Yale Forklift A7S6 (GP40UX, GP45UX, GP50UX5) Service Manual PDF

Yale Forklift A7S6 (GP40UX, GP45UX, GP50UX5) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift A7S6 (GP40UX, GP45UX, GP50UX5) Service Manual – PDF DOWNLOAD

Language : English
Pages : 440
Downloadable : Yes
File Type : PDF

PART NO. 550277201

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yale Forklift A7S6 (GP40UX, GP45UX, GP50UX5) Service Manual – PDF DOWNLOAD

550277201 0100YRM5001 (09 2023) US EN 1
General 7
Description 8
Hood, Seat, Floor Plate and Covers Replacement 10
Disassemble (4-5T Trucks) 10
Re-assemble 16
Steering Column 17
Description 17
Steering Column Repair 17
Disassemble 17
Disassemble Steering Hoses 19
Clean 20
Inspect 20
Re-assemble 20
Counterweight Replacement 21
Remove (4-5T Trucks) 21
Remove (5-7T Trucks) 23
Install (4-5T Trucks) 25
Install (5-7T Trucks) 25
Overhead Guard Replacement 26
Remove and Install 26
Operator Restraint System Replacement 29
Description 29
Emergency Locking Retractor (ELR) 29
Engine and Transmission Replacement 30
Remove 30
Disassemble (4-5T Trucks) 30
Disassemble (5-7T Trucks) 31
Re-assemble (4-5T Trucks) 33
Re-assemble (5-7T Trucks) 33
Exhaust System Repair 34
Remove and Disassemble Exhaust System 34
Inspect 34
Re-assemble Exhaust System 34
Cooling System 35
Description 35
Hydraulic Filter Assembly Repair 36
Disassemble 36
Clean and Inspect 37
Re-assemble 38
Fuel and Hydraulic Tanks Repair 39
Inspect 39
Clean 39
Steam Method of Cleaning 39
Chemical Solution Method of Cleaning 40
Additional Preparations for Repair 41
Small Leaks, Repair 41
Large Leaks, Repair 41
Preparations for Use After Repair 41
Safety Labels 42
550277203 0700YRM5003 (08 2023) US EN 47
General 53
Cooling System Checks 53
Water Flow Restrictions in Radiator 53
Radiator Hoses 53
Water Pump 53
Flushing the Cooling System 54
Cooling System, Clean 54
Radiator Replacement (4-5T Trucks) 56
Remove Radiator 56
Install Radiator 60
Radiator Replacement (5-7T Trucks) 61
Remove Radiator 61
Install Radiator 65
Fan Assembly Replacement 66
Fan Removal 66
Inspect 67
Fan Installation 67
550277204 0900YRM5004 (07 2023) US EN 69
Air-Intake and Exhaust System 75
Air-Intake and Exhaust System (Mitsubishi S6S and Mitsubishi S6S-T Engine) 75
Remove 75
Inspect 75
Install 75
Air-intake System (Kubota Engine) 77
Remove 77
Install 77
LPG Tank and Bracket Replacement with Swing-Out Bracket (Kubota WG3800 Engine) 78
Remove LPG Tank 78
Install LPG Tank 79
Remove LPG Bracket 79
Install LPG Bracket 80
Fuel Filter and Fuel Level Sensor Repair 81
FUEL FILTER ELEMENT (4-5T Trucks) 81
Remove 81
Install (4-5T Trucks) 82
Fuel Level Sensor (4-5T Trucks) 82
Remove (4-5T Trucks) 82
Install (4-5T Trucks) 82
FUEL FILTER ELEMENT (5-7T Trucks) 82
Remove 82
Install (5-7T Trucks) 83
Fuel Level Sensor (5-7T Trucks) 83
Remove (5-7T Trucks) 83
Install (5-7T Trucks) 83
LPG Converter (Kubota WG3800 Dual Fuel Engine) 84
Remove 84
Exhaust System 87
Remove (4-5T Trucks) 87
Install (4-5T Trucks) 89
Remove (5-7T Trucks) 93
Install (5-7T Trucks) 98
550286759 1300YRM5005 (07 2023) US EN 101
General 107
Serial Number 108
Transmission 109
Remove and Install 109
Remove 109
Remove Transmission 109
Remove Torque Converter 111
Remove Speed Differential 111
Remove Speed Reducer 112
Disassemble Output Shaft 112
Remove Control Valve and Solenoid Valve 118
Remove Transmission Box 118
Remove Clutch I 118
Remove Clutch II 120
Remove Torque Converter Housing 122
Remove Torque Converter 122
Installation 122
Install Torque Converter 122
Install Clutch I 122
Install Clutch II 123
Install Torque Converter Housing 123
Install Transmission Box 123
Install Speed Differential 123
Re-assemble Output Shaft 123
Install Speed Reducer 123
Install Control Valve and Solenoid Valve 123
Install Torque Converter 124
Clean and Inspect 124
Pedal 125
Remove and Install 125
Remove Pedal 125
Install Pedal 126
Clean and Inspect 126
550286760 1400YRM5006 (07 2023) US EN 129
General 135
Drive Axle Repair 135
Remove and Disassemble 135
Clean and Inspect 140
Re-assemble and Install 140
550286761 1600YRM5007 (09 2023) US EN 143
General 149
Steering Axle Assembly Repair 151
Remove 151
Disassemble (4-5T Trucks) 152
Disassemble (5-7T Trucks) 154
Clean 156
Inspect 156
Re-assemble (4-5T Trucks) 156
Re-assemble (5-7T Trucks) 157
Reinstall 158
Steering Cylinder Repair 159
Remove and Disassemble (4-5T Trucks) 159
Remove and Disassemble (5-7T Trucks) 160
Clean and Inspect 161
Assemble and Install (4-5T Trucks) 161
Assemble and Install (5-7T Trucks) 162
550286762 1800YRM5008 (07 2023) US EN 165
GENERAL 171
SERVICE BRAKE REPAIR 172
REMOVE AND DISASSEMBLE 172
CLEAN 174
INSPECT 174
ASSEMBLE AND INSTALL 175
ADJUST 175
PARKING BRAKE REPAIR 176
REMOVE AND DISASSEMBLE 176
ASSEMBLE AND INSTALL 177
ADJUST 177
MASTER CYLINDER REPAIR 178
REMOVE 178
INSTALL 179
BRAKE SYSTEM TROUBLESHOOTING 180
SERVICE BRAKE ADJUSTMENT 181
SERVICE BRAKE AIR REMOVAL 181
550286763 1900YRM5009 (07 2023) US EN 183
Cylinder 189
General 189
Safety Procedures When Working Near Mast 189
Integral Sideshift Cylinder Repair 189
Remove 189
Disassemble 191
Clean 191
Inspect 192
Re-assemble 192
Install 192
Check Integral Sideshift Cylinder Guide Sleeve Leak 192
Free-Lift Cylinder 193
Remove 193
Disassemble and Re-assemble 195
Clean 195
Inspect 196
Install 198
Main Lift Cylinder Repair 198
Remove 198
Disassemble and Re-assemble 200
Clean 200
Inspect 200
Install 201
MAIN LIFT CYLINDER LEAK CHECK 201
Tilt Cylinder Repair 201
Remove 201
Disassemble and Re-assemble 204
Clean 204
Inspect 204
Install 204
Hydraulic Gear Pump 205
General 205
Hydraulic Gear Pump Repair 206
Remove 206
Disassemble 208
Re-assemble 209
Examination and Repair 210
Pump Body 210
Bearing 211
Gear 212
Oil Seal 212
Main Control Valve 213
General 213
Main Control Valve 213
Description 213
Remove 215
Clean and Inspect 219
Install 219
550286764 2200YRM5010 (09 2023) US EN 221
General 227
Combination Switch 227
Remove and Install 227
Display and Rocker Switch 229
Remove and Install 229
Battery and Power Distribution Module 231
Remove and Install (4-5T Trucks) 231
Remove and Install (5-7T Trucks) 232
Auxiliary Relay and Fuse Box 233
Remove and Install 233
Sensors and Switches 234
General 234
Accelerator Pedal Position Sensor 234
Remove and Install 234
Parking Brake Sensor 234
Remove and Install 234
Fuel Level Sensor (4-5T Trucks) 235
Remove and Install 235
Fuel Level Sensor (5-7T Trucks) 236
Remove and Install 236
Torque Converter Temperature Sensor 237
Remove and Install 237
Engine Coolant Temperature Sensor 238
Remove and Install 238
Oil Pressure Sensor 240
Remove and Install 240
Lights 243
Lights 243
Remove and Install 243
550286765 4000YRM5011 (09 2023) US EN 245
General 251
Safety Procedures When Working Near Mast 252
Fork Replacement 253
Standard Carriage and Integral Sideshift Carriage 253
Remove 253
Install 254
Checks 254
Carriages Repair, Three-Stage FFL Mast 256
Standard Carriage 256
Remove 256
Clean and Inspect 256
Install 257
Integral Sideshift Carriage 257
Remove 257
Clean and Inspect 261
Assemble 261
Install 261
Three-Stage Mast With Full Free-Lift Repair 262
Remove 262
Disassemble and Re-assemble 263
Clean and Inspect 265
Carriage Adjustments 266
Lift Chains Adjustment 267
Mast Adjustments 268
Load Roller, Adjust 268
Mast Side Kicking, Adjust 269
550286766 8000YRM5012 (07 2023) US EN 271
Electrical Schematics 277
Electrical Schematics 277
Hydraulic Schematics 280
Hydraulic System Main Oil Circuit 280
Power Distribution Module (PDM) Schematics 282
550286767 8000YRM5013 (07 2023) US EN 309
General 315
How to Move a Disabled Truck 315
How to Tow Truck 315
How to Put a Truck on Blocks 316
How to Raise Drive Tires 316
How to Raise Steering Tires 316
HOW TO CLEAN A Truck 317
Maintenance Schedule 319
Periodical Maintenance 319
Oils Used for Truck 340
Maintenance Procedures Every 8 Hours or Daily 341
How to Make Checks With Engine Stopped 341
Tires and Wheels 341
Safety Labels 341
Mast, Carriage, Lift Chains, Header Hoses, and Attachment 341
Emergency Locking Retractor (ELR) 342
Adjust Seat – Standard Full Suspension 342
Hood and Seat Latches 343
Engine Compartment 343
Fuel, Oil, and Coolant Leaks, Check 343
Hydraulic Hoses 344
Coolant Hoses 344
Steering Column 344
Transmission 344
Hydraulic System Oil 344
Engine Oil 344
Check Engine Oil Level 344
Forks 345
Inspect 345
Remove 346
Adjust 346
How to Make Checks With Engine Running 346
Indicator Lights, Horn, Fuses, and Relays 346
Service Brakes 349
Operation, Check 349
Parking Brake 349
Engine Oil Pressure 349
Cooling System 349
Steering System 349
Control Levers and Pedals 349
Lift System, Operate 350
Maintenance Procedures Every 50 Hours or Daily 351
Kubota V3800 Engine 351
Fuel Tank Water Drainage (Mitsubishi Engine S6S) 351
Maintenance Procedures Every 250 Hours or Quarterly 352
Mitsubishi Engine S6S 352
Engine Oil and Oil Filter 352
Drain Engine Oil 352
Refill Engine Oil 352
Change Oil Filter 353
Inspect and Adjust Belt and Tension 354
Inspect Belt 354
Adjust Belt Tension (Alternator Side) 354
Check and Clean Radiator Fins 355
Kubota V3800 Engine and Kubota WG3800 Engine 355
Check Radiator Hose and Clamp Bands 355
Clean Air Cleaner Primay Element 356
Adjust Fan Belt Tension 357
Maintenance Procedures Every 500 Hours or Semi-annually 360
Mitsubishi Engine S6S 360
Replace Fuel Filter 360
Kubota V3800 Engine and Kubota WG3800 360
Change Engine Oil 360
Replace Oil Filter Cartridge 362
Replace Water Separator Filter – Kubota V3800 Engine 362
Cleaning Water Jacket and Radiator Interior – Kubota V3800 Engine 363
Maintenance Procedures Every 1000 Hours or Annually 366
Mitsubishi Engine S6S 366
Inspect Starter 366
Inspect Alternator 366
Kubota V3800 Engine 366
Check Valve Clearance 366
Kubota WG3800 Engine 369
Check Valve Clearance 369
Maintenance Procedures Every 1500 Hours or Annually 370
Kubota V3800 Engine and Kubota WG3800 Engine 370
Replace Air Cleaner Element 370
Kubota WG3800 Engine 370
Clean Water Jacket and Radiator Interior 370
Maintenance Procedures Every 3000 Hours or Two Years 372
Mitsubishi Engine S6S 372
Change Coolant 372
Safety Procedures When Working Near Mast 373
550286768 8000YRM5014 (07 2023) US EN 375
Truck Main Technical Parameters 381
Main Technical Parameters 381
Truck Lifting Capacity 393
Counterweight Weights 393
Tire Sizes 393
Capacities 394
Recommended Lubricants 395
Lubricant Specifications 395
Electrical System 396
Transmission Oil Pressures 397
Hydraulic System Relief Pressures 397
Steering System 398
Mast Speeds 398
Tilt Angles 398
Engine Specifications 399
550286769 8000YRM5015 (07 2023) US EN 403
Operator Station General Description and Principles of Operation 409
General Description and Location 409
Display Switch Cluster 411
Dash Display 411
Manual Control Levers 413
General Description 413
System Components 413
Lift/Lower 413
Tilt 413
Sideshift 413
Sideshift Fork Positioner 413
Accelerator Control 414
Description 414
Remove and Install 414
Combination Switch 414
Sequential Seatbelt Module 416
General Description 416
Seat Switch/Sensor 416
Buckle Switch 416
Sequential Seatbelt Module 416
Lighting 416
Front End, Mast 417
Description 417
Carriages 417
Description 417
Principles of Operation 417
Integral Sideshift Carriage 417
Mast Mounts 418
Description 418
Principles of Operation 418
Two-Stage Limited Free-Lift (LFL) Mast 420
Description 420
Principles of Operation 420
Two-Stage Full Free-lift (FFL) Mast 422
Description 422
Principles of Operation 422
Three-Stage Full Free-Lift (FFL) Mast 423
Description 423
Principles of Operation 423
Lift Cylinders 425
Description 425
Tilt and Sideshift Cylinders 428
Description 428
Tilt Cylinder 428
Sideshift Cylinder 428
Lowering Control Valves 428
Description 428
Chassis 429
Description 429
Examination and Maintenance 430
Leakage of Hydraulic Oil and Transmission Case Oil 430
Tire Air Pressure (Pneumatic Tire) 430
Wheel Hub Nut Torque 430
Overhead Guard 432
Coolant Level (Mitsubishi S6S Engine) 432
Engine Oil Level 432
Fan Belt Tension Level 432
Rear Combination Light 433
Hydraulic Oil Level 433
Pipeline Cylinder 433
Transmission Oil Level 433
Backrest 435
Fork and Fork Positioning Pin 436
Headlights 436
Gear-shift Handle 436
Multi-way Valve Operating Handle 436
Parking Brake Operation 436
Display Panel 436
Fuel Level 436
Lights 436
Turn Signal 437
Horn Pushbutton 437
Idle Stroke of Brake Pedal 437
Mast Operation 437
Lifting Chain Tension 437
Steering Wheel Free Stroke 437
Exhaust Gas 438
Inching Pedal (Hydraulic Transmission lift truck) 438
Brake 438
Steering Wheel 438
Parking Brake 438
Reversing light and Reversing Buzzer 438
Troubleshooting 439