Yale B878 (GDP GLP60-70CA Europe) Service Manual - PDF DOWNLAOD

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Service Manuals Manuals Available For B878 (GDP/GLP60-70CA Europe) Note: Service manuals do not contain serial number specific data.

Manual

Manual Title

Release Date

0100YRM0322

FRAME

02-2007

0600YRM0590

GM V-6 4.3 ENGINE

08-2005

0600YRM1070

PERKINS DIESEL ENGINE 1104 SERIES (RE)

06-2007

0700YRM0626

COOLING SYSTEM

03-2003

0900YRM1088

ELECTRONIC CONTROLLED LPG/GASOLINE FUEL SYSTEM GM 3.0L AND 4.3L EPA COMPLIANT ENGINES

05-2006

1300YRM0324

2-SPEED POWERSHIFT TRANSMISSION DESCRIPTION AND OPERATION

10-2003

1300YRM0325

2-SPEED POWERSHIFT TRANSMISSION REPAIR

10-2003

1400YRM0046

DIFFERENTIAL

03-2011

1400YRM0049

DRIVE AXLE

09-2003

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Yale Axcess Online

1600YRM0054

STEERING CONTROL UNIT

10-2003

1600YRM0326

STEERING AXLE

03-2007

1800YRM0327

BRAKE SYSTEM

09-2003

1900YRM0097

HYDRAULIC GEAR PUMPS

01-2012

1900YRM0328

HYDRAULIC SYSTEM

09-2003

2000YRM0090

MAIN CONTROL VALVE

10-2003

2100YRM0103

TILT CYLINDERS

03-2007

2200YRM0002

ALTERNATOR

10-2003

2200YRM0106

STARTER

03-2003

2200YRM0143

INSTRUMENT PANEL INDICATORS AND SENDERS

02-2007

2200YRM1090

ELECTRONIC CONTROL MODULE (ECM) DIAGNOSTIC TROUBLESHOOTING GM 3.0L AND 4.3L EPA COMPLIANT ENGINES

04-2005

2200YRM1097

HIGH VOLTAGE SWITCH IGNITION (HVS) GM 3.0L AND 4.3L

01-2012

4000YRM0135

LIFT CYLINDERS

03-2011

4000YRM0329

MAST DESCRIPTION AND REPAIR

09-2010

8000YRM0231

METRIC AND INCH (SAE) FASTENERS

12-2004

8000YRM0331

CAPACITIES AND SPECIFICATIONS

09-2003

8000YRM0341

PERIODIC MAINTENANCE

06-2009

8000YRM0519

DIAGRAMS

06-2007

©2012 Yale Axcess Online

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524185155-0100YRM0322-(02-2007)-UK-EN

Frame GDP60-70CA (GP/GLP/GDP135-155CA) [A878, B878]

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Safety Precautions Maintenance and Repair • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

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TABLE OF CONTENTS General Description Counterweight Repair Remove Install Hood Repair Remove Install Overhead Guard Repair Remove Install Operator Restraint System Repair Automatic Locking Retractor (ALR) Emergency Locking Retractor (ELR) Hydraulic Tank Repair Remove Inspect Small Leaks Repair Large Leaks Repair Clean Steam Method Chemical Solution Method Other Methods of Preparation for Repair Install Fuel Tank Repair Remove Repair Install Radiator Repair Remove Install Engine Repair Remove Install Throttle Pedal Adjustment Perkins 1104C-44(RE) Diesel Engine Safety Labels Cab Repair Cab, Replace

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Window, Replace Windshield Wipers and Heater This section is for the following models: GDP60-70CA (GP/GLP/GDP135-155CA) [A878, B878]

General This section has the description of the frame and some connected parts. See Figure 1. Procedures for the removal and installation of the counterweight, hood, overhead guard, and engine are under Counterweight Repair, Hood Repair, Overhead Guard Repair, and Engine Repair. Checks for the operator restraint system and procedures for the repair of tanks and replacement of safety labels are included.

1. Overhead Guard 2. Counterweight 3. Hood 4. Floor Plate 5. Frame

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Figure 1. Frame and Connected Parts

Description The frame is one weldment and includes the hydraulic tank and the fuel tank for gasoline and diesel fuel.

There is a counterweight for each capacity of lift truck. The counterweights are similar, but are different weights.

An overhead guard is fastened to the frame of the lift truck. The overhead guard has the mounts for the seat plate and the hood.

The hood is connected at mounts on the cowl and the frame.

Counterweight Repair Remove

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: upright, 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: a. Before removing the upright and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. b. Before removing the counterweight, put blocks under the upright 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 that any blocks used to support the lift truck are solid, one-piece units.

WARNING Do not operate the lift truck if the capscrew for the counterweight is not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

1. Remove the grille and the cover for the hydraulic pump.

2. Remove the bracket for the rear hood mount from the frame. Put a block between the hood and the radiator.

WARNING Make sure any lifting devices have the correct capacity for the parts being removed.

3. Put a lifting strap through the hole in the counterweight. Connect a lifting device to the strap. Remove the bolt that holds the counterweight to the frame. See Figure 2.

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4. Lift the counterweight from the frame. Put the counterweight in a position so it has stability.

Install 1. Connect a strap and lifting device to the counterweight. Lift the counterweight into position on the frame. Make sure the counterweight is in position on the mounts.

2. Install the bolt for the counterweight. Install the cover for the hydraulic pump. Install the grille.

3. Install the bracket for the hood mount. Install the capscrews for the hood mount. Adjust the hood as described in the procedures for the hood.

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1. Counterweight 2. Lifting Device 3. Lifting Eye Weight of Counterweights GDP135CA (GP/GLP/GDP135CA)

GDP155CA (GP/GLP/GDP155CA)

2689 to 2749 kg (5929 to 6062 lb)

3540 to 3610 kg (7804 to 7959 lb) Figure 2. Counterweight

Hood Repair Remove Remove the hood (both sides) as an assembly. Remove the capscrews that hold the hood mount bracket to the frame. Remove the capscrews that hold the hood to the bracket on the overhead guard. Lift the hood from the frame.

Install Install the hood assembly on the frame. Install the capscrews that hold the brackets to the frame and bracket on the overhead guard. If necessary, adjust the hood as follows: 1. Loosen the capscrews at the mounts for the hood assembly. Put the hood assembly in a position so the center of the hood is in the center of the counterweight and overhead guard. Tighten the capscrews.

2. Adjust the mount (on the frame) and the hood stops at the rear of the hood so the top of the hood aligns with the counterweight. Make sure the hood does not touch the counterweight.

3. Adjust the other hood stops so they just touch the sides of the hood when they are closed.

Overhead Guard Repair Remove

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the

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following assemblies will cause large changes in the center of gravity: upright, 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: a. Before removing the upright and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. b. Before removing the counterweight, put blocks under the upright 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 that any blocks used to support the lift truck are solid, one-piece units.

WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.

Changes that are made by welding or by drilling holes that are too big in the wrong location can reduce the strength of the overhead guard. See the instructions for Changes to the Overhead Guard in the Periodic Maintenance section included with this lift truck.

1. Remove the hood as an assembly. Disconnect the hose to the air cleaner. Disconnect the exhaust system from the overhead guard leg. Remove the capscrews that hold the brake reservoir to the overhead guard. If a cab is installed, disconnect the wiring harness for the cab. Lift the doors from the cab. See Figure 3.

2. Connect a lifting device to the top of the overhead guard. Remove the capscrews (in the engine compartment) that hold the overhead guard to the frame. Remove the capscrews that hold the overhead guard to the cowl. Lift the overhead guard from the lift truck.

Install 1. Connect a lifting device to the top of the overhead guard. Put the overhead guard in position on the lift truck. See Figure 3.

2. Make sure the rubber bushings are in the mount holes at the rear of the overhead guard. Install the capscrews at the rear of the overhead guard. Install the capscrews that hold the overhead guard to the cowl and tighten them to 285 N•m (210 lbf ft). Connect the wiring harness for the cab. Install the doors for the cab.

3. Connect the hose for the air cleaner. Connect the exhaust system. Install the brake fluid reservoir.

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Figure 3. Overhead Guard and Cab Mounting Legend for Figure 3 http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0322.html (9 of 25)26.03.2012 14:57:53

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1. Overhead Guard 2. Cowl 3. frame 4. Rubber Bushing

Operator Restraint System Repair The seat belt, hip restraint brackets, seat, and mounting are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition.

Automatic Locking Retractor (ALR) NOTE: Lift trucks produced before November 2005 are equipped with the ALR type seat belts.

The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 4.

Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt.

When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat.

A seat belt that is damaged worn or does not operate properly will not give protection when it is needed.

The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 4.

The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly.

Make sure the seat belt pulls out and retracts smoothly. if the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly.

• With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly.

• With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

Make sure the seat rails and latch striker are not loose. The seat rails must lock securely in position but move freely when unlocked. The seat rails must be securely attached to the mounting surface. The hood must be fully closed. Lift the hood to make sure it is closed and will not move.

Adjust hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See the section Hood Repair in this manual for the adjustment procedures for the hood.

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NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR 1. FORWARD/BACKWARD ADJUSTMENT 2. SWIVEL ADJUSTMENT 3. OPERATOR WEIGHT ADJUSTMENT 4. SEAT POSITION ADJUSTMENT (seat rail) 5. SEAT BELT Figure 4. Operator Restraint System (Swivel Seat Shown)

Hydraulic Tank Repair Remove

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: a. Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. b. 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 that any blocks used to support the lift truck are solid, one piece units.

1. Remove the engine and transmission. See Engine Repair.

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2. Remove the drain plug and drain the oil from the tank. Disconnect the hydraulic lines at the tank and put caps on the open lines.

3. Remove the hooks that hold the tank to the frame. Remove the hydraulic tank.

Inspect Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

Small Leaks Repair Use the following procedure to repair small leaks: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.

Large Leaks Repair 1. Use one of the procedures described under Clean to clean and prepare the tank for repairs.

2. Use acceptable welding practices to repair the tank. See the American National Standards Safety In Welding and Cutting AWS Z 49.1 - 1999.

Clean

WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside of a building, make sure there is enough ventilation. See the following manuals for additional information: • "Safe Practices for Welding and Cutting Containers that have Held Combustibles" by the American Welding Society, F4.1 - 1999.

• "Safety in Welding and Cutting," American National Standard, AWS Z 49.1 - 1999.

When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank. http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0322.html (12 of 25)26.03.2012 14:57:53

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Connect a ground wire to the tank to prevent static electricity.

Steam Method Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug.

2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.

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.

4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come out of all openings.

5. Flush the inside of the tank with boiling water. Make sure all loose material is removed from the inside of the tank.

6. Make an inspection of the inside of the tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors.

7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

Chemical Solution Method If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.

3. Drain the tank. Flush the inside of the tank with boiling water. Make sure all the cleaning compound is removed.

4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 to Step 3. Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors.

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5. Check the tank for flammable vapors using a special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

Other Methods of Preparation for Repair If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.

2. Use acceptable welding practices to repair the tank. See the American National Standard "Safety In Welding And Cutting" AWS Z 49.1 - 1999.

Install 1. Put the tank in position in the frame and install the hooks.

2. Connect the hydraulic lines to the fittings on the tank.

3. Install the engine and transmission. Fill the tank with the correct hydraulic oil. Operate the system and check for leaks and correct operation.

Fuel Tank Repair Remove

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: a. Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward. b. 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 that any blocks used to support the lift truck are solid, one piece units.

1. Remove the engine and transmission. See Engine Repair.

WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. Clean all fuel spills. Make sure the fuel from the tank is put in a closed container.

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2. Remove the drain plug and drain the fuel from the tank. Disconnect the fuel lines at the tank and put caps on the openings.

3. Remove the filler neck from the fuel tank. Remove the hooks that hold the tank to the frame. Remove the fuel tank.

Repair Repair the fuel tank as described in the repair procedures for the hydraulic tank.

Install 1. Put the tank in position in the frame. Install the filler neck and the hooks.

2. Install the engine and transmission. Connect the fuel lines to the tank.

Radiator Repair Remove 1. Remove the hood as an assembly.

2. Drain the coolant from the radiator. Disconnect the radiator hoses. If equipped, disconnect the lines from the powershift transmission. Put caps on the open lines.

3. Remove the screws that hold the fan shroud to the radiator. Remove the nuts that hold the radiator to the frame.

4. Remove the radiator.

Install 1. Put the fan shroud in position over the fan. Install the radiator to the mounts on the frame. Install the fan shroud on the radiator.

2. Connect the radiator hoses and lines for the powershift transmission.

3. Install the hood. Fill the radiator with coolant, then operate the engine and check for leaks.

Engine Repair Remove

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: a. Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

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b. 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 that any blocks used to support the lift truck are solid, one-piece units.

1. Disconnect the cables at the battery.

2. Remove the hood. Remove the air cleaner assembly. Disconnect the brake fluid reservoir from the bracket. If necessary, remove the overhead guard. See Overhead Guard Repair.

3. Drain the coolant from the cooling system. Remove the radiator. See Radiator Repair.

4. Disconnect the drive shaft for the hydraulic pump at the crankshaft pulley.

5. Disconnect the exhaust system.

6. Disconnect the hydraulic lines at the steering pump. Put caps on the open lines.

7. Disconnect fuel lines and the throttle linkage.

8. Disconnect wires and wiring harnesses at the engine.

9. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (1000 lb) (engine only).

10. On units with a powershift transmission, remove the capscrews that hold the torque converter to the flywheel. Put blocks under the output end of the transmission. Remove the capscrews that connect the engine to the flywheel housing.

11. Remove the capscrews that hold the mount at the fan end of the engine to the frame.

12. Carefully lift the engine from the frame. Make sure all the connections have been removed. Make sure the torque converter stays with the transmission and does not fall.

Install 1. Connect a lifting device to the engine. Make sure the lifting device has a capacity of 450 kg (1000 lb).

2. Make sure the drive plate is installed on the torque converter. Lubricate the pilot bushing in the flywheel with multipurpose grease. Install the engine in the frame. Make sure the torque converter stays in the transmission. Fit the flywheel on the pilot of the torque converter. Install the capscrews that hold the flywheel housing to the engine. Tighten the capscrews to 31 N•m (23 lbf ft).

3. Install the capscrews and washers for the engine mount at the fan end of the engine. Install the capscrews and adjust the mounts at the flywheel end of the engine. Tighten the capscrews to the correct torque values as shown on Figure 5.

4. Install the capscrews that hold the drive plate for the torque converter to the flywheel. Tighten the capscrews to 44 N•m (32 lbf ft) on all units. Remove the lifting device.

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5. Connect the wiring harness and wires at the engine.

6. Connect the throttle linkage and fuel lines at the engine.

7. Connect the pipe for the exhaust system.

8. Connect the drive shaft for the hydraulic pump.

9. See Radiator Repair, and install the radiator. Connect radiator hoses and cooling line for the powershift transmission.

10. See Overhead Guard Repair, and install the overhead guard. Install the brake fluid reservoir on the bracket. Install the hood. Connect the cables at the battery.

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Figure 5. Engine Mounts Legend for Figure 5 A. Fan End of Engine B. Flywheel End of Engine Torques C

66 N•m (48 lbf ft)

D

56 N•m (41 lbf ft)

E

110 N•m (81 lbf ft)

F

165 N•m (122 lbf ft)

1. Mount Bracket 2. Washer* 3. Capscrew 4. Engine Mount

5. Bolt 6. Lockwasher 7. Nut

*Install four washers on right-hand side and three washers on left-hand side of truck.

Throttle Pedal Adjustment Perkins 1104C-44(RE) Diesel Engine http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0322.html (18 of 25)26.03.2012 14:57:53

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NOTE: The procedures below are for lift trucks equipped with the Perkins 1104C-44(RE) Diesel Engine. If your lift truck has either a gas or LPG engine, see the section LPG Fuel System 900 YRM 348 for the procedures to adjust the throttle linkage.

1. Adjust the cable adjustment nuts to allow for a 3.0 mm (0.12 in.) maximum of free play on the throttle cable length. See Figure 6. Secure cable length by tightening cable lock nuts.

2. Set pedal stop to 35 ±2 mm (1.40 ±0.08 in.). Secure in place with pedal stop jam nuts.

NOTE: The Foot Directional Control pedal is shown. The adjustment procedures for the accelerator pedal are the same.

1. monotrol pedal 2. diesel injector pump 3. cable adjustment nuts 4. cable lock nuts 5. pedal stop jam nuts 6. pedal stop 7. up position pedal stop 8. capscrew Figure 6. Foot Directional Control and Accelerator Pedal Adjustment

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3. With the pedal against the stop, adjust the throttle cable to ensure that the diesel injector pump is at full power (the injection pump lever is touching the lever stop in Figure 7).

4. Release the throttle pedal and adjust the up position pedal stop until the tension is removed from the cable when the injection pump lever is returned to the idle position. Tighten up position pedal stop with capscrew. See Figure 6.

NOTE: Diesel injector pump is shown in the idle position.

1. injection pump lever 2. lever stop Figure 7. Diesel Injector Pump

Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards.

It is important that all safety labels are installed on the lift truck and can be read.

DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped and the nameplate must show the new capacity rating. Contact your dealer for Yale lift trucks for a replacement nameplate.

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solvents, always follow the recommendations of the manufacturer.

If a label must be replaced, use the following procedure to install a new label: 1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint with a cleaning solvent.

2. Remove the paper from the back of the label. Do not touch the adhesive surface.

3. Carefully hold the decal in the correct position above the surface. See Figure 8. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure all air is removed from under the label and the corners and edges are tight.

Legend for Figure 8 1. Mast Warning 2. No Riders 3. Lift/Tilt 4. Patents and Trademarks 5. Overhead Guard Impact Rating 6. Nameplate Cover 7. Fan Warning 8. Park Brake Warning 9. Yale Decal 10. Antifreeze 11. Nameplate 12. Mast Warning 13. Operator Warning 14. Operator Restraint 15. Radial Tire Warning 16. Inspection Plate 17. LPG Tank 18. Fan Warning 19. Flammable LP Gas 20. Sideshift, Auxiliary Function 21. Yale Decal 22. Ether Warning 23. EFI 24. Impact Resistance Window 25. Replace OperatING Manual

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Figure 8. Label Positions

Cab Repair Some lift trucks are equipped with a cab. See Figure 9. The cab has an overhead guard with doors and windows. The cab has front and rear windshield wipers and a heater with a fan. The heater is on a mount http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0322.html (22 of 25)26.03.2012 14:57:53

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on the instrument panel.

Cab, Replace NOTE: Disconnect all electric wires. Remove any other parts between the cab and the lift truck. Remove the cab assembly. Use a crane to lift the cab.

Each leg of the cab assembly is attached to the lift truck frame with a bolt, washers, and rubber pads. See Figure 3. If necessary, the cab can be replaced as a complete unit.

Window, Replace The front, rear, and side windows and window frames are replaced as single units. A window and frame are not available as separate units. The top window has no frame.

WARNING All windows installed in the cab are made of special material, not regular glass. New windows must meet the material and thickness specifications of the original windows. See Table 1 for the correct window materials.

1. Remove the rivets or screws that hold the window frames to the cab assembly. Use a chisel and a punch if necessary to completely remove the rivets.

2. Have a dealer for Yale lift trucks or a qualified supplier of glass, replace any damaged window or frame parts. Make sure the material and the thickness of the window parts are according to the specifications in Table 1.

3. Install the new window in the position on the cab. Align the window frame with the opening in the cab frame or door frame. Use a drill to make new holes for the fasteners if new window frames are used.

Some windows are installed with an adhesive/sealant (Yale part no. 580003761). Before applying the adhesive/sealant, clean the area with window weld primer (Yale part no. 580003760).

Windshield Wipers and Heater

WARNING When the heater hoses must be replaced in the cab, make sure to use heater hoses of the correct material and size. All hoses must conform to SAE Specification 20R3 Class C or 20R3 Class D-2.

Observe the previous WARNING when replacing heater hoses in the cab.

Table 1. Material Specifications for Cab Windows Location of Window

Yale Part No.

Material Specification

Thickness mm

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Front

580005577

Clear Laminated Safety Glass per ANSI Z26.1 AS1

5.9 to 7.5

0.23 to 0.30

Rear

580005586

Clear Laminated Tempered Safety Glass per ANSI Z26.1 AS2

5.6 to 6.8

0.22 to 0.27

Side

580005555

Clear Laminated Tempered Safety Glass per ANSI Z26.1 AS2

5.6 to 6.8

0.22 to 0.27

RH

580005590

Clear Tempered Safety Glass per ANSI Z26.1 AS2

5.6 to 6.2

0.22 to 0.24

LH

580005587

Clear Tempered Safety Glass per ANSI Z26.1 AS2

5.6 to 6.2

0.22 to 0.24

580005502

Clear Lexan MR 5004 or Equivalent

6.0

0.24

Doors

Top

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1. Cab Frame Assembly 2. Wiper Assembly (Front) 3. Windshield 4. Top Window 5. Wiper Assembly (Rear) 6. Door Window (RH) 7. Door Assembly (RH) 8. Rear Window 9. Side Window Figure 9. Cab

Yale Europe Materials Handling Limited Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom

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GM Engines 4.3 Liter V-6 GP/GLP/GDP070-110LG/MG [B813]; GC/GLC070-120LG/MG [B818]; GDP60-70CA (GP/GLP/GDP135-155CA) [A878, B878]; GC/GLC/GDC135-155CA [A879, B879]; GLP/GDP35-50LJ/MJ (GP/GLP/GDP070-120LJ/MJ) [C813, E813]; GC070-120LJ/MJ, GC080LJ-BCS [C818,D818]

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Safety Precautions Maintenance and Repair • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

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electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

TABLE OF CONTENTS General Description Engine Removal and Installation Cylinder Head Repair Remove and Disassemble Clean and Inspect Valve Guides and Seats, Repairs Valves, Repair

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Valve Seats, Repair Valve Springs Rocker Arm Studs (Early Models) Rocker Arm Studs (Late Models) Assemble and Install Cylinder Block Cleaning and Inspection Piston Bore Preparation Engine Mounts Installation Lubrication System Repair Oil Pump, Remove and Disassemble Clean and Inspect Oil Pump, Assemble and Install Oil Sump, Install Timing Cover, Timing Sprockets, Camshaft, and Valve Lifters Timing Cover Remove Install Timing Sprockets Remove Install Camshaft Remove Inspect Install Balance Shaft Remove Install Hydraulic Valve Lifters Remove Disassemble Clean and Inspect Assemble Install Crankshaft Repair Remove Inspect and Repair How to Check Clearance Between Main Bearings and Their Journals Install Piston and Connecting Rod Assemblies Repair Connecting Rod Bearings, Replace Piston and Connecting Rod Assemblies, Remove Disassemble Piston, Clean and Inspect Cylinder Bores, Inspect and Repair http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0590.html (4 of 100)26.03.2012 14:59:55

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Piston Rings Assemble Piston and Connecting Rod Assemblies, Install Flywheel and Flywheel Housing Repair Flywheel, Repair Flywheel, Install GP/GLP/GDP070-110LG/MG, GC/GLC070-120LG/MG, GLC60-70CA (GC/GLC/GDC135-155CA) GDP60-70CA (GP/GLP/GDP135-155CA) Flywheel Housing, GP/GLP/GDP070-110LG/MG, GLP/GDP35-50LJ/MJ (GP/GLP/GDP070-120LJ/MJ), GC/ GLC070-120LG/MG, GC080LJ-BCS, and GLC60-70CA (GC/GLC/GDC135-155CA) Engine Adapter, GDP60-70CA (GP/GLP/GDP135-155CA) Coolant Pump Repair Thermostat Replacement Fan Mount Repair (Early Models) Fan Mount Assembly Repair (Late Models) Drive Belt Installation Valve Clearance Adjustment (Early Models) Valve Clearance Adjustment (New Models) Compression Check Engine Specifications Engine Data Cylinder Head Hydraulic Valve Lifter Camshaft Pistons Crankshaft Connecting Rods Balance Shaft Cooling System Lubrication System Torque Specifications Troubleshooting This section is for the following models: GP/GLP/GDP070-110LG/MG [B813]; GC/GLC070-120LG/MG [B818]; GDP60-70CA (GP/GLP/GDP135-155CA) [A878, B878]; GC/GLC/GDC135-155CA [A879, B879]; GLP/GDP35-50LJ/MJ (GP/GLP/GDP070-120LJ/MJ) [C813, E813]; GC070-120LJ/MJ, GC080LJ-BCS [C818,D818]

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General NOTE: This YRM applies to different model years of the GM 4.3 liter, V-6 engine. While there can be physical differences in the parts, many of the procedures will apply to all of the models. If the different parts require separate procedures, all the procedures will be given.

CAUTION Changes to the engines have occurred at each model year. Do not install parts from one model year engine into another model year engine. Installation of the wrong parts will cause poor performance, wear, and failure of the engine.

CAUTION Disconnect the battery cables before doing any disassembly and repair of the engine or parts of the electrical system.

The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors.

• Do not disconnect an electric wire before the engine is stopped and the switches are OFF. • Do not cause a short circuit by connection of the electric wires to the wrong terminals. Make sure a correct identification of the wire is made before it is connected.

• Make sure a battery is the correct voltage and polarity before it is connected.

• Do not check for current flow by making a spark because the electronic components can be damaged.

This YRM has the description and the repair instructions for the GM 4.3 liter, V-6 engine. Checks and Adjustments, Troubleshooting procedures, and Specifications are also included.

Description The cylinder block is made of cast iron. The arrangement of the cylinders is in a V shape, with three cylinders on each bank. From the front, cylinders on the right bank are numbered 1, 3, and 5 and cylinders on the left bank are numbered 2, 4, and 6.

The cylinder heads are cast iron and have one intake valve and one exhaust valve for each cylinder. A spark plug is located between the valves in the side of the cylinder head. The valve guides and seats are integral to the cylinder head.

The crankshaft is supported by four main bearings. The number four bearing at the rear of the engine is the end thrust bearing. The bearings are retained by bearing caps that are matched with the block for proper alignment and clearances.

The camshaft is steel and is supported by four bearings pressed into the engine block. The camshaft is driven by a chain from the crankshaft. A spiral gear machined into the camshaft near the rear journal drives a shaft assembly which operates the oil pump drive shaft assembly.

The pistons are made of cast aluminum and have two compression rings and one oil control ring assembly.

The piston is a low-friction, lightweight design with a flat top and barrel-shaped skirt. The piston pins are http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0590.html (6 of 100)26.03.2012 14:59:55

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offset to reduce piston slap. They have a floating fit in the piston and are retained by a press fit in the connecting rod. The connecting rods are forged steel and are machined with the rod cap installed for proper clearances and alignment.

The balance shaft is cast iron and mounted in the crankcase above and in-line with the camshaft. The balance shaft is driven by a gear from the camshaft.

The valve mechanism is actuated by push rods and rocker arms from the camshaft. The rocker arm pivots on a ball to open the valve. Later model engines have hydraulic valve lifters that keep all parts of the valve train in constant contact. Each lifter acts as an automatic adjuster and maintains zero lash in the valve train, eliminating the need for periodic valve adjustment.

When the engine has a gasoline fuel system, it has electronic fuel injection with an electronic engine control system. When the engine has a LPG fuel system, it uses an LPG carburetor with the Microprocessor Spark Timing System (MSTS).

Engine Removal and Installation The Removal and Installation procedures for the engine are in the Frame section for each model of lift truck.

See the Transmission sections to separate the transmission from the engine.

Cylinder Head Repair Remove and Disassemble

WARNING Disconnect the battery cables before making repairs to the engine.

1. Drain cooling system.

2. Disconnect and remove coolant hose from housing for thermostat.

3. Remove air cleaner, distributor, throttle body, intake manifold, and exhaust manifolds. Remove drive belt (s) and remove brackets for drive belt tensioner and alternator.

4. Remove spark plugs.

5. Remove rocker arm cover. See Figure 1.

NOTE: For year 2002 or later model engines, go to Step 10.

6. Remove nuts and balls for rocker arms. Remove rocker arms and push rods. Keep parts for each rocker arm assembly together. Mark assemblies so they can be installed in their original positions.

7. Remove rocker arm studs.

8. Remove capscrews that hold cylinder head to block. Remove capscrews in the reverse order of the tightening sequence shown in Figure 12. Remove cylinder head and gasket.

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9. Use a valve spring compressor and remove valve stem keys, caps, springs, and oil seals. Discard oil seals. Remove valves. Organize valves and springs so they can be installed in their original positions.

10. Remove valve rocker arms. See Figure 2.

11. Remove valve rocker arm supports.

12. Remove valve push rods.

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1. Rocker Cover 2. Nut 3. Ball 4. Rocker Arm

5. Cylinder Head 6. Head Gasket 7. Gasket Figure 1. Cylinder Head

Clean and Inspect 1. Clean carbon from valve ports and combustion chambers in cylinder head.

2. Clean carbon and oil from valves, push rods, and rocker arms.

3. Clean valve guides.

4. Clean surfaces of cylinder head where gaskets fit.

5. Inspect cylinder head for cracks in ports, combustion chambers, and external surfaces.

6. Measure cylinder head for warping with a straight edge and feeler gauge. Refer to Engine Specifications for tolerances.

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1. Valve Rocker Arm 2. Valve Rocker Arm Support 3. Push rod Figure 2. Remove Valve Rocker Arm and Push Rod (Year 2002 or Later Engine Models) 7. Inspect valves for burned or damaged areas in seat surfaces. Inspect for cracks and damaged or worn valve stems. Valve stems with excessive guide clearance must be repaired or replaced. Refer to Engine Specifications.

Valve Guides and Seats, Repairs Measure the clearance between the valve stem and the guide as shown in Figure 3. See Engine Specifications for maximum clearances. If the clearance is more than the maximum amount, oversize valves or new valve guides must be installed. Use a reamer of the correct size when installing new valve guides.

Use normal service procedures when grinding the valve seats. See the Engine Specifications for dimensions.

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NOTE: Before any work is performed on the valve faces and seats, make sure the clearance of the valve stems in their valve guides is within specifications.

A correction for minimum wear and damage to the valve and seat can be done by a process called lapping.

When the valve seats are lapped, keep the valve faces and seats within the specifications. Make sure all of the lapping compound is removed from the valve and valve seat when the process is completed.

Valves with minor pits in the valve faces can be machined to the proper angle. There are many different types of equipment for repairing valve faces. Follow the instructions of the manufacturer of the equipment that you are using. Valves must be machined to the proper specifications. See Figure 4.

1. Valve Stem 2. Dial Indicator Figure 3. Valve Steam Clearance

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NOTE: Seat width dimension applies to the 46° face only.

1. Cylinder Head Figure 4. Valve Seat Specifications for Inlet and Exhaust Valves Replace a valve if any of the following conditions are present: • Valve stem is worn below specifications.

• Valve stem is bent.

• Valve face is warped.

• Any part of the valve is cracked.

• Any wear or damage to the valve face that cannot be removed by resurfacing and still meet the specifications shown in Figure 5.

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Figure 5. Valve Head Measurements

Valve Seats, Repair NOTE: Before any work is done on the valve faces and seats, make sure the clearance of the valve stems in their valve guides is within specifications.

CAUTION The exhaust valve seats in these cylinder heads are induction-hardened. Removal of too much valve seat material will damage the valve seats which will require replacement of the cylinder head.

Damaged valve seats can be resurfaced with a tool that is designed to repair valve seats. There are many different types of equipment for repairing valve seats. Follow the instructions of the manufacturer of the equipment that you are using.

The valve seats are ground at three different angles: 30°, 46°, and 60°. This method makes a valve seat that is the proper width and produces the correct contact line between the valve and valve seat. The specifications for the valve seats are shown in the Engine Specifications section and in Figure 4.

• If the contact line is too high, it can be made lower by using a 30° stone.

• If the contact line is too low, it can be raised using the 46° stone.

• If the seat is too narrow, it can be made wider using a 46° stone.

• If the seat is too wide, it can be made narrower using a 60° stone.

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The correct dimensions for the valve seat widths and valve/valve seat overlap are shown in Figure 6. The valve seat widths are the dimensions of the 46° face only. The valve/valve seat overlap is the distance from the edge of the seat to the outside edge of the valve.

Valve Springs Measure the length of the valve springs. The correct length is 51.6 mm (2.03 in.).

WARNING Be careful when testing the valve springs. These springs can come loose with enough force to cause an injury. Always use equipment that was designed to test springs. Always wear eye and face protection while testing valve springs.

Use a special tool to check the tension of the valve springs. Compress the spring to the correct height and check the tension. For the correct specifications, see Figure 7. Replace valve springs that are not within specifications.

A. Exhaust Valve B. Inlet Valve 1. Cylinder Head 2. Valve Figure 6. Valve Seat Widths and Valve/Valve Seat Overlap

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