Beruflich Dokumente
Kultur Dokumente
General
NOTE: For lift trucks equipped with a PSI 2.0L LPG
WARNING engine, see PSI 2.0L LPG Fuel System
The lift truck must be put on blocks for some 0900YRM1739 for procedures to remove and install
types of maintenance and repairs. The removal of the exhaust system components. If lift truck is
the following assemblies will cause large changes equipped with a Yanmar 2.6L diesel engine, see
in the center of gravity: mast, drive axle, engine Exhaust System Repair in this manual for procedures.
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in This section contains the description of the frame (see
the following positions to maintain stability: Figure 1) and connected parts. Procedures for
• Before removing the mast and drive axle, removing and installing the counterweight, hood,
put blocks under the counterweight so the overhead guard, engine and transmission, cooling
lift truck cannot fall backward. system, exhaust system (see NOTE above), and
other components attached to the frame are found in
• Before removing the counterweight, put this section. Checks for the operator restraint system
blocks under the mast assembly so the lift and procedures for the repair of tanks and installation
truck cannot fall forward. of safety labels are also included.
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. See the Operating Manual or the
section Periodic Maintenance 8000YRM1750
1
Description 0100 YRM 1735
Description
The frame is one weldment and includes the hydraulic The overhead guard, cowl, and hood are installed on
tank and fuel tank for gasoline or diesel fuel. See Fig- the frame. The hood is connected to the frame with
ure 1. hinges. Two gas-controlled springs provide assis-
tance when raising the hood and hold the hood in the
There is a counterweight for each capacity of lift truck. open position. The floor plate and side covers can be
The counterweights are similar in appearance, but are removed for access to the engine, transmission, and
different weights. See Counterweight Replacement other components.
section.
2
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
1. TILT LEVER
2. GAS CYLINDER
3
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLC030-035VX, GLC040SVX
(D809)
4
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
5
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
Figure 5. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP16-18VX, GLP/
GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810)
6
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
7
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
8
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
13. Remove five fasteners securing dash to the top of • See Figure 4 for lift truck models
cowl. See Figure 7. Remove four clips, located GLC030-035VX, GLC040SVX (D809)
underneath dash, that attach dash to the kick • See Figure 5 for lift truck models GLP/
panel. Lift to remove dash. GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809) 19. Remove two capscrews and hood latch striker
• See Figure 5 for lift truck models GLP/ bolt from mounting bracket. See Figure 9.
GDP16-18VX, GLP/GDP20SVX (GLP/
20. Remove two capscrews and hood latch from
GDP030-035VX, GLP/GDP040SVX) (D810)
hood. See Figure 9.
14. Lift kick panel and remove from truck.
21. Remove capscrews and washers at the top of gas
15. Remove three capscrews and clip nuts from seal springs. Remove gas springs from hood.
plate. Remove seal plate from frame.
22. Remove hinge screws, located in the rear of the
16. Remove two capscrews and washers from cover hood. See Figure 10.
plate and remove seat box. Disconnect seat wire
23. Remove hood from lift truck.
harness connector. See Figure 8.
9
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
10
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
11
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
12
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
A. HOOD LATCH AND HOOD LATCH STRIKER B. HOOD LATCH AND HOOD LATCH STRIKER
BOLT FOR LIFT TRUCK MODELS BOLT FOR LIFT TRUCK MODELS GLP/
GLC030-035VX, GLC040SVX (D809) GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
1. CAPSCREW (HOOD LATCH STRIKER BOLT) 5. HOOD LATCH
2. CAPSCREW (HOOD LATCH) 6. BUMPER
3. HOOD LATCH STRIKER BOLT
4. HOOD LATCH STRIKER BOLT MOUNTING
BRACKET
13
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
CAUTION
When installing the seat to the hood, DO NOT use
an impact wrench to install the capscrews. Dam-
NOTE: LEFT SIDE SHOWN. age can be caused to the threads on the screws
and in the holes.
1. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION
SEAT 8. Place seat on hood. Align holes in seat with holes
2. MOUNTING LOCATION FOR CYLINDER END in hood as noted during removal. Insert washers
OF GAS SPRING FOR SEMI OR FULL SUS- and capscrews. Tighten capscrews to
PENSION SEAT 18 N•m (159 lbf in).
Figure 12. Gas Spring Installation, Lift Truck
9. Install radiator cover and seals to frame.
Models GLC030-035VX, GLC040SVX (D809)
• See Figure 4 for lift truck models
4. Install hood latch to hood using two capscrews. GLC030-035VX, GLC040SVX (D809)
See Figure 9. • See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
5. Install latch striker bolt in highest slot position on GDP030-035VX, GLP/GDP040SVX) (D810)
mounting bracket. See Figure 9. Check that latch
striker bolt is in center of jaws of hood latch when
hood closes. Open and close hood to ensure that
14
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
10. Connect seat wire harness. Install seat box to 16. For lift truck models GLC030-035VX,
cover plate with two capscrews and washers. GLC040SVX (D809), install left and right step
Tighten capscrews to 1.2 N•m (10.6 lbf in). See plates, and six capscrews to frame. See Figure 6.
Figure 8.
For lift truck models GLP/GDP16-18VX, GLP/
11. Install seal plate using three capscrews and clip GDP20SVX (GLP/GDP030-035VX, GLP/
nuts. GDP040SVX) (D810), install left and right step
plates, six clip nuts, and three capscrews onto
12. Install kick panel onto truck. frame. See Figure 6.
• See Figure 4 for lift truck models 17. For lift truck models GLP/GDP16-18VX, GLP/
GLC030-035VX, GLC040SVX (D809) GDP20SVX (GLP/GDP030-035VX, GLP/
• See Figure 5 for lift truck models GLP/ GDP040SVX) (D810), install left and right step
GDP16-18VX, GLP/GDP20SVX (GLP/ covers, eight clip nuts, and eight capscrews onto
GDP030-035VX, GLP/GDP040SVX) (D810) frame. See Figure 6.
13. Install dash to top of cowl. See Figure 7. Install 18. Install left and right rear covers, washers and cap-
four clips to attach the dash to kick panel. screw onto frame.
14. Install upper steering column cover to dash. 19. Install floor mat and floor plate.
15. Install left and right front covers, washers, and 20. If truck is equipped with an LPG tank, swing LPG
capscrews onto frame. tank into position on back of counterweight. See
PSI 2.0L LPG Fuel System 0900YRM1739 for
• See Figure 4 for lift truck models procedures.
GLC030-035VX, GLC040SVX (D809)
21. Connect the battery.
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/ 22. Adjust the steering column and seat positions.
GDP030-035VX, GLP/GDP040SVX) (D810)
15
Steering Column 0100 YRM 1735
Steering Column
DESCRIPTION 2. Attach a tag on the battery connector or negative
battery cable stating, DO NOT CONNECT BAT-
This section describes the repair procedures for the TERY. Move the steering column to the most for-
steering column. The steering column assembly ward position.
mounts to the cowl inside the operator compartment
and is the mechanical connection between the steer-
ing wheel and the steering control unit. The steering CAUTION
column includes the steering wheel, housing, bracket If a puller tool is used to remove steering wheel
and lower shaft. For lift truck models GLC030-035VX, from steering column, be careful not to damage
GLC040SVX (D809), capscrews and bushings attach horn wires.
the steering column to the cowl standoffs. For lift truck
models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ NOTE: This procedure is for the removal of all com-
GDP030-035VX, GLP/GDP040SVX) (D810), cap- ponents of the steering column assembly. Not all
screws, bushings and isolators attach the steering components are removed for a repair procedure. Do
column to the cowl standoffs. See Figure 13. only those steps of the procedure necessary to re-
move the required component.
STEERING COLUMN REPAIR NOTE: Tag wires prior to disconnecting them.
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
1. STEERING WHEEL
2. STEERING COLUMN Figure 14. Steering Wheel Remove/Install
3. COWL
Figure 13. Steering Column and Cowl
16
0100 YRM 1735 Steering Column
NOTE: Perform Step 5 for lift trucks GLC030-035VX, NOTE: Perform Step 6 for lift trucks GLP/
GLC040SVX (D809). GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
5. Remove four capscrews, four bushings, and
steering column from cowl standoffs. See Fig- 6. Remove four capscrews, four bushings, four iso-
ure 15. lators, steering column, and four isolators from
cowl standoffs. See Figure 15.
17
Steering Column 0100 YRM 1735
Disassemble Assemble
NOTE: Remove and discard snap rings if installed. NOTE: This procedure is for the installation of all
components of the steering column assembly. Not all
1. Remove two pins and gas spring from housing. components are removed for a repair procedure. Do
See Figure 16. only those steps of the procedure necessary to install
the required component.
2. Remove two pivot bolts, two bushings, two nuts
and bracket from housing. 1. Install fastener, connector bracket and connector,
two horn contacts, and four screws. See Fig-
3. Remove split pin and lower shaft from upper
ure 16.
shaft. See Figure 16.
2. Assemble lower shaft and upper shaft, secure
4. Remove connector from connector bracket. Re-
with spit pin.
move connector bracket, fastener, four screws
and two horn contacts from housing. 3. Install two pivot bolts, two bushings, two nuts and
bracket onto housing. See Figure 16.
Clean
4. Install gas spring and two pins on housing. See
Figure 16.
WARNING
Cleaning solvents can be flammable and toxic and Install
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac- NOTE: Lubricate spline end of lower shaft with multi
turer’s recommended safety precautions. purpose grease. See Periodic Maintenance
8000YRM1750 for procedures.
WARNING NOTE: Perform Step 1 for lift trucks GLC030-035VX,
Compressed air is used for cleaning and drying GLC040SVX (D809).
purposes, or for cleaning restrictions. Wear pro-
tective clothing (goggles/shields, gloves, etc.). 1. Install steering column, four bushings and four
Make sure the path of the compressed air is away capscrews on cowl standoffs. Tighten capscrews
from all personnel to avoid injury. to 38 N•m (28 lbf ft). See Figure 15.
1. Clean metal parts in solvent. Remove all traces of NOTE: Perform Step 2 for lift trucks GLP/
old lubricant and dirt. Clean nonmetal parts with GDP16-18VX, GLP/GDP20SVX (GLP/
warm soapy water and a lint free cloth. GDP030-035VX, GLP/GDP040SVX) (D810).
2. After cleaning, dry parts with compressed air. DO 2. Install four isolators, steering column, four isola-
NOT dry parts with a cloth. tors, four bushings, and four capscrews on cowl
standoffs. Tighten capscrews to 38 N•m (28 lbf ft).
Inspect See Figure 15
1. Inspect for loose, burned, missing, cracked or 3. Install floor plate, floor mats, and steering column
damaged hardware. covers. See Hood, Seat, and Side Covers Re-
placement section for procedures.
2. Inspect all parts for dents, holes, bends, burrs,
rust, corrosion or marred finishes. 4. Install steering wheel and hex nut on steering col-
umn, tighten hex nut to 40 to 54 N•m (30 to
3. Replace all defective or damaged parts. 40 lbf ft). Connect electrical wiring and install horn
button. See Figure 14.
18
0100 YRM 1735 Steering Column
5. Remove tag from negative battery connector and 6. Remove blocks from each side of tires.
connect to battery. Adjust steering column to neu-
tral position.
1. BRACKET 9. PIN
2. SPACER 10. LOWER SHAFT
3. JOINT 11. GAS SPRING
4. NUT 12. BOLT
5. WASHER 13. BUSHING
6. SCREW 14. CONNECTOR
7. UPPER SHAFT 15. FASTENER
8. HOUSING 16. HORN CONTACT
Figure 16. Steering Column Assembly
For procedures to remove and install the LPG tank, LPG tank bracket, and the LPG tank alignment pin, see PSI
2.0L LPG Fuel System 0900YRM1739 for procedures.
19
Counterweight Replacement 0100 YRM 1735
Counterweight Replacement
REMOVE unit. Permit the pressure in the fuel system to de-
crease slowly. Fuel leaving the fitting removes
heat. Use a cloth to protect your hands from the
WARNING cold fitting.
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of NOTE: The counterweight is held in position on the
the following assemblies will cause large changes frame by two hooks that are part of the frame. See
in the center of gravity: mast, drive axle, engine Figure 17.
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in One M24 × 3 x 90 capscrew holds the counterweight
the following positions to maintain stability: to the lower part of the frame. See Figure 17.
• 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.
WARNING
DO NOT operate the lift truck if the capscrew for
the counterweight is not installed. When the cap-
screw is removed, the counterweight can fall from
the lift truck.
WARNING
LPG can cause an explosion. DO NOT cause NOTE: COUNTERWEIGHT FOR LIFT TRUCK MOD-
sparks or permit flammable material near the LPG ELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
system. LPG fuel systems can be disconnected GDP030-035VX, GLP/GDP040SVX) (D810) SHOWN.
indoors only if the lift truck is at least 8 m (26 ft) COUNTERWEIGHT ARRANGEMENT FOR LIFT
from any open flame, motor vehicles, electrical TRUCK MODELS GLC030-035VX, GLC040SVX
equipment, or ignition source. (D809) IS SIMILAR.
Close the shutoff valve on the LPG tank before 1. FRAME HOOKS
any part of the engine fuel system is disconnec- 2. COUNTERWEIGHT SEAL
3. CAPSCREW (M24 × 3 X 90)
ted. Run the engine until the fuel in the system is 4. TOW PIN
used and the engine stops. 5. COUNTERWEIGHT
If the engine will not run, close the shutoff valve Figure 17. Counterweight Arrangement
on the LPG tank. Loosen the fitting on the supply
hose from the LPG tank where it enters the filter
20
0100 YRM 1735 Counterweight Replacement
1. If lift truck is equipped with an overhead exhaust The approximate weights of the counterweight
system, remove the overhead exhaust pipe be- castings are shown in:
fore removing the counterweight.
Table 2 for lift truck models
If lift truck is equipped with an LPG fuel system, • GLC030-035VX, GLC040SVX (D809)
see PSI 2.0L LPG Fuel System 0900YRM1739 for
procedures to remove the overhead exhaust pipe. Table 3 for lift truck models
If lift truck is equipped with a diesel fuel system, • GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
see Exhaust System Repair in this manual for pro- GDP030-035VX, GLP/GDP040SVX) (D810)
cedures to remove the overhead exhaust pipe. 3. Install a lifting eye in the lift hole of the counter-
2. If the lift truck has an LPG fuel system, see PSI weight. See Figure 18. Connect a crane to the lift-
2.0L LPG Fuel System 0900YRM1739 to remove ing eye and raise the crane until it holds part of
the LPG tank and bracket, before removing the the weight of the counterweight. Remove the tow
counterweight, and for additional information on pin and remove the capscrew and washer that
the LPG fuel system. hold counterweight to frame. Use crane to lift
counterweight from lift truck. Put counterweight on
the floor so that it has stability and will not fall
WARNING over. Take care not to damage exhaust or cooling
The counterweight is heavy. Make sure that the components.
eyebolt and lifting devices have enough capacity
to lift the weight.
Model Kg Lb
GLC030VX 772 1702
GLC035VX 963 2123
GLC040SVX 1131 2493
Model Kg Lb
GLP/GDP16VX (GLP/GDP030VX) 813 1792
GLP/GDP18VX (GLP/GDP035VX) 887 1955
GLP/GDP20SVX (GLP/ 1047 2308
GDP040SVX)
21
Counterweight Replacement 0100 YRM 1735
INSTALL
1. Make sure the seals are on the counterweight.
See Figure 18.
1. CAPSCREW
2. WASHER
3. COUNTERWEIGHT
4. LIFT HOLE
5. LIFTING EYEBOLT
6. TOW PIN
7. LPG ACCESS HOLE
8. COUNTERWEIGHT SEAL
22
0100 YRM 1735 Counterweight Replacement
1. TOW PIN
2. D-RING
3. WIRE LOOP
4. TOW PIN HOLE
23
Overhead Guard Replacement 0100 YRM 1735
24
0100 YRM 1735 Overhead Guard Replacement
25
Operator Restraint System Replacement 0100 YRM 1735
26
0100 YRM 1735 Operator Restraint System Replacement
27
Engine Replacement 0100 YRM 1735
Engine Replacement
REMOVE 2. Remove overhead guard. See Overhead Guard
Replacement section for procedures.
WARNING 3. Remove floor mat and floor plate.
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 WARNING
in the center of gravity: mast, drive axle, engine DO NOT remove the radiator cap from the radiator
and transmission, and counterweight. When the when the engine is hot. When the radiator cap is
lift truck is put on blocks, put additional blocks in removed, the pressure is released from the sys-
the following positions to maintain stability: tem. If the system is hot, the steam and boiling
coolant can cause burns.
• Before removing the mast and drive axle,
put blocks under the counterweight so the 4. Let coolant cool to ambient temperature. Place a
lift truck cannot fall backward. drain pan with a capacity greater than the ca-
• Before removing the counterweight, put pacity of the cooling system under radiator. Re-
blocks under the mast assembly so the lift move radiator cap. See Periodic Maintenance
truck cannot fall forward. 8000YRM1750 for coolant capacity.
28
0100 YRM 1735 Engine Replacement
10. Remove air intake components from engine. Breathing fuel vapor may cause nausea, uncon-
• Lift trucks equipped with LPG engine - sciousness or death. Avoid breathing fuel vapor.
Disconnect air restriction sensor. Discon- 13. Disconnect the fuel lines at the engine. Put caps
nect and remove intake hose from LPG on fuel lines to prevent fuel leakage. See Fig-
fuel mixer and air intake housing. Discon- ure 26.
nect and remove dirty air hose from air in-
take housing. Remove two capscrews (un-
derneath mounting bracket) and air intake
from mounting bracket. See Figure 25.
• Lift trucks equipped with diesel engine -
Disconnect air restriction sensor. Discon-
nect and remove intake hose from intake
manifold. Disconnect and remove dirty air
hose from air intake housing. Remove two
capscrews (underneath mounting bracket)
and air intake from mounting bracket. See
Figure 25.
WARNING 1. BATTERY
2. BATTERY TRAY
All fuels are very flammable and can burn or 3. PDM
cause an explosion. DO NOT use an open flame to 4. BATTERY LOCKDOWN BAR
check the fuel level or to check for leaks in the 5. CAPSCREW/CLIP NUT
fuel system. 6. GROUND STRAP
29
Engine Replacement 0100 YRM 1735
30
0100 YRM 1735 Engine Replacement
A. AIR INTAKE SYSTEM - LIFT TRUCKS EQUIP- B. AIR INTAKE SYSTEM - LIFT TRUCKS EQUIP-
PED WITH LPG ENGINE PED WITH DIESEL ENGINE
1. LPG FUEL MIXER 5. MOUNTING BRACKET
2. AIR INTAKE HOSE 6. CAPSCREW
3. DIRTY AIR HOSE 7. INTAKE MANIFOLD (DIESEL)
4. AIR INTAKE HOUSING 8. SILENCER (DIESEL)
31
Engine Replacement 0100 YRM 1735
32
0100 YRM 1735 Engine Replacement
33
Engine Replacement 0100 YRM 1735
WARNING CAUTION
The engine is heavy. Make sure that any lifting de- Keep the engine level when the engine is separa-
vice has enough capacity to lift the engine. The ted from the transmission so the drive plate is not
engine can weigh approximately198 kg (437 lb). damaged.
20. Remove flange nuts, washers, capscrews, and 21. Use the lifting device to carefully move the engine
isolators from engine mounts. See Figure 29 and away from the torque converter. Make sure all ho-
Figure 30. Remove engine adapter to transmis- ses, wires, and cables are disconnected from the
sion bolts. engine, then lift the engine from the frame and
place engine on blocks.
CAUTION 22. Remove torque converter from torque converter
When separating the engine away from the trans- housing. See Figure 28.
mission, place a piece of plywood in front of radi-
ator. This will keep the engine from damaging the
radiator.
34
0100 YRM 1735 Engine Replacement
1. Install torque converter in torque converter hous- 6. Install converter housing cover, two washers, and
ing. two capscrews on torque converter housing.
Tighten capscrews to 19 N•m (168 lbf in). See
2. Connect lifting device to engine and lift engine Figure 28.
into frame.
35
Engine Replacement 0100 YRM 1735
7. Use access port on side of engine and install underside of mounting bracket. Connect
bolts to hold torque converter to flywheel. Tighten dirty air hose to intake housing. Connect
bolts to 56 N•m (41 lbf ft). See Figure 27. intake hose to LPG fuel mixer. Connect air
restrictor sensor. See Figure 25.
For lift trucks equipped with a diesel engine, install
• Lift trucks equipped with diesel engine -
two capscrews and dust cover over access port.
Place air intake on mounting bracket and
See Figure 27.
use two capscrews to attach air intake to
8. Connect engine wire harness connectors to right underside of mounting bracket. Connect
hand chassis harness connectors. See Figure 26. dirty air hose to intake housing. Connect
intake hose to intake manifold. Connect air
restriction sensor. See Figure 25.
WARNING
All fuels are very flammable and can burn or 13. Connect the coolant hoses and lines to the trans-
cause an explosion. DO NOT use an open flame to mission. Fill cooling system with a mixture of 50
check the fuel level or to check for leaks in the percent deionized water and 50 percent ethylene
fuel system. glycol boron-free antifreeze.
No smoking. 14. Connect the PDM and connect the ground strap
to lift truck frame and attach it to battery. Install
Breathing fuel vapor may cause nausea, uncon- the battery and battery tray. See Figure 24.
sciousness or death. Avoid breathing fuel vapor.
15. Install hood and seat combination and rear side
9. Remove caps from fuel lines and connect fuel covers. See section Hood, Seat, and Side Covers
lines to engine. See Figure 26. Replacement for procedures.
10. Install radiator fan pulley, shroud, and fan assem- 16. Install floor plate and floor mat.
bly. See Cooling System 0700YRM1737 for in-
stallation procedures. 17. Install overhead guard. See section Overhead
Guard Replacement.
11. Connect exhaust system components.
18. If lift truck is equipped with an LPG fuel tank,
• See PSI 2.0L LPG Fuel System
swing tank into position on back of counterweight
0900YRM1739 for procedures to install ex-
and open shutoff valve on tank. See PSI 2.0L
haust system components for lift trucks
LPG Fuel System 0900YRM1739 for procedures.
equipped with an LPG engine.
• See Exhaust System Repair in this manual 19. Check all fluid levels as described in Periodic
for procedures to install exhaust system Maintenance 8000YRM1750.
components for lift trucks equipped with a
diesel engine.
36
0100 YRM 1735 Transmission Replacement
Transmission Replacement
REMOVE NOTE: When disconnecting wiring harness connec-
tors during removal, tag each connector to aid in con-
necting wiring harness during installation.
WARNING
The lift truck must be put on blocks for some 3. Disconnect the engine wiring harness from trans-
types of maintenance and repairs. The removal of mission wiring harness. See Figure 26.
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine, 4. Disconnect transmission cooling lines from trans-
transmission, and counterweight. When the lift mission. See Figure 31.
truck is put on blocks put additional blocks in the
following positions to maintain stability:
CAUTION
• Before removing the mast and drive axle, Disposal of lubricants and fluids must meet local
put blocks under the counterweight so the environmental regulations.
lift truck cannot fall backward.
• Before removing the counterweight, put 5. Place a suitable container under transmission; re-
blocks under the mast assembly so the lift move drain fitting from transmission housing and
truck cannot fall forward. drain transmission oil.
The surface must be solid, even, and level when 6. Disconnect and cap suction hose from hydraulic
the lift truck is put on blocks. Make sure that any gear pump inlet port. Cap hydraulic gear pump in-
blocks used to support the lift truck are solid, let port. See Figure 31.
one-piece units. See the Operating Manual or Peri- NOTE: Perform Step 7 if lift truck is equipped with a
odic Maintenance 8000YRM1750.
Quick-LokTM hydraulic hose and adapter.
37
Transmission Replacement 0100 YRM 1735
A. LIFT TRUCKS EQUIPPED WITH LPG ENGINE B. LIFT TRUCKS EQUIPPED WITH DIESEL EN-
GINE
1. TRANSMISSION HOUSING
2. DRAIN FITTING
3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
5. HYDRAULIC GEAR PUMP INLET HOSE AND PORT
6. HYDRAULIC GEAR PUMP OUTLET HOSE AND PORT
7. TRANSMISSION COOLING HOSES/LINES
Figure 31. Transmission Hydraulic and Cooling Hoses and Gear Pump Arrangement
38
0100 YRM 1735 Transmission Replacement
INSTALL
WARNING
The transmission is heavy. Make sure that any lift-
ing device has enough capacity to lift the weight.
The transmission can weigh approximately
84 kg (185 lb).
1. MOUNT BRACKET
2. CAPSCREW
3. WASHER
4. SNUBBING WASHER
5. ISOLATOR
Figure 32. Rear-Mount, Transmission
39
Transmission Replacement 0100 YRM 1735
5. Install isolators, snubbing washers, washer, and 12. Connect transmission wiring harness to engine
capscrew on mounting bracket at the rear of the wiring harness. See Figure 26.
transmission. Tighten capscrew to 225 to
250 N•m (166 to 184 lbf ft). See Figure 32. 13. Install the seal plate for the brake and throttle
pedals. See Hood, Seat, and Side Covers Re-
6. Remove lifting device from transmission. placement section for procedures.
8. Connect hydraulic inlet hose to fitting on hydraulic 14. Install engine to lift truck. See Engine Replace-
gear pump outlet port. See Figure 31. ment section for procedures.
9. Connect suction hose to hydraulic gear pump inlet 15. Fill transmission oil. For fill instruction, oil type,
port. See Figure 31. and amount, see Periodic Maintenance
8000YRM1750.
10. Install drain fitting on transmission housing.
40
0100 YRM 1735 Throttle Pedal and Cable Adjustment
NOTE: THROTTLE PEDAL NOT SHOWN IN FULLY DEPRESSED POSITION (WIDE OPEN POSITION).
1. COWL 7. PEDAL STOP
2. BELLCRANK 8. THROTTLE CABLE
3. PUSH ROD 9. CABLE BRACKET
4. BALL END 10. JAM NUTS
5. THROTTLE PEDAL 11. THROTTLE CRANK
6. JAM NUT
Figure 34. Throttle Pedal and Cable Adjustment, Yanmar Diesel Engine
41
Throttle Pedal and Cable Adjustment 0100 YRM 1735
42
0100 YRM 1735 Exhaust System Repair
LIFT TRUCKS EQUIPPED WITH YANMAR Inspect the following items in the exhaust system:
2.6L DIESEL ENGINE • Inspect all exhaust pipes for damage, corro-
sion, and rust and replace as needed.
Counterweight Exhaust System
• If equipped, inspect all exhaust wraps for wear,
The muffler is installed inside the cavity of the coun- proper fit, contamination with oil or antifreeze,
terweight. A short exhaust pipe sends exhaust gases gaps in coverage, failed fasteners and replace
out of lift truck through a grille in the counterweight. as needed. If replacing an exhaust pipe section
that has a wrap, also replace the wrap. DO
Remove and Disassemble NOT reuse wraps if they have been removed
for a service operation.
• Inspect the catalytic converter (if equipped)
WARNING and muffler for damage, corrosion, and rust.
Exhaust system components are hot to touch. Be Replace as needed.
sure exhaust system components are cool before
starting disassembly, or personal injury may oc- Assemble and Install
cur.
1. Install engine exhaust pipe to engine exhaust
1. Remove counterweight. See section Counter- manifold. Tighten locknuts to 22 N•m (195 lbf in).
weight Replacement for procedures.
2. If lift truck is equipped with a catalytic converter,
2. Remove clamp that attaches tail pipe to muffler. install catalytic converter to engine exhaust pipe
See Figure 36. and lower exhaust pipe to catalytic converter us-
ing two clamps (9 and 12, Figure 36).
3. Remove clamp and lower exhaust pipe from muf-
fler. See Figure 36. If lift truck is not equipped with catalytic converter,
install lower exhaust pipe to engine exhaust pipe
4. Remove the locknuts, capscrews, spacers, and
with clamp (9 and 12, Figure 36).
isolators that fasten muffler to lift truck frame and
remove muffler from lift truck. See Figure 36. 3. Place muffler onto the frame of lift truck and install
the isolators, spacers, capscrews, and locknuts to
5. If lift truck is not equipped with a catalytic con-
secure muffler to lift truck. Tighten locknuts to
verter, remove four locknuts attaching engine ex-
22 N•m (195 lbf in).
haust pipe to engine exhaust manifold and re-
move engine exhaust pipe from engine manifold 4. Install lower exhaust pipe to muffler with clamp.
and lower exhaust pipe (9 and 12, Figure 36). Re- See Figure 36.
move lower exhaust pipe.
5. Install tail pipe on muffler with clamp. See Fig-
If lift truck is equipped with a catalytic converter, re- ure 36.
move clamps securing engine exhaust pipe and
lower exhaust pipe to catalytic converter. Remove 6. Install counterweight. See section Counterweight
four locknuts attaching engine exhaust pipe to en- Replacement for procedures.
43
Exhaust System Repair 0100 YRM 1735
44
0100 YRM 1735 Exhaust System Repair
The muffler is installed inside the cavity of counter- Inspect the following items in the exhaust system:
weight. A long exhaust pipe, located above the over- • Inspect all exhaust pipes for damage, corro-
head guard, sends exhaust gases out of the lift truck. sion, and rust and replace as needed.
Remove and Disassemble • If equipped, inspect all exhaust wraps for wear,
proper fit, contamination with oil or antifreeze,
gaps in coverage, failed fasteners and replace
WARNING as needed. If replacing an exhaust pipe section
Exhaust system components are hot to touch. Be that has a wrap, also replace the wrap. DO
sure exhaust system components are cool before NOT reuse wraps if they have been removed
starting disassembly, or personal injury may oc- for a service operation.
cur. • Inspect the catalytic converter (if equipped)
and muffler for damage, corrosion, and rust.
1. Lift cover and remove three capscrews and wash-
Replace as needed.
ers that attach overhead exhaust pipe to counter-
weight. Remove clamp between overhead ex-
Assemble and Install
haust pipe and exhaust pipe (6, Figure 37) and
remove overhead exhaust pipe. 1. Install engine exhaust pipe to engine exhaust
manifold. Tighten locknuts to 22 N•m (195 lbf in).
2. Remove counterweight. See Counterweight Re-
placement for procedures. 2. If lift truck is equipped with a catalytic converter,
install catalytic converter to engine exhaust pipe
3. Remove clamp that attaches exhaust pipe to muf-
and lower exhaust pipe to catalytic converter us-
fler (6, Figure 37).
ing two clamps (13 and 14, Figure 37).
4. Remove clamp that attaches lower exhaust pipe
If lift truck is not equipped with catalytic converter,
to muffler (13, Figure 37).
install lower exhaust pipe to engine exhaust pipe
5. Remove locknuts, capscrews, isolators, and with clamp (13 and 14, Figure 37).
spacers that fasten the muffler to lift truck frame
3. Place muffler onto the frame of lift truck and install
and remove muffler from lift truck.
the isolators, spacers, capscrews, and locknuts to
6. If lift truck is not equipped with a catalytic con- secure muffler to lift truck. Tighten locknuts to
verter, remove four locknuts attaching engine ex- 22 N•m (195 lbf in).
haust pipe to engine exhaust manifold and re-
4. Install lower exhaust pipe to muffler with clamp.
move engine exhaust pipe from engine manifold
and lower exhaust pipe (13 and 14, Figure 37). 5. Install exhaust pipe (6, Figure 37) to muffler with
Remove lower exhaust pipe. clamp.
If lift truck is equipped with a catalytic converter, re- 6. Install counterweight. See Counterweight Re-
move clamps securing engine exhaust pipe and placement for procedures.
lower exhaust pipe to catalytic converter (13 and
14, Figure 37). Remove four locknuts attaching en- 7. Insert overhead exhaust pipe in hole of counter-
gine exhaust pipe to engine exhaust manifold and weight. Attach overhead exhaust pipe to exhaust
remove engine exhaust pipe from engine manifold pipe (2 and 6, Figure 37) and secure with clamp.
and catalytic converter. Remove lower exhaust Install and tighten three capscrews to
pipe from catalytic converter. 22 N•m (195 lbf in) to secure overhead exhaust
pipe to counterweight. Cover capscrews with
cover.
45
Exhaust System Repair 0100 YRM 1735
46
0100 YRM 1735 Exhaust System Repair
1. COVER 9. ISOLATOR
2. OVERHEAD EXHAUST PIPE 10. SPACER
3. CAPSCREW 11. LOCKNUT
4. WASHER 12. EXHAUST SHIELD
5. CLAMP 13. LOWER EXHAUST PIPE
6. EXHAUST PIPE 14. ENGINE EXHAUST PIPE
7. MUFFLER 15. GASKET
8. CAPSCREW 16. CATALYTIC CONVERTER
Cooling System
DESCRIPTION • Fan shroud
• Coolant hoses and lines
The cooling system is used to cool the engine and
maintain it at the correct operating temperature. The • Coolant reservoir
cooling system is comprised of the following main
components: For the procedures to repair, clean, inspect, and in-
stall the radiator and cooling system components, re-
• Radiator fer to Cooling System 0700YRM1737.
• Fan and belt
47
Hydraulic Filter Assembly Repair 0100 YRM 1735
1. LID
2. O-RING (LID)
3. DIPSTICK HOLDER
4. PLUG
5. O-RING (FILTER ELEMENT)
6. QUAD RING
7. SPRING
8. HYDRAULIC FILTER
9. BOWL
10. LID ASSEMBLY
11. FILTER HEAD ASSEMBLY
12. HYDRAULIC FILTER (BOWL) ASSEMBLY
INSTALL
1. Lubricate sealing surfaces on filter housing and
cover plate with clean hydraulic oil.
CAUTION
Additives may damage the hydraulic system. Be-
fore using additives, contact your local Yale
dealer.
48
0100 YRM 1735 Hydraulic Filter Assembly Repair
Make a visual inspection of all sides of the tank. In- When cleaning with steam, use a hose with a mini-
spect the welds for cracks and leakage. Check for wet mum diameter of 19 mm (0.75 in.). Control the pres-
areas, accumulation of dirt, and loose or missing paint sure of the steam by a valve installed at the nozzle of
caused by leakage. Areas of the tank that are not the hose. If a metal nozzle is used, it must be made of
easily seen can be checked with an inspection mirror a material that does not make sparks. Make an elec-
and a light that is approved for locations with flamma- trical connection between the nozzle and the tank.
ble vapors. See Figure 39. Connect a ground wire to the tank to prevent static
electricity.
1. Place a drain pan with enough capacity to hold all
fluid from tank under the tank’s drain plug.
49
Fuel and Hydraulic Tanks Repair 0100 YRM 1735
Steam Method of Cleaning Use the following procedure to clean the tank with
steam:
WARNING 1. Remove all the parts from the tank. Install the
Compressed air can move particles so that they drain plug. See Figure 39.
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is 2. Fill the tank ¼ full with a solution of water and so-
away from all personnel. Wear protective goggles dium bicarbonate or sodium carbonate. Mix
or a face shield to prevent injury to the eyes. 0.5 kg (1 lb) per 4 liter (1 gal) of water.
50
0100 YRM 1735 Fuel and Hydraulic Tanks Repair
5. Flush the inside of the tank with boiling water. 4. Make an inspection of the inside of the tank. If the
Make sure all loose material is removed from in- tank is not clean, repeat Step 1 through Step 3.
side of tank. Make another inspection of the tank. When mak-
ing inspections, use a light that is approved for lo-
6. Make an inspection of the inside of the tank. If it is cations with flammable vapors.
not clean, repeat Step 4 and Step 5 and make an-
other inspection. When making inspections, use a 5. Check tank for flammable vapors using special in-
light that is approved for locations with flammable dicator for gas vapors. If the amount of flammable
vapors. vapors is not below the lower flammable limit, re-
peat the cleaning procedures.
7. Put plugs in all openings in the tank. Wait 15 mi-
nutes, then remove the inlet and outlet plugs. Test ADDITIONAL PREPARATIONS FOR
a sample of the vapor with a special indicator for REPAIR
gas vapors. If the amount of flammable vapors is
above the lower flammable limit, repeat cleaning If nitrogen gas or carbon dioxide gas is available, pre-
procedures. pare the tank for welding using these gases. See the
manual Safe Practices for Welding and Cutting Con-
Chemical Solution Method of Cleaning tainers That Have Held Combustibles by the Ameri-
can Welding Society, F4.1 - 1999. If these gases are
not available, another method using water can be
WARNING used as follows:
When cleaning the tank, DO NOT use solutions
that make dangerous gases at normal tempera- 1. Fill the tank with water to just below the point
tures or when heated. Wear eye and face protec- where the work will be done. Make sure the space
tion. Protect the body from burns. above the level of the water has a vent.
51
Fuel and Hydraulic Tanks Repair 0100 YRM 1735
PREPARATIONS FOR USE AFTER 2. If there are no leaks coming from the tank, re-
REPAIR move all the water from the tank.
Safety Labels
NOTE: Not all labels that are used on the lift trucks
WARNING covered in this manual are shown in Figure 40. See
Safety labels are installed on the lift truck to pro- the Parts Manual for a complete listing of all labels
vide information about operation and possible used on these lift trucks and their part numbers.
hazards. It is important that all safety labels are
installed on the lift truck and can be read. If a new label must be installed, use the following pro-
cedure to install a new label.
DO NOT add to or modify the lift truck. Any
change to the lift truck, the tires, or its equipment 1. Make sure the surface is dry and has no oil or
can change the lifting capacity. The lift truck must grease. DO NOT use solvent on new paint. Clean
be rated as equipped, and the Nameplate must the surface of old paint with a cleaning solvent.
show the new capacity rating. Contact your dealer
for a new Nameplate. 2. Remove the paper from the back of the label. DO
NOT touch the adhesive surface.
WARNING 3. Carefully hold the label in the correct position
Cleaning solvents can be flammable and toxic and above the surface. The label cannot be moved af-
can cause skin irritation. When using cleaning ter it touches the surface. Put the label on the sur-
solvents, always follow the recommendations of face. Make sure that all air is removed from under
the manufacturer. the label, and the corners and edges are tight.
52
0100 YRM 1735 Safety Labels
53
Safety Labels 0100 YRM 1735
1. LPG TANK WARNING 15. STABILITY SYSTEM LABEL (ON BOTH SIDE
2. FLAMMABLE LPG LABEL OF TRUCK)**
3. ETHER WARNING (DIESEL ONLY)* 16. FUEL TYPE LABEL
4. OPERATOR WARNING 17. LIFT AND TILT LABEL
5. OVERHEAD GUARD LABEL** 18. SPLIT WHEEL WARNING*
6. MAST WARNING LABEL 19. TIPOVER WARNING
7. NAMEPLATE 20. PARKING BRAKE WARNING LABEL
8. TRANSMISSION LABEL (EXAMPLE ONLY) 21. INSPECTION PLATE**
9. MAST WARNING 22. RADIAL TIRES AND WHEELS*
10. DRIVE TRAIN PROTECTION LABEL** 23. SOOT TRAP WARNING (DIESEL ONLY)*
11. NO ONE ON OR UNDER FORKS WARNING 24. ANTIFREEZE WARNING
12. LOCKING GAS SPRING CAUTION 25. FAN WARNING
13. HOOD OPENING CAUTION 26. BORON-FREE LABEL
14. NO RIDERS LABEL 27. DIESEL FUEL LABEL*
54
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