Yale d809 glc040svx lift truck service repair manual by 163048

GLC030-035VX, GLC040SVX (D809) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................ PSI 2.0 LPG ENGINE...................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... PSI 2.0L LPG FUEL SYSTEM........................................................................................ SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ DRIVE AXLE................................................................................................................... STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC CLEANLINESS PROCEDURES............................................................... HYDRAULIC GEAR PUMPS.......................................................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N B551, B555, B559).................................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. ENGINE ELECTRICAL SYSTEM, PSI 2.0L ENGINE..................................................... MAST REPAIR (S/N B551, B555, B559)........................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

550108490 550108491 550108492 550096320 550108494 550108495 550108496 550108497 550108498 550073240 550108499 550108500 550108501 524223769 524223770 524223771 550108502 550108503 550108504 524150797 524223780 550108505 550108506 550108507 524221866

0100 YRM 1735 0600 YRM 1736 0700 YRM 1737 0900 YRM 1677 0900 YRM 1739 1300 YRM 1740 1400 YRM 1741 1600 YRM 1742 1800 YRM 1743 1900 YRM 1620 1900 YRM 1744 2000 YRM 1745 2100 YRM 1746 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1747 2200 YRM 1748 4000 YRM 1749 8000 YRM 0231 8000 YRM 1134 8000 YRM 1750 8000 YRM 1751 8000 YRM 1753 9000 YRM 1112

12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 12/14 10/13 12/14 12/14 12/14 12/14 12/14

PART NO. 550108487 (12/14)

0100 YRM 1735

General

General WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: â&#x20AC;˘

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

â&#x20AC;˘

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

NOTE: For lift trucks equipped with a PSI 2.0L LPG engine, see PSI 2.0L LPG Fuel System 0900YRM1739 for procedures to remove and install the exhaust system components. If lift truck is equipped with a Yanmar 2.6L diesel engine, see Exhaust System Repair in this manual for procedures. This section contains the description of the frame (see Figure 1) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine and transmission, cooling system, exhaust system (see NOTE above), and other components attached to the frame are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the section Periodic Maintenance 8000YRM1750

Description

0100 YRM 1735

Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1. There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights. See Counterweight Replacement section.

The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the frame with hinges. Two gas-controlled springs provide assistance when raising the hood and hold the hood in the open position. The floor plate and side covers can be removed for access to the engine, transmission, and other components.

The muffler is fastened to the frame inside the counterweight.

1. 2. 3. 4.

COWL PLATE FENDERS FRAME HOOD MOUNTS

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

0100 YRM 1735

Hood, Seat, and Side Covers Replacement

Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat all the way to the rear of the hood. 2. Use tilt lever and tilt steering column all the way forward. See Figure 2.

7. Remove capscrews, washers, and left and right rear side covers from frame. 8. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), remove eight capcrews, eight clip nuts, and left and right step covers from frame. See Figure 6. 9. For lift truck models GLC030-035VX, GLC040SVX (D809), remove six capscrews and left and right step plates from frame. See Figure 6. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), remove six capscrews, six clip nuts, and left and right step plates from frame. See Figure 6.

1. TILT LEVER 2. GAS CYLINDER Figure 2. Steering Column Tilt Lever 3. If your truck is equipped with an LPG tank, swing tank off to the side. See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures. 4. Raise hood latch on the left, front corner of the hood to unlatch and lift up hood. See Figure 3. 5. Disconnect the battery. 6. Remove floor mat and floor plate. •

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

1. HOOD LATCH 2. HOOD Figure 3. Hood Latch

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLC030-035VX, GLC040SVX (D809) 4

0100 YRM 1735

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

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

RADIATOR COVER WASHER CAPSCREW RIGHT REAR COVER INSERT LEFT REAR COVER LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER CLIP NUT DASH PANEL SEAL

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

KICK PANEL FLOOR PLATE GROMMET SEAL PLATE LEFT STEP PLATE RIGHT STEP PLATE LEFT FRONT COVER RIGHT FRONT COVER FLOOR MAT CLIP

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

Figure 5. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810) 6

0100 YRM 1735

Hood, Seat, and Side Covers Replacement Legend for Figure 5

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

CAPSCREW WASHER INSERT RADIATOR COVER LOWER STEERING COLUMN COVER UPPER STEERING COLUMN COVER CLIP NUT DASH PANEL KICK PANEL GROMMET SEAL PLATE SEAL

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

FUEL SHIELD (DIESEL) LEFT REAR COVER RIGHT REAR COVER FLOOR PLATE FLOOR MAT RIGHT STEP COVER LEFT STEP COVER RIGHT FRONT COVER LEFT FRONT COVER RIGHT STEP PLATE LEFT STEP PLATE CLIP

Hood, Seat, and Side Covers Replacement

Figure 6. Step Covers and Step Plates Remove/Install

0100 YRM 1735

Hood, Seat, and Side Covers Replacement Legend for Figure 6

NOTE: RIGHT SIDE SHOWN. PROCEDURES ARE THE SAME FOR LEFT SIDE. A. STEP PLATE FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809) B. STEP PLATE AND STEP COVER FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) 1. STEP PLATE 2. CAPSCREW 3. RIGHT REAR COVER

4. RIGHT STEP COVER 5. CLIP NUT

10. Remove capscrews, washers, and left and right front cover from frame. •

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

11. Use tilt lever and fully lower steering column. See Figure 2. 12. Remove upper steering column cover by pulling up on upper steering column cover to release latches (one on either side), and pulling cover away from steering column. See Figure 7. 13. Remove five fasteners securing dash to the top of cowl. See Figure 7. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash. • •

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809) See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

14. Lift kick panel and remove from truck. 15. Remove three capscrews and clip nuts from seal plate. Remove seal plate from frame. 16. Remove two capscrews and washers from cover plate and remove seat box. Disconnect seat wire harness connector. See Figure 8.

CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews. Damage can be caused to the threads on the screws and in the holes. NOTE: Before removing seat from hood, tag or mark holes that mount seat to hood. This will aid in correctly installing seat to hood. 17. Remove four capscrews and washers attaching seat to hood. Lift seat up and remove from hood. 18. Remove radiator cover and seals from lift truck frame. •

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

19. Remove two capscrews and hood latch striker bolt from mounting bracket. See Figure 9. 20. Remove two capscrews and hood latch from hood. See Figure 9. 21. Remove capscrews and washers at the top of gas springs. Remove gas springs from hood. 22. Remove hinge screws, located in the rear of the hood. See Figure 10. 23. Remove hood from lift truck.

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

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

3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER Figure 7. Remove Dash From Cowl

0100 YRM 1735

Hood, Seat, and Side Covers Replacement

A. FULL SUSPENSION SEAT B. SEMI- AND NON- SUSPENSION SEATS 1. 2. 3. 4. 5.

CAPSCREWS WASHERS SEAT BOX SEAT WIRE HARNESS CONNECTOR COVER PLATE Figure 8. Seat Wire Harness Connector

Hood, Seat, and Side Covers Replacement

Figure 9. Hood Latch and Hood Latch Striker Bolt Remove/Install

0100 YRM 1735

Hood, Seat, and Side Covers Replacement Legend for Figure 9

A. HOOD LATCH AND HOOD LATCH STRIKER BOLT FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809)

B. HOOD LATCH AND HOOD LATCH STRIKER BOLT FOR LIFT TRUCK MODELS GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

1. 2. 3. 4.

5. HOOD LATCH 6. BUMPER

CAPSCREW (HOOD LATCH STRIKER BOLT) CAPSCREW (HOOD LATCH) HOOD LATCH STRIKER BOLT HOOD LATCH STRIKER BOLT MOUNTING BRACKET

INSTALL

•

See Figure 11 and Table 1 for lift truck models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810)

•

See Figure 12 for lift truck models GLC030-035VX, GLC040SVX (D809)

1. Place hood onto the lift truck frame. 2. Install hinge screws, located in the rear of the hood, and tighten to 38 N•m (28 lbf ft). See Figure 10.

NOTE: LEFT SIDE SHOWN.

1. HINGE SCREWS 2. HINGE 3. HOOD Figure 10. Hood Removal/Installation 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 N•m (170 lbf in).

A. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT B. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT WITH CAB 1. MOUNTING POINTS FOR GAS SPRING ON HOOD Figure 11. Gas Spring Installation, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

Hood, Seat, and Side Covers Replacement

0100 YRM 1735

Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) 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 EControl

Seat With E-Control

N/A

Cab

N/A

the bolt strikes hood latch properly and that the bumpers contact the 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 hood latch striker bolt and adjust bolt up or down as required for correct alignment. 6. 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. 7. 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 6.

CAUTION NOTE: LEFT SIDE SHOWN. 1. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT 2. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT Figure 12. Gas Spring Installation, Lift Truck Models GLC030-035VX, GLC040SVX (D809) 4. Install hood latch to hood using two capscrews. See Figure 9. 5. Install latch striker bolt in highest slot position on mounting bracket. See Figure 9. Check that latch striker bolt is in center of jaws of hood latch when hood closes. Open and close hood to ensure that 14

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. 8. Place seat on hood. Align holes in seat with holes in hood as noted during removal. Insert washers and capscrews. Tighten capscrews to 18 N•m (159 lbf in). 9. Install radiator cover and seals to frame. •

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

0100 YRM 1735 10. Connect seat wire harness. Install seat box to cover plate with two capscrews and washers. Tighten capscrews to 1.2 N•m (10.6 lbf in). See Figure 8. 11. Install seal plate using three capscrews and clip nuts. 12. Install kick panel onto truck.

Hood, Seat, and Side Covers Replacement 16. For lift truck models GLC030-035VX, GLC040SVX (D809), install left and right step plates, and six capscrews to frame. See Figure 6. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), install left and right step plates, six clip nuts, and three capscrews onto frame. See Figure 6.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

17. For lift truck models GLP/GDP16-18VX, GLP/ GDP20SVX (GLP/GDP030-035VX, GLP/ GDP040SVX) (D810), install left and right step covers, eight clip nuts, and eight capscrews onto frame. See Figure 6.

13. Install dash to top of cowl. See Figure 7. Install four clips to attach the dash to kick panel.

18. Install left and right rear covers, washers and capscrew onto frame.

14. Install upper steering column cover to dash.

19. Install floor mat and floor plate.

15. Install left and right front covers, washers, and capscrews onto frame.

20. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight. See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures.

•

See Figure 4 for lift truck models GLC030-035VX, GLC040SVX (D809)

•

See Figure 5 for lift truck models GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

21. Connect the battery. 22. Adjust the steering column and seat positions.

Steering Column

0100 YRM 1735

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 truck models GLC030-035VX, GLC040SVX (D809), capscrews and bushings attach the steering column to the cowl standoffs. For lift truck models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810), capscrews, bushings and isolators attach the steering column to the cowl standoffs. See Figure 13.

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

WARNING Disconnect the battery before removing any covers to avoid injury to personnel.

2. Attach a tag on the battery connector or negative battery cable stating, DO NOT CONNECT BATTERY. Move the steering column to the most forward position.

CAUTION If a puller tool is used to remove steering wheel from steering column, be careful not to damage horn wires. NOTE: This procedure is for the removal of all components of the steering column assembly. Not all components are removed for a repair procedure. Do only those steps of the procedure necessary to remove the required component. NOTE: Tag wires prior to disconnecting them. 3. Remove the horn button assembly and disconnect electrical wires. Remove large hex nut and steering wheel from steering column. See Figure 14. 4. Remove steering column covers. Remove floor mats and floor plate. See Hood, Seat, and Side Covers Replacement section for procedures.

1. 2. 3. 4. 1. STEERING WHEEL 2. STEERING COLUMN 3. COWL Figure 13. Steering Column and Cowl

HORN BUTTON HEX NUT STEERING WHEEL STEERING COLUMN Figure 14. Steering Wheel Remove/Install

0100 YRM 1735

Steering Column

NOTE: Perform Step 5 for lift trucks GLC030-035VX, GLC040SVX (D809). 5. Remove four capscrews, four bushings, and steering column from cowl standoffs. See Figure 15.

NOTE: Perform Step 6 for lift trucks GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) 6. Remove four capscrews, four bushings, four isolators, steering column, and four isolators from cowl standoffs. See Figure 15.

NOTE: STEERING COLUMN FOR LIFT TRUCKS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810) SHOWN. STEERING COLUMN FOR LIFT TRUCKS GLC030-035VX, GLC040SVX (D809) IS SIMILAR. 1. CAPSCREW 2. BUSHING 3. ISOLATOR

4. STEERING COLUMN 5. COWL STANDOFF Figure 15. Steering Column Remove/Install

Steering Column

0100 YRM 1735

Disassemble

Assemble

NOTE: Remove and discard snap rings if installed.

NOTE: This procedure is for the installation of all components of the steering column assembly. Not all components are removed for a repair procedure. Do only those steps of the procedure necessary to install the required component.

1. Remove two pins and gas spring from housing. See Figure 16. 2. Remove two pivot bolts, two bushings, two nuts and bracket from housing. 3. Remove split pin and lower shaft from upper shaft. See Figure 16. 4. Remove connector from connector bracket. Remove connector bracket, fastener, four screws and two horn contacts from housing.

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.

1. Install fastener, connector bracket and connector, two horn contacts, and four screws. See Figure 16. 2. Assemble lower shaft and upper shaft, secure with spit pin. 3. Install two pivot bolts, two bushings, two nuts and bracket onto housing. See Figure 16. 4. Install gas spring and two pins on housing. See Figure 16.

Install NOTE: Lubricate spline end of lower shaft with multi purpose grease. See Periodic Maintenance 8000YRM1750 for procedures. NOTE: Perform Step 1 for lift trucks GLC030-035VX, GLC040SVX (D809). 1. Install steering column, four bushings and four capscrews on cowl standoffs. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 15.

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.

NOTE: Perform Step 2 for lift trucks GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810).

2. After cleaning, dry parts with compressed air. DO NOT dry parts with a cloth.

2. Install four isolators, steering column, four isolators, four bushings, and four capscrews on cowl standoffs. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 15

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.

3. Install floor plate, floor mats, and steering column covers. See Hood, Seat, and Side Covers Replacement section for procedures. 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 14.

0100 YRM 1735

Steering Column

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.

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

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

BRACKET SPACER JOINT NUT WASHER SCREW UPPER SHAFT HOUSING

PIN LOWER SHAFT GAS SPRING BOLT BUSHING CONNECTOR FASTENER HORN CONTACT

Figure 16. Steering Column Assembly

LPG Tank and Bracket Assembly For procedures to remove and install the LPG tank, LPG tank bracket, and the LPG tank alignment pin, see PSI 2.0L LPG Fuel System 0900YRM1739 for procedures.

Counterweight Replacement

0100 YRM 1735

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.

unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting. NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. See Figure 17. One M24 × 3 x 90 capscrew holds the counterweight to the lower part of the frame. See Figure 17.

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.

NOTE: COUNTERWEIGHT FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) SHOWN. COUNTERWEIGHT ARRANGEMENT FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809) IS SIMILAR.

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.

1. 2. 3. 4. 5.

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

FRAME HOOKS COUNTERWEIGHT SEAL CAPSCREW (M24 × 3 X 90) TOW PIN COUNTERWEIGHT Figure 17. Counterweight Arrangement

0100 YRM 1735

Counterweight Replacement

1. If lift truck is equipped with an overhead exhaust system, remove the overhead exhaust pipe before removing the counterweight.

The approximate weights of the counterweight castings are shown in: Table 2 for lift truck models

If lift truck is equipped with an LPG fuel system, see PSI 2.0L LPG Fuel System 0900YRM1739 for procedures to remove the overhead exhaust pipe.

•

GLC030-035VX, GLC040SVX (D809)

Table 3 for lift truck models •

If lift truck is equipped with a diesel fuel system, see Exhaust System Repair in this manual for procedures to remove the overhead exhaust pipe.

GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810)

3. Install a lifting eye in the lift hole of the counterweight. See Figure 18. Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the counterweight. Remove the tow pin and remove the capscrew and washer that hold counterweight to frame. Use crane to lift counterweight from lift truck. Put counterweight on the floor so that it has stability and will not fall over. Take care not to damage exhaust or cooling components.

2. If the lift truck has an LPG fuel system, see PSI 2.0L LPG Fuel System 0900YRM1739 to remove the LPG tank and bracket, before removing the counterweight, and for additional information on the LPG fuel system.

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight.

Table 2. Weight of Counterweights, Lift Truck Models GLC030-035VX, GLC040SVX (D809) Model

GLC030VX

772

1702

GLC035VX

963

2123

GLC040SVX

1131

2493

Table 3. Weight of Counterweights, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) Model

GLP/GDP16VX (GLP/GDP030VX)

813

1792

GLP/GDP18VX (GLP/GDP035VX)

887

1955

GLP/GDP20SVX (GLP/ GDP040SVX)

1047

2308

Counterweight Replacement

0100 YRM 1735

INSTALL 1. Make sure the seals are on the counterweight. See Figure 18. 2. Use a crane to install the counterweight on the lift truck. When the counterweight is installed, make sure the hooks on the frame (see Figure 17) fully engage the counterweight so it is aligned with the parts of the frame. Install and tighten the M24 × 3 x 90 capscrew to 555 N•m (409 lbf ft). 3. Install tow pin. See Tow Pin Remove and Install for procedures. 4. If lift truck has an LPG fuel system, see PSI 2.0L LPG Fuel System 0900YRM1739, to install LPG tank and bracket, after counterweight has been installed. 5. If lift truck is equipped with an overhead exhaust system, install the overhead exhaust pipe. If lift truck is equipped with an LPG fuel system, see PSI 2.0L LPG Fuel System 0900YRM1739 for procedures to install the overhead exhaust pipe. If lift truck is equipped with a diesel fuel system, see Exhaust System Repair in this manual for procedures to install the overhead exhaust pipe.

NOTE: COUNTERWEIGHT AND COMPONENT PARTS FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809) SHOWN. COUNTERWEIGHT AND COMPONENT PARTS FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) ARE SIMILAR. 1. 2. 3. 4. 5. 6. 7. 8.

CAPSCREW WASHER COUNTERWEIGHT LIFT HOLE LIFTING EYEBOLT TOW PIN LPG ACCESS HOLE COUNTERWEIGHT SEAL Figure 18. Counterweight Component Parts

0100 YRM 1735

Counterweight Replacement

TOW PIN REMOVE AND INSTALL 1. To remove the tow pin, pull up on the wire loop that is attached to the D-Ring, and pull tow pin out of counterweight. See Figure 19. 2. To install the tow pin, insert it through the hole in the counterweight. See Figure 19.

1. 2. 3. 4.

TOW PIN D-RING WIRE LOOP TOW PIN HOLE Figure 19. Tow Pin

Overhead Guard Replacement

0100 YRM 1735

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

WARNING DO NOT weld mounts for lights or accessories to legs of the overhead guard. Changes that are made by welding, or by drilling holes that are too big or in the wrong location, can reduce the strength of the overhead guard.

Remove and install the capscrews. See Figure 21. 4. Remove fender cover, dash, and kick panel to remove and install the three capscrews on front legs of overhead guard. See Hood, Seat, and Side Covers Replacement for 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 21.

See your dealer for Yale lift trucks BEFORE performing any changes to the overhead guard. NOTE: The lift trucks covered in this manual are equipped with either a high or low overhead guard. The removal and installation procedures for both types of overhead guards are the same. No welding or drilling on legs of overhead guard is permitted as per previous WARNING. NOTE: The lifting device can be connected to any number of positions on the overhead guard depending upon the lifting device available. The ideal choices are a four point sling connected to all four corners on the top of the overhead guard, or a two point sling connected to two opposite corners of the overhead guard. If a single point hoist is used, make sure that the lift point is as close to the center of the overhead guard. If during the initial start of the lift the overhead guard is off balance lower immediately and move the hoist to a more centered point. 1. Connect a lifting device to remove or install the overhead guard. Loosen clamp and disconnect the air intake hose from the elbow. Remove bolts, elbow, retainer, and grommet from the overhead guard rear leg. See Figure 20. 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.

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

CLAMP AIR INTAKE HOSE BOLTS ELBOW RETAINER GROMMET Figure 20. Disconnect Air Intake Hose

0100 YRM 1735

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 2200YRM1747 for procedures to replace these lights.

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

CAPSCREWS (FRONT LEGS) CAPSCREWS (REAR LEGS) HANDLE FRAME REAR LEG FRONT LEG Figure 21. Overhead Guard

Operator Restraint System Replacement

0100 YRM 1735

Operator Restraint System Replacement DESCRIPTION The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 22.

nism. If the truck tips, travels off a dock, or comes to a sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat. A seat belt that is damaged worn or does not operate properly will not provide protection when it is needed. The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 22 and Figure 23. NOTE: The following seat belt operation checks must be performed three times before replacing the seat belt assembly:

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

HOOD LATCH STRIKER BOLT HOOD LATCH HOOD SEAT RAILS HIP RESTRAINT SEAT BELT SEAT HOOD HINGE Figure 22. Operator Restraint System

EMERGENCY LOCKING RETRACTOR (ELR) NOTE: The lift truck models covered in this manual are equipped with the ELR type seat belts. See Figure 22 and Figure 23. When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mecha-

•

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. See Figure 22. Adjust hood, hood latch, and hood latch striker bolt 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 adjustment procedures for the hood.

0100 YRM 1735

Operator Restraint System Replacement

A. STANDARD, NON-SUSPENSION SEAT B. FULL SUSPENSION SEAT

C. SEMI-SUSPENSION SEAT

1. 2. 3. 4.

5. BACKREST ANGLE ADJUSTMENT LEVER 6. HIP RESTRAINT 7. SWIVEL LATCH RELEASE LEVER

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

Figure 23. Seat Adjustment Controls

Engine Replacement

0100 YRM 1735

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: â&#x20AC;˘

â&#x20AC;˘

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.

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. 1. If lift truck is equipped with an LPG fuel system, close the shutoff valve on the tank and run engine until all fuel is gone and engine stops. Swing LPG tank to side of lift truck. See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures.

2. Remove overhead guard. See Overhead Guard Replacement section for procedures. 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 the capacity of the cooling system under radiator. Remove radiator cap. See Periodic Maintenance 8000YRM1750 for coolant capacity.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 5. Open drain plug or disconnect the bottom radiator hose to drain coolant from radiator and engine. 6. Remove hood and seat combination and rear side covers. See section Hood, Seat, and Side Covers Replacement for procedures. 7. Disconnect the ground strap from the frame and remove the Power Distribution Module (PDM) from battery tray. See Figure 24. 8. Remove three capscrews and clip nuts from battery tray and remove battery and battery tray from lift truck frame. See Figure 24. 9. Disconnect the remaining coolant hoses from the radiator and cap them to prevent leakage. See Cooling System 0700YRM1737 for procedures.

0100 YRM 1735 10. Remove air intake components from engine. •

•

Lift trucks equipped with LPG engine Disconnect air restriction sensor. Disconnect and remove intake hose from LPG fuel mixer and air intake housing. Disconnect and remove dirty air hose from air intake housing. Remove two capscrews (underneath mounting bracket) and air intake from mounting bracket. See Figure 25.

Engine Replacement Breathing fuel vapor may cause nausea, unconsciousness or death. Avoid breathing fuel vapor. 13. Disconnect the fuel lines at the engine. Put caps on fuel lines to prevent fuel leakage. See Figure 26.

Lift trucks equipped with diesel engine Disconnect air restriction sensor. Disconnect and remove intake hose from intake manifold. Disconnect and remove dirty air hose from air intake housing. Remove two capscrews (underneath mounting bracket) and air intake from mounting bracket. See Figure 25.

11. Disconnect the exhaust system. •

•

See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures to remove exhaust system for lift trucks equipped with LPG fuel system. See Exhaust System Repair in this manual for procedures to remove exhaust system for lift trucks equipped with a diesel engine.

12. Remove the radiator fan pulley, shroud, and fan assembly. See Cooling System 0700YRM1737 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.

NOTE: POWER DISTRIBUTION MODULE (PDM) FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809) EQUIPPED WITH PSI 2.0L LPG ENGINE SHOWN. THE LOCATION AND ARRANGEMENT OF PDM FOR LIFT TRUCK MODELS GLP/ GDP16-18VX, GLP/GDP20SVX (GLP/ GDP030-035VX, GLP/GDP040SVX) (D810) EQUIPPED WITH A PSI 2.0L LPG OR YANMAR DIESEL ENGINE IS SIMILAR. 1. 2. 3. 4. 5. 6.

BATTERY BATTERY TRAY PDM BATTERY LOCKDOWN BAR CAPSCREW/CLIP NUT GROUND STRAP

Figure 24. Power Distribution Module, Remove/ Install

Engine Replacement

0100 YRM 1735

Figure 25. Air Intake Remove/Install

0100 YRM 1735

Engine Replacement Legend for Figure 25

A. AIR INTAKE SYSTEM - LIFT TRUCKS EQUIPPED WITH LPG ENGINE

B. AIR INTAKE SYSTEM - LIFT TRUCKS EQUIPPED WITH DIESEL ENGINE

1. 2. 3. 4.

5. 6. 7. 8.

MOUNTING BRACKET CAPSCREW INTAKE MANIFOLD (DIESEL) SILENCER (DIESEL)

1. 2. 3. 4. 5.

LPG FUEL LINE LPG LOCK-OFF DIESEL FUEL LINES DIESEL FUEL FILTER ENGINE WIRE HARNESS

LPG FUEL MIXER AIR INTAKE HOSE DIRTY AIR HOSE AIR INTAKE HOUSING

NOTE: Tag wires and connectors prior to disconnecting to aid in re-connecting. 14. Disconnect engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck. See Figure 26. 15. Remove torque converter from flywheel. •

Lift trucks equipped with LPG engine Use access port on side of engine and remove the four bolts that attach the flywheel to torque converter. See Figure 27.

•

Lift trucks equipped with diesel engine Remove two capscrews and dust cover from access port. Use access port on the side of engine and remove the four bolts that attach flywheel to torque converter. See Figure 27.

16. Connect a lifting device to engine. Put a block under the transmission housing to support the transmission. 17. Remove two capscrews, two washers, and torque converter housing cover. See Figure 28. 18. Remove four flange bolts from torque converter housing and flywheel housing on transmission side. See Figure 28. 19. Remove six hex head capscrews from flywheel housing and torque converter housing on flywheel housing side. See Figure 28.

Figure 26. Fuel Line and Engine Wire Harness Disconnection

Engine Replacement

0100 YRM 1735

A. DIESEL ENGINE

B. LPG ENGINE

1. BOLT 2. DUST COVER

3. ACCESS PORT 4. FLYWHEEL HOUSING Figure 27. Torque Converter Bolt Access

0100 YRM 1735

Engine Replacement

NOTE: LPG ENGINE SHOWN. DIESEL ENGINE IS SIMILAR. 1. 2. 3. 4. 5.

FLANGE BOLTS HEX HEAD CAPSCREW CAPSCREW WASHER TORQUE CONVERTER HOUSING COVER

6. 7. 8. 9. 10.

EYEBOLT BRACKET TORQUE CONVERTER HOUSING FLYWHEEL HOUSING TRANSMISSION ASSEMBLY ENGINE ASSEMBLY

Figure 28. Flywheel and Torque Converter Housings

Engine Replacement

0100 YRM 1735

WARNING

CAUTION

The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately198 kg (437 lb).

Keep the engine level when the engine is separated from the transmission so the drive plate is not damaged.

20. Remove flange nuts, washers, capscrews, and isolators from engine mounts. See Figure 29 and Figure 30. Remove engine adapter to transmission bolts.

21. 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.

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.

22. Remove torque converter from torque converter housing. See Figure 28.

NOTE: LEFT SIDE SHOWN. RIGHT SIDE IS SIMILAR. A. LPG ENGINE

B. DIESEL ENGINE

1. FRAME MOUNT 2. LEFT ENGINE MOUNT

3. FLANGE NUT 4. ISOLATOR Figure 29. Engine Mounting Arrangement

0100 YRM 1735

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 approximately198 kg (437 lb).

CAUTION

3. Install capscrews, washers, isolators, and flange nuts to mount engine to frame. See Figure 29 and Figure 30. Tighten flange nuts to 150 N•m (110 lbf ft). 4. Install six hex head capscrews on flywheel housing and torque converter housing from flywheel housing side. Tighten capscrews to 38 N•m (28 lbf ft). See Figure 28.

Keep the engine level when installing the engine to the transmission so the drive plate is not damaged.

5. Install four flange bolts on torque converter housing and flywheel housing from transmission side. Tighten bolts to 38 N•m (28 lbf ft).

1. Install torque converter in torque converter housing.

6. Install converter housing cover, two washers, and two capscrews on torque converter housing. Tighten capscrews to 19 N•m (168 lbf in). See Figure 28.

2. Connect lifting device to engine and lift engine into frame.

A. LPG ENGINE

B. DIESEL ENGINE

1. 2. 3. 4.

5. 6. 7. 8.

CAPSCREW WASHER LEFT ENGINE MOUNT ISOLATOR

FLANGE NUT RIGHT ENGINE MOUNT CROSSMEMBER FLANGE CAPSCREW

Figure 30. Engine Mounts

Engine Replacement

0100 YRM 1735

7. Use access port on side of engine and install bolts to hold torque converter to flywheel. Tighten bolts to 56 N•m (41 lbf ft). See Figure 27. For lift trucks equipped with a diesel engine, install two capscrews and dust cover over access port. See Figure 27. 8. Connect engine wire harness connectors to right hand chassis harness connectors. See Figure 26.

WARNING

underside of mounting bracket. Connect dirty air hose to intake housing. Connect intake hose to LPG fuel mixer. Connect air restrictor sensor. See Figure 25. •

Lift trucks equipped with diesel engine Place air intake on mounting bracket and use two capscrews to attach air intake to underside of mounting bracket. Connect dirty air hose to intake housing. Connect intake hose to intake manifold. Connect air restriction sensor. See Figure 25.

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.

13. 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.

No smoking.

14. 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 24.

Breathing fuel vapor may cause nausea, unconsciousness or death. Avoid breathing fuel vapor. 9. Remove caps from fuel lines and connect fuel lines to engine. See Figure 26. 10. Install radiator fan pulley, shroud, and fan assembly. See Cooling System 0700YRM1737 for installation procedures. 11. Connect exhaust system components. •

See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures to install exhaust system components for lift trucks equipped with an LPG engine.

•

See Exhaust System Repair in this manual for procedures to install exhaust system components for lift trucks equipped with a diesel engine.

12. Install air intake components to engine. •

Lift trucks equipped with LPG engine Place air intake on mounting bracket and use two capscrews to attach air intake to

15. Install hood and seat combination and rear side covers. See section Hood, Seat, and Side Covers Replacement for procedures. 16. Install floor plate and floor mat. 17. Install overhead guard. See section Overhead Guard Replacement. 18. If lift truck is equipped with an LPG fuel tank, swing tank into position on back of counterweight and open shutoff valve on tank. See PSI 2.0L LPG Fuel System 0900YRM1739 for procedures. 19. Check all fluid levels as described in Periodic Maintenance 8000YRM1750.

0100 YRM 1735

Transmission Replacement

Transmission 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, transmission, and counterweight. When the lift truck is put on blocks put additional blocks in the following positions to maintain stability:

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. See Figure 26. 4. Disconnect transmission cooling lines from transmission. See Figure 31.

CAUTION

â&#x20AC;˘

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

Disposal of lubricants and fluids must meet local environmental regulations.

â&#x20AC;˘

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

5. Place a suitable container under transmission; remove drain fitting from transmission housing and drain transmission oil.

6. Disconnect and cap suction hose from hydraulic gear pump inlet port. Cap hydraulic gear pump inlet port. See Figure 31.

WARNING The transmission is heavy. Make sure that any lifting device has enough capacity to lift the weight. The transmission can weigh approximately 84 kg (185 lb). NOTE: Make sure the transmission is supported by blocks or a lifting device before removing the engine. 1. Remove engine from lift truck. See Engine Replacement section for procedures. 2. Remove seal plate for brake and throttle pedals. See Hood, Seat, and Side Covers Replacement for procedures.

NOTE: Perform Step 7 if lift truck is equipped with a Quick-LokTM hydraulic hose and adapter. 7. Remove adapter and Quick-LokTM hydraulic hose from hydraulic gear pump outlet port. Cap hydraulic gear pump outlet port. NOTE: Perform Step 8 for lift trucks NOT equipped with a Quick-LokTM hydraulic hose and adapter. 8. Disconnect and cap hydraulic inlet hose from hydraulic gear pump outlet port. Cap hydraulic gear pump outlet port. See Figure 31. 9. Remove the capscrew, washer, snubbing washers, and isolators from the mount bracket at the rear of the transmission. See Figure 32.

Transmission Replacement

0100 YRM 1735

NOTE: OUICK-LOKTM HYDRAULIC HOSE AND ADAPTER NOT SHOWN. A. LIFT TRUCKS EQUIPPED WITH LPG ENGINE 1. 2. 3. 4. 5. 6. 7.

B. LIFT TRUCKS EQUIPPED WITH DIESEL ENGINE

TRANSMISSION HOUSING DRAIN FITTING HYDRAULIC GEAR PUMP SUCTION HOSE HYDRAULIC GEAR PUMP INLET HOSE AND PORT HYDRAULIC GEAR PUMP OUTLET HOSE AND PORT TRANSMISSION COOLING HOSES/LINES Figure 31. Transmission Hydraulic and Cooling Hoses and Gear Pump Arrangement

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