GLC/GDC60VX, GLC/GDC70VX (C879)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 524288189 0100 YRM 1316 08/13
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM (GM 4.3L)...................................................................................... 524262275 0900 YRM 1242 08/12
THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... 524288194 1300 YRM 1317 03/13
TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... 524294873 1300 YRM 1343 03/14
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)................... 524288199 1400 YRM 1318 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... 524294878 2100 YRM 1328 02/14
HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 524223772 2200 YRM 1142 04/14
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)................................................................................ 524265342 4000 YRM 1250 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
DIAGRAMS..................................................................................................................... 524223779 8000 YRM 1152 04/14
PERIODIC MAINTENANCE............................................................................................ 524288207 8000 YRM 1319 01/14
CAPACITIES AND SPECIFICATIONS........................................................................... 524288212 8000 YRM 1320 12/12
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
9000 YRM 1112 ON CD
PART NO. 524288184 (12/14)
100 YRM 1316 Description

General
• GM Engines, 4.3 Liter V-6 600 YRM 1251
WARNING • Kubota Diesel 3.8L Engines 600 YRM 1557
The lift truck must be put on blocks for some types
of maintenance and repairs. The removal of the If additional transmission repairs are necessary for lift
following assemblies will cause large changes in trucks covered in this manual see:
the center of gravity: mast, drive axle, engine and • Powershift Transmission, Repair 1300 YRM 1129
transmission, and counterweight. When the lift • Powershift Transmission, Repair 1300 YRM 1529
truck is put on blocks, put additional blocks in the • One and Two Speed Transmissions, Repair 1300
following positions to maintain stability: YRM 1569
• Before removing the mast and drive axle, put • Three-Speed Powershift Transmission Repair
blocks under the counterweight so the lift truck 1300 YRM 1317
cannot fall backward. • Two-Speed Powershift Transmission Repair 1300
• Before removing the counterweight, put blocks YRM 1343
under the mast assembly so the lift truck cannot
fall forward. This section contains the description of the frame (see
Figure 1) and connected parts. Procedures for remov-
The surface must be solid, even, and level when ing and installing the counterweight, hood, overhead
the lift truck is put on blocks. Make sure any blocks guard, engine and transmission, and exhaust system
used to support the lift truck are solid, one-piece are found in this section. Checks for the operator re-
units. See the procedure How to Put Lift Truck straint system and procedures for the repair of tanks
on Blocks in the Operating Manual or the Periodic and installation of safety labels are also included.
Maintenance section for your lift truck.

If additional engine repairs are necessary for lift trucks

covered in this manual see:

Description
The frame is one weldment and includes the hydraulic The overhead guard, cowl, and hood are installed on
tank and fuel tank for gasoline or diesel fuel. See Fig- the frame. The hood is connected to the frame with
ure 1. hinges. Two gas-controlled springs provide assistance
when raising the hood and hold the hood in the open po-
There is a counterweight for each capacity of lift truck. sition. The floor plate and side covers can be removed
The counterweights are similar in appearance, but are for access to the engine, transmission, and other com-
different weights. See Table 2. ponents.
The muffler is fastened to the frame inside the counter-
weight.

1
Description 100 YRM 1316

1. COWL PLATE 4. COUNTERWEIGHT MOUNTS

2. FENDERS 5. HYDRAULIC TANK
3. HOOD MOUNTS 6. FUEL TANK (GAS OR DIESEL)

Figure 1. Frame

2
100 YRM 1316 Hood, Seat, Dash, and Side Covers Replacement

Hood, Seat, Dash, and Side Covers Replacement

REMOVE • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879,
1. Remove the floor mat and floor plate. See Figure 3. D879)
2. Slide the seat to the closest position to the steering LPG Fuel System, GM 4.3L Engine With PSI 900
column. YRM 1556 for lift truck models:
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
3. Fully tilt the steering column forward.
GDC135VX, GC/GLC/GDC155VX) (D879, E879,
4. If your truck is equipped with an LPG tank, swing F879)
the tank off to the side. Push in the bracket re-
5. Raise the hood latch, unlatch and lift up the hood.
lease pin, swing the tank and bracket out to the
See Figure 2.
side of the lift truck. If your truck is equipped with
a swing-out and drop-down LPG tank bracket (EZ 6. Remove the two capscrews holding the left and
Tank Bracket), swing the tank down to the side of right rear side panel to the frame. Remove the rear
the truck for ease of removal. See one of the fol- side panel from the frame. See Figure 3.
lowing Service Manuals for procedures to swing
the LPG tank to the side.

LPG Fuel System, GM 4.3L Engine With GFI 900

YRM 1242 for lift truck models:

3
Hood, Seat, Dash, and Side Covers Replacement 100 YRM 1316

NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.

A. SIDE VIEW OF HOOD AND SEAT D. 3-D VIEW OF VENTED HOOD WITH SWIVEL
B. SIDE VIEW OF HOOD SEAT
C. BOTTOM VIEW OF HOOD
1. SEAT 10. SEAT WIRE HARNESS BRACKETS
2. HOOD 11. SEAT LINER
3. FRAME 12. HOOD LATCH
4. SEAT WIRE HARNESS 13. ATTACHMENT HOLES ATTACHING HOOD TO
5. SEAT WIRE HARNESS CONNECTOR SEAT (NON-SUSPENSION)
6. CABLE CLIPS 14. ATTACHMENT HOLES ATTACHING HOOD TO
7. HINGE SCREWS SEAT (FULL SUSPENSION)
8. GAS SPRING 15. SPACER
9. ATTACHMENT HOLES ATTACHING HOOD TO 16. FLANGE NUTS
SEAT (SEMI-SUSPENSION)

Figure 2. Hood and Seat Arrangement

4
100 YRM 1316 Hood, Seat, Dash, and Side Covers Replacement

1. DEBRIS COVER 10. FLOOR PLATE

2. COUNTERWEIGHT COVER 11. SPLASH SHIELD
3. RADIATOR COVER (GAS AND DIESEL)
4. LEFT SIDE REAR PANEL (GAS AND DIESEL 12. CAPSCREW
SHOWN) 13. FOLD OVER NUT
5. RIGHT SIDE REAR PANEL 14. SEAL PLATE ASSEMBLY
6. UPPER STEERING 15. RIGHT SIDE FRONT
COLUMN COVER FENDER COVER
7. LOWER STEERING 16. RIGHT SIDE STEP PLATE
COLUMN COVER 17. RIGHT SIDE STEP PLATE
8. SEAL 18. DASH ASSEMBLY
9. FLOOR MAT 19. KICK PANEL

Figure 3. Side Covers, Floor Plate, and Cowl Components

5
Hood, Seat, Dash, and Side Covers Replacement 100 YRM 1316

7. Remove the two capscrews holding the left and cable clips from the seat wire harness. If truck is
right fender covers to the front overhead guard leg. equipped with a swivel seat, remove seat wire har-
Remove covers. See Figure 3. ness from seat wire harness bracket attached to the
underside of the hood and behind the seat. See
8. Remove the four capscrews holding the left and Figure 2.
right front side panels to the frame. Remove pan-
els. 16. Remove the four flange nuts holding the seat to the
hood. Lift the seat off the hood. Pull the seat wire
9. Fully lower the steering column. harness through the hood. See Figure 2.
10. Remove upper steering column cover by pulling 17. Remove the capscrews and washers at the top of
up on upper steering column cover to release the the gas springs. Remove gas springs from the
latches (one on either side), and pulling cover away hood. See Figure 2.
from steering column. See Figure 4.
18. Remove the hinge screws, located in the rear of the
11. Remove the five fasteners (see Figure 4) securing hood.
the dash to the top of the cowl. Remove the four
clips, located underneath dash, that attach the dash 19. Lift the hood from the truck. See Figure 2.
to the kick panel. Lift to remove the dash.
INSTALL
12. Lift the kick panel to remove it from the truck. See
Figure 3. 1. Place the hood onto the lift truck frame.

13. Remove the three capscrews holding the seal plate. 2. Install the hinge screws, located in the rear of the
Remove seal plate. See Figure 5. hood, and tighten to 38 N•m (28 lbf ft). See Fig-
ure 2.
14. Disconnect the seat wire harness connector. See
Figure 2. 3. Align the holes in the gas springs with holes in the
hood. There are two sets of holes used to install
the gas springs to the hood, based on the type of
CAUTION seat the installed on the lift truck. One set is for
When removing the seat from the hood, do not use installing the cylinder end of the gas springs and
an impact wrench to remove the capscrews. Dam- the other set is for attaching the rod end of the
age can be caused to the threads on the screws and gas springs. Install capscrews and washers to at-
in the holes. tach gas springs to the hood. Refer to Figure 6
and Table 1 for correct holes used to connect the
15. If the seat is to be removed, and truck is equipped
rod end of the cylinder, depending on the type of
with a non-swivel seat, remove the seat wire har-
seat installed on the lift truck. Tighten capscrews
ness from the seat wire harness brackets that are
to 19.2 N•m (170 lbf in).
attached to the underside of the hood. Remove the

6
100 YRM 1316 Hood, Seat, Dash, and Side Covers Replacement

NOTE: TOP VIEW OF DASH SHOWN.

A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN SCREWS 3. UPPER STEERING COLUMN COVER
2. COWL 4. LOWER STEERING COLUMN COVER

Figure 4. Remove Dash From Cowl

7
Hood, Seat, Dash, and Side Covers Replacement 100 YRM 1316

1. CAPSCREWS 2. SEAL PLATE

Figure 5. Remove Seal Plate From Dash

8
100 YRM 1316 Hood, Seat, Dash, and Side Covers Replacement

NOTE: SEE TABLE 1 FOR HOLES TO USE TO ATTACH ROD END OF GAS SPRING.
A. LEFT SIDE C. FULL SUSPENSION SEAT
B. RIGHT SIDE D. NON-SUSPENSION SEAT
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

Figure 6. Gas Spring Installation

9
Hood, Seat, Dash, and Side Covers Replacement 100 YRM 1316

Table 1. Gas Spring Installation, Holes for Installing Rod Ends (See Figure 6)

Counterweight Full or Semi Suspension Seat Non-Suspension Seat

Type
Left Side Right Side Left Side Right Side
Standard 2 2 1 1
Counterweight

4. Install latch striker in highest slot position. Check 7. Align the holes in the seat with the holes in the
that latch striker is in center of jaws of hood latch hood. Insert washers and capscrews. Tighten cap-
when hood closes. Open and close the hood to en- screws to 18 N•m (159 lbf in).
sure that the center pin strikes the hood latch prop-
erly and that the stop screw contacts the frame. A 8. If truck is equipped with a non-swivel seat, tie cable
properly closed hood MUST click twice on the hood clips to seat wire harness and insert harness into
latch. If the hood latch does not close properly, seat wire harness brackets under hood. If truck is
loosen the capscrews on the back of the center pin equipped with a swivel seat, secure seat harness
and adjust the center pin up or down as required for to bracket. See Figure 2.
correct alignment. See Figure 7.
9. Check operation of hood latch. Have an opera-
5. Push down until hood just touches rubber bumper. tor sit in the seat. Make sure hood is fully closed
Make sure latch striker is still in center of hood latch. (two clicks). Also check that hood touches rubber
Open hood and tighten capscrews for latch. bumper. If necessary, repeat Step 5.

10. Using three capscrews, Install seal plate. See Fig-

CAUTION ure 5.
When installing the seat to the hood, do not use an
11. Install kick panel onto truck. See Figure 3.
impact wrench to install the capscrews. Damage
can be caused to the threads on the screws and in 12. Install dash and allen screws to top of cowl. See
the holes. Figure 4. Tighten capscrews to 0.5 to 0.6 N•m (5 to
6 lbf in).
6. Place the seat on the hood and thread the seat wire
harness through the hole in the hood. See Figure 2. 13. Install four clips to attach the dash to kick panel.
See Figure 4.

10
100 YRM 1316 Hood, Seat, Dash, and Side Covers Replacement

14. Install upper and lower steering column covers by

connecting the two covers together and pressing
each side until latched.

15. Using four capscrews, install the left and right front
side panels to frame. See Figure 3.

16. Using two capscrews install the left and right fender
covers to front of overhead guard legs.

17. Using two capscrews, install the left and right rear
side covers to frame. See Figure 3.

18. Install the floor mat and floor plate.

19. If truck is equipped with an LPG tank, swing

LPG tank into position on back of counterweight.
See one of the following Service Manuals for
procedures to swing the LPG tank onto the coun-
terweight.

LPG Fuel System, GM 4.3L Engine With GFI 900

YRM 1242 for lift truck models:
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879,
D879)

LPG Fuel System, GM 4.3L Engine With PSI 900

YRM 1556 for lift truck models:
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (D879, E879,
F879)

20. Adjust the steering column and seat positions. 1. HOOD 3. CENTER PIN
2. HOOD LATCH 4. CAPSCREW

Figure 7. Hood Latch Adjustment

11
Steering Column 100 YRM 1316

Steering Column
DESCRIPTION NOTE: Perform Step 5 for lift trucks equipped with gas
or LPG engines.
This section describes the repair procedures for the
steering column. The steering column assembly 5. Remove four capscrews, four bushings and steer-
mounts to the cowl inside the operator compartment ing column from cowl standoffs. See Figure 10.
and is the mechanical connection between the steering
wheel and the steering control unit. The steering col- NOTE: Perform Step 6 for lift trucks equipped with
umn includes the steering wheel, housing, bracket and diesel engines.
lower shaft. For lift trucks with gas and LPG engines,
6. Remove four capscrews, four bushings, four isola-
bolts and bushings attach the steering column to the
tors, steering column and four isolators from cowl
cowl standoffs. For lift trucks with diesel engines, bolts,
standoffs. See Figure 10.
bushings and isolators attach the steering column to
the cowl standoffs. See Figure 8.
Disassemble
STEERING COLUMN REPAIR NOTE: Remove and discard snap rings if installed.

Remove 1. Remove two pins and gas spring from housing.

1. Put blocks on each side (front and back) of tires to See Figure 11, for lift trucks manufactured before
prevent lift truck from moving. January, 2012.

See Figure 12, for lift trucks manufactured after Jan-

WARNING uary, 2012.
Disconnect the battery before removing any covers
to avoid injury to personnel. 2. Remove two pivot bolts, two bushings, two nuts and
bracket from housing.
2. Attach a tag on battery connector or negative bat-
tery cable stating, DO NOT CONNECT BATTERY. See Figure 11, for lift trucks manufactured before
Move steering column to most FORWARD position. January, 2012.

See Figure 12, for lift trucks manufactured after Jan-

CAUTION uary, 2012.
If a puller tool is used to remove steering wheel
from steering column, be careful not to damage 3. Remove split pin and lower shaft from upper shaft.
horn wires.
See Figure 11, for lift trucks manufactured before
NOTE: This procedure is for removal of all components January, 2012.
of steering column assembly. Not all components are
See Figure 12, for lift trucks manufactured after Jan-
removed for a repair procedure. Do only those steps of
uary, 2012.
procedure necessary to remove required component.
4. Remove connector from connector bracket. Re-
NOTE: Tag wires prior to disconnect.
move connector bracket, fastener, four screws and
3. Remove horn button assembly and disconnect two horn contacts from housing.
electrical wires. Remove large hex nut and steer-
See Figure 11, for lift trucks manufactured before
ing wheel from steering column. See Figure 9.
January, 2012.
4. Remove steering column covers. Remove floor
See Figure 12, for lift trucks manufactured after Jan-
mats and floor plate. See section Hood, Seat,
uary, 2012.
Dash, and Side Covers Replacement.

12
100 YRM 1316 Steering Column

1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR. 4. STEERING COLUMN

1. STEERING WHEEL Figure 9. Steering Wheel Remove/Install

2. STEERING COLUMN
3. COWL

Figure 8. Steering Column and Cowl

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

1. CAPSCREW 4. STEERING COLUMN
2. BUSHING 5. COWL STANDOFF
3. ISOLATOR

Figure 10. Steering Column Remove/Install

13
Steering Column 100 YRM 1316

Figure 11. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012

14
100 YRM 1316 Steering Column

Legend for Figure 11

1. PIN 9. CONNECTOR BRACKET
2. LOWER SHAFT 10. PIVOT BOLT
3. SPLIT PIN 11. BUSHING
4. UPPER SHAFT 12. NUT
5. HOUSING 13. GAS SPRING
6. HORN CONTACT 14. BRACKET
7. SCREW 15. CONNECTOR
8. FASTENER

15
Steering Column 100 YRM 1316

1. BRACKET 9. PIN
2. SPACER 10. LOWER SHAFT
3. JOINT 11. GAS SPRING
4. NUT 12. BOLT
5. WASHER 13. BUSHING
6. SCREW 14. CONNECTOR
7. UPPER SHAFT 15. FASTENER
8. HOUSING 16. HORN CONTACT

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

Clean 1. Clean metal parts in solvent. Remove all traces of

old lubricant and dirt. Clean nonmetal parts with
WARNING warm soapy water and a lint free cloth.
Cleaning solvents can be flammable and toxic and 2. After cleaning, dry parts with compressed air. DO
can cause skin irritation. When using cleaning NOT dry parts with a cloth.
solvents, always follow the solvent manufacturer’s
recommended safety precautions. Inspect

WARNING 1. Inspect for loose, burned, missing, cracked or dam-

aged hardware.
Compressed air is used for cleaning and drying pur-
poses, or for cleaning restrictions. Wear protective 2. Inspect all parts for dents, holes, bends, burrs, rust,
clothing (goggles/shields, gloves, etc.). Make sure corrosion or marred finishes.
the path of the compressed air is away from all per-
sonnel to avoid injury. 3. Replace all defective or damaged parts.

16
100 YRM 1316 LPG Tank and Bracket Replacement

Assemble See Figure 11, for lift trucks manufactured before

January 2012.
NOTE: This procedure is for installation of all compo-
nents of steering column assembly. Not all components See Figure 12, for lift trucks manufactured after Jan-
are removed for a repair procedure. Do only those steps uary 2012.
of procedure necessary to install required component.
Install
NOTE: Perform Step 1 only for lift trucks manufactured
before January, 2012. NOTE: Lubricate spline end of lower shaft with multi
purpose grease, see Periodic Maintenance Manual
1. Lubricate horn contact slip rings with a small for your lift truck.
amount of conductive grease (Yale P/N
582014302). NOTE: Perform Step 1 for lift trucks equipped with gas
or LPG engines.
2. Install fastener, connector bracket and connector,
two horn contacts and four screws. 1. Install steering column, four bushings and four
bolts on cowl standoffs. Tighten bolts to 38 N•m
See Figure 11, for lift trucks manufactured before (28 lbf ft). See Figure 10.
January 2012.
NOTE: Perform Step 2 for lift trucks equipped with
See Figure 12, for lift trucks manufactured after Jan- diesel engines.
uary 2012.
2. Install four isolators, steering column, four isola-
3. Assemble lower shaft and upper shaft, secure with tors, four bushings, and four bolts on cowl standoffs.
spit pin. Tighten bolts to 38 N•m (28 lbf ft). See Figure 10.
See Figure 11, for lift trucks manufactured before 3. Install floor plate, floor mats, and steering column
January 2012. covers. See section Hood, Seat, Dash, and Side
Covers Replacement.
See Figure 12, for lift trucks manufactured after Jan-
uary 2012. 4. Install steering wheel and hex nut on steering col-
umn, tighten hex nut to 40 to 54 N•m (30 to 40 lbf ft).
4. Install two pivot bolts, two bushings, two nuts and
Connect electrical wiring and install horn button.
bracket onto housing.
See Figure 9.
See Figure 11, for lift trucks manufactured before
5. Remove tag from negative battery connector and
January 2012.
connect to battery. Adjust steering column to neu-
See Figure 12, for lift trucks manufactured after Jan- tral position.
uary 2012.
6. Remove blocks from each side of tires.
5. Install gas spring and two pins on housing.

LPG Tank and Bracket Replacement

For procedures to remove and install the LPG tank, LPG LPG Fuel System, GM 4.3L Engine With GFI 900
tank bracket, and the LPG tank alignment pin, see one YRM 1242 for lift truck models
of the following Service Manuals. • GLC60VX, GLC70VX (GLC135VX, GLC155VX)
(C879, D879)
LPG Fuel System, GM 4.3L Engine With PSI 900
YRM 1556 for lift truck models LPG Fuel System, GM 4.3L Engine With PSI 900
• GLC40, 45, 55VX; GLC55SVX; (GLC080, 100, YRM 1556 for lift truck models
120VX; GLC080, 100VXBCS; GLC120SVX; • GLC60VX, GLC70VX (GLC135VX, GLC155VX)
GLC120VXPRS) (E818, F818) (D879, E879, F879)
• GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-
55VX (GLP080, 90, 100, 110, 120VX) (G813, H813,
J813)

17
Counterweight Replacement 100 YRM 1316

Counterweight Replacement
REMOVE NOTE: The counterweight is held in position on frame
by two hooks that are part of frame. One M30 x 3.5
WARNING x 120 capscrew holds counterweight to lower part of
frame. See Figure 13.
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the NOTE: If lift truck is equipped with an overhead exhaust
following assemblies will cause large changes in system, remove overhead exhaust pipe before remov-
the center of gravity: mast, drive axle, engine and ing counterweight. See section Exhaust System Repair
transmission, and counterweight. When the lift for procedures.
truck is put on blocks, put additional blocks in the
following positions to maintain stability: 1. If lift truck has an LPG fuel system, see one of the
• Before removing the mast and drive axle, put following Service Manuals to remove the LPG tank
blocks under the counterweight so the lift truck and bracket so that the counterweight can be re-
cannot fall backward. moved.
• Before removing the counterweight, put blocks
under the mast assembly so the lift truck cannot LPG Fuel System, GM 4.3L Engine With GFI 900
fall forward. YRM 1242 for lift truck models
The surface must be solid, even, and level when • GLC60VX, GLC70VX (GLC135VX, GLC155VX)
the lift truck is put on blocks. Make sure that any (C879, D879)
blocks used to support the lift truck are solid, one-
LPG Fuel System, GM 4.3L Engine With PSI 900
piece units. See the procedure How to Put Lift Truck
YRM 1556 for lift truck models
on Blocks in the Operating Manual or the Periodic
• GLC60VX, GLC70VX (GLC135VX, GLC155VX)
Maintenance section for your lift truck.
(D879, E879, F879)

WARNING
WARNING
DO NOT operate the lift truck if the capscrew for the
The counterweight is heavy. Make sure that the eye-
counterweight is not installed. When the capscrew
bolt and lifting devices have enough capacity to lift
is removed, the counterweight can fall from the lift
the weight. The approximate weights of the coun-
truck.
terweight castings are shown in Table 2.

WARNING 2. Install a lifting eye in lift hole of counterweight. See

LPG can cause an explosion. DO NOT cause sparks Figure 13. Connect a crane to lifting eye and raise
or permit flammable material near the LPG system. crane until it holds part of weight of counterweight.
LPG fuel systems can be disconnected indoors Remove tow pin and remove capscrew that holds
only if the lift truck is at least 8 m (26 ft) from any counterweight to frame. See Figure 13. Use crane
open flame, motor vehicles, electrical equipment, to lift counterweight from lift truck. Put counter-
or ignition source. weight on floor so that it has stability and will not
fall over. Take care not to damage exhaust or cool-
Close the shutoff valve on the LPG tank before any ing components.
part of the engine fuel system is disconnected. Run
the engine until the fuel in the system is used and INSTALL
the engine stops.
1. Make sure seals are on counterweight. See Fig-
If the engine will not run, close the shutoff valve on ure 14.
the LPG tank. Loosen the fitting on the supply hose
from the LPG tank where it enters the filter unit. 2. Use a crane to install counterweight on lift truck.
Permit the pressure in the fuel system to decrease When counterweight is installed, make sure hooks
slowly. Fuel leaving the fitting removes heat. Use a on frame fully engage counterweight so it is aligned
cloth to protect your hands from the cold fitting. with parts of frame. Install and tighten capscrew to
1020 N•m (750 lbf ft).

18
100 YRM 1316 Counterweight Replacement

3. Install tow pin and roll pin, if equipped. See section

Tow Pin for procedures.

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.

LPG Fuel System, GM 4.3L Engine With GFI 900

YRM 1242 for lift truck models
• GLC60VX, GLC70VX (GLC135VX, GLC155VX)
(C879, D879)

LPG Fuel System, GM 4.3L Engine With PSI 900

YRM 1556 for lift truck models
• GLC60VX, GLC70VX (GLC135VX, GLC155VX)
(D879, E879, F879)

5. If lift truck is equipped with an overhead exhaust

system, install overhead exhaust pipe. See section
Exhaust System Repair for procedures.

TOW PIN
Remove and Install
1. FRAME HOOK
1. Remove tow pin from counterweight by driving roll 2. SEALS
pin out. See Figure 15. 3. CAPSCREW
4. COUNTERWEIGHT COVER
2. Install tow pin into counterweight and install roll pin. 5. COUNTERWEIGHT
6. TOW PIN
7. ROLL PIN
Remove and Install For Lift Truck 8. WASHER
ModelsGLC55SVX (GC/GLC80XVBCS,
Figure 13. Counterweight Installation
GC/GLC100VXBCS; GC/GLC120SVX; and
GC/GLC120VXPRS) (E818, F818) and Table 2. Weight of Counterweights
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX Model Weight
(GP/GLP/GDP080, 090, 100, 110, 120VX) GLC/GDC60VX 2779 kg (6126 lb)
(J813) GLC/GDC70VX
GC/GLC/GDC135VX
1. Remove tow pin from counterweight by grasping GC/GLC/GDC155VX
wire and pulling tow pin from counterweight. See (C879, D879, E879,
Figure 16. F879)

2. Install tow pin into counterweight dropping tow pin

into counterweight.

19
Counterweight Replacement 100 YRM 1316

1. CAPSCREW 5. ROLL PIN

2. COUNTERWEIGHT COVER 6. WASHER
3. COUNTERWEIGHT 7. SEALS
4. TOW PIN

Figure 14. Counterweight Components

20
100 YRM 1316 Counterweight Replacement

1. TOW PIN 2. ROLL PIN 1. WIRE 2. TOW PIN

Figure 15. Tow Pin Figure 16. Tow Pin

21
Overhead Guard Replacement 100 YRM 1316

Overhead Guard Replacement

REMOVE NOTE: Perform Step 2 for lift truck models GLC/
GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
WARNING GC/GLC/GDC155VX) (F879) equipped with Diesel
Particulate Filter (DPF).
DO NOT operate the lift truck without the overhead
guard correctly fastened to the lift truck. 2. Disconnect wires from back of DPF display. See
Figure 19.
WARNING
3. Disconnect wires between frame and overhead
DO NOT weld mounts for lights or accessories to
guard. When overhead guard is lifted from frame,
legs of the overhead guard. Changes that are made
make sure that electrical wires are moved through
by welding, or by drilling holes that are too big or in
holes in overhead guard so that they are not dam-
the wrong location, can reduce the strength of the
aged.
overhead guard.
NOTE: Perform Step 4 for lift truck models GLC/
See your dealer for Yale lift trucks BEFORE perform-
GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
ing any changes to the overhead guard.
GC/GLC/GDC155VX) (C879, D879, E879).
NOTE: The lift trucks covered in this YRM are equipped
4. The rear legs of overhead guard have two cap-
with either a high or low overhead guard. The removal
screws that are located under hood inside engine
and installation procedures for both types of overhead
compartment, next to radiator. Remove capscrews.
guards are the same.
See Figure 18.
No welding or drilling on legs of overhead guard is per-
NOTE: Perform Step 5 for lift truck models GLC/
mitted as per previous WARNING.
GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
NOTE: The lifting device can be connected to any num- GC/GLC/GDC155VX) (F879).
ber of positions on overhead guard depending upon lift-
5. The rear legs of overhead guard have three cap-
ing device available. The ideal choices are a four point
screws and a nut that are located under hood in-
sling connected to all four corners on top of overhead
side engine compartment, next to radiator. Remove
guard, or a two point sling connected to two opposite
capscrews and nuts. See Figure 19.
corners of overhead guard. If a single point hoist is
used, make sure that lift point is in center of overhead 6. Remove fender cover, dash, and kick panel to
guard. If during initial start of lift, the overhead guard remove two capscrews on front legs of overhead
is off balance, lower immediately and move hoist to a guard. See Hood, Seat, Dash, and Side Covers
more centered point. Replacement for removal procedures.
1. Connect a lifting device to remove overhead guard. 7. Using a lifting device, remove overhead guard from
Loosen clamp and disconnect air intake hose from frame and place on floor.
elbow. Remove bolts, elbow, retainer, and grommet
from overhead guard rear leg. See Figure 17.

22
100 YRM 1316 Overhead Guard Replacement

INSTALL LED TAIL, BACKUP, AND BRAKE LIGHTS,

REPLACE
1. Connect lifting device to top of overhead guard. In-
stall overhead guard in position on lift truck. These light assemblies are nonrepairable and must be
replaced as an assembly. See section Electrical Sys-
2. Install two capscrews on front legs of overhead
tem 2200 YRM 1142 for procedures to replace these
guard. Tighten capscrews to 66 N•m (49 lbf ft).
lights.
See Figure 18.

NOTE: Perform Step 3 for lift truck models GLC/

GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (F879) equipped with Diesel
Particulate Filter (DPF).

3. Connect wires to back of DPF display. See Fig-

ure 19.

4. Install fender cover, dash, and kick panel. See

Hood, Seat, Dash, and Side Covers Replacement
for installation procedures.

5. Install two capscrews on rear legs of overhead

guard. Tighten capscrews to 66 N•m (49 lbf ft).
See Figure 18.

NOTE: Perform Step 6 for lift truck models GLC/

GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (F879).

6. Install three capscrews and nut on rear legs of

overhead guard. Tighten capscrews to 66 N•m
(49 lbf ft). See Figure 19.

7. Connect air intake hose by installing bolts, elbow,

retainer, and grommet to overhead guard rear leg.
See Figure 17.

1. CLAMP 4. ELBOW
2. AIR INTAKE HOSE 5. RETAINER
3. BOLTS 6. GROMMET

Figure 17. Disconnect Air Intake Hose

23
Overhead Guard Replacement 100 YRM 1316

1. CAPSCREWS - FRONT LEGS

2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME
5. DPF DISPLAY
6. NUT

Figure 19. Overhead Guard

1. CAPSCREWS - FRONT LEGS
2. HANDLE
3. CAPSCREWS - REAR LEGS
4. FRAME

Figure 18. Overhead Guard

24
100 YRM 1316 Operator Restraint System Replacement

Operator Restraint System Replacement

DESCRIPTION seat belt. Seat belt will retract and internal latch will
unlock. If seat belt cannot be pulled from retractor
The seat belt, hip restraint brackets, seat and mount- assembly or belt will not retract, replace seat belt as-
ing, hood, and latches are all part of operator restraint sembly.
system. Each item must be checked to make sure it • With hood closed and in locked position, pull seat belt
is attached securely, functions correctly, and is in good with a sudden jerk. Make sure seat belt will not pull
condition. See Figure 20. from retractor assembly. If seat belt can be pulled
from retractor, when it is pulled with a sudden jerk,
The seat belt, when properly buckled across operator,
replace seat belt assembly.
will permit slight operator repositioning without activat-
• With hood in open position, make sure seat belt will
ing locking mechanism. If truck tips, travels off a dock,
not pull from retractor assembly. If seat belt can be
or comes to a sudden stop, locking mechanism will be
pulled from retractor, with hood in open position, re-
activated and hold the operator’s lower torso in seat.
place seat belt assembly.
A seat belt that is damaged, worn or does not operate
Make sure seat rails and latch striker are not loose. The
properly will not provide protection when it is needed.
seat rails must lock tightly in position, but move freely
The end of belt must fasten correctly in latch. The seat
when unlocked. The seat rails must be correctly fas-
belt must be in good condition. Replace seat belt if
tened to hood and hood fastened to hinges on frame.
damage or wear is seen. See Figure 20.
The hood must be fully closed. Attempt to lift hood to
The following seat belt operation checks must be per- make sure it is closed.
formed:
Adjust hood, hood latch, and latch striker when any of
• With hood closed and in locked position, pull seat belt
parts of operator restraint system are installed or re-
slowly from retractor assembly. Make sure seat belt
placed. See section Hood, Seat, Dash, and Side Cov-
pulls out and retracts smoothly. If seat belt does not
ers Replacement in this manual for adjustment proce-
pull out of retractor assembly, internal latch may be
dures for hood.
locked. Pull firmly on seat belt and hold for a mo-
ment to remove slack from belt in retractor. Release

25
Operator Restraint System Replacement 100 YRM 1316

1. WEIGHT ADJUSTMENT LEVER 5. HOOD

2. HIP RESTRAINT 6. SEAT RAIL
3. SEAT BELT LATCH 7. SPACER
4. SEAT

Figure 20. Operator Restraint System

26
100 YRM 1316 Engine Replacement

Engine Replacement
REMOVE ENGINE ONLY 2. If lift truck is equipped with an LPG fuel tank, swing
tank to side. See one of the following Service Man-
WARNING uals:
The lift truck must be put on blocks for some types LPG Fuel System, GM 4.3L Engine With GFI 900
of maintenance and repairs. The removal of the YRM 1242 for lift truck models
following assemblies will cause large changes in • GLC60VX, GLC70VX (GLC135VX, GLC155VX)
the center of gravity: mast, drive axle, engine and (C879, D879)
transmission, and counterweight. When the lift
truck is put on blocks, put additional blocks in the LPG Fuel System, GM 4.3L Engine With PSI 900
following positions to maintain stability: YRM 1556 for lift truck models
• Before removing the mast and drive axle, put • GLC60VX, GLC70VX (GLC135VX, GLC155VX)
blocks under the counterweight so the lift truck (D879, E879, F879)
cannot fall backward.
• Before removing the counterweight, put blocks 3. Remove floor mat and floor plate.
under the mast assembly so the lift truck cannot
fall forward. WARNING
The surface must be solid, even, and level when DO NOT remove the radiator cap from the radiator
the lift truck is put on blocks. Make sure that any when the engine is hot. When the radiator cap is
blocks used to support the lift truck are solid, one- removed, the pressure is released from the system.
piece units. See the procedure How to Put Lift Truck If the system is hot, the steam and boiling coolant
on Blocks in the Operating Manual or the Periodic can cause burns.
Maintenance section for your lift truck. 4. Let coolant cool to ambient temperature. Place a
The engine can be removed with or without transmis- drain pan with a capacity greater than capacity of
sion. Follow procedures below to remove engine with- cooling system under radiator. Remove radiator
out transmission. See Figure 21. cap.

WARNING CAUTION
Always disconnect the cables at the battery before Disposal of lubricants and fluids must meet local
you make repairs to the engine. Disconnect the ca- environmental regulations.
ble at the negative terminal first.
5. Open drain plug or loosen hose clamp and discon-
nect bottom radiator hose to drain coolant from ra-
WARNING diator and engine.
LPG can cause an explosion. DO NOT cause sparks
or permit flammable material near the LPG system. See Figure 22 and Figure 23 for lift trucks equipped
LPG fuel systems can be disconnected indoors with GM 4.3L engine.
only if the lift truck is at least 8 m (26 ft) from any See Figure 24 for lift truck models equipped with
open flame, motor vehicles, electrical equipments, Cummins QSB 3.3L diesel engine.
or ignition source.
See Figure 25 and Figure 26 for lift truck models
1. For lift trucks equipped with an LPG fuel system, equipped with Kubota 3.8L diesel engine.
close shutoff valve on tank and run engine until all
fuel is gone and engine stops. See Figure 27 for lift truck models equipped with
Cummins 4.5L diesel engine.

27
Engine Replacement 100 YRM 1316

Figure 21. Engine and Transmission Mounting Arrangement

28
100 YRM 1316 Engine Replacement

Legend for Figure 21

NOTE: PART OF FRAME NOT SHOWN FOR CLARITY.

A. GM 4.3L ENGINE C. CUMMINS QSB 3.3L DIESEL ENGINE
B. CUMMINS 4.5L DIESEL ENGINE D. KUBOTA 3.8L DIESEL ENGINE
1. TRANSMISSION ISOLATOR ASSEMBLY 6. FRAME
2. TRANSMISSION MOUNTING BRACKET 7. ENGINE HARNESS CONNECTOR
3. ENGINE MOUNTING BRACKET 8. LEFT CHASSIS WIRING HARNESS
4. ENGINE CROSSMEMBER CONNECTOR
5. ENGINE ISOLATOR ASSEMBLY

29
Engine Replacement 100 YRM 1316

Figure 22. GM 4.3L LPG Engine with GFI and Transmission

30
100 YRM 1316 Engine Replacement

Legend for Figure 22

NOTE: GFI FUEL SYSTEM SHOWN. PSI FUEL SYSTEM IS SIMILAR.

NOTE: GM 4.3L GASOLINE ENGINE IS SIMILAR.

A. TOP VIEW B. LEFT SIDE VIEW
1. BOTTOM RADIATOR HOSE 16. FUEL LINES
2. AIR FILTER HOSE 17. LEFT SIDE ENGINE MOUNT
3. AIR FILTER AND BRACKET ASSEMBLY 18. STARTER MOTOR
4. LEFT HAND CHASSIS HARNESS CONNECTOR 19. CAPSCREWS
5. ENGINE HARNESS CONNECTOR 20. BELL HOUSING
6. LPG REGULATOR CONNECTOR 21. RADIATOR CAP
7. RIGHT HAND CHASSIS HARNESS 22. OUTPUT YOKE
8. ELECTRONIC CONTROL MODULE (ECM) 23. TRANSMISSION MOUNT
9. POWER DISTRIBUTION MODULE (PDM) 24. FLANGE NUT
10. BATTERY AND BATTERY TRAY 25. WASHERS
11. COOLANT HOSES 26. ISOLATORS
12. FAN PULLEY AND FAN SPACER 27. BRAKE COOLING LINES
13. FAN 28. BATTERY CABLE (POSITIVE)
14. SHROUD 29. BATTERY CABLE (NEGATIVE)
15. EXHAUST PIPE TO EXHAUST MANIFOLD

31
Engine Replacement 100 YRM 1316

Figure 23. GM 4.3L LPG Engine with PSI and Transmission

32
100 YRM 1316 Engine Replacement

Legend for Figure 23

NOTE: GM 4.3L GASOLINE ENGINE IS SIMILAR.

A. TOP VIEW B. LEFT SIDE VIEW
1. BOTTOM RADIATOR HOSE 16. FUEL LINES
2. AIR FILTER HOSE 17. LEFT SIDE ENGINE MOUNT
3. AIR FILTER AND BRACKET ASSEMBLY 18. STARTER MOTOR
4. LEFT HAND CHASSIS HARNESS CONNECTOR 19. CAPSCREWS
5. ENGINE HARNESS CONNECTOR 20. BELL HOUSING
6. FUEL SENDING UNIT 21. RADIATOR CAP
7. RIGHT HAND CHASSIS HARNESS 22. OUTPUT YOKE
8. ELECTRONIC CONTROL MODULE (ECM) 23. TRANSMISSION MOUNT
9. POWER DISTRIBUTION MODULE (PDM) 24. FLANGE NUT
10. BATTERY AND BATTERY TRAY 25. WASHERS
11. COOLANT HOSES 26. ISOLATORS
12. FAN PULLEY AND FAN SPACER 27. BRAKE COOLING LINES
13. FAN 28. BATTERY CABLE (POSITIVE)
14. SHROUD 29. BATTERY CABLE (NEGATIVE)
15. EXHAUST PIPE TO EXHAUST MANIFOLD

33
Engine Replacement 100 YRM 1316

Figure 24. Cummins QSB 3.3L Diesel Engine and Transmission

34
100 YRM 1316 Engine Replacement

Legend for Figure 24

A. TOP VIEW B. LEFT SIDE VIEW
1. RADIATOR CAP 11. HYDRAULIC SUPPLY LINE
2. SHROUD 12. TRANSMISSION MOUNTING BRACKET
3. BOTTOM COOLANT HOSE 13. ELECTRONIC CONTROL MODULE
4. AIR FILTER HOSE 14. RIGHT HAND ENGINE HARNESS
5. AIR FILTER AND BRACKET 15. HYDRAULIC RETURN LINE
6. EXHAUST PIPE TO EXHAUST MANIFOLD 16. BATTERY AND BATTERY TRAY
7. ENGINE MOUNTING BRACKETS 17. BATTERY CABLE (POSITIVE)
8. FUEL LINES 18. BATTERY CABLE (NEGATIVE)
9. ENGINE HARNESS CONNECTOR 19. FAN SPACER AND FAN PULLEY
10. BRAKE COOLING LINE 20. CHARGE AIR HOSE

35
Engine Replacement 100 YRM 1316

Figure 25. Kubota 3.8L Engine and Transmission for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879)

36
100 YRM 1316 Engine Replacement

Legend for Figure 25

A. TOP VIEW B. SIDE VIEW
1. SHROUD 9. BRAKE COOLING LINE
2. RADIATOR CAP 10. ENGINE HARNESS CONNECTOR
3. BATTERY CABLE (NEGATIVE) 11. AIR FILTER AND BRACKET
4. BATTERY AND BATTERY TRAY 12. AIR FILTER HOSE
5. BATTERY CABLE (POSITIVE) 13. FAN, SPACER, AND FAN PULLEY
6. TRANSMISSION COOLING HOSE 14. BOTTOM COOLANT HOSE
7. HYDRAULIC SUPPLY LINE 15. ENGINE MOUNTS
8. TRANSMISSION MOUNTING BRACKET 16. EXHAUST PIPE TO EXHAUST MANIFOLD

37
Engine Replacement 100 YRM 1316

Figure 26. Kubota 3.8L Engine and Transmission for Lift Truck Model GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (F879)

38
100 YRM 1316 Engine Replacement

Legend for Figure 26

A. TOP VIEW
B. SIDE VIEW
1. SHROUD 9. BRAKE COOLING LINE
2. RADIATOR CAP 10. ENGINE HARNESS CONNECTOR
3. BATTERY CABLE (NEGATIVE) 11. AIR FILTER AND BRACKET
4. BATTERY AND BATTERY TRAY 12. AIR FILTER HOSE
5. BATTERY CABLE (POSITIVE) 13. FAN, SPACER, AND FAN PULLEY
6. TRANSMISSION COOLING HOSE 14. BOTTOM COOLANT HOSE
7. HYDRAULIC SUPPLY LINE 15. ENGINE MOUNTS
8. TRANSMISSION MOUNTING BRACKET 16. EXHAUST PIPE TO EXHAUST MANIFOLD

39
Engine Replacement 100 YRM 1316

Figure 27. Cummins 4.5L Diesel Engine and Transmission

40
100 YRM 1316 Engine Replacement

Legend for Figure 27

A. TOP VIEW C. LEFT SIDE VIEW
B. RIGHT SIDE VIEW
1. RIGHT HAND CHASSIS HARNESS 15. AIR FILTER AND BRACKET ASSEMBLY
CONNECTOR 16. AIR FILTER HOSE
2. THROTTLE CABLE 17. EXHAUST PIPE TO EXHAUST MANIFOLD
3. BATTERY AND BATTERY TRAY 18. BOTTOM RADIATOR HOSE
4. RADIATOR CAP 19. COOLANT HOSES
5. FUEL LINES 20. BRAKE COOLING LINES
6. ENGINE HARNESS CONNECTOR 21. TRANSMISSION BELL HOUSING
7. LEFT HAND CHASSIS HARNESS CONNECTOR 22. FAN PULLEY AND FAN SPACER
8. CAPSCREW 23. BATTERY CABLE (POSITIVE)
9. ISOLATORS 24. BATTERY CABLE NEGATIVE
10. WASHERS 25. POWER DISTRIBUTION MODULE (PDM)
11. FLANGE NUTS 26. TRANSMISSION HARNESS CONNECTOR
12. OUTPUT YOKE 27. SHROUD
13. TRANSMISSION MOUNT 28. FAN
14. ENGINE MOUNTS

41
Engine Replacement 100 YRM 1316

6. Remove hood and seat combination and rear side 10. On lift trucks equipped with GM 4.3L gasoline en-
covers. See section Hood, Seat, Dash, and Side gine or a Cummins 4.5L diesel engine, disconnect
Covers Replacement for procedures. left hand chassis harness connector from engine
harness connector.
7. Loosen clamp and remove air filter hose from air
inlet, located on left rear overhead guard leg. See Figure 22 for lift truck models equipped with
GFI.
See Figure 22 and Figure 23 for lift truck models
equipped with GM 4.3L engine. See Figure 23 for lift truck models equipped with
PSI.
See Figure 24 for lift truck models equipped with
Cummins QSB 3.3L diesel engine. See Figure 27 for lift truck models equipped with
Cummins 4.5L diesel engine.
See Figure 25 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ NOTE: Perform Step 11 for lift truck models equipped
GDC155VX) (E879) equipped with the Kubota 3.8L with GFI fuel system.
diesel engine.
11. On lift trucks equipped with GM 4.3L LPG engine,
See Figure 26 for lift truck model GLC/GDC60VX, disconnect left hand chassis harness connector
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ from LPG regulator connector and engine harness
GDC155VX) (F879) equipped with the Kubota 3.8L connector. See Figure 22.
diesel engine.
12. On lift trucks equipped with GM 4.3L engine or Kub-
See Figure 27 for lift truck models equipped with ota 3.8L engine, disconnect engine harness con-
Cummins 4.5L diesel engine. nectors from electronic control module (ECM).

8. Remove air filter and bracket assembly. See Figure 22 and Figure 23 for lift truck models
equipped with GM 4.3L engine.
See Figure 22 and Figure 23 for lift truck models
equipped with GM 4.3L engine. See Figure 25 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
See Figure 24 for lift truck models equipped with GDC155VX) (E879) equipped with the Kubota 3.8L
Cummins QSB 3.3L diesel engine. diesel engine.
See Figure 25 for lift truck model GLC/GDC60VX, See Figure 26 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L GDC155VX) (F879) equipped with the Kubota 3.8L
diesel engine. diesel engine.
See Figure 26 for lift truck model GLC/GDC60VX, 13. Disconnect engine harness connector from right
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ hand chassis harness connector.
GDC155VX) (F879) equipped with the Kubota 3.8L
diesel engine. 14. Disconnect ground strap from frame and remove
power distribution module (PDM) from battery tray.
See Figure 27 for lift truck models equipped with See Figure 28.
Cummins 4.5L diesel engine.
15. For lift trucks equipped with either a Cummins QSB
9. For lift trucks equipped with Cummins 4.5L diesel 3.3L, a Cummins 4.5L, or Kubota diesel engines,
engine, disconnect throttle cable from fuel injection remove battery from battery tray and remove three
pump. capscrews from battery tray. Remove battery tray.
See Figure 27 for lift trucks equipped with a Cum- 16. For lift trucks equipped with GM 4.3L engine, re-
mins 4.5L diesel engine. move three capscrews from battery tray and re-
move battery, battery tray, and Electronic Control
NOTE: When disconnecting wiring harness connectors,
Module (ECM).
tag each connector to aid in connecting wiring harness
during installation.

42
100 YRM 1316 Engine Replacement

See Figure 27 for lift truck models equipped with

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 assem-

bly. See section Cooling System 700 YRM 1123
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, uncon-

sciousness 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 22 and Figure 23 for lift truck models

equipped with GM 4.3L engine.

See Figure 24 for lift truck models equipped with

1. BATTERY Cummins QSB 3.3L diesel engine.
2. BATTERY TRAY
3. PDM See Figure 25 for lift truck model GLC/GDC60VX,
4. BATTERY LOCKDOWN BAR GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
5. GROUND STRAP GDC155VX) (E879) equipped with the Kubota 3.8L
Figure 28. Power Distribution Module, diesel engine.
Disconnection See Figure 26 for lift truck model GLC/GDC60VX,
17. Loosen hose clamps and disconnect remaining GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
coolant hoses from radiator and cap them to pre- GDC155VX) (F879) equipped with the Kubota 3.8L
vent leakage. diesel engine.

See Figure 22 and Figure 23 for lift truck models See Figure 27 for lift truck models equipped with
equipped with GM 4.3L engine. Cummins 4.5L diesel engine.

See Figure 24 for lift truck models equipped with 21. Lift trucks equipped with GM 4.3L engine, remove
Cummins QSB 3.3L diesel engine. left side engine mount to access starter motor. See
Figure 22 and Figure 23.
See Figure 25 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ 22. Disconnect positive battery (B+) and negative bat-
GDC155VX) (E879) equipped with the Kubota 3.8L tery cable from starter motor.
diesel engine. 23. Lift trucks equipped with GM 4.3L engine, remove
See Figure 26 for lift truck model GLC/GDC60VX, starter motor to reach four torque converter access
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ bolts. See Figure 22 and Figure 23.
GDC155VX) (F879) equipped with the Kubota 3.8L
diesel engine.

43
Engine Replacement 100 YRM 1316

24. For lift trucks equipped with a Cummins QSB 3.3L 30. Remove flange nuts, washers, bolts, and isolators
diesel engine, remove oil cooler to reach access from engine mounts. See Figure 21 or Figure 33.
port. See Yale Axcess Online.

25. Lift trucks equipped with Cummins QSB 3.3L diesel CAUTION
engine, remove bolts and cover to get to access When separating the engine away from the trans-
port. See Figure 31. mission, place a piece of plywood in front of radi-
ator. This will keep the engine from damaging the
26. Lift trucks equipped with Kubota diesel engine, re- radiator.
move bolts and cover to reach access port. See
Figure 32.
CAUTION
27. Use access port on engine to remove bolts that at- Keep the engine level when the engine is separated
taching flywheel to torque converter. from the transmission so the drive plate is not dam-
aged.
See Figure 29 for lift trucks equipped with a GM
4.3L gas or LPG engine. 31. Use lifting device to carefully move engine away
from torque converter. Make sure all hoses, wires,
See Figure 30 for lift trucks equipped with a Cum- and cables are disconnected from engine, then lift
mins 4.5L diesel engine. engine from frame and place engine on blocks.
See Figure 31 for lift trucks equipped with a Cum-
mins QSB 3.3L diesel engine.

See Figure 32 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.

See Figure 22 and Figure 23 for lift truck models

equipped with GM 4.3L engine.

See Figure 24 for lift truck models equipped with

Cummins QSB 3.3L diesel engine.

See Figure 25 for lift truck model GLC/GDC60VX,

GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L
diesel engine.

See Figure 26 for lift truck model GLC/GDC60VX,

GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879) equipped with the Kubota 3.8L 1. ACCESS PORT
2. ENGINE MOUNTING BRACKET AND
diesel engine. HARDWARE
See Figure 27 for lift truck models equipped with Figure 29. GM 4.3L Engine Removal Access Port
Cummins 4.5L diesel engine.

WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The en-
gine can weigh approximately 363 kg (800 lb).

44
100 YRM 1316 Engine Replacement

Legend for Figure 31

1. ACCESS PORT
2. ENGINE MOUNTING BRACKET AND
HARDWARE

1. ACCESS PORT
2. ENGINE MOUNTING BRACKET AND
HARDWARE

Figure 30. Cummins 4.5L Engine Access Port NOTE: KUBOTA 3.8L SHOWN. KUBOTA 3.6L SIMI-
LAR.
1. ACCESS PORT
2. ENGINE MOUNTING BRACKET AND
HARDWARE

Figure 32. Kubota Diesel Engine Access Port

Figure 31. Cummins QSB 3.3L Diesel Engine

Access Port

45
Engine Replacement 100 YRM 1316

A. ENGINE MOUNTS FOR GM 4.3L C. ENGINE MOUNTS FOR CUMMINS QSB 3.3L
B. ENGINE MOUNTS FOR CUMMINS 4.5L D. ENGINE MOUNTS FOR KUBOTA DIESEL
1. ENGINE MOUNTS 6. PIN
2. CAPSCREW 7. CROSSMEMBER
3. WASHER 8. LOCK NUT
4. ISOLATOR 9. FLANGE BOLT
5. FLANGE NUT

Figure 33. Engine Mounts Assembly

46
100 YRM 1316 Engine Replacement

INSTALL ENGINE ONLY to secure engine to frame. Tighten flange nuts to

320 N•m (236 lbf ft). See Figure 33.
WARNING 5. Install capscrews to secure transmission bell hous-
The engine is heavy. Make sure that any lifting de- ing to torque converter adapter. Tighten capscrews
vice has enough capacity to lift the engine. The en- to 38 N•m (28 lbf ft).
gine weighs approximately 363 kg (800 lb).
6. Use access port on engine to install four bolts to
hold torque converter to flywheel. Tighten bolts to
CAUTION
55 N•m (41 lbf ft).
Keep the engine level when installing the engine to
the transmission so the drive plate is not damaged. 7. For Cummins QSB 3.3L diesel engine, install cover
and bolts to access port. See Figure 31.
1. Connect lifting device to engine and lift engine into
frame. 8. For Kubota 3.8L diesel engine, install cover and
bolts to access port. See Figure 32.
2. Align transmission bell housing to torque converter
adapter. 9. Remove blocks from under transmission and dis-
connect lifting device from engine.
See Figure 22 and Figure 23 for lift truck models
equipped with GM 4.3L engine. 10. Lift trucks equipped with Cummins QSB 3.3L diesel
engine, install oil cooler. See Yale Axcess Online.
See Figure 24 for lift truck models equipped with
Cummins QSB 3.3L diesel engine. 11. Lift trucks equipped with GM 4.3L engine, in-
stall starter motor. Tighten capscrews to 52 N•m
See Figure 25 for lift truck model GLC/GDC60VX, (38 lbf ft).
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L 12. Connect positive battery (B+) cable to starter motor.
diesel engine. Tighten terminal nut to 8 to 11 N•m (71 to 97 lbf in).
See Figure 26 for lift truck model GLC/GDC60VX, 13. Connect negative battery cable to starter motor.
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879) equipped with the Kubota 3.8L 14. Lift trucks equipped with GM 4.3L engine, install left
diesel engine. side engine mount on engine. Tighten capscrews
to 90 N•m (66 lbf ft).
See Figure 27 for lift truck models equipped with
Cummins 4.5L diesel engine. 15. For lift trucks equipped with GM 4.3L engine, con-
nect exhaust pipes to exhaust manifolds. Tighten
NOTE: Perform Step 3 on lift trucks equipped with GM lock nuts to 39 N•m (29 lbf ft). See Figure 22 and
4.3L gas/LPG engine or Kubota diesel engine. Figure 23.
3. If isolators fell from engine mounts during removal, 16. For lift truck equipped with Kubota diesel engine,
install isolators on engine mounts and install wash- connect exhaust pipes to exhaust manifold.
ers, capscrews and flange nuts for engine mounts
to secure engine to frame. Tighten flange nuts to See Figure 25 for lift truck model GLC/GDC60VX,
150 N•m (110 lbf ft). See Figure 33. GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879)
NOTE: Perform Step 4 on lift trucks equipped with either
a Cummins QSB 3.3L or Cummins 4.5L diesel engine. See Figure 26 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
4. If isolators fell from engine mounts during removal, GDC155VX) (F879).
install isolators on engine mounts and install wash-
ers, capscrews and flange nuts for engine mounts

47
Engine Replacement 100 YRM 1316

17. For lift trucks equipped with Cummins QSB 3.3L or 24. Connect engine harness connector to right hand
Cummins 4.5L diesel engine, connect exhaust pipe chassis harness connector.
to exhaust manifold. Tighten lock nut to 22 N•m
(16 lbf ft). See Figure 22 and Figure 23 for lift trucks equipped
with a GM 4.3L engine.
See Figure 24 for lift truck models equipped with
Cummins QSB 3.3L diesel engine. See Figure 25 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
See Figure 27 for lift truck models equipped with GDC155VX) (E879) equipped with the Kubota 3.8L
Cummins 4.5L diesel engine. diesel engine.

18. Remove caps from fuel lines and connect fuel lines See Figure 26 for lift truck model GLC/GDC60VX,
at engine. GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879) equipped with the Kubota 3.8L
19. Install radiator shroud, fan pulley, and fan assembly. diesel engine.
See section Cooling System 700 YRM 1123 for
Fan Installation procedures. See Figure 27 for lift trucks equipped with a Cum-
mins 4.5L diesel engine.
20. Remove cap from bottom radiator hose and install
hoses to radiator. 25. For lift trucks equipped with GM 4.3L or Kubota
3.8L engine, connect engine harness connectors to
See Figure 22 and Figure 23 for lift truck models Electronic Control Module (ECM).
equipped with GM 4.3L engine.
See Figure 22 and Figure 23 for lift truck models
See Figure 24 for lift truck models equipped with equipped with GM 4.3L engine.
Cummins QSB 3.3L diesel engine.
See Figure 25 for lift truck model GLC/GDC60VX,
See Figure 25 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (E879) equipped with the Kubota 3.8L
GDC155VX) (E879) equipped with the Kubota 3.8L diesel engine.
diesel engine.
See Figure 26 for lift truck model GLC/GDC60VX,
See Figure 26 for lift truck model GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) (F879) equipped with the Kubota 3.8L
GDC155VX) (F879) equipped with the Kubota 3.8L diesel engine.
diesel engine.
NOTE: Perform Step 26 for lift truck models equipped
See Figure 27 for lift truck models equipped with with GFI fuel system.
Cummins 4.5L diesel engine.
26. For lift trucks equipped with GM 4.3L LPG engine,
NOTE: Perform Step 21 on lift trucks equipped with ei- connect left hand chassis harness connector to
ther a Cummins QSB 3.3L, a Cummins 4.5L, or Kubota LPG regulator connector and engine harness con-
diesel engine. nector. See Figure 22.
21. Using three capscrews install battery tray and bat- 27. For lift trucks equipped with either a GM 4.3L gaso-
tery. line engine or a Cummins 4.5L diesel engine, con-
nect left hand chassis harness connector to engine
NOTE: Perform Step 22 on lift trucks equipped with GM
harness connector.
4.3L engine.
See Figure 22 for lift truck models equipped with
22. Using three capscrews install battery tray, battery,
GFI.
and Electronic Control Module (ECM).
See Figure 23 for lift truck models equipped with
23. Install Power Distribution Module (PDM) on battery
PSI.
tray and connect ground strap to lift truck frame.
See Figure 28. See Figure 27 for lift trucks equipped with a Cum-
mins 4.5L diesel engine.

48
100 YRM 1316 Engine Replacement

28. For lift trucks equipped with Cummins 4.5L diesel 37. For lift trucks equipped with and LPG fuel system,
engine, connect throttle cable to fuel injection swing LPG tank and bracket back to original posi-
pump. See Figure 27. tion until locked and open shutoff valve.

29. Install air filter and bracket assembly. 38. Inspect fuel system for leaks when fuel valve is
open. There are four methods used to inspect fuel
30. Connect air filter hose to air inlet located on left rear system for leaks:
over head guard leg and tighten clamp.
a. Sound - Listen for sound of fuel escaping from
31. Install hood and seat combination, and rear side a tank fitting or hose connection.
covers. See section Hood, Seat, Dash, and Side
Covers Replacement, Install for procedures. b. Smell - Fuel has a very distinctive odor. If you
smell fuel, DO NOT start engine.
32. Close drain plug and remove caps from remain-
ing coolant hoses and connect hoses to radiator. c. Soapy Water - This method is used in conjunc-
Tighten hose clamps and fill cooling system with tion with Step b above. If odor of fuel is present,
antifreeze. See Cooling System 700 YRM 1123 but escaping fuel cannot be heard, apply soapy
for radiator fill procedures. Install radiator cap. water to fittings and observe for bubbles.

33. Check all fluid levels as described in d. Frost - If amount of fuel escaping is sufficient,
frost may appear on fittings.
Periodic Maintenance 8000 YRM 1319 for lift truck
models REMOVE ENGINE AND TRANSMISSION
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879,
WARNING
D879)
The lift truck must be put on blocks for some types
Periodic Maintenance 8000 YRM 1571 for lift truck of maintenance and repairs. The removal of the
models following assemblies will cause large changes in
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ the center of gravity: mast, drive axle, engine and
GDC135VX, GC/GLC/GDC155VX) (E879) transmission, and counterweight. When the lift
truck is put on blocks, put additional blocks in the
Periodic Maintenance 8000 YRM 1606 for lift truck following positions to maintain stability:
model • Before removing the mast and drive axle, put
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ blocks under the counterweight so the lift truck
GDC135VX, GC/GLC/GDC155VX) (F879) cannot fall backward.
• Before removing the counterweight, put blocks
34. Connect positive battery cable to battery. under the mast assembly so the lift truck cannot
35. Connect negative battery cable to battery. fall forward.

36. Install floor plate and floor mat. 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-
WARNING piece units. See the procedure How to Put Lift Truck
All fuels are very flammable and can burn or cause on Blocks in the Operating Manual or the Periodic
an explosion. DO NOT use an open flame to check Maintenance section for your lift truck.
the fuel level or to check for leaks in the fuel system.
The engine can be removed with or without transmis-
No smoking. sion. Follow procedures below to remove engine with
transmission. See Figure 21.
Breathing fuel vapor may cause nausea, uncon-
sciousness or death. Long term exposure to
gasoline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.

49
Engine Replacement 100 YRM 1316

See Figure 26 for lift truck model GLC/GDC60VX,

WARNING GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
Always disconnect the cables at the battery before GDC155VX) (F879) equipped with the Kubota 3.8L
you make repairs to the engine. Disconnect the ca- diesel engine.
ble at the negative terminal first.
See Figure 27 for lift truck models equipped with
Cummins 4.5L diesel engine.
WARNING
LPG can cause an explosion. DO NOT cause sparks 5. Remove overhead guard, see Overhead Guard Re-
or permit flammable material near the LPG system. placement for Remove procedures.
LPG fuel systems can be disconnected indoors
only if the lift truck is at least 8 m (26 ft) from any 6. Remove hood and seat combination and rear side
open flame, motor vehicles, electrical equipments, covers. See section Hood, Seat, Dash, and Side
or ignition source. Covers Replacement for procedures.

1. For lift trucks equipped with an LPG fuel system, 7. Remove floor mat and floor plate.
close shutoff valve on tank and run engine until all
8. Loosen clamp and remove air filter hose from air
fuel is gone and engine stops.
inlet, located on left rear over head guard leg.
2. If lift truck is equipped with an LPG fuel tank, swing
See Figure 22 and Figure 23 for lift truck models
tank to side. See one of the following Service Man-
equipped with GM 4.3L engine.
uals.
See Figure 24 for lift truck models equipped with
LPG Fuel System, GM 4.3L Engine With GFI 900
Cummins QSB 3.3L diesel engine.
YRM 1242 for lift truck models:
• GLC60VX, GLC70VX (GLC135VX, GLC155VX) See Figure 25 for lift truck model GLC/GDC60VX,
(C879, D879) GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L
LPG Fuel System, GM 4.3L Engine With PSI 900
diesel engine.
YRM 1556 for lift truck models:
• GLC60VX, GLC70VX (GLC135VX, GLC155VX) See Figure 26 for lift truck model GLC/GDC60VX,
(D879, E879, F879) GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879) equipped with the Kubota 3.8L
3. Let coolant cool to ambient temperature. Place a
diesel engine.
drain pan with a capacity greater than capacity of
cooling system under radiator. Remove radiator See Figure 27 for lift truck models equipped with
cap. Cummins 4.5L diesel engine.
NOTE: Disposal of lubricants and fluids must meet local 9. For lift trucks equipped with Cummins 4.5L diesel
environmental regulations. engine, disconnect throttle cable from fuel injection
pump. See Figure 27 for lift truck models equipped
4. Open drain plug or loosen hose clamp and discon-
with Cummins 4.5L diesel engine.
nect bottom radiator hose to drain coolant from ra-
diator and engine. NOTE: When disconnecting wiring harness connectors
during removal, tag each connector to aid in connecting
See Figure 22 and Figure 23 for lift truck models
wiring harness during installation.
equipped with GM 4.3L engine.
10. For lift trucks equipped with GM 4.3L gasoline en-
See Figure 24 for lift truck models equipped with
gine or Cummins 4.5L diesel engine, disconnect left
Cummins QSB 3.3L diesel engine.
hand chassis harness connector from engine har-
See Figure 25 for lift truck model GLC/GDC60VX, ness connector.
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L
diesel engine.

50
100 YRM 1316 Engine Replacement

See Figure 22 for lift truck models equipped with three capscrews from battery tray and remove bat-
GFI. tery and battery tray.

See Figure 23 for lift truck models equipped with 18. For lift trucks equipped with GM 4.3L engine, re-
PSI. move three capscrews from battery tray and re-
move battery, battery tray, and Electronic Control
See Figure 27 for lift truck models equipped with Module (ECM).
Cummins 4.5L diesel engine.

NOTE: Perform Step 11 for lift truck models equipped CAUTION

with GFI fuel system. Disposal of lubricants and fluids must meet local
environmental regulations.
11. For lift trucks equipped with GM 4.3L LPG engine,
disconnect left hand chassis harness connector 19. Place a drain pan under hydraulic tank, remove
from LPG regulator connector and engine harness drain plug at bottom of hydraulic oil tank, and drain
connector. See Figure 22. oil from tank. After oil has finished draining, install
drain plug to hydraulic tank.
12. For lift trucks equipped with GM 4.3L or Kubota
3.8L engine, disconnect engine harness connec- 20. Place drain pan under hydraulic gear pump assem-
tors from Electronic Control Module (ECM). bly.
See Figure 22 and Figure 23 for lift truck models a. For lift truck models equipped with a hydraulic
equipped with GM 4.3L engine. gear pump on transmission, disconnect the
suction hose and hydraulic hose from hydraulic
See Figure 25 for lift truck model GLC/GDC60VX,
gear pump assembly. Put caps on all hose
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
fitting and hydraulic gear pump ports. See
GDC155VX) (E879) equipped with the Kubota 3.8L
Hydraulic Gear Pump 1900 YRM 1136 for
diesel engine.
more information.
See Figure 26 for lift truck model GLC/GDC60VX,
21. Loosen hose clamps and disconnect remaining
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
coolant hoses from radiator and cap them, to pre-
GDC155VX) (F879) equipped with the Kubota 3.8L
vent leakage.
diesel engine.
22. Place drain pan under transmission oil cooler lines
13. For lift trucks equipped with Cummins QSB 3.3L
at transmission. Loosen hose clamps and discon-
diesel engine, disconnect alternator harness from
nect transmission oil cooler lines at transmission
Electronic Control Module (ECM).
and cap to prevent leakage.
See Figure 24 for lift truck models equipped with
23. Place drain pan under supply and return brake cool-
Cummins QSB 3.3L diesel engine.
ing lines (if equipped) and remove cooling lines at
14. Disconnect engine harness connector from right transmission and cap to prevent leakage.
hand chassis harness connector.
24. Disconnect exhaust pipes from exhaust manifold.
15. Disconnect battery positive (B+) and negative cable See Exhaust System Repair for removal proce-
from starter motor. dures.

16. Disconnect ground strap from frame and remove 25. Remove radiator fan pulley, shroud, and fan assem-
power distribution module (PDM) from battery tray. bly. See section Cooling System 700 YRM 1123
for removal procedures.
17. For lift trucks equipped with Cummins QSB 3.3L,
Cummins 4.5L, or Kubota diesel engine, remove

51
Engine Replacement 100 YRM 1316

See Figure 26 for lift truck model GLC/GDC60VX,

WARNING GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
All fuels are very flammable and can burn or cause GDC155VX) (F879) equipped with the Kubota 3.8L
an explosion. DO NOT use an open flame to check diesel engine.
the fuel level or to check for leaks in the fuel system.
See Figure 27 for lift truck models equipped with
No smoking. Cummins 4.5L diesel engine.
Breathing fuel vapor may cause nausea, uncon- 29. Remove flange nuts, capscrews, washers and iso-
sciousness or death. Long term exposure to lators from transmission mount. See Figure 34.
gasoline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor. 30. Remove capscrews and washers from engine
mounts. See Figure 33.
26. Loosen hose clamps (if equipped) and disconnect
fuel lines at engine. Put caps on fuel lines to prevent NOTE: Make sure engine and transmission assembly
fuel leakage. can be raised at an angle so they will clear frame.

See Figure 22 and Figure 23 for lift truck models 31. Use lifting device to carefully lift engine and trans-
equipped with GM 4.3L engine. mission from frame. Slip transmission output yoke
out of transmission. Make sure not to damage seal.
See Figure 24 for lift truck models equipped with Place engine and transmission on blocks.
Cummins QSB 3.3L diesel engine.
INSTALL ENGINE AND TRANSMISSION
See Figure 25 for lift truck model GLC/GDC60VX,
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L WARNING
diesel engine. The engine and transmission are heavy. Make sure
that any lifting device has enough capacity to lift
See Figure 26 for lift truck model GLC/GDC60VX, the weight. The engine and transmission can weigh
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ approximately 680 kg (1500 lb).
GDC155VX) (F879) equipped with the Kubota 3.8L
diesel engine. NOTE: Make sure engine and transmission assembly
can be raised at an angle so they will clear frame.
See Figure 27 for lift truck models equipped with
Cummins 4.5L diesel engine. 1. Connect a lifting device to engine and transmission
and lift engine and transmission into lift truck frame.
WARNING 2. Install transmission output yoke onto transmission.
The engine and transmission are heavy. Make sure Be sure to not damage seal. Tighten bolt to 38 N•m
that any lifting device has enough capacity to lift (28 lbf ft).
the weight. The engine and transmission can weigh
approximately 680 kg (1500 lb). NOTE: Perform Step 3 on lift trucks equipped with Cum-
mins 4.5L or Cummins QSB 3.3L diesel engines.
27. Connect a lifting device to support transmission and
engine combination. 3. If isolators fell from engine mounts during removal,
install isolators to engine mounts and install wash-
28. Disconnect output yoke from transmission. ers, capscrews, and flange nuts for engine mounts
to secure engine to frame. Tighten flange nuts to
See Figure 22 and Figure 23 for lift truck models 320 N•m (236 lbf ft). See Figure 33.
equipped with GM 4.3L engine.
NOTE: Perform Step 4 on lift trucks equipped with GM
See Figure 24 for lift truck models equipped with 4.3L gas/LPG engine or Kubota diesel engine.
Cummins QSB 3.3L diesel engine.
4. If isolators fell from engine mounts during removal,
See Figure 25 for lift truck model GLC/GDC60VX, install isolators to engine mounts and install wash-
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ ers, capscrews, and flange nuts for engine mounts
GDC155VX) (E879) equipped with the Kubota 3.8L to secure engine to frame. Tighten flange nuts to
diesel engine. 150 N•m (110 lbf ft). See Figure 33.

52
100 YRM 1316 Engine Replacement

5. If isolators fell from transmission mount, install iso- 16. For lift trucks equipped with Cummins 4.5L, QSB
lators to transmission mount and install washers, 3.3L, or Kubota diesel engines, install battery and
lock washers, and capscrews. Tighten capscrews battery tray using three capscrews.
to 225 to 250 N•m (166 to 184 lbf ft). See Figure 34.
17. For lift trucks equipped with GM 4.3L engine, install
6. Remove lifting device from engine and transmission battery, battery tray, and Electronic Control Module
combination. (ECM).

7. Install radiator shroud, fan pulley, and fan assembly. 18. Install Power Distribution Module to battery tray and
See section Cooling System 700 YRM 1123 for connect ground strap to lift truck frame. See Fig-
Fan Installation procedures. ure 28.

8. Remove cap from bottom radiator hose and install

hose on radiator.

9. For lift trucks equipped with GM 4.3L engine, con-

nect exhaust pipes to exhaust manifolds. Tighten
lock nuts to 39 N•m (29 lbf ft). See Figure 22 and
Figure 23.

10. For lift trucks equipped with Kubota diesel engine,

connect exhaust pipe to exhaust manifold.

See Figure 25 for lift truck model GLC/GDC60VX,

GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L
diesel engine.

See Figure 26 for lift truck model GLC/GDC60VX,

GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879) equipped with the Kubota 3.8L
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 27.

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.

a. For lift truck models equipped with a hydraulic

gear pump on transmission, remove plugs from
1. ISOLATOR CAPSCREW
hydraulic gear pump ports, and connect suc- 2. LOCKWASHER
tion hose and hydraulic hose to hydraulic gear 3. WASHER
pump assembly. See Hydraulic Gear Pump 4. ISOLATOR
1900 YRM 1136 for more information. 5. MOUNTING BRACKET
6. MOUNTING BRACKET CAPSCREW
15. Remove caps from fuel lines and connect fuel lines
at engine. Tighten hose clamps (if equipped). Figure 34. Transmission Mounting Assembly

53
Engine Replacement 100 YRM 1316

19. Connect positive batter (B+) cable to starter motor. 24. For lift trucks equipped with either a GM 4.3L (gaso-
Tighten terminal nut to 8 to 11 N•m (71 to 97 lbf in). line) engine or a Cummins 4.5L diesel engine, con-
nect left hand chassis harness connector to engine
20. Connect negative battery cable to starter motor. harness connector.
21. Connect engine harness connector to right hand See Figure 22 for lift truck models equipped with
chassis harness connector. GFI.
See Figure 22 and Figure 23 for lift truck models See Figure 23 for lift truck models equipped with
equipped with GM 4.3L engine. PSI.
See Figure 25 for lift truck model GLC/GDC60VX, See Figure 27 for lift truck models equipped with
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ Cummins 4.5L diesel engine.
GDC155VX) (E879) equipped with the Kubota 3.8L
diesel engine. 25. Install air filter and bracket assembly.

See Figure 26 for lift truck model GLC/GDC60VX, 26. Connect air filter hose to air inlet and tighten clamp.
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (F879) equipped with the Kubota 3.8L 27. For lift trucks equipped with Cummins 4.5L diesel
diesel engine. engine, connect throttle cable to fuel injection
pump. See Figure 27.
See Figure 27 for lift truck models equipped with
Cummins 4.5L diesel engine. 28. Close drain plug and remove caps and connect
coolant hoses to radiator. Tighten hose clamps
22. For lift trucks equipped with GM 4.3L or Kubota and fill cooling system with antifreeze. See Cool-
3.8L engine, connect engine harness connectors to ing System 700 YRM 1123 for radiator refill proce-
Electronic Control Module (ECM). dures. Install radiator cap.

See Figure 22 and Figure 23 for lift truck models 29. Check all fluid levels as described in
equipped with GM 4.3L engine.
Periodic Maintenance 8000 YRM 1319 for lift truck
See Figure 25 for lift truck model GLC/GDC60VX, models
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC155VX) (E879) equipped with the Kubota 3.8L GDC135VX, GC/GLC/GDC155VX) (C879,
diesel engine. D879)

See Figure 26 for lift truck model GLC/GDC60VX, Periodic Maintenance 8000 YRM 1571 for lift truck
GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ models
GDC155VX) (F879) equipped with the Kubota 3.8L • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
diesel engine. GDC135VX, GC/GLC/GDC155VX) (E879)

NOTE: Perform Step 23 for lift truck models equipped Periodic Maintenance 8000 YRM 1606 for lift truck
with GFI fuel system. model
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
23. For lift trucks equipped with GM 4.3L LPG engine, GDC135VX, GC/GLC/GDC155VX) (F879)
connect left hand chassis harness connector to
LPG regulator connector and engine harness con-
nector. See Figure 22.

54
100 YRM 1316 Electronic Throttle Replacement

30. Install hood and seat combination, and rear side 35. For lift trucks equipped with and LPG fuel system,
covers. See section Hood, Seat, Dash, and Side swing LPG tank and bracket back to original posi-
Covers Replacement Install for procedures. tion until locked, connect LPG fuel line, and open
shutoff valve.
31. Install overhead guard. See Overhead Guard Re-
placement, Install for procedures. 36. Inspect fuel system for leaks when fuel valve is
open. There are four methods used to inspect fuel
32. Connect positive battery cable. system for leaks:
33. Connect negative battery cable. a. Sound - Listen for sound of fuel escaping from
a tank fitting or hose connection.
34. Install floor plate and floor mat.
b. Smell - Fuel has a very distinctive odor. If you
WARNING smell fuel, DO NOT start engine.
All fuels are very flammable and can burn or cause c. Soapy Water - This method is used in conjunc-
an explosion. DO NOT use an open flame to check tion with Step b above. If odor of fuel is present,
the fuel level or to check for leaks in the fuel system. but escaping fuel cannot be heard, apply soapy
No smoking. water to fittings and observe for bubbles.

Breathing fuel vapor may cause nausea, uncon- d. Frost - If the amount of fuel escaping is suffi-
sciousness or death. Long term exposure to cient, frost may appear on fittings.
gasoline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.

Electronic Throttle Replacement

CUMMINS 4.5L DIESEL ENGINE WITH 6. If necessary, remove capscrews and throttle lever
ELECTRONIC THROTTLE adapter. See Figure 36.

Remove 7. Disconnect engine harness electrical connector

from pull actuator harness connector. See Fig-
1. Disconnect engine harness electrical connector ure 39.
from throttle position sensor (TPS). See Figure 35.
8. Remove capscrews and pull actuator from mount-
2. Remove Torx-head screws, washers, and remove ing bracket. See Figure 40.
TPS and tapped TPS plate. See Figure 36.
9. If necessary, remove clevis with linkage assembly,
3. Remove capscrews and TPS bracket. See Fig- lockwasher, and nut from pull actuator. See Fig-
ure 37. ure 39.

4. Remove TPS rotor. See Figure 38.

5. Remove capscrews, nuts, and linkage assembly.

See Figure 35.

55
Electronic Throttle Replacement 100 YRM 1316

Figure 35. Electronic Throttle System

56
100 YRM 1316 Electronic Throttle Replacement

Legend for Figure 35

1. THROTTLE POSITION SENSOR (TPS) 6. CLEVIS
2. CAPSCREW 7. ADJUSTMENT NUT
3. LINKAGE ASSEMBLY 8. TORX-HEAD SCREWS
4. NUT 9. PULL ACTUATOR CONNECTOR
5. PULL ACTUATOR 10. ENGINE HARNESS CONNECTOR

57
Electronic Throttle Replacement 100 YRM 1316

Legend for Figure 36

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 36. TPS Assembly

58
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