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YALE (A878) GP155CA LIFT TRUCK Service Repair Manual PDF
YALE (A878) GP155CA LIFT TRUCK Service Repair Manual PDF
Capacities
Item Quantity
Engine Oil
GM 4.3L V-6 4.7 liter (5.0 qt)
Perkins 1004.4 8.0 liter (8.5 qt)
Cooling System
GM 4.3L V-6 19.9 liter (21.0 qt)
Perkins 1004.4 15.1 liter (16.0 qt)
Hydraulic System
Manual Transmission Initial Fill 51.1 liter (13.5 gal)
Powershift Transmission Initial Fill 49.7 liter (13.1 gal)
Manual Transmission 9.5 liter (10.0 qt)
Powershift Transmission 15.1 liter (16.0 qt)
Speed Reducer and Differential 14.3 liter (15.1 qt)
Differential for Powershift Transmission 14.3 liter (15.1 qt)
Brake Fluid 0.2 liter (0.4 pt)
Fuel Tank 60.0 liter (15.9 gal)
1
Wheel Nut Torque 8000 YRM 331
Tire Sizes
Model Steering Drive
Bias Ply Tires 8.25 × 15-12 Ply 8.25 × 15-12 Ply
7.50R 15-12 Ply 7.50 × 15-10 Ply
Radial Tires
8.25R 15-12 Ply 8.25 × 15-12 Ply
Tire Pressure
Bias Ply Tires
Tire Size kPa psi
8.25 × 15 - 12 Ply 690 100
Radial Tires
Tire Size kPa psi
7.50 × 15 - 12 Ply 1000 145
8.25 × 15 - 12 Ply 1000 145
Electrical System
Alternator Output
11 amps @ 650 rpm (hot)
GM 4.3L V-6 Engine
33 amps @ 2500 rpm (hot)
25 amps @ 750 rpm (hot)
Perkins 1004.4 Engine
38 amps @ 2500 rpm (hot)
All Models - 12 volt, Negative Ground
2
8000 YRM 331 Hydraulic System
Engine Specifications
Item GM 4.3L V-6 Perkins 1004.4
No. of Cylinders 6 4
Firing Order 1-6-5-4-3-2 1-3-4-2
Bore 101.6 mm (3.99 in.) 100.0 mm (3.937 in.)
Stroke 88.4 mm (3.48 in.) 127.0 mm (5.00 in.)
3
Displacement 4.3 liter (262.4 in. ) 4.06 liter (244.0 in. 3 )
Compression Ratio 9.3:1 16.5:1
Idle Speed 625 to 675 rpm 725 to 775 rpm
Idle-Up Speed (LPG) 1200 rpm (maximum) N/A
Governed Speed 2400 to 2500 rpm 2400 to 2500 rpm
Stall Speed 1810 rpm (Gas)
(Engine at 50 hours) 2000 to 2100 rpm
1735 rpm (LPG)
Timing 0 BTDC at 650 rpm 16 BTDC (Static)
Oil Pressure (Minimum) 207 to 308 kPa (30 to 45 psi) 280 kPa (40 psi) @ 2500 rpm
@ 2000 rpm
Valve Clearance
Intake Not Adjustable 0.20 mm (0.008 in.) Cold
Exhaust Not Adjustable 0.45 mm (0.018 in.) Cold
Hydraulic System
Item Specification
Hydraulic System Capacity 51.1 liter (13.5 gal)
Hydraulic Pump Output 32.2 liter/min (8.5 gal/min) @ 700 rpm (No Load)
Main Pump 123.0 liter/min (32.5 gal/min) @ 2500 rpm (No Load)
Steering Pump 15.1 liter/min (4.0 gal/min) @ 1500 rpm (No Load)
Relief Pressures*
Main Control Valve
Main Pump 20.88 to 21.20 MPa (3025 to 3075 psi) @ 2500 rpm
Auxiliary Relief Valve 15.34 to 15.68 MPa (2225 to 2275 psi) @ 2500 rpm
Steering Pump 13.8 MPa (2000 psi)
Steering Control Unit (Manifold Block) 12.06 to 12.11 MPa (1736 to 1808 psi)
*Oil Temperature at 49 C (120 F) and engine speed at 2500 rpm.
3
Transmission Oil Pressures 8000 YRM 331
Mast Speeds
Two-Stage Masts
Lifting Lowering
Unit No Load Rated Load No Load Rated Load
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
GDP60CA 0.44 86 0.41 80 0.53 104 0.58 114
(GP/GLP/
GDP135CA)
GDP70CA 0.44 86 0.41 80 0.53 104 0.58 114
(GP/GLP/
GDP155CA)
4
8000 YRM 331 Torque Specifications
Torque Specifications
ENGINE - GM 4.3L V-6 Flywheel Capscrews
105 N•m (77 lbf ft)
Intake Manifold Capscrews
47 N•m (35 lbf ft) Fuel Injector Capscrews
12 N•m (9 lbf ft)
Valve Cover Capscrews
10 N•m (7 lbf ft) Fuel Tube Nuts
18 N•m (14 lbf ft)
Exhaust Manifold Capscrews
Center Port 35 N•m (26 lbf ft) Cold Start Aid
Outer Port 27 N•m (20 lbf ft) 13 N•m (10 lbf ft)
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Torque Specifications 8000 YRM 331
6
1400 YRM 46 Differential Repair
General
This section contains description and repair procedures for the differential. There is a Specifications section and a
Troubleshooting section at the end of this section.
Description
This differential is fastened to the drive axle housing of from the pinion through the differential assembly to
the lift truck. The differential provides a single-speed the axles. The differential assembly permits the drive
reduction for an increase in torque to the drive wheels. wheels to rotate at different speeds during a turn. See
There is a housing, a ring and pinion gear set, and the Figure 1.
differential assembly. The ring gear transfers power
Differential Repair
REMOVE the drive axle is necessary, see the Drive Axle service
manual for your lift truck model.
NOTE: The repair procedures cover all units unless oth-
erwise indicated. 1. Remove the mast. See the Mast service manual
for your lift truck model for the removal procedures.
Differential Carrier From Axle Housing,
Remove 2. Raise the end of the vehicle where the axle is
mounted. Use a jack or other lifting tool, and place
NOTE: The differential assembly can normally be re- safety stands under each side of the axle. See
moved without removing the drive axle. If removal of Figure 2.
1
Differential Repair 1400 YRM 46
2
1400 YRM 46 Differential Repair
Figure 2. Lift Truck Support 8. Remove the axle shafts from the axle housing. See
the Drive Axle manual for your model of lift truck for
the procedures.
WARNING
Block the wheels to prevent the lift truck from mov- 9. Place a transmission jack under the differential car-
ing. Support the lift truck with safety stands. DO rier for support. See Figure 4.
3
Differential Repair 1400 YRM 46
10. Remove all but the top two differential carrier hous-
ing capscrews. See Figure 4.
4
1400 YRM 46 Differential Repair
2. Remove the thrust screw and jam nut from the dif-
CAUTION ferential carrier. See Figure 6.
When using a pry bar, be careful not to damage the
differential carrier or housing flange. Damage to
these surfaces will cause oil leaks.
1. DIFFERENTIAL CARRIER
2. REPAIR STAND
5
Differential Repair 1400 YRM 46
1. BEARING CAP
2. BEARING ADJUSTING RING
6
1400 YRM 46 Differential Repair
CAUTION
Do not use a hammer or mallet to loosen and
remove the yoke or flange. A hammer or mallet
can damage the parts and cause driveline runout
or driveline imbalance problems after carrier to
driveline assembly.
7
Differential Repair 1400 YRM 46
CAUTION
Do not use a pry bar to remove the pinion carrier
from the carrier. A pry bar can damage the bearing
case, shims, and differential carrier.
1. Remove the capscrews and washers that hold the b. Drill each rivet head on the ring gear side of the
case halves together and separate the case halves. assembly to a depth equal to the thickness of
If necessary, use a brass, plastic, or leather mallet one rivet head. Use a drill bit that is 1/32 of
to loosen the parts. an inch smaller than the body diameter of the
rivets. See Figure 15.
8
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