TROUBLESHOOTING AND REPAIR.................................................................... LIFT CYLINDERS........................................................................................................... MAST DESCRIPTION AND REPAIR.............................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... CAPACITIES AND SPECIFICATIONS........................................................................... PERIODIC MAINTENANCE............................................................................................ DIAGRAMS.....................................................................................................................
524185155 524153897 524150774 524150775 524153900 524185156 524185157 524185158 524150779 524185159 524185160 524150783 524185161 524153907 524185163 524185164 524150790 524150791 524150792 524153914 524185165 524153916 524153917 524153918 524150794 524185167 524150797 524185168 524185169 524185171
0100 YRM 0322 0600 YRM 0590 0600 YRM 0705 0700 YRM 0626 0900 YRM 0348 1300 YRM 0324 1300 YRM 0325 1300 YRM 0344 1400 YRM 0046 1400 YRM 0049 1600 YRM 0054 1600 YRM 0326 1800 YRM 0327 1900 YRM 0097 1900 YRM 0328 2000 YRM 0090 2100 YRM 0103 2200 YRM 0002 2200 YRM 0106 2200 YRM 0107 2200 YRM 0143 2200 YRM 0765 2200 YRM 0781 2200 YRM 0782 4000 YRM 0135 4000 YRM 0329 8000 YRM 0231 8000 YRM 0331 8000 YRM 0341 8000 YRM 0519
02/07 04/14 03/06 03/03 03/03 10/03 10/03 03/03 08/12 09/03 10/03 03/07 09/03 05/12 09/03 10/03 03/07 12/04 12/04 03/08 02/07 03/03 03/03 03/03 03/11 09/10 10/13 09/03 06/09 06/07
PART NO. 524185128 (04/14)
8000 YRM 331
Capacities
Lift Truck Weights Model
kg
lb
GDP60CA (GP/GLP/GDP135CA)
8,035
16,720
GDP70CA (GP/GLP/GDP155CA)
8,560
18,870
NOTE: Lift trucks equipped with overhead guard, 4340 mm (171.0 in.) two-stage mast, carriage, load backrest extension, forks, gasoline engine, manual transmission, and operator.
Capacities Item
Quantity
Engine Oil GM 4.3L V-6
4.7 liter (5.0 qt)
Perkins 1004.4
8.0 liter (8.5 qt)
Cooling System GM 4.3L V-6
19.9 liter (21.0 qt)
Perkins 1004.4
15.1 liter (16.0 qt)
Hydraulic System Manual Transmission
Initial Fill 51.1 liter (13.5 gal)
Powershift Transmission
Initial Fill 49.7 liter (13.1 gal)
Manual Transmission
9.5 liter (10.0 qt)
Powershift Transmission
15.1 liter (16.0 qt)
Speed Reducer and Differential
14.3 liter (15.1 qt)
Differential for Powershift Transmission
14.3 liter (15.1 qt)
Brake Fluid Fuel Tank
0.2 liter (0.4 pt) 60.0 liter (15.9 gal)
1
Wheel Nut Torque
8000 YRM 331
Tire Sizes Model
Steering
Drive
Bias Ply Tires
8.25 × 15-12 Ply
8.25 × 15-12 Ply
7.50R 15-12 Ply
7.50 × 15-10 Ply
8.25R 15-12 Ply
8.25 × 15-12 Ply
Radial Tires
Tire Pressure Bias Ply Tires Tire Size
kPa
psi
8.25 × 15 - 12 Ply
690
100
Radial Tires Tire Size
kPa
psi
7.50 × 15 - 12 Ply
1000
145
8.25 × 15 - 12 Ply
1000
145
Electrical System Alternator Output 11 amps @ 650 rpm (hot)
GM 4.3L V-6 Engine
33 amps @ 2500 rpm (hot) 25 amps @ 750 rpm (hot)
Perkins 1004.4 Engine
38 amps @ 2500 rpm (hot)
All Models - 12 volt, Negative Ground
Wheel Nut Torque All Wheels
2
N•m
lbf ft
610 to 680
450 to 502
8000 YRM 331
Hydraulic System
Engine Specifications Item
GM 4.3L V-6
Perkins 1004.4
6
4
1-6-5-4-3-2
1-3-4-2
Bore
101.6 mm (3.99 in.)
100.0 mm (3.937 in.)
Stroke
88.4 mm (3.48 in.)
127.0 mm (5.00 in.)
No. of Cylinders Firing Order
Displacement Compression Ratio Idle Speed Idle-Up Speed (LPG) Governed Speed Stall Speed (Engine at 50 hours) Timing
3
4.3 liter (262.4 in. )
4.06 liter (244.0 in. 3 )
9.3:1
16.5:1
625 to 675 rpm
725 to 775 rpm
1200 rpm (maximum)
N/A
2400 to 2500 rpm
2400 to 2500 rpm
1810 rpm (Gas)
2000 to 2100 rpm
1735 rpm (LPG) 0 BTDC at 650 rpm
16 BTDC (Static)
207 to 308 kPa (30 to 45 psi) @ 2000 rpm
280 kPa (40 psi) @ 2500 rpm
Intake
Not Adjustable
0.20 mm (0.008 in.) Cold
Exhaust
Not Adjustable
0.45 mm (0.018 in.) Cold
Oil Pressure (Minimum) Valve Clearance
Hydraulic System Item
Specification
Hydraulic System Capacity Hydraulic Pump Output Main Pump Steering Pump
51.1 liter (13.5 gal) 32.2 liter/min (8.5 gal/min) @ 700 rpm (No Load) 123.0 liter/min (32.5 gal/min) @ 2500 rpm (No Load) 15.1 liter/min (4.0 gal/min) @ 1500 rpm (No Load)
Relief Pressures* Main Control Valve Main Pump
20.88 to 21.20 MPa (3025 to 3075 psi) @ 2500 rpm
Auxiliary Relief Valve
15.34 to 15.68 MPa (2225 to 2275 psi) @ 2500 rpm
Steering Pump Steering Control Unit (Manifold Block)
13.8 MPa (2000 psi) 12.06 to 12.11 MPa (1736 to 1808 psi)
*Oil Temperature at 49 C (120 F) and engine speed at 2500 rpm.
3
Transmission Oil Pressures
8000 YRM 331
Mast Speeds Two-Stage Masts Lifting Unit
No Load
Lowering Rated Load
No Load
Rated Load
m/sec
ft/min
m/sec
ft/min
m/sec
ft/min
m/sec
ft/min
GDP60CA (GP/GLP/ GDP135CA)
0.44
86
0.41
80
0.53
104
0.58
114
GDP70CA (GP/GLP/ GDP155CA)
0.44
86
0.41
80
0.53
104
0.58
114
Transmission Oil Pressures Port No.
Transmission Pressures*
1
System Pressure
1179 to 1427 kPa (171 to 207 psi)
2
Torque Converter Pressure
765 to 903 kPa (111 to 131 psi)
Clutch Pressure
855 to 993 kPa (124 to 144 psi)
Solenoid Pressure
827 to 1103 kPa (120 to 160 psi)
3, 4, 5, 6, 7 8, 9 10, 11
Lubrication Pressure
131 to 173 kPa (19 to 25 psi)
12, 13
Lubrication Pressure
62 to 104 kPa (9 to 15 psi)
*Oil temperature at least 82 C (180 F) and engine speed at 2000 rpm. 1. System Pressure Check Port
8. Reverse Solenoid Check Port
2. Torque Converter Check Port
9. Forward Solenoid Check Port
3. Common Clutch Pressure Check Port
10. Reverse-High Lubrication Check Port
4. Reverse-Low Check Port
11. Forward-High Lubrication Check Port
5. Reverse-High Check Port
12. Reverse-Low Lubrication Check Port
6. Forward-Low Check Port
13. Forward-Low Lubrication Check Port
7. Forward-High Check Port
4
8000 YRM 331
Torque Specifications
Torque Specifications ENGINE - GM 4.3L V-6 Intake Manifold Capscrews 47 N•m (35 lbf ft) Valve Cover Capscrews 10 N•m (7 lbf ft) Exhaust Manifold Capscrews Center Port 35 N•m (26 lbf ft) Outer Port 27 N•m (20 lbf ft) Engine Mount Capscrews 50 N•m (37 lbf ft) Camshaft Sprocket Capscrews 27 N•m (20 lbf ft) Vibration Dampener Capscrew 81 N•m (60 lbf ft) Main Bearing Capscrews 95 to 115 N•m (70 to 85 lbf ft) Connecting Rod Nuts 57 to 64 N•m (42 to 47 lbf ft) Flywheel Capscrews 79 N•m (58 lbf ft) Engine Adapter Capscrews 47 N•m (35 lbf ft)
ENGINE - PERKINS 1004.4 Engine Mount to Engine Capscrews 56 N•m (41 lbf ft) Flywheel Housing Capscrews 75 N•m (55 lbf ft) Cylinder Head 110 N•m (80 lbf ft) Connecting Rod Nuts 155 N•m (114 lbf ft) Main Bearing Capscrews 265 N•m (196 lbf ft) Camshaft Gear Capscrew 78 N•m (58 lbf ft) Idler Gear Capscrews 44 N•m (33 lbf ft)
Flywheel Capscrews 105 N•m (77 lbf ft) Fuel Injector Capscrews 12 N•m (9 lbf ft) Fuel Tube Nuts 18 N•m (14 lbf ft) Cold Start Aid 13 N•m (10 lbf ft)
CLUTCH Pressure Plate Capscrews 20 N•m (15 lbf ft) Clutch Housing Capscrews 31 N•m (23 lbf ft) Universal Joint Capscrews 28 N•m (20 lbf ft)
MANUAL TRANSMISSION Cluster Gear Retainer 20 to 35 N•m (15 to 25 lbf ft) Main Shaft Bearing Retainer 20 to 35 N•m (15 to 25 lbf ft) Yoke Nut on Mainshaft 120 to 175 N•m (90 to 130 lbf ft) Input Shaft Retainer 20 to 35 N•m (15 to 25 lbf ft) Transmission Cover Capscrews 25 to 55 N•m (20 to 40 lbf ft) Transmission to Clutch Housing Capscrews 110 N•m (80 lbf ft) Universal Joint Capscrews 28 N•m (20 lbf ft)
POWERSHIFT TRANSMISSION Torque Converter Housing Capscrews 31 N•m (23 lbf ft) Torque Converter Drive Plate Capscrews 44 N•m (32 lbf ft)
5
Torque Specifications Engine Mount Capscrews at Torque Converter Housing 110 N•m (80 lbf ft) Universal Joint Capscrews 50 N•m (37 lbf ft) Transmission Cover Capscrews 38 N•m (28 lbf ft) Manifold Block Capscrews 38 N•m (28 lbf ft) Oil Pump Capscrews 38 N•m (28 lbf ft) Torque Converter Housing to Transmission Capscrews 38 N•m (28 lbf ft) Control Valve Capscrews 19 N•m (14 lbf ft)
SPEED REDUCER Bearing Cover Capscrews 27 N•m (20 lbf ft) Speed Reducer Housing to Differential Capscrews 110 N•m (80 lbf ft) Pinion Nut 855 to 1100 N•m (630 to 812 lbf ft) Universal Joint Capscrews 28 N•m (20 lbf ft)
DRIVE AXLE Drive Axle to Frame Capscrews 610 N•m (450 lbf ft) Axle Shaft Capscrews 165 N•m (122 lbf ft)
STEERING SYSTEM Axle Mount Capscrews 320 N•m (235 lbf ft) Bearing Cap for Spindle 44 N•m (32 lbf ft)
6
8000 YRM 331 Tie Rod Nut 163 N•m (120 lbf ft) Steering Cylinder Capscrews 245 N•m (180 lbf ft)
BRAKE SYSTEM Back Plate Nuts 125 N•m (90 lbf ft) Brake Drum and Wheel Nuts 610 to 680 N•m (450 to 500 lbf ft) Wheel Bearing Adjustment Nut 200 N•m (150 lbf ft) Initial 35 N•m (25 lbf ft) Final Wheel Bearing Lock Nut 135 N•m (100 lbf ft)
HYDRAULIC SYSTEM Pump Driveshaft GM 4.3L V-6 Universal Joint Capscrews 50 N•m (37 lbf ft) Crankshaft Pulley Capscrews 50 N•m (37 lbf ft)
TILT CYLINDER Rod Nut on Piston 407 to 441 N•m (300 to 325 lbf ft) Retainer 542 to 610 N•m (400 to 460 lbf ft) Rod End Lock Nut 77 N•m (57 lbf ft)
MAST Pivot Cap Capscrews 165 N•m (122 lbf ft) Lift Cylinder Mount Capscrews 555 N•m (410 lbf ft) Sideshift Carriage Guide Roller Nuts 345 N•m (255 lbf ft) Side Roller Capscrews 90 N•m (66 lbf ft) Cylinder Rod Nut 163 to 190 N•m (120 to 140 lbf ft) Cylinder Retainer 169 to 237 N•m (125 to 175 lbf ft)
1400 YRM 46
Differential Repair
General This section contains description and repair procedures for the differential. There is a Specifications section and a Troubleshooting section at the end of this section.
Description This differential is fastened to the drive axle housing of the lift truck. The differential provides a single-speed reduction for an increase in torque to the drive wheels. There is a housing, a ring and pinion gear set, and the differential assembly. The ring gear transfers power
from the pinion through the differential assembly to the axles. The differential assembly permits the drive wheels to rotate at different speeds during a turn. See Figure 1.
Differential Repair REMOVE NOTE: The repair procedures cover all units unless otherwise indicated.
Differential Carrier From Axle Housing, Remove NOTE: The differential assembly can normally be removed without removing the drive axle. If removal of
the drive axle is necessary, see the Drive Axle service manual for your lift truck model. 1. Remove the mast. See the Mast service manual for your lift truck model for the removal procedures. 2. Raise the end of the vehicle where the axle is mounted. Use a jack or other lifting tool, and place safety stands under each side of the axle. See Figure 2.
1
Differential Repair
1400 YRM 46
Figure 1. Typical Differential Assembly
2
1400 YRM 46
Differential Repair
Legend for Figure 1 NOTE: *SOME AXLES DO NOT HAVE THE PARTS DESCRIBED. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
PINION NUT WASHER* INPUT YOKE* DEFLECTOR TRIPLE-LIP OIL SEAL DIFFERENTIAL CARRIER FILL PLUG ADJUSTMENT RING LOCK PLATE CAPSCREW SIDE GEAR THRUST WASHER CASE HALF BEARING CONE BEARING CUP PINION SPIDER
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
CAPSCREW OR RIVET* RING GEAR CASE HALF, FLANGE NUT* NUT WASHER THRUST BLOCK* BEARING CAP COTTER PIN (ADJUSTING RING)* JAM NUT* THRUST SCREW* RETAINING RING WASHER SPIGOT BEARING PINION SPACER
34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.
SHIM PINION CARRIER COVER BOLT SHIFT FORK SPRING SHIFT SHAFT PIN AIR CYLINDER TUBE SCREW IN DIFFERENTIAL LOCK CYLINDER CYLINDER COVER GASKET PLUG SHIFT COLLAR PISTON O-RING
NOT work under a lift truck supported only by jacks. Jacks can slip and fall over. Serious personal injury can result. 3. Place jack stands under each spring seat of the axle, to hold the lift truck in the raised position. 4. Remove plug from the bottom of the axle housing and drain the oil from the axle assembly. 5. Disconnect the drive shaft at the differential. If a speed reducer or gear box is installed, remove the speed reducer or gear box. 6. Some units have a drum or disc brake attached to the output yoke. Disconnect any brake linkage or brake lines. See the Brake manual for your unit.
1. SAFETY STANDS
Figure 2. Lift Truck Support
WARNING Block the wheels to prevent the lift truck from moving. Support the lift truck with safety stands. DO
7. Disconnect the driveline universal joint from the pinion input yoke or flange on the differential carrier. See Figure 3. 8. Remove the axle shafts from the axle housing. See the Drive Axle manual for your model of lift truck for the procedures. 9. Place a transmission jack under the differential carrier for support. See Figure 4.
3
Differential Repair
1. BEARING CUPS 2. END YOKE 3. YOKE SADDLE
1400 YRM 46
4. WELD YOKE 5. BEARING STRAP 6. CAPSCREWS
7. U-JOINT CROSS 8. SLIP YOKE 9. TUBING
Figure 3. Typical Driveline Universal Joint Legend for Figure 4 1. WOOD BLOCK 2. TRANSMISSION JACK 3. CAPSCREWS 10. Remove all but the top two differential carrier housing capscrews. See Figure 4. 11. Loosen the top two differential carrier housing capscrews and leave them attached to the assembly. The capscrews will hold the differential carrier in the housing. 12. Loosen the differential carrier in the axle housing. Use a leather mallet to hit the mounting flange of the differential carrier at several points.
Figure 4. Differential Carrier Support
4
13. After the differential carrier is loosened, remove the top two capscrews.
1400 YRM 46
CAUTION
Differential Repair 2. Remove the thrust screw and jam nut from the differential carrier. See Figure 6.
When using a pry bar, be careful not to damage the differential carrier or housing flange. Damage to these surfaces will cause oil leaks. 14. Remove the differential carrier from the axle housing. Use a pry bar with a round end, to help remove differential carrier from housing. 15. Remove the differential carrier assembly from under the lift truck. 16. Use a lifting device and lift the differential carrier by the input yoke or flange and place the assembly on a repair stand. See Figure 5.
Figure 6. Thrust Screw and Jam Nut Removal 3. Rotate the differential carrier until the ring gear is at the top of the assembly. 4. Mark one differential carrier leg and bearing cap to correctly match the parts during differential carrier assembly. Mark the parts using a center punch and hammer. See Figure 7.
1. DIFFERENTIAL CARRIER 2. REPAIR STAND
Figure 5. Differential Carrier Stand
Differential and Ring Gear From Differential Carrier, Remove NOTE: Some of the parts described below are not found on some differential carrier models. See Figure 1. NOTE: Before working on the differential carrier, inspect the hypoid gear set for damage. If inspection shows no damage, the same gear set can be used again. Measure the backlash of the gear set and make a record of the dimension. See the section Ring Gear Backlash, Adjust. During differential reassembly, adjust the backlash to the original recorded dimension when the gear set is installed into the differential carrier.
1. BEARING CAP 2. DIFFERENTIAL CARRIER LEG 3. MATCHMARKS
Figure 7. Mark Differential Carrier Leg and Bearing Cap
1. Loosen the jam nuts on the thrust screw.
5
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Differential Repair
1400 YRM 46
5. Remove the cotter pins that hold the bearing adjusting rings in position. Some differential carrier models have dowel pins or lock plates holding the bearing adjusting rings in position. Each lock plate is held in position by two capscrews. See Figure 8. 6. Remove capscrews and washers holding the two bearing caps on the differential carrier. See Figure 8.
1. BEARING CAP 2. BEARING ADJUSTING RING
Figure 9. Bearing Cap Removal 8. Use a lifting device and lift the main differential and ring gear assembly from the differential carrier. See Figure 10.
1. COTTER PIN
2. LOCK PLATE
Figure 8. Bearing Adjusting Ring Removal 7. Remove the bearing caps and bearing adjusting rings from the differential carrier. See Figure 9.
1. 2. 3. 4.
BEARING CUP DIFFERENTIAL CARRIER BEARING BORE PUT ADHESIVE HERE (INSTALLATION ONLY)
Figure 10. Main Differential and Ring Gear Assembly Removal
6
1400 YRM 46
Differential Repair
Drive Pinion and Pinion Carrier From Differential Carrier, Remove NOTE: Some of the parts described below are not found on some differential carrier models. See Figure 1. 1. Fasten a yoke or flange bar to the input yoke or flange. When the nut is removed, the bar will hold the drive pinion in position. See Figure 11. 2. Remove the nut and washer from the drive pinion. 3. Remove the yoke or flange bar.
A. YOKE PULLER
B. FLANGE PULLER
Figure 12. Yoke and Flange Puller Tools 5. Remove the capscrews and washers that hold the pinion carrier in the differential carrier. See Figure 13.
1. FLANGE BAR
2. YOKE BAR
Figure 11. Flange and Yoke Bar
CAUTION Do not use a hammer or mallet to loosen and remove the yoke or flange. A hammer or mallet can damage the parts and cause driveline runout or driveline imbalance problems after carrier to driveline assembly. 4. Remove the yoke or flange from the drive pinion. If the yoke or flange is tight on the pinion, use a puller for removal. See Figure 12.
1. DRIVE PINION AND PINION CARRIER 2. SHIMS 3. CAPSCREWS
Figure 13. Pinion Carrier Removal
7
Differential Repair
1400 YRM 46
WARNING
2. Remove the differential spider, four pinion gears, two side gears, and six thrust washers from inside the case halves. See Figure 14.
Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury.
CAUTION Do not use a pry bar to remove the pinion carrier from the carrier. A pry bar can damage the bearing case, shims, and differential carrier. 6. Remove the drive pinion, pinion carrier, and shims from the differential carrier. See Figure 13. If the pinion carrier is tight on the differential carrier, hit the pinion carrier at several points around the flange area with a leather, plastic or rubber mallet. 7. Inspect the shims. If they are in good condition, keep the shims together for use during differential carrier assembly. 8. If the shims are to be replaced, first measure the total thickness of the pack. Make a note of the dimension. The dimension will be needed to calculate the depth of the drive pinion in the differential carrier when the gear set is installed.
DISASSEMBLE Differential and Ring Gear Assembly, Disassemble NOTE: Some of the parts described below are not found on some differential carrier models. See Figure 1. NOTE: Make sure there are matching marks on the case halves of the differential assembly. See Step 4 in the section Differential and Ring Gear From Differential Carrier, Remove. See Figure 7.
WARNING Use a brass or leather mallet for assembly and disassembly procedures. Do not hit steel parts with a steel hammer. Pieces of a part can break off and cause serious personal injury. 1. Remove the capscrews and washers that hold the case halves together and separate the case halves. If necessary, use a brass, plastic, or leather mallet to loosen the parts.
8
1. THRUST WASHER 2. SIDE GEAR 3. SPIDER, PINIONS, AND THRUST WASHERS
Figure 14. Ring Gear Disassembly 3. If the ring gear needs to be replaced, remove bolts, nuts, and washers holding the ring gear to the flange case half.
CAUTION Do not remove the rivets or rivet heads with a chisel and hammer. Using a flat edge tool can cause damage to the flange case. See Figure 15. 4. If your differential model uses rivets to hold the ring gear to the flange case half, remove the rivets as follows: a. Center punch each rivet head in the center, on the ring gear side of the assembly. b. Drill each rivet head on the ring gear side of the assembly to a depth equal to the thickness of one rivet head. Use a drill bit that is 1/32 of an inch smaller than the body diameter of the rivets. See Figure 15.