z43 180309152305

GP/GLP/GDP040VX, GP/GLP/GDP050VX, GP/GLP/GDP060VX, GP/GLP/
GDP070VX (B875)
SERVICE MANUAL CONTENTS
PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 524223754 0100 YRM 1120 12/12
OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14
GM 2.4L ENGINE REPAIR............................................................................................. 524223755 0600 YRM 1121 12/12
MAZDA FE AND F2 ENGINES....................................................................................... 524223756 0600 YRM 1122 03/12
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM (GM).............................................................................................. 524223758 0900 YRM 1124 02/12
LPG FUEL SYSTEM (MAZDA)....................................................................................... 524223759 0900 YRM 1125 10/05
GASOLINE FUEL SYSTEM GM 2.4L ENGINE.............................................................. 524223760 0900 YRM 1126 02/10
GASOLINE FUEL SYSTEM (MAZDA)........................................................................... 524223761 0900 YRM 1127 05/05
GASOLINE FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT
ENGINES.................................................................................................................... 524289373 0900 YRM 1325 12/09
LPG FUEL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT
ENGINES.................................................................................................................... 524289374 0900 YRM 1326 09/12
1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... 524223762 1300 YRM 1129 09/09
SINGLE SPEED POWERSHIFT ALUMINUM TRANSMISSION REPAIR..................... 550010194 1300 YRM 1421 08/13
SINGLE SPEED POWERSHIFT ALUMINUM CHAIN DRIVE TRANSMISSION............ 550030170 1300 YRM 1447 08/13
POWERSHIFT TRANSMISSION REPAIR...................................................................... 550043436 1300 YRM 1529 08/13
DRIVE AXLE - DRY BRAKE........................................................................................... 524240909 1400 YRM 1214 11/12
DRIVE AXLE (WET BRAKE).......................................................................................... 524240908 1400 YRM 1215 02/12
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524223765 1800 YRM 1135 12/12
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 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.................................................................................................. 524223772 2200 YRM 1142 04/14
ELECTRICAL SYSTEM (MAZDA).................................................................................. 524223773 2200 YRM 1143 10/05
ELECTRICAL SYSTEM MAZDA 2.0L AND 2.2L 2007 EMISSION COMPLIANT
ENGINES.................................................................................................................... 524289375 2200 YRM 1327 09/12
MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508,
B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551,
C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ 524223776 4000 YRM 1148 02/14
MAST REPAIR (S/N F507, F508, F562, F563)............................................................... 550093755 4000 YRM 1669 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 524223777 8000 YRM 1150 08/13
CAPACITIES AND SPECIFICATIONS........................................................................... 524223778 8000 YRM 1151 08/13
DIAGRAMS..................................................................................................................... 524223779 8000 YRM 1152 04/14
DIAGRAMS AND SCHEMATICS.................................................................................... 524329117 8000 YRM 1387 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
100 YRM 1120 Description
General
Periodic Maintenance 8000 YRM 1207 for lift truck
WARNING models
The lift truck must be put on blocks for some types • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
of maintenance and repairs. The removal of the (C809)
following assemblies will cause large changes in • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
the center of gravity: mast, drive axle, engine and (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
transmission, and counterweight. When the lift GP/GLP/GDP040SVX) (C810)
truck is put on blocks, put additional blocks in the
following positions to maintain stability: NOTE: For exhaust system procedure for lift trucks
• Before removing the mast and drive axle, put equipped with a Mazda 2007 emissions compliant
blocks under the counterweight so the lift truck engine and for lift trucks built after January, 2010 go to
cannot fall backward. section LPG Fuel System, Mazda FE and F2 Emis-
• Before removing the counterweight, put blocks sion Compliant Engines 900 YRM 1326 or Gasoline
under the mast assembly so the lift truck cannot Fuel System, Mazda FE and F2Emission Compliant
fall forward. Engines 900 YRM 1325 for exhaust system proce-
dures.
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks For lift trucks built after January, 2010 and equipped
used to support the lift truck are solid, one-piece with a GM 2.4L engine, go to section LPG Fuel System,
units. See the Operating Manual or the section GM 2.4L Engine 900 YRM 1124 for exhaust system
procedures.
models This section contains the description of the frame (see
• GLC20-35VX (GC/GLC040-070VX, Figure 1) and connected parts. Procedures for remov-
GC/GLC055SVX) (A910) ing and installing the counterweight, hood, overhead
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) guard, engine, cooling system, and exhaust system
(B875) (see NOTE above) 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.
Description
The frame is one weldment and includes the hydraulic Table 6 for lift truck models
tank and fuel tank for gasoline or diesel fuel. See Fig- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
ure 1. (B875)
There is a counterweight for each capacity of lift truck. The muffler is fastened to the frame inside the counter-
The counterweights are similar in appearance, but are weight.
different weights.
The overhead guard, cowl, and hood are installed on
See Table 3 for lift truck models the frame. The hood is connected to the frame with
• GLC20-35VX (GC/GLC040-070VX, hinges. Two gas-controlled springs provide assistance
GC/GLC055SVX) (A910) when raising the hood and hold the hood in the open po-
sition. The floor plate and side covers can be removed
Table 4 for lift truck models for access to the engine, transmission, and other com-
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX ponents.
(C809)
Table 5 for lift truck models

• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810)
1
Hood, Seat, and Side Covers Replacement 100 YRM 1120
1. COWL PLATE 5. COUNTERWEIGHT MOUNTS

2. FENDERS 6. FUEL TANK (GAS OR DIESEL)
3. FRAME 7. HYDRAULIC TANK
4. HOOD MOUNTS
Figure 1. Frame
Hood, Seat, and Side Covers Replacement

REMOVE See Figure 3 for lift truck models
• GLC20-35VX (GC/GLC040-070VX,
1. Slide seat to the closest position to steering column. GC/GLC055SVX) (A910)
• GLP/GDP16VX, GLP/GDP18VX,
2. Fully tilt steering column forward.
GLP/GDP20SVX (GP/GLP/GDP030VX,
3. If your truck is equipped with an LPG tank, swing GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
tank off to the side. (C810)
• GC/GLC030VX, GC/GLC035VX,
4. Raise latch on the left, front corner of the hood to GC/GLC040SVX (C809)
unlatch and lift up hood. See Figure 2.
See Figure 4 for lift truck models
5. Remove floor mat and floor plate. • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
2
100 YRM 1120 Hood, Seat, and Side Covers Replacement
NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.

A. SIDE VIEW OF HOOD AND SEAT D. SIDE VIEW OF VENTED HOOD WITH SWIVEL
B. SIDE VIEW OF HOOD SEAT
C. BOTTOM VIEW OF HOOD
1. SEAT 10. ATTACHMENT HOLES ATTACHING HOOD TO
2. HOOD SEAT (SEMI-SUSPENSION)
3. FRAME 11. SEAT WIRE HARNESS BRACKETS
4. SEAT WIRE HARNESS 12. SEAT LINER
5. SEAT WIRE HARNESS CONNECTOR (WITHOUT 13. HOOD LATCH
ELECTRONIC CONTROL) 14. ATTACHMENT HOLES ATTACHING HOOD TO
6. SEAT WIRE HARNESS CONNECTOR (WITH SEAT (NON-SUSPENSION)
ELECTRONIC CONTROL) 15. ATTACHMENT HOLES ATTACHING HOOD TO
7. CABLE CLIPS SEAT (FULL SUSPENSION)
8. HINGE SCREWS 16. SPACER
9. GAS SPRING
Figure 2. Hood and Seat Arrangement
3
1. LOWER STEERING COLUMN COVER 14. LEFT HAND FRONT PANEL

2. UPPER STEERING COLUMN COVER 15. LEFT HAND STEP PANEL
3. INSERT 16. LEFT HAND TREAD PLATE
4. CLIP 17. PLATE ASSEMBLY SEAL
5. DASHBOARD 18. RIGHT HAND FENDER COVER
6. CAPSCREW 19. FLOOR MAT
7. SEAL 20. RIGHT HAND TREAD PLATE
8. GROMMET 21. RIGHT HAND FRONT PANEL
9. LEFT HAND REAR PANEL 22. RIGHT HAND STEP PANEL
10. FLOOR PLATE 23. RIGHT HAND REAR PANEL
11. LEFT HAND FENDER COVER 24. RADIATOR COVER
12. SCREW 25. KICK PANEL
13. NUT 26. PLATE ASSEMBLY
Figure 3. Side Cover, Floor Plate, and Cowl Components, Lift Truck Models GLC20-35VX
(GC/GLC040-070VX,GC/GLC055SVX ) (A910), GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/GDP030-35VX,
GP/GLP/GDP040SVX ) (C810), and GC/GLC030-035VX, GC/GLC040SVX (C809)
4
6. Remove two capscrews holding left and right rear 12. Lift the kick panel to remove from truck.
side covers to the frame. Remove rear side covers
from frame. See Figure 3 for lift truck models
See Figure 3 for lift truck models GC/GLC055SVX) (A910)
• GLC20-35VX (GC/GLC040-070VX, • GLP/GDP16VX, GLP/GDP18VX,
GC/GLC055SVX) (A910) GLP/GDP20SVX (GP/GLP/GDP030VX,
• GLP/GDP16VX, GLP/GDP18VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GLP/GDP20SVX (GP/GLP/GDP030VX, (C810)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) • GC/GLC030VX, GC/GLC035VX,
(C810) GC/GLC040SVX (C809)
GC/GLC040SVX (C809) See Figure 4 for lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
See Figure 4 for lift truck models (B875)
(B875) 13. Remove three capscrews holding the seal plate.
Remove seal plate. See Figure 6.
7. Remove two capscrews holding left and right fender
covers to front overhead guard leg. Remove cov- 14. Disconnect seat wire harness connector. See Fig-
ers. ure 2.
See Figure 3 for lift truck models CAUTION

When removing the seat from the hood, DO NOT use
GC/GLC055SVX) (A910)
an impact wrench to remove the capscrews. Dam-
age can be caused to the threads on the screws and
in the holes.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810) 15. If seat is to be removed, and truck is equipped with
• GC/GLC030VX, GC/GLC035VX, a non-swivel seat, remove seat wire harness from
GC/GLC040SVX (C809) 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
(B875)
wire harness bracket attached to underside of the
8. Remove four capscrews holding left and right front hood and behind the seat (see Figure 2).
side covers to frame. Remove covers.
16. Remove four capscrews and washers holding the
9. Fully lower steering column. seat to hood. Lift seat off the hood. Pull seat wire
harness through hood. See Figure 2.
10. Remove upper steering column cover by pulling up
on upper steering column cover to release latches 17. Remove capscrews and washers at the top of gas
(one on either side), and pulling cover away from springs. Remove gas springs from hood.
steering column. See Figure 5.
18. Remove hinge screws, located in the rear of the
11. Remove five fasteners (see Figure 5) securing dash hood.
to the top of cowl. Remove four clips, located un-
19. Lift hood from the truck. See Figure 2.
derneath dash, that attach dash to the kick panel.
Lift to remove dash.
5
Figure 4. Side Covers, Floor Plate, and Cowl Components, Lift Truck Models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)
6
Legend for Figure 4

1. DASH ASSEMBLY 15. LEFT STEP PANEL
2. UPPER STEERING COLUMN COVER 16. RIGHT STEP PANEL
3. LOWER STEERING COLUMN COVER 17. LEFT STEP PLATE
4. KICK PANEL 18. RIGHT STEP PLATE
5. MUD GUARD (LH) 19. LEFT REAR PANEL
6. MUD GUARD (RH) 20. RIGHT REAR PANEL
7. LOCK NUT 21. FLOOR MAT
8. NUT 22. FLOOR PLATE
9. COVER 23. RADIATOR COVER
10. BRACKET 24. SEALS
11. PLATE ASSEMBLY 25. CAPSCREW
12. GROMMET 26. CLIP NUT
13. LEFT FRONT PANEL 27. INSERT
14. RIGHT FRONT PANEL 28. PLATE ASSEMBLY SEAL
NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN SCREWS 3. UPPER STEERING COLUMN COVER
2. COWL 4. LOWER STEERING COLUMN COVER
Figure 5. Remove Dash From Cowl
7
INSTALL See Figure 7 and Table 1 for lift truck models

1. Place hood onto the lift truck frame. GLP/GDP20SVX (GP/GLP/GDP030VX,
2. Install hinge screws, located in the rear of the hood,
(C810) and GLC20-35VX (GC/GLC040-070VX,
and tighten to 38 N•m (28 lbf ft). See Figure 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
GC/GLC040SVX (C809)
(170 lbf in).
See Figure 9 and Table 2 for lift truck models
(B875)
1. CAPSCREWS 2. SEAL PLATE
Figure 6. Remove Seal Plate From Dash
8
Legend for Figure 7
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
SUSPENSION SEAT
C. MOUNTING LOCATION FOR CYLINDER
SUSPENSION SEAT WITH CAB*
1. MOUNTING POINTS FOR GAS SPRING ON
HOOD
Figure 7. Gas Spring Installation, Lift Truck Models
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX *CAB ONLY ON LIFT TRUCK MODELS GLP/
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/
GP/GLP/GDP030SVX) (C810) and GLC20-35VX GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/
(GC/GLC040-070VX, GC/GLC055SVX) (A910) GDP030SVX) (C810)
Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX,

GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP030SVX) (C810) and
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)
Full or Semi Non-Suspension Seat

Suspension Seat
Frame Hood Frame Hood
Left Side Right Left Side Right Left Side Right Left Side Right
Side Side Side 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
9
Legend for Figure 8
NOTE: LEFT SIDE SHOWN.

1. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION SEAT
2. MOUNTING LOCATION FOR CYLINDER
SUSPENSION SEAT
Figure 8. Gas Spring Installation, Lift Truck Models

GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
Figure 9. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
10
Legend for Figure 9

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 (B875) LIFT TRUCKS WITHOUT CAB
E. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT,
LIFT TRUCKS GLP/GDP20-35VX (B875) WITHOUT CAB
1. MOUNTING POINTS FOR GAS SPRING ON HOOD
Table 2. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
Full or Semi Non-Suspension Seat

Suspension Seat
Frame Hood Frame Hood
Left Side Right Left Side Right Left Side Right Left Side Right
Side Side Side Side
Non-Cab D D 3 3 C C 1 1
GP/GLP/
GDP040-
070VX
(B875)
Non-Cab E E 2 2 C C 1 1
GLP/
GDP20-
35VX
(B875)
Cab D D 1 1 N/A N/A N/A N/A
11
4. Install latch striker in highest slot position. Check

that latch striker is in center of jaws of hood latch CAUTION
when hood closes. Open and close hood to ensure When installing the seat to the hood, DO NOT use
that center pin strikes hood latch properly and that an impact wrench to install the capscrews. Damage
the stop screw contacts frame. A properly closed can be caused to the threads on the screws and in
hood MUST click twice on the hood latch. If the the holes.
hood latch does not close properly, loosen cap-
screws on the back of center pin and adjust center 7. Place seat on the hood and thread seat wire har-
pin up or down as required for correct alignment. ness through the hole in the hood. See Figure 2.
See Figure 10.
8. Align holes in the seat with the holes in hood. In-
5. Push down until hood just touches rubber bumper. sert washers and capscrews. Tighten capscrews to
Make sure latch striker is still in center of hood latch. 18 N•m (159 lbf in).
Open hood and tighten capscrews for latch.
9. If truck is equipped with a non-swivel seat, tie cable
6. Check operation of hood latch. Have an operator sit clips to seat wire harness and insert harness into
in seat. Make sure hood is fully closed (two clicks). seat wire harness brackets under hood. If truck is
Also check that hood touches rubber bumper. If equipped with a swivel seat, secure seat harness
necessary, repeat Step 5. to bracket. See Figure 2.
10. Install seal plate using three capscrews. See Fig-

ure 6.
11. Install kick panel onto truck.

(C810)
GC/GLC040SVX (C809)

(B875)
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.

1. HOOD 4. CAPSCREW
2. HOOD LATCH (C810)
3. CENTER PIN • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
Figure 10. Hood Latch Adjustment
12
100 YRM 1120 Steering Column
See Figure 4 for lift truck models GP/GLP/GDP035VX, GP/GLP/GDP040SVX)

• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (C810)
(B875) • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
15. Using two capscrews, install left and right fender
covers to front of overhead guard legs. See Figure 4 for lift truck models
16. Using two capscrews, install left and right rear side (B875)
covers to frame.
17. Install floor mat and floor plate.
• GLC20-35VX (GC/GLC040-070VX, 18. If truck is equipped with an LPG tank, swing LPG
GC/GLC055SVX) (A910) tank into position on back of counterweight.
GLP/GDP20SVX (GP/GLP/GDP030VX, 19. Adjust the steering column and seat positions.
Steering Column
DESCRIPTION NOTE: This procedure is for the removal of all compo-
nents of the steering column assembly. Not all com-
This section describes the repair procedures for the ponents are removed for a repair procedure. Do only
steering column. The steering column assembly those steps of the procedure necessary to remove the
mounts to the cowl inside the operator compartment required component.
and is the mechanical connection between the steering
wheel and the steering control unit. The steering col- NOTE: Tag wires prior to disconnect.
umn includes the steering wheel, housing, bracket and
lower shaft. For lift trucks with gas and LPG engines, 3. Remove the horn button assembly and disconnect
bolts and bushings attach the steering column to the electrical wires. Remove large hex nut and steering
cowl standoffs. For lift trucks with diesel engines, bolts, wheel from steering column. See Figure 12.
bushings and isolators attach the steering column to
the cowl standoffs. See Figure 11.
STEERING COLUMN REPAIR

Remove
1. Put blocks on each side (front and back) of tires to
prevent lift truck from moving.
WARNING
Disconnect the battery before removing any covers
to avoid injury to personnel.
2. Attach a tag on the battery connector or nega-

tive battery cable stating, DO NOT CONNECT
BATTERY. Move the steering column to the most
FORWARD position.
CAUTION NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

If a puller tool is used to remove steering wheel 1. STEERING WHEEL
from steering column, be careful not to damage 2. STEERING COLUMN
horn wires. 3. COWL
Figure 11. Steering Column and Cowl
13
Steering Column 100 YRM 1120
4. Remove steering column covers. Remove floor

mats and floor plate. See section Hood, Seat, and
Side Covers Replacement.
NOTE: Perform Step 5 for lift trucks equipped with gas

or LPG engines.
5. Remove four capscrews, four bushings and steer-

ing column from cowl standoffs. See Figure 13.
NOTE: Perform Step 6 for lift trucks equipped with

diesel engines.
6. Remove four capscrews, four bushings, four isola-

tors, steering column and four isolators from cowl
standoffs. See Figure 13.
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
Figure 12. Steering Wheel Remove/Install
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

1. CAPSCREW 4. STEERING COLUMN
2. BUSHING 5. COWL STANDOFF
3. ISOLATOR
Figure 13. Steering Column Remove/Install
14
Disassemble the path of the compressed air is away from all per-
sonnel to avoid injury.
NOTE: Remove and discard snap rings if installed.
1. Clean metal parts in solvent. Remove all traces of
1. Remove two pins and gas spring from housing. old lubricant and dirt. Clean nonmetal parts with
warm soapy water and a lint free cloth.
See Figure 14, for lift trucks manufactured before
January, 2012. 2. After cleaning, dry parts with compressed air. DO
NOT dry parts with a cloth.
See Figure 15, for lift trucks manufactured after Jan-
uary, 2012.
Inspect
2. Remove two pivot bolts, two bushings, two nuts and
1. Inspect for loose, burned, missing, cracked or dam-
bracket from housing.
aged hardware.
2. Inspect all parts for dents, holes, bends, burrs, rust,
January, 2012.
corrosion or marred finishes.
3. Replace all defective or damaged parts.
uary, 2012.
3. Remove split pin and lower shaft from upper shaft. Assemble
See Figure 14, for lift trucks manufactured before NOTE: This procedure is for the installation of all com-
January, 2012. ponents of the steering column assembly. Not all com-
ponents are removed for a repair procedure. Do only
See Figure 15, for lift trucks manufactured after Jan- those steps of the procedure necessary to install the
uary, 2012. required component.
4. Remove connector from connector bracket. Re- NOTE: Perform Step 1 only for lift trucks manufactured
move connector bracket, fastener, four screws and before January, 2012.
two horn contacts from housing.
1. Lubricate the horn contact slip rings with a
See Figure 14, for lift trucks manufactured before small amount of conductive grease (Yale P/N
January, 2012. 582014302).
See Figure 15, for lift trucks manufactured after Jan- 2. Install fastener, connector bracket and connector,
uary, 2012. two horn contacts and four screws.
Clean See Figure 14, for lift trucks manufactured before

January 2012.
WARNING See Figure 15, for lift trucks manufactured after Jan-
Cleaning solvents can be flammable and toxic and uary 2012.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s 3. Assemble lower shaft and upper shaft, secure with
recommended safety precautions. spit pin.

WARNING January 2012.
Compressed air is used for cleaning and drying pur-
poses, or for cleaning restrictions. Wear protective See Figure 15, for lift trucks manufactured after Jan-
clothing (goggles/shields, gloves, etc.). Make sure uary 2012.
15
Steering Column 100 YRM 1120
Figure 14. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012
16
Legend for Figure 14

1. PIN 9. CONNECTOR BRACKET
2. LOWER SHAFT 10. PIVOT BOLT
3. SPLIT PIN 11. BUSHING
4. UPPER SHAFT 12. NUT
5. HOUSING 13. GAS SPRING
6. HORN CONTACT 14. BRACKET
7. SCREW 15. CONNECTOR
8. FASTENER
1. BRACKET 9. PIN
2. SPACER 10. LOWER SHAFT
3. JOINT 11. GAS SPRING
4. NUT 12. BOLT
5. WASHER 13. BUSHING
6. SCREW 14. CONNECTOR
7. UPPER SHAFT 15. FASTENER
8. HOUSING 16. HORN CONTACT
Figure 15. Steering Column Assembly, Lift Trucks Manufactured After January, 2012
17
LPG Tank and Bracket Assembly 100 YRM 1120
4. Install two pivot bolts, two bushings, two nuts and • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
bracket onto housing. (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
January 2012. NOTE: Perform Step 1 for lift trucks equipped with gas
or LPG engines.
uary 2012. 1. Install steering column, four bushings and four
bolts on cowl standoffs. Tighten bolts to 38 N•m
5. Install gas spring and two pins on housing. (28 lbf ft). See Figure 13.
See Figure 14, for lift trucks manufactured before NOTE: Perform Step 2 for lift trucks equipped with
January 2012. diesel engines.
See Figure 15, for lift trucks manufactured after Jan- 2. Install four isolators, steering column, four isola-
uary 2012. tors, four bushings, and four bolts on cowl standoffs.
Tighten bolts to 38 N•m (28 lbf ft). See Figure 13.
Install
3. Install floor plate, floor mats, and steering column
NOTE: Lubricate spline end of lower shaft with multi covers. See section Hood, Seat, and Side Covers
purpose grease. See one of the Service Manuals for Replacement.
procedures
4. Install steering wheel and hex nut on steering col-
Periodic Maintenance 8000 YRM 1150 for lift truck umn, tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft).
models Connect electrical wiring and install horn button.
• GLC20-35VX (GC/GLC040-070VX, See Figure 12.
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 5. Remove tag from negative battery connector and
(B875) connect to battery. Adjust steering column to neu-
tral position.
models 6. Remove blocks from each side of tires.
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
LPG Tank and Bracket Assembly

For procedures to remove and install the LPG tank, LPG • GLP20-35VX (GLP040-070VX) (B875)
tank bracket, and the LPG tank alignment pin, see one • GLC030VX, GLC035VX, GLC040SVX (C809)
of the following Service Manuals. • GLP16VX, GLP18VX, GLP20SVX (GLP030VX,
GLP035VX, GLP040SVX) (C810)
LPG Fuel System, GM 2.4L Engine 900 YRM 1124 for
lift truck models LPG Fuel System, Mazda FE and F2 Emission Com-
• GLC20-35VX (GLC040-070VX, GLC055SVX) pliant Engines 900 YRM 1326 for lift truck models
(A910) • GLC20-35VX (GLC040-070VX, GLC055SVX)
• GLP20-35VX (GLP040-070VX) (B875) (A910)
• GLP20-35VX (GLP040-070VX) (B875)
LPG Fuel System, Mazda 2.0L and 2.2L Engines 900 • GLC030VX, GLC035VX, GLC040SVX (C809)
SRM 1125 for lift truck models • GLP16VX, GLP18VX, GLP20SVX (GLP030VX,
• GLC20-35VX (GLC040-070VX, GLC055SVX) GLP035VX, GLP040SVX) (C810)
(A910)
18
100 YRM 1120 Counterweight Replacement
Counterweight Replacement
REMOVE NOTE: The counterweight is held in position on the
frame by two hooks that are part of the frame. See Fig-
WARNING ure 16.
The lift truck must be put on blocks for some types One M24 × 3 x 140 capscrew holds the counterweight
of maintenance and repair. The removal of the to the lower part of the frame on lift truck models
following assemblies will cause large changes in • GLC30-35VX (GC/GLC060-070VX) (A910)
the center of gravity: mast, drive axle, engine and • GLP/GDP30-35VX (GP/GLP/GDP060-070VX)
transmission, and counterweight. When the lift (B875)
truck is put on blocks, put additional blocks in the
following positions to maintain stability: One M24 × 3 x 90 capscrew holds the counterweight to
• Before removing the mast and drive axle, put the lower part of the frame on lift truck models
blocks under the counterweight so the lift truck • GLC20-25VX (GC/GLC040-050VX,
cannot fall backward. GC/GLC055SVX) (A910)
• Before removing the counterweight, put blocks • GLP/GDP20-25VX (GP/GLP/GDP040-050VX)
under the mast assembly so the lift truck cannot (B875)
fall forward. • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
The surface must be solid, even, and level when (C809)
the lift truck is put on blocks. Make sure that any • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
blocks used to support the lift truck are solid, one- (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
piece units. See the procedure How to Put Lift Truck GP/GLP/GDP040SVX) (C810)
on Blocks in the Operating Manual or the Periodic
Maintenance section for your lift truck. NOTE: For exhaust system procedure for lift trucks
equipped with a Mazda 2007 emissions compliant
engine and for lift trucks built after January, 2010 go to
WARNING section LPG Fuel System, Mazda FE and F2 Emis-
DO NOT operate the lift truck if the capscrew for the sion Compliant Engines 900 YRM 1326 or Gasoline
counterweight is not installed. When the capscrew Fuel System, Mazda FE and F2Emission Compliant
is removed, the counterweight can fall from the lift Engines 900 YRM 1325.
truck.
For exhaust system procedures for lift trucks built after
WARNING January, 2010 and equipped with a GM 2.4L engine,
go to section LPG Fuel System, GM 2.4L Engine 900
LPG can cause an explosion. DO NOT cause sparks
YRM 1124.
or permit flammable material near the LPG system.
LPG fuel systems can be disconnected indoors NOTE: For overhead exhaust system procedures for lift
only if the lift truck is at least 8 m (26 ft) from any trucks equipped with a Mazda 2007 emissions compli-
open flame, motor vehicles, electrical equipment, ant engine and for lift trucks built after January, 2010 go
or ignition source. to section LPG Fuel System, Mazda FE and F2 Emis-
sion Compliant Engines 900 YRM 1326 or LPG Fuel
Close the shutoff valve on the LPG tank before any
System, Mazda FE and F2 Engines 900 YRM 1125.
part of the engine fuel system is disconnected. Run
the engine until the fuel in the system is used and NOTE: If lift truck is equipped with an overhead exhaust
the engine stops. system, remove the overhead exhaust pipe before re-
moving the counterweight. See the section Exhaust
If the engine will not run, close the shutoff valve on
System Repair for the procedures.
the LPG tank. Loosen the fitting on the supply hose
from the LPG tank where it enters the filter unit.
Permit the pressure in the fuel system to decrease
slowly. Fuel leaving the fitting removes heat. Use a
cloth to protect your hands from the cold fitting.
19
Counterweight Replacement 100 YRM 1120
1. If the lift truck has an LPG fuel system, see one Table 5 for lift truck models
of the following Service Manuals to remove the • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
LPG tank and bracket, before removing the coun- (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
terweight, and for additional information on the LPG GP/GLP/GDP040SVX) (C810)
fuel systems
LPG Fuel System, GM 2.4L Engine 900 YRM • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
1124 for lift truck model (B875)
GC/GLC055SVX) (A910) 2. Install a lifting eye in the lift hole of the counter-
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) weight. See Figure 16 and Figure 17. Connect a
(B875) crane to the lifting eye and raise the crane until it
holds part of the weight of the counterweight. Re-
LPG Fuel System, Mazda FE and F2 Engines 900 move the tow pin and remove the capscrew that
YRM 1125 for lift truck models holds the counterweight to the frame. See Fig-
• GC/GLC030VX, GC/GLC035VX, ure 16. Use the crane to lift the counterweight from
GC/GLC040SVX (C809) the lift truck. Put counterweight on the floor so that
• GLP/GDP16VX, GLP/GDP18VX, it has stability and will not fall over. Take care not to
GLP/GDP20SVX (GP/GLP/GDP030VX, damage exhaust or cooling components.
(C810)
(B875)
LPG Fuel System, Mazda FE and F2 Emission

Compliant Engines 900 YRM 1326 for lift truck
models
GC/GLC040SVX (C809)
(C810)
(B875)
WARNING
The counterweight is heavy. Make sure that the eye-
bolt and lifting devices have enough capacity to lift
the weight. The approximate weights of the coun- 1. FRAME HOOK
terweight castings are shown in . 2. LOWER FRAME MOUNT
3. TOW PIN
Table 3 for lift truck models 4. ROLL PIN
• GLC20-35VX (GC/GLC040-070VX, 5. CAPSCREW
GC/GLC055SVX) (A910) 6. WASHERS
7. LIFT HOLE
Figure 16. Counterweight Installation
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
20
100 YRM 1120 Counterweight Replacement
Table 3. Weight of Counterweights, Table 5. Weight of Counterweights,

Lift Truck Models GLC20-35VX Lift Truck Models GLP/GDP16-18VX,
(GC/GLC040-070VX,GC/GLC055SVX ) (A910) GP/GLP/GDP20SVX (GP/GLP/GDP030-35VX,
Model Kg Lb
Model Kg Lb
GLC20VX 1040 2293
(GC/GLC040VX) GLP/GDP16VX 812 1790
(GP/GLP/GDP030VX)
GLC25VX 1395 3075
(GC/GLC050VX) GLP/GDP18VX 887 1955
(GP/GLP/GDP035VX)
GC/GLC055SVX 1643 3622
GLP/GDP20SVX (GP/ 1047 2308
GLC30VX 1819 4010
GLP/GDP040SVX)
(GC/GLC060VX)
GLC35VX 2153 4747
(GC/GLC070VX) Table 6. Weight of Counterweights,
Lift Truck Models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875)
Table 4. Weight of Counterweights, Lift
Truck Models GC/GLC030VX, GC/GLC035VX, Model Kg Lb
GC/GLC040SVX (C809)
GLP/GDP20VX 994 2191
(GP/GLP/GDP040VX)
Model Kg Lb
GLP/GDP25VX 1338 2950
GC/GLC030VX 772 1702
(GP/GLP/GDP050VX)
GC/GLC035VX 963 2123
GC/GLC040SVX 1131 2493 GLP/GDP060SVX)
GLP/GDP070SVX)
21
Counterweight Replacement 100 YRM 1120
INSTALL • GLC20-35VX (GC/GLC040-070VX,

1. Make sure the seals are on the counterweight. See • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
Figure 17. (B875)
2. Use a crane to install the counterweight on the lift
truck. When the counterweight is installed, make
sure the hooks on the frame fully engage the coun-
terweight so it is aligned with the parts of the frame.
Install and tighten the M24 × 3 capscrew to 555 N•m
(409 lbf ft).
3. Install tow pin and roll pin. See Tow Pin, Remove
and Install for procedures.
4. If the lift truck has an LPG fuel system, see one of

the following Service Manuals to install the LPG
tank and bracket, after the counterweight has been
installed.
LPG Fuel System, GM 2.4L Engine 900 YRM

1124 for lift truck models
(B875)
LPG Fuel System, Mazda FE and F2 Engines 900

YRM 1125 for lift truck models 1. CAPSCREW 7. ROLL PIN
• GC/GLC030VX, GC/GLC035VX, 2. LOCKWASHER 8. SEAL
GC/GLC040SVX (C809) 3. WASHER 9. LIFT HOLE
4. COUNTERWEIGHT 10. LPG ACCESS
• GLP/GDP16VX, GLP/GDP18VX, 5. LIFTING EYEBOLT HOLE
GLP/GDP20SVX (GP/GLP/GDP030VX, 6. TOW PIN
(C810) Figure 17. Counterweight
GC/GLC055SVX) (A910) NOTE: For overhead exhaust system procedures for lift
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) trucks equipped with a Mazda 2007 emissions compli-
(B875) ant engine and for lift trucks built after January, 2010 go
to section LPG Fuel System, Mazda FE and F2 Emis-
LPG Fuel System, Mazda FE and F2 Emission sion Compliant Engines 900 YRM 1326 or LPG Fuel
Compliant Engines 900 YRM 1326 for lift truck System, Mazda FE and F2 Engines 900 YRM 1125.
models
• GC/GLC030VX, GC/GLC035VX, 5. If lift truck is equipped with an overhead exhaust
GC/GLC040SVX (C809) system, install the overhead exhaust pipe. See the
• GLP/GDP16VX, GLP/GDP18VX, section Exhaust System Repair for the procedures.
(C810)
22
100 YRM 1120 Overhead Guard Replacement
TOW PIN, REMOVE AND INSTALL

1. Remove the tow pin from the counterweight by driv-
ing the roll pin out. See Figure 18.
2. Install tow pin into counterweight and install roll pin.
1. TOW PIN 2. ROLL PIN
Figure 18. Tow Pin
Overhead Guard Replacement

REMOVE AND INSTALL NOTE: The lifting device can be connected to any num-
ber of positions on the overhead guard depending upon
WARNING the lifting device available. The ideal choices are a four
point sling connected to all four corners on the top of
DO NOT operate the lift truck without the overhead
the overhead guard, or a two point sling connected to
guard correctly fastened to the lift truck.
two opposite corners of the overhead guard. If a sin-
gle point hoist is used, make sure that the lift point is as
WARNING close to the center of the overhead guard. If during the
DO NOT weld mounts for lights or accessories to initial start of the lift the overhead guard is off balance
legs of the overhead guard. Changes that are made lower immediately and move the hoist to a more cen-
by welding, or by drilling holes that are too big or in tered point.
the wrong location, can reduce the strength of the
overhead guard. 1. Connect a lifting device to remove or install the
overhead guard. Loosen clamp and disconnect
See your dealer for Yale lift trucks BEFORE perform- the air intake hose from the elbow. Remove bolts,
ing any changes to the overhead guard. elbow, retainer, and grommet from the overhead
guard rear leg. See Figure 19.
NOTE: The lift trucks covered in this YRM are equipped
with either a high or low overhead guard. The removal 2. Disconnect any wires between the frame and the
and installation procedures for both types of overhead overhead guard. When the overhead guard is lifted
guards are the same. from the frame, make sure that any electrical wires
are moved through the holes in the frame so that
No welding or drilling on legs of overhead guard is per- they are not damaged.
mitted as per previous WARNING.
23
Overhead Guard Replacement 100 YRM 1120
3. The rear legs of the overhead guard have two cap- LED TAIL, BACKUP, AND BRAKE LIGHTS,
screws that are located under the hood inside the REPLACE
engine compartment, next to the radiator. Remove
and install the capscrews. See Figure 20. These light assemblies are nonrepairable and must be
replaced as an assembly. See the section Electrical
4. Remove the fender cover, dash, and kick panel to System 2200 YRM 1142 for the procedures to replace
remove and install the three capscrews on the front these lights.
legs of the overhead guard. See Hood, Seat, and
Side Covers Replacement for the removal proce-
dures.
5. When installing the overhead guard, tighten the

capscrews for the overhead guard legs to 66 N•m
(49 lbf ft). See Figure 20.
1. CAPSCREWS - FRONT LEGS

2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME
Figure 20. Overhead Guard
1. CLAMP 4. ELBOW
2. AIR INTAKE HOSE 5. RETAINER
3. BOLTS 6. GROMMET
Figure 19. Disconnect Air Intake Hose
24
100 YRM 1120 Operator Restraint System Replacement
Operator Restraint System Replacement

DESCRIPTION NOTE: The following seat belt operation checks must
be performed three times before replacing the seat belt
The seat belt, hip restraint brackets, seat and mounting, assembly.
hood, and latches are all part of the operator restraint • With the hood closed and in the locked position, pull
system. Each item must be checked to make sure it the seat belt slowly from the retractor assembly. Make
is attached securely, functions correctly, and is in good sure the seat belt pulls out and retracts smoothly. If
condition. See Figure 21. the seat belt cannot be pulled from the retractor as-
sembly or the belt will not retract, replace the seat belt
Automatic Locking Retractor (ALR) assembly.
• With the hood closed and in the locked position, pull
NOTE: GC/GLC040-070VX, GC/GLC055SVX (A910)
the seat belt with a sudden jerk. Make sure the seat
lift trucks produced before November 2005 are
belt will not pull from the retractor assembly. If the
equipped with the ALR type seat belts.
seat belt can be pulled from the retractor, when it is
The seat belt must fasten securely. Make sure the seat pulled with a sudden jerk, replace the seat belt as-
belt extends and retracts smoothly and is not frayed or sembly.
torn. If the seat belt is damaged or does not operate • With the hood in the open position, make sure the
properly, it must be replaced. See Figure 21. seat belt will not pull from the retractor assembly. If
the seat belt can be pulled from the retractor, with
Emergency Locking Retractor (ELR) the hood in the open position, replace the seat belt
assembly.
NOTE: Lift trucks produced after November 2005 are
equipped with the Emergency Locking Retractor (ELR) Make sure the seat rails and latch striker are not loose.
style seat belt. The seat rails must lock securely in position but move
freely when unlocked. The seat rails must be securely
When the ELR style seat belt is properly buckled across attached to the mounting surface. The hood must be
the operator, the belt will permit slight operator reposi- fully closed. Lift the hood to make sure it is closed and
tioning without activating the locking mechanism. If the will not move.
truck tips, travels off a dock, or comes to a sudden stop,
the locking mechanism will be activated and hold the Adjust hood, hood latch, and latch striker when any of
operator’s lower torso in the seat. the parts of the operator restraint system are installed or
replaced. See the section Hood, Seat, and Side Covers
A seat belt that is damaged worn or does not operate Replacement in this manual for the adjustment proce-
properly will not provide protection when it is needed. dures for the hood.
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 21 and
Figure 22.
25
Operator Restraint System Replacement 100 YRM 1120
A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR

1. LATCH STRIKER 7. ARM REST
2. HOOD LATCH 8. SEAT BELT
3. FORWARD/BACKWARD ADJUSTMENT 9. SEAT
4. HOOD 10. HIP RESTRAINT
5. OPERATOR WEIGHT ADJUSTMENT 11. HOOD HINGE
6. SEAT RAIL
Figure 21. Operator Restraint System
Figure 22. Operator Restraint System
26
100 YRM 1120 Engine Replacement

A. STANDARD, NON-SUSPENSION SEAT B. FULL SUSPENSION SEAT
1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 6. ARMREST
3. RIDE POSITION INDICATOR 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER
Engine Replacement
REMOVE WARNING
LPG can cause an explosion. DO NOT cause sparks
WARNING or permit flammable material near the LPG system.
The lift truck must be put on blocks for some types LPG fuel systems can be disconnected indoors
of maintenance and repairs. The removal of the only if the lift truck is at least 8 m (26 ft) from any
following assemblies will cause large changes in open flame, motor vehicles, electrical equipments,
the center of gravity: mast, drive axle, engine and or ignition source.
transmission, and counterweight. When the lift
truck is put on blocks, put additional blocks in the 1. For lift trucks equipped with an LPG fuel system,
following positions to maintain stability: close the shutoff valve on the tank and run engine
• Before removing the mast and drive axle, put until all fuel is gone and engine stops.
blocks under the counterweight so the lift truck
2. If lift truck is equipped with an LPG fuel tank, swing
cannot fall backward.
tank to the side. See one of the following Service
• Before removing the counterweight, put blocks
Manuals for procedures:
under the mast assembly so the lift truck cannot
fall forward. LPG Fuel System, GM 2.4L Engine 900 YRM
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
(B875)
models
YRM 1125 for lift truck models
• GLC20-35VX (GC/GLC040-070VX,GC/
GLC055SVX ) (A910)
GC/GLC040SVX (C809)
(B875
Periodic Maintenance 8000 YRM 1207 for lift truck GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
models (C810)
• GC/GLC030-035VX, GC/GLC040SVX (C809) • GLC20-35VX (GC/GLC040-070VX,
• GLP/GDP16-18VX, GP/GLP/GDP20SVX (GP/GLP/ GC/GLC055SVX) (A910)
GDP030-35VX, GP/GLP/GDP040SVX) (C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
WARNING
Always disconnect the cables at the battery before
you make repairs to the engine. Disconnect the ca-
ble at the negative terminal first.
27
Engine Replacement 100 YRM 1120
LPG Fuel System, Mazda FE and F2 Emission 10. Disconnect the ground strap from the frame and
Compliant Engines 900 YRM 1326 for lift truck remove the power distribution module (PDM) from
models the battery tray. See Figure 23.
GC/GLC040SVX (C809) 11. Remove three capscrews from the battery tray and
• GLP/GDP16VX, GLP/GDP18VX, remove the battery and battery tray. See Figure 23.
12. Disconnect the remaining coolant hoses from the
radiator and cap them to prevent leakage.
(C810)
• GLC20-35VX (GC/GLC040-070VX, 13. On lift trucks equipped with a Mazda engine (ex-
GC/GLC055SVX) (A910) cept Mazda 2007 emission compliant engines and
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) lift trucks built after January, 2010 equipped with
(B875) a Mazda engine) and Basic Powershift Transmis-
sion, disconnect the throttle linkage (see the sec-
3. Remove overhead guard. See section Overhead
tion Powershift Transmission, Repair 1300 YRM
Guard Replacement for procedures.
1129). Disconnect the exhaust system.
4. Remove the floor mat and floor plate.
14. Remove the radiator fan pulley, shroud, and fan as-
sembly. See the section Cooling System 700 YRM
WARNING 1123 for the removal procedures.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
5. Let coolant cool to ambient temperature. Place a

drain pan with a capacity greater than the capacity
of the cooling system under radiator. Remove radi-
ator cap.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
6. Open the drain plug or disconnect the bottom radi-

ator hose to drain coolant from radiator and engine.
7. Remove the hood and seat combination and rear

side covers. See the section Hood, Seat, and Side
1. BATTERY
Covers Replacement for procedures. 2. BATTERY TRAY
3. PDM
NOTE: Trucks equipped with a Yanmar Diesel Engine 4. BATTERY LOCKDOWN BAR
do not have an ECM. 5. GROUND STRAP
8. On lift trucks with the GM 2.4L engine, disconnect Figure 23. Power Distribution Module,
the ECM from air filter and remove two bolts hold- Disconnection
ing ECM and mounting bracket to air filter, before
removing the air filter.
9. On lift trucks equipped with a Mazda 2.0L or 2.2L

engine, disconnect ECM connector from ECM. Re-
move two bolts and ECM bracket, with ECM at-
tached, from engine block.
28
module (ECM) connector and governor controller

WARNING from the side of the frame before removing the en-
All fuels are very flammable and can burn or cause gine from the truck.
an explosion. DO NOT use an open flame to check
the fuel level or to check for leaks in the fuel system. 17. 2007 Mazda emission compliant engines only
- Disconnect the engine harness connectors from
No smoking. the right hand chassis harness connectors before
removing the engine from the truck.
Breathing fuel vapor may cause nausea, uncon-
sciousness or death. Long term exposure to 18. Lift trucks built after January, 2010 equipped
gasoline vapors may cause liver or kidney damage with Mazda engines - Disconnect the engine har-
and cancer. Avoid breathing vapor. ness connectors from the right hand chassis har-
ness connectors before removing the engine from
15. Disconnect the fuel lines at the engine. Put caps the truck.
on fuel lines to prevent fuel leakage.
19. Use the access port on the side of engine and re-
NOTE: Lift trucks equipped with Yanmar diesel engine move the four bolts that attach the flywheel to the
do not have an ECM. torque converter. See Figure 24.
NOTE: Lift trucks equipped with 2007 Mazda emission 20. Connect a lifting device to the engine. Put a block
compliant engines and lift trucks built after January, under the transmission housing to support the
2010 equipped with Mazda engines, do not have a transmission.
governor controller and the ECM for these engines is
mounted on the side of the engine. NOTE: Perform Step 21 for lift trucks equipped with iron
housing transmission.
16. For lift trucks built before 2007, equipped with
Mazda engines - Disconnect the electronic control 21. Remove capscrews from transmission bell housing.
A. TYPICAL FOR MAZDA AND YANMAR ENGINES B. TYPICAL FOR GM ENGINES

1. ACCESS PORT 2. FLYWHEEL HOUSING
Figure 24. Torque Converter Bolt Access
29
NOTE: Perform Step 22 through Step 24 for lift trucks

equipped with aluminum housing transmission. WARNING
The engine is heavy. Make sure that any lifting de-
22. Remove two capscrews, two washers, and con- vice has enough capacity to lift the engine. The en-
verter housing cover from torque converter hous- gine can weigh approximately 194 kg (428 lb).
ing. See Figure 25.
25. Remove the flange nuts, washers, bolts, and iso-
23. Remove four flange bolts from torque converter lators from the engine mounts. Remove engine
housing and flywheel housing on transmission adapter to transmission bolts. On trucks equipped
side. See Figure 25. with a GM 2.4L engine, remove one starter bolt.
See Figure 26 and Figure 27.
24. Remove six hex head capscrews and six lock wash-
ers from flywheel housing and torque converter
housing on flywheel housing side. See Figure 25.
NOTE: TYPICAL FOR ALL ENGINES. GM 2.4L LPG AND ALUMINUM CASE TRANSMISSION SHOWN.
1. CONVERTER HOUSING COVER 7. FLYWHEEL HOUSING
2. CAPSCREW 8. TRANSMISSION ASSEMBLY
3. WASHER 9. FLANGE BOLT
4. TORQUE CONVERTER HOUSING 10. LOCKWASHER
5. EYEBOLT BRACKET 11. ENGINE ASSEMBLY
6. HEX HEAD CAPSCREW
Figure 25. Flywheel and Torque Converter Housings
30
A. MAZDA ENGINE
B. GM 2.4L ENGINE
1. FRAME
2. ENGINE MOUNT
3. FLANGE NUT
Figure 26. Engine Removal
A. MAZDA AND YANMAR ENGINE MOUNT

B. GM ENGINE MOUNT
1. LEFT ENGINE MOUNT
2. RIGHT ENGINE MOUNT
3. WASHER
4. CAPSCREW
5. CROSSMEMBER
6. ISOLATOR
7. FLANGE NUT
Figure 27. Engine Mounts
31
6. Install six lock washers and six capscrews on

CAUTION flywheel housing and torque converter housing
When separating the engine away from the trans- from flywheel housing side. Tighten capscrews to
mission, place a piece of plywood in front of radi- 38 N•m (28 lbf ft). See Figure 25.
ator. This will keep the engine from damaging the
radiator. 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 25.
CAUTION
Keep the engine level when the engine is separated 8. On trucks equipped with a GM 2.4L engine, install
from the transmission so the drive plate is not dam- starter bolt.
aged.
9. Install converter housing cover, two washers,
26. Use the lifting device to carefully move the engine and two capscrews on torque converter housing.
away from the torque converter. Make sure all Tighten capscrews to 19 N•m (168 lbf in). See
hoses, wires, and cables are disconnected from Figure 25.
the engine, then lift the engine from the frame and
place engine on blocks. NOTE: For procedures to install exhaust pipe to ex-
haust manifold for lift trucks equipped with a Mazda
27. Remove torque converter from torque converter 2007 emissions compliant engine and for lift trucks built
housing. after January, 2010 equipped with a Mazda engine, see
Gasoline Fuel System, Mazda FE and F2Emission
INSTALL Compliant Engines 900 YRM 1325 or LPG Fuel Sys-
tem, Mazda FE and F2 Emission Compliant Engines
WARNING 900 YRM 1326.
The engine is heavy. Make sure that any lifting de-
10. Install exhaust pipe to exhaust manifold. See Ex-
vice has enough capacity to lift the engine. The en-
haust System Repair.
gine can weigh approximately 194 kg (428 lb).
11. For lift trucks built before 2007, equipped with
CAUTION Mazda engines - Connect the ECM connector and
governor controller to lift truck frame.
Keep the engine level when installing the engine to
the transmission so the drive plate is not damaged. 12. On lift trucks equipped with a Mazda 2.0L or 2.2L
engine, install ECM bracket with ECM attached and
1. Install torque converter in torque converter housing.
two bolts on engine block.
2. Connect lifting device to engine and lift engine into
frame. WARNING
3. Install isolators on engine mounts. Install the nuts All fuels are very flammable and can burn or cause
and bolts for the engine mounts to secure engine to an explosion. DO NOT use an open flame to check
frame. See Figure 26 and Figure 27. Tighten the the fuel level or to check for leaks in the fuel system.
nuts to 150 N•m (110 lbf ft). No smoking.
4. Use access port on side of engine and install bolts Breathing fuel vapor may cause nausea, uncon-
to hold torque converter to flywheel. Tighten bolt to sciousness or death. Long term exposure to
56 N•m (41 lbf ft). See Figure 24. gasoline vapors may cause liver or kidney damage
NOTE: Perform Step 5 for lift trucks equipped with iron and cancer. Avoid breathing vapor.
transmission housing. 13. Connect the wires and wiring harnesses at the en-
5. Align transmission bell housing holes with flywheel gine. Remove caps from fuel lines and connect the
housing holes and install capscrews. Tighten cap- fuel lines at the engine.
screws to 38 N•m (28 lbf ft).
NOTE: Perform Step 6 through Step 9 for lift trucks

equipped with aluminum transmission housing.
32
NOTE: On trucks equipped with the GM 2.4L engine, LPG Fuel System, Mazda FE and F2 Emission
connect the ECM and install ECM and mounting bracket Compliant Engines 900 YRM 1326 for lift truck
to air filter with two bolts, before installing the air filter to models
lift truck. • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
14. On lift trucks equipped with a Mazda engine (ex- • GLP/GDP16VX, GLP/GDP18VX,
cept Mazda 2007, and later, emission compliant GLP/GDP20SVX (GP/GLP/GDP030VX,
engines) and Basic Powershift Transmission, con- GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
nect the throttle linkage (see the section Power- (C810)
shift Transmission, Repair 1300 YRM 1129). In- • GLC20-35VX (GC/GLC040-070VX,
stall the air filter assembly. GC/GLC055SVX) (A910)
15. Connect the coolant hoses and lines to the trans-
(B875)
mission. Fill cooling system with a mixture of 50
percent deionized water and 50 percent ethylene 19. Install the rear side covers, floor plates, floor mat,
glycol boron-free antifreeze. and hood and seat combination. See the section
Hood, Seat, and Side Covers Replacement for the
16. Install the radiator shroud, fan pulley, and fan as-
procedures.
sembly. See the section Cooling System 700 YRM
1123 for the installation procedures. 20. If removed, install Overhead guard. See section
Overhead Guard Replacement for procedures.
17. Connect the PDM and connect the ground strap to
lift truck frame and attach it to battery. Install the 21. Check all fluid levels as described in the section
battery and battery tray. See Figure 23.
18. If lift truck is equipped with an LPG tank, swing tank models
into position on truck. See one of the following Ser- • GLC20-35VX (GC/GLC040-070VX,
vice Manuals for procedures: GC/GLC055SVX) (A910)
LPG Fuel System, GM 2.4L Engine 900 YRM
(B875)
• GLC20-35VX (GC/GLC040-070VX, Periodic Maintenance 8000 YRM 1207 for lift truck
GC/GLC055SVX) (A910) models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GC/GLC030VX, GC/GLC035VX,
(B875) GC/GLC040SVX (C809)
YRM 1125 for lift truck models
(C810)
GC/GLC040SVX (C809)
GLP/GDP20SVX (GP/GLP/GDP030VX, CAUTION
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) Disposal of lubricants and fluids must meet local
(C810) environmental regulations.
GC/GLC055SVX) (A910) 22. Empty drain pan contents.
(B875)
33
Transmission Replacement 100 YRM 1120
23. If lift truck is equipped with an LPG fuel tank, swing • GLC20-35VX (GC/GLC040-070VX,
tank into position on back of counterweight and GC/GLC055SVX) (A910)
open shutoff valve on tank. See one of the follow- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
ing Service Manuals. (B875)
LPG Fuel System, GM 2.4L Engine 900 YRM LPG Fuel System, Mazda FE and F2 Emission
1124 for lift truck models Compliant Engines 900 YRM 1326 for lift truck
• GLC20-35VX (GC/GLC040-070VX, models
GC/GLC055SVX) (A910) • GC/GLC030VX, GC/GLC035VX,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GC/GLC040SVX (C809)
(B875) • GLP/GDP16VX, GLP/GDP18VX,
LPG Fuel System, Mazda FE and F2 Engines 900 GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
YRM 1125 for lift truck models (C810)
• GC/GLC030VX, GC/GLC035VX, • GLC20-35VX (GC/GLC040-070VX,
GC/GLC040SVX (C809) GC/GLC055SVX) (A910)
• GLP/GDP16VX, GLP/GDP18VX, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GLP/GDP20SVX (GP/GLP/GDP030VX, (B875)
(C810)
Transmission Replacement
REMOVE TRANSMISSION WITH IRON See section Periodic Maintenance 8000 YRM 1150
HOUSING for lift truck models
WARNING
The lift truck must be put on blocks for some types (B875)
of maintenance and repairs. The removal of the fol-
lowing assemblies will cause large changes in the 1. Remove engine from lift truck. See section Re-
center of gravity: mast, drive axle, engine, trans- move, Engine Replacement for procedures.
mission, and counterweight. When the lift truck is
put on blocks put additional blocks in the following 2. Remove the seal plate for the brake and throttle
positions to maintain stability: pedals. See Figure 6.
• Before removing the mast and drive axle, put
blocks under the counterweight so the lift truck NOTE: When disconnecting wiring harness connectors
cannot fall backward. during removal, tag each connector to aid in connecting
• Before removing the counterweight, put blocks wiring harness during installation.
under the mast assembly so the lift truck cannot 3. Disconnect the engine wiring harness from trans-
fall forward. mission wiring harness.
The surface must be solid, even, and level when the 4. Disconnect transmission cooling lines.
used to support the lift truck are solid, one-piece NOTE: Step 5 applies to lift truck models equipped with
units. See the Operating Manual or a hydraulic gear pump.
See section Periodic Maintenance 8000 YRM 1207 5. Remove the hydraulic hose between the hydraulic
for lift truck models pump and the tank. Put a cap on the tank fitting.
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX Remove the supply line from hydraulic pump to the
(C809) main control valve.
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
34
100 YRM 1120 Transmission Replacement
NOTE: Step 6 and Step 7 apply to lift truck models 8. Connect a lifting device to support the transmission.
GLP/GDP20-35VX (B875) equipped with a variable dis-
placement pump (VDP): 9. Remove the capscrew, washer, snubbing washers,
and isolators from the mount bracket at the rear of
6. Remove the hydraulic supply (suction) hose be- the transmission. See Figure 29.
tween the variable displacement pump and hy-
draulic tank. Put a cap on the hydraulic tank fitting. 10. Use a lifting device to carefully lift the transmission
See Figure 28. out of the frame. Slip the transmission output yoke
out of the transmission. Make sure to not damage
7. Remove the hydraulic supply hose, load sense line, the seal.
drain case line, and hydraulic inlet line from the vari-
able displacement pump. Put cap on all variable
displacement pump and hose openings. See Fig-
ure 28.
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. TRANSMISSION HOUSING NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.

2. VARIABLE DISPLACEMENT PUMP
3. LOAD SENSE LINE 1. MOUNT BRACKET
4. HYDRAULIC INLET LINE 2. CAPSCREW
5. DRAIN CASE LINE 3. WASHER
6. HYDRAULIC SUPPLY (SUCTION) HOSE 4. SNUBBING WASHER
5. ISOLATOR
Figure 28. Hydraulic Hose Connections, Lift Truck
Models GLP/GDP20-35VX (B875) Equipped With Figure 29. Rear Mount - Transmission
Variable Displacement pump
35
INSTALL TRANSMISSION WITH IRON 10. Install engine in lift truck. See section Install, En-
HOUSING gine Replacement for procedures.
REMOVE TRANSMISSION WITH

WARNING
ALUMINUM HOUSING
The transmission can weigh approximately 317 kg WARNING
(699 lb). The lift truck must be put on blocks for some types
of maintenance and repairs. The removal of the fol-
1. Using a lifting device, install transmission in lift truck lowing assemblies will cause large changes in the
frame. Place a block under the transmission hous- center of gravity: mast, drive axle, engine, trans-
ing to support the transmission. mission, and counterweight. When the lift truck is
put on blocks put additional blocks in the following
2. Install the transmission output yoke on the trans-
positions to maintain stability:
mission. Be sure to not damage the seal. Tighten
• Before removing the mast and drive axle, put
the bolt to 38 N•m (28 lbf ft).
blocks under the counterweight so the lift truck
3. Install the isolators, snubbing washers, washer, and cannot fall backward.
capscrew on the mounting bracket at the rear of the • Before removing the counterweight, put blocks
transmission. See Figure 29. Tighten capscrew to under the mast assembly so the lift truck cannot
225 to 250 N•m (166 to 184 lbf ft). fall forward.
4. Remove lifting device from the transmission. The surface must be solid, even, and level when the
NOTE: Step 5 applies to lift truck models equipped with used to support the lift truck are solid, one-piece
a hydraulic gear pump. units. See the Operating Manual or
5. Install the hydraulic hose between the pump and See section Periodic Maintenance 8000 YRM 1207
the tank. Install the hydraulic filter and hoses. Con- for lift truck models
nect the supply line to the main control valve. See • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
Hydraulic Gear Pump 1900 YRM 1136 for more (C809)
information on installing hydraulic hoses to gear • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
pump. (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
NOTE: Step 6 and Step 7 apply to lift truck models
GLP/GDP20-35VX (B875) equipped with a variable dis- See section Periodic Maintenance 8000 YRM 1150
placement pump (VDP). for lift truck models
6. Install the hydraulic supply hose between the vari- GC/GLC055SVX) (A910)
able displacement pump and hydraulic tank. See • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
Figure 28. (B875)
7. Install the hydraulic supply hose, load sense line,
drain case line, and hydraulic inlet line on the vari- WARNING
able displacement pump. See Figure 28. See Hy- The transmission is heavy. Make sure that any lift-
draulic Gear Pump 1900 YRM 1136 for more in- ing device has enough capacity to lift the weight.
formation on installing hydraulic hoses to variable The transmission can weigh approximately 83.8 kg
displacement pump. (184.7 lb).
8. Connect the transmission wiring harness to engine NOTE: Make sure the transmission is supported by
wiring harness. Connect transmission cooling blocks or a lifting device before removing the engine.
lines.
1. Remove engine from lift truck. See section Re-
9. Install the seal plate for the brake and throttle ped- move, Engine Replacement for procedures.
als. See Figure 6.
36
2. Remove the seal plate for the brake and throttle • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
pedals. See Figure 6. (B875)
NOTE: When disconnecting wiring harness connectors See Figure 34 for lift truck models GLP/GDP20-
during removal, tag each connector to aid in connecting 35VX (B875) equipped with a variable displace-
wiring harness during installation. ment pump.
3. Disconnect the engine wiring harness from trans- NOTE: Perform Step 6 and Step 7 for lift trucks
mission wiring harness. equipped with wet brakes.
4. Disconnect transmission cooling lines from trans- 6. Place a suitable container under transmission; dis-
mission. connect wet disk brake hose assembly from trans-
mission and drain transmission and transaxle oil.
See Figure 30 and Figure 31 for the following lift
truck models equipped with a hydraulic gear pump See Figure 32 and Figure 33 for lift truck mod-
• GC/GLC030VX, GC/GLC035VX, els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GC/GLC040SVX (C809) (B875) equipped with a hydraulic gear pump.
GLP/GDP20SVX (GP/GLP/GDP030VX, See Figure 35 for lift truck models GLP/GDP20-
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) 35VX (B875) equipped with a variable displace-
(C810) ment pump.
7. Disconnect and cap high temp hose assembly from
transmission cooling support port. Cap transmis-
sion cooling supply port.
(B875)
See Figure 32 and Figure 33 for lift truck mod-
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875) equipped with a hydraulic gear pump.
See Figure 35 for lift truck models GLP/GDP20-
See Figure 34 and Figure 35 for lift truck models
35VX (B875) equipped with a variable displace-
GLP/GDP20-35VX (B875) equipped with a variable
ment pump.
displacement pump.
8. Disconnect and cap suction hose from hydraulic
CAUTION gear pump inlet port. Cap hydraulic gear pump in-
let port.
Disposal of lubricants and fluids must meet local
environmental regulations. See Figure 30 and Figure 31 for the following lift
truck models equipped with a hydraulic gear pump
NOTE: Perform Step 5 for lift trucks equipped with dry
brakes.
GC/GLC040SVX (C809)
5. Place a suitable container under transmission; re- • GLP/GDP16VX, GLP/GDP18VX,
move drain fitting from transmission housing and GLP/GDP20SVX (GP/GLP/GDP030VX,
drain transmission oil. GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810)
See Figure 30 and Figure 31 for the following lift • GLC20-35VX (GC/GLC040-070VX,
truck models equipped with a hydraulic gear pump GC/GLC055SVX) (A910)
• GC/GLC030VX, GC/GLC035VX, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GC/GLC040SVX (C809) (B875)
GLP/GDP20SVX (GP/GLP/GDP030VX, See Figure 32 and Figure 33 for the following lift
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) truck models equipped with a hydraulic gear pump
(C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLC20-35VX (GC/GLC040-070VX, (B875)
37

displacement pump.
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND

ADAPTERS NOT SHOWN.
1. TRANSMISSION HOUSING
2. DRAIN FITTING
3. HYDRAULIC GEAR PUMP
1. TRANSMISSION HOUSING 4. SUCTION HOSE
2. DRAIN FITTING 5. HYDRAULIC GEAR PUMP INLET PORT
3. HYDRAULIC GEAR PUMP 6. HYDRAULIC GEAR PUMP OUTLET PORT
4. SUCTION HOSE 7. HYDRAULIC INLET HOSE
5. HYDRAULIC GEAR PUMP INLET PORT 8. TRANSMISSION COOLING LINE
6. HYDRAULIC GEAR PUMP OUTLET PORT
7. HYDRAULIC INLET HOSE Figure 31. Hydraulic Hose, Dry Brakes (Aluminum
8. TRANSMISSION COOLING LINE Transmission After January, 2011)
Figure 30. Hydraulic Hose, Dry Brakes (Aluminum

Transmission Prior to January, 2011)
Figure 32. Hydraulic Hose, Wet Brakes (Aluminum

Transmission Prior to January, 2011)
38

2. WET DISK BRAKE HOSE ASSEMBLY
3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
5. HYDRAULIC GEAR PUMP INLET PORT
7. HYDRAULIC INLET HOSE
8. HIGH TEMP HOSE ASSEMBLY
9. TRANSMISSION COOLING SUPPLY PORT
2. DRAIN FITTING
3. VARIABLE DISPLACEMENT PUMP
4. LOAD SENSE LINE
5. DRAIN CASE LINE
7. TRANSMISSION COOLING LINES
8. SUCTION HOSE
NOTE: QUICK-LOK™ HYDRAULIC HOSE AND 9. PUMP INLET PORT
10. PUMP OUTLET PORT
ADAPTERS NOT SHOWN.
1. TRANSMISSION HOUSING Figure 34. Hydraulic Hose, Dry Brakes (Aluminum
2. WET DISK BRAKE HOSE ASSEMBLY Transmission After January, 2011), Lift Truck
3. HYDRAULIC GEAR PUMP Models GLP/GDP20-35VX (B875) Equipped With
4. SUCTION HOSE Variable Displacement Pump
5. HYDRAULIC GEAR PUMP INLET PORT
8. HIGH TEMP HOSE ASSEMBLY
9. TRANSMISSION COOLING SUPPLY PORT

Transmission After January, 2011)
39
10. For lift trucks not equipped with Quick-Lok hydraulic

hose and adapters, disconnect and cap hydraulic
inlet hose from hydraulic gear pump outlet port.
Cap hydraulic gear pump outlet port.

GC/GLC040SVX (C809)
(C810)
(B875)


displacement pump.
NOTE: Step 11 applies only to lift truck models GLP/

GDP20-35VX (B875) equipped with a variable displace-
ment pump.
2. VARIABLE DISPLACEMENT PUMP 11. Disconnect and cap the load sense line and drain
3. LOAD SENSE LINE case line from the variable displacement pump.
4. DRAIN CASE LINE See Figure 34 and Figure 35.
6. HIGH TEMPERATURE LINE
7. TRANSMISSION COOLING SUPPLY PORT 12. Remove the capscrew, washer, snubbing washers,
8. TRANSMISSION COOLING HOSES and isolators from the mount bracket at the rear of
9. WET DISK BRAKE HOSE ASSEMBLY the transmission. See Figure 36.
10. PUMP INLET PORT
11. PUMP OUTLET PORT 13. Use the lifting device to carefully lift the transmis-
12. SUCTION HOSE sion from the frame. Slip the transmission output
yoke out of the transmission. Make sure to not dam-
age the seal.
Transmission After January, 2011), Lift Truck
Models GLP/GDP20-35VX (B875) Equipped With 14. Remove flange head capscrew, yoke, and spacer
Variable Displacement Pump from transmission. Make sure to not damage the
seal. See Figure 37.
NOTE: Perform Step 9 for lift truck models GLP/GDP20-
35VX (GP/GLP/GDP040-070VX) (B875) equipped with NOTE: Note position of oil seal prior to removal to aid
a Quick-Lok™ hydraulic hose and adapter. in installation.
9. Remove adapter and Quick-Lok hydraulic hose 15. Remove oil seal from transmission housing. See
from hydraulic gear pump outlet port. Cap hy- Figure 37.
draulic gear pump outlet port.
40
1. FLANGE HEAD CAPSCREW

2. STAT-O-SEAL
3. YOKE
4. OIL SEAL
5. SPACER
Figure 37. Drive Shaft Yoke
INSTALL TRANSMISSION WITH

ALUMINUM HOUSING
WARNING
The transmission can weigh approximately 83.8 kg
(184.7 lb).
1. Using a lifting device, install transmission in lift truck

frame. Place a block under the transmission hous-
ing to support the transmission.
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY. 2. Install oil seal on back of transmission housing. See
Figure 37.
1. MOUNT BRACKET
2. CAPSCREW 3. Install new stat-o-seal on yoke. See Figure 37.
3. WASHER
4. SNUBBING WASHER 4. Install spacer, yoke, and flange head capscrew on
5. ISOLATOR back of transmission. See Figure 37. Tighten cap-
Figure 36. Rear Mount- Transmission screw to 77 N•m (57 lbf ft).
41
5. Install isolators, snubbing washers, washer, and See Figure 32 and Figure 33 for lift truck mod-
capscrew on mounting bracket at the rear of the els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
transmission. See Figure 36. Tighten capscrew to (B875) equipped with a hydraulic gear pump.
225 to 250 N•m (166 to 184 lbf ft).
6. Remove lifting device from transmission. GLP/GDP20-35VX (B875) equipped with a variable
displacement pump.
NOTE: Perform Step 7 for lift truck models GLP/GDP20-
35VX (GP/GLP/GDP040-070VX) (B875) equipped with NOTE: Perform Step 10 for lift trucks equipped with dry
a Quick-Lok™ hydraulic hose and adapter. brakes.
7. Remove cap and install adapter and Quick-Lok hy- 10. Install drain fitting on transmission housing.
draulic hose to hydraulic gear pump outlet port.
Tighten adapter to 59 to 69 N•m (44 to 51 lbf ft). See Figure 30 and Figure 31 for the following lift
8. For lift truck not equipped with Quick-Lok hydraulic • GC/GLC030VX, GC/GLC035VX,
hose and adapters, connect hydraulic inlet hose to GC/GLC040SVX (C809)
fitting on hydraulic gear pump outlet port. • GLP/GDP16VX, GLP/GDP18VX,
See Figure 30 and Figure 31 for the following lift GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
truck models equipped with a hydraulic gear pump (C810)
• GC/GLC030VX, GC/GLC035VX, • GLC20-35VX (GC/GLC040-070VX,
GC/GLC040SVX (C809) GC/GLC055SVX) (A910)
• GLP/GDP16VX, GLP/GDP18VX, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GLP/GDP20SVX (GP/GLP/GDP030VX, (B875)
(C810) See Figure 34 for lift truck models GLP/GDP20-
• GLC20-35VX (GC/GLC040-070VX, 35VX (B875) equipped with a variable displace-
GC/GLC055SVX) (A910) ment pump.
(B875) NOTE: Perform Step 11 and Step 12 for lift trucks
equipped with wet brakes.
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 11. Connect high temp hose assembly to transmission
(B875) equipped with a hydraulic gear pump. cooling support port.
See Figure 34 and Figure 35 for lift truck models See Figure 32 and Figure 33 for lift truck mod-
GLP/GDP20-35VX (B875) equipped with a variable els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
displacement pump. (B875) equipped with a hydraulic gear pump.
9. Connect suction hose to hydraulic gear pump inlet See Figure 35 for lift truck models GLP/GDP20-
port. 35VX (B875) equipped with a variable displace-
ment pump.
truck models equipped with a hydraulic gear pump 12. Connect wet disk brake hose assembly to transmis-
• GC/GLC030VX, GC/GLC035VX, sion.
GC/GLC040SVX (C809)
(B875) equipped with a variable displacement
pump.
(C810)
• GLC20-35VX (GC/GLC040-070VX, See Figure 35 for lift truck models GLP/GDP20-
GC/GLC055SVX) (A910) 35VX (B875) equipped with a variable displace-
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) ment pump.
(B875)
42
13. Connect transmission cooling lines to transmission. The transmission can weigh approximately 83.8 kg
(184.7 lb).
truck models equipped with a hydraulic gear pump NOTE: Make sure the transmission is supported by
• GC/GLC030VX, GC/GLC035VX, blocks or a lifting device before installing the engine.
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, 17. Install engine to lift truck. See section Install, En-
GLP/GDP20SVX (GP/GLP/GDP030VX, gine Replacement for procedures.
NOTE: Perform Step 18 for lift trucks equipped with dry
(C810)
brakes.
GC/GLC055SVX) (A910) 18. Fill transmission oil. For fill instruction, oil type, and
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) amount,
(B875)
See section Periodic Maintenance 8000 YRM
See Figure 32 and Figure 33 for lift truck mod- 1207 for lift truck models
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GC/GLC030VX, GC/GLC035VX,
(B875) equipped with a hydraulic gear pump. GC/GLC040SVX (C809)
displacement pump.
(C810)
NOTE: Step 14 applies only to lift truck models GLP/
See section Periodic Maintenance 8000 YRM
GDP20-35VX (B875) equipped with a variable displace-
ment pump.
14. Connect the load sense line and drain case line GC/GLC055SVX) (A910)
to the variable displacement pump. See Figure 34 • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
and Figure 35. (B875)
15. Connect transmission wiring harness to engine NOTE: Perform Step 19 for lift truck equipped with wet
wiring harness. brakes.
16. Install the seal plate for the brake and throttle ped- 19. Fill transmission and transaxle oil. For fill instruc-
als. See Figure 6. tion, oil type, and amount, see section Periodic
Maintenance 8000 YRM 1150 for lift truck model
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
WARNING (B875).
43
Throttle Pedal and Cable Adjustment 100 YRM 1120
Throttle Pedal and Cable Adjustment

NOTE: There are no throttle pedal and cable adjust- 4. Connect throttle cable to bellcrank and engine. See
ments for lift trucks equipped with the GM 2.4L engine. Figure 38.
The GM 2.4L engines have an electronic throttle that is
self-adjusting and self-calibrating. 5. With throttle pedal in full up position, adjust throttle
cable, using the jam nuts (item #10 in Figure 38) to
NOTE: For the Mazda 2007 emission compliant en- remove all slack from the cable. Cable should be
gines and for lift trucks built after January, 2010 and adjusted to the point where additional adjustment
equipped with a Mazda engine, there is only a throttle will pull the throttle crank off the idle stop. Tighten
pedal stop adjustment. The engine has an electronic jam nuts to 8 to 15 N•m (71 to 133 lbf in).
throttle that is self-adjusting and self-calibrating. See
Throttle Pedal Stop Adjustment for procedures. NOTE: If lift truck is equipped with a Electronic Control
Transmission, see the section Calibration Procedures
MAZDA GAS/LPG ENGINES WITH BASIC 8000 YRM 1134 for additional adjustment procedures
POWER SHIFT TRANSMISSION AND before going onto Step 7.
ELECTRONIC TRANSMISSION (EXCEPT 6. Fully depress pedal and verify that full pedal stroke
MAZDA EMISSION COMPLIANT ENGINES) brings the throttle crank to within 3.0 mm (0.12 in.)
of the wide open throttle stop. See Figure 38.
1. Remove floor plate and disconnect throttle cable
from the bellcrank and engine. See Figure 38. 7. Install floor plate. Fully depress throttle pedal and
adjust pedal stop so that it touches floor plate.
2. Fully depress throttle pedal and verify that the di- Tighten jam nuts 8 to 15 N•m (71 to 133 lbf in)
mension between the bellcrank and cowl plate is 6 (item #12 in Figure 38).
±2 mm (0.24 ±0.08 in.).
3. If dimension is not correct, adjust ball ends on

push rod so that a minimum of 6 mm (0.24 in.) of
threaded rod screws into each ball end.
NOTE: THROTTLE PEDAL SHOWN IN WIDE OPEN POSITION (FULLY DEPRESSED POSITION).
A. MAZDA GAS ENGINE B. MAZDA LPG ENGINE
1. BELL CRANK 7. FLOOR PLATE
2. COWL 8. THROTTLE CABLE
3. PUSH ROD 9. BRACKET
4. BALL END 10. JAM NUTS
5. PEDAL STOP 11. THROTTLE CRANK
6. THROTTLE PEDAL 12. JAM NUT
44
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GP/GLP/GDP040VX, GP/GLP/GDP050VX, GP/GLP/GDP060VX, GP/GLP/

Table 5 for lift truck models

1. COWL PLATE 5. COUNTERWEIGHT MOUNTS

Hood, Seat, and Side Covers Replacement

NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.

Figure 2. Hood and Seat Arrangement

1. LOWER STEERING COLUMN COVER 14. LEFT HAND FRONT PANEL

See Figure 3 for lift truck models CAUTION

Legend for Figure 4

NOTE: TOP VIEW OF DASH SHOWN.

Figure 5. Remove Dash From Cowl

INSTALL See Figure 7 and Table 1 for lift truck models

1. CAPSCREWS 2. SEAL PLATE

Figure 6. Remove Seal Plate From Dash

Legend for Figure 7

NOTE: LEFT SIDE SHOWN

Table 1. Gas Spring Installation, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX,

Full or Semi Non-Suspension Seat

Legend for Figure 8

NOTE: LEFT SIDE SHOWN.

Figure 8. Gas Spring Installation, Lift Truck Models

Legend for Figure 9

Full or Semi Non-Suspension Seat

4. Install latch striker in highest slot position. Check

10. Install seal plate using three capscrews. See Fig-

11. Install kick panel onto truck.

See Figure 3 for lift truck models

See Figure 4 for lift truck models

12. Install dash to top of cowl. See Figure 5. Install four

13. Install upper steering column cover to dash.

See Figure 3 for lift truck models

See Figure 4 for lift truck models GP/GLP/GDP035VX, GP/GLP/GDP040SVX)

STEERING COLUMN REPAIR

2. Attach a tag on the battery connector or nega-

CAUTION NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

Figure 11. Steering Column and Cowl

4. Remove steering column covers. Remove floor

NOTE: Perform Step 5 for lift trucks equipped with gas

5. Remove four capscrews, four bushings and steer-

NOTE: Perform Step 6 for lift trucks equipped with

6. Remove four capscrews, four bushings, four isola-

Figure 12. Steering Wheel Remove/Install

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

Figure 13. Steering Column Remove/Install

Clean See Figure 14, for lift trucks manufactured before

See Figure 14, for lift trucks manufactured before

Legend for Figure 14

LPG Tank and Bracket Assembly

LPG Fuel System, Mazda FE and F2 Emission

Table 3. Weight of Counterweights, Table 5. Weight of Counterweights,

INSTALL • GLC20-35VX (GC/GLC040-070VX,

4. If the lift truck has an LPG fuel system, see one of

LPG Fuel System, GM 2.4L Engine 900 YRM

LPG Fuel System, Mazda FE and F2 Engines 900

TOW PIN, REMOVE AND INSTALL

2. Install tow pin into counterweight and install roll pin.

1. TOW PIN 2. ROLL PIN

Figure 18. Tow Pin

Overhead Guard Replacement

5. When installing the overhead guard, tighten the

1. CAPSCREWS - FRONT LEGS

Figure 20. Overhead Guard

Figure 19. Disconnect Air Intake Hose