YALE (B910) GC040VX LIFT TRUCK Service Repair Manual

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Text of YALE (B910) GC040VX LIFT TRUCK Service Repair Manual

  • GC040VX, GLC040VX, GC050VX, GLC050VX, GC055SVX, GLC055SVX,GC060VX, GLC060VX, GC/GLC070VX (B910)

    SERVICE MANUAL CONTENTS

    SECTIONPART

    NUMBERYRM

    NUMBERREV

    DATEFRAME............................................................................................................................ 550096314 0100 YRM 1672 04/14KUBOTA SPARK IGNITED 2.5L LPG............................................................................ 550096316 0600 YRM 1670 12/14MAZDA 2.2L ENGINE..................................................................................................... 550096315 0600 YRM 1673 04/14COOLING SYSTEM........................................................................................................ 550096317 0700 YRM 1674 03/14LPG FUEL SYSTEM, MAZDA 2.2L ENGINE................................................................. 550096318 0900 YRM 1675 03/14GASOLINE FUEL SYSTEM, MAZDA 2.2L ENGINE...................................................... 550096319 0900 YRM 1676 04/14LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550096321 1300 YRM 1678 04/14DRIVE AXLE REPAIR (WET BRAKE)........................................................................... 550096322 1400 YRM 1679 12/14DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 550096323 1400 YRM 1680 04/14STEERING AXLE............................................................................................................ 550096324 1600 YRM 1681 04/14BRAKE SYSTEM............................................................................................................ 550096325 1800 YRM 1682 04/14HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14HYDRAULIC GEAR PUMPS.......................................................................................... 550096326 1900 YRM 1683 04/14MAIN CONTROL VALVE................................................................................................ 550096327 2000 YRM 1684 04/14CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 12/14CYLINDER REPAIR (MAST S/N D515, E509, E564)..................................................... 550100651 2100 YRM 1692 12/14WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14ELECTRICAL SYSTEM.................................................................................................. 550096328 2200 YRM 1685 04/14ELECTRICAL SYSTEM, MAZDA 2.2L ENGINE............................................................ 550096329 2200 YRM 1686 04/14MAST REPAIR (S/N F507, F508, F562, F563)............................................................... 550093755 4000 YRM 1669 12/14MAST REPAIR (S/N D515, E509, E564)........................................................................ 550100656 4000 YRM 1693 12/14METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14PERIODIC MAINTENANCE............................................................................................ 550096306 8000 YRM 1687 04/14CAPACITIES AND SPECIFICATIONS........................................................................... 550096330 8000 YRM 1688 04/14DIAGRAMS AND SCHEMATICS.................................................................................... 550096331 8000 YRM 1689 04/14DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

    9000 YRM 1112 ON CDPART NO. 550096298 (12/14)

  • General

    WARNING The lift truck must be put on blocks for sometypes of maintenance and repairs. The removal ofthe following assemblies will cause large changesin the center of gravity: mast, drive axle, engineand transmission, and counterweight. When thelift truck is put on blocks, put additional blocks inthe following positions to maintain stability:

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

    Before removing the counterweight, putblocks under the mast assembly so the lifttruck cannot fall forward.

    The surface must be solid, even, and level whenthe lift truck is put on blocks. Make sure that anyblocks used to support the lift truck are solid,one-piece units. See the Operating Manual orPeriodic Maintenance 8000YRM1687.

    NOTE: For exhaust system procedures on lift trucksequipped with a Mazda engine go to LPG FuelSystem, Mazda 2.2L Engine 0900YRM1675 orGasoline Fuel System, Mazda 2.2L Engine0900YRM1676 .

    NOTE: For exhaust system procedures on lift trucksequipped with Kubota engine go to LPG FuelSystem, Kubota 2.5L Engine 0900YRM1677.

    NOTE: For exhaust system procedures on lift trucksequipped with Yanmar engine go to Exhaust SystemRepair in this manual.

    This section contains the description of the frame andconnected parts; procedures for removing andinstalling counterweight, hood, overhead guard,engine, transmission, cooling system, and exhaustsystem (see above NOTES). Checks for the operatorrestraint system and procedures for the repair oftanks and installation of safety labels are alsoincluded.

    DescriptionThe frame is one weldment and includes the hydraulictank and fuel tank for gasoline or diesel fuel. See Fig-ure 1.

    See Table 3 for lift truck models: GLC20-35VX (GC/GLC40-70VX, GC/

    GLC055SVX) (B910)

    See Table 4 for lift truck models: GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

    (C875)

    The muffler is fastened to the frame inside the coun-terweight.

    The overhead guard, cowl, and hood are installed onthe frame. The hood is connected to the frame withhinges. Two gas-controlled springs provide assis-tance when raising the hood and hold the hood in theopen position. The floor plate and side covers can beremoved for access to the engine, transmission, andother components.

    0100 YRM 1672 General

    1

  • 1. COWL PLATE2. FENDERS3. FRAME4. HOOD MOUNTS

    5. COUNTERWEIGHT MOUNTS6. FUEL TANK (GAS OR DIESEL)7. HYDRAULIC TANK

    Figure 1. Frame

    Hood, Seat, and Side Covers ReplacementREMOVE1. Slide seat to the closest position to steering col-

    umn.

    2. Fully tilt steering column forward.

    3. If your truck is equipped with an LPG tank, swingtank off to the side.

    4. Raise latch on the left, front corner of the hood tounlatch and lift up hood. See Figure 2.

    5. Remove floor mat and floor plate.

    Hood, Seat, and Side Covers Replacement 0100 YRM 1672

    2

  • NOTE: SWIVEL SEAT AND VENTED HOOD ARE OPTIONAL FEATURES.

    A. SIDE VIEW OF HOOD AND SEATB. SIDE VIEW OF HOOD

    C. BOTTOM VIEW OF HOODD. SIDE VIEW OF VENTED HOOD WITH SWIVEL

    SEAT

    1. SEAT2. HOOD3. FRAME4. SEAT WIRE HARNESS5. SEAT WIRE HARNESS CONNECTOR (WITH-

    OUT ELECTRONIC CONTROL)6. SEAT WIRE HARNESS CONNECTOR (WITH

    ELECTRONIC CONTROL)7. CABLE CLIPS8. HINGE SCREWS

    9. GAS SPRING10. ATTACHMENT HOLES ATTACHING HOOD TO

    SEAT (SEMI-SUSPENSION)11. SEAT WIRE HARNESS BRACKETS12. SEAT LINER13. HOOD LATCH14. ATTACHMENT HOLES ATTACHING HOOD TO

    SEAT (NON-SUSPENSION)15. ATTACHMENT HOLES ATTACHING HOOD TO

    SEAT (FULL SUSPENSION)16. SPACER

    Figure 2. Hood and Seat Arrangement

    0100 YRM 1672 Hood, Seat, and Side Covers Replacement

    3

  • Figure 3. Side Cover, Floor Plate, and Cowl Components GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX)(B910)

    Hood, Seat, and Side Covers Replacement 0100 YRM 1672

    4

  • Legend for Figure 3

    1. LOWER STEERING COLUMN COVER2. UPPER STEERING COLUMN COVER3. INSERT4. CLIP5. DASHBOARD6. CAPSCREW7. SEAL8. GROMMET9. LEFT HAND REAR PANEL10. FLOOR PLATE11. LEFT HAND FENDER COVER12. SCREW13. NUT

    14. LEFT HAND FRONT PANEL15. LEFT HAND STEP PANEL16. LEFT HAND TREAD PLATE17. PLATE ASSEMBLY SEAL18. RIGHT HAND FENDER COVER19. FLOOR MAT20. RIGHT HAND TREAD PLATE21. RIGHT HAND FRONT PANEL22. RIGHT HAND STEP PANEL23. RIGHT HAND REAR PANEL24. RADIATOR COVER25. KICK PANEL26. PLATE ASSEMBLY

    0100 YRM 1672 Hood, Seat, and Side Covers Replacement

    5

  • Figure 4. Side Covers, Floor Plate, and Cowl Components GLP/GDP20-35VX (GP/GLP/GDP040-070VX)(C875)

    Hood, Seat, and Side Covers Replacement 0100 YRM 1672

    6

  • Legend for Figure 4

    1. DASH ASSEMBLY2. UPPER STEERING COLUMN COVER3. LOWER STEERING COLUMN COVER4. KICK PANEL5. MUD GUARD (LH)6. MUD GUARD (RH)7. LOCK NUT8. NUT9. COVER10. BRACKET11. PLATE ASSEMBLY12. GROMMET13. LEFT FRONT PANEL14. RIGHT FRONT PANEL

    15. LEFT STEP PANEL16. RIGHT STEP PANEL17. LEFT STEP PLATE18. RIGHT STEP PLATE19. LEFT REAR PANEL20. RIGHT REAR PANEL21. FLOOR MAT22. FLOOR PLATE23. RADIATOR COVER24. SEALS25. CAPSCREW26. CLIP NUT27. INSERT28. PLATE ASSEMBLY SEAL

    6. Remove two capscrews holding left and right rearside covers to the frame. Remove rear side cov-ers from frame.

    7. Remove two capscrews holding left and rightfender covers to front overhead guard leg. Re-move covers.

    8. Remove four capscrews holding left and rightfront side covers to fra