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GLP/GDP20VX, GLP/GDP25VX, GLP/GDP30VX, GLP/GDP35VX (B875) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 2.4L ENGINE REPAIR............................................................................................. MAZDA FE AND F2 ENGINES....................................................................................... YANMAR DIESEL ENGINES.......................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM).............................................................................................. LPG FUEL SYSTEM (MAZDA)....................................................................................... LPG FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT ENGINES.................................................................................................................... 1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... SINGLE SPEED POWERSHIFT ALUMINUM TRANSMISSION REPAIR..................... SINGLE SPEED POWERSHIFT ALUMINUM CHAIN DRIVE TRANSMISSION............ POWERSHIFT TRANSMISSION REPAIR...................................................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE (WET BRAKE).......................................................................................... STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ MAIN CONTROL VALVE (WITH VARIABLE DISPLACEMENT PUMP)....................... CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. ELECTRICAL SYSTEM (MAZDA).................................................................................. ELECTRICAL SYSTEM (MAZDA 2LTR 2007)............................................................... MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ MAST REPAIR (S/N F507, F508, F562, F563)............................................................... METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS..................................................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524223754 524306203 524223755 524223756 524240453 524223757 524223758 524223759

0100 YRM 1120 0100 YRM 1290 0600 YRM 1121 0600 YRM 1122 0600 YRM 1205 0700 YRM 1123 0900 YRM 1124 0900 YRM 1125

12/12 04/14 12/12 03/12 12/14 03/13 02/12 10/05

524289374 524223762 550010194 550030170 550043436 524240909 524240908 524223764 524223765 524223766 550073240 524223767 550031265

0900 YRM 1326 1300 YRM 1129 1300 YRM 1421 1300 YRM 1447 1300 YRM 1529 1400 YRM 1214 1400 YRM 1215 1600 YRM 1133 1800 YRM 1135 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2000 YRM 1457

09/12 09/09 08/13 08/13 08/13 11/12 02/12 07/13 12/12 04/14 12/14 04/14 01/14

524223768 550093750 524223769 524223770 524223771 524223772 524223773 524289675

2100 YRM 1139 2100 YRM 1668 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142 2200 YRM 1143 2200 YRM 1327

02/14 12/14 12/14 12/14 12/14 04/14 10/05 09/12

524223776 550093755 524150797 524223780 524242683 524223778 524223779 524329117 550001092 550055283 524221866

4000 YRM 1148 4000 YRM 1669 8000 YRM 0231 8000 YRM 1134 8000 YRM 1150 8000 YRM 1151 8000 YRM 1152 8000 YRM 1387 8000 YRM 1409 8000 YRM 1585 9000 YRM 1112

02/14 12/14 10/13 12/14 08/13 08/13 04/14 04/14 04/14 04/14 12/14

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 524242682 (12/14)


100 YRM 1120

Description

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. 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 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX GP/GLP/GDP035VX, (GP/GLP/GDP030VX, GP/GLP/GDP040SVX) (C810) NOTE: For exhaust system procedure for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 or Gasoline Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1325 for exhaust system procedures. For lift trucks built after January, 2010 and equipped with a GM 2.4L engine, go to section LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for exhaust system 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, cooling system, and exhaust system (see NOTE above) 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.

Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1.

Table 6 for lift truck models (GP/GLP/GDP040-070VX) • GLP/GDP20-35VX (B875)

There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights.

The muffler is fastened to the frame inside the counterweight.

See Table 3 for lift truck models (GC/GLC040-070VX, • GLC20-35VX GC/GLC055SVX) (A910) Table 4 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809)

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.

Table 5 for lift truck models • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX GP/GLP/GDP035VX, (GP/GLP/GDP030VX, GP/GLP/GDP040SVX) (C810)

1


Hood, Seat, and Side Covers Replacement

1. 2. 3. 4.

100 YRM 1120

COWL PLATE FENDERS FRAME HOOD MOUNTS

5. COUNTERWEIGHT MOUNTS 6. FUEL TANK (GAS OR DIESEL) 7. HYDRAULIC TANK

Figure 1. Frame

Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat to the closest position to steering column. 2. Fully tilt steering column forward. 3. If your truck is equipped with an LPG tank, swing tank off to the side. 4. Raise latch on the left, front corner of the hood to unlatch and lift up hood. See Figure 2. 5. Remove floor mat and floor plate.

2

See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)


100 YRM 1120

Hood, Seat, and Side Covers Replacement

NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES. A. SIDE VIEW OF HOOD AND SEAT B. SIDE VIEW OF HOOD C. BOTTOM VIEW OF HOOD

D. SIDE VIEW OF VENTED HOOD WITH SWIVEL SEAT

1. 2. 3. 4. 5.

10. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (SEMI-SUSPENSION) 11. SEAT WIRE HARNESS BRACKETS 12. SEAT LINER 13. HOOD LATCH 14. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (NON-SUSPENSION) 15. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (FULL SUSPENSION) 16. SPACER

6. 7. 8. 9.

SEAT HOOD FRAME SEAT WIRE HARNESS SEAT WIRE HARNESS CONNECTOR (WITHOUT ELECTRONIC CONTROL) SEAT WIRE HARNESS CONNECTOR (WITH ELECTRONIC CONTROL) CABLE CLIPS HINGE SCREWS GAS SPRING

Figure 2. Hood and Seat Arrangement

3


Hood, Seat, and Side Covers Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER INSERT CLIP DASHBOARD CAPSCREW SEAL GROMMET LEFT HAND REAR PANEL FLOOR PLATE LEFT HAND FENDER COVER SCREW NUT

100 YRM 1120

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

LEFT HAND FRONT PANEL LEFT HAND STEP PANEL LEFT HAND TREAD PLATE PLATE ASSEMBLY SEAL RIGHT HAND FENDER COVER FLOOR MAT RIGHT HAND TREAD PLATE RIGHT HAND FRONT PANEL RIGHT HAND STEP PANEL RIGHT HAND REAR PANEL RADIATOR COVER KICK PANEL PLATE ASSEMBLY

Figure 3. Side Cover, Floor Plate, and Cowl Components, Lift Truck Models GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX ) (A910), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX ) (C810), and GC/GLC030-035VX, GC/GLC040SVX (C809)

4


100 YRM 1120 6. Remove two capscrews holding left and right rear side covers to the frame. Remove rear side covers from frame. See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 7. Remove two capscrews holding left and right fender covers to front overhead guard leg. Remove covers. See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 8. Remove four capscrews holding left and right front side covers to frame. Remove covers.

Hood, Seat, and Side Covers Replacement 12. Lift the kick panel to remove from truck. See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 13. Remove three capscrews holding the seal plate. Remove seal plate. See Figure 6. 14. Disconnect seat wire harness connector. See Figure 2.

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. 15. If seat is to be removed, and truck is equipped with a non-swivel seat, remove seat wire harness from seat wire harness brackets that are attached to the underside of hood. Remove the cable clips from the seat wire harness. If truck is equipped with a swivel seat, remove seat wire harness from seat wire harness bracket attached to underside of the hood and behind the seat (see Figure 2).

9. Fully lower steering column.

16. Remove four capscrews and washers holding the seat to hood. Lift seat off the hood. Pull seat wire harness through hood. See Figure 2.

10. 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 5.

17. Remove capscrews and washers at the top of gas springs. Remove gas springs from hood.

11. Remove five fasteners (see Figure 5) securing dash to the top of cowl. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash.

19. Lift hood from the truck. See Figure 2.

18. Remove hinge screws, located in the rear of the hood.

5


Hood, Seat, and Side Covers Replacement

100 YRM 1120

Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

6


100 YRM 1120

Hood, Seat, and Side Covers Replacement

Legend for Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

DASH ASSEMBLY UPPER STEERING COLUMN COVER LOWER STEERING COLUMN COVER KICK PANEL MUD GUARD (LH) MUD GUARD (RH) LOCK NUT NUT COVER BRACKET PLATE ASSEMBLY GROMMET LEFT FRONT PANEL RIGHT FRONT PANEL

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

LEFT STEP PANEL RIGHT STEP PANEL LEFT STEP PLATE RIGHT STEP PLATE LEFT REAR PANEL RIGHT REAR PANEL FLOOR MAT FLOOR PLATE RADIATOR COVER SEALS CAPSCREW CLIP NUT INSERT PLATE ASSEMBLY SEAL

NOTE: TOP VIEW OF DASH SHOWN. A. INDICATES TO PULL UP TO UNLATCH 1. ALLEN SCREWS 2. COWL

3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER

Figure 5. Remove Dash From Cowl

7


Hood, Seat, and Side Covers Replacement

INSTALL 1. Place hood onto the lift truck frame. 2. Install hinge screws, located in the rear of the hood, and tighten to 38 N•m (28 lbf ft). See Figure 2. 3. Align top holes in the gas springs with holes in hood. Install capscrews and washers to attach gas springs to hood. Tighten capscrews to 19.2 N•m (170 lbf in).

100 YRM 1120 See Figure 7 and Table 1 for lift truck models • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP030SVX) (C810) and GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) See Figure 8 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 9 and Table 2 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

1. CAPSCREWS

2. SEAL PLATE

Figure 6. Remove Seal Plate From Dash

8


100 YRM 1120

Hood, Seat, and Side Covers Replacement

Legend for Figure 7 NOTE: LEFT SIDE SHOWN A. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT B. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT WITH CAB* 1. MOUNTING POINTS FOR GAS SPRING ON HOOD

Figure 7. Gas Spring Installation, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP030SVX) (C810) and GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

*CAB ONLY ON LIFT TRUCK MODELS GLP/ GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/ GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP030SVX) (C810)

Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP030SVX) (C810) and GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) Full or Semi Suspension Seat Frame

Non-Suspension Seat Hood

Frame

Hood

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Seat Without E-Control

B

B

3

3

A

A

1

1

Seat With E-Control

B

B

2

2

N/A

N/A

N/A

N/A

Cab

C

C

2

2

N/A

N/A

N/A

N/A

9


Hood, Seat, and Side Covers Replacement

100 YRM 1120

Legend for Figure 8 NOTE: LEFT SIDE SHOWN. 1. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT 2. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT

Figure 8. Gas Spring Installation, Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809)

Figure 9. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

10


100 YRM 1120

Hood, Seat, and Side Covers Replacement

Legend for Figure 9 A. B. C. D.

LEFT SIDE RIGHT SIDE MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT, LIFT TRUCKS WITH CAB OR GP/GLP/GDP040-070VX (B875) LIFT TRUCKS WITHOUT CAB E. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT, LIFT TRUCKS GLP/GDP20-35VX (B875) WITHOUT CAB 1. MOUNTING POINTS FOR GAS SPRING ON HOOD

Table 2. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Full or Semi Suspension Seat Frame

Non-Suspension Seat Hood

Frame

Hood

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Non-Cab GP/GLP/ GDP040070VX (B875)

D

D

3

3

C

C

1

1

Non-Cab GLP/ GDP2035VX (B875)

E

E

2

2

C

C

1

1

Cab

D

D

1

1

N/A

N/A

N/A

N/A

11


Hood, Seat, and Side Covers Replacement 4. Install latch striker in highest slot position. Check that latch striker is in center of jaws of hood latch when hood closes. Open and close hood to ensure that center pin strikes hood latch properly and that the stop screw contacts frame. A properly closed hood MUST click twice on the hood latch. If the hood latch does not close properly, loosen capscrews on the back of center pin and adjust center pin up or down as required for correct alignment. See Figure 10. 5. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood latch. Open hood and tighten capscrews for latch. 6. Check operation of hood latch. Have an operator sit in seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 5.

100 YRM 1120

CAUTION When installing the seat to the hood, DO NOT use an impact wrench to install the capscrews. Damage can be caused to the threads on the screws and in the holes. 7. Place seat on the hood and thread seat wire harness through the hole in the hood. See Figure 2. 8. Align holes in the seat with the holes in hood. Insert washers and capscrews. Tighten capscrews to 18 N•m (159 lbf in). 9. If truck is equipped with a non-swivel seat, tie cable clips to seat wire harness and insert harness into seat wire harness brackets under hood. If truck is equipped with a swivel seat, secure seat harness to bracket. See Figure 2. 10. Install seal plate using three capscrews. See Figure 6. 11. Install kick panel onto truck. See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 12. Install dash to top of cowl. See Figure 5. Install four clips to attach the dash to kick panel. 13. Install upper steering column cover to dash. 14. Using four capscrews, install left and right front side covers to frame.

1. HOOD 2. HOOD LATCH 3. CENTER PIN

4. CAPSCREW

Figure 10. Hood Latch Adjustment

12

See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809)


100 YRM 1120

Steering Column

See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 15. Using two capscrews, install left and right fender covers to front of overhead guard legs. 16. Using two capscrews, install left and right rear side covers to frame. See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,

GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 17. Install floor mat and floor plate. 18. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight. 19. Adjust the steering column and seat positions.

Steering Column DESCRIPTION This section describes the repair procedures for the steering column. The steering column assembly mounts to the cowl inside the operator compartment and is the mechanical connection between the steering wheel and the steering control unit. The steering column includes the steering wheel, housing, bracket and lower shaft. For lift trucks with gas and LPG engines, bolts and bushings attach the steering column to the cowl standoffs. For lift trucks with diesel engines, bolts, bushings and isolators attach the steering column to the cowl standoffs. See Figure 11.

NOTE: This procedure is for the removal of all components of the steering column assembly. Not all components are removed for a repair procedure. Do only those steps of the procedure necessary to remove the required component. NOTE: Tag wires prior to disconnect. 3. Remove the horn button assembly and disconnect electrical wires. Remove large hex nut and steering wheel from steering column. See Figure 12.

STEERING COLUMN REPAIR Remove 1. Put blocks on each side (front and back) of tires to prevent lift truck from moving.

WARNING Disconnect the battery before removing any covers to avoid injury to personnel. 2. Attach a tag on the battery connector or negative battery cable stating, DO NOT CONNECT BATTERY. Move the steering column to the most FORWARD position.

CAUTION If a puller tool is used to remove steering wheel from steering column, be careful not to damage horn wires.

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR. 1. STEERING WHEEL 2. STEERING COLUMN 3. COWL

Figure 11. Steering Column and Cowl

13


Steering Column

100 YRM 1120 4. Remove steering column covers. Remove floor mats and floor plate. See section Hood, Seat, and Side Covers Replacement. NOTE: Perform Step 5 for lift trucks equipped with gas or LPG engines. 5. Remove four capscrews, four bushings and steering column from cowl standoffs. See Figure 13. NOTE: Perform Step 6 for lift trucks equipped with diesel engines. 6. Remove four capscrews, four bushings, four isolators, steering column and four isolators from cowl standoffs. See Figure 13.

1. 2. 3. 4.

HORN BUTTON HEX NUT STEERING WHEEL STEERING COLUMN

Figure 12. Steering Wheel Remove/Install

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR. 1. CAPSCREW 2. BUSHING 3. ISOLATOR

4. STEERING COLUMN 5. COWL STANDOFF

Figure 13. Steering Column Remove/Install

14


100 YRM 1120

Disassemble NOTE: Remove and discard snap rings if installed. 1. Remove two pins and gas spring from housing. See Figure 14, for lift trucks manufactured before January, 2012. See Figure 15, for lift trucks manufactured after January, 2012. 2. Remove two pivot bolts, two bushings, two nuts and bracket from housing. See Figure 14, for lift trucks manufactured before January, 2012. See Figure 15, for lift trucks manufactured after January, 2012. 3. Remove split pin and lower shaft from upper shaft. See Figure 14, for lift trucks manufactured before January, 2012. See Figure 15, for lift trucks manufactured after January, 2012. 4. Remove connector from connector bracket. Remove connector bracket, fastener, four screws and two horn contacts from housing.

Steering Column the path of the compressed air is away from all personnel to avoid injury. 1. Clean metal parts in solvent. Remove all traces of old lubricant and dirt. Clean nonmetal parts with warm soapy water and a lint free cloth. 2. After cleaning, dry parts with compressed air. DO NOT dry parts with a cloth.

Inspect 1. Inspect for loose, burned, missing, cracked or damaged hardware. 2. Inspect all parts for dents, holes, bends, burrs, rust, corrosion or marred finishes. 3. Replace all defective or damaged parts.

Assemble NOTE: This procedure is for the installation of all components of the steering column assembly. Not all components are removed for a repair procedure. Do only those steps of the procedure necessary to install the required component. NOTE: Perform Step 1 only for lift trucks manufactured before January, 2012.

See Figure 14, for lift trucks manufactured before January, 2012.

1. Lubricate the horn contact slip rings with a small amount of conductive grease (Yale P/N 582014302).

See Figure 15, for lift trucks manufactured after January, 2012.

2. Install fastener, connector bracket and connector, two horn contacts and four screws.

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions.

WARNING Compressed air is used for cleaning and drying purposes, or for cleaning restrictions. Wear protective clothing (goggles/shields, gloves, etc.). Make sure

See Figure 14, for lift trucks manufactured before January 2012. See Figure 15, for lift trucks manufactured after January 2012. 3. Assemble lower shaft and upper shaft, secure with spit pin. See Figure 14, for lift trucks manufactured before January 2012. See Figure 15, for lift trucks manufactured after January 2012.

15


Steering Column

100 YRM 1120

Figure 14. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012

16


100 YRM 1120

Steering Column

Legend for Figure 14 1. 2. 3. 4. 5. 6. 7. 8.

PIN LOWER SHAFT SPLIT PIN UPPER SHAFT HOUSING HORN CONTACT SCREW FASTENER

9. 10. 11. 12. 13. 14. 15.

CONNECTOR BRACKET PIVOT BOLT BUSHING NUT GAS SPRING BRACKET CONNECTOR

1. 2. 3. 4. 5. 6. 7. 8.

BRACKET SPACER JOINT NUT WASHER SCREW UPPER SHAFT HOUSING

9. 10. 11. 12. 13. 14. 15. 16.

PIN LOWER SHAFT GAS SPRING BOLT BUSHING CONNECTOR FASTENER HORN CONTACT

Figure 15. Steering Column Assembly, Lift Trucks Manufactured After January, 2012

17


LPG Tank and Bracket Assembly 4. Install two pivot bolts, two bushings, two nuts and bracket onto housing. See Figure 14, for lift trucks manufactured before January 2012. See Figure 15, for lift trucks manufactured after January 2012. 5. Install gas spring and two pins on housing.

100 YRM 1120 • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) NOTE: Perform Step 1 for lift trucks equipped with gas or LPG engines. 1. Install steering column, four bushings and four bolts on cowl standoffs. Tighten bolts to 38 N•m (28 lbf ft). See Figure 13.

See Figure 14, for lift trucks manufactured before January 2012.

NOTE: Perform Step 2 for lift trucks equipped with diesel engines.

See Figure 15, for lift trucks manufactured after January 2012.

2. Install four isolators, steering column, four isolators, four bushings, and four bolts on cowl standoffs. Tighten bolts to 38 N•m (28 lbf ft). See Figure 13.

Install NOTE: Lubricate spline end of lower shaft with multi purpose grease. See one of the Service Manuals for procedures Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809)

3. Install floor plate, floor mats, and steering column covers. See section Hood, Seat, and Side Covers Replacement. 4. Install steering wheel and hex nut on steering column, tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft). Connect electrical wiring and install horn button. See Figure 12. 5. Remove tag from negative battery connector and connect to battery. Adjust steering column to neutral position. 6. Remove blocks from each side of tires.

LPG Tank and Bracket Assembly For procedures to remove and install the LPG tank, LPG tank bracket, and the LPG tank alignment pin, see one of the following Service Manuals. LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models • GLC20-35VX (GLC040-070VX, GLC055SVX) (A910) • GLP20-35VX (GLP040-070VX) (B875) LPG Fuel System, Mazda 2.0L and 2.2L Engines 900 SRM 1125 for lift truck models • GLC20-35VX (GLC040-070VX, GLC055SVX) (A910)

18

• GLP20-35VX (GLP040-070VX) (B875) • GLC030VX, GLC035VX, GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GLP030VX, GLP035VX, GLP040SVX) (C810) LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 for lift truck models • GLC20-35VX (GLC040-070VX, GLC055SVX) (A910) • GLP20-35VX (GLP040-070VX) (B875) • GLC030VX, GLC035VX, GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GLP030VX, GLP035VX, GLP040SVX) (C810)


100 YRM 1120

Counterweight Replacement

Counterweight Replacement REMOVE WARNING The lift truck must be put on blocks for some types of maintenance and repair. 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. 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, onepiece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck.

WARNING DO NOT operate the lift truck if the capscrew for the counterweight is not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

WARNING LPG can cause an explosion. DO NOT cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source. Close the shutoff valve on the LPG tank before any part of the engine fuel system is disconnected. Run the engine until the fuel in the system is used and the engine stops. If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. See Figure 16. One M24 × 3 x 140 capscrew holds the counterweight to the lower part of the frame on lift truck models • GLC30-35VX (GC/GLC060-070VX) (A910) • GLP/GDP30-35VX (GP/GLP/GDP060-070VX) (B875) One M24 × 3 x 90 capscrew holds the counterweight to the lower part of the frame on lift truck models • GLC20-25VX (GC/GLC040-050VX, GC/GLC055SVX) (A910) • GLP/GDP20-25VX (GP/GLP/GDP040-050VX) (B875) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) NOTE: For exhaust system procedure for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 or Gasoline Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1325. For exhaust system procedures for lift trucks built after January, 2010 and equipped with a GM 2.4L engine, go to section LPG Fuel System, GM 2.4L Engine 900 YRM 1124. NOTE: For overhead exhaust system procedures for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 or LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125. NOTE: If lift truck is equipped with an overhead exhaust system, remove the overhead exhaust pipe before removing the counterweight. See the section Exhaust System Repair for the procedures.

19


Counterweight Replacement

100 YRM 1120

1. If the lift truck has an LPG fuel system, see one of the following Service Manuals to remove the LPG tank and bracket, before removing the counterweight, and for additional information on the LPG fuel systems LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck model • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

Table 5 for lift truck models • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) Table 6 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 2. Install a lifting eye in the lift hole of the counterweight. See Figure 16 and Figure 17. Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the counterweight. Remove the tow pin and remove the capscrew that holds the counterweight to the frame. See Figure 16. Use the crane to lift the counterweight from the lift truck. Put counterweight on the floor so that it has stability and will not fall over. Take care not to damage exhaust or cooling components.

LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in . Table 3 for lift truck models • GLC20-35VX GC/GLC055SVX) (A910)

(GC/GLC040-070VX,

Table 4 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809)

20

1. 2. 3. 4. 5. 6. 7.

FRAME HOOK LOWER FRAME MOUNT TOW PIN ROLL PIN CAPSCREW WASHERS LIFT HOLE

Figure 16. Counterweight Installation


100 YRM 1120

Counterweight Replacement

Table 3. Weight of Counterweights, Lift Truck Models GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX ) (A910) Model

Kg

Lb

GLC20VX (GC/GLC040VX)

1040

2293

GLC25VX (GC/GLC050VX)

1395

GC/GLC055SVX

1643

3622

GLC30VX (GC/GLC060VX)

1819

4010

GLC35VX (GC/GLC070VX)

2153

4747

3075

Table 5. Weight of Counterweights, Lift Truck Models GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810) Model

Kg

Lb

GLP/GDP16VX (GP/GLP/GDP030VX)

812

1790

GLP/GDP18VX (GP/GLP/GDP035VX)

887

1955

GLP/GDP20SVX (GP/ GLP/GDP040SVX)

1047

2308

Table 6. Weight of Counterweights, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

Table 4. Weight of Counterweights, Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) Model

Kg

Lb

GC/GLC030VX

772

1702

GC/GLC035VX

963

2123

GC/GLC040SVX

1131

2493

Model

Kg

Lb

GLP/GDP20VX (GP/GLP/GDP040VX)

994

2191

GLP/GDP25VX (GP/GLP/GDP050VX)

1338

2950

GLP/GDP30SVX (GP/ GLP/GDP060SVX)

1664

3668

GLP/GDP35SVX (GP/ GLP/GDP070SVX)

1965

4332

21


Counterweight Replacement

100 YRM 1120

INSTALL

• GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

1. Make sure the seals are on the counterweight. See Figure 17. 2. Use a crane to install the counterweight on the lift truck. When the counterweight is installed, make sure the hooks on the frame fully engage the counterweight so it is aligned with the parts of the frame. Install and tighten the M24 × 3 capscrew to 555 N•m (409 lbf ft). 3. Install tow pin and roll pin. See Tow Pin, Remove and Install for procedures. 4. If the lift truck has an LPG fuel system, see one of the following Service Manuals to install the LPG tank and bracket, after the counterweight has been installed. LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)

22

1. 2. 3. 4. 5. 6.

CAPSCREW LOCKWASHER WASHER COUNTERWEIGHT LIFTING EYEBOLT TOW PIN

7. 8. 9. 10.

ROLL PIN SEAL LIFT HOLE LPG ACCESS HOLE

Figure 17. Counterweight NOTE: For overhead exhaust system procedures for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 or LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125. 5. If lift truck is equipped with an overhead exhaust system, install the overhead exhaust pipe. See the section Exhaust System Repair for the procedures.


100 YRM 1120

Overhead Guard Replacement

TOW PIN, REMOVE AND INSTALL 1. Remove the tow pin from the counterweight by driving the roll pin out. See Figure 18. 2. Install tow pin into counterweight and install roll pin.

1. TOW PIN

2. ROLL PIN

Figure 18. Tow Pin

Overhead Guard Replacement REMOVE AND INSTALL WARNING DO NOT operate the lift truck without the overhead guard correctly fastened to the lift truck.

WARNING DO NOT weld mounts for lights or accessories to legs of the overhead guard. Changes that are made by welding, or by drilling holes that are too big or in the wrong location, can reduce the strength of the overhead guard. See your dealer for Yale lift trucks BEFORE performing any changes to the overhead guard. NOTE: The lift trucks covered in this YRM are equipped with either a high or low overhead guard. The removal and installation procedures for both types of overhead guards are the same. No welding or drilling on legs of overhead guard is permitted as per previous WARNING.

NOTE: The lifting device can be connected to any number of positions on the overhead guard depending upon the lifting device available. The ideal choices are a four point sling connected to all four corners on the top of the overhead guard, or a two point sling connected to two opposite corners of the overhead guard. If a single point hoist is used, make sure that the lift point is as close to the center of the overhead guard. If during the initial start of the lift the overhead guard is off balance lower immediately and move the hoist to a more centered point. 1. Connect a lifting device to remove or install the overhead guard. Loosen clamp and disconnect the air intake hose from the elbow. Remove bolts, elbow, retainer, and grommet from the overhead guard rear leg. See Figure 19. 2. Disconnect any wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that any electrical wires are moved through the holes in the frame so that they are not damaged.

23


Overhead Guard Replacement 3. The rear legs of the overhead guard have two capscrews that are located under the hood inside the engine compartment, next to the radiator. Remove and install the capscrews. See Figure 20. 4. Remove the fender cover, dash, and kick panel to remove and install the three capscrews on the front legs of the overhead guard. See Hood, Seat, and Side Covers Replacement for the removal procedures.

100 YRM 1120

LED TAIL, BACKUP, AND BRAKE LIGHTS, REPLACE These light assemblies are nonrepairable and must be replaced as an assembly. See the section Electrical System 2200 YRM 1142 for the procedures to replace these lights.

5. When installing the overhead guard, tighten the capscrews for the overhead guard legs to 66 N•m (49 lbf ft). See Figure 20.

1. 2. 3. 4.

CAPSCREWS - FRONT LEGS HANDLE CAPSCREWS - REAR LEGS FRAME

Figure 20. Overhead Guard 1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS

4. ELBOW 5. RETAINER 6. GROMMET

Figure 19. Disconnect Air Intake Hose

24


100 YRM 1120

Operator Restraint System Replacement

Operator Restraint System Replacement DESCRIPTION The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 21.

Automatic Locking Retractor (ALR) NOTE: GC/GLC040-070VX, GC/GLC055SVX (A910) lift trucks produced before November 2005 are equipped with the ALR type seat belts. The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 21.

Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt. When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat. A seat belt that is damaged worn or does not operate properly will not provide protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 21 and Figure 22.

NOTE: The following seat belt operation checks must be performed three times before replacing the seat belt assembly. • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly. • With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly. • With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly. Make sure the seat rails and latch striker are not loose. The seat rails must lock securely in position but move freely when unlocked. The seat rails must be securely attached to the mounting surface. The hood must be fully closed. Lift the hood to make sure it is closed and will not move. Adjust hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See the section Hood, Seat, and Side Covers Replacement in this manual for the adjustment procedures for the hood.

25


Operator Restraint System Replacement

100 YRM 1120

A. AUTOMATIC LOCKING RETRACTOR

B. EMERGENCY LOCKING RETRACTOR

1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11.

LATCH STRIKER HOOD LATCH FORWARD/BACKWARD ADJUSTMENT HOOD OPERATOR WEIGHT ADJUSTMENT SEAT RAIL

ARM REST SEAT BELT SEAT HIP RESTRAINT HOOD HINGE

Figure 21. Operator Restraint System

Figure 22. Operator Restraint System

26


100 YRM 1120

Engine Replacement

Legend for Figure 22 A. STANDARD, NON-SUSPENSION SEAT

B. FULL SUSPENSION SEAT

1. 2. 3. 4.

5. BACKREST ANGLE ADJUSTMENT LEVER 6. ARMREST 7. SWIVEL LATCH RELEASE LEVER

SEAT BELT WEIGHT ADJUSTMENT KNOB RIDE POSITION INDICATOR FORWARD/BACKWARD ADJUSTMENT LEVER

Engine Replacement REMOVE 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. 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 8000 YRM 1150 for lift truck models (GC/GLC040-070VX,GC/ • GLC20-35VX GLC055SVX ) (A910) (GP/GLP/GDP040-070VX) • GLP/GDP20-35VX (B875 Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/GLP/ GDP030-35VX, GP/GLP/GDP040SVX) (C810)

WARNING LPG can cause an explosion. DO NOT cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipments, or ignition source. 1. For lift trucks equipped with an LPG fuel system, close the shutoff valve on the tank and run engine until all fuel is gone and engine stops. 2. If lift truck is equipped with an LPG fuel tank, swing tank to the side. See one of the following Service Manuals for procedures: LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models (GC/GLC040-070VX, • GLC20-35VX (A910) GC/GLC055SVX) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models GC/GLC035VX, • GC/GLC030VX, GC/GLC040SVX (C809) GLP/GDP18VX, • GLP/GDP16VX, (GP/GLP/GDP030VX, GLP/GDP20SVX GP/GLP/GDP040SVX) GP/GLP/GDP035VX, (C810) (GC/GLC040-070VX, • GLC20-35VX GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

WARNING Always disconnect the cables at the battery before you make repairs to the engine. Disconnect the cable at the negative terminal first.

27


Engine Replacement LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 3. Remove overhead guard. See section Overhead Guard Replacement for procedures. 4. Remove the floor mat and floor plate.

WARNING

100 YRM 1120 10. Disconnect the ground strap from the frame and remove the power distribution module (PDM) from the battery tray. See Figure 23. 11. Remove three capscrews from the battery tray and remove the battery and battery tray. See Figure 23. 12. Disconnect the remaining coolant hoses from the radiator and cap them to prevent leakage. 13. On lift trucks equipped with a Mazda engine (except Mazda 2007 emission compliant engines and lift trucks built after January, 2010 equipped with a Mazda engine) and Basic Powershift Transmission, disconnect the throttle linkage (see the section Powershift Transmission, Repair 1300 YRM 1129). Disconnect the exhaust system. 14. Remove the radiator fan pulley, shroud, and fan assembly. See the section Cooling System 700 YRM 1123 for the removal procedures.

DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 5. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under radiator. Remove radiator cap.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Open the drain plug or disconnect the bottom radiator hose to drain coolant from radiator and engine. 7. Remove the hood and seat combination and rear side covers. See the section Hood, Seat, and Side Covers Replacement for procedures. NOTE: Trucks equipped with a Yanmar Diesel Engine do not have an ECM. 8. On lift trucks with the GM 2.4L engine, disconnect the ECM from air filter and remove two bolts holding ECM and mounting bracket to air filter, before removing the air filter. 9. On lift trucks equipped with a Mazda 2.0L or 2.2L engine, disconnect ECM connector from ECM. Remove two bolts and ECM bracket, with ECM attached, from engine block.

28

1. 2. 3. 4. 5.

BATTERY BATTERY TRAY PDM BATTERY LOCKDOWN BAR GROUND STRAP

Figure 23. Power Distribution Module, Disconnection


100 YRM 1120

Engine Replacement

WARNING All fuels are very flammable and can burn or cause an explosion. DO NOT use an open flame to check the fuel level or to check for leaks in the fuel system. No smoking. Breathing fuel vapor may cause nausea, unconsciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor. 15. Disconnect the fuel lines at the engine. Put caps on fuel lines to prevent fuel leakage. NOTE: Lift trucks equipped with Yanmar diesel engine do not have an ECM. NOTE: Lift trucks equipped with 2007 Mazda emission compliant engines and lift trucks built after January, 2010 equipped with Mazda engines, do not have a governor controller and the ECM for these engines is mounted on the side of the engine. 16. For lift trucks built before 2007, equipped with Mazda engines - Disconnect the electronic control

module (ECM) connector and governor controller from the side of the frame before removing the engine from the truck. 17. 2007 Mazda emission compliant engines only - Disconnect the engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck. 18. Lift trucks built after January, 2010 equipped with Mazda engines - Disconnect the engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck. 19. Use the access port on the side of engine and remove the four bolts that attach the flywheel to the torque converter. See Figure 24. 20. Connect a lifting device to the engine. Put a block under the transmission housing to support the transmission. NOTE: Perform Step 21 for lift trucks equipped with iron housing transmission. 21. Remove capscrews from transmission bell housing.

A. TYPICAL FOR MAZDA AND YANMAR ENGINES

B. TYPICAL FOR GM ENGINES

1. ACCESS PORT

2. FLYWHEEL HOUSING

Figure 24. Torque Converter Bolt Access

29


Engine Replacement

100 YRM 1120

NOTE: Perform Step 22 through Step 24 for lift trucks equipped with aluminum housing transmission. 22. Remove two capscrews, two washers, and converter housing cover from torque converter housing. See Figure 25. 23. Remove four flange bolts from torque converter housing and flywheel housing on transmission side. See Figure 25. 24. Remove six hex head capscrews and six lock washers from flywheel housing and torque converter housing on flywheel housing side. See Figure 25.

WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 194 kg (428 lb). 25. Remove the flange nuts, washers, bolts, and isolators from the engine mounts. Remove engine adapter to transmission bolts. On trucks equipped with a GM 2.4L engine, remove one starter bolt. See Figure 26 and Figure 27.

NOTE: TYPICAL FOR ALL ENGINES. GM 2.4L LPG AND ALUMINUM CASE TRANSMISSION SHOWN. 1. 2. 3. 4. 5. 6.

CONVERTER HOUSING COVER CAPSCREW WASHER TORQUE CONVERTER HOUSING EYEBOLT BRACKET HEX HEAD CAPSCREW

7. 8. 9. 10. 11.

FLYWHEEL HOUSING TRANSMISSION ASSEMBLY FLANGE BOLT LOCKWASHER ENGINE ASSEMBLY

Figure 25. Flywheel and Torque Converter Housings

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100 YRM 1120

Engine Replacement

A. MAZDA ENGINE B. GM 2.4L ENGINE 1. FRAME 2. ENGINE MOUNT 3. FLANGE NUT

Figure 26. Engine Removal

A. MAZDA AND YANMAR ENGINE MOUNT B. GM ENGINE MOUNT 1. 2. 3. 4. 5. 6. 7.

LEFT ENGINE MOUNT RIGHT ENGINE MOUNT WASHER CAPSCREW CROSSMEMBER ISOLATOR FLANGE NUT

Figure 27. Engine Mounts

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Engine Replacement

CAUTION When separating the engine away from the transmission, place a piece of plywood in front of radiator. This will keep the engine from damaging the radiator.

CAUTION Keep the engine level when the engine is separated from the transmission so the drive plate is not damaged. 26. Use the lifting device to carefully move the engine away from the torque converter. Make sure all hoses, wires, and cables are disconnected from the engine, then lift the engine from the frame and place engine on blocks. 27. Remove torque converter from torque converter housing.

INSTALL WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 194 kg (428 lb).

CAUTION Keep the engine level when installing the engine to the transmission so the drive plate is not damaged. 1. Install torque converter in torque converter housing. 2. Connect lifting device to engine and lift engine into frame.

100 YRM 1120 6. Install six lock washers and six capscrews on flywheel housing and torque converter housing from flywheel housing side. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 25. 7. Install four flange bolts on torque converter housing and flywheel housing from transmission side. Tighten bolts to 38 N•m (28 lbf ft). See Figure 25. 8. On trucks equipped with a GM 2.4L engine, install starter bolt. 9. Install converter housing cover, two washers, and two capscrews on torque converter housing. Tighten capscrews to 19 N•m (168 lbf in). See Figure 25. NOTE: For procedures to install exhaust pipe to exhaust manifold for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 equipped with a Mazda engine, see Gasoline Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1325 or LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326. 10. Install exhaust pipe to exhaust manifold. See Exhaust System Repair. 11. For lift trucks built before 2007, equipped with Mazda engines - Connect the ECM connector and governor controller to lift truck frame. 12. On lift trucks equipped with a Mazda 2.0L or 2.2L engine, install ECM bracket with ECM attached and two bolts on engine block.

WARNING

3. Install isolators on engine mounts. Install the nuts and bolts for the engine mounts to secure engine to frame. See Figure 26 and Figure 27. Tighten the nuts to 150 N•m (110 lbf ft).

All fuels are very flammable and can burn or cause an explosion. DO NOT use an open flame to check the fuel level or to check for leaks in the fuel system.

4. Use access port on side of engine and install bolts to hold torque converter to flywheel. Tighten bolt to 56 N•m (41 lbf ft). See Figure 24.

Breathing fuel vapor may cause nausea, unconsciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor.

NOTE: Perform Step 5 for lift trucks equipped with iron transmission housing. 5. Align transmission bell housing holes with flywheel housing holes and install capscrews. Tighten capscrews to 38 N•m (28 lbf ft). NOTE: Perform Step 6 through Step 9 for lift trucks equipped with aluminum transmission housing.

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No smoking.

13. Connect the wires and wiring harnesses at the engine. Remove caps from fuel lines and connect the fuel lines at the engine.


100 YRM 1120 NOTE: On trucks equipped with the GM 2.4L engine, connect the ECM and install ECM and mounting bracket to air filter with two bolts, before installing the air filter to lift truck. 14. On lift trucks equipped with a Mazda engine (except Mazda 2007, and later, emission compliant engines) and Basic Powershift Transmission, connect the throttle linkage (see the section Powershift Transmission, Repair 1300 YRM 1129). Install the air filter assembly. 15. Connect the coolant hoses and lines to the transmission. Fill cooling system with a mixture of 50 percent deionized water and 50 percent ethylene glycol boron-free antifreeze. 16. Install the radiator shroud, fan pulley, and fan assembly. See the section Cooling System 700 YRM 1123 for the installation procedures. 17. Connect the PDM and connect the ground strap to lift truck frame and attach it to battery. Install the battery and battery tray. See Figure 23. 18. If lift truck is equipped with an LPG tank, swing tank into position on truck. See one of the following Service Manuals for procedures: LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

Engine Replacement LPG Fuel System, Mazda FE and F2 Emission Compliant Engines 900 YRM 1326 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 19. Install the rear side covers, floor plates, floor mat, and hood and seat combination. See the section Hood, Seat, and Side Covers Replacement for the procedures. 20. If removed, install Overhead guard. See section Overhead Guard Replacement for procedures. 21. Check all fluid levels as described in the section Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 22. Empty drain pan contents.

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YALE B875 GDP25VX LIFT TRUCK Service Repair Manual  
YALE B875 GDP25VX LIFT TRUCK Service Repair Manual  
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