GLP030VX, GDP030VX, GLP035VX, GDP035VX, GLP040SVX, GDP040SVX

(D810)
SERVICE MANUAL CONTENTS
PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 550108490 0100 YRM 1735 12/14
OPERATOR'S CAB........................................................................................................ 550108590 0100 YRM 1752 12/14
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
PSI 2.0 LPG ENGINE...................................................................................................... 550108491 0600 YRM 1736 12/14
COOLING SYSTEM........................................................................................................ 550108492 0700 YRM 1737 12/14
PSI 2.0L LPG FUEL SYSTEM........................................................................................ 550108494 0900 YRM 1739 12/14
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550108495 1300 YRM 1740 12/14
DRIVE AXLE................................................................................................................... 550108496 1400 YRM 1741 12/14
STEERING AXLE............................................................................................................ 550108497 1600 YRM 1742 12/14
BRAKE SYSTEM............................................................................................................ 550108498 1800 YRM 1743 12/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
HYDRAULIC GEAR PUMPS.......................................................................................... 550108499 1900 YRM 1744 12/14
MAIN CONTROL VALVE................................................................................................ 550108500 2000 YRM 1745 12/14
CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 12/14
CYLINDER REPAIR (MAST S/N B551, B555, B559).................................................... 550108501 2100 YRM 1746 12/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 550108502 2200 YRM 1747 12/14
ENGINE ELECTRICAL SYSTEM, PSI 2.0L ENGINE..................................................... 550108503 2200 YRM 1748 12/14
MAST REPAIR (S/N B551, B555, B559)........................................................................ 550108504 4000 YRM 1749 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 550108505 8000 YRM 1750 12/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550108506 8000 YRM 1751 12/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550108507 8000 YRM 1753 12/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

PART NO. 550108582 (12/14)

0100 YRM 1735
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
General
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.
1
Description 0100 YRM 1735

Description
The frame is one weldment and includes the hydraulic The overhead guard, cowl, and hood are installed on
tank and fuel tank for gasoline or diesel fuel. See Fig- the frame. The hood is connected to the frame with
ure 1. hinges. Two gas-controlled springs provide assis-
tance when raising the hood and hold the hood in the
There is a counterweight for each capacity of lift truck. open position. The floor plate and side covers can be
The counterweights are similar in appearance, but are removed for access to the engine, transmission, and
different weights. See Counterweight Replacement other components.
section.

The muffler is fastened to the frame inside the coun-

terweight.

1. COWL PLATE 5. COUNTERWEIGHT MOUNTS

2. FENDERS 6. FUEL TANK (DIESEL)
3. FRAME 7. HYDRAULIC TANK
4. HOOD MOUNTS

Figure 1. Frame Components

2
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Hood, Seat, and Side Covers Replacement

REMOVE 7. Remove capscrews, washers, and left and right
rear side covers from frame.
1. Slide seat all the way to the rear of the hood.
8. For lift truck models GLP/GDP16-18VX, GLP/
2. Use tilt lever and tilt steering column all the way GDP20SVX (GLP/GDP030-035VX, GLP/
forward. See Figure 2. GDP040SVX) (D810), remove eight capcrews,
eight clip nuts, and left and right step covers from
frame. See Figure 6.

9. For lift truck models GLC030-035VX,

GLC040SVX (D809), remove six capscrews and
left and right step plates from frame. See Fig-
ure 6.

For lift truck models GLP/GDP16-18VX, GLP/

GDP20SVX (GLP/GDP030-035VX, GLP/
GDP040SVX) (D810), remove six capscrews, six
clip nuts, and left and right step plates from frame.
See Figure 6.

1. TILT LEVER
2. GAS CYLINDER

Figure 2. Steering Column Tilt Lever

3. If your truck is equipped with an LPG tank, swing

tank off to the side. See PSI 2.0L LPG Fuel Sys-
tem 0900YRM1739 for procedures.

4. Raise hood latch on the left, front corner of the

hood to unlatch and lift up hood. See Figure 3.

5. Disconnect the battery.

6. Remove floor mat and floor plate.

• See Figure 4 for lift truck models 1. HOOD LATCH

GLC030-035VX, GLC040SVX (D809) 2. HOOD
• See Figure 5 for lift truck models GLP/
Figure 3. Hood Latch
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)

3
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLC030-035VX, GLC040SVX
(D809)

4
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Legend for Figure 4

1. RADIATOR COVER 12. KICK PANEL

2. WASHER 13. FLOOR PLATE
3. CAPSCREW 14. GROMMET
4. RIGHT REAR COVER 15. SEAL PLATE
5. INSERT 16. LEFT STEP PLATE
6. LEFT REAR COVER 17. RIGHT STEP PLATE
7. LOWER STEERING COLUMN COVER 18. LEFT FRONT COVER
8. UPPER STEERING COLUMN COVER 19. RIGHT FRONT COVER
9. CLIP NUT 20. FLOOR MAT
10. DASH PANEL 21. CLIP
11. SEAL

5
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

Figure 5. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP16-18VX, GLP/
GDP20SVX (GLP/GDP030-035VX, GLP/GDP040SVX) (D810)

6
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Legend for Figure 5

1. CAPSCREW 13. FUEL SHIELD (DIESEL)

2. WASHER 14. LEFT REAR COVER
3. INSERT 15. RIGHT REAR COVER
4. RADIATOR COVER 16. FLOOR PLATE
5. LOWER STEERING COLUMN COVER 17. FLOOR MAT
6. UPPER STEERING COLUMN COVER 18. RIGHT STEP COVER
7. CLIP NUT 19. LEFT STEP COVER
8. DASH PANEL 20. RIGHT FRONT COVER
9. KICK PANEL 21. LEFT FRONT COVER
10. GROMMET 22. RIGHT STEP PLATE
11. SEAL PLATE 23. LEFT STEP PLATE
12. SEAL 24. CLIP

7
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

Figure 6. Step Covers and Step Plates Remove/Install

8
0100 YRM 1735
Legend for Figure 6
NOTE: RIGHT SIDE SHOWN. PROCEDURES ARE THE SAME FOR LEFT SIDE.
A. STEP PLATE FOR LIFT TRUCK MODELS GLC030-035VX, GLC040SVX (D809)
B. STEP PLATE AND STEP COVER FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
1. STEP PLATE
2. CAPSCREW
3. RIGHT REAR COVER
10. Remove capscrews, washers, and left and right
front cover from frame.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
11. Use tilt lever and fully lower steering column. See
Figure 2.
12. 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 7.
13. Remove five fasteners securing dash to the top of
cowl. See Figure 7. Remove four clips, located
underneath dash, that attach dash to the kick
panel. Lift to remove dash.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
14. Lift kick panel and remove from truck.
15. Remove three capscrews and clip nuts from seal
plate. Remove seal plate from frame.
16. Remove two capscrews and washers from cover
plate and remove seat box. Disconnect seat wire
harness connector. See Figure 8.
Hood, Seat, and Side Covers Replacement
4. RIGHT STEP COVER
5. CLIP NUT
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.
NOTE: Before removing seat from hood, tag or mark
holes that mount seat to hood. This will aid in cor-
rectly installing seat to hood.
17. Remove four capscrews and washers attaching
seat to hood. Lift seat up and remove from hood.
18. Remove radiator cover and seals from lift truck
frame.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
19. Remove two capscrews and hood latch striker
bolt from mounting bracket. See Figure 9.
20. Remove two capscrews and hood latch from
hood. See Figure 9.
21. Remove capscrews and washers at the top of gas
springs. Remove gas springs from hood.
22. Remove hinge screws, located in the rear of the
hood. See Figure 10.
23. Remove hood from lift truck.
9
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH

1. FASTENERS 3. UPPER STEERING COLUMN COVER
2. COWL 4. LOWER STEERING COLUMN COVER

Figure 7. Remove Dash From Cowl

10
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

A. FULL SUSPENSION SEAT

B. SEMI- AND NON- SUSPENSION SEATS
1. CAPSCREWS
2. WASHERS
3. SEAT BOX
4. SEAT WIRE HARNESS CONNECTOR
5. COVER PLATE

Figure 8. Seat Wire Harness Connector

11
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

Figure 9. Hood Latch and Hood Latch Striker Bolt Remove/Install

12
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

Legend for Figure 9

A. HOOD LATCH AND HOOD LATCH STRIKER B. HOOD LATCH AND HOOD LATCH STRIKER
BOLT FOR LIFT TRUCK MODELS BOLT FOR LIFT TRUCK MODELS GLP/
GLC030-035VX, GLC040SVX (D809) GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
1. CAPSCREW (HOOD LATCH STRIKER BOLT) 5. HOOD LATCH
2. CAPSCREW (HOOD LATCH) 6. BUMPER
3. HOOD LATCH STRIKER BOLT
4. HOOD LATCH STRIKER BOLT MOUNTING
BRACKET

INSTALL • See Figure 11 and Table 1 for lift truck mod-

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 10.
els GLP/GDP16-18VX, GLP/GDP20SVX
(GLP/GDP030-035VX, GLP/GDP040SVX)
(D810)
• See Figure 12 for lift truck models
GLC030-035VX, GLC040SVX (D809)

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-
1. HINGE SCREWS PENSION SEAT WITH CAB
2. HINGE
3. HOOD 1. MOUNTING POINTS FOR GAS SPRING ON
Figure 10. Hood Removal/Installation HOOD

Figure 11. Gas Spring Installation, Lift Truck

Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
3. Align top holes in the gas springs with holes in
GDP030-035VX, GLP/GDP040SVX) (D810)
hood. Install capscrews and washers to attach
gas springs to hood. Tighten capscrews to
19 N•m (170 lbf in).

13
Hood, Seat, and Side Covers Replacement 0100 YRM 1735

Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)

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 B B 3 3 A A 1 1
Without E-
Control
Seat With B B 2 2 N/A N/A N/A N/A
E-Control
Cab C C 2 2 N/A N/A N/A N/A

the bolt strikes hood latch properly and that the

bumpers contact the frame. A properly closed
hood MUST click twice on the hood latch. If the
hood latch does not close properly, loosen cap-
screws on the back of hood latch striker bolt and
adjust bolt up or down as required for correct
alignment.

6. 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.

7. 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 6.

CAUTION
When installing the seat to the hood, DO NOT use
an impact wrench to install the capscrews. Dam-
NOTE: LEFT SIDE SHOWN. age can be caused to the threads on the screws
and in the holes.
1. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION
SEAT 8. Place seat on hood. Align holes in seat with holes
2. MOUNTING LOCATION FOR CYLINDER END in hood as noted during removal. Insert washers
OF GAS SPRING FOR SEMI OR FULL SUS- and capscrews. Tighten capscrews to
PENSION SEAT 18 N•m (159 lbf in).
Figure 12. Gas Spring Installation, Lift Truck
9. Install radiator cover and seals to frame.
Models GLC030-035VX, GLC040SVX (D809)
• See Figure 4 for lift truck models
4. Install hood latch to hood using two capscrews. GLC030-035VX, GLC040SVX (D809)
See Figure 9. • See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
5. Install latch striker bolt in highest slot position on GDP030-035VX, GLP/GDP040SVX) (D810)
mounting bracket. See Figure 9. Check that latch
striker bolt is in center of jaws of hood latch when
hood closes. Open and close hood to ensure that

14
0100 YRM 1735 Hood, Seat, and Side Covers Replacement

10. Connect seat wire harness. Install seat box to 16. For lift truck models GLC030-035VX,
cover plate with two capscrews and washers. GLC040SVX (D809), install left and right step
Tighten capscrews to 1.2 N•m (10.6 lbf in). See plates, and six capscrews to frame. See Figure 6.
Figure 8.
For lift truck models GLP/GDP16-18VX, GLP/
11. Install seal plate using three capscrews and clip GDP20SVX (GLP/GDP030-035VX, GLP/
nuts. GDP040SVX) (D810), install left and right step
plates, six clip nuts, and three capscrews onto
12. Install kick panel onto truck. frame. See Figure 6.
• See Figure 4 for lift truck models 17. For lift truck models GLP/GDP16-18VX, GLP/
GLC030-035VX, GLC040SVX (D809) GDP20SVX (GLP/GDP030-035VX, GLP/
• See Figure 5 for lift truck models GLP/ GDP040SVX) (D810), install left and right step
GDP16-18VX, GLP/GDP20SVX (GLP/ covers, eight clip nuts, and eight capscrews onto
GDP030-035VX, GLP/GDP040SVX) (D810) frame. See Figure 6.

13. Install dash to top of cowl. See Figure 7. Install 18. Install left and right rear covers, washers and cap-
four clips to attach the dash to kick panel. screw onto frame.

14. Install upper steering column cover to dash. 19. Install floor mat and floor plate.

15. Install left and right front covers, washers, and
capscrews onto frame.
• See Figure 4 for lift truck models
GLC030-035VX, GLC040SVX (D809)
• See Figure 5 for lift truck models GLP/
GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810)
20. If truck is equipped with an LPG tank, swing LPG
tank into position on back of counterweight. See
PSI 2.0L LPG Fuel System 0900YRM1739 for
procedures.
21. Connect the battery.
22. Adjust the steering column and seat positions.

15
Steering Column
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 truck models GLC030-035VX,
GLC040SVX (D809), capscrews and bushings attach
the steering column to the cowl standoffs. For lift truck
models GLP/GDP16-18VX, GLP/GDP20SVX (GLP/
GDP030-035VX, GLP/GDP040SVX) (D810), cap-
screws, bushings and isolators attach the steering
column to the cowl standoffs. See Figure 13.
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.
1. STEERING WHEEL
2. STEERING COLUMN
3. COWL
Figure 13. Steering Column and Cowl
16
0100 YRM 1735
2. Attach a tag on the battery connector or negative
battery cable stating, DO NOT CONNECT BAT-
TERY. Move the steering column to the most for-
ward position.
CAUTION
If a puller tool is used to remove steering wheel
from steering column, be careful not to damage
horn wires.
NOTE: This procedure is for the removal of all com-
ponents of the steering column assembly. Not all
components are removed for a repair procedure. Do
only those steps of the procedure necessary to re-
move the required component.
NOTE: Tag wires prior to disconnecting them.
3. Remove the horn button assembly and discon-
nect electrical wires. Remove large hex nut and
steering wheel from steering column. See Fig-
ure 14.
4. Remove steering column covers. Remove floor
mats and floor plate. See Hood, Seat, and Side
Covers Replacement section for procedures.
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
Figure 14. Steering Wheel Remove/Install
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