Page 1

Service Repair GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [J813]

PART NO. 550068693

8000 YRM 1605


8000 YRM 1605

Lift Truck Lifting Capacity

Lift Truck Lifting Capacity Model

Weight

GLP/GDP40VX5, GLP/GDP40VX6 (GP/GLP/GDP080VX) (J813)

3629 kg (8000 lb)

GLP/GDP45SVX5 (GP/GLP/GDP090VX) (J813)

4082 kg (9000 lb)

GLP/GDP45VX6 (GP/GLP/GDP100VX) (J813)

4536 kg (10000 lb)

GLP/GDP50VX (GP/GLP/GDP100VX) (J813)

4989 kg (11000 lb)

GLP/GDP55VX (GP/GLP/GDP120VX) (J813)

5443 kg (12000 lb)

NOTE: Load center at 500 mm (24 in.).

Counterweight Weights Model

Weight

GLP/GDP40VX5 (GP/GLP/GDP080VX) (J813)

2108 kg (4647 lb)

GLP/GDP40VX6 (J813)

2314 kg (5102 lb)

GLP/GDP45SVX5 (GP/GLP/GDP090VX) (J813)

2455 kg (5412 lb)

GLP/GDP45VX6 (GP/GLP/GDP100VX) (J813)

2642 kg (5825 lb)

GLP/GDP50VX (GP/GLP/GDP100VX) (J813)

2936 kg (6473 lb)

GLP/GDP55VX (GP/GLP/GDP120VX) (J813)

3226 kg (7112 lb)

1


Tire Sizes

8000 YRM 1605

Tire Sizes Truck

Drive Tires

Steer Tires

GLP/GDP40VX5 GLP/GDP45SVX5 (GP/GLP/ GDP080VX GP/GLP/GDP090VX) (J813)

250 x 15

7.00 x 12

250 x 70 x R15

28 x 9 to 15

28 x 12.5 to 15 29 x 8 Dual 7.00 x 15 Dual 7.00 x R15 Dual GLP/GDP45VX6 GLP/GDP50VX GLP/GDP55VX (GP/GLP/GDP100VX GP/GLP/GDP110VX GP/GLP/ GDP120VX) (J813)

300 x 15

7.00 x 12

315 x 70 x R15

28 x 9 to 15

32 x 12.1 to 15 355 x 65 x 15 355 x 50 x 20 8.25 x 15 Dual 8.25 x R15 Dual

2


8000 YRM 1605

Capacities

Capacities Table 1. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Item

Quantity

Specifications

Fuel Capacity Gas (Short Wheel Base)

79 liter (20.8 gal)

86 Octane

Gas (Long Wheel Base)

100.3 liter (26.5 gal)

86 Octane

LPG

15.1 - 20.4 kg (33.5 - 45.0 lb) Full

LPG-HD 5, HD 10

Kubota 3.6L Diesel (Short Wheel Base)

79 liter (20.8 gal)

Diesel No. 2

Kubota 3.6L Diesel (Long Wheel Base)

100.3 liter (26.5 gal)

Diesel No. 2

Kubota 3.8L Diesel (Short Wheel Base)

79 liter (20.8 gal)

Ultra Low Sulfur ≤15 ppm Diesel No.2

Kubota 3.8L Diesel (Long Wheel Base)

100.3 liter (26.5 gal)

Ultra Low Sulfur ≤15 ppm Diesel No.2

Engine Oil GM 4.3L

4.7 liter (5 qt)

−7°C (−20°F) and below SAE 5W-20 16°C (60 °F) and below SAE 5W-30 −18°C (0°F) and above SAE 10W-30 API SL ILSAC GF4

Kubota Diesel

13.2 liter (13.9 qt)

−15°C (5°F) and above SAE 15W-40 −25°C (−13°F) SAE 10W-30 Below −25°C (-13°F) SAE 5W-30 API CJ-4

3


Capacities

8000 YRM 1605

Table 1. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) (Continued) Item

Quantity

Specifications

Cooling System GM 4.3L

15.1 liter (15.9 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water.

Kubota Diesel

11 liter (11.6 qt)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water.

Hydraulic Tank Oil Capacity GM 4.3L (Short Wheel Base)

62.0 liter (65.5 qt) Drain and Fill

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. ISO VG-46 Hydraulic Oil −15°C (5°F) and above

GM 4.3L (Long Wheel Base)

78 liter (82.4 qt) Drain and Fill

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. ISO VG-46 Hydraulic Oil −15°C (5°F) and above

4


8000 YRM 1605

Capacities

Table 1. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) (Continued) Item

Quantity

Kubota Diesel (Short Wheel Base)

62.0 liter (65.5 qt) Drain and Fill

Specifications

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. ISO VG-46 Hydraulic Oil −15°C (5°F) and above

Kubota Diesel (Long Wheel Base)

78.0 liter (82.4 qt) Drain and Fill

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. ISO VG-46 Hydraulic Oil −15°C (5°F) and above

Transmission Standard Transmission

20 liter (21.0 qt)

John Deere JDM J20C

Techtronix Transmission

20 liter (21.0 qt)

John Deere JDM J20C

0.35 liter (0.74 pt)

Dexron III

Brake Oil (Master Cylinder)

Transmission and Wet Brake Drive Axle - Dana Axle Only Transmission and Planetary Carrier Housing Center body (Dana Axle Only)

31.3 liter (33.0 qt)

John Deere JDM J20C

2.0 liter (2.1 qt)

SAE 80W-90

10.3 liter (10.9 qt)

John Deere JDM J20C

9.3 liter (9.9 qt)

John Deere JDM J20C

Wet Brake Drive Axle - NMHG Axle Only New or Rebuilt Axle Service Fill

5


Electrical System

8000 YRM 1605

Electrical System Table 2. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Item

GM 4.3L

Kubota Diesel

12-volt, negative ground

12-volt, negative ground

AC-41-993

N/A

1.5 mm (0.059 in.)

N/A

Gas

Not Adjustable

N/A

LPG

Not Adjustable

N/A

N/A

Not Adjustable

Battery Spark Plugs Spark Plug Gap Ignition Timing:

Diesel

GM 4.3L Alternator Output (14 Volts)

G and LPG

GS and LPS

Idle

50 amps @ 750rpm

38 amps @ 750rpm

Governed Speed

65 amps @ 2400 rpm

45 amps @ 2400 rpm

Kubota 3.6L Diesel Alternator Output (13.5 Volts)

D

Low Idle

30 amps @ 850 rpm

Governed Speed

80 amps @ 2470 rpm Kubota 3.8L Diesel

6

Alternator Output (13.5 Volts)

D

DS

Low Idle

30 amps @ 800 rpm

25 amps @ 800 rpm

Governed Speed

80 amps @ 2200 rpm

45 amps @ 2200 rpm


8000 YRM 1605

Transmission Oil Pressures

Transmission Oil Pressures 1-Speed Transmission All Pressures at 2500 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump

Port 2

Port 3

Port 5

Port 6

***Low Pressure

***High Pressure

Reverse Clutch

Forward Clutch

Torque Converter

Lubrication

1138 ±96* kPa (165 ±14 psi)

1482 ±96* kPa (215 ±15 psi)

983 ±58** kPa (142.5 ±8.5 psi)

983 ±58** kPa (142.5 ±8.5 psi)

738 ±52 kPa (107 ±7.5 psi)

55 ±28 kPa (8 ±4 psi)

*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***High pressure port is used when the lift truck is equipped with a dry brake system. The low pressure port is used when the lift truck is equipped with a wet brake system.

7


Transmission Oil Pressures

8000 YRM 1605

2-Speed Transmission All Pressures at 2500 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump ***Low Pressure

***High Pressure

Port 2

Port 3

Port 4

Port 5

Port 6

Reverse Clutch

Forward Low Clutch

Forward High Clutch

Torque Converter

Lubrication

983 ±58** kPa (142.5 ±8.5 psi)

738 ±52 kPa (107 ±7.5 psi)

1138 ±96* kPa 1482 ±96* kPa 983 ±58** kPa 983 ±58** kPa (142.5 (142.5 (165 ±14 psi) (215 ±15 psi) ±8.5 psi) ±8.5 psi)

55 ±28 kPa (8 ±4 psi)

*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***High pressure port is used when the lift truck is equipped with a dry brake system. The low pressure port is used when the lift truck is equipped with a wet brake system.

8


8000 YRM 1605

Hydraulic System Relief Pressures

Hydraulic System Relief Pressures Table 3. Hydraulic Systems With Hydraulic Gear Pump Item

Specification

Oil Temperature for Setting Relief Pressure

50 to 65°C (122 to 149°F)

Primary Relief Valve Pressure (High Idle)

22.1 ±0.48 MPa (3205 ± 70 psi)

Secondary Relief Valve Pressure (High Idle)

15.51 ±0.48 MPa (2250 ±70 psi)

Table 4. Hydraulic Systems With Variable Displacement Pump Item

Specification

Oil Temperature for Setting Relief Pressure

50 to 65°C (122 to 149°F)

Primary Relief Valve Pressure (High Idle)

23.7 ±0.50 MPa (3437 ± 72.5 psi)

Secondary Relief Valve Pressure (High Idle)

15.50 ±0.50 MPa (2248 ±72.5 psi)

Maximum Allowable Leakage at 1A Port to Tank

22.7 cc @ 19.3 MPa (2799 psi)

Steering System Table 5. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Item Oil Temperature

Quantity 50 to 65°C (122 to 149°F)

Steering Relief Pressure at 800 rpms (GM 4.3L and Kubota 3.8L Diesel Engine)

12.4 ±0.3 MPa (1798 ±43.5 psi)

Steering Relief Pressure at 850 rpms (Kubota 3.6L Diesel Engine)

12.4 ±0.3 MPa (1798 ±43.5 psi)

Steering Cylinder Stroke (Each Side)

200.85 mm (7.9 in.)

Inside Steering Tire Angle

80°

Number of Turns to Lock Turning Radius (±50 mm NO LOAD)

3.984 Outside

Inside

GLP/GDP40VX5 (GP/GLP/GDP080VX)

2570

49

GLP/GDP40VX6

2599

49

GLP/GDP45SVX5 (GP/GLP/GDP090VX)

2619

49

GLP/GDP45VX6 (GP/GLP/GDP100VX)

2837

131

GLP/GDP55VX (GP/GLP/GDP110VX)

2877

131

GLP/GDP55VX (GP/GLP/GDP120VX)

2915

131

9


Mast Speeds

8000 YRM 1605

Stall Speeds (in RPM ±100 rpm) GM 4.3L Transmission

New Engine

Broken-In Engine

Standard

2000

2100

Techtronix 100

2000

2100

Techtronix 100X

2000

2100

Techtronix 200X

Stall Speed Not Valid

Stall Speed Not Valid

New Engine

Broken-In Engine

Standard

1950

2000

Techtronix 100

1950

2000

Techtronix 100X

1950

2000

Techtronix 200X

Stall Speed Not Valid

Stall Speed Not Valid

New Engine

Broken-In Engine

Standard

1900

1970

Techtronix 100

1900

1970

Techtronix 100X

1900

1970

Techtronix 200X

Stall Speed Not Valid

Stall Speed Not Valid

KUBOTA 3.6L DIESEL Transmission

KUBOTA 3.8L DIESEL Transmission

Mast Speeds NOTE: Lift speed is measured in meters/sec at governed engine RPM with full open valve and 65°C (149°F) oil temperature.

Lowering speed is measured in meters/sec with full open valve and 65°C (149°F) oil temperature. Plus or minus 10% acceptable lifting or lowering.

Table 6. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine

Mast

GM 4.3L (Standard Displacement Pump)

10

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.62

0.61

2-Stage FFL

0.36

0.50

0.55

0.54

3-Stage FFL

0.44

0.53

0.58

0.57


8000 YRM 1605

Mast Speeds

Table 7. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine

Mast

Kubota 3.6 L Diesel (Standard Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.71

0.60

2-Stage FFL

0.36

0.50

0.61

0.53

3-Stage FFL

0.44

0.53

0.65

0.56

Table 8. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine

Mast

Kubota 3.8 L Diesel (Standard Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.66

0.60

2-Stage FFL

0.36

0.50

0.58

0.53

3-Stage FFL

0.44

0.53

0.61

0.56

Table 9. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine

Mast

GM 4.3L (Standard Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.57

0.56

2-Stage FFL

0.32

0.45

0.54

0.52

3-Stage FFL

0.39

0.47

0.55

0.54

Table 10. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine

Mast

Kubota 3.6 L Diesel (Standard Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.56

0.48

2-Stage FFL

0.32

0.45

0.53

0.46

3-Stage FFL

0.39

0.47

0.51

0.44

Table 11. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine

Mast

Kubota 3.8 L Diesel (Standard Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.53

0.48

2-Stage FFL

0.32

0.45

0.50

0.46

3-Stage FFL

0.39

0.47

0.51

0.47

11


Mast Speeds

8000 YRM 1605

Table 12. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine GM 4.3L (Low Displacement Pump)

Mast

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.49

0.47

2-Stage FFL

0.36

0.50

0.43

0.42

3-Stage FFL

0.44

0.53

0.45

0.44

Table 13. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine

Mast

Kubota 3.6 L Diesel (Low Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.60

0.53

2-Stage FFL

0.36

0.50

0.54

0.47

3-Stage FFL

0.44

0.53

0.56

0.49

Table 14. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine

Mast

Kubota 3.8 L Diesel (Low Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.57

0.53

2-Stage FFL

0.36

0.50

0.51

0.47

3-Stage FFL

0.44

0.53

0.53

0.49

Table 15. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine GM 4.3L (Low Displacement Pump)

Mast

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.45

0.44

2-Stage FFL

0.32

0.45

0.43

0.42

3-Stage FFL

0.39

0.47

0.44

0.43

Table 16. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine

Mast

Kubota 3.6 L Diesel (Low Displacement Pump)

12

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.43

0.39

2-Stage FFL

0.32

0.45

0.41

0.36

3-Stage FFL

0.39

0.47

0.42

0.37


8000 YRM 1605

Tilt Angles

Table 17. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine

Mast

Kubota 3.8 L Diesel (Low Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.41

0.39

2-Stage FFL

0.32

0.45

0.39

0.36

3-Stage FFL

0.39

0.47

0.40

0.37

Table 18. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine GM 4.3L (Variable Displacement Pump)

Mast

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.63

0.61

2-Stage FFL

0.36

0.50

0.56

0.55

3-Stage FFL

0.44

0.53

0.59

0.58

Table 19. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813) Model/ Engine

Mast

Kubota 3.8 L Diesel (Variable Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.47

0.55

0.63

0.62

2-Stage FFL

0.36

0.50

0.56

0.55

3-Stage FFL

0.44

0.53

0.59

0.58

Table 20. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine GM 4.3L (Variable Displacement Pump)

Mast

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.49

0.48

2-Stage FFL

0.32

0.45

0.46

0.45

3-Stage FFL

0.39

0.47

0.48

0.47

Table 21. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110, 120VX) (J813) Model/ Engine

Mast

Kubota 3.8 L Diesel (Variable Displacement Pump)

Lowering M/Sec

Lifting M/Sec

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.42

0.51

0.46

0.45

2-Stage FFL

0.32

0.45

0.43

0.42

3-Stage FFL

0.39

0.47

0.44

0.43

13


Front End Equipment - Mast Creep

8000 YRM 1605

Tilt Angles Truck should be on level ground and in unloaded condition. Table 22. Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Forward

Tolerance

Back

Tolerance

12°

+1°, −0.5°

+0°, −0.5°

+1°, −0.5°

10°

+0°, −0.5°

+1°, −0.5°

+0°, −0.5°

Front End Equipment - Mast Creep MAST CREEP

NOTE: Mast should be 90° vertical prior to test.

Measure with load at 2.5 m (8.0 ft) high and with the lift, tilt, and auxiliary control levers in neutral position. Table 23. Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Hydraulic Oil Temperature

14

Maximum Vertical Creep at Carriage

Maximum Tilt Creep Mast Angle

Cylinder Stroke

°C

°F

mm/Min

in./Min

°/Min

mm/Min

in./Min

20

68

2.2

0.086

0.11

1.129

0.051

30

86

3.9

0.154

0.20

1.95

0.120

40

104

6.5

0.256

0.32

3.67

0.145

50

122

10.0

0.394

0.50

5.88

0.232

60

140

14.5

0.571

0.73

8.59

0.388


8000 YRM 1605

Engine Specifications

Engine Specifications Item No. of Cylinders Firing Order

GM 4.3L 6 1-6-5-4-3-2

Bore

101.6 mm (3.9 in.)

Stroke

88.4 mm (3.48 in.)

Displacement

4.3 liter (262.4 in.3)

Horsepower (Gasoline)

100 @ 2400 rpm

Horsepower (LPG)

93 @ 2400 rpm

Engine Timing

Timing is controlled by the Electronic Control Module (ECM)

Compression Ratio Gas

9.4:1

LPG

9.4:1

Oil Pressure With PSI Installed

124 kPa (18 psi) @ 2000 80°C (176°F)

Valve Clearance Intake

Not Adjustable

Exhaust

Not Adjustable

Idle Speed - Gas

750 ±25 rpm

Idle Speed - LPG

750 ±25 rpm

Governed Speed High Idle (No Load)

2400 ±25 rpm

Thermostat Range START TO OPEN

82 ±1.5°C (180 ±35°F)

FULL OPEN

128 ±1.5°C (260 ±35°F)

Cooling System Pressure

103 kPa (15 psi)

15


Torque Specifications

8000 YRM 1605

Item No. of Cylinders

Kubota 3.6L Diesel 4

Firing Order

1-3-4-2

Bore and Stroke

98 mm × 120 mm (3.86 in. × 4.72 in.)

Displacement

3620 cc

Compression Ratio

21.8:1

Power/rpm

57 kW (76 hp) @ 2200 rpm

Oil Pressure

50 kPa (7 psi)

Valve Clearance Intake

0.23 to 0.27 mm (0.009 to 0.011 in.)

Exhaust

0.23 to 0.27 mm (0.009 to 0.011 in.)

Idle Speed

850 ±50 rpm

Governed Speed High Idle (No Load)

2400 ±50 rpm

Thermostat Range START TO OPEN

75°C (180°F)

FULL OPEN

90°C (203°F)

Cooling System Pressure

103 kPa (15 psi) Item

No. of Cylinders Firing Order Bore and Stroke Displacement Compression Ratio

Kubota 3.8L Diesel 4 1-3-4-2 100 mm × 120 mm (3.94 in. × 4.72 in.) 3769 cc 17.5:1

Horsepower/rpm

74 @ 2200 rpm

Oil Pressure

50 kPa (7 psi)

Valve Clearance Intake

0.23 to 0.27 mm (0.009 to 0.011 in.)

Exhaust

0.23 to 0.27 mm (0.009 to 0.011 in.)

Idle Speed

800 ±25 rpm

Governed Speed High Idle (No Load)

2200 ±25 rpm

Thermostat Range START TO OPEN

75°C (180°F)

FULL OPEN

90°C (203°F)

Cooling System Pressure

103 kPa (15 psi)

16


8000 YRM 1605

Torque Specifications

Torque Specifications FRAME Overhead Guard Mount Capscrews 66 N•m (49 lbf ft) Cowl-to-Overhead Guard Legs 66 N•m (49 lbf ft) Steering Column Nut 40 to 54 N•m (30 to 40 lbf ft) Counterweight Capscrews 1020 N•m (750 lbf ft)

MAST Mast Mounting Capscrews Mast to Drive Axle 522 to 575 N•m (385 to 424 lbf ft) Tilt/Cylinder Adjust 66 to 73 N•m (49 to 54 lbf ft) Pivot Pin Retainer 66 to 73 N•m (49 to 54 lbf ft)

STEERING SYSTEM Hub Nut (Slotted Nut) 200 to 220 N•m (148 to 162 lbf ft) initial 35 to 40 N•m (25 to 30 lbf in) final Steering Axle Mounting Bolts and Nuts 215 N•m (159 lbf ft) Bearing Cap Capscrew 52 N•m (38 lbf ft) Tie Rod Nut 175 N•m (129 lbf ft) Steering Cylinder 225 N•m (166 lbf ft)

STEER AXLE Cushion Truck Wheel Nuts 610 to 680 N•m (450 to 502 lbf ft) Pneumatic Truck Wheel Nuts 610 to 680 N•m (450 to 502 lbf ft)

DRIVE AXLE, WET BRAKE (DANA SPICER AXLE) Drive Shaft Capscrews 55 to 63 N•m (41 to 46 lbf ft)

Drive Axle Center Body Drain Plug 30 to 50 N•m (22 to 37 lbf ft) Drive Axle Center Body Fill/Level Plug 30 to 50 N•m (22 to 37 lbf ft) Planetary Carrier Housing Drain Plug 30 to 50 N•m (22 to 37 lbf ft) Planetary Carrier Housing Fill/Level Plug 30 to 50 N•m (22 to 37 lbf ft) Wheel Hub Nut 500 to 600 N•m (369 to 443 lbf ft) Parking Brake Lever Capscrew 21 to 30 N•m (186 to 266 lbf in) Drive Axle Arm to Drive Axle Central Body Nuts 199 to 243 N•m (147 to 179 lbf ft) Wheel Hub to Drive Axle Arm Nuts 199 to 243 N•m (147 to 179 lbf ft)

DRIVE AXLE, WET BRAKE (NMHG AXLE) Drive Shaft Capscrews 55 to 63 N•m (41 to 46 lbf ft) Drive Axle to Frame Mounting Capscrews 820 to 902 N•m (605 to 665 lbf ft) Drive Axle Center Body Drain Plug 50 to 55 N•m (37 to 41 lbf ft) Drive Axle Center Body Fill/Level Plug 50 to 55 N•m (37 to 41 lbf ft) Planetary Carrier Housing Drain Plug 50 to 55 N•m (37 to 41 lbf ft) Planetary Carrier Housing Fill/Level Plug 50 to 55 N•m (37 to 41 lbf ft) Wheel Hub Nuts 500 to 600 N•m (369 to 443 lbf ft) Wheel Hub Coupler Nuts 90 to 99 N•m (66 to 73 lbf ft)

TRANSMISSION Transmission Mounting Bracket Capscrews 66 to 73 N•m (49 to 54 lbf ft)

Drive Axle to Frame Mounting Capscrews 820 to 902 N•m (605 to 665 lbf ft)

17


Torque Specifications

8000 YRM 1605

Transmission to Drive Axle Bolt 225 to 250 N•m (166 to 184 lbf ft)

Balance Shaft Gear Capscrew 20 N•m (177 lbf in) Plus 35 Degrees

Transmission Housing Bolts 38 N•m (28 lbf ft)

Balance Shaft Retainer Capscrews 12 N•m (106 lbf in)

Drive Plate to Torque Converter Capscrews 55.6 N•m (41 lbf ft)

Camshaft Retainer Screws 12 N•m (106 lbf in)

Hydraulic Gear Pump to Transmission Flange Head Capscrews 38 N•m (28 lbf ft)

Camshaft Sprocket Capscrews 28 N•m (21 lbf ft)

Variable Displacement Pump to Transmission Flange Head Capscrews 38 N•m (28 lbf ft) Charge Pump to Transmission Capscrews - Lift Trucks Manufactured Before July, 2013 19 N•m (168 lbf in) Charge Pump to Transmission Capscrews - Lift Trucks Manufactured After July, 2013 First pass, torque in star pattern to 6 N•m (53 lbf in)

Camshaft Sprocket Nut 25 N•m (18 lbf ft) Chain Control Block for Hydraulic Pump Drive 19 N•m (168 lbf in) with Adhesive Sealant Connecting Rod Cap 27 N•m (240 lbf in) After this step, tighten nuts an additional 70 degrees. Coolant Pump to Engine Block 41 N•m (30 lbf ft)

Second pass, torque in star pattern to

Cooling Fan to Pulley 24 N•m (212 lbf in)

19 N•m (168 lbf in)

Cylinder Head

Transmission Enable Valve Capscrews 3 to 4 N•m (27 to 35 lbf in)

See the section for torque value and tightening sequence to use.

Forward and Reverse Valves Capscrews 3 to 4 N•m (27 to 35 lbf in)

Distributor Mount Capscrew 25 N•m (18 lbf ft)

Control Valve Mounting Capscrews 13.3 N•m (118 lbf in) initial 19 N•m (168 lbf in) final

Exhaust Manifold 15 N•m (133 lbf in) - first step 30 N•m (22 lbf ft) - second step

Torque Converter Housing Cover Plate 7.9 N•m (5.8 lbf ft)

Flywheel 100 N•m (74 lbf ft)

Torque Converter Housing Cover 19 N•m (168 lbf ft)

Flywheel Housing 48 N•m (35 lbf ft)

Transmission Input/Output Shaft Speed Sensor Capscrew 6.9 N•m (5 lbf ft)

Inlet Manifold to Cylinder Head 3 N•m (27 lbf in) - first step 12 N•m (106 lbf ft) - second step 15 N•m (133 lbf in) - third step (final)

ENGINE - GM 4.3L Alternator Pulley 61 N•m (45 lbf ft)

Main Bearing Cap 105 N•m (77 lbf ft) Motor Mount to Engine 31 N•m (23 lbf ft)

18


8000 YRM 1605

Torque Specifications

Oil Pump Cover 12 N•m (106 lbf in)

Connecting Rod Bolt 79 to 83 N•m (58 to 61 lbf ft)

Oil Pump to Crankcase 90 N•m (66 lbf ft)

Crankshaft Pulley Bolt 255 to 274 N•m (188 to 202 lbf ft)

Oil Pressure Switch 27 N•m (20 lbf ft)

Cylinder Head Bolt 98.1 to 107 N•m (72.4 to 79.5 lbf ft)

Oil Screen Support to Crankcase 50 N•m (37 lbf ft)

Cylinder Head Cover Screw, Upper 10 to 11 N•m (61 to 99 lbf in)

Oil Pan to Crankcase Capscrews 25 N•m (18 lbf ft) Nuts 25 N•m (18 lbf ft)

Cylinder Head Cover Screw, Lower 7 to 11 N•m (87 to 99 lbf in)

Rear Oil Seal Retainer Screws and Nut 15 N•m (133 lbf in) Rocker Arm Cover 12 N•m (106 lbf in) Rocker Arm Nuts 25 N•m (18 lbf ft) Rocker Arm Studs 47 N•m (35 lbf ft) Rocker Arm Bolts 30 N•m (22 lbf ft) Thermostat Housing 25 N•m (18 lbf ft) Timing Cover 12 N•m (106 lbf in) Valve Lifter Retainer Capscrews 16 N•m (142 lbf in) Vibration Damper 95 N•m (70 lbf ft)

ENGINE - KUBOTA 3.6L DIESEL Alternator Pulley Nut 58.4 to 78.9 N•m (43.1 to 58.2 lbf ft) Bearing Cap Set Bolt 138 to 147 N•m (102 to 108 lbf ft) Boost Actuator 40 to 45 N•m (29 to 33 lbf ft) Camshaft Setscrew 24 to 27 N•m (18 to 20 lbf in)

Engine Oil Pump Cover Screw 7.9 to 9.3 N•m (70 to 82 lbf in) Engine Oil Cooler Joint Bolt 40 to 44 N•m (29 to 32 lbf ft) Flywheel Bolts 98.1 to 107 N•m (72.4 to 79.5 lbf ft) Flywheel Housing Bolts 78 to 90 N•m (58 to 66 lbf ft) Fuel Injector 49 to 68 N•m (37 to 50 lbf ft) Fuel Injector Nut 18 to 20 N•m (13 to 15 lbf in) Fuel Pump Gear Cover Mounting Screw 24 to 27 N•m (18 to 20 lbf ft) Fuel Injection Pump Assembly Mounting Nut 18 to 20 N•m (13 to 15 lbf ft) Fuel Injection Pump Assembly Gear Mounting Nut 74 to 83 N•m (55 to 61 lbf ft) Fuel Injection Pump Mounting Nut 18 to 20 N•m (13 to 15 lbf ft) Fuel Injection Pump Mounting Screw 24 to 27 N•m (18 to 20 lbf ft) Fuel Overflow Pipe Retaining Nut 20 to 24 N•m (15 to 18 lbf ft) Glow Plug 20 to 24 N•m (15 to 18 lbf ft) Governor Connecting Rod Lock Nut 2.8 to 4.0 N•m (24.7 to 35.0 lbf in)

19


Torque Specifications

8000 YRM 1605

Idler Gear Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

Camshaft Position Sensor Mounting Screw 4 to 5 N•m (35 to 44 lbf in)

Oil Pressure Switch Screw 15 to 19 N•m (11 to 14 lbf ft)

Camshaft Pulsar Gear Mounting Screw 4.7 to 5.6 N•m (41.6 to 49.6 lbf in)

Overflow Pipe Joint Screw 9.8 to 11.2 N•m (86.7 to 99.1 lbf in)

Camshaft to Cylinder Head Setscrew 24 to 27 N•m (18 to 20 lbf ft)

Rocker Arm Bracket Nut 49 to 55 N•m (37 to 41 lbf ft)

Common Fuel Rail Mounting Bracket Screw 24 to 27 N•m (18 to 20 lbf ft)

Starter Solenoid Nut (B Terminal) 9.8 to 11 N•m (87 to 97 lbf in)

Connecting Rod Cap Screw 79 to 83 N•m (58 to 61 lbf ft)

Timing Gear Case Cover Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

Coolant Temperature Sensor Mounting Screw 16 to 23 N•m (12 to 17 lbf ft)

Timing Gear Case Plate Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

Crankshaft Position Sensor Mounting Screw 4 to 5 N•m (35 to 44 lbf in)

Thermostat Cover Bolts 23 to 28 N•m (17 to 21 lbf ft)

Crankshaft Pulley Mounting Screw 255 to 274 N•m (188 to 202 lbf ft)

Electronic Throttle Shoulder Bolt 25.6 N•m (226.6 lbf in)

Crankcase Housing to Engine Block Mounting Screw 49 to 55 N•m (37 to 41 lbf ft)

Electronic Throttle Linkage Capscrew 10.5 N•m (92.9 lbf in) Electronic Throttle Bellcrank Weldment Stud Nut 10.5 N•m (92.9 lbf in) Electronic Throttle Lever Plate Capscrew 7.9 N•m (70 lbf in) Electronic Throttle Inline Ball Joint 7.9 N•m (70 lbf in) Electronic Throttle Fuel Shut Off Solenoid Allenhead Capscrews 10.5 N•m (92.9 lbf in)

Cylinder Head Mounting Screw 98 to 107 N•m (72.4 to 79.5 lbf ft) Cylinder Head Valve Cover, Upper 6.9 to 11.2 N•m (61 to 99 lbf in) Cylinder Head Cover, Lower 9.8 to 11.2 N•m (87 to 99 lbf ft) Engine Oil Pressure Switch Mounting Screw 15 to 19 N•m (11 to 14 lbf ft) Flywheel Housing Mounting Screw 78 to 90 N•m (58 to 66 lbf ft)

Throttle Position Sensor Torx-head Schrews 2.25 N•m (20 lbf in)

Flywheel Mounting Screw 98 to 107 N•m (72.4 to 79.5 lbf ft)

Electronic Throttle Ball Joint Rod Nut 25.6 N•m (226.6 lbf in)

Fuel Injection Pump Gear Cover Mounting Screw 24 to 27 N•m (18 to 20 lbf ft)

ENGINE - KUBOTA 3.8L DIESEL

Fuel Injection Pump Gear Mounting Nut 24 to 27 N•m (18 to 20 lbf ft)

Alternator Pulley 58.4 to 78.9 N•m (43.1 to 58.2 lbf ft) B Terminal Starter Nut 9.8 to 11 N•m (86.7 to 97.4 lbf in)

20

Fuel Injection Harness Terminal Nut 1.6 to 2.2 N•m (14 to 19.5 lbf in) Fuel Injection Line Clamp Nut 24 to 27 N•m (18 to 20 lbf ft)


8000 YRM 1605

Torque Specifications

Fuel Injection Pipe to Cylinder Head Retainer Nut 23 to 36 N•m (17 to 26 lbf ft)

Fuel Injection Pump Mounting Nut 27 to 27 N•m (18 to 20 lbf ft)

Fuel Injection Overflow Pipe to Cylinder Head Joint Screw 7.9 to 12 N•m (69.9 to 106 lbf in)

Intake Air Temperature Sensor 30 to 39 N•m (22 to 28 lbf ft)

Fuel Injection Overflow Pipe To Injection Pump Joint Screw 16 to 19 N•m (12 to 14 lbf ft)

Main Bearing Cap Mounting Screw 138 to 147 N•m (102 to 108 lbf ft)

21


0100 YRM 1243

General

General WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •

Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure any blocks used to support the lift truck are solid, one-piece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck.

If additional engine repairs are necessary for lift trucks covered in this manual see: •

GM 4.3L V-6 Engines 0600YRM1251

Kubota Diesel 3.8L Engines 0600YRM1557

Kubota Diesel 3.6L Engine 0600YRM1579

If additional transmission repairs are necessary for lift trucks covered in this manual see: •

Powershift Transmission 1300YRM1129

Powershift Transmission 1300YRM1529

One and Two Speed Transmissions 1300YRM1569

This section contains the description of the frame (see Figure 1 or Figure 2) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine and transmission, and exhaust system are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

1


Description

0100 YRM 1243

Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1 or Figure 2. There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights. See Table 2.

The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the frame with hinges. Two gas-controlled springs provide assistance when raising the hood and hold the hood in the open position. The floor plate and side covers can be removed for access to the engine, transmission, and other components.

The muffler is fastened to the frame inside the counterweight.

1. COWL PLATE 2. FENDERS 3. HOOD MOUNTS

4. COUNTERWEIGHT MOUNTS 5. HYDRAULIC TANK 6. FUEL TANK (GAS OR DIESEL) Figure 1. Frame for Lift Trucks with Single Hydraulic Tank

2


0100 YRM 1243

1. COWL PLATE 2. FENDERS 3. HOOD MOUNTS

Description

4. COUNTERWEIGHT MOUNTS 5. HYDRAULIC TANKS Figure 2. Frame for Lift Trucks with Dual Hydraulic Tanks

3


Hood, Seat, and Side Covers Replacement

0100 YRM 1243

Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat to the closest position to steering column. 2. Fully tilt steering column forward. 3. If your truck is equipped with an LPG tank, swing tank off to the side. 4. Raise latch on the left, front corner of hood to unlatch and lift up hood. See Figure 3. 5. Remove floor mat and floor plate. See Figure 4. 6. Remove two capscrews holding left and right rear side covers to the frame. Remove rear side covers from frame. See Figure 4. 7. Remove two capscrews holding left and right fender covers to front overhead guard leg. Remove covers. See Figure 4. 8. Remove four capscrews holding left and right front side covers to frame. Remove covers. 9. Fully lower the steering column. 10. Remove upper steering column cover by pulling up on upper steering column cover to release latches (one on either side), and pulling cover away from steering column. See Figure 5. 11. Remove five fasteners (see Figure 5) securing dash to the top of cowl. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash. 12. Lift kick panel to remove it from truck. See Figure 4. 13. Remove three capscrews holding the seal plate. Remove seal plate. See Figure 6. 14. Disconnect seat wire harness connector. See Figure 3.

4

CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews. Damage can be caused to the threads on the screws and in the holes. 15. If seat is to be removed, and truck is equipped with a non-swivel seat, remove seat wire harness from seat wire harness brackets that are attached to the underside of hood. Remove the cable clips from the seat wire harness. If truck is equipped with a swivel seat, remove seat wire harness from seat wire harness bracket attached to underside of hood and behind the seat. See Figure 3. 16. Remove four capscrews and washers holding seat to the hood. Lift seat off the hood. Pull seat wire harness through hood. See Figure 3. 17. Remove capscrews and washers at top of the gas springs. Remove gas springs from hood. 18. Remove hinge screws, located in the rear of the hood. 19. Lift hood from the truck. See Figure 3.

INSTALL 1. Place hood onto the lift truck frame. 2. Install hinge screws, located in the rear of the hood, and tighten to 38 N•m (28 lbf ft). See Figure 3. 3. Align top holes in the gas springs with holes in hood. There are two sets of holes used to install the gas springs to hood, based on the type of seat installed on lift truck. One set is for installing the cylinder end of the gas springs and the other set is for attaching the rod end of the gas springs. Install capscrews and washers to attach gas springs to the hood. Refer to Figure 7 and Table 1 for correct holes used to connect the rod end of the cylinder, depending on the type of seat installed on the lift truck. Tighten capscrews to 19.2 N•m (170 lbf in).


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YALE (J813) GDP40VX5 LIFT TRUCK Service Repair Manual  
YALE (J813) GDP40VX5 LIFT TRUCK Service Repair Manual  
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