YALE B910 GLC30VX LIFT TRUCK Service Repair Manual by 1639589

GLC20VX, GLC25VX, GLC30VX, GLC35VX (B910) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................ KUBOTA SPARK IGNITED 2.5L LPG............................................................................ MAZDA 2.2L ENGINE..................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM, MAZDA 2.2L ENGINE................................................................. LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ DRIVE AXLE REPAIR (WET BRAKE)........................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC CLEANLINESS PROCEDURES............................................................... HYDRAULIC GEAR PUMPS.......................................................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... CYLINDER REPAIR (MAST S/N D515, E509, E564)..................................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. ELECTRICAL SYSTEM, MAZDA 2.2L ENGINE............................................................ MAST REPAIR (S/N F507, F508, F562, F563)............................................................... MAST REPAIR (S/N D515, E509, E564)........................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

550096314 550096316 550096315 550096317 550096318 550096320 550096321 550096322 550096323 550096324 550096325 550073240 550096326 550096327 550093750 550100651 524223769 524223770 524223771 550096328 550096329 550093755 550100656 524150797 524223780 550096309 550096330 550096331 524221866

0100 YRM 1672 0600 YRM 1670 0600 YRM 1673 0700 YRM 1674 0900 YRM 1675 0900 YRM 1677 1300 YRM 1678 1400 YRM 1679 1400 YRM 1680 1600 YRM 1681 1800 YRM 1682 1900 YRM 1620 1900 YRM 1683 2000 YRM 1684 2100 YRM 1668 2100 YRM 1692 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1685 2200 YRM 1686 4000 YRM 1669 4000 YRM 1693 8000 YRM 0231 8000 YRM 1134 8000 YRM 1687 8000 YRM 1688 8000 YRM 1689 9000 YRM 1112

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

9000 YRM 1112 ON CD PART NO. 550096301 (12/14)

0100 YRM 1672

General

General WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •

Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

•

Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or Periodic Maintenance 8000YRM1687.

NOTE: For exhaust system procedures on lift trucks equipped with a Mazda engine go to LPG Fuel System, Mazda 2.2L Engine 0900YRM1675 or Gasoline Fuel System, Mazda 2.2L Engine 0900YRM1676 . NOTE: For exhaust system procedures on lift trucks equipped with Kubota engine go to LPG Fuel System, Kubota 2.5L Engine 0900YRM1677. NOTE: For exhaust system procedures on lift trucks equipped with Yanmar engine go to Exhaust System Repair in this manual. This section contains the description of the frame and connected parts; procedures for removing and installing counterweight, hood, overhead guard, engine, transmission, cooling system, and exhaust system (see above NOTES). Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1. See Table 3 for lift truck models: •

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

GC/

See Table 4 for lift truck models: •

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875)

The muffler is fastened to the frame inside the counterweight. 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.

Hood, Seat, and Side Covers Replacement

1. 2. 3. 4.

0100 YRM 1672

COWL PLATE FENDERS FRAME HOOD MOUNTS

5. COUNTERWEIGHT MOUNTS 6. FUEL TANK (GAS OR DIESEL) 7. HYDRAULIC TANK Figure 1. Frame

Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat to the closest position to steering column. 2. Fully tilt steering column forward.

3. If your truck is equipped with an LPG tank, swing tank off to the side. 4. Raise latch on the left, front corner of the hood to unlatch and lift up hood. See Figure 2. 5. Remove floor mat and floor plate.

0100 YRM 1672

Hood, Seat, and Side Covers Replacement

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

C. BOTTOM VIEW OF HOOD D. SIDE VIEW OF VENTED HOOD WITH SWIVEL SEAT

1. 2. 3. 4. 5.

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

SEAT HOOD FRAME SEAT WIRE HARNESS SEAT WIRE HARNESS CONNECTOR (WITHOUT ELECTRONIC CONTROL) 6. SEAT WIRE HARNESS CONNECTOR (WITH ELECTRONIC CONTROL) 7. CABLE CLIPS 8. HINGE SCREWS

Figure 2. Hood and Seat Arrangement

Hood, Seat, and Side Covers Replacement

0100 YRM 1672

Figure 3. Side Cover, Floor Plate, and Cowl Components GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX) (B910)

0100 YRM 1672

Hood, Seat, and Side Covers Replacement Legend for Figure 3

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

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

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

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

Hood, Seat, and Side Covers Replacement

0100 YRM 1672

Figure 4. Side Covers, Floor Plate, and Cowl Components GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875) 6

0100 YRM 1672

Hood, Seat, and Side Covers Replacement Legend for Figure 4

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

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

6. Remove two capscrews holding left and right rear side covers to the frame. Remove rear side covers from frame. 7. Remove two capscrews holding left and right fender covers to front overhead guard leg. Remove covers. 8. Remove four capscrews holding left and right front side covers to frame. Remove covers. 9. Fully lower steering column.

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

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

10. Remove upper steering column cover by pulling up on upper steering column cover to release latches (one on either side), and pulling cover away from steering column. See Figure 5. 11. Remove five Allen screws (see Figure 5) from dash and cowl. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash. 12. Lift the kick panel to remove from truck. 13. Remove three capscrews holding the seal plate. Remove seal plate. See Figure 6.

Hood, Seat, and Side Covers Replacement

0100 YRM 1672

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

3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER Figure 5. Remove Dash From Cowl

0100 YRM 1672

1. CAPSCREWS

Hood, Seat, and Side Covers Replacement

2. SEAL PLATE Figure 6. Remove Seal Plate From Dash

Hood, Seat, and Side Covers Replacement 14. Disconnect seat wire harness connector. See Figure 2.

CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews. Damage can be caused to the threads on the screws and in the holes.

0100 YRM 1672 See Figure 7 and Table 1 for lift truck models: •

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

GC/

See Figure 8 and Table 2 for lift truck models •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

15. If seat is to be removed, and truck is equipped with a non-swivel seat, remove seat wire harness from seat wire harness brackets that are attached to the underside of hood. Remove the cable clips from the seat wire harness. If truck is equipped with a swivel seat, remove seat wire harness from seat wire harness bracket attached to underside of the hood and behind the seat (see Figure 2). 16. Remove four capscrews and washers holding the seat to hood. Lift seat off the hood. Pull seat wire harness through hood. See Figure 2. 17. Remove capscrews and washers at the top of gas springs. Remove gas springs from hood.

NOTE: LEFT SIDE SHOWN

INSTALL

A. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT B. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT WITH CAB

1. Place hood onto the lift truck frame.

1. MOUNTING POINTS FOR GAS SPRING ON HOOD

18. Remove hinge screws, located in the rear of the hood. 19. Lift hood from the truck. See Figure 2.

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

Figure 7. Gas Spring Installation, Lift Truck Models GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX) (B910)

0100 YRM 1672

Hood, Seat, and Side Covers Replacement

Table 1. Gas Spring Installation, Lift Truck Models GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX) (B910) Full or Semi Suspension Seat Frame

Non-Suspension Seat

Hood

Frame

Hood

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Seat Without E-Control

Seat With E-Control

N/A

Cab

N/A

A. LEFT SIDE B. RIGHT SIDE C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT

D. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT, LIFT TRUCKS WITH CAB OR (GP/GLP/GDP040-070VX) (C875) LIFT TRUCKS WITHOUT CAB E. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT, LIFT TRUCKS GLP/ GDP20-35VX (C875) WITHOUT CAB

1. MOUNTING POINTS FOR GAS SPRING ON HOOD Figure 8. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875)

Hood, Seat, and Side Covers Replacement

0100 YRM 1672

Table 2. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875) Full or Semi Suspension Seat Frame

Non-Suspension Seat

Hood

Frame

Hood

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Left Side

Right Side

Non-Cab

Cab

N/A

4. Install latch striker in highest slot position. Check that latch striker is in center of jaws of hood latch when hood closes. Open and close hood to ensure that center pin strikes hood latch properly and that the stop screw contacts frame. A properly closed hood MUST click twice on the hood latch. If the hood latch does not close properly, loosen capscrews on the back of center pin and adjust center pin up or down as required for correct alignment. See Figure 9.

1. HOOD 2. HOOD LATCH

3. CENTER PIN 4. CAPSCREW

Figure 9. Hood Latch Adjustment

0100 YRM 1672

Hood, Seat, and Side Covers Replacement

5. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood latch. Open hood and tighten capscrews for latch. 6. Check operation of hood latch. Have an operator sit in seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 5.

When installing the seat to the hood, DO NOT use an impact wrench to install the capscrews. Damage can be caused to the threads on the screws and in the holes. 7. Place seat on the hood and thread seat wire harness through the hole in the hood. See Figure 2. 8. Align holes in the seat with the holes in hood. Insert washers and capscrews. Tighten capscrews to 18 N•m (159 lbf in). 9. If truck is equipped with a non-swivel seat, tie cable clips to seat wire harness and insert harness into seat wire harness brackets under hood. If truck is equipped with a swivel seat, secure seat harness to bracket. See Figure 2. 10. Install seal plate using three capscrews. See Figure 6. 11. Install kick panel onto truck.

See Figure 4 for lift truck models:

(GP/GLP/

12. Install dash to top of cowl. See Figure 5. Install four clips to attach the dash to kick panel. 13. Install upper steering column cover to dash. 14. Using four capscrews, install left and right front side covers to frame.

•

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

GC/

See Figure 4 for lift truck models: •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

15. Using two capscrews, install left and right fender covers to front of overhead guard legs. 16. Using two capscrews, install left and right rear side covers to frame. See Figure 3 for lift truck models: •

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

GC/

See Figure 4 for lift truck models: •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

17. Install floor mat and floor plate.

See Figure 3 for lift truck models: GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

GLP/GDP20-35VX GDP040-070VX) (C875)

See Figure 3 for lift truck models:

CAUTION

•

GC/

18. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight. 19. Adjust the steering column and seat positions.

Steering Column

0100 YRM 1672

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 10.

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 11.

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR. 1. STEERING WHEEL 2. STEERING COLUMN 3. COWL Figure 10. Steering Column and Cowl

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

1. 2. 3. 4.

HORN BUTTON HEX NUT STEERING WHEEL STEERING COLUMN Figure 11. Steering Wheel Remove/Install

0100 YRM 1672

Steering Column

4. Remove steering column covers. Remove floor mats and floor plate. See section Hood, Seat, and Side Covers Replacement. NOTE: Perform Step 5 for lift trucks equipped with gas or LPG engines.

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 12.

5. Remove four capscrews, four isolators, four bushings, and steering column from cowl standoffs. See Figure 12.

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

4. STEERING COLUMN 5. COWL STANDOFF Figure 12. Steering Column Remove/Install

Disassemble NOTE: Remove and discard snap rings if installed. 1. Remove two pins and gas spring from housing. See Figure 13. 2. Remove two pivot bolts, two bushings, two nuts and bracket from housing. See Figure 13.

3. Remove split pin and lower shaft from upper shaft. See Figure 13. 4. Remove connector from connector bracket. Remove connector bracket, fastener, four screws and two horn contacts from housing. See Figure 13.

Steering Column

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

0100 YRM 1672

BRACKET SPACER JOINT NUT WASHER SCREW UPPER SHAFT HOUSING

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

PIN LOWER SHAFT GAS SPRING BOLT BUSHING CONNECTOR FASTENER HORN CONTACT

Figure 13. Steering Column

Clean

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

WARNING Compressed air is used for cleaning and drying purposes, or for cleaning restrictions. Wear protective clothing (goggles/shields, gloves, etc.). Make sure the path of the compressed air is away from all personnel to avoid injury.

0100 YRM 1672 1. Clean metal parts in solvent. Remove all traces of old lubricant and dirt. Clean nonmetal parts with warm soapy water and a lint free cloth. 2. After cleaning, dry parts with compressed air. DO NOT dry parts with a cloth.

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

Assemble 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. 1. Install fastener, connector bracket and connector, two horn contacts and four screws. See Figure 13. 2. Assemble lower shaft and upper shaft, secure with spit pin. See Figure 13. 3. Install two pivot bolts, two bushings, two nuts and bracket onto housing. See Figure 13. 4. Install gas spring and two pins on housing. See Figure 13.

Steering Column Periodic Maintenance 8000YRM1687 for lift truck models •

GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (B910)

GC/

•

GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

NOTE: Perform Step 1 for lift trucks equipped with gas or LPG engines. 1. Install steering column, four isolators, four bushings, and four bolts on cowl standoffs. Tighten bolts to 38 N•m (28 lbf ft). See Figure 12. NOTE: Perform Step 2 for lift trucks equipped with diesel engines. 2. Install steering column, four isolators, four bushings, and four bolts on cowl standoffs. Tighten bolts to 38 N•m (28 lbf ft). See Figure 12. 3. Install floor plate, floor mats, and steering column covers. See section Hood, Seat, and Side Covers Replacement. 4. Install steering wheel and hex nut on steering column, tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft). Connect electrical wiring and install horn button. See Figure 11. 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.

Install NOTE: Lubricate spline end of lower shaft with multi purpose grease. See one of Service Manuals below for procedures

LPG Tank and Bracket Assembly

0100 YRM 1672

LPG Tank and Bracket Assembly For procedures to remove and install the LPG tank, LPG tank bracket, and the LPG tank alignment pin see the following Service Manuals: •

•

LPG Fuel System, Kubota 2.5L Engine 0900YRM1677 for lift trucks equipped with a Kubota 2.5L LPG engine

LPG Fuel System, Mazda 2.2L Engine 0900YRM1675 for lift truck models equipped with a Mazda 2.2L LPG engine

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, 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.

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.

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. See Figure 14. One M24 × 3 x 140 capscrew holds counterweight to lower part of frame on lift truck models: •

GLC30-35VX (GC/GLC060-070VX, GLC055SVX) (B910)

GC/

•

GLP/GDP30-35VX (GP/GLP/GDP060-070VX) (C875)

One M24 × 3 x 90 capscrew holds counterweight to lower part of frame on lift truck models: •

GLC20-55VX (GC/GLC040-050VX) (B910)

•

GLP/GDP20-25VX (GP/GLP/GDP040-050VX) (C875)

NOTE: For overhead exhaust system removal procedure, for lift trucks equipped with a Mazda engine, see LPG Fuel System, Mazda 2.2L Engine 0900YRM1675 or Gasoline Fuel System, Mazda 2.2L Engine 0900YRM1676. NOTE: For overhead exhaust system removal procedure, for lift truck equipped with a Kubota engine, see LPG Fuel System, Kubota 2.5L Engine 0900YRM1677

0100 YRM 1672

Counterweight Replacement

NOTE: To remove overhead exhaust pipe, for lift trucks equipped with a Yanmar engine and overhead exhaust see section Exhaust System Repair in this manual 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, before removing the counterweight LPG Fuel System, Mazda 2.2L 0900YRM1675 for lift truck models:

Engine

•

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

•

GLP/GDP30-35VX GDP040-070VX) (C875)

GC/

(GP/GLP/

LPG Fuel System, Kubota 2.5L 0900YRM1677 for lift truck models

Engine

•

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

GC/

(GP/GLP/

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:

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

FRAME LOWER FRAME MOUNT WASHER CAPSCREW TOW PIN LIFT HOLE SEAL FRAME HOOK Figure 14. Counterweight Installation

Table 3 for lift truck models: •

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

GC/

Table 4 for lift truck models: •

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875)

2. Install a lifting eyebolt in lift hole of counterweight. See Figure 14. Connect a crane to lifting eyebolt and raise crane until it holds par of the weight of counterweight. Remove tow pin. See Figure 14 and Figure 15. Remove capscrew and washer that hold counterweight to frame. See Figure 14 and Figure 15.

Table 3. Weight of Counterweights, Lift Truck Models GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX) (B910) Model

GLC20VX (GC/ GLC040VX)

1040

2293

GLC25VX (GC/ GLC050VX)

1395

3075

GC/GLC055SVX

1643

3622

GLC30VX (GC/ GLC060VX)

1819

4010

GLC35VX (GC/ GLC070VX)

2153

4747

Use crane to lift counterweight from lift truck frame. Place counterweight on floor so that is has stability and will not fall over. Take care not to damage exhaust or cooling components.

Counterweight Replacement

0100 YRM 1672 LPG Fuel System, Kubota 2.5L 0900YRM1677 for lift truck models

Table 4. Weight of Counterweights, Lift Truck Models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (C875) Model

GLP/GDP20VX (GP/GLP/GDP040VX)

994

2191

GLP/GDP25VX (GP/GLP/GDP050VX)

1338

2950

GLP/GDP30SVX (GP/ GLP/GDP060SVX)

1664

3668

GLP/GDP35SVX (GP/ GLP/GDP070SVX)

1965

4332

Engine

•

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

GC/

(GP/GLP/

6. If lift truck is equipped with a Yanmar engine and an overhead exhaust system, install the overhead pipe. See section Exhaust System Repair in this manual for procedures.

INSTALL 1. Make sure seals are on counterweight. Figure 15. 2. Use a crane to install counterweight on lift truck frame. When counterweight is installed, make sure hooks on frame fully engage counterweight so it is aligned with parts of frame. 3. Install washer and M24 × 3 capscrew. Tighten capscrew to 555 N•m (409 lbf ft). See Figure 14 and Figure 15. 4. Install tow pin. See Figure 15. 5. 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, Mazda 2.2L 0900YRM1675 for lift truck models

Engine

•

GLC20-35VX (GC/GLC40-70VX, GLC055SVX) (B910)

•

GLP/GDP30-35VX GDP040-070VX) (C875)

GC/

(GP/GLP/

1. 2. 3. 4. 5.

TOW PIN CAPSCREW WASHER COUNTERWEIGHT LPG ACCESS HOLE

6. 7. 8. 9. 10.

NUT SEAL WASHER LIFTING EYEBOLT LIFT HOLE

Figure 15. Counterweight

0100 YRM 1672

Overhead Guard Replacement

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

1. Connect a lifting device to remove or install the overhead guard. Loosen clamp and disconnect the air intake hose from the elbow. Remove bolts, elbow, retainer, and grommet from the overhead guard rear leg. See Figure 16.

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 Hyster lift trucks BEFORE performing any changes to the overhead guard. NOTE: The lift trucks covered in this YRM are equipped with either a high or low overhead guard. The removal and installation procedures for both types of overhead guards are the same. No welding or drilling on legs of overhead guard is permitted as per previous WARNING. NOTE: The lifting device can be connected to any number of positions on the overhead guard depending upon the lifting device available. The ideal choices are a four point sling connected to all four corners on the top of the overhead guard, or a two point sling connected to two opposite corners of the overhead guard. If a single point hoist is used, make sure that the lift point is as close to the center of the overhead guard. If during the initial start of the lift the overhead guard is off balance lower immediately and move the hoist to a more centered point.

1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS

4. ELBOW 5. RETAINER 6. GROMMET

Figure 16. Disconnect Air Intake Hose

Operator Restraint System Replacement

0100 YRM 1672

2. Disconnect any wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that any electrical wires are moved through the holes in the frame so that they are not damaged. 3. The rear legs of the overhead guard have two capscrews that are located under the hood inside the engine compartment, next to the radiator. Remove and install the capscrews. See Figure 17. 4. Remove the fender cover, dash, and kick panel to remove and install the three capscrews on the front legs of the overhead guard. See Hood, Seat, and Side Covers Replacement for the removal procedures. 5. When installing the overhead guard, tighten the capscrews for the overhead guard legs to 66 Nâ&#x20AC;˘m (49 lbf ft). See Figure 17.

LED TAIL, BACKUP, AND BRAKE LIGHTS, REPLACE These light assemblies are nonrepairable and must be replaced as an assembly. See Electrical System 2200YRM1685for the procedures to replace these lights. 1. 2. 3. 4.

CAPSCREWS - FRONT LEGS HANDLE CAPSCREWS - REAR LEGS FRAME Figure 17. Overhead Guard

Operator Restraint System Replacement DESCRIPTION

Emergency Locking Retractor (ELR)

The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 18.

When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator's lower torso in the seat.

0100 YRM 1672 A seat belt that is damaged worn or does not operate properly will not provide protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 18 and Figure 19.

Operator Restraint System Replacement Adjust hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See the section Hood, Seat, and Side Covers Replacement in this manual for the adjustment procedures for the hood.

NOTE: The following seat belt operation checks must be performed three times before replacing the seat belt assembly. •

With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly. Make sure the seat belt pulls out and retracts smoothly. If the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly.

•

With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly.

•

With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

Make sure the seat rails and latch striker are not loose. The seat rails must lock securely in position but move freely when unlocked. The seat rails must be securely attached to the mounting surface. The hood must be fully closed. Lift the hood to make sure it is closed and will not move.

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

OPERATOR WEIGHT ADJUSTMENT FORWARD/BACKWARD ADJUSTMENT SEAT BELT HIP RESTRAINT SEAT SEAT RAIL Figure 18. Operator Restraint System

Engine Replacement

0100 YRM 1672

A. STANDARD, NON-SUSPENSION SEAT

B. FULL SUSPENSION SEAT

1. 2. 3. 4.

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

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

Figure 19. Operator Restraint System

Engine Replacement REMOVE

•

WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •

Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875)

0100 YRM 1672

Engine Replacement

WARNING

CAUTION

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. 1. For lift trucks equipped with an LPG fuel system, close the shutoff valve on the tank and run engine until all fuel is gone and engine stops. 2. If lift truck is equipped with an LPG fuel tank, swing tank to the side. See one of the following Service Manuals for procedures LPG Fuel System, Mazda 2.2L 0900YRM1675 for lift truck models

Engine

•

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

LPG Fuel System, Kubota 2.5L 0900YRM1677 for lift truck models

Disposal of lubricants and fluids must meet local environmental regulations. 6. Open the drain plug or disconnect the bottom radiator hose to drain coolant from radiator and engine. 7. Remove the hood and seat combination and rear side covers. See the section Hood, Seat, and Side Covers Replacement for procedures. 8. On lift trucks equipped with a Mazda 2.2L engine, disconnect ECM connector from ECM. Remove two bolts and ECM bracket, with ECM attached, from engine block. 9. Disconnect the ground strap from the frame and remove the power distribution module (PDM) from the battery tray. See Figure 20. 10. Remove three capscrews from the battery tray and remove the battery and battery tray. See Figure 20.

(GP/GLP/ Engine

•

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

3. Remove overhead guard. See section Overhead Guard Replacement for procedures. 4. Remove the 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. 5. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under radiator. Remove radiator cap.

1. 2. 3. 4. 5.

BATTERY BATTERY TRAY PDM BATTERY LOCKDOWN BAR GROUND STRAP Figure 20. Power Distribution Module, Disconnection

Engine Replacement 11. Disconnect the remaining coolant hoses from the radiator and cap them to prevent leakage. 12. On lift trucks equipped with a Mazda engine and Basic Powershift Transmission, disconnect the throttle linkage (see the section 2-Speed Powershift Transmission Repair 1300YRM1690. Disconnect the exhaust system. 13. Remove the radiator fan pulley, shroud, and fan assembly. See the section Cooling System 0700YRM1674 for the removal procedures.

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. 14. Disconnect the fuel lines at the engine. Put caps on fuel lines to prevent fuel leakage. NOTE: Lift trucks equipped with Yanmar diesel engine do not have an ECM. 15. Disconnect the electronic control module (ECM) connector and governor controller from the side of the frame before removing the engine from the truck.

0100 YRM 1672 16. Disconnect the engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck. 17. Use the access port on the side of engine and remove the four bolts that attach the flywheel to the torque converter. See Figure 21. 18. Connect a lifting device to the engine. Put a block under the transmission housing to support the transmission. NOTE: Perform Step 19 for lift trucks equipped with iron housing transmission. 19. Remove capscrews from transmission bell housing. NOTE: Perform Step 20 through Step 22 for lift trucks equipped with aluminum housing transmission. 20. Remove two capscrews, two washers, and converter housing cover from torque converter housing. See Figure 22. 21. Remove four flange bolts from torque converter housing and flywheel housing on transmission side. See Figure 22. 22. Remove six hex head capscrews and six lock washers from flywheel housing and torque converter housing on flywheel housing side. See Figure 22.

0100 YRM 1672

Engine Replacement

A. KUBOTA 2.5L ENGINE B. YANMAR 3.3L ENGINE

C. MAZDA 2.2L ENGINE

1. ACCESS PORT

2. FLYWHEEL HOUSING Figure 21. Torque Converter Bolt Access

Engine Replacement

0100 YRM 1672

NOTE: KUBOTA 2.5L ENGINE AND ALUMINUM CASE TRANSMISSION SHOWN. 1. 2. 3. 4. 5. 6.

FLANGE BOLT TRANSMISSION ASSEMBLY FLYWHEEL HOUSING LOCKWASHER HEX HEAD CAPSCREW ENGINE ASSEMBLY

7. 8. 9. 10. 11.

TORQUE CONVERTER HOUSING CONVERTER HOUSING COVER WASHER CAPSCREW EYEBOLT BRACKET

Figure 22. Flywheel and Torque Converter Housings

0100 YRM 1672

WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 194 kg (428 lb). 23. Remove the flange nuts, washers, bolts, and isolators from the engine mounts. Remove engine adapter to transmission bolts. See Figure 23 and Figure 24.

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. 24. Use the lifting device to carefully move the engine away from the torque converter. Make sure all hoses, wires, and cables are disconnected from the engine, then lift the engine from the frame and place engine on blocks. 25. Remove torque converter from torque converter housing.

Engine Replacement

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

CAUTION Keep the engine level when installing the engine to the transmission so the drive plate is not damaged. 1. Install torque converter in torque converter housing. 2. Connect lifting device to engine and lift engine into frame. 3. Install isolators on engine mounts. Install the nuts and bolts for the engine mounts to secure engine to frame. See Figure 23 and Figure 24. Tighten the nuts to 150 N•m (110 lbf ft). 4. Use access port on side of engine and install bolts to hold torque converter to flywheel. Tighten bolt to 56 N•m (41 lbf ft). See Figure 21. NOTE: Perform Step 5 for lift trucks equipped with iron transmission housing. 5. Align transmission bell housing holes with flywheel housing holes and install capscrews. Tighten capscrews to 38 N•m (28 lbf ft).

Engine Replacement

0100 YRM 1672

A. MAZDA ENGINE B. YANMAR ENGINE

C. KUBOTA ENGINE

1. FRAME 2. ENGINE MOUNT

3. FLANGE NUT Figure 23. Engine Removal

0100 YRM 1672

Engine Replacement

A. MAZDA ENGINE MOUNT B. YANMAR ENGINE MOUNT

C. KUBOTA ENGINE MOUNT

1. CAPSCREW 2. WASHER 3. RIGHT ENGINE MOUNT

4. SNUBBING WASHER 5. ISOLATOR 6. LOCKNUT Figure 24. Engine Mounts

Engine Replacement NOTE: Perform Step 6 through Step 8 for lift trucks equipped with aluminum transmission housing. 6. Install six lock washers and six capscrews on flywheel housing and torque converter housing from flywheel housing side. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 22. 7. Install four flange bolts on torque converter housing and flywheel housing from transmission side. Tighten bolts to 38 N•m (28 lbf ft). See Figure 22. 8. Install converter housing cover, two washers, and two capscrews on torque converter housing. Tighten capscrews to 19 N•m (168 lbf in). See Figure 22. 9. Install exhaust pipe to exhaus manifold. See Exhaust System Repair.

0100 YRM 1672 13. On lift trucks equipped with a Mazda engines and Basic Powershift Transmission, connect the throttle linkage (see the section 2-Speed Powershift Transmission Repair 1300YRM1690. Connect exhaust system. 14. Connect the coolant hoses and lines to the transmission. Fill cooling system with a mixture of 50 percent deionized water and 50 percent ethylene glycol boron-free antifreeze. 15. Install the radiator shroud, fan pulley, and fan assembly. See the section Cooling System 0700YRM1674 for the installation procedures. 16. Connect the PDM and connect the ground strap to lift truck frame and attach it to battery. Install the battery and battery tray. See Figure 25.

NOTE: Lift trucks equipped with Yanmark diesel engine do not have an ECM. 10. Connect the ECM connector and governor controller to lift truck frame. 11. Install ECM bracket with ECM attached and two bolts on engine block.

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

1. 2. 3. 4. 5.

BATTERY BATTERY TRAY PDM BATTERY LOCKDOWN BAR GROUND STRAP

Figure 25. Power Distribution Module, Connection

0100 YRM 1672

Transmission Replacement

17. If lift truck is equipped with an LPG tank, swing tank into position on truck. See one of the following Service Manuals for procedures LPG Fuel System, Mazda 2.2L 0900YRM1675 for lift truck models

Engine

•

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

LPG Fuel System, Kubota 2.5L 0900YRM1677 for lift truck models

19. If removed, install Overhead guard. See section Overhead Guard Replacement for procedures. 20. Check all fluid levels as described in the section Periodic Maintenance 8000YRM1687 for lift truck models:

(GP/GLP/

•

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

Engine

•

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 21. Empty drain pan contents.

18. Install the rear side covers, floor plates, floor mat, and hood and seat combination. See the section Hood, Seat, and Side Covers Replacement for the procedures.

Transmission Replacement REMOVE TRANSMISSION WITH IRON HOUSING 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, transmission, and counterweight. When the lift truck is put on blocks put additional blocks in the following positions to maintain stability:

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875)

•

Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

1. Remove engine from lift truck. See section Remove, Engine Replacement in this manual for procedures.

•

Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

2. Remove the seal plate for the brake and throttle pedals. See Figure 26.

Transmission Replacement

1. CAPSCREWS

0100 YRM 1672

2. SEAL PLATE Figure 26. Remove Seal Plate From Dash

0100 YRM 1672

Transmission Replacement

NOTE: When disconnecting wiring harness connectors during removal, tag each connector to aid in connecting wiring harness during installation. 3. Disconnect the engine wiring harness from transmission wiring harness. 4. Disconnect transmission cooling lines. NOTE: Step 5 applies to lift truck models equipped with a hydraulic gear pump. 5. Remove the hydraulic hose between the hydraulic pump and the tank. Put a cap on the tank fitting. Remove the supply line from hydraulic pump to the main control valve. NOTE: Step 6 and Step 7 apply to lift truck models GLP/GDP20-35VX (C875) equipped with a variable displacement pump (VDP): 6. Remove the hydraulic supply (suction) hose between the variable displacement pump and hydraulic tank. Put a cap on the hydraulic tank fitting. See Figure 27. 7. Remove the hydraulic supply hose, load sense line, drain case line, and hydraulic inlet line from the variable displacement pump. Put cap on all variable displacement pump and hose openings. See Figure 27.

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

TRANSMISSION HOUSING VARIABLE DISPLACEMENT PUMP LOAD SENSE LINE HYDRAULIC INLET LINE DRAIN CASE LINE HYDRAULIC SUPPLY (SUCTION) HOSE Figure 27. Hydraulic Hose Connections

Transmission Replacement

WARNING The transmission is heavy. Make sure that any lifting device has enough capacity to lift the weight. The transmission can weigh approximately 317 kg (699 lb). 8. Connect a lifting device to support the transmission. 9. Remove the capscrew, washer, snubbing washers, and isolators from the mount bracket at the rear of the transmission. See Figure 28.

0100 YRM 1672 10. Use a lifting device to carefully lift the transmission out of the frame. Slip the transmission output yoke out of the transmission. Make sure to not damage the seal.

INSTALL TRANSMISSION WITH IRON HOUSING WARNING The transmission is heavy. Make sure that any lifting device has enough capacity to lift the weight. The transmission can weigh approximately 317 kg (699 lb). 1. Using a lifting device, install transmission in lift truck frame. Place a block under the transmission housing to support the transmission. 2. Install the transmission output yoke on the transmission. Be sure to not damage the seal. Tighten the bolt to 38 Nâ&#x20AC;˘m (28 lbf ft). 3. Install the isolators, snubbing washers, washer, and capscrew on the mounting bracket at the rear of the transmission. See Figure 28. Tighten capscrew to 225 to 250 Nâ&#x20AC;˘m (166 to 184 lbf ft). 4. Remove lifting device from the transmission. NOTE: Step 5 applies to lift truck models equipped with a hydraulic gear pump. 5. Install the hydraulic hose between the pump and the tank. Install the hydraulic filter and hoses. Connect the supply line to the main control valve. See Hydraulic System 1900YRM1683Hydraulic System SRM needs linked (1900SRM1683) & (1900YRM1683) Bob for more information on installing hydraulic hoses to gear pump.

NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. A. IRON CASE TRANSMISSION B. ALUMINUM CASE TRANSMISSION 1. 2. 3. 4. 5.

CAPSCREW WASHER SNUBBING WASHER ISOLATOR MOUNT BRACKET Figure 28. Rear Mount - Transmission

NOTE: Step 6 and Step 7 apply to lift truck models GLP/GDP20-35VX (C875) equipped with a variable displacement pump (VDP). 6. Install the hydraulic supply hose between the variable displacement pump and hydraulic tank. See Figure 27.

0100 YRM 1672 7. Install the hydraulic supply hose, load sense line, drain case line, and hydraulic inlet line on the variable displacement pump. See Figure 27. See Hydraulic System 1900YRM1683 for more information on installing hydraulic hoses to variable displacement pump. 8. Connect the transmission wiring harness to engine wiring harness. Connect transmission cooling lines. 9. Install the seal plate for the brake and throttle pedals. See Figure 6.

Transmission Replacement •

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C875)

WARNING The transmission is heavy. Make sure that any lifting device has enough capacity to lift the weight. The transmission can weigh approximately 83.8 kg (184.7 lb). NOTE: Make sure the transmission is supported by blocks or a lifting device before removing the engine.

10. Install engine in lift truck. See section Install, Engine Replacement in this manual for procedures.

1. Remove engine from lift truck. See section Remove, Engine Replacement in this manual for procedures.

REMOVE TRANSMISSION WITH ALUMINUM HOUSING

2. Remove the seal plate for the brake and throttle pedals. See Figure 6.

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, 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.

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 31 and Figure 32 for lift truck models equipped with a variable displacement pump: •

GLP/GDP20-35VX (C875)

Transmission Replacement

0100 YRM 1672

NOTE: QUICK-LOK™ HYDRAULIC HOSE AND ADAPTERS NOT SHOWN. 1. 2. 3. 4. 5. 6. 7. 8.

TRANSMISSION HOUSING DRAIN FITTING HYDRAULIC GEAR PUMP SUCTION HOSE HYDRAULIC GEAR PUMP INLET PORT HYDRAULIC GEAR PUMP OUTLET PORT HYDRAULIC INLET HOSE TRANSMISSION COOLING LINE

Figure 29. Hydraulic Hose, Dry Brakes (Aluminum Transmission)

NOTE: QUICK-LOK™ HYDRAULIC HOSE AND ADAPTERS NOT SHOWN. 1. 2. 3. 4. 5. 6. 7. 8. 9.

TRANSMISSION HOUSING WET DISK BRAKE HOSE ASSEMBLY HYDRAULIC GEAR PUMP SUCTION HOSE HYDRAULIC GEAR PUMP INLET PORT HYDRAULIC GEAR PUMP OUTLET PORT HYDRAULIC INLET HOSE HIGH TEMP HOSE ASSEMBLY TRANSMISSION COOLING SUPPLY PORT

Figure 30. Hydraulic Hose, Wet Brakes (Aluminum Transmission)

0100 YRM 1672

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

TRANSMISSION HOUSING DRAIN FITTING VARIABLE DISPLACEMENT PUMP LOAD SENSE LINE DRAIN CASE LINE HYDRAULIC INLET HOSE TRANSMISSION COOLING LINES SUCTION HOSE PUMP INLET PORT PUMP OUTLET PORT

Figure 31. Hydraulic Hose, Dry Brakes Lift Truck Models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (C875) Equipped With Variable Displacement Pump

Transmission Replacement

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

TRANSMISSION HOUSING VARIABLE DISPLACEMENT PUMP LOAD SENSE LINE DRAIN CASE LINE HYDRAULIC INLET HOSE HIGH TEMPERATURE LINE TRANSMISSION COOLING SUPPLY PORT TRANSMISSION COOLING HOSES WET DISK BRAKE HOSE ASSEMBLY PUMP INLET PORT PUMP OUTLET PORT SUCTION HOSE

Figure 32. Hydraulic Hose, Wet Brakes Lift Truck Models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (C875) Equipped With Variable Displacement Pump

Transmission Replacement

0100 YRM 1672

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. NOTE: Perform Step 5 for lift trucks equipped with dry brakes. 5. Place a suitable container under transmission; remove drain fitting from transmission housing and drain transmission oil. See Figure 29 for lift truck models equipped with a hydraulic gear pump and dry brakes •

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 31 for lift truck models GLP/ GDP20-35VX (C875) equipped with a variable displacement pump. NOTE: Perform Step 6 and Step 7 for lift trucks equipped with wet brakes. 6. Place a suitable container under transmission; disconnect wet disk brake hose assembly from transmission and drain transmission and transaxle oil. See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 32 for lift truck models GLP/ GDP20-35VX (C875) equipped with a variable displacement pump 7. Disconnect and cap high temp hose assembly from transmission cooling support port. Cap transmission cooling supply port. See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 32 for lift truck models GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (C875) equipped with a variable displacement pump

8. Disconnect and cap suction hose from hydraulic gear pump inlet port. Cap hydraulic gear pump inlet port. See Figure 29 for lift truck models equipped with a hydraulic gear pump and dry brakes •

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (C875) equipped with a variable displacement pump: NOTE: Perform Step 9 for lift truck models GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (C875) equipped with a Quick-Lok™ hydraulic hose and adapter: 9. Remove adapter and Quick-Lok hydraulic hose from hydraulic gear pump outlet port. Cap hydraulic gear pump outlet port. 10. For lift trucks not equipped with Quick-Lok hydraulic hose and adapters, disconnect and cap hydraulic inlet hose from hydraulic gear pump outlet port. Cap hydraulic gear pump outlet port. See Figure 29 for lift truck models equipped with a hydraulic gear pump and dry brakes •

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (C875) equipped with a variable displacement pump: NOTE: Step 11 applies only to lift truck models GLP/ GDP20-35VX (C875) equipped with a variable displacement pump.

0100 YRM 1672 11. Disconnect and cap the load sense line and drain case line from the variable displacement pump. See Figure 31 and Figure 32. 12. Remove the capscrew, washer, snubbing washers, and isolators from the mount bracket at the rear of the transmission. See Figure 33.

Transmission Replacement NOTE: Note position of oil seal prior to removal to aid in installation. 15. Remove oil seal from transmission housing. See Figure 34.

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

FLANGE HEAD CAPSCREW STAT-O-SEAL YOKE OIL SEAL SPACER TRANSMISSION HOUSING Figure 34. Drive Shaft Yoke

INSTALL TRANSMISSION WITH ALUMINUM HOUSING WARNING NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. A. IRON CASE TRANSMISSION B. ALUMINUM CASE TRANSMISSION 1. 2. 3. 4. 5.

CAPSCREW WASHER SNUBBING WASHER ISOLATOR MOUNT BRACKET Figure 33. Rear Mount - Transmission

The transmission is heavy. Make sure that any lifting device has enough capacity to lift the weight. The transmission can weigh approximately 83.8 kg (184.7 lb). 1. Using a lifting device, install transmission in lift truck frame. Place a block under the transmission housing to support the transmission. 2. Install oil seal on back of transmission housing. See Figure 34. 3. Install new stat-o-seal on yoke. See Figure 34.

13. Use the lifting device to carefully lift the transmission from the frame. Slip the transmission output yoke out of the transmission. Make sure to not damage the seal. 14. Remove flange head capscrew, yoke, and spacer from transmission. Make sure to not damage the seal. See Figure 34.

4. Install spacer, yoke, and flange head capscrew on back of transmission. See Figure 34. Tighten capscrew to 77 N•m (57 lbf ft). 5. Install isolators, snubbing washers, washer, and capscrew on mounting bracket at the rear of the transmission. See Figure 33. Tighten capscrew to 225 to 250 N•m (166 to 184 lbf ft).

Transmission Replacement

0100 YRM 1672

6. Remove lifting device from transmission. NOTE: Perform Step 7 for lift truck models GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (C875) equipped with a Quick-Lok™ hydraulic hose and adapter: 7. Remove cap and install adapter and Quick-Lok hydraulic hose to hydraulic gear pump outlet port. Tighten adapter to 59 to 69 N•m (44 to 51 lbf ft).

See Figure 29 for lift truck models equipped with a hydraulic gear pump and dry brakes •

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 31 for lift truck models GLP/ GDP20-35VX (C875) equipped with a variable displacement pump.

8. For lift truck not equipped with Quick-Lok hydraulic hose and adapters, connect hydraulic inlet hose to fitting on hydraulic gear pump outlet port.

NOTE: Perform Step 11 and Step 12 for lift trucks equipped with wet brakes.

See Figure 29 for lift truck models equipped with a hydraulic gear pump and dry brakes

11. Connect high temp hose assembly to transmission cooling support port.

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GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (C875) equipped with a variable displacement pump. 9. Connect suction hose to hydraulic gear pump inlet port. See Figure 29 for lift truck models equipped with a hydraulic gear pump and dry brakes •

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (C875) equipped with a variable displacement pump. NOTE: Perform Step 10 for lift trucks equipped with dry brakes. 10. Install drain fitting on transmission housing.

See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 32 for lift truck models GLP/ GDP20-35VX (C875) equipped with a variable displacement pump. 12. Connect wet disk brake hose assembly to transmission. See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 32 for lift truck models GLP/ GDP20-35VX (C875) equipped with a variable displacement pump. 13. Connect transmission cooling lines to transmission. See Figure 29 for lift truck models equipped with a hydraulic gear pump and dry brakes •

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

See Figure 30 for lift truck models equipped with a hydraulic gear pump and wet brakes •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

0100 YRM 1672

Throttle Pedal and Cable Adjustment

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (C875) equipped with a variable displacement pump: NOTE: Step 14 applies only to lift truck models GLP/ GDP20-35VX (C875) equipped with a variable displacement pump. 14. Connect the load sense line and drain case line to the variable displacement pump. See Figure 31 and Figure 32. 15. Connect transmission wiring harness to engine wiring harness. 16. Install the seal plate for the brake and throttle pedals. See Figure 6.

17. Install engine to lift truck. See section Install, Engine Replacement in this manual for procedures. NOTE: Perform Step 18 for lift trucks equipped with dry brakes. 18. Fill transmission oil. For fill instruction, oil type, and amount See section Periodic Maintenance 8000YRM1687 for lift truck models •

GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (B910)

•

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

NOTE: Perform Step 19 for lift trucks equipped with wet brakes. 19. Fill transmission and transaxle oil. For fill instruction, oil type, and amount See section Periodic Maintenance 8000YRM1687 for lift truck model •

GLP/GDP20-35VX GDP040-070VX) (C875)

(GP/GLP/

Throttle Pedal and Cable Adjustment NOTE: For Mazda engine, there is only a throttle pedal stop adjustment. The engine has an electronic throttle that is self-adjusting and self-calibrating. See Throttle Pedal Stop Adjustment for procedures.

MAZDA GAS/LPG ENGINES WITH BASIC POWER SHIFT TRANSMISSION AND ELECTRONIC TRANSMISSION 1. Remove floor plate and disconnect throttle cable from bellcrank and engine. See Figure 35. 2. Fully depress throttle pedal and verify that dimension between bellcrank and cowl plate is 6 ±2 mm (0.24 ±0.08 in.). 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. 4. Connect throttle cable to bellcrank and engine. See Figure 35.

5. With throttle pedal in full up position, adjust throttle cable, using jam nuts (item #10 in Figure 35) to remove all slack from cable. Cable should be adjusted to point where additional adjustment will pull throttle crank off idle stop. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in). NOTE: If lift truck is equipped with a Electronic Control Transmission, see section Calibration Procedures 8000YRM1134 for additional adjustment procedures before going onto Step 7. 6. Fully depress pedal and verify that full pedal stroke brings throttle crank to within 3.0 mm (0.12 in.) of wide open throttle stop. See Figure 35. 7. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate. Tighten jam nuts 8 to 15 N•m (71 to 133 lbf in) (item #12 in Figure 35).

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