Yale A910 (GC GLC040-GLC070VX) Service Manual - PDF DOWNLOAD

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Service Manuals Manuals Available For A910 (GC/GLC040-GLC070VX) Note: Service manuals do not contain serial number specific data.

Manual

Manual Title

Release Date

GM POWERTRAIN 0100YRM1120

FRAME

08-2011

0600YRM1121

GM 2.4L ENGINE REPAIR

02-2010

0700YRM1123

COOLING SYSTEM

08-2011

0900YRM1124

LPG FUEL SYSTEM GM 2.4L ENGINE

01-2011

0900YRM1126

GASOLINE FUEL SYSTEM GM 2.4L ENGINE

02-2010

MAZDA POWERTRAIN 0100YRM1120

FRAME

08-2011

0600YRM1122

MAZDA FE AND F2 ENGINES

07-2011

0700YRM1123

COOLING SYSTEM

08-2011

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0900YRM1125

LPG FUEL SYSTEM MAZDA FE AND F2 ENGINE

05-2005

0900YRM1127

GASOLINE FUEL SYSTEM (MAZDA)

05-2005

0900YRM1325

GASOLINE FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT ENGINES

12-2009

0900YRM1326

LPG FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT ENGINES

07-2011

2200YRM1143

ELECTRICAL SYSTEM (MAZDA)

05-2005

2200YRM1327

ELECTRICAL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT ENGINES

07-2011

1300YRM1129

1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR

09-2009

1300YRM1421

SINGLE SPEED POWERSHIFT ALUMINUM TRANSMISSION REPAIR

12-2010

1300YRM1447

SINGLE SPEED POWERSHIFT ALUMINUM CHAIN DRIVE TRANSMISSION

07-2011

1400YRM1132

DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR

11-2008

1800YRM1135

BRAKE SYSTEM

07-2011

1600YRM1133

STEERING AXLE

07-2010

1900YRM1136

HYDRAULIC GEAR PUMP

07-2011

2000YRM1137

MAIN CONTROL VALVE

08-2011

2100YRM1139

CYLINDERS REPAIR

08-2011

4000YRM1148

MAST REPAIR 2, 3, AND 4-STAGE MASTS

08-2011

2200YRM1128

WIRE HARNESS REPAIR

07-2011

2200YRM1130

USER INTERFACE - SUPERVISOR

06-2011

DRIVETRAIN

HYDRAULICS

ELECTRICAL

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2200YRM1131

USER INTERFACE - SERVICE

06-2011

2200YRM1142

ELECTRICAL SYSTEM

08-2011

REFERENCE MATERIAL 8000YRM0231

METRIC AND INCH (SAE) FASTENERS

12-2004

8000YRM1134

CALIBRATION PROCEDURES

09-2011

8000YRM1150

PERIODIC MAINTENANCE

08-2011

8000YRM1151

CAPACITIES AND SPECIFICATIONS

06-2011

8000YRM1152

DIAGRAMS

06-2011

8000YRM1387

DIAGRAMS AND SCHEMATICS

06-2011

8000YRM1409

DIAGRAMS AND SCHEMATICS

06-2011

DIAGNOSTIC TROUBLESHOOTING 9000YRM1112

DIAGNOSTICS TROUBLESHOOTING

©2011 Yale Axcess Online

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08-2011

524223754-0100YRM1120-(08-2011)-US-EN

Frame GC/GLC030VX, GC/GLC035VX, GC/ GLC040SVX [C809]; GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) [C810]; GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]

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Safety Precautions Maintenance and Repair • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly. http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (2 of 95)30.09.2011 9:56:14

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• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.

Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

TABLE OF CONTENTS General Description Hood, Seat, and Side Covers Replacement Remove Install Steering Column Description Steering Column Repair Remove http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (3 of 95)30.09.2011 9:56:14

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Disassemble Clean Inspect Assemble Install Counterweight Replacement Remove Install Tow Pin, Remove and Install Overhead Guard Replacement Remove and Install LED Tail, Backup, and Brake Lights, Replace Operator Restraint System Replacement Description Automatic Locking Retractor (ALR) Emergency Locking Retractor (ELR) Engine Replacement Remove Install Transmission Replacement Remove Transmission with Iron Housing Install Transmission with Iron Housing Remove Transmission with Aluminum Housing Install Transmission with Aluminum Housing Throttle Pedal and Cable Adjustment Mazda Gas/LPG Engines With Basic Power Shift Transmission and Electronic Transmission (Except Mazda Emission Compliant Engines) Mazda Gasoline Engine With Electronic Transmission Throttle Pedal Stop Adjustment Yanmar Diesel Engine With Basic Power Shift Transmission Yanmar Diesel Engine With Electronic Throttle Exhaust System Repair Lift Trucks With Counterweight Exhaust System Mazda Gas and LPG Engines Remove and Disassemble Inspect Assemble and Install Yanmar Diesel Engine Remove and Disassemble Inspect Assemble and Install Lift Trucks With Overhead Exhaust System Yanmar Diesel Engine

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Remove and Disassemble Inspect Assemble and Install Mazda Gas and LPG Engines Remove and Disassemble Inspect Assemble and Install Cooling System Description Hydraulic Filter Assembly Repair Remove Clean and Inspect Install Fuel and Hydraulic Tanks Repair Inspect Clean Steam Method of Cleaning Chemical Solution Method of Cleaning Additional Preparations for Repair Small Leaks, Repair Large Leaks, Repair Preparations for Use After Repair Safety Labels This section is for the following models: GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809]; GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) [C810]; GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]

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

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cannot fall backward.

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

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the section Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) NOTE: For exhaust system procedure for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 or Gasoline Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1325 for exhaust system procedures.

For lift trucks built after January, 2010 and equipped with a GM 2.4L engine, go to section LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for exhaust system procedures.

This section contains the description of the frame (see Figure 1) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine, cooling system, exhaust system (see NOTE above), and LPG fuel tank bracket are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

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

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

See Table 1 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) Table 2 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) Table 3 for lift truck models • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) Table 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (6 of 95)30.09.2011 9:56:14

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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.

1. Cowl plate 2. fenders 3. frame 4. 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.

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

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. seat 2. hood 3. frame 4. seat wire harness http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (8 of 95)30.09.2011 9:56:14

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5. seat wire harness connector (without electronic control) 6. seat wire harness connector (with electronic control) 7. cable clips 8. hinge screws 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 Figure 2. Hood and Seat Arrangement

1. Lower Steering Column Cover 2. Upper Steering Column Cover 3. insert 4. CLIP 5. DASHBOARD 6. CAPSCREW 7. SEAL 8. GROMMET 9. LEFT HAND REAR PANEL 10. FLOOR PLATE 11. LEFT HAND FENDER COVER 12. SCREW http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (9 of 95)30.09.2011 9:56:14

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13. NUT 14. LEFT HAND FRONT PANEL 15. left HAND step PANEL 16. LEFT HAND TREAD PLATE 17. PLATE ASSEMBLY SEAL 18. RIGHT HAND FENDER COVER 19. FLOOR MAT 20. RIGHT HAND TREAD PLATE 21. RIGHT HAND FRONT PANEL 22. RIGHT HAND STEP PANEL 23. RIGHT HAND REAR PANEL 24. RADIATOR COVER 25. KICK PANEL 26. PLATE ASSEMBLY Figure 3. Side Cover, Floor Plate, and Cowl Components, Lift Truck Models GLC20-35VX (GC/ GLC040-070VX,GC/GLC055SVX ) (A910), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX ) (C810), and GC/GLC030-035VX, GC/GLC040SVX (C809)

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Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP20-35VX (GP/ GLP/GDP040-070VX) (B875) Legend for Figure 4 1. dash assembly 2. upper steering column cover 3. lower steering column cover 4. kick panel 5. mud guard (lh) 6. mud guard (rh) 7. lock nut 8. nut 9. cover 10. bracket 11. plate assembly 12. grommet 13. left front panel 14. right front panel 15. left step panel 16. right step panel 17. left step plate 18. right step plate 19. left rear panel 20. right rear panel 21. floor mat 22. floor plate 23. radiator cover 24. seals 25. capscrew 26. clip nut 27. insert 28. PLATE ASSEMBLY SEAL 6. Remove two capscrews holding left and right rear side covers to the frame. Remove rear side covers from frame.

See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (11 of 95)30.09.2011 9:56:14

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7. Remove two capscrews holding left and right fender covers to front overhead guard leg. Remove covers.

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

9. Fully lower steering column.

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

12. Lift the kick panel to remove from truck.

See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 13. Remove three capscrews holding the seal plate. Remove seal plate. See Figure 6.

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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 14. Disconnect seat wire harness connector. See Figure 2.

CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews.

Damage can be caused to the threads on the screws and in the holes.

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

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.

18. Remove hinge screws, located in the rear of the hood. http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (13 of 95)30.09.2011 9:56:14

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

1. capscrews 2. seal plate Figure 6. Remove Seal Plate From Dash

Install 1. Place hood onto the lift truck frame.

2. Install hinge screws, located in the rear of the hood, and tighten to 38 N•m (28 lbf ft). See Figure 2.

3. Align top holes in the gas springs with holes in hood. Install capscrews and washers to attach gas springs to hood. Tighten capscrews to 19.2 N•m (170 lbf in).

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

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required for correct alignment. See Figure 7.

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1. HOOD 2. HOOD LATCH

3. CENTER PIN 4. CAPSCREW Figure 7. Hood Latch Adjustment

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.

CAUTION When installing the seat to the hood, DO NOT use an impact wrench to install the capscrews.

Damage can be caused to the threads on the screws and in the holes.

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

8. Align holes in the seat with the holes in hood. Insert washers and capscrews. Tighten capscrews to 18 N•m (159 lbf in).

9. If truck is equipped with a non-swivel seat, tie cable clips to seat wire harness and insert harness into seat wire harness brackets under hood. If truck is equipped with a swivel seat, secure seat harness to bracket. See Figure 2.

10. Install seal plate using three capscrews. See Figure 6.

11. Install kick panel onto truck.

See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 12. Install dash to top of cowl. See Figure 5. Install four clips to attach the dash to kick panel.

13. Install upper steering column cover to dash.

14. Using four capscrews, install left and right front side covers to frame.

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See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 15. Using two capscrews, install left and right fender covers to front of overhead guard legs.

16. Using two capscrews, install left and right rear side covers to frame.

See Figure 3 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 17. Install floor mat and floor plate.

18. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight.

19. Adjust the steering column and seat positions.

Steering Column Description This section describes the repair procedures for the steering column. The Steering Column Assembly mounts to the cowl inside the operator compartment and is the mechanical connection between the steering wheel and the steering control unit. The steering column includes the steering wheel, housing, bracket and lower shaft. For lift trucks with gas and LPG engines, bolts and bushings attach the steering column to the cowl standoffs. For lift trucks with diesel engines, bolts, bushings and isolators attach the steering column to the cowl standoffs. See Figure 8.

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Figure 8. Steering Column and Cowl Legend for Figure 8 NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR. 1. Steering Wheel 2. Steering Column 3. Cowl

Steering Column Repair Remove 1. Put blocks on each side (front and back) of tires to prevent lift truck from moving.

CAUTION http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (18 of 95)30.09.2011 9:56:14

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Disconnect the negative battery cable on internal combustion trucks. Disconnect the battery before removing any covers.

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. All components are not often removed for a repair procedure. Do only those steps of the procedure necessary to remove the required component.

NOTE: Tag wires prior to disconnect.

3. Remove the horn button assembly and disconnect electrical wires. Remove large hex nut and steering wheel from steering column. See Figure 9.

4. Remove steering column covers. Remove floor mats and floor plate. See section Hood, Seat, and Side Covers Replacement.

NOTE: Perform Step 5 for lift trucks equipped with gas or LPG engines.

5. Remove four capscrews, four bushings and steering column from cowl standoffs. See Figure 10.

NOTE: Perform Step 6 for lift trucks equipped with diesel engines.

6. Remove four capscrews, four bushings, four isolators, steering column and four isolators from cowl standoffs. See Figure 10.

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1. Horn Button 2. HEX Nut 3. Steering Wheel 4. Steering Column Figure 9. Steering Wheel Remove/Install

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NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR. 1. Capscrew 2. Bushing 3. Isolator 4. Steering Column 5. Cowl Standoff Figure 10. Steering Column Remove/Install

Disassemble NOTE: Remove and discard snap rings if installed.

1. Remove two pins and gas spring from housing. See Figure 11.

2. Remove two pivot bolts, two bushings, two nuts and bracket from housing. See Figure 11.

3. Remove split pin and lower shaft from upper shaft. See Figure 11.

4. Remove, connector from connector bracket. Remove connector bracket, fastener, four screws and two horn contacts from housing. See Figure 11.

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.

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

1. Clean metal parts in solvent. Remove all traces of old lubricant and dirt. Clean nonmetal parts with warm soapy water and a lint free cloth.

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

Inspect 1. Inspect for loose, burned, missing, cracked or damaged hardware.

2. Inspect all parts for dents, holes, bends, burrs, rust, corrosion or marred finishes.

3. Replace all defective or damaged parts.

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

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

Install fastener, connector bracket and connector, two horn contacts and four screws. See Figure 11.

2. Assemble lower shaft and upper shaft, secure with spit pin. See Figure 11.

3. Install two pivot bolts, two bushings, two nuts and bracket onto housing. See Figure 11.

4. Install gas spring and two pins on housing. See Figure 11.

Legend for Figure 11 1. PIN 2. LOWER SHAFT 3. Split Pin 4. UPPER SHAFT 5. HOUSING 6. HORN CONTACT 7. SCREW 8. FASTENER 9. CONNECTOR bracket 10. Pivot BOLT 11. BUSHING 12. NUT 13. GAS SPRING 14. BRACKET 15. Connector

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Figure 11. Steering Column Assembly

Install NOTE: Lubricate spline end of lower shaft with multi purpose grease, see Periodic Maintenance Manual for your lift truck.

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NOTE: Perform Step 1 for lift trucks equipped with gas or LPG engines.

1. Install steering column, four bushings and four bolts on cowl standoffs. Tighten bolts to 38 N•m (28 lbf ft). See Figure 10.

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

2. Install four isolators, steering column, four isolators, four bushings, and four bolts on cowl standoffs.

Tighten bolts to 38 N•m (28 lbf ft). See Figure 10.

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

4. Install steering wheel and hex nut on steering column, tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft).

Connect electrical wiring and install horn button. See Figure 9.

5. Remove tag from negative battery connector and connect to battery. Adjust steering column to neutral position.

6. Remove blocks from each side of tires.

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 Operating Manual or the section .

Periodic Maintenance 8000 YRM 1150 for lift truck models: • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810)

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

WARNING LPG can cause an explosion. DO NOT cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source.

Close the shutoff valve on the LPG tank before any part of the engine fuel system is disconnected.

Run the engine until the fuel in the system is used and the engine stops.

If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame.

One M24 × 3 x 140 capscrew holds the counterweight to the lower part of the frame on lift truck models • GLC30-35VX (GC/GLC060-070VX) (A910) • GLP/GDP30-35VX (GP/GLP/GDP060-070VX) (B875) One M24 × 3 x 90 capscrew holds the counterweight to the lower part of the frame on lift truck models • GLC20-25VX (GC/GLC040-050VX, GC/GLC055SVX) (A910) • GLP/GDP20-25VX (GP/GLP/GDP040-050VX) (B875) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) See Figure 12.

NOTE: For exhaust system procedure for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 or Gasoline Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1325.

For exhaust system procedures for lift trucks built after January, 2010 and equipped with a GM 2.4L engine, go to section LPG Fuel System, GM 2.4L Engine 900 YRM 1124.

NOTE: For overhead exhaust system procedures for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 or LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125.

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removing the counterweight. See the section Exhaust System Repair for the procedures.

1. If the lift truck has an LPG fuel system, use the procedures in the section LPG Tank and Bracket Replacement, to remove the LPG tank and bracket so that the counterweight can be removed.

Additional information on the LPG fuel system can be found in the following sections: • LPG Fuel System, GM 2.4L Engine 900 YRM 1124 • LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 • LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in Table 1 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) Table 2 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) Table 3 for lift truck models • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) Table 4 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 2. Install a lifting eye in the lift hole of the counterweight. See Figure 12 and Figure 13. Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the counterweight. Remove the tow pin and remove the capscrew that holds the counterweight to the frame. See Figure 12. Use the crane to lift the counterweight from the lift truck. Put counterweight on the floor so that it has stability and will not fall over. Take care not to damage exhaust or cooling components.

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1. Frame hook 2. lower frame mount 3. tow pin 4. roll pin

5. capscrew 6. washers 7. lift hole

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Figure 12. Counterweight Installation Table 1. Weight of Counterweights, Lift Truck Models GLC20-35VX (GC/GLC040-070VX,GC/ GLC055SVX ) (A910) Model

Kg

Lb

GLC20VX (GC/GLC040VX)

1040

2293

GLC25VX (GC/GLC050VX)

1395

3075

GC/GLC055SVX

1643

3622

GLC30VX (GC/GLC060VX)

1819

4010

GLC35VX (GC/GLC070VX)

2153

4747

Table 2. Weight of Counterweights, Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/ GLC040SVX (C809) Model

kg

lb

GC/GLC030VX

772

1702

GC/GLC035VX

963

2123

GC/GLC040SVX

1131

2493

Table 3. Weight of Counterweights, Lift Truck Models GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/ GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810) Model

kg

lb

GLP/GDP16VX (GP/GLP/GDP030VX)

812

1790

GLP/GDP18VX (GP/GLP/GDP035VX)

887

1955

GLP/GDP20SVX (GP/GLP/GDP040SVX)

1047

2308

Table 4. Weight of Counterweights, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Model

kg

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GLP/GDP20VX (GP/GLP/GDP040VX)

996

2196

GLP/GDP25VX (GP/GLP/GDP050VX)

1340

2954

GLP/GDP30SVX (GP/GLP/GDP060SVX)

1666

3673

GLP/GDP35SVX (GP/GLP/GDP070SVX)

1967

4336

Install 1. Make sure the seals are on the counterweight. See Figure 13.

2. Use a crane to install the counterweight on the lift truck. When the counterweight is installed, make sure the hooks on the frame fully engage the counterweight so it is aligned with the parts of the frame.

Install and tighten the M24 × 3 capscrew to 555 N•m (409 lbf ft).

3. Install tow pin and roll pin. See Tow Pin, Remove and Install for procedures.

4. If the lift truck has an LPG fuel system, use the procedures in the section LPG Tank and Bracket Replacement, to install the LPG tank and bracket after the counterweight has been installed.

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1. Capscrew 2. lockwasher 3. washer 4. counterweight 5. lifting eyebolt

6. tow pin 7. roll pin 8. seal 9. lift hole 10. lpg access hole Figure 13. Counterweight

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NOTE: For overhead exhaust system procedures for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 go to section LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 or LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125.

5. If lift truck is equipped with an overhead exhaust system, install the overhead exhaust pipe. See the section Exhaust System Repair for the procedures.

Tow Pin, Remove and Install 1. Remove the tow pin from the counterweight by driving the roll pin out. See Figure 14.

2. Install tow pin into counterweight and install roll pin.

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Figure 14. Tow Pin

Overhead Guard Replacement Remove and Install

WARNING DO NOT operate the lift truck without the overhead guard correctly fastened to the lift truck.

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

See your dealer for Yale lift trucks BEFORE performing any changes to the overhead guard.

NOTE: The lift trucks covered in this YRM are equipped with either a high or low overhead guard. The removal and installation procedures for both types of overhead guards are the same.

No welding or drilling on legs of overhead guard is permitted as per previous WARNING. NOTE: The lifting device can be connected to any number of positions on the overhead guard depending upon the lifting device available. The ideal choices are a four point sling connected to all four corners on the top of the overhead guard, or a two point sling connected to two opposite corners of the overhead guard. If a single point hoist is used, make sure that the lift point is as close to the center of the overhead guard. If during the initial start of the lift the overhead guard is off balance lower immediately and move the hoist to a more centered point.

1. Connect a lifting device to remove or install the overhead guard. Loosen clamp and disconnect the air intake hose from the elbow. Remove bolts, elbow, retainer, and grommet from the overhead guard rear leg. See Figure 15.

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 16.

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 N•m (49 lbf ft). See Figure 16.

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1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS Figure 15. Disconnect Air Intake Hose

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1. Capscrews - front legs 2. handle

3. capscrews - rear legs 4. frame Figure 16. Overhead Guard

LED Tail, Backup, and Brake Lights, Replace These light assemblies are nonrepairable and must be replaced as an assembly. See the section Electrical System 2200 YRM 1142 for the procedures to replace these lights.

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 17.

Automatic Locking Retractor (ALR) NOTE: GC/GLC040-070VX, GC/GLC055SVX (A910) lift trucks produced before November 2005 are equipped with the ALR type seat belts.

The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 17.

Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt.

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

A seat belt that is damaged worn or does not operate properly will not provide protection when it is needed.

The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 17 and Figure 18.

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

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retractor assembly or the belt will not retract, replace the seat belt assembly.

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

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

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

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

A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR 1. LATCH STRIKER 2. HOOD LATCH 3. FORWARD/BACKWARD ADJUSTMENT 4. hood 5. OPERATOR WEIGHT ADJUSTMENT 6. seat rail 7. ARM REST 8. SEAT BELT 9. SEAT 10. HIP RESTRAINT 11. HOOD HINGE Figure 17. Operator Restraint System

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A. standard, non-suspension seat B. full suspension seat 1. seat belt 2. weight adjustment knob 3. ride position indicator 4. forward/backward adjustment lever 5. backrest angle adjustment lever 6. armrest 7. swivel latch release lever Figure 18. 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.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any

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blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the section Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX ) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875 Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810)

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. 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 the section LPG Tank and Bracket Replacement, for the procedures.

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.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

6. Open the drain plug or disconnect the bottom radiator hose to drain coolant from radiator and engine.

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NOTE: Trucks equipped with a Yanmar diesel engine do not have an ECM. 8. On lift trucks with the GM 2.4L engine, disconnect the ECM from air filter and remove two bolts holding ECM and mounting bracket to air filter, before removing the air filter.

9. On lift trucks equipped with a Mazda 2.0L or 2.2L engine, disconnect ECM connector from ECM. Remove two bolts and ECM bracket, with ECM attached, from engine block.

10. Disconnect the ground strap from the frame and remove the power distribution module (PDM) from the battery tray. See Figure 19.

11. Remove three capscrews from the battery tray and remove the battery and battery tray. See Figure 19.

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1. battery 2. battery tray 3. pdm

4. battery lockdown bar 5. ground strap Figure 19. Power Distribution Module, Disconnection

12. Disconnect the remaining coolant hoses from the radiator and cap them to prevent leakage.

13. On lift trucks equipped with a Mazda engine (except Mazda 2007 emission compliant engines and lift trucks built after January, 2010 equipped with a Mazda engine) and Basic Powershift Transmission, disconnect the throttle linkage (see the section Powershift Transmission, Repair 1300 YRM 1129).

Disconnect the exhaust system.

14. Remove the radiator fan pulley, shroud, and fan assembly. See the section Cooling System 700 YRM 1123 for the removal procedures.

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

No smoking.

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

15. Disconnect the fuel lines at the engine. Put caps on fuel lines to prevent fuel leakage.

NOTE: Lift trucks equipped with Yanmar diesel engine do not have an ECM. NOTE: Lift trucks equipped with 2007 Mazda emission compliant engines and lift trucks built after January, 2010 equipped with Mazda engines, do not have a governor controller and the ECM for these engines is mounted on the side of the engine.

16. For lift trucks built before 2007, equipped with Mazda engines - Disconnect the electronic control module (ECM) connector and governor controller from the side of the frame before removing the engine from the truck.

17. 2007 Mazda emission compliant engines only - Disconnect the engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck.

18. Lift trucks built after January, 2010 equipped with Mazda engines - Disconnect the engine harness connectors from the right hand chassis harness connectors before removing the engine from the truck.

19. Use the access port on the side of engine and remove the four bolts that attach the flywheel to the torque converter. See Figure 20.

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20. Connect a lifting device to the engine. Put a block under the transmission housing to support the transmission.

NOTE: Perform Step 21 for lift trucks equipped with iron housing transmission.

21. Remove capscrews from transmission bell housing.

NOTE: Perform Step 22 through Step 24 for lift trucks equipped with aluminum housing transmission.

22. Remove two capscrews, two washers, and converter housing cover from torque converter housing.

See Figure 21.

A. typical for mazda and yanmar engines B. typical for gm engines 1. access port 2. flywheel housing Figure 20. Torque Converter Bolt Access 23. Remove four flange bolts from torque converter housing and flywheel housing on transmission side. See Figure 21.

24. Remove six hex head capscrews and six lock washers from flywheel housing and torque converter housing on flywheel housing side. See Figure 21.

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

25. Remove the flange nuts, washers, bolts, and isolators from the engine mounts. Remove engine adapter to transmission bolts. On trucks equipped with a GM 2.4L engine, remove one starter bolt. See Figure 22 and Figure 23.

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

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

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

27. Remove torque converter from torque converter housing.

NOTE: TYPICAL FOR ALL ENGINES. GM 2.4L LPG AND ALUMINUM CASE TRANSMISSION SHOWN. 1. converter housing cover 2. capscrew 3. washer 4. torque converter housing 5. eyebolt bracket 6. hex head capscrew 7. flywheel housing 8. transmission assembly 9. flange bolt 10. lockwasher http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (42 of 95)30.09.2011 9:56:14

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11. engine assembly Figure 21. Flywheel and Torque Converter Housings

A. mazda B. gm engine 2.4L engine

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1. frame 2. engine mount

3. flange nut Figure 22. Engine Removal

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A. mazda and Yanmar engine mount 1. left engine mount 2. right engine mount 3. washer

B. gm engine mount

4. capscrew 5. crossmember 6. isolator 7. flange nut

Figure 23. Engine Mounts

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.

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3. Install isolators on engine mounts. Install the nuts and bolts for the engine mounts to secure engine to frame. See Figure 22 and Figure 23. 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 20.

NOTE: Perform Step 5 for lift trucks equipped with iron transmission housing.

5. Align transmission bell housing holes with flywheel housing holes and install capscrews. Tighten capscrews to 38 N•m (28 lbf ft).

NOTE: Perform Step 6 through Step 9 for lift trucks equipped with aluminum transmission housing.

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 21.

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 21.

8. On trucks equipped with a GM 2.4L engine, install starter bolt.

9. Install converter housing cover, two washers, and two capscrews on torque converter housing. Tighten capscrews to 19 N•m (168 lbf in). See Figure 21.

NOTE: For procedures to install exhaust pipe to exhaust manifold for lift trucks equipped with a Mazda 2007 emissions compliant engine and for lift trucks built after January, 2010 equipped with a Mazda engine, see Gasoline Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1325 or LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326.

10. Install exhaust pipe to exhaust manifold. See Exhaust System Repair.

11. For lift trucks built before 2007, equipped with Mazda engines - Connect the ECM connector and governor controller to lift truck frame.

12. On lift trucks equipped with a Mazda 2.0L or 2.2L engine, install ECM bracket with ECM attached and two bolts on engine block.

WARNING 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.

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

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NOTE: On trucks equipped with the GM 2.4L engine, connect the ECM and install ECM and mounting bracket to air filter with two bolts, before installing the air filter to lift truck.

14. On lift trucks equipped with a Mazda engine (except Mazda 2007, and later, emission compliant engines) and Basic Powershift Transmission, connect the throttle linkage (see the section Powershift Transmission, Repair 1300 YRM 1129). Install the air filter assembly.

15. Connect the coolant hoses and lines to the transmission. Fill cooling system with a mixture of 50 percent deionized water and 50 percent ethylene glycol boron-free antifreeze.

16. Install the radiator shroud, fan pulley, and fan assembly. See the section Cooling System 700 YRM 1123 for the installation procedures.

17. Connect the PDM and connect the ground strap to lift truck frame and attach it to battery. Install the battery and battery tray. See Figure 19. If lift truck is equipped with an LPG tank, swing tank into position on truck. See the section LPG Tank and Bracket Replacement, for the procedures.

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.

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 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

21. Empty drain pan contents.

22. If lift truck is equipped with an LPG fuel tank, swing tank into position on back of counterweight and open shutoff valve on tank.

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 http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (47 of 95)30.09.2011 9:56:14

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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 See section Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) See section Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 1. Remove engine from lift truck. See section Remove, Engine Replacement for procedures.

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

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 (B875) 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 24.

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 24.

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1. transmission housing 2. variable displacement pump 3. load sense line

4. hydraulic inlet line 5. drain case line 6. hydraulic supply (suction) hose

Figure 24. Hydraulic Hose Connections, Lift Truck Models GLP/GDP20-35VX (B875) Equipped With Variable Displacement pump http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (49 of 95)30.09.2011 9:56:14

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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 25.

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.

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NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. 1. mount bracket 2. capscrew 3. washer

4. snubbing washer 5. isolator Figure 25. Rear Mount - Transmission

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 N•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 25. Tighten capscrew to 225 to 250 N•m (166 to 184 lbf ft).

4. Remove lifting device from the transmission.

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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 Gear Pump 1900 YRM 1136 for more information on installing hydraulic hoses to gear pump.

NOTE: Step 6 and Step 7 apply to lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump (VDP).

6. Install the hydraulic supply hose between the variable displacement pump and hydraulic tank. See Figure 24.

7. Install the hydraulic supply hose, load sense line, drain case line, and hydraulic inlet line on the variable displacement pump. See Figure 24. See Hydraulic Gear Pump 1900 YRM 1136 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.

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

Remove Transmission with Aluminum 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: • 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 See section Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) See section Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

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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.

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

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

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 from transmission.

See Figure 26 and Figure 27 for the following lift truck models equipped with a hydraulic gear pump: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Figure 28 and Figure 29 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 30 and Figure 31 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

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Figure 26. Hydraulic Hose, Dry Brakes (Aluminum Transmission Prior to January, 2011) Legend for Figure 26 1. transmission housing 2. drain fitting 3. hydraulic gear pump 4. suction hose 5. hydraulic gear pump inlet port 6. hydraulic gear pump outlet port 7. hydraulic inlet hose 8. transmission cooling line

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NOTE: Quick-Lok™ hydraulic hose and adapters not shown.

1. transmission housing 2. drain fitting 3. hydraulic gear pump 4. suction hose 5. hydraulic gear pump inlet port 6. hydraulic gear pump outlet port 7. hydraulic inlet hose 8. transmission cooling line Figure 27. Hydraulic Hose, Dry Brakes (Aluminum Transmission After January, 2011)

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1. Transmission Housing 2. wet disk brake hose assembly 3. Hydraulic gear pump 4. suction hose 5. hydraulic gear pump inlet port 6. hydraulic gear pump outlet port 7. hydraulic inlet hose 8. high temp hose assembly 9. transmission cooling supply port Figure 28. Hydraulic Hose, Wet Brakes (Aluminum Transmission Prior to January, 2011)

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