Yale A7S1 Manual de usuario

Maintenance

A7S1

SERVICE MANUAL

GLP/GDP20UX, GLP/GDP25UX, GLP/GDP30UX, GLP/

GDP35UX

PART NO. 550216372 8000 YRM 2199

INTRODUCTION

The Service Manuals are updated on a regular basis, but may not reflect the latest design changes to the product.

Updated technical service information may be available from your local authorized YALE® distributor. Service

Manuals provide general guidelines for maintenance and service and are intended for use by trained and

experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service

Manual could result in damage to the products, personal injury, property damage or death.

FOREWORD

This manual describes the structure and working principles of the 2-3.5T internal combustion forklift truck and

provides instructions for servicing and maintenance.

To ensure safety and get the best out of your forklift, all operators, equipment managers and maintenance

personnel should carefully read this manual.

Only trained and qualified personnel are permitted to carry out servicing and repairs on the forklift truck.

Series Model Engine Transmission

2-2.5T

GLP/GDP20-25UX NISSAN K21 LPG YQXD30H(PHF)

GLP/GDP20-25UX NISSAN K21 GAS YQXD30H(PHF)

GLP/GDP20-25UX NISSAN K21 DUAL YQXD30H(PHF)

GLP/GDP20-25UX NISSAN K25 LPG YQXD30H(PHF)

GLP/GDP20-25UX NISSAN K25 GAS YQXD30H(PHF)

GLP/GDP20-25UX NISSAN K25 DUAL YQXD30H(PHF)

Series Model Engine Transmission

2-2.5T

GLP/GDP20-25UX MITSUBISHI S4S-455 YQXD30(PHF)

GLP/GDP20-25UX PSI 4G64 2.4L YQXD30(PHF)

GLP/GDP20-25UX XINCHAI 4D27G31 YQXD30A(PHF)

GLP/GDP20-25UX YANMAR 4TNE92 YQXD30(PHF)

3-3.5T

GLP/GDP30-35UX NISSAN K25 LPG YQXD30H(PHF)

GLP/GDP30-35UX NISSAN K25 GAS YQXD30H(PHF)

GLP/GDP30-35UX NISSAN K25 DUAL YQXD30H(PHF)

GLP/GDP30-35UX MITSUBISHI S4S-455 YQXD30(PHF)

GLP/GDP30-35UX PSI 4G64 2.4L YQXD30(PHF)

GLP/GDP30-35UX XINCHAI 4D27G31 YQXD30A(PHF)

GLP/GDP30-35UX YANMAR 4TNE94 YQXD30(PHF)

GLP/GDP30-35UX YANMAR 4TNE98 YQXD30(PHF)

NOTE: DUAL designates DUAL FUEL or BI-FUEL.

TABLE OF CONTENTS

Forklift Truck Main Parts......................................................................................................................................... 1

Description of Forklift Truck Main Parts................................................................................................................1

Forklift Main Technical Parameters......................................................................................................................... 2

Main Technical Parameters.................................................................................................................................. 2

Power System......................................................................................................................................................... 5

Engine System......................................................................................................................................................5

Engine Overview................................................................................................................................................5

Fuel System....................................................................................................................................................... 6

Fuel Tank.........................................................................................................................................................7

Fuel Level Sensor............................................................................................................................................8

Maintenance of Fuel System...........................................................................................................................9

Fuel filter service...........................................................................................................................................9

Hydraulic Transmission Case and Torque Converter............................................................................................10

Overview.............................................................................................................................................................10

Torque Converter................................................................................................................................................ 11

Hydraulic Clutch..................................................................................................................................................12

Control Valve, Safety Valve, and Inching Valve.................................................................................................. 13

Transmission Case............................................................................................................................................. 15

Transmission Pump............................................................................................................................................ 15

Transmission hydraulic schematic .....................................................................................................................15

Speed Reducer and Speed Differential.............................................................................................................. 16

Speed Reducer................................................................................................................................................ 16

Speed Differential.............................................................................................................................................17

Towing the Lift Truck...........................................................................................................................................17

Oil Inlet/Outlet Connection Location................................................................................................................... 17

Drive Axle..............................................................................................................................................................18

Overview.............................................................................................................................................................18

Maintenance of Drive Axle..................................................................................................................................19

Steering System....................................................................................................................................................20

Steering System................................................................................................................................................. 20

Overview.......................................................................................................................................................... 20

Hydraulic Steering Gear Assembly................................................................................................................20

Steering Cylinder...........................................................................................................................................21

Inspection of Reassembled Steering System.................................................................................................. 22

Troubleshoot Steering System.........................................................................................................................23

Steering and Drive Axle Information..................................................................................................................... 24

Steering Axle...................................................................................................................................................... 24

Overview.......................................................................................................................................................... 24

Steering Knuckle and Steering King Pin.......................................................................................................... 25

Steering Wheel Bearing Pre-load Information..................................................................................................26

Brake System........................................................................................................................................................26

Overview.............................................................................................................................................................27

Brake Master Cylinder........................................................................................................................................ 27

Wheel Brake....................................................................................................................................................... 27

Automatic Brake Adjuster................................................................................................................................... 31

Manual Brake......................................................................................................................................................32

Adjustment of Brake Pedal................................................................................................................................. 32

Maintenance....................................................................................................................................................... 32

Disassemble, Wheel Brake..............................................................................................................................33

Examination of Wheel Brake............................................................................................................................35

Assemble, Wheel Brake...................................................................................................................................36

Operating Test Automatic Clearance Regulator...............................................................................................38

Table of Contents

TABLE OF CONTENTS (Continued)

Troubleshoot Wheel Brake...............................................................................................................................39

Hydraulic System.................................................................................................................................................. 41

Overview.............................................................................................................................................................41

Steering Control Unit.......................................................................................................................................... 42

Multi-way Valve and Priority spool .....................................................................................................................42

Operation of Spool Valve................................................................................................................................. 42

Neutral Position............................................................................................................................................. 42

Spool Valve (Pushed In):...............................................................................................................................43

Spool Valve (Pulled out):............................................................................................................................... 43

Primary Relief Valve and Priority Spool........................................................................................................... 43

Inclined Auto-Lock Valve..................................................................................................................................44

Hydraulic System Main Oil Circuit ..................................................................................................................... 45

Lift Cylinder.........................................................................................................................................................47

Velocity Fuse...................................................................................................................................................... 49

Tilt Cylinder.........................................................................................................................................................50

Maintenance of Hydraulic Pump.........................................................................................................................51

Disassemble, Main Oil Pump...........................................................................................................................51

Inspection and Repair...................................................................................................................................... 51

Assemble, Main Oil Pump................................................................................................................................54

Test...................................................................................................................................................................55

Troubleshoot Hydraulic System..........................................................................................................................59

Lifting System........................................................................................................................................................60

Safety Procedures When Working Near Mast....................................................................................................60

Overview.............................................................................................................................................................62

Inside and Outside Masts................................................................................................................................... 62

Carriage..............................................................................................................................................................63

Adjustment of Lifting System.............................................................................................................................. 63

Electrical System...................................................................................................................................................64

Overview.............................................................................................................................................................64

Power supply system....................................................................................................................................... 64

Starting system................................................................................................................................................ 64

Ignition system (ICE forklift truck).................................................................................................................... 64

Preheating system (diesel forklift truck)........................................................................................................... 64

Dash Instrument Display System.....................................................................................................................65

Lighting, sound and alarm system................................................................................................................... 65

Electrical Box......................................................................................................................................................65

Battery................................................................................................................................................................ 65

Description and Summary of Basic Truck Operations........................................................................................ 65

Introduction to the Power Distribution Module (PDM)........................................................................................ 67

Electrical Schematics..........................................................................................................................................67

Troubleshoot Electrical System.......................................................................................................................... 81

Troubleshooting............................................................................................................................................... 81

Drive, Operation, and Routine Maintenance of Forklift Truck............................................................................... 82

Cooling System Troubleshooting and Service....................................................................................................82

Coolant level check..........................................................................................................................................82

Flushing the cooling system.............................................................................................................................82

Adding antifreeze/coolant.................................................................................................................................82

Cleaning the radiator........................................................................................................................................82

Oils Used for Forklift Truck................................................................................................................................. 83

Hydraulic Oil Gauge and Hydraulic Oil fill...........................................................................................................83

General inspection requirements..................................................................................................................... 83

Fill Level Requirements....................................................................................................................................83

Table of Contents

TABLE OF CONTENTS (Continued)

Lubrication System............................................................................................................................................. 83

PDM Schematics...................................................................................................................................................85

Table of Contents

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