YALE B910 GLC20VX, GLC25VX, GLC30VX, GLC35VX Lift Truck Service Repair Manual (Europe)

Maintenance ELECTRICAL SYSTEM GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [B910]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [C875] PART NO. 550096328 2200 YRM 1685

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale ® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con- tained in the Service Manual could result in damage to the products, personal injury, property damage or death. • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

©2014 Yale Materials Handling Corp. TABLE OF CONTENTS General ..................................................................................................................................................................... 1 Display Switch Cluster .............................................................................................................................................. 2 Remove ................................................................................................................................................................ 2 Install .................................................................................................................................................................... 4 Direction Control and Turn Signal Levers .............................................................................................................4 Remove ............................................................................................................................................................ 4 Install ................................................................................................................................................................ 4 Key Switch ............................................................................................................................................................ 6 Remove ............................................................................................................................................................ 6 Install ................................................................................................................................................................ 6 Display Switch Cluster Panel Bezel and Overlay ................................................................................................. 7 Remove ............................................................................................................................................................ 7 Install ................................................................................................................................................................ 7 Steering Column Repair ........................................................................................................................................... 7 Remove ................................................................................................................................................................ 7 Disassemble ......................................................................................................................................................... 8 Assemble .............................................................................................................................................................. 8 Install .................................................................................................................................................................... 8 Sensors and Switches ............................................................................................................................................ 10 General ............................................................................................................................................................... 10 Dash and Kick Panel, Remove and Install ..................................................................................................... 10 Remove ......................................................................................................................................................10 Install ..........................................................................................................................................................10 Accelerator Pedal Position Sensor ..................................................................................................................... 12 Remove .......................................................................................................................................................... 12 Install .............................................................................................................................................................. 12 Brake Fluid Level Switch .................................................................................................................................... 15 Remove .......................................................................................................................................................... 15 Install .............................................................................................................................................................. 15 Service Brake Pedal Position Sensor ................................................................................................................. 16 Remove .......................................................................................................................................................... 16 Install .............................................................................................................................................................. 16 Parking Brake Sensor .........................................................................................................................................17 Remove .......................................................................................................................................................... 17 Install .............................................................................................................................................................. 18 Service Brake Pressure Sensor ......................................................................................................................... 18 Remove .......................................................................................................................................................... 18 Install .............................................................................................................................................................. 18 Sensor Microswitch Foot Directional Control.......................................................................................................18 Remove .......................................................................................................................................................... 18 Install .............................................................................................................................................................. 20 Low Coolant Level Sensor ..................................................................................................................................20 Remove .......................................................................................................................................................... 20 Install .............................................................................................................................................................. 22 Fuel Level Sensor, Gas and Diesel Engines Only ..............................................................................................22 Remove .......................................................................................................................................................... 22 Install .............................................................................................................................................................. 22 Seat Sensor (Operator Presence System) ......................................................................................................... 23 Non-Suspension and Semi-Suspension Seats .............................................................................................. 23 Remove ......................................................................................................................................................23 Table of Contents i

TABLE OF CONTENTS (Continued) Install ..........................................................................................................................................................23 Full Suspension And Swivel Seats .................................................................................................................24 Remove ......................................................................................................................................................24 Install ..........................................................................................................................................................24 Hood Shut Off Switch ......................................................................................................................................... 25 Remove .......................................................................................................................................................... 25 Install .............................................................................................................................................................. 25 Hydraulic Filter Pressure Switch .........................................................................................................................26 Remove .......................................................................................................................................................... 26 Install .............................................................................................................................................................. 27 Transmission Speed Sensor .............................................................................................................................. 27 Remove .......................................................................................................................................................... 27 Install .............................................................................................................................................................. 28 Transmission Pressure Sensors .........................................................................................................................28 Remove .......................................................................................................................................................... 28 Install .............................................................................................................................................................. 28 Transmission Temperature Sensor .................................................................................................................... 29 Remove .......................................................................................................................................................... 29 Install .............................................................................................................................................................. 29 Return to Set Tilt (Tilt Angle) Sensor .................................................................................................................. 29 Remove .......................................................................................................................................................... 29 Install .............................................................................................................................................................. 29 Rear Horn Button Switch .................................................................................................................................... 30 Remove .......................................................................................................................................................... 30 Install .............................................................................................................................................................. 30 Impact Sensor .................................................................................................................................................... 30 Remove .......................................................................................................................................................... 30 Install .............................................................................................................................................................. 31 Load Weight Sensor ........................................................................................................................................... 32 Remove .......................................................................................................................................................... 32 Install .............................................................................................................................................................. 32 Engine and Fuel Sensors and Switches, Gas and LPG Trucks Equipped with Mazda 2.2L Engine ..................33 Engine and Fuel Sensors and Switches, Kubota 2.5L LPG Engine ................................................................... 33 Crankshaft Position Sensor ............................................................................................................................34 Remove ......................................................................................................................................................34 Install ..........................................................................................................................................................34 Camshaft Position Sensor ..............................................................................................................................34 Remove ......................................................................................................................................................34 Install ..........................................................................................................................................................34 Engine Coolant Temperature (ECT) Sensor .................................................................................................. 35 Remove ......................................................................................................................................................35 Install ..........................................................................................................................................................35 Manifold Absolute Pressure (MAP) Sensor ....................................................................................................35 Remove ......................................................................................................................................................35 Install ..........................................................................................................................................................35 Oil Pressure Sensor ....................................................................................................................................... 36 Remove ......................................................................................................................................................36 Install ..........................................................................................................................................................36 Knock Sensor ................................................................................................................................................. 36 Remove ......................................................................................................................................................36 Table of Contents ii

TABLE OF CONTENTS (Continued) Install ..........................................................................................................................................................36 Oxygen Sensors .............................................................................................................................................36 Air Flow Restriction Switch .............................................................................................................................36 Remove ......................................................................................................................................................36 Install ..........................................................................................................................................................36 Engine and Fuel Sensors and Switches, Yanmar Diesel Engine ....................................................................... 38 Air Filter Restriction Switch ............................................................................................................................ 38 Remove ......................................................................................................................................................38 Install ..........................................................................................................................................................38 Oil Pressure Sensor ....................................................................................................................................... 38 Remove ......................................................................................................................................................38 Install ..........................................................................................................................................................38 Engine Speed Sensor .................................................................................................................................... 39 Remove ......................................................................................................................................................39 Install ..........................................................................................................................................................39 Engine Coolant Temperature (ECT) Sensor .................................................................................................. 39 Remove ......................................................................................................................................................39 Install ..........................................................................................................................................................39 Throttle Position Sensor (TPS) ...................................................................................................................... 41 Remove ......................................................................................................................................................41 Install ..........................................................................................................................................................41 Fuel/Water Separator Sensor ........................................................................................................................ 42 Remove ......................................................................................................................................................42 Install ..........................................................................................................................................................42 Glow Plug Relay .............................................................................................................................................43 Remove ......................................................................................................................................................43 Install ..........................................................................................................................................................43 Vehicle System Manager (VSM) ............................................................................................................................. 45 General ............................................................................................................................................................... 45 VSM Replacement ..............................................................................................................................................45 Remove .......................................................................................................................................................... 45 Install .............................................................................................................................................................. 45 Programming a New VSM and/or Display Switch Cluster .................................................................................. 47 General .......................................................................................................................................................... 47 PC Service Tool Software .............................................................................................................................. 47 Data Transferring ........................................................................................................................................... 47 New VSM ................................................................................................................................................... 47 New (Blank) Display Switch Cluster ...........................................................................................................48 Used (Non-Blank) Display Switch Cluster ..................................................................................................48 Power Distribution Module (PDM) and Component Parts ...................................................................................... 49 Remove .............................................................................................................................................................. 49 PDM as a Unit ................................................................................................................................................ 49 Install .................................................................................................................................................................. 49 PDM as a Unit ................................................................................................................................................ 49 Remove and Install ............................................................................................................................................. 51 PDM Component Parts .................................................................................................................................. 51 Battery .................................................................................................................................................................... 52 Remove .............................................................................................................................................................. 52 Install .................................................................................................................................................................. 52 Lights ...................................................................................................................................................................... 52 Table of Contents iii

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YALE B910 GLC20VX, GLC25VX, GLC30VX, GLC35VX Lift Truck Service Repair Manual (Europe)

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