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Yale GLP20LX User Manual

Yale GLP20LX
69 pages
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GLP20LX, GLP25LX, GDP20LX, GDP25LX (B974)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 550109110 0100 YRM 1766 12/14
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
PSI 2.4L ENGINE............................................................................................................ 550108890 0600 YRM 1755 12/14
COOLING SYSTEM........................................................................................................ 550109111 0700 YRM 1767 12/14
FUEL SYSTEM PSI 2.4L................................................................................................ 550108892 0900 YRM 1757 12/14
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550108495 1300 YRM 1740 12/14
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 550109112 1400 YRM 1768 12/14
STEERING AXLE REPAIR............................................................................................. 550109113 1600 YRM 1769 12/14
BRAKE SYSTEM............................................................................................................ 550108498 1800 YRM 1743 12/14
HYDRAULIC 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)....................................................... 550109114 2100 YRM 1770 12/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
ELECTRICAL SYSTEM.................................................................................................. 550109115 2200 YRM 1771 12/14
ENGINE ELECTRICAL SYSTEM, PSI 2.4L ENGINE..................................................... 550109116 2200 YRM 1772 12/14
MAST REPAIR (S/N A698 AND A699)........................................................................... 550109117 4000 YRM 1773 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
PERIODIC MAINTENANCE............................................................................................ 550109197 8000 YRM 1774 12/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550109119 8000 YRM 1775 12/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550109120 8000 YRM 1776 12/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 550022929 9000 YRM 1434 12/14
PART NO. 550109188 (12/14)

Table of Contents

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Yale GLP20LX Specifications

General IconGeneral
ModelGLP20LX
Load Capacity2000 kg
Mast Type2-Stage / 3-Stage
Rated Capacity2000 kg
Overall Width1150 mm
Lift Height3000 mm
CategoryForklifts
Lift Speed (loaded/unloaded)0.45/0.55 m/s
Lowering Speed (loaded/unloaded)0.5 m/s

Summary

General Lift Truck Information

Frame Description and Components

Overview of the lift truck frame and its connected parts, including diagrams and component identification.

Hood, Seat, and Side Covers Replacement

Remove Hood, Seat, and Side Covers

Step-by-step guide for removing hood, seat, and side covers for service or access.

Install Hood, Seat, and Side Covers

Procedures for correctly installing hood, seat, and side covers after maintenance.

Steering Column Service

Steering Column Repair Procedures

Detailed instructions for removing, disassembling, cleaning, and installing the steering column assembly.

Counterweight Replacement

Remove Counterweight Safely

Safety precautions and steps for safely removing the counterweight, including lifting procedures.

Install Counterweight Correctly

Procedures for correctly installing the counterweight, including lifting and securing.

Overhead Guard Replacement

Remove Overhead Guard Assembly

Steps and safety notes for removing the overhead guard assembly.

Install Overhead Guard Assembly

Instructions for re-installing the overhead guard, ensuring proper wiring and security.

Overhead Guard Rain Top Service

Procedures for removing, cleaning, inspecting, and installing the optional overhead guard rain top.

Operator Restraint System Service

Emergency Locking Retractor (ELR) Checks

Checks and replacement procedures for the seat belt and its locking mechanism.

Engine Replacement Procedures

Engine Removal Steps

Procedures for removing the engine, including safety warnings and considerations for different engine types.

Engine Installation Steps

Steps for installing the engine, including connecting components and fluids.

Transmission Replacement

Transmission Removal Steps

Steps and safety precautions for removing the transmission, including draining fluids.

Transmission Installation Steps

Procedures for installing the transmission, including filling fluids and connecting components.

Throttle Pedal and Cable Adjustment

PSI 2.4L Engine Throttle Pedal Stop Adjustment

Adjusting the pedal stop on PSI 2.4L engines for proper floor contact.

Yanmar Diesel Engine Throttle Pedal and Cable Adjustment

Adjusting the throttle pedal and cable on Yanmar diesel engines for correct operation.

Cooling System Overview

Cooling System Components Description

Overview of the cooling system components and their function in engine temperature regulation.

Hydraulic Filter Maintenance

Hydraulic Filter Removal Procedure

Step-by-step instructions for safely removing the hydraulic filter, including precautions for hot oil.

Hydraulic Filter Installation Procedure

Procedures for installing a new hydraulic filter, including lubrication and sealing.

Tank Repair and Cleaning

Tank Inspection for Leaks and Damage

Visual inspection procedures for hydraulic and diesel tanks, checking for leaks and weld integrity.

Tank Cleaning Methods

Methods for cleaning tanks, including steam and chemical solutions, with safety warnings.

Lift Truck Label Replacement

Safety Label Installation Guidelines

Procedures for correctly applying safety and identification labels to the lift truck.

Yanmar Diesel Engine General Information

Yanmar Engine Component Identification

Identification of major engine components for Yanmar diesel engines, with diagrams.

Yanmar Engine Label Locations

Typical locations of engine nameplate and emission control information labels.

Cylinder Head Assembly Repair

Glow Plug Service

Procedures for removing and installing glow plugs, including electrical connections.

Valve Cover Service

Steps for removing and installing the valve cover, including gasket replacement.

Rocker Arm Assembly Service

Instructions for removing, disassembling, cleaning, and assembling the rocker arm mechanism.

Valve Clearance Adjustments

Procedures for measuring and adjusting valve clearances for proper engine timing.

Cylinder Head Assembly Removal

Steps for removing and disassembling the cylinder head, including fuel system components.

Valves and Valve Springs Service

Procedures for removing and reinstalling valve springs, keepers, and seals.

Valve Guides Removal

Instructions for removing valve guides from the cylinder head.

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