2. General
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or
Periodic Maintenance 8000YRM1762.
NOTE: For exhaust system procedures on lift trucks
equipped with a PSI 2.4L engine go to Fuel System
PSI 2.4L 0900YRM1757.
NOTE: For exhaust system procedures on lift trucks
equipped with Kubota engine go to .
NOTE: For exhaust system procedures on lift trucks
equipped with Yanmar engine go toExhaust System
Repair in this manual.
This section contains the description of the frame and
connected parts; procedures for removing and
installing counterweight, hood, overhead guard,
engine, transmission, cooling system, and exhaust
system (see above NOTES). 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:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Table 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875)
The muffler is fastened to the frame inside the coun-
terweight.
The overhead guard, cowl, and hood are installed on
the frame. The hood is connected to the frame with
hinges. Two gas-controlled springs provide assis-
tance when raising the hood and hold the hood in the
open position. The floor plate and side covers can be
removed for access to the engine, transmission, and
other components.
0100 YRM 1754 General
1
3. 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 col-
umn.
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:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
SeeFigure 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
6. Remove two capscrews holding left and right rear
side covers to the frame. Remove rear side cov-
ers from frame.
See Figure 3 for lift truck models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Figure 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
Description 0100 YRM 1754
2
4. 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 (WITH-
OUT 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
14. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (NON-SUSPENSION)
15. ATTACHMENT HOLES ATTACHING HOOD TO
SEAT (FULL SUSPENSION)
16. SPACER
Figure 2. Hood and Seat Arrangement
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
3
5. 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 GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX)
(C910)
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
4
6. Figure 4. Side Covers, Floor Plate, and Cowl Components GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875)
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
5
7. Legend for Figure 4
1. DASH ASSEMBLY
2. UPPER STEERING COLUMN COVER
3. LOWER STEERING COLUMN COVER
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
7. Remove two capscrews holding left and right
fender covers to front overhead guard leg. Re-
move covers.
See Figure 3 for lift truck models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Figure 4 for lift truck models
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
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 allen screws (see Figure 5) from
dash and cowl. Remove four clips, located under-
neath dash, that attach dash to the kick panel. Lift
to remove dash.
12. Lift the kick panel to remove from truck.
See Figure 3 for lift truck models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Figure 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
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.
Damage 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.
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
6
8. 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 5. Remove Dash From Cowl
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
7
9. 1. CAPSCREWS 2. SEAL PLATE
Figure 6. Remove Seal Plate From Dash
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
8
10. 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 Fig-
ure 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:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Figure 8 and Table 2 for lift truck models
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
NOTE: LEFT SIDE SHOWN
A. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION
SEAT
B. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR SEMI OR FULL SUS-
PENSION SEAT
C. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR SEMI OR FULL SUS-
PENSION SEAT WITH CAB
1. MOUNTING POINTS FOR GAS SPRING ON
HOOD
Figure 7. Gas Spring Installation, Lift Truck
Models GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
Table 1. Gas Spring Installation, Lift Truck Models GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX)
(C910)
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
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
9
11. 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) (D875) LIFT TRUCKS WITHOUT CAB
E. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION
SEAT, LIFT TRUCKS GLP/GDP20-35VX (D875) WITHOUT CAB
1. MOUNTING POINTS FOR GAS SPRING ON HOOD
Figure 8. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
Table 2. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
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 D D 3 3 C C 1 1
Non-Cab E E 2 2 C C 1 1
Cab D D 1 1 N/A N/A N/A N/A
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
10
12. 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 en-
sure that center pin strikes hood latch properly
and that the stop screw contacts frame. A prop-
erly closed hood MUST click twice on the hood
latch. If the hood latch does not close properly,
loosen capscrews on the back of center pin and
adjust center pin up or down as required for cor-
rect alignment. See Figure 9.
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.
1. HOOD
2. HOOD LATCH
3. CENTER PIN
4. CAPSCREW
Figure 9. Hood Latch Adjustment
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.
CAUTION
When installing the seat to the hood, DO NOT use
an impact wrench to install the capscrews. Dam-
age 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 ca-
ble 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.
See Figure 3 for lift truck models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Figure 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
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.
See Figure 3 for lift truck models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Figure 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
11
13. 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.
See Figure 3 for lift truck models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
See Figure 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
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 steer-
ing wheel and the steering control unit. The steering
column includes the steering wheel, housing, bracket
and lower shaft. For lift trucks with gas and LPG en-
gines, bolts and bushings attach the steering column
to the cowl standoffs. For lift trucks with diesel en-
gines, bolts, bushings and isolators attach the steer-
ing column to the cowl standoffs. See Figure 10.
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.
1. STEERING WHEEL
2. STEERING COLUMN
3. COWL
Figure 10. Steering Column and Cowl
STEERING COLUMN REPAIR
Remove
1. Put blocks on each side (front and back) of tires
to prevent lift truck from moving.
WARNING
Disconnect the battery before removing any cov-
ers to avoid injury to personnel.
2. Attach a tag on battery connector or negative bat-
tery cable stating, DO NOT CONNECT BAT-
TERY. 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 compo-
nents of steering column assembly. Not all compo-
nents are removed for a repair procedure. Do only
those steps of procedure necessary to remove re-
quired 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 11.
4. Remove steering column covers. Remove floor
mats and floor plate. See section Hood, Seat, and
Side Covers Replacement.
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
12
14. 1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
Figure 11. Steering Wheel Remove/Install
NOTE: Perform Step 5 for lift trucks equipped with
gas or LPG engines.
5. Remove four capscrews, four isolators, four bush-
ings, and steering column from cowl standoffs.
See Figure 12.
NOTE: Perform Step 6 for lift trucks equipped with
diesel engines.
6. Remove four capscrews, four bushings, four iso-
lators, steering column and four isolators from
cowl standoffs. See Figure 12.
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.
1. CAPSCREW
2. BUSHING
3. ISOLATOR
4. STEERING COLUMN
5. COWL STANDOFF
Figure 12. Steering Column Remove/Install
0100 YRM 1754 Steering Column
13
15. Disassemble
NOTE: Remove and discard snap rings if installed.
1. Remove two pins and gas spring from housing.
See Figure 13.
2. Remove two pivot bolts, two bushings, two nuts
and bracket from housing. See Figure 13.
3. Remove split pin and lower shaft from upper
shaft. See Figure 13.
4. Remove connector from connector bracket. Re-
move connector bracket, fastener, four screws
and two horn contacts from housing. See Fig-
ure 13.
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety precautions.
WARNING
Compressed air is used for cleaning and drying
purposes, or for cleaning restrictions. Wear pro-
tective clothing (goggles/shields, gloves, etc.).
Make sure the path of the compressed air is away
from all personnel to avoid injury.
1. Clean metal parts in solvent. Remove all traces of
old lubricant and dirt. Clean nonmetal parts with
warm soapy water and a lint free cloth.
2. After cleaning, dry parts with compressed air. DO
NOT dry parts with a cloth.
Inspect
1. Inspect for loose, burned, missing, cracked or
damaged hardware.
2. Inspect all parts for dents, holes, bends, burrs,
rust, corrosion or marred finishes.
3. Replace all defective or damaged parts.
Assemble
This procedure is for installation of all components of
steering column assembly. Not all components are re-
moved for a repair procedure. Do only those steps of
procedure necessary to install required component.
1. Install fastener, connector bracket and connector,
two horn contacts and four screws. See Fig-
ure 13.
2. Assemble lower shaft and upper shaft, secure
with spit pin. See Figure 13.
3. Install two pivot bolts, two bushings, two nuts and
bracket onto housing. See Figure 13.
4. Install gas spring and two pins on housing. See
Figure 13.
Install
NOTE: Lubricate spline end of lower shaft with multi
purpose grease.
See Periodic Maintenance 8000YRM1762 for lift
truck models
• GLC20-35VX (GC/GLC040-070VX, GC/
GLC055SVX) (C910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875)
NOTE: Perform Step 1 for lift trucks equipped with
gas or LPG engines.
1. Install steering column, four isolators, four bush-
ings, and four bolts on cowl standoffs. Tighten
bolts to 38 N•m (28 lbf ft). See Figure 12.
NOTE: Perform Step 2 for lift trucks equipped with
diesel engines.
2. Install steering column, four isolators, four bush-
ings, and four bolts on cowl standoffs. Tighten
bolts to 38 N•m (28 lbf ft). See Figure 12.
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 11.
Steering Column 0100 YRM 1754
14
16. 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.
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 13. Steering Column
0100 YRM 1754 Steering Column
15
17. LPG Tank and Bracket Assembly
For procedures to remove and install the LPG tank,
LPG tank bracket, and the LPG tank alignment pin
see the following Service Manuals:
• Fuel System PSI 2.4L 0900YRM1757 for lift
truck models equipped with a PSI 2.4L Dual
Fuel engine
• LPG Fuel System, Kubota 2.5L Engine
0900YRM1677 for lift trucks equipped with a
Kubota 2.5L LPG engine
Counterweight Replacement
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the procedure How to Put Lift
Truck on Blocks in the Operating Manual or the
Periodic Maintenance Manual for your lift truck.
WARNING
DO NOT operate the lift truck if the capscrew for
the counterweight is not installed. When the cap-
screw is removed, the counterweight can fall from
the lift truck.
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
from any open flame, motor vehicles, electrical
equipment, or ignition source.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is disconnec-
ted. 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 de-
crease 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. See Fig-
ure 14.
One M24 × 3 x 140 capscrew holds counterweight to
lower part of frame on lift truck models:
• GLC30-35VX (GC/GLC060-070VX, GC/
GLC055SVX) (C910)
• GLP/GDP30-35VX (GP/GLP/GDP060-070VX)
(D875)
One M24 × 3 x 90 capscrew holds counterweight to
lower part of frame on lift truck models:
• GLC20-55VX (GC/GLC040-050VX) (C910)
• GLP/GDP20-25VX (GP/GLP/GDP040-050VX)
(D875)
NOTE: For overhead exhaust system removal proce-
dure, for lift trucks equipped with a PSI 2.4L engine,
see Fuel System PSI 2.4L 0900YRM1757.
NOTE: For overhead exhaust system removal proce-
dure, for lift truck equipped with a Kubota engine, see
LPG Fuel System, Kubota 2.5L Engine
0900YRM1677.
LPG Tank and Bracket Assembly 0100 YRM 1754
16
18. NOTE: To remove overhead exhaust pipe, for lift
trucks equipped with a Yanmar engine and overhead
exhaust see section Exhaust System Repair in this
manual 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, before removing the counter-
weight
Fuel System PSI 2.4L 0900YRM1757 for lift truck
models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
• GLP/GDP30-35VX (GP/GLP/
GDP040-070VX) (D875)
for lift truck models
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
WARNING
The counterweight is heavy. Make sure that the
eyebolt and lifting devices have enough capacity
to lift the weight. The approximate weights of the
counterweight castings are shown in:
Table 3 for lift truck models:
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
Table 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875)
2. Install a lifting eyebolt in lift hole of counterweight.
See Figure 14.
Connect a crane to lifting eyebolt and raise crane
until it holds par of the weight of counterweight.
Remove tow pin. See Figure 14 and Figure 15.
Remove capscrew and washer that hold counter-
weight to frame. See Figure 14 and Figure 15.
Use crane to lift counterweight from lift truck frame.
Place counterweight on floor so that is has stability
and will not fall over. Take care not to damage ex-
haust or cooling components.
1. FRAME
2. LOWER FRAME MOUNT
3. WASHER
4. CAPSCREW
5. TOW PIN
6. LIFT HOLE
7. SEAL
8. FRAME HOOK
Figure 14. Counterweight Installation
Table 3. Weight of Counterweights, Lift Truck
Models GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
Model Kg Lb
GLC20VX (GC/
GLC040VX)
1040 2293
GLC25VX (GC/
GLC050VX)
1395 3075
GC/GLC055SVX 1600 3527
GLC30VX (GC/
GLC060VX)
1819 4010
GLC35VX (GC/
GLC070VX)
2153 4747
0100 YRM 1754 Counterweight Replacement
17
19. Table 4. Weight of Counterweights, Lift Truck
Models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
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
INSTALL
1. Make sure seals are on counterweight. Figure 15.
2. Use a crane to install counterweight on lift truck
frame. When counterweight is installed, make
sure hooks on frame fully engage counterweight
so it is aligned with parts of frame.
3. Install washer and M24 × 3 capscrew. Tighten
capscrew to 555 N•m (409 lbf ft). See Figure 14
and Figure 15.
4. Install tow pin. See Figure 15.
5. 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 instal-
led.
Fuel System PSI 2.4L 0900YRM1757 for lift truck
models
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
• GLP/GDP30-35VX (GP/GLP/
GDP040-070VX) (D875)
LPG Fuel System, Kubota 2.5L Engine
0900YRM1677 for lift truck models
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
6. If lift truck is equipped with a Yanmar engine and
an overhead exhaust system, install the overhead
pipe. See section Exhaust System Repair in this
manual for procedures.
1. TOW PIN
2. CAPSCREW
3. WASHER
4. COUNTERWEIGHT
5. LPG ACCESS HOLE
6. NUT
7. SEAL
8. WASHER
9. LIFTING EYEBOLT
10. LIFT HOLE
Figure 15. Counterweight
Counterweight Replacement 0100 YRM 1754
18
20. Overhead Guard Replacement
REMOVE AND INSTALL
WARNING
DO NOT operate the lift truck without the over-
head guard correctly fastened to the lift truck.
WARNING
DO NOT weld mounts for lights or accessories to
legs of the overhead guard. Changes that are
made by welding, or by drilling holes that are too
big or in the wrong location, can reduce the
strength of the overhead guard.
See your dealer for Hyster lift trucks BEFORE per-
forming any changes to the overhead guard.
NOTE: The lift trucks covered in this YRM are equip-
ped with either a high or low overhead guard. The re-
moval and installation procedures for both types of
overhead guards are the same.
No welding or drilling on legs of overhead guard is
permitted as per previous WARNING.
NOTE: The lifting device can be connected to any
number of positions on the overhead guard depend-
ing upon the lifting device available. The ideal choices
are a four point sling connected to all four corners on
the top of the overhead guard, or a two point sling
connected to two opposite corners of the overhead
guard. If a single point hoist is used, make sure that
the lift point is as close to the center of the overhead
guard. If during the initial start of the lift the overhead
guard is off balance lower immediately and move the
hoist to a more centered point.
1. Connect a lifting device to remove or install the
overhead guard. Loosen clamp and disconnect
the air intake hose from the elbow. Remove bolts,
elbow, retainer, and grommet from the overhead
guard rear leg. See Figure 16.
2. Disconnect any wires between the frame and the
overhead guard. When the overhead guard is lif-
ted from the frame, make sure that any electrical
wires are moved through the holes in the frame
so that they are not damaged.
3. The rear legs of the overhead guard have two
capscrews that are located under the hood inside
the engine compartment, next to the radiator. Re-
move and install the capscrews. See Figure 17.
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
procedures.
5. When installing the overhead guard, tighten the
capscrews for the overhead guard legs to
66 N•m (49 lbf ft). See Figure 17.
LED TAIL, BACKUP, AND BRAKE
LIGHTS, REPLACE
These light assemblies are nonrepairable and must
be replaced as an assembly. See Electrical System
2200YRM1760 for the procedures to replace these
lights.
1. CLAMP
2. AIR INTAKE HOSE
3. BOLTS
4. ELBOW
5. RETAINER
6. GROMMET
Figure 16. Disconnect Air Intake Hose
0100 YRM 1754 Overhead Guard Replacement
19
21. Figure 17. Overhead Guard
Legend for Figure 17
1. CAPSCREWS - FRONT LEGS
2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME
Operator Restraint System Replacement
DESCRIPTION
The seat belt, hip restraint brackets, seat and mount-
ing, hood, and latches are all part of the operator re-
straint system. Each item must be checked to make
sure it is attached securely, functions correctly, and is
in good condition. See Figure 18.
Emergency Locking Retractor (ELR)
When the ELR style seat belt is properly buckled
across the operator, the belt will permit slight operator
repositioning without activating the locking mecha-
nism. If the truck tips, travels off a dock, or comes to a
sudden stop, the locking mechanism will be activated
and hold the operator's lower torso in the seat.
A seat belt that is damaged worn or does not operate
properly will not provide protection when it is needed.
The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the
seat belt if damage or wear is seen. See Figure 18
and Figure 19.
NOTE: The following seat belt operation checks must
be performed three times before replacing the seat
belt assembly.
• With the hood closed and in the locked posi-
tion, pull the seat belt slowly from the retractor
assembly. Make sure the seat belt pulls out
and retracts smoothly. If the seat belt cannot
be pulled from the retractor assembly or the
belt will not retract, replace the seat belt as-
sembly.
Overhead Guard Replacement 0100 YRM 1754
20
22. • With the hood closed and in the locked posi-
tion, pull the seat belt with a sudden jerk. Make
sure the seat belt will not pull from the retractor
assembly. If the seat belt can be pulled from
the retractor, when it is pulled with a sudden
jerk, replace the seat belt assembly.
• With the hood in the open position, make sure
the seat belt will not pull from the retractor as-
sembly. If the seat belt can be pulled from the
retractor, with the hood in the open position, re-
place 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 adjust-
ment procedures for the hood.
1. OPERATOR WEIGHT ADJUSTMENT
2. FORWARD/BACKWARD ADJUSTMENT
3. SEAT BELT
4. HIP RESTRAINT
5. SEAT
6. SEAT RAIL
Figure 18. Operator Restraint System
0100 YRM 1754 Operator Restraint System Replacement
21
23. 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
Figure 19. Operator Restraint System
Engine Replacement
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or Peri-
odic Maintenance 8000YRM1762 for your lift truck.
WARNING
Always disconnect the cables at the battery be-
fore you make repairs to the engine. Disconnect
the cable at the negative terminal first.
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
Operator Restraint System Replacement 0100 YRM 1754
22
24. 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
Fuel System PSI 2.4L 0900YRM1757 for lift truck
models
• GLC20-35VX (GC/GLC040-070VX,GC/
GLC055SVX ) (C910)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
LPG Fuel System, Kubota 2.5L Engine
0900YRM1677 for lift truck models
• GLC20-35VX (GC/GLC040-070VX,GC/
GLC055SVX ) (C910)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
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 sys-
tem. 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 ca-
pacity of the cooling system under radiator. Re-
move radiator cap.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
6. Open the drain plug or disconnect the bottom ra-
diator hose to drain coolant from radiator and en-
gine.
7. Remove the hood and seat combination and rear
side covers. See the section Hood, Seat, and
Side Covers Replacement for procedures.
8. Disconnect the ground strap from the frame and
remove the power distribution module (PDM) from
the battery tray. See Figure 20.
9. Remove three capscrews from the battery tray
and remove the battery and battery tray. See Fig-
ure 20.
10. Disconnect the remaining coolant hoses from the
radiator and cap them to prevent leakage.
11. On lift trucks equipped with a Basic Powershift
Transmission, disconnect the throttle linkage. See
the section 2-Speed Powershift Transmission
Repair 1300YRM1764. Disconnect the exhaust
system.
12. Remove the radiator fan pulley, shroud, and fan
assembly. See the section Cooling System
0700YRM1756 for the removal procedures.
1. BATTERY
2. BATTERY TRAY
3. PDM
4. BATTERY LOCKDOWN BAR
5. GROUND STRAP
Figure 20. Power Distribution Module,
Disconnection
0100 YRM 1754 Engine Replacement
23
25. 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 gas-
oline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
13. Disconnect the fuel lines at the engine. Put caps
on fuel lines to prevent fuel leakage.
NOTE: Lift trucks equipped with Yanmar diesel en-
gine do not have an ECM.
14. Disconnect the electronic control module (ECM)
connector and governor controller from the side of
the frame before removing the engine from the
truck.
15. Disconnect the engine harness connectors from
the right hand chassis harness connectors before
removing the engine from the truck.
16. 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 21.
17. Connect a lifting device to the engine. Put a block
under the transmission housing to support the
transmission.
NOTE: Perform Step 18 for lift trucks equipped with
iron housing transmission.
18. Remove capscrews from transmission bell hous-
ing.
NOTE: Perform Step 19 through Step 21 for lift
trucks equipped with aluminum housing transmission.
19. Remove two capscrews, two washers, and con-
verter housing cover from torque converter hous-
ing. See Figure 22.
20. Remove four flange bolts from torque converter
housing and flywheel housing on transmission
side. See Figure 22.
21. Remove six hex head capscrews and six lock
washers from flywheel housing and torque con-
verter housing on flywheel housing side. See Fig-
ure 22.
WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The
engine can weigh approximately 194 kg (428 lb).
22. Remove the flange nuts, washers, bolts, and iso-
lators from the engine mounts. Remove engine
adapter to transmission bolts. See Figure 23 and
Figure 24.
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 separa-
ted from the transmission so the drive plate is not
damaged.
23. Use the lifting device to carefully move the engine
away from the torque converter. Make sure all ho-
ses, wires, and cables are disconnected from the
engine, then lift the engine from the frame and
place engine on blocks.
24. Remove torque converter from torque converter
housing.
Engine Replacement 0100 YRM 1754
24
26. A. KUBOTA 2.5L ENGINE
B. YANMAR 3.3L ENGINE
C. PSI 2.4L ENGINE
1. ACCESS PORT 2. FLYWHEEL HOUSING
Figure 21. Torque Converter Bolt Access
0100 YRM 1754 Engine Replacement
25
28. A. PSI ENGINE
B. YANMAR ENGINE
C. KUBOTA ENGINE
1. FRAME
2. ENGINE MOUNT
3. FLANGE NUT
Figure 23. Engine Removal
0100 YRM 1754 Engine Replacement
27
29. INSTALL
WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The
engine 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 dam-
aged.
1. Install torque converter in torque converter hous-
ing.
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 23 and Figure 24. 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 21.
NOTE: Perform Step 5 for lift trucks equipped with
iron transmission housing.
5. Align transmission bell housing holes with fly-
wheel housing holes and install capscrews.
Tighten capscrews to 38 N•m (28 lbf ft).
NOTE: Perform Step 6 through Step 8 for lift trucks
equipped with aluminum transmission housing.
6. Install six lock washers and six capscrews on fly-
wheel housing and torque converter housing from
flywheel housing side. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 22.
A. PSI ENGINE MOUNT
B. YANMAR ENGINE MOUNT
C. KUBOTA ENGINE MOUNT
1. CAPSCREW
2. WASHER
3. RIGHT ENGINE MOUNT
4. SNUBBING WASHER
5. ISOLATOR
6. LOCKNUT
Figure 24. Engine Mounts
Engine Replacement 0100 YRM 1754
28
30. 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 22.
8. Install converter housing cover, two washers, and
two capscrews on torque converter housing.
Tighten capscrews to 19 N•m (168 lbf in). See
Figure 22.
9. Install exhaust pipe to exhaus manifold. See Ex-
haust System Repair.
NOTE: Lift trucks equipped with Yanmark diesel en-
gine do not have an ECM.
10. Connect the ECM connector and governor con-
troller to lift truck frame.
11. 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 gas-
oline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
12. Connect the wires and wiring harnesses at the
engine. Remove caps from fuel lines and connect
the fuel lines at the engine.
13. On lift trucks equipped with a Basic Powershift
Transmission, connect the throttle linkage. See
the section 2-Speed Powershift Transmission
Repair 1300YRM1764. Connect exhaust system.
14. 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.
15. Install the radiator shroud, fan pulley, and fan as-
sembly. See the section Cooling System
0700YRM1756 for the installation procedures.
16. 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 25.
1. BATTERY
2. BATTERY TRAY
3. PDM
4. BATTERY LOCKDOWN BAR
5. GROUND STRAP
Figure 25. Power Distribution Module, Connection
17. If lift truck is equipped with an LPG tank, swing
tank into position on truck. See one of the follow-
ing Service Manuals for procedures
Fuel System PSI 2.4L 0900YRM1757 for lift truck
models
• GLC20-35VX (GC/GLC040-070VX,GC/
GLC055SVX ) (C910)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
LPG Fuel System, Kubota 2.5L Engine
0900YRM1677 for lift truck models
• GLC20-35VX (GC/GLC040-070VX,GC/
GLC055SVX ) (C910)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
18. 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.
19. If removed, install Overhead guard. See section
Overhead Guard Replacement for procedures.
0100 YRM 1754 Engine Replacement
29
31. 20. Check all fluid levels as described in Periodic
Maintenance 8000YRM1762.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
21. Empty drain pan contents.
Transmission Replacement
REMOVE TRANSMISSION WITH IRON
HOUSING
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine,
transmission, and counterweight. When the lift
truck is put on blocks put additional blocks in the
following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or Peri-
odic Maintenance Manual for your lift truck.
1. Remove engine from lift truck. See section Engine
Replacement, Remove in this manual for proce-
dures.
2. Remove the seal plate for the brake and throttle
pedals. See Figure 26.
NOTE: When disconnecting wiring harness connec-
tors during removal, tag each connector to aid in con-
necting wiring harness during installation.
3. Disconnect the engine wiring harness from trans-
mission wiring harness.
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.
NOTE: Step 6 and Step 7 apply to lift truck models
GLP/GDP20-35VX (D875) equipped with a variable
displacement 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 fit-
ting. See Figure 27.
7. Remove the hydraulic supply hose, load sense
line, drain case line, and hydraulic inlet line from
the variable displacement pump. Put cap on all
variable displacement pump and hose openings.
See Figure 27.
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).
8. Connect a lifting device to support the transmis-
sion.
9. Remove the capscrew, washer, snubbing wash-
ers, and isolators from the mount bracket at the
rear of the transmission. See Figure 28.
10. Use a lifting device to carefully lift the transmis-
sion out of the frame. Slip the transmission output
yoke out of the transmission. Make sure to not
damage the seal.
Engine Replacement 0100 YRM 1754
30
32. 1. CAPSCREWS 2. SEAL PLATE
Figure 26. Remove Seal Plate From Dash
0100 YRM 1754 Transmission Replacement
31
33. 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 27. Hydraulic Hose Connections
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.
A. IRON CASE TRANSMISSION
B. ALUMINUM CASE TRANSMISSION
1. CAPSCREW
2. WASHER
3. SNUBBING WASHER
4. ISOLATOR
5. MOUNT BRACKET
Figure 28. Rear Mount - Transmission
Transmission Replacement 0100 YRM 1754
32
34. INSTALL TRANSMISSION WITH IRON
HOUSING
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. Using a lifting device, install transmission in lift
truck frame. Place a block under the transmission
housing 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 28. Tighten cap-
screw 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.
Connect the supply line to the main control valve.
See Hydraulic Gear Pumps 1900YRM1744.
NOTE: Step 6 and Step 7 apply to lift truck models
GLP/GDP20-35VX (D875) equipped with a variable
displacement pump (VDP).
6. Install the hydraulic supply hose between the vari-
able displacement pump and hydraulic tank. See
Figure 27.
7. Install the hydraulic supply hose, load sense line,
drain case line, and hydraulic inlet line on the vari-
able displacement pump. See Figure 27. See Hy-
draulic Gear Pumps 1900YRM1744 for more in-
formation on installing hydraulic hoses to variable
displacement pump.
8. Connect the transmission wiring harness to en-
gine wiring harness. Connect transmission cool-
ing lines.
9. Install the seal plate for the brake and throttle
pedals. See Figure 26.
10. Install engine in lift truck. See section Engine Re-
placement, Install in this manual for procedures.
REMOVE TRANSMISSION WITH
ALUMINUM HOUSING
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine,
transmission, and counterweight. When the lift
truck is put on blocks put additional blocks in the
following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or Peri-
odic Maintenance Manual for your lift truck.
WARNING
The transmission is heavy. Make sure that any lift-
ing device has enough capacity to lift the weight.
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 Engine
Replacement, Remove in this manual for proce-
dures.
2. Remove the seal plate for the brake and throttle
pedals. See Figure 26.
NOTE: When disconnecting wiring harness connec-
tors during removal, tag each connector to aid in con-
necting wiring harness during installation.
3. Disconnect the engine wiring harness from trans-
mission wiring harness.
4. Disconnect transmission cooling lines from trans-
mission.
0100 YRM 1754 Transmission Replacement
33
35. See Figure 29 for lift truck models equipped with
hydraulic gear pump and dry brakes
• GLC20-35VX (GC/GLC040-070VX,GC/
GLC055SVX ) (C910)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
See Figure 30 for lift truck models equipped with a
hydraulic gear pump and wet brakes
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
See Figure 31 and Figure 32 for lift truck models
equipped with a variable displacement pump:
• GLP/GDP20-35VX (D875)
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND
ADAPTERS NOT SHOWN.
1. TRANSMISSION HOUSING
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 29. Hydraulic Hose, Dry Brakes (Aluminum
Transmission)
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND
ADAPTERS NOT SHOWN.
1. TRANSMISSION HOUSING
2. WET DISK BRAKE HOSE ASSEMBLY
3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
5. HYDRAULIC GEAR PUMP INLET PORT
6. HYDRAULIC GEAR PUMP OUTLET PORT
7. HYDRAULIC INLET HOSE
8. HIGH TEMP HOSE ASSEMBLY
9. TRANSMISSION COOLING SUPPLY PORT
Figure 30. Hydraulic Hose, Wet Brakes (Aluminum
Transmission)
Transmission Replacement 0100 YRM 1754
34
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