Yale D879 (GC GLC GDC135VX, GC GLC GDC155VX) Service Manual - PDF DOWNLOAD

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Service Manuals Manuals Available For D879 (GC/GLC/GDC135VX, GC/GLC/GDC155VX) Note: Service manuals do not contain serial number specific data.

Manual

Manual Title

Release Date

CUMMINS POWERTRAIN QSB3.3 - TROUBLESHOOTING AND REPAIR - BASE ENGINE QSB3.3 - TROUBLESHOOTING AND REPAIR - ELECTRONIC CONTROL SYSTEM QSB3.3 - WIRING DIAGRAM 0100YRM1316

FRAME

08-2011

0700YRM1123

COOLING SYSTEM

08-2011

GM POWERTRAIN 0100YRM1316

FRAME

08-2011

0600YRM1251

GM ENGINE REPAIR, V6, 4.3L ENGINE

07-2008

0700YRM1123

COOLING SYSTEM

08-2011

0900YRM1242

LPG FUEL SYSTEM (GM 4.3L)

08-2011

0900YRM1244

GASOLINE FUEL SYSTEM (GM 4.3L)

02-2010

0900YRM1556

LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI

08-2011

2200YRM1097

HIGH VOLTAGE SWITCH (HVS) IGNITION GM 4.3L EPA COMPLIANT ENGINES

06-2010

1300YRM1317

THREE-SPEED POWERSHIFT TRANSMISSION REPAIR

10-2010

1300YRM1343

TWO-SPEED POWERSHIFT TRANSMISSION REPAIR

10-2010

1400YRM1318

DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)

07-2008

1800YRM1247

BRAKE SYSTEM

09-2010

DRIVETRAIN

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Yale Axcess Online

HYDRAULICS 1600YRM1133

STEERING AXLE

07-2010

1900YRM1136

HYDRAULIC GEAR PUMP

07-2011

2000YRM1137

MAIN CONTROL VALVE

08-2011

2100YRM1328

CYLINDERS REPAIR

06-2010

4000YRM1250

MAST REPAIR

05-2011

2200YRM1128

WIRE HARNESS REPAIR

07-2011

2200YRM1130

USER INTERFACE - SUPERVISOR

06-2011

2200YRM1131

USER INTERFACE - SERVICE

06-2011

2200YRM1142

ELECTRICAL SYSTEM

08-2011

ELECTRICAL

REFERENCE MATERIAL 8000YRM0231

METRIC AND INCH (SAE) FASTENERS

12-2004

8000YRM1134

CALIBRATION PROCEDURES

09-2011

8000YRM1319

PERIODIC MAINTENANCE

08-2011

8000YRM1320

CAPACITIES AND SPECIFICATIONS

08-2011

8000YRM1387

DIAGRAMS AND SCHEMATICS

06-2011

8000YRM1409

DIAGRAMS AND SCHEMATICS

06-2011

DIAGNOSTIC TROUBLESHOOTING 9000YRM1112

DIAGNOSTICS TROUBLESHOOTING

©2011 Yale Axcess Online

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08-2011

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524288189-0100YRM1316-(08-2011)-US-EN

Frame GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879, D879]

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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.

• 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

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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, Dash, and Side Covers Replacement Remove Install Steering Column Description Steering Column Repair Remove Disassemble Clean Inspect Assemble Install LPG Tank and Bracket Replacement Remove LPG Tank LPG Tank Bracket Install LPG Tank Bracket LPG Tank Counterweight Replacement Remove Install Tow Pin, Remove and Install Overhead Guard Replacement Remove Install LED Tail, Backup, and Brake Lights, Replace Engine Replacement Remove Engine Only Install Engine only Remove Engine and Transmission Install Engine and Transmission Electronic Throttle Replacement Cummins 4.5L Diesel Engine With Electronic Throttle

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Remove Install Pull Actuator Linkage Adjustment Low Idle Adjustment Throttle Pedal and Cable Adjustment Cummins 4.5L Diesel Engine Exhaust System Repair GM 4.3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (C879, D879) Cummins QSB 3.3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) Remove Inspect Install Cummins 4.5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) Remove Inspect Install Cooling System Description Hydraulic Filter Assembly Repair Remove Disassemble Clean Inspect Assemble 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: GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,GC/GLC/GDC155VX) [C879, D879]

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

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

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure any blocks used to support the lift truck are solid, one-piece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck.

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, exhaust system, and LPG fuel tank and bracket are found in this section. Checks for the operator restraint system and procedures for the repair of tanks and installation of safety labels are also included.

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

There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights. See Table 2.

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.

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1. cowl plate 2. fenders 3. hood mounts 4. counterweight mounts 5. hydraulic tank 6. fuel tank (gas or diesel) Figure 1. Frame

Hood, Seat, Dash, and Side Covers Replacement Remove 1. Remove the floor mat and floor plate. See Figure 3.

2. Slide the seat to the closest position to the steering column.

3. Fully tilt the steering column forward.

4. If your truck is equipped with an LPG tank, swing the tank off to the side. Push in the bracket release pin, swing the tank and bracket out to the side of the lift truck. If your truck is equipped with a swing-out and drop-down LPG tank bracket (EZ Tank Bracket), swing the tank down to the side of the truck for ease of removal. See LPG Tank and Bracket.

5. Raise the hood latch, unlatch and lift up the hood. See Figure 2.

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6. Remove the two capscrews holding the left and right rear side panel to the frame. Remove the rear side panel from the frame. See Figure 3.

NOTE: Swivel seat and vented hood are optional features.

A. side view of hood and seat B. side view of hood C. bottom view of hood D. 3-D view of vented hood with swivel seat 1. seat 2. hood 3. frame 4. seat wire harness 5. seat wire harness connector 6. cable clips 7. hinge screws 8. gas spring 9. attachment holes attaching hood to seat (semi-suspension) 10. seat wire harness brackets 11. seat liner 12. hood latch http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1316.html (7 of 92)14.10.2011 14:58:43

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13. attachment holes attaching hood to seat (non-suspension) 14. attachment holes attaching hood to seat (full suspension) 15. Spacer 16. flange nuts Figure 2. Hood and Seat Arrangement

1. debris cover 2. Counterweight cover 3. radiator cover 4. left side rear panel (Gas and Diesel shown) 5. Right side rear panel 6. upper steering column cover 7. lower steering column cover

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8. seal 9. floor mat 10. floor plate 11. splash shield (Gas and diesel) 12. capscrew 13. fold over nut 14. seal plate assembly 15. right side front fender cover 16. right side step plate 17. right side step plate 18. dash assembly 19. Kick panel Figure 3. Side Covers, Floor Plate, and Cowl Components 7. Remove the two capscrews holding the left and right fender covers to the front overhead guard leg. Remove covers. See Figure 3.

8. Remove the four capscrews holding the left and right front side panels to the frame. Remove panels.

9. Fully lower the steering column.

10. Remove upper steering column cover by pulling up on upper steering column cover to release the latches (one on either side), and pulling cover away from steering column. See Figure 4.

11. Remove the five fasteners (see Figure 4) securing the dash to the top of the cowl. Remove the four clips, located underneath dash, that attach the dash to the kick panel. Lift to remove the dash.

12. Lift the kick panel to remove it from the truck. See Figure 3.

13. Remove the three capscrews holding the seal plate. Remove seal plate. See Figure 5.

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

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NOTE: Top view of dash shown.

A. Indicates to Pull up to unlatch 1. Allen screws 2. cowl 3. upper steering column cover 4. lower steering column cover Figure 4. Remove Dash From Cowl

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1. capscrews 2. seal plate Figure 5. Remove Seal Plate From Dash

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

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

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

16. Remove the four flange nuts holding the seat to the hood. Lift the seat off the hood. Pull the seat wire harness through the hood. See Figure 2.

17. Remove the capscrews and washers at the top of the gas springs. Remove gas springs from the hood. See Figure 2.

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

Install 1. Place the hood onto the lift truck frame.

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

3. Align the holes in the gas springs with holes in the hood. There are two sets of holes used to install the gas springs to the hood, based on the type of seat the installed on the lift truck. One set is for installing the cylinder end of the gas springs and the other set is for attaching the rod end of the gas springs. Install capscrews and washers to attach gas springs to the hood. Refer to Figure 6 and Table 1 for correct holes used to connect the rod end of the cylinder, depending on the type of seat installed on the lift truck.

Tighten capscrews to 19.2 N•m (170 lbf in).

NOTE: See Table 1 for holes to use to attach rod end of gas spring.

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D. non-suspension seat 1. mounting location for cylinder end of gas spring for non-suspension seat 2. mounting location for cylinder end of gas spring for semi or full suspension seat Figure 6. Gas Spring Installation Table 1. Gas Spring Installation, Holes for Installing Rod Ends (See Figure 6) Counterweight Type Standard Counterweight

Full or Semi Suspension Seat

Non-Suspension Seat

Left Side

Right Side

Left Side

Right Side

2

2

1

1

4. Install latch striker in highest slot position. Check that latch striker is in center of jaws of hood latch when hood closes. Open and close the hood to ensure that the center pin strikes the hood latch properly and that the stop screw contacts the frame. A properly closed hood MUST click twice on the hood latch. If the hood latch does not close properly, loosen the capscrews on the back of the center pin and adjust the center pin up or down as required for correct alignment. See Figure 7.

5. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood latch. Open hood and tighten capscrews for latch.

CAUTION When installing the seat to the hood, do not use an impact wrench to install the capscrews. Damage can be caused to the threads on the screws and in the holes.

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

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

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

9. Check operation of hood latch. Have an operator sit in the seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 5.

10. Using three capscrews, Install seal plate. See Figure 5.

11. Install kick panel onto truck. See Figure 3.

12. Install dash to top of cowl. See Figure 4. Install four clips to attach the dash to kick panel. Tighten capscrews to 0.5 to 0.6 N•m (5 to 6 lbf in).

13. Install upper and lower steering column covers by connecting the two covers together and pressing each side until latched.

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14. Using four capscrews, install the left and right front side panels to frame. See Figure 3.

15. Using two capscrews install the 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 the left and right rear side covers to frame. See Figure 3.

17. Install the floor mat and floor plate.

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

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.

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

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

CAUTION If a puller tool is used to remove steering wheel from steering column, be careful not to damage horn wires.

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

NOTE: Tag wires prior to disconnect.

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

4. Steering Column

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1. Horn Button 2. HEX Nut 3. Steering Wheel Figure 9. Steering Wheel Remove/Install 4. Remove steering column covers. Remove floor mats and floor plate. See section Hood, Seat, Dash, 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.

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 http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1316.html (18 of 92)14.10.2011 14:58:43

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Disassemble NOTE: Remove and discard snap rings if installed.

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

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

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

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

Clean

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

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

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

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

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

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

3. Replace all defective or damaged parts.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

6. Remove blocks from each side of tires.

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Figure 11. Steering Column Assembly Legend for Figure 11 1. PIN 2. LOWER SHAFT 3. Split Pin 4. UPPER SHAFT http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1316.html (21 of 92)14.10.2011 14:58:43

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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

LPG Tank and Bracket Replacement Remove LPG Tank

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

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

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

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

NOTE: The LPG tank bracket used on these trucks to mount the LPG tank onto the counterweight come in two styles. One style of bracket swings out tot he side of the truck and the other swings out to the side and drops down (EZ Tank Bracket). See Figure 12.

1. Turn the shutoff valve clockwise until the valve is completely closed.

2. Run the engine until it stops. If truck is equipped with a key switch, turn the key switch to the OFF position. If truck is equipped with a Power ON/OFF button, press the Power ON/OFF button to turn power off.

3. Disconnect the fitting on the LPG tank. See Figure 12.

4. Push in the bracket release pin, swing the tank and bracket out to the side of the lift truck. If your lift truck is equipped with a swing-out and drop-down LPG tank bracket (EZ Tank Bracket), swing the tank down tot he side of the truck for ease of removal. See Figure 12.

5. Unlatch the tank strap and remove the LPG tank from the bracket.

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A. swing-out lpg bracket B. swing-out and drop-down lpg bracket (EZ Tank Bracket) 1. lpg tank 2. tank strap 3. fitting 4. hydrostatic relief valve 5. manifold block 6. alignment pin 7. stop pin 8. bracket handle 9. bracket pivot 10. gas spring (drop-down bracket only) 11. bracket release pin (button) Figure 12. LPG Tank and Bracket

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NOTE: The LPG tank must be removed from the lift truck before removing the LPG bracket. See LPG Tank.

1. Disconnect the hose from the LPG fuel lock-off connection on the LPG regulator, and remove hose through hole in counterweight. See Figure 13.

WARNING When removing the capscrews for the LPG tank bracket, only remove the capscrew (1, Figure 14) with the LPG bracket in the swing-out or extended position. The LPG tank bracket is heavy and difficult to handle if all the capscrews are removed with the bracket in the swing-out position.

Personal injury and damage to the lift truck can result if the bracket is removed and handled while in the swing-out or extended position.

2. Remove capscrew (1, Figure 14) first, then remove rest of capscrews (2, Figure 14) that attach the LPG bracket to counterweight.

3. Remove the LPG tank bracket from the lift truck.

NOTE: EZ Tank Bracket™ shown.

A. side view of counterweight and lpg fuel system B. front view of counterweight and lpg fuel system 1. quick-disconnect connection 2. hose assembly 3. capscrew 4. hose assembly to lpg regulator/lock-off (through hole in counterweight) 5. mounting bracket 6. lpg regulator connection 7. lpg fuel filter http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1316.html (24 of 92)14.10.2011 14:58:43

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8. lpg regulator filter hose 9. LPG regulator 10. hose to intake manifold 11. coolant hoses 12. hose to fuel rail 13. tank strap 14. lpg tank bracket Figure 13. LPG Tank Hose Connections, GM 4.3L Engine

Install LPG Tank Bracket 1. Install and tighten three capscrews (2, Figure 14) to 38 N•m (28 lbf ft) to secure the LPG bracket onto the counterweight.

2. Install and tighten capscrew (1, Figure 14) to 38 N•m (28 lbf ft).

LPG Tank

WARNING When closing the LPG tank strap, do not wrap your fingers around the strap handle. The strap can close quickly and with enough force to cause injury to the fingers and hand.

NOTE: The LPG bracket must be in the swing-out position to install the LPG tank. If your lift truck has the swing-out and drop-down bracket (EZ Tank Bracket), position the bracket in the drop-down position.

1. Place the LPG tank into the bracket. Be sure the alignment pin on the bracket (see Figure 12) is properly aligned with the hole on the tank. Secure the tank strap around the tank and close the strap.

2. If lift truck is equipped with the swing-out and drop-down bracket (EZ Tank Bracket) raise bracket to the up position.

3. Pull the stop pin (see Figure 12) and swing the LPG tank bracket into the resting position on the counterweight. Be sure that the bracket locks into position.

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A. Lpg bracket - swing out option B. lpg bracket - swing out and drop down option (EZ Tank Bracket) 1. capscrew - remove with bracket in swing out (extended) position 2. capscrew - remove with bracket in resting position on counterweight.

Figure 14. LPG Tank Bracket Install

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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 1319.

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

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

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

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

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

NOTE: The counterweight is held in position on the frame by two hooks that are part of the frame. One M30 x 3.5 x 120 capscrew holds the counterweight to the lower part of the frame. See Figure 15.

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, use the procedures in the section LPG Tank and Bracket Replacement, to remove the LPG tank and bracket so that the counterweight can be removed.

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Additional information on the LPG fuel system can be found in the section LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 or LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556.

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in Table 2 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 2. Install a lifting eye in the lift hole of the counterweight. See Figure 15. 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 15. Use the crane to lift the counterweight from the lift truck. Put counterweight on the floor so that it has stability and will not fall over.

Take care not to damage exhaust or cooling components.

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1. frame hook 2. seals 3. capscrew 4. counterweight cover

5. counterweight 6. tow pin 7. roll pin 8. washer Figure 15. Counterweight Installation Table 2. Weight of Counterweights

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Model

Weight

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

2779 kg (6126 lb)

Install 1. Make sure the seals are on the counterweight. See Figure 16.

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 capscrew to 1020 N•m (750 lbf ft).

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

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

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. counterweight cover 3. counterweight 4. tow pin 5. roll pin 6. washer 7. seals Figure 16. Counterweight Components

Tow Pin, Remove and Install 1. Remove the tow pin from the counterweight by driving the roll pin out. See Figure 17.

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

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1. tow 2. roll pin pin Figure 17. Tow Pin

Overhead Guard Replacement Remove

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

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

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strength of the overhead guard.

See your dealer for 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 in 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 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 18.

2. Disconnect wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that electrical wires are moved through the holes in the overhead guard 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 the capscrews. See Figure 19.

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1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS Figure 18. Disconnect Air Intake Hose 4. Remove the fender cover, dash, and kick panel to remove the three capscrews on the front legs of the overhead guard. See Hood, Seat, Dash, and Side Covers Replacement for the removal procedures.

5. Using a lifting device, remove overhead guard from frame and place on floor.

Install 1. Connect lifting device to top of overhead guard. Install overhead guard in position on lift truck.

2. Install the three capscrews on the front legs of the overhead guard. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 19.

3. Install the fender cover, dash, and kick panel. See Hood, Seat, Dash, and Side Covers Replacement for the installation procedures.

4. Install the two capscrews on the rear legs of the overhead guard. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 19.

5. Connect air intake hose by installing bolts, elbow, retainer, and grommet to overhead guard rear leg.

See Figure 18.

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3. Bottom Coolant Hose 4. Air filter hose 5. Air Filter And Bracket 6. Exhaust Pipe To Exhaust Manifold 7. Engine Mounting Brackets 8. Fuel Lines 9. Engine Harness Connector 10. Brake Cooling Line 11. Hydraulic Supply Line 12. Transmission Mounting Bracket 13. Electronic Control Module 14. Right Hand Engine Harness 15. Hydraulic Return Line 16. Battery and Battery Tray 17. Battery Cable (Positive) 18. Battery Cable (Negative) 19. Fan Spacer and Fan Pulley 20. Charge Air Hose 6. Remove the hood and seat combination and rear side covers. See the section Hood, Seat, Dash, and Side Covers Replacement for procedures.

7. Loosen clamp and remove air filter hose from air inlet, located on left rear over head guard leg.

See Figure 21 for lift truck models equipped with GM 4.3L LPG Engine.

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

8. Remove the air filter, and bracket assembly.

See Figure 21 for lift truck models equipped with GM 4.3L LPG Engine.

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

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Figure 23. Cummins 4.5L Diesel Engine and Transmission Removal Legend for Figure 23 A. top view B. right side view

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C. left side view 1. right hand chassis harness connector 2. throttle cable 3. battery and battery tray 4. radiator cap 5. fuel lines 6. engine harness connector 7. left hand chassis harness connector 8. capscrew 9. isolators 10. washers 11. flange nuts 12. output yoke 13. transmission mount 14. engine mounts 15. air filter and bracket assembly 16. air filter hose 17. exhaust pipe to exhaust manifold 18. bottom radiator hose 19. coolant hoses 20. brake cooling lines 21. transmission bell housing 22. fan pulley and fan spacer 23. battery cable (Positive) 24. Battery cable negative 25. power distribution module (pdm) 26. transmission harness connector 27. shroud 28. fan 9. For lift trucks equipped with Cummins 4.5L diesel engine, disconnect throttle cable from fuel injection pump. See Figure 23.

NOTE: When disconnecting wiring harness connectors, tag each connector to aid in connecting wiring harness during installation.

10. On lift trucks equipped with GM 4.3L gasoline engine or Cummins 4.5L diesel engine, disconnect the left hand chassis harness connector from the engine harness connector. See Figure 21.

11. On lift trucks equipped with GM 4.3L LPG engine, disconnect the left hand chassis harness connector from the LPG regulator connector and engine harness connector.

12. On lift trucks equipped with GM 4.3L engine, disconnect the engine harness connectors from the electronic control module (ECM).

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

14. Disconnect the ground strap from the frame and remove the power distribution module (PDM) from the battery tray. See Figure 24.

15. For lift trucks equipped with QSB 3.3L and Cummins 4.5L diesel engines, remove battery from battery tray and remove three capscrews from battery tray. Remove battery tray.

16. For lift trucks equipped with GM 4.3L engine, remove the three capscrews from the battery tray and remove battery, battery tray, and electronic control module (ECM).

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1. battery 2. battery tray 3. pdm

4. battery lockdown bar 5. ground strap Figure 24. Power Distribution Module, Disconnection

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

See Figure 21 for lift truck models equipped with GM 4.3L LPG Engine.

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

18. Disconnect the exhaust pipes from the exhaust manifolds. See Exhaust System Repair for the http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1316.html (46 of 92)14.10.2011 14:58:43

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procedures.

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

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

No smoking.

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

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

See Figure 21 for lift truck models equipped with GM 4.3L LPG Engine.

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

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

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

23. Lift trucks equipped with GM 4.3L engine, remove starter motor to access the four torque converter access bolts. See Figure 21.

24. Lift trucks equipped with QSB 3.3L diesel engine, remove oil cooler to access the access port. See Yale Axcess Online.

25. Lift trucks equipped with QSB 3.3L diesel engine, remove bolts and cover to access the access port.

See Figure 27.

NOTE: Access port on QSB 3.3L Cummins engine is in the same location as the Cummins 4.5L engine.

26. Use the access port on engine and remove the bolts that attach the flywheel to the torque converter.

See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine.

See Figure 26 for lift trucks equipped with a Cummins 4.5L diesel engine.

See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L engine.

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1. Access Port 2. Engine Mounting bracket and hardware Figure 25. GM 4.3L Engine Removal Access Port

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1. access port 2. engine mounting bracket and hardware Figure 26. Cummins 4.5L Engine Access Port 27. Connect a lifting device to the engine. Put a block under the transmission housing to support the transmission.

28. Remove capscrews from transmission bell housing.

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See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

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

29. Remove the flange nuts, washers, bolts, and isolators from the engine mounts. See Figure 20 and Figure 28.

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1. access port 2. engine mounting bracket and hardware Figure 27. Cummins QSB 3.3L Engine Access Port

A. engine mounts for gm 4.3l B. engine mounts for cummins 4.5L C. engine mounts for cummins QSB 3.3L 1. engine mounts 2. capscrew 3. washer 4. isolator 5. flange nut 6. pin 7. crossmember 8. lock nut 9. flange bolt http://www.yaleaxcessonline.com/lib/service/US/EN/html/0100YRM1316.html (51 of 92)14.10.2011 14:58:43

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Figure 28. Engine Mounts Assembly

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.

30. 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.

Install Engine only

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

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

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

2. Align transmission bell housing to torque converter adapter.

See Figure 21 for lift truck models equipped with GM 4.3L LPG Engine.

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

3. For lift trucks equipped with GM 4.3L gas/LPG engine. If Isolators fell from the engine mounts during removal, install isolators on engine mounts and install washers, capscrews and flange nuts for the engine mounts to secure engine to the frame. Tighten flange nuts to 150 N•m (110 lbf ft). See Figure 21.

4. For lift trucks equipped with QSB 3.3L and Cummins 4.5L diesel engines. If Isolators fell from the engine mounts during removal, install isolators on engine mounts and install washers, capscrews and flange nuts for the engine mounts to secure engine to the frame. Tighten flange nuts to 320 N•m (236 lbf ft).

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

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5. Install capscrews to secure transmission bell housing to torque converter adapter. Tighten capscrews to 38 N•m (28 lbf ft).

6. Use access port on engine and install four bolts to hold torque converter to flywheel. Tighten bolts to 56 N•m (41 lbf ft).

7. For QSB 3.3L only, install cover and bolts to access port. See Figure 27.

8. Remove blocks from under the transmission and disconnect lifting device from engine.

9. Lift trucks equipped with QSB 3.3L diesel engine, install oil cooler. See Yale Axcess Online.

10. Lift trucks equipped with GM 4.3L engine, install starter motor. Tighten capscrews to 52 N•m (38 lbf ft).

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

12. Connect negative battery cable to starter motor.

13. Lift trucks equipped with GM 4.3L engine, install the left side engine mount on engine. Tighten capscrews to 90 N•m (66 lbf ft).

14. For lift trucks equipped with GM 4.3L engine, connect the exhaust pipes to the exhaust manifolds.

Tighten lock nuts to 39 N•m (29 lbf ft). See Figure 21.

15. For lift trucks equipped with QSB 3.3L and Cummins 4.5L diesel engines, connect the exhaust pipe to the exhaust manifold. Tighten lock nut to 22 N•m (16 lbf ft).

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

16. Remove caps from fuel lines and connect fuel lines at the engine.

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

18. Remove cap from bottom radiator hose and install hoses to radiator.

See Figure 21 for lift truck models equipped with GM 4.3L LPG Engine.

See Figure 22 for lift truck models equipped with Cummins QSB 3.3L Engine.

See Figure 23 for lift truck models equipped with Cummins 4.5L Diesel Engine.

19. For lift trucks equipped with QSB 3.3L and Cummins 4.5L diesel engines. Using three capscrews install battery tray and battery.

20. For Lift trucks equipped with GM 4.3L engine. Using three capscrews install battery tray, battery, and Electronic Control Module (ECM).

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21. Install Power Distribution Module on battery tray and connect ground strap to lift truck frame. See Figure 24.

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

See Figure 21 for lift trucks equipped with a GM 4.3L gas or LPG engine.

See Figure 23 for lift trucks equipped with a Cummins 4.5L diesel engine.

23. For lift trucks equipped with GM 4.3L engine, connect engine harness connectors to the electronic Control Module (ECM). See Figure 21.

24. For lift trucks equipped with GM 4.3L LPG engine, connect the left hand chassis harness connector to the LPG regulator connector and engine harness connector.

25. For lift trucks equipped with GM 4.3L (gasoline) engine and Cummins 4.5L diesel engine, connect the left hand chassis harness connector to the engine harness connector.

See Figure 21 for lift trucks equipped with a GM 4.3L gas or LPG engine.

See Figure 23 for lift trucks equipped with a Cummins 4.5L diesel engine.

26. For lift trucks equipped with Cummins 4.5L diesel engine, connect throttle cable to fuel injection pump.

See Figure 23.

27. Install air filter and bracket assembly.

28. Connect air filter hose to air inlet located on left rear over head guard leg and tighten clamp.

29. Install the hood and seat combination, and rear side covers. See the section hood Install for procedures.

30. Close drain plug and remove caps from remaining coolant hoses and connect hoses to radiator. Fill cooling system with antifreeze. See Cooling System 700 YRM 1123 for radiator fill procedures. Install radiator cap.

31. Check all fluid levels as described in the section Periodic Maintenance 8000 YRM 1319.

32. Connect positive battery cable to battery.

33. Connect negative battery cable to battery.

34. Install floor plate and floor mat.

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.

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1. TPS 2. TPS Rotor Figure 33. TPS Rotor 5. Remove the capscrews, nuts, and linkage assembly. See Figure 30.

6. If necessary, remove the capscrews and throttle lever adapter. See Figure 31.

7. Disconnect the engine harness electrical connector from the pull actuator harness connector. See Figure 34.

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1. Pull actuator 2. nut 3. lockwasher 4. clevis with linkage assembly 5. pull actuator harness connector Figure 34. Pull Actuator and Linkage Assembly 8. Remove the capscrews and pull actuator from mounting bracket. See Figure 35.

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1. mounting bracket 2. capscrew 3. fuel pump 4. pull actuator 5. foldover nut Figure 35. Pull Actuator Mounting 9. If necessary, remove the clevis with linkage assembly, lockwasher, and nut from the pull actuator. See Figure 34.

Install 1. Install the TPS rotor and throttle lever adapter. Tighten capscrews to 7.9 N•m (70 lbf in). See Figure 31.

2. Place the rod end of the linkage assembly on the top side of the throttle lever adapter and align the rod end hole with the hole on the throttle lever adapter. See Figure 36.

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1. throttle lever adapter 2. rod end

3. clevis 4. capscrew 5. nut

Figure 36. Rod End and Throttle Lever Alignment NOTE: When installing the TPS, rotate the sensor rotor clockwise to match D-shape on the TPS rotor. See Figure 37.

NOTE: The TPS mounting screws are non-magnetic stainless steel to avoid interference with the sensor magnet and must be reused if the TPS is replaced.

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3. Place the TPS in position and install Torx-head screws. Tighten Torx-head screws to 2.25 N•m (20 lbf in). See Figure 31.

1. sensor rotor 2. TPS 3. tps rotor 4. D-shape Figure 37. TPS and Rotor 4. Connect the TPS electrical connector.

5. Turn the lever clockwise to verify that the TPS does not bind or stick.

6. Place the pull actuator in position on the mounting bracket and install capscrews. Tighten to 38 N•m (28 lbf ft). See Figure 35.

7. Install the clevis with linkage assembly onto the threaded end of the pull actuator rod. Leave loose for adjustment. See Figure 34.

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8. Verify that the clevis is in the position shown in Figure 38. Adjust as needed.

9. Verify that the rod ends of the linkage assembly are parallel to each other. Adjust as needed. See Figure 38.

NOTE: DO NOT force the lever or pull actuator rod when installing.

10. Place the rod end on the top side of the throttle lever adapter and align the rod end hole with the hole on the throttle lever. Install capscrew and nut and tighten to 6.8 N•m (60 lbf in). See Figure 36.

11. Connect the pull actuator harness connector to engine harness connector. See Figure 34.

1. pull actuator 2. lock nut 3. clevis 4. Turnbuckle nut 5. turnbuckle 6. rod ends (must be parallel to each other) Figure 38. Linkage Assembly

Pull Actuator Linkage Adjustment 1. Check the low idle stop position to see if the throttle lever is in contact with the low idle stop. If

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adjustment is necessary, refer to Step 3. See Figure 39.

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

3. If the linkage adjustment is not providing enough range, remove capscrew and nut from clevis and rod ends. Lengthen or shorten the linkage by loosening the turnbuckle nuts to adjust the threaded length of the rod ends in the turnbuckle. Attach adjusted rod ends to clevis with capscrew and nut. Verify the lever contacts the low idle stop at the idle position, and the lever contacts the high idle stop at the high idle position. Verify that the lever rotates freely without sticking or binding. See Figure 39.

6. lock nut 7. adjusting screw(Low Idle) 8. rod ends

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1. tps 2. Low idle stop 3. turnbuckle nut 4. turnbuckle 5. clevis Figure 39. Low Idle and Pull Actuator Adjustment Location

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

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

1. Loosen lock nut. See Figure 39.

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

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

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

Cummins 4.5L Diesel Engine 1. Remove floor plate and disconnect throttle cable from the bellcrank and engine. See Figure 40.

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.). See Figure 40.

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 40.

5. With throttle pedal in full up position, adjust throttle cable, using the jam nuts (item #10 in Figure 40) 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.

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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. control lever Figure 40. Cummins 4.5L Throttle Pedal and Cable Adjustment

Exhaust System Repair GM 4.3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879)

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NOTE: For lift trucks with engine indicated above, see LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242, LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556, or Gasoline Fuel System, GM 4.3L Engine 900 YRM 1244.

Cummins QSB 3.3L Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) Remove NOTE: If the lift truck is equipped with the standard exhaust system, go to Step 6.

1. Remove the clamp attaching the overhead guard exhaust pipe to the lower overhead guard exhaust pipe. See Figure 41.

2. Remove the capscrews from the flange cover.

3. Remove overhead exhaust pipe and flange cover from the counter weight.

4. Remove the counterweight from the lift truck. See Counterweight Replacement.

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

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

7. Remove the turbo exhaust clamp.

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

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

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

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

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

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

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

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

• Muffler for damage, corrosion, and rust. Replace as needed.

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1. Overhead Exhaust Pipe 2. Flange Cover 3. Clamp 4. Muffler 5. Upper Tailpipe 6. Upper Tailpipe-Exhaust Wrap 7. Lower Header-exhaust Wrap 8. Lower Header-Exhaust Pipe 9. Bellow Pipe-exhaust Wrap 10. Bellow Pipe 11. Upper Header-Exhaust wrap 12. Upper Header-Exhaust Pipe 13. Turbo Exhaust Clamp 14. Turbo Manifold-Exhaust Wrap 15. Exhaust Mounting Bracket

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16. Lower Exhaust Pipe-Overhead 17. Capscrew 18. Exhaust Pipe Figure 41. Cummins QSB 3.3 Engine Exhaust System

Install 1. Connect the upper header exhaust pipe to the turbo manifold exhaust.

2. Connect the bellow pipe to the upper header exhaust pipe.

3. Connect the lower exhaust pipe to the bellow pipe.

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

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

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

7. Install the turbo exhaust clamps.

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

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

10. Install the counterweight to the lift truck. See Counterweight Replacement.

11. Install over head exhaust pipe and flange cover to the counterweight.

12. Install the capscrews to the flange cover 13. Install the clamp attaching the overhead guard exhaust pipe to the lower overhead guard exhaust pipe. See Figure 41.

Cummins 4.5L Diesel Engine for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/ GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Remove

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

NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 4. Lift trucks equipped with overhead exhaust follow Step 5 through Step 10.

1. Remove the counterweight before removing the muffler and other Components of the exhaust system.

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

2. Remove clamps that attach exhaust pipes (1 and 4, Figure 42) to muffler. Remove exhaust pipe (1, Figure 42) from muffler.

3. Remove exhaust pipe (4, Figure 42) from the engine exhaust manifold and remove exhaust pipe from muffler. Discard gasket.

4. Remove the washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame.

Remove muffler from lift truck frame.

NOTE: The exhaust pipe (13, Figure 42) must be removed before removing the counterweight and the other components of the exhaust system.

5. Remove the clamp that attaches the exhaust pipe (13) to the exhaust pipe (1). See Figure 42.

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

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

8. Remove clamps that attach exhaust pipes (1 and 4, Figure 42) to muffler.

9. Remove exhaust pipe (4, Figure 42) from the engine exhaust manifold and remove exhaust pipe from muffler. Discard gasket.

10. Remove the washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame. Remove muffler from lift truck frame.

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

• Exhaust pipe heat shields for damage. Replace as needed.

• Muffler for damage, corrosion, and rust. Replace as needed.

Install NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 4. Lift trucks equipped with overhead exhaust follow Step 5 through Step 10.

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

2. Connect exhaust pipes (1 and 4, Figure 42) to muffler and install clamps to attach exhaust pipes to muffler.

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to 22 N•m (195 lbf in).

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

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

6. Install new gasket and install exhaust pipe (4, Figure 42) to engine exhaust manifold. Tighten locknuts to 22 N•m (195 lbf in).

7. Connect exhaust pipes (1 and 4, Figure 42) to muffler and install clamp to attach exhaust pipe to the muffler.

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

9. Connect exhaust pipe (13, Figure 42) to exhaust pipe (1, Figure 42) and install clamp to attach exhaust pipe (13) to the exhaust pipe (1).

10. Install three flange bolts to secure the tail pipe to the counterweight and place flange cover over the flange bolts.

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1. exhaust pipe 2. clamp 3. muffler 4. exhaust pipe 5. locknut 6. gasket 7. washer 8. isolator 9. spacer 10. capscrew 11. flange bolt (Overhead Exhaust) 12. flange cover (Overhead exhaust) 13. exhaust pipe (Overhead exhaust) 14. Cover Figure 42. Cummins 4.5L Diesel Engine Exhaust System

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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

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 the hydraulic pumps without oil in the hydraulic system. The operation of the hydraulic pumps without oil will damage the pumps.

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

NOTE: When disconnecting the hydraulic hoses, note the location of the hoses to aid in installation.

1. Put lift truck on a level surface and lower the carriage. Disconnect hydraulic hoses and pressure sensor from the hydraulic oil filter assembly. Install caps and covers on hoses to prevent foreign matter from getting into the hydraulic system. Unscrew four capscrews from filter assembly. See Figure 43. Lift the hydraulic filter assembly enough to allow the hydraulic oil to drain from the assembly into hydraulic reservoir.

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

2. Remove the hydraulic filter assembly from the hydraulic reservoir and place into the container.

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1. Remove lid, spring, and O-ring from hydraulic filter assembly. Discard O-ring. See Figure 43.

2. Remove and discard filter and O-ring from hydraulic filter assembly. DO NOT allow dirt to enter the filter assembly or other hydraulic components.

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

4. Remove and discard O-ring from bowl assembly.

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1. lid 2. spring 3. o-ring 4. capscrew 5. head

6. fitting 7. quad ring 8. filter 9. bowl Figure 43. Hydraulic Filter Assembly

Clean

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

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

Use solvent to clean any accumulation of dirt or loose paint from all hydraulic filter assembly parts. Use a clean, lint-free cloth to dry parts prior to inspection.

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Assemble 1. Lubricate new O-ring with hydraulic oil and install, with bowl, on head. See Figure 43.

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

3. Lubricate new O-ring with hydraulic oil and seat in filter element. Install new filter element in hydraulic filter assembly.

4. Lubricate new O-ring with hydraulic oil and install O-ring, spring, and lid on hydraulic filter assembly.

Install 1. Install hydraulic filter assembly in hydraulic reservoir with four capscrews. Tighten capscrews to 19 N•m (168 lbf in). See Figure 43.

2. Connect the pressure sensor and hydraulic hoses to hydraulic filter assembly as noted during removal.

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

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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 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.

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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.

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

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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 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 give 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

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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 and Figure 45 for lift truck models • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 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.

3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure that all air is removed from under the label, and the corners and edges are tight.

1. ether warning label (Diesel only)

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2. lpg tank nameplate 3. rivet 4. flammable lpg label 5. fuel only label (Unleaded/diesel) 6. Yale logo plate 7. fastener 8. fan warning label 9. boron-free label 10. fan warning label 11. impact warning label 12. antifreeze label 13. hood opening label (LPG only) 14. swivel seat warning (Europe only) 15. parking brake warning label 16. joystick warning label 17. model label 18. operator restraint label 19. Yale label (Horizontal) 20. operator warning label 21. no riders label 22. mast warning label 23. inspection plate 24. pinch point label 25. Yale label (Vertical) 26. mast warning label Figure 44. Safety Label Position (Exterior)

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1. nameplate 2. rivet 3. cover 4. drive train protection label 5. standard powershift transmission LABEL 6. TECHTRONIX 332 TRANSMISSION 7. NAMEPLATE TAG 8. PATENTS AND TRADE MARKS LABEL 9. PARKING BRAKE WARNING LABEL 10. battery switch label Figure 45. Safety Label Position (Interior) for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/ GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879)

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Yale Materials Handling Corp.

1400 Sullivan Dr., Greenville, NC 27834-2011

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Cooling System 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]; GLC050LX [A967]; GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLP/GDP2025LX (GLP/GDP050LX) [A974]; GLC40, 45, 55VX; GLC55SVX (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) [E818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) [C879, D879]; GLP/GDP60VX, GLP/ GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) [A909]

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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.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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• 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 Cooling System Checks Exhaust Leaks Into Cooling System Water Flow Restrictions in Radiator Radiator Hoses Water Pump Flushing the Cooling System Cooling System, Clean Radiator Replacement Radiator, Remove for Lift Trucks 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); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); http://www.yaleaxcessonline.com/lib/service/US/EN/html/0700YRM1123.html (3 of 65)14.10.2011 15:11:50

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GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Radiator, Remove for Lift Truck Models GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/ GLC/GDC135VX) (C879, D879) Radiator, Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Radiator, Install 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); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Radiator, Install for Lift Truck Models GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/ GDC135VX) (C879, D879) Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Fan Assembly Replacement Fan Removal Inspect Fan Installation 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]; GLC050LX [A967]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLP/GDP20-25LX (GLP/GDP050LX) [A974]; GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) [E818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) [F813, G813]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879, D879]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) [A909]

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General This section contains the repair and replacement instructions for the radiator, coolant level sensor, fan assembly (pusher type), fan shroud, coolant hoses, coolant recovery bottle, and optional debris screen.

Cooling System Checks Exhaust Leaks Into Cooling System

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

To check for exhaust leaks into the cooling system, use a Combustion Leak Test Kit for this purpose. Follow the manufacturer’s instructions when doing the test.

Water Flow Restrictions in Radiator

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

To check for water flow restrictions in the radiator, run engine until it is warm.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.

Shut engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will be hotter near the top radiator hose.) Cold spots on radiator indicate restrictions.

If radiator has leaks, either replace the radiator or have it repaired by trained personnel.

Radiator Hoses

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system. http://www.yaleaxcessonline.com/lib/service/US/EN/html/0700YRM1123.html (5 of 65)14.10.2011 15:11:50

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Inspect all radiator hoses. If they feel spongy or have visible cracks, replace hoses.

Water Pump

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury.

Run engine until it is warm. Check the operation of water pump by holding the top radiator hose. If the pump is operating, there will be pressure surges in the hose.

Check for leaks around the timing belt cover near the base of the oil pump.

Check the weep hole where coolant that leaks past the water pump seal can be drained before reaching the water pump bearings. If there is a drip, check the pump shaft seal and water pump. Replacement of the pump shaft seal or water pump may be necessary.

For repair procedures for the GM 2.4L water pump, refer to the section GM Engine Repair, GM 2.4 Liter Engine 600 YRM 1121.

For repair procedures for the Mazda FE and F2 water pump, refer to the section Mazda Engine, FE and F2 600 YRM 1122.

For replacement procedures for the Yanmar 2.6L and 3.3L water pump, refer to the section Yanmar Diesel Engines, 2.6L and 3.3L 600 YRM 1205.

For replacement procedures for the GM 4.3L water pump, refer to the section GM Engines, 4.3 Liter V-6 600 YRM 1251.

For replacement procedures for the GM 5.7L water pump, refer to the section GM Engines, 5.7 Liter V-8 LPG 600 YRM 1432.

For repair procedures for the Cummins 4.5L and QSB 3.3L water pump, contact your local Yale dealer or see Yale Axcess Online.

Flushing the Cooling System Cooling System, Clean

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shield to prevent injury to the eyes.

WARNING The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while checking the radiator fins.

1. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.

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.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.

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

2. Drain cooling system. Fill cooling system with clean water. See sections below for more information: • Radiator, Remove for Lift Trucks 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); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/ GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) • Radiator, Remove for Lift Truck Models GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/ GDC135VX, GC/GLC/GDC135VX) (C879, D879) • Radiator, Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 3. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool.

4. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is clean.

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Follow the manufacturer’s instructions when using a chemical radiator cleaner.

5. If water does not clean system, use a chemical radiator cleaner.

CAUTION Follow the manufacturer’s instructions when using special equipment to reverse clean the radiator.

6. If radiator or cooling system is very dirty or has a restriction, use reverse cleaning method. This method uses water pressure to force water through radiator in opposite direction of normal flow.

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

7. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50 percent concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to −37°C (−35°F). Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

Radiator Replacement Radiator, Remove for Lift Trucks 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); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/ GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.

1. Turn OFF truck.

2. Remove the hood and seat combination.

See section Frame 100 YRM 1120 for lift truck models listed below: • 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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See section Frame 100 YRM 1243 for lift truck models listed below: • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) See section Frame 100 YRM 1423 for lift truck models listed below: • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)

WARNING Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so that no one connects the cables on the terminals.

3. Disconnect the negative battery cable.

4. Disconnect the positive battery cable.

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 lower hose.

7. Lift trucks equipped with a Cummins QSB 3.3L diesel engine: Loosen clamps and disconnect the charge air cooler hoses from radiator. See Figure 6.

8. Disconnect and cap radiator hoses.

9. Disconnect hose from reservoir and remove reservoir.

See Figure 1 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) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) http://www.yaleaxcessonline.com/lib/service/US/EN/html/0700YRM1123.html (9 of 65)14.10.2011 15:11:50

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See Figure 2 or Figure 3 for lift truck model • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818) See Figure 4 or Figure 5 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) See Figure 6 for lift truck models below equipped with a Cummins QSB 3.3L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813 • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) See Figure 7 for lift truck models below equipped with Yanmar 2.6L diesel engine • GDP20-25LX (GDP050LX) (A974) 10. Remove battery and battery tray.

11. If equipped, disconnect electrical connector to the coolant level sensor.

Legend for Figure 1 A. Radiator with external cooler B. Radiator With Internal Cooler, modine shown 1. radiator 2. cap 3. upper hose 4. lower hose 5. clamp 6. shroud 7. clip 8. washer 9. screw 10. clip 11. upper radiator bracket 12. capscrew, GC/GLC040-070VX, GC/GLC055SVX [A910] AND GLC050LX (a967) 13. insert 14. lower bracket, GC/GLC040-070VX, GC/GLC055SVX [A910] AND GLC050LX (a967) 15. nut-clip, GC/GLC040-070VX, GC/GLC055SVX [A910] AND GLC050LX (a967) 16. isolator 17. coolant LEVEL sensor 18. reservoir 19. tube 20. outlet ASSEMBLY 21. hose 22. reservoir outlet 23. cap 24. bushing 25. screen assembly (Optional) 26. heat shield 27. reservoir bracket 28. heat shield, GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875] AND GLP20-25LX (glp050LX) (A974)

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9. If necessary, disconnect electrical connector from the coolant level sensor.

10. Remove screws, washers, and clip nuts from the shroud and radiator and move shroud out of the way.

11. Remove fan. See Fan Removal procedures.

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.

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

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

13. Open drain plug, loosen clamps and disconnect the lower radiator hoses from radiator to allow coolant to drain into a suitable container. Install caps on hoses. See Figure 8.

14. Lift trucks equipped with a Cummins QSB 3.3L diesel engine: Loosen clamps and disconnect the charge air cooler hoses from radiator. See Figure 6.

15. Loosen clamp and disconnect remote refill hose from radiator. Install cap on hose.

NOTE: Tag the transmission lines before disconnecting from oil cooler.

16. Disconnect transmission lines from oil cooler. Install caps on transmission lines. Drain transmission oil from oil cooler into a suitable container. Install caps on the oil cooler ports.

NOTE: Removing the radiator from lift truck requires two people.

17. Remove radiator from lift truck frame.

18. If necessary, remove the coolant level sensor from radiator. See Figure 14.

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1. debris cover 2. counterweight cover 3. radiator cover 4. upper bracket 5. capscrews 6. remote fill hose 7. hose clamps

8. oil cooler 9. transmission oil cooler lines 10. fittings 11. upper hose 12. lower hose 13. remote fill 14. radiator cap

Figure 8. Radiator Removal for Lift Truck Models GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/ GDC135VX, GC/GLC/GDC135VX) (C879, D879)

Radiator, Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.

1. Turn off truck.

WARNING Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so that no one connects the cables on the terminals.

2. Disconnect the negative battery cable.

3. Disconnect the positive battery cable.

NOTE: Perform Step 4 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878).

4. Open hood and loosen clamp and disconnect inlet hose that attaches to the hood support. See Figure 15.

NOTE: Perform Step 5 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909).

5. Open hood, loosen clamp, and disconnect dirty air hose attached to hood support.

See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)

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See Figure 17 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 6. Lift trucks equipped with GM 4.3L (Gas/LPG) engine, loosen clamp and disconnect inlet hose from air filter and remove inlet hose. See Figure 15.

NOTE: Perform Step 7 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878).

7. Lift trucks equipped with the Cummins 4.5L or QSB 3.3L diesel engine loosen clamp and disconnect inlet hose from silencer. Remove silencer. See Figure 15.

NOTE: Before lifting the hood assembly from the lift truck frame, make sure to use a lifting device and lifting straps as shown in Figure 9. The hood assembly weighs approximately 45.6 kg (101 lb).

8. Remove hood assembly. For hood assembly removal procedures, see Frame 100 YRM 1321.

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1. pre- 2. strap cleaner clamp Figure 9. Hood Assembly Removal 9. Disconnect and cap auxiliary coolant reservoir hose. See Figure 15.

10. Remove capscrews from the auxiliary coolant reservoir bracket and upper bracket. Remove auxiliary coolant reservoir assembly.

11. Remove the four capscrews from the upper radiator bracket. Remove bracket.

12. If necessary, disconnect electrical connector from the coolant level sensor.

13. Remove screws, washers and clip nuts from the shroud and move shroud out of the way.

NOTE: Perform Step 14 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/ GLP/GDP155VX) (C878, D878).

14. Remove capscrews, washers, fan, fan spacer, and shroud. See Figure 15.

NOTE: Perform Step 15 for lift truck model GLP\GDP80VX, GLP\GDP80VX9, GLP\GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909).

15. Remove capscrews, washer, fan, fan spacers, and fan shroud.

See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) See Figure 17 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909)

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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.

16. Let coolant cool to ambient temperature. Place a drain pan with a capacity equal to or greater than the capacity of the cooling system under the radiator. Remove radiator cap.

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

17. Open drain plug or loosen clamp and disconnect lower radiator hose to allow coolant to drain.

See Figure 15 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) See Figure 17 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 18. Lift trucks equipped with a Cummins QSB 3.3L diesel engine, loosen clamps and disconnect the charge air cooler hoses from radiator. See Figure 6.

19. Disconnect and cap upper radiator hose.

NOTE: Tag the transmission lines before disconnecting from oil cooler.

20. Disconnect and cap transmission lines from oil cooler and allow transmission oil to drain from oil cooler into a suitable container, then cap the oil cooler ports.

21. For lift trucks equipped with GM 5.7L LPG engine, remove capscrews from baffles and remove baffles from radiator assembly. Remove capscrews securing cooling baffle to radiator assembly. See Figure 10.

NOTE: Removing the radiator from lift truck requires two people.

22. Remove radiator from lift truck frame.

23. If necessary, remove the coolant level sensor from radiator.

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1. baffle 2. isolator 3. upper bracket 4. cap 5. reservoir outlet 6. bushing 7. hose 8. reservoir 9. radiator 10. capscrew 11. shroud 12. clamp 13. upper hose 14. lower hose 15. seal 16. cooling baffle 17. drain hose 18. plastic tube Figure 10. GM 5.7L Cooling System, Lift Truck Models GLP80VX, GLP80VX9, GLP90VX (A909)

Radiator, Install 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); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) http://www.yaleaxcessonline.com/lib/service/US/EN/html/0700YRM1123.html (29 of 65)14.10.2011 15:11:50

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(E818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) 1. If removed, install the coolant level sensor.

2. Install radiator into truck.

3. Install upper radiator bracket.

4. Install fan, fan spacer, and pulley.

5. Install the radiator shroud.

6. If equipped, connect the electrical connector to the coolant level sensor.

NOTE: For Mazda LPG engine, the LPG converter bracket and screws must be installed to hold the converter.

7. Uncap radiator and reservoir ports and install the reservoir.

8. Connect the reservoir hose from reservoir to the radiator.

9. Lift trucks equipped with Cummins QSB 3.3L engine, uncap the charge air cooler hoses and connect the hoses to radiator. See Figure 6.

10. Uncap the upper hose and connect the hose to radiator.

11. Close the drain plug or install lower hose.

WARNING DO NOT use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

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

12. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to −37°C (−35°F).

13. Use the same coolant mixture and fill the reservoir between the ADD and FULL marks.

See Figure 11, 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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• GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) See Figure 12, for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)

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1. Reservoir 2. Add Mark 3. Full Mark Figure 11. Reservoir 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); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP/GDP20-25LX (GLP/GDP050LX) (A974)

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1. Auxiliary coolant reservoir 2. full "hot" Mark 3. Full "Cold" Mark 4. Add "cold" Mark Figure 12. Reservoir for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) and GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878), and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 14. Install battery and battery tray.

15. Connect the positive battery cable.

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16. Connect negative battery cable.

17. Install the hood and seat combination.

See section Frame 100 YRM 1120 for lift truck models listed below: • 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 section Frame 100 YRM 1243 for lift truck models listed below: • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) See section Frame 100 YRM 1423 for lift truck models listed below: • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury.

18. Start and run engine until thermostat opens. (The upper hose will be warm.)

19. On lift trucks equipped with a GM 2.4L engine, bleed air from the cooling system by opening the bleed screw located on the left side behind the alternator. When the air has been bled from the system close the bleed screw. See Figure 13.

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1. manifold 2. coolant hoses

3. bleed screw 4. radiator hose Figure 13. Bleed Screw, GM 2.4L Engine

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

20. Check coolant level at the reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

Radiator, Install for Lift Truck Models GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/

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GDC135VX, GC/GLC/GDC135VX) (C879, D879) 1. If necessary, install coolant level sensor.

NOTE: Installing the radiator into lift truck frame requires two people.

2. Install radiator into lift truck frame.

3. Remove caps from the oil cooler and transmission lines and connect lines into oil cooler. See Figure 8.

4. Uncap and connect remote refill hose onto radiator and tighten hose clamp. See Figure 8.

5. Close drain plug and uncap the upper and lower radiator hoses and connect hoses onto radiator and tighten hose clamp. See Figure 8.

6. Uncap the charge air cooler hoses and connect the hoses to radiator. See Figure 6.

7. Install fan. See Fan Installation procedures.

8. Align shroud to radiator and install two capscrews, washers and clip nuts. See Figure 14.

9. If necessary, connect electrical connector onto the coolant level sensor.

10. Install upper radiator bracket and four capscrews.

CAUTION The counterweight cover is extremely heavy 185 kg (408 lb). Make sure that the eyebolts and lifting device have sufficient capacity to lift the weight.

11. If removed, install two eyebolts in the hole on each end of the counterweight cover. Connect a suitable lifting device to the eyebolts and carefully install the counterweight cover into the lift truck frame.

See Figure 8.

12. Install two bolts to counterweights cover. Tighten to 38 N•m (28 lbf ft).

13. Install debris cover.

14. Install radiator cover.

15. Connect positive battery cable.

16. Connect negative battery cable.

WARNING DO NOT use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

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Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

17. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to −37°C (−35°F).

18. Install radiator cap.

19. Use the same coolant mixture and fill the reservoir between the ADD and FULL marks. See Figure 12.

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and cause serious injury.

20. Start and run the engine until thermostat opens (The upper radiator hose will be warm).

CAUTION Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

21. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

22. Shut down the engine for one minute or longer prior to checking the transmission oil level. If the transmission oil is low, add transmission oil, specified in Periodic Maintenance 8000 YRM 1319, to the transmission at the dipstick tube at the correct level indicated on the dipstick.

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A. Lower hose (cummins 4.5L diesel) B. Lower hose (Gas and LPG) C. Upper hose (gas and lpg) D. upper hose (cummins 4.5L Diesel) 1. radiator (with external oil cooler) 2. shroud 3. washer 4. screw 5. clip nut 6. clip spring 7. clamp 8. upper radiator bracket 9. capscrew 10. insert 11. isolator 12. reservoir 13. bracket (Coolant fill) 14. outlet assembly 15. outlet http://www.yaleaxcessonline.com/lib/service/US/EN/html/0700YRM1123.html (38 of 65)14.10.2011 15:11:50

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16. cap 17. bushing 18. hose 19. hose 20. remote fill hose 21. remote fill 22. radiator cap 23. screen 24. coolant level sensor 25. drain plug Figure 14. Cooling System for Lift Truck Models GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/ GDC135VX, GC/GLC/GDC135VX) (C879, D879)

Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 1. If necessary, install coolant level sensor.

NOTE: Installing the radiator into lift truck frame requires two people.

2. Install radiator into lift truck frame.

3. For lift trucks equipped with GM 5.7L LPG engine, use capscrews and install baffles to radiator assembly. See Figure 10. Use capscrews and attach radiator assembly to cooling baffle.

4. Install upper radiator bracket and four capscrews.

See Figure 15 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) See Figure 17 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 5. Install coolant reservoir bracket and coolant reservoir assembly onto upper bracket and tighten capscrews.

See Figure 15 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) See Figure 17 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 6. Uncap and connect auxiliary coolant reservoir hose and tighten clamp.

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8. Close drain plug and uncap the lower radiator hose and connect hose onto radiator and tighten clamp.

9. Uncap and connect upper radiator hose and tighten clamp.

10. Lift trucks equipped with Cummins QSB 3.3L diesel engine, uncap the charge air cooler hoses and connect the hoses to the radiator. See Figure 6.

11. Install fan. See Fan Installation procedures.

12. Align shroud to radiator and install capscrews, washers and clip nuts.

See Figure 15 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) See Figure 17 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 13. If necessary, connect electrical connector onto the coolant level sensor.

14. Lift truck equipped GM 4.3L (Gas/LPG) engine, install air intake hose to air filter and tighten clamp.

15. Lift trucks equipped with Cummins 4.5L or QSB 3.3L diesel engine, install silencer and connect hose from air filter side and tighten clamp. See Figure 15.

16. Lift trucks equipped with Cummins QSB 3.3L diesel engine and GM 5.7L LPG engine, connect dirty air hose to hood support and install and tighten clamp.

See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) See Figure 17 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909) 17. Install hood assembly. For hood install procedures, see section Frame 100 YRM 1321.

18. Lift truck equipped GM 4.3L (Gas/LPG) engine, open hood assembly and connect intake hose to hood support and tighten clamp. See Figure 15.

19. Lift trucks equipped with Cummins 4.5L or QSB 3.3L diesel engine, open hood assembly and connect hose to hood support and tighten clamp.

See Figure 15 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) See Figure 16 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)

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20. Connect positive battery cable.

21. Connect negative battery cable.

WARNING DO NOT use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTION Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

22. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to −37°C (−35°F).

23. Install radiator cap.

24. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and FULL marks. See Figure 12.

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and cause serious injury.

25. Start and run the engine until thermostat opens (The upper radiator hose will be warm).

CAUTION Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

26. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

27. Shut down the engine for one minute or longer prior to checking the transmission oil level. If the transmission oil is low, add transmission oil at the dipstick tube at the correct level indicated on the dipstick. See one of the following sections Periodic Maintenance 8000 YRM 1322 for lift truck models: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878/D878) Periodic Maintenance 8000 YRM 1407 for lift truck model: • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) http://www.yaleaxcessonline.com/lib/service/US/EN/html/0700YRM1123.html (41 of 65)14.10.2011 15:11:50

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(A909)

Figure 15. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) (Sheet 1 of 2)

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Figure 15. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) (Sheet 2 of 2) Legend for Figure 15 A. GM 4.3L (Gas/LPG)

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B. Cummins 4.5L (Diesel) 1. Air Intake (Without Pre-Cleaner) 2. Pre-cleaner 3. hood assembly 4. clamp 5. inlet hose 6. silencer (Diesel) 7. air filter 8. upper radiator bracket 9. isolator 10. insert 11. capscrew 12. radiator (With External oil cooler) 13. upper hose 14. lower hose 15. clip nut 16. washer 17. screw 18. shroud 19. fan 20. fan spacer 21. transmission lines 22. auxiliary coolant reservoir and bracket assembly 23. outlet 24. cap 25. bushing 26. hose 27. auxiliary coolant reservoir hose 28. drain plug 29. radiator cap 30. hood support

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1. pre-cleaner 2. clamp 3. hood support 4. hood assembly 5. dirty air hose 6. clean air hose 7. air filter 8. air cleaner bracket 9. capscrew 10. nut 11. auxiliary coolant reservoir hose 12. reservoir outlet 13. cap 14. bushing 15. coolant recovery reservoir 16. tube 17. coolant level sensor 18. upper bracket 19. radiator isolator 20. radiator 21. cac hose 22. cac tube 23. insulated clamp 24. lower radiator hose 25. upper radiator hose 26. shroud and baffle 27. washer 28. fan 29. spacer 30. auxiliary coolant reservoir assembly 31. clip nut Figure 16. Cooling System Cummins QSB 3.3L Diesel Engine for Lift Truck Model GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909)

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524223757-0700YRM1123-(08-2011)-US-EN

1. pre-cleaner 2. clamp 3. hood support 4. hood 5. dirty air hose 6. clean air hose 7. air filter 8. air cleaner bracket 9. capscrew 10. nut 11. radiator isolator 12. upper bracket 13. radiator 14. baffle 15. coolant recovery reservoir 16. lower radiator hose 17. upper radiator hose 18. seal 19. baffle 20. fan shroud 21. fan http://www.yaleaxcessonline.com/lib/service/US/EN/html/0700YRM1123.html (46 of 65)14.10.2011 15:11:50