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GP/GLP/GDP080, 090, 100, 110, 120VX (H813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ GM 4.3L V-6 ENGINES................................................................................................... KUBOTA ENGINE REPAIR............................................................................................ KUBOTA DIESEL 3.6L ENGINE.................................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ GASOLINE FUEL SYSTEM............................................................................................ 1 AND 2 SP PS TRANSMISSION REPAIR.................................................................... DRIVE AXLE - DRY BRAKE........................................................................................... DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ WET BRAKES - NMHG.................................................................................................. HYDRAULIC GEAR PUMP............................................................................................. HYDRAULIC CLEANLINESS PROCEDURES............................................................... MAIN CONTROL VALVE................................................................................................ CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564).......................................................................................................................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. WIRE HARNESS REPAIR.............................................................................................. USER INTERFACE......................................................................................................... USER INTERFACE......................................................................................................... ELECTRICAL SYSTEM.................................................................................................. MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706, A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749, B750, B751, B752, B753, B754)................................................................................ METRIC AND INCH (SAE) FASTENERS....................................................................... CALIBRATION PROCEDURES...................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS AND SCHEMATICS.................................................................................... DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................

PART NUMBER

YRM NUMBER

REV DATE

524262274 524306203 524265337 550048607 550055279 524223757 550043871 550048401 550048681 524262277 524262278 550055280 524223764 524262279 550064329 524223766 550073240 524223767

0100 YRM 1243 0100 YRM 1290 0600 YRM 1251 0600 YRM 1557 0600 YRM 1579 0700 YRM 1123 0900 YRM 1556 0900 YRM 1570 1300 YRM 1569 1400 YRM 1245 1400 YRM 1246 1400 YRM 1582 1600 YRM 1133 1800 YRM 1247 1800 YRM 1597 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137

05/14 04/14 05/14 03/13 01/14 03/13 04/14 09/13 08/13 01/12 12/13 12/13 07/13 03/13 12/13 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 550048682 550048683 550055283 524221866

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

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

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. 9000 YRM 1112 ON CD PART NO. 550048599 (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.

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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]

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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.

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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)

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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)

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YALE H813 GP-GLP-GDP 120VX LIFT TRUCK Service Repair Manual  
YALE H813 GP-GLP-GDP 120VX LIFT TRUCK Service Repair Manual  
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