Yale a909 gdp80vx9 lift truck service repair manual by 1636645

GDP80VX, GDP80VX9, GDP90VX (A909) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

OPERATOR'S CAB........................................................................................................ FRAME............................................................................................................................ GM ENGINES 5.7 LITER V-8 LPG................................................................................. COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM GM 5.7L ENGINE......................................................................... THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... DRIVE AXLE WET BRAKE (SPICER)............................................................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIR (S/N A513, A514, A613, A614, A643, A644, A683, A684)................... METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

524306203 524288879 550021072 524223757 550021077 524288194 524296605 524223764 524262279 524223766 550073240 524223767 524294878 524208014 524223769 524223770 524223771 524223772 550000873 524150797 524223780 550001097 550000875 550001092 524221866

0100 YRM 1290 0100 YRM 1321 0600 YRM 1432 0700 YRM 1123 0900 YRM 1433 1300 YRM 1317 1400 YRM 1344 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2100 YRM 1328 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142 4000 YRM 1406 8000 YRM 0231 8000 YRM 1134 8000 YRM 1407 8000 YRM 1408 8000 YRM 1409 9000 YRM 1112

04/14 08/12 07/12 03/13 07/12 03/13 12/13 07/13 03/13 04/14 12/14 04/14 02/14 05/14 12/14 12/14 12/14 04/14 02/14 10/13 12/14 10/14 08/12 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. 550000868 (12/14)

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

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.

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

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

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 â&#x20AC;˘

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 â&#x20AC;˘

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.

Cab Replacement

0100 YRM 1290

Figure 6. Heater Hose Connection

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

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

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

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)

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)

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/

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

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

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

0100 YRM 1290

Cab Replacement

Figure 15. Dash Installation

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.

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

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.

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

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

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.

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.

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

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

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.

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

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.

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

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

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.

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