PDF Service Manual Yale A875 (GP/GLP050-060TG) Forklift - 3 MB
This comprehensive service manual provides all the information needed to service and repair the Yale A875 series forklift, covering models GP050TG, GLP050TG, GP060TG, and GLP060TG.
It includes detailed instructions for maintenance, troubleshooting, and major repairs on the engine, transmission, and hydraulic systems.
With clear diagrams and specifications, this manual is an essential tool for any technician working on these reliable machines.
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--- Page 1 ---
Maintenance
COOLING SYSTEM
INTERNAL COMBUSTION ENGINE
POWERED UNITS
PART NO. 524150775 700 YRM 626
--- Page 3 ---
2100 YRM 103 Torque Specifications
Table 1. Movement Rates (Maximum) for Tilt Cylinders (Continued)
Lift Truck Model Hydraulic Oil Temperature/Mast
Tilt Rate
20 C (68 F) 60 C (140 F)
mm/min in./min mm/min in./min
GDP/GLP80-120DB (GP/GDP/ 1.8 0.07 11.7 0.05
GLP170-280DB), GDP/GLP130-160EB
(GP/GDP/GLP300-360EB)
GLC60-70CA (GC/GLC/GDC135-155CA) 1.2 0.05 8.2 0.32
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment
Adjust the tilt cylinders as described in the Mast section.
Torque Specifications
PISTON ROD NUT GLP/GDP300-360EA
1105 to 1140 N•m (815 to 840 lbf ft)
ERP16-20ATF
163 to 190 N•m (120 to 140 lbf ft) GDP/GLP80-120DB (GP/GDP/GLP170-280DB),
GDP/GLP130-160EB (GP/GDP/GLP300-360EB)
ERC20-30AGF (ERC040-065GH) (A908), 950 to 983 N•m (701 to 725 lbf ft)
ERC20-30AGF (ERC040-065RF/ZF RG/ZTG)
(E108), ERP20-30ALF (B216), and ERP20-30ALF GP130-160EB (GP300-360EB)
(ERP040-060DH) (D216/E216) 1105 to 1140 N•m (815 to 841 lbf ft)
150 N•m (110 lbf ft)
GC/GLC030-040AF
ERC35-55HD/HG (ERC070-120HD/HG) (A839) and 163 to 190 N•m (120 to 140 lbf ft)
ERC35-55HG (ERC70-120HH) (B839/C839)
400 to 440 N•m (295 to 325 lbf ft) GC/GLC070-120LG/MG
400 to 440 N•m (295 to 325 lbf ft)
GC/GLC030-040AF, GDP/GLP16-20AF
(GP/GLP/GDP030-040AF), ERC/P16-20AAF GLC60-70CA (GC/GLC/GDC135-155CA)
(ERC030-040AF, AG/BG) (A814), and 407 to 440 N•m (300 to 325 lbf ft)
ERC/P16-20AAF (ERC030-040AH) (B814/C814)
163 to 190 N•m (120 to 140 lbf ft) RETAINER
GC/GLC040-065RG/TG/ZG, GLP/GDP20-30RF/TF ERP16-20ATF
(GP/GLP/GDP040-060RG/TG/ZG) 163 to 176 N•m (120 to 130 lbf ft)
150 N•m (110 lbf ft)
ERC20-30AGF (ERC040-065GH) (A908),
GP/GLP/GDP070-110LG/MG ERC20-30AGF (ERC040-065RF/ZF RG/ZG)
400 to 440 N•m (295 to 325 lbf ft) (E108), ERP20-30ALF (B216), ERP20-30ALF
(ERP040-060DH) (D216/E216)
GDP60-70CA (GP/GLP/GDP135-155CA) 170 to 237 N•m (125 to 175 lbf ft)
407 to 440 N•m (300 to 325 lbf ft)
ERC35-55HD/HG (ERC070-120HD/HG) (A839) and
GLP/GDP165-280DA ERC35-55HG (ERC70-120HH) (B839/C839)
950 to 985 N•m (700 to 725 lbf ft) 400 to 500 N•m (295 to 370 lbf ft)
7
--- Page 4 ---
2200 YRM 0002 General Check and Adjustment
General Check and Adjustment
There are no adjustments for the alternator or most When connecting a charger or another battery, con-
regulators. One Delco alternator and the Leece-Ne- nect the positive terminals to the positive terminal of
ville alternator has a voltage adjustment. the battery. Then connect the negative terminal to a
clean metal part of the engine. Disconnect the
Always check the general condition of the complete charger or other battery in the reverse order. Prob-
system before doing a complete check on each part. lems in the charging circuit are indicated by one or
Check the general condition of the following parts: (1) more of the following:
battery, (2) battery cables and connections, and (3) • The starter motor turns slowly. The battery volt-
alternator and regulator wires and connectors. Also age is low because of low alternator output or a
check the condition and tension of the fan belt for the bad battery.
alternator.
• The specific gravity readings are low. Battery is
not fully charged or is damaged.
CAUTION • The battery uses more than 30 ml (1 oz) of wa-
NEVER operate the engine if the alternator output ter per cell per month. The alternator output is
BAT terminal is not connected to the battery. too high.
Do not short-circuit or connect jumper wires to The two problems of the charging circuit are low out-
any of the alternator terminals unless told to by put and high output. Low output causes a low battery
the procedures. and difficult starting. A high output causes heating of
the battery and evaporation of water from the electro-
Make sure polarity is correct before connecting a lyte. The following two checks will find out if the alter-
battery charger or another battery. nator, regulator, or wiring has a charging fault. The
two checks will also find out if the charging system
Remove the battery cables and clean the terminals has a correct output. Do the following two checks be-
and cable connectors. Inspect the insulation on the fore removal, disassembly, or replacement of alterna-
wires. Make sure all the fasteners and connections tor or regulator.
are clean and tight. If necessary, use a water and
soda solution to clean the top of the battery. Do NOT NOTE: Information on alternators manufactured out-
remove the cell caps or permit the water and soda side the United States is in the YRM sections for lift
solution to get in the battery. trucks that use those alternators.
WARNING
Put the transmission in NEUTRAL. Apply the park-
ing brake.
CAUTION
Do not change the polarity of the circuits. Do not
connect any wires in the circuits, except as de-
scribed in these instructions. Never connect the
wire from the terminal marked BAT to an open cir-
cuit.
13
--- Page 5 ---
2200 YRM 0106 Starter Repair
5. Remove the armature from the drive end housing. 6. Align the marks and install the thrust washer and
Tilt the armature to disengage the linkage from the commutator end frame. Install and tighten the
the drive clutch. On some models it is necessary through bolts.
to remove the linkage before removing the arma-
ture. 7. Make sure the solenoid cover is not damaged. In-
stall the plunger spring and the solenoid. Install
6. Remove the thrust collar from the armature shaft. and tighten the solenoid mount screws. Connect
Put a metal tube with a 13 mm (0.5 in.) inside di- the field coil strap to terminal M with the screw
ameter over the end of the shaft. See Figure 4. and lockwasher.
Hit the tube to move the retainer. Remove the
snap ring. Remove the drive clutch.
7. Remove the center bearing plate. Remove the
seal from the plate.
CLEAN
CAUTION
Never use solvent on the drive clutch, armature,
or field windings. Use a cloth to clean these parts.
Use solvent to clean all parts of the starter, except the
windings and the drive clutch. Dry the parts with com-
pressed air.
ASSEMBLE
1. Install a new seal in the center bearing plate. See
Figure 2 and Figure 5.
2. Lubricate the armature shaft and the bushings
with a silicone lubricant.
3. Put the center bearing plate, drive clutch, retainer,
snap ring, and thrust washer on the armature
shaft. Install the snap ring, thrust washer, and re-
tainer as shown in Figure 5.
4. Install the shaft assembly in the drive end hous- 1. METAL TUBE, 13 mm (0.5 in.) INSIDE DIAME-
ing. Make sure the linkage is engaged in the drive TER
2. RETAINER
clutch. Install and tighten the four screws for the
bearing plate. Figure 4. Retainer Removal
5. Install the field frame over the armature. Retract
the brush springs and slide the brushes on the
commutator.
7
--- Page 6 ---
8000 YRM 0231 General
Table 4. Torque Nuts With Nylon Insert
7
--- Page 7 ---
8000 YRM 0231 General
Table 6. Torque Values for Inch Fasteners*
Grade 21 Grade 52 Grade 83
Size and Pitch
lbf ft N•m lbf ft N•m lbf ft N•m
1/4 1/4 20 UNC 28 45 66 67 9 10 9 10 12 14
UNF
5/16 5/16 18 UNC 24 89 11 13 13 14 18 20 18 20 25 28
UNF
3/8 3/8 16 UNC 24 15 17 20 23 23 26 31 36 33 37 44 50
UNF
7/16 7/16 14 UNC 20 24 27 33 36 37 41 50 56 52 58 71 79
UNF
1/2 1/2 13 UNC 20 37 41 50 56 57 85 77 115 80 90 110 120
UNF
9/16 9/16 12 UNC 18 53 59 72 80 82 91 110 125 115 130 155 175
UNF
5/8 5/8 11 UNC 18 73 83 99 110 115 130 155 175 160 180 215 245
UNF
3/4 3/4 10 UNC 16 130 145 175 200 225 270 300 280 315 380 425
UNF 195
7/8 7/8 9 UNC 14 125 140 170 320 355 435 480 455 500 615 680
UNF 185
11 8 UNC 14 185 210 255 485 540 655 735 680 765 925 1,040
UNF 285
1-1/8 1-1/8 7 UNC 12 265 300 360 595 670 805 905 965 1,080 1,310 1,470
UNF 405
1-1/4 1-1/4 7 UNC 12 375 415 510 840 930 1,140 1,260 1,360 1,500 1,850 2,050
UNF 565
1-3/8 1-3/8 6 UNC 12 490 560 665 1,100 1,250 1,490 1,700 1,780 2,040 2,420 2,760
UNF 760
1-1/2 1-1/2 6 UNC 12 650 735 885 1,460 1,650 1,980 2,230 2,370 2,670 3,210 3,620
UNF 995
* Unless otherwise specified 1 Approximately equal to metric Property Class 5.8 2 Approximately equal to metric
Property Class 8.8 3 Approximately equal to metric Property Class 10.9
9
--- Page 8 ---
2200 YRM 107 Distributor Repair
A. FIRING ORDER 1-3-4-2 C. FIRING ORDER 1-8-4-3-6-5-7-2
B. FIRING ORDER 1-5-3-6-2-4 D. FIRING ORDER 1-6-5-4-3-2
1. FOUR CYLINDER 3. V8
2. SIX CYLINDER 4. V6
Figure 8. Firing Order
11
--- Page 9 ---
2200 YRM 765 Operation
Figure 3. Electronic Engine Control System
Operation
DISTRIBUTOR
The distributor uses an internal magnetic pickup as-
sembly that consists of a permanent magnet, pole piece
with internal teeth and pickup coil. See Figure 4. When
the rotating teeth of the timer core (permanent magnet)
line up with the teeth of the pole piece, voltage is in-
duced in the pickup coil. This voltage signals the igni-
tion control module to trigger the primary ignition circuit
bypass mode. Current flow in the primary circuit is in-
terrupted and a high voltage of up to 35,000 volts is in-
duced in the ignition coil secondary winding. This high
voltage is directed through the secondary ignition circuit
to fire the spark plugs.
The principle of magnetic induction also controls the po-
larity of the voltage generated in the pickup coil. An in-
creasing magnetic field will generate a voltage in the
coil that is the opposite polarity of a magnetic field that
is decreasing. This signal pulse causes the integrated
circuits in the ignition module to generate a square wave
signal. The ignition module and a magnetic pulse gen- 1. ROTOR 5. COIL
erator control the primary circuit to the ignition coil when 2. TIMER 6. POLE PIECE
CORE/SHAFT 7. IGNITION MODULE
the engine is started. After the engine is started, the 3. RETAINER 8. HOUSING
MSTS module receives the square wave signal from the 4. SHIELD
magnetic pulse generator and ignition module as one of
the signals to control the EST. The pole piece has the Figure 4. Distributor
same number of teeth as the engine has cylinders so
that a spark voltage is correctly sent to each spark plug
as the shaft in the distributor rotates.
3
--- Page 10 ---
2200 YRM 765 DTC-14 Engine Coolant Temperature (ECT) (Low Temperature Indicated)
Figure 21. ECT Sensor Troubleshooting Diagram (Low Temperature)
25
--- Page 11 ---
Electronic Engine Control Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description and Operation................................................................................................................................... 1
General ........................................................................................................................................................... 1
Electronic Control Module (ECM).................................................................................................................... 1
Diagnostic Connector ................................................................................................................................. 1
How ECM Begins Operation ....................................................................................................................... 5
Electronic Engine Control................................................................................................................................ 6
What ECM Does ......................................................................................................................................... 6
Distributor ................................................................................................................................................... 8
Ignition Module ........................................................................................................................................... 8
When Engine Is Being Started.................................................................................................................... 9
When Engine Is Running ............................................................................................................................ 10
Electronic Control Module (ECM) with Ignition Module Distributor, Corrections ......................................... 10
Fuel Control..................................................................................................................................................... 11
Throttle Body Injection (TBI) ....................................................................................................................... 12
Fuel Injectors .............................................................................................................................................. 12
Fuel Pressure Regulator ............................................................................................................................. 12
Throttle Position Sensor (TPS) ................................................................................................................... 13
Idle Air Control (IAC)................................................................................................................................... 13
GM 4.3L Engine Governor System ............................................................................................................. 14
GM 3.0L Engine Governor System ............................................................................................................. 14
Vacuum Ports.............................................................................................................................................. 16
Fuel Pump .................................................................................................................................................. 16
ECM Sensors and Controllers......................................................................................................................... 18
Manifold Absolute Pressure (MAP)............................................................................................................. 18
Engine Coolant Temperature (ECT) Sensor ............................................................................................... 18
This section is for the following models:
GM 3.0L EngineGP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-
060RG/TG/ZG) [A875];
GC/GLC040-065RG/TG/ZG [E187]
GM 4.3L EngineGDP60-70CA (GP/GLP/GDP135-155CA) [A878];
GLC60-70CA (GC/GLC/GDC135-155CA) [A879];
GP/GLP/GDP070-110LG/MG [B813];
GC/GLC070-120LG/MG [B818]
©2003 Yale Materials Handling Corp. i
--- Page 12 ---
Maintenance
ELECTRONIC ENGINE
CONTROL
TROUBLESHOOTING AND REPAIR
GM 3.0L ENGINE
GP/GLP/GDP2.00-3.00RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) [A875];
GC/GLC040-065RG/TG/ZG [E187]
GM 4.3L ENGINE
GDP60-70CA (GP/GLP/GDP135-155CA) [A878];
GLC60-70CA (GC/GLC/GDC135-155CA) [A879];
GP/GLP/GDP070-110LG/MG [B813];
GC/GLC070-120LG/MG [B818]
PART NO. 524153918 2200 YRM 782
--- Page 13 ---
2200 YRM 782 A-3 - Starter Rotates Engine, Engine Will Not Run
A-3 - Starter Rotates Engine, Engine Will Not Run
CIRCUIT DESCRIPTION
Before using this chart, battery condition, engine crank-
ing speed, and fuel quantity must be checked to make
sure they are correct. See Figure 12.
Figure 12. Chart A-3 - Starter Rotates Engine, Engine Will Not Run
TEST DESCRIPTION 4. Test light will flash, indicating the ECM is controlling
the injector.
The numbers below are a reference to the bold numbers
in Figure 13. 5. Fuel spray from the injector indicates that fuel is
available. However, the engine can be getting too
1. A Malfunction Indicator Lamp ON is a test to deter- much fuel. No fuel spray from injector indicates a
mine if there is battery and ignition voltage at the fault in the fuel system or no ECM control of injector.
ECM.
• If no SCAN data is caused by an ECM problem, OTHER TROUBLESHOOTING CHECKS
Figure 11 will diagnose the ECM.
• If throttle or coolant sensors are not within these • Water or foreign material can cause a no start con-
ranges, the ECM can be using the wrong mode dition during freezing weather. The engine can start
for starting. after approximately 5 minutes in a heated shop.
• SCAN Tool will display RPM during cranking if • A MAP sensor voltage reading between 0.5 to 3.0
pulses are received at the ECM. volts can cause a no start condition. Disconnect the
MAP sensor. If the engine starts, replace the MAP
2. If RPM was indicated during crank, the ignition sensor. See MAP Sensor, Replace in Sensors Re-
module is receiving a crank signal, but No Spark pair.
at this test indicates the ignition module is not • If fuel pump fuse is damaged, test current draw of
triggering the coil. pump motor in tank. If more than 5 to 6 amps, correct
the circuit or replace the pump motor in the tank.
3. While cranking engine, there must be no fuel spray
with the injector electrical connector disconnected.
Replace injector or seals if fuel sprays or drips.
17
--- Page 14 ---
2200 YRM 782 DTC 31 Engine Governor Circuit
DTC 31 Engine Governor Circuit
CIRCUIT DESCRIPTION by loosening the throttle cable. The system is capable
of reducing the throttle back to near idle position.
The ECM sends a controlled signal pulse to the gov-
ernor control module (circuit JR) to drive the governor A DTC 31 will find a damaged ECM, governor module,
motor. See Figure 32. motor, linkage, or wiring. If DTC 31 is set, the ECM will
limit engine RPMs by momentarily reducing fuel (at a
Depending on the need of the engine for the governor, slightly higher RPMs than governor calibration).
the module translates the ECM data into the correct
value of D.C. current (circuits JP and JQ) to the mo-
tor. This current causes the motor to limit engine speed
Figure 32. DTC 31 Engine Governor Circuit
TEST DESCRIPTION 2. Applying Battery + to motor will not let the throttle
plate open.
The numbers below are a reference to bold numbers in
Figure 33. 3. This test requires complete governor control to de-
termine if ECM or governor system has a fault.
DTC 31 will set if the ECM is commanding near 100% Throttle plate must not open during this test.
authority.
OTHER TROUBLESHOOTING CHECKS
1. This check determines if the governor control mod-
ule has a voltage supply to operate. A SCAN Tool displays governor TPS. Watch this value
as engine rpm increases beyond the governor limits.
CAUTION This test will allow you to see the ECM’s control try to
limit engine speed.
DO NOT hold current to the motor for longer than
30 seconds, as the motor can be damaged.
39
--- Page 15 ---
2200 YRM 782 B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test
Figure 49. Chart B-2 - Manifold Absolute Pressure (MAP) Sensor Output Test
61
--- Page 16 ---
2200 YRM 782 Wiring
NOTE: Not all Metri-Pack connectors have a seal.
Do the following procedures to remove and install a ter-
minal:
1. Open any secondary locks that hold wires and
seals in their positions. Slide seals along wires
from ends of connector.
2. Hold wire and use it to push terminal to its forward
position in connector body. Hold terminal in this
position.
3. Find lock tab for terminal in connector channel.
Push a removal tool (pick) of correct size into con-
nector channel. See Figure 78 and Figure 80.
1. WIRE 4. YALE TOOL KIT
2. TERMINAL OTC P/N 7733
3. LOCK TAB
Figure 78. Micro-Pack Connector
Metri-Pack® Connectors, shown in Figure 79, come in
several sizes and types that are used on the wire har-
ness. These connectors are made by Packard Electric 1. PICK 3. TERMINAL
Company. The typical connectors used on lift trucks 2. LOCK TAB 4. CONNECTOR
are No. 56, No. 150, No. 280, No. 480, and No. 630. BODY
Some of these connectors are push-to-seat and others
Figure 80. Metri-Pack Pull-to-Seat Connector
are pull-to-seat. Make sure connector is correctly iden-
tified before it is changed. Terminals can be damaged 4. Use removal tool to move lock tab and release ter-
if they are removed or installed wrong. minal from its seat.
Push-To-Seat - Gently pull wire to remove terminal
from back of connector. See Figure 80.
Pull-To-Seat - Gently push wire to remove terminal
through front of connector. See Figure 81.
CAUTION
Work carefully and do not use enough force to dam-
age terminal or connector.
5. Inspect terminal and connector for damage. Make
repairs as necessary. See Figure 82.
1. PICK 3. TERMINAL 6. If terminal will be used again, make sure lock tab
2. LOCK TAB 4. CONNECTOR
BODY is correctly bent so that terminal will be locked in
connector again.
Figure 79. Metri-Pack Push-to-Seat Connector
83
--- Page 17 ---
100 YRM 505 Counterweight Repair
Counterweight Repair
slowly. Fuel leaving the fitting removes heat. Use a
WARNING cloth to protect your hands from the cold fitting.
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the 1. If the lift truck has an LPG fuel system, use the
following assemblies will cause large changes in following procedure to remove the LPG tank and
the center of gravity: mast, drive axle, engine and bracket so that the counterweight can be removed.
transmission, and counterweight. When the lift See Figure 5.
truck is put on blocks, put additional blocks in the
following positions to maintain stability: Additional information on the LPG fuel system can
• Before removing the mast and drive axle, put be found in the following sections:LPG Fuel Sys-
blocks under the counterweight so the lift truck tem, GM 2.2L and 3.0L Engines 900 YRM 498,
cannot fall backward. LPG Fuel System, Mazda FE Engine 900 YRM
• Before removing the counterweight, put blocks 523, or Electronic Controlled LPG/Gasoline Fuel
under the mast assembly so the lift truck cannot System, GM 3.0L and 4.3L EPA Compliant En-
fall forward. gines 900 YRM 1088.
The surface must be solid, even, and level when a. LPG tanks can be removed and replaced in-
the lift truck is put on blocks. Make sure that any doors only if the lift truck is at least 8 m (26 ft)
blocks used to support the lift truck are solid, one- from any flame or ignition source.
piece units. See the Operating Manual or Periodic
b. Move the lift truck to the area where tanks are
Maintenance 8000 YRM 707 for your lift truck.
changed.
The counterweight is held in position on the frame by
c. Turn the shutoff valve clockwise until the valve
two hooks that are part of the frame. One M24 × 3
is completely closed.
capscrew holds the counterweight to the lower part of
the frame. d. Run the engine until it stops, then turn the key
switch to the OFF position.
REMOVE
e. Disconnect the quick-disconnect fitting.
WARNING f. Release the LPG tank latch and remove the
Do not operate the lift truck if the capscrew for the tank from the bracket.
counterweight is not installed. When the capscrew
is removed, the counterweight can fall from the lift 2. If an overhead exhaust is installed, remove it as