Maintenance
FRAME
GLC030-035VX, GLC040SVX [D809];
GLP/GDP16-18VX, GLP/GDP20SVX
(GLP/GDP030-035VX, GLP/GDP040SVX) [D810]
PART NO. 550108490 0100 YRM 1735
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 re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.
©2014 Yale Materials Handling Corp.
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Description ................................................................................................................................................................ 2
Hood, Seat, and Side Covers Replacement ............................................................................................................. 3
Remove ................................................................................................................................................................ 3
Install .................................................................................................................................................................. 13
Steering Column ..................................................................................................................................................... 16
Description ..........................................................................................................................................................16
Steering Column Repair ..................................................................................................................................... 16
Remove .......................................................................................................................................................... 16
Disassemble ...................................................................................................................................................18
Clean .............................................................................................................................................................. 18
Inspect ............................................................................................................................................................18
Assemble ....................................................................................................................................................... 18
Install .............................................................................................................................................................. 18
LPG Tank and Bracket Assembly ........................................................................................................................... 19
Counterweight Replacement .................................................................................................................................. 20
Remove .............................................................................................................................................................. 20
Install .................................................................................................................................................................. 22
Tow Pin Remove and Install ............................................................................................................................... 23
Overhead Guard Replacement ............................................................................................................................... 24
Remove and Install ............................................................................................................................................. 24
LED Tail, Backup, and Brake Lights, Replace ....................................................................................................25
Operator Restraint System Replacement ............................................................................................................... 26
Description ..........................................................................................................................................................26
Emergency Locking Retractor (ELR) .................................................................................................................. 26
Engine Replacement .............................................................................................................................................. 28
Remove .............................................................................................................................................................. 28
Install .................................................................................................................................................................. 35
Transmission Replacement .................................................................................................................................... 37
Remove .............................................................................................................................................................. 37
Install .................................................................................................................................................................. 39
Throttle Pedal and Cable Adjustment ..................................................................................................................... 40
Yanmar Diesel Engine With Basic Powershift Transmission ..............................................................................40
Yanmar Diesel Engine With Electronic Throttle ..................................................................................................42
Throttle Pedal Stop Adjustment .......................................................................................................................... 42
Exhaust System Repair .......................................................................................................................................... 43
Lift Trucks Equipped With PSI 2.0L LPG Engine ............................................................................................... 43
Lift Trucks Equipped With Yanmar 2.6L Diesel Engine ...................................................................................... 43
Counterweight Exhaust System ..................................................................................................................... 43
Remove and Disassemble ......................................................................................................................... 43
Inspect ....................................................................................................................................................... 43
Assemble and Install .................................................................................................................................. 43
Overhead Exhaust System ............................................................................................................................ 45
Remove and Disassemble ......................................................................................................................... 45
Inspect ....................................................................................................................................................... 45
Assemble and Install .................................................................................................................................. 45
Cooling System ....................................................................................................................................................... 47
Description ..........................................................................................................................................................47
Hydraulic Filter Assembly Repair ............................................................................................................................ 47
Remove .............................................................................................................................................................. 47
Table of Contents
i
TABLE OF CONTENTS (Continued)
Clean and Inspect ...............................................................................................................................................48
Install .................................................................................................................................................................. 48
Fuel and Hydraulic Tanks Repair ........................................................................................................................... 49
Inspect ................................................................................................................................................................ 49
Clean .................................................................................................................................................................. 49
Steam Method of Cleaning .............................................................................................................................50
Chemical Solution Method of Cleaning .......................................................................................................... 51
Additional Preparations For Repair .................................................................................................................... 51
Small Leaks, Repair ........................................................................................................................................... 51
Large Leaks, Repair ........................................................................................................................................... 51
Preparations For Use After Repair ..................................................................................................................... 52
Safety Labels .......................................................................................................................................................... 52
This section is for the following models:
(GLC030-035VX, GLC040SVX) [D809];
GLP/GDP16-18VX, GLP/GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX)
[D810]
Table of Contents
ii
General
WARNING
The lift truck must be put on blocks for some
types of maintenance and repairs. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
• Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
• Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or the
section Periodic Maintenance 8000YRM1750
NOTE: For lift trucks equipped with a PSI 2.0L LPG
engine, see PSI 2.0L LPG Fuel System
0900YRM1739 for procedures to remove and install
the exhaust system components. If lift truck is
equipped with a Yanmar 2.6L diesel engine, see
Exhaust System Repair in this manual for procedures.
This section contains the description of the frame (see
Figure 1) and connected parts. Procedures for
removing and installing the counterweight, hood,
overhead guard, engine and transmission, cooling
system, exhaust system (see NOTE above), and
other components attached to the frame are found in
this section. Checks for the operator restraint system
and procedures for the repair of tanks and installation
of safety labels are also included.
0100 YRM 1735 General
1
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Description
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