Yale GDP25LX

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1. ALLEN HEAD SCREWS

2. COWL

3. DASH PANEL

4. KICK PANEL

5. KICK PANEL NOTCHES

6. SEAL PLATE

7. CAPSCREWS

8. CLIPS

Figure 6. Dash Panel, Kick Panel, and Seal Plate Removal

0100 YRM 1766 Hood, Seat, and Side Covers Replacement

Main Page

Contents1
General2
Warning2
Frame, LPG2
Frame, Dual Fuel or Diesel3
Hood, Seat, and Side Covers Replacement4
Hood Latch4
Side Cover, Floor Plate, and Cowl Components5
Dash Panel and Upper Steering Column Cover Removal7
Dash Panel, Kick Panel, and Seal Plate Removal8
Disconnect Seat Wire Harness9
Remove Seat from Hood10
Gas Spring and Hood Removal10
Install11
Gas Spring and Seat Hole Alignment11
Hood Latch Adjustment12
Description13
Steering Column Repair13
Steering Column and Cowl13
Steering Column Remove/Install14
Clean15
Inspect15
Assemble15
Steering Column Assembly16
Counterweight Replacement17
Weight of Counterweights17
Counterweight Installation18
Counterweight with Lifting Eyebolts18
Overhead Guard Replacement19
Clean and Inspect20
Overhead Guard Rain Top21
Operator Restraint System Replacement22
Emergency Locking Retractor (ELR)22
Engine Replacement23
LPG Engine23
Operator Restraint System23
PSI Engine and Transmission Mounting Arrangement24
PSI Engine and Transmission Remove25
Power Distribution Module and Battery Tray26
Transmission Electrical Connectors28
PSI Engine Removal Access Port28
PSI Flywheel and Torque Converter Housings29
PSI Engine and Frame30
PSI Engine Mounts30
Diesel Engine31
No Smoking31
Yanmar Diesel Engine and Transmission Mounting Arrangement32
Yanmar 2.6L Diesel Engine and Transmission Removal33
Yanmar Torque Converter Bolt Access35
Yanmar Flywheel and Torque Converter Housings36
Yanmar Engine Mounts37
Transmission Replacement39
Hydraulic Hose, Aluminum Transmission Housing40
Rear Mount-Transmission40
Drive Shaft Yoke41
Throttle Pedal and Cable Adjustment42
Throttle Pedal Stop Adjustment42
Yanmar Diesel Engine with Electronic Throttle42
Throttle Pedal Stop Adjustment, PSI 2.4L Engines42
Cooling System43
Throttle Pedal and Cable Adjustment, Yanmar Diesel Engine43
Hydraulic Filter Repair44
Hydraulic Filter44
Clean and Inspect44
Tank Repair45
Hydraulic and Diesel Tanks45
Steam Method of Cleaning46
Hydraulic and Fuel Tanks46
Chemical Solution Method of Cleaning47
Small Leaks, Repair47
Large Leaks, Repair47
Preparations for Use after Repair47
Label Replacement48
Warning and Safety Labels for Lift Trucks with PSI Engine49
Warning and Safety Labels for Lift Trucks with Yanmar Diesel Engine51
Engine Identification53
Major Engine Component Identification53
Major Engine Components53
Location of Labels54
Engine Nameplate (Typical)54
Typical Location of Engine Labels54
Engine Removal and Installation55
Cylinder Head Assembly Repair55
Cylinder Head Components56
Glow Plugs58
Valve Cover58
Rocker Arm Assembly59
Push Rods61
Rocker Arm Inside Diameter61
Rocker Arm Shaft Outside Diameter61
Push Rod Inspection61
Valve Clearance Adjustments62
Valve Clearance Measurement63
Valve Clearance Adjustment63
Valve Cap Check63
Cylinder Head Assembly64
Fuel Filter Housing Assembly64
Intake Manifold65
Exhaust Manifold66
Cylinder Head and Gasket67
Cylinder Head Bolt Loosening Sequence67
Valves and Valve Springs, Remove68
Valve Guides, Remove68

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