YALE B875 GDP050VX LIFT TRUCK Service Repair Manual

GP/GLP/GDP040VX, GP/GLP/GDP050VX, GP/GLP/GDP060VX, GP/GLP/
GDP070VX (B875)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524223754 0100 YRM 1120 12/12
OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14
GM 2.4L ENGINE REPAIR............................................................................................. 524223755 0600 YRM 1121 12/12
MAZDA FE AND F2 ENGINES....................................................................................... 524223756 0600 YRM 1122 03/12
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM (GM).............................................................................................. 524223758 0900 YRM 1124 02/12
LPG FUEL SYSTEM (MAZDA)....................................................................................... 524223759 0900 YRM 1125 10/05
GASOLINE FUEL SYSTEM GM 2.4L ENGINE.............................................................. 524223760 0900 YRM 1126 02/10
GASOLINE FUEL SYSTEM (MAZDA)........................................................................... 524223761 0900 YRM 1127 05/05
GASOLINE FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT
ENGINES.................................................................................................................... 524289373 0900 YRM 1325 12/09
LPG FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT
ENGINES.................................................................................................................... 524289374 0900 YRM 1326 09/12
1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... 524223762 1300 YRM 1129 09/09
SINGLE SPEED POWERSHIFT ALUMINUM TRANSMISSION REPAIR..................... 550010194 1300 YRM 1421 08/13
SINGLE SPEED POWERSHIFT ALUMINUM CHAIN DRIVE TRANSMISSION............ 550030170 1300 YRM 1447 08/13
POWERSHIFT TRANSMISSION REPAIR...................................................................... 550043436 1300 YRM 1529 08/13
DRIVE AXLE - DRY BRAKE........................................................................................... 524240909 1400 YRM 1214 11/12
DRIVE AXLE (WET BRAKE).......................................................................................... 524240908 1400 YRM 1215 02/12
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524223765 1800 YRM 1135 12/12
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 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.................................................................................................. 524223772 2200 YRM 1142 04/14
ELECTRICAL SYSTEM (MAZDA).................................................................................. 524223773 2200 YRM 1143 10/05
ELECTRICAL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT
ENGINES.................................................................................................................... 524289375 2200 YRM 1327 09/12
MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508,
B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551,
C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ 524223776 4000 YRM 1148 02/14
MAST REPAIR (S/N F507, F508, F562, F563)............................................................... 550093755 4000 YRM 1669 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 524223777 8000 YRM 1150 08/13
CAPACITIES AND SPECIFICATIONS........................................................................... 524223778 8000 YRM 1151 08/13
DIAGRAMS..................................................................................................................... 524223779 8000 YRM 1152 04/14
DIAGRAMS AND SCHEMATICS.................................................................................... 524329117 8000 YRM 1387 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

100 YRM 1120 Description
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 8000 YRM 1150 for lift truck
models
• GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
models
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810)
NOTE: For exhaust system procedure for lift trucks
equipped with a Mazda 2007 emissions compliant
engine and for lift trucks built after January, 2010 go to
section LPG Fuel System, Mazda FE and F2 Emis-
sion Compliant Engines 900 YRM 1326 or Gasoline
Fuel System, Mazda FE and F2Emission Compliant
Engines 900 YRM 1325 for exhaust system proce-
dures.
For lift trucks built after January, 2010 and equipped
with a GM 2.4L engine, go to section LPG Fuel System,
GM 2.4L Engine 900 YRM 1124 for exhaust system
procedures.
This section contains the description of the frame (see
Figure 1) and connected parts. Procedures for remov-
ing and installing the counterweight, hood, overhead
guard, engine, cooling system, and exhaust system
(see NOTE above) are found in this section. Checks
for the operator restraint system and procedures for
the repair of tanks and installation of safety labels are
also included.
Description
The frame is one weldment and includes the hydraulic
tank and fuel tank for gasoline or diesel fuel. See Fig-
ure 1.
There is a counterweight for each capacity of lift truck.
The counterweights are similar in appearance, but are
different weights.
See Table 3 for lift truck models
Table 4 for lift truck models
(C809)
(B875)
The muffler is fastened to the frame inside the counter-
weight.
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 po-
sition. The floor plate and side covers can be removed
for access to the engine, transmission, and other com-
ponents.
1

Hood, Seat, and Side Covers Replacement 100 YRM 1120
1. COWL PLATE
2. FENDERS
3. FRAME
4. HOOD MOUNTS
5. COUNTERWEIGHT MOUNTS
6. FUEL TANK (GAS OR DIESEL)
7. HYDRAULIC TANK
Figure 1. Frame
Hood, Seat, and Side Covers Replacement
REMOVE
1. Slide seat to the closest position to steering column.
2. Fully tilt steering column forward.
3. If your truck is equipped with an LPG tank, swing
tank off to the side.
4. Raise latch on the left, front corner of the hood to
unlatch and lift up hood. See Figure 2.
5. Remove floor mat and floor plate.
See Figure 3 for lift truck models
• GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
• GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
(B875)
2

100 YRM 1120 Hood, Seat, and Side Covers Replacement
NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.
A. SIDE VIEW OF HOOD AND SEAT
B. SIDE VIEW OF HOOD
C. BOTTOM VIEW OF HOOD
D. SIDE VIEW OF VENTED HOOD WITH SWIVEL
SEAT
1. SEAT
2. HOOD
3. FRAME
4. SEAT WIRE HARNESS
5. SEAT WIRE HARNESS CONNECTOR (WITHOUT
ELECTRONIC CONTROL)
6. SEAT WIRE HARNESS CONNECTOR (WITH
ELECTRONIC CONTROL)
7. CABLE CLIPS
8. HINGE SCREWS
9. GAS SPRING
10. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (SEMI-SUSPENSION)
11. SEAT WIRE HARNESS BRACKETS
12. SEAT LINER
13. HOOD LATCH
SEAT (NON-SUSPENSION)
SEAT (FULL SUSPENSION)
16. SPACER
Figure 2. Hood and Seat Arrangement
3

1. LOWER STEERING COLUMN COVER
2. UPPER STEERING COLUMN COVER
3. INSERT
4. CLIP
5. DASHBOARD
6. CAPSCREW
7. SEAL
8. GROMMET
9. LEFT HAND REAR PANEL
10. FLOOR PLATE
11. LEFT HAND FENDER COVER
12. SCREW
13. NUT
14. LEFT HAND FRONT PANEL
15. LEFT HAND STEP PANEL
16. LEFT HAND TREAD PLATE
17. PLATE ASSEMBLY SEAL
18. RIGHT HAND FENDER COVER
19. FLOOR MAT
20. RIGHT HAND TREAD PLATE
21. RIGHT HAND FRONT PANEL
22. RIGHT HAND STEP PANEL
23. RIGHT HAND REAR PANEL
24. RADIATOR COVER
25. KICK PANEL
26. PLATE ASSEMBLY
Figure 3. Side Cover, Floor Plate, and Cowl Components, Lift Truck Models GLC20-35VX
(GC/GLC040-070VX,GC/GLC055SVX ) (A910), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX,
GP/GLP/GDP040SVX ) (C810), and GC/GLC030-035VX, GC/GLC040SVX (C809)
4

6. Remove two capscrews holding left and right rear
side covers to the frame. Remove rear side covers
from frame.
(C810)
GC/GLC040SVX (C809)
(B875)
7. Remove two capscrews holding left and right fender
covers to front overhead guard leg. Remove cov-
ers.
(C810)
GC/GLC040SVX (C809)
(B875)
8. Remove four capscrews holding left and right front
side covers to frame. Remove covers.
9. Fully lower steering column.
10. Remove upper steering column cover by pulling up
on upper steering column cover to release latches
(one on either side), and pulling cover away from
steering column. See Figure 5.
11. Remove five fasteners (see Figure 5) securing dash
to the top of cowl. Remove four clips, located un-
derneath dash, that attach dash to the kick panel.
Lift to remove dash.
12. Lift the kick panel to remove from truck.
(C810)
GC/GLC040SVX (C809)
(B875)
13. Remove three capscrews holding the seal plate.
Remove seal plate. See Figure 6.
14. Disconnect seat wire harness connector. See Fig-
ure 2.
CAUTION
When removing the seat from the hood, DO NOT use
an impact wrench to remove the capscrews. Dam-
age can be caused to the threads on the screws and
in the holes.
15. If seat is to be removed, and truck is equipped with
a non-swivel seat, remove seat wire harness from
seat wire harness brackets that are attached to the
underside of hood. Remove the cable clips from
the seat wire harness. If truck is equipped with a
swivel seat, remove seat wire harness from seat
wire harness bracket attached to underside of the
hood and behind the seat (see Figure 2).
16. Remove four capscrews and washers holding the
seat to hood. Lift seat off the hood. Pull seat wire
harness through hood. See Figure 2.
17. Remove capscrews and washers at the top of gas
springs. Remove gas springs from hood.
18. Remove hinge screws, located in the rear of the
hood.
19. Lift hood from the truck. See Figure 2.
5

Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)
6

Legend for Figure 4
1. DASH ASSEMBLY
4. KICK PANEL
5. MUD GUARD (LH)
6. MUD GUARD (RH)
7. LOCK NUT
8. NUT
9. COVER
10. BRACKET
11. PLATE ASSEMBLY
12. GROMMET
13. LEFT FRONT PANEL
14. RIGHT FRONT PANEL
15. LEFT STEP PANEL
16. RIGHT STEP PANEL
17. LEFT STEP PLATE
18. RIGHT STEP PLATE
19. LEFT REAR PANEL
20. RIGHT REAR PANEL
21. FLOOR MAT
22. FLOOR PLATE
23. RADIATOR COVER
24. SEALS
25. CAPSCREW
26. CLIP NUT
27. INSERT
28. PLATE ASSEMBLY SEAL
NOTE: TOP VIEW OF DASH SHOWN.
A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN SCREWS
2. COWL
Figure 5. Remove Dash From Cowl
7

INSTALL
1. Place hood onto the lift truck frame.
2. Install hinge screws, located in the rear of the hood,
and tighten to 38 N•m (28 lbf ft). See Figure 2.
3. Align top holes in the gas springs with holes in
hood. Install capscrews and washers to attach gas
springs to hood. Tighten capscrews to 19.2 N•m
(170 lbf in).
See Figure 7 and Table 1 for lift truck models
(C810) and GLC20-35VX (GC/GLC040-070VX,
GC/GLC040SVX (C809)
See Figure 9 and Table 2 for lift truck models
(B875)
1. CAPSCREWS 2. SEAL PLATE
Figure 6. Remove Seal Plate From Dash
8

Figure 7. Gas Spring Installation, Lift Truck Models
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
GP/GLP/GDP030SVX) (C810) and GLC20-35VX
(GC/GLC040-070VX, GC/GLC055SVX) (A910)
Legend for Figure 7
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
SUSPENSION SEAT
C. MOUNTING LOCATION FOR CYLINDER
SUSPENSION SEAT WITH CAB*
1. MOUNTING POINTS FOR GAS SPRING ON
HOOD
*CAB ONLY ON LIFT TRUCK MODELS GLP/
GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/
GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/
GDP030SVX) (C810)
Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP030SVX) (C810) and
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)
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
Without
E-Control
B B 3 3 A A 1 1
Seat With
E-Control
B B 2 2 N/A N/A N/A N/A
Cab C C 2 2 N/A N/A N/A N/A
9

Figure 8. Gas Spring Installation, Lift Truck Models
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
Legend for Figure 8
NOTE: LEFT SIDE SHOWN.
1. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION SEAT
2. MOUNTING LOCATION FOR CYLINDER
SUSPENSION SEAT
Figure 9. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
10

Legend for Figure 9
A. LEFT SIDE
B. RIGHT SIDE
C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT
D. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT,
LIFT TRUCKS WITH CAB OR GP/GLP/GDP040-070VX (B875) LIFT TRUCKS WITHOUT CAB
E. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT,
LIFT TRUCKS GLP/GDP20-35VX (B875) WITHOUT CAB
1. MOUNTING POINTS FOR GAS SPRING ON HOOD
Table 2. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
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
Non-Cab
GP/GLP/
GDP040-
070VX
(B875)
D D 3 3 C C 1 1
Non-Cab
GLP/
GDP20-
35VX
(B875)
E E 2 2 C C 1 1
Cab D D 1 1 N/A N/A N/A N/A
11

4. Install latch striker in highest slot position. Check
that latch striker is in center of jaws of hood latch
when hood closes. Open and close hood to ensure
that center pin strikes hood latch properly and that
the stop screw contacts frame. A properly closed
hood MUST click twice on the hood latch. If the
hood latch does not close properly, loosen cap-
screws on the back of center pin and adjust center
pin up or down as required for correct alignment.
See Figure 10.
5. Push down until hood just touches rubber bumper.
Make sure latch striker is still in center of hood latch.
Open hood and tighten capscrews for latch.
6. Check operation of hood latch. Have an operator sit
in seat. Make sure hood is fully closed (two clicks).
Also check that hood touches rubber bumper. If
necessary, repeat Step 5.
1. HOOD
2. HOOD LATCH
3. CENTER PIN
4. CAPSCREW
Figure 10. Hood Latch Adjustment
CAUTION
When installing the seat to the hood, DO NOT use
an impact wrench to install the capscrews. Damage
can be caused to the threads on the screws and in
the holes.
7. Place seat on the hood and thread seat wire har-
ness through the hole in the hood. See Figure 2.
8. Align holes in the seat with the holes in hood. In-
sert washers and capscrews. Tighten capscrews to
18 N•m (159 lbf in).
9. If truck is equipped with a non-swivel seat, tie cable
clips to seat wire harness and insert harness into
seat wire harness brackets under hood. If truck is
equipped with a swivel seat, secure seat harness
to bracket. See Figure 2.
10. Install seal plate using three capscrews. See Fig-
ure 6.
11. Install kick panel onto truck.
(C810)
GC/GLC040SVX (C809)
(B875)
12. Install dash to top of cowl. See Figure 5. Install four
clips to attach the dash to kick panel.
13. Install upper steering column cover to dash.
14. Using four capscrews, install left and right front side
covers to frame.
(C810)
GC/GLC040SVX (C809)
12

100 YRM 1120 Steering Column
(B875)
15. Using two capscrews, install left and right fender
covers to front of overhead guard legs.
16. Using two capscrews, install left and right rear side
covers to frame.
(C810)
GC/GLC040SVX (C809)
(B875)
17. Install floor mat and floor plate.
18. If truck is equipped with an LPG tank, swing LPG
tank into position on back of counterweight.
19. Adjust the steering column and seat positions.
Steering Column
DESCRIPTION
This section describes the repair procedures for the
steering column. The steering column assembly
mounts to the cowl inside the operator compartment
and is the mechanical connection between the steering
wheel and the steering control unit. The steering col-
umn 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 11.
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 covers
to avoid injury to personnel.
2. Attach a tag on the battery connector or nega-
tive 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 compo-
nents of the steering column assembly. Not all com-
ponents are removed for a repair procedure. Do only
those steps of the procedure necessary to remove the
required component.
NOTE: Tag wires prior to disconnect.
3. Remove the horn button assembly and disconnect
electrical wires. Remove large hex nut and steering
wheel from steering column. See Figure 12.
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.
1. STEERING WHEEL
2. STEERING COLUMN
3. COWL
Figure 11. Steering Column and Cowl
13

Steering Column 100 YRM 1120
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
Figure 12. Steering Wheel Remove/Install
4. Remove steering column covers. Remove floor
mats and floor plate. See section Hood, Seat, and
Side Covers Replacement.
NOTE: Perform Step 5 for lift trucks equipped with gas
or LPG engines.
5. Remove four capscrews, four bushings and steer-
ing column from cowl standoffs. See Figure 13.
NOTE: Perform Step 6 for lift trucks equipped with
diesel engines.
6. Remove four capscrews, four bushings, four isola-
tors, steering column and four isolators from cowl
standoffs. See Figure 13.
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.
1. CAPSCREW
2. BUSHING
3. ISOLATOR
4. STEERING COLUMN
5. COWL STANDOFF
Figure 13. Steering Column Remove/Install
14

Disassemble
NOTE: Remove and discard snap rings if installed.
1. Remove two pins and gas spring from housing.
See Figure 14, for lift trucks manufactured before
January, 2012.
See Figure 15, for lift trucks manufactured after Jan-
uary, 2012.
2. Remove two pivot bolts, two bushings, two nuts and
bracket from housing.
January, 2012.
uary, 2012.
3. Remove split pin and lower shaft from upper shaft.
January, 2012.
uary, 2012.
4. Remove connector from connector bracket. Re-
move connector bracket, fastener, four screws and
two horn contacts from housing.
January, 2012.
uary, 2012.
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety precautions.
WARNING
Compressed air is used for cleaning and drying pur-
poses, or for cleaning restrictions. Wear protective
clothing (goggles/shields, gloves, etc.). Make sure
the path of the compressed air is away from all per-
sonnel 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 dam-
aged 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 com-
ponents of the steering column assembly. Not all com-
ponents are removed for a repair procedure. Do only
those steps of the procedure necessary to install the
required component.
NOTE: Perform Step 1 only for lift trucks manufactured
before January, 2012.
1. Lubricate the horn contact slip rings with a
small amount of conductive grease (Yale P/N
582014302).
2. Install fastener, connector bracket and connector,
two horn contacts and four screws.
January 2012.
uary 2012.
3. Assemble lower shaft and upper shaft, secure with
spit pin.
January 2012.
uary 2012.
15

Steering Column 100 YRM 1120
Figure 14. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012
16

Legend for Figure 14
1. PIN
2. LOWER SHAFT
3. SPLIT PIN
4. UPPER SHAFT
5. HOUSING
6. HORN CONTACT
7. SCREW
8. FASTENER
9. CONNECTOR BRACKET
10. PIVOT BOLT
11. BUSHING
12. NUT
13. GAS SPRING
14. BRACKET
15. CONNECTOR
1. BRACKET
2. SPACER
3. JOINT
4. NUT
5. WASHER
6. SCREW
7. UPPER SHAFT
8. HOUSING
9. PIN
10. LOWER SHAFT
11. GAS SPRING
12. BOLT
13. BUSHING
14. CONNECTOR
15. FASTENER
16. HORN CONTACT
Figure 15. Steering Column Assembly, Lift Trucks Manufactured After January, 2012
17

LPG Tank and Bracket Assembly 100 YRM 1120
4. Install two pivot bolts, two bushings, two nuts and
bracket onto housing.
January 2012.
uary 2012.
5. Install gas spring and two pins on housing.
January 2012.
uary 2012.
Install
NOTE: Lubricate spline end of lower shaft with multi
purpose grease. See one of the Service Manuals for
procedures
models
(B875)
models
(C809)
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 13.
NOTE: Perform Step 2 for lift trucks equipped with
diesel engines.
2. Install four isolators, steering column, four isola-
tors, four bushings, and four bolts on cowl standoffs.
Tighten bolts to 38 N•m (28 lbf ft). See Figure 13.
3. Install floor plate, floor mats, and steering column
covers. See section Hood, Seat, and Side Covers
Replacement.
4. Install steering wheel and hex nut on steering 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 12.
5. Remove tag from negative battery connector and
connect to battery. Adjust steering column to neu-
tral position.
6. Remove blocks from each side of tires.
LPG Tank and Bracket Assembly
For procedures to remove and install the LPG tank, LPG
tank bracket, and the LPG tank alignment pin, see one
of the following Service Manuals.
LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for
lift truck models
• GLC20-35VX (GLC040-070VX, GLC055SVX)
(A910)
• GLP20-35VX (GLP040-070VX) (B875)
LPG Fuel System, Mazda 2.0L and 2.2L Engines 900
SRM 1125 for lift truck models
(A910)
• GLP20-35VX (GLP040-070VX) (B875)
• GLC030VX, GLC035VX, GLC040SVX (C809)
• GLP16VX, GLP18VX, GLP20SVX (GLP030VX,
GLP035VX, GLP040SVX) (C810)
LPG Fuel System, Mazda FE and F2 Emission Com-
pliant Engines 900 YRM 1326 for lift truck models
(A910)
• GLP20-35VX (GLP040-070VX) (B875)
• GLC030VX, GLC035VX, GLC040SVX (C809)
• GLP16VX, GLP18VX, GLP20SVX (GLP030VX,
GLP035VX, GLP040SVX) (C810)
18

100 YRM 1120 Counterweight Replacement
Counterweight Replacement
REMOVE
WARNING
of maintenance and repair. The removal of the
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 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. See Fig-
ure 16.
One M24 × 3 x 140 capscrew holds the counterweight
to the lower part of the frame on lift truck models
• GLC30-35VX (GC/GLC060-070VX) (A910)
(B875)
One M24 × 3 x 90 capscrew holds the counterweight to
the lower part of the frame on lift truck models
(B875)
(C809)
NOTE: For exhaust system procedure for lift trucks
equipped with a Mazda 2007 emissions compliant
engine and for lift trucks built after January, 2010 go to
section LPG Fuel System, Mazda FE and F2 Emis-
sion Compliant Engines 900 YRM 1326 or Gasoline
Fuel System, Mazda FE and F2Emission Compliant
Engines 900 YRM 1325.
For exhaust system procedures for lift trucks built after
January, 2010 and equipped with a GM 2.4L engine,
go to section LPG Fuel System, GM 2.4L Engine 900
YRM 1124.
NOTE: For overhead exhaust system procedures for lift
trucks equipped with a Mazda 2007 emissions compli-
ant engine and for lift trucks built after January, 2010 go
to section LPG Fuel System, Mazda FE and F2 Emis-
sion Compliant Engines 900 YRM 1326 or LPG Fuel
System, Mazda FE and F2 Engines 900 YRM 1125.
NOTE: If lift truck is equipped with an overhead exhaust
system, remove the overhead exhaust pipe before re-
moving the counterweight. See the section Exhaust
System Repair for the procedures.
19

Counterweight Replacement 100 YRM 1120
1. If the lift truck has an LPG fuel system, see one
of the following Service Manuals to remove the
LPG tank and bracket, before removing the coun-
terweight, and for additional information on the LPG
fuel systems
LPG Fuel System, GM 2.4L Engine 900 YRM
1124 for lift truck model
(B875)
LPG Fuel System, Mazda FE and F2 Engines 900
YRM 1125 for lift truck models
GC/GLC040SVX (C809)
(C810)
(B875)
LPG Fuel System, Mazda FE and F2 Emission
Compliant Engines 900 YRM 1326 for lift truck
models
GC/GLC040SVX (C809)
(C810)
(B875)
WARNING
The counterweight is heavy. Make sure that the eye-
bolt and lifting devices have enough capacity to lift
the weight. The approximate weights of the coun-
terweight castings are shown in .
(C809)
(B875)
2. Install a lifting eye in the lift hole of the counter-
weight. See Figure 16 and Figure 17. Connect a
crane to the lifting eye and raise the crane until it
holds part of the weight of the counterweight. Re-
move the tow pin and remove the capscrew that
holds the counterweight to the frame. See Fig-
ure 16. 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.
1. FRAME HOOK
2. LOWER FRAME MOUNT
3. TOW PIN
4. ROLL PIN
5. CAPSCREW
6. WASHERS
7. LIFT HOLE
Figure 16. Counterweight Installation
20

100 YRM 1120 Counterweight Replacement
Table 3. Weight of Counterweights,
Lift Truck Models GLC20-35VX
(GC/GLC040-070VX,GC/GLC055SVX ) (A910)
Model Kg Lb
GLC20VX
(GC/GLC040VX)
1040 2293
GLC25VX
(GC/GLC050VX)
1395 3075
GC/GLC055SVX 1643 3622
GLC30VX
(GC/GLC060VX)
1819 4010
GLC35VX
(GC/GLC070VX)
2153 4747
Table 4. Weight of Counterweights, Lift
Truck Models GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
Model Kg Lb
GC/GLC030VX 772 1702
GC/GLC035VX 963 2123
GC/GLC040SVX 1131 2493
Lift Truck Models GLP/GDP16-18VX,
GP/GLP/GDP20SVX (GP/GLP/GDP030-35VX,
Model Kg Lb
GLP/GDP16VX
(GP/GLP/GDP030VX)
812 1790
GLP/GDP18VX
(GP/GLP/GDP035VX)
887 1955
GLP/GDP20SVX (GP/
GLP/GDP040SVX)
1047 2308
Lift Truck Models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)
Model Kg Lb
GLP/GDP20VX
(GP/GLP/GDP040VX)
994 2191
GLP/GDP25VX
(GP/GLP/GDP050VX)
1338 2950
GLP/GDP30SVX (GP/
GLP/GDP060SVX)
1664 3668
GLP/GDP35SVX (GP/
GLP/GDP070SVX)
1965 4332
21

Counterweight Replacement 100 YRM 1120
INSTALL
1. Make sure the seals are on the counterweight. See
Figure 17.
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 coun-
terweight so it is aligned with the parts of the frame.
Install and tighten the M24 × 3 capscrew to 555 N•m
(409 lbf ft).
3. Install tow pin and roll pin. See Tow Pin, Remove
and Install for procedures.
4. If the lift truck has an LPG fuel system, see one of
the following Service Manuals to install the LPG
tank and bracket, after the counterweight has been
installed.
1124 for lift truck models
(B875)
GC/GLC040SVX (C809)
(C810)
(B875)
models
GC/GLC040SVX (C809)
(C810)
(B875)
1. CAPSCREW
2. LOCKWASHER
3. WASHER
4. COUNTERWEIGHT
5. LIFTING EYEBOLT
6. TOW PIN
7. ROLL PIN
8. SEAL
9. LIFT HOLE
10. LPG ACCESS
HOLE
Figure 17. Counterweight
NOTE: For overhead exhaust system procedures for lift
trucks equipped with a Mazda 2007 emissions compli-
ant engine and for lift trucks built after January, 2010 go
to section LPG Fuel System, Mazda FE and F2 Emis-
sion Compliant Engines 900 YRM 1326 or LPG Fuel
System, Mazda FE and F2 Engines 900 YRM 1125.
5. If lift truck is equipped with an overhead exhaust
system, install the overhead exhaust pipe. See the
section Exhaust System Repair for the procedures.
22

100 YRM 1120 Overhead Guard Replacement
TOW PIN, REMOVE AND INSTALL
1. Remove the tow pin from the counterweight by driv-
ing the roll pin out. See Figure 18.
2. Install tow pin into counterweight and install roll pin.
1. TOW PIN 2. ROLL PIN
Figure 18. Tow Pin
Overhead Guard Replacement
REMOVE AND INSTALL
WARNING
DO NOT operate the lift truck without the overhead
guard correctly fastened to the lift truck.
WARNING
DO NOT weld mounts for lights or accessories to
legs of the overhead guard. Changes that are made
by welding, or by drilling holes that are too big or in
the wrong location, can reduce the strength of the
overhead guard.
See your dealer for Yale lift trucks BEFORE perform-
ing 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 per-
mitted as per previous WARNING.
NOTE: The lifting device can be connected to any num-
ber 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 sin-
gle 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 cen-
tered 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 19.
2. Disconnect any wires between the frame and the
overhead guard. When the overhead guard is lifted
from the frame, make sure that any electrical wires
are moved through the holes in the frame so that
they are not damaged.
23

Overhead Guard Replacement 100 YRM 1120
3. The rear legs of the overhead guard have two cap-
screws that are located under the hood inside the
engine compartment, next to the radiator. Remove
and install the capscrews. See Figure 20.
4. Remove the fender cover, dash, and kick panel to
remove and install the three capscrews on the front
legs of the overhead guard. See Hood, Seat, and
Side Covers Replacement for the removal 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 20.
1. CLAMP
2. AIR INTAKE HOSE
3. BOLTS
4. ELBOW
5. RETAINER
6. GROMMET
Figure 19. Disconnect Air Intake Hose
LED TAIL, BACKUP, AND BRAKE LIGHTS,
REPLACE
These light assemblies are nonrepairable and must be
replaced as an assembly. See the section Electrical
System 2200 YRM 1142 for the procedures to replace
these lights.
1. CAPSCREWS - FRONT LEGS
2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME
Figure 20. Overhead Guard
24

100 YRM 1120 Operator Restraint System Replacement
Operator Restraint System Replacement
DESCRIPTION
The seat belt, hip restraint brackets, seat and mounting,
hood, and latches are all part of the operator restraint
system. Each item must be checked to make sure it
is attached securely, functions correctly, and is in good
condition. See Figure 21.
Automatic Locking Retractor (ALR)
NOTE: GC/GLC040-070VX, GC/GLC055SVX (A910)
lift trucks produced before November 2005 are
equipped with the ALR type seat belts.
The seat belt must fasten securely. Make sure the seat
belt extends and retracts smoothly and is not frayed or
torn. If the seat belt is damaged or does not operate
properly, it must be replaced. See Figure 21.
Emergency Locking Retractor (ELR)
NOTE: Lift trucks produced after November 2005 are
equipped with the Emergency Locking Retractor (ELR)
style seat belt.
When the ELR style seat belt is properly buckled across
the operator, the belt will permit slight operator reposi-
tioning without activating the locking mechanism. If the
truck tips, travels off a dock, or comes to a sudden stop,
the locking mechanism will be activated and hold the
operator’s lower torso in the seat.
A seat belt that is damaged worn or does not operate
properly will not provide protection when it is needed.
The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the
seat belt if damage or wear is seen. See Figure 21 and
Figure 22.
NOTE: The following seat belt operation checks must
be performed three times before replacing the seat belt
assembly.
• With the hood closed and in the locked position, pull
the seat belt slowly from the retractor assembly. Make
sure the seat belt pulls out and retracts smoothly. If
the seat belt cannot be pulled from the retractor as-
sembly or the belt will not retract, replace the seat belt
assembly.
• With the hood closed and in the locked position, pull
the seat belt with a sudden jerk. Make sure the seat
belt will not pull from the retractor assembly. If the
seat belt can be pulled from the retractor, when it is
pulled with a sudden jerk, replace the seat belt as-
sembly.
• With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly. If
the seat belt can be pulled from the retractor, with
the hood in the open position, replace the seat belt
assembly.
Make sure the seat rails and latch striker are not loose.
The seat rails must lock securely in position but move
freely when unlocked. The seat rails must be securely
attached to the mounting surface. The hood must be
fully closed. Lift the hood to make sure it is closed and
will not move.
Adjust hood, hood latch, and latch striker when any of
the parts of the operator restraint system are installed or
replaced. See the section Hood, Seat, and Side Covers
Replacement in this manual for the adjustment proce-
dures for the hood.
25

Operator Restraint System Replacement 100 YRM 1120
A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR
1. LATCH STRIKER
2. HOOD LATCH
3. FORWARD/BACKWARD ADJUSTMENT
4. HOOD
5. OPERATOR WEIGHT ADJUSTMENT
6. SEAT RAIL
7. ARM REST
8. SEAT BELT
9. SEAT
10. HIP RESTRAINT
11. HOOD HINGE
Figure 21. Operator Restraint System
Figure 22. Operator Restraint System
26

100 YRM 1120 Engine Replacement
A. STANDARD, NON-SUSPENSION SEAT B. FULL SUSPENSION SEAT
1. SEAT BELT
2. WEIGHT ADJUSTMENT KNOB
3. RIDE POSITION INDICATOR
4. FORWARD/BACKWARD ADJUSTMENT LEVER
5. BACKREST ANGLE ADJUSTMENT LEVER
6. ARMREST
7. SWIVEL LATCH RELEASE LEVER
Engine Replacement
REMOVE
WARNING
of maintenance and repairs. The removal of the
fall forward.
units. See the Operating Manual or the section
models
• GLC20-35VX (GC/GLC040-070VX,GC/
GLC055SVX ) (A910)
(B875
models
• GC/GLC030-035VX, GC/GLC040SVX (C809)
• GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/GLP/
GDP030-35VX, GP/GLP/GDP040SVX) (C810)
WARNING
Always disconnect the cables at the battery before
you make repairs to the engine. Disconnect the ca-
ble at the negative terminal first.
WARNING
LPG can cause an explosion. DO NOT cause sparks
or permit flammable material near the LPG system.
LPG fuel systems can be disconnected indoors
only if the lift truck is at least 8 m (26 ft) from any
open flame, motor vehicles, electrical equipments,
or ignition source.
1. For lift trucks equipped with an LPG fuel system,
close the shutoff valve on the tank and run engine
until all fuel is gone and engine stops.
2. If lift truck is equipped with an LPG fuel tank, swing
tank to the side. See one of the following Service
Manuals for procedures:
(B875)
GC/GLC040SVX (C809)
(C810)
(B875)
27

Engine Replacement 100 YRM 1120
models
GC/GLC040SVX (C809)
(C810)
(B875)
3. Remove overhead guard. See section Overhead
Guard Replacement for procedures.
4. Remove the floor mat and floor plate.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
5. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capacity
of the cooling system under radiator. Remove radi-
ator cap.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
6. Open the drain plug or disconnect the bottom radi-
ator hose to drain coolant from radiator and engine.
7. Remove the hood and seat combination and rear
side covers. See the section Hood, Seat, and Side
Covers Replacement for procedures.
NOTE: Trucks equipped with a Yanmar Diesel Engine
do not have an ECM.
8. On lift trucks with the GM 2.4L engine, disconnect
the ECM from air filter and remove two bolts hold-
ing ECM and mounting bracket to air filter, before
removing the air filter.
9. On lift trucks equipped with a Mazda 2.0L or 2.2L
engine, disconnect ECM connector from ECM. Re-
move two bolts and ECM bracket, with ECM at-
tached, from engine block.
10. Disconnect the ground strap from the frame and
remove the power distribution module (PDM) from
the battery tray. See Figure 23.
11. Remove three capscrews from the battery tray and
remove the battery and battery tray. See Figure 23.
12. Disconnect the remaining coolant hoses from the
radiator and cap them to prevent leakage.
13. On lift trucks equipped with a Mazda engine (ex-
cept Mazda 2007 emission compliant engines and
lift trucks built after January, 2010 equipped with
a Mazda engine) and Basic Powershift Transmis-
sion, disconnect the throttle linkage (see the sec-
tion Powershift Transmission, Repair 1300 YRM
1129). Disconnect the exhaust system.
14. Remove the radiator fan pulley, shroud, and fan as-
sembly. See the section Cooling System 700 YRM
1123 for the removal procedures.
1. BATTERY
2. BATTERY TRAY
3. PDM
4. BATTERY LOCKDOWN BAR
5. GROUND STRAP
Figure 23. Power Distribution Module,
Disconnection
28

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. Long term exposure to
gasoline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
15. Disconnect the fuel lines at the engine. Put caps
on fuel lines to prevent fuel leakage.
NOTE: Lift trucks equipped with Yanmar diesel engine
do not have an ECM.
NOTE: Lift trucks equipped with 2007 Mazda emission
compliant engines and lift trucks built after January,
2010 equipped with Mazda engines, do not have a
governor controller and the ECM for these engines is
mounted on the side of the engine.
16. For lift trucks built before 2007, equipped with
Mazda engines - Disconnect the electronic control
module (ECM) connector and governor controller
from the side of the frame before removing the en-
gine from the truck.
17. 2007 Mazda emission compliant engines only
- Disconnect the engine harness connectors from
the right hand chassis harness connectors before
removing the engine from the truck.
18. Lift trucks built after January, 2010 equipped
with Mazda engines - Disconnect the engine har-
ness connectors from the right hand chassis har-
ness connectors before removing the engine from
the truck.
19. Use the access port on the side of engine and re-
move the four bolts that attach the flywheel to the
torque converter. See Figure 24.
20. Connect a lifting device to the engine. Put a block
under the transmission housing to support the
transmission.
NOTE: Perform Step 21 for lift trucks equipped with iron
housing transmission.
21. Remove capscrews from transmission bell housing.
A. TYPICAL FOR MAZDA AND YANMAR ENGINES B. TYPICAL FOR GM ENGINES
1. ACCESS PORT 2. FLYWHEEL HOUSING
Figure 24. Torque Converter Bolt Access
29

NOTE: Perform Step 22 through Step 24 for lift trucks
equipped with aluminum housing transmission.
22. Remove two capscrews, two washers, and con-
verter housing cover from torque converter hous-
ing. See Figure 25.
23. Remove four flange bolts from torque converter
housing and flywheel housing on transmission
side. See Figure 25.
24. Remove six hex head capscrews and six lock wash-
ers from flywheel housing and torque converter
housing on flywheel housing side. See Figure 25.
WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The en-
gine can weigh approximately 194 kg (428 lb).
25. Remove the flange nuts, washers, bolts, and iso-
lators from the engine mounts. Remove engine
adapter to transmission bolts. On trucks equipped
with a GM 2.4L engine, remove one starter bolt.
See Figure 26 and Figure 27.
NOTE: TYPICAL FOR ALL ENGINES. GM 2.4L LPG AND ALUMINUM CASE TRANSMISSION SHOWN.
1. CONVERTER HOUSING COVER
2. CAPSCREW
3. WASHER
4. TORQUE CONVERTER HOUSING
5. EYEBOLT BRACKET
6. HEX HEAD CAPSCREW
7. FLYWHEEL HOUSING
8. TRANSMISSION ASSEMBLY
9. FLANGE BOLT
10. LOCKWASHER
11. ENGINE ASSEMBLY
Figure 25. Flywheel and Torque Converter Housings
30

A. MAZDA ENGINE
B. GM 2.4L ENGINE
1. FRAME
2. ENGINE MOUNT
3. FLANGE NUT
Figure 26. Engine Removal
A. MAZDA AND YANMAR ENGINE MOUNT
B. GM ENGINE MOUNT
1. LEFT ENGINE MOUNT
2. RIGHT ENGINE MOUNT
3. WASHER
4. CAPSCREW
5. CROSSMEMBER
6. ISOLATOR
7. FLANGE NUT
Figure 27. Engine Mounts
31

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.
CAUTION
Keep the engine level when the engine is separated
from the transmission so the drive plate is not dam-
aged.
26. Use the lifting device to carefully move the engine
away from the torque converter. Make sure all
hoses, wires, and cables are disconnected from
the engine, then lift the engine from the frame and
place engine on blocks.
27. Remove torque converter from torque converter
housing.
INSTALL
WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The en-
gine can weigh approximately 194 kg (428 lb).
CAUTION
Keep the engine level when installing the engine to
the transmission so the drive plate is not damaged.
1. Install torque converter in torque converter housing.
2. Connect lifting device to engine and lift engine into
frame.
3. Install isolators on engine mounts. Install the nuts
and bolts for the engine mounts to secure engine to
frame. See Figure 26 and Figure 27. Tighten the
nuts to 150 N•m (110 lbf ft).
4. Use access port on side of engine and install bolts
to hold torque converter to flywheel. Tighten bolt to
56 N•m (41 lbf ft). See Figure 24.
NOTE: Perform Step 5 for lift trucks equipped with iron
transmission housing.
5. Align transmission bell housing holes with flywheel
housing holes and install capscrews. Tighten cap-
screws to 38 N•m (28 lbf ft).
NOTE: Perform Step 6 through Step 9 for lift trucks
equipped with aluminum transmission housing.
6. Install six lock washers and six capscrews on
flywheel housing and torque converter housing
from flywheel housing side. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 25.
7. Install four flange bolts on torque converter hous-
ing and flywheel housing from transmission side.
Tighten bolts to 38 N•m (28 lbf ft). See Figure 25.
8. On trucks equipped with a GM 2.4L engine, install
starter bolt.
9. Install converter housing cover, two washers,
and two capscrews on torque converter housing.
Tighten capscrews to 19 N•m (168 lbf in). See
Figure 25.
NOTE: For procedures to install exhaust pipe to ex-
haust manifold for lift trucks equipped with a Mazda
2007 emissions compliant engine and for lift trucks built
after January, 2010 equipped with a Mazda engine, see
Gasoline Fuel System, Mazda FE and F2Emission
Compliant Engines 900 YRM 1325 or LPG Fuel Sys-
tem, Mazda FE and F2 Emission Compliant Engines
900 YRM 1326.
10. Install exhaust pipe to exhaust manifold. See Ex-
haust System Repair.
11. For lift trucks built before 2007, equipped with
Mazda engines - Connect the ECM connector and
governor controller to lift truck frame.
12. On lift trucks equipped with a Mazda 2.0L or 2.2L
engine, install ECM bracket with ECM attached and
two bolts on engine block.
WARNING
All fuels are very flammable and can burn or cause
an explosion. DO NOT use an open flame to check
the fuel level or to check for leaks in the fuel system.
No smoking.
Breathing fuel vapor may cause nausea, uncon-
sciousness or death. Long term exposure to
gasoline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
13. Connect the wires and wiring harnesses at the en-
gine. Remove caps from fuel lines and connect the
fuel lines at the engine.
32

NOTE: On trucks equipped with the GM 2.4L engine,
connect the ECM and install ECM and mounting bracket
to air filter with two bolts, before installing the air filter to
lift truck.
14. On lift trucks equipped with a Mazda engine (ex-
cept Mazda 2007, and later, emission compliant
engines) and Basic Powershift Transmission, con-
nect the throttle linkage (see the section Power-
shift Transmission, Repair 1300 YRM 1129). In-
stall the air filter assembly.
15. 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.
16. Install the radiator shroud, fan pulley, and fan as-
sembly. See the section Cooling System 700 YRM
1123 for the installation procedures.
17. Connect the PDM and connect the ground strap to
lift truck frame and attach it to battery. Install the
battery and battery tray. See Figure 23.
18. If lift truck is equipped with an LPG tank, swing tank
into position on truck. See one of the following Ser-
vice Manuals for procedures:
(B875)
GC/GLC040SVX (C809)
(C810)
(B875)
models
GC/GLC040SVX (C809)
(C810)
(B875)
19. Install the rear side covers, floor plates, floor mat,
and hood and seat combination. See the section
Hood, Seat, and Side Covers Replacement for the
procedures.
20. If removed, install Overhead guard. See section
Overhead Guard Replacement for procedures.
21. Check all fluid levels as described in the section
models
(B875)
models
GC/GLC040SVX (C809)
(C810)
CAUTION
22. Empty drain pan contents.
33

Transmission Replacement 100 YRM 1120
23. If lift truck is equipped with an LPG fuel tank, swing
tank into position on back of counterweight and
open shutoff valve on tank. See one of the follow-
ing Service Manuals.
(B875)
GC/GLC040SVX (C809)
(C810)
(B875)
models
GC/GLC040SVX (C809)
(C810)
(B875)
Transmission Replacement
REMOVE TRANSMISSION WITH IRON
HOUSING
WARNING
of maintenance and repairs. The removal of the fol-
lowing assemblies will cause large changes in the
center of gravity: mast, drive axle, engine, trans-
mission, and counterweight. When the lift truck is
put on blocks put additional blocks in the following
positions to maintain stability:
fall forward.
units. See the Operating Manual or
See section Periodic Maintenance 8000 YRM 1207
for lift truck models
(C809)
(B875)
1. Remove engine from lift truck. See section Re-
move, Engine Replacement for procedures.
2. Remove the seal plate for the brake and throttle
pedals. See Figure 6.
NOTE: When disconnecting wiring harness connectors
during removal, tag each connector to aid in connecting
wiring harness during installation.
3. Disconnect the engine wiring harness from trans-
mission wiring harness.
4. Disconnect transmission cooling lines.
NOTE: Step 5 applies to lift truck models equipped with
a hydraulic gear pump.
5. Remove the hydraulic hose between the hydraulic
pump and the tank. Put a cap on the tank fitting.
Remove the supply line from hydraulic pump to the
main control valve.
34

100 YRM 1120 Transmission Replacement
NOTE: Step 6 and Step 7 apply to lift truck models
GLP/GDP20-35VX (B875) equipped with a variable dis-
placement pump (VDP):
6. Remove the hydraulic supply (suction) hose be-
tween the variable displacement pump and hy-
draulic tank. Put a cap on the hydraulic tank fitting.
See Figure 28.
7. Remove the hydraulic supply hose, load sense line,
drain case line, and hydraulic inlet line from the vari-
able displacement pump. Put cap on all variable
displacement pump and hose openings. See Fig-
ure 28.
WARNING
The transmission is heavy. Make sure that any lift-
ing device has enough capacity to lift the weight.
The transmission can weigh approximately 317 kg
(699 lb).
1. TRANSMISSION HOUSING
2. VARIABLE DISPLACEMENT PUMP
3. LOAD SENSE LINE
4. HYDRAULIC INLET LINE
5. DRAIN CASE LINE
6. HYDRAULIC SUPPLY (SUCTION) HOSE
Figure 28. Hydraulic Hose Connections, Lift Truck
Models GLP/GDP20-35VX (B875) Equipped With
Variable Displacement pump
8. Connect a lifting device to support the transmission.
9. Remove the capscrew, washer, snubbing washers,
and isolators from the mount bracket at the rear of
the transmission. See Figure 29.
10. Use a lifting device to carefully lift the transmission
out of the frame. Slip the transmission output yoke
out of the transmission. Make sure to not damage
the seal.
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.
1. MOUNT BRACKET
2. CAPSCREW
3. WASHER
4. SNUBBING WASHER
5. ISOLATOR
Figure 29. Rear Mount - Transmission
35

INSTALL TRANSMISSION WITH IRON
HOUSING
WARNING
The transmission can weigh approximately 317 kg
(699 lb).
1. Using a lifting device, install transmission in lift truck
frame. Place a block under the transmission hous-
ing to support the transmission.
2. Install the transmission output yoke on the trans-
mission. Be sure to not damage the seal. Tighten
the bolt to 38 N•m (28 lbf ft).
3. Install the isolators, snubbing washers, washer, and
capscrew on the mounting bracket at the rear of the
transmission. See Figure 29. Tighten capscrew to
225 to 250 N•m (166 to 184 lbf ft).
4. Remove lifting device from the transmission.
NOTE: Step 5 applies to lift truck models equipped with
a hydraulic gear pump.
5. Install the hydraulic hose between the pump and
the tank. Install the hydraulic filter and hoses. Con-
nect the supply line to the main control valve. See
Hydraulic Gear Pump 1900 YRM 1136 for more
information on installing hydraulic hoses to gear
pump.
NOTE: Step 6 and Step 7 apply to lift truck models
GLP/GDP20-35VX (B875) equipped with a variable dis-
placement pump (VDP).
6. Install the hydraulic supply hose between the vari-
able displacement pump and hydraulic tank. See
Figure 28.
7. Install the hydraulic supply hose, load sense line,
drain case line, and hydraulic inlet line on the vari-
able displacement pump. See Figure 28. See Hy-
draulic Gear Pump 1900 YRM 1136 for more in-
formation on installing hydraulic hoses to variable
displacement pump.
8. Connect the transmission wiring harness to engine
wiring harness. Connect transmission cooling
lines.
9. Install the seal plate for the brake and throttle ped-
als. See Figure 6.
10. Install engine in lift truck. See section Install, En-
gine Replacement for procedures.
REMOVE TRANSMISSION WITH
ALUMINUM HOUSING
WARNING
of maintenance and repairs. The removal of the fol-
lowing assemblies will cause large changes in the
center of gravity: mast, drive axle, engine, trans-
mission, and counterweight. When the lift truck is
put on blocks put additional blocks in the following
positions to maintain stability:
fall forward.
units. See the Operating Manual or
(C809)
(B875)
WARNING
The transmission can weigh approximately 83.8 kg
(184.7 lb).
NOTE: Make sure the transmission is supported by
blocks or a lifting device before removing the engine.
1. Remove engine from lift truck. See section Re-
move, Engine Replacement for procedures.
36

2. Remove the seal plate for the brake and throttle
pedals. See Figure 6.
NOTE: When disconnecting wiring harness connectors
during removal, tag each connector to aid in connecting
wiring harness during installation.
3. Disconnect the engine wiring harness from trans-
mission wiring harness.
4. Disconnect transmission cooling lines from trans-
mission.
See Figure 30 and Figure 31 for the following lift
truck models equipped with a hydraulic gear pump
GC/GLC040SVX (C809)
(C810)
(B875)
See Figure 32 and Figure 33 for lift truck mod-
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875) equipped with a hydraulic gear pump.
See Figure 34 and Figure 35 for lift truck models
GLP/GDP20-35VX (B875) equipped with a variable
displacement pump.
CAUTION
NOTE: Perform Step 5 for lift trucks equipped with dry
brakes.
5. Place a suitable container under transmission; re-
move drain fitting from transmission housing and
drain transmission oil.
GC/GLC040SVX (C809)
(C810)
(B875)
See Figure 34 for lift truck models GLP/GDP20-
35VX (B875) equipped with a variable displace-
ment pump.
NOTE: Perform Step 6 and Step 7 for lift trucks
equipped with wet brakes.
6. Place a suitable container under transmission; dis-
connect wet disk brake hose assembly from trans-
mission and drain transmission and transaxle oil.
ment pump.
7. Disconnect and cap high temp hose assembly from
transmission cooling support port. Cap transmis-
sion cooling supply port.
ment pump.
8. Disconnect and cap suction hose from hydraulic
gear pump inlet port. Cap hydraulic gear pump in-
let port.
GC/GLC040SVX (C809)
(C810)
(B875)
(B875)
37

displacement pump.
2. DRAIN FITTING
3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
5. HYDRAULIC GEAR PUMP INLET PORT
6. HYDRAULIC GEAR PUMP OUTLET PORT
7. HYDRAULIC INLET HOSE
8. TRANSMISSION COOLING LINE
Figure 30. Hydraulic Hose, Dry Brakes (Aluminum
Transmission Prior to January, 2011)
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND
ADAPTERS NOT SHOWN.
2. DRAIN FITTING
4. SUCTION HOSE
8. TRANSMISSION COOLING LINE
Transmission After January, 2011)
Figure 32. Hydraulic Hose, Wet Brakes (Aluminum
Transmission Prior to January, 2011)
38

2. WET DISK BRAKE HOSE ASSEMBLY
4. SUCTION HOSE
8. HIGH TEMP HOSE ASSEMBLY
9. TRANSMISSION COOLING SUPPLY PORT
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND
ADAPTERS NOT SHOWN.
4. SUCTION HOSE
8. HIGH TEMP HOSE ASSEMBLY
Transmission After January, 2011)
2. DRAIN FITTING
4. LOAD SENSE LINE
5. DRAIN CASE LINE
7. TRANSMISSION COOLING LINES
8. SUCTION HOSE
9. PUMP INLET PORT
10. PUMP OUTLET PORT
Transmission After January, 2011), Lift Truck
Variable Displacement Pump
39

3. LOAD SENSE LINE
4. DRAIN CASE LINE
6. HIGH TEMPERATURE LINE
8. TRANSMISSION COOLING HOSES
10. PUMP INLET PORT
11. PUMP OUTLET PORT
12. SUCTION HOSE
Transmission After January, 2011), Lift Truck
Variable Displacement Pump
NOTE: Perform Step 9 for lift truck models GLP/GDP20-
35VX (GP/GLP/GDP040-070VX) (B875) equipped with
a Quick-Lok™ hydraulic hose and adapter.
9. Remove adapter and Quick-Lok hydraulic hose
from hydraulic gear pump outlet port. Cap hy-
draulic gear pump outlet port.
10. For lift trucks not equipped with Quick-Lok hydraulic
hose and adapters, disconnect and cap hydraulic
inlet hose from hydraulic gear pump outlet port.
Cap hydraulic gear pump outlet port.
GC/GLC040SVX (C809)
(C810)
(B875)
displacement pump.
NOTE: Step 11 applies only to lift truck models GLP/
GDP20-35VX (B875) equipped with a variable displace-
ment pump.
11. Disconnect and cap the load sense line and drain
case line from the variable displacement pump.
See Figure 34 and Figure 35.
12. Remove the capscrew, washer, snubbing washers,
and isolators from the mount bracket at the rear of
the transmission. See Figure 36.
13. Use the lifting device to carefully lift the transmis-
sion from the frame. Slip the transmission output
yoke out of the transmission. Make sure to not dam-
age the seal.
14. Remove flange head capscrew, yoke, and spacer
from transmission. Make sure to not damage the
seal. See Figure 37.
NOTE: Note position of oil seal prior to removal to aid
in installation.
15. Remove oil seal from transmission housing. See
Figure 37.
40

NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.
1. MOUNT BRACKET
2. CAPSCREW
3. WASHER
4. SNUBBING WASHER
5. ISOLATOR
Figure 36. Rear Mount- Transmission
1. FLANGE HEAD CAPSCREW
2. STAT-O-SEAL
3. YOKE
4. OIL SEAL
5. SPACER
Figure 37. Drive Shaft Yoke
INSTALL TRANSMISSION WITH
ALUMINUM HOUSING
WARNING
(184.7 lb).
1. Using a lifting device, install transmission in lift truck
frame. Place a block under the transmission hous-
ing to support the transmission.
2. Install oil seal on back of transmission housing. See
Figure 37.
3. Install new stat-o-seal on yoke. See Figure 37.
4. Install spacer, yoke, and flange head capscrew on
back of transmission. See Figure 37. Tighten cap-
screw to 77 N•m (57 lbf ft).
41

5. Install isolators, snubbing washers, washer, and
capscrew on mounting bracket at the rear of the
transmission. See Figure 36. Tighten capscrew to
225 to 250 N•m (166 to 184 lbf ft).
6. Remove lifting device from transmission.
NOTE: Perform Step 7 for lift truck models GLP/GDP20-
35VX (GP/GLP/GDP040-070VX) (B875) equipped with
a Quick-Lok™ hydraulic hose and adapter.
7. Remove cap and install adapter and Quick-Lok hy-
draulic hose to hydraulic gear pump outlet port.
Tighten adapter to 59 to 69 N•m (44 to 51 lbf ft).
8. For lift truck not equipped with Quick-Lok hydraulic
hose and adapters, connect hydraulic inlet hose to
fitting on hydraulic gear pump outlet port.
GC/GLC040SVX (C809)
(C810)
(B875)
displacement pump.
9. Connect suction hose to hydraulic gear pump inlet
port.
GC/GLC040SVX (C809)
(C810)
(B875)
displacement pump.
brakes.
10. Install drain fitting on transmission housing.
GC/GLC040SVX (C809)
(C810)
(B875)
ment pump.
NOTE: Perform Step 11 and Step 12 for lift trucks
equipped with wet brakes.
11. Connect high temp hose assembly to transmission
cooling support port.
ment pump.
12. Connect wet disk brake hose assembly to transmis-
sion.
(B875) equipped with a variable displacement
pump.
ment pump.
42

13. Connect transmission cooling lines to transmission.
GC/GLC040SVX (C809)
(C810)
(B875)
displacement pump.
NOTE: Step 14 applies only to lift truck models GLP/
GDP20-35VX (B875) equipped with a variable displace-
ment pump.
14. Connect the load sense line and drain case line
to the variable displacement pump. See Figure 34
and Figure 35.
15. Connect transmission wiring harness to engine
wiring harness.
16. Install the seal plate for the brake and throttle ped-
als. See Figure 6.
WARNING
(184.7 lb).
NOTE: Make sure the transmission is supported by
blocks or a lifting device before installing the engine.
17. Install engine to lift truck. See section Install, En-
gine Replacement for procedures.
brakes.
18. Fill transmission oil. For fill instruction, oil type, and
amount,
See section Periodic Maintenance 8000 YRM
GC/GLC040SVX (C809)
(C810)
See section Periodic Maintenance 8000 YRM
(B875)
NOTE: Perform Step 19 for lift truck equipped with wet
brakes.
19. Fill transmission and transaxle oil. For fill instruc-
tion, oil type, and amount, see section Periodic
Maintenance 8000 YRM 1150 for lift truck model
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875).
43

Throttle Pedal and Cable Adjustment 100 YRM 1120
Throttle Pedal and Cable Adjustment
NOTE: There are no throttle pedal and cable adjust-
ments for lift trucks equipped with the GM 2.4L engine.
The GM 2.4L engines have an electronic throttle that is
self-adjusting and self-calibrating.
NOTE: For the Mazda 2007 emission compliant en-
gines and for lift trucks built after January, 2010 and
equipped with a Mazda engine, there is only a throttle
pedal stop adjustment. The engine has an electronic
throttle that is self-adjusting and self-calibrating. See
Throttle Pedal Stop Adjustment for procedures.
MAZDA GAS/LPG ENGINES WITH BASIC
POWER SHIFT TRANSMISSION AND
ELECTRONIC TRANSMISSION (EXCEPT
MAZDA EMISSION COMPLIANT ENGINES)
1. Remove floor plate and disconnect throttle cable
from the bellcrank and engine. See Figure 38.
2. Fully depress throttle pedal and verify that the di-
mension between the bellcrank and cowl plate is 6
±2 mm (0.24 ±0.08 in.).
3. If dimension is not correct, adjust ball ends on
push rod so that a minimum of 6 mm (0.24 in.) of
threaded rod screws into each ball end.
4. Connect throttle cable to bellcrank and engine. See
Figure 38.
5. With throttle pedal in full up position, adjust throttle
cable, using the jam nuts (item #10 in Figure 38) to
remove all slack from the cable. Cable should be
adjusted to the point where additional adjustment
will pull the throttle crank off the idle stop. Tighten
jam nuts to 8 to 15 N•m (71 to 133 lbf in).
NOTE: If lift truck is equipped with a Electronic Control
Transmission, see the section Calibration Procedures
8000 YRM 1134 for additional adjustment procedures
before going onto Step 7.
6. Fully depress pedal and verify that full pedal stroke
brings the throttle crank to within 3.0 mm (0.12 in.)
of the wide open throttle stop. See Figure 38.
7. Install floor plate. Fully depress throttle pedal and
adjust pedal stop so that it touches floor plate.
Tighten jam nuts 8 to 15 N•m (71 to 133 lbf in)
(item #12 in Figure 38).
NOTE: THROTTLE PEDAL SHOWN IN WIDE OPEN POSITION (FULLY DEPRESSED POSITION).
A. MAZDA GAS ENGINE B. MAZDA LPG ENGINE
1. BELL CRANK
2. COWL
3. PUSH ROD
4. BALL END
5. PEDAL STOP
6. THROTTLE PEDAL
7. FLOOR PLATE
8. THROTTLE CABLE
9. BRACKET
10. JAM NUTS
11. THROTTLE CRANK
12. JAM NUT
44

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