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GP/GLP/GDP/GTP0-40VX, GP/GLP/GDP/GTP050VX, GP/GLP/GDP/ GTP060VX, GP/GLP/GDP/GTP070VX (C875) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

OPERATOR'S CAB........................................................................................................ FRAME............................................................................................................................ YANMAR DIESEL ENGINES.......................................................................................... KUBOTA SPARK IGNITED 2.5L LPG............................................................................ MAZDA 2.2L ENGINE..................................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM, MAZDA 2.2L ENGINE................................................................. GASOLINE FUEL SYSTEM, MAZDA 2.2L ENGINE...................................................... LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... DRIVE AXLE REPAIR (WET BRAKE)........................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC CLEANLINESS PROCEDURES............................................................... HYDRAULIC GEAR PUMPS.......................................................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... CYLINDER REPAIR (MAST S/N D515, E509, E564)..................................................... WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. ELECTRICAL SYSTEM, MAZDA 2.2L ENGINE............................................................ MAST REPAIR (S/N F507, F508, F562, F563)............................................................... MAST REPAIR (S/N D515, E509, E564)........................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

524306203 550096314 524240453 550096316 550096315 550096317 550096318 550096319 550096320 550096321 550096632 550096322 550096323 550096324 550096325 550073240 550096326 550096327 550093750 550100651 524223769 524223770 524223771 550096328 550096329 550093755 550100656 524150797 524223780 550096306 550096330 550096331 524221866

0100 YRM 1290 0100 YRM 1672 0600 YRM 1205 0600 YRM 1670 0600 YRM 1673 0700 YRM 1674 0900 YRM 1675 0900 YRM 1676 0900 YRM 1677 1300 YRM 1678 1300 YRM 1690 1400 YRM 1679 1400 YRM 1680 1600 YRM 1681 1800 YRM 1682 1900 YRM 1620 1900 YRM 1683 2000 YRM 1684 2100 YRM 1668 2100 YRM 1692 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1685 2200 YRM 1686 4000 YRM 1669 4000 YRM 1693 8000 YRM 0231 8000 YRM 1134 8000 YRM 1687 8000 YRM 1688 8000 YRM 1689 9000 YRM 1112

04/14 04/14 12/14 12/14 04/14 03/14 03/14 04/14 12/14 04/14 04/14 12/14 04/14 04/14 04/14 12/14 04/14 04/14 12/14 12/14 12/14 12/14 12/14 04/14 04/14 12/14 12/14 10/13 12/14 04/14 04/14 04/14 12/14

9000 YRM 1112 ON CD PART NO. 550096624 (12/14)


0100 YRM 1290

General

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

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

Figure 1. Operator Cab

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


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YALE (C875) GP70VX LIFT TRUCK Service Repair Manual  
YALE (C875) GP70VX LIFT TRUCK Service Repair Manual  
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