GLC030-035VX, GLC040SVX (D809)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 550108490 0100 YRM 1735 12/14
PSI 2.0 LPG ENGINE...................................................................................................... 550108491 0600 YRM 1736 12/14
COOLING SYSTEM........................................................................................................ 550108492 0700 YRM 1737 12/14
LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14
PSI 2.0L LPG FUEL SYSTEM........................................................................................ 550108494 0900 YRM 1739 12/14
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550108495 1300 YRM 1740 12/14
DRIVE AXLE................................................................................................................... 550108496 1400 YRM 1741 12/14
STEERING AXLE............................................................................................................ 550108497 1600 YRM 1742 12/14
BRAKE SYSTEM............................................................................................................ 550108498 1800 YRM 1743 12/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
HYDRAULIC GEAR PUMPS.......................................................................................... 550108499 1900 YRM 1744 12/14
MAIN CONTROL VALVE................................................................................................ 550108500 2000 YRM 1745 12/14
CYLINDER REPAIR (MAST S/N B551, B555, B559).................................................... 550108501 2100 YRM 1746 12/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 550108502 2200 YRM 1747 12/14
ENGINE ELECTRICAL SYSTEM, PSI 2.0L ENGINE..................................................... 550108503 2200 YRM 1748 12/14
MAST REPAIR (S/N B551, B555, B559)........................................................................ 550108504 4000 YRM 1749 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 550108505 8000 YRM 1750 12/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550108506 8000 YRM 1751 12/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550108507 8000 YRM 1753 12/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

PART NO. 550108487 (12/14)

0100 YRM 1735
General
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or the
section Periodic Maintenance 8000YRM1750
General
NOTE: For lift trucks equipped with a PSI 2.0L LPG
engine, see PSI 2.0L LPG Fuel System
0900YRM1739 for procedures to remove and install
the exhaust system components. If lift truck is
equipped with a Yanmar 2.6L diesel engine, see
Exhaust System Repair in this manual for procedures.
This section contains the description of the frame (see
Figure 1) and connected parts. Procedures for
removing and installing the counterweight, hood,
overhead guard, engine and transmission, cooling
system, exhaust system (see NOTE above), and
other components attached to the frame are found in
this section. Checks for the operator restraint system
and procedures for the repair of tanks and installation
of safety labels are also included.
1
Description 0100 YRM 1735

Description
The frame is one weldment and includes the hydraulic The overhead guard, cowl, and hood are installed on
tank and fuel tank for gasoline or diesel fuel. See Fig- the frame. The hood is connected to the frame with
ure 1. hinges. Two gas-controlled springs provide assis-
tance when raising the hood and hold the hood in the
There is a counterweight for each capacity of lift truck. open position. The floor plate and side covers can be
The counterweights are similar in appearance, but are removed for access to the engine, transmission, and
different weights. See Counterweight Replacement other components.
section.

The muffler is fastened to the frame inside the coun-

terweight.

1. COWL PLATE 5. COUNTERWEIGHT MOUNTS

2. FENDERS 6. FUEL TANK (DIESEL)
3. FRAME 7. HYDRAULIC TANK
4. HOOD MOUNTS

Figure 1. Frame Components

2
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Hood, Seat, and Side Covers Replacement

REMOVE 7. Remove capscrews, washers, and left and right
rear side covers from frame.
1. Slide seat all the way to the rear of the hood.
8. For lift truck models GLP/GDP16-18VX, GLP/
2. Use tilt lever and tilt steering column all the way GDP20SVX (GLP/GDP030-035VX, GLP/
forward. See Figure 2. GDP040SVX) (D810), remove eight capcrews,
eight clip nuts, and left and right step covers from
frame. See Figure 6.

9. For lift truck models GLC030-035VX,

GLC040SVX (D809), remove six capscrews and
left and right step plates from frame. See Fig-
ure 6.

For lift truck models GLP/GDP16-18VX, GLP/

GDP20SVX (GLP/GDP030-035VX, GLP/
GDP040SVX) (D810), remove six capscrews, six
clip nuts, and left and right step plates from frame.
See Figure 6.

1. TILT LEVER
2. GAS CYLINDER

Figure 2. Steering Column Tilt Lever

3. If your truck is equipped with an LPG tank, swing

tank off to the side. See PSI 2.0L LPG Fuel Sys-
tem 0900YRM1739 for procedures.

4. Raise hood latch on the left, front corner of the

hood to unlatch and lift up hood. See Figure 3.

5. Disconnect the battery.

6. Remove floor mat and floor plate.

• See Figure 4 for lift truck models 1. HOOD LATCH

GLC030-035VX, GLC040SVX (D809) 2. HOOD
• See Figure 5 for lift truck models GLP/
Figure 3. Hood Latch
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)

3
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

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

4
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Legend for Figure 4

1. RADIATOR COVER 12. KICK PANEL

2. WASHER 13. FLOOR PLATE
3. CAPSCREW 14. GROMMET
4. RIGHT REAR COVER 15. SEAL PLATE
5. INSERT 16. LEFT STEP PLATE
6. LEFT REAR COVER 17. RIGHT STEP PLATE
7. LOWER STEERING COLUMN COVER 18. LEFT FRONT COVER
8. UPPER STEERING COLUMN COVER 19. RIGHT FRONT COVER
9. CLIP NUT 20. FLOOR MAT
10. DASH PANEL 21. CLIP
11. SEAL

5
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

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

6
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Legend for Figure 5

1. CAPSCREW 13. FUEL SHIELD (DIESEL)

2. WASHER 14. LEFT REAR COVER
3. INSERT 15. RIGHT REAR COVER
4. RADIATOR COVER 16. FLOOR PLATE
5. LOWER STEERING COLUMN COVER 17. FLOOR MAT
6. UPPER STEERING COLUMN COVER 18. RIGHT STEP COVER
7. CLIP NUT 19. LEFT STEP COVER
8. DASH PANEL 20. RIGHT FRONT COVER
9. KICK PANEL 21. LEFT FRONT COVER
10. GROMMET 22. RIGHT STEP PLATE
11. SEAL PLATE 23. LEFT STEP PLATE
12. SEAL 24. CLIP

7
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

Figure 6. Step Covers and Step Plates Remove/Install

8
0100 YRM 1735
Legend for Figure 6
NOTE: RIGHT SIDE SHOWN. PROCEDURES ARE THE SAME FOR LEFT SIDE.
A. STEP PLATE FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809)
B. STEP PLATE AND STEP COVER FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
1. STEP PLATE
2. CAPSCREW
3. RIGHT REAR COVER
10. Remove capscrews, washers, and left and right
front cover from frame.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
11. Use tilt lever and fully lower steering column. See
Figure 2.
12. Remove upper steering column cover by pulling
up on upper steering column cover to release
latches (one on either side), and pulling cover
away from steering column. See Figure 7.
13. Remove five fasteners securing dash to the top of
cowl. See Figure 7. Remove four clips, located
underneath dash, that attach dash to the kick
panel. Lift to remove dash.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
14. Lift kick panel and remove from truck.
15. Remove three capscrews and clip nuts from seal
plate. Remove seal plate from frame.
16. Remove two capscrews and washers from cover
plate and remove seat box. Disconnect seat wire
harness connector. See Figure 8.
Hood, Seat, and Side Covers Replacement
4. RIGHT STEP COVER
5. CLIP NUT
CAUTION
When removing the seat from the hood, DO NOT
use an impact wrench to remove the capscrews.
Damage can be caused to the threads on the
screws and in the holes.
NOTE: Before removing seat from hood, tag or mark
holes that mount seat to hood. This will aid in cor-
rectly installing seat to hood.
17. Remove four capscrews and washers attaching
seat to hood. Lift seat up and remove from hood.
18. Remove radiator cover and seals from lift truck
frame.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
19. Remove two capscrews and hood latch striker
bolt from mounting bracket. See Figure 9.
20. Remove two capscrews and hood latch from
hood. See Figure 9.
21. Remove capscrews and washers at the top of gas
springs. Remove gas springs from hood.
22. Remove hinge screws, located in the rear of the
hood. See Figure 10.
23. Remove hood from lift truck.
9
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH

1. FASTENERS 3. UPPER STEERING COLUMN COVER
2. COWL 4. LOWER STEERING COLUMN COVER

Figure 7. Remove Dash From Cowl

10
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

A. FULL SUSPENSION SEAT

B. SEMI- AND NON- SUSPENSION SEATS
1. CAPSCREWS
2. WASHERS
3. SEAT BOX
4. SEAT WIRE HARNESS CONNECTOR
5. COVER PLATE

Figure 8. Seat Wire Harness Connector

11
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

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

12
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Legend for Figure 9

A. HOOD LATCH AND HOOD LATCH STRIKER B. HOOD LATCH AND HOOD LATCH STRIKER
BOLT FOR LIFT TRUCK MODELS BOLT FOR LIFT TRUCK MODELS GLP/
GLC030-035VX, GLC040SVX (D809) GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
1. CAPSCREW (HOOD LATCH STRIKER BOLT) 5. HOOD LATCH
2. CAPSCREW (HOOD LATCH) 6. BUMPER
3. HOOD LATCH STRIKER BOLT
4. HOOD LATCH STRIKER BOLT MOUNTING
BRACKET

INSTALL • See Figure 11 and Table 1 for lift truck mod-

1. Place hood onto the lift truck frame.
2. Install hinge screws, located in the rear of the
hood, and tighten to 38 N•m (28 lbf ft). See Fig-
ure 10.
els GLP/GDP16-18VX, GLP/GDP20SVX
(GLP/GDP030-035VX, GLP/GDP040SVX)
(D810)
• See Figure 12 for lift truck models
GLC030-035VX, GLC040SVX (D809)

NOTE: LEFT SIDE SHOWN.

A. MOUNTING LOCATION FOR CYLINDER END

OF GAS SPRING FOR NON-SUSPENSION
SEAT
B. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR SEMI OR FULL SUS-
PENSION SEAT
C. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR SEMI OR FULL SUS-
1. HINGE SCREWS PENSION SEAT WITH CAB
2. HINGE
3. HOOD 1. MOUNTING POINTS FOR GAS SPRING ON
Figure 10. Hood Removal/Installation HOOD

Figure 11. Gas Spring Installation, Lift Truck

Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
3. Align top holes in the gas springs with holes in
GDP030-035VX, GLP/GDP040SVX) (D810)
hood. Install capscrews and washers to attach
gas springs to hood. Tighten capscrews to
19 N•m (170 lbf in).

13
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

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

Full or Semi-Suspension Seat Non-Suspension Seat

Frame Hood Frame Hood
Left Side Right Side Left Side Right Side Left Side Right Side Left Side Right Side
Seat B B 3 3 A A 1 1
Without E-
Control
Seat With B B 2 2 N/A N/A N/A N/A
E-Control
Cab C C 2 2 N/A N/A N/A N/A

the bolt strikes hood latch properly and that the

bumpers contact the frame. A properly closed
hood MUST click twice on the hood latch. If the
hood latch does not close properly, loosen cap-
screws on the back of hood latch striker bolt and
adjust bolt up or down as required for correct
alignment.

6. Push down until hood just touches rubber

bumper. Make sure latch striker is still in center of
hood latch. Open hood and tighten capscrews for
latch.

7. Check operation of hood latch. Have an operator

sit in seat. Make sure hood is fully closed (two
clicks). Also check that hood touches rubber
bumper. If necessary, repeat Step 6.

CAUTION
When installing the seat to the hood, DO NOT use
an impact wrench to install the capscrews. Dam-
NOTE: LEFT SIDE SHOWN. age can be caused to the threads on the screws
and in the holes.
1. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION
SEAT 8. Place seat on hood. Align holes in seat with holes
2. MOUNTING LOCATION FOR CYLINDER END in hood as noted during removal. Insert washers
OF GAS SPRING FOR SEMI OR FULL SUS- and capscrews. Tighten capscrews to
PENSION SEAT 18 N•m (159 lbf in).
Figure 12. Gas Spring Installation, Lift Truck
9. Install radiator cover and seals to frame.
Models GLC030-035VX, GLC040SVX (D809)
• See Figure 4 for lift truck models
4. Install hood latch to hood using two capscrews. GLC030-035VX, GLC040SVX (D809)
See Figure 9. • See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
5. Install latch striker bolt in highest slot position on GDP030-035VX, GLP/GDP040SVX) (D810)
mounting bracket. See Figure 9. Check that latch
striker bolt is in center of jaws of hood latch when
hood closes. Open and close hood to ensure that

14
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

10. Connect seat wire harness. Install seat box to 16. For lift truck models GLC030-035VX,
cover plate with two capscrews and washers. GLC040SVX (D809), install left and right step
Tighten capscrews to 1.2 N•m (10.6 lbf in). See plates, and six capscrews to frame. See Figure 6.
Figure 8.
For lift truck models GLP/GDP16-18VX, GLP/
11. Install seal plate using three capscrews and clip GDP20SVX (GLP/GDP030-035VX, GLP/
nuts. GDP040SVX) (D810), install left and right step
plates, six clip nuts, and three capscrews onto
12. Install kick panel onto truck. frame. See Figure 6.
• See Figure 4 for lift truck models 17. For lift truck models GLP/GDP16-18VX, GLP/
GLC030-035VX, GLC040SVX (D809) GDP20SVX (GLP/GDP030-035VX, GLP/
• See Figure 5 for lift truck models GLP/ GDP040SVX) (D810), install left and right step
GDP16-18VX, GLP/GDP20SVX (GLP/ covers, eight clip nuts, and eight capscrews onto
GDP030-035VX, GLP/GDP040SVX) (D810) frame. See Figure 6.

13. Install dash to top of cowl. See Figure 7. Install 18. Install left and right rear covers, washers and cap-
four clips to attach the dash to kick panel. screw onto frame.

14. Install upper steering column cover to dash. 19. Install floor mat and floor plate.

15. Install left and right front covers, washers, and
capscrews onto frame.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
20. If truck is equipped with an LPG tank, swing LPG
tank into position on back of counterweight. See
PSI 2.0L LPG Fuel System 0900YRM1739 for
procedures.
21. Connect the battery.
22. Adjust the steering column and seat positions.

15
Steering Column
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 steer-
ing wheel and the steering control unit. The steering
column includes the steering wheel, housing, bracket
and lower shaft. For lift truck models GLC030-035VX,
GLC040SVX (D809), capscrews and bushings attach
the steering column to the cowl standoffs. For lift truck
models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810), cap-
screws, bushings and isolators attach the steering
column to the cowl standoffs. See Figure 13.
STEERING COLUMN REPAIR
Remove
1. Put blocks on each side (front and back) of tires
to prevent lift truck from moving.
WARNING
Disconnect the battery before removing any cov-
ers to avoid injury to personnel.
1. STEERING WHEEL
2. STEERING COLUMN
3. COWL
Figure 13. Steering Column and Cowl
16
0100 YRM 1735
2. Attach a tag on the battery connector or negative
battery cable stating, DO NOT CONNECT BAT-
TERY. Move the steering column to the most for-
ward 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 com-
ponents of the steering column assembly. Not all
components are removed for a repair procedure. Do
only those steps of the procedure necessary to re-
move the required component.
NOTE: Tag wires prior to disconnecting them.
3. Remove the horn button assembly and discon-
nect electrical wires. Remove large hex nut and
steering wheel from steering column. See Fig-
ure 14.
4. Remove steering column covers. Remove floor
mats and floor plate. See Hood, Seat, and Side
Covers Replacement section for procedures.
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
Figure 14. Steering Wheel Remove/Install
0100 YRM 1735 Steering Column

NOTE: Perform Step 5 for lift trucks GLC030-035VX,
GLC040SVX (D809).
5. Remove four capscrews, four bushings, and
steering column from cowl standoffs. See Fig-
ure 15.
NOTE: Perform Step 6 for lift trucks GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
6. Remove four capscrews, four bushings, four iso-
lators, steering column, and four isolators from
cowl standoffs. See Figure 15.

NOTE: STEERING COLUMN FOR LIFT TRUCKS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/GDP030-035VX,

GLP/GDP040SVX) (D810) SHOWN. STEERING COLUMN FOR LIFT TRUCKS GLC030-035VX, GLC040SVX
(D809) IS SIMILAR.
1. CAPSCREW 4. STEERING COLUMN
2. BUSHING 5. COWL STANDOFF
3. ISOLATOR

Figure 15. Steering Column Remove/Install

17
Steering Column
Disassemble
NOTE: Remove and discard snap rings if installed.
1. Remove two pins and gas spring from housing.
See Figure 16.
2. Remove two pivot bolts, two bushings, two nuts
and bracket from housing.
3. Remove split pin and lower shaft from upper
shaft. See Figure 16.
4. Remove connector from connector bracket. Re-
move connector bracket, fastener, four screws
and two horn contacts from housing.
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufac-
turer’s recommended safety precautions.
WARNING
Compressed air is used for cleaning and drying
purposes, or for cleaning restrictions. Wear pro-
tective 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.
18
0100 YRM 1735
Assemble
NOTE: This procedure is for the installation of all
components of the steering column assembly. Not all
components are removed for a repair procedure. Do
only those steps of the procedure necessary to install
the required component.
1. Install fastener, connector bracket and connector,
two horn contacts, and four screws. See Fig-
ure 16.
2. Assemble lower shaft and upper shaft, secure
with spit pin.
3. Install two pivot bolts, two bushings, two nuts and
bracket onto housing. See Figure 16.
4. Install gas spring and two pins on housing. See
Figure 16.
Install
NOTE: Lubricate spline end of lower shaft with multi
purpose grease. See Periodic Maintenance
8000YRM1750 for procedures.
NOTE: Perform Step 1 for lift trucks GLC030-035VX,
GLC040SVX (D809).
1. Install steering column, four bushings and four
capscrews on cowl standoffs. Tighten capscrews
to 38 N•m (28 lbf ft). See Figure 15.
NOTE: Perform Step 2 for lift trucks GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810).
2. Install four isolators, steering column, four isola-
tors, four bushings, and four capscrews on cowl
standoffs. Tighten capscrews to 38 N•m (28 lbf ft).
See Figure 15
3. Install floor plate, floor mats, and steering column
covers. See Hood, Seat, and Side Covers Re-
placement section for procedures.
4. Install steering wheel and hex nut on steering col-
umn, tighten hex nut to 40 to 54 N•m (30 to
40 lbf ft). Connect electrical wiring and install horn
button. See Figure 14.
0100 YRM 1735 Steering Column

5. Remove tag from negative battery connector and 6. Remove blocks from each side of tires.
connect to battery. Adjust steering column to neu-
tral position.

1. BRACKET 9. PIN
2. SPACER 10. LOWER SHAFT
3. JOINT 11. GAS SPRING
4. NUT 12. BOLT
5. WASHER 13. BUSHING
6. SCREW 14. CONNECTOR
7. UPPER SHAFT 15. FASTENER
8. HOUSING 16. HORN CONTACT
Figure 16. Steering Column Assembly

LPG Tank and Bracket Assembly

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

19
Counterweight Replacement 0100 YRM 1735

Counterweight Replacement
REMOVE unit. Permit the pressure in the fuel system to de-
crease slowly. Fuel leaving the fitting removes
heat. Use a cloth to protect your hands from the
WARNING cold fitting.
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of NOTE: The counterweight is held in position on the
the following assemblies will cause large changes frame by two hooks that are part of the frame. See
in the center of gravity: mast, drive axle, engine Figure 17.
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in One M24 × 3 x 90 capscrew holds the counterweight
the following positions to maintain stability: to the lower part of the frame. See Figure 17.
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.

The surface must be solid, even, and level when

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

WARNING
DO NOT operate the lift truck if the capscrew for
the counterweight is not installed. When the cap-
screw 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.
NOTE: COUNTERWEIGHT FOR LIFT TRUCK MOD-
ELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810) SHOWN.
COUNTERWEIGHT ARRANGEMENT FOR LIFT
TRUCK MODELS GLC030-035VX, GLC040SVX
(D809) IS SIMILAR.

Close the shutoff valve on the LPG tank before 1. FRAME HOOKS
any part of the engine fuel system is disconnec- 2. COUNTERWEIGHT SEAL
3. CAPSCREW (M24 × 3 X 90)
ted. Run the engine until the fuel in the system is 4. TOW PIN
used and the engine stops. 5. COUNTERWEIGHT
If the engine will not run, close the shutoff valve Figure 17. Counterweight Arrangement
on the LPG tank. Loosen the fitting on the supply
hose from the LPG tank where it enters the filter

20
0100 YRM 1735 Counterweight Replacement

1. If lift truck is equipped with an overhead exhaust The approximate weights of the counterweight
system, remove the overhead exhaust pipe be- castings are shown in:
fore removing the counterweight.
Table 2 for lift truck models
If lift truck is equipped with an LPG fuel system, • GLC030-035VX, GLC040SVX (D809)
see PSI 2.0L LPG Fuel System 0900YRM1739 for
procedures to remove the overhead exhaust pipe. Table 3 for lift truck models

If lift truck is equipped with a diesel fuel system,
see Exhaust System Repair in this manual for pro-
cedures to remove the overhead exhaust pipe.
2. If the lift truck has an LPG fuel system, see PSI
2.0L LPG Fuel System 0900YRM1739 to remove
the LPG tank and bracket, before removing the
counterweight, and for additional information on
the LPG fuel system.
WARNING
The counterweight is heavy. Make sure that the
eyebolt and lifting devices have enough capacity
to lift the weight.
• GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
3. Install a lifting eye in the lift hole of the counter-
weight. See Figure 18. Connect a crane to the lift-
ing eye and raise the crane until it holds part of
the weight of the counterweight. Remove the tow
pin and remove the capscrew and washer that
hold counterweight to frame. Use crane to lift
counterweight from lift truck. Put counterweight on
the floor so that it has stability and will not fall
over. Take care not to damage exhaust or cooling
components.

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

Model Kg Lb
GLC030VX 772 1702
GLC035VX 963 2123
GLC040SVX 1131 2493

Table 3. Weight of Counterweights, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/

GDP030-035VX, GLP/GDP040SVX) (D810)

Model Kg Lb
GLP/GDP16VX (GLP/GDP030VX) 813 1792
GLP/GDP18VX (GLP/GDP035VX) 887 1955
GLP/GDP20SVX (GLP/ 1047 2308
GDP040SVX)

21
Counterweight Replacement 0100 YRM 1735

INSTALL
1. Make sure the seals are on the counterweight.
See Figure 18.

2. Use a crane to install the counterweight on the lift

truck. When the counterweight is installed, make
sure the hooks on the frame (see Figure 17) fully
engage the counterweight so it is aligned with the
parts of the frame. Install and tighten the M24 × 3
x 90 capscrew to 555 N•m (409 lbf ft).

3. Install tow pin. See Tow Pin Remove and Install

for procedures.

4. If lift truck has an LPG fuel system, see PSI 2.0L

LPG Fuel System 0900YRM1739, to install LPG
tank and bracket, after counterweight has been
installed.

5. If lift truck is equipped with an overhead exhaust

system, install the overhead exhaust pipe.

If lift truck is equipped with an LPG fuel system,

see PSI 2.0L LPG Fuel System 0900YRM1739 for
procedures to install the overhead exhaust pipe.
If lift truck is equipped with a diesel fuel system,
see Exhaust System Repair in this manual for pro-
cedures to install the overhead exhaust pipe.
NOTE: COUNTERWEIGHT AND COMPONENT
PARTS FOR LIFT TRUCK MODELS GLC030-035VX,
GLC040SVX (D809) SHOWN. COUNTERWEIGHT
AND COMPONENT PARTS FOR LIFT TRUCK MOD-
ELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810) ARE
SIMILAR.

1. CAPSCREW
2. WASHER
3. COUNTERWEIGHT
4. LIFT HOLE
5. LIFTING EYEBOLT
6. TOW PIN
7. LPG ACCESS HOLE
8. COUNTERWEIGHT SEAL

Figure 18. Counterweight Component Parts

22
0100 YRM 1735 Counterweight Replacement

TOW PIN REMOVE AND INSTALL

1. To remove the tow pin, pull up on the wire loop
that is attached to the D-Ring, and pull tow pin out
of counterweight. See Figure 19.

2. To install the tow pin, insert it through the hole in

the counterweight. See Figure 19.

1. TOW PIN
2. D-RING
3. WIRE LOOP
4. TOW PIN HOLE

Figure 19. Tow Pin

23
Overhead Guard Replacement 0100 YRM 1735

Overhead Guard Replacement

REMOVE AND INSTALL
WARNING
DO NOT operate the lift truck without the over-
head guard correctly fastened to the lift truck.
WARNING
DO NOT weld mounts for lights or accessories to
legs of the overhead guard. Changes that are
made by welding, or by drilling holes that are too
big or in the wrong location, can reduce the
strength of the overhead guard.
Remove and install the capscrews. See Fig-
ure 21.
4. Remove fender cover, dash, and kick panel to re-
move and install the three capscrews on front
legs of overhead guard. See Hood, Seat, and
Side Covers Replacement for removal proce-
dures.
5. When installing the overhead guard, tighten the
capscrews for the overhead guard legs to
66 N•m (49 lbf ft). See Figure 21.

See your dealer for Yale lift trucks BEFORE per-

forming any changes to the overhead guard.

NOTE: The lift trucks covered in this manual are

equipped with either a high or low overhead guard.
The removal and installation procedures for both
types of overhead guards are the same.

No welding or drilling on legs of overhead guard is

permitted as per previous WARNING.

NOTE: The lifting device can be connected to any

number of positions on the overhead guard depend-
ing upon the lifting device available. The ideal choices
are a four point sling connected to all four corners on
the top of the overhead guard, or a two point sling
connected to two opposite corners of the overhead
guard. If a single point hoist is used, make sure that
the lift point is as close to the center of the overhead
guard. If during the initial start of the lift the overhead
guard is off balance lower immediately and move the
hoist to a more centered point.

1. Connect a lifting device to remove or install the

overhead guard. Loosen clamp and disconnect
the air intake hose from the elbow. Remove bolts,
elbow, retainer, and grommet from the overhead
guard rear leg. See Figure 20. 1. CLAMP
2. AIR INTAKE HOSE
3. BOLTS
2. Disconnect any wires between the frame and the 4. ELBOW
overhead guard. When the overhead guard is lif- 5. RETAINER
ted from the frame, make sure that any electrical 6. GROMMET
wires are moved through the holes in the frame
so that they are not damaged. Figure 20. Disconnect Air Intake Hose

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.

24
0100 YRM 1735 Overhead Guard Replacement

LED TAIL, BACKUP, AND BRAKE

LIGHTS, REPLACE
These light assemblies are nonrepairable and must
be replaced as an assembly. See section Electrical
System 2200YRM1747 for procedures to replace
these lights.

1. CAPSCREWS (FRONT LEGS)

2. CAPSCREWS (REAR LEGS)
3. HANDLE
4. FRAME
5. REAR LEG
6. FRONT LEG

Figure 21. Overhead Guard

25
Operator Restraint System Replacement 0100 YRM 1735

Operator Restraint System Replacement

DESCRIPTION
The seat belt, hip restraint brackets, seat and mount-
ing, hood, and latches are all part of the operator re-
straint system. Each item must be checked to make
sure it is attached securely, functions correctly, and is
in good condition. See Figure 22.
nism. If the truck tips, travels off a dock, or comes to a
sudden stop, the locking mechanism will be activated
and hold the operator’s lower torso in the seat.
A seat belt that is damaged worn or does not operate
properly will not provide protection when it is needed.
The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the
seat belt if damage or wear is seen. See Figure 22
and Figure 23.

NOTE: The following seat belt operation checks must

be performed three times before replacing the seat
belt assembly:
• With the hood closed and in the locked posi-
tion, pull the seat belt slowly from the retractor
assembly. Make sure the seat belt pulls out
and retracts smoothly. If the seat belt cannot
be pulled from the retractor assembly or the
belt will not retract, replace the seat belt as-
sembly.
• With the hood closed and in the locked posi-
tion, pull the seat belt with a sudden jerk. Make
sure the seat belt will not pull from the retractor
assembly. If the seat belt can be pulled from
the retractor, when it is pulled with a sudden
1. HOOD LATCH STRIKER BOLT jerk, replace the seat belt assembly.
2. HOOD LATCH • With the hood in the open position, make sure
3. HOOD the seat belt will not pull from the retractor as-
4. SEAT RAILS
5. HIP RESTRAINT sembly. If the seat belt can be pulled from the
6. SEAT BELT retractor, with the hood in the open position, re-
7. SEAT place the seat belt assembly.
8. HOOD HINGE
Figure 22. Operator Restraint System Make sure the seat rails and latch striker are not
loose. The seat rails must lock securely in position but
move freely when unlocked. The seat rails must be
EMERGENCY LOCKING RETRACTOR securely attached to the mounting surface. The hood
(ELR) must be fully closed. Lift the hood to make sure it is
closed and will not move. See Figure 22.
NOTE: The lift truck models covered in this manual
are equipped with the ELR type seat belts. See Fig- Adjust hood, hood latch, and hood latch striker bolt
ure 22 and Figure 23. when any of the parts of the operator restraint system
are installed or replaced. See the section Hood, Seat,
When the ELR style seat belt is properly buckled and Side Covers Replacement in this manual for ad-
across the operator, the belt will permit slight operator justment procedures for the hood.
repositioning without activating the locking mecha-

26
0100 YRM 1735 Operator Restraint System Replacement

A. STANDARD, NON-SUSPENSION SEAT C. SEMI-SUSPENSION SEAT

B. FULL SUSPENSION SEAT
1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 6. HIP RESTRAINT
3. RIDE POSITION INDICATOR 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER

Figure 23. Seat Adjustment Controls

27
Engine Replacement
Engine Replacement
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or Peri-
odic Maintenance 8000YRM1750.
WARNING
Always disconnect the cables at the battery be-
fore you make repairs to the engine. Disconnect
the cable at the negative terminal first.
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
from any open flame, motor vehicles, electrical
equipments, or ignition source.
1. If lift truck is equipped with an LPG fuel system,
close the shutoff valve on the tank and run engine
until all fuel is gone and engine stops. Swing LPG
tank to side of lift truck. See PSI 2.0L LPG Fuel
System 0900YRM1739 for procedures.
28
0100 YRM 1735
2. Remove overhead guard. See Overhead Guard
Replacement section for procedures.
3. Remove floor mat and floor plate.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the sys-
tem. If the system is hot, the steam and boiling
coolant can cause burns.
4. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the ca-
pacity of the cooling system under radiator. Re-
move radiator cap. See Periodic Maintenance
8000YRM1750 for coolant capacity.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
5. Open drain plug or disconnect the bottom radiator
hose to drain coolant from radiator and engine.
6. Remove hood and seat combination and rear side
covers. See section Hood, Seat, and Side Covers
Replacement for procedures.
7. Disconnect the ground strap from the frame and
remove the Power Distribution Module (PDM)
from battery tray. See Figure 24.
8. Remove three capscrews and clip nuts from bat-
tery tray and remove battery and battery tray from
lift truck frame. See Figure 24.
9. Disconnect the remaining coolant hoses from the
radiator and cap them to prevent leakage. See
Cooling System 0700YRM1737 for procedures.
0100 YRM 1735 Engine Replacement

10. Remove air intake components from engine. Breathing fuel vapor may cause nausea, uncon-
• Lift trucks equipped with LPG engine - sciousness or death. Avoid breathing fuel vapor.
Disconnect air restriction sensor. Discon- 13. Disconnect the fuel lines at the engine. Put caps
nect and remove intake hose from LPG on fuel lines to prevent fuel leakage. See Fig-
fuel mixer and air intake housing. Discon- ure 26.
nect and remove dirty air hose from air in-
take housing. Remove two capscrews (un-
derneath mounting bracket) and air intake
from mounting bracket. See Figure 25.
• Lift trucks equipped with diesel engine -
Disconnect air restriction sensor. Discon-
nect and remove intake hose from intake
manifold. Disconnect and remove dirty air
hose from air intake housing. Remove two
capscrews (underneath mounting bracket)
and air intake from mounting bracket. See
Figure 25.

11. Disconnect the exhaust system.

• See PSI 2.0L LPG Fuel System
0900YRM1739 for procedures to remove
exhaust system for lift trucks equipped with
LPG fuel system.
• See Exhaust System Repair in this manual
for procedures to remove exhaust system
for lift trucks equipped with a diesel engine.
12. Remove the radiator fan pulley, shroud, and fan
assembly. See Cooling System 0700YRM1737
for the removal procedures.
NOTE: POWER DISTRIBUTION MODULE (PDM)
FOR LIFT TRUCK MODELS GLC030-035VX,
GLC040SVX (D809) EQUIPPED WITH PSI 2.0L LPG
ENGINE SHOWN. THE LOCATION AND ARRANGE-
MENT OF PDM FOR LIFT TRUCK MODELS GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810) EQUIP-
PED WITH A PSI 2.0L LPG OR YANMAR DIESEL
ENGINE IS SIMILAR.

WARNING 1. BATTERY
2. BATTERY TRAY
All fuels are very flammable and can burn or 3. PDM
cause an explosion. DO NOT use an open flame to 4. BATTERY LOCKDOWN BAR
check the fuel level or to check for leaks in the 5. CAPSCREW/CLIP NUT
fuel system. 6. GROUND STRAP

No smoking. Figure 24. Power Distribution Module, Remove/

Install

29
Engine Replacement 0100 YRM 1735

Figure 25. Air Intake Remove/Install

30
0100 YRM 1735 Engine Replacement

Legend for Figure 25

A. AIR INTAKE SYSTEM - LIFT TRUCKS EQUIP- B. AIR INTAKE SYSTEM - LIFT TRUCKS EQUIP-
PED WITH LPG ENGINE PED WITH DIESEL ENGINE
1. LPG FUEL MIXER 5. MOUNTING BRACKET
2. AIR INTAKE HOSE 6. CAPSCREW
3. DIRTY AIR HOSE 7. INTAKE MANIFOLD (DIESEL)
4. AIR INTAKE HOUSING 8. SILENCER (DIESEL)

NOTE: Tag wires and connectors prior to disconnect-

ing to aid in re-connecting.

14. Disconnect engine harness connectors from the

right hand chassis harness connectors before re-
moving the engine from the truck. See Figure 26.

15. Remove torque converter from flywheel.

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

16. Connect a lifting device to engine. Put a block un-

der the transmission housing to support the trans-
mission.

17. Remove two capscrews, two washers, and torque

converter housing cover. See Figure 28.

18. Remove four flange bolts from torque converter

housing and flywheel housing on transmission
side. See Figure 28.

19. Remove six hex head capscrews from flywheel

housing and torque converter housing on flywheel
housing side. See Figure 28.
1. LPG FUEL LINE
2. LPG LOCK-OFF
3. DIESEL FUEL LINES
4. DIESEL FUEL FILTER
5. ENGINE WIRE HARNESS

Figure 26. Fuel Line and Engine Wire Harness

Disconnection

31
Engine Replacement 0100 YRM 1735

A. DIESEL ENGINE B. LPG ENGINE

1. BOLT 3. ACCESS PORT
2. DUST COVER 4. FLYWHEEL HOUSING
Figure 27. Torque Converter Bolt Access

32
0100 YRM 1735 Engine Replacement

NOTE: LPG ENGINE SHOWN. DIESEL ENGINE IS SIMILAR.

1. FLANGE BOLTS 6. EYEBOLT BRACKET

2. HEX HEAD CAPSCREW 7. TORQUE CONVERTER HOUSING
3. CAPSCREW 8. FLYWHEEL HOUSING
4. WASHER 9. TRANSMISSION ASSEMBLY
5. TORQUE CONVERTER HOUSING COVER 10. ENGINE ASSEMBLY

Figure 28. Flywheel and Torque Converter Housings

33
Engine Replacement 0100 YRM 1735

WARNING CAUTION
The engine is heavy. Make sure that any lifting de- Keep the engine level when the engine is separa-
vice has enough capacity to lift the engine. The ted from the transmission so the drive plate is not
engine can weigh approximately198 kg (437 lb). damaged.

20. Remove flange nuts, washers, capscrews, and
isolators from engine mounts. See Figure 29 and
Figure 30. Remove engine adapter to transmis-
sion bolts.
CAUTION
When separating the engine away from the trans-
mission, place a piece of plywood in front of radi-
ator. This will keep the engine from damaging the
radiator.
21. Use the lifting device to carefully move the engine
away from the torque converter. Make sure all ho-
ses, wires, and cables are disconnected from the
engine, then lift the engine from the frame and
place engine on blocks.
22. Remove torque converter from torque converter
housing. See Figure 28.

NOTE: LEFT SIDE SHOWN. RIGHT SIDE IS SIMILAR.

A. LPG ENGINE B. DIESEL ENGINE

1. FRAME MOUNT 3. FLANGE NUT
2. LEFT ENGINE MOUNT 4. ISOLATOR

Figure 29. Engine Mounting Arrangement

34
0100 YRM 1735 Engine Replacement

INSTALL 3. Install capscrews, washers, isolators, and flange

nuts to mount engine to frame. See Figure 29 and
Figure 30. Tighten flange nuts to
WARNING 150 N•m (110 lbf ft).
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The 4. Install six hex head capscrews on flywheel hous-
engine can weigh approximately198 kg (437 lb). ing and torque converter housing from flywheel
housing side. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 28.
CAUTION
Keep the engine level when installing the engine 5. Install four flange bolts on torque converter hous-
to the transmission so the drive plate is not dam- ing and flywheel housing from transmission side.
aged. Tighten bolts to 38 N•m (28 lbf ft).

1. Install torque converter in torque converter hous-
ing.
2. Connect lifting device to engine and lift engine
into frame.
6. Install converter housing cover, two washers, and
two capscrews on torque converter housing.
Tighten capscrews to 19 N•m (168 lbf in). See
Figure 28.

A. LPG ENGINE B. DIESEL ENGINE

1. CAPSCREW 5. FLANGE NUT
2. WASHER 6. RIGHT ENGINE MOUNT
3. LEFT ENGINE MOUNT 7. CROSSMEMBER
4. ISOLATOR 8. FLANGE CAPSCREW

Figure 30. Engine Mounts

35
Engine Replacement
7. Use access port on side of engine and install
bolts to hold torque converter to flywheel. Tighten
bolts to 56 N•m (41 lbf ft). See Figure 27.
For lift trucks equipped with a diesel engine, install
two capscrews and dust cover over access port.
See Figure 27.
8. Connect engine wire harness connectors to right
hand chassis harness connectors. See Figure 26.
WARNING
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, uncon-
sciousness or death. Avoid breathing fuel vapor.
9. Remove caps from fuel lines and connect fuel
lines to engine. See Figure 26.
10. Install radiator fan pulley, shroud, and fan assem-
bly. See Cooling System 0700YRM1737 for in-
stallation procedures.
11. Connect exhaust system components.
• See PSI 2.0L LPG Fuel System
0900YRM1739 for procedures to install ex-
haust system components for lift trucks
equipped with an LPG engine.
• See Exhaust System Repair in this manual
for procedures to install exhaust system
components for lift trucks equipped with a
diesel engine.
12. Install air intake components to engine.
• Lift trucks equipped with LPG engine -
Place air intake on mounting bracket and
use two capscrews to attach air intake to
36
0100 YRM 1735
underside of mounting bracket. Connect
dirty air hose to intake housing. Connect
intake hose to LPG fuel mixer. Connect air
restrictor sensor. See Figure 25.
• Lift trucks equipped with diesel engine -
Place air intake on mounting bracket and
use two capscrews to attach air intake to
underside of mounting bracket. Connect
dirty air hose to intake housing. Connect
intake hose to intake manifold. Connect air
restriction sensor. See Figure 25.
13. Connect the coolant hoses and lines to the trans-
mission. Fill cooling system with a mixture of 50
percent deionized water and 50 percent ethylene
glycol boron-free antifreeze.
14. Connect the PDM and connect the ground strap
to lift truck frame and attach it to battery. Install
the battery and battery tray. See Figure 24.
15. Install hood and seat combination and rear side
covers. See section Hood, Seat, and Side Covers
Replacement for procedures.
16. Install floor plate and floor mat.
17. Install overhead guard. See section Overhead
Guard Replacement.
18. If lift truck is equipped with an LPG fuel tank,
swing tank into position on back of counterweight
and open shutoff valve on tank. See PSI 2.0L
LPG Fuel System 0900YRM1739 for procedures.
19. Check all fluid levels as described in Periodic
Maintenance 8000YRM1750.
0100 YRM 1735
Transmission Replacement
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine,
transmission, and counterweight. When the lift
truck is put on blocks put additional blocks in the
following positions to maintain stability:
• 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 Peri-
odic Maintenance 8000YRM1750.
WARNING
The transmission is heavy. Make sure that any lift-
ing device has enough capacity to lift the weight.
The transmission can weigh approximately
84 kg (185 lb).
NOTE: Make sure the transmission is supported by
blocks or a lifting device before removing the engine.
1. Remove engine from lift truck. See Engine Re-
placement section for procedures.
2. Remove seal plate for brake and throttle pedals.
See Hood, Seat, and Side Covers Replacement
for procedures.
Transmission Replacement
NOTE: When disconnecting wiring harness connec-
tors during removal, tag each connector to aid in con-
necting wiring harness during installation.
3. Disconnect the engine wiring harness from trans-
mission wiring harness. See Figure 26.
4. Disconnect transmission cooling lines from trans-
mission. See Figure 31.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
5. Place a suitable container under transmission; re-
move drain fitting from transmission housing and
drain transmission oil.
6. Disconnect and cap suction hose from hydraulic
gear pump inlet port. Cap hydraulic gear pump in-
let port. See Figure 31.
NOTE: Perform Step 7 if lift truck is equipped with a
Quick-LokTM hydraulic hose and adapter.
7. Remove adapter and Quick-LokTM hydraulic hose
from hydraulic gear pump outlet port. Cap hy-
draulic gear pump outlet port.
NOTE: Perform Step 8 for lift trucks NOT equipped
with a Quick-LokTM hydraulic hose and adapter.
8. Disconnect and cap hydraulic inlet hose from hy-
draulic gear pump outlet port. Cap hydraulic gear
pump outlet port. See Figure 31.
9. Remove the capscrew, washer, snubbing wash-
ers, and isolators from the mount bracket at the
rear of the transmission. See Figure 32.
37
Transmission Replacement 0100 YRM 1735

NOTE: OUICK-LOKTM HYDRAULIC HOSE AND ADAPTER NOT SHOWN.

A. LIFT TRUCKS EQUIPPED WITH LPG ENGINE B. LIFT TRUCKS EQUIPPED WITH DIESEL EN-
GINE
1. TRANSMISSION HOUSING
2. DRAIN FITTING
3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
5. HYDRAULIC GEAR PUMP INLET HOSE AND PORT
6. HYDRAULIC GEAR PUMP OUTLET HOSE AND PORT
7. TRANSMISSION COOLING HOSES/LINES
Figure 31. Transmission Hydraulic and Cooling Hoses and Gear Pump Arrangement

38
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.