Yale C810 (GP GDP GLP030-040VX SVX) Service Manual - PDF DOWNLOAD

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Service Manuals Manuals Available For C810 (GP/GDP/GLP030-040VX/SVX) Note: Service manuals do not contain serial number specific data.

Manual

Manual Title

Release Date

MAZDA POWERTRAIN 0100YRM1120

FRAME

12-2011

0100YRM1290

OPERATOR'S CAB

01-2012

0600YRM1122

MAZDA FE AND F2 ENGINES

03-2012

0700YRM1123

COOLING SYSTEM

01-2012

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

03-2012

2200YRM1143

ELECTRICAL SYSTEM (MAZDA)

05-2005

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2200YRM1327

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

07-2011

YANMAR POWERTRAIN 0100YRM1120

FRAME

12-2011

0100YRM1290

OPERATOR'S CAB

01-2012

0600YRM1205

YANMAR DIESEL ENGINE

07-2011

0700YRM1123

COOLING SYSTEM

01-2012

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

1300YRM1529

POWERSHIFT TRANSMISSION REPAIR

10-2011

1400YRM1206

DRIVE AXLE

11-2008

1800YRM1135

BRAKE SYSTEM

11-2011

1600YRM1133

STEERING AXLE

01-2012

1900YRM1136

HYDRAULIC GEAR PUMP

01-2012

2000YRM1137

MAIN CONTROL VALVE

03-2012

2100YRM1139

CYLINDERS REPAIR

01-2012

4000YRM1148

MAST REPAIR 2, 3, AND 4-STAGE MASTS

02-2012

2200YRM1128

WIRE HARNESS REPAIR

01-2012

2200YRM1130

USER INTERFACE - SUPERVISOR

01-2012

DRIVETRAIN

HYDRAULICS

ELECTRICAL

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2200YRM1131

USER INTERFACE - SERVICE

01-2012

2200YRM1142

ELECTRICAL SYSTEM

03-2012

REFERENCE MATERIAL 8000YRM0231

METRIC AND INCH (SAE) FASTENERS

12-2004

8000YRM1134

CALIBRATION PROCEDURES

01-2012

8000YRM1152

DIAGRAMS

10-2011

8000YRM1207

PERIODIC MAINTENANCE

02-2012

8000YRM1208

CAPACITIES AND SPECIFICATIONS

11-2010

8000YRM1387

DIAGRAMS AND SCHEMATICS

06-2011

8000YRM1409

DIAGRAMS AND SCHEMATICS

06-2011

DIAGNOSTIC TROUBLESHOOTING 9000YRM1112

DIAGNOSTICS TROUBLESHOOTING

©2012 Yale Axcess Online

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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 102)05.04.2012 11:16:56

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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 102)05.04.2012 11:16:56

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Disassemble Clean Inspect Assemble Install LPG Tank and Bracket Assembly 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

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Yanmar Diesel Engine 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: http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (5 of 102)05.04.2012 11:16:56

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• 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) 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, and exhaust system (see NOTE above) are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

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

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 http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (6 of 102)05.04.2012 11:16:56

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• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 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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5. Remove floor mat and floor plate.

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

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2. hood 3. frame 4. seat wire harness 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 http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (9 of 102)05.04.2012 11:16:56

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10. FLOOR PLATE 11. LEFT HAND FENDER COVER 12. SCREW 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 http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (11 of 102)05.04.2012 11:16:56

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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) 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.

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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.

NOTE: Top view of dash shown.

A. Indicates to Pull up to unlatch 1. Allen screws 2. cowl 3. upper steering column cover http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (13 of 102)05.04.2012 11:16:56

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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.

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

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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 required for correct alignment. See Figure 7.

5. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood

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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.

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.

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1. HOOD 2. HOOD LATCH

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

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

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

WARNING

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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 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 • For lift trucks manufactured before January 2012 See Figure 12 • For lift trucks manufactured after January 2012 2. Remove two pivot bolts, two bushings, two nuts and bracket from housing.

See Figure 11 • For lift trucks manufactured before January 2012 See Figure 12 • For lift trucks manufactured after January 2012

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3. Remove split pin and lower shaft from upper shaft.

See Figure 11 • For lift trucks manufactured before January 2012 See Figure 12 • For lift trucks manufactured after January 2012 4. Remove, connector from connector bracket. Remove connector bracket, fastener, four screws and two horn contacts from housing.

See Figure 11 • For lift trucks manufactured before January 2012 See Figure 12 • For lift trucks manufactured after January 2012

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Figure 11. Steering Column Assembly , Lift Trucks Manufactured Before January, 2012 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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1. bracket 2. spacer 3. joint 4. nut 5. washer 6. screw 7. upper shaft 8. housing 9. pin 10. lower shaft 11. gas spring 12. bolt 13. bushing 14. connector 15. fastener 16. horn contact Figure 12. Steering Column Assembly, Lift Trucks Manufactured After January, 2012

Clean

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

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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. Not all components are removed for a repair procedure. Do only those steps of the procedure necessary to install the required component.

NOTE: Perform Step 1 only for lift trucks manufactured before January, 2012 1. Lubricate the horn contact slip rings with a small amount of conductive grease Yale P/N 582014302 2. Install fastener, connector bracket and connector, two horn contacts and four screws.

See Figure 11 • For lift trucks manufactured before January 2012 See Figure 12 • For lift trucks manufactured after January 2012 3. Assemble lower shaft and upper shaft, secure with spit pin.

See Figure 11 • For lift trucks manufactured before January 2012 See Figure 12 • For lift trucks manufactured after January 2012 4. Install two pivot bolts, two bushings, two nuts and bracket onto housing.

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See Figure 11 • For lift trucks manufactured before January 2012 See Figure 12 • For lift trucks manufactured after January 2012

Install NOTE: Lubricate spline end of lower shaft with multi purpose grease. See one of the Service Manuals for procedures Periodic Maintenance 8000 YRM 1150 for lift truck models: • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) NOTE: Perform Step 1 for lift trucks equipped with gas or LPG engines.

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

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

LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models: • GLC20-35VX (GLC040-070VX, GLC055SVX) (A910) • GLP20-35VX (GLP040-070VX) (B875) http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (27 of 102)05.04.2012 11:16:56

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LPG Fuel System, Mazda 2.0L and 2.2L Engines 900 SRM 1125 for lift truck models: • GLC20-35VX (GLC040-070VX, GLC055SVX) (A910) • GLP20-35VX (GLP040-070VX) (B875) • GLC030VX, GLC035VX, GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GLP030VX, GLP035VX, GLP040SVX) (C810) LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 for lift truck models: • GLC20-35VX (GLC040-070VX, GLC055SVX) (A910) • GLP20-35VX (GLP040-070VX) (B875) • GLC030VX, GLC035VX, GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GLP030VX, GLP035VX, GLP040SVX) (C810)

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)

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.

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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 13.

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.

NOTE: If lift truck is equipped with an overhead exhaust system, remove the overhead exhaust pipe before removing the counterweight. See the section Exhaust System Repair for the procedures.

1. If the lift truck has an LPG fuel system, see one of the following Service Manuals to remove the LPG tank and bracket, before removing the counterweight, and for additional information on the LPG fuel system: LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models: • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (29 of 102)05.04.2012 11:16:56

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• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in : Table 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 13 and Figure 14. 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 13. 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.

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

Kg

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Lb

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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

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1. Frame hook 2. lower frame mount 3. tow pin 4. roll pin 5. capscrew 6. washers 7. lift hole Figure 13. Counterweight Installation

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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

lb

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 14.

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

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

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

4. If the lift truck has an LPG fuel system, see one of the following Service Manuals to install the LPG tank and bracket, after the counterweight has been installed.

LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models: • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

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LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 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.

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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 14. Counterweight

Tow Pin, Remove and Install 1. Remove the tow pin from the counterweight by driving the roll pin out. See Figure 15.

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

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1. tow 2. roll pin pin Figure 15. 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 http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (36 of 102)05.04.2012 11:16:56

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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 16.

2. Disconnect any wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that any electrical wires are moved through the holes in the frame so that they are not damaged.

3. The rear legs of the overhead guard have two capscrews that are located under the hood inside the engine compartment, next to the radiator. Remove and install the capscrews. See Figure 17.

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

5. When installing the overhead guard, tighten the capscrews for the overhead guard legs to 66 N•m (49 lbf ft). See Figure 17.

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1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS Figure 16. Disconnect Air Intake Hose

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1. Capscrews - front legs 2. handle

3. capscrews - rear legs 4. frame Figure 17. 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 18.

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 18.

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 18 and Figure 19.

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 18. 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 19. Operator Restraint System

Engine Replacement Remove

WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

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

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

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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 one of the following Service Manuals for procedures: LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models: • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 3. Remove overhead guard. See section Overhead Guard Replacement for procedures. http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (43 of 102)05.04.2012 11:16:56

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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.

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

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

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

10. Disconnect the ground strap from the frame and remove the power distribution module (PDM) from the battery tray. See Figure 20.

11. Remove three capscrews from the battery tray and remove the battery and battery tray. See Figure 20.

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1. battery 2. battery tray 3. pdm

4. battery lockdown bar 5. ground strap Figure 20. 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.

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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 21.

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 22.

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A. typical for mazda and yanmar engines B. typical for gm engines 1. access port 2. flywheel housing Figure 21. Torque Converter Bolt Access 23. Remove four flange bolts from torque converter housing and flywheel housing on transmission side. See Figure 22.

24. Remove six hex head capscrews and six lock washers from flywheel housing and torque converter housing on flywheel housing side. See Figure 22.

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 23 and Figure 24.

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

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

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.

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27. Remove torque converter from torque converter housing.

Install

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

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

1. Install torque converter in torque converter housing.

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 http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (48 of 102)05.04.2012 11:16:56

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8. transmission assembly 9. flange bolt 10. lockwasher 11. engine assembly Figure 22. Flywheel and Torque Converter Housings 2. Connect lifting device to engine and lift engine into frame.

3. Install isolators on engine mounts. Install the nuts and bolts for the engine mounts to secure engine to frame. See Figure 23 and Figure 24. Tighten the nuts to 150 N•m (110 lbf ft).

4. Use access port on side of engine and install bolts to hold torque converter to flywheel. Tighten bolt to 56 N•m (41 lbf ft). See Figure 21.

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

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

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 22.

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A. mazda B. gm engine 2.4L engine 1. frame 2. engine mount

3. flange nut

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Figure 23. Engine Removal 7. Install four flange bolts on torque converter housing and flywheel housing from transmission side.

Tighten bolts to 38 N•m (28 lbf ft). See Figure 22.

8. 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 22.

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.

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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 24. Engine Mounts 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. http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (52 of 102)05.04.2012 11:16:56

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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.

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 20.

18. If lift truck is equipped with an LPG tank, swing tank into position on truck. See one of the following Service Manuals for procedures: LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for lift truck models: • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2 Engines 900 YRM 1125 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 for lift truck models: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (53 of 102)05.04.2012 11:16:56

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GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) 19. Install the rear side covers, floor plates, floor mat, and hood and seat combination. See the section Hood, Seat, and Side Covers Replacement for the procedures.

20. If removed, install Overhead guard. See section Overhead Guard Replacement for procedures.

21. Check all fluid levels as described in the section Periodic Maintenance 8000 YRM 1150 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Periodic Maintenance 8000 YRM 1207 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/ GDP035VX, GP/GLP/GDP040SVX) (C810)

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

22. Empty drain pan contents.

23. 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 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)

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• 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 25.

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 25.

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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 25. 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 (56 of 102)05.04.2012 11:16:56

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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 26.

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

4. snubbing washer 5. isolator Figure 26. Rear Mount - Transmission

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

Install Transmission with Iron Housing

WARNING The transmission is heavy. Make sure that any lifting device has enough capacity to lift the weight.

The transmission can weigh approximately 317 kg (699 lb).

1. Using a lifting device, install transmission in lift truck frame. Place a block under the transmission housing to support the transmission.

2. Install the transmission output yoke on the transmission. Be sure to not damage the seal. Tighten the bolt to 38 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 26. 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 25.

7. Install the hydraulic supply hose, load sense line, drain case line, and hydraulic inlet line on the variable displacement pump. See Figure 25. 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 27 and Figure 28 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 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

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Figure 27. Hydraulic Hose, Dry Brakes (Aluminum Transmission Prior to January, 2011) Legend for Figure 27 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 28. Hydraulic Hose, Dry Brakes (Aluminum Transmission After January, 2011)

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

NOTE: Perform Step 5 for lift trucks equipped with dry brakes.

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

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transmission oil.

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 29. Hydraulic Hose, Wet Brakes (Aluminum Transmission Prior to January, 2011) See Figure 27 and Figure 28 for the following lift truck models equipped with a hydraulic gear pump:

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

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3. load sense line 4. drain case line 5. hydraulic inlet hose 6. high temperature line 7. transmission cooling supply port 8. transmission cooling hoses 9. wet disk brake hose assembly 10. pump inlet port 11. pump outlet port 12. suction hose Figure 32. Hydraulic Hose, Wet Brakes (Aluminum Transmission After January, 2011), Lift Truck Models GLP/GDP20-35VX (B875) Equipped With Variable Displacement Pump 7. Disconnect and cap high temp hose assembly from transmission cooling support port. Cap transmission cooling supply port.

See Figure 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

8. Disconnect and cap suction hose from hydraulic gear pump inlet port. Cap hydraulic gear pump inlet port.

See Figure 27 and Figure 28 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 29 and Figure 30 for the following lift truck models equipped with a hydraulic gear pump: • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

NOTE: Perform Step 9 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a Quick-Lok™ hydraulic hose and adapter.

9. Remove adapter and Quick-Lok hydraulic hose from hydraulic gear pump outlet port. Cap hydraulic gear pump outlet port.

10. For lift trucks not equipped with Quick-Lok hydraulic hose and adapters, disconnect and cap hydraulic inlet hose from hydraulic gear pump outlet port. Cap hydraulic gear pump outlet port.

See Figure 27 and Figure 28 for the following lift truck models equipped with a hydraulic gear pump: • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809)

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• 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 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

NOTE: Step 11 applies only to lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

11. Disconnect and cap the load sense line and drain case line from the variable displacement pump. See Figure 31 and Figure 32.

12. Remove the capscrew, washer, snubbing washers, and isolators from the mount bracket at the rear of the transmission. See Figure 33.

13. Use the lifting device to carefully lift the transmission from the frame. Slip the transmission output yoke out of the transmission. Make sure to not damage the seal.

14. Remove flange head capscrew, yoke, and spacer from transmission. Make sure to not damage the seal. See Figure 34.

NOTE: Note position of oil seal prior to removal to aid in installation.

15. Remove oil seal from transmission housing. See Figure 34.

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NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. 1. MOUNT BRACKET 2. CAPSCREW 3. WASHER

4. SNUBBING WASHER 5. ISOLATOR Figure 33. Rear Mount- Transmission

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1. flange head capscrew 2. stat-o-seal 3. yoke 4. oil seal 5. spacer 6. transmission housing Figure 34. Drive Shaft Yoke

Install Transmission with Aluminum Housing

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).

1. Using a lifting device, install transmission in lift truck frame. Place a block under the transmission housing to support the transmission.

2. Install oil seal on back of transmission housing. See Figure 34.

3. Install new stat-o-seal on yoke. See Figure 34.

4. Install spacer, yoke, and flange head capscrew on back of transmission. See Figure 34. Tighten capscrew to 77 N•m (57 lbf ft).

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transmission. See Figure 33. Tighten capscrew to 225 to 250 N•m (166 to 184 lbf ft).

6. Remove lifting device from transmission.

NOTE: Perform Step 7 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a Quick-Lok™ hydraulic hose and adapter.

7. Remove cap and install adapter and Quick-Lok hydraulic hose to hydraulic gear pump outlet port.

Tighten adapter to 59 to 69 N•m (44 to 51 lbf ft).

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

See Figure 27 and Figure 28 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 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

9. Connect suction hose to hydraulic gear pump inlet port.

See Figure 27 and Figure 28 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 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

NOTE: Perform Step 10 for lift trucks equipped with dry brakes.

10. Install drain fitting on transmission housing.

See Figure 27 and Figure 28 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)

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• GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Figure 31 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

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

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

See Figure 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

12. Connect wet disk brake hose assembly to transmission.

See Figure 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a variable displacement pump.

See Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

13. Connect transmission cooling lines to transmission.

See Figure 27 and Figure 28 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 29 and Figure 30 for lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) equipped with a hydraulic gear pump.

See Figure 31 and Figure 32 for lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

NOTE: Step 14 applies only to lift truck models GLP/GDP20-35VX (B875) equipped with a variable displacement pump.

14. Connect the load sense line and drain case line to the variable displacement pump. See Figure 31 and Figure 32.

15. Connect transmission wiring harness to engine wiring harness.

16. Install the seal plate for the brake and throttle pedals. See Figure 6.

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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 installing the engine.

17. Install engine to lift truck. See section Install, Engine Replacement for procedures.

NOTE: Perform Step 18 for lift trucks equipped with dry brakes.

18. Fill transmission oil. For fill instruction, oil type, and amount, See section Periodic Maintenance 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) NOTE: Perform Step 19 for lift truck equipped with wet brakes.

19. Fill transmission and transaxle oil. For fill instruction, oil type, and amount, see section Periodic Maintenance 8000 YRM 1150 for lift truck model GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875).

Throttle Pedal and Cable Adjustment NOTE: There are no throttle pedal and cable adjustments for lift trucks equipped with the GM 2.4L engine.

The GM 2.4L engines have an electronic throttle that is self-adjusting and self-calibrating.

NOTE: For the Mazda 2007 emission compliant engines and for lift trucks built after January, 2010 and equipped with a Mazda engine, there is only a throttle pedal stop adjustment. The engine has an electronic throttle that is self-adjusting and self-calibrating. See Throttle Pedal Stop Adjustment for procedures.

Mazda Gas/LPG Engines With Basic Power Shift Transmission and Electronic Transmission (Except Mazda Emission Compliant Engines) 1. Remove floor plate and disconnect throttle cable from the bellcrank and engine. See Figure 35.

2. Fully depress throttle pedal and verify that the dimension between the bellcrank and cowl plate is 6 ±2 mm (0.24 ±0.08 in.).

3. If dimension is not correct, adjust ball ends on push rod so that a minimum of 6 mm (0.24 in.) of threaded rod screws into each ball end.

4. Connect throttle cable to bellcrank and engine. See Figure 35.

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5. With throttle pedal in full up position, adjust throttle cable, using the jam nuts (item #10 in Figure 35) to remove all slack from the cable. Cable should be adjusted to the point where additional adjustment will pull the throttle crank off the idle stop. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in).

NOTE: If lift truck is equipped with a Electronic Control Transmission, see the section Calibration Procedures 8000 YRM 1134 for additional adjustment procedures before going onto Step 7.

6. Fully depress pedal and verify that full pedal stroke brings the throttle crank to within 3.0 mm (0.12 in.) of the wide open throttle stop. See Figure 35.

7. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate.

Tighten jam nuts 8 to 15 N•m (71 to 133 lbf in) (item #12 in Figure 35).

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Figure 35. Throttle Pedal and Cable Adjustment; Mazda Gas/LPG Engines With Basic Power Shift Transmission, and Mazda LPG Engine With Electronic Transmission Legend for Figure 35 NOTE: Throttle pedal shown in wide open position (fully depressed position).

A. mazda gas engine B. mazda lpg engine 1. bell crank 2. cowl 3. push rod 4. ball end 5. pedal stop 6. throttle pedal 7. floor plate 8. throttle cable 9. bracket 10. jam nuts 11. throttle crank 12. jam nut

Mazda Gasoline Engine With Electronic Transmission 1. Remove floor plate. If necessary, remove throttle cable from bellcrank follower and throttle crank.

2. Back out bellcrank screw to ensure clearance when accelerator pedal is fully released, and the bellcrank follower is pulled against the stop block located on bracket. See Figure 36.

3. If removed, connect throttle cable to bellcrank follower and throttle crank.

4. With throttle pedal in full up position, adjust throttle cable, using the jam nuts (item #12 in Figure 36) to remove all slack from the cable. Cable should be adjusted to the point where additional adjustment will pull the throttle crank off the idle stop. Tighten jam nuts 8 to 15 N•m (71 to 133 lbf in).

NOTE: See the section Calibration Procedures 8000 YRM 1134 for additional adjustment procedures before going onto Step 6.

5. Fully depress pedal and verify that full pedal stroke brings the throttle crank to within 3.0 mm (0.12 in.) of the wide open throttle stop. See Figure 36.

6. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate.

Tighten jam nuts 8 to 15 N•m (71 to 133 lbf in). See Figure 36.

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1. bellcrank 2. bellcrank follower 3. cowl 4. throttle pedal 5. push rod 6. ball end 7. floor plate 8. throttle cable 9. screw 10. jam nut 11. bracket 12. jam nuts 13. throttle crank 14. stop block 15. pedal stop Figure 36. Throttle Pedal and Cable Adjustment; Mazda Gasoline Engine With Electronic Transmission

Throttle Pedal Stop Adjustment Fully depress throttle pedal and adjust pedal stop so that it touches floor plate. Tighten jam nut to 10 N•m (88.5 lbf in). See Figure 37.

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1. throttle pedal position sensor 2. jam nut 3. pedal stop 4. floor plate Figure 37. Throttle Pedal Stop Adjustment

Yanmar Diesel Engine With Basic Power Shift Transmission 1. Remove floor plate and disconnect throttle cable from the bellcrank and engine.

2. Fully depress throttle pedal and verify that the dimension between the bellcrank and cowl plate is 5 ±1 mm (0.20 ±0.04 in.). See Figure 38.

3. If dimension is not correct, adjust ball ends on push rod so that a minimum of 6 mm (0.24 in.) of threaded rod screws into each ball end. After adjusting push rod, tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in).

4. Connect throttle cable to bellcrank and engine. See Figure 38.

5. With throttle pedal in full up position, adjust throttle cable, using the jam nuts (item #10 in Figure 38) to remove all slack from the cable. Cable should be adjusted to the point where additional adjustment will pull the control lever off the idle stop. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in).

6. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate.

Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in) (item #6 in Figure 38).

Yanmar Diesel Engine With Electronic Throttle If lift truck is equipped with an electronic throttle, see the section Yanmar Diesel Engines, 2.6L and 3.3L 600 YRM 1205 for adjustment procedures.

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NOTE: Throttle pedal not shown in fully depressed position (wide open position).

1. cowl 2. bellcrank 3. push rod 4. ball end 5. throttle pedal 6. jam nut 7. pedal stop 8. throttle cable 9. cable bracket 10. jam nuts 11. throttle crank Figure 38. Throttle Pedal and Cable Adjustment, Yanmar Diesel Engine

Exhaust System Repair Lift Trucks With Counterweight Exhaust System Mazda Gas and LPG Engines NOTE: The Mazda engines covered in this section are non-emissions compliant engines ONLY. For exhaust system repair procedures for Mazda 2007 emissions compliant engines and for lift trucks built after January, 2010, see 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.

NOTE: Remove the counterweight before removing the muffler and other parts of the exhaust system. See the section Counterweight Replacement for the removal procedures for the counterweight. http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (80 of 102)05.04.2012 11:16:56

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Remove and Disassemble The muffler is installed inside the cavity of the counterweight. A short exhaust pipe sends the exhaust gases out of the lift truck through a grille in the counterweight.

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

1. Remove the bracket that attaches the catalytic converter to the frame. See Figure 39. Disconnect the oxygen sensor.

2. Disconnect the exhaust pipes (11 and 15 in Figure 39) from the catalytic converter and remove and discard the gaskets from the catalytic converter. Remove the catalytic converter from the lift truck.

3. Remove the exhaust pipe (15 in Figure 39) from the engine exhaust manifold.

4. Remove the clamps that hold the two exhaust pipes (8 and 11, Figure 39) to the muffler. Remove the exhaust pipes from the muffler.

5. Remove the plain flanged nuts that attach the muffler to the frame of the lift truck. Remove the muffler from the lift truck.

Inspect Inspect the following items in the exhaust system: • Exhaust pipes for damage, corrosion, and rust and replace as needed.

• If equipped, inspect all exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as needed. If replacing an exhaust pipe section that has a wrap, also replace the wrap. DO NOT reuse wraps if they have been removed for a service operation.

• Catalytic converter and muffler for damage, corrosion, and rust. Replace as needed.

Assemble and Install 1. Place the muffler onto the frame of the truck and install the plain flanged nuts. Tighten the nuts to 39 N•m (29 lbf ft).

2. Install the exhaust pipes (8 and 11, Figure 39) onto the muffler. Install the clamps on the pipes to hold them onto the muffler.

3. Install the exhaust pipe (15, Figure 39) onto the engine exhaust manifold.

4. Place the catalytic converter on the lift truck frame. For lift trucks equipped with a Mazda gas or LPG engine, make sure that the embossed F is facing up. Install new gaskets onto the catalytic converter and install the exhaust pipes onto the catalytic converter.

5. Install the bracket that attaches the catalytic converter to the frame. See Figure 39. Connect the oxygen sensor. http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (81 of 102)05.04.2012 11:16:56

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6. Install the counterweight. See the section Counterweight Replacement for installation procedures.

NOTE: The exhaust wraps shown are not on all lift truck models.

1. capscrew 2. washer 3. spacer 4. isolator 5. bracket 6. flange nut 7. nut 8. exhaust pipe 9. clamp 10. muffler 11. exhaust pipe 12. lockwasher 13. gasket 14. catalytic converter 15. exhaust pipe 16. exhaust wrap 17. oxygen sensor Figure 39. Counterweight Exhaust System - Mazda

Yanmar Diesel Engine Remove and Disassemble

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

1. Remove the counterweight. See the section Counterweight Replacement for the removal procedures.

2. Remove clamp that attaches exhaust pipe to muffler (Figure 40). Remove exhaust pipe.

3. Remove clamp that attaches the lower exhaust pipe to muffler. On lift truck models GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810) the muffler is positioned vertically and lower exhaust pipe is on the bottom. On lift truck models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875), the muffler is positioned horizontally and the lower exhaust pipe protrudes from the side (see Figure 40).

4. Remove the washers, isolators, spacers, and capscrews that fasten the muffler to the lift truck frame and remove muffler from lift truck.

5. If lift truck is not equipped with a catalytic converter, remove four locknuts attaching engine exhaust pipe to engine exhaust manifold and remove engine exhaust pipe from engine manifold and lower exhaust pipe. Remove lower exhaust pipe.

If lift truck is equipped with a catalytic converter, remove clamps securing engine exhaust pipe and lower exhaust pipe to catalytic converter. Remove four locknuts attaching engine exhaust pipe to engine exhaust manifold and remove engine exhaust pipe from engine manifold and catalytic converter. Remove lower exhaust pipe from catalytic converter.

Inspect Inspect the following items in the exhaust system: • Inspect all exhaust pipes for damage, corrosion, and rust and replace as needed.

• If equipped, inspect all exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as needed. If replacing an exhaust pipe section that has a wrap, also replace the wrap. DO NOT reuse wraps if they have been removed for a service operation.

• Inspect the catalytic converter (if equipped) and muffler for damage, corrosion, and rust. Replace as needed.

Assemble and Install 1. Install engine exhaust pipe to engine exhaust manifold. Tighten locknuts to 22 N•m (195 lbf in).

2. If lift truck is equipped with a catalytic converter, install catalytic converter to engine exhaust pipe and lower exhaust pipe to catalytic converter using two clamps. If lift truck is not equipped with catalytic converter, install lower exhaust pipe to engine exhaust pipe with clamp.

3. Place muffler onto the frame of lift truck and install the washers, isolators, spacers, and capscrews to secure muffler to lift truck. Tighten capscrews to 22 N•m (195 lbf in).

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5. Install exhaust pipe on muffler with clamp.

6. Install the counterweight. See the section Counterweight Replacement for installation procedures.

Figure 40. Counterweight Exhaust System Yanmar Diesel Engine

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Legend for Figure 40 NOTE: Exhaust system for GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) lift trucks shown.

Overhead exhaust system for GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/ GDP040SVX) (C810) is similar.

NOTE: Exhaust system with catalytic converter shown.

1. capscrew 2. washer 3. spacer 4. isolator 5. locknut 6. muffler 7. gasket 8. engine exhaust pipe 9. clamp 10. catalytic converter 11. sock 12. lower exhaust pipe 13. counterweight exhaust pipe

Lift Trucks With Overhead Exhaust System The muffler is installed inside the cavity of the counterweight. A long exhaust pipe, located above the overhead guard, sends the exhaust gases out of the lift truck.

Yanmar Diesel Engine Remove and Disassemble

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

1. On trucks equipped with overhead exhaust system, lift cover and remove three capscrews that attach the overhead exhaust pipe to counterweight. Remove clamp between overhead exhaust pipe and exhaust pipe (13 in Figure 41) and remove overhead exhaust pipe.

2. Remove the counterweight. See the section Counterweight Replacement for the removal procedures.

3. On lift trucks with overhead exhaust system, remove clamp that attaches exhaust pipe to muffler (13 in Figure 41). On lift trucks with counterweight exhaust system, remove clamp that attaches exhaust pipe to muffler (17 in Figure 41). Remove exhaust pipe.

4. Remove clamp that attaches the lower exhaust pipe to muffler. On lift truck models GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/GDP040SVX) (C810) the muffler is positioned vertically and lower exhaust pipe is on the bottom. On lift truck models GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875), the muffler is positioned horizontally and the lower exhaust pipe protrudes from the side (see Figure 41).

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and remove muffler from lift truck.

6. If lift truck is not equipped with a catalytic converter, remove four locknuts attaching engine exhaust pipe to engine exhaust manifold and remove engine exhaust pipe from engine manifold and lower exhaust pipe. Remove lower exhaust pipe.

If lift truck is equipped with a catalytic converter, remove clamps securing engine exhaust pipe and lower exhaust pipe to catalytic converter. Remove four locknuts attaching engine exhaust pipe to engine exhaust manifold and remove engine exhaust pipe from engine manifold and catalytic converter. Remove lower exhaust pipe from catalytic converter.

Inspect Inspect the following items in the exhaust system: • Inspect all exhaust pipes for damage, corrosion, and rust and replace as needed.

• If equipped, inspect all exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as needed. If replacing an exhaust pipe section that has a wrap, also replace the wrap. DO NOT reuse wraps if they have been removed for a service operation.

• Inspect the catalytic converter (if equipped) and muffler for damage, corrosion, and rust. Replace as needed.

Assemble and Install 1. Install engine exhaust pipe to engine exhaust manifold. Tighten locknuts to 22 N•m (195 lbf in).

2. If lift truck is equipped with a catalytic converter, install catalytic converter to engine exhaust pipe and lower exhaust pipe to catalytic converter using two clamps. If lift truck is not equipped with catalytic converter, install lower exhaust pipe to engine exhaust pipe with clamp.

3. Place muffler onto the frame of lift truck and install the washers, isolators, spacers, and capscrews to secure muffler to lift truck. Tighten capscrews to 22 N•m (195 lbf in).

4. Install lower exhaust pipe to muffler with clamp.

5. Install exhaust pipe (13 for overhead exhaust or 17 for counterweight exhaust in Figure 41) to muffler with clamp.

6. Install the counterweight. See the section Counterweight Replacement for installation procedures.

7. On trucks equipped with overhead exhaust system, insert overhead exhaust pipe in hole of counterweight. Attach overhead exhaust pipe to exhaust pipe and secure with clamp. Install and tighten three capscrews to 22 N•m (195 lbf in) to secure overhead exhaust pipe to counterweight. Cover capscrews with cover.

Legend for Figure 41 NOTE: Exhaust system for GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) lift trucks shown.

Overhead exhaust system for GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/GLP/ GDP040SVX) (C810) is similar.

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NOTE: Exhaust system with catalytic converter shown.

1. capscrew 2. washer 3. spacer 4. isolator 5. locknut 6. muffler 7. gasket 8. engine exhaust pipe 9. clamp 10. catalytic converter 11. sock 12. lower exhaust pipe 13. exhaust pipe 14. cover 15. overhead exhaust pipe 16. fastener* 17. counterweight exhaust pipe* 18. cover* *Items used only on counterweight exhaust system

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Figure 41. Exhaust System - Yanmar Diesel Engine

Mazda Gas and LPG Engines NOTE: The Mazda engines covered in this section are non-emissions compliant engines ONLY. For exhaust system repair procedures for Mazda 2007 emissions compliant engines and for lift trucks built after January, 2010, see LPG Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1326 or http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (88 of 102)05.04.2012 11:16:56

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Gasoline Fuel System, Mazda FE and F2Emission Compliant Engines 900 YRM 1325.

Remove and Disassemble

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

1. Lift cover and remove three capscrews that attach the overhead exhaust pipe to counterweight.

Remove clamp between overhead exhaust pipe and exhaust pipe (20 in Figure 42) and remove overhead exhaust pipe.

2. Remove the counterweight. See the section Counterweight Replacement for procedures.

3. Remove clamp that attaches exhaust pipe to muffler (20 in Figure 42). Remove exhaust pipe.

4. Remove bracket that attaches the catalytic converter to the frame. Disconnect the oxygen sensor.

5. Disconnect upper and lower exhaust pipes from catalytic converter and remove and discard the gaskets from catalytic converter. Remove catalytic converter from lift truck. See Figure 42.

6. Remove engine exhaust pipe from engine exhaust manifold.

7. Remove clamp securing exhaust pipe (8, in Figure 42) to muffler and remove pipe from muffler.

8. Remove the washers, isolators, spacers, and capscrews that fasten the muffler to the lift truck frame and remove muffler from lift truck.

Inspect Inspect the following items in the exhaust system: • Inspect all exhaust pipes for damage, corrosion, and rust and replace as needed.

• If equipped, inspect all exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as needed. If replacing an exhaust pipe section that has a wrap, also replace the wrap. DO NOT reuse wraps if they have been removed for a service operation.

• Inspect the catalytic converter and muffler for damage, corrosion, and rust. Replace as needed.

Assemble and Install 1. Install washers, isolators, spacer, and capscrews to secure muffler to lift truck frame. Tighten capscrews to 39 N•m (29 lbf ft).

2. Install the exhaust pipes (8 and 20, Figure 42) onto the muffler. Install the clamps on the pipes to hold them onto the muffler.

3. Install engine exhaust pipe to engine exhaust manifold using four locknuts. Tighten locknuts to 22 N•m (195 lbf in). See Figure 42.

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4. Use new gaskets and install catalytic converter to upper and lower exhaust pipes. Tighten nuts to 66 N•m (49 lbf ft).

5. Install the counterweight. See the section Counterweight Replacement for the installation procedures.

6. Insert overhead exhaust pipe in hole of counterweight. Attach overhead exhaust pipe to exhaust pipe and secure with clamp. Install and tighten three capscrews to 22 N•m (195 lbf in) to secure overhead exhaust pipe to counterweight. Cover capscrews with cover.

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Figure 42. Overhead Exhaust System - Mazda Gas and LPG Engines Legend for Figure 42 NOTE: Overhead exhaust system for GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) lift trucks shown. Overhead exhaust system for GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX, GP/ GLP/GDP040SVX) (C810) is similar.

1. capscrew 2. washer 3. spacer 4. isolator 5. locknut 6. muffler 7. clamp 8. upper exhaust pipe 9. nut 10. lockwasher 11. exhaust flange 12. gasket 13. catalytic converter 14. plug 15. copper ring 16. engine exhaust pipe 17. lower exhaust pipe 18. bracket 19. flange nut 20. exhaust pipe 21. overhead exhaust pipe 22. cover

Cooling System Description The cooling system is used to cool the engine and keep it at the correct operating temperature. The cooling system is comprised of the following main components: • Radiator • Fan and belt • Fan shroud • Coolant hoses and lines • Coolant reservoir For the procedures to repair, clean, inspect, and install the radiator and cooling system components, refer to Cooling System 700 YRM 1123.

Hydraulic Filter Assembly Repair Remove

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

CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Dirt can cause damage to the components of the hydraulic system.

Never operate they hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

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

1. Put lift truck on level surface and lower carriage.

2. Unscrew and remove lid and spring from head. Remove and discard O-ring from lid. See Figure 43.

NOTE: Have container large enough to hold filter element and allow for final hydraulic oil draining.

NOTE: Note placement of filter element and handle prior to removal to aid in installation.

3. Remove filter element and O-ring from bowl and place in container. Cover head to prevent any foreign material from getting into the hydraulic tank. See Figure 43.

4. After filter element has drained, discard filter element and O-ring.

5. Remove and discard O-ring from top of bowl. See Figure 43.

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1. Oring 2. spring 3. lid 4. head 5. quad ring

6. filter element 7. bowl 8. dipstick plug 9. filter housing 10. cover plate Figure 43. Hydraulic Filter

6. Remove and discard quad ring from head. See Figure 43.

Clean and Inspect 1. Clean housing and cover plate as necessary.

2. Inspect filter housing, especially sealing surfaces, for damage. Replace if damaged.

3. Inspect dipstick plug. Replace O-ring and plug as necessary.

Install 1. Lubricate sealing surfaces on filter housing and cover plate with clean hydraulic oil.

2. Lubricate new quad ring with clean hydraulic oil and install onto head. See Figure 43.

3. Lubricate new O-ring with clean hydraulic oil and install onto top of bowl. See Figure 43.

4. Lubricate new O-ring with clean hydraulic oil and install on bottom of new filter element. See Figure 43.

5. Install new filter element into bowl as noted during removal. See Figure 43.

6. Lubricate new O-ring with clean hydraulic oil and install on lid. See Figure 43.

7. Install spring and lid onto head. See Figure 43. Hand tighten lid.

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer.

8. Start lift truck, and allow it to run for 30 seconds. Check for leaks. Stop engine and check hydraulic oil level. Add oil, if necessary. Use hydraulic oil indicated in 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/ http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1120.html (94 of 102)05.04.2012 11:16:56

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GDP035VX, GP/GLP/GDP040SVX) (C810)

Fuel and Hydraulic Tanks Repair Inspect

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

• Safety in Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.

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

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer.

Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

Clean

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

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

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the pressure

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of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank.

Connect a ground wire to the tank to prevent static electricity.

Steam Method of Cleaning

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

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam.

Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug.

2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.

3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank.

4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings.

5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank.

6. Make an inspection of the inside of the tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors.

7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.

Chemical Solution Method of Cleaning

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

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

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

If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkaline base. Follow the instructions given by the manufacturer.

2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.

3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed.

4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 through Step 3.

Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors.

5. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

Additional Preparations for Repair If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.

2. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

Small Leaks, Repair Use the following procedure to repair small leaks: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.

Large Leaks, Repair

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1. Use one of the procedures described under Clean to clean and prepare the tank for repairs.

2. Contact your dealer for Yale lift trucks for welding instructions.

3. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

Preparations for Use After Repair 1. Add more water to the tank so that the water goes above the point of where the work was done. Check for any leaks coming from tank.

2. If there are no leaks coming from the tank, remove all the water from the tank.

Safety Labels WARNING Safety labels are installed on the lift truck to provide information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read.

DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped, and the nameplate must show the new capacity rating. Contact your dealer for a new nameplate.

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

NOTE: Not all labels that are used on the lift trucks covered in this manual are shown in Figure 44 and Figure 45. See the Parts Manual for a complete listing of all labels used on these lift trucks and their part numbers.

If a new label must be installed, use the following procedure to install a new label.

See Figure 44 for lift truck models • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) See Figure 45 for lift truck models • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) 1. Make sure the surface is dry and has no oil or grease. DO NOT use solvent on new paint. Clean the surface of old paint with a cleaning solvent.

2. Remove the paper from the back of the label. DO NOT touch the adhesive surface.

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