YALE (J813) GDP40VX5 LIFT TRUCK Service Repair Manual PDF

Service Repair
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6,

GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
[J813]
PART NO. 550068693 8000 YRM 1605

8000 YRM 1605 Lift Truck Lifting Capacity
Lift Truck Lifting Capacity
Model Weight
GLP/GDP40VX5, GLP/GDP40VX6 (GP/GLP/GDP080VX) (J813) 3629 kg (8000 lb)
GLP/GDP45SVX5 (GP/GLP/GDP090VX) (J813) 4082 kg (9000 lb)
GLP/GDP45VX6 (GP/GLP/GDP100VX) (J813) 4536 kg (10000 lb)
GLP/GDP50VX (GP/GLP/GDP100VX) (J813) 4989 kg (11000 lb)
NOTE: Load center at 500 mm (24 in.).
Counterweight Weights
Model Weight
GLP/GDP40VX6 (J813) 2314 kg (5102 lb)
GLP/GDP45SVX5 (GP/GLP/GDP090VX) (J813) 2455 kg (5412 lb)
1
Tire Sizes 8000 YRM 1605
Tire Sizes
Truck Drive Tires Steer Tires

GLP/GDP40VX5 GLP/GDP45SVX5 (GP/GLP/ 250 x 15 7.00 x 12
GDP080VX GP/GLP/GDP090VX) (J813)
250 x 70 x R15 28 x 9 to 15
28 x 12.5 to 15
29 x 8 Dual
7.00 x 15 Dual
7.00 x R15 Dual
GLP/GDP45VX6 GLP/GDP50VX GLP/GDP55VX 300 x 15 7.00 x 12

(GP/GLP/GDP100VX GP/GLP/GDP110VX GP/GLP/
GDP120VX) (J813) 315 x 70 x R15 28 x 9 to 15
32 x 12.1 to 15
355 x 65 x 15
355 x 50 x 20
8.25 x 15 Dual
8.25 x R15 Dual
2
8000 YRM 1605 Capacities
Capacities
Table 1. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (J813)
Item Quantity Specifications

Fuel Capacity
Gas (Short Wheel Base) 79 liter (20.8 gal) 86 Octane
Gas (Long Wheel Base) 100.3 liter (26.5 gal) 86 Octane
LPG 15.1 - 20.4 kg (33.5 - 45.0 lb) LPG-HD 5, HD 10
Full
Kubota 3.6L Diesel (Short Wheel Base) 79 liter (20.8 gal) Diesel No. 2
Kubota 3.6L Diesel (Long Wheel Base) 100.3 liter (26.5 gal) Diesel No. 2
Kubota 3.8L Diesel (Short Wheel Base) 79 liter (20.8 gal) Ultra Low Sulfur ≤15 ppm
Diesel No.2
Kubota 3.8L Diesel (Long Wheel Base) 100.3 liter (26.5 gal) Ultra Low Sulfur ≤15 ppm
Diesel No.2
Engine Oil
GM 4.3L 4.7 liter (5 qt) −7°C (−20°F) and below
SAE 5W-20
16°C (60 °F) and below
SAE 5W-30
−18°C (0°F) and above
SAE 10W-30 API SL IL-
SAC GF4
Kubota Diesel 13.2 liter (13.9 qt) −15°C (5°F) and above
SAE 15W-40
−25°C (−13°F)
SAE 10W-30
Below −25°C (-13°F)
SAE 5W-30
API CJ-4
3
Capacities 8000 YRM 1605

090, 100, 110, 120VX) (J813) (Continued)

Cooling System
GM 4.3L 15.1 liter (15.9 qt)
CAUTION
Additives may damage the
cooling system. Before using
additives, contact your local
Yale dealer.
Use Ethylene Glycol Boron-free
Antifreeze. Purchase a pre-dilu-
ted 50/50 solution; or mix 50%
concentrate with 50% distilled
or deionized water.
Kubota Diesel 11 liter (11.6 qt)
CAUTION
cooling system. Before using
additives, contact your local
Yale dealer.
Use Ethylene Glycol Boron-free
Antifreeze. Purchase a pre-dilu-
ted 50/50 solution; or mix 50%
concentrate with 50% distilled
or deionized water.
Hydraulic Tank Oil Capacity
GM 4.3L (Short Wheel Base) 62.0 liter (65.5 qt)
Drain and Fill CAUTION
hydraulic system. Before us-
ing additives, contact your lo-
cal Yale dealer.
ISO VG-46 Hydraulic Oil
GM 4.3L (Long Wheel Base) 78 liter (82.4 qt)
cal Yale dealer.
4
8000 YRM 1605 Capacities

090, 100, 110, 120VX) (J813) (Continued)

Kubota Diesel (Short Wheel Base) 62.0 liter (65.5 qt)
cal Yale dealer.
Kubota Diesel (Long Wheel Base) 78.0 liter (82.4 qt)
cal Yale dealer.
Transmission
Standard Transmission 20 liter (21.0 qt) John Deere
JDM J20C
Techtronix Transmission 20 liter (21.0 qt) John Deere
JDM J20C
Brake Oil (Master Cylinder) 0.35 liter (0.74 pt) Dexron III
Transmission and Wet Brake Drive Axle - Dana Axle Only
Transmission and Planetary Carrier 31.3 liter (33.0 qt) John Deere
Housing JDM J20C
Center body (Dana Axle Only) 2.0 liter (2.1 qt) SAE 80W-90
Wet Brake Drive Axle - NMHG Axle Only
New or Rebuilt Axle 10.3 liter (10.9 qt) John Deere
JDM J20C
Service Fill 9.3 liter (9.9 qt) John Deere
JDM J20C
5
Electrical System 8000 YRM 1605
Electrical System
090, 100, 110, 120VX) (J813)
Item GM 4.3L Kubota Diesel

Battery 12-volt, negative ground 12-volt, negative ground
Spark Plugs AC-41-993 N/A
Spark Plug Gap 1.5 mm (0.059 in.) N/A
Ignition Timing:
Gas Not Adjustable N/A
LPG Not Adjustable N/A
Diesel N/A Not Adjustable
GM 4.3L
Alternator Output (14 Volts) G and LPG GS and LPS
Idle 50 amps @ 750rpm 38 amps @ 750rpm
Governed Speed 65 amps @ 2400 rpm 45 amps @ 2400 rpm
Kubota 3.6L Diesel
Alternator Output (13.5 Volts) D
Low Idle 30 amps @ 850 rpm
Governed Speed 80 amps @ 2470 rpm
Kubota 3.8L Diesel
Alternator Output (13.5 Volts) D DS
Low Idle 30 amps @ 800 rpm 25 amps @ 800 rpm
Governed Speed 80 amps @ 2200 rpm 45 amps @ 2200 rpm
6
8000 YRM 1605 Transmission Oil Pressures
Transmission Oil Pressures
1-Speed Transmission All Pressures at 2500 rpm and Oil at 50 to 65°C (120 to 150°F)
Port 1 Transmission Pump Port 2 Port 3 Port 5 Port 6
***Low Pressure ***High Pres- Reverse Clutch Forward Clutch Torque Con- Lubrication
sure verter
1138 ±96* kPa 1482 ±96* kPa 983 ±58** kPa 983 ±58** kPa 738 ±52 kPa 55 ±28 kPa (8
(165 ±14 psi) (215 ±15 psi) (142.5 ±8.5 psi) (142.5 ±8.5 psi) (107 ±7.5 psi) ±4 psi)
*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed man-
ufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***High pressure port is used when the lift
truck is equipped with a dry brake system. The low pressure port is used when the lift truck is equipped with a
wet brake system.
7
Transmission Oil Pressures 8000 YRM 1605
2-Speed Transmission All Pressures at 2500 rpm and Oil at 50 to 65°C (120 to 150°F)
Port 1 Transmission Pump Port 2 Port 3 Port 4 Port 5 Port 6
***Low Pres- ***High Pres- Reverse Forward Low Forward Torque
Lubrication
sure sure Clutch Clutch High Clutch Converter
1138 ±96* kPa 1482 ±96* kPa 983 ±58** kPa 983 ±58** kPa 983 738 ±52 kPa 55 ±28 kPa (8
(165 ±14 psi) (215 ±15 psi) (142.5 (142.5 ±58** kPa (107 ±4 psi)
±8.5 psi) ±8.5 psi) (142.5 ±7.5 psi)
±8.5 psi)
*Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed man-
ufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***High pressure port is used when the lift
truck is equipped with a dry brake system. The low pressure port is used when the lift truck is equipped with a
wet brake system.
8
8000 YRM 1605 Hydraulic System Relief Pressures
Hydraulic System Relief Pressures

Table 3. Hydraulic Systems With Hydraulic Gear Pump
Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 22.1 ±0.48 MPa (3205 ± 70 psi)
Secondary Relief Valve Pressure (High Idle) 15.51 ±0.48 MPa (2250 ±70 psi)
Table 4. Hydraulic Systems With Variable Displacement Pump
Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 23.7 ±0.50 MPa (3437 ± 72.5 psi)
Secondary Relief Valve Pressure (High Idle) 15.50 ±0.50 MPa (2248 ±72.5 psi)
Maximum Allowable Leakage at 1A Port to Tank 22.7 cc @ 19.3 MPa (2799 psi)
Steering System
090, 100, 110, 120VX) (J813)
Item Quantity
Oil Temperature 50 to 65°C (122 to 149°F)
Steering Relief Pressure at 800 rpms (GM 4.3L and Ku- 12.4 ±0.3 MPa (1798 ±43.5 psi)
bota 3.8L Diesel Engine)
Steering Relief Pressure at 850 rpms (Kubota 3.6L Die- 12.4 ±0.3 MPa (1798 ±43.5 psi)
sel Engine)
Steering Cylinder Stroke (Each Side) 200.85 mm (7.9 in.)
Inside Steering Tire Angle 80°
Number of Turns to Lock 3.984
Turning Radius (±50 mm NO LOAD) Outside Inside
GLP/GDP40VX5 (GP/GLP/GDP080VX) 2570 49
GLP/GDP40VX6 2599 49
GLP/GDP45SVX5 (GP/GLP/GDP090VX) 2619 49
GLP/GDP45VX6 (GP/GLP/GDP100VX) 2837 131
GLP/GDP55VX (GP/GLP/GDP110VX) 2877 131
GLP/GDP55VX (GP/GLP/GDP120VX) 2915 131
9
Mast Speeds 8000 YRM 1605
Stall Speeds (in RPM ±100 rpm)

GM 4.3L
Transmission New Engine Broken-In Engine
Standard 2000 2100
Techtronix 100 2000 2100
Techtronix 100X 2000 2100
Techtronix 200X Stall Speed Not Valid Stall Speed Not Valid
KUBOTA 3.6L DIESEL

Standard 1950 2000
KUBOTA 3.8L DIESEL

Standard 1900 1970
Mast Speeds
NOTE: Lift speed is measured in meters/sec at gov- Lowering speed is measured in meters/sec with full
erned engine RPM with full open valve and open valve and 65°C (149°F) oil temperature.
65°C (149°F) oil temperature.
Plus or minus 10% acceptable lifting or lowering.
Table 6. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)
Lowering M/Sec Lifting M/Sec

Model/ Engine Mast
No Load Rated Load No Load Rated Load
GM 4.3L (Standard 2-Stage LFL 0.47 0.55 0.62 0.61

Displacement 2-Stage FFL 0.36 0.50 0.55 0.54
Pump) 3-Stage FFL 0.44 0.53 0.58 0.57
10
8000 YRM 1605 Mast Speeds

Model/ Engine Mast
Kubota 3.6 L Diesel 2-Stage LFL 0.47 0.55 0.71 0.60

(Standard Displace- 2-Stage FFL 0.36 0.50 0.61 0.53
ment Pump) 3-Stage FFL 0.44 0.53 0.65 0.56

Model/ Engine Mast

(Standard Displace- 2-Stage FFL 0.36 0.50 0.58 0.53
Table 9. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110,

120VX) (J813)

Model/ Engine Mast
GM 4.3L (Standard 2-Stage LFL 0.42 0.51 0.57 0.56

Pump) 3-Stage FFL 0.39 0.47 0.55 0.54
120VX) (J813)

Model/ Engine Mast

(Standard Dis- 2-Stage FFL 0.32 0.45 0.53 0.46
placement Pump) 3-Stage FFL 0.39 0.47 0.51 0.44
120VX) (J813)

Model/ Engine Mast

(Standard Dis- 2-Stage FFL 0.32 0.45 0.50 0.46
placement Pump) 3-Stage FFL 0.39 0.47 0.51 0.47
11
Mast Speeds 8000 YRM 1605

Model/ Engine Mast
2-Stage LFL 0.47 0.55 0.49 0.47
GM 4.3L (Low Dis-
2-Stage FFL 0.36 0.50 0.43 0.42
placement Pump)
3-Stage FFL 0.44 0.53 0.45 0.44

Model/ Engine Mast

(Low Displacement 2-Stage FFL 0.36 0.50 0.54 0.47
Pump) 3-Stage FFL 0.44 0.53 0.56 0.49

Model/ Engine Mast

Pump) 3-Stage FFL 0.44 0.53 0.53 0.49
120VX) (J813)

Model/ Engine Mast
2-Stage LFL 0.42 0.51 0.45 0.44
GM 4.3L (Low Dis-
2-Stage FFL 0.32 0.45 0.43 0.42
placement Pump)
3-Stage FFL 0.39 0.47 0.44 0.43
120VX) (J813)

Model/ Engine Mast

Pump) 3-Stage FFL 0.39 0.47 0.42 0.37
12
8000 YRM 1605 Tilt Angles
120VX) (J813)

Model/ Engine Mast

Pump) 3-Stage FFL 0.39 0.47 0.40 0.37

Model/ Engine Mast
GM 4.3L (Variable 2-Stage LFL 0.47 0.55 0.63 0.61

Pump) 3-Stage FFL 0.44 0.53 0.59 0.58

Model/ Engine Mast

(Variable Displace- 2-Stage FFL 0.36 0.50 0.56 0.55
120VX) (J813)

Model/ Engine Mast
GM 4.3L (Variable 2-Stage LFL 0.42 0.51 0.49 0.48

Pump) 3-Stage FFL 0.39 0.47 0.48 0.47
120VX) (J813)

Model/ Engine Mast

(Variable Displace- 2-Stage FFL 0.32 0.45 0.43 0.42
13
Front End Equipment - Mast Creep 8000 YRM 1605
Tilt Angles
Truck should be on level ground and in unloaded condition.
Table 22. Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX

(GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
Forward Tolerance Back Tolerance

12° +1°, −0.5° 6° +0°, −0.5°
6° +1°, −0.5° 10° +0°, −0.5°
6° +1°, −0.5° 6° +0°, −0.5°
Front End Equipment - Mast Creep

MAST CREEP NOTE: Mast should be 90° vertical prior to test.
Measure with load at 2.5 m (8.0 ft) high and with the
lift, tilt, and auxiliary control levers in neutral position.
Table 23. Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX

(GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
Maximum Vertical Creep at Maximum Tilt Creep

Hydraulic Oil Temperature
Carriage Mast Angle Cylinder Stroke
°C °F mm/Min in./Min °/Min mm/Min in./Min
20 68 2.2 0.086 0.11 1.129 0.051
30 86 3.9 0.154 0.20 1.95 0.120
40 104 6.5 0.256 0.32 3.67 0.145
50 122 10.0 0.394 0.50 5.88 0.232
60 140 14.5 0.571 0.73 8.59 0.388
14
8000 YRM 1605 Engine Specifications
Engine Specifications
Item GM 4.3L
No. of Cylinders 6
Firing Order 1-6-5-4-3-2
Bore 101.6 mm (3.9 in.)
Stroke 88.4 mm (3.48 in.)
Displacement 4.3 liter (262.4 in.3)
Horsepower (Gasoline) 100 @ 2400 rpm
Horsepower (LPG) 93 @ 2400 rpm
Engine Timing Timing is controlled by the Electronic Control Module
(ECM)
Compression Ratio
Gas 9.4:1
LPG 9.4:1
Oil Pressure With PSI Installed 124 kPa (18 psi)
@ 2000 80°C (176°F)
Valve Clearance
Intake Not Adjustable
Exhaust Not Adjustable
Idle Speed - Gas 750 ±25 rpm
Idle Speed - LPG 750 ±25 rpm
Governed Speed High Idle (No Load) 2400 ±25 rpm
Thermostat Range
START TO OPEN 82 ±1.5°C (180 ±35°F)
FULL OPEN 128 ±1.5°C (260 ±35°F)
Cooling System Pressure 103 kPa (15 psi)
15
Torque Specifications 8000 YRM 1605
Item Kubota 3.6L Diesel

No. of Cylinders 4
Firing Order 1-3-4-2
Bore and Stroke 98 mm × 120 mm (3.86 in. × 4.72 in.)
Displacement 3620 cc
Compression Ratio 21.8:1
Power/rpm 57 kW (76 hp) @ 2200 rpm
Oil Pressure 50 kPa (7 psi)
Valve Clearance
Intake 0.23 to 0.27 mm (0.009 to 0.011 in.)
Exhaust 0.23 to 0.27 mm (0.009 to 0.011 in.)
Idle Speed 850 ±50 rpm
Thermostat Range
START TO OPEN 75°C (180°F)
FULL OPEN 90°C (203°F)
Item Kubota 3.8L Diesel

No. of Cylinders 4
Firing Order 1-3-4-2
Bore and Stroke 100 mm × 120 mm (3.94 in. × 4.72 in.)
Displacement 3769 cc
Compression Ratio 17.5:1
Horsepower/rpm 74 @ 2200 rpm
Oil Pressure 50 kPa (7 psi)
Valve Clearance
Intake 0.23 to 0.27 mm (0.009 to 0.011 in.)
Exhaust 0.23 to 0.27 mm (0.009 to 0.011 in.)
Idle Speed 800 ±25 rpm
Thermostat Range
START TO OPEN 75°C (180°F)
FULL OPEN 90°C (203°F)
16
8000 YRM 1605 Torque Specifications
Torque Specifications
FRAME Drive Axle Center Body Drain Plug
30 to 50 N•m (22 to 37 lbf ft)
Overhead Guard Mount Capscrews
66 N•m (49 lbf ft) Drive Axle Center Body Fill/Level Plug
30 to 50 N•m (22 to 37 lbf ft)
Cowl-to-Overhead Guard Legs
66 N•m (49 lbf ft) Planetary Carrier Housing Drain Plug
30 to 50 N•m (22 to 37 lbf ft)
Steering Column Nut
40 to 54 N•m (30 to 40 lbf ft) Planetary Carrier Housing Fill/Level Plug
30 to 50 N•m (22 to 37 lbf ft)
Counterweight Capscrews
1020 N•m (750 lbf ft) Wheel Hub Nut
500 to 600 N•m (369 to 443 lbf ft)
MAST
Parking Brake Lever Capscrew
Mast Mounting Capscrews 21 to 30 N•m (186 to 266 lbf in)
Mast to Drive Axle 522 to 575 N•m (385 to
424 lbf ft) Drive Axle Arm to Drive Axle Central Body Nuts
Tilt/Cylinder Adjust 66 to 73 N•m (49 to 54 lbf ft) 199 to 243 N•m (147 to 179 lbf ft)
Pivot Pin Retainer 66 to 73 N•m (49 to 54 lbf ft)
Wheel Hub to Drive Axle Arm Nuts
STEERING SYSTEM 199 to 243 N•m (147 to 179 lbf ft)
Hub Nut (Slotted Nut) DRIVE AXLE, WET BRAKE (NMHG AXLE)
200 to 220 N•m (148 to 162 lbf ft) initial
35 to 40 N•m (25 to 30 lbf in) final Drive Shaft Capscrews
55 to 63 N•m (41 to 46 lbf ft)
Steering Axle Mounting Bolts and Nuts
215 N•m (159 lbf ft) Drive Axle to Frame Mounting Capscrews
820 to 902 N•m (605 to 665 lbf ft)
Bearing Cap Capscrew
52 N•m (38 lbf ft) Drive Axle Center Body Drain Plug
50 to 55 N•m (37 to 41 lbf ft)
Tie Rod Nut
175 N•m (129 lbf ft) Drive Axle Center Body Fill/Level Plug
50 to 55 N•m (37 to 41 lbf ft)
Steering Cylinder
225 N•m (166 lbf ft) Planetary Carrier Housing Drain Plug
50 to 55 N•m (37 to 41 lbf ft)
STEER AXLE
Planetary Carrier Housing Fill/Level Plug
Cushion Truck Wheel Nuts 50 to 55 N•m (37 to 41 lbf ft)
610 to 680 N•m (450 to 502 lbf ft)
Wheel Hub Nuts
Pneumatic Truck Wheel Nuts 500 to 600 N•m (369 to 443 lbf ft)
610 to 680 N•m (450 to 502 lbf ft)
Wheel Hub Coupler Nuts
DRIVE AXLE, WET BRAKE (DANA 90 to 99 N•m (66 to 73 lbf ft)
SPICER AXLE)
TRANSMISSION
Drive Shaft Capscrews
55 to 63 N•m (41 to 46 lbf ft) Transmission Mounting Bracket Capscrews
66 to 73 N•m (49 to 54 lbf ft)
Drive Axle to Frame Mounting Capscrews
820 to 902 N•m (605 to 665 lbf ft)
17
Transmission to Drive Axle Bolt Balance Shaft Gear Capscrew

225 to 250 N•m (166 to 184 lbf ft) 20 N•m (177 lbf in) Plus 35 Degrees
Transmission Housing Bolts Balance Shaft Retainer Capscrews

38 N•m (28 lbf ft) 12 N•m (106 lbf in)
Drive Plate to Torque Converter Capscrews Camshaft Retainer Screws

55.6 N•m (41 lbf ft) 12 N•m (106 lbf in)
Hydraulic Gear Pump to Transmission Flange Camshaft Sprocket Capscrews

Head Capscrews 28 N•m (21 lbf ft)
38 N•m (28 lbf ft)
Camshaft Sprocket Nut
Variable Displacement Pump to Transmission 25 N•m (18 lbf ft)
Flange Head Capscrews
38 N•m (28 lbf ft) Chain Control Block for Hydraulic Pump Drive
19 N•m (168 lbf in) with Adhesive Sealant
Charge Pump to Transmission Capscrews - Lift
Trucks Manufactured Before July, 2013 Connecting Rod Cap
19 N•m (168 lbf in) 27 N•m (240 lbf in)
Charge Pump to Transmission Capscrews - Lift After this step, tighten nuts an additional 70 de-
Trucks Manufactured After July, 2013 grees.
First pass, torque in star pattern to Coolant Pump to Engine Block

41 N•m (30 lbf ft)
6 N•m (53 lbf in)
Cooling Fan to Pulley
Second pass, torque in star pattern to 24 N•m (212 lbf in)
19 N•m (168 lbf in) Cylinder Head
Transmission Enable Valve Capscrews See the section for torque value and tightening se-
3 to 4 N•m (27 to 35 lbf in) quence to use.
Forward and Reverse Valves Capscrews Distributor Mount Capscrew

3 to 4 N•m (27 to 35 lbf in) 25 N•m (18 lbf ft)
Control Valve Mounting Capscrews Exhaust Manifold

13.3 N•m (118 lbf in) initial 15 N•m (133 lbf in) - first step
19 N•m (168 lbf in) final 30 N•m (22 lbf ft) - second step
Torque Converter Housing Cover Plate Flywheel

7.9 N•m (5.8 lbf ft) 100 N•m (74 lbf ft)
Torque Converter Housing Cover Flywheel Housing

19 N•m (168 lbf ft) 48 N•m (35 lbf ft)
Transmission Input/Output Shaft Speed Sensor Inlet Manifold to Cylinder Head

Capscrew 3 N•m (27 lbf in) - first step
6.9 N•m (5 lbf ft) 12 N•m (106 lbf ft) - second step
15 N•m (133 lbf in) - third step (final)
ENGINE - GM 4.3L
Main Bearing Cap
Alternator Pulley 105 N•m (77 lbf ft)
61 N•m (45 lbf ft)
Motor Mount to Engine
31 N•m (23 lbf ft)
18
Oil Pump Cover Connecting Rod Bolt

12 N•m (106 lbf in) 79 to 83 N•m (58 to 61 lbf ft)
Oil Pump to Crankcase Crankshaft Pulley Bolt

90 N•m (66 lbf ft) 255 to 274 N•m (188 to 202 lbf ft)
Oil Pressure Switch Cylinder Head Bolt

27 N•m (20 lbf ft) 98.1 to 107 N•m (72.4 to 79.5 lbf ft)
Oil Screen Support to Crankcase Cylinder Head Cover Screw, Upper

50 N•m (37 lbf ft) 10 to 11 N•m (61 to 99 lbf in)
Oil Pan to Crankcase Cylinder Head Cover Screw, Lower

Capscrews 25 N•m (18 lbf ft) 7 to 11 N•m (87 to 99 lbf in)
Nuts 25 N•m (18 lbf ft)
Engine Oil Pump Cover Screw
Rear Oil Seal Retainer Screws and Nut 7.9 to 9.3 N•m (70 to 82 lbf in)
15 N•m (133 lbf in)
Engine Oil Cooler Joint Bolt
Rocker Arm Cover 40 to 44 N•m (29 to 32 lbf ft)
12 N•m (106 lbf in)
Flywheel Bolts
Rocker Arm Nuts 98.1 to 107 N•m (72.4 to 79.5 lbf ft)
25 N•m (18 lbf ft)
Flywheel Housing Bolts
Rocker Arm Studs 78 to 90 N•m (58 to 66 lbf ft)
47 N•m (35 lbf ft)
Fuel Injector
Rocker Arm Bolts 49 to 68 N•m (37 to 50 lbf ft)
30 N•m (22 lbf ft)
Fuel Injector Nut
Thermostat Housing 18 to 20 N•m (13 to 15 lbf in)
25 N•m (18 lbf ft)
Fuel Pump Gear Cover Mounting Screw
Timing Cover 24 to 27 N•m (18 to 20 lbf ft)
12 N•m (106 lbf in)
Fuel Injection Pump Assembly Mounting Nut
Valve Lifter Retainer Capscrews 18 to 20 N•m (13 to 15 lbf ft)
16 N•m (142 lbf in)
Fuel Injection Pump Assembly Gear Mounting
Vibration Damper Nut
95 N•m (70 lbf ft) 74 to 83 N•m (55 to 61 lbf ft)
ENGINE - KUBOTA 3.6L DIESEL Fuel Injection Pump Mounting Nut

18 to 20 N•m (13 to 15 lbf ft)
Alternator Pulley Nut
58.4 to 78.9 N•m (43.1 to 58.2 lbf ft) Fuel Injection Pump Mounting Screw
24 to 27 N•m (18 to 20 lbf ft)
Bearing Cap Set Bolt
138 to 147 N•m (102 to 108 lbf ft) Fuel Overflow Pipe Retaining Nut
20 to 24 N•m (15 to 18 lbf ft)
Boost Actuator
40 to 45 N•m (29 to 33 lbf ft) Glow Plug
20 to 24 N•m (15 to 18 lbf ft)
Camshaft Setscrew
24 to 27 N•m (18 to 20 lbf in) Governor Connecting Rod Lock Nut
2.8 to 4.0 N•m (24.7 to 35.0 lbf in)
19
Idler Gear Mounting Screw Camshaft Position Sensor Mounting Screw

24 to 27 N•m (18 to 20 lbf ft) 4 to 5 N•m (35 to 44 lbf in)
Oil Pressure Switch Screw Camshaft Pulsar Gear Mounting Screw

15 to 19 N•m (11 to 14 lbf ft) 4.7 to 5.6 N•m (41.6 to 49.6 lbf in)
Overflow Pipe Joint Screw Camshaft to Cylinder Head Setscrew

9.8 to 11.2 N•m (86.7 to 99.1 lbf in) 24 to 27 N•m (18 to 20 lbf ft)
Rocker Arm Bracket Nut Common Fuel Rail Mounting Bracket Screw
49 to 55 N•m (37 to 41 lbf ft) 24 to 27 N•m (18 to 20 lbf ft)
Starter Solenoid Nut (B Terminal) Connecting Rod Cap Screw

9.8 to 11 N•m (87 to 97 lbf in) 79 to 83 N•m (58 to 61 lbf ft)
Timing Gear Case Cover Mounting Screw Coolant Temperature Sensor Mounting Screw
Timing Gear Case Plate Mounting Screw Crankshaft Position Sensor Mounting Screw
24 to 27 N•m (18 to 20 lbf ft) 4 to 5 N•m (35 to 44 lbf in)
Thermostat Cover Bolts Crankshaft Pulley Mounting Screw

Electronic Throttle Shoulder Bolt Crankcase Housing to Engine Block Mounting

25.6 N•m (226.6 lbf in) Screw
49 to 55 N•m (37 to 41 lbf ft)
Electronic Throttle Linkage Capscrew
10.5 N•m (92.9 lbf in) Cylinder Head Mounting Screw
98 to 107 N•m (72.4 to 79.5 lbf ft)
Electronic Throttle Bellcrank Weldment Stud Nut
10.5 N•m (92.9 lbf in) Cylinder Head Valve Cover, Upper
6.9 to 11.2 N•m (61 to 99 lbf in)
Electronic Throttle Lever Plate Capscrew
7.9 N•m (70 lbf in) Cylinder Head Cover, Lower
9.8 to 11.2 N•m (87 to 99 lbf ft)
Electronic Throttle Inline Ball Joint
7.9 N•m (70 lbf in) Engine Oil Pressure Switch Mounting Screw
15 to 19 N•m (11 to 14 lbf ft)
Electronic Throttle Fuel Shut Off Solenoid Allen-
head Capscrews Flywheel Housing Mounting Screw
10.5 N•m (92.9 lbf in) 78 to 90 N•m (58 to 66 lbf ft)
Throttle Position Sensor Torx-head Schrews Flywheel Mounting Screw

2.25 N•m (20 lbf in) 98 to 107 N•m (72.4 to 79.5 lbf ft)
Electronic Throttle Ball Joint Rod Nut Fuel Injection Pump Gear Cover Mounting Screw
25.6 N•m (226.6 lbf in) 24 to 27 N•m (18 to 20 lbf ft)
ENGINE - KUBOTA 3.8L DIESEL Fuel Injection Pump Gear Mounting Nut
24 to 27 N•m (18 to 20 lbf ft)
Alternator Pulley
58.4 to 78.9 N•m (43.1 to 58.2 lbf ft) Fuel Injection Harness Terminal Nut
1.6 to 2.2 N•m (14 to 19.5 lbf in)
B Terminal Starter Nut
9.8 to 11 N•m (86.7 to 97.4 lbf in) Fuel Injection Line Clamp Nut
24 to 27 N•m (18 to 20 lbf ft)
20
Fuel Injection Pipe to Cylinder Head Retainer Nut Fuel Injection Pump Mounting Nut
Fuel Injection Overflow Pipe to Cylinder Head Intake Air Temperature Sensor
Joint Screw 30 to 39 N•m (22 to 28 lbf ft)
7.9 to 12 N•m (69.9 to 106 lbf in)
Main Bearing Cap Mounting Screw
Fuel Injection Overflow Pipe To Injection Pump 138 to 147 N•m (102 to 108 lbf ft)
Joint Screw
16 to 19 N•m (12 to 14 lbf ft)
21
0100 YRM 1243 General
General
If additional engine repairs are necessary for lift trucks
WARNING covered in this manual see:
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of • GM 4.3L V-6 Engines 0600YRM1251
the following assemblies will cause large changes • Kubota Diesel 3.8L Engines 0600YRM1557
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the • Kubota Diesel 3.6L Engine 0600YRM1579
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability: If additional transmission repairs are necessary for lift
trucks covered in this manual see:
• Before removing the mast and drive axle,
put blocks under the counterweight so the • Powershift Transmission 1300YRM1129
lift truck cannot fall backward. • Powershift Transmission 1300YRM1529
• Before removing the counterweight, put • One and Two Speed Transmissions
blocks under the mast assembly so the lift 1300YRM1569
truck cannot fall forward.
This section contains the description of the frame (see
The surface must be solid, even, and level when Figure 1 or Figure 2) and connected parts.
the lift truck is put on blocks. Make sure any Procedures for removing and installing the
blocks used to support the lift truck are solid, counterweight, hood, overhead guard, engine and
one-piece units. See the procedure How to Put Lift transmission, and exhaust system are found in this
Truck on Blocks in the Operating Manual or the section. Checks for the operator restraint system and
Periodic Maintenance section for your lift truck. procedures for the repair of tanks and installation of
safety labels are also included.
1
Description 0100 YRM 1243
Description
The frame is one weldment and includes the hydraulic The overhead guard, cowl, and hood are installed on
tank and fuel tank for gasoline or diesel fuel. See Fig- the frame. The hood is connected to the frame with
ure 1 or Figure 2. hinges. Two gas-controlled springs provide assis-
tance when raising the hood and hold the hood in the
There is a counterweight for each capacity of lift truck. open position. The floor plate and side covers can be
The counterweights are similar in appearance, but are removed for access to the engine, transmission, and
different weights. See Table 2. other components.
The muffler is fastened to the frame inside the coun-

terweight.
1. COWL PLATE 4. COUNTERWEIGHT MOUNTS

2. FENDERS 5. HYDRAULIC TANK
3. HOOD MOUNTS 6. FUEL TANK (GAS OR DIESEL)
Figure 1. Frame for Lift Trucks with Single Hydraulic Tank
2
0100 YRM 1243 Description
1. COWL PLATE 4. COUNTERWEIGHT MOUNTS

2. FENDERS 5. HYDRAULIC TANKS
3. HOOD MOUNTS
Figure 2. Frame for Lift Trucks with Dual Hydraulic Tanks
3
Hood, Seat, and Side Covers Replacement 0100 YRM 1243
Hood, Seat, and Side Covers Replacement

REMOVE
CAUTION
1. Slide seat to the closest position to steering col- When removing the seat from the hood, DO NOT
umn. use an impact wrench to remove the capscrews.
2. Fully tilt steering column forward. Damage can be caused to the threads on the
screws and in the holes.
3. If your truck is equipped with an LPG tank, swing
tank off to the side. 15. If seat is to be removed, and truck is equipped
with a non-swivel seat, remove seat wire harness
4. Raise latch on the left, front corner of hood to un- from seat wire harness brackets that are attached
latch and lift up hood. See Figure 3. to the underside of hood. Remove the cable clips
from the seat wire harness. If truck is equipped
5. Remove floor mat and floor plate. See Figure 4. with a swivel seat, remove seat wire harness from
seat wire harness bracket attached to underside
6. Remove two capscrews holding left and right rear of hood and behind the seat. See Figure 3.
side covers to the frame. Remove rear side cov-
ers from frame. See Figure 4. 16. Remove four capscrews and washers holding
seat to the hood. Lift seat off the hood. Pull seat
7. Remove two capscrews holding left and right wire harness through hood. See Figure 3.
fender covers to front overhead guard leg. Re-
move covers. See Figure 4. 17. Remove capscrews and washers at top of the gas
springs. Remove gas springs from hood.
8. Remove four capscrews holding left and right
front side covers to frame. Remove covers. 18. Remove hinge screws, located in the rear of the
hood.
9. Fully lower the steering column.
19. Lift hood from the truck. See Figure 3.
10. Remove upper steering column cover by pulling
up on upper steering column cover to release INSTALL
latches (one on either side), and pulling cover
away from steering column. See Figure 5. 1. Place hood onto the lift truck frame.
11. Remove five fasteners (see Figure 5) securing 2. Install hinge screws, located in the rear of the
dash to the top of cowl. Remove four clips, loca- hood, and tighten to 38 N•m (28 lbf ft). See Fig-
ted underneath dash, that attach dash to the kick ure 3.
panel. Lift to remove dash.
3. Align top holes in the gas springs with holes in
12. Lift kick panel to remove it from truck. See Fig- hood. There are two sets of holes used to install
ure 4. the gas springs to hood, based on the type of seat
installed on lift truck. One set is for installing the
13. Remove three capscrews holding the seal plate. cylinder end of the gas springs and the other set
Remove seal plate. See Figure 6. is for attaching the rod end of the gas springs. In-
stall capscrews and washers to attach gas
14. Disconnect seat wire harness connector. See Fig- springs to the hood. Refer to Figure 7 and Table 1
ure 3. for correct holes used to connect the rod end of
the cylinder, depending on the type of seat instal-
led on the lift truck. Tighten capscrews to
19.2 N•m (170 lbf in).
4
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for your reading.
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Service Repair

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6,

PART NO. 550068693 8000 YRM 1605

Lift Truck Lifting Capacity

Truck Drive Tires Steer Tires

7.00 x R15 Dual

GLP/GDP45VX6 GLP/GDP50VX GLP/GDP55VX 300 x 15 7.00 x 12

8.25 x R15 Dual

Item Quantity Specifications

Table 1. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,

Item Quantity Specifications

Table 1. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,

Item Quantity Specifications

Item GM 4.3L Kubota Diesel

Transmission Oil Pressures

Hydraulic System Relief Pressures

Table 4. Hydraulic Systems With Variable Displacement Pump

Stall Speeds (in RPM ±100 rpm)

KUBOTA 3.6L DIESEL

KUBOTA 3.8L DIESEL

Table 6. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

GM 4.3L (Standard 2-Stage LFL 0.47 0.55 0.62 0.61

Table 7. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

Kubota 3.6 L Diesel 2-Stage LFL 0.47 0.55 0.71 0.60

Table 8. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

Kubota 3.8 L Diesel 2-Stage LFL 0.47 0.55 0.66 0.60

Table 9. Lift Truck Models GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP100, 110,

Lowering M/Sec Lifting M/Sec

GM 4.3L (Standard 2-Stage LFL 0.42 0.51 0.57 0.56

Lowering M/Sec Lifting M/Sec

Kubota 3.6 L Diesel 2-Stage LFL 0.42 0.51 0.56 0.48

Lowering M/Sec Lifting M/Sec

Kubota 3.8 L Diesel 2-Stage LFL 0.42 0.51 0.53 0.48

Table 12. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

Table 13. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

Kubota 3.6 L Diesel 2-Stage LFL 0.47 0.55 0.60 0.53

Table 14. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

Kubota 3.8 L Diesel 2-Stage LFL 0.47 0.55 0.57 0.53

Lowering M/Sec Lifting M/Sec

Lowering M/Sec Lifting M/Sec

Kubota 3.6 L Diesel 2-Stage LFL 0.42 0.51 0.43 0.39

Lowering M/Sec Lifting M/Sec

Kubota 3.8 L Diesel 2-Stage LFL 0.42 0.51 0.41 0.39

Table 18. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

GM 4.3L (Variable 2-Stage LFL 0.47 0.55 0.63 0.61

Table 19. Lift Truck Models GLP/GDP40VX5/VX6 (GP/GLP/GDP080VX, GP/GLP/GDP090VX) (J813)

Lowering M/Sec Lifting M/Sec

Kubota 3.8 L Diesel 2-Stage LFL 0.47 0.55 0.63 0.62

Lowering M/Sec Lifting M/Sec

GM 4.3L (Variable 2-Stage LFL 0.42 0.51 0.49 0.48

Lowering M/Sec Lifting M/Sec

Kubota 3.8 L Diesel 2-Stage LFL 0.42 0.51 0.46 0.45

Truck should be on level ground and in unloaded condition.

Table 22. Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX

Forward Tolerance Back Tolerance

Front End Equipment - Mast Creep