Professional Documents
Culture Documents
General
NOTE: For exhaust system procedures on lift trucks
WARNING equipped with a PSI 2.4L engine go to Fuel System
The lift truck must be put on blocks for some PSI 2.4L 0900YRM1757.
types of maintenance and repairs. The removal of
the following assemblies will cause large changes NOTE: For exhaust system procedures on lift trucks
in the center of gravity: mast, drive axle, engine equipped with Kubota engine go to .
and transmission, and counterweight. When the
NOTE: For exhaust system procedures on lift trucks
lift truck is put on blocks, put additional blocks in
equipped with Yanmar engine go toExhaust System
the following positions to maintain stability:
Repair in this manual.
• Before removing the mast and drive axle,
put blocks under the counterweight so the This section contains the description of the frame and
lift truck cannot fall backward. connected parts; procedures for removing and
• Before removing the counterweight, put installing counterweight, hood, overhead guard,
blocks under the mast assembly so the lift engine, transmission, cooling system, and exhaust
truck cannot fall forward. system (see above NOTES). Checks for the operator
restraint system and procedures for the repair of
The surface must be solid, even, and level when tanks and installation of safety labels are also
the lift truck is put on blocks. Make sure that any included.
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or
Periodic Maintenance 8000YRM1762.
Description
The frame is one weldment and includes the hydraulic The muffler is fastened to the frame inside the coun-
tank and fuel tank for gasoline or diesel fuel. See Fig- terweight.
ure 1.
The overhead guard, cowl, and hood are installed on
There is a counterweight for each capacity of lift truck. the frame. The hood is connected to the frame with
The counterweights are similar in appearance, but are hinges. Two gas-controlled springs provide assis-
different weights. tance when raising the hood and hold the hood in the
open position. The floor plate and side covers can be
See Table 3 for lift truck models: removed for access to the engine, transmission, and
• GLC20-35VX (GC/GLC40-70VX, GC/ other components.
GLC055SVX) (C910)
1
Description 0100 YRM 1754
Figure 1. Frame
2
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
3
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
Figure 3. Side Cover, Floor Plate, and Cowl Components GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX)
(C910)
4
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
Figure 4. Side Covers, Floor Plate, and Cowl Components GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875)
5
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
7. Remove two capscrews holding left and right 13. Remove three capscrews holding the seal plate.
fender covers to front overhead guard leg. Re- Remove seal plate. See Figure 6.
move covers.
14. Disconnect seat wire harness connector. See Fig-
See Figure 3 for lift truck models: ure 2.
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910) CAUTION
See Figure 4 for lift truck models When removing the seat from the hood, DO NOT
use an impact wrench to remove the capscrews.
• GLP/GDP20-35VX (GP/GLP/
Damage can be caused to the threads on the
GDP040-070VX) (D875)
screws and in the holes.
8. Remove four capscrews holding left and right
15. If seat is to be removed, and truck is equipped
front side covers to frame. Remove covers.
with a non-swivel seat, remove seat wire harness
9. Fully lower steering column. from seat wire harness brackets that are attached
to the underside of hood. Remove the cable clips
10. Remove upper steering column cover by pulling from the seat wire harness. If truck is equipped
up on upper steering column cover to release with a swivel seat, remove seat wire harness from
latches (one on either side), and pulling cover seat wire harness bracket attached to underside
away from steering column. See Figure 5. of the hood and behind the seat (see Figure 2).
11. Remove five allen screws (see Figure 5) from 16. Remove four capscrews and washers holding the
dash and cowl. Remove four clips, located under- seat to hood. Lift seat off the hood. Pull seat wire
neath dash, that attach dash to the kick panel. Lift harness through hood. See Figure 2.
to remove dash.
17. Remove capscrews and washers at the top of gas
12. Lift the kick panel to remove from truck. springs. Remove gas springs from hood.
See Figure 3 for lift truck models: 18. Remove hinge screws, located in the rear of the
• GLC20-35VX (GC/GLC40-70VX, GC/ hood.
GLC055SVX) (C910) 19. Lift hood from the truck. See Figure 2.
See Figure 4 for lift truck models:
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
6
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
7
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
8
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
INSTALL
1. Place hood onto the lift truck frame.
See Figure 7 and Table 1 for lift truck models: NOTE: LEFT SIDE SHOWN
• GLC20-35VX (GC/GLC40-70VX, GC/
GLC055SVX) (C910) A. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR NON-SUSPENSION
SEAT
See Figure 8 and Table 2 for lift truck models B. MOUNTING LOCATION FOR CYLINDER END
• GLP/GDP20-35VX (GP/GLP/ OF GAS SPRING FOR SEMI OR FULL SUS-
GDP040-070VX) (D875) PENSION SEAT
C. MOUNTING LOCATION FOR CYLINDER END
OF GAS SPRING FOR SEMI OR FULL SUS-
PENSION SEAT WITH CAB
1. MOUNTING POINTS FOR GAS SPRING ON
HOOD
Table 1. Gas Spring Installation, Lift Truck Models GLC20-35VX (GC/GLC40-70VX, GC/ GLC055SVX)
(C910)
9
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
A. LEFT SIDE
B. RIGHT SIDE
C. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR NON-SUSPENSION SEAT
D. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION
SEAT, LIFT TRUCKS WITH CAB OR (GP/GLP/GDP040-070VX) (D875) LIFT TRUCKS WITHOUT CAB
E. MOUNTING LOCATION FOR CYLINDER END OF GAS SPRING FOR SEMI OR FULL SUSPENSION
SEAT, LIFT TRUCKS GLP/GDP20-35VX (D875) WITHOUT CAB
1. MOUNTING POINTS FOR GAS SPRING ON HOOD
Figure 8. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
Table 2. Gas Spring Installation, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
10
0100 YRM 1754 Hood, Seat, and Side Covers Replacement
4. Install latch striker in highest slot position. Check 6. Check operation of hood latch. Have an operator
that latch striker is in center of jaws of hood latch sit in seat. Make sure hood is fully closed (two
when hood closes. Open and close hood to en- clicks). Also check that hood touches rubber
sure that center pin strikes hood latch properly bumper. If necessary, repeat Step 5.
and that the stop screw contacts frame. A prop-
erly closed hood MUST click twice on the hood
latch. If the hood latch does not close properly, CAUTION
loosen capscrews on the back of center pin and When installing the seat to the hood, DO NOT use
adjust center pin up or down as required for cor- an impact wrench to install the capscrews. Dam-
rect alignment. See Figure 9. age can be caused to the threads on the screws
and in the holes.
5. Push down until hood just touches rubber
bumper. Make sure latch striker is still in center of 7. Place seat on the hood and thread seat wire har-
hood latch. Open hood and tighten capscrews for ness through the hole in the hood. See Figure 2.
latch.
8. Align holes in the seat with the holes in hood. In-
sert washers and capscrews. Tighten capscrews
to 18 N•m (159 lbf in).
11
Hood, Seat, and Side Covers Replacement 0100 YRM 1754
15. Using two capscrews, install left and right fender See Figure 4 for lift truck models:
covers to front of overhead guard legs. • GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
16. Using two capscrews, install left and right rear
side covers to frame. 17. Install floor mat and floor plate.
See Figure 3 for lift truck models: 18. If truck is equipped with an LPG tank, swing LPG
• GLC20-35VX (GC/GLC40-70VX, GC/ tank into position on back of counterweight.
GLC055SVX) (C910)
19. Adjust the steering column and seat positions.
Steering Column
DESCRIPTION STEERING COLUMN REPAIR
This section describes the repair procedures for the Remove
steering column. The steering column assembly
mounts to the cowl inside the operator compartment 1. Put blocks on each side (front and back) of tires
and is the mechanical connection between the steer- to prevent lift truck from moving.
ing wheel and the steering control unit. The steering
column includes the steering wheel, housing, bracket WARNING
and lower shaft. For lift trucks with gas and LPG en-
Disconnect the battery before removing any cov-
gines, bolts and bushings attach the steering column
ers to avoid injury to personnel.
to the cowl standoffs. For lift trucks with diesel en-
gines, bolts, bushings and isolators attach the steer- 2. Attach a tag on battery connector or negative bat-
ing column to the cowl standoffs. See Figure 10. tery cable stating, DO NOT CONNECT BAT-
TERY. 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.
12
0100 YRM 1754 Steering Column
1. HORN BUTTON
2. HEX NUT
3. STEERING WHEEL
4. STEERING COLUMN
13
Steering Column 0100 YRM 1754
Disassemble Assemble
NOTE: Remove and discard snap rings if installed. This procedure is for installation of all components of
steering column assembly. Not all components are re-
1. Remove two pins and gas spring from housing.
moved for a repair procedure. Do only those steps of
See Figure 13.
procedure necessary to install required component.
2. Remove two pivot bolts, two bushings, two nuts
and bracket from housing. See Figure 13. 1. Install fastener, connector bracket and connector,
two horn contacts and four screws. See Fig-
3. Remove split pin and lower shaft from upper ure 13.
shaft. See Figure 13.
2. Assemble lower shaft and upper shaft, secure
4. Remove connector from connector bracket. Re- with spit pin. See Figure 13.
move connector bracket, fastener, four screws
and two horn contacts from housing. See Fig- 3. Install two pivot bolts, two bushings, two nuts and
ure 13. bracket onto housing. See Figure 13.
WARNING Install
Cleaning solvents can be flammable and toxic and
NOTE: Lubricate spline end of lower shaft with multi
can cause skin irritation. When using cleaning
purpose grease.
solvents, always follow the solvent manufactur-
er's recommended safety precautions. See Periodic Maintenance 8000YRM1762 for lift
truck models
WARNING • GLC20-35VX (GC/GLC040-070VX, GC/
Compressed air is used for cleaning and drying GLC055SVX) (C910)
purposes, or for cleaning restrictions. Wear pro- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
tective clothing (goggles/shields, gloves, etc.). (D875)
Make sure the path of the compressed air is away
from all personnel to avoid injury. NOTE: Perform Step 1 for lift trucks equipped with
gas or LPG engines.
1. Clean metal parts in solvent. Remove all traces of 1. Install steering column, four isolators, four bush-
old lubricant and dirt. Clean nonmetal parts with ings, and four bolts on cowl standoffs. Tighten
warm soapy water and a lint free cloth. bolts to 38 N•m (28 lbf ft). See Figure 12.
2. After cleaning, dry parts with compressed air. DO NOTE: Perform Step 2 for lift trucks equipped with
NOT dry parts with a cloth. diesel engines.
3. Replace all defective or damaged parts. 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). Connect electrical wiring and install horn
button. See Figure 11.
14
0100 YRM 1754 Steering Column
5. Remove tag from negative battery connector and 6. Remove blocks from each side of tires.
connect to battery. Adjust steering column to neu-
tral position.
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 13. Steering Column
15
LPG Tank and Bracket Assembly 0100 YRM 1754
Counterweight Replacement
REMOVE Close the shutoff valve on the LPG tank before
any part of the engine fuel system is disconnec-
ted. Run the engine until the fuel in the system is
WARNING used and the engine stops.
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of If the engine will not run, close the shutoff valve
the following assemblies will cause large changes on the LPG tank. Loosen the fitting on the supply
in the center of gravity: mast, drive axle, engine hose from the LPG tank where it enters the filter
and transmission, and counterweight. When the unit. Permit the pressure in the fuel system to de-
lift truck is put on blocks, put additional blocks in crease slowly. Fuel leaving the fitting removes
the following positions to maintain stability: heat. Use a cloth to protect your hands from the
• Before removing the mast and drive axle, cold fitting.
put blocks under the counterweight so the NOTE: The counterweight is held in position on
lift truck cannot fall backward. frame by two hooks that are part of frame. See Fig-
• Before removing the counterweight, put ure 14.
blocks under the mast assembly so the lift
truck cannot fall forward. One M24 × 3 x 140 capscrew holds counterweight to
lower part of frame on lift truck models:
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any • GLC30-35VX (GC/GLC060-070VX, GC/
blocks used to support the lift truck are solid, GLC055SVX) (C910)
one-piece units. See the procedure How to Put Lift • GLP/GDP30-35VX (GP/GLP/GDP060-070VX)
Truck on Blocks in the Operating Manual or the (D875)
Periodic Maintenance Manual for your lift truck.
One M24 × 3 x 90 capscrew holds counterweight to
lower part of frame on lift truck models:
WARNING
• GLC20-55VX (GC/GLC040-050VX) (C910)
DO NOT operate the lift truck if the capscrew for
the counterweight is not installed. When the cap- • GLP/GDP20-25VX (GP/GLP/GDP040-050VX)
screw is removed, the counterweight can fall from (D875)
the lift truck.
NOTE: For overhead exhaust system removal proce-
dure, for lift trucks equipped with a PSI 2.4L engine,
WARNING see Fuel System PSI 2.4L 0900YRM1757.
LPG can cause an explosion. DO NOT cause
NOTE: For overhead exhaust system removal proce-
sparks or permit flammable material near the LPG
dure, for lift truck equipped with a Kubota engine, see
system. LPG fuel systems can be disconnected
LPG Fuel System, Kubota 2.5L Engine
indoors only if the lift truck is at least 8 m (26 ft)
0900YRM1677.
from any open flame, motor vehicles, electrical
equipment, or ignition source.
16
0100 YRM 1754 Counterweight Replacement
Remove tow pin. See Figure 14 and Figure 15. GLC30VX (GC/
1819 4010
GLC060VX)
Remove capscrew and washer that hold counter- GLC35VX (GC/
weight to frame. See Figure 14 and Figure 15. 2153 4747
GLC070VX)
Use crane to lift counterweight from lift truck frame.
Place counterweight on floor so that is has stability
and will not fall over. Take care not to damage ex-
haust or cooling components.
17
Counterweight Replacement 0100 YRM 1754
• GLP/GDP20-35VX (GP/GLP/
Table 4. Weight of Counterweights, Lift Truck GDP040-070VX) (D875)
Models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875) 6. If lift truck is equipped with a Yanmar engine and
an overhead exhaust system, install the overhead
Model Kg Lb pipe. See section Exhaust System Repair in this
GLP/GDP20VX manual for procedures.
994 2191
(GP/GLP/GDP040VX)
GLP/GDP25VX
1338 2950
(GP/GLP/GDP050VX)
GLP/GDP30SVX (GP/
1664 3668
GLP/GDP060SVX)
GLP/GDP35SVX (GP/
1965 4332
GLP/GDP070SVX)
INSTALL
1. Make sure seals are on counterweight. Figure 15.
18
0100 YRM 1754 Overhead Guard Replacement
See your dealer for Hyster lift trucks BEFORE per- LED TAIL, BACKUP, AND BRAKE
forming any changes to the overhead guard. LIGHTS, REPLACE
NOTE: The lift trucks covered in this YRM are equip- These light assemblies are nonrepairable and must
ped with either a high or low overhead guard. The re- be replaced as an assembly. See Electrical System
moval and installation procedures for both types of 2200YRM1760 for the procedures to replace these
overhead guards are the same. lights.
19
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.