GLC030-035VX, GLC040SVX (D809) SERVICE MANUAL CONTENTS SECTION
PART NUMBER
YRM NUMBER
REV DATE
FRAME............................................................................................................................ PSI 2.0 LPG ENGINE...................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... PSI 2.0L LPG FUEL SYSTEM........................................................................................ SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ DRIVE AXLE................................................................................................................... STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC CLEANLINESS PROCEDURES............................................................... HYDRAULIC GEAR PUMPS.......................................................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N B551, B555, B559).................................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. ENGINE ELECTRICAL SYSTEM, PSI 2.0L ENGINE..................................................... MAST REPAIR (S/N B551, B555, B559)........................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................
550108490 550108491 550108492 550096320 550108494 550108495 550108496 550108497 550108498 550073240 550108499 550108500 550108501 524223769 524223770 524223771 550108502 550108503 550108504 524150797 524223780 550108505 550108506 550108507 524221866
0100 YRM 1735 0600 YRM 1736 0700 YRM 1737 0900 YRM 1677 0900 YRM 1739 1300 YRM 1740 1400 YRM 1741 1600 YRM 1742 1800 YRM 1743 1900 YRM 1620 1900 YRM 1744 2000 YRM 1745 2100 YRM 1746 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1747 2200 YRM 1748 4000 YRM 1749 8000 YRM 0231 8000 YRM 1134 8000 YRM 1750 8000 YRM 1751 8000 YRM 1753 9000 YRM 1112
12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 10/13 12/14 12/14 12/14 12/14 12/14
PART NO. 550108487 (12/14)
0100 YRM 1735
General
General WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •
Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.
•
Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.
NOTE: For lift trucks equipped with a PSI 2.0L LPG engine, see PSI 2.0L LPG Fuel System 0900YRM1739 for procedures to remove and install the exhaust system components. If lift truck is equipped with a Yanmar 2.6L diesel engine, see Exhaust System Repair in this manual for procedures. This section contains the description of the frame (see Figure 1) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine and transmission, cooling system, exhaust system (see NOTE above), and other components attached to the frame are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.
The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the section Periodic Maintenance 8000YRM1750
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Description
0100 YRM 1735
Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1. There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights. See Counterweight Replacement section.
The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the frame with hinges. Two gas-controlled springs provide assistance when raising the hood and hold the hood in the open position. The floor plate and side covers can be removed for access to the engine, transmission, and other components.
The muffler is fastened to the frame inside the counterweight.
1. 2. 3. 4.
COWL PLATE FENDERS FRAME HOOD MOUNTS
5. COUNTERWEIGHT MOUNTS 6. FUEL TANK (DIESEL) 7. HYDRAULIC TANK Figure 1. Frame Components
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0100 YRM 1735
Hood, Seat, and Side Covers Replacement
Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat all the way to the rear of the hood. 2. Use tilt lever and tilt steering column all the way forward. See Figure 2.
7. Remove capscrews, washers, and left and right rear side covers from frame. 8. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), remove eight capcrews, eight clip nuts, and left and right step covers from frame. See Figure 6. 9. For lift truck models GLC030-035VX, GLC040SVX (D809), remove six capscrews and left and right step plates from frame. See Figure 6. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), remove six capscrews, six clip nuts, and left and right step plates from frame. See Figure 6.
1. TILT LEVER 2. GAS CYLINDER Figure 2. Steering Column Tilt Lever 3. If your truck is equipped with an LPG tank, swing tank off to the side. See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures. 4. Raise hood latch on the left, front corner of the hood to unlatch and lift up hood. See Figure 3. 5. Disconnect the battery. 6. Remove floor mat and floor plate. •
See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)
•
See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)
1. HOOD LATCH 2. HOOD Figure 3. Hood Latch
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Hood, Seat, and Side Covers Replacement
0100 YRM 1735
Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLC030-035VX, GLC040SVX (D809) 4
0100 YRM 1735
Hood, Seat, and Side Covers Replacement Legend for Figure 4
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
RADIATOR COVER WASHER CAPSCREW RIGHT REAR COVER INSERT LEFT REAR COVER LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER CLIP NUT DASH PANEL SEAL
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
KICK PANEL FLOOR PLATE GROMMET SEAL PLATE LEFT STEP PLATE RIGHT STEP PLATE LEFT FRONT COVER RIGHT FRONT COVER FLOOR MAT CLIP
5
Hood, Seat, and Side Covers Replacement
0100 YRM 1735
Figure 5. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810) 6
0100 YRM 1735
Hood, Seat, and Side Covers Replacement Legend for Figure 5
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
CAPSCREW WASHER INSERT RADIATOR COVER LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER CLIP NUT DASH PANEL KICK PANEL GROMMET SEAL PLATE SEAL
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
FUEL SHIELD (DIESEL) LEFT REAR COVER RIGHT REAR COVER FLOOR PLATE FLOOR MAT RIGHT STEP COVER LEFT STEP COVER RIGHT FRONT COVER LEFT FRONT COVER RIGHT STEP PLATE LEFT STEP PLATE CLIP
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Hood, Seat, and Side Covers Replacement
Figure 6. Step Covers and Step Plates Remove/Install
8
0100 YRM 1735
0100 YRM 1735
Hood, Seat, and Side Covers Replacement Legend for Figure 6
NOTE: RIGHT SIDE SHOWN. PROCEDURES ARE THE SAME FOR LEFT SIDE. A. STEP PLATE FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809) B. STEP PLATE AND STEP COVER FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) 1. STEP PLATE 2. CAPSCREW 3. RIGHT REAR COVER
4. RIGHT STEP COVER 5. CLIP NUT
10. Remove capscrews, washers, and left and right front cover from frame. •
See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)
•
See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)
11. Use tilt lever and fully lower steering column. See Figure 2. 12. Remove upper steering column cover by pulling up on upper steering column cover to release latches (one on either side), and pulling cover away from steering column. See Figure 7. 13. Remove five fasteners securing dash to the top of cowl. See Figure 7. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash. • •
See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809) See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)
14. Lift kick panel and remove from truck. 15. Remove three capscrews and clip nuts from seal plate. Remove seal plate from frame. 16. Remove two capscrews and washers from cover plate and remove seat box. Disconnect seat wire harness connector. See Figure 8.
CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews. Damage can be caused to the threads on the screws and in the holes. NOTE: Before removing seat from hood, tag or mark holes that mount seat to hood. This will aid in correctly installing seat to hood. 17. Remove four capscrews and washers attaching seat to hood. Lift seat up and remove from hood. 18. Remove radiator cover and seals from lift truck frame. •
See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)
•
See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)
19. Remove two capscrews and hood latch striker bolt from mounting bracket. See Figure 9. 20. Remove two capscrews and hood latch from hood. See Figure 9. 21. Remove capscrews and washers at the top of gas springs. Remove gas springs from hood. 22. Remove hinge screws, located in the rear of the hood. See Figure 10. 23. Remove hood from lift truck.
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Hood, Seat, and Side Covers Replacement
0100 YRM 1735
NOTE: TOP VIEW OF DASH SHOWN. A. INDICATES TO PULL UP TO UNLATCH 1. FASTENERS 2. COWL
3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER Figure 7. Remove Dash From Cowl
10
0100 YRM 1735
Hood, Seat, and Side Covers Replacement
A. FULL SUSPENSION SEAT B. SEMI- AND NON- SUSPENSION SEATS 1. 2. 3. 4. 5.
CAPSCREWS WASHERS SEAT BOX SEAT WIRE HARNESS CONNECTOR COVER PLATE Figure 8. Seat Wire Harness Connector
11
Hood, Seat, and Side Covers Replacement
Figure 9. Hood Latch and Hood Latch Striker Bolt Remove/Install
12
0100 YRM 1735