Yale d879 gdc60 vx lift truck (europe) service repair manual

GLC/GDC60VX, GLC/GDC70VX (D879)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524288189 0100 YRM 1316 08/13
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM (GM 4.3L)...................................................................................... 524262275 0900 YRM 1242 08/12
LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14
THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... 524288194 1300 YRM 1317 03/13
TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... 524294873 1300 YRM 1343 03/14
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)................... 524288199 1400 YRM 1318 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13
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 A513, A514, A613, A614, B513, B514)..................... 524294878 2100 YRM 1328 02/14
HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14
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
MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706,
A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749,
B750, B751, B752, B753, B754)................................................................................ 524265342 4000 YRM 1250 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 524288207 8000 YRM 1319 01/14
CAPACITIES AND SPECIFICATIONS........................................................................... 524288212 8000 YRM 1320 12/12
DIAGRAMS AND SCHEMATICS.................................................................................... 524329117 8000 YRM 1387 04/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550001092 8000 YRM 1409 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
9000 YRM 1112 ON CD
PART NO. 524329187 (12/14)

100 YRM 1316 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 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.
If additional engine repairs are necessary for lift trucks
covered in this manual see:
• GM Engines, 4.3 Liter V-6 600 YRM 1251
• Kubota Diesel 3.8L Engines 600 YRM 1557
If additional transmission repairs are necessary for lift
trucks covered in this manual see:
• Powershift Transmission, Repair 1300 YRM 1129
• Powershift Transmission, Repair 1300 YRM 1529
• One and Two Speed Transmissions, Repair 1300
YRM 1569
• Three-Speed Powershift Transmission Repair
1300 YRM 1317
• Two-Speed Powershift Transmission Repair 1300
YRM 1343
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 and transmission, and exhaust system
are found in this section. Checks for the operator re-
straint 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 2.
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

Description 100 YRM 1316
1. COWL PLATE
2. FENDERS
3. HOOD MOUNTS
4. COUNTERWEIGHT MOUNTS
5. HYDRAULIC TANK
6. FUEL TANK (GAS OR DIESEL)
Figure 1. Frame
2

100 YRM 1316 Hood, Seat, Dash, and Side Covers Replacement
Hood, Seat, Dash, and Side Covers Replacement
REMOVE
1. Remove the floor mat and floor plate. See Figure 3.
2. Slide the seat to the closest position to the steering
column.
3. Fully tilt the steering column forward.
4. If your truck is equipped with an LPG tank, swing
the tank off to the side. Push in the bracket re-
lease pin, swing the tank and bracket out to the
side of the lift truck. If your truck is equipped with
a swing-out and drop-down LPG tank bracket (EZ
Tank Bracket), swing the tank down to the side of
the truck for ease of removal. See one of the fol-
lowing Service Manuals for procedures to swing
the LPG tank to the side.
LPG Fuel System, GM 4.3L Engine With GFI 900
YRM 1242 for lift truck models:
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879,
D879)
LPG Fuel System, GM 4.3L Engine With PSI 900
GDC135VX, GC/GLC/GDC155VX) (D879, E879,
F879)
5. Raise the hood latch, unlatch and lift up the hood.
See Figure 2.
6. Remove the two capscrews holding the left and
right rear side panel to the frame. Remove the rear
side panel from the frame. See Figure 3.
3

Hood, Seat, Dash, and Side Covers Replacement 100 YRM 1316
NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.
A. SIDE VIEW OF HOOD AND SEAT
B. SIDE VIEW OF HOOD
C. BOTTOM VIEW OF HOOD
D. 3-D VIEW OF VENTED HOOD WITH SWIVEL
SEAT
1. SEAT
2. HOOD
3. FRAME
4. SEAT WIRE HARNESS
5. SEAT WIRE HARNESS CONNECTOR
6. CABLE CLIPS
7. HINGE SCREWS
8. GAS SPRING
9. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (SEMI-SUSPENSION)
10. SEAT WIRE HARNESS BRACKETS
11. SEAT LINER
12. HOOD LATCH
SEAT (NON-SUSPENSION)
SEAT (FULL SUSPENSION)
15. SPACER
16. FLANGE NUTS
Figure 2. Hood and Seat Arrangement
4

1. DEBRIS COVER
2. COUNTERWEIGHT COVER
3. RADIATOR COVER
4. LEFT SIDE REAR PANEL (GAS AND DIESEL
SHOWN)
5. RIGHT SIDE REAR PANEL
6. UPPER STEERING
COLUMN COVER
7. LOWER STEERING
COLUMN COVER
8. SEAL
9. FLOOR MAT
10. FLOOR PLATE
11. SPLASH SHIELD
(GAS AND DIESEL)
12. CAPSCREW
13. FOLD OVER NUT
14. SEAL PLATE ASSEMBLY
15. RIGHT SIDE FRONT
FENDER COVER
16. RIGHT SIDE STEP PLATE
17. RIGHT SIDE STEP PLATE
18. DASH ASSEMBLY
19. KICK PANEL
Figure 3. Side Covers, Floor Plate, and Cowl Components
5

7. Remove the two capscrews holding the left and
right fender covers to the front overhead guard leg.
Remove covers. See Figure 3.
8. Remove the four capscrews holding the left and
right front side panels to the frame. Remove pan-
els.
9. Fully lower the steering column.
10. Remove upper steering column cover by pulling
up on upper steering column cover to release the
latches (one on either side), and pulling cover away
from steering column. See Figure 4.
11. Remove the five fasteners (see Figure 4) securing
the dash to the top of the cowl. Remove the four
clips, located underneath dash, that attach the dash
to the kick panel. Lift to remove the dash.
12. Lift the kick panel to remove it from the truck. See
Figure 3.
13. Remove the three capscrews holding the seal plate.
Remove seal plate. See Figure 5.
14. Disconnect the seat wire harness connector. See
Figure 2.
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 the seat is to be removed, and truck is equipped
with a non-swivel seat, remove the seat wire har-
ness from the seat wire harness brackets that are
attached to the underside of the hood. Remove the
cable clips from the seat wire harness. If truck is
equipped with a swivel seat, remove seat wire har-
ness from seat wire harness bracket attached to the
underside of the hood and behind the seat. See
Figure 2.
16. Remove the four flange nuts holding the seat to the
hood. Lift the seat off the hood. Pull the seat wire
harness through the hood. See Figure 2.
17. Remove the capscrews and washers at the top of
the gas springs. Remove gas springs from the
hood. See Figure 2.
18. Remove the hinge screws, located in the rear of the
hood.
19. Lift the hood from the truck. See Figure 2.
INSTALL
1. Place the hood onto the lift truck frame.
2. Install the hinge screws, located in the rear of the
hood, and tighten to 38 N•m (28 lbf ft). See Fig-
ure 2.
3. Align the holes in the gas springs with holes in the
hood. There are two sets of holes used to install
the gas springs to the hood, based on the type of
seat the installed on the lift truck. One set is for
installing the cylinder end of the gas springs and
the other set is for attaching the rod end of the
gas springs. Install capscrews and washers to at-
tach gas springs to the hood. Refer to Figure 6
and Table 1 for correct holes used to connect the
rod end of the cylinder, depending on the type of
seat installed on the lift truck. Tighten capscrews
to 19.2 N•m (170 lbf in).
6

NOTE: TOP VIEW OF DASH SHOWN.
A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN SCREWS
2. COWL
3. UPPER STEERING COLUMN COVER
4. LOWER STEERING COLUMN COVER
Figure 4. Remove Dash From Cowl
7

1. CAPSCREWS 2. SEAL PLATE
Figure 5. Remove Seal Plate From Dash
8

NOTE: SEE TABLE 1 FOR HOLES TO USE TO ATTACH ROD END OF GAS SPRING.
A. LEFT SIDE
B. RIGHT SIDE
C. FULL SUSPENSION SEAT
D. NON-SUSPENSION SEAT
1. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT
2. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT
Figure 6. Gas Spring Installation
9

Table 1. Gas Spring Installation, Holes for Installing Rod Ends (See Figure 6)
Full or Semi Suspension Seat Non-Suspension SeatCounterweight
Type
Left Side Right Side Left Side Right Side
Standard
Counterweight
2 2 1 1
4. Install latch striker in highest slot position. Check
that latch striker is in center of jaws of hood latch
when hood closes. Open and close the hood to en-
sure that the center pin strikes the hood latch prop-
erly and that the stop screw contacts the frame. A
properly closed hood MUST click twice on the hood
latch. If the hood latch does not close properly,
loosen the capscrews on the back of the center pin
and adjust the center pin up or down as required for
correct alignment. See Figure 7.
5. Push down until hood just touches rubber bumper.
Make sure latch striker is still in center of hood latch.
Open hood and tighten capscrews for latch.
CAUTION
When installing the seat to the hood, do not use an
impact wrench to install the capscrews. Damage
can be caused to the threads on the screws and in
the holes.
6. Place the seat on the hood and thread the seat wire
harness through the hole in the hood. See Figure 2.
7. Align the holes in the seat with the holes in the
hood. Insert washers and capscrews. Tighten cap-
screws to 18 N•m (159 lbf in).
8. If truck is equipped with a non-swivel seat, tie cable
clips to seat wire harness and insert harness into
seat wire harness brackets under hood. If truck is
equipped with a swivel seat, secure seat harness
to bracket. See Figure 2.
9. Check operation of hood latch. Have an opera-
tor sit in the seat. Make sure hood is fully closed
(two clicks). Also check that hood touches rubber
bumper. If necessary, repeat Step 5.
10. Using three capscrews, Install seal plate. See Fig-
ure 5.
11. Install kick panel onto truck. See Figure 3.
12. Install dash and allen screws to top of cowl. See
Figure 4. Tighten capscrews to 0.5 to 0.6 N•m (5 to
6 lbf in).
13. Install four clips to attach the dash to kick panel.
See Figure 4.
10

14. Install upper and lower steering column covers by
connecting the two covers together and pressing
each side until latched.
15. Using four capscrews, install the left and right front
side panels to frame. See Figure 3.
16. Using two capscrews install the left and right fender
covers to front of overhead guard legs.
17. Using two capscrews, install the left and right rear
side covers to frame. See Figure 3.
18. Install the floor mat and floor plate.
19. If truck is equipped with an LPG tank, swing
LPG tank into position on back of counterweight.
See one of the following Service Manuals for
procedures to swing the LPG tank onto the coun-
terweight.
D879)
GDC135VX, GC/GLC/GDC155VX) (D879, E879,
F879)
20. Adjust the steering column and seat positions. 1. HOOD
2. HOOD LATCH
3. CENTER PIN
4. CAPSCREW
Figure 7. Hood Latch Adjustment
11

Steering Column 100 YRM 1316
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 8.
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 battery connector or negative bat-
tery cable stating, DO NOT CONNECT BATTERY.
Move steering column to 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 removal of all components
of steering column assembly. Not all components are
removed for a repair procedure. Do only those steps of
procedure necessary to remove required component.
NOTE: Tag wires prior to disconnect.
3. Remove horn button assembly and disconnect
electrical wires. Remove large hex nut and steer-
ing wheel from steering column. See Figure 9.
4. Remove steering column covers. Remove floor
mats and floor plate. See section Hood, Seat,
Dash, and Side Covers Replacement.
NOTE: Perform Step 5 for lift trucks equipped with gas
or LPG engines.
5. Remove four capscrews, four bushings and steer-
ing column from cowl standoffs. See Figure 10.
NOTE: Perform Step 6 for lift trucks equipped with
diesel engines.
6. Remove four capscrews, four bushings, four isola-
tors, steering column and four isolators from cowl
standoffs. See Figure 10.
Disassemble
NOTE: Remove and discard snap rings if installed.
1. Remove two pins and gas spring from housing.
See Figure 11, for lift trucks manufactured before
January, 2012.
See Figure 12, for lift trucks manufactured after 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.
12

100 YRM 1316 Steering Column
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.
1. STEERING WHEEL
2. STEERING COLUMN
3. COWL
Figure 8. Steering Column and Cowl
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
Figure 9. Steering Wheel Remove/Install
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.
1. CAPSCREW
2. BUSHING
3. ISOLATOR
4. STEERING COLUMN
5. COWL STANDOFF
Figure 10. Steering Column Remove/Install
13

Figure 11. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012
14

100 YRM 1316 Steering Column
Legend for Figure 11
1. PIN
2. LOWER SHAFT
3. SPLIT PIN
4. UPPER SHAFT
5. HOUSING
6. HORN CONTACT
7. SCREW
8. FASTENER
9. CONNECTOR BRACKET
10. PIVOT BOLT
11. BUSHING
12. NUT
13. GAS SPRING
14. BRACKET
15. CONNECTOR
15

1. BRACKET
2. SPACER
3. JOINT
4. NUT
5. WASHER
6. SCREW
7. UPPER SHAFT
8. HOUSING
9. PIN
10. LOWER SHAFT
11. GAS SPRING
12. BOLT
13. BUSHING
14. CONNECTOR
15. FASTENER
16. HORN CONTACT
Figure 12. Steering Column Assembly, Lift Trucks Manufactured After January, 2012
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s
recommended safety precautions.
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.
16

100 YRM 1316 LPG Tank and Bracket Replacement
Assemble
NOTE: This procedure is for installation of all compo-
nents of steering column assembly. Not all components
are removed for a repair procedure. Do only those steps
of procedure necessary to install required component.
NOTE: Perform Step 1 only for lift trucks manufactured
before January, 2012.
1. Lubricate 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.
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 Periodic Maintenance Manual
for your lift truck.
NOTE: Perform Step 1 for lift trucks equipped with gas
or LPG engines.
1. Install steering column, four bushings and four
bolts on cowl standoffs. Tighten bolts to 38 N•m
(28 lbf ft). See Figure 10.
NOTE: Perform Step 2 for lift trucks equipped with
diesel engines.
2. Install four isolators, steering column, four isola-
tors, four bushings, and four bolts on cowl standoffs.
Tighten bolts to 38 N•m (28 lbf ft). See Figure 10.
3. Install floor plate, floor mats, and steering column
covers. See section Hood, Seat, Dash, and Side
Covers Replacement.
4. Install steering wheel and hex nut on steering 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 9.
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 Replacement
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.
YRM 1556 for lift truck models
• GLC40, 45, 55VX; GLC55SVX; (GLC080, 100,
120VX; GLC080, 100VXBCS; GLC120SVX;
GLC120VXPRS) (E818, F818)
• GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-
55VX (GLP080, 90, 100, 110, 120VX) (G813, H813,
J813)
• GLC60VX, GLC70VX (GLC135VX, GLC155VX)
(C879, D879)
(D879, E879, F879)
17

Counterweight Replacement 100 YRM 1316
Counterweight Replacement
REMOVE
WARNING
of maintenance and repair. The removal of the
fall forward.
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
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 frame
by two hooks that are part of frame. One M30 x 3.5
x 120 capscrew holds counterweight to lower part of
frame. See Figure 13.
NOTE: If lift truck is equipped with an overhead exhaust
system, remove overhead exhaust pipe before remov-
ing counterweight. See section Exhaust System Repair
for procedures.
1. If lift truck has an LPG fuel system, see one of the
following Service Manuals to remove the LPG tank
and bracket so that the counterweight can be re-
moved.
(C879, D879)
(D879, E879, F879)
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 Table 2.
2. Install a lifting eye in lift hole of counterweight. See
Figure 13. Connect a crane to lifting eye and raise
crane until it holds part of weight of counterweight.
Remove tow pin and remove capscrew that holds
counterweight to frame. See Figure 13. Use crane
to lift counterweight from lift truck. Put counter-
weight on floor so that it has stability and will not
fall over. Take care not to damage exhaust or cool-
ing components.
INSTALL
1. Make sure seals are on counterweight. See Fig-
ure 14.
2. Use a crane to install counterweight on lift truck.
When counterweight is installed, make sure hooks
on frame fully engage counterweight so it is aligned
with parts of frame. Install and tighten capscrew to
1020 N•m (750 lbf ft).
18

100 YRM 1316 Counterweight Replacement
3. Install tow pin and roll pin, if equipped. See section
Tow Pin for procedures.
4. If lift truck has an LPG fuel system, see one of the
following Service Manuals to install LPG tank and
bracket, after counterweight has been installed.
(C879, D879)
(D879, E879, F879)
5. If lift truck is equipped with an overhead exhaust
system, install overhead exhaust pipe. See section
Exhaust System Repair for procedures.
TOW PIN
Remove and Install
1. Remove tow pin from counterweight by driving roll
pin out. See Figure 15.
2. Install tow pin into counterweight and install roll pin.
Remove and Install For Lift Truck
ModelsGLC55SVX (GC/GLC80XVBCS,
GC/GLC100VXBCS; GC/GLC120SVX; and
GC/GLC120VXPRS) (E818, F818) and
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(J813)
1. Remove tow pin from counterweight by grasping
wire and pulling tow pin from counterweight. See
Figure 16.
2. Install tow pin into counterweight dropping tow pin
into counterweight.
1. FRAME HOOK
2. SEALS
3. CAPSCREW
5. COUNTERWEIGHT
6. TOW PIN
7. ROLL PIN
8. WASHER
Figure 13. Counterweight Installation
Table 2. Weight of Counterweights
Model Weight
GLC/GDC60VX
GLC/GDC70VX
GC/GLC/GDC135VX
GC/GLC/GDC155VX
(C879, D879, E879,
F879)
2779 kg (6126 lb)
19

Counterweight Replacement 100 YRM 1316
1. CAPSCREW
3. COUNTERWEIGHT
4. TOW PIN
5. ROLL PIN
6. WASHER
7. SEALS
Figure 14. Counterweight Components
20

100 YRM 1316 Counterweight Replacement
1. TOW PIN 2. ROLL PIN
Figure 15. Tow Pin
1. WIRE 2. TOW PIN
Figure 16. Tow Pin
21

Overhead Guard Replacement 100 YRM 1316
Overhead Guard Replacement
REMOVE
WARNING
DO NOT operate the lift truck without the overhead
guard correctly fastened to the lift truck.
WARNING
DO NOT weld mounts for lights or accessories to
legs of the overhead guard. Changes that are made
by welding, or by drilling holes that are too big or in
the wrong location, can reduce the 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 overhead guard depending upon lift-
ing device available. The ideal choices are a four point
sling connected to all four corners on top of overhead
guard, or a two point sling connected to two opposite
corners of overhead guard. If a single point hoist is
used, make sure that lift point is in center of overhead
guard. If during initial start of lift, the overhead guard
is off balance, lower immediately and move hoist to a
more centered point.
1. Connect a lifting device to remove overhead guard.
Loosen clamp and disconnect air intake hose from
elbow. Remove bolts, elbow, retainer, and grommet
from overhead guard rear leg. See Figure 17.
NOTE: Perform Step 2 for lift truck models GLC/
GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (F879) equipped with Diesel
Particulate Filter (DPF).
2. Disconnect wires from back of DPF display. See
Figure 19.
3. Disconnect wires between frame and overhead
guard. When overhead guard is lifted from frame,
make sure that electrical wires are moved through
holes in overhead guard so that they are not dam-
aged.
GC/GLC/GDC155VX) (C879, D879, E879).
4. The rear legs of overhead guard have two cap-
screws that are located under hood inside engine
compartment, next to radiator. Remove capscrews.
See Figure 18.
GC/GLC/GDC155VX) (F879).
5. The rear legs of overhead guard have three cap-
screws and a nut that are located under hood in-
side engine compartment, next to radiator. Remove
capscrews and nuts. See Figure 19.
6. Remove fender cover, dash, and kick panel to
remove two capscrews on front legs of overhead
guard. See Hood, Seat, Dash, and Side Covers
Replacement for removal procedures.
7. Using a lifting device, remove overhead guard from
frame and place on floor.
22

100 YRM 1316 Overhead Guard Replacement
INSTALL
1. Connect lifting device to top of overhead guard. In-
stall overhead guard in position on lift truck.
2. Install two capscrews on front legs of overhead
guard. Tighten capscrews to 66 N•m (49 lbf ft).
See Figure 18.
GC/GLC/GDC155VX) (F879) equipped with Diesel
Particulate Filter (DPF).
3. Connect wires to back of DPF display. See Fig-
ure 19.
4. Install fender cover, dash, and kick panel. See
Hood, Seat, Dash, and Side Covers Replacement
for installation procedures.
5. Install two capscrews on rear legs of overhead
guard. Tighten capscrews to 66 N•m (49 lbf ft).
See Figure 18.
GC/GLC/GDC155VX) (F879).
6. Install three capscrews and nut on rear legs of
overhead guard. Tighten capscrews to 66 N•m
(49 lbf ft). See Figure 19.
7. Connect air intake hose by installing bolts, elbow,
retainer, and grommet to overhead guard rear leg.
See Figure 17.
LED TAIL, BACKUP, AND BRAKE LIGHTS,
REPLACE
These light assemblies are nonrepairable and must be
replaced as an assembly. See section Electrical Sys-
tem 2200 YRM 1142 for procedures to replace these
lights.
1. CLAMP
2. AIR INTAKE HOSE
3. BOLTS
4. ELBOW
5. RETAINER
6. GROMMET
Figure 17. Disconnect Air Intake Hose
23

Overhead Guard Replacement 100 YRM 1316
1. CAPSCREWS - FRONT LEGS
2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME
Figure 18. Overhead Guard
1. CAPSCREWS - FRONT LEGS
2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME
5. DPF DISPLAY
6. NUT
Figure 19. Overhead Guard
24

100 YRM 1316 Operator Restraint System Replacement
Operator Restraint System Replacement
DESCRIPTION
The seat belt, hip restraint brackets, seat and mount-
ing, hood, and latches are all part of operator restraint
system. Each item must be checked to make sure it
is attached securely, functions correctly, and is in good
condition. See Figure 20.
The seat belt, when properly buckled across operator,
will permit slight operator repositioning without activat-
ing locking mechanism. If truck tips, travels off a dock,
or comes to a sudden stop, locking mechanism will be
activated and hold the operator’s lower torso in seat.
A seat belt that is damaged, worn or does not operate
properly will not provide protection when it is needed.
The end of belt must fasten correctly in latch. The seat
belt must be in good condition. Replace seat belt if
damage or wear is seen. See Figure 20.
The following seat belt operation checks must be per-
formed:
• With hood closed and in locked position, pull seat belt
slowly from retractor assembly. Make sure seat belt
pulls out and retracts smoothly. If seat belt does not
pull out of retractor assembly, internal latch may be
locked. Pull firmly on seat belt and hold for a mo-
ment to remove slack from belt in retractor. Release
seat belt. Seat belt will retract and internal latch will
unlock. If seat belt cannot be pulled from retractor
assembly or belt will not retract, replace seat belt as-
sembly.
• With hood closed and in locked position, pull seat belt
with a sudden jerk. Make sure seat belt will not pull
from retractor assembly. If seat belt can be pulled
from retractor, when it is pulled with a sudden jerk,
replace seat belt assembly.
• With hood in open position, make sure seat belt will
not pull from retractor assembly. If seat belt can be
pulled from retractor, with hood in open position, re-
place seat belt assembly.
Make sure seat rails and latch striker are not loose. The
seat rails must lock tightly in position, but move freely
when unlocked. The seat rails must be correctly fas-
tened to hood and hood fastened to hinges on frame.
The hood must be fully closed. Attempt to lift hood to
make sure it is closed.
Adjust hood, hood latch, and latch striker when any of
parts of operator restraint system are installed or re-
placed. See section Hood, Seat, Dash, and Side Cov-
ers Replacement in this manual for adjustment proce-
dures for hood.
25

Operator Restraint System Replacement 100 YRM 1316
1. WEIGHT ADJUSTMENT LEVER
2. HIP RESTRAINT
3. SEAT BELT LATCH
4. SEAT
5. HOOD
6. SEAT RAIL
7. SPACER
Figure 20. Operator Restraint System
26

100 YRM 1316 Engine Replacement
Engine Replacement
REMOVE ENGINE ONLY
WARNING
fall forward.
The engine can be removed with or without transmis-
sion. Follow procedures below to remove engine with-
out transmission. See Figure 21.
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
open flame, motor vehicles, electrical equipments,
or ignition source.
1. For lift trucks equipped with an LPG fuel system,
close shutoff valve on 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 side. See one of the following Service Man-
uals:
(C879, D879)
(D879, E879, F879)
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 system.
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 capacity of
cooling system under radiator. Remove radiator
cap.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
5. Open drain plug or loosen hose clamp and discon-
nect bottom radiator hose to drain coolant from ra-
diator and engine.
See Figure 22 and Figure 23 for lift trucks equipped
with GM 4.3L engine.
See Figure 24 for lift truck models equipped with
Cummins QSB 3.3L diesel engine.
See Figure 25 and Figure 26 for lift truck models
equipped with Kubota 3.8L diesel engine.
Cummins 4.5L diesel engine.
27

Engine Replacement 100 YRM 1316
Figure 21. Engine and Transmission Mounting Arrangement
28

NOTE: PART OF FRAME NOT SHOWN FOR CLARITY.
A. GM 4.3L ENGINE
B. CUMMINS 4.5L DIESEL ENGINE
C. CUMMINS QSB 3.3L DIESEL ENGINE
D. KUBOTA 3.8L DIESEL ENGINE
1. TRANSMISSION ISOLATOR ASSEMBLY
2. TRANSMISSION MOUNTING BRACKET
3. ENGINE MOUNTING BRACKET
4. ENGINE CROSSMEMBER
5. ENGINE ISOLATOR ASSEMBLY
6. FRAME
7. ENGINE HARNESS CONNECTOR
8. LEFT CHASSIS WIRING HARNESS
CONNECTOR
29

Figure 22. GM 4.3L LPG Engine with GFI and Transmission
30

NOTE: GFI FUEL SYSTEM SHOWN. PSI FUEL SYSTEM IS SIMILAR.
NOTE: GM 4.3L GASOLINE ENGINE IS SIMILAR.
A. TOP VIEW B. LEFT SIDE VIEW
1. BOTTOM RADIATOR HOSE
2. AIR FILTER HOSE
3. AIR FILTER AND BRACKET ASSEMBLY
4. LEFT HAND CHASSIS HARNESS CONNECTOR
6. LPG REGULATOR CONNECTOR
7. RIGHT HAND CHASSIS HARNESS
8. ELECTRONIC CONTROL MODULE (ECM)
9. POWER DISTRIBUTION MODULE (PDM)
10. BATTERY AND BATTERY TRAY
11. COOLANT HOSES
12. FAN PULLEY AND FAN SPACER
13. FAN
14. SHROUD
15. EXHAUST PIPE TO EXHAUST MANIFOLD
16. FUEL LINES
17. LEFT SIDE ENGINE MOUNT
18. STARTER MOTOR
19. CAPSCREWS
20. BELL HOUSING
21. RADIATOR CAP
22. OUTPUT YOKE
23. TRANSMISSION MOUNT
24. FLANGE NUT
25. WASHERS
26. ISOLATORS
27. BRAKE COOLING LINES
28. BATTERY CABLE (POSITIVE)
29. BATTERY CABLE (NEGATIVE)
31

Figure 23. GM 4.3L LPG Engine with PSI and Transmission
32

NOTE: GM 4.3L GASOLINE ENGINE IS SIMILAR.
2. AIR FILTER HOSE
6. FUEL SENDING UNIT
8. ELECTRONIC CONTROL MODULE (ECM)
11. COOLANT HOSES
13. FAN
14. SHROUD
16. FUEL LINES
17. LEFT SIDE ENGINE MOUNT
18. STARTER MOTOR
19. CAPSCREWS
20. BELL HOUSING
21. RADIATOR CAP
22. OUTPUT YOKE
24. FLANGE NUT
25. WASHERS
26. ISOLATORS
33

Figure 24. Cummins QSB 3.3L Diesel Engine and Transmission
34

1. RADIATOR CAP
2. SHROUD
3. BOTTOM COOLANT HOSE
4. AIR FILTER HOSE
5. AIR FILTER AND BRACKET
7. ENGINE MOUNTING BRACKETS
8. FUEL LINES
10. BRAKE COOLING LINE
11. HYDRAULIC SUPPLY LINE
13. ELECTRONIC CONTROL MODULE
14. RIGHT HAND ENGINE HARNESS
15. HYDRAULIC RETURN LINE
19. FAN SPACER AND FAN PULLEY
20. CHARGE AIR HOSE
35

Figure 25. Kubota 3.8L Engine and Transmission for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879)
36

A. TOP VIEW B. SIDE VIEW
1. SHROUD
2. RADIATOR CAP
6. TRANSMISSION COOLING HOSE
12. AIR FILTER HOSE
13. FAN, SPACER, AND FAN PULLEY
15. ENGINE MOUNTS
37

Figure 26. Kubota 3.8L Engine and Transmission for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879)
38

A. TOP VIEW
B. SIDE VIEW
1. SHROUD
2. RADIATOR CAP
6. TRANSMISSION COOLING HOSE
12. AIR FILTER HOSE
13. FAN, SPACER, AND FAN PULLEY
15. ENGINE MOUNTS
39

Figure 27. Cummins 4.5L Diesel Engine and Transmission
40

A. TOP VIEW
B. RIGHT SIDE VIEW
C. LEFT SIDE VIEW
CONNECTOR
2. THROTTLE CABLE
4. RADIATOR CAP
5. FUEL LINES
8. CAPSCREW
9. ISOLATORS
10. WASHERS
11. FLANGE NUTS
12. OUTPUT YOKE
14. ENGINE MOUNTS
16. AIR FILTER HOSE
19. COOLANT HOSES
21. TRANSMISSION BELL HOUSING
24. BATTERY CABLE NEGATIVE
26. TRANSMISSION HARNESS CONNECTOR
27. SHROUD
28. FAN
41

6. Remove hood and seat combination and rear side
Covers Replacement for procedures.
7. Loosen clamp and remove air filter hose from air
inlet, located on left rear overhead guard leg.
equipped with GM 4.3L engine.
See Figure 25 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L
diesel engine.
GDC155VX) (F879) equipped with the Kubota 3.8L
diesel engine.
8. Remove air filter and bracket assembly.
diesel engine.
diesel engine.
9. For lift trucks equipped with Cummins 4.5L diesel
engine, disconnect throttle cable from fuel injection
pump.
See Figure 27 for lift trucks equipped with a Cum-
mins 4.5L diesel engine.
NOTE: When disconnecting wiring harness connectors,
tag each connector to aid in connecting wiring harness
during installation.
10. On lift trucks equipped with GM 4.3L gasoline en-
gine or a Cummins 4.5L diesel engine, disconnect
left hand chassis harness connector from engine
harness connector.
GFI.
PSI.
NOTE: Perform Step 11 for lift truck models equipped
with GFI fuel system.
11. On lift trucks equipped with GM 4.3L LPG engine,
disconnect left hand chassis harness connector
from LPG regulator connector and engine harness
connector. See Figure 22.
12. On lift trucks equipped with GM 4.3L engine or Kub-
ota 3.8L engine, disconnect engine harness con-
nectors from electronic control module (ECM).
diesel engine.
diesel engine.
13. Disconnect engine harness connector from right
hand chassis harness connector.
14. Disconnect ground strap from frame and remove
power distribution module (PDM) from battery tray.
See Figure 28.
15. For lift trucks equipped with either a Cummins QSB
3.3L, a Cummins 4.5L, or Kubota diesel engines,
remove battery from battery tray and remove three
capscrews from battery tray. Remove battery tray.
16. For lift trucks equipped with GM 4.3L engine, re-
move three capscrews from battery tray and re-
move battery, battery tray, and Electronic Control
Module (ECM).
42

1. BATTERY
2. BATTERY TRAY
3. PDM
4. BATTERY LOCKDOWN BAR
5. GROUND STRAP
Figure 28. Power Distribution Module,
Disconnection
17. Loosen hose clamps and disconnect remaining
coolant hoses from radiator and cap them to pre-
vent leakage.
diesel engine.
diesel engine.
18. Disconnect exhaust pipes from exhaust manifolds.
See Exhaust System Repair for procedures.
19. Remove radiator fan pulley, shroud, and fan assem-
bly. See section Cooling System 700 YRM 1123
for removal procedures.
WARNING
All fuels are very flammable and can burn or cause
an explosion. DO NOT use an open flame to check
the fuel level or to check for leaks in the fuel system.
No smoking.
Breathing fuel vapor may cause nausea, uncon-
sciousness or death. Long term exposure to
gasoline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
20. Disconnect fuel lines at engine. Put caps on fuel
lines to prevent fuel leakage.
diesel engine.
diesel engine.
21. Lift trucks equipped with GM 4.3L engine, remove
left side engine mount to access starter motor. See
Figure 22 and Figure 23.
22. Disconnect positive battery (B+) and negative bat-
tery cable from starter motor.
23. Lift trucks equipped with GM 4.3L engine, remove
starter motor to reach four torque converter access
bolts. See Figure 22 and Figure 23.
43

24. For lift trucks equipped with a Cummins QSB 3.3L
diesel engine, remove oil cooler to reach access
port. See Yale Axcess Online.
25. Lift trucks equipped with Cummins QSB 3.3L diesel
engine, remove bolts and cover to get to access
port. See Figure 31.
26. Lift trucks equipped with Kubota diesel engine, re-
move bolts and cover to reach access port. See
Figure 32.
27. Use access port on engine to remove bolts that at-
taching flywheel to torque converter.
See Figure 29 for lift trucks equipped with a GM
4.3L gas or LPG engine.
mins QSB 3.3L diesel engine.
See Figure 32 for lift trucks equipped with a Kubota
diesel engine.
28. Connect a lifting device to engine. Put a block under
transmission housing to support transmission.
29. Remove capscrews from transmission bell housing.
diesel engine.
diesel engine.
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 363 kg (800 lb).
30. Remove flange nuts, washers, bolts, and isolators
from engine mounts. See Figure 21 or Figure 33.
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.
31. Use lifting device to carefully move engine away
from torque converter. Make sure all hoses, wires,
and cables are disconnected from engine, then lift
engine from frame and place engine on blocks.
1. ACCESS PORT
2. ENGINE MOUNTING BRACKET AND
HARDWARE
Figure 29. GM 4.3L Engine Removal Access Port
44

1. ACCESS PORT
HARDWARE
Figure 30. Cummins 4.5L Engine Access Port
Figure 31. Cummins QSB 3.3L Diesel Engine
Access Port
1. ACCESS PORT
HARDWARE
NOTE: KUBOTA 3.8L SHOWN. KUBOTA 3.6L SIMI-
LAR.
1. ACCESS PORT
HARDWARE
Figure 32. Kubota Diesel Engine Access Port
45

A. ENGINE MOUNTS FOR GM 4.3L
B. ENGINE MOUNTS FOR CUMMINS 4.5L
C. ENGINE MOUNTS FOR CUMMINS QSB 3.3L
D. ENGINE MOUNTS FOR KUBOTA DIESEL
1. ENGINE MOUNTS
2. CAPSCREW
3. WASHER
4. ISOLATOR
5. FLANGE NUT
6. PIN
7. CROSSMEMBER
8. LOCK NUT
9. FLANGE BOLT
Figure 33. Engine Mounts Assembly
46

INSTALL ENGINE ONLY
WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The en-
gine weighs approximately 363 kg (800 lb).
CAUTION
Keep the engine level when installing the engine to
the transmission so the drive plate is not damaged.
1. Connect lifting device to engine and lift engine into
frame.
2. Align transmission bell housing to torque converter
adapter.
diesel engine.
diesel engine.
NOTE: Perform Step 3 on lift trucks equipped with GM
4.3L gas/LPG engine or Kubota diesel engine.
3. If isolators fell from engine mounts during removal,
install isolators on engine mounts and install wash-
ers, capscrews and flange nuts for engine mounts
to secure engine to frame. Tighten flange nuts to
150 N•m (110 lbf ft). See Figure 33.
NOTE: Perform Step 4 on lift trucks equipped with either
a Cummins QSB 3.3L or Cummins 4.5L diesel engine.
install isolators on engine mounts and install wash-
ers, capscrews and flange nuts for engine mounts
5. Install capscrews to secure transmission bell hous-
ing to torque converter adapter. Tighten capscrews
to 38 N•m (28 lbf ft).
6. Use access port on engine to install four bolts to
hold torque converter to flywheel. Tighten bolts to
55 N•m (41 lbf ft).
7. For Cummins QSB 3.3L diesel engine, install cover
and bolts to access port. See Figure 31.
8. For Kubota 3.8L diesel engine, install cover and
bolts to access port. See Figure 32.
9. Remove blocks from under transmission and dis-
connect lifting device from engine.
10. Lift trucks equipped with Cummins QSB 3.3L diesel
engine, install oil cooler. See Yale Axcess Online.
11. Lift trucks equipped with GM 4.3L engine, in-
stall starter motor. Tighten capscrews to 52 N•m
(38 lbf ft).
12. Connect positive battery (B+) cable to starter motor.
Tighten terminal nut to 8 to 11 N•m (71 to 97 lbf in).
13. Connect negative battery cable to starter motor.
14. Lift trucks equipped with GM 4.3L engine, install left
side engine mount on engine. Tighten capscrews
to 90 N•m (66 lbf ft).
15. For lift trucks equipped with GM 4.3L engine, con-
nect exhaust pipes to exhaust manifolds. Tighten
lock nuts to 39 N•m (29 lbf ft). See Figure 22 and
Figure 23.
16. For lift truck equipped with Kubota diesel engine,
connect exhaust pipes to exhaust manifold.
GDC155VX) (E879)
GDC155VX) (F879).
47

17. For lift trucks equipped with Cummins QSB 3.3L or
Cummins 4.5L diesel engine, connect exhaust pipe
to exhaust manifold. Tighten lock nut to 22 N•m
(16 lbf ft).
18. Remove caps from fuel lines and connect fuel lines
at engine.
19. Install radiator shroud, fan pulley, and fan assembly.
See section Cooling System 700 YRM 1123 for
Fan Installation procedures.
20. Remove cap from bottom radiator hose and install
hoses to radiator.
diesel engine.
diesel engine.
NOTE: Perform Step 21 on lift trucks equipped with ei-
ther a Cummins QSB 3.3L, a Cummins 4.5L, or Kubota
diesel engine.
21. Using three capscrews install battery tray and bat-
tery.
4.3L engine.
22. Using three capscrews install battery tray, battery,
and Electronic Control Module (ECM).
23. Install Power Distribution Module (PDM) on battery
tray and connect ground strap to lift truck frame.
See Figure 28.
24. Connect engine harness connector to right hand
chassis harness connector.
See Figure 22 and Figure 23 for lift trucks equipped
with a GM 4.3L engine.
diesel engine.
diesel engine.
25. For lift trucks equipped with GM 4.3L or Kubota
3.8L engine, connect engine harness connectors to
Electronic Control Module (ECM).
diesel engine.
diesel engine.
26. For lift trucks equipped with GM 4.3L LPG engine,
connect left hand chassis harness connector to
LPG regulator connector and engine harness con-
nector. See Figure 22.
27. For lift trucks equipped with either a GM 4.3L gaso-
line engine or a Cummins 4.5L diesel engine, con-
nect left hand chassis harness connector to engine
harness connector.
GFI.
PSI.
48

engine, connect throttle cable to fuel injection
pump. See Figure 27.
29. Install air filter and bracket assembly.
30. Connect air filter hose to air inlet located on left rear
over head guard leg and tighten clamp.
31. Install hood and seat combination, and rear side
Covers Replacement, Install for procedures.
32. Close drain plug and remove caps from remain-
ing coolant hoses and connect hoses to radiator.
Tighten hose clamps and fill cooling system with
antifreeze. See Cooling System 700 YRM 1123
for radiator fill procedures. Install radiator cap.
33. Check all fluid levels as described in
Periodic Maintenance 8000 YRM 1319 for lift truck
models
D879)
models
GDC135VX, GC/GLC/GDC155VX) (E879)
model
GDC135VX, GC/GLC/GDC155VX) (F879)
34. Connect positive battery cable to battery.
35. Connect negative battery cable to battery.
36. Install floor plate and floor mat.
WARNING
No smoking.
37. For lift trucks equipped with and LPG fuel system,
swing LPG tank and bracket back to original posi-
tion until locked and open shutoff valve.
38. Inspect fuel system for leaks when fuel valve is
open. There are four methods used to inspect fuel
system for leaks:
a. Sound - Listen for sound of fuel escaping from
a tank fitting or hose connection.
b. Smell - Fuel has a very distinctive odor. If you
smell fuel, DO NOT start engine.
c. Soapy Water - This method is used in conjunc-
tion with Step b above. If odor of fuel is present,
but escaping fuel cannot be heard, apply soapy
water to fittings and observe for bubbles.
d. Frost - If amount of fuel escaping is sufficient,
frost may appear on fittings.
REMOVE ENGINE AND TRANSMISSION
WARNING
fall forward.
The engine can be removed with or without transmis-
sion. Follow procedures below to remove engine with
transmission. See Figure 21.
49

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
open flame, motor vehicles, electrical equipments,
or ignition source.
1. For lift trucks equipped with an LPG fuel system,
close shutoff valve on 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 side. See one of the following Service Man-
uals.
(C879, D879)
(D879, E879, F879)
3. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than capacity of
cooling system under radiator. Remove radiator
cap.
NOTE: Disposal of lubricants and fluids must meet local
4. Open drain plug or loosen hose clamp and discon-
nect bottom radiator hose to drain coolant from ra-
diator and engine.
diesel engine.
diesel engine.
5. Remove overhead guard, see Overhead Guard Re-
placement for Remove procedures.
6. Remove hood and seat combination and rear side
Covers Replacement for procedures.
7. Remove floor mat and floor plate.
8. Loosen clamp and remove air filter hose from air
inlet, located on left rear over head guard leg.
diesel engine.
diesel engine.
engine, disconnect throttle cable from fuel injection
pump. See Figure 27 for lift truck models equipped
with Cummins 4.5L diesel engine.
NOTE: When disconnecting wiring harness connectors
during removal, tag each connector to aid in connecting
wiring harness during installation.
10. For lift trucks equipped with GM 4.3L gasoline en-
gine or Cummins 4.5L diesel engine, disconnect left
hand chassis harness connector from engine har-
ness connector.
50

GFI.
PSI.
disconnect left hand chassis harness connector
from LPG regulator connector and engine harness
connector. See Figure 22.
3.8L engine, disconnect engine harness connec-
tors from Electronic Control Module (ECM).
diesel engine.
diesel engine.
13. For lift trucks equipped with Cummins QSB 3.3L
diesel engine, disconnect alternator harness from
14. Disconnect engine harness connector from right
hand chassis harness connector.
15. Disconnect battery positive (B+) and negative cable
from starter motor.
16. Disconnect ground strap from frame and remove
power distribution module (PDM) from battery tray.
17. For lift trucks equipped with Cummins QSB 3.3L,
Cummins 4.5L, or Kubota diesel engine, remove
three capscrews from battery tray and remove bat-
tery and battery tray.
18. For lift trucks equipped with GM 4.3L engine, re-
move three capscrews from battery tray and re-
move battery, battery tray, and Electronic Control
Module (ECM).
CAUTION
Disposal of lubricants and fluids must meet local
19. Place a drain pan under hydraulic tank, remove
drain plug at bottom of hydraulic oil tank, and drain
oil from tank. After oil has finished draining, install
drain plug to hydraulic tank.
20. Place drain pan under hydraulic gear pump assem-
bly.
a. For lift truck models equipped with a hydraulic
gear pump on transmission, disconnect the
suction hose and hydraulic hose from hydraulic
gear pump assembly. Put caps on all hose
fitting and hydraulic gear pump ports. See
Hydraulic Gear Pump 1900 YRM 1136 for
more information.
21. Loosen hose clamps and disconnect remaining
coolant hoses from radiator and cap them, to pre-
vent leakage.
22. Place drain pan under transmission oil cooler lines
at transmission. Loosen hose clamps and discon-
nect transmission oil cooler lines at transmission
and cap to prevent leakage.
23. Place drain pan under supply and return brake cool-
ing lines (if equipped) and remove cooling lines at
transmission and cap to prevent leakage.
24. Disconnect exhaust pipes from exhaust manifold.
See Exhaust System Repair for removal proce-
dures.
25. Remove radiator fan pulley, shroud, and fan assem-
bly. See section Cooling System 700 YRM 1123
for removal procedures.
51

WARNING
No smoking.
26. Loosen hose clamps (if equipped) and disconnect
fuel lines at engine. Put caps on fuel lines to prevent
fuel leakage.
diesel engine.
diesel engine.
WARNING
The engine and transmission are heavy. Make sure
that any lifting device has enough capacity to lift
the weight. The engine and transmission can weigh
approximately 680 kg (1500 lb).
27. Connect a lifting device to support transmission and
engine combination.
28. Disconnect output yoke from transmission.
diesel engine.
diesel engine.
29. Remove flange nuts, capscrews, washers and iso-
lators from transmission mount. See Figure 34.
30. Remove capscrews and washers from engine
mounts. See Figure 33.
NOTE: Make sure engine and transmission assembly
can be raised at an angle so they will clear frame.
31. Use lifting device to carefully lift engine and trans-
mission from frame. Slip transmission output yoke
out of transmission. Make sure not to damage seal.
Place engine and transmission on blocks.
INSTALL ENGINE AND TRANSMISSION
WARNING
The engine and transmission are heavy. Make sure
that any lifting device has enough capacity to lift
the weight. The engine and transmission can weigh
approximately 680 kg (1500 lb).
NOTE: Make sure engine and transmission assembly
can be raised at an angle so they will clear frame.
1. Connect a lifting device to engine and transmission
and lift engine and transmission into lift truck frame.
2. Install transmission output yoke onto transmission.
Be sure to not damage seal. Tighten bolt to 38 N•m
(28 lbf ft).
NOTE: Perform Step 3 on lift trucks equipped with Cum-
mins 4.5L or Cummins QSB 3.3L diesel engines.
install isolators to engine mounts and install wash-
ers, capscrews, and flange nuts for engine mounts
4.3L gas/LPG engine or Kubota diesel engine.
install isolators to engine mounts and install wash-
ers, capscrews, and flange nuts for engine mounts
52

5. If isolators fell from transmission mount, install iso-
lators to transmission mount and install washers,
lock washers, and capscrews. Tighten capscrews
to 225 to 250 N•m (166 to 184 lbf ft). See Figure 34.
6. Remove lifting device from engine and transmission
combination.
7. Install radiator shroud, fan pulley, and fan assembly.
See section Cooling System 700 YRM 1123 for
Fan Installation procedures.
8. Remove cap from bottom radiator hose and install
hose on radiator.
9. For lift trucks equipped with GM 4.3L engine, con-
nect exhaust pipes to exhaust manifolds. Tighten
lock nuts to 39 N•m (29 lbf ft). See Figure 22 and
Figure 23.
10. For lift trucks equipped with Kubota diesel engine,
connect exhaust pipe to exhaust manifold.
diesel engine.
diesel engine.
11. For lift trucks equipped with Cummins 4.5L engine,
connect exhaust pipe to exhaust manifold. Tighten
lock nut to 22 N•m (16 lbf ft). See Figure 27.
12. Remove cap and connect supply and return brake
cooling lines at transmission.
13. Remove cap and connect transmission oil cooler
lines at transmission.
14. Connect hydraulic connections to the hydraulic
pump.
a. For lift truck models equipped with a hydraulic
gear pump on transmission, remove plugs from
hydraulic gear pump ports, and connect suc-
tion hose and hydraulic hose to hydraulic gear
pump assembly. See Hydraulic Gear Pump
1900 YRM 1136 for more information.
15. Remove caps from fuel lines and connect fuel lines
at engine. Tighten hose clamps (if equipped).
16. For lift trucks equipped with Cummins 4.5L, QSB
3.3L, or Kubota diesel engines, install battery and
battery tray using three capscrews.
17. For lift trucks equipped with GM 4.3L engine, install
battery, battery tray, and Electronic Control Module
(ECM).
18. Install Power Distribution Module to battery tray and
connect ground strap to lift truck frame. See Fig-
ure 28.
1. ISOLATOR CAPSCREW
2. LOCKWASHER
3. WASHER
4. ISOLATOR
5. MOUNTING BRACKET
6. MOUNTING BRACKET CAPSCREW
Figure 34. Transmission Mounting Assembly
53

19. Connect positive batter (B+) cable to starter motor.
Tighten terminal nut to 8 to 11 N•m (71 to 97 lbf in).
20. Connect negative battery cable to starter motor.
21. Connect engine harness connector to right hand
chassis harness connector.
diesel engine.
diesel engine.
3.8L engine, connect engine harness connectors to
diesel engine.
diesel engine.
connect left hand chassis harness connector to
LPG regulator connector and engine harness con-
nector. See Figure 22.
24. For lift trucks equipped with either a GM 4.3L (gaso-
line) engine or a Cummins 4.5L diesel engine, con-
nect left hand chassis harness connector to engine
harness connector.
GFI.
PSI.
25. Install air filter and bracket assembly.
26. Connect air filter hose to air inlet and tighten clamp.
engine, connect throttle cable to fuel injection
pump. See Figure 27.
28. Close drain plug and remove caps and connect
coolant hoses to radiator. Tighten hose clamps
and fill cooling system with antifreeze. See Cool-
ing System 700 YRM 1123 for radiator refill proce-
dures. Install radiator cap.
29. Check all fluid levels as described in
models
D879)
models
GDC135VX, GC/GLC/GDC155VX) (E879)
model
GDC135VX, GC/GLC/GDC155VX) (F879)
54

100 YRM 1316 Electronic Throttle Replacement
30. Install hood and seat combination, and rear side
Covers Replacement Install for procedures.
31. Install overhead guard. See Overhead Guard Re-
placement, Install for procedures.
32. Connect positive battery cable.
33. Connect negative battery cable.
34. Install floor plate and floor mat.
WARNING
No smoking.
35. For lift trucks equipped with and LPG fuel system,
swing LPG tank and bracket back to original posi-
tion until locked, connect LPG fuel line, and open
shutoff valve.
36. Inspect fuel system for leaks when fuel valve is
open. There are four methods used to inspect fuel
system for leaks:
a. Sound - Listen for sound of fuel escaping from
a tank fitting or hose connection.
b. Smell - Fuel has a very distinctive odor. If you
smell fuel, DO NOT start engine.
c. Soapy Water - This method is used in conjunc-
tion with Step b above. If odor of fuel is present,
but escaping fuel cannot be heard, apply soapy
water to fittings and observe for bubbles.
d. Frost - If the amount of fuel escaping is suffi-
cient, frost may appear on fittings.
Electronic Throttle Replacement
CUMMINS 4.5L DIESEL ENGINE WITH
ELECTRONIC THROTTLE
Remove
1. Disconnect engine harness electrical connector
from throttle position sensor (TPS). See Figure 35.
2. Remove Torx-head screws, washers, and remove
TPS and tapped TPS plate. See Figure 36.
3. Remove capscrews and TPS bracket. See Fig-
ure 37.
4. Remove TPS rotor. See Figure 38.
5. Remove capscrews, nuts, and linkage assembly.
See Figure 35.
6. If necessary, remove capscrews and throttle lever
adapter. See Figure 36.
7. Disconnect engine harness electrical connector
from pull actuator harness connector. See Fig-
ure 39.
8. Remove capscrews and pull actuator from mount-
ing bracket. See Figure 40.
9. If necessary, remove clevis with linkage assembly,
lockwasher, and nut from pull actuator. See Fig-
ure 39.
55

Electronic Throttle Replacement 100 YRM 1316
Figure 35. Electronic Throttle System
56

1. THROTTLE POSITION SENSOR (TPS)
2. CAPSCREW
3. LINKAGE ASSEMBLY
4. NUT
5. PULL ACTUATOR
6. CLEVIS
7. ADJUSTMENT NUT
8. TORX-HEAD SCREWS
9. PULL ACTUATOR CONNECTOR
57

Figure 36. TPS Assembly
1. TORX-HEAD SCREW
2. LOCKWASHER
3. TPS
4. TPS BRACKET
5. ACTUATOR
6. TPS ROTOR
7. MAGNET
8. TPS PLATE
9. THROTTLE LEVER ADAPTER
10. FUEL PUMP
11. CAPSCREWS
58

1. CAPSCREW 2. TPS BRACKET
Figure 37. TPS Bracket
1. TPS 2. TPS ROTOR
Figure 38. TPS Rotor
1. PULL ACTUATOR
2. NUT
3. LOCKWASHER
4. CLEVIS WITH LINKAGE ASSEMBLY
5. PULL ACTUATOR HARNESS CONNECTOR
Figure 39. Pull Actuator and Linkage Assembly
1. MOUNTING BRACKET
2. CAPSCREW
3. FUEL PUMP
4. PULL ACTUATOR
5. FOLDOVER NUT
Figure 40. Pull Actuator Mounting
59

Install
1. Install TPS rotor and throttle lever adapter. Tighten
capscrews to 7.9 N•m (70 lbf in). See Figure 36.
2. Place rod end of linkage assembly on top side of
throttle lever adapter and align rod end hole with
hole on throttle lever adapter. See Figure 41.
NOTE: When installing TPS, rotate sensor rotor clock-
wise to match D-shape on TPS rotor. See Figure 42.
NOTE: The TPS mounting screws are non-magnetic
stainless steel to avoid interference with sensor mag-
net and must be reused if TPS is replaced.
3. Place TPS in position and install Torx-head screws.
Tighten Torx-head screws to 2.25 N•m (20 lbf in).
See Figure 36.
4. Connect TPS electrical connector.
5. Turn lever clockwise to verify that TPS does not bind
or stick.
6. Place pull actuator in position on mounting bracket
and install capscrews. Tighten to 38 N•m (28 lbf ft).
See Figure 40.
7. Install clevis with linkage assembly onto threaded
end of pull actuator rod. Leave loose for adjust-
ment. See Figure 39.
8. Verify that clevis is in position shown in Figure 43.
Adjust as needed.
9. Verify that rod ends of linkage assembly are parallel
to each other. Adjust as needed. See Figure 43.
NOTE: DO NOT force lever or pull actuator rod when
installing.
10. Place rod end on top side of throttle lever adapter
and align rod end hole with hole on throttle lever.
Install capscrew and nut and tighten to 6.8 N•m
(60 lbf in). See Figure 41.
1. THROTTLE LEVER ADAPTER
2. ROD END
3. CLEVIS
4. CAPSCREW
5. NUT
Figure 41. Rod End and Throttle Lever Alignment
60

1. SENSOR ROTOR
2. TPS
3. TPS ROTOR
4. D-SHAPE
Figure 42. TPS and Rotor
11. Connect pull actuator harness connector to engine
harness connector. See Figure 39.
Pull Actuator Linkage Adjustment
1. Check low idle stop position to see if throttle lever
is in contact with low idle stop. If adjustment is
necessary, refer to Step 3. See Figure 44.
2. When condition in Step 1 is met, check if actuator is
fully extended by manually turning actuator to high
idle position. The throttle lever should contact high
idle stop. Verify that lever rotates freely, without
binding or sticking.
3. If linkage adjustment is not providing enough
range, remove capscrew and nut from clevis and
rod ends. Lengthen or shorten linkage by loos-
ening turnbuckle nuts to adjust threaded length
of rod ends in turnbuckle. Attach adjusted rod
ends to clevis with capscrew and nut. Verify lever
contacts low idle stop at idle position, and lever
contacts high idle stop at high idle position. Verify
that lever rotates freely without sticking or binding.
See Figure 44.
Low Idle Adjustment
CAUTION
DO NOT attempt to adjust high idle speed limit
screws. This may impair the safety and perfor-
mance of the lift truck and shorten its engine life. If
the idle speed limit screws require adjustment, see
your authorized Cummins industrial engine dealer
or distributor.
NOTE: Make sure engine is running prior to making low
idle adjustment.
1. Loosen lock nut. See Figure 44.
2. Turn adjustment screw until correct RPM, identi-
fied in Periodic Maintenance 8000 YRM 1319, has
been set.
3. After RPM has been set. Use a screwdriver to hold
adjustment screw in place and tighten lock nut.
61

Throttle Pedal and Cable Adjustment 100 YRM 1316
1. PULL ACTUATOR
2. LOCK NUT
3. CLEVIS
4. TURNBUCKLE NUT
5. TURNBUCKLE
6. ROD ENDS (MUST
BE PARALLEL TO
EACH OTHER)
Figure 43. Linkage Assembly
1. TPS
2. LOW IDLE STOP
3. TURNBUCKLE NUT
4. TURNBUCKLE
5. CLEVIS
6. LOCK NUT
7. ADJUSTING
SCREW(LOW IDLE)
8. ROD ENDS
Figure 44. Low Idle and Pull Actuator Adjustment
Location
Throttle Pedal and Cable Adjustment
NOTE: There are no throttle pedal and cable adjust-
ments for lift trucks equipped with GM 4.3L or Kubota
3.8L Diesel engine. The GM 4.3L and Kubota 3.8L
Diesel engines have an electronic throttle that is self-ad-
justing and self-calibrating.
CUMMINS 4.5L DIESEL ENGINE
1. Remove floor plate and disconnect throttle cable
from bellcrank and engine. See Figure 45.
2. Fully depress throttle pedal and verify that dimen-
sion between bellcrank and cowl plate is 6 ±2 mm
(0.24 ±0.08 in.). See Figure 45.
3. If dimension is not correct, adjust ball ends on
push rod so that a minimum of 6 mm (0.24 in.)
of threaded rod screws into each ball end. After
adjusting push rod, tighten jam nuts to 8 to 15 N•m
(71 to 133 lbf in).
4. Connect throttle cable to bellcrank and engine. See
Figure 45.
5. With throttle pedal in full up position, adjust throt-
tle cable, using jam nuts (item #10 in Figure 45) to
remove all slack from cable. Cable should be ad-
justed to point where additional adjustment will pull
control lever off idle stop. Tighten jam nuts to 8 to
15 N•m (71 to 133 lbf in).
6. Install floor plate. Fully depress throttle pedal and
adjust pedal stop so that it touches floor plate.
Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in)
(item #6 in Figure 45).
62

100 YRM 1316 Throttle Pedal and Cable Adjustment
1. COWL
2. BELLCRANK
3. PUSH ROD
4. BALL END
5. THROTTLE PEDAL
6. JAM NUT
7. PEDAL STOP
8. THROTTLE CABLE
9. JAM NUTS
10. CONTROL LEVER
11. CLAMP STRAP
Figure 45. Cummins 4.5L Throttle Pedal and Cable Adjustment
63

Exhaust System Repair 100 YRM 1316
Exhaust System Repair
GM 4.3L ENGINE FOR LIFT TRUCK
MODELS GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879, E879, F879)
NOTE: For lift trucks equipped with engine indicated
above, see the Fuel System service manual for your
lift truck model.
CUMMINS QSB 3.3L ENGINE FOR
LIFT TRUCK MODELS GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879, D879)
Remove
NOTE: If the lift truck is equipped with the standard ex-
haust system, go to Step 6.
1. Remove the clamp attaching the overhead guard
exhaust pipe to the lower overhead guard exhaust
pipe. See Figure 46.
2. Remove the capscrews from the flange cover.
3. Remove overhead exhaust pipe and flange cover
from the counter weight.
4. Remove the counterweight from the lift truck. See
Counterweight Replacement.
5. Remove clamp and lower overhead guard exhaust
pipe from muffler.
6. Remove the turbo manifold–exhaust wrap, up-
per header–exhaust wrap, bellow pipe–exhaust
wrap, lower header–exhaust wrap, and upper tail
pipe–exhaust wrap.
7. Remove the turbo exhaust clamp.
8. Remove the clamp from the muffler and upper tail
pipe, and remove the muffler from the lift truck.
9. Remove the clamp from the upper tail pipe and
lower header exhaust pipe, and disconnect the up-
per tail pipe from the lower header exhaust pipe.
10. Remove the clamp from the lower header exhaust
pipe and exhaust mounting bracket.
11. Disconnect the lower exhaust pipe from the bellow
pipe.
12. Disconnect the bellow pipe from the upper header
exhaust pipe.
13. Disconnect the upper header exhaust pipe from the
turbo manifold exhaust.
Inspect
Inspect the following items in the exhaust system:
• Exhaust pipes for damage, corrosion, and rust. Re-
place as needed.
• If equipped, exhaust wraps for wear, proper fit, con-
tamination with oil or antifreeze, gaps in coverage,
failed fasteners and replace as needed. If replacing
an exhaust pipe section that has a wrap, also replace
the wrap. Do not reuse wraps if they have been re-
moved for a service operation.
• Muffler for damage, corrosion, and rust. Replace as
needed.
Install
1. Connect the upper header exhaust pipe to the turbo
manifold exhaust.
2. Connect the bellow pipe to the upper header ex-
haust pipe.
3. Connect the lower exhaust pipe to the bellow pipe.
4. Install the clamp to the lower header exhaust pipe
and exhaust mounting brackets.
5. Install the clamp to the upper tail pipe and lower
header exhaust pipe, and install the upper tail pipe
to the lower header exhaust pipe.
6. Install the clamp to the muffler and upper tail pipe,
and install the muffler to the frame of the lift truck.
7. Install the turbo exhaust clamps.
8. Install the upper tail pipe-exhaust wrap, lower
header-exhaust wrap, bellow pipe-exhaust wrap,
upper header-exhaust wrap, and turbo manifold-ex-
haust wrap.
9. Install clamp and lower overhead guard exhaust
pipe to muffler.
64

100 YRM 1316 Exhaust System Repair
1. OVERHEAD EXHAUST PIPE
2. FLANGE COVER
3. CLAMP
4. MUFFLER
5. UPPER TAILPIPE
6. UPPER TAILPIPE-EXHAUST WRAP
7. LOWER HEADER-EXHAUST WRAP
8. LOWER HEADER-EXHAUST PIPE
9. BELLOW PIPE-EXHAUST WRAP
10. BELLOW PIPE
11. UPPER HEADER-EXHAUST WRAP
12. UPPER HEADER-EXHAUST PIPE
13. TURBO EXHAUST CLAMP
14. TURBO MANIFOLD-EXHAUST WRAP
15. EXHAUST MOUNTING BRACKET
16. LOWER EXHAUST PIPE-OVERHEAD
17. CAPSCREW
18. EXHAUST PIPE
Figure 46. Cummins QSB 3.3 Engine Exhaust System
65

10. Install the counterweight to the lift truck. See Coun-
terweight Replacement.
11. Install over head exhaust pipe and flange cover to
the counterweight.
12. Install the capscrews to the flange cover
13. Install the clamp attaching the overhead guard ex-
haust pipe to the lower overhead guard exhaust
pipe. See Figure 46.
CUMMINS 4.5L DIESEL ENGINE FOR
GC/GLC/GDC155VX) (C879, D879)
Remove
WARNING
Exhaust system components are hot to touch. Be
sure exhaust system components are cool before
starting disassembly, or personal injury may occur.
NOTE: Lift trucks equipped with standard exhaust fol-
low Step 1 through Step 4. Lift trucks equipped with
overhead exhaust follow Step 5 through Step 10.
1. Remove the counterweight before removing the
muffler and other components of the exhaust sys-
tem. See the section Counterweight Replacement
for the removal procedures for the counterweight.
2. Remove clamps that attach exhaust pipes (1 and
4, Figure 47) to muffler. Remove exhaust pipe (1,
Figure 47) from muffler.
3. Remove exhaust pipe (4, Figure 47) from the en-
gine exhaust manifold and remove exhaust pipe
from muffler. Discard gasket.
4. Remove the washers, isolators, spacers, locknuts,
and capscrews that attach muffler to lift truck frame.
Remove muffler from lift truck frame.
NOTE: The exhaust pipe (13, Figure 47) must be re-
moved before removing the counterweight and the other
components of the exhaust system.
5. Remove the clamp that attaches the exhaust pipe
(13) to the exhaust pipe (1). See Figure 47.
6. Remove flange cover and three flange bolts that
secures the exhaust pipe to the counterweight and
remove exhaust pipe.
7. Remove counterweight. See the section Counter-
weight Replacement for the removal procedures for
the counterweight.
8. Remove clamps that attach exhaust pipes (1 and 4,
Figure 47) to muffler.
9. Remove exhaust pipe (4, Figure 47) from the en-
gine exhaust manifold and remove exhaust pipe
from muffler. Discard gasket.
Inspect
place as needed.
• Exhaust pipe heat shields for damage. Replace as
needed.
needed.
Install
1. Place the muffler on the lift truck frame and install
the washers, isolators, spacers, locknuts, and cap-
screws to attach muffler to lift truck frame. Tighten
locknuts to 22 N•m (195 lbf in).
2. Connect exhaust pipes (1 and 4, Figure 47) to muf-
fler and install clamps to attach exhaust pipes to
muffler.
3. Install new gasket and install exhaust pipe (4, Fig-
ure 47) to engine exhaust manifold. Tighten lock-
nuts to 22 N•m (195 lbf in).
4. Install counterweight. See the section Counter-
weight Replacement for the installation procedures
for the counterweight.
screws to attach muffler to lift truck frame. Tighten
locknuts to 22 N•m (195 lbf in).
6. Install new gasket and install exhaust pipe (4, Fig-
ure 47) to engine exhaust manifold. Tighten lock-
nuts to 22 N•m (195 lbf in).
66

1. EXHAUST PIPE
2. CLAMP
3. MUFFLER
4. EXHAUST PIPE
5. LOCKNUT
6. GASKET
7. WASHER
8. ISOLATOR
9. SPACER
10. CAPSCREW
11. FLANGE BOLT (OVERHEAD EXHAUST)
12. FLANGE COVER (OVERHEAD EXHAUST)
13. EXHAUST PIPE (OVERHEAD EXHAUST)
14. COVER
Figure 47. Cummins 4.5L Diesel Engine Exhaust System
67

7. Connect exhaust pipes (1 and 4, Figure 47) to muf-
fler and install clamp to attach exhaust pipe to the
muffler.
8. Install the counterweight. See the section Counter-
9. Connect exhaust pipe (13, Figure 47) to exhaust
pipe (1, Figure 47) and install clamp to attach ex-
haust pipe (13) to the exhaust pipe (1).
10. Install three flange bolts to secure the tail pipe to
the counterweight and place flange cover over the
flange bolts.
KUBOTA 3.8L DIESEL ENGINE FOR
GC/GLC/GDC155VX) (E879)
Remove
WARNING
Exhaust system components are hot to touch. Be
sure exhaust system components are cool before
starting disassembly, or personal injury may occur.
NOTE: Remove the turbo manifold-exhaust wrap and
other exhaust wrap material prior to removing exhaust
components.
1. Remove the counterweight before removing the
muffler and other components of the exhaust sys-
tem. See the section Counterweight Replacement
for the removal procedures for the counterweight.
2. Remove clamps that attaches the tail pipe to muf-
fler, the exhaust pipe to the muffler, the header-ex-
haust pipe to the bellow pipe, and the exhaust pipe
to the exhaust mounting brackets. See Figure 48.
3. Remove the exhaust clamp connecting the bellows
pipe to the exhaust pipe.
4. Remove the four nuts connecting the header-ex-
haust pipe to the exhaust manifold. See Figure 48.
5. Remove exhaust pipe from the muffler and the bel-
low pipe, and the header-exhaust pipe from the en-
gine exhaust manifold. Discard gasket. See Fig-
ure 48.
7. Remove the clamp that attaches the tail pipe to the
muffler. See Figure 48.
8. Remove flange cover and three flange bolts that se-
cures the over head exhaust pipe to the counter-
weight and remove tail pipe.
9. Remove counterweight. See the section Counter-
weight Replacement for the removal procedures for
the counterweight.
10. Remove clamps that attach exhaust pipe to muffler
and the clamps that attach the exhaust pipe to the
exhaust mounting brackets. See Figure 48.
11. Remove the clamp connecting the bellow pipe to
the header-exhaust pipe. See Figure 48.
12. Remove the exhaust clamp connecting the bellows
pipe to the exhaust pipe.
13. Remove the four nuts connecting the header-ex-
haust pipe to the exhaust manifold. See Figure 48.
14. Remove exhaust pipe from the muffler and the bel-
low pipe, and the header-exhaust pipe from the en-
gine exhaust manifold. Discard gasket. See Fig-
ure 48.
68

1. MUFFLER
2. EXHAUST PIPE
3. TAILPIPE-EXHAUST WRAP
4. BELLOW PIPE-EXHAUST WRAP
5. BELLOW PIPE
6. HEADER-EXHAUST WRAP
7. HEADER-EXHAUST PIPE
8. CLAMP
9. TURBO MANIFOLD-EXHAUST WRAP
10. EXHAUST MOUNTING BRACKET
11. NUT
12. TAIL PIPE
13. CAPSCREW
14. FLANGE COVER
15. OVERHEAD EXHAUST PIPE
Figure 48. Kubota 3.8L Diesel Engine Exhaust System
69

Inspect
place as needed.
• Exhaust pipe heat shields for damage. Replace as
needed.
needed.
Install
screws to attach muffler to lift truck frame.
2. Install new gasket at exhaust manifold and header-
exhaust pipe junction and install header-exhaust
pipe. Secure the header-exhaust pipe using four
nuts. DO NOT tighten nuts. See Figure 48.
3. Install exhaust pipe in bellow pipe. Secure exhaust
clamp connecting exhaust pipe and bellow pipe.
DO NOT tighten capscrews on exhaust clamp.
4. Connect exhaust pipe to muffler and install clamp.
Tighten clamp.
5. Connect tail pipe to muffler and install clamp.
Tighten clamp.
6. Install clamps around exhaust pipe and header ex-
haust pipe in exhaust mounting brackets. Tighten
nuts at header-exhaust pipe and exhaust mainifold
junction. Tighten exhaust clamp connecting ex-
haust pipe and bellow pipe to 70 N•m (52 lbf ft)
and tighten clamps holding exhaust pipe and bellow
pipe to exhaust mounting brackets. See Figure 48.
7. Install counterweight. See the section Counter-
screws to attach muffler to lift truck frame.
9. Install new gasket at exhaust manifold and header-
exhaust pipe junction and install header-exhaust
pipe. Secure the header-exhaust pipe using four
nuts. DO NOT tighten nuts. See Figure 48.
10. Install exhaust pipe in bellow pipe. Secure exhaust
clamp connecting exhaust pipe and bellow pipe.
DO NOT tighten capscrews on exhaust clamp.
11. Connect exhaust pipe to muffler and install clamp.
Tighten clamp.
70

Yale d879 gdc60 vx lift truck (europe) service repair manual

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