Yale f813 gp glp gdp 110vx lift truck service repair manual by freemanualdownload7dt

GP/GLP/GDP80VX, GP/GLP/GDP90VX, GP/GLPGDP100VX, GP/GLP/ GDP110VX, GP/GLP/GDP120VX (F813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM 4.3L)...................................................................................... GASOLINE FUEL SYSTEM (GM 4.3L).......................................................................... 1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ 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).......................................................................................................................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524262274 524306203 524265337 524223757 524262275 524262276 524223762 524262277 524262278 524223764 524262279 524223766 550073240 524223767

0100 YRM 1243 0100 YRM 1290 0600 YRM 1251 0700 YRM 1123 0900 YRM 1242 0900 YRM 1244 1300 YRM 1129 1400 YRM 1245 1400 YRM 1246 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137

05/14 04/14 05/14 03/13 08/12 06/12 09/09 01/12 12/13 07/13 03/13 04/14 12/14 04/14

524223768 524208014 524223769 524223770 524223771 524223772

2100 YRM 1139 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142

02/14 05/14 12/14 12/14 12/14 04/14

524265342 524150797 524223780 524223779 524262280 524262281 524221866

4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1152 8000 YRM 1248 8000 YRM 1249 9000 YRM 1112

02/14 10/13 12/14 04/14 04/13 08/11 12/14

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 524278306 (12/14)

0100 YRM 1243

General

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 any blocks used to support the lift truck are solid, one-piece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck.

If additional engine repairs are necessary for lift trucks covered in this manual see: •

GM 4.3L V-6 Engines 0600YRM1251

•

Kubota Diesel 3.8L Engines 0600YRM1557

•

Kubota Diesel 3.6L Engine 0600YRM1579

If additional transmission repairs are necessary for lift trucks covered in this manual see: •

Powershift Transmission 1300YRM1129

•

Powershift Transmission 1300YRM1529

•

One and Two Speed Transmissions 1300YRM1569

This section contains the description of the frame (see Figure 1 or Figure 2) and connected parts. Procedures for removing and installing the counterweight, hood, overhead guard, engine and transmission, and exhaust system 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

0100 YRM 1243

Description The frame is one weldment and includes the hydraulic tank and fuel tank for gasoline or diesel fuel. See Figure 1 or Figure 2. There is a counterweight for each capacity of lift truck. The counterweights are similar in appearance, but are different weights. See Table 2.

The overhead guard, cowl, and hood are installed on the frame. The hood is connected to the frame with hinges. Two gas-controlled springs provide assistance when raising the hood and hold the hood in the open position. The floor plate and side covers can be removed for access to the engine, transmission, and other components.

The muffler is fastened to the frame inside the counterweight.

1. COWL PLATE 2. FENDERS 3. HOOD MOUNTS

4. COUNTERWEIGHT MOUNTS 5. HYDRAULIC TANK 6. FUEL TANK (GAS OR DIESEL) Figure 1. Frame for Lift Trucks with Single Hydraulic Tank

0100 YRM 1243

1. COWL PLATE 2. FENDERS 3. HOOD MOUNTS

Description

4. COUNTERWEIGHT MOUNTS 5. HYDRAULIC TANKS Figure 2. Frame for Lift Trucks with Dual Hydraulic Tanks

Hood, Seat, and Side Covers Replacement

0100 YRM 1243

Hood, Seat, and Side Covers Replacement REMOVE 1. Slide seat to the closest position to steering column. 2. Fully tilt steering column forward. 3. If your truck is equipped with an LPG tank, swing tank off to the side. 4. Raise latch on the left, front corner of hood to unlatch and lift up hood. See Figure 3. 5. Remove floor mat and floor plate. See Figure 4. 6. Remove two capscrews holding left and right rear side covers to the frame. Remove rear side covers from frame. See Figure 4. 7. Remove two capscrews holding left and right fender covers to front overhead guard leg. Remove covers. See Figure 4. 8. Remove four capscrews holding left and right front side covers to frame. Remove covers. 9. Fully lower the steering column. 10. Remove upper steering column cover by pulling up on upper steering column cover to release latches (one on either side), and pulling cover away from steering column. See Figure 5. 11. Remove five fasteners (see Figure 5) securing dash to the top of cowl. Remove four clips, located underneath dash, that attach dash to the kick panel. Lift to remove dash. 12. Lift kick panel to remove it from truck. See Figure 4. 13. Remove three capscrews holding the seal plate. Remove seal plate. See Figure 6. 14. Disconnect seat wire harness connector. See Figure 3.

CAUTION When removing the seat from the hood, DO NOT use an impact wrench to remove the capscrews. Damage can be caused to the threads on the screws and in the holes. 15. If seat is to be removed, and truck is equipped with a non-swivel seat, remove seat wire harness from seat wire harness brackets that are attached to the underside of hood. Remove the cable clips from the seat wire harness. If truck is equipped with a swivel seat, remove seat wire harness from seat wire harness bracket attached to underside of hood and behind the seat. See Figure 3. 16. Remove four capscrews and washers holding seat to the hood. Lift seat off the hood. Pull seat wire harness through hood. See Figure 3. 17. Remove capscrews and washers at top of the gas springs. Remove gas springs from hood. 18. Remove hinge screws, located in the rear of the hood. 19. Lift hood from the truck. See Figure 3.

INSTALL 1. Place hood onto the lift truck frame. 2. Install hinge screws, located in the rear of the hood, and tighten to 38 Nâ&#x20AC;˘m (28 lbf ft). See Figure 3. 3. Align top holes in the gas springs with holes in hood. There are two sets of holes used to install the gas springs to hood, based on the type of seat installed on lift truck. One set is for installing the cylinder end of the gas springs and the other set is for attaching the rod end of the gas springs. Install capscrews and washers to attach gas springs to the hood. Refer to Figure 7 and Table 1 for correct holes used to connect the rod end of the cylinder, depending on the type of seat installed on the lift truck. Tighten capscrews to 19.2 Nâ&#x20AC;˘m (170 lbf in).

0100 YRM 1243

Hood, Seat, and Side Covers Replacement

NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES. A. SIDE VIEW OF HOOD AND SEAT B. SIDE VIEW OF HOOD

C. BOTTOM VIEW OF HOOD D. SIDE VIEW OF VENTED HOOD WITH SWIVEL SEAT

1. 2. 3. 4. 5. 6. 7. 8. 9.

10. 11. 12. 13.

SEAT HOOD FRAME SEAT WIRE HARNESS SEAT WIRE HARNESS CONNECTOR CABLE CLIPS HINGE SCREWS GAS SPRING ATTACHMENT HOLES ATTACHING HOOD TO SEAT (SEMI-SUSPENSION)

SEAT WIRE HARNESS BRACKETS SEAT LINER HOOD LATCH ATTACHMENT HOLES ATTACHING HOOD TO SEAT (NON-SUSPENSION) 14. ATTACHMENT HOLES ATTACHING HOOD TO SEAT (FULL SUSPENSION) 15. SPACER 16. FLANGE NUT

Figure 3. Hood and Seat Arrangement

Hood, Seat, and Side Covers Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

UPPER STEERING COLUMN COVER LOWER STEERING COLUMN COVER CAPSCREW DASH ASSEMBLY INSERT SCREW CLIP SEAL GROMMET KICK PANEL LEFT REAR SIDE COVER SEAL PLATE ASSEMBLY FLOOR MAT FLOOR PLATE CLIP NUT FOLDOVER NUT LEFT FENDER COVER LEFT FRONT SIDE COVER

0100 YRM 1243

19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

LEFT PANEL LEFT STEP PLATE LOCK NUT RIGHT FRONT SIDE COVER RIGHT FENDER COVER RIGHT STEP PLATE RIGHT PANEL RIGHT REAR SIDE COVER SPLASH SHIELD RADIATOR COVER GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/ GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818, F818) 29. RADIATOR COVER (GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

Figure 4. Side Covers, Floor Plate, and Cowl Components 6

0100 YRM 1243

Hood, Seat, and Side Covers Replacement

NOTE: TOP VIEW OF DASH SHOWN. A. INDICATES TO PULL UP TO UNLATCH 1. ALLEN SCREWS 2. COWL

3. UPPER STEERING COLUMN COVER 4. LOWER STEERING COLUMN COVER Figure 5. Remove Dash From Cowl

Hood, Seat, and Side Covers Replacement

1. CAPSCREWS

0100 YRM 1243

2. SEAL PLATE Figure 6. Remove Seal Plate From Dash

0100 YRM 1243

Hood, Seat, and Side Covers Replacement

Figure 7. Gas Spring Installation

Hood, Seat, and Side Covers Replacement

0100 YRM 1243 Legend for Figure 7

NOTE: SEE TABLE 1 FOR HOLES TO USE TO ATTACH ROD END OF GAS SPRING. A. GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/ GLC120SVX; GC/GLC120VXPRS) (E818, F818) B. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

C. LEFT SIDE D. RIGHT SIDE

1. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT 2. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION SEAT Table 1. Gas Spring Installation, Holes for Installing Rod Ends (See Figure 7) Counterweight Type

Full or Semi Suspension Seat

Non-Suspension Seat

Left Side

Right Side

Left Side

Right Side

Standard Counterweight GLC40, 45, 50, 55VX (GC/GLC080, 100, 120VX) (E818, F818)

Standard Counterweight GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

BCS and PRS Counterweights GLC55SVX (GC/ GLC080, 100VXBCS, GC/ GLC120SVX; GC/ GLC120VXPRS) (E818, F818)

0100 YRM 1243 4. Install latch striker in highest slot position. Check that latch striker is in center of jaws of hood latch when hood closes. Open and close hood to ensure that center pin strikes hood latch properly and that the stop screw contacts the frame. A properly closed hood MUST click twice on the hood latch. If the hood latch does not close properly, loosen capscrews on the back of center pin and adjust center pin up or down as required for correct alignment. See Figure 8. 5. Push down until hood just touches rubber bumper. Make sure latch striker is still in center of hood latch. Open hood and tighten capscrews for latch.

Steering Column 6. Check operation of hood latch. Have an operator sit in seat. Make sure hood is fully closed (two clicks). Also check that hood touches rubber bumper. If necessary, repeat Step 5.

CAUTION When installing the seat to the hood, DO NOT use an impact wrench to install the capscrews. Damage can be caused to the threads on the screws and in the holes. 7. Place seat on the hood and thread seat wire harness through the hole in the hood. See Figure 3. 8. Align holes in the seat with the holes in hood. Insert washers and capscrews. Tighten capscrews to 18 Nâ&#x20AC;˘m (159 lbf in). 9. If truck is equipped with a non-swivel seat, tie cable clips to seat wire harness and insert harness into seat wire harness brackets under hood. If truck is equipped with a swivel seat, secure seat harness to bracket. See Figure 3. 10. Install seal plate using three capscrews. See Figure 6. 11. Install kick panel onto truck. See Figure 4. 12. Install dash to top of cowl. See Figure 5. Install four clips to attach dash to kick panel. 13. Install upper steering column cover to dash. 14. Using four capscrews, install left and right front side covers to frame. See Figure 4. 15. Using two capscrews, install left and right fender covers to front of overhead guard legs. 16. Using two capscrews, install left and right rear side covers to frame. See Figure 4. 17. Install floor mat and floor plate. 18. If truck is equipped with an LPG tank, swing LPG tank into position on back of counterweight. 19. Adjust the steering column and seat positions.

1. HOOD 3. CENTER PIN 2. HOOD LATCH 4. CAPSCREW Figure 8. Hood Latch Adjustment

Steering Column

0100 YRM 1243

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 steering wheel and the steering control unit. The steering column includes the steering wheel, housing, bracket and lower shaft. For lift trucks with gas and LPG engines, bolts and bushings attach the steering column to the cowl standoffs. For lift trucks with diesel engines, bolts, bushings and isolators attach the steering column to the cowl standoffs. See Figure 9.

STEERING COLUMN REPAIR

2. Attach a tag on battery connector or negative battery cable stating, DO NOT CONNECT BATTERY. Move steering column to most FORWARD position.

CAUTION If a puller tool is used to remove steering wheel from steering column, be careful not to damage horn wires. NOTE: This procedure is for removal of all components of steering column assembly. Not all components are removed for a repair procedure. Do only those steps of procedure necessary to remove required component.

Remove

NOTE: Tag wires prior to disconnect.

1. Put blocks on each side (front and back) of tires to prevent lift truck from moving.

3. Remove horn button assembly and disconnect electrical wires. Remove large hex nut and steering wheel from steering column. See Figure 10.

WARNING Disconnect the battery before removing any covers to avoid injury to personnel.

4. Remove steering column covers. Remove floor mats and floor plate. See section Hood, Seat, and Side Covers Replacement.

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

1. 2. 3. 4.

1. STEERING WHEEL 2. STEERING COLUMN 3. COWL Figure 9. Steering Column and Cowl

HORN BUTTON HEX NUT STEERING WHEEL STEERING COLUMN Figure 10. Steering Wheel Remove/Install

0100 YRM 1243

Steering Column

NOTE: Perform Step 5 for lift trucks equipped with gas or LPG engines.

See Figure 12, for lift trucks manufactured before January, 2012.

5. Remove four capscrews, four bushings and steering column from cowl standoffs. See Figure 11.

See Figure 13, for lift trucks manufactured after January, 2012.

NOTE: Perform Step 6 for lift trucks equipped with diesel engines.

3. Remove split pin and lower shaft from upper shaft.

6. Remove four capscrews, four bushings, four isolators, steering column and four isolators from cowl standoffs. See Figure 11.

See Figure 12, for lift trucks manufactured before January, 2012.

Disassemble 1. Remove two pins and gas spring from housing. See Figure 12, for lift trucks manufactured before January, 2012. See Figure 13, for lift trucks manufactured after January, 2012. 2. Remove two pivot bolts, two bushings, two nuts and bracket from housing.

1. CAPSCREW 2. BUSHING 3. ISOLATOR

See Figure 13, for lift trucks manufactured after January, 2012. 4. Remove connector from connector bracket. Remove connector bracket, fastener, four screws and two horn contacts from housing. See Figure 12, for lift trucks manufactured before January, 2012. See Figure 13, for lift trucks manufactured after January, 2012.

4. STEERING COLUMN 5. COWL STANDOFF Figure 11. Steering Column Remove/Install

Steering Column

0100 YRM 1243

Figure 12. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012

0100 YRM 1243

Steering Column Legend for Figure 12

1. 2. 3. 4. 5. 6. 7. 8.

PIN LOWER SHAFT SPLIT PIN UPPER SHAFT HOUSING HORN CONTACT SCREW FASTENER

9. 10. 11. 12. 13. 14. 15.

CONNECTOR BRACKET PIVOT BOLT BUSHING NUT GAS SPRING BRACKET CONNECTOR

1. 2. 3. 4. 5. 6. 7. 8.

BRACKET SPACER JOINT NUT WASHER SCREW UPPER SHAFT HOUSING

9. 10. 11. 12. 13. 14. 15. 16.

PIN LOWER SHAFT GAS SPRING BOLT BUSHING CONNECTOR FASTENER HORN CONTACT

Figure 13. Steering Column Assembly, Lift Trucks Manufactured After January, 2012

Steering Column

Clean

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety precautions.

WARNING Compressed air is used for cleaning and drying purposes, or for cleaning restrictions. Wear protective clothing (goggles/shields, gloves, etc.). Make sure the path of the compressed air is away from all personnel to avoid injury. 1. Clean metal parts in solvent. Remove all traces of old lubricant and dirt. Clean nonmetal parts with warm soapy water and a lint free cloth. 2. After cleaning, dry parts with compressed air. DO NOT dry parts with a cloth.

Inspect 1. Inspect for loose, burned, missing, cracked or damaged hardware. 2. Inspect all parts for dents, holes, bends, burrs, rust, corrosion or marred finishes. 3. Replace all defective or damaged parts.

Assemble NOTE: This procedure is for installation of all components of steering column assembly. Not all components are removed for a repair procedure. Do only those steps of procedure necessary to install required component. NOTE: PerformStep 1 only for lift trucks manufactured before January, 2012. 1. Lubricate horn contact slip rings with a small amount of conductive grease (Yale P/N 582014302). 2. Install fastener, connector bracket and connector, two horn contacts and four screws. See Figure 12, for lift trucks manufactured before January 2012. See Figure 13, for lift trucks manufactured after January 2012.

0100 YRM 1243 3. Assemble lower shaft and upper shaft, secure with spit pin. See Figure 12, for lift trucks manufactured before January 2012. See Figure 13, for lift trucks manufactured after January 2012. 4. Install two pivot bolts, two bushings, two nuts and bracket onto housing. See Figure 12, for lift trucks manufactured before January 2012. See Figure 13, for lift trucks manufactured after January 2012. 5. Install gas spring and two pins on housing. See Figure 12, for lift trucks manufactured before January 2012. See Figure 13, for lift trucks manufactured after January 2012.

Install NOTE: Lubricate spline end of lower shaft with multi purpose grease, see Periodic Maintenance Manual for your lift truck. NOTE: Perform Step 1 for lift trucks equipped with gas or LPG engines. 1. Install steering column, four bushings and four bolts on cowl standoffs. Tighten bolts to 38 N•m (28 lbf ft). See Figure 11. NOTE: Perform Step 2 for lift trucks equipped with diesel engines. 2. Install four isolators, steering column, four isolators, four bushings, and four bolts on cowl standoffs. Tighten bolts to 38 N•m (28 lbf ft). See Figure 11. 3. Install floor plate, floor mats, and steering column covers. See section Hood, Seat, and Side Covers Replacement. 4. Install steering wheel and hex nut on steering column, tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft). Connect electrical wiring and install horn button. See Figure 10.

0100 YRM 1243

LPG Tank and Bracket Replacement

5. Remove tag from negative battery connector and connect to battery. Adjust steering column to neutral position.

6. Remove blocks from each side of tires.

LPG Tank and Bracket Replacement For procedures to remove and install the LPG tank, LPG tank bracket, and the LPG tank alignment pin, see one of the following Service Manuals. LPG Fuel System 0900YRM1242 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813)

LPG Fuel System 0900YRM1556 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (G813, H813, J813)

Counterweight Replacement REMOVE WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •

Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

•

Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, onepiece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck.

WARNING DO NOT operate the lift truck if the capscrew for the counterweight is not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

WARNING LPG can cause an explosion. DO NOT cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source. Close the shutoff valve on the LPG tank before any part of the engine fuel systemis disconnected. Run the engine until the fuel in the system is used and the engine stops. If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting. NOTE: The counterweight is held in position on frame by two hooks that are part of frame. See Figure 14. One M30 × 3.5 x 120 capscrew holds counterweight to lower part of frame on lift truck models •

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

Counterweight Replacement One M30 X 3.5 X 140 capscrew holds counterweight to lower part of frame for lift truck models •

GLC40, 45, 55VX (GC/GLC080, 100, 120VX) (E818, F818)

One M30 x 3.5 x 160 capscrew holds counterweight to lower part of frame for lift truck models •

GLC55SVX (GC/GLC080VXBCS, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

NOTE: If lift truck is equipped with an overhead exhaust system, remove overhead exhaust pipe before removing counterweight. See section Exhaust System Repair for procedures. 1. If lift truck has an LPG fuel system, see one of the following Service Manuals to remove the LPG tank and bracket so that the counterweight can be removed. LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models

•

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813)

0100 YRM 1243 LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) ( G813, H813, J813 )

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in Table 2. 2. Install a lifting eye in lift hole of counterweight. See Figure 14. Connect a crane to lifting eye and raise crane until it holds part of weight of counterweight. If counterweight is equipped with a tow pin, remove tow pin and remove capscrew that holds counterweight to frame. If counterweight is not equipped with a tow pin, remove capscrew that holds counterweight to frame. See Figure 14. Use crane to lift counterweight from lift truck. Put counterweight on floor so that it has stability and will not fall over. Take care not to damage exhaust or cooling components.

0100 YRM 1243

Counterweight Replacement

A. COUNTERWEIGHT USED ON GLC40, 45, 55VX (GC/GLC080, 100, 120VX (E818, F818) AND GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) LIFT TRUCK MODELS B. COUNTERWEIGHT USED ON GLC55SVX (GC/GLC80XVBCS, GC/GLC100VXBCS; GC/GLC120SVX; AND GC/GLC120VXPRS) (E818, F818) LIFT TRUCK MODELS C. COUNTERWEIGHT USED ON GLC40, 45, 55VX (GC/GLC080, 100, 120VX (E818, F818) AND GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) LIFT TRUCK MODELS 1. 2. 3. 4. 5.

FRAME HOOK SEAL LIFT HOLE TOW PIN ROLL PIN

6. 7. 8. 9.

WASHERS CAPSCREW WIRE O-RING

Figure 14. Counterweight Installation 19

Counterweight Replacement

0100 YRM 1243

Table 2. Weight of Counterweights Model

Weight

GLC40VX (GC/GLC080VX)

2249 kg (4958 lb)

GLC45VX (GC/GLC100VX)

2552 kg (5626 lb)

GLC/GDC55VX (GC/GLC120VX)

3170 kg (6988 lb)

GC/GLC080VXBCS

2149 kg (4738 lb)

GLC55SVX (GC/GLC100VXBCS, GC/GLC120SVX)

3205 kg (7066 lb)

(GC/GLC120VXPRS)

3773 kg (8318 lb)

GLP/GDP40VX5 (GP/GLP/GDP080VX)

2172 kg (4788 lb)

GLP/GDP40VX6

2370 kg (5225 lb)

GLP/GDP45SVX5 (GP/GLP/GDP090VX)

2504 kg (5520 lb)

GLP/GDP45VX6 (GP/GLP/GDP100VX)

2709 kg (5972 lb)

GLP/GDP50VX (GP/GLP/GDP100VX)

3009 kg (6634 lb)

GLP/GDP55VX (GP/GLP/GDP120VX)

3294 kg (7262 lb)

INSTALL

4. If lift truck has an LPG fuel system, see one of the following Service Manuals to install LPG tank and bracket, after counterweight has been installed.

1. Make sure seals are on counterweight. See Figure 15for lift truck models •

•

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818) GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813, H813)

LPG Fuel System, GM 4.3L Engine With GFI 900 YRM 1242 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813)

See Figure 16 for lift truck models •

GLC55SVX (GC/GLC80XVBCS, GLC100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818)

GC/ AND

LPG Fuel System, GM 4.3L Engine With PSI 900 YRM 1556 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) ( G813, H813, J813 )

See Figure 17 for lift truck models •

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) ( J813 )

2. Use a crane to install counterweight on lift truck. When counterweight is installed, make sure hooks on frame fully engage counterweight so it is aligned with parts of frame. Install and tighten capscrew to 1020 N•m (750 lbf ft). 3. Install tow pin and roll pin, if equipped. See section Tow Pin for procedures.

5. If lift truck is equipped with an overhead exhaust system, install overhead exhaust pipe. See section Exhaust System Repair for procedures.

0100 YRM 1243

1. 2. 3. 4.

SEALS COUNTERWEIGHT CAPSCREW LOCKWASHER

Counterweight Replacement

5. WASHER 6. TOW PIN 7. ROLL PIN

Figure 15. Counterweight Components for Lift Truck Models GLC40, 45, 55VX (GC/GLC080, 100, 120VX (E818, F818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813)

Counterweight Replacement

1. CAPSCREW 2. WASHER

0100 YRM 1243

3. COUNTERWEIGHT 4. SEAL

Figure 16. Counterweight Components for Lift Truck Models GLC55SVX (GC/GLC080, 100VXBCS; GC/GLC/GDC120SVX; GC/GLC/GDC120VXPRS (E818, F818)

0100 YRM 1243

1. SEALS 2. COUNTERWEIGHT 3. TOW PIN

Counterweight Replacement

4. WASHER 5. CAPSCREW

Figure 17. Counterweight Components for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)

Counterweight Replacement

TOW PIN Remove and Install For Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813) 1. Remove tow pin from counterweight by driving 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

0100 YRM 1243

Remove and Install For Lift Truck Models GLC55SVX (GC/GLC80XVBCS, GC/ GLC100VXBCS; GC/GLC120SVX; and GC/ GLC120VXPRS) (E818, F818) and GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (J813) 1. Remove tow pin from counterweight by grasping wire and pulling tow pin from counterweight. See Figure 19. 2. Install tow pin into counterweight dropping tow pin into counterweight.

1. WIRE 2. TOW PIN Figure 19. Tow Pin

0100 YRM 1243

Overhead Guard Replacement

Overhead Guard Replacement REMOVE WARNING DO NOT operate the lift truck without the overhead guard correctly fastened to the lift truck.

WARNING DO NOT weld mounts for lights or accessories to legs of the overhead guard. Changes that are made by welding, or by drilling holes that are too big or in the wrong location, can reduce the strength of the overhead guard. See your dealer for Yale lift trucks BEFORE performing any changes to the overhead guard. NOTE: The lift trucks covered in this YRM are equipped with either a high or low overhead guard. The removal and installation procedures for both types of overhead guards are the same. No welding or drilling on legs of overhead guard is permitted as per previous WARNING. NOTE: The lifting device can be connected to any number of positions on overhead guard depending upon lifting device available. The ideal choices are a four point sling connected to all four corners on top of overhead guard, or a two point sling connected to two opposite corners of overhead guard. If a single point hoist is used, make sure that lift point is in center of overhead guard. If during initial start of lift, the overhead guard is off balance, lower immediately and move hoist to a more centered point. 1. Connect a lifting device to remove overhead guard. Loosen clamp and disconnect air intake hose from elbow. Remove bolts, elbow, retainer, and grommet from overhead guard rear leg. See Figure 20. 2. Disconnect wires between frame and overhead guard. When overhead guard is lifted from frame, make sure that electrical wires are moved through holes in overhead guard so that they are not damaged. 3. The rear legs of overhead guard have two capscrews that are located under hood inside engine compartment, next to radiator. Remove capscrews. See Figure 21.

1. CLAMP 2. AIR INTAKE HOSE 3. BOLTS

4. ELBOW 5. RETAINER 6. GROMMET

Figure 20. Disconnect Air Intake Hose 4. Remove fender cover, dash, and kick panel to remove two capscrews on front legs of overhead guard. See Hood, Seat, and Side Covers Replacement for removal procedures. 5. Using a lifting device, remove overhead guard from frame and place on floor.

INSTALL 1. Connect lifting device to top of overhead guard. Install overhead guard in position on lift truck. 2. Install two capscrews on front legs of overhead guard. Tighten capscrews to 66 Nâ&#x20AC;˘m (49 lbf ft). See Figure 21. 3. Install fender cover, dash, and kick panel. See Hood, Seat, and Side Covers Replacement for installation procedures. 25

Operator Restraint System Replacement

0100 YRM 1243

4. Install two capscrews on rear legs of overhead guard. Tighten capscrews to 66 Nâ&#x20AC;˘m (49 lbf ft). See Figure 21. 5. Connect air intake hose by installing bolts, elbow, retainer, and grommet to overhead guard rear leg. See Figure 20.

LED TAIL, BACKUP, AND BRAKE LIGHTS, REPLACE These light assemblies are nonrepairable and must be replaced as an assembly. See section Electrical System 2200YRM1142 for procedures to replace these lights.

1. 2. 3. 4.

CAPSCREWS - FRONT LEGS HANDLE CAPSCREWS - REAR LEGS FRAME Figure 21. Overhead Guard

Operator Restraint System Replacement DESCRIPTION The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 22. The seat belt, when properly buckled across operator, will permit slight operator repositioning without activating locking mechanism.

If truck tips, travels off a dock, or comes to a sudden stop, locking mechanism will be activated and hold the operator's lower torso in seat. A seat belt that is damaged, worn or does not operate properly will not provide protection when it is needed. The end of belt must fasten correctly in latch. The seat belt must be in good condition. Replace seat belt if damage or wear is seen. See Figure 22.

0100 YRM 1243

Engine Replacement

The following seat belt operation checks must be performed: •

•

1. 2. 3. 4.

With hood closed and in locked position, pull seat belt slowly from retractor assembly. Make sure seat belt pulls out and retracts smoothly. If seat belt does not pull out of retractor assembly, internal latch may be locked. Pull firmly on seat belt and hold for a moment to remove slack from belt in retractor. Release seat belt. Seat belt will retract and internal latch will unlock. If seat belt cannot be pulled from retractor assembly or belt will not retract, replace seat belt assembly. With hood closed and in locked position, pull seat belt with a sudden jerk. Make sure seat belt will not pull from retractor assembly. If seat belt can be pulled from retractor, when it is pulled with a sudden jerk, replace seat belt assembly.

WEIGHT ADJUSTMENT LEVER HIP RESTRAINT SEAT BELT LATCH SEAT

•

With hood in open position, make sure seat belt will not pull from retractor assembly. If seat belt can be pulled from retractor, with hood in open position, replace seat belt assembly.

Make sure seat rails and latch striker are not loose. The seat rails must lock tightly in position, but move freely when unlocked. The seat rails must be correctly fastened to hood and hood fastened to hinges on frame. The hood must be fully closed. Attempt to lift hood to make sure it is closed. Adjust hood, hood latch, and latch striker when any of parts of operator restraint system are installed or replaced. See section Hood, Seat, and Side Covers Replacement in this manual for adjustment procedures for hood.

5. HOOD 6. SEAT RAIL 7. SPACER Figure 22. Operator Restraint System

Engine Replacement

0100 YRM 1243

Engine Replacement REMOVE ENGINE ONLY 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: •

•

WARNING Always disconnect the cables at the battery before you make repairs to the engine. Disconnect the cable at the negative terminal first.

1. For lift trucks equipped with an LPG fuel system, close shutoff valve on tank and run engine until all fuel is gone and engine stops. 2. If lift truck is equipped with an LPG fuel tank, swing tank to side. See one of the following Service Manuals: LPG Fuel System 0900YRM1242 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813)

LPG Fuel System 0900YRM1556 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (G813, H813, J813)

3. Remove floor mat and floor plate.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 4. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than capacity of cooling system under radiator. Remove radiator cap.

0100 YRM 1243

Engine Replacement

NOTE: PART OF FRAME NOT SHOWN FOR CLARITY. A. GM 4.3L ENGINE B. CUMMINS 4.5L DIESEL ENGINE

C. CUMMINS QSB 3.3L DIESEL ENGINE

1. 2. 3. 4.

5. 6. 7. 8.

TRANSMISSION ISOLATOR ASSEMBLY TRANSMISSION MOUNTING BRACKET ENGINE MOUNTING BRACKET ENGINE CROSSMEMBER

ENGINE ISOLATOR ASSEMBLY FRAME ENGINE HARNESS CONNECTOR LEFT CHASSIS WIRING HARNESS CONNECTOR

Figure 23. Engine and Transmission Mounting Arrangement for GM4.3L Engines, Cummins 4.5L Diesel Engines, and Cummins QSB 3.3L Diesel Engines

Engine Replacement

0100 YRM 1243

NOTE: PART OF FRAME NOT SHOWN FOR CLARITY. A. KUBOTA 3.8L DIESEL ENGINE FOR LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) B. KUBOTA 3.8L DIESEL ENGINE FOR LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) C. KUBOTA 3.6L DIESEL ENGINE 1. TRANSMISSION ISOLATOR ASSEMBLY 2. TRANSMISSION MOUNTING BRACKET 3. ENGINE ISOLATOR ASSEMBLY

4. ENGINE MOUNTING BRACKET 5. ENGINE HARNESS CONNECTOR 6. FRAME

Figure 24. Engine and Transmission Mounting Arrangement for Kubota Engines

0100 YRM 1243

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 5. Open drain plug or loosen hose clamp and disconnect bottom radiator hose to drain coolant from radiator and engine. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tanks. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tanks. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012.

Engine Replacement See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine.

Engine Replacement

0100 YRM 1243

Figure 25. GM 4.3L LPG Engine and Transmission with Single Hydraulic Tank

0100 YRM 1243

Engine Replacement Legend for Figure 25

NOTE: GM 4.3L GASOLINE ENGINE IS SIMILAR. A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

BOTTOM RADIATOR HOSE AIR FILTER HOSE AIR FILTER AND BRACKET ASSEMBLY LEFT HAND CHASSIS HARNESS CONNECTOR ENGINE HARNESS CONNECTOR LPG REGULATOR CONNECTOR RIGHT HAND CHASSIS HARNESS ELECTRONIC CONTROL MODULE (ECM) POWER DISTRIBUTION MODULE (PDM) BATTERY AND BATTERY TRAY COOLANT HOSES FAN PULLEY AND FAN SPACER

FAN SHROUD EXHAUST PIPE TO EXHAUST MANIFOLD FUEL LINES RADIATOR CAP TRANSMISSION MOUNT BRAKE COOLING LINES BATTERY CABLE (POSITIVE) BATTERY CABLE (NEGATIVE) HYDRAULIC RETURN HOSE TRANSMISSION OIL COOLER LINES HYDRAULIC SUPPLY HOSE

Engine Replacement

0100 YRM 1243

Figure 26. GM 4.3L LPG Engine and Transmission with Dual Hydraulic Tanks

0100 YRM 1243

Engine Replacement Legend for Figure 26

A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Engine Replacement

0100 YRM 1243

Figure 27. Cummins QSB 3.3L Diesel Engine and Transmission

0100 YRM 1243

Engine Replacement Legend for Figure 27

A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

RADIATOR CAP SHROUD BOTTOM COOLANT HOSE AIR FILTER HOSE AIR FILTER AND BRACKET EXHAUST PIPE TO EXHAUST MANIFOLD ENGINE MOUNTING BRACKETS FUEL LINES ENGINE HARNESS CONNECTOR BRAKE COOLING LINE

HYDRAULIC SUPPLY LINE TRANSMISSION MOUNTING BRACKET ELECTRONIC CONTROL MODULE RIGHT HAND ENGINE HARNESS HYDRAULIC RETURN LINE BATTERY AND BATTERY TRAY BATTERY CABLE (POSITIVE) BATTERY CABLE (NEGATIVE) FAN SPACER AND FAN PULLEY CHARGE AIR HOSE

Engine Replacement

0100 YRM 1243

Figure 28. Kubota 3.8L Engine and Transmission for Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) Manufactured Before February, 2012.

0100 YRM 1243

Engine Replacement Legend for Figure 28

A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19.

RADIATOR CAP SHROUD BOTTOM COOLANT HOSE AIR FILTER HOSE AIR FILTER AND BRACKET EXHAUST PIPE TO EXHAUST MANIFOLD ENGINE MOUNTING BRACKETS FUEL LINES ENGINE HARNESS CONNECTOR BRAKE COOLING LINE

Engine Replacement

0100 YRM 1243

Figure 29. Kubota 3.8L Engine and Transmission for Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) Manufactured After February, 2012.

0100 YRM 1243

Engine Replacement Legend for Figure 29

A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19.

RADIATOR CAP SHROUD BOTTOM COOLANT HOSE AIR FILTER HOSE AIR FILTER AND BRACKET EXHAUST PIPE TO EXHAUST MANIFOLD ENGINE MOUNTING BRACKETS FUEL LINES ENGINE HARNESS CONNECTOR BRAKE COOLING LINE

Engine Replacement

0100 YRM 1243

Figure 30. Kubota 3.8L Engine and Transmission for Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 42

0100 YRM 1243

Engine Replacement Legend for Figure 30

A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19.

RADIATOR CAP SHROUD BOTTOM COOLANT HOSE AIR FILTER HOSE AIR FILTER AND BRACKET EXHAUST PIPE TO EXHAUST MANIFOLD ENGINE MOUNTING BRACKETS FUEL LINES ENGINE HARNESS CONNECTOR BRAKE COOLING LINE

Engine Replacement

0100 YRM 1243

Figure 31. Kubota 3.6L Engine and Transmission for Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) Manufactured Before February, 2012

0100 YRM 1243

Engine Replacement Legend for Figure 31

A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

RADIATOR CAP SHROUD LOWER COOLANT HOSE AIR FILTER HOSE AIR FILTER AND BRACKET EXHAUST PIPE TO EXHAUST MANIFOLD ENGINE MOUNTING BRACKETS FUEL LINES ENGINE HARNESS CONNECTOR BRAKE COOLING LINE

HYDRAULIC SUPPLY LINE TRANSMISSION MOUNTING BRACKET UPPER COOLANT HOSE RIGHT HAND ENGINE HARNESS HYDRAULIC RETURN LINE BATTERY AND BATTERY TRAY BATTERY CABLE (POSITIVE) BATTERY CABLE (NEGATIVE) FAN SPACER AND FAN PULLEY THROTTLE CABLE

Engine Replacement

0100 YRM 1243

Figure 32. Kubota 3.6L Engine and Transmission for Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) Manufactured After February, 2012 and Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 46

0100 YRM 1243

Engine Replacement Legend for Figure 32

A. TOP VIEW

B. LEFT SIDE VIEW

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

RADIATOR CAP SHROUD LOWER COOLANT HOSE AIR FILTER HOSE AIR FILTER AND BRACKET EXHAUST PIPE TO EXHAUST MANIFOLD ENGINE MOUNTING BRACKETS FUEL LINES ENGINE HARNESS CONNECTOR BRAKE COOLING LINE

Engine Replacement

0100 YRM 1243

Figure 33. Cummins 4.5L Diesel Engine and Transmission

0100 YRM 1243

Engine Replacement Legend for Figure 33

A. TOP VIEW B. RIGHT SIDE VIEW

C. LEFT SIDE VIEW

1. RIGHT HAND CHASSIS HARNESS CONNECTOR 2. THROTTLE CABLE 3. BATTERY AND BATTERY TRAY 4. RADIATOR CAP 5. FUEL LINES 6. ENGINE HARNESS CONNECTOR 7. LEFT HAND CHASSIS HARNESS CONNECTOR 8. CAPSCREW 9. ISOLATORS 10. WASHERS 11. FLANGE NUTS 12. OUTPUT YOKE 13. TRANSMISSION MOUNT 14. ENGINE MOUNTS

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

6. Remove hood and seat combination and rear side covers. See section Hood Repair for procedures. 7. Loosen clamp and remove air filter hose from air inlet, located on left rear overhead guard leg. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tank. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,

AIR FILTER AND BRACKET ASSEMBLY AIR FILTER HOSE EXHAUST PIPE TO EXHAUST MANIFOLD BOTTOM RADIATOR HOSE COOLANT HOSES BRAKE COOLING LINES TRANSMISSION BELL HOUSING FAN PULLEY AND FAN SPACER BATTERY CABLE (POSITIVE) BATTERY CABLE NEGATIVE POWER DISTRIBUTION MODULE (PDM) TRANSMISSION HARNESS CONNECTOR SHROUD FAN

090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 8. Remove air filter, and bracket assembly. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tanks. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012.

Engine Replacement See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 9. For lift trucks equipped with Cummins 4.5L and Kubota 3.6L diesel engine, disconnect throttle cable from fuel injection pump. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine.

0100 YRM 1243 See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. NOTE: When disconnecting wiring harness connectors, tag each connector to aid in connecting wiring harness during installation. 10. On lift trucks equipped with either a GM 4.3L gasoline engine, a Cummins 4.5L diesel engine, or Kubota 3.6L diesel engine, disconnect left hand chassis harness connector from engine harness connector. See Figure 25 for lift trucks equipped with a GM 4.3L gasoline engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift truck models equipped with Cummins 4.5L diesel engine. NOTE: Perform Step 11 for lift truck models equipped with GFI fuel system. 11. On lift trucks equipped with GM 4.3L LPG engine, disconnect left hand chassis harness connector from LPG regulator connector and engine harness connector. See Figure 25. 12. On lift trucks equipped with GM 4.3L engine or Kubota 3.8L engine, disconnect engine harness connectors from electronic control module (ECM). See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tanks.

0100 YRM 1243

Engine Replacement

See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tanks.

090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012.

See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012.

See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine.

See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. 13. Disconnect engine harness connector from right hand chassis harness connector. 14. Disconnect ground strap from frame and remove power distribution module (PDM) from battery tray. See Figure 34. 15. For lift trucks equipped with either a Cummins QSB 3.3L, a Cummins 4.5L, or Kubota diesel engines, remove battery from battery tray and remove three capscrews from battery tray. Remove battery tray. 16. For lift trucks equipped with GM 4.3L engine, remove three capscrews from battery tray and remove battery, battery tray, and Electronic Control Module (ECM). 17. Loosen hose clamps and disconnect remaining coolant hoses from radiator and cap them to prevent leakage. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tanks. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,

1. 2. 3. 4. 5.

BATTERY BATTERY TRAY PDM BATTERY LOCKDOWN BAR GROUND STRAP Figure 34. Power Distribution Module, Disconnection

Engine Replacement See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012.

See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine.

See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine.

See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine.

18. Disconnect exhaust pipes from exhaust manifolds. See Exhaust System Repair for procedures. 19. Remove radiator fan pulley, shroud, and fan assembly. See section Cooling System 0700YRM1123 for removal procedures.

WARNING All fuels are very flammable and can burn or cause an explosion. DO NOT use an open flame to check the fuel level or to check for leaks in the fuel system. No smoking. Breathing fuel vapor may cause nausea, unconsciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor. 20. Disconnect fuel lines at engine. Put caps on fuel lines to prevent fuel leakage. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tanks. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine.

0100 YRM 1243

See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 21. Lift trucks equipped with GM 4.3L engine, remove left side engine mount to access starter motor. See Figure 25 or Figure 26. 22. Disconnect positive battery (B+) from starter motor. 23. Lift trucks equipped with GM 4.3L engine, remove starter motor to reach four torque converter access bolts. See Figure 25 or Figure 26.

0100 YRM 1243 24. For lift trucks equipped with a Cummins QSB 3.3L diesel engine, remove oil cooler to reach access port. See Yale Axcess Online. 25. Lift trucks equipped with Cummins QSB 3.3L diesel engine, remove bolts and cover to get to access port. See Figure 37. 26. Lift trucks equipped with Kubota diesel engine, remove bolts and cover to reach access port. See Figure 38.

Engine Replacement See Figure 38 for lift trucks equipped with a Kubota diesel engine. 28. Connect a lifting device to engine. Put a block under transmission housing to support transmission. 29. Remove capscrews from transmission bell housing.

WARNING

27. Use access port on engine to remove bolts that attaching flywheel to torque converter.

The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 363 kg (800 lb).

See Figure 35 for lift trucks equipped with a GM 4.3L gas or LPG engine.

30. Remove flange nuts, washers, bolts, and isolators from engine mounts. See Figure 23 or Figure 39.

See Figure 36 for lift trucks equipped with a Cummins 4.5L diesel engine. See Figure 37 for lift trucks equipped with a Cummins QSB 3.3L diesel engine.

1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE 1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE

Figure 36. Cummins 4.5L Engine Access Port

Figure 35. GM 4.3L Engine Removal Access Port

Engine Replacement

1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE Figure 37. Cummins QSB 3.3L Diesel Engine Access Port

0100 YRM 1243

NOTE: KUBOTA 3.8L DIESEL ENGINE FOR LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/ GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) SHOWN. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (J813) IS SIMILAR. NOTE: KUBOTA 3.8L SHOWN. KUBOTA 3.6L SIMILAR. 1. ACCESS PORT 2. ENGINE MOUNTING BRACKET AND HARDWARE Figure 38. Kubota Diesel Engine Access Port

0100 YRM 1243

Engine Replacement

A. ENGINE MOUNTS FOR GM 4.3L B. ENGINE MOUNTS FOR CUMMINS 4.5L

C. ENGINE MOUNTS FOR CUMMINS QSB 3.3L D. ENGINE MOUNTS FOR KUBOTA DIESEL

1. 2. 3. 4. 5.

6. 7. 8. 9.

ENGINE MOUNTS CAPSCREW WASHER ISOLATOR FLANGE NUT

PIN CROSSMEMBER LOCK NUT FLANGE BOLT

Figure 39. Engine Mounts Assembly

Engine Replacement

CAUTION When separating the engine away from the transmission, place a piece of plywood in front of radiator. This will keep the engine from damaging the radiator.

CAUTION Keep the engine level when the engine is separated from the transmission so the drive plate is not damaged. 31. Use lifting device to carefully move engine away from torque converter. Make sure all hoses, wires, and cables are disconnected from engine, then lift engine from frame and place engine on blocks.

INSTALL ENGINE ONLY WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine weighs approximately 363 kg (800 lb).

CAUTION Keep the engine level when installing the engine to the transmission so the drive plate is not damaged. 1. Connect lifting device to engine and lift engine into frame. 2. Align transmission bell housing to torque converter adapter. See Figure 25 for lift truck models equipped with GM 4.3L engine and single hydraulic tank. See Figure 26 for lift truck models equipped with GM 4.3L engine and dual hydraulic tank. See Figure 27 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012.

0100 YRM 1243 See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift truck models equipped with Cummins 4.5L diesel engine. NOTE: Perform Step 3 on lift trucks equipped with GM 4.3L gas/LPG engine or Kubota diesel engine. 3. If isolators fell from engine mounts during removal, install isolators on engine mounts and install washers, capscrews and flange nuts for engine mounts to secure engine to frame. Tighten flange nuts to 150 Nâ&#x20AC;˘m (110 lbf ft). See Figure 39. NOTE: Perform Step 4 on lift trucks equipped with either a Cummins QSB 3.3L or Cummins 4.5L diesel engine. 4. If isolators fell from engine mounts during removal, install isolators on engine mounts and install washers, capscrews and flange nuts for engine mounts to secure engine to frame. Tighten flange nuts to 320 Nâ&#x20AC;˘m (236 lbf ft). See Figure 39.

0100 YRM 1243 5. Install capscrews to secure transmission bell housing to torque converter adapter. Tighten capscrews to 38 N•m (28 lbf ft). 6. Use access port on engine to install four bolts to hold torque converter to flywheel. Tighten bolts to 55 N•m (41 lbf ft). 7. For Cummins QSB 3.3L diesel engine, install cover and bolts to access port. See Figure 37. 8. For Kubota 3.8L diesel engine, install cover and bolts to access port. See Figure 38. 9. Remove blocks from under transmission and disconnect lifting device from engine. 10. Lift trucks equipped with Cummins QSB 3.3L diesel engine, install oil cooler. See Yale Axcess Online. 11. Lift trucks equipped with GM 4.3L engine, install starter motor. Tighten capscrews to 52 N•m (38 lbf ft). 12. Connect positive battery (B+) cable to starter motor. Tighten terminal nut to 8 to 11 N•m (71 to 97 lbf in). 13. Lift trucks equipped with GM 4.3L engine, install left side engine mount on engine. Tighten capscrews to 90 N•m (66 lbf ft). 14. For lift trucks equipped with GM 4.3L engine, connect exhaust pipes to exhaust manifolds. Tighten lock nuts to 39 N•m (29 lbf ft). See Figure 25 or Figure 26.

Engine Replacement See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. 16. For lift trucks equipped with Cummins QSB 3.3L or Cummins 4.5L diesel engine, connect exhaust pipe to exhaust manifold. Tighten lock nut to 22 N•m (16 lbf ft). See Figure 27 for lift truck models equipped with Cummins QSB 3.3L diesel engine. See Figure 33 for lift truck models equipped with Cummins 4.5L diesel engine.

15. For lift trucks equipped with Kubota diesel engine, connect exhaust pipes to exhaust manifolds.

17. Remove caps from fuel lines and connect fuel lines at engine.

18. Install radiator shroud, fan pulley, and fan assembly. See section Cooling System 0700YRM1123 for Fan Installation procedures.

19. Remove cap from bottom radiator hose and install hoses to radiator. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tank. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine.

Engine Replacement See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. NOTE: Perform Step 20 on lift trucks equipped with either a Cummins QSB 3.3L, a Cummins 4.5L, or Kubota diesel engine.

0100 YRM 1243 22. Install Power Distribution Module (PDM) on battery tray and connect ground strap to lift truck frame. See Figure 34. 23. Connect engine harness connector to right hand chassis harness connector. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tank. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine.

NOTE: Perform Step 21 on lift trucks equipped with GM 4.3L engine.

See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine.

21. Using three capscrews install battery tray, battery, and Electronic Control Module (ECM).

See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine.

20. Using three capscrews install battery tray and battery.

0100 YRM 1243 24. For lift trucks equipped with GM 4.3L or Kubota 3.8L engine, connect engine harness connectors to Electronic Control Module (ECM). See Figure 25 for lift trucks equipped with a GM 4.3L engine and single hydraulic tank. SeeFigure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tank. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. NOTE: Perform Step 25 for lift truck models equipped with GFI fuel system. 25. For lift trucks equipped with GM 4.3L LPG engine, connect left hand chassis harness connector to LPG regulator connector and engine harness connector. See Figure 25 or Figure 26. 26. For lift trucks equipped with either a GM 4.3L gasoline engine, Kubota 3.6L diesel engine, or Cummins 4.5L diesel engine, connect left hand chassis harness connector to engine harness connector. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tank. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012.

Engine Replacement See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 27. For lift trucks equipped with Cummins 4.5L diesel engine or Kubota 3.6L diesel engine, connect throttle cable to fuel injection pump. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 28. Install air filter and bracket assembly. 29. Connect air filter hose to air inlet located on left rear over head guard leg and tighten clamp. 30. Install hood and seat combination, and rear side covers. See section Hood Repair, Hood RepairHood Repair for procedures.

Engine Replacement 31. Close drain plug and remove caps from remaining coolant hoses and connect hoses to radiator. Tighten hose clamps and fill cooling system with antifreeze. See Cooling System 0700YRM1123 for radiator fill procedures. Install radiator cap. 32. Check all fluid levels as described in Periodic Maintenance 8000YRM1248 for lift truck models •

•

GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818) GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (F813, G813)

Periodic Maintenance 8000YRM1558 for lift truck models •

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (H813)

Periodic Maintenance 8000YRM1598 for lift truck model •

GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (F818)

Periodic Maintenance 8000YRM1604 for lift truck model •

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)

33. Connect positive battery cable to battery. 34. Connect negative battery cable to battery. 35. Install floor plate and floor mat.

WARNING All fuels are very flammable and can burn or cause an explosion. DO NOT use an open flame to check the fuel level or to check for leaks in the fuel system. No smoking.

0100 YRM 1243 Breathing fuel vapor may cause nausea, unconsciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor. 36. For lift trucks equipped with and LPG fuel system, swing LPG tank and bracket back to original position until locked and open shutoff valve. 37. Inspect fuel system for leaks when fuel valve is open. There are four methods used to inspect fuel system for leaks: a. Sound - Listen for sound of fuel escaping from a tank fitting or hose connection. b. Smell - Fuel has a very distinctive odor. If you smell fuel, DO NOT start engine. c. Soapy Water - This method is used in conjunction with Step b above. If odor of fuel is present, but escaping fuel cannot be heard, apply soapy water to fittings and observe for bubbles. d. Frost - If amount of fuel escaping is sufficient, frost may appear on fittings.

REMOVE ENGINE AND TRANSMISSION 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.

0100 YRM 1243 The engine can be removed with or without transmission. Follow procedures below to remove engine with transmission. See Figure 23.

WARNING Always disconnect the cables at the battery before you make repairs to the engine. Disconnect the cable at the negative terminal first.

WARNING

Engine Replacement 4. Open drain plug or loosen hose clamp and disconnect bottom radiator hose to drain coolant from radiator and engine. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tank. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine.

LPG can cause an explosion. DO NOT cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipments, or ignition source.

1. For lift trucks equipped with an LPG fuel system, close shutoff valve on tank and run engine until all fuel is gone and engine stops.

2. If lift truck is equipped with an LPG fuel tank, swing tank to side. See one of the following Service Manuals. LPG Fuel System 0900YRM1242 for lift truck models: •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (F813, G813)

LPG Fuel System 0900YRM1556 for lift truck models: •

GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, 120VX; GLC080, 100VXBCS; GLC120SVX; GLC120VXPRS) (E818, F818)

•

GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GLP080, 90, 100, 110, 120VX) (G813, H813, J813)

See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine.

3. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than capacity of cooling system under radiator. Remove radiator cap.

See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine.

NOTE: Disposal of lubricants and fluids must meet local environmental regulations.

See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine.

Engine Replacement 5. Remove overhead guard, see Overhead Guard Replacement for Remove procedures. 6. Remove hood and seat combination and rear side covers. See section Hood Repair for procedures. 7. Remove floor mat and floor plate. 8. Loosen clamp and remove air filter hose from air inlet, located on left rear over head guard leg. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L LPG engine and dual hydraulic tanks. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine.

0100 YRM 1243 See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 9. For lift trucks equipped with Cummins 4.5L or Kubota 3.6L diesel engine, disconnect throttle cable from fuel injection pump. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. NOTE: When disconnecting wiring harness connectors during removal, tag each connector to aid in connecting wiring harness during installation. 10. For lift trucks equipped with either a GM 4.3L gasoline engine, Kubota 3.6L diesel engine, or Cummins 4.5L diesel engine, disconnect left hand chassis harness connector from engine harness connector. See Figure 25 for lift trucks equipped with a GM 4.3L engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L engine and dual hydraulic tank.

0100 YRM 1243 See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. NOTE: Perform Step 11 for lift truck models equipped with GFI fuel system. 11. For lift trucks equipped with GM 4.3L LPG engine, disconnect left hand chassis harness connector from LPG regulator connector and engine harness connector. See Figure 25. 12. For lift trucks equipped with GM 4.3L or Kubota 3.8L engine, disconnect engine harness connectors from Electronic Control Module (ECM).

Engine Replacement See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. 13. For lift trucks equipped with Cummins QSB 3.3L diesel engine, disconnect alternator harness from Electronic Control Module (ECM). See Figure 27 for lift truck models equipped with Cummins QSB 3.3L diesel engine. 14. Disconnect engine harness connector from right hand chassis harness connector. 15. Disconnect battery positive (B+) and negative cable from starter motor. 16. Disconnect ground strap from frame and remove power distribution module (PDM) from battery tray. 17. For lift trucks equipped with Cummins QSB 3.3L, Cummins 4.5L, or Kubota diesel engine, remove three capscrews from battery tray and remove battery and battery tray. 18. For lift trucks equipped with GM 4.3L engine, remove three capscrews from battery tray and remove battery, battery tray, and Electronic Control Module (ECM).

CAUTION

See Figure 25 for lift trucks equipped with a GM 4.3L engine and single hydraulic tank.

Disposal of lubricants and fluids must meet local environmental regulations.

See Figure 26 for lift trucks equipped with a GM 4.3L engine and dual hydraulic tanks.

19. Place a drain pan under hydraulic tank, remove drain plug at bottom of hydraulic oil tank, and drain oil from tank. After oil has finished draining, install drain plug to hydraulic tank.

See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012.

20. Place drain pan under hydraulic gear pump assembly. a. For lift truck models equipped with a hydraulic gear pump on transmission, disconnect the suction hose and hydraulic hose from hydraulic gear pump assembly. Put caps on all hose fitting and hydraulic gear pump ports. See Hydraulic Gear Pump 1900YRM1136 for more information.

Engine Replacement b. For lift truck models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (G813, H813, J813) equipped with a variable displacement pump (VDP) on transmission, disconnect suction hose, hydraulic hose, drain case line, and load sense line from VDP assembly. Put caps on all hose fitting and variable displacement pump ports. See Hydraulic Gear Pump 1900YRM1136 for more information. 21. Loosen hose clamps and disconnect remaining coolant hoses from radiator and cap them, to prevent leakage. 22. Place drain pan under transmission oil cooler lines at transmission. Loosen hose clamps and disconnect transmission oil cooler lines at transmission and cap to prevent leakage. 23. Place drain pan under supply and return brake cooling lines (if equipped) and remove cooling lines at transmission and cap to prevent leakage. 24. Disconnect exhaust pipes from exhaust manifold. See Exhaust System Repair for removal procedures. 25. Remove radiator fan pulley, shroud, and fan assembly. See section Cooling System 0700YRM1123 for removal procedures.

WARNING All fuels are very flammable and can burn or cause an explosion. DO NOT use an open flame to check the fuel level or to check for leaks in the fuel system. No smoking. Breathing fuel vapor may cause nausea, unconsciousness or death. Long term exposure to gasoline vapors may cause liver or kidney damage and cancer. Avoid breathing vapor. 26. Loosen hose clamps (if equipped) and disconnect fuel lines at engine. Put caps on fuel lines to prevent fuel leakage. See Figure 25 for lift trucks equipped with a GM 4.3L engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L engine and dual hydraulic tanks.

0100 YRM 1243 See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine.

WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb). 27. Connect a lifting device to support transmission and engine combination.

0100 YRM 1243 28. Disconnect output yoke from transmission. See Figure 25 for lift trucks equipped with a GM 4.3L engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L engine and dual hydraulic tanks. See Figure 27 for lift trucks equipped with a Cummins QSB 3.3L diesel engine. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine.

Engine Replacement 30. Remove capscrews and washers from engine mounts. See Figure 39. NOTE: Make sure engine and transmission assembly can be raised at an angle so they will clear frame. 31. Use lifting device to carefully lift engine and transmission from frame. Slip transmission output yoke out of transmission. Make sure not to damage seal. Place engine and transmission on blocks.

INSTALL ENGINE AND TRANSMISSION WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb). NOTE: Make sure engine and transmission assembly can be raised at an angle so they will clear frame. 1. Connect a lifting device to engine and transmission and lift engine and transmission into lift truck frame. 2. Install transmission output yoke onto transmission. Be sure to not damage seal. Tighten bolt to 38 N•m (28 lbf ft). NOTE: Perform Step 3 on lift trucks equipped with Cummins 4.5L or Cummins QSB 3.3L diesel engines. 3. If isolators fell from engine mounts during removal, install isolators to engine mounts and install washers, capscrews, and flange nuts for engine mounts to secure engine to frame. Tighten flange nuts to 320 N•m (236 lbf ft). See Figure 39. NOTE: Perform Step 4 on lift trucks equipped with GM 4.3L gas/LPG engine or Kubota diesel engine. 4. If isolators fell from engine mounts during removal, install isolators to engine mounts and install washers, capscrews, and flange nuts for engine mounts to secure engine to frame. Tighten flange nuts to 150 N•m (110 lbf ft). See Figure 39. 5. If isolators fell from transmission mount, install isolators to transmission mount and install washers, lock washers, and capscrews. Tighten capscrews to 225 to 250 N•m (166 to 184 lbf ft). See Figure 40.

29. Remove flange nuts, capscrews, washers and isolators from transmission mount. See Figure 40.

Engine Replacement

0100 YRM 1243 10. For lift trucks equipped with Kubota diesel engine, connect exhaust pipe to exhaust manifold. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012. See Figure 29 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured after February, 2012. See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012.

1. 2. 3. 4. 5. 6.

ISOLATOR CAPSCREW LOCKWASHER WASHER ISOLATOR MOUNTING BRACKET MOUNTING BRACKET CAPSCREW Figure 40. Transmission Mounting Assembly

6. Remove lifting device from engine and transmission combination. 7. Install radiator shroud, fan pulley, and fan assembly. See section Cooling System 0700YRM1123 for Fan Installation procedures. 8. Remove cap from bottom radiator hose and install hose on radiator. 9. For lift trucks equipped with GM 4.3L engine, connect exhaust pipes to exhaust manifolds. Tighten lock nuts to 39 N•m (29 lbf ft). See Figure 25. 66

See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. 11. For lift trucks equipped with Cummins 4.5L engine, connect exhaust pipe to exhaust manifold. Tighten lock nut to 22 N•m (16 lbf ft). See Figure 33. 12. Remove cap and connect supply and return brake cooling lines at transmission. 13. Remove cap and connect transmission oil cooler lines at transmission. 14. Connect hydraulic connections to the hydraulic pump.

0100 YRM 1243

Engine Replacement

a. For lift truck models equipped with a hydraulic gear pump on transmission, remove plugs from hydraulic gear pump ports, and connect suction hose and hydraulic hose to hydraulic gear pump assembly. See Hydraulic Gear Pump 1900YRM1136 for more information.

b. For lift truck models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (G813, H813, J813) equipped with a variable displacement pump (VDP) on transmission, remove plugs from VDP ports, and connect suction hose, hydraulic hose, drain case line, and load sense line to VDP assembly. See Hydraulic Gear Pump 1900YRM1136 for more information.

See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine.

15. Remove caps from fuel lines and connect fuel lines at engine. Tighten hose clamps (if equipped). 16. For lift trucks equipped with Cummins 4.5L, QSB 3.3L, or Kubota diesel engines, install battery and battery tray using three capscrews. 17. For lift trucks equipped with GM 4.3L engine, install battery, battery tray, and Electronic Control Module (ECM). 18. Install Power Distribution Module to battery tray and connect ground strap to lift truck frame. See Figure 34. 19. Connect positive batter (B+) cable to starter motor. Tighten terminal nut to 8 to 11 Nâ&#x20AC;¢m (71 to 97 lbf in). 20. Connect negative battery cable to starter motor. 21. Connect engine harness connector to right hand chassis harness connector. See Figure 25 for lift trucks equipped with a GM 4.3L engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L engine and dual hydraulic tanks. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012.

See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 22. For lift trucks equipped with GM 4.3L or Kubota 3.8L engine, connect engine harness connectors to Electronic Control Module (ECM). See Figure 25 for lift trucks equipped with a GM 4.3L engine and single hydraulic tank. See Figure 26 for lift trucks equipped with a GM 4.3L engine and dual hydraulic tanks. See Figure 28 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.8L diesel engine, manufactured before February, 2012.

26. Connect air filter hose to air inlet and tighten clamp.

See Figure 30 for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.8L diesel engine.

28. Close drain plug and remove caps and connect coolant hoses to radiator. Tighten hose clamps and fill cooling system with antifreeze. See Cooling System 0700YRM1123 for radiator refill procedures. Install radiator cap.

NOTE: Perform Step 23 for lift truck models equipped with GFI fuel system. 23. For lift trucks equipped with GM 4.3L LPG engine, connect left hand chassis harness connector to LPG regulator connector and engine harness connector. See Figure 25. 24. For lift trucks equipped with either a GM 4.3L (gasoline) engine, Kubota 3.6L diesel engine, or a Cummins 4.5L diesel engine, connect left hand chassis harness connector to engine harness connector. See Figure 25 for lift trucks equipped with a GM 4.3L gas or LPG engine. See Figure 31 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) equipped with a Kubota 3.6L diesel engine, manufactured before February, 2012. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5,GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813), manufactured after February, 2012, equipped with a Kubota 3.6L diesel engine. See Figure 32 for lift trucks models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with a Kubota 3.6L diesel engine. See Figure 33 for lift trucks equipped with a Cummins 4.5L diesel engine. 25. Install air filter and bracket assembly.

0100 YRM 1243

27. For lift trucks equipped with Cummins 4.5L diesel engine, connect throttle cable to fuel injection pump. See Figure 33.

29. Check all fluid levels as described in Periodic Maintenance 8000YRM1248 for lift truck models •

GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818)

•

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (F813, G813)

Periodic Maintenance 8000YRM1558 for lift truck models •

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX ) (H813)

Periodic Maintenance 8000YRM1598 for lift truck model •

GLC40, 45, 55VX; GLC55SVX; (GC/ GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (F818)

Periodic Maintenance 8000YRM1604 for lift truck model •

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)

30. Install hood and seat combination, and rear side covers. See section Hood RepairHood RepairHood Repair for procedures. 31. Install overhead guard. See Overhead Guard Replacement, Install for procedures.

0100 YRM 1243

Electronic Throttle Replacement

32. Connect positive battery cable. 33. Connect negative battery cable. 34. Install floor plate and floor mat.

36. Inspect fuel system for leaks when fuel valve is open. There are four methods used to inspect fuel system for leaks: a. Sound - Listen for sound of fuel escaping from a tank fitting or hose connection. b. Smell - Fuel has a very distinctive odor. If you smell fuel, DO NOT start engine. c. Soapy Water - This method is used in conjunction with Step b above. If odor of fuel is present, but escaping fuel cannot be heard, apply soapy water to fittings and observe for bubbles. d. Frost - If the amount of fuel escaping is sufficient, frost may appear on fittings.

35. For lift trucks equipped with and LPG fuel system, swing LPG tank and bracket back to original position until locked, connect LPG fuel line, and open shutoff valve.

Electronic Throttle Replacement CUMMINS 4.5L DIESEL ENGINE WITH ELECTRONIC THROTTLE Remove 1. Disconnect engine harness electrical connector from throttle position sensor (TPS). See Figure 41. 2. Remove Torx-head screws, washers, and remove TPS and tapped TPS plate. See Figure 42. 3. Remove capscrews and TPS bracket. See Figure 43. 4. Remove TPS rotor. See Figure 44. 5. Remove capscrews, nuts, and linkage assembly. See Figure 41. 6. If necessary, remove capscrews and throttle lever adapter. See Figure 42. 7. Disconnect engine harness electrical connector from pull actuator harness connector. See Figure 45.

9. If necessary, remove clevis with linkage assembly, lockwasher, and nut from pull actuator. See Figure 45.

Install 1. Install TPS rotor and throttle lever adapter. Tighten capscrews to 7.9 Nâ&#x20AC;˘m (70 lbf in). See Figure 42. 2. Place rod end of linkage assembly on top side of throttle lever adapter and align rod end hole with hole on throttle lever adapter. See Figure 47. NOTE: When installing TPS, rotate sensor rotor clockwise to match D-shape on TPS rotor. See Figure 48. NOTE: The TPS mounting screws are non-magnetic stainless steel to avoid interference with sensor magnet and must be reused if TPS is replaced. 3. Place TPS in position and install Torx-head screws. Tighten Torx-head screws to 2.25 Nâ&#x20AC;˘m (20 lbf in). See Figure 42.

8. Remove capscrews and pull actuator from mounting bracket. See Figure 46.

Electronic Throttle Replacement

0100 YRM 1243

Figure 41. Electronic Throttle System

0100 YRM 1243

Electronic Throttle Replacement Legend for Figure 41

1. 2. 3. 4. 5.

THROTTLE POSITION SENSOR (TPS) CAPSCREW LINKAGE ASSEMBLY NUT PULL ACTUATOR

6. 7. 8. 9. 10.

CLEVIS ADJUSTMENT NUT TORX-HEAD SCREWS PULL ACTUATOR CONNECTOR ENGINE HARNESS CONNECTOR

Electronic Throttle Replacement

0100 YRM 1243

1. CAPSCREW

2. TPS BRACKET

Figure 43. TPS Bracket

1. TORX-HEAD SCREW 2. LOCKWASHER 3. TPS 4. TPS BRACKET 5. ACTUATOR 6. TPS ROTOR

7. MAGNET 8. TPS PLATE 9. THROTTLE LEVER ADAPTER 10. FUEL PUMP 11. CAPSCREWS

Figure 42. TPS Assembly

1. TPS

2. TPS ROTOR Figure 44. TPS Rotor

0100 YRM 1243

1. 2. 3. 4. 5.

Electronic Throttle Replacement

PULL ACTUATOR NUT LOCKWASHER CLEVIS WITH LINKAGE ASSEMBLY PULL ACTUATOR HARNESS CONNECTOR

Figure 45. Pull Actuator and Linkage Assembly

1. THROTTLE LEVER ADAPTER 2. ROD END

3. CLEVIS 4. CAPSCREW 5. NUT

Figure 47. Rod End and Throttle Lever Alignment

1. MOUNTING BRACKET 2. CAPSCREW

3. FUEL PUMP 4. PULL ACTUATOR 5. FOLDOVER NUT

1. SENSOR ROTOR 2. TPS

3. TPS ROTOR 4. D-SHAPE

Figure 48. TPS and Rotor

Figure 46. Pull Actuator Mounting

Electronic Throttle Replacement

0100 YRM 1243

4. Connect TPS electrical connector.

Pull Actuator Linkage Adjustment

5. Turn lever clockwise to verify that TPS does not bind or stick.

1. Check low idle stop position to see if throttle lever is in contact with low idle stop. If adjustment is necessary, refer to Step 3. See Figure 50.

6. Place pull actuator in position on mounting bracket and install capscrews. Tighten to 38 Nâ&#x20AC;˘m (28 lbf ft). See Figure 46. 7. Install clevis with linkage assembly onto threaded end of pull actuator rod. Leave loose for adjustment. See Figure 45. 8. Verify that clevis is in position shown in Figure 49. Adjust as needed. 9. Verify that rod ends of linkage assembly are parallel to each other. Adjust as needed. See Figure 49. NOTE: DO NOT force lever or pull actuator rod when installing.

2. When condition in Step 1 is met, check if actuator is fully extended by manually turning actuator to high idle position. The throttle lever should contact high idle stop. Verify that lever rotates freely, without binding or sticking. 3. If linkage adjustment is not providing enough range, remove capscrew and nut from clevis and rod ends. Lengthen or shorten linkage by loosening turnbuckle nuts to adjust threaded length of rod ends in turnbuckle. Attach adjusted rod ends to clevis with capscrew and nut. Verify lever contacts low idle stop at idle position, and lever contacts high idle stop at high idle position. Verify that lever rotates freely without sticking or binding. See Figure 50.

10. Place rod end on top side of throttle lever adapter and align rod end hole with hole on throttle lever. Install capscrew and nut and tighten to 6.8 Nâ&#x20AC;˘m (60 lbf in). See Figure 47. 11. Connect pull actuator harness connector to engine harness connector. See Figure 45.

1. 2. 3. 4. 5. 6.

PULL ACTUATOR LOCK NUT CLEVIS TURNBUCKLE NUT TURNBUCKLE ROD ENDS (MUST BE PARALLEL TO EACH OTHER) Figure 49. Linkage Assembly

1. 2. 3. 4. 5. 6. 7. 8.

TPS LOW IDLE STOP TURNBUCKLE NUT TURNBUCKLE CLEVIS LOCK NUT ADJUSTING SCREW (LOW IDLE) ROD ENDS

Figure 50. Low Idle and Pull Actuator Adjustment Location

0100 YRM 1243

Throttle Pedal and Cable Adjustment

Low Idle Adjustment

1. Loosen lock nut. See Figure 50.

CAUTION DO NOT attempt to adjust high idle speed limit screws. This may impair the safety and performance of the lift truck and shorten its engine life. If the idle speed limit screws require adjustment, see your authorized Cummins industrial engine dealer or distributor.

2. Turn adjustment screw until correct RPM, identified in Periodic Maintenance 8000YRM1248, has been set. 3. After RPM has been set. Use a screwdriver to hold adjustment screw in place and tighten lock nut.

NOTE: Make sure engine is running prior to making low idle adjustment.

Throttle Pedal and Cable Adjustment NOTE: There are no throttle pedal and cable adjustments for lift trucks equipped with GM 4.3L or Kubota 3.8L Diesel engine. The GM 4.3L and Kubota 3.8L Diesel engines have an electronic throttle that is selfadjusting and self-calibrating.

CUMMINS 4.5L DIESEL ENGINE WITH BASIC POWER SHIFT TRANSMISSION 1. Remove floor plate and disconnect throttle cable from bellcrank and engine. See Figure 51. 2. Fully depress throttle pedal and verify that dimension between bellcrank and cowl plate is 6 ±2 mm (0.24 ± 0.08 in.). See Figure 51. 3. If dimension is not correct, adjust ball ends on push rod so that a minimum of6 mm (0.24 in.) of threaded rod screws into each ball end. After adjusting push rod, tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in). 4. Connect throttle cable to bellcrank and engine. See Figure 51. 5. With throttle pedal in full up position, adjust throttle cable, using jam nuts (item #10 in Figure 51) to remove all slack from cable. Cable should be adjusted to point where additional adjustment will pull control lever off idle stop. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in).

KUBOTA 3.6L DIESEL ENGINE 1. Remove floor plate and disconnect throttle cable from bellcrank and engine. See Figure 52. 2. Fully depress throttle pedal and verify that dimension between bellcrank and cowl plate is 9 mm (0.35 in.). See Figure 52. 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. After adjusting push rod, tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in). 4. Connect throttle cable to bellcrank and engine. See Figure 52. 5. With throttle pedal in full up position, adjust throttle cable, using jam nuts (6, Figure 50) to remove all slack from cable. Cable should be adjusted to point where additional adjustment will pull control lever off idle stop. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in). 6. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate. Tighten jam nuts (6, Figure 50) to 8 to 15 N•m (71 to 133 lbf in).

6. Install floor plate. Fully depress throttle pedal and adjust pedal stop so that it touches floor plate. Tighten jam nuts to 8 to 15 N•m (71 to 133 lbf in) (item #6 in Figure 51).

Throttle Pedal and Cable Adjustment

1. 2. 3. 4. 5. 6.

COWL BELLCRANK PUSH ROD BALL END THROTTLE PEDAL JAM NUT

0100 YRM 1243

7. 8. 9. 10. 11.

PEDAL STOP THROTTLE CABLE JAM NUTS CONTROL LEVER CLAMP STRAP

Figure 51. Cummins 4.5L Throttle Pedal and Cable Adjustment

0100 YRM 1243

1. 2. 3. 4. 5.

COWL BELLCRANK PUSH ROD BALL END THROTTLE PEDAL

Throttle Pedal and Cable Adjustment

6. 7. 8. 9. 10.

JAM NUT PEDAL STOP THROTTLE CABLE CABLE BRACKET CONTROL LEVER

Figure 52. Kubota 3.6L Throttle Pedal and Cable Adjustment

Exhaust System Repair

0100 YRM 1243

Exhaust System Repair GM 4.3L ENGINE FOR LIFT TRUCK MODELS GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/ GLC120VXPRS) (E818, F818) AND GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813) NOTE: For lift trucks equipped with engine indicated above, see Fuel System service manual for your lift truck model.

CUMMINS 4.5L DIESEL ENGINE FOR LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813) Remove

5. Remove clamp that attaches exhaust pipe (13, Figure 53) to exhaust pipe (1, Figure 53). 6. Remove flange cover and three flange bolts that secures exhaust pipe to counterweight and remove exhaust pipe. 7. Remove counterweight. See section Counterweight Replacement for removal procedures for counterweight. 8. Remove clamps that attach exhaust pipes (1 and 4, Figure 53) to muffler. 9. Remove exhaust pipe (4, Figure 53) from engine exhaust manifold and remove exhaust pipe from muffler. Discard gasket. 10. Remove washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame. Remove muffler from lift truck frame.

Inspect

WARNING Exhaust system components are hot to touch. Be sure exhaust system components are cool before starting disassembly, or personal injury may occur.

Inspect following items in exhaust system: •

Inspect all exhaust pipes for damage, corrosion, and rust. Replace as needed.

•

If equipped, inspect all exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as needed. If replacing an exhaust pipe section that has a wrap, also replace wrap. DO NOT reuse wraps if they have been removed for a service operation.

•

Inspect muffler for damage, corrosion, and rust. Replace as needed.

NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 4. Lift trucks equipped with overhead exhaust follow Step 5 through Step 10. 1. Remove counterweight before removing muffler and other components of exhaust system. See section Counterweight Replacement for removal procedures for counterweight. 2. Remove clamps that attach exhaust pipes (1 and 4, Figure 53) to muffler. Remove exhaust pipe (1, Figure 53) from muffler. 3. Remove exhaust pipe (4, Figure 53) from engine exhaust manifold and remove exhaust pipe from muffler. Discard gasket. 4. Remove washers, isolators, spacers, locknuts, and capscrews that attach muffler to lift truck frame. Remove muffler from lift truck frame. NOTE: The exhaust pipe (13, Figure 53) must be removed before removing counterweight and other components of exhaust system.

Install NOTE: Lift trucks equipped with standard exhaust follow Step 1 through Step 4. Lift trucks equipped with overhead exhaust follow Step 5 through Step 10. 1. Place muffler on lift truck frame and install washers, isolators, spacers, locknuts, and capscrews to attach muffler to lift truck frame. Tighten locknuts to 22 N•m (195 lbf in). 2. Connect exhaust pipes (1 and 4, Figure 53) to muffler and install clamps to attach exhaust pipes to muffler.

0100 YRM 1243

Exhaust System Repair

3. Install new gasket and install exhaust pipe (4, Figure 53) to engine exhaust manifold. Tighten locknuts to 22 Nâ&#x20AC;¢m (195 lbf in).

4. Install counterweight. See section Counterweight Replacement for installation procedures for counterweight.

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13.

EXHAUST PIPE CLAMP MUFFLER EXHAUST PIPE LOCKNUT GASKET WASHER

ISOLATOR SPACER CAPSCREW FLANGE BOLT (OVERHEAD EXHAUST) FLANGE COVER (OVERHEAD EXHAUST) EXHAUST PIPE (OVERHEAD EXHAUST)

Figure 53. Cummins 4.5L Diesel Engine Exhaust System

Exhaust System Repair 5. Place muffler on lift truck frame and install washers, isolators, spacers, locknuts, and capscrews to attach muffler to lift truck frame. Tighten locknuts to 22 N•m (195 lbf in). 6. Install new gasket and install exhaust pipe (4, Figure 53) to engine exhaust manifold. Tighten locknuts to 22 N•m (195 lbf in). 7. Connect exhaust pipes (1 and 4, Figure 53) to muffler and install clamp to attach exhaust pipe to muffler. 8. Install counterweight. See section Counterweight Replacement for installation procedures for counterweight. 9. Connect exhaust (13, Figure 53) to exhaust pipe (1, Figure 53) and install clamp to attach exhaust pipe (13) to exhaust pipe (1). 10. Install three flange bolts to secure tail pipe to counterweight and place flange cover over flange bolts.

0100 YRM 1243 1. Remove clamp attaching overhead guard exhaust pipe to lower overhead guard exhaust pipe. See Figure 54. 2. Remove capscrews from flange cover. 3. Remove overhead exhaust pipe and flange cover from counter weight. 4. Remove counterweight from lift truck. See Counterweight Replacement. 5. Remove clamp and lower overhead guard exhaust pipe from muffler. 6. Remove turbo manifold–exhaust wrap, upper header–exhaust wrap, bellow pipe–exhaust wrap, lower header–exhaust wrap, and upper tail pipe– exhaust wrap. 7. Remove turbo exhaust clamp. 8. Remove clamp from muffler and upper tail pipe, and remove muffler from lift truck.

CUMMINS QSB 3.3L ENGINE FOR LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)

9. Remove clamp from upper tail pipe and lower header exhaust pipe, and disconnect upper tail pipe from lower header exhaust pipe.

Remove

11. Disconnect lower exhaust pipe from bellow pipe.

10. Remove clamp from lower header exhaust pipe and exhaust mounting bracket.

12. Disconnect bellow pipe from upper header exhaust pipe. 13. Disconnect upper header exhaust pipe from turbo manifold exhaust.

0100 YRM 1243

1. 2. 3. 4. 5. 6. 7. 8. 9.

Exhaust System Repair

OVERHEAD EXHAUST PIPE FLANGE COVER CLAMP MUFFLER UPPER TAILPIPE UPPER TAILPIPE-EXHAUST WRAP LOWER HEADER-EXHAUST WRAP LOWER HEADER-EXHAUST PIPE BELLOW PIPE-EXHAUST WRAP

10. 11. 12. 13. 14. 15. 16. 17. 18.

BELLOW PIPE UPPER HEADER-EXHAUST WRAP UPPER HEADER-EXHAUST PIPE TURBO EXHAUST CLAMP TURBO MANIFOLD-EXHAUST WRAP EXHAUST MOUNTING BRACKET LOWER EXHAUST PIPE-OVERHEAD CAPSCREW EXHAUST PIPE

Figure 54. Cummins QSB 3.3 Engine Exhaust System 81

Exhaust System Repair

Inspect Inspect following items in exhaust system:

0100 YRM 1243 13. Install clamp attaching overhead guard exhaust pipe to lower overhead guard exhaust pipe. See Figure 54.

•

Exhaust pipes for damage, corrosion, and rust. Replace as needed.

•

If equipped, exhaust wraps for wear, proper fit, contamination with oil or antifreeze, gaps in coverage, failed fasteners and replace as needed. If replacing an exhaust pipe section that has a wrap, also replace wrap. DO NOT reuse wraps if they have been removed for a service operation.

KUBOTA DIESEL ENGINE FOR LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) AND GLP/GDP40VX5/ VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) EQUIPPED WITH KUBOTA 3.6L DIESEL ENGINE

•

Muffler for damage, corrosion, and rust. Replace as needed.

Remove

Install NOTE: When installing clamps, make sure pipe ends are not deformed. 1. Connect upper header exhaust pipe to turbo manifold exhaust. 2. Connect bellow pipe to upper header exhaust pipe. 3. Connect lower exhaust pipe to bellow pipe. 4. Install clamp to lower header exhaust pipe and exhaust mounting brackets.

WARNING Exhaust system components are hot to touch. Be sure exhaust system components are cool before starting disassembly, or personal injury may occur. NOTE: If lift truck is equipped with standard exhaust system, go to Step 6. 1. Remove clamp attaching overhead guard exhaust pipe to lower overhead guard exhaust pipe. See Figure 55. 2. Remove capscrews from flange cover. See Figure 55.

5. Install clamp to upper tail pipe and lower header exhaust pipe, and install upper tail pipe to lower header exhaust pipe.

3. Remove overhead exhaust pipe and flange cover from counter weight. See Figure 55.

6. Install clamp to muffler and upper tail pipe, and install muffler to frame of lift truck.

4. Remove counterweight from lift truck. See Counterweight Replacement.

7. Install turbo exhaust clamps.

5. Remove clamp and exhaust pipe from muffler. See Figure 55.

8. Install upper tail pipe-exhaust wrap, lower headerexhaust wrap, bellow pipe-exhaust wrap, upper header-exhaust wrap, and turbo manifold-exhaust wrap. 9. Install clamp and lower overhead guard exhaust pipe to muffler. 10. Install counterweight to lift truck. See Counterweight Replacement. 11. Install over head exhaust pipe and flange cover to counterweight. 12. Install capscrews to flange cover.

6. Remove turbo manifold–exhaust wrap, header– exhaust wrap, bellow pipe–exhaust wrap, and exhaust pipe wrap from exhaust system. See Figure 55. 7. Remove clamp from muffler and tail pipe. Remove muffler from lift truck. See Figure 55. 8. Remove two clamps from exhaust pipe and two exhaust mounting brackets. See Figure 55. 9. Remove clamp from bellow pipe and header exhaust pipe. Disconnect tail pipe from bellow pipe. See Figure 55.

0100 YRM 1243

Exhaust System Repair

NOTE: LIFT TRUCKS EQUIPPED WITH AIR CONDITIONING WILL HAVE A 101.6 mm (4 in.) EXHAUST EXTENSION (NOT SHOWN) ON OVERHEAD EXHAUST PIPE. 1. 2. 3. 4. 5. 6. 7. 8.

MUFFLER EXHAUST PIPE EXHAUST PIPE WRAP BELLOW PIPE-EXHAUST WRAP BELLOW PIPE HEADER-EXHAUST WRAP HEADER-EXHAUST PIPE CLAMP

9. 10. 11. 12. 13. 14. 15.

TURBO MANIFOLD-EXHAUST WRAP EXHAUST MOUNTING BRACKET NUT TAILPIPE CAPSCREW FLANGE COVER OVERHEAD EXHAUST PIPE

Figure 55. Kubota Engine Exhaust System

Exhaust System Repair

Inspect Inspect following items in exhaust system: •

Exhaust pipes for damage, corrosion, and rust. Replace as needed.

•

Muffler for damage, corrosion, and rust. Replace as needed.

Install NOTE: Lift trucks equipped with standard exhaust follow steps Step 1 through Step 6. NOTE: When installing clamps, make sure pipe ends are not deformed. 1. Connect tail pipe to bellow pipe. See Figure 55. 2. Connect bellow pipe to header exhaust pipe. See Figure 55. 3. Install clamp to bellow pipe and header exhaust pipe. See Figure 55. 4. Install two clamps to exhaust pipe and two exhaust mounting brackets. See Figure 55. 5. Install muffler onto frame of lift truck. Install clamp to muffler and tail pipe. See Figure 55. 6. Install exhaust pipe-exhaust wrap, bellow pipe-exhaust wrap, header-exhaust wrap, and turbo manifold-exhaust wrap. See Figure 55. 7. Install clamp and exhaust pipe to muffler. See Figure 55.

0100 YRM 1243

KUBOTA DIESEL ENGINE FOR LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) Remove

WARNING The lift truck must be put on blocks for some types of maintenance and repairs. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: •

Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or the Periodic Maintenance section for your lift truck. NOTE: A Parked Regeneration should be performed prior to removing DPF for service. See Step 3 for procedures. NOTE: Some components may require penetrating lubrication to assist in their removal. DO NOT apply penetrating lubrication to gaskets or electronics. NOTE: Allow exhaust components to cool before attempting to service them. 1. Put lift truck on blocks. See the procedure How to Put Lift Truck on Blocks in the Operating Manual or Periodic Maintenance 8000YRM1604.

8. Install counterweight to lift truck. See Counterweight Replacement.

2. Disconnect negative battery cable from battery.

9. Install over head exhaust pipe and flange cover to counterweight. See Figure 55.

3. Remove two capscrews from counterweight and counterweight grille. See Figure 57.

10. Install capscrews to flange cover. See Figure 55.

4. Remove counterweight grille. See Figure 57.

11. Install clamp attaching overhead guard exhaust pipe to lower overhead guard exhaust pipe. See Figure 55.

0100 YRM 1243

Exhaust System Repair

A. LONG WHEEL BASE

B. SHORT WHEEL BASE

1. 2. 3. 4.

5. 6. 7. 8.

NUTS WASHERS FRAME BRACKET CLAMP

U-BOLT CLAMP BRACKET CAPSCREWS FOLD OVER NUT

Figure 56. Kubota 3.8L Diesel Engine Exhaust Repair for Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)

Exhaust System Repair

0100 YRM 1243 NOTE: Perform Step 13 for lift trucks equipped with a tail pipe exhaust. 13. Remove four lock nuts, tail pipe, and gasket from DPF. See Figure 58. 14. Remove radiator, shroud, engine fan, and coolant hoses. See Cooling System 0700YRM1123 for procedures. 15. Disconnect sensor connectors from wiring harness. Undo clips holding sensor wires. 16. Remove two capscrews securing DPF pressure sensor to frame. See Figure 60. 17. Remove two nuts, two washers, u-bolt, plate, and heat shield from exhaust pipe near exhaust manifold. See Figure 59.

1. COUNTERWEIGHT 2. COUNTERWEIGHT GRILLE 3. CAPSCREWS Figure 57. Counterweight and Grille NOTE: For lift trucks equipped with an overhead exhaust perform Step 5 through Step 7. 5. Remove flange cover and capscrews that secures overhead exhaust pipe to counterweight. See Figure 58. 6. Remove clamp that connects exhaust pipe (intermediate pipe) to overhead exhaust pipe together. See Figure 58. 7. Remove overhead exhaust pipe. NOTE: Perform Step 8 and Step 9 for lift trucks equipped with a tail pipe. 8. Remove four locknuts, tail pipe, and gasket from DPF. Discard gasket. See Figure 58. 9. Remove counterweight. See Counterweight Replacement, Remove for procedures. NOTE: Perform Step 10 through Step 12 for lift trucks equipped with an overhead exhaust system. 10. Remove two nuts, two washers, clamp, and u-bolt from exhaust pipe (elbow) and exhaust pipe (intermediate pipe). See Figure 58. 11. Remove exhaust pipe (intermediate pipe). 12. Remove four locknuts, exhaust pipe (elbow), and gasket from DPF. See Figure 58. 86

NOTE: Perform Step 18 and Step 19 on long wheel base lift trucks. 18. Remove four capscrews and foldover nuts from clamp bracket. See Figure 56. 19. Remove two nuts, two washers, clamp, and u-bolt from exhaust pipe and clamp bracket. See Figure 56. 20. Remove two nuts, two washers, clamp, and u-bolt from exhaust pipe and frame bracket. See Figure 56. 21. Remove four locknuts from exhaust pipe flange and DPF In. See Figure 59. 22. Remove four capscrews and four nuts from Diesel Particulate Filter (DPF) support brackets. See Figure 60.

WARNING The DPF is heavy. Make sure lifting device has enough capacity to lift DPF. The DPF weighs approximately 25 kg (55 lb). Make sure not to damage the DPF muffler assembly by falling or impact as it contains a ceramic filter. Even if there is no apparent damage, a dropped or shocked DPF will need to be replaced with a new one. 23. Remove four DPF support bracket capscrews and nuts from PDF to support bracket. See Figure 60. 24. Attach a lifting device to DPF and remove DPF from lift truck. Discard gaskets.

0100 YRM 1243

Exhaust System Repair

25. Store DPF in a safe location away from traffic and other potential hazards. Cap ends of DPF to prevent debris and other contaminants from entering DPF. Remove lifting device. 26. Remove four lock nuts that connect exhaust pipe (engine out) flange and exhaust manifold. See Figure 59. 27. If threads on studs in exhaust manifold are stripped or studs are damaged, remove and discard studs.

Inspect Inspect following items in exhaust system: •

Exhaust pipes for damage, corrosion, and rust. Replace as needed.

•

Exhaust pipe heat shields for damage. Replace as needed.

•

The differential pressure pipes on DPF for damage or cracking. Replace as needed.

•

DPF for damage or cracking. Replace as needed.

28. Remove exhaust pipe from lift truck. Discard gaskets.

NOTE: LIFT TRUCKS EQUIPPED WITH AIR CONDITIONING WILL HAVE A 101.6 mm (4 in.) EXHAUST EXTENSION (NOT SHOWN) ON OVERHEAD EXHAUST PIPE. A. OVERHEAD EXHAUST

B. COUNTERWEIGHT EXHAUST

1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13.

DIESEL PARTICULATE FILTER CPASCREWS GASKET LOCKNUT EXHAUST PIPE (ELBOW) NUTS WASHER

CLAMP U-BOLT EXHAUST PIPE (INTERMEDIATE PIPE) EXHAUST PIPE (OVERHEAD EXHAUST) EXHAUST FLANGE COVER TAIL PIPE

Figure 58. Kubota 3.8L Diesel Engine Overhead Exhaust

Exhaust System Repair

0100 YRM 1243

NOTE: LONG WHEEL BASE OPTION SHOWN. SHORT WHEEL BASE IS SIMILAR. 1. 2. 3. 4. 5. 6. 7.

DIESEL PARTICULATE FILTER (DPF) IN GASKET LOCKNUT DIESEL PARTICULATE FILTER (DPF) OUT EXHAUST PIPE (ENGINE OUT) U0BOLT CLAMP

8. 9. 10. 11. 12. 13.

PLATE HEATSHIELD WASHER NUT EXHAUST MANIFOLD EXHAUST PIPE (ENGINE OUT) FLANGE

Figure 59. Diesel Particulate Filter and Exhaust Pipe

0100 YRM 1243

Exhaust System Repair

Diesel Particulate Filter Disassemble 1. Remove hose clamps securing hoses to pressure tubes. See Figure 60. 2. Disconnect pressure tubes from their fittings on DPF. Mark which pressure tube goes to which fitting on DPF to aid in installation. See Figure 60.

4. Disconnect temperature sensors from fittings on DPF. Mark temperature sensors and their corresponding fittings on DPF to aid in installation. See See Figure 60. 5. Remove sixteen capscrews and nuts. See Figure 60. 6. Remove DOC from DPF collar and DPF filter compartment. See Figure 60.

3. Pull pressure tube from pressure hose on pressure sensor and remove pressure tubes from PDF. See Figure 60.

7. Remove DPF filter compartment from DPF outlet. See Figure 60.

1. DIFFERENTIAL PRESSURE SENSOR (DELTA P SENSOR) 2. DELTA P CAPSCREWS 3. CLAMPS 4. PRESSURE HOSE 5. CLIP 6. PRESSURE TUBE 7. TEMPERATURE SENSOR 8. DIESEL OXIDATION CATALYST (DOC) 9. CAPSCREW 10. NUT

11. 12. 13. 14. 15. 16. 17. 18. 19.

DPF COLAR DPF SUPPORT BRACKET CAPSCREW DPF SUPPORT BRACKET NUT DPF SUPPORT BRACKET MOUNTING BRACKET CAPSCREW MOUNTING BRACKET NUT FILTER COMPARTMENT MOUNTING BRACKET DPF OUTLET

Figure 60. Diesel Particulate Filter

Exhaust System Repair

0100 YRM 1243

CLEAN AND INSPECT It is recommended to have filter cleaned by an authorized Hyster dealer every 3000 hours. If pressure tubes are damaged or cracked discard old pressure tubs and replace with new ones. If pressure hoses are damaged or cracked, replace them with new hoses. All gaskets must be replaced with new gaskets. Once filter has been removed check to see that surface of filter compartment on exhaust gas outlet side in not darkened. If surface is darkened, check whether there are cracks or a loss of sealing part of vents on both ends of filter. If fifteen or more sealing parts are missing filter compartment cannot be reused. Before DPF compartment is cleaned or after DPF compartment has been cleaned, measure depth of ash (depth of remaining ash) with a pin gauge at positions shown in Figure 61. NOTE: Select a metal pin gauge having a wire size slightly thinner that the cell width 0.5 to 1.0 mm (0.020 to 0.039 in.) diameter. DO NOT push pin forcibly. Measurement Total

21 places

57 mm (2.2 in.)

10 mm (0.39 in.)

35 mm (1.4 in.)

138 mm (5.43 in.)

226 mm (8.9 in.)

NOTE: If depth of ash (depth of remaining ash) is out of allowable limit, filter compartment (DPF) cannot be reused. Replace filter compartment (DPF) with a new one.

A. EXHAUST INLET SIDE B. EXHAUST OUTLET SIDE 1. PIN GAUGE 2. FILTER COMPARTMENT (DPF) Figure 61. Filter Reuse Check

0100 YRM 1243

Assembly 1. Wipe off anti-seize or lubricating compound from threads of temperature sensors and pressure tube fittings. 2. Apply new anti-seize or lubricating compound to threaded ends of temperature sensors and pressure tube fittings. 3. Assemble DPF Outlet, with new gasket, onto DPF filter compartment with new or cleaned filter using eight capscrews and eight nuts. See Figure 60. DO NOT tighten capscrews and nuts. 4. Assemble DPF filter compartment, with new gasket, onto DPF collar. See Figure 60.

Exhaust System Repair 1. If studs in exhaust manifold were removed, install all studs with end stamp ISOM or M away from engine. Use new studs if studs were removed.

WARNING The DPF is heavy. Make sure lifting device has enough capacity to lift DPF. The DPF weighs approximately 25 kg (55 lb). Make sure not to damage the DPF muffler assembly by falling or impact as it contains a ceramic filter. Even if there is no apparent damage, a dropped or shocked DPF will need to be replaced with a new one. 2. Attach lifting device to DPF and install DPF into lift truck.

5. Assemble DPF collar, with new gasket, onto DOC using eight capscrews and eight nuts. See Figure 60. DO NOT tighten capscrews and nuts.

3. Install four DPF support bracket capscrews and nuts into DPF and DPF support bracket. See Figure 60. Tighten capscrews and nuts to 49 to 55 N•m (37 to 41 lbf ft).

6. In a star pattern begin tightening sixteen capscrews and nut to 49 to 55 N•m (37 to 41 lbf ft).

4. Remove lifting device and caps on ends of DPF.

7. Install mounting bracket using four mounting capscrews and four mounting nuts. See Figure 60. DO NOT tighten capscrews and nuts. 8. Install (3) temperature sensors in their designated fittings on DPF as indicated during removal. Tighten 25 to 34 N•m (18 to 25 lbf ft). See Figure 60. 9. Install hose clamps on pressure tubes. See Figure 60. 10. Install pressure tubes into hose ends at pressure sensor and tighten threaded end of pressure tube at fitting indicated during removal. See Figure 60. Tighten pressure tube fittings to 16 to 22 N•m (12 to 16 lbf ft). 11. Pinch hose clamps and slide into position sealing pressure tubes and pressure hose together. 12. Tighten four mounting capscrews and mounting nuts securing DPF on mounting bracket to 49 to 55 N•m (37 to 41 lbf ft).

Install NOTE: DO NOT tighten exhaust clamps until exhaust system has been completely installed in lift truck.

5. Install new gasket on exhaust manifold. See Figure 59. 6. Install new gasket on DPF in. See Figure 59. 7. Install exhaust pipe into lift truck. NOTE: Exhaust pipes to be installed so flex joint is in a straight line with no preload. 8. Install four locknuts securing exhaust manifold to exhaust pipe. See Figure 59. Tighten locknuts finger tight. 9. Install four locknuts securing exhaust pipe to DPF in. See Figure 59. Tighten locknuts finger tight. NOTE: Perform Step 10 and Step 11 on long wheel base lift trucks. 10. Install four capscrews and foldover nuts in clamp bracket. See Figure 56. 11. Install u-bolt onto exhaust pipe and into clamp bracket. Install two nuts and two washers onto ubolt. See Figure 56. Tighten nuts finger tight. 12. Install u-bolt onto exhaust pipe and into frame bracket. Install two nuts and two washers onto ubolt. See Figure 56. Tighten nuts finger tight.

Cooling System

0100 YRM 1243

13. Tighten locknuts (installed during Step 8) on exhaust manifold to 49 to 55 N•m (37 to 41 lbf ft). See Figure 59. 14. Tighten locknuts (installed during Step 9) on DPF in to 49 to 55 N•m (37 to 41 lbf ft). See Figure 59. 15. Install u-bolt, plate, heat shield, two washers, and two nuts onto exhaust pipe near exhaust manifold. See Figure 59. 16. Tighten nuts on clamps retaining exhaust pipe (engine out). See Figure 59 and Figure 56. 17. Connect sensor connectors to wiring harness. Redo clips holding sensor wires. 18. Install radiator, shroud, engine fan, and coolant hoses. See Cooling System 0700YRM1123 for procedures. 19. Install two capscrews securing DPF pressure sensor to frame. See Figure 60. 20. Install counterweight. See Counterweight Replacement, Install for procedures. NOTE: For lift trucks equipped with an overhead exhaust perform Step 22 through Step 30. 21. Install new gasket on DPF out. See Figure 59 and Figure 58. 22. Install exhaust pipe (elbow) and four locknuts. Tighten locknuts to 49 to 55 N•m (37 to 41 lbf ft).

24. Install overhead exhaust pipe onto exhaust pipe (intermediate pipe). 25. Install u-bolt, clamp, washers and nuts clamping together exhaust pipe (intermediate pipe) to exhaust pipe (elbow). 26. Install overhead exhaust pipe into counterweight and onto exhaust pipe (intermediate pipe). 27. Install u-bolt, clamp, washers, and nuts clamping together exhaust pipe (intermediate pipe) to overhead exhaust pipe. 28. Tighten nuts on clamps for both exhaust pipe (intermediate pipe) onto exhaust pipe (elbow) connection and exhaust pipe (intermediate pipe) to overhead exhaust pipe connection. 29. Install three capscrews into overhead exhaust pipe flange and counterweight. Tighten capscrews. 30. Install exhaust flange cover onto overhead exhaust flange. NOTE: Perform Step 31 for lift trucks equipped with a tail pipe. 31. Install tail pipe and four lock nuts onto DPF outlet. Tighten locknuts to 49 to 55 N•m (37 to 41 lbf ft). 32. Install counterweight grill using two capscrews. Tighten capscrews to 38 N•m (28 lbf ft).

23. Install exhaust pipe (intermediate pipe) onto exhaust pipe (elbow) and orientate so overhead exhaust pipe can be installed onto exhaust pipe (intermediate pipe). See Figure 58.

Cooling System DESCRIPTION The cooling system is used to cool engine and keep it at correct operating temperature. The cooling system is comprised of following main components:

•

Radiator

•

Fan and belt

•

Fan shroud

•

Coolant hoses and lines

•

Coolant reservoir

For procedures to repair, clean, inspect, and install radiator and cooling system components, refer to Cooling System 0700YRM1123.

0100 YRM 1243

Hydraulic Filter Assembly Repair

Hydraulic Filter Assembly Repair REMOVE WARNING At operating temperature, the hydraulic oil is HOT. DO NOT permit the hot oil to touch the skin and cause a burn.

3. Remove head, quad ring, two fittings, and two Orings from hydraulic filter assembly. Discard quad ring and O-rings. 4. Remove and discard O-ring from bowl assembly.

CAUTION DO NOT permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed. Dirt can cause damage to the components of the hydraulic system. Never operate the hydraulic pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. NOTE: When disconnecting hydraulic hoses, note location of hoses to aid in installation. NOTE: Have a container large enough to hold filter assembly and allow for final hydraulic oil draining. 1. Put lift truck on a level surface and lower carriage. Loosen hose clamps. Disconnect hydraulic hoses and pressure sensor from hydraulic oil filter assembly. Install caps and covers on hoses to prevent foreign matter from getting into hydraulic system. Unscrew four capscrews from filter assembly. See Figure 62. Lift hydraulic filter assembly enough to allow hydraulic oil to drain from assembly into hydraulic reservoir. 2. Remove hydraulic filter assembly from hydraulic reservoir and place into container.

DISASSEMBLE 1. Remove lid, spring, and O-ring from hydraulic filter assembly. Discard O-ring. See Figure 62. 2. Remove and discard filter and O-ring from hydraulic filter assembly. DO NOT allow dirt to enter filter assembly or other hydraulic components.

1. 2. 3. 4. 5.

LID SPRING O-RING CAPSCREW HEAD

6. 7. 8. 9.

FITTING QUAD RING FILTER BOWL

Figure 62. Hydraulic Filter Assembly

Fuel and Hydraulic Tanks Repair

CLEAN

0100 YRM 1243 3. Lubricate new O-ring with hydraulic oil and seat in filter element. Install new filter element in hydraulic filter assembly.

WARNING Cleaning solvents can be flammable and toxic and may cause skin irritation. When using cleaning solvents, always follow the safety instructions of the solvent manufacturer.

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local Yaledealer. Use solvent to clean any accumulation of dirt or loose paint from all hydraulic filter assembly parts. Use a clean, lint-free cloth to dry parts prior to inspection.

4. Lubricate new O-ring with hydraulic oil and install O-ring, spring, and lid on hydraulic filter assembly.

INSTALL 1. Install hydraulic filter assembly in hydraulic reservoir with four capscrews. Tighten capscrews to 19 N•m (168 lbf in). See Figure 62. NOTE: Step 2 only applies to lift truck model GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813).

INSPECT

2. Install hydraulic filter assembly in hydraulic reservoir with four capscrews. Tighten capscrews to 8 to 10 N•m (71 to 97 lbf in). See Figure 62.

Make a visual inspection of all hydraulic filter assembly parts for dents, holes, nicks, or scratches. Replace any worn or damaged parts.

3. Connect pressure sensor and hydraulic hoses to hydraulic filter assembly as noted during removal. Tighten hose clamps

ASSEMBLE

4. Fill hydraulic tank with correct hydraulic oil and check hydraulic oil level. See the appropriate Periodic Maintenance service manual for your lift truck, for the correct hydraulic oil type and capacity.

1. Lubricate new O-ring with hydraulic oil and install, with bowl, on head. See Figure 62. 2. Lubricate new quad ring with hydraulic oil and install on head. Lubricate two O-rings with hydraulic oil and install, with two fittings, on head.

Fuel and Hydraulic Tanks Repair INSPECT WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside a building, make sure there is enough ventilation. See the following manuals for additional information:

•

Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 1999.

•

Safety in Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.

WARNING DO NOT use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

CAUTION Additives may damage the hydraulic system. Before using additives, contact your local dealer. Make a visual inspection of all sides of tank. Inspect welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

0100 YRM 1243 1. Place a drain pan with enough capacity to hold all fluid from tank under tank's drain plug. 2. Remove drain plug and drain contents of tank into drain pan. 3. After all fluid has been drained, reinstall drain plug and remove drain pan from under lift truck.

CLEAN WARNING When cleaning the tank, DO NOT use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control pressure of steam by a valve installed at nozzle of hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between nozzle and tank. Connect a ground wire to tank to prevent static electricity.

Fuel and Hydraulic Tanks Repair

WARNING Be careful when cleaning with steam. Steam can cause serious burns. Wear protective clothing, gloves, and eye protection. Never expose your skin to steam. Use following procedure to clean tank with steam: 1. Remove all parts from tank. Install drain plug. 2. Fill tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water. 3. Mix solution in tank using air pressure. Make sure all surfaces on inside of tank are flushed with solution. Drain tank. 4. Put steam into tank until tank does not have odors and metal is hot. Steam vapors must come from all openings. 5. Flush inside of tank with boiling water. Make sure all loose material is removed from inside of tank. 6. Make an inspection of inside of tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors. 7. Put plugs in all openings in tank. Wait 15 minutes, then remove inlet and outlet plugs. Test a sample of vapor with a special indicator for gas vapors. If amount of flammable vapors is above lower flammable limit, repeat cleaning procedures.

Steam Method of Cleaning

Safety Labels

Chemical Solution Method of Cleaning

WARNING When cleaning the tank, DO NOT use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

0100 YRM 1243 See manual Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. Fill tank with water to just below point where work will be done. Make sure space above level of water has a vent. 2. Use acceptable welding practices to repair tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

SMALL LEAKS, REPAIR Use following procedure to repair small leaks:

CAUTION Disposal of lubricants, fluids, and chemicals must meet local environmental regulations. If tank cannot be cleaned with steam, use following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkaline base. Follow instructions given by manufacturer. 2. Fill tank with cleaning solution. Use compressed air to mix solution in tank. 3. Drain tank. Flush inside of tank with hot (boiling) water. Make sure all cleaning compound is removed. 4. Make an inspection of inside of tank. If tank is not clean, repeat Step 1 through Step 3. Make another inspection of tank. When making inspections, use a light that is approved for locations with flammable vapors. 5. Check tank for flammable vapors using special indicator for gas vapors. If amount of flammable vapors is not below lower flammable limit, repeat cleaning procedures.

ADDITIONAL PREPARATIONS FOR REPAIR If nitrogen gas or carbon dioxide gas is available, prepare tank for welding using these gases.

1. Use steam to clean area around leak. Remove all paint and dirt around leak. 2. Apply LoctiteÂŽ 290 to leak. Follow instructions of manufacturer.

LARGE LEAKS, REPAIR 1. Use one of procedures described under Clean to clean and prepare tank for repairs. 2. Contact your dealer for lift trucks for welding instructions. 3. Use acceptable welding practices to repair tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

PREPARATIONS FOR USE AFTER REPAIR 1. Add more water to tank so that water goes above point of where work was done. Check for any leaks coming from tank. 2. If there are no leaks coming from tank, remove all water from the tank.

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