Figure 44. Warning and Safety Labels for Lift Trucks with Yanmar Diesel Engine
Label Replacement
0100 YRM 1766
50
Page 1: ...LIC CLEANLINESS PROCEDURES 550073240 1900 YRM 1620 12 14 HYDRAULIC GEAR PUMPS 550108499 1900 YRM 1744 12 14 MAIN CONTROL VALVE 550108500 2000 YRM 1745 12 14 CYLINDER REPAIR MAST S N A698 AND A699 5501...
Page 2: ...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 Periodic M...
Page 3: ...1 COWL PLATE 2 FENDER 3 FRAME 4 HOOD MOUNT 5 COUNTERWIEGHT SUPPORT 6 FUEL TANK 7 HYDRAULIC TANK Figure 2 Frame Dual Fuel or Diesel General 0100 YRM 1766 2...
Page 4: ...System PSI 2 4L 0900YRM1757 for procedures 4 Raise the hood latch on the left front corner of the hood to unlatch and lift up the hood See Fig ure 3 5 Remove the floor mat and floor plate See Fig ure...
Page 5: ...Figure 4 Side Cover Floor Plate and Cowl Components Hood Seat and Side Covers Replacement 0100 YRM 1766 4...
Page 6: ...R 8 RIGHT FRONT SIDE COVER 9 LEFT STEP PANEL 10 RIGHT STEP PANEL 11 LEFT STEP PLATE 12 RIGHT STEP PLATE 13 LEFT REAR SIDE COVER 14 RIGHT REAR SIDE COVER 15 FLOOR MAT 16 FLOOR PLATE 17 RADIATOR COVER 1...
Page 7: ...ee Figure 5 10 Remove the five Allen Head screws see Fig ure 5 securing the dash to top of cowl 11 Pull kick panel up from bottom and out to remove kick panel from seal plate and clips on dash panel 1...
Page 8: ...HEAD SCREWS 2 COWL 3 DASH PANEL 4 KICK PANEL 5 KICK PANEL NOTCHES 6 SEAL PLATE 7 CAPSCREWS 8 CLIPS Figure 6 Dash Panel Kick Panel and Seal Plate Removal 0100 YRM 1766 Hood Seat and Side Covers Replac...
Page 9: ...See Figure 8 Remove the four capscrews and nuts holding the seat to the hood Lift the seat off the hood See Figure 8 Close hood 16 Remove the nuts from ball studs on gas springs Remove gas springs fro...
Page 10: ...E SAME 1 CAPSCREW 2 NUT 3 HOLE FOR CHASSIS HARNESS 4 HOOD LINER A HOOD HINGE ARRANGEMENT B GAS SPRING ARRANGEMENT LEFT SIDE SHOWN 1 NUT 2 CAPSCREW 3 HOOD HINGE MOUNT 4 HOOD HINGE ARM 5 HOOD 6 BALL STU...
Page 11: ...latch properly and that the stop screw contacts the frame A properly closed hood MUST click twice on the hood latch If the hood latch does not close properly loosen the capscrews on the back of the c...
Page 12: ...and secure dash panel to cowl using five Allen Head screws Tighten Al len Head screws to 3 5 N m 31 lbf in See Fig ure 5 12 Align notches on kick panel to clips on dash panel and push kick panel into...
Page 13: ...of tires to prevent lift truck from moving CAUTION Disconnect the negative battery cable on internal combustion trucks Disconnect the battery before removing any covers 2 Attach a tag on the battery...
Page 14: ...g column and four isolators from cowl standoffs See Figure 14 Disassemble NOTE Remove and discard snap rings if installed 1 Remove two pins and gas spring from housing See Figure 15 2 Remove two pivot...
Page 15: ...the horn contact slip rings with a small amount of conductive grease Yale P N 582014302 See Figure 15 2 Install fastener connector bracket and connector two horn contacts and four screws 3 Assemble lo...
Page 16: ...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 15 FASTENER 16 HORN CONTACT Figure 15 Steering Column Assembly 0100 YRM 1766...
Page 17: ...PG tank Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit Permit the pressure in the fuel system to de crease slowly Fuel leaving the fitting removes heat Use a c...
Page 18: ...erweight and frame See Figure 16 and Figure 17 Tighten capscrew to 555 N m 409 lbf ft 1 SEAL 2 COUNTERWEIGHT 3 TOW PIN 4 CAPSCREW 5 WASHER 6 FRAME Figure 16 Counterweight Installation 4 Install tow pi...
Page 19: ...the lift the overhead guard is off balance lower immediately and move the hoist to a more centered point No welding or drilling on legs of overhead guard is permitted as per previous WARNING 1 Connec...
Page 20: ...See Figure 19 4 Remove two capscrews two wheel nuts right bracket and left bracket from front corner of over head guard See Figure 19 NOTE Note position of rain top on overhead guard before removal 5...
Page 21: ...OP 2 CAPSCREW 3 WHEEL NUT 4 LOCKNUT 5 WASHER 6 LEFT BRACKET 7 RIGHT BRACKET 8 CENTER BRACKET 9 BUSHING 10 SEALER 11 OVERHEAD GUARD Figure 19 Overhead Guard Rain Top Overhead Guard Replacement 0100 YRM...
Page 22: ...out of the retractor assembly the internal latch may be locked Pull firmly on the seat belt and hold for a mo ment to remove slack from the belt in the re tractor Release the seat belt Seat belt will...
Page 23: ...of gravity mast drive axle engine and transmission and counterweight When the lift truck is put on blocks put additional blocks in the following positions to maintain stability Before removing the mas...
Page 24: ...off valve on the LPG tank and run engine until all fuel is gone and engine stops 2 For removal of the LPG Tank see service manual Fuel System PSI 2 4L 0900YRM1757 for the pro cedures 3 Remove overhead...
Page 25: ...Figure 22 PSI Engine and Transmission Remove Engine Replacement 0100 YRM 1766 24...
Page 26: ...pen the drain plug or disconnect the bottom ra diator hose to drain coolant from radiator and en gine See Figure 22 7 Remove the hood and seat combination and rear side covers See section Hood Seat an...
Page 27: ...a block under the transmission housing to support the transmission 18 Remove four capscrews from torque converter housing and flywheel housing on transmission side See Figure 26 19 Remove six capscrew...
Page 28: ...TOR 4 TRANSDUCER CONNECTOR 5 TRANSMISSION SENSOR PLUG 6 SOLENOID VALVE CONNECTOR 7 ENGINE WIRING HARNESS Figure 24 Transmission Electrical Connectors 1 ACCESS PORT 2 ENGINE MOUNTING BRACKET AND HARD W...
Page 29: ...YEBOLT BRACKET 2 TORQUE CONVERTER HOUSING 3 FLYWHEEL HOUSING 4 CAPSCREW 5 TRANSMISSION ASSEMBLY 6 ENGINE ASSEMBLY Figure 26 PSI Flywheel and Torque Converter Housings Engine Replacement 0100 YRM 1766...
Page 30: ...OCK NUT Figure 27 PSI Engine and Frame 1 CAPSCREW 2 WASHER 3 SNUBBING WASHER 4 ISOLATOR 5 LOCKNUT 6 CROSSMEMBER OPTIONAL 7 LEFT ENGINE MOUNT 8 RIGHT ENGINE MOUNT Figure 28 PSI Engine Mounts 0100 YRM 1...
Page 31: ...radiator Remove radiator cap CAUTION Disposal of lubricants and fluids must meed local environmental regulations 4 Open drain plug or disconnect bottom radiator hose to drain coolant from radiator and...
Page 32: ...0LX B974 SHOWN 1 TRANSMISSION ISOLATOR 2 TRANSMISSION MOUNTING BRACKET 3 ENGINE ISOLATOR 4 ENGINE MOUNTING BRACKET 5 FRAME 6 ENGINE WIRING HARNESS 7 CHASSIS WIRING HARNESS Figure 29 Yanmar Diesel Engi...
Page 33: ...Figure 30 Yanmar 2 6L Diesel Engine and Transmission Removal Engine Replacement 0100 YRM 1766 32...
Page 34: ...OOLER LINES 16 ELECTRONIC CONTROL MODULE ECM AND BRACKET 17 FAN 18 FAN PULLEY AND FAN SPACER 19 BOTTOM RADIATOR HOSE 20 FUEL LINE 21 HYDRAULIC SUPPLY HOSE 1 BATTERY LOCKDOWN BAR 2 CAP 3 FLANGE NUT 4 L...
Page 35: ...sing side See Fig ure 34 WARNING The engine is heavy Make sure that any lifting de vice has enough capacity to lift the engine The engine can weigh approximately 194 kg 428 lb 17 Remove flange locknut...
Page 36: ...SING 2 EYEBOLT BRACKET 3 HEX HEAD CAPSCREW 4 FLYWHEEL HOUSING 5 LOCKWASHER 6 FLANGE BOLT 7 TRANSMISSION ASSEMBLY 8 ENGINE ASSEMBLY Figure 34 Yanmar Flywheel and Torque Converter Housings 0100 YRM 1766...
Page 37: ...ix capscrews in torque converter housing and flywheel housing from flywheel housing side Tighten capscrews to 38 N m 28 lbf ft See Fig ure 26 7 Install exhaust pipe to exhaust manifold See Fuel System...
Page 38: ...ne and install four bolts attached flywheel to torque converter See Figure 33 Tighten bolts to 55 N m 41 lbf ft 5 Install six hex head capscrews and six lockwash ers on flywheel housing and torque con...
Page 39: ...truck cannot fall backward Before removing the counterweight put blocks under the mast assembly so the lift truck cannot fall forward The surface must be solid even and level when the lift truck is pu...
Page 40: ...DRAULIC GEAR PUMP INLET PORT 6 HYDRAULIC GEAR OUTLET PUMP 7 HYDRAULIC GEAR PUMP Figure 36 Hydraulic Hose Aluminum Transmission Housing NOTE DRIVE AXLE NOT SHOWN FOR CLARITY 1 MOUNTING BRACKET 2 CAPSCR...
Page 41: ...ew stat o seal on yoke See Figure 38 4 Install spacer yoke and flange head capscrew on back of transmission housing See Figure 38 Tighten capscrew to 77 N m 57 lbf ft 5 Install isolators snubbing wash...
Page 42: ...ion between the bellcrank and cowl plate is 5 1 mm 0 20 0 04 in See Figure 40 3 If dimension is not correct adjust ball ends on push rod so that a minimum of 6 mm 0 24 in of threaded rod screws into e...
Page 43: ...0 Throttle Pedal and Cable Adjustment Yanmar Diesel Engine Cooling System DESCRIPTION The cooling system is used to cool the engine and keep it at the correct operating temperature The cool ing system...
Page 44: ...place in container Cover head to prevent any foreign material from getting into the hydraulic tank See Figure 41 4 After filter element has drained discard filter ele ment and O ring 5 Remove and dis...
Page 45: ...of the tank In spect 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 w...
Page 46: ...n 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 from all the openings 5 F...
Page 47: ...elow the lower flammable limit repeat the cleaning procedures ADDITIONAL PREPARATIONS FOR REPAIR If nitrogen gas or carbon dioxide gas is available pre pare the tank for welding using these gases See...
Page 48: ...l are shown in and Figure 44 See the Parts Manual for a complete listing of all labels used on these lift trucks and their part numbers See Figure 43 for lift truck models below with PSI en gine GLC05...
Page 49: ...Figure 43 Warning and Safety Labels for Lift Trucks with PSI Engine Label Replacement 0100 YRM 1766 48...
Page 50: ...UL LABEL 10 NAMEPLATE 11 NO ONE ON OR UNDER FORKS 12 LOCKING GAS SPRING 13 LIFT AND TILT LABEL 14 FLAMMABLE LP GAS 15 LPG TANK WARNING 16 AIR FILTER INSTALL CAUTION 17 FAN WARNING 18 BORON FREE LABEL...
Page 51: ...Figure 44 Warning and Safety Labels for Lift Trucks with Yanmar Diesel Engine Label Replacement 0100 YRM 1766 50...
Page 52: ...ING 9 TIP OVER WARNING 10 LIFT AND TILT LABEL 11 NOTICE TO USER LABEL 12 NAMEPLATE 13 PINCH POINT WARNING 14 NO ONE ON OR UNDER FORKS 15 NO RIDERS 16 LOCKING GAS SPRING 17 TRANSMISSION LABEL EXAMPLE O...
Page 53: ...n lift truck GLP GDP20 35VX GP GLP GDP040 070VX B875 C875 4TNE92 NMHA 1688253 2 6L engine 2008 Yale Part No 580090035 used in lift truck models GLP GDP16 18VX GLP GDP20SVX GP GLP GDP030 035VX GP GLP G...
Page 54: ...shown in Figure 2 The typical location of the engine nameplate is shown in Figure 2 The engine nameplate is shown in Figure 3 1 ENGINE NAMEPLATE 2 EMISSION CONTROL INFORMATION LABEL Figure 2 Typical...
Page 55: ...GP GLP GDP030VX GP GLP GDP035VX GP GLP GDP040SVX C810 GLP GDP20 35VX GP GLP GDP040 070VX B875 See section Frame 0100YRM1423 for lift truck mod els GLP GDP20 25LX GLP GDP050LX A974 See section Frame 0...
Page 56: ...Figure 4 Cylinder Head Components Cylinder Head Assembly Repair 0600 YRM 1205 4...
Page 57: ...E SPRING 13 VALVE STEM SEAL 14 VALVE GUIDE 15 INTAKE VALVE 16 EXHAUST VALVE 17 CYLINDER HEAD GASKET 18 CYLINDER HEAD 19 GLOW PLUG 20 GLOW PLUG COVER 21 PUSH ROD 22 SUPPORT BRACKET BOLT 23 ROCKER ARM S...
Page 58: ...Plugs Install 1 Install the glow plugs into the cylinder head 2 Connect the glow plug harness to the glow plugs 3 Install the glow plug covers on each glow plug 4 Connect the negative battery cable VA...
Page 59: ...d on the valve cover nuts 5 Install and tighten the valve cover nuts Refer to Standard Torque Specifications ROCKER ARM ASSEMBLY Remove 1 Remove the valve cover See Valve CoverRe move 2 Remove the bol...
Page 60: ...OCKER ARM SHAFT 5 ROCKER ARM SHAFT RETAINING RING 6 SUPPORT BRACKET STUD 7 SUPPORT BRACKET 8 ROCKER ARM SHAFT SPRING 9 ROCKER ARM 10 SUPPORT BRACKET BOLT 11 ROCKER ARM SHAFT RETAINING SCREW 12 CYLINDE...
Page 61: ...2 Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the inspection block 3 Use a feeler gauge to measure the gap Refer to the Engine Specifications f...
Page 62: ...is cold NOTE The cylinder to be adjusted first does not have to be the number one cylinder Select and adjust the cylinder where the piston is the nearest to top dead center TDC after rotating and mak...
Page 63: ...rt a 0 2 mm 0 008 in feeler gauge between the rocker arm and valve cap and adjust the clearance so there is a slight drag on the feeler gauge when sliding it between the rocker arm and valve cap Tight...
Page 64: ...e Fuel System Repair 7 If equipped remove the pull actuator and mount ing bracket See Fuel System Repair 8 Disconnect the electrical connector for the fuel fil ter sensor 9 Tag and disconnect the fuel...
Page 65: ...e intake manifold to the cylinder head and remove the intake manifold and gasket Discard gasket See Figure 15 1 GASKET 2 INTAKE MANIFOLD 3 BOLT 4 CYLINDER HEAD Figure 15 Intake Manifold 0600 YRM 1205...
Page 66: ...pe from the exhaust manifold 13 Remove the bolts retaining the exhaust manifold to the cylinder head and remove the exhaust manifold and gasket Discard gasket See Fig ure 16 1 CYLINDER HEAD 2 BOLT 3 E...
Page 67: ...B FAN SIDE Figure 17 Cylinder Head Bolt Loosening Sequence 17 Remove the cylinder head bolts See Figure 18 18 Lift the cylinder head away from the cylinder block Place the cylinder head on a work benc...
Page 68: ...Remove the spring retainer valve spring and valve stem seal 5 Repeat this procedure until all intake and exhaust valve springs and valve stem seals are removed NOTE If existing valves are going to be...
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