Yale GP80VX, Service Manual

Page 1: ...YRM 1620 12 14 MAIN CONTROL VALVE 524223767 2000 YRM 1137 04 14 CYLINDER REPAIR MAST S N A551 A555 A559 A661 A662 A663 A66 B507 B508 B509 B551 B555 B559 B562 B563 B564 B661 B662 B663 C515 C551 C555 C...

Page 2: ...dic 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 maki...

Page 3: ...24 Overhead Guard Replacement 25 Remove 25 Install 25 LED Tail Backup and Brake Lights Replace 26 Operator Restraint System Replacement 26 Description 26 Engine Replacement 28 Remove Engine Only 28 I...

Page 4: ...X J813 84 Remove 84 Inspect 87 Diesel Particulate Filter 89 Disassemble 89 CLEAN AND INSPECT 90 Assembly 91 Install 91 Cooling System 92 Description 92 Hydraulic Filter Assembly Repair 93 Remove 93 Di...

Page 5: ...ee 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 t...

Page 6: ...coun terweight 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 assis tance when raising the hood and hold...

Page 7: ...1 COWL PLATE 2 FENDERS 3 HOOD MOUNTS 4 COUNTERWEIGHT MOUNTS 5 HYDRAULIC TANKS Figure 2 Frame for Lift Trucks with Dual Hydraulic Tanks 0100 YRM 1243 Description 3...

Page 8: ...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 b...

Page 9: ...EAT WIRE HARNESS CONNECTOR 6 CABLE CLIPS 7 HINGE SCREWS 8 GAS SPRING 9 ATTACHMENT HOLES ATTACHING HOOD TO SEAT SEMI SUSPENSION 10 SEAT WIRE HARNESS BRACKETS 11 SEAT LINER 12 HOOD LATCH 13 ATTACHMENT H...

Page 10: ...LEFT STEP PLATE 21 LOCK NUT 22 RIGHT FRONT SIDE COVER 23 RIGHT FENDER COVER 24 RIGHT STEP PLATE 25 RIGHT PANEL 26 RIGHT REAR SIDE COVER 27 SPLASH SHIELD 28 RADIATOR COVER GLC40 45 55VX GLC55SVX GC GL...

Page 11: ...OF DASH SHOWN A INDICATES TO PULL UP TO UNLATCH 1 ALLEN SCREWS 2 COWL 3 UPPER STEERING COLUMN COVER 4 LOWER STEERING COLUMN COVER Figure 5 Remove Dash From Cowl 0100 YRM 1243 Hood Seat and Side Covers...

Page 12: ...1 CAPSCREWS 2 SEAL PLATE Figure 6 Remove Seal Plate From Dash Hood Seat and Side Covers Replacement 0100 YRM 1243 8...

Page 13: ...Figure 7 Gas Spring Installation 0100 YRM 1243 Hood Seat and Side Covers Replacement 9...

Page 14: ...R CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT Table 1 Gas Spring Installation Holes for Installing Rod Ends See Figure 7 Counterweight Type Full or Semi Suspension Seat Non Suspension...

Page 15: ...s on the screws and in the holes 7 Place seat on the hood and thread seat wire har ness through the hole in the hood See Figure 3 8 Align holes in the seat with the holes in hood In sert washers and c...

Page 16: ...IESEL SHOWN LPG AND GAS SIMILAR 1 STEERING WHEEL 2 STEERING COLUMN 3 COWL Figure 9 Steering Column and Cowl 2 Attach a tag on battery connector or negative bat tery cable stating DO NOT CONNECT BAT TE...

Page 17: ...vot bolts two bushings two nuts and bracket from housing See Figure 12 for lift trucks manufactured before January 2012 See Figure 13 for lift trucks manufactured after January 2012 3 Remove split pin...

Page 18: ...Figure 12 Steering Column Assembly Lift Trucks Manufactured Before January 2012 Steering Column 0100 YRM 1243 14...

Page 19: ...OLT 11 BUSHING 12 NUT 13 GAS SPRING 14 BRACKET 15 CONNECTOR 1 BRACKET 2 SPACER 3 JOINT 4 NUT 5 WASHER 6 SCREW 7 UPPER SHAFT 8 HOUSING 9 PIN 10 LOWER SHAFT 11 GAS SPRING 12 BOLT 13 BUSHING 14 CONNECTOR...

Page 20: ...ure 12 for lift trucks manufactured before January 2012 See Figure 13 for lift trucks manufactured after January 2012 3 Assemble lower shaft and upper shaft secure with spit pin See Figure 12 for lift...

Page 21: ...rface 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 onepiece units See the procedure How to Put Lift Truck on Blo...

Page 22: ...13 G813 LPG Fuel System GM 4 3L Engine With PSI 900 YRM 1556 for lift truck models GLC40 45 55VX GLC55SVX GLC080 100 120VX GLC080 100VXBCS GLC120SVX GLC120VXPRS E818 F818 GLP40VX5 VX6 GLP45SVX5 GLP45V...

Page 23: ...XVBCS GC GLC100VXBCS GC GLC120SVX AND GC GLC120VXPRS E818 F818 LIFT TRUCK MODELS C COUNTERWEIGHT USED ON GLC40 45 55VX GC GLC080 100 120VX E818 F818 AND GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP...

Page 24: ...GLP50 55VX GLP080 90 100 110 120VX J813 2 Use a crane to install counterweight on lift truck When counterweight is installed make sure hooks on frame fully engage counterweight so it is aligned with...

Page 25: ...7 ROLL PIN Figure 15 Counterweight Components for Lift Truck Models GLC40 45 55VX GC GLC080 100 120VX E818 F818 and GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 11...

Page 26: ...EW 2 WASHER 3 COUNTERWEIGHT 4 SEAL Figure 16 Counterweight Components for Lift Truck Models GLC55SVX GC GLC080 100VXBCS GC GLC GDC120SVX GC GLC GDC120VXPRS E818 F818 Counterweight Replacement 0100 YRM...

Page 27: ...TOW PIN 4 WASHER 5 CAPSCREW Figure 17 Counterweight Components for Lift Truck Models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX J813 0100 YRM 1243 Coun...

Page 28: ...L PIN Figure 18 Tow Pin Remove and Install For Lift Truck Models GLC55SVX GC GLC80XVBCS GC GLC100VXBCS GC GLC120SVX and GC GLC120VXPRS E818 F818 and GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP...

Page 29: ...r head guard is off balance lower immediately and move hoist to a more centered point 1 Connect a lifting device to remove overhead guard Loosen clamp and disconnect air intake hose from elbow Remove...

Page 30: ...rackets seat and mount ing hood and latches are all part of operator restraint system Each item must be checked to make sure it is attached securely functions correctly and is in good condition See Fi...

Page 31: ...when it is pulled with a sudden jerk replace seat belt as sembly With hood in open position make sure seat belt will not pull from retractor assembly If seat belt can be pulled from retractor with hoo...

Page 32: ...NING LPG can cause an explosion DO NOT cause sparks or permit flammable material near the LPG system LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m 26 ft from any...

Page 33: ...TRANSMISSION MOUNTING BRACKET 3 ENGINE MOUNTING BRACKET 4 ENGINE CROSSMEMBER 5 ENGINE ISOLATOR ASSEMBLY 6 FRAME 7 ENGINE HARNESS CONNECTOR 8 LEFT CHASSIS WIRING HARNESS CONNEC TOR Figure 23 Engine an...

Page 34: ...NE FOR LIFT TRUCK MODELS GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX J813 C KUBOTA 3 6L DIESEL ENGINE 1 TRANSMISSION ISOLATOR ASSEMBLY 2 TRANSMISSION MOU...

Page 35: ...P080 090 100 110 120VX H813 equipped with a Ku bota 3 8L diesel engine manufactured after Febru ary 2012 See Figure 30 for lift truck models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX...

Page 36: ...Figure 25 GM 4 3L LPG Engine and Transmission with Single Hydraulic Tank Engine Replacement 0100 YRM 1243 32...

Page 37: ...HT HAND CHASSIS HARNESS 8 ELECTRONIC CONTROL MODULE ECM 9 POWER DISTRIBUTION MODULE PDM 10 BATTERY AND BATTERY TRAY 11 COOLANT HOSES 12 FAN PULLEY AND FAN SPACER 13 FAN 14 SHROUD 15 EXHAUST PIPE TO EX...

Page 38: ...Figure 26 GM 4 3L LPG Engine and Transmission with Dual Hydraulic Tanks Engine Replacement 0100 YRM 1243 34...

Page 39: ...ESS 8 ELECTRONIC CONTROL MODULE ECM 9 POWER DISTRIBUTION MODULE PDM 10 BATTERY AND BATTERY TRAY 11 COOLANT HOSES 12 FAN PULLEY AND FAN SPACER 13 FAN 14 SHROUD 15 EXHAUST PIPE TO EXHAUST MANIFOLD 16 FU...

Page 40: ...Figure 27 Cummins QSB 3 3L Diesel Engine and Transmission Engine Replacement 0100 YRM 1243 36...

Page 41: ...OUNTING BRACKETS 8 FUEL LINES 9 ENGINE HARNESS CONNECTOR 10 BRAKE COOLING LINE 11 HYDRAULIC SUPPLY LINE 12 TRANSMISSION MOUNTING BRACKET 13 ELECTRONIC CONTROL MODULE 14 RIGHT HAND ENGINE HARNESS 15 HY...

Page 42: ...3 8L Engine and Transmission for Lift Truck Models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX H813 Manufactured Before February 2012 Engine Replacement...

Page 43: ...ENGINE MOUNTING BRACKETS 8 FUEL LINES 9 ENGINE HARNESS CONNECTOR 10 BRAKE COOLING LINE 11 HYDRAULIC SUPPLY LINE 12 TRANSMISSION MOUNTING BRACKET 13 ELECTRONIC CONTROL MODULE 14 RIGHT HAND ENGINE HARN...

Page 44: ...3 8L Engine and Transmission for Lift Truck Models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX H813 Manufactured After February 2012 Engine Replacement...

Page 45: ...ENGINE MOUNTING BRACKETS 8 FUEL LINES 9 ENGINE HARNESS CONNECTOR 10 BRAKE COOLING LINE 11 HYDRAULIC SUPPLY LINE 12 TRANSMISSION MOUNTING BRACKET 13 ELECTRONIC CONTROL MODULE 14 RIGHT HAND ENGINE HARN...

Page 46: ...Figure 30 Kubota 3 8L Engine and Transmission for Lift Truck Models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX J813 Engine Replacement 0100 YRM 1243 42...

Page 47: ...ENGINE MOUNTING BRACKETS 8 FUEL LINES 9 ENGINE HARNESS CONNECTOR 10 BRAKE COOLING LINE 11 HYDRAULIC SUPPLY LINE 12 TRANSMISSION MOUNTING BRACKET 13 ELECTRONIC CONTROL MODULE 14 RIGHT HAND ENGINE HARN...

Page 48: ...3 6L Engine and Transmission for Lift Truck Models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX H813 Manufactured Before February 2012 Engine Replacement...

Page 49: ...E MOUNTING BRACKETS 8 FUEL LINES 9 ENGINE HARNESS CONNECTOR 10 BRAKE COOLING LINE 11 HYDRAULIC SUPPLY LINE 12 TRANSMISSION MOUNTING BRACKET 13 UPPER COOLANT HOSE 14 RIGHT HAND ENGINE HARNESS 15 HYDRAU...

Page 50: ...40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX H813 Manufactured After February 2012 and Lift Truck Models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55...

Page 51: ...E MOUNTING BRACKETS 8 FUEL LINES 9 ENGINE HARNESS CONNECTOR 10 BRAKE COOLING LINE 11 HYDRAULIC SUPPLY LINE 12 TRANSMISSION MOUNTING BRACKET 13 UPPER COOLANT HOSE 14 RIGHT HAND ENGINE HARNESS 15 HYDRAU...

Page 52: ...Figure 33 Cummins 4 5L Diesel Engine and Transmission Engine Replacement 0100 YRM 1243 48...

Page 53: ...trucks models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX H813 equipped with a Ku bota 3 8L diesel engine manufactured after Febru ary 2012 See Figure 30...

Page 54: ...bruary 2012 equipped with a Kubota 3 6L die sel engine See Figure 32 for lift trucks models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 120VX J813 equipped wit...

Page 55: ...For lift trucks equipped with GM 4 3L engine re move three capscrews from battery tray and re move battery battery tray and Electronic Control Module ECM 17 Loosen hose clamps and disconnect remainin...

Page 56: ...ee Figure 27 for lift trucks equipped with a Cum mins QSB 3 3L diesel engine See Figure 28 for lift trucks models GLP GDP40VX5 VX6 GLP GDP45SVX5 GLP GDP45VX6 GLP GDP50 55VX GP GLP GDP080 090 100 110 1...

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