Page 1

GLP/GDP40VX5, GLP/GDP40VX6, GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50VX, GLP/GDP55VX (H813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... KUBOTA ENGINE REPAIR............................................................................................ KUBOTA DIESEL 3.6L ENGINE.................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM 4.3L)...................................................................................... LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 1 AND 2 SP PS TRANSMISSION REPAIR.................................................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ WET BRAKES - NMHG.................................................................................................. HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ MAIN CONTROL VALVE (WITH VARIABLE DISPLACEMENT PUMP)....................... CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524262274 524306203 524265337 550048607 550055279 524223757 524262275 550043871 550048681 524262277 524262278 550055280 524223764 524262279 550064329 524223766 550073240 524223767 550031265

0100 YRM 1243 0100 YRM 1290 0600 YRM 1251 0600 YRM 1557 0600 YRM 1579 0700 YRM 1123 0900 YRM 1242 0900 YRM 1556 1300 YRM 1569 1400 YRM 1245 1400 YRM 1246 1400 YRM 1582 1600 YRM 1133 1800 YRM 1247 1800 YRM 1597 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2000 YRM 1457

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

524223768 524208014 524223769 524223770 524223771 524223772

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

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

524265342 524150797 524223780 550048690 550048683 550055283 524221866

4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1558 8000 YRM 1559 8000 YRM 1585 9000 YRM 1112

02/14 10/13 12/14 12/13 07/14 04/14 12/14

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 550048602 (12/14)


SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

• • • • • • • • • • • •

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. Do not lift heavy parts by hand, use a lifting mechanism. Wear safety glasses. DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. Keep the unit clean and the working area clean and orderly. Use the correct tools for the job. Keep the tools clean and in good condition. Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. Be sure to follow the WARNING and CAUTION notes in the instructions. Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage. On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.


Table of Contents

TABLE OF CONTENTS General ..................................................................................................................................................................... 1 Cab Replacement ..................................................................................................................................................... 2 Remove, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/ GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/ GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)................................................................................................2 Install, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/ GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/ GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)..............................................................................................21 Remove, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and , GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).......................................... 22 Install, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)..................................................................... 29 Door Assemblies .....................................................................................................................................................31 Right Side Door Assembly, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)...................................................................................................................................31 Remove ..........................................................................................................................................................31 Disassemble ...................................................................................................................................................38 Door Cover With Heater Unit ..................................................................................................................... 38 Door Cover With Air Conditioner/Heater Unit ............................................................................................ 40 Heater Assembly ........................................................................................................................................42 Air Conditioner and Heater Unit Assembly ................................................................................................ 42 Door Lock Assembly ..................................................................................................................................45 Windows .................................................................................................................................................... 46 Clean ..............................................................................................................................................................46 Inspect ............................................................................................................................................................46 Assemble ....................................................................................................................................................... 46 Windows .................................................................................................................................................... 46 Door Lock Assembly ..................................................................................................................................46 Heater Assembly ........................................................................................................................................47 Air Conditioner and Heater Unit Assembly ................................................................................................ 47 Door Cover With Heater Unit ..................................................................................................................... 47 Door Cover With Air Conditioner and Heater Unit ..................................................................................... 48 Install ..............................................................................................................................................................48 Left Side Door Assembly, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)...................................................................................................................................49 Remove ..........................................................................................................................................................49 Disassemble ...................................................................................................................................................49 Door Cover .................................................................................................................................................49 Door Lock Assembly ..................................................................................................................................50 Windows .................................................................................................................................................... 50

©2014 Yale Materials Handling Corp.

i


Table of Contents

TABLE OF CONTENTS (Continued) Clean ..............................................................................................................................................................50 Inspect ............................................................................................................................................................50 Assemble ....................................................................................................................................................... 50 Windows .................................................................................................................................................... 50 Door Lock Assembly ..................................................................................................................................50 Door Cover .................................................................................................................................................50 Install ..............................................................................................................................................................51 Right and Left Side Door Assemblies, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)............. 51 Remove ..........................................................................................................................................................51 Disassemble ...................................................................................................................................................52 Door Cover .................................................................................................................................................52 Door Lock Assembly ..................................................................................................................................53 Windows .................................................................................................................................................... 54 Clean ..............................................................................................................................................................54 Inspect ............................................................................................................................................................54 Assemble ....................................................................................................................................................... 54 Windows .................................................................................................................................................... 54 Door Lock Assembly ..................................................................................................................................54 Door Cover .................................................................................................................................................55 Install ..............................................................................................................................................................55 Window Wipers Replacement .................................................................................................................................55 General ...............................................................................................................................................................55 Front Wiper Assembly and Motor ....................................................................................................................... 55 Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)....................................................................................................... 55 Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)....................................................................................................... 57 Remove, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)............................................................................................. 57 Install, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)............................................................................................. 61 Rear Wiper Assembly and Motor ........................................................................................................................62 Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)................................................................ 62 Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)................................................................ 62 Remove, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)............................ 64 Install, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)................................ 64 Remove, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)........................... 67

ii


Table of Contents

TABLE OF CONTENTS (Continued) Install, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)................................... 67 Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)......................................69 Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)....................................................... 69 Window Replacement .............................................................................................................................................71 General ...............................................................................................................................................................71 Remove Door Window, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)...................................................................................................................................71 Install Door Windows, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)...................................................................................................................................72 Remove Door Window, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) .................................72 Install Door Window, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).......................................... 74 Heater Replacement ...............................................................................................................................................74 Remove, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).......................................... 74 Install, for Lift truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)............................................................77 Heater and Air Conditioner Assembly .....................................................................................................................78 Air Conditioner Condenser Unit ..........................................................................................................................78 Remove ..........................................................................................................................................................78 Install ..............................................................................................................................................................79 Air Conditioner Receiver/Drier Unit .................................................................................................................... 80 Remove ..........................................................................................................................................................80 Install ..............................................................................................................................................................81 Air Conditioner Compressor ............................................................................................................................... 81 Light Replacement ..................................................................................................................................................82 Work Lights (Front and Rear) ............................................................................................................................. 82 Remove ..........................................................................................................................................................82 Install ..............................................................................................................................................................82 Strobe Light ........................................................................................................................................................ 84 Remove ..........................................................................................................................................................84 Install ..............................................................................................................................................................85 Turn, Stop, Tail, and Backup Light ..................................................................................................................... 85 Remove ..........................................................................................................................................................85

iii


Table of Contents

TABLE OF CONTENTS (Continued) Install ..............................................................................................................................................................85 Front Marker/Turn Signal Lights ......................................................................................................................... 86 Remove ..........................................................................................................................................................86 Install ..............................................................................................................................................................86 Display Switches .....................................................................................................................................................87 Electrical Schematics ..............................................................................................................................................91 Optional Equipment ................................................................................................................................................ 91 Heavy Duty Pre-Cleaner .....................................................................................................................................91 Remove ..........................................................................................................................................................91 Clean ..............................................................................................................................................................92 Inspect ............................................................................................................................................................92 Install ..............................................................................................................................................................92 Fan ..................................................................................................................................................................... 93 Remove ..........................................................................................................................................................93 Install ..............................................................................................................................................................93 Mirror .................................................................................................................................................................. 93 Remove ..........................................................................................................................................................93 Install ..............................................................................................................................................................93 Label Replacement .................................................................................................................................................95 This section is for the following models: GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX [C810]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875, C875]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878, E878]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) [A909, B909]

iv


0100 YRM 1290

General

General The overhead guard is an integral part of operator cab. The operator cab is installed on a platform above main frame members. Step plates on both sides of lift truck provide access to operator cab. The operator

cab is a separate unit and can be removed as a complete unit from module and frame of the lift truck. See Figure 1.

Figure 1. Operator Cab

1


Cab Replacement

0100 YRM 1290

Cab Replacement REMOVE, FOR LIFT TRUCK MODELS GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) NOTE: The EZ Tank Bracket used on these trucks to mount LPG tank onto counterweight come in two styles. One style of bracket swings out to side of truck and other swings out to side and drops down. NOTE: On lift trucks equipped with LPG, make sure to release EZ Tank Bracket before opening hood. 1. For lift truck models GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810), tilt steering column to UP position, slide seat assembly forward, open rear door, and open hood to disconnect battery. See Figure 2.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator is hot and the cap is removed, the pressure is released from the system and the steam and boiling coolant can cause burns. Wait 30 minutes for the engine to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to remove, check, or fix any part of the cooling system. NOTE: Removing radiator cap will help depressurize cooling system. 4. Remove radiator cover to access radiator cap. Remove radiator cap. See Figure 5.

2. Tilt steering column to UP position, slide seat assembly forward, open rear sliding window, and open hood to disconnect battery. See Figure 3 for lift truck models •

GLP/GDP20-35VX GDP040-070VX) (B875, C875)

(GP/GLP/

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

3. Disconnect air filter hose from rear left corner leg of cab frame. See Figure 4.

WARNING DO NOT disconnect the heater hoses from the engine when the engine is hot or when the cooling system is under pressure, to do so could cause serious injury.

2

1. LATCH 2. HINGE

3. REAR DOOR

Figure 2. Rear Door and Latch for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810)


0100 YRM 1290

Cab Replacement

A. LIFT TRUCKS MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) AND GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) WITHOUT AIR CONDITIONING. B. LIFT TRUCKS MODELS GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) WITH AIR CONDITIONING. 1. REAR BOTTOM WINDOW 2. RELEASE LATCH

3. AC HOSE

Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) Legend for Figure 4 NOTE: AIR FILTER HOSE FOR GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813) SHOWN. AIR FILTER HOSE FOR OTHER LIFT TRUCK MODELS ARE SIMILAR. 1. CAPSCREW 2. AIR FILTER HOSE

Figure 4. Air Filter Hose Removal

3


Cab Replacement

0100 YRM 1290

A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) C. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) D. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 1. RADIATOR COVER

2. RADIATOR CAP Figure 5. Radiator Cover and Cap Location

4


0100 YRM 1290

CAUTION DO NOT allow any fluid to drain when disconnecting the heater hose from the engine. The method will help when purging the system during installation. 5. Disconnect and cap heater hoses from engine. See Figure 6.

WARNING Replacement, installation and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid must be performed by a certified technician. 6. Contact a certified air conditioning specialist to have the refrigerant extracted from the air conditioning system. NOTE: Step 7 is for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or a Kubota diesel engine. 7. If lift truck cab is equipped with an air conditioner/ heater unit, disconnect AC refrigerant hoses from refrigerant compressor. See Figure 7 for lift truck models •

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

See Figure 8 for lift truck models •

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

Cab Replacement 8. Open left side door, remove lock nut, and disconnect gas spring from cab mounting bracket. See Figure 9. 9. Lift left side door up and over hinge pin and set aside. See Figure 10.

WARNING DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator cab) or engine when the engine is hot or under pressure, to do so could cause serious injury. 10. Disconnect heater hose quick disconnect fittings. a. For lift truck models GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810), open right side door and push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly hoses (see Figure 6). Disconnect heater wire harness connection. See Figure 11. b. For lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875), open right side door and remove radiator cover to access quick disconnect fittings. Push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly (see Figure 6). Disconnect heater wire harness connection. See Figure 11. c. For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), open right side door and located on inner rear cover there are two port holes (see Figure 6). Push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly and disconnect heater wire harness connection. See Figure 11.

NOTE: Removing door assemblies requires two people.

5


Cab Replacement

0100 YRM 1290

Figure 6. Heater Hose Connection

6


0100 YRM 1290

Cab Replacement Legend for Figure 6

NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. LIFT TRUCK MODELS GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) C. LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)

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

1. QUICK DISCONNECT FITTING 2. INNER REAR COVER 3. RADIATOR COVER

4. RIGHT SIDE DOOR ASSEMBLY 5. HEATER HOSES

7


Cab Replacement

0100 YRM 1290

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 1. HOSE FITTING 2. REFRIGERANT COMPRESSOR

3. AC/HEATER UNIT 4. ENGINE

Figure 7. AC Refrigerant Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with Cummins QSB 3.3L Engine

8


0100 YRM 1290

Cab Replacement

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. KUBOTA 3.8L DIESEL ENGINE SHOWN, 3.6L DIESEL ENGINE SIMILAR. A. LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) B. LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 1. HOSE FITTING 2. REFRIGERANT COMPRESSOR

3. AC/HEATER UNIT 4. ENGINE

Figure 8. AC Refrigerant Hose Connection, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813) with Kubota Diesel Engine 9


Cab Replacement

0100 YRM 1290 Legend for Figure 10 NOTE: RIGHT SIDE DOOR HINGE SHOWN. 1. HINGE PIN 2. DOOR HINGE

NOTE: RIGHT SIDE DOOR SHOWN. 1. GAS SPRING 2. CAB MOUNTING BRACKET 3. LOCK NUT Figure 9. Gas Spring Mounting Removal NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 1. HEATER WIRE HARNESS CONNECTOR 2. REAR GRAB HANDLE HORN BUTTON CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS) Figure 11. Heater Wire Harness and Rear Grab Handle Horn Button Connectors

Figure 10. Door Removal

10


0100 YRM 1290 11. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or Kubota diesel engine, if lift truck cab is equipped with an air conditioner/heater unit, disconnect AC hoses. a. Remove six fasteners and remove rear cover.

Cab Replacement See Figure 14 for lift truck models •

c. Disconnect air conditioner wire harness. See Figure 12 for lift truck models •

See Figure 12 for lift truck models •

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

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

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

b. Disconnect air conditioner hoses at bulkhead bracket and at receiver/drier. See Figure 12 for lift truck models •

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

See Figure 13 for lift truck models •

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

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

See Figure 14 for lift truck models •

See Figure 14 for lift truck models •

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

See Figure 13 for lift truck models

See Figure 13 for lift truck models •

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

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

12. Remove lock nut and disconnect gas spring from cab mounting bracket. See Figure 9. 13. Lift door up and over hinge pin and set aside. See Figure 10. NOTE: Wiper motor cover must be removed before dash assembly can be removed. 14. Unclip and remove front wiper motor cover. See Figure 15 for lift truck models •

GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810)

GLP/GDP20-35VX GDP040-070VX) (B875, C875)

(GP/GLP/

11


Cab Replacement

0100 YRM 1290

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW

B. TOP VIEW

1. 2. 3. 4.

5. 6. 7. 8.

HOSE WRAP FASTENERS REAR COVER AIR CONDITIONER HOSES

BULKHEAD BRACKET RECEIVER/DRIER FITTINGS AIR CONDITIONER WIRE HARNESS

Figure 12. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) With a Cummins QSB 3.3L Diesel Engine

12


0100 YRM 1290

Cab Replacement

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW

B. TOP VIEW

1. 2. 3. 4.

5. 6. 7. 8.

HOSE WRAP FASTENERS REAR COVER AIR CONDITIONER HOSES

BULKHEAD BRACKET RECEIVER/DRIER FITTINGS AIR CONDITIONER WIRE HARNESS

Figure 13. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) With a Kubota Diesel Engine

13


Cab Replacement

0100 YRM 1290

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW

B. TOP VIEW

1. 2. 3. 4.

5. 6. 7. 8.

HOSE WRAP FASTENERS REAR COVER AIR CONDITIONER HOSES

BULKHEAD BRACKET RECEIVER/DRIER FITTINGS AIR CONDITIONER WIRE HARNESS

Figure 14. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) With a Kubota Diesel Engine

14


0100 YRM 1290

Cab Replacement

Figure 15. Dash Installation

15


Cab Replacement

0100 YRM 1290 Legend for Figure 15

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810) AND GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) B. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 1. 2. 3. 4.

CAPSCREWS FRONT WIPER MOTOR COVER DASH ASSEMBLY KICK PANEL

15. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813), remove two lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 15. 16. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813), remove three lock nuts from front wiper motor cover. Remove front wiper motor cover.

16

5. 6. 7. 8.

COWL PANEL FRONT OPERATOR CAB LEGS LOCK NUT FLANGE BOLT

17. Remove five capscrews from top of dash assembly and cowl panel. 18. Remove two flange bolts securing cowl panel to front operator cab legs. 19. Unclip dash assembly from kick panel. Remove dash assembly. 20. Remove kick panel from seal plate assembly. See Figure 16.


0100 YRM 1290

Cab Replacement

Figure 16. Seal Plate Assembly, Kick Panel, and Floor Plate Removal

17


Cab Replacement

0100 YRM 1290 Legend for Figure 16

NOTE: CAB REMOVED FOR CLARITY. A. GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810) AND GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)

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

1. 2. 3. 4.

5. FLOOR PLATE (LEFT SIDE) 6. FLOOR PLATE (RIGHT SIDE) 7. FLOOR PLATE

CAPSCREWS KICK PANEL SEAL PLATE ASSEMBLY SEAL

21. Remove capscrews and seal plate assembly from lift truck frame. 22. Disconnect rear grab handle horn button connector from right-hand chassis harness, located in right rear corner leg of cab frame. See Figure 11. 23. Disconnect light harness connector from Vehicle Systems Manager (VSM) and right-hand chassis harness connector. See Figure 17. NOTE: Perform Step 24 and Step 25 for lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (J813) equipped with Diesel Particulate Filter (DPF). 24. Disconnect light harness connector from Vehicle Systems Manager (VSM) and right-hand chassis harness connector. See Figure 18. 25. Disconnect Diesel Particulate Filter (DPF) display harness connector from cowl harness. See Figure 18. 26. Remove rear panels, front panels, and fender covers to access cab mounting capscrews and flange nuts. See Figure 19. 27. Remove front and rear cab capscrews and flange nuts from lift truck frame. See Figure 20.

18

NOTE: KICK PANEL REMOVED FOR CLARITY. 1. VSM 2. LIGHT HARNESS CONNECTOR (TO VSM) 3. HARNESS CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS) Figure 17. Light Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models GLP/ GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/ GDP030VX (C810), GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875, C875) and GLP/GDP40VX5/ VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)


0100 YRM 1290

Cab Replacement

NOTE: KICK PANEL REMOVED FOR CLARITY. 1. VSM 2. DPF DISPLAY HARNESS CONNECTOR (TO COWL HARNESS) 3. LIGHT HARNESS CONNECTOR (TO VSM) 4. HARNESS CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS) Figure 18. Electrical Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (J813)

NOTE: LEFT CLARITY. 1. 2. 3. 4. 5. 6.

SIDE

DOOR

REMOVED

FOR

REAR PANEL (LPG) REAR PANEL (GAS AND DIESEL) FRONT PANEL FENDER COVER SCREWS CAPSCREWS Figure 19. Front and Rear Panels and Fender Cover Removal

19


Cab Replacement

0100 YRM 1290

WARNING Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb). 28. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 21.

CAUTION Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected and are not damaged. 29. Carefully lift operator cab away from lift truck. Set operator cab in a storage area and place blocks under operator cab to make it stable and prevent damage to parts still attached.

NOTE: ILLUSTRATION FOR REFERENCE PURPOSES ONLY. ACTUAL LIFT TRUCK MAY BE SLIGHTLY DIFFERENT. A. FRONT VIEW B. REAR VIEW 1. CAPSCREWS 2. FLANGE NUTS Figure 20. Front and Rear Cab Mounting Figure 21. Lift Strap Connection

20


0100 YRM 1290

INSTALL, FOR LIFT TRUCK MODELS GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 1. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 21. 2. Carefully lift operator cab onto lift truck frame making sure that front and rear leg mounting holes are aligned with frame mounting holes. 3. Install capscrews and flange nuts to rear operator cab legs. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 20. 4. Install capscrews and lock nuts to front operator's cab legs. Tighten capscrews to 66 N•m (49 lbf ft). 5. Install fender covers, front panel, and rear panels to frame. See Figure 19. Tighten capscrews to 10.8 N•m (7.96 lbf ft). 6. Connect light harness connector to Vehicle Systems Manager (VSM) and right-hand chassis harness. See Figure 17. NOTE: Perform Step 7 and Step 8 for lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with Diesel Particulate Filter (DPF). 7. Connect light harness connector to Vehicle Systems Manager (VSM) and right-hand chassis harness. See Figure 18. 8. Connect Diesel Particulate Filter (DPF) harness connector to cowl harness. See Figure 18. 9. Connect right-hand chassis harness to rear grab handle horn button connector. See Figure 11.

Cab Replacement 11. Install floor plate and floor mat. Tighten capscrews to 10.8 N•m (7.96 lbf ft). 12. Install kick panel onto seal plate assembly. 13. Install two flange bolts securing cowl to front operator cab legs. See Figure 15. 14. Install dash assembly onto kick panel and install five capscrews to secure dash assembly to cowl panel. 15. Install and clip front wiper motor cover for lift truck models •

GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810)

GLP/GDP20-35VX GDP040-070VX) (B875, C875)

(GP/GLP/

16. Install front wiper motor cover and tighten two lock nuts for lift truck models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813). 17. Install front wiper motor cover and tighten three lock nuts for lift truck models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813). 18. Install right side door onto cab by lifting door up and over top and bottom hinge pins. See Figure 10. 19. Connect gas spring and lock nut to cab mounting bracket. See Figure 9. 20. Connect heater hoses to heater assembly and connect heater wire harness connection. See Figure 6 and Figure 11. 21. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with a Cummins QSB 3.3L engine and equipped with an air conditioner/heater unit, connect AC hoses. Tighten AC hose at bulkhead bracket to 29 to 37 N•m (21 to 27 lbf ft) and AC hose to receiver/drier to 15 to 18 N•m (133 to 159 lbf in). See Figure 12.

10. Install seal plate assembly to lift truck frame and tighten capscrews. See Figure 16.

21


Cab Replacement 22. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813) with a Kubota engine and equipped with an air conditioner/heater unit, connect AC hoses. Tighten AC hose at bulkhead bracket to 29 to 37 N•m (21 to 27 lbf ft) and AC hose to receiver/drier to 20 to 27 N•m (177 to 239 lbf in). See Figure 13. 23. Install left side door onto cab by lifting door up and over top and bottom hinge pins. See Figure 10. 24. Connect gas spring and lock nut to cab mounting bracket. See Figure 9. 25. Uncap and connect heater hoses at engine. See Figure 6. 26. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or a Kubota diesel engine and equipped with an air conditioner/heater unit, connect AC refrigerant hoses to refrigerant compressor. See Figure 7 for lift truck models •

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

See Figure 8 for lift models •

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

27. Check coolant level, fill if necessary. 28. Install radiator cap and radiator cover. See Figure 5. 29. Connect air filter hose onto rear left corner leg of cab frame. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 4. 30. Connect battery and close hood. 31. Start engine and turn on heater to ON position, run engine approximately 1 to 2 minutes or until heater supply hose is fully purged.

22

0100 YRM 1290

WARNING Replacement, installation and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid must be performed by a certified technician. 32. Contact a certified air conditioning specialist to have the refrigerant refilled into air conditioning system. 33. On lift trucks equipped with an air conditioner/ heater unit, start engine and turn on heater to ON position, run engine approximately 1 to 2 minutes or until heater supply hose is fully purged. NOTE: The EZ Tank Bracket used on these trucks to mount LPG tank onto counterweight comes in two styles. One style of bracket swings out to side of truck and other swings out to side and drops down. 34. Lift trucks equipped with a LPG engine, swing EZ Tank Bracket back to its original and locked position.

REMOVE, FOR LIFT TRUCK MODELS GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) AND , GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) NOTE: Removing door assemblies from operators cab requires two people. 1. Open right side door and remove hair pin from rod pin. See Figure 22. 2. Remove rod pin and spacers from link. 3. Remove right side door from cab frame by lifting door up and over hinge pin and set door aside. See Figure 23. 4. Repeat Step 1 through Step 3 for removal of left side door. 5. Remove front floor mat and floor plate. See Figure 24. 6. Disconnect battery.


0100 YRM 1290

Cab Replacement

NOTE: RIGHT SIDE DOOR SHOWN

NOTE: RIGHT SIDE DOOR HINGE SHOWN

1. 2. 3. 4.

1. HINGE PIN 2. DOOR HINGE

ROD PIN SPACERS HAIR PIN DOOR ASSEMBLY

Figure 23. Door Removal

Figure 22. Door Link Removal

23


Cab Replacement

1. 2. 3. 4. 5.

0100 YRM 1290

DASH ASSEMBLY KICK PANEL SEAL PLATE ASSEMBLY FRONT FLOOR MAT REAR FLOOR MAT

6. 7. 8. 9.

FLANGE BOLT REAR FLOOR PLATE FRONT FLOOR PLATE MODULE

Figure 24. Seal Plate Assembly, Kick Panel, and Floor Plate Removal

24


0100 YRM 1290

Cab Replacement

7. Remove two screws holding right side rear cover to rear overhead guard leg. See Figure 25.

NOTE: RIGHT SIDE VIEW SHOWN. 1. 2. 3. 4. 5. 6.

RIGHT SIDE REAR COVER RIGHT SIDE FRONT COVER SCREWS REAR FLOOR PLATE FRONT FLOOR PLATE CLIP NUTS Figure 25. Side Cover Removal

8. Remove two screws holding right side front cover to frame. Remove right side rear cover. 9. Remove two screws securing right side front cover to front overhead guard leg. Remove right side front cover. 10. Repeat Step 7 through Step 9 to remove left side covers. NOTE: Perform Step 11 for early model GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878). 11. Remove two lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 26.

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

CAPSCREWS FRONT WIPER MOTOR COVER DASH ASSEMBLY KICK PANEL COWL PANEL FRONT OPERATORS CAB LEGS LOCK NUT FLANGE BOLT Figure 26. Dash Removal, Early Model GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Trucks

NOTE: Perform Step 12 on later model lift trucks •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

12. Remove three lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 27.

25


Cab Replacement

1. 2. 3. 4.

CAPSCREWS FRONT WIPER MOTOR COVER DASH ASSEMBLY KICK PANEL

0100 YRM 1290

5. 6. 7. 8.

COWL PANEL FRONT OPERATORS CAB LEGS LOCK NUT FLANGE BOLT

Figure 27. Dash Removal, Later Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878) Lift Trucks and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) Lift Truck Models

26


0100 YRM 1290 13. Remove five capscrews from top of dash assembly and cowl panel. 14. Unclip dash assembly from kick panel. Remove dash assembly. 15. Remove kick panel from seal plate assembly. See Figure 24. 16. Remove two flange bolts securing cowl panel to front operator cab legs. See Figure 26 for early model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) lift trucks.

Cab Replacement 22. Open right side hood door and remove both wiper motor washer tubes from t-fitting and disconnect washer pump harness connector from washer fluid reservoir. 23. Disconnect rear grab handle horn button connector from right hand chassis harness. 24. Remove bottom flange bolt securing right side rear operator cab leg to module. 25. Open left side hood door and remove bottom flange bolt securing rear left side operator cab leg to module.

See Figure 27 for later model lift trucks •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

17. Disconnect three harness connectors from right side front operator cab leg that are connected to Vehicle Systems Manager (VSM) and right hand chassis harness connectors. See Figure 28. NOTE: PerformStep 18 and Step 19 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878) and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (B909) equipped with Diesel Particulate Filter (DPF). 18. Disconnect three harness connectors from right side front operator cab leg that are connected to Vehicle System Manager (VSM) and right-hand chassis harness connectors. See Figure 29. 19. Disconnect Diesel Particulate Filter (DPF) display harness connector from cowl harness. See Figure 29. 20. Remove four flange bolts securing right and left side of front operator cab legs to module. See Figure 30.

NOTE: KICK PANEL REMOVED FOR CLARITY. 1. VSM 2. HARNESS CONNECTOR (TO VSM) 3. HARNESS CONNECTOR (TO RIGHT HAND CHASSIS HARNESS) Figure 28. Light Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909)

21. From inside cab, remove six flange bolts securing right and left side rear operator cab legs to module.

27


Cab Replacement

0100 YRM 1290

NOTE: KICK PANEL REMOVED FOR CLARITY. 1. VSM 2. DPF DISPLAY HARNESS CONNECTOR (TO COWL) 3. HARNESS CONNECTOR (TO VSM) 4. HARNESS CONNECTOR (TO RIGHT HAND CHASSIS HARNESS) Figure 29. Electrical Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878) and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (B909)

Figure 30. Front and Rear Cab Mounting

28


0100 YRM 1290

Cab Replacement

Legend for Figure 30 NOTE: RIGHT SIDE SHOWN. WIPER COVER AND ASSEMBLY FOR EARLY MODEL GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) LIFT TRUCKS SHOWN. THE FRONT AND REAR CAB MOUNTING IS SAME FOR LATER MODEL GLP/GDP60VX, GLP/ GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878) LIFT TRUCKS AND ON GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) LIFT TRUCK MODELS. A. REAR VIEW 1. 2. 3. 4. 5. 6. 7.

B. FRONT VIEW

INSTALL, FOR LIFT TRUCK MODELS GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) 1. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 31.

FLANGE BOLTS REAR OPERATOR CAB LEG REAR LIGHT HARNESS WASHER PUMP HARNESS CONNECTOR WASHER FLUID RESERVOIR MODULE COWL PANEL

WARNING Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb). 26. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 31.

CAUTION Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected correctly and are not damaged. 27. Carefully lift operator cab up and away from lift truck. Set operator cab in a storage area and place blocks under operator cab to make it stable and prevent damage to wire harness and parts still attached.

Figure 31. Lift Strap Connection

29


Cab Replacement 2. Carefully lift operator cab onto lift truck frame making sure that front and rear leg mounting holes are aligned with module mounting holes.

0100 YRM 1290 See Figure 27 for later model lift trucks

3. Open left side hood door and install bottom flange bolt to secure rear left side operator cab leg to module. Tighten flange bolt to 165 N•m (122 lbf ft). See Figure 30. 4. Open right side hood door and install bottom flange bolt to secure rear right side operator cab leg to module. Tighten flange bolt to 165 N•m (122 lbf ft). 5. Connect rear grab handle horn button harness connector to right hand chassis harness. 6. Connect both wiper motor washer tubes to t-fitting and connect washer pump harness connector to washer fluid reservoir. 7. Install two flange bolts to secure right and left side front operator cab legs to module. Tighten flange bolt to 165 N•m (122 lbf ft). 8. From inside cab, install four remaining flange bolts to right and left side rear operator cab legs to module. Tighten flange bolt to 165 N•m (122 lbf ft). 9. Connect three harness connectors on front right side operator cab leg to Vehicle System Manager (VSM) and right hand chassis harness. See Figure 28. NOTE: Perform Step 10 and Step 11 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878) and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (B909) equipped with Diesel Particulate Filter (DPF). 10. Connect three harness connectors on front right side operator cab leg to Vehicle System Manager (VSM) and right-hand chassis harness. See Figure 29. 11. Connect Diesel Particulate Filter (DPF) display harness connector from cowl harness. See Figure 29. 12. Install two flange bolts to secure cowl panel to front operator cab legs. See Figure 26 for early model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) lift trucks. 30

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

13. Install kick panel to seal plate assembly. See Figure 24. 14. Install and clip dash assembly onto kick panel. See Figure 26. 15. Install five capscrews to top of dash assembly to secure dash assembly onto cowl panel. Tighten capscrew to 3.5 N•m (30 lbf in). NOTE: Perform Step 16 on early model GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) lift trucks. 16. Install front wiper motor cover using two lock nuts. See Figure 26. NOTE: Perform Step 17 on later model lift trucks •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

17. Install front wiper motor cover using three lock nuts. See Figure 27. 18. Install right side front cover to front overhead guard leg using two screws. See Figure 25. 19. Install right side rear cover to right side front cover and install and tighten two screws to frame. 20. Align right side rear cover to rear overhead guard leg and install and tighten two screws to rear overhead guard leg and install and tighten two screws to rear overhead guard leg. 21. Repeat Step 18 through Step 20 to install left side covers. 22. Connect battery. 23. Install front floor plate and floor mat. See Figure 24.


0100 YRM 1290

Door Assemblies

NOTE: Installing door assemblies onto operator cab requires two people. 24. Lift door up and over top and bottom hinge pins. See Figure 23.

26. Install hair pin into rod pin. 27. Repeat steps Step 24 through Step 26 for installation of left side door.

25. Align link and spacers into guide and install rod pin. See Figure 22.

Door Assemblies RIGHT SIDE DOOR ASSEMBLY, LIFT TRUCK MODELS GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) Remove

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When radiator cap is removed, the pressure is released from cooling system. If cooling system is hot, the steam and boiling coolant can cause burns. Wait 30 minutes for the engine to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to remove the radiator cap. NOTE: Removing radiator cap will help depressurize cooling system. 1. Remove radiator cover to access radiator cap. Remove radiator cap. See Figure 32.

WARNING

NOTE: Removing right side door assembly requires two people. 2. Disconnect heater hose quick disconnect fittings. See Figure 33. a. For lift truck models GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810), open right side door and push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly hoses. See Figure 33. Disconnect heater wire harness connection. See Figure 34. b. For lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875), open right side door and remove radiator cover to access quick disconnect fittings. Push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly hoses. See Figure 33. Disconnect heater wire harness connection. See Figure 34. c. For lift truck models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) equipped with a heater unit, open right side door and locate two port holes on inner rear cover. Push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly. See Figure 33. Disconnect heater wire harness connection. See Figure 34.

DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator cab) or engine when the engine is hot or under pressure. Serious injury can occur.

31


Door Assemblies

0100 YRM 1290

A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) C. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813) D. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 1. RADIATOR COVER

2. RADIATOR CAP Figure 32. Radiator Cover and Cap Location

32


0100 YRM 1290

Door Assemblies

NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) C. GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) D. GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813) 1. QUICK DISCONNECT FITTING 2. INNER REAR COVER 3. RADIATOR COVER

4. RIGHT SIDE DOOR ASSEMBLY 5. HEATER HOSES Figure 33. Heater Hose Connection

33


Door Assemblies

0100 YRM 1290 See Figure 35 for lift truck models •

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

See Figure 36 for lift truck models •

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

See Figure 37 for lift truck models •

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

b. Disconnect air conditioner hoses at bulkhead bracket and at receiver/drier. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 1. HEATER WIRE HARNESS CONNECTOR 2. REAR GRAB HANDLE HORN BUTTON CONNECTOR (TO RIGHT-HAND CHASSIS HARNESS) Figure 34. Heater Wire Harness and Rear Grab Handle Horn Button Connectors

See Figure 35 for lift truck models •

See Figure 36 for lift truck models •

WARNING Replacement, installation and repairs to air conditioning units that require discharging and/or refilling of the refrigerant fluid must be performed by a certified technician. 3. Contact a certified air conditioning specialist to have the refrigerant extracted from air conditioning system. 4. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or Kubota diesel engine, if lift truck cab is equipped with an air conditioner/heater unit, disconnect AC hoses. a. Remove six fasteners and remove rear cover.

34

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

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

See Figure 37 for lift truck models •

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

c. Disconnect air conditioner wire harness. See Figure 35 for lift truck models •

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


0100 YRM 1290

Door Assemblies

See Figure 36 for lift truck models •

See Figure 37 for lift truck models

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

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

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW

B. TOP VIEW

1. 2. 3. 4.

5. 6. 7. 8.

HOSE WRAP FASTENERS REAR COVER AIR CONDITIONER HOSES

BULKHEAD BRACKET RECEIVER/DRIER FITTINGS AIR CONDITIONER WIRE HARNESS

Figure 35. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)

35


Door Assemblies

0100 YRM 1290

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW

B. TOP VIEW

1. 2. 3. 4.

5. 6. 7. 8.

HOSE WRAP FASTENERS REAR COVER AIR CONDITIONER HOSES

BULKHEAD BRACKET RECEIVER/DRIER FITTINGS AIR CONDITIONER WIRE HARNESS

Figure 36. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)

36


0100 YRM 1290

Door Assemblies

NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW

B. TOP VIEW

1. 2. 3. 4.

5. 6. 7. 8.

HOSE WRAP FASTENERS REAR COVER AIR CONDITIONER HOSES

BULKHEAD BRACKET RECEIVER/DRIER FITTINGS AIR CONDITIONER WIRE HARNESS

Figure 37. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)

37


Door Assemblies 5. Disconnect gas spring. See Figure 38.

0100 YRM 1290 2. Remove fan and heater knobs from knob plate. Remove four screws that fasten knob plate to heater valve and switch plate. Remove knob plate from door cover. 3. Remove two fasteners from top of door cover. 4. Remove five plugs along sides and front of door cover. Remove two capscrews and washers from bottom of door cover. Remove door cover from door frame. 5. Remove prefilter, located on bottom of door frame.

NOTE: RIGHT SIDE DOOR SHOWN. 1. GAS SPRING 2. MOUNTING BRACKET 3. LOCK NUT Figure 38. Gas Spring Mounting Installation 6. Remove right side door from cab frame by lifting door up and over hinge pin. See Figure 39.

Disassemble Door Cover With Heater Unit 1. Remove four screws and washers that attach handle to door cover. Remove handle and two handle plates. See Figure 40.

38

NOTE: RIGHT SIDE DOOR HINGE SHOWN. 1. HINGE PIN

2. DOOR HINGE

Figure 39. Door Removal


0100 YRM 1290

Door Assemblies

Figure 40. Right Side Door Cover Removal, Heater Unit

39


Door Assemblies

0100 YRM 1290 Legend for Figure 40

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

PLUG FASTENER GAS SPRING FAN AND HEATER KNOBS SCREW KNOB PLATE HANDLE HANDLE PLATES

Door Cover With Air Conditioner/Heater Unit NOTE: Only lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or Kubota diesel engine may be equipped with an air conditioner/heater unit. NOTE: The procedures in this section remove air conditioner/heater unit assembly door cover from right side door. For procedures to remove or replace other components of air conditioner/heater unit assembly, go to Heater and Air Conditioner Assembly section. 1. Remove four screws and washers that attach handle to door cover. Remove handle. See Figure 41. 2. Remove hose wrap from AC hoses. See Figure 35 for lift truck models •

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

See Figure 36 for lift truck models •

40

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

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

WASHER HEATER/FAN LOUVER CAPSCREW DOOR COVER PRE-FILTER HEATER VALVE AND SWITCH PLATE STAR NUT

See Figure 37 for lift truck models •

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

3. Remove fan and heater/AC knobs from knob plate. Remove four screws that fasten knob plate to heater valve and switch plate. Remove knob plate and heater valve from door cover. See Figure 41. 4. Remove two fasteners from top of door cover. 5. Remove four capscrews that fasten AC rocker switch plate to door cover. Remove AC rocker switch plate from door cover. See Figure 41. 6. Remove five plugs, washers, and star nuts along sides and front of door cover. Remove two capscrews and washers from bottom of door cover. Remove door cover from door frame. 7. Remove prefilter, located on bottom of door frame. See Figure 41.


0100 YRM 1290

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

Door Assemblies

CAPSCREW AC ROCKER SWITCH PLATE AC ROCKER SWITCH HEATER/AC KNOBS HANDLE HEATER VALVE AND SWITCH PLATE FASTENER

8. 9. 10. 11. 12. 13. 14.

HEATER, FAN, AND AC LOUVER PRE-FILTER DOOR COVER WASHER PLUG WASHER STAR NUT

Figure 41. Right Side Door Cover Removal, Air Conditioner/Heater Unit

41


Door Assemblies

0100 YRM 1290

Heater Assembly

Air Conditioner and Heater Unit Assembly

NOTE: The heater assembly is non-repairable, replace as a complete unit. See Parts Manual.

NOTE: Only lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or Kubota diesel engine may be equipped with an air conditioner/heater unit.

1. Remove lock nut from heater valve and switch plate. See Figure 42. 2. Disconnect heater switch connector from heater switch. 3. Remove two screws from heater valve and switch plate and remove plate. 4. Disconnect supply hose at heater valve and disconnect return hose from heater coil.

NOTE: The procedures in this section remove air conditioner/heater unit assembly from right side door. For procedures to remove or replace other components of air conditioner/heater unit assembly, go to Heater and Air Conditioner Assembly section.

5. Remove two nuts and washers from heater assembly bracket. Remove heater assembly and bracket from door frame.

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

LOCK NUT NUT WASHER HEATER ASSEMBLY BRACKET SUPPLY HOSE HEATER ASSEMBLY

7. 8. 9. 10. 11. 12.

HEATER VALVE AND SWITCH PLATE HEATER VALVE HEATER SWITCH RETURN HOSE SCREWS HEATER COIL

Figure 42. Heater Assembly Removal

42


0100 YRM 1290 NOTE: The air conditioner and heater assembly is non-repairable, replace as a complete unit. See Parts Manual.

Door Assemblies See Figure 44 for lift truck models •

1. Remove lock nut from heater valve and switch plate.

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

See Figure 43 for lift truck models •

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

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

HEATER RETURN HOSE HEATER SUPPLY HOSE AC HOSES HEATER VALVE AND SWITCH PLATE LOCKNUT MOUNTING BRACKET

7. 8. 9. 10. 11. 12.

CAPSCREW AC/HEATER UNIT HEATER VALVE AC ROCKER SWITCH HEATER COIL AC EXPANSION VALVE

Figure 43. Air Conditioner/Heater Unit Assembly Removal, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813)

43


Door Assemblies 2. Disconnect heater switch connector from heater switch plate. 3. Remove four screws from heater valve and switch plate and remove plate.

0100 YRM 1290 5. Disconnect supply hose at heater valve and disconnect return hose from heater coil. See Figure 43 for lift truck models •

4. Disconnect AC rocker switch. See Figure 43 for lift truck models •

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

See Figure 44 for lift truck models •

See Figure 44 for lift truck models •

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

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

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

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

SCREW AC ROCKER SWITCH HEATER VALVE LOCKNUT SWITCH PLATE AC/ HEATER UNIT

7. 8. 9. 10. 11. 12.

AC HOSES HEATER SUPPLY HOSE HEATER RETURN HOSE HEATER COIL AC EXPANSION VALVE MOUNTING BRACKET

Figure 44. Air Conditioner/Heater Unit Assembly Removal, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)

44


0100 YRM 1290

Door Assemblies

6. Disconnect AC hoses from the AC expansion valve.

See Figure 43 for lift truck models •

See Figure 43 for lift truck models •

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

See Figure 44 for lift truck models •

See Figure 44 for lift truck models •

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

7. Remove four screws from AC/heater assembly mounting bracket. Remove AC/heater assembly and mounting bracket from door frame.

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

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

Door Lock Assembly 1. Remove inside lever handle cover. See Figure 45.

A. LEVER IN CLOSED POSITION

B. LEVER IN OPEN POSITION

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

7. 8. 9. 10. 11. 12.

INSIDE LEVER HANDLE CAPSCREWS INSIDE LEVER HANDLE COVER CAPSCREW (OUTSIDE HANDLE) LOCK NUT RELEASE BAR

DOOR LOCK ASSEMBLY RELEASE LEVER NUT MOUNTING PLATE SCREWS WASHER

Figure 45. Door Lock and Lever Disassembly

45


Door Assemblies 2. Place inside lever handle in closed position. Remove lock nut from release bar at inside lever handle. Pull inside lever handle to open position. Remove release bar from inside lever handle. 3. Remove two capscrews and inside lever handle and mounting plate. 4. Remove lock nut from release bar and release bar from door lock assembly. 5. Remove two nuts and capscrews from door lock assembly. Remove door lock assembly from door frame. 6. Remove screw and washer from release lever and release lever from outside door handle assembly. See Figure 45 and Figure 46. 7. Remove four capscrews that fasten outside door handle to door. Remove outside door handle from door. 8. Remove seal and grip from outside handle assembly. Discard seal. See Figure 46.

0100 YRM 1290

Windows For procedures to remove and install door windows, see section Window Replacement.

Clean

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Check door assembly and parts for oil, grease, dirt, and other debris. Clean door assembly and parts with a clean cloth, soap, and water. Compressed air can be used to dry door assembly and parts.

Inspect Inspect all hoses for cracks and wear. Replace damaged hoses. Inspect seals around door window and door lock assembly and replace if damaged. Check door lock and latch assembly. Make sure it opens, shuts, and locks door securely and there is no rust, grease, oil, or dirt on door lock and latch assembly parts. Inspect windows for cracks or chips. Replace windows if damaged.

Assemble Windows For procedures to remove and install door windows, see section Window Replacement.

Door Lock Assembly 1. Install new seal and grip to outside handle assembly. See Figure 46.

1. 2. 3. 4.

LATCH STRIKER ASSEMBLY SEAL OUTSIDE HANDLE ASSEMBLY GRIP Figure 46. Outside Handle Disassembly

46

2. Apply Loctite® 242 to threads of four capscrews and secure outside door handle to door (see Figure 45). Tighten capscrews to 19.2 N•m (170 lbf in). 3. Apply Loctite® 242 to capscrew and install release lever to rear of outside door handle assembly. Tighten capscrew to 5.0 N•m (44 lbf in).


0100 YRM 1290 4. Install door lock assembly onto door frame using two capscrews and nuts. Tighten capscrews to 19.2 N•m (170 lbf in). 5. Install inside lever handle and mounting plate to door frame. Tighten capscrews to 19.2 N•m (170 lbf in). 6. Place inside lever handle in closed position (see Figure 45). Insert release bar into door lock assembly end and into inside lever handle. Secure release bar with lock nuts. 7. Install cover onto inside lever assembly.

Heater Assembly 1. Secure heater assembly to door frame with mounting bracket. Insert washers and two lock nuts onto mounting bracket, and tighten to 19.2 N•m (170 lbf in). See Figure 42. 2. Connect supply and return hoses to heater valve. 3. Install heater valve and switch plate using two screws. 4. Connect heater switch connector to heater switch. 5. Secure heater valve and switch plate with lock nut.

Air Conditioner and Heater Unit Assembly NOTE: The procedures in this section install air conditioner/heater unit assembly to right side door. For procedures to install or replace other components of air conditioner/heater unit assembly, go to Heater and Air Conditioner Assembly section. 1. Insert four nuts and capscrews and secure air conditioner/heater unit assembly to door frame and mounting bracket. 2. Connect AC hoses to AC expansion valve. See Figure 43 for lift truck models •

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

Door Assemblies See Figure 44 for lift truck models •

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

3. Connect supply and return hoses to heater valve. 4. Connect AC rocker switch. 5. Install heater valve and switch plate using four screws. See Figure 43 for lift truck models •

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

See Figure 44 for lift truck models •

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

6. Connect heater switch connector to heater switch. 7. Secure heater valve and switch plate with lock nut.

Door Cover With Heater Unit 1. Install pre-filter on bottom of door frame. See Figure 40. 2. Align holes on door cover with holes that are on door frame. Install five plugs into holes that are along sides and front of door cover. Secure bottom of door cover using two capscrews and washers. 3. Install two fasteners into holes on top of door cover. See Figure 40. 4. Install knob plate on heater valve and switch plate with four screws. Install fan and heater knobs on knob plate. 5. Install handle and handle plates on door with four screws and washers.

47


Door Assemblies

0100 YRM 1290

Door Cover With Air Conditioner and Heater Unit

2. Connect gas spring and lock nut to mounting bracket on operator cab frame. See Figure 38.

NOTE: The procedures in this section install air conditioner/heater unit assembly door cover onto right side door. For procedures to install or replace other components of air conditioner/heater unit assembly, go to Heater and Air Conditioner Assembly section.

3. Connect heater hoses to heater assembly and connect heater wire harness connection. See Figure 33 and Figure 34.

1. Install pre-filter on bottom of door frame. See Figure 41. 2. Align holes on door cover with holes that are on door frame. Install five plugs into holes that are along sides and front of door cover. Secure bottom of door cover using two capscrews and washers. 3. Install AC rocker switch plate to door cover using four capscrews. 4. Install two fasteners into holes on top of door cover. See Figure 41. 5. Install knob plate on heater valve and switch plate with four screws. Install fan and AC/heater knobs on knob plate. 6. Install hose wrap around AC hoses. See Figure 35 for lift truck models •

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

See Figure 36 for lift truck models •

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

See Figure 37 for lift truck models •

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

7. Install handle and handle plates on door with four screws and washers.

Install 1. Install right side door onto cab by lifting door over top and bottom hinge pins. See Figure 39.

48

4. On lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or Kubota diesel engine and equipped with an air conditioner/heater unit.

WARNING Replacement, installation and repairs to air conditioning units that require discharging and/or refilling of the refrigerant fluid must be performed by a certified technician. 5. Contact a certified air conditioning specialist to have the refrigerant refilled into the air conditioning system. a. Connect AC hoses at bulkhead bracket and to receiver/drier. See Figure 35 for lift truck models •

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

See Figure 36 for lift truck models •

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

See Figure 37 for lift truck models •

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

b. Install rear cover with six fasteners. See Figure 35 for lift truck models •

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


0100 YRM 1290

Door Assemblies

See Figure 36 for lift truck models •

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

See Figure 37 for lift truck models •

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

6. Install radiator cover. See Figure 32.

LEFT SIDE DOOR ASSEMBLY, LIFT TRUCK MODELS GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/

1. 2. 3. 4.

FASTENER PLUG COVER SCREW

GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) Remove NOTE: Removing left side door assembly requires two people. 1. Open left side door and disconnect gas spring. See Figure 38. 2. Remove left side door from cab frame by lifting door over hinge pin. See Figure 39.

Disassemble Door Cover 1. Remove cover from rear of handle and remove screw. Remove capscrew from door lock cover and remove door lock cover from lock assembly. See Figure 47.

5. 6. 7. 8.

CAPSCREW DOOR LOCK COVER HANDLE DOOR LOCK ASSEMBLY

Figure 47. Left Side Door Cover Removal

49


Door Assemblies 2. Remove two capscrews that secure handle to door lock assembly. Remove handle from door. 3. Remove two fasteners from top of door cover. Remove five plugs along edges of door cover and remove door cover from door frame.

Door Lock Assembly 1. Remove capscrew and washer from release lever. Remove release lever from door. See Figure 48. 2. Remove four capscrews and two washers (right side only) from rear of outside handle. Remove outside door handle from door. 3. Remove grip and seal from outside handle. Discard seal. See Figure 46.

0100 YRM 1290

Clean

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Check door assembly and parts for oil, grease, dirt, and other debris. Clean door assembly and parts with a clean cloth and soap and water. Compressed air can be used for drying door assembly and parts.

Inspect Inspect seals around window, door, and door lock assembly and replace if damaged. Check door lock and latch assembly. Make sure it opens, shuts, and locks door securely and there is no rust, grease, oil, or dirt on door lock and latch assembly parts. Inspect window for cracks or chips. Replace window if damaged.

Assemble Windows For procedures to remove and install door windows, see section Window Replacement.

Door Lock Assembly 1. Install seal and grip (see Figure 46) onto outside door handle. Place outside door handle onto door frame. Apply Loctite® 242 to threads of four capscrews and secure outside handle to door frame using capscrews and washers. The washers go on right side from inside cab. Tighten capscrews to 19.2 N•m (170 lbf in). 1. CAPSCREW 2. WASHER 3. RELEASE LEVER Figure 48. Release Lever Removal

Windows For procedures to remove and install door windows, see section Window Replacement.

50

2. Apply Loctite® 242 to capscrew and install release lever to rear of outside door handle. Tighten capscrew and washer to 5.0 N•m (44 lbf in). See Figure 48.

Door Cover 1. Place door cover onto door frame. Install two fasteners onto top of door cover and install five plugs along edges of door cover. See Figure 47.


0100 YRM 1290

Door Assemblies

2. Install handle to latch assembly with two capscrews. Tighten capscrews to 19.2 N•m (170 lbf in). Secure lock cover to door lock assembly with capscrew.

1. Open right side door and remove hair pin from rod pin. See Figure 49.

3. Secure handle to rear of door cover with screw. Tighten screw to 5.0 N•m (44 lbf in). Push cover into place over screw.

3. Remove right side door from cab frame by lifting door up and over hinge pin. See Figure 39.

Install

2. Remove rod pin and spacers from link.

4. To remove left door, repeat Step 1 through Step 3.

1. Install left side door onto cab by lifting door over top and bottom hinge pins. See Figure 39. 2. Connect gas spring to mounting bracket on operator cab frame. See Figure 9.

RIGHT AND LEFT SIDE DOOR ASSEMBLIES, LIFT TRUCK MODELS GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) NOTE: The right and left doors are identical and are repaired and serviced in same manner on lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Remove

NOTE: RIGHT SIDE DOOR SHOWN 1. ROD PIN 2. SPACERS

3. HAIR PIN 4. DOOR ASSEMBLY

Figure 49. Door Link Removal

NOTE: Removing door assemblies from operators cab requires two people.

51


Door Assemblies

0100 YRM 1290

Disassemble

two capscrews and washers that secure handle to door lock assembly. Remove handle and door lock assembly from door frame. See Figure 50.

Door Cover 1. Remove cover from rear of handle and remove screw. Remove capscrew from door lock cover and remove cover from lock assembly. Remove

2. Remove five plugs that secure door cover to door frame and remove cover from frame.

NOTE: RIGHT SIDE DOOR SHOWN. 1. 2. 3. 4.

COVER SCREW CAPSCREW LOCK COVER

5. 6. 7. 8.

DOOR LOCK WASHER HANDLE PLUG

Figure 50. Door Cover Removal

52


0100 YRM 1290

Door Assemblies

Door Lock Assembly 1. Remove capscrew and washer from release lever. Remove release lever from rear of outside door handle. See Figure 51.

2. Remove four screws from rear of outside door handle. Remove outside door handle from door. 3. Remove grip and seal from outside door handle. See Figure 52.

NOTE: RIGHT SIDE DOOR SHOWN. 1. SCREW 2. WASHER

3. RELEASE LEVER 4. CAPSCREW Figure 51. Release Lever Removal

53


Door Assemblies

0100 YRM 1290

Windows

Inspect

For procedures to remove and install door windows, see section Window Replacement.

Inspect seals around window, door, and door lock assembly and replace if damaged. Check door lock and latch assembly. Make sure it opens, shuts, and locks door securely and there is no rust, grease, oil, or dirt on door lock and latch assembly parts. Inspect window for cracks or chips. Replace window if damaged.

Clean

WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes. Check door assembly parts for oil, grease, dirt, and other debris. Clean door assembly and parts with a clean cloth, soap, and water. Compressed air can be used for drying door assembly and parts.

Assemble Windows For procedures to remove and install door windows, see section Window Replacement.

Door Lock Assembly 1. Install grip and seal to outside door handle assembly. See Figure 52.

NOTE: RIGHT SIDE DOOR SHOWN. 1. LATCH STRIKER ASSEMBLY 2. SEAL

3. OUTSIDE DOOR HANDLE 4. GRIP Figure 52. Outside Handle Removal

54


0100 YRM 1290

Window Wipers Replacement

2. Apply Loctite® 242 to threads of four screws. Use screws to install outside door handle to door frame. Tighten screws to 19.2 N•m (170 lbf in). See Figure 51. 3. Apply Loctite® 242 to threads of capscrew for release lever and install release lever to rear of outside door handle assembly. Tighten capscrew to 5.0 N•m (44 lbf in).

Door Cover 1. Place door cover onto door frame. Install two fasteners onto top of door cover. Install five plugs along edges of door cover. See Figure 50.

3. Secure handle to rear of door cover with screw. Tighten screw to 5.0 N•m (44 lbf in). Push cover into place over screw.

Install NOTE: The installation procedures outlined below apply to both left and right side doors. 1. Lift door over top and bottom hinge. See Figure 39. 2. Align link and spacers into guide and install rod pin. See Figure 49. 3. Install hair pin into rod pin.

2. Install handle to lock assembly with two capscrews and washers. Tighten capscrews to 19.2 N•m (170 lbf in). Install lock cover to lock assembly with capscrew. See Figure 50.

Window Wipers Replacement GENERAL Two window wiper motor assemblies are installed in operator cab. The front window motor assembly has two wiper arms connected to a single wiper blade. The rear window has a wiper motor assembly that has one wiper arm attached to a single wiper blade.

FRONT WIPER ASSEMBLY AND MOTOR Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)

2. Disconnect cab harness connector from wiper motor. 3. Open hardware covers at base of wiper arms and remove two lock nuts and lockwashers from wiper arms. Remove wiper arms and blade from wiper motor. 4. Remove cap and jam nut. 5. Remove one flange nut (right side) and two grommets from threaded shafts on wiper motor that pass through two holes in window. Remove wiper motor from front window.

1. Remove wiper motor cover from wiper motor. See Figure 53.

55


Window Wipers Replacement

0100 YRM 1290

Figure 53. Front Wiper and Motor Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)

56


0100 YRM 1290

Window Wipers Replacement Legend for Figure 53

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

FRONT WINDOW WIPER BLADE WIPER ARM LOCKWASHER LOCK NUT WIPER HOSE JAM NUT

Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) 1. Install wiper motor to front window using one flange nut (right side) and two grommets onto threaded shafts on wiper motor. Insert shafts through two holes in front window. See Figure 53.

8. 9. 10. 11. 12. 13. 14.

CAP FLANGE NUT GROMMET WIPER MOTOR COVER CAB HARNESS CONNECTOR (WIPER MOTOR) WIPER MOTOR HARDWARE COVERS •

See Figure 55 for later lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

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

2. Install cap and jam nut. NOTE: Inspect wiper blade. If it is cracked, split, or worn, replace with new blade before installing wiper arms onto front window. 3. Install wiper arms and blade to front window using two lock nuts and lockwashers. Close hardware covers at base of wiper arms. 4. Connect cab harness connector to wiper motor. 5. Install wiper motor cover to wiper motor.

Remove, Lift Truck Models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 1. Open hardware covers at base of wiper arms and remove two nuts and external tooth lockwashers from wiper arms.

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878)

2. Remove wiper blade and wiper arm from wiper motor threaded shafts. 3. Remove two hardware covers, nuts, washers, and lockwashers from two threaded shafts that pass through two holes in wiper motor housing. Remove wiper arms from front window. 4. Remove two lock nuts that secure front wiper motor cover to wiper motor housing. Remove cover. See Figure 54 for lift truck models •

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

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) lift trucks

See Figure 54 for early model lift trucks •

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

57


Window Wipers Replacement

0100 YRM 1290

Figure 54. Front Wiper and Motor Remove, GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Lift Trucks and Early Model GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Trucks

58


0100 YRM 1290

Window Wipers Replacement Legend for Figure 54

A. OUTSIDE OF CAB

B. INSIDE OF CAB

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

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

WIPER BLADE WIPER ARM LOCKWASHERS WASHERS NUTS HARDWARE COVER EXTERNAL TOOTH LOCKWASHER LOCK NUTS

FRONT WIPER MOTOR COVER WIPER MOTOR WIPER MOTOR BRACKET ASSEMBLY CAPSCREWS THREADED SHAFTS WIPER MOTOR HOUSING CAB HARNESS

59


Window Wipers Replacement

0100 YRM 1290

Figure 55. Front Wiper and Motor Remove, Later Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813), GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) Lift Truck Models

60


0100 YRM 1290

Window Wipers Replacement Legend for Figure 55

A. OUTSIDE OF CAB

B. INSIDE OF CAB

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

8. 9. 10. 11. 12. 13. 14.

WIPER BLADE WIPER ARM LOCKWASHER WASHER NUTS HARDWARE COVER EXTERNAL TOOTH LOCKWASHER

5. Remove three lock nuts that secure front wiper motor cover to wiper motor housing. Remove cover. See Figure 55 for later lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

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

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

6. Disconnect cab harness from wiper motor harness. 7. Remove wiper motor and bracket from wiper motor housing. 8. Remove three capscrews and external tooth lockwashers and remove wiper motor from wiper motor bracket assembly. See Figure 54 for early lift truck models •

GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) lift trucks

See Figure 55 for later lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

WIPER MOTOR HOUSING THREADED SHAFTS WIPER MOTOR BRACKET ASSEMBLY WIPER MOTOR FRONT WIPER MOTOR COVER LOCKNUTS CAPSCREW AND EXTERNAL TOOTH LOCKWASHER •

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

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

Install, Lift Truck Models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 1. Install wiper motor to wiper motor bracket using three capscrews and external tooth lockwashers. See Figure 54 for lift truck models •

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

Early model GLP/GDP60VX, GLP/ GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878)

See Figure 55 for later lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)

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Window Wipers Replacement •

GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

2. Install wiper motor and bracket into wiper motor housing. 3. Connect wiper motor harness to cab harness. 4. Attach front wiper motor cover to wiper motor housing with two lock nuts. See Figure 54 for lift truck models •

GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Early model GLP/GDP60VX, GLP/ GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878)

5. Attach front wiper motor cover to wiper motor housing with three lock nuts. See Figure 55 for later lift truck models •

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813) GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909)

6. Install two washers, nuts, and hardware covers onto threaded shafts. NOTE: Inspect wiper blade. If it is cracked, split, or worn, replace with new blade before installing wiper arms onto front window. 7. Install wiper arms onto wiper motor threaded shafts, using two external tooth lockwashers and nuts. Close hardware cover at base of wiper arms.

REAR WIPER ASSEMBLY AND MOTOR Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/

62

0100 YRM 1290

GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810) 1. To replace rear wiper motor assembly, open hardware covers at base of wiper arms and remove nut and lockwasher from wiper arm. Remove wiper arm and blade. See Figure 56. 2. Remove hardware cover, nut, retainer, washer, and grommet from threaded shaft that passes through window of operator cab. 3. Remove wiper motor cover by pulling backward. The cover is held in place by plastic tabs on inside of cover. 4. Disconnect wiring harness connector and remove water tube. Remove washer reservoir from reservoir mounting bracket. NOTE: The left mounting stud is also spray nozzle for window washer. See Figure 56. 5. From inside cab, remove nuts and washers from wiper motor mounting studs that pass through window from back side. Remove wiper motor from rear window.

Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810) 1. Insert wiper motor mounting studs through holes in window. Place motor on mounting studs and secure motor to mounting studs with two washers and nuts. See Figure 56. 2. Install washer reservoir onto reservoir mounting bracket and connect wiring harness connector and water tube. 3. Install wiper motor cover. The cover snaps into place with plastic tabs. 4. Install grommet, washer, retainer, nut, and hardware cover on threaded shaft that passes through window of operator cab. NOTE: Inspect wiper blade. If it is worn or cracked, replace with new wiper blade. 5. Attach wiper arm to threaded shaft with lockwasher and nut. Install wiper blade onto wiper arm.


0100 YRM 1290

Window Wipers Replacement

Figure 56. Rear Wiper and Reservoir Bottle Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)

63


Window Wipers Replacement

0100 YRM 1290 Legend for Figure 56

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

REAR WINDOW GROMMET WASHER MOUNTING STUD GROMMET WASHER RETAINER NUT HARDWARE COVER WASHER NUT WIPER ARM

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

WIPER BLADE SPRAY NOZZLE MOUNTING STUD WASHER RESERVOIR RESERVOIR MOUNTING BRACKET WATER TUBE WIRE HARNESS CONNECTOR WIPER MOTOR COVER NUT WASHER WIPER MOTOR THREADED SHAFT

Remove, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)

Install, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)

1. Disconnect washer tube connector. See Figure 57.

1. Place wiper motor mount stud through hole. Install rear wiper motor to lift truck using motor mount grommet, flange nut, and cover. See Figure 57.

2. Open hardware cover at base of wiper arm and remove nut and washer from wiper arm. Remove wiper arm and blade from window. Remove wiper blade from wiper arm.

2. Install reservoir onto mounting bracket with washer and nut. See Figure 58.

3. Remove cap, nut, and wiper arm grommet from wiper motor shaft.

3. Connect washer pump connectors to cab wire harness.

4. Disconnect wiper motor connector from cab wire harness. See Figure 58.

4. Insert washer tube through hole and secure tube to window with nut and washer.

5. Remove cover, flange nut, and motor mount grommet from motor mount stud. See Figure 57.

5. Connect rear wiper motor connector to cab wire harness.

6. Disconnect rear wiper motor connector, and remove rear wiper motor from window. See Figure 57.

6. Install wiper arm grommet, nut, and cap onto rear wiper motor shaft.

7. Remove nut and washer and remove washer tube from hole. See Figure 58. 8. Disconnect washer pump connectors from cab wire harness. 9. Remove nut and washer from mounting bracket and remove washer reservoir from mounting bracket.

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NOTE: Inspect wiper blade for cracks and wear. Replace with new blade if old blade is worn or damaged. 7. Install wiper blade onto wiper arm. Install wiper blade and arm to window using nut and washer. See Figure 57. Close hardware cover. 8. Connect washer tube to wiper arm.


0100 YRM 1290

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

WIPER BLADE WIPER ARM WASHER TUBE WASHER TUBE CONNECTOR NUT WASHER CAP

Window Wipers Replacement

8. 9. 10. 11. 12. 13. 14.

NUT HARDWARE COVER WIPER ARM GROMMET FLANGE NUT MOTOR MOUNT GROMMET MOTOR MOUNT STUD WIPER MOTOR SHAFT

Figure 57. Rear Wiper Removal, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)

65


Window Wipers Replacement

1. 2. 3. 4. 5.

WASHER TUBE NUT WASHER WASHER RESERVOIR WASHER PUMP CONNECTORS

0100 YRM 1290

6. 7. 8. 9.

WIPER MOTOR CONNECTOR REAR WIPER MOTOR CAB WIRE HARNESS MOUNTING BRACKET

Figure 58. Washer Bottle and Wiper Motor Removal

66


0100 YRM 1290

Window Wipers Replacement

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

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

1. Disconnect washer tube connector. See Figure 59.

1. From inside of cab, install washer reservoir and mounting bracket using four capscrews, nuts, and washers. See Figure 59.

2. Lift up hardware cover at base of wiper arm and remove nut and washer from wiper arm. Remove wiper arm and blade from rear window. Remove wiper blade from wiper arm. See Figure 57. 3. Remove cap, nut, and wiper arm grommet from wiper motor shaft. 4. Open both doors of cab. From inside of cab, remove five screws from inner cover and remove inner cover from cab. 5. Disconnect wiper motor from cab harness from inside cab. From outside of cab, remove nut and washer from wiper motor mount. Remove wiper motor from cab. 6. Remove radiator cover (see Figure 5) and disconnect washer reservoir pump connectors and disconnect washer fluid hose. 7. From inside cab, remove four capscrews, nuts, and washers from washer reservoir mounting bracket. Remove washer reservoir and mounting bracket from lift truck.

2. Connect washer reservoir pump connectors and washer fluid hose. Install radiator cover. See Figure 5. 3. Place wiper motor onto wiper motor mount and secure using nut and washer. Connect wiper motor to cab harness. 4. Install inner cover using five screws. 5. Install cap, nut, and wiper arm grommet onto threaded wiper motor shaft that passes through window of operator's cab. NOTE: Inspect wiper blade for cracks and wear. Replace with new blade if old blade is worn or damaged. 6. Install wiper blade to wiper arm. Install wiper arm and blade to window using nut and washer. Close hardware cover at base of wiper arm. 7. Connect washer tube connector.

67


Window Wipers Replacement

0100 YRM 1290

Figure 59. Washer Reservoir and Rear Wiper Removal, Lift Truck Models GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

68


0100 YRM 1290

Window Wipers Replacement Legend for Figure 59

A. INNER REAR COVER B. WASHER RESERVOIR AND PUMP

C. WIPER ARM

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

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

SCREWS INNER REAR COVER WASHER RESERVOIR WASHER WIPER MOTOR NUT CAPSCREW WASHER MOUNTING BRACKET

WASHER RESERVOIR PUMP CONNECTOR WASHER RESERVOIR PUMP WASHER FLUID HOSE CAB HARNESS WASHER TUBE CONNECTOR WIPER ARM WIPER MOTOR MOUNT

Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878), GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878, E878) and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

1. Open hardware cover at base of wiper arm and remove nut and washer. Remove wiper arm and blade. See Figure 60.

1. Install washer reservoir using four flange bolts. Connect water tubes at T-fitting and cab harness to washer reservoir. See Figure 60.

2. Disconnect water tube from water tube nozzle.

2. Install wiper motor to rear window using two grommets, washers, and mounting studs. Connect cab harness to wiper motor.

3. Remove hardware cover, nut, retainer, washer, and grommet from threaded shaft on wiper motor. 4. Remove wiper motor cover by pulling backward. The cover is held in place by plastic tabs on the inside of cover. 5. Disconnect cab harness from wiper motor. Remove two mounting studs, washers, and grommets that attached wiper motor to window. Remove wiper motor from window. 6. Disconnect water tubes at T-fitting and cab harness from washer reservoir. Remove four flange bolts from washer reservoir and remove reservoir from lift truck.

3. Install wiper motor cover. The cover snaps into place with plastic tabs. 4. Install grommet, washer, retainer, nut, and hardware cover onto threaded shaft of wiper motor. See Figure 60. NOTE: Inspect wiper blade for cracks and wear. Replace with new blade if old blade is worn or damaged. 5. Install wiper arm and blade with washer and nut. 6. Connect water tube onto water tube nozzle.

69


Window Replacement

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

COVER NUT WASHER WIPER MOTOR REAR WINDOW GROMMET MOUNTING STUD RETAINER HARDWARE COVER WIPER MOTOR CONNECTOR

0100 YRM 1290

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

CAB HARNESS WATER TUBE NOZZLE WATER TUBE FRONT WATER TUBE T-FITTING FLANGE BOLTS WASHER RESERVOIR RESERVOIR PUMP WIPER BLADE WIPER ARM

Figure 60. Rear Wiper, Motor, and Washer Reservoir Removal, Lift Truck Models GLP/GDP60VX, GLP/ GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

70


0100 YRM 1290

Window Replacement

Window Replacement GENERAL See the Parts Manual for window replacement part numbers for the front, back, and top windows. To replace the door windows, see the procedures below.

REMOVE DOOR WINDOW, LIFT TRUCK MODELS GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) NOTE: The procedures described below apply to sliding and non-sliding right side door windows.

The procedures to remove sliding and non-sliding left side door windows are same as right side. To remove lower window on left side door, perform Step 5 and Step 6. 1. Slide window open half way. Grab window sides and lift window off window guide. See Figure 61. 2. Remove two setscrews from window mounting bracket and remove window from mounting bracket. 3. Remove side seal from side of sliding window. 4. Remove two capscrews from window handle and remove handle from window. To remove non-sliding window, repeat Step 1 through Step 4.

NOTE: RIGHT SIDE DOOR SHOWN. 1. 2. 3. 4.

SETSCREWS MOUNTING BRACKET SLIDING WINDOW SIDE SEAL

5. 6. 7. 8.

WINDOW GUIDE WINDOW HANDLE NON SLIDING WINDOW CAPSCREWS

Figure 61. Sliding Window Removal

71


Window Replacement

0100 YRM 1290

NOTE: The lower window on left side door is glued into place on door frame. 5. On outside of door, cut seal that holds window in place on door frame. See Figure 62.

NOTE: The procedures described below apply to sliding and non-sliding right side door windows. The procedures to install sliding and non-sliding left side door windows are same as right side. To install lower window on left side door, perform Step 5 and Step 6. NOTE: See Parts Manual for window replacement part numbers. 1. Attach window handle to window with two bolts. See Figure 62. 2. Install side seal to side of sliding window. 3. Place window in mounting bracket and secure window to mounting bracket with setscrews. 4. Place window onto window guide. Open and close window (sliding window only) to ensure it is properly installed onto window guide. Perform Step 1 through Step 4 to install non-sliding window. 5. Apply adhesive to side of new seal that goes against window and install seal onto new window. See Figure 62. 6. Apply adhesive to other side of seal and press seal and window into door frame.

1. DOOR FRAME 2. SEAL

3. WINDOW

Figure 62. Lower Window Removal (Left Side Door) 6. Remove window and seal from door frame. Remove any excess seal material and adhesive from door frame.

INSTALL DOOR WINDOWS, LIFT TRUCK MODELS GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

72

REMOVE DOOR WINDOW, LIFT TRUCK MODELS GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) AND GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) NOTE: The procedures described below apply to sliding and non-sliding left side door windows. The procedures to remove sliding and non-sliding right side door windows are same as left side. To remove lower windows, go to Step 5. 1. Slide window open half way. Grab window sides and lift window off window guide. See Figure 63. 2. Remove two setscrews from window mounting bracket and remove window from mounting bracket. See Figure 63. 3. Remove side seal from side of sliding window.


0100 YRM 1290

Window Replacement

4. Remove two capscrews and washers from window slide/locking handle and remove handle from window.

To remove non-sliding window, repeat Step 1 through Step 4.

NOTE: LEFT SIDE DOOR SHOWN. 1. 2. 3. 4. 5.

SETSCREW MOUNTING BRACKET SLIDING WINDOW SIDE SEAL CAPSCREW

6. 7. 8. 9.

WASHER SLIDE/LOCKING HANDLE WINDOW GUIDE NON-SLIDING WINDOW

Figure 63. Sliding Window Removal

73


Heater Replacement

0100 YRM 1290

5. To remove lower window, remove seal from window and remove window from door frame. See Figure 64.

Perform Step 2 through Step 5 to install non-sliding window.

INSTALL DOOR WINDOW, LIFT TRUCK MODELS GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) AND GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) NOTE: The procedures described below apply to sliding and non-sliding left side door windows. The procedures to install sliding and non-sliding right side door windows are same as left side. To install lower windows, go to Step 1. NOTE: See Parts Manual for window replacement part numbers. 1. Install seal around lower window. Install seal and window into door frame. See Figure 64. 2. Attach handle to window with two capscrews and washers. See Figure 63. 3. Install side seal from side of sliding window. 4. Place window onto mounting bracket and secure window to mounting bracket with setscrews.

NOTE: LEFT SIDE DOOR SHOWN. 1. SEAL 2. WINDOW 3. DOOR FRAME Figure 64. Lower Window Removal

5. Place window onto window guide. Open and close window (slide window only) to ensure it is properly installed onto window guide.

Heater Replacement REMOVE, FOR LIFT TRUCK MODELS GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) AND GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909)

5. Loosen strap clamps and remove formed hose from fresh air intake vent to heater box. See Figure 67.

1. Remove front and rear floor mat and front floor plate. See Figure 65.

7. Disconnect heater control harness from heater and cab harness and unclip heater control harness from seat support.

2. Remove four flange bolts and rear floor plate. See Figure 65. 3. Disconnect battery. 4. Remove right side rear panel. See Figure 66.

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6. Remove flange bolts, clip nuts, and fresh air intake vent located outside on module. See Figure 68.

8. Remove four screws from heater control at top of seat surround. Remove Heater control. 9. Loosen strap clamps and disconnect front and rear duct heater hoses at top of surround cover.


0100 YRM 1290

1. FRONT FLOOR MAT 2. REAR FLOOR MAT 3. FLANGE BOLT

Heater Replacement

4. REAR FLOOR PLATE 5. FRONT FLOOR PLATE 6. MODULE Figure 65. Floor Plate Removal NOTE: RIGHT SIDE VIEW SHOWN. 1. SCREWS 2. RIGHT SIDE REAR PANEL Figure 66. Right Side Rear Panel Removal

75


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YALE H813 GLP40VX6 LIFT TRUCK (EUROPE) Service Repair Manual  
YALE H813 GLP40VX6 LIFT TRUCK (EUROPE) Service Repair Manual  
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