Yale d879 glc70vx lift truck (europe) service repair manual by 1636772

GLC/GDC60VX, GLC/GDC70VX (D879) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM 4.3L)...................................................................................... LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)................... STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524288189 524265337 524223757 524262275 550043871 524288194 524294873 524288199 524223764 524262279 524223766 550073240 524223767 524294878 524208014 524223769 524223770 524223771 524223772

0100 YRM 1316 0600 YRM 1251 0700 YRM 1123 0900 YRM 1242 0900 YRM 1556 1300 YRM 1317 1300 YRM 1343 1400 YRM 1318 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2100 YRM 1328 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142

08/13 05/14 03/13 08/12 04/14 03/13 03/14 12/13 07/13 03/13 04/14 12/14 04/14 02/14 05/14 12/14 12/14 12/14 04/14

524265342 524150797 524223780 524288207 524288212 524329117 550001092 524221866

4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1319 8000 YRM 1320 8000 YRM 1387 8000 YRM 1409 9000 YRM 1112

02/14 10/13 12/14 01/14 12/12 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. 524329187 (12/14)

100 YRM 1316

Description

General • GM Engines, 4.3 Liter V-6 600 YRM 1251 • Kubota Diesel 3.8L Engines 600 YRM 1557

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 any blocks used to support the lift truck are solid, one-piece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck.

If additional transmission repairs are necessary for lift trucks covered in this manual see: • Powershift Transmission, Repair 1300 YRM 1129 • Powershift Transmission, Repair 1300 YRM 1529 • One and Two Speed Transmissions, Repair 1300 YRM 1569 • Three-Speed Powershift Transmission Repair 1300 YRM 1317 • Two-Speed Powershift Transmission Repair 1300 YRM 1343 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, and exhaust system 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.

If additional engine repairs are necessary for lift trucks covered in this manual see:

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 Table 2.

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.

Description

1. COWL PLATE 2. FENDERS 3. HOOD MOUNTS

100 YRM 1316

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

Figure 1. Frame

100 YRM 1316

Hood, Seat, Dash, and Side Covers Replacement

Hood, Seat, Dash, and Side Covers Replacement REMOVE 1. Remove the floor mat and floor plate. See Figure 3. 2. Slide the seat to the closest position to the steering column. 3. Fully tilt the steering column forward. 4. If your truck is equipped with an LPG tank, swing the tank off to the side. Push in the bracket release pin, swing the tank and bracket out to the side of the lift truck. If your truck is equipped with a swing-out and drop-down LPG tank bracket (EZ Tank Bracket), swing the tank down to the side of the truck for ease of removal. See one of the following Service Manuals for procedures to swing the LPG tank to the side.

• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models: • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879, E879, F879) 5. Raise the hood latch, unlatch and lift up the hood. See Figure 2. 6. Remove the two capscrews holding the left and right rear side panel to the frame. Remove the rear side panel from the frame. See Figure 3.

LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models:

Hood, Seat, Dash, and Side Covers Replacement

100 YRM 1316

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. 3-D VIEW OF VENTED HOOD WITH SWIVEL SEAT

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13.

SEAT HOOD FRAME SEAT WIRE HARNESS SEAT WIRE HARNESS CONNECTOR CABLE CLIPS HINGE SCREWS GAS SPRING ATTACHMENT HOLES ATTACHING HOOD TO SEAT (SEMI-SUSPENSION)

SEAT WIRE HARNESS BRACKETS SEAT LINER HOOD LATCH ATTACHMENT HOLES ATTACHING HOOD TO SEAT (NON-SUSPENSION) 14. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (FULL SUSPENSION) 15. SPACER 16. FLANGE NUTS

Figure 2. Hood and Seat Arrangement

100 YRM 1316

1. 2. 3. 4. 5. 6. 7. 8. 9.

Hood, Seat, Dash, and Side Covers Replacement

DEBRIS COVER COUNTERWEIGHT COVER RADIATOR COVER LEFT SIDE REAR PANEL (GAS AND DIESEL SHOWN) RIGHT SIDE REAR PANEL UPPER STEERING COLUMN COVER LOWER STEERING COLUMN COVER SEAL FLOOR MAT

10. FLOOR PLATE 11. SPLASH SHIELD (GAS AND DIESEL) 12. CAPSCREW 13. FOLD OVER NUT 14. SEAL PLATE ASSEMBLY 15. RIGHT SIDE FRONT FENDER COVER 16. RIGHT SIDE STEP PLATE 17. RIGHT SIDE STEP PLATE 18. DASH ASSEMBLY 19. KICK PANEL

Figure 3. Side Covers, Floor Plate, and Cowl Components

Hood, Seat, Dash, and Side Covers Replacement 7. Remove the two capscrews holding the left and right fender covers to the front overhead guard leg. Remove covers. See Figure 3. 8. Remove the four capscrews holding the left and right front side panels to the frame. Remove panels. 9. Fully lower the steering column. 10. Remove upper steering column cover by pulling up on upper steering column cover to release the latches (one on either side), and pulling cover away from steering column. See Figure 4. 11. Remove the five fasteners (see Figure 4) securing the dash to the top of the cowl. Remove the four clips, located underneath dash, that attach the dash to the kick panel. Lift to remove the dash. 12. Lift the kick panel to remove it from the truck. See Figure 3. 13. Remove the three capscrews holding the seal plate. Remove seal plate. See Figure 5. 14. Disconnect the 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 the seat is to be removed, and truck is equipped with a non-swivel seat, remove the seat wire harness from the seat wire harness brackets that are attached to the underside of the hood. Remove the

100 YRM 1316 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 the underside of the hood and behind the seat. See Figure 2. 16. Remove the four flange nuts holding the seat to the hood. Lift the seat off the hood. Pull the seat wire harness through the hood. See Figure 2. 17. Remove the capscrews and washers at the top of the gas springs. Remove gas springs from the hood. See Figure 2. 18. Remove the hinge screws, located in the rear of the hood. 19. Lift the hood from the truck. See Figure 2.

INSTALL 1. Place the hood onto the lift truck frame. 2. Install the hinge screws, located in the rear of the hood, and tighten to 38 Nâ&#x20AC;˘m (28 lbf ft). See Figure 2. 3. Align the holes in the gas springs with holes in the hood. There are two sets of holes used to install the gas springs to the hood, based on the type of seat the installed on the lift truck. One set is for installing the cylinder end of the gas springs and the other set is for attaching the rod end of the gas springs. Install capscrews and washers to attach gas springs to the hood. Refer to Figure 6 and Table 1 for correct holes used to connect the rod end of the cylinder, depending on the type of seat installed on the lift truck. Tighten capscrews to 19.2 Nâ&#x20AC;˘m (170 lbf in).

100 YRM 1316

Hood, Seat, Dash, and Side Covers Replacement

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 4. Remove Dash From Cowl

Hood, Seat, Dash, and Side Covers Replacement

1. CAPSCREWS

100 YRM 1316

2. SEAL PLATE

Figure 5. Remove Seal Plate From Dash

100 YRM 1316

Hood, Seat, Dash, and Side Covers Replacement

NOTE: SEE TABLE 1 FOR HOLES TO USE TO ATTACH ROD END OF GAS SPRING. A. LEFT SIDE B. RIGHT SIDE

C. FULL SUSPENSION SEAT D. NON-SUSPENSION SEAT

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 6. Gas Spring Installation

Hood, Seat, Dash, and Side Covers Replacement

100 YRM 1316

Table 1. Gas Spring Installation, Holes for Installing Rod Ends (See Figure 6) Counterweight Type Standard Counterweight

Full or Semi Suspension Seat Left Side

Right Side

Left Side

Right Side

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 the hood to ensure that the center pin strikes the hood latch properly and that the stop screw contacts the frame. A properly closed hood MUST click twice on the hood latch. If the hood latch does not close properly, loosen the capscrews on the back of the center pin and adjust the center pin up or down as required for correct alignment. See Figure 7. 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.

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. 6. Place the seat on the hood and thread the seat wire harness through the hole in the hood. See Figure 2.

Non-Suspension Seat

7. Align the holes in the seat with the holes in the hood. Insert washers and capscrews. Tighten capscrews to 18 Nâ&#x20AC;˘m (159 lbf in). 8. 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. 9. Check operation of hood latch. Have an operator sit in the seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 5. 10. Using three capscrews, Install seal plate. See Figure 5. 11. Install kick panel onto truck. See Figure 3. 12. Install dash and allen screws to top of cowl. See Figure 4. Tighten capscrews to 0.5 to 0.6 Nâ&#x20AC;˘m (5 to 6 lbf in). 13. Install four clips to attach the dash to kick panel. See Figure 4.

100 YRM 1316

Hood, Seat, Dash, and Side Covers Replacement

14. Install upper and lower steering column covers by connecting the two covers together and pressing each side until latched. 15. Using four capscrews, install the left and right front side panels to frame. See Figure 3. 16. Using two capscrews install the left and right fender covers to front of overhead guard legs. 17. Using two capscrews, install the left and right rear side covers to frame. See Figure 3. 18. Install the floor mat and floor plate. 19. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight. See one of the following Service Manuals for procedures to swing the LPG tank onto the counterweight. LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models: • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models: • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879, E879, F879) 20. Adjust the steering column and seat positions.

1. HOOD 2. HOOD LATCH

3. CENTER PIN 4. CAPSCREW

Figure 7. Hood Latch Adjustment

Steering Column

100 YRM 1316

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 8.

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 10. 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 10.

Disassemble

STEERING COLUMN REPAIR

NOTE: Remove and discard snap rings if installed.

Remove

1. Remove two pins and gas spring from housing.

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 battery connector or negative battery cable stating, DO NOT CONNECT BATTERY. Move steering column to 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: This procedure is for removal of all components of steering column assembly. Not all components are removed for a repair procedure. Do only those steps of procedure necessary to remove required component. NOTE: Tag wires prior to disconnect. 3. Remove horn button assembly and disconnect electrical wires. Remove large hex nut and steering wheel from steering column. See Figure 9. 4. Remove steering column covers. Remove floor mats and floor plate. See section Hood, Seat, Dash, and Side Covers Replacement.

See Figure 11, for lift trucks manufactured before January, 2012. See Figure 12, for lift trucks manufactured after January, 2012. 2. Remove two pivot bolts, two bushings, two nuts and bracket from housing. See Figure 11, for lift trucks manufactured before January, 2012. See Figure 12, for lift trucks manufactured after January, 2012. 3. Remove split pin and lower shaft from upper shaft. See Figure 11, for lift trucks manufactured before January, 2012. See Figure 12, 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. See Figure 11, for lift trucks manufactured before January, 2012. See Figure 12, for lift trucks manufactured after January, 2012.

100 YRM 1316

Steering Column

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

1. 2. 3. 4.

HORN BUTTON HEX NUT STEERING WHEEL STEERING COLUMN

Figure 9. Steering Wheel Remove/Install

Figure 8. Steering Column and Cowl

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

4. STEERING COLUMN 5. COWL STANDOFF

Figure 10. Steering Column Remove/Install 13

Steering Column

100 YRM 1316

Figure 11. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012

100 YRM 1316

Steering Column

Legend for Figure 11 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

Steering Column

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

BRACKET SPACER JOINT NUT WASHER SCREW UPPER SHAFT HOUSING

100 YRM 1316

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

PIN LOWER SHAFT GAS SPRING BOLT BUSHING CONNECTOR FASTENER HORN CONTACT

Figure 12. Steering Column Assembly, Lift Trucks Manufactured After January, 2012

Clean WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturerâ&#x20AC;&#x2122;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 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.

100 YRM 1316

LPG Tank and Bracket Replacement

Assemble NOTE: This procedure is for installation of all components of steering column assembly. Not all components are removed for a repair procedure. Do only those steps of procedure necessary to install required component. NOTE: Perform Step 1 only for lift trucks manufactured before January, 2012. 1. Lubricate horn contact slip rings with a small amount of conductive grease (Yale P/N 582014302). 2. Install fastener, connector bracket and connector, two horn contacts and four screws. See Figure 11, for lift trucks manufactured before January 2012. See Figure 12, for lift trucks manufactured after January 2012. 3. Assemble lower shaft and upper shaft, secure with spit pin. See Figure 11, for lift trucks manufactured before January 2012. See Figure 12, for lift trucks manufactured after January 2012. 4. Install two pivot bolts, two bushings, two nuts and bracket onto housing. See Figure 11, for lift trucks manufactured before January 2012. See Figure 12, for lift trucks manufactured after January 2012.

See Figure 11, for lift trucks manufactured before January 2012. See Figure 12, for lift trucks manufactured after January 2012.

Install NOTE: Lubricate spline end of lower shaft with multi purpose grease, see Periodic Maintenance Manual for your lift truck. 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 10. NOTE: Perform Step 2 for lift trucks equipped with diesel engines. 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 10. 3. Install floor plate, floor mats, and steering column covers. See section Hood, Seat, Dash, 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 9. 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.

5. Install gas spring and two pins on housing.

LPG Tank and Bracket Replacement 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 4.3L Engine With PSI 900 YRM 1556 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818) • GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP5055VX (GLP080, 90, 100, 110, 120VX) (G813, H813, J813)

LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (C879, D879) LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879, E879, F879)

Counterweight Replacement

100 YRM 1316

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 frame by two hooks that are part of frame. One M30 x 3.5 x 120 capscrew holds counterweight to lower part of frame. See Figure 13. NOTE: If lift truck is equipped with an overhead exhaust system, remove overhead exhaust pipe before removing counterweight. See section Exhaust System Repair for procedures. 1. If lift truck has an LPG fuel system, see one of the following Service Manuals to remove the LPG tank and bracket so that the counterweight can be removed. LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (C879, D879) LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879, E879, F879)

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 2. 2. Install a lifting eye in lift hole of counterweight. See Figure 13. Connect a crane to lifting eye and raise crane until it holds part of weight of counterweight. Remove tow pin and remove capscrew that holds counterweight to frame. See Figure 13. Use crane to lift counterweight from lift truck. Put counterweight on floor so that it has stability and will not fall over. Take care not to damage exhaust or cooling components.

INSTALL 1. Make sure seals are on counterweight. See Figure 14. 2. Use a crane to install counterweight on lift truck. When counterweight is installed, make sure hooks on frame fully engage counterweight so it is aligned with parts of frame. Install and tighten capscrew to 1020 N•m (750 lbf ft).

100 YRM 1316

Counterweight Replacement

3. Install tow pin and roll pin, if equipped. See section Tow Pin for procedures. 4. If lift truck has an LPG fuel system, see one of the following Service Manuals to install LPG tank and bracket, after counterweight has been installed. LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (C879, D879) LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879, E879, F879) 5. If lift truck is equipped with an overhead exhaust system, install overhead exhaust pipe. See section Exhaust System Repair for procedures.

TOW PIN Remove and Install 1. Remove tow pin from counterweight by driving roll pin out. See Figure 15. 2. Install tow pin into counterweight and install roll pin.

Remove and Install For Lift Truck ModelsGLC55SVX (GC/GLC80XVBCS, GC/GLC100VXBCS; GC/GLC120SVX; and GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 1. Remove tow pin from counterweight by grasping wire and pulling tow pin from counterweight. See Figure 16.

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

FRAME HOOK SEALS CAPSCREW COUNTERWEIGHT COVER COUNTERWEIGHT TOW PIN ROLL PIN WASHER

Figure 13. Counterweight Installation Table 2. Weight of Counterweights Model

Weight

GLC/GDC60VX GLC/GDC70VX GC/GLC/GDC135VX GC/GLC/GDC155VX (C879, D879, E879, F879)

2779 kg (6126 lb)

2. Install tow pin into counterweight dropping tow pin into counterweight.

Counterweight Replacement

1. 2. 3. 4.

CAPSCREW COUNTERWEIGHT COVER COUNTERWEIGHT TOW PIN

100 YRM 1316

5. ROLL PIN 6. WASHER 7. SEALS

Figure 14. Counterweight Components

100 YRM 1316

1. TOW PIN

Counterweight Replacement

2. ROLL PIN

Figure 15. Tow Pin

1. WIRE

2. TOW PIN

Figure 16. Tow Pin

Overhead Guard Replacement

100 YRM 1316

Overhead Guard Replacement REMOVE 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 overhead guard depending upon lifting device available. The ideal choices are a four point sling connected to all four corners on top of overhead guard, or a two point sling connected to two opposite corners of overhead guard. If a single point hoist is used, make sure that lift point is in center of overhead guard. If during initial start of lift, the overhead guard is off balance, lower immediately and move hoist to a more centered point. 1. Connect a lifting device to remove overhead guard. Loosen clamp and disconnect air intake hose from elbow. Remove bolts, elbow, retainer, and grommet from overhead guard rear leg. See Figure 17.

NOTE: Perform Step 2 for lift truck models GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) equipped with Diesel Particulate Filter (DPF). 2. Disconnect wires from back of DPF display. See Figure 19. 3. Disconnect wires between frame and overhead guard. When overhead guard is lifted from frame, make sure that electrical wires are moved through holes in overhead guard so that they are not damaged. NOTE: Perform Step 4 for lift truck models GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879). 4. The rear legs of overhead guard have two capscrews that are located under hood inside engine compartment, next to radiator. Remove capscrews. See Figure 18. NOTE: Perform Step 5 for lift truck models GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879). 5. The rear legs of overhead guard have three capscrews and a nut that are located under hood inside engine compartment, next to radiator. Remove capscrews and nuts. See Figure 19. 6. Remove fender cover, dash, and kick panel to remove two capscrews on front legs of overhead guard. See Hood, Seat, Dash, and Side Covers Replacement for removal procedures. 7. Using a lifting device, remove overhead guard from frame and place on floor.

100 YRM 1316

INSTALL 1. Connect lifting device to top of overhead guard. Install overhead guard in position on lift truck. 2. Install two capscrews on front legs of overhead guard. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 18.

Overhead Guard Replacement

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

NOTE: Perform Step 3 for lift truck models GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) equipped with Diesel Particulate Filter (DPF). 3. Connect wires to back of DPF display. See Figure 19. 4. Install fender cover, dash, and kick panel. See Hood, Seat, Dash, and Side Covers Replacement for installation procedures. 5. Install two capscrews on rear legs of overhead guard. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 18. NOTE: Perform Step 6 for lift truck models GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879). 6. Install three capscrews and nut on rear legs of overhead guard. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 19. 7. Connect air intake hose by installing bolts, elbow, retainer, and grommet to overhead guard rear leg. See Figure 17. 1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS

4. ELBOW 5. RETAINER 6. GROMMET

Figure 17. Disconnect Air Intake Hose

Overhead Guard Replacement

100 YRM 1316

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

CAPSCREWS - FRONT LEGS HANDLE CAPSCREWS - REAR LEGS FRAME DPF DISPLAY NUT

Figure 19. Overhead Guard 1. 2. 3. 4.

CAPSCREWS - FRONT LEGS HANDLE CAPSCREWS - REAR LEGS FRAME

Figure 18. Overhead Guard

100 YRM 1316

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 operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 20. The seat belt, when properly buckled across operator, will permit slight operator repositioning without activating locking mechanism. If truck tips, travels off a dock, or comes to a sudden stop, locking mechanism will be activated and hold the operator’s lower torso in seat. A seat belt that is damaged, worn or does not operate properly will not provide protection when it is needed. The end of belt must fasten correctly in latch. The seat belt must be in good condition. Replace seat belt if damage or wear is seen. See Figure 20. The following seat belt operation checks must be performed: • With hood closed and in locked position, pull seat belt slowly from retractor assembly. Make sure seat belt pulls out and retracts smoothly. If seat belt does not pull out of retractor assembly, internal latch may be locked. Pull firmly on seat belt and hold for a moment to remove slack from belt in retractor. Release

seat belt. Seat belt will retract and internal latch will unlock. If seat belt cannot be pulled from retractor assembly or belt will not retract, replace seat belt assembly. • With hood closed and in locked position, pull seat belt with a sudden jerk. Make sure seat belt will not pull from retractor assembly. If seat belt can be pulled from retractor, when it is pulled with a sudden jerk, replace seat belt assembly. • With hood in open position, make sure seat belt will not pull from retractor assembly. If seat belt can be pulled from retractor, with hood in open position, replace seat belt assembly. Make sure seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked. The seat rails must be correctly fastened to hood and hood fastened to hinges on frame. The hood must be fully closed. Attempt to lift hood to make sure it is closed. Adjust hood, hood latch, and latch striker when any of parts of operator restraint system are installed or replaced. See section Hood, Seat, Dash, and Side Covers Replacement in this manual for adjustment procedures for hood.

Operator Restraint System Replacement

1. 2. 3. 4.

WEIGHT ADJUSTMENT LEVER HIP RESTRAINT SEAT BELT LATCH SEAT

100 YRM 1316

5. HOOD 6. SEAT RAIL 7. SPACER

Figure 20. Operator Restraint System

100 YRM 1316

Engine Replacement

Engine Replacement REMOVE ENGINE ONLY 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, 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. The engine can be removed with or without transmission. Follow procedures below to remove engine without transmission. See Figure 21.

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

2. If lift truck is equipped with an LPG fuel tank, swing tank to side. See one of the following Service Manuals: LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (C879, D879) LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models • GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879, E879, F879) 3. Remove floor mat and floor plate.

WARNING 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. 4. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than capacity of cooling system under radiator. Remove radiator cap.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 5. Open drain plug or loosen hose clamp and disconnect bottom radiator hose to drain coolant from radiator and engine. See Figure 22 and Figure 23 for lift trucks equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 and Figure 26 for lift truck models equipped with Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine.

Engine Replacement

100 YRM 1316

Figure 21. Engine and Transmission Mounting Arrangement

100 YRM 1316

Engine Replacement

Legend for Figure 21 NOTE: PART OF FRAME NOT SHOWN FOR CLARITY. A. GM 4.3L ENGINE B. CUMMINS 4.5L DIESEL ENGINE

C. CUMMINS QSB 3.3L DIESEL ENGINE D. KUBOTA 3.8L DIESEL ENGINE

1. 2. 3. 4. 5.

6. FRAME 7. ENGINE HARNESS CONNECTOR 8. LEFT CHASSIS WIRING HARNESS CONNECTOR

TRANSMISSION ISOLATOR ASSEMBLY TRANSMISSION MOUNTING BRACKET ENGINE MOUNTING BRACKET ENGINE CROSSMEMBER ENGINE ISOLATOR ASSEMBLY

Engine Replacement

100 YRM 1316

Figure 22. GM 4.3L LPG Engine with GFI and Transmission

100 YRM 1316

Engine Replacement

Legend for Figure 22 NOTE: GFI FUEL SYSTEM SHOWN. PSI FUEL SYSTEM IS SIMILAR. NOTE: GM 4.3L GASOLINE ENGINE IS SIMILAR. A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

BOTTOM RADIATOR HOSE AIR FILTER HOSE AIR FILTER AND BRACKET ASSEMBLY LEFT HAND CHASSIS HARNESS CONNECTOR ENGINE HARNESS CONNECTOR LPG REGULATOR CONNECTOR RIGHT HAND CHASSIS HARNESS ELECTRONIC CONTROL MODULE (ECM) POWER DISTRIBUTION MODULE (PDM) BATTERY AND BATTERY TRAY COOLANT HOSES FAN PULLEY AND FAN SPACER FAN SHROUD EXHAUST PIPE TO EXHAUST MANIFOLD

FUEL LINES LEFT SIDE ENGINE MOUNT STARTER MOTOR CAPSCREWS BELL HOUSING RADIATOR CAP OUTPUT YOKE TRANSMISSION MOUNT FLANGE NUT WASHERS ISOLATORS BRAKE COOLING LINES BATTERY CABLE (POSITIVE) BATTERY CABLE (NEGATIVE)

Engine Replacement

100 YRM 1316

Figure 23. GM 4.3L LPG Engine with PSI and Transmission

100 YRM 1316

Engine Replacement

Legend for Figure 23 NOTE: GM 4.3L GASOLINE ENGINE IS SIMILAR. A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

BOTTOM RADIATOR HOSE AIR FILTER HOSE AIR FILTER AND BRACKET ASSEMBLY LEFT HAND CHASSIS HARNESS CONNECTOR ENGINE HARNESS CONNECTOR FUEL SENDING UNIT RIGHT HAND CHASSIS HARNESS ELECTRONIC CONTROL MODULE (ECM) POWER DISTRIBUTION MODULE (PDM) BATTERY AND BATTERY TRAY COOLANT HOSES FAN PULLEY AND FAN SPACER FAN SHROUD EXHAUST PIPE TO EXHAUST MANIFOLD

Engine Replacement

100 YRM 1316

Figure 24. Cummins QSB 3.3L Diesel Engine and Transmission

100 YRM 1316

Engine Replacement

Legend for Figure 24 A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

RADIATOR CAP SHROUD BOTTOM COOLANT HOSE AIR FILTER HOSE AIR FILTER AND BRACKET EXHAUST PIPE TO EXHAUST MANIFOLD ENGINE MOUNTING BRACKETS FUEL LINES ENGINE HARNESS CONNECTOR BRAKE COOLING LINE

HYDRAULIC SUPPLY LINE TRANSMISSION MOUNTING BRACKET ELECTRONIC CONTROL MODULE RIGHT HAND ENGINE HARNESS HYDRAULIC RETURN LINE BATTERY AND BATTERY TRAY BATTERY CABLE (POSITIVE) BATTERY CABLE (NEGATIVE) FAN SPACER AND FAN PULLEY CHARGE AIR HOSE

Engine Replacement

100 YRM 1316

Figure 25. Kubota 3.8L Engine and Transmission for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879)

100 YRM 1316

Engine Replacement

Legend for Figure 25 A. TOP VIEW

B. SIDE VIEW

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

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

SHROUD RADIATOR CAP BATTERY CABLE (NEGATIVE) BATTERY AND BATTERY TRAY BATTERY CABLE (POSITIVE) TRANSMISSION COOLING HOSE HYDRAULIC SUPPLY LINE TRANSMISSION MOUNTING BRACKET

BRAKE COOLING LINE ENGINE HARNESS CONNECTOR AIR FILTER AND BRACKET AIR FILTER HOSE FAN, SPACER, AND FAN PULLEY BOTTOM COOLANT HOSE ENGINE MOUNTS EXHAUST PIPE TO EXHAUST MANIFOLD

Engine Replacement

100 YRM 1316

Figure 26. Kubota 3.8L Engine and Transmission for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879)

100 YRM 1316

Engine Replacement

Legend for Figure 26 A. TOP VIEW B. SIDE VIEW 1. 2. 3. 4. 5. 6. 7. 8.

SHROUD RADIATOR CAP BATTERY CABLE (NEGATIVE) BATTERY AND BATTERY TRAY BATTERY CABLE (POSITIVE) TRANSMISSION COOLING HOSE HYDRAULIC SUPPLY LINE TRANSMISSION MOUNTING BRACKET

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

BRAKE COOLING LINE ENGINE HARNESS CONNECTOR AIR FILTER AND BRACKET AIR FILTER HOSE FAN, SPACER, AND FAN PULLEY BOTTOM COOLANT HOSE ENGINE MOUNTS EXHAUST PIPE TO EXHAUST MANIFOLD

Engine Replacement

100 YRM 1316

Figure 27. Cummins 4.5L Diesel Engine and Transmission

100 YRM 1316

Engine Replacement

Legend for Figure 27 A. TOP VIEW B. RIGHT SIDE VIEW

C. LEFT SIDE VIEW

1. RIGHT HAND CHASSIS HARNESS CONNECTOR 2. THROTTLE CABLE 3. BATTERY AND BATTERY TRAY 4. RADIATOR CAP 5. FUEL LINES 6. ENGINE HARNESS CONNECTOR 7. LEFT HAND CHASSIS HARNESS CONNECTOR 8. CAPSCREW 9. ISOLATORS 10. WASHERS 11. FLANGE NUTS 12. OUTPUT YOKE 13. TRANSMISSION MOUNT 14. ENGINE MOUNTS

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

AIR FILTER AND BRACKET ASSEMBLY AIR FILTER HOSE EXHAUST PIPE TO EXHAUST MANIFOLD BOTTOM RADIATOR HOSE COOLANT HOSES BRAKE COOLING LINES TRANSMISSION BELL HOUSING FAN PULLEY AND FAN SPACER BATTERY CABLE (POSITIVE) BATTERY CABLE NEGATIVE POWER DISTRIBUTION MODULE (PDM) TRANSMISSION HARNESS CONNECTOR SHROUD FAN

Engine Replacement 6. Remove hood and seat combination and rear side covers. See section Hood, Seat, Dash, and Side Covers Replacement for procedures. 7. Loosen clamp and remove air filter hose from air inlet, located on left rear overhead guard leg. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. 8. Remove air filter and bracket assembly. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine.

10. On lift trucks equipped with GM 4.3L gasoline engine or a Cummins 4.5L diesel engine, disconnect left hand chassis harness connector from engine harness connector. See Figure 22 for lift truck models equipped with GFI. See Figure 23 for lift truck models equipped with PSI. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. NOTE: Perform Step 11 for lift truck models equipped with GFI fuel system. 11. On lift trucks equipped with GM 4.3L LPG engine, disconnect left hand chassis harness connector from LPG regulator connector and engine harness connector. See Figure 22. 12. On lift trucks equipped with GM 4.3L engine or Kubota 3.8L engine, disconnect engine harness connectors from electronic control module (ECM). See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine.

See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine.

See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine.

13. Disconnect engine harness connector from right hand chassis harness connector.

See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. 9. For lift trucks equipped with Cummins 4.5L diesel engine, disconnect throttle cable from fuel injection pump. See Figure 27 for lift trucks equipped with a Cummins 4.5L diesel engine. NOTE: When disconnecting wiring harness connectors, tag each connector to aid in connecting wiring harness during installation.

100 YRM 1316

14. Disconnect ground strap from frame and remove power distribution module (PDM) from battery tray. See Figure 28. 15. For lift trucks equipped with either a Cummins QSB 3.3L, a Cummins 4.5L, or Kubota diesel engines, remove battery from battery tray and remove three capscrews from battery tray. Remove battery tray. 16. For lift trucks equipped with GM 4.3L engine, remove three capscrews from battery tray and remove battery, battery tray, and Electronic Control Module (ECM).

100 YRM 1316

Engine Replacement See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. 18. Disconnect exhaust pipes from exhaust manifolds. See Exhaust System Repair for procedures. 19. Remove radiator fan pulley, shroud, and fan assembly. See section Cooling System 700 YRM 1123 for removal procedures.

BATTERY BATTERY TRAY PDM BATTERY LOCKDOWN BAR GROUND STRAP

Figure 28. Power Distribution Module, Disconnection

See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

17. Loosen hose clamps and disconnect remaining coolant hoses from radiator and cap them to prevent leakage.

See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine.

See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine.

See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine.

See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine.

21. Lift trucks equipped with GM 4.3L engine, remove left side engine mount to access starter motor. See Figure 22 and Figure 23.

See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

22. Disconnect positive battery (B+) and negative battery cable from starter motor.

See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine.

23. Lift trucks equipped with GM 4.3L engine, remove starter motor to reach four torque converter access bolts. See Figure 22 and Figure 23.

Engine Replacement 24. For lift trucks equipped with a Cummins QSB 3.3L diesel engine, remove oil cooler to reach access port. See Yale Axcess Online. 25. Lift trucks equipped with Cummins QSB 3.3L diesel engine, remove bolts and cover to get to access port. See Figure 31. 26. Lift trucks equipped with Kubota diesel engine, remove bolts and cover to reach access port. See Figure 32. 27. Use access port on engine to remove bolts that attaching flywheel to torque converter. See Figure 29 for lift trucks equipped with a GM 4.3L gas or LPG engine. See Figure 30 for lift trucks equipped with a Cummins 4.5L diesel engine.

100 YRM 1316 30. Remove flange nuts, washers, bolts, and isolators from engine mounts. See Figure 21 or Figure 33.

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. 31. Use lifting device to carefully move engine away from torque converter. Make sure all hoses, wires, and cables are disconnected from engine, then lift engine from frame and place engine on blocks.

See Figure 31 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 32 for lift trucks equipped with a Kubota diesel engine. 28. Connect a lifting device to engine. Put a block under transmission housing to support transmission. 29. Remove capscrews from transmission bell housing. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine.

WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 363 kg (800 lb).

1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE

Figure 29. GM 4.3L Engine Removal Access Port

100 YRM 1316

Engine Replacement

Legend for Figure 31 1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE

1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE

Figure 30. Cummins 4.5L Engine Access Port

NOTE: KUBOTA 3.8L SHOWN. KUBOTA 3.6L SIMILAR. 1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE

Figure 32. Kubota Diesel Engine Access Port

Figure 31. Cummins QSB 3.3L Diesel Engine Access Port

Engine Replacement

100 YRM 1316

A. ENGINE MOUNTS FOR GM 4.3L B. ENGINE MOUNTS FOR CUMMINS 4.5L

C. ENGINE MOUNTS FOR CUMMINS QSB 3.3L D. ENGINE MOUNTS FOR KUBOTA DIESEL

1. 2. 3. 4. 5.

6. 7. 8. 9.

ENGINE MOUNTS CAPSCREW WASHER ISOLATOR FLANGE NUT

PIN CROSSMEMBER LOCK NUT FLANGE BOLT

Figure 33. Engine Mounts Assembly

100 YRM 1316

INSTALL ENGINE ONLY WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine weighs approximately 363 kg (800 lb).

CAUTION Keep the engine level when installing the engine to the transmission so the drive plate is not damaged. 1. Connect lifting device to engine and lift engine into frame. 2. Align transmission bell housing to torque converter adapter. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. NOTE: Perform Step 3 on lift trucks equipped with GM 4.3L gas/LPG engine or Kubota diesel engine. 3. If isolators fell from engine mounts during removal, install isolators on engine mounts and install washers, capscrews and flange nuts for engine mounts to secure engine to frame. Tighten flange nuts to 150 N•m (110 lbf ft). See Figure 33. NOTE: Perform Step 4 on lift trucks equipped with either a Cummins QSB 3.3L or Cummins 4.5L diesel engine. 4. If isolators fell from engine mounts during removal, install isolators on engine mounts and install washers, capscrews and flange nuts for engine mounts

Engine Replacement to secure engine to frame. Tighten flange nuts to 320 N•m (236 lbf ft). See Figure 33. 5. Install capscrews to secure transmission bell housing to torque converter adapter. Tighten capscrews to 38 N•m (28 lbf ft). 6. Use access port on engine to install four bolts to hold torque converter to flywheel. Tighten bolts to 55 N•m (41 lbf ft). 7. For Cummins QSB 3.3L diesel engine, install cover and bolts to access port. See Figure 31. 8. For Kubota 3.8L diesel engine, install cover and bolts to access port. See Figure 32. 9. Remove blocks from under transmission and disconnect lifting device from engine. 10. Lift trucks equipped with Cummins QSB 3.3L diesel engine, install oil cooler. See Yale Axcess Online. 11. Lift trucks equipped with GM 4.3L engine, install starter motor. Tighten capscrews to 52 N•m (38 lbf ft). 12. Connect positive battery (B+) cable to starter motor. Tighten terminal nut to 8 to 11 N•m (71 to 97 lbf in). 13. Connect negative battery cable to starter motor. 14. Lift trucks equipped with GM 4.3L engine, install left side engine mount on engine. Tighten capscrews to 90 N•m (66 lbf ft). 15. For lift trucks equipped with GM 4.3L engine, connect exhaust pipes to exhaust manifolds. Tighten lock nuts to 39 N•m (29 lbf ft). See Figure 22 and Figure 23. 16. For lift truck equipped with Kubota diesel engine, connect exhaust pipes to exhaust manifold. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879).

Engine Replacement 17. For lift trucks equipped with Cummins QSB 3.3L or Cummins 4.5L diesel engine, connect exhaust pipe to exhaust manifold. Tighten lock nut to 22 Nâ&#x20AC;˘m (16 lbf ft). See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. 18. Remove caps from fuel lines and connect fuel lines at engine. 19. Install radiator shroud, fan pulley, and fan assembly. See section Cooling System 700 YRM 1123 for Fan Installation procedures. 20. Remove cap from bottom radiator hose and install hoses to radiator. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. NOTE: Perform Step 21 on lift trucks equipped with either a Cummins QSB 3.3L, a Cummins 4.5L, or Kubota diesel engine. 21. Using three capscrews install battery tray and battery. NOTE: Perform Step 22 on lift trucks equipped with GM 4.3L engine. 22. Using three capscrews install battery tray, battery, and Electronic Control Module (ECM). 23. Install Power Distribution Module (PDM) on battery tray and connect ground strap to lift truck frame. See Figure 28.

100 YRM 1316 24. Connect engine harness connector to right hand chassis harness connector. See Figure 22 and Figure 23 for lift trucks equipped with a GM 4.3L engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift trucks equipped with a Cummins 4.5L diesel engine. 25. For lift trucks equipped with GM 4.3L or Kubota 3.8L engine, connect engine harness connectors to Electronic Control Module (ECM). See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. NOTE: Perform Step 26 for lift truck models equipped with GFI fuel system. 26. For lift trucks equipped with GM 4.3L LPG engine, connect left hand chassis harness connector to LPG regulator connector and engine harness connector. See Figure 22. 27. For lift trucks equipped with either a GM 4.3L gasoline engine or a Cummins 4.5L diesel engine, connect left hand chassis harness connector to engine harness connector. See Figure 22 for lift truck models equipped with GFI. See Figure 23 for lift truck models equipped with PSI. See Figure 27 for lift trucks equipped with a Cummins 4.5L diesel engine.

100 YRM 1316

Engine Replacement

28. For lift trucks equipped with Cummins 4.5L diesel engine, connect throttle cable to fuel injection pump. See Figure 27.

37. For lift trucks equipped with and LPG fuel system, swing LPG tank and bracket back to original position until locked and open shutoff valve.

29. Install air filter and bracket assembly.

38. Inspect fuel system for leaks when fuel valve is open. There are four methods used to inspect fuel system for leaks:

30. Connect air filter hose to air inlet located on left rear over head guard leg and tighten clamp. 31. Install hood and seat combination, and rear side covers. See section Hood, Seat, Dash, and Side Covers Replacement, Install for procedures. 32. Close drain plug and remove caps from remaining coolant hoses and connect hoses to radiator. Tighten hose clamps and fill cooling system with antifreeze. See Cooling System 700 YRM 1123 for radiator fill procedures. Install radiator cap. 33. Check all fluid levels as described in Periodic Maintenance 8000 YRM 1319 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) Periodic Maintenance 8000 YRM 1571 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879) Periodic Maintenance 8000 YRM 1606 for lift truck model • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (F879) 34. Connect positive battery cable to battery. 35. Connect negative battery cable to battery. 36. Install floor plate and floor mat.

a. Sound - Listen for sound of fuel escaping from a tank fitting or hose connection. b. Smell - Fuel has a very distinctive odor. If you smell fuel, DO NOT start engine. c. Soapy Water - This method is used in conjunction with Step b above. If odor of fuel is present, but escaping fuel cannot be heard, apply soapy water to fittings and observe for bubbles. d. Frost - If amount of fuel escaping is sufficient, frost may appear on fittings.

REMOVE ENGINE AND TRANSMISSION 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, 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. The engine can be removed with or without transmission. Follow procedures below to remove engine with transmission. See Figure 21.

Engine Replacement

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

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.

5. Remove overhead guard, see Overhead Guard Replacement for Remove procedures.

1. For lift trucks equipped with an LPG fuel system, close shutoff valve on tank and run engine until all fuel is gone and engine stops.

7. Remove floor mat and floor plate.

2. If lift truck is equipped with an LPG fuel tank, swing tank to side. See one of the following Service Manuals. LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models: â&#x20AC;˘ GLC60VX, GLC70VX (GLC135VX, GLC155VX) (C879, D879) LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models: â&#x20AC;˘ GLC60VX, GLC70VX (GLC135VX, GLC155VX) (D879, E879, F879) 3. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than capacity of cooling system under radiator. Remove radiator cap. NOTE: Disposal of lubricants and fluids must meet local environmental regulations. 4. Open drain plug or loosen hose clamp and disconnect bottom radiator hose to drain coolant from radiator and engine. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

6. Remove hood and seat combination and rear side covers. See section Hood, Seat, Dash, and Side Covers Replacement for procedures.

8. Loosen clamp and remove air filter hose from air inlet, located on left rear over head guard leg. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. 9. For lift trucks equipped with Cummins 4.5L diesel engine, disconnect throttle cable from fuel injection pump. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. NOTE: When disconnecting wiring harness connectors during removal, tag each connector to aid in connecting wiring harness during installation. 10. For lift trucks equipped with GM 4.3L gasoline engine or Cummins 4.5L diesel engine, disconnect left hand chassis harness connector from engine harness connector.

100 YRM 1316

Engine Replacement

See Figure 22 for lift truck models equipped with GFI.

three capscrews from battery tray and remove battery and battery tray.

See Figure 23 for lift truck models equipped with PSI.

18. For lift trucks equipped with GM 4.3L engine, remove three capscrews from battery tray and remove battery, battery tray, and Electronic Control Module (ECM).

See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. NOTE: Perform Step 11 for lift truck models equipped with GFI fuel system. 11. For lift trucks equipped with GM 4.3L LPG engine, disconnect left hand chassis harness connector from LPG regulator connector and engine harness connector. See Figure 22. 12. For lift trucks equipped with GM 4.3L or Kubota 3.8L engine, disconnect engine harness connectors from Electronic Control Module (ECM). See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 19. Place a drain pan under hydraulic tank, remove drain plug at bottom of hydraulic oil tank, and drain oil from tank. After oil has finished draining, install drain plug to hydraulic tank. 20. Place drain pan under hydraulic gear pump assembly. a. For lift truck models equipped with a hydraulic gear pump on transmission, disconnect the suction hose and hydraulic hose from hydraulic gear pump assembly. Put caps on all hose fitting and hydraulic gear pump ports. See Hydraulic Gear Pump 1900 YRM 1136 for more information.

See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine.

21. Loosen hose clamps and disconnect remaining coolant hoses from radiator and cap them, to prevent leakage.

13. For lift trucks equipped with Cummins QSB 3.3L diesel engine, disconnect alternator harness from Electronic Control Module (ECM).

22. Place drain pan under transmission oil cooler lines at transmission. Loosen hose clamps and disconnect transmission oil cooler lines at transmission and cap to prevent leakage.

See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. 14. Disconnect engine harness connector from right hand chassis harness connector. 15. Disconnect battery positive (B+) and negative cable from starter motor. 16. Disconnect ground strap from frame and remove power distribution module (PDM) from battery tray.

23. Place drain pan under supply and return brake cooling lines (if equipped) and remove cooling lines at transmission and cap to prevent leakage. 24. Disconnect exhaust pipes from exhaust manifold. See Exhaust System Repair for removal procedures. 25. Remove radiator fan pulley, shroud, and fan assembly. See section Cooling System 700 YRM 1123 for removal procedures.

17. For lift trucks equipped with Cummins QSB 3.3L, Cummins 4.5L, or Kubota diesel engine, remove

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. 26. Loosen hose clamps (if equipped) and disconnect fuel lines at engine. Put caps on fuel lines to prevent fuel leakage. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine.

WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb). 27. Connect a lifting device to support transmission and engine combination. 28. Disconnect output yoke from transmission. See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine. See Figure 24 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

100 YRM 1316 See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. 29. Remove flange nuts, capscrews, washers and isolators from transmission mount. See Figure 34. 30. Remove capscrews and washers from engine mounts. See Figure 33. NOTE: Make sure engine and transmission assembly can be raised at an angle so they will clear frame. 31. Use lifting device to carefully lift engine and transmission from frame. Slip transmission output yoke out of transmission. Make sure not to damage seal. Place engine and transmission on blocks.

INSTALL ENGINE AND TRANSMISSION WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb). NOTE: Make sure engine and transmission assembly can be raised at an angle so they will clear frame. 1. Connect a lifting device to engine and transmission and lift engine and transmission into lift truck frame. 2. Install transmission output yoke onto transmission. Be sure to not damage seal. Tighten bolt to 38 N•m (28 lbf ft). NOTE: Perform Step 3 on lift trucks equipped with Cummins 4.5L or Cummins QSB 3.3L diesel engines. 3. If isolators fell from engine mounts during removal, install isolators to engine mounts and install washers, capscrews, and flange nuts for engine mounts to secure engine to frame. Tighten flange nuts to 320 N•m (236 lbf ft). See Figure 33. NOTE: Perform Step 4 on lift trucks equipped with GM 4.3L gas/LPG engine or Kubota diesel engine. 4. If isolators fell from engine mounts during removal, install isolators to engine mounts and install washers, capscrews, and flange nuts for engine mounts to secure engine to frame. Tighten flange nuts to 150 N•m (110 lbf ft). See Figure 33.

100 YRM 1316 5. If isolators fell from transmission mount, install isolators to transmission mount and install washers, lock washers, and capscrews. Tighten capscrews to 225 to 250 N•m (166 to 184 lbf ft). See Figure 34.

Engine Replacement 16. For lift trucks equipped with Cummins 4.5L, QSB 3.3L, or Kubota diesel engines, install battery and battery tray using three capscrews.

6. Remove lifting device from engine and transmission combination.

17. For lift trucks equipped with GM 4.3L engine, install battery, battery tray, and Electronic Control Module (ECM).

7. Install radiator shroud, fan pulley, and fan assembly. See section Cooling System 700 YRM 1123 for Fan Installation procedures.

18. Install Power Distribution Module to battery tray and connect ground strap to lift truck frame. See Figure 28.

8. Remove cap from bottom radiator hose and install hose on radiator. 9. For lift trucks equipped with GM 4.3L engine, connect exhaust pipes to exhaust manifolds. Tighten lock nuts to 39 N•m (29 lbf ft). See Figure 22 and Figure 23. 10. For lift trucks equipped with Kubota diesel engine, connect exhaust pipe to exhaust manifold. See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. 11. For lift trucks equipped with Cummins 4.5L engine, connect exhaust pipe to exhaust manifold. Tighten lock nut to 22 N•m (16 lbf ft). See Figure 27. 12. Remove cap and connect supply and return brake cooling lines at transmission. 13. Remove cap and connect transmission oil cooler lines at transmission. 14. Connect hydraulic connections to the hydraulic pump. a. For lift truck models equipped with a hydraulic gear pump on transmission, remove plugs from hydraulic gear pump ports, and connect suction hose and hydraulic hose to hydraulic gear pump assembly. See Hydraulic Gear Pump 1900 YRM 1136 for more information. 15. Remove caps from fuel lines and connect fuel lines at engine. Tighten hose clamps (if equipped).

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

ISOLATOR CAPSCREW LOCKWASHER WASHER ISOLATOR MOUNTING BRACKET MOUNTING BRACKET CAPSCREW

Figure 34. Transmission Mounting Assembly

Engine Replacement 19. Connect positive batter (B+) cable to starter motor. Tighten terminal nut to 8 to 11 N•m (71 to 97 lbf in). 20. Connect negative battery cable to starter motor.

100 YRM 1316 24. For lift trucks equipped with either a GM 4.3L (gasoline) engine or a Cummins 4.5L diesel engine, connect left hand chassis harness connector to engine harness connector.

21. Connect engine harness connector to right hand chassis harness connector.

See Figure 22 for lift truck models equipped with GFI.

See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine.

See Figure 23 for lift truck models equipped with PSI.

See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine.

See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine. See Figure 27 for lift truck models equipped with Cummins 4.5L diesel engine. 22. For lift trucks equipped with GM 4.3L or Kubota 3.8L engine, connect engine harness connectors to Electronic Control Module (ECM). See Figure 22 and Figure 23 for lift truck models equipped with GM 4.3L engine.

25. Install air filter and bracket assembly. 26. Connect air filter hose to air inlet and tighten clamp. 27. For lift trucks equipped with Cummins 4.5L diesel engine, connect throttle cable to fuel injection pump. See Figure 27. 28. Close drain plug and remove caps and connect coolant hoses to radiator. Tighten hose clamps and fill cooling system with antifreeze. See Cooling System 700 YRM 1123 for radiator refill procedures. Install radiator cap. 29. Check all fluid levels as described in

See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.

Periodic Maintenance 8000 YRM 1319 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879)

See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine.

Periodic Maintenance 8000 YRM 1571 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (E879)

NOTE: Perform Step 23 for lift truck models equipped with GFI fuel system.

Periodic Maintenance 8000 YRM 1606 for lift truck model • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (F879)

23. For lift trucks equipped with GM 4.3L LPG engine, connect left hand chassis harness connector to LPG regulator connector and engine harness connector. See Figure 22.

100 YRM 1316

Electronic Throttle Replacement

30. Install hood and seat combination, and rear side covers. See section Hood, Seat, Dash, and Side Covers Replacement Install for procedures. 31. Install overhead guard. See Overhead Guard Replacement, Install for procedures. 32. Connect positive battery cable. 33. Connect negative battery cable. 34. Install floor plate and floor mat.

35. For lift trucks equipped with and LPG fuel system, swing LPG tank and bracket back to original position until locked, connect LPG fuel line, and open shutoff valve. 36. Inspect fuel system for leaks when fuel valve is open. There are four methods used to inspect fuel system for leaks: a. Sound - Listen for sound of fuel escaping from a tank fitting or hose connection. b. Smell - Fuel has a very distinctive odor. If you smell fuel, DO NOT start engine.

c. Soapy Water - This method is used in conjunction with Step b above. If odor of fuel is present, but escaping fuel cannot be heard, apply soapy water to fittings and observe for bubbles. d. Frost - If the amount of fuel escaping is sufficient, frost may appear on fittings.

Electronic Throttle Replacement CUMMINS 4.5L DIESEL ENGINE WITH ELECTRONIC THROTTLE

6. If necessary, remove capscrews and throttle lever adapter. See Figure 36.

Remove

7. Disconnect engine harness electrical connector from pull actuator harness connector. See Figure 39.

1. Disconnect engine harness electrical connector from throttle position sensor (TPS). See Figure 35. 2. Remove Torx-head screws, washers, and remove TPS and tapped TPS plate. See Figure 36. 3. Remove capscrews and TPS bracket. See Figure 37.

8. Remove capscrews and pull actuator from mounting bracket. See Figure 40. 9. If necessary, remove clevis with linkage assembly, lockwasher, and nut from pull actuator. See Figure 39.

4. Remove TPS rotor. See Figure 38. 5. Remove capscrews, nuts, and linkage assembly. See Figure 35.

Electronic Throttle Replacement

100 YRM 1316

Figure 35. Electronic Throttle System

100 YRM 1316

Electronic Throttle Replacement

Legend for Figure 35 1. 2. 3. 4. 5.

THROTTLE POSITION SENSOR (TPS) CAPSCREW LINKAGE ASSEMBLY NUT PULL ACTUATOR

6. 7. 8. 9. 10.

CLEVIS ADJUSTMENT NUT TORX-HEAD SCREWS PULL ACTUATOR CONNECTOR ENGINE HARNESS CONNECTOR

Electronic Throttle Replacement

100 YRM 1316

Legend for Figure 36 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Figure 36. TPS Assembly

TORX-HEAD SCREW LOCKWASHER TPS TPS BRACKET ACTUATOR TPS ROTOR MAGNET TPS PLATE THROTTLE LEVER ADAPTER FUEL PUMP CAPSCREWS

100 YRM 1316

Electronic Throttle Replacement

1. CAPSCREW

2. TPS BRACKET

Figure 37. TPS Bracket

1. 2. 3. 4. 5.

PULL ACTUATOR NUT LOCKWASHER CLEVIS WITH LINKAGE ASSEMBLY PULL ACTUATOR HARNESS CONNECTOR

Figure 39. Pull Actuator and Linkage Assembly

1. TPS

2. TPS ROTOR

Figure 38. TPS Rotor 1. 2. 3. 4. 5.

MOUNTING BRACKET CAPSCREW FUEL PUMP PULL ACTUATOR FOLDOVER NUT

Figure 40. Pull Actuator Mounting

Electronic Throttle Replacement

Install 1. Install TPS rotor and throttle lever adapter. Tighten capscrews to 7.9 N•m (70 lbf in). See Figure 36. 2. Place rod end of linkage assembly on top side of throttle lever adapter and align rod end hole with hole on throttle lever adapter. See Figure 41.

100 YRM 1316 NOTE: DO NOT force lever or pull actuator rod when installing. 10. Place rod end on top side of throttle lever adapter and align rod end hole with hole on throttle lever. Install capscrew and nut and tighten to 6.8 N•m (60 lbf in). See Figure 41.

NOTE: When installing TPS, rotate sensor rotor clockwise to match D-shape on TPS rotor. See Figure 42. NOTE: The TPS mounting screws are non-magnetic stainless steel to avoid interference with sensor magnet and must be reused if TPS is replaced. 3. Place TPS in position and install Torx-head screws. Tighten Torx-head screws to 2.25 N•m (20 lbf in). See Figure 36. 4. Connect TPS electrical connector. 5. Turn lever clockwise to verify that TPS does not bind or stick. 6. Place pull actuator in position on mounting bracket and install capscrews. Tighten to 38 N•m (28 lbf ft). See Figure 40. 7. Install clevis with linkage assembly onto threaded end of pull actuator rod. Leave loose for adjustment. See Figure 39. 8. Verify that clevis is in position shown in Figure 43. Adjust as needed. 9. Verify that rod ends of linkage assembly are parallel to each other. Adjust as needed. See Figure 43.

1. 2. 3. 4. 5.

THROTTLE LEVER ADAPTER ROD END CLEVIS CAPSCREW NUT

Figure 41. Rod End and Throttle Lever Alignment

100 YRM 1316

Electronic Throttle Replacement 3. If linkage adjustment is not providing enough range, remove capscrew and nut from clevis and rod ends. Lengthen or shorten linkage by loosening turnbuckle nuts to adjust threaded length of rod ends in turnbuckle. Attach adjusted rod ends to clevis with capscrew and nut. Verify lever contacts low idle stop at idle position, and lever contacts high idle stop at high idle position. Verify that lever rotates freely without sticking or binding. See Figure 44.

Low Idle Adjustment CAUTION

Figure 42. TPS and Rotor

DO NOT attempt to adjust high idle speed limit screws. This may impair the safety and performance of the lift truck and shorten its engine life. If the idle speed limit screws require adjustment, see your authorized Cummins industrial engine dealer or distributor.

11. Connect pull actuator harness connector to engine harness connector. See Figure 39.

NOTE: Make sure engine is running prior to making low idle adjustment.

Pull Actuator Linkage Adjustment

1. Loosen lock nut. See Figure 44.

1. Check low idle stop position to see if throttle lever is in contact with low idle stop. If adjustment is necessary, refer to Step 3. See Figure 44.

2. Turn adjustment screw until correct RPM, identified in Periodic Maintenance 8000 YRM 1319, has been set.

2. When condition in Step 1 is met, check if actuator is fully extended by manually turning actuator to high idle position. The throttle lever should contact high idle stop. Verify that lever rotates freely, without binding or sticking.

3. After RPM has been set. Use a screwdriver to hold adjustment screw in place and tighten lock nut.

1. SENSOR ROTOR 2. TPS

3. TPS ROTOR 4. D-SHAPE

Throttle Pedal and Cable Adjustment

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

PULL ACTUATOR LOCK NUT CLEVIS TURNBUCKLE NUT TURNBUCKLE ROD ENDS (MUST BE PARALLEL TO EACH OTHER)

Figure 43. Linkage Assembly

100 YRM 1316

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

TPS LOW IDLE STOP TURNBUCKLE NUT TURNBUCKLE CLEVIS LOCK NUT ADJUSTING SCREW(LOW IDLE) 8. ROD ENDS

Figure 44. Low Idle and Pull Actuator Adjustment Location

Throttle Pedal and Cable Adjustment NOTE: There are no throttle pedal and cable adjustments for lift trucks equipped with GM 4.3L or Kubota 3.8L Diesel engine. The GM 4.3L and Kubota 3.8L Diesel engines have an electronic throttle that is self-adjusting and self-calibrating.

CUMMINS 4.5L DIESEL ENGINE 1. Remove floor plate and disconnect throttle cable from bellcrank and engine. See Figure 45. 2. Fully depress throttle pedal and verify that dimension between bellcrank and cowl plate is 6 ±2 mm (0.24 ±0.08 in.). See Figure 45. 3. If dimension is not correct, adjust ball ends on push rod so that a minimum of 6 mm (0.24 in.) of threaded rod screws into each ball end. After

adjusting push rod, tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in). 4. Connect throttle cable to bellcrank and engine. See Figure 45. 5. With throttle pedal in full up position, adjust throttle cable, using jam nuts (item #10 in Figure 45) to remove all slack from cable. Cable should be adjusted to point where additional adjustment will pull control lever off idle stop. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in). 6. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in) (item #6 in Figure 45).

100 YRM 1316

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

Throttle Pedal and Cable Adjustment

COWL BELLCRANK PUSH ROD BALL END THROTTLE PEDAL JAM NUT

7. 8. 9. 10. 11.

PEDAL STOP THROTTLE CABLE JAM NUTS CONTROL LEVER CLAMP STRAP

Figure 45. Cummins 4.5L Throttle Pedal and Cable Adjustment

Exhaust System Repair

100 YRM 1316

Exhaust System Repair GM 4.3L ENGINE FOR LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

11. Disconnect the lower exhaust pipe from the bellow pipe.

NOTE: For lift trucks equipped with engine indicated above, see the Fuel System service manual for your lift truck model.

13. Disconnect the upper header exhaust pipe from the turbo manifold exhaust.

CUMMINS QSB 3.3L ENGINE FOR LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Remove NOTE: If the lift truck is equipped with the standard exhaust system, go to Step 6. 1. Remove the clamp attaching the overhead guard exhaust pipe to the lower overhead guard exhaust pipe. See Figure 46.

12. Disconnect the bellow pipe from the upper header exhaust pipe.

Inspect Inspect the following items in the exhaust system: • Exhaust pipes for damage, corrosion, and rust. Replace as needed. • If equipped, exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as needed. If replacing an exhaust pipe section that has a wrap, also replace the wrap. Do not reuse wraps if they have been removed for a service operation. • Muffler for damage, corrosion, and rust. Replace as needed.

Install

2. Remove the capscrews from the flange cover. 3. Remove overhead exhaust pipe and flange cover from the counter weight. 4. Remove the counterweight from the lift truck. See Counterweight Replacement.

1. Connect the upper header exhaust pipe to the turbo manifold exhaust. 2. Connect the bellow pipe to the upper header exhaust pipe. 3. Connect the lower exhaust pipe to the bellow pipe.

5. Remove clamp and lower overhead guard exhaust pipe from muffler.

4. Install the clamp to the lower header exhaust pipe and exhaust mounting brackets.

6. Remove the turbo manifold–exhaust wrap, upper header–exhaust wrap, bellow pipe–exhaust wrap, lower header–exhaust wrap, and upper tail pipe–exhaust wrap.

5. Install the clamp to the upper tail pipe and lower header exhaust pipe, and install the upper tail pipe to the lower header exhaust pipe.

7. Remove the turbo exhaust clamp.

6. Install the clamp to the muffler and upper tail pipe, and install the muffler to the frame of the lift truck.

8. Remove the clamp from the muffler and upper tail pipe, and remove the muffler from the lift truck.

7. Install the turbo exhaust clamps.

9. Remove the clamp from the upper tail pipe and lower header exhaust pipe, and disconnect the upper tail pipe from the lower header exhaust pipe.

8. Install the upper tail pipe-exhaust wrap, lower header-exhaust wrap, bellow pipe-exhaust wrap, upper header-exhaust wrap, and turbo manifold-exhaust wrap.

10. Remove the clamp from the lower header exhaust pipe and exhaust mounting bracket.

9. Install clamp and lower overhead guard exhaust pipe to muffler.

100 YRM 1316

1. 2. 3. 4. 5. 6. 7. 8. 9.

Exhaust System Repair

OVERHEAD EXHAUST PIPE FLANGE COVER CLAMP MUFFLER UPPER TAILPIPE UPPER TAILPIPE-EXHAUST WRAP LOWER HEADER-EXHAUST WRAP LOWER HEADER-EXHAUST PIPE BELLOW PIPE-EXHAUST WRAP

10. 11. 12. 13. 14. 15. 16. 17. 18.

BELLOW PIPE UPPER HEADER-EXHAUST WRAP UPPER HEADER-EXHAUST PIPE TURBO EXHAUST CLAMP TURBO MANIFOLD-EXHAUST WRAP EXHAUST MOUNTING BRACKET LOWER EXHAUST PIPE-OVERHEAD CAPSCREW EXHAUST PIPE

Figure 46. Cummins QSB 3.3 Engine Exhaust System

Exhaust System Repair 10. Install the counterweight to the lift truck. See Counterweight Replacement. 11. Install over head exhaust pipe and flange cover to the counterweight. 12. Install the capscrews to the flange cover 13. Install the clamp attaching the overhead guard exhaust pipe to the lower overhead guard exhaust pipe. See Figure 46.

CUMMINS 4.5L DIESEL ENGINE FOR LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Remove WARNING Exhaust system components are hot to touch. Be sure exhaust system components are cool before starting disassembly, or personal injury may occur. NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 4. Lift trucks equipped with overhead exhaust follow Step 5 through Step 10. 1. Remove the counterweight before removing the muffler and other components of the exhaust system. See the section Counterweight Replacement for the removal procedures for the counterweight. 2. Remove clamps that attach exhaust pipes (1 and 4, Figure 47) to muffler. Remove exhaust pipe (1, Figure 47) from muffler. 3. Remove exhaust pipe (4, Figure 47) from the engine exhaust manifold and remove exhaust pipe from muffler. Discard gasket. 4. Remove the washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame. Remove muffler from lift truck frame. NOTE: The exhaust pipe (13, Figure 47) must be removed before removing the counterweight and the other components of the exhaust system.

100 YRM 1316 7. Remove counterweight. See the section Counterweight Replacement for the removal procedures for the counterweight. 8. Remove clamps that attach exhaust pipes (1 and 4, Figure 47) to muffler. 9. Remove exhaust pipe (4, Figure 47) from the engine exhaust manifold and remove exhaust pipe from muffler. Discard gasket. 10. Remove the washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame. Remove muffler from lift truck frame.

Inspect Inspect the following items in the exhaust system: • Exhaust pipes for damage, corrosion, and rust. Replace as needed. • Exhaust pipe heat shields for damage. Replace as needed. • Muffler for damage, corrosion, and rust. Replace as needed.

Install NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 4. Lift trucks equipped with overhead exhaust follow Step 5 through Step 10. 1. Place the muffler on the lift truck frame and install the washers, isolators, spacers, locknuts, and capscrews to attach muffler to lift truck frame. Tighten locknuts to 22 N•m (195 lbf in). 2. Connect exhaust pipes (1 and 4, Figure 47) to muffler and install clamps to attach exhaust pipes to muffler. 3. Install new gasket and install exhaust pipe (4, Figure 47) to engine exhaust manifold. Tighten locknuts to 22 N•m (195 lbf in). 4. Install counterweight. See the section Counterweight Replacement for the installation procedures for the counterweight.

5. Remove the clamp that attaches the exhaust pipe (13) to the exhaust pipe (1). See Figure 47.

5. Place the muffler on the lift truck frame and install the washers, isolators, spacers, locknuts, and capscrews to attach muffler to lift truck frame. Tighten locknuts to 22 N•m (195 lbf in).

6. Remove flange cover and three flange bolts that secures the exhaust pipe to the counterweight and remove exhaust pipe.

6. Install new gasket and install exhaust pipe (4, Figure 47) to engine exhaust manifold. Tighten locknuts to 22 N•m (195 lbf in).

100 YRM 1316

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

EXHAUST PIPE CLAMP MUFFLER EXHAUST PIPE LOCKNUT GASKET WASHER

Exhaust System Repair

8. 9. 10. 11. 12. 13. 14.

ISOLATOR SPACER CAPSCREW FLANGE BOLT (OVERHEAD EXHAUST) FLANGE COVER (OVERHEAD EXHAUST) EXHAUST PIPE (OVERHEAD EXHAUST) COVER

Figure 47. Cummins 4.5L Diesel Engine Exhaust System

Exhaust System Repair 7. Connect exhaust pipes (1 and 4, Figure 47) to muffler and install clamp to attach exhaust pipe to the muffler. 8. Install the counterweight. See the section Counterweight Replacement for the installation procedures for the counterweight. 9. Connect exhaust pipe (13, Figure 47) to exhaust pipe (1, Figure 47) and install clamp to attach exhaust pipe (13) to the exhaust pipe (1). 10. Install three flange bolts to secure the tail pipe to the counterweight and place flange cover over the flange bolts.

KUBOTA 3.8L DIESEL ENGINE FOR LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879) Remove WARNING

100 YRM 1316 3. Remove the exhaust clamp connecting the bellows pipe to the exhaust pipe. 4. Remove the four nuts connecting the header-exhaust pipe to the exhaust manifold. See Figure 48. 5. Remove exhaust pipe from the muffler and the bellow pipe, and the header-exhaust pipe from the engine exhaust manifold. Discard gasket. See Figure 48. 6. Remove the washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame. Remove muffler from lift truck frame. 7. Remove the clamp that attaches the tail pipe to the muffler. See Figure 48. 8. Remove flange cover and three flange bolts that secures the over head exhaust pipe to the counterweight and remove tail pipe. 9. Remove counterweight. See the section Counterweight Replacement for the removal procedures for the counterweight.

Exhaust system components are hot to touch. Be sure exhaust system components are cool before starting disassembly, or personal injury may occur.

10. Remove clamps that attach exhaust pipe to muffler and the clamps that attach the exhaust pipe to the exhaust mounting brackets. See Figure 48.

NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 6. Lift trucks equipped with overhead exhaust follow Step 7 through Step 15.

11. Remove the clamp connecting the bellow pipe to the header-exhaust pipe. See Figure 48.

NOTE: Remove the turbo manifold-exhaust wrap and other exhaust wrap material prior to removing exhaust components. 1. Remove the counterweight before removing the muffler and other components of the exhaust system. See the section Counterweight Replacement for the removal procedures for the counterweight. 2. Remove clamps that attaches the tail pipe to muffler, the exhaust pipe to the muffler, the header-exhaust pipe to the bellow pipe, and the exhaust pipe to the exhaust mounting brackets. See Figure 48.

12. Remove the exhaust clamp connecting the bellows pipe to the exhaust pipe. 13. Remove the four nuts connecting the header-exhaust pipe to the exhaust manifold. See Figure 48. 14. Remove exhaust pipe from the muffler and the bellow pipe, and the header-exhaust pipe from the engine exhaust manifold. Discard gasket. See Figure 48. 15. Remove the washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame. Remove muffler from lift truck frame.

100 YRM 1316

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

Exhaust System Repair

MUFFLER EXHAUST PIPE TAILPIPE-EXHAUST WRAP BELLOW PIPE-EXHAUST WRAP BELLOW PIPE HEADER-EXHAUST WRAP HEADER-EXHAUST PIPE CLAMP

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

TURBO MANIFOLD-EXHAUST WRAP EXHAUST MOUNTING BRACKET NUT TAIL PIPE CAPSCREW FLANGE COVER OVERHEAD EXHAUST PIPE

Figure 48. Kubota 3.8L Diesel Engine Exhaust System

Exhaust System Repair

Install NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 7. Lift trucks equipped with overhead exhaust follow Step 8 through Step 15. 1. Place the muffler on the lift truck frame and install the washers, isolators, spacers, locknuts, and capscrews to attach muffler to lift truck frame. 2. Install new gasket at exhaust manifold and headerexhaust pipe junction and install header-exhaust pipe. Secure the header-exhaust pipe using four nuts. DO NOT tighten nuts. See Figure 48. 3. Install exhaust pipe in bellow pipe. Secure exhaust clamp connecting exhaust pipe and bellow pipe. DO NOT tighten capscrews on exhaust clamp. 4. Connect exhaust pipe to muffler and install clamp. Tighten clamp.

100 YRM 1316 5. Connect tail pipe to muffler and install clamp. Tighten clamp. 6. Install clamps around exhaust pipe and header exhaust pipe in exhaust mounting brackets. Tighten nuts at header-exhaust pipe and exhaust mainifold junction. Tighten exhaust clamp connecting exhaust pipe and bellow pipe to 70 N•m (52 lbf ft) and tighten clamps holding exhaust pipe and bellow pipe to exhaust mounting brackets. See Figure 48. 7. Install counterweight. See the section Counterweight Replacement for the installation procedures for the counterweight. 8. Place the muffler on the lift truck frame and install the washers, isolators, spacers, locknuts, and capscrews to attach muffler to lift truck frame. 9. Install new gasket at exhaust manifold and headerexhaust pipe junction and install header-exhaust pipe. Secure the header-exhaust pipe using four nuts. DO NOT tighten nuts. See Figure 48. 10. Install exhaust pipe in bellow pipe. Secure exhaust clamp connecting exhaust pipe and bellow pipe. DO NOT tighten capscrews on exhaust clamp. 11. Connect exhaust pipe to muffler and install clamp. Tighten clamp.

100 YRM 1316 12. Connect tail pipe to muffler and install clamp. Tighten clamp. 13. Install clamps around exhaust pipe and header exhaust pipe in exhaust mounting brackets. Tighten nuts at header-exhaust pipe and exhaust mainifold junction. Tighten exhaust clamp connecting exhaust pipe and bellow pipe to 70 Nâ&#x20AC;˘m (52 lbf ft) and tighten clamps holding exhaust pipe and bellow pipe to exhaust mounting brackets. See Figure 48. 14. Install the counterweight. See the section Counterweight Replacement for the installation procedures for the counterweight. 15. Install three flange bolts to secure the tail pipe to the counterweight and place flange cover over the flange bolts.

KUBOTA 3.8L DIESEL ENGINE FOR LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879) Remove WARNING Exhaust system components are hot to touch. Be sure exhaust system components are cool before starting disassembly, or personal injury may occur.

Exhaust System Repair NOTE: Remove the turbo manifold-exhaust wrap and other exhaust wrap material prior to removing exhaust components. 1. Remove flange cover and three capscrews that secures the over head exhaust pipe to the counterweight and remove tail pipe. 2. Remove the counterweight before removing the Diesel Particulate Filter (DPF) and other components of the exhaust system. See the section Counterweight Replacement for the removal procedures for the counterweight. 3. Remove two clamps that attach the exhaust pipe to the exhaust mounting brackets. See Figure 49. 4. Remove the four nuts connecting the exhaust pipe to the turbo manifold. See Figure 49. 5. Remove four nuts connecting exhaust pipe to DPF. See Figure 49. 6. Remove exhaust pipe and two gaskets from turbo manifold and DPF. See Figure 49. 7. Remove four capscrews, four nuts and gasket from DPF. See Figure 49. 8. Remove six capscrews that attach DPF to lift truck frame. Remove DPF from lift truck frame. See Figure 49.

Exhaust System Repair

100 YRM 1316

Figure 49. Kubota 3.8L Diesel Engine Exhaust System

100 YRM 1316

Cooling System

Legend for Figure 49 1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

NUT WASHER GASKET EXHAUST MOUNTING BRACKET CLAMP

Install 1. Place the DPF on lift truck frame and install six capscrews to attach DPF to lift truck frame. 2. Install new gasket at turbo manifold and exhaust pipe junction and install exhaust pipe. Secure the exhaust pipe using four nuts. DO NOT tighten nuts. See Figure 49.

EXHAUST PIPE OVERHEAD EXHAUST PIPE CAPSCREW DIESEL PARTICULATE FILTER (DPF) FLANGE COVER

3. Install new gasket at DPF and exhaust pipe junction. See Figure 49. 4. Using four capscrews, connect exhaust pipe to DPF. See Figure 49. 5. Install two clamps around exhaust pipe in exhaust mounting brackets. Tighten nuts at exhaust pipe and turbo manifold junction. See Figure 49. 6. Install the counterweight. See the section Counterweight Replacement for the installation procedures for the counterweight. 7. Install overhead tailpipe to exhaust pipe. 8. Install three capscrews to secure the tail pipe to the counterweight and place flange cover over the flange bolts. See Figure 49.

Cooling System DESCRIPTION The cooling system is used to cool engine and keep it at correct operating temperature. The cooling system is comprised of following main components: • Radiator • Fan and belt

• Fan shroud • Coolant hoses and lines • Coolant reservoir For procedures to repair, clean, inspect, and install radiator and cooling system components, refer to Cooling System 700 YRM 1123.

Hydraulic Filter Assembly Repair

100 YRM 1316

Hydraulic Filter Assembly Repair REMOVE WARNING At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

3. Remove head, quad ring, two fittings, and two O-rings from hydraulic filter assembly. Discard quad ring and O-rings. 4. Remove and discard O-ring from bowl assembly.

CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Dirt can cause damage to the components of the hydraulic system. Never operate the hydraulic pumps without oil in the hydraulic system. The operation of the hydraulic pumps without oil will damage the pumps.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. NOTE: When disconnecting hydraulic hoses, note location of hoses to aid in installation. NOTE: Have a container large enough to hold filter assembly and allow for final hydraulic oil draining. 1. Put lift truck on a level surface and lower carriage. Loosen hose clamps. Disconnect hydraulic hoses and pressure sensor from hydraulic oil filter assembly. Install caps and covers on hoses to prevent foreign matter from getting into hydraulic system. Unscrew four capscrews from filter assembly. See Figure 50. Lift hydraulic filter assembly enough to allow hydraulic oil to drain from assembly into hydraulic reservoir. 2. Remove hydraulic filter assembly from hydraulic reservoir and place into container.

DISASSEMBLE 1. Remove lid, spring, and O-ring from hydraulic filter assembly. Discard O-ring. See Figure 50. 2. Remove and discard filter and O-ring from hydraulic filter assembly. DO NOT allow dirt to enter filter assembly or other hydraulic components.

1. 2. 3. 4. 5.

LID SPRING O-RING CAPSCREW HEAD

6. 7. 8. 9.

FITTING QUAD RING FILTER BOWL

Figure 50. Hydraulic Filter Assembly

100 YRM 1316

Fuel and Hydraulic Tanks Repair

CLEAN

2. Lubricate new quad ring with hydraulic oil and install on head. Lubricate two O-rings with hydraulic oil and install, with two fittings, on head.

WARNING Cleaning solvents can be flammable and toxic and may cause skin irritation. When using cleaning solvents, always follow the safety instructions of the solvent manufacturer.

3. Lubricate new O-ring with hydraulic oil and seat in filter element. Install new filter element in hydraulic filter assembly. 4. Lubricate new O-ring with hydraulic oil and install O-ring, spring, and lid on hydraulic filter assembly.

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yaledealer. Use solvent to clean any accumulation of dirt or loose paint from all hydraulic filter assembly parts. Use a clean, lint-free cloth to dry parts prior to inspection.

INSPECT Make a visual inspection of all hydraulic filter assembly parts for dents, holes, nicks, or scratches. Replace any worn or damaged parts.

ASSEMBLE

INSTALL 1. Install hydraulic filter assembly in hydraulic reservoir with four capscrews. Tighten capscrews to 19 N•m (168 lbf in). See Figure 50. 2. Connect pressure sensor and hydraulic hoses to hydraulic filter assembly as noted during removal. Tighten hose clamps 3. Fill hydraulic tank with correct hydraulic oil and check hydraulic oil level. See the appropriate Periodic Maintenance service manual for your lift truck, for the correct hydraulic oil type and capacity.

1. Lubricate new O-ring with hydraulic oil and install, with bowl, on head. See Figure 50.

Fuel and Hydraulic Tanks Repair INSPECT WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside a building, make sure there is enough ventilation. See the following manuals for additional information: • Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. • Safety in Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.

WARNING DO NOT use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. Make a visual inspection of all sides of tank. Inspect welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors. 1. Place a drain pan with enough capacity to hold all fluid from tank under tank’s drain plug. 2. Remove drain plug and drain contents of tank into drain pan. 3. After all fluid has been drained, reinstall drain plug and remove drain pan from under lift truck.

Fuel and Hydraulic Tanks Repair

CLEAN WARNING When cleaning the tank, DO NOT use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

100 YRM 1316

Steam Method of Cleaning WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control pressure of steam by a valve installed at nozzle of hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between nozzle and tank. Connect a ground wire to tank to prevent static electricity.

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. Use following procedure to clean tank with steam: 1. Remove all parts from tank. Install drain plug. 2. Fill tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water. 3. Mix solution in tank using air pressure. Make sure all surfaces on inside of tank are flushed with solution. Drain tank. 4. Put steam into tank until tank does not have odors and metal is hot. Steam vapors must come from all openings.

100 YRM 1316 5. Flush inside of tank with boiling water. Make sure all loose material is removed from inside of tank. 6. Make an inspection of inside of tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors. 7. Put plugs in all openings in tank. Wait 15 minutes, then remove inlet and outlet plugs. Test a sample of vapor with a special indicator for gas vapors. If amount of flammable vapors is above lower flammable limit, repeat cleaning procedures.

Chemical Solution Method of Cleaning WARNING When cleaning the tank, DO NOT use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

Fuel and Hydraulic Tanks Repair

CAUTION Disposal of lubricants, fluids, and chemicals must meet local environmental regulations. If tank cannot be cleaned with steam, use following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkaline base. Follow instructions given by manufacturer. 2. Fill tank with cleaning solution. Use compressed air to mix solution in tank. 3. Drain tank. Flush inside of tank with hot (boiling) water. Make sure all cleaning compound is removed. 4. Make an inspection of inside of tank. If tank is not clean, repeat Step 1 through Step 3. Make another inspection of tank. When making inspections, use a light that is approved for locations with flammable vapors. 5. Check tank for flammable vapors using special indicator for gas vapors. If amount of flammable vapors is not below lower flammable limit, repeat cleaning procedures.

Safety Labels

100 YRM 1316

ADDITIONAL PREPARATIONS FOR REPAIR

2. Apply LoctiteÂŽ 290 to leak. Follow instructions of manufacturer.

If nitrogen gas or carbon dioxide gas is available, prepare tank for welding using these gases. See manual Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows:

LARGE LEAKS, REPAIR

1. Fill tank with water to just below point where work will be done. Make sure space above level of water has a vent. 2. Use acceptable welding practices to repair tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

SMALL LEAKS, REPAIR Use following procedure to repair small leaks: 1. Use steam to clean area around leak. Remove all paint and dirt around leak.

1. Use one of procedures described under Clean to clean and prepare tank for repairs. 2. Contact your dealer for Yale lift trucks for welding instructions. 3. Use acceptable welding practices to repair tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

PREPARATIONS FOR USE AFTER REPAIR 1. Add more water to tank so that water goes above point of where work was done. Check for any leaks coming from tank. 2. If there are no leaks coming from tank, remove all water from the tank.

Safety Labels WARNING Safety labels are installed on the lift truck to provide information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read. DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped, and the nameplate must show the new capacity rating. Contact your dealer for a new nameplate.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer. NOTE: Not all labels that are used on lift trucks covered in this manual are shown in Figure 51, Figure 52 and Figure 53. See Parts Manual for a complete listing of all labels used on these lift trucks and their part numbers.

If a new label must be installed, use following procedure to install a new label. See Figure 51, Figure 52 and Figure 53 for lift truck models GLC/GDC70VX (GC/GLC/ â&#x20AC;˘ GLC/GDC60VX, GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) 1. Make sure surface is dry and has no oil or grease. DO NOT use solvent on new paint. Clean surface of old paint with a cleaning solvent. 2. Remove paper from back of label. DO NOT touch adhesive surface. 3. Carefully hold label in correct position above surface. The label cannot be moved after it touches surface. Put label on surface. Make sure that all air is removed from under label, and corners and edges are tight.

100 YRM 1316

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

ETHER WARNING LABEL (DIESEL ONLY) LPG TANK NAMEPLATE RIVET FLAMMABLE LPG LABEL FUEL ONLY LABEL (UNLEADED/DIESEL) YALE LOGO PLATE FASTENER FAN WARNING LABEL BORON-FREE LABEL FAN WARNING LABEL IMPACT WARNING LABEL ANTIFREEZE LABEL HOOD OPENING LABEL (LPG ONLY)

Safety Labels

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

SWIVEL SEAT WARNING (EUROPE ONLY) PARKING BRAKE WARNING LABEL JOYSTICK WARNING LABEL MODEL LABEL OPERATOR RESTRAINT LABEL YALE LABEL (HORIZONTAL) OPERATOR WARNING LABEL NO RIDERS LABEL MAST WARNING LABEL PINCH POINT LABEL YALE LABEL (VERTICAL) MAST WARNING LABEL

Figure 51. Safety Label Position (Exterior) for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879)

Safety Labels

100 YRM 1316

Figure 52. Safety Label Position (Exterior) for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879)

100 YRM 1316

Safety Labels

Legend for Figure 52 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

NO ONE UNDER FORKS PINCH POINT LABEL YALE LABEL (VERTICAL) MAST WARNING LABEL DPF LABEL OPERATOR WARNING LABEL IMPACT WARNING LABEL LPG TANK NAMEPLATE LPG TANK NAMEPLATE MODEL LABEL ETHER WARNING LABEL (DIESEL ONLY) FLAMMABLE LPG LABEL FAN WARNING LABEL BORON-FREE LABEL

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

FAN WARNING LABEL ANTIFREEZE LABEL FUEL LABEL (UNLEADED) FUEL LABEL (DIESEL) FUEL LABEL (DIESEL) YALE LOGO PLATE FASTNER OPERATOR RESTRAINT LABEL YALE LABEL (HORIZONTAL) HOOD OPENING LABEL (LPG ONLY) SWIVEL SEAT WARNING (EUROPE ONLY) JOYSTICK WARNING LABEL LOCKING GAS SPRING CAUTION NO RIDERS LABEL

Safety Labels

100 YRM 1316

Figure 53. Safety Label Position (Interior) for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)

100 YRM 1316

Safety Labels

Legend for Figure 53 1. 2. 3. 4. 5.

NAMEPLATE RIVET COVER DRIVE TRAIN PROTECTION LABEL STANDARD POWERSHIFT TRANSMISSION LABEL

6. 7. 8. 9. 10. 11.

TECHTRONIX 332 TRANSMISSION NAMEPLATE TAG PATENTS AND TRADE MARKS LABEL PARKING BRAKE WARNING LABEL BATTERY SWITCH LABEL UL LABEL

0600 YRM 1251

General

General CAUTION Disconnect the battery cables before doing any disassembly and repair of the engine or parts of the electrical system. The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: •

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DO NOT disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors. DO NOT disconnect an electric wire before the engine is stopped and the switches are OFF.

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DO NOT cause a short circuit by connection of the electric wires to the wrong terminals. Make sure a correct identification of the wire is made before it is connected.

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Make sure a battery is the correct voltage and polarity before it is connected.

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DO NOT check for current flow by making a spark because the electronic components can be damaged.

This YRM has repair instructions for GM 4.3 liter, V-6 engine. Checks and Adjustments and Specifications are also included.

Engine Removal and Installation The Removal and Installation procedures for the engine are in the Frame section for each model of lift truck. If engine and transmission were removed from lift truck as a unit, see Transmission sections to separate transmission from engine. The Removal and Installation procedures for the gasoline and LPG components of the engine are covered in the Gasoline Fuel System and LPG Fuel System sections for each model of lift truck.

Cylinder Head Repair REMOVE AND DISASSEMBLE WARNING Disconnect the battery cables before making repairs to the engine. 1. Drain cooling system. 2. Loosen hose clamp and remove coolant hose from thermostat housing.

3. Remove air cleaner, distributor, intake manifold, and exhaust manifolds. Remove drive belt(s) and remove brackets for drive belt tensioner and alternator. 4. Remove spark plugs and spark plug wire shields. 5. Remove valve rocker arm cover bolts and grommets. Discard grommets. 6. Remove rocker arm cover. See Figure 1.

NOTE: Prior to removing distributor, mark location of distributor on distributor and engine to aid in proper installation. For more information regarding removal and installation of distributor, see High Voltage Switch (HVS) Ignition 2200YRM1097.

Cylinder Head Repair

0600 YRM 1251 8. Remove valve rocker arm supports. 9. Remove valve push rods.

1. ROCKER COVER BOLTS 2. ROCKER COVER 3. CYLINDER HEAD Figure 1. Rocker Cover Removal 7. Remove valve rocker arms. Organize rocker arms so they can be installed in their original positions. See Figure 2.

1. VALVE ROCKER ARM 2. VALVE ROCKER ARM SUPPORT 3. PUSH ROD Figure 2. Remove Valve Rocker Arm and Push Rod

0600 YRM 1251

Cylinder Head Repair

10. Remove capscrews that hold cylinder head to block in the sequence shown in Figure 3. Remove cylinder head and gasket. Discard cylinder head gasket.

A. FAN END Figure 3. Cylinder Head Capscrew Removal Sequence 11. Using a valve spring compressor, remove valve stem keys, caps, springs, and oil seals. Discard oil seals. Remove valves. Organize valves and springs so they can be installed in their original positions. See Figure 4.

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

VALVE STEM KEYS VALVE SPRING CAP VALVE SPRING VALVE VALVE STEM OIL SEAL CYLINDER HEAD Figure 4. Valve Removal

Cylinder Head Repair

0600 YRM 1251

CLEAN AND INSPECT

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Damage to gasket surfaces

1. Clean carbon from valve ports and combustion chambers in cylinder head. Use care not to scuff the combustion chambers.

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Damage to threaded bolt holes

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Burnt or eroded areas in combustion chamber

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Cracks in exhaust ports and combustion chambers

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External cracks in water chamber

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Restrictions in intake or exhaust passages

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Restrictions in cooling system passages

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Rusted, damaged, or leaking core plugs

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 procedures.

WARNING Compressed air can move particles so they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. 2. Using cleaning solvent, clean following items: •

Valve stem keys

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Valve spring cap

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Valve spring

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Valve

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Cylinder head

When cleaning is complete, dry components with compressed air. See Figure 5. 3. Clean valve guides.

CAUTION To prevent possible gouging of the cylinder head surfaces, use care when removing gasket material. 4. Remove all gasket material from surfaces of cylinder head. 5. Inspect cylinder head for following defects:

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

VALVE STEM KEYS VALVE SPRING CAP VALVE SPRING VALVE VALVE STEM OIL SEAL CYLINDER HEAD Figure 5. Valve Component Cleaning

0600 YRM 1251 6. Measure cylinder head for warpage with a straight edge and feeler gauge. See Figure 6. •

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Cylinder Head Repair 7. Inspect valves for: •

Burnt or damaged areas

A cylinder head block deck with warpage in excess of 0.10 mm (0.004 in.) within a 152.4 mm (6.0 in.) area must be repaired or replaced.

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Undersized margin

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Bent stem

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Scoring or other damage to stem

A cylinder head exhaust manifold mounting surface with a warpage in excess of 0.05 mm (0.002 in.) within a 152.4 mm (6.0 in.) area must be repaired or replaced.

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Worn key groove

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Worn stem tip

See Figure 7.

A cylinder head intake manifold mounting surface with a warpage in excess of 0.10 mm (0.004 in.) within a 152.4 mm (6.0 in.) area must be repaired or replaced.

1. 2. 3. 4. 5. 6. Figure 6. Cylinder Head Warpage Inspection

BURNT OR DAMAGED AREAS UNDERSIZED MARGIN BENT STEM SCORING/DAMAGE TO THE STEM WORN KEY GROOVE WORN STEM TIP Figure 7. Valve Inspection

Cylinder Head Repair Valve stems with excessive guide clearance must be repaired or replaced. Refer to Engine Specifications. 8. Inspect valve contact surface for the following: •

Undersized margin

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Pitted surface

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Burnt or eroded areas

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Acceptable edge margin

See Figure 8.

0600 YRM 1251 2. Remove each spark plug and spark plug wire shield. NOTE: If spark plugs are not being replaced label each spark plug to its corresponding cylinder. 3. Remove rocker cover bolts and grommets. Discard grommets. Repeat for other rocker cover. 4. Remove rocker covers. Disconnect the Positive Crankcase Ventilation valve from the air inlet hose. 5. Perform cylinder leak down test for each cylinder. See Cylinder Leak Down Test. 6. Remove valve rocker arms. Organize rocker arms so they can be installed in their original positions. Repeat for other side. 7. Using a valve spring compressor, remove valve stem keys, caps, springs, and oil seals. Discard oil seals. Organize springs so they can be installed in their original positions. Repeat for other each cylinder.

Cylinder Leak Down Test NOTE: Rotate crankshaft to place piston in cylinder being tested at top dead center (TDC) of the compression stroke, with both valves closed. Lock crankshaft balancer in place to prevent piston movement. 1. 2. 3. 4.

UNDERSIZED MARGIN PITTED SURFACE BURNT OR ERODED AREAS ACCEPTABLE EDGE MARGIN Figure 8. Valve Contact Surface Inspection Valves with excessive damage must be replaced. Minor imperfections of valve or valve seat may be repaired. Refer to Valve Guides and Seats, Repairs or Valves, Repair.

VALVE OIL SEALS The following procedure addresses replacement of valve oil seals. If ONLY valve oil seals are being replaced, it is not necessary to remove the cylinder head.

Remove and Disassemble 1. Remove spark plug wires from spark plugs and position spark plug wires out of way. 6

1. Install the J 35667-A Cylinder Head Leakdown Tester (Yale P/N 582026435) tester in the spark plug port on cylinder to be tested. 2. Apply shop air pressure to J 35667-A Cylinder Head Leakdown Tester (Yale P/N 582026435) tester and adjust according to manufactures instructions. 3. Record cylinder leakage value. Cylinder leakage exceeding 25 percent is considered excessive and may require component service. Air leakage from intake or exhaust system may indicate a worn or burnt valve or a broken valve spring. •

Ensure that both valves are closed.

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Inspect cylinder head for a broken valve spring.

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Remove and inspect suspect cylinder head. See Cylinder Head Repair, Remove and Disassemble.

0600 YRM 1251

Cylinder Head Repair

Air leakage from crankcase, oil level indicator, or oil fill tube may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damage cylinder head. •

Remove piston from the suspect cylinder. See Piston and Connecting Rod Assemblies, Remove.

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Inspect piston and connecting rod assembly. See Piston, Clean and Inspect.

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Inspect engine block. See Engine Block, Clean and Inspect.

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Inspect cylinder head. See Cylinder Head Repair, Clean and Inspect.

Air bubbles in cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket. •

Remove both cylinder heads. See Cylinder Head Repair, Remove and Disassemble.

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Inspect engine block. See Engine Block, Clean and Inspect.

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Inspect cylinder head. See Cylinder Head Repair, Clean and Inspect.

Clean and Inspect

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 procedures.

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

VALVE STEM KEYS VALVE SPRING CAP VALVE SPRING VALVE VALVE STEM OIL SEAL CYLINDER HEAD Figure 9. Valve Component Cleaning

3. Clean valve guides.

Assemble and Install 1. Using GM tool J-42073 (Yale P/N 582024511), install oil seal in lower groove. Install shim, damper, spring, shield, and cap or rotator. Using a spring compressor, compress assembly and install retainers. Measure height of valve spring as shown in Figure 13. Measure from top of shim to top of retainer cap. Install shims to get correct height shown in Figure 10. The installed height of valve spring must not be less than minimum height.

1. Using cleaning solvent, clean the following items: •

Valve stem keys

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Valve spring cap

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Valve spring

2. When cleaning is complete, dry components with compressed air. See Figure 9.

Cylinder Head Repair

0600 YRM 1251 2. Apply a molybdenum grease or equivalent to following valve rocker arm contact surfaces: •

Valve push rod socket

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Roller pivot

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Valve stem tip

See Figure 11.

NOTE: THIS LIST IS FOR 4.3L GASOLINE ENGINES. A. VARIATION FROM VERTICAL: LESS THAN 1.6 mm (0.063 in.) B. FREE LENGTH: 51.3 mm (2.02 in.) C. SPRING COMPRESSED TO 338 TO 374 N (76 TO 84 lbf) AT 43.2 mm (1.70 in.) CLOSED SPRING COMPRESSED TO 832 TO 903 N (187 TO 203 lbf) AT 32.3 mm (1.27 in.) OPEN D. INSTALLED HEIGHT INTAKE: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) EXHAUST: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) NOTE: THIS LIST IS FOR 4.3L LPG ENGINES. A. VARIATION FROM VERTICAL: LESS THAN 1.6 mm (0.063 in.) B. FREE LENGTH: 50 mm (2.0 in.) C. SPRING COMPRESSED TO 265 N (59.5 lbf) AT 43.2 mm (1.70 in.) CLOSED SPRING COMPRESSED TO 718 N (161.5 lbf) AT 32.3 mm (1.27 in.) OPEN D. INSTALLED HEIGHT INTAKE: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) EXHAUST: 42.92 TO 43.43 mm (1.670 TO 1.700 in.) Figure 10. Valve Spring Specifications

1. 2. 3. 4.

VALVE PUSH ROD SOCKET ROLLER PIVOT VALVE STEM TIP ROCKER ARM BOLT

Figure 11. Lubricate Valve Rocker Arm Surfaces 3. Install valve rocker arm assemblies as follows: a. Finger start rocker arm bolt at location 1 in Figure 12. b. Finger start rocker arm bolt at location 2 in Figure 12.

0600 YRM 1251

Cylinder Head Repair

c. Finger start rocker arm bolt at location 3 in Figure 12. d. Finger start remaining three valve rocker arm bolts. Repeat for other side.

NOTE: ONCE THE VALVE ROCKER ARM ASSEMBLIES ARE INSTALLED AND PROPERLY TORQUED, NO ADDITIONAL VALVE LASH ADJUSTMENT IS REQUIRED. 1. CRANKSHAFT BALANCER ALIGNMENT MARK 2. ENGINE FRONT COVER ALIGNMENT TAB 1. BOLT AT LOCATION 1 2. BOLT AT LOCATION 2 3. BOLT AT LOCATION 3

Figure 13. Rotate Crankshaft Balancer

Figure 12. Install Valve Rocker Arm Assemblies

5. Tighten valve rocker arm bolts to 30 N•m (22 lbf ft). See Figure 19. Repeat for other side.

4. Rotate crankshaft balancer to position crankshaft balancer alignment mark 57 to 63 degrees clockwise or counterclockwise from engine front cover alignment tab. See Figure 13.

6. Use new gasket and install rocker covers. Install new grommets on capscrews and install capscrews into rocker covers. Tighten capscrews to 12 N•m (107 lbf in). See Figure 22. Repeat for other side.

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