service repair manual

1. GLC030-035VX, GLC040SVX (D809)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
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)

2. 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
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.
0100 YRM 1735 General
1

3. Description
The frame is one weldment and includes the hydraulic
tank and fuel tank for gasoline or diesel fuel. See Fig-
ure 1.
There is a counterweight for each capacity of lift truck.
The counterweights are similar in appearance, but are
different weights. See Counterweight Replacement
section.
The muffler is fastened to the frame inside the coun-
terweight.
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 assis-
tance when raising the hood and hold the hood in the
open position. The floor plate and side covers can be
removed for access to the engine, transmission, and
other components.
1. COWL PLATE
2. FENDERS
3. FRAME
4. HOOD MOUNTS
5. COUNTERWEIGHT MOUNTS
6. FUEL TANK (DIESEL)
7. HYDRAULIC TANK
Figure 1. Frame Components
Description 0100 YRM 1735
2

4. Hood, Seat, and Side Covers Replacement
REMOVE
1. Slide seat all the way to the rear of the hood.
2. Use tilt lever and tilt steering column all the way
forward. See Figure 2.
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
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
7. Remove capscrews, washers, and left and right
rear side covers from frame.
8. For lift truck models GLP/GDP16-18VX, GLP/
GDP20SVX (GLP/GDP030-035VX, GLP/
GDP040SVX) (D810), remove eight capcrews,
eight clip nuts, and left and right step covers from
frame. See Figure 6.
9. For lift truck models GLC030-035VX,
GLC040SVX (D809), remove six capscrews and
left and right step plates from frame. See 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. HOOD LATCH
2. HOOD
Figure 3. Hood Latch
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
3

5. Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLC030-035VX, GLC040SVX
(D809)
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
4

6. Legend for Figure 4
1. RADIATOR COVER
2. WASHER
3. CAPSCREW
4. RIGHT REAR COVER
5. INSERT
6. LEFT REAR COVER
7. LOWER STEERING COLUMN COVER
8. UPPER STEERING COLUMN COVER
9. CLIP NUT
10. DASH PANEL
11. SEAL
12. KICK PANEL
13. FLOOR PLATE
14. GROMMET
15. SEAL PLATE
16. LEFT STEP PLATE
17. RIGHT STEP PLATE
18. LEFT FRONT COVER
19. RIGHT FRONT COVER
20. FLOOR MAT
21. CLIP
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
5

7. Figure 5. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP16-18VX, GLP/
GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810)
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
6

8. Legend for Figure 5
1. CAPSCREW
2. WASHER
3. INSERT
4. RADIATOR COVER
5. LOWER STEERING COLUMN COVER
6. UPPER STEERING COLUMN COVER
7. CLIP NUT
8. DASH PANEL
9. KICK PANEL
10. GROMMET
11. SEAL PLATE
12. SEAL
13. FUEL SHIELD (DIESEL)
14. LEFT REAR COVER
15. RIGHT REAR COVER
16. FLOOR PLATE
17. FLOOR MAT
18. RIGHT STEP COVER
19. LEFT STEP COVER
20. RIGHT FRONT COVER
21. LEFT FRONT COVER
22. RIGHT STEP PLATE
23. LEFT STEP PLATE
24. CLIP
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
7

9. Figure 6. Step Covers and Step Plates Remove/Install
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
8

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

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12. NOTE: TOP VIEW OF DASH SHOWN.
A. INDICATES TO PULL UP TO UNLATCH
1. FASTENERS
2. COWL
3. UPPER STEERING COLUMN COVER
4. LOWER STEERING COLUMN COVER
Figure 7. Remove Dash From Cowl
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
10

13. 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
0100 YRM 1735 Hood, Seat, and Side Covers Replacement
11

14. Figure 9. Hood Latch and Hood Latch Striker Bolt Remove/Install
Hood, Seat, and Side Covers Replacement 0100 YRM 1735
12