Page 1

GP/GLP/GDP80VX, GP/GLP/GDP90VX, GP/GLPGDP100VX, GP/GLP/ GDP110VX, GP/GLP/GDP120VX (G813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM (GM 4.3L)...................................................................................... GASOLINE FUEL SYSTEM (GM 4.3L).......................................................................... LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ GASOLINE FUEL SYSTEM............................................................................................ 1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... POWERSHIFT TRANSMISSION REPAIR...................................................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ 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.................................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524262274 524306203 524265337 524223757 524262275 524262276 550043871 550048401 524223762 550043436 524262277 524262278 524223764 524262279 524223766 550073240 524223767

0100 YRM 1243 0100 YRM 1290 0600 YRM 1251 0700 YRM 1123 0900 YRM 1242 0900 YRM 1244 0900 YRM 1556 0900 YRM 1570 1300 YRM 1129 1300 YRM 1529 1400 YRM 1245 1400 YRM 1246 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137

05/14 04/14 05/14 03/13 08/12 06/12 04/14 09/13 09/09 08/13 01/12 12/13 07/13 03/13 04/14 12/14 04/14

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 524262280 524262281 524329117 550001092 524221866

4000 YRM 1250 8000 YRM 0231 8000 YRM 1134 8000 YRM 1248 8000 YRM 1249 8000 YRM 1387 8000 YRM 1409 9000 YRM 1112

02/14 10/13 12/14 04/13 08/11 04/14 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. 524329176 (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.


Cooling System

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................ Cooling System Checks ...................................................................................................................................... Exhaust Leaks Into Cooling System ............................................................................................................... Water Flow Restrictions in Radiator ................................................................................................................ Radiator Hoses ............................................................................................................................................... Water Pump .................................................................................................................................................... Flushing the Cooling System............................................................................................................................... Cooling System, Clean.................................................................................................................................... Radiator Replacement......................................................................................................................................... Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) .............................................................................................................................. Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974) Equipped with Oil Cooler................................................................................................................................. Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) .................................................................................................................................................... Radiator, 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) ....................................................... Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) .............................................................................................................................. Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974) Equipped with Oil Cooler................................................................................................................................. Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) .................................................................................................................................................... Radiator, 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) ....................................................... Fan Assembly Replacement................................................................................................................................ Fan Removal ................................................................................................................................................... Inspect............................................................................................................................................................. Fan Installation ................................................................................................................................................

©2013 Yale Materials Handling Corp.

1 1 1 1 1 1 2 2 3

3

19

21

24

29

33

34

37 47 47 62 62

i


Table of Contents

Cooling System

TABLE OF CONTENTS (Continued) This section is for the following models: GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809]; GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810]; GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910]; GLC050LX [A967]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLP/GDP20-25LX (GLP/GDP050LX) [A974]; GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813]; GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) [C879, D879, E879, F879]; 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]

ii


700 YRM 1123

Cooling System Checks

General This section contains the repair and replacement instructions for the radiator, coolant level sensor, fan

assembly (pusher type), fan shroud, coolant hoses, coolant recovery bottle, and optional debris screen.

Cooling System Checks EXHAUST LEAKS INTO COOLING SYSTEM WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

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 check or fix any part of the cooling system. Inspect all radiator hoses. If they feel spongy or have visible cracks, replace hoses.

To check for exhaust leaks into the cooling system, use a Combustion Leak Test Kit for this purpose. Follow the manufacturer’s instructions when doing the test.

WATER PUMP

WATER FLOW RESTRICTIONS IN RADIATOR

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. To check for water flow restrictions in the radiator, run engine until it is warm.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator 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 check or fix any part of the cooling system.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Run engine until it is warm. Check the operation of water pump by holding the top radiator hose. If the pump is operating, there will be pressure surges in the hose. Check for leaks around the timing belt cover near the base of the oil pump. Check the weep hole where coolant that leaks past the water pump seal can be drained before reaching the water pump bearings. If there is a drip, check the pump shaft seal and water pump. Replacement of the pump shaft seal or water pump may be necessary.

Shut engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will be hotter near the top radiator hose.) Cold spots on radiator indicate restrictions.

For repair procedures for the GM 2.4L water pump, refer to the section GM Engine Repair, GM 2.4 Liter Engine 600 YRM 1121.

If radiator has leaks, either replace the radiator or have it repaired by trained personnel.

For repair procedures for the Mazda FE and F2 water pump, refer to the section Mazda Engine, FE and F2 600 YRM 1122.

RADIATOR HOSES WARNING

For replacement procedures for the Yanmar 2.6L and 3.3L water pump, refer to the section Yanmar Diesel Engines, 2.6L, 3.0L and 3.3L 600 YRM 1205.

The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.

1


Flushing the Cooling System

700 YRM 1123

For replacement procedures for the GM 4.3L water pump, refer to the section GM Engines, 4.3 Liter V-6 600 YRM 1251. For replacement procedures for the GM 5.7L water pump, refer to the section GM Engines, 5.7 Liter V-8 LPG 600 YRM 1432.

For replacement procedures for the Kubota water pump, refer to the section • Kubota Diesel 3.8L Engines 600 YRM 1557 • Kubota Diesel 3.6L Engine 600 YRM 1579 • Kubota Diesel 3.8L Engines, with Diesel Particulate Filter (DPF) 600 YRM 1590 For replacement procedures for the Cummins 4.5L and QSB 3.3L water pump, contact your local Yale dealer or see Yale Axcess Online.

Flushing the Cooling System COOLING SYSTEM, CLEAN WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

WARNING The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while checking the radiator fins. 1. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator 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 check or fix any part of the cooling system.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

2

2. Drain cooling system. Fill cooling system with clean water. See sections below for more information: • Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) • Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) • Radiator, 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) 3. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool. 4. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is clean.


700 YRM 1123

Radiator Replacement method uses water pressure to force water through radiator in opposite direction of normal flow.

CAUTION Follow the manufacturer’s instructions when using a chemical radiator cleaner. 5. If water does not clean system, use a chemical radiator cleaner.

CAUTION Follow the manufacturer’s instructions when using special equipment to reverse clean the radiator. 6. If radiator or cooling system is very dirty or has a restriction, use reverse cleaning method. This

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. 7. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50 percent concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F). Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

Radiator Replacement RADIATOR, REMOVE FOR LIFT TRUCKS MODELS GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) AND GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) WARNING

See Frame 100 YRM 1120 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Frame 100 YRM 1243 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Frame 100 YRM 1423 for lift truck models • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)

The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator 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 check or fix any part of the cooling system.

Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so that no one connects the cables on the terminals.

1. Turn OFF truck.

4. Disconnect the positive battery cable.

WARNING

3. Disconnect the negative battery cable.

2. Remove the hood and seat combination.

3


Radiator Replacement

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 5. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under radiator. Remove radiator cap.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Open the drain plug or loosen hose clamp and disconnect the lower hose. 7. Lift trucks equipped with a Cummins QSB 3.3L diesel engine: Loosen clamps and disconnect the charge air cooler hoses from charge air cooler. See Figure 6. 8. Lift trucks equipped with a Kubota 3.8L diesel engine: Loosen clamps and disconnect transmission cooler hoses from transmission cooler. See Figure 8. 9. Once coolant is drained from engine, loosen hose clamps and disconnect coolant hoses from radiator. Cap radiator hoses. 10. Loosen hose clamp and disconnect hose from reservoir and remove reservoir. See Figure 1 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809 • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) See Figure 2 or Figure 3 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;

4

700 YRM 1123 GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 4 or Figure 5 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) See Figure 6 for lift truck models below equipped with a Cummins QSB 3.3L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813 • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879) See Figure 7 for lift truck models below equipped with Yanmar 2.6L diesel engine • GDP20-25LX (GDP050LX) (A974) See Figure 8 for lift truck models below equipped with a Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813) 11. Remove battery and battery tray. 12. If equipped, disconnect electrical connector to the coolant level sensor. NOTE: For Mazda LPG engine, the LPG converter bracket needs to be moved for clearance of radiator. 13. Remove screws and washers from the shroud and move shroud out of the way. 14. Place radiator guard shield between radiator and fan so damage to radiator does not occur during fan removal. 15. Remove fan, fan spacer, and pulley. 16. Remove radiator guard shield. 17. Remove capscrews and upper radiator bracket. See Figure 1 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809 • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)


700 YRM 1123 • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) See Figure 2 or Figure 3 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 4 or Figure 5 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)

Radiator Replacement • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879) See Figure 7 for lift truck models below equipped with Yanmar 2.6L diesel engine • GDP20-25LX (GDP050LX) (A974) See Figure 8 for lift truck models below equipped with a Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813) 18. Remove radiator from truck. 19. If necessary, remove the coolant level sensor.

See Figure 6 for lift truck models below equipped with a Cummins QSB 3.3L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813

5


Radiator Replacement

700 YRM 1123

Figure 1. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP20-25LX (GLP050LX) (A974)

6


700 YRM 1123

Radiator Replacement

Legend for Figure 1 A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER, MODINE SHOWN

C. RESERVOIR BEFORE MAY ’06 D. RESERVOIR AFTER MAY ’06

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

15. NUT-CLIP, GC/GLC040-070VX, GC/GLC055SVX [A910] AND GLC050LX (A967) 16. ISOLATOR 17. COOLANT LEVEL SENSOR 18. RESERVOIR 19. TUBE 20. OUTLET ASSEMBLY 21. HOSE 22. RESERVOIR OUTLET 23. CAP 24. BUSHING 25. SCREEN ASSEMBLY (OPTIONAL) 26. HEAT SHIELD 27. RESERVOIR BRACKET 28. HEAT SHIELD, GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875] AND GLP20-25LX (GLP050LX) (A974)

RADIATOR CAP UPPER HOSE LOWER HOSE CLAMP SHROUD CLIP WASHER SCREW CLIP UPPER RADIATOR BRACKET CAPSCREW, GC/GLC040-070VX, GC/GLC055SVX [A910] AND GLC050LX (A967) 13. INSERT 14. LOWER BRACKET, GC/GLC040-070VX, GC/GLC055SVX [A910] AND GLC050LX (A967)

7


Radiator Replacement

700 YRM 1123

Figure 2. Cooling System for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) Before 2011

8


700 YRM 1123

Radiator Replacement

Legend for Figure 2 A. RADIATOR WITH EXTERNAL COOLER

B. RADIATOR WITH INTERNAL COOLER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

RADIATOR SHROUD WASHER SCREW CLIP NUT CLIP UPPER HOSE LOWER HOSE CLAMP UPPER RADIATOR BRACKET INSERT CAPSCREW ISOLATOR RESERVOIR

RESERVOIR BRACKET OUTLET ASSEMBLY OUTLET CAP BUSHING HOSE TUBE STRAP NUT SCREEN BAFFLE (RH AND LH) RADIATOR CAP COOLANT LEVEL SENSOR

9


Radiator Replacement

700 YRM 1123

Figure 3. Cooling System for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) After 2011

10


700 YRM 1123

Radiator Replacement

Legend for Figure 3 A. RADIATOR WITH EXTERNAL COOLER

B. RADIATOR WITH INTERNAL COOLER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

RADIATOR SHROUD WASHER SCREW CLIP NUT CLIP UPPER HOSE LOWER HOSE CLAMP UPPER RADIATOR BRACKET INSERT CAPSCREW ISOLATOR

RESERVOIR OUTLET ASSEMBLY OUTLET CAP BUSHING HOSE TUBE NUT SCREEN BAFFLE (RH AND LH) RADIATOR CAP COOLANT LEVEL SENSOR

11


Radiator Replacement

700 YRM 1123

Figure 4. Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Before 2011

12


700 YRM 1123

Radiator Replacement

Legend for Figure 4 A. RADIATOR WITH INTERNAL COOLER

B. RADIATOR WITH EXTERNAL COOLER

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

CAPSCREW INSERT UPPER RADIATOR BRACKET RADIATOR CAP ISOLATOR CLIP NUT COOLANT LEVEL SENSOR RADIATOR CLIP RADIATOR SHROUD CLAMP LOWER HOSE SCREW

WASHER SCREEN STRAP RESERVOIR BRACKET RESERVOIR OUTLET ASSEMBLY OUTLET CAP BUSHING TUBE UPPER HOSE DRAIN PLUG OIL COOLER

13


Radiator Replacement

700 YRM 1123

Figure 5. Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) After 2011

14


700 YRM 1123

Radiator Replacement

Legend for Figure 5 A. RADIATOR WITH INTERNAL COOLER

B. RADIATOR WITH EXTERNAL COOLER

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

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

CAPSCREW INSERT UPPER RADIATOR BRACKET RADIATOR CAP ISOLATOR CLIP NUT COOLANT LEVEL SENSOR RADIATOR CLIP RADIATOR SHROUD CLAMP LOWER HOSE

SCREW WASHER SCREEN RESERVOIR OUTLET ASSEMBLY OUTLET CAP BUSHING TUBE UPPER HOSE DRAIN PLUG OIL COOLER

15


Radiator Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

RADIATOR RADIATOR CAP HARNESS CLIP UPPER RADIATOR BRACKET INSERT ISOLATOR CAPSCREW CLAMP TUBE UPPER HOSE CLAMP CHARGE AIR COOLER HOSE CLAMP CHARGE AIR COOLER HOSE SHROUD

700 YRM 1123

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

CLAMP CHARGE AIR COOLER HOSE SCREW WASHER CLIP LOWER HOSE RESERVOIR BUSHING RESERVOIR CAP RESERVOIR OUTLET HOSE TUBE COOLANT LEVEL SENSOR SEAL

Figure 6. Cummins 3.3L Cooling System With Charge Air Cooler for GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)

16


700 YRM 1123

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

LOWER HOSE CLAMP UPPER HOSE RESERVOIR OUTLET ASSEMBLY BUSHING CAP RESERVOIR OUTLET HOSE CAPSCREW INSERT RADIATOR CAP

Radiator Replacement

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

ISOLATOR UPPER RADIATOR BRACKET RADIATOR PLUG - COOLANT LEVEL SENSOR HEAT SHIELD CLIP NUT WASHER SCREW DRAIN PLUG SHROUD TUBE

Figure 7. Yanmar 2.6L Cooling System for Lift Truck Models GDP20-25LX (GDP050LX) (A974)

17


Radiator Replacement

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

RADIATOR RADIATOR CAP UPPER RADIATOR BRACKET ISOLATOR CAPSCREW INSERT CLAMP TUBE UPPER HOSE LOWER HOSE

700 YRM 1123

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

TRANSMISSION COOLER RETURN LINE TRANSMISSION COOLER SUPPLY LINE SCREW WASHER SHROUD RESERVOIR BUSHING RESERVOIR CAP RESERVOIR OUTLET COOLANT LEVEL SENSOR

Figure 8. Kubota 3.8L Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)

18


700 YRM 1123

RADIATOR, REMOVE FOR LIFT TRUCKS MODELS GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) AND GLP/GDP20-25LX (GLP/GDP050LX) (A974) EQUIPPED WITH OIL COOLER WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator 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 check or fix any part of the cooling system. 1. Turn OFF truck. 2. Remove the hood and seat combination. See section Frame 100 YRM 1120 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) See section Frame 100 YRM 1423 for lift truck models • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)

WARNING Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so that no one connects the cables on the terminals.

Radiator Replacement removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 5. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under radiator. Remove radiator cap.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Open the drain plug or loosen hose clamp and disconnect the lower hose. 7. Loosen clamps and disconnect oil cooler hoses from oil cooler adapters. See Figure 9. 8. Remove oil cooler adapters and O-rings from radiator. Discard O-rings. See Figure 9. 9. Once coolant is drained from engine, loosen hose clamps and disconnect coolant hoses from radiator. Cap radiator hoses. 10. Loosen hose clamp and disconnect hose from reservoir and remove reservoir. See Figure 9. 11. Remove battery and battery tray. 12. If equipped, disconnect electrical connector to the coolant level sensor. NOTE: For Mazda LPG engine, the LPG converter bracket needs to be moved for clearance of radiator. 13. Remove screws and washers from the shroud and move shroud out of the way. 14. Place radiator guard shield between radiator and fan so damage to radiator does not occur during fan removal. 15. Remove fan, fan spacer, and pulley.

3. Disconnect the negative battery cable.

16. Remove radiator guard shield.

4. Disconnect the positive battery cable.

17. Remove capscrews and upper radiator bracket. See Figure 9.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is

18. Remove radiator from truck. 19. If necessary, remove the coolant level sensor.

19


Radiator Replacement

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

RADIATOR CAP UPPER HOSE LOWER HOSE CLAMP SHROUD O-RING OIL COOLER ADAPTER OIL COOLER HOSE UPPER RADIATOR BRACKET

700 YRM 1123

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

CAPSCREW INSERT ISOLATOR RESERVOIR TUBE OUTLET ASSEMBLY HOSE RESERVOIR OUTLET CAP BUSHING

Figure 9. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974)

20


700 YRM 1123

RADIATOR, REMOVE FOR LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator 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 check or fix any part of the cooling system. 1. Turn off truck.

WARNING Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so that no one connects the cables on the terminals. 2. Disconnect the negative battery cable. 3. Disconnect the positive battery cable.

Radiator Replacement 11. Place a radiator guard shield between radiator and fan so damage to radiator does not occur during fan removal. 12. Remove fan. See Fan Removal procedures. 13. Remove radiator guard shield.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 14. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under the radiator. Remove radiator cap.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 15. Open drain plug, loosen clamp and disconnect the lower radiator hose from radiator to allow coolant to drain into a suitable container. Install caps on hose. See Figure 10.

4. Remove radiator cover. See Figure 10. 5. Remove debris cover.

CAUTION The counterweight cover is extremely heavy 185 kg (408 lb). Make sure that the eyebolts and lifting device have sufficient capacity to lift the weight. 6. Remove two bolts from counterweight cover. 7. Install two eyebolts in the hole on each end of the counterweight cover. Connect a suitable lifting device to the eyebolts and carefully remove the counterweight cover from lift truck. 8. Remove four capscrews from upper radiator bracket. Remove bracket. See Figure 23. 9. If necessary, disconnect electrical connector from the coolant level sensor. 10. Remove screws, washers, and clip nuts from the shroud and radiator and move shroud out of the way.

16. Once coolant is drained from engine, loosen hose clamp and disconnect upper radiator hose from radiator. Install cap on hose. See Figure 10. 17. Lift trucks equipped with a Cummins QSB 3.3L diesel engine: Loosen clamps and disconnect the charge air cooler hoses from charge air cooler. See Figure 11. 18. Loosen clamp and disconnect remote refill hose from radiator. Install cap on hose. NOTE: Tag the transmission lines before disconnecting from oil cooler. 19. Disconnect transmission lines from oil cooler. Install caps on transmission lines. Drain transmission oil from oil cooler into a suitable container. Install caps on the oil cooler ports. NOTE: Removing the radiator from lift truck requires two people. 20. Remove radiator from lift truck frame. 21. If necessary, remove the coolant level sensor from radiator. See Figure 23.

21


Radiator Replacement

700 YRM 1123

Legend for Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Figure 10. Radiator Removal for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879)

22

DEBRIS COVER COUNTERWEIGHT COVER RADIATOR COVER UPPER BRACKET CAPSCREWS REMOTE FILL HOSE HOSE CLAMPS OIL COOLER TRANSMISSION OIL COOLER LINES FITTINGS UPPER HOSE LOWER HOSE REMOTE FILL RADIATOR CAP


700 YRM 1123

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

RADIATOR RADIATOR CAP HARNESS CLIP UPPER RADIATOR BRACKET INSERT ISOLATOR CAPSCREW CLAMP TUBE UPPER HOSE CLAMP CHARGE AIR COOLER HOSE CLAMP CHARGE AIR COOLER HOSE SHROUD

Radiator Replacement

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

CLAMP CHARGE AIR COOLER HOSE SCREW WASHER CLIP LOWER HOSE RESERVOIR BUSHING RESERVOIR CAP RESERVOIR OUTLET HOSE TUBE COOLANT LEVEL SENSOR SEAL

Figure 11. Cummins 3.3L Cooling System With Charge Air Cooler for GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879)

23


Radiator Replacement

RADIATOR, 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) WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator 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 check or fix any part of the cooling system. 1. Turn off truck.

WARNING Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so that no one connects the cables on the terminals. 2. Disconnect the negative battery cable. 3. Disconnect the positive battery cable. NOTE: Perform Step 4 for lift truck models GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878). 4. Open hood and loosen clamp and disconnect inlet hose that attaches to the hood support. See Figure 25. NOTE: Perform Step 5 for lift truck model GDP80VX, GDP80VX9, GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909). 5. Open hood, loosen clamp, and disconnect dirty air hose attached to hood support. See Figure 26 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) See Figure 27 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP/GLP170VX, GLP/GLP175VX36, GLP/GLP190VX) (A909, B909)

24

700 YRM 1123 See Figure 28 for lift truck models equipped with Kubota 3.8L Diesel engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (B909) 6. Lift trucks equipped with GM 4.3L (Gas/LPG) engine, loosen clamp and disconnect inlet hose from air filter and remove inlet hose. See Figure 25. NOTE: Perform Step 7 for lift truck models GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878). 7. Lift trucks equipped with the Kubota 3.8L, Cummins 4.5L, or QSB 3.3L diesel engine loosen clamp and disconnect inlet hose from silencer. Remove silencer. See Figure 25. NOTE: Before lifting the hood assembly from the lift truck frame, make sure to use a lifting device and lifting straps as shown in Figure 12. The hood assembly weighs approximately 45.6 kg (101 lb). 8. Remove hood assembly. For hood assembly removal procedures, see Frame 100 YRM 1321 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C879, D879) Frame 100 YRM 1581 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909) 9. Disconnect and cap auxiliary coolant reservoir hose. See Figure 25. 10. Remove capscrews from the auxiliary coolant reservoir bracket and upper bracket. Remove auxiliary coolant reservoir assembly. 11. Remove the four capscrews from the upper radiator bracket. Remove bracket. 12. If necessary, disconnect electrical connector from the coolant level sensor. 13. Remove screws, washers and clip nuts from the shroud and move shroud out of the way.


700 YRM 1123

Radiator Replacement See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909 B909) See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 17. Remove radiator guard shield.

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 18. Let coolant cool to ambient temperature. Place a drain pan with a capacity equal to or greater than the capacity of the cooling system under the radiator. Remove radiator cap.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 1. PRE-CLEANER

2. STRAP CLAMP

Figure 12. Hood Assembly Removal 14. Place a radiator guard shield between radiator and fan so damage to radiator does not occur during fan removal. NOTE: Perform Step 15 for lift truck models GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878). 15. Remove capscrews, washers, fan, fan spacer, and shroud. See Figure 25. NOTE: Perform Step 16 for lift truck model GLP\ GDP80VX, GLP\GDP80VX9, GLP\GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

19. Open drain plug or loosen clamp and disconnect lower radiator hose to allow coolant to drain. See Figure 25 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

16. Remove capscrews, washer, fan, fan spacers, and fan shroud.

See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (B909)

See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

20. Lift trucks equipped with a Cummins QSB 3.3L or Kubota 3.8L diesel engine, loosen clamps and disconnect the charge air cooler hoses from radiator. See Figure 13 or Figure 15.

25


Radiator Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

RADIATOR RADIATOR CAP HARNESS CLIP UPPER RADIATOR BRACKET INSERT ISOLATOR CAPSCREW CLAMP TUBE UPPER HOSE CLAMP CHARGE AIR COOLER HOSE CLAMP CHARGE AIR COOLER HOSE SHROUD

700 YRM 1123

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

CLAMP CHARGE AIR COOLER HOSE SCREW WASHER CLIP LOWER HOSE RESERVOIR BUSHING RESERVOIR CAP RESERVOIR OUTLET HOSE TUBE COOLANT LEVEL SENSOR SEAL

Figure 13. Cummins 3.3L Cooling System With Charge Air Cooler for GDP60VX, GDP70VX (GDP135VX, GDP155VX) (D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

26


700 YRM 1123 21. Once coolant is drained from engine, loosen hose clamps and disconnect radiator hoses from radiator. Cap hoses. NOTE: Tag the transmission lines before disconnecting from oil cooler. 22. Disconnect and cap transmission lines from oil cooler and allow transmission oil to drain from oil

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

BAFFLE ISOLATOR UPPER BRACKET CAP RESERVOIR OUTLET BUSHING HOSE RESERVOIR RADIATOR

Radiator Replacement cooler into a suitable container, then cap the oil cooler ports. 23. For lift trucks equipped with GM 5.7L LPG engine, remove capscrews from baffles and remove baffles from radiator assembly. Remove capscrews securing cooling baffle to radiator assembly. See Figure 14.

10. 11. 12. 13. 14. 15. 16. 17. 18.

CAPSCREW SHROUD CLAMP UPPER HOSE LOWER HOSE SEAL COOLING BAFFLE DRAIN HOSE PLASTIC TUBE

Figure 14. GM 5.7L Cooling System, Lift Truck Models GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

27


Radiator Replacement

700 YRM 1123

Figure 15. Kubota 3.8L Cooling System, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)

28


700 YRM 1123

Radiator Replacement

Legend for Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

RADIATOR RADIATOR CAP UPPER RADIATOR BRACKET INSERT ISOLATOR CAPSCREW CLAMP TUBE UPPER HOSE CHARGE AIR COOLER HOSE CHARGE AIR COOLER HOSE

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

CHARGE AIR COOLER HOSE LOWER HOSE SHROUD RESERVOIR BUSHING RESERVOIR CAP RESERVOIR OUTLET HOSE COOLANT LEVEL SENSOR SEAL

NOTE: Removing the radiator from lift truck requires two people.

5. Place shroud in lift truck. DO NOT install on radiator.

24. Remove radiator from lift truck frame.

NOTE: Pull radiator shroud away from radiator while installing fan, fan spacer, and pulley.

25. If necessary, remove the coolant level sensor from radiator.

RADIATOR, INSTALL FOR LIFT TRUCK MODELS GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) AND GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 1. If removed, install the coolant level sensor.

6. Install fan, fan spacer, and pulley. 7. Remove radiator guard shield. 8. Install the radiator shroud on radiator using screws and washers taken out during removal.. 9. If equipped, connect the electrical connector to the coolant level sensor. NOTE: For Mazda LPG engine, the LPG converter bracket and screws must be installed to hold the converter. 10. Uncap radiator and reservoir ports and install the reservoir. 11. Connect the reservoir hose from reservoir to the radiator. Tighten hose clamp. 12. Lift trucks equipped with Cummins QSB 3.3L engine, uncap the charge air cooler hoses and connect the hoses to charge air cooler. See Figure 6. 13. Lift trucks equipped with Kubota 3.8L diesel engine: Uncap transmission cooler hoses and connect hoses to transmission cooler. See Figure 8.

2. Install radiator into truck.

14. Uncap the upper hose and connect the hose to radiator. Tighten hose clamp.

3. Install upper radiator bracket, using capscrews taken out during removal.

15. Close the drain plug or install lower hose. Tighten hose clamp.

4. Place a radiator guard shield between radiator and fan, so damage to radiator does not occur during fan installation

29


Radiator Replacement

700 YRM 1123

WARNING DO NOT use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. 16. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F). 17. Use the same coolant mixture and fill the reservoir between the ADD and FULL marks. See Figure 16 or Figure 17, for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875 • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) See Figure 18, for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) See Figure 19 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813)

30

1. RESERVOIR 2. ADD MARK

3. FULL MARK

Figure 16. Reservoir for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP/GDP20-25LX (GLP/GDP050LX) (A974) Before May ’06


700 YRM 1123

1. RESERVOIR 2. ADD MARK

Radiator Replacement

3. FULL MARK

Figure 17. Reservoir for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910); GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP/GDP20-25LX (GLP/GDP050LX) (A974) After May ’06

1. 2. 3. 4.

AUXILIARY COOLANT RESERVOIR FULL "HOT" MARK FULL "COLD" MARK ADD "COLD" MARK

Figure 18. Reservoir for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813)

31


Radiator Replacement

700 YRM 1123 See section Frame 100 YRM 1243 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See section Frame 100 YRM 1423 for lift truck models • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)

WARNING 1. 2. 3. 4.

AUXILIARY COOLANT RESERVOIR FULL "HOT" MARK FULL "COLD" MARK ADD "COLD" MARK

Figure 19. Reservoir 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 battery and battery tray. 19. Connect the positive battery cable. 20. Connect negative battery cable. 21. Install the hood and seat combination. See section Frame 100 YRM 1120 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

32

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. 22. Start and run engine until thermostat opens. (The upper hose will be warm.) 23. On lift trucks equipped with a GM 2.4L engine, bleed air from the cooling system by opening the bleed screw located on the left side behind the alternator. When the air has been bled from the system close the bleed screw. See Figure 20.

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. 24. Check coolant level at the reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.


700 YRM 1123

Radiator Replacement 6. Install fan, fan spacer, and pulley. 7. Remove radiator guard shield. 8. Install the radiator shroud on radiator using screws and washers taken out during removal.. 9. If equipped, connect the electrical connector to the coolant level sensor. NOTE: For Mazda LPG engine, the LPG converter bracket and screws must be installed to hold the converter. 10. Uncap radiator and reservoir ports and install the reservoir. 11. Connect the reservoir hose from reservoir to the radiator. Tighten hose clamp. See Figure 9. 12. Install new O-rings on oil cooler connectors. See Figure 9.

1. MANIFOLD 2. COOLANT HOSES

3. BLEED SCREW 4. RADIATOR HOSE

Figure 20. Bleed Screw, GM 2.4L Engine

RADIATOR, INSTALL FOR LIFT TRUCK MODELS GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) AND GLP/GDP20-25LX (GLP/GDP050LX) (A974) EQUIPPED WITH OIL COOLER 1. If removed, install the coolant level sensor.

13. Install oil cooler adapters to radiator. Torque adapters to 14.7 to 17.6 N•m (130 to 156 lbf in). See Figure 9. 14. Uncap oil cooler hoses and connect hoses to oil cooler adapters. See Figure 9. 15. Uncap the upper hose and connect the hose to radiator. Tighten hose clamp. See Figure 9. 16. Close the drain plug or install lower hose. Tighten hose clamp.

WARNING DO NOT use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

2. Install radiator into truck. 3. Install upper radiator bracket, using capscrews taken out during removal. 4. Place a radiator guard shield between radiator and fan, so damage to radiator does not occur during fan installation

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

5. Place shroud in lift truck. DO NOT install on radiator.

17. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F).

NOTE: Pull radiator shroud away from radiator while installing fan, fan spacer, and pulley.

18. Use the same coolant mixture and fill the reservoir between the ADD and FULL marks. See Figure 21.

33


Radiator Replacement

700 YRM 1123

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. 23. Start and run engine until thermostat opens. (The upper hose will be warm.)

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. 1. RESERVOIR 2. ADD MARK

3. FULL MARK

Figure 21. Reservoir for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974) 19. Install battery and battery tray. 20. Connect the positive battery cable.

24. Check coolant level at the reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

RADIATOR, INSTALL FOR LIFT TRUCK MODELS S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) 1. If necessary, install coolant level sensor.

21. Connect negative battery cable.

NOTE: Installing the radiator into lift truck frame requires two people.

22. Install the hood and seat combination.

2. Install radiator into lift truck frame.

See section Frame 100 YRM 1120 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) See section Frame 100 YRM 1423 for lift truck models • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974)

3. Remove caps from the oil cooler and transmission lines and connect lines into oil cooler. See Figure 10. 4. Uncap and connect remote refill hose onto radiator and tighten hose clamp. See Figure 10. 5. Close drain plug and uncap the upper and lower radiator hoses and connect hoses onto radiator and tighten hose clamps. See Figure 10. 6. Uncap the charge air cooler hoses and connect the hoses to charge air cooler. See Figure 11. 7. Install fan. See Fan Installation procedures. 8. Align shroud to radiator and install two capscrews, washers and clip nuts. See Figure 23.

34


700 YRM 1123

Radiator Replacement

9. If necessary, connect electrical connector onto the coolant level sensor. 10. Install upper radiator bracket and four capscrews.

CAUTION The counterweight cover is extremely heavy 185 kg (408 lb). Make sure that the eyebolts and lifting device have sufficient capacity to lift the weight. 11. If removed, install two eyebolts in the hole on each end of the counterweight cover. Connect a suitable lifting device to the eyebolts and carefully install the counterweight cover into the lift truck frame. See Figure 10. 12. Install two bolts to counterweights cover. Tighten to 38 N•m (28 lbf ft). 13. Install debris cover. 14. Install radiator cover. 15. Connect positive battery cable.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and cause serious injury. 20. Start and run the engine until thermostat opens (The upper radiator hose will be warm).

CAUTION Additives may damage the cooling system. Before using additives, contact you local Yale dealer. 21. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir. 22. Shut down the engine for one minute or longer prior to checking the transmission oil level. If the transmission oil is low, add transmission oil to the transmission at the dipstick tube to the correct level indicated on the dipstick. Oil is specified in Periodic Maintenance section for your lift truck.

16. Connect negative battery cable.

WARNING DO NOT use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTION Additives may damage the cooling system. Before using additives, contact you local Yale dealer. 17. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F). 18. Install radiator cap. 19. Use the same coolant mixture and fill the reservoir between the ADD and FULL marks. See Figure 22.

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. contact with these parts can cause serious injury.

1. 2. 3. 4.

AUXILIARY COOLANT RESERVOIR FULL "HOT" MARK FULL "COLD" MARK ADD "COLD" MARK

Figure 22. Reservoir for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879)

35


Radiator Replacement

700 YRM 1123

Figure 23. Cooling System for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879)

36


700 YRM 1123

Radiator Replacement

Legend for Figure 23 A. LOWER HOSE (CUMMINS 4.5L/KUBOTA 3.8L DIESEL) B. LOWER HOSE (GAS AND LPG) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

RADIATOR (WITH EXTERNAL OIL COOLER) SHROUD WASHER SCREW CLIP NUT CLIP SPRING CLAMP UPPER RADIATOR BRACKET CAPSCREW INSERT ISOLATOR RESERVOIR BRACKET (COOLANT FILL)

RADIATOR, 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) 1. If necessary, install coolant level sensor. NOTE: Installing the radiator into lift truck frame requires two people. 2. Install radiator into lift truck frame. 3. For lift trucks equipped with GM 5.7L LPG engine, use capscrews and install baffles to radiator assembly. See Figure 14. Use capscrews and attach radiator assembly to cooling baffle. 4. Install upper radiator bracket and four capscrews. See Figure 25 for lift truck models GLP/GDP70VX (GP/GLP/ • GLP/GDP60VX, GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

C. UPPER HOSE (GAS AND LPG) D. UPPER HOSE (CUMMINS 4.5L/KUBOTA 3.8L DIESEL) 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

OUTLET ASSEMBLY OUTLET CAP BUSHING HOSE HOSE REMOTE FILL HOSE REMOTE FILL RADIATOR CAP SCREEN COOLANT LEVEL SENSOR DRAIN PLUG See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (B909)

5. Install coolant reservoir bracket and coolant reservoir assembly onto upper bracket and tighten capscrews. See Figure 25 for lift truck models (GP/GLP/ • GLP/GDP60VX, GLP/GDP70VX GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909) See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 6. Uncap and connect auxiliary coolant reservoir hose and tighten clamp. 7. Remove caps from the oil cooler and transmission lines and connect lines into oil cooler. 8. Close drain plug and uncap the lower radiator hose and connect hose onto radiator and tighten clamp.

37


Radiator Replacement 9. Uncap and connect upper radiator hose and tighten clamp. 10. Lift trucks equipped with Cummins QSB 3.3L or Kubota 3.8L diesel engine, uncap the charge air cooler hoses and connect the hoses to the charge air cooler. See Figure 13 or Figure 15. 11. Install fan. See Fan Installation procedures.

700 YRM 1123 See Figure 27 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909) See Figure 28 for lift truck models equipped with Kubota 3.8L Diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909)

12. Align shroud to radiator and install capscrews, washers and clip nuts.

17. Install hood assembly. For hood install procedures, see section

See Figure 25 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

Frame 100 YRM 1321 for lift truck models • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C879, D879)

See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909) See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 13. If necessary, connect electrical connector onto the coolant level sensor. 14. Lift truck equipped GM 4.3L (Gas/LPG) engine, install air intake hose to air filter and tighten clamp. 15. Lift trucks equipped with Cummins 4.5L or QSB 3.3L diesel engine, install silencer and connect hose from air filter side and tighten clamp. See Figure 25. 16. Lift trucks equipped with Cummins QSB 3.3L, Kubota 3.8L diesel engine or GM 5.7L LPG engine, connect dirty air hose to hood support and install and tighten clamp. See Figure 26 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

Frame 100 YRM 1581 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909) 18. Lift truck equipped GM 4.3L (Gas/LPG) engine, open hood assembly and connect intake hose to hood support and tighten clamp. See Figure 25. 19. Lift trucks equipped with Kubota 3.8L, Cummins 4.5L, or QSB 3.3L diesel engine, open hood assembly and connect hose to hood support and tighten clamp. See Figure 25 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 26 for lift truck models below equipped with Cummins QSB 3.3L diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 28 for lift truck models equipped with Kubota 3.8L Diesel engine • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909) 20. Connect positive battery cable. 21. Connect negative battery cable.

38


700 YRM 1123

WARNING DO NOT use an alcohol or methanol base antifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTION Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

Radiator Replacement 26. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir. 27. Shut down the engine for one minute or longer prior to checking the transmission oil level. If the transmission oil is low, add transmission oil at the dipstick tube at the correct level indicated on the dipstick. Oil is specified in Periodic Maintenance section for your lift truck.

22. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F). 23. Install radiator cap. 24. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and FULL marks. See Figure 24.

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and cause serious injury. 25. Start and run the engine until thermostat opens (The upper radiator hose will be warm).

CAUTION Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

1. 2. 3. 4.

AUXILIARY COOLANT RESERVOIR FULL "HOT" MARK FULL "COLD" MARK ADD "COLD" MARK

Figure 24. Reservoir 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)

39


Radiator Replacement

700 YRM 1123

Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) (Sheet 1 of 3)

40


700 YRM 1123

Radiator Replacement

Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) (Sheet 2 of 3)

41


Radiator Replacement

700 YRM 1123

Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) (Sheet 3 of 3)

42


700 YRM 1123

Radiator Replacement

Legend for Figure 25 A. GM 4.3L (GAS/LPG) B. CUMMINS 4.5L (DIESEL)

C. KUBOTA (DIESEL)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

17. 18. 19. 20. 21. 22.

AIR INTAKE (WITHOUT PRE-CLEANER) PRE-CLEANER HOOD ASSEMBLY CLAMP INLET HOSE SILENCER (DIESEL) AIR FILTER UPPER RADIATOR BRACKET ISOLATOR INSERT CAPSCREW RADIATOR (WITH EXTERNAL OIL COOLER) UPPER HOSE LOWER HOSE CLIP NUT WASHER

23. 24. 25. 26. 27. 28. 29. 30.

SCREW SHROUD FAN FAN SPACER TRANSMISSION LINES AUXILIARY COOLANT RESERVOIR AND BRACKET ASSEMBLY OUTLET CAP BUSHING HOSE AUXILIARY COOLANT RESERVOIR HOSE DRAIN PLUG RADIATOR CAP HOOD SUPPORT

43


Radiator Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

PRE-CLEANER CLAMP HOOD SUPPORT HOOD ASSEMBLY DIRTY AIR HOSE CLEAN AIR HOSE AIR FILTER AIR CLEANER BRACKET CAPSCREW NUT AUXILIARY COOLANT RESERVOIR HOSE RESERVOIR OUTLET CAP BUSHING COOLANT RECOVERY RESERVOIR TUBE

700 YRM 1123

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

COOLANT LEVEL SENSOR UPPER BRACKET RADIATOR ISOLATOR RADIATOR CAC HOSE CAC TUBE INSULATED CLAMP LOWER RADIATOR HOSE UPPER RADIATOR HOSE SHROUD AND BAFFLE WASHER FAN SPACER AUXILIARY COOLANT RESERVOIR ASSEMBLY CLIP NUT

Figure 26. Cooling System Cummins QSB 3.3L Diesel Engine for Lift Truck Model GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

44


700 YRM 1123

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

PRE-CLEANER CLAMP HOOD SUPPORT HOOD DIRTY AIR HOSE CLEAN AIR HOSE AIR FILTER AIR CLEANER BRACKET CAPSCREW NUT RADIATOR ISOLATOR UPPER BRACKET

Radiator Replacement

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

RADIATOR BAFFLE COOLANT RECOVERY RESERVOIR LOWER RADIATOR HOSE UPPER RADIATOR HOSE SEAL BAFFLE FAN SHROUD FAN SPACER FAN MOUNTING SCREWS

Figure 27. Cooling System GM 5.7L LPG Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

45


Radiator Replacement

700 YRM 1123

Figure 28. Cooling System Kubota 3.8L Diesel Engine for Lift Truck Model GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909)

46


700 YRM 1123

Fan Assembly Replacement

Legend for Figure 28 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

PRE-CLEANER CLAMP HOOD SUPPORT HOOD ASSEMBLY DIRTY AIR HOSE CLEAN AIR HOSE AIR FILTER AIR CLEANER BRACKET CAPSCREW NUT AUXILIARY COOLANT RESERVOIR HOSE RESERVOIR OUTLET CAP BUSHING COOLANT RECOVERY RESERVOIR

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

TUBE COOLANT LEVEL SENSOR UPPER BRACKET RADIATOR ISOLATOR RADIATOR CAC HOSE CAC TUBE AIR FLOW SENSOR LOWER RADIATOR HOSE UPPER RADIATOR HOSE SHROUD AND BAFFLE WASHER FAN SPACER

Fan Assembly Replacement FAN REMOVAL WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator 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 check or fix any part of the cooling system.

WARNING The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while removing fan assembly. NOTE: The fan that is used is a pusher-type fan. Do not replace with a puller-type fan. 1. Turn OFF lift truck. 2. If equipped, turn the LPG tank valve to the OFF position. 3. If equipped, release the LPG tank bracket and swing tank away from the lift truck.

NOTE: Perform Step 4 through Step 6 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) 4. Release the steering tilt latch and move the steering wheel forward. 5. Release the seat latch and move the seat forward. 6. Release hood latch and raise hood to open position.

47


Fan Assembly Replacement NOTE: Perform Step 7 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) 7. Release hood cover latch on hood cover and swing hood cover up.

WARNING To prevent a short circuit during fan belt removal, disconnect the battery negative cable at the battery negative terminal. Install a lock or tag on the connector to prevent connection. A tool could cause a short circuit, the high current flow from the battery can cause an injury or parts damage. 8. Disconnect the negative battery cable from the negative battery terminal. 9. Remove screws and washers from the radiator shroud. Lean radiator shroud toward the fan. See Figure 29 for lift truck models below equipped with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar 3.3L engine • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) See Figure 30 for lift truck models below equipped with Yanmar 2.6L engine. • GDP20-25LX (GDP050LX) (A974) See Figure 31 for lift truck models below equipped with Mazda FE and F2 engines • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) • GLP20-35VX (GP/GLP040-070VX) (B875) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GP/ GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810)

48

700 YRM 1123 See Figure 32 for lift truck models below equipped with GM 4.3L engine • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 33 for lift truck models below equipped with Cummins 4.5L engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813) See Figure 34 for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) See Figure 35 for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota engines • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, E878) See Figure 36 for lift truck models below equipped with Cummins QSB 3.3L diesel engines • GDC60VX, GDC70VX (GDC135VX, GDC155VX) (D879) • GDP60VX, GDP70VX (GDP135VX, GDP155VX) (D878) • GDP40VX5/VX6; GDP45SVX5, GDP45VX6, GDP50-55VX (GDP080, 090, 100, 110, 120VX) (G813) See Figure 37 for lift truck models below equipped with Cummins QSB 3.3L diesel engines • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 38 for lift truck models below equipped with GM 5.7L LPG engine • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)


700 YRM 1123 See Figure 39 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813)

1. 2. 3. 4.

FAN SPACER WASHER CAPSCREW

Fan Assembly Replacement See Figure 40 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)

5. SCREW 6. RADIATOR SHROUD 7. RADIATOR

Figure 29. Fan Removal for GM 2.4L, Yanmar 2.6L, Yanmar 3.0L and Yanmar 3.3L Engines, Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), and GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)

49


Fan Assembly Replacement

1. 2. 3. 4.

SPACER FAN WASHER CAPSCREW

700 YRM 1123

5. SHROUD 6. SCREW 7. RADIATOR

Figure 30. Fan Removal for Yanmar 2.6L Engine, Lift Truck Models GDP20-25LX (GDP050LX) (A974)

50


700 YRM 1123

Fan Assembly Replacement

NOTE: MODINE RADIATOR SHOWN, COPAR RADIATOR SIMILAR. 1. SPACER, GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) AND GC/GLC030-035VX, GC/GLC040SVX (C809) LIFT TRUCKS ONLY 2. FAN 3. CAPSCREW

4. 5. 6. 7. 8.

WASHER SCREW WASHER RADIATOR SHROUD RADIATOR

Figure 31. Fan Removal for Mazda FE and F2 Engines, Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLC050LX (A967), GLP20-25LX (GLP050LX) (A974), GLP20-35VX (GP/GLP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809), and GLP16VX, GLP18VX, GLP20SVX (GP/GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810)

51


Fan Assembly Replacement

1. 2. 3. 4.

FAN SPACER WASHER CAPSCREW

700 YRM 1123

5. SCREW 6. RADIATOR SHROUD 7. RADIATOR

Figure 32. Fan Removal for GM 4.3L Engine, Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GP/GLP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

52


700 YRM 1123

1. 2. 3. 4. 5.

SPACER FAN WASHER CAPSCREW RADIATOR SHROUD

Fan Assembly Replacement

6. 7. 8. 9.

SCREW LOCKWASHER CLIP NUT RADIATOR

Figure 33. Fan Removal for Cummins 4.5L Engine, Lift truck Models GDP40VX5/VX6;GDP45SVX5, GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (F813)

53


Fan Assembly Replacement

700 YRM 1123

A. GM 4.3L AND KUBOTA 3.8L

B. CUMMINS 4.5L (DIESEL)

1. 2. 3. 4.

5. SCREW 6. SHROUD 7. RADIATOR

FAN FAN SPACER WASHER CAPSCREW

Figure 34. Fan Removal for GM 4.3L, Cummins 4.5L and Kubota 3.8L Engines, Lift truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879)

54


700 YRM 1123

Fan Assembly Replacement

A. GM 4.3L AND KUBOTA

B. CUMMINS 4.5L (DIESEL)

1. 2. 3. 4.

5. SCREW 6. SHROUD 7. RADIATOR

FAN FAN SPACER WASHER CAPSCREW

Figure 35. Fan Removal for GM 4.3L, Cummins 4.5L, and Kubota Engines, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

55


Fan Assembly Replacement

1. 2. 3. 4.

SPACER FAN SCREW WASHER

700 YRM 1123

5. 6. 7. 8.

WASHER CAPSCREW SHROUD RADIATOR

Figure 36. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models GDP40VX5/VX6; GDP45SVX5, GDP45VX6, GDP50-55VX (GDP080, 090, 100, 110, 120VX) (G813), GDC60VX, GDC70VX (GDC135VX, GDC155VX) (D879), and GDP60VX, GDP70VX (GDP135VX, GDP155VX) (D878)

56


700 YRM 1123

1. 2. 3. 4.

RADIATOR SHROUD SCREW WASHER SPACER

Fan Assembly Replacement

5. CAPSCREW 6. FAN 7. RADIATOR

Figure 37. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

57


Fan Assembly Replacement

1. 2. 3. 4.

FAN SHROUD SCREW WASHER SPACER

700 YRM 1123

5. CAPSCREW 6. FAN 7. RADIATOR ASSEMBLY

Figure 38. Fan Removal for GM 5.7L LPG Engine, Lift Truck Models GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

58


700 YRM 1123

1. 2. 3. 4.

FAN FAN SPACER WASHER CAPSCREW

Fan Assembly Replacement

5. SCREW 6. SHROUD 7. RADIATOR

Figure 39. Fan Removal for Kubota 3.8L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)

59


Fan Assembly Replacement

1. 2. 3. 4.

FAN SHROUD SCREW WASHER SPACER

700 YRM 1123

5. CAPSCREW 6. FAN 7. RADIATOR ASSEMBLY

Figure 40. Fan Removal for Kubota 3.8L Diesel Engine, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909) 10. Remove capscrews, washers, and spacer from the fan pulley. See Figure 29 for lift truck models below equipped with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar 3.3L engine • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)

60

See Figure 30 for lift truck models below equipped with Yanmar 2.6L engine • GDP20-25LX (GDP050LX) (A974) See Figure 32 for lift truck models below equipped with GM 4.3L engine • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)


700 YRM 1123 See Figure 33 for lift truck models below equipped with Cummins 4.5L engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813) See Figure 34. for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) See Figure 35 for lift truck models below equipped with GM 4.3L, Cummins 4.5L, Kubota engines • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 39 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813) NOTE: Perform Step 11 for lift truck model GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) and GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (B909). 11. For lift trucks equipped with Cummins QSB 3.3L diesel engines, GM 5.7L LPG engines, or Kubota 3.8L diesel engines, remove capscrews, washers, and spacers from fan. See Figure 37 for lift truck models below equipped with Cummins QSB 3.3L diesel engines • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 38 for lift truck models below equipped with GM 5.7L LPG engine • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) See Figure 40 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)

Fan Assembly Replacement NOTE: Perform Step 12 for lift truck models • GC/GLC030-035VX, GC/GLC040SVX (C809) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLP20-25LX (GLP050LX) (A974) . 12. For lift trucks equipped with Mazda FE and F2 engines, remove capscrews, washers, and spacer from the fan pulley. See Figure 31 for lift truck models below equipped with Mazda FE and F2 engines • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) • GLP20-35VX (GP/GLP040-070VX) (B875) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GP/ GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810) NOTE: Perform Step 13 for lift truck models • GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/ GDP030-035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC050LX (A967) 13. For lift trucks equipped with Mazda FE or F2 engines, remove the capscrews and washers retaining the fan. See Figure 31 for lift truck models below equipped with Mazda FE and F2 engines • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) • GLP20-35VX (GP/GLP040-070VX) (B875) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GP/ GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810) 14. Remove the fan.

61


Fan Assembly Replacement

INSPECT WARNING DO NOT try to repair a damaged fan. If a fan has a bent blade or is cracked, install a new fan. A damaged fan can break during use and cause damage or serious injury. 1. Inspect the fan for any damage. 2. If the fan is damaged, replace the entire fan.

FAN INSTALLATION WARNING The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while installing fan assembly. 1. Install the lower portion of the shroud in the retaining clips and lean the shroud toward the engine. 2. Install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 52 N•m (38 lbf). See Figure 29 for lift truck models below equipped with GM 2.4L, Yanmar 2.6L, Yanmar3.0L or Yanmar 3.3L engine • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) GLP/GDP18VX, • GLP/GDP16VX, (GP/GLP/GDP030VX, GLP/GDP20SVX GP/GLP/GDP040SVX) GP/GLP/GDP035VX, (C810) See Figure 30 for lift truck models below equipped with Yanmar 2.6L engine. • GDP20-25LX (GDP050LX) (A974) See Figure 32 for lift truck models below equipped with GM 4.3L engine • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, GC/GLC080, 100VXBCS; 100, 120VX; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) GLP/GDP45SVX5, • GLP/GDP40VX5/VX6; GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

62

700 YRM 1123 See Figure 33 for lift truck models below equipped with Cummins 4.5L engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813) See Figure 34. for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) See Figure 35 for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota engines • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 39 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813) NOTE: Perform Step 3 for lift truck models GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909). 3. Install spacers, washers, and capscrews onto fan. See Figure 37 for lift truck models below equipped with Cummins QSB 3.3L diesel engines • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 38 for lift truck models below equipped with GM 5.7L LPG engine • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) See Figure 40 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)


700 YRM 1123

Fan Assembly Replacement

NOTE: Perform Step 4 for 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) • GLP20-25LX (GLP050LX) (A974)

See Figure 34 for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879)

4. Install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 27 N•m (20 lbf ft).

See Figure 35 for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota engines • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

See Figure 31 for lift truck models below equipped with Mazda FE and F2 engines • GLP16VX, GLP18VX, GLP20SVX (GP/ GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810) • GLP20-35VX (GP/GLP040-070VX) (B875) • GLP20-25LX (GLP050LX) (A974) NOTE: Perform Step 5 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC050LX (A967) 5. Place the fan in position of the pulley and install capscrews and washers. Tighten the capscrews to 27 N•m (20 lbf ft). See Figure 31 for lift truck models below equipped with Mazda FE or F2 engines • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC050LX (A967) 6. Install the spacer, washers, and capscrews to the fan. Tighten the capscrews to 27 N•m (20 lbf ft). See Figure 32 for lift truck models below equipped with GM 4.3L engine • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)

7. Lean the radiator shroud back toward the radiator. Install the screws and washers and install the radiator shroud cover. See Figure 29 for lift truck models below equipped with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar 3.3L engine • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) See Figure 30 for lift truck models below equipped with Yanmar 2.6L engine • GDP20-25LX (GDP050LX) (A974) See Figure 31 for lift truck models below equipped with Mazda FE or F2 engines • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) • GLP20-35VX (GP/GLP040-070VX) (B875) • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP16VX, GLP18VX, GLP20SVX (GP/ GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810)

63


Fan Assembly Replacement See Figure 32 for lift truck models below equipped with GM 4.3L engine • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) See Figure 33 for lift truck models below equipped with Cummins 4.5L engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813) See Figure 34. for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) See Figure 35 for lift truck models below equipped with GM 4.3L, Cummins 4.5L, or Kubota engines • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) See Figure 36 for lift truck models below equipped with Cummins QSB 3.3L diesel engines • GDC60VX, GDC70VX (GDC135VX, GDC155VX) (D879) • GDP60VX, GDP70VX (GDP135VX, GDP155VX) (D878) • GDP40VX5/VX6; GDP45SVX5, GDP45VX6, GDP50-55VX (GDP080, 090, 100, 110, 120VX) (G813) See Figure 37 for lift truck models below equipped with Cummins QSB 3.3L diesel engines • GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909) See Figure 38 for lift truck models below equipped with GM 5.7L LPG engine • GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909) See Figure 39 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813)

64

700 YRM 1123 See Figure 40 for lift truck models below equipped with Kubota 3.8L diesel engine • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909) 8. Reconnect the negative battery cable to the negative terminal of the battery. NOTE: Perform Step 9 through Step 11 for lift truck models • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809) • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) • GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) • GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) 9. Lower the hood and ensure that the hood latches. 10. Move the seat back. 11. Release the steering wheel tilt latch and move the steering wheel back. NOTE: Perform Step 12 for lift truck models • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) 12. Close hood cover. 13. If equipped, swing the LPG tank bracket back toward the truck and re-latch. 14. If equipped, turn the LPG tank valve to the ON position.


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


Thank you very much for your reading. Please Click Here Then Get More Information.

Yale g813 glp90vx lift truck service repair manual  
Yale g813 glp90vx lift truck service repair manual  
Advertisement