Yale D878 (GLP GDP60VX, GLP GDP70VX Europe) Service Manual - PDF DOWNLOAD

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Service Manuals Manuals Available For D878 (GLP/GDP60VX, GLP/GDP70VX Europe) Note: Service manuals do not contain serial number specific data.

Manual

Manual Title

Release Date

0100YRM1290

OPERATOR'S CAB

07-2011

0100YRM1321

FRAME

08-2011

0600YRM1251

GM ENGINE REPAIR - V6, 4.3L ENGINE

07-2008

0700YRM1123

COOLING SYSTEM

08-2011

0900YRM1242

LPG FUEL SYSTEM (GM 4.3L)

08-2011

1300YRM1317

TRANSMISSION REPAIR (DANA SPICER) 3x2

10-2010

1300YRM1343

TRANSMISSION REPAIR (DANA SPICER) 2x2

10-2010

1400YRM1344

DRIVE AXLE WET BRAKE (SPICER)

06-2010

1600YRM1133

STEERING AXLE

07-2010

1800YRM1247

BRAKE SYSTEM

09-2010

1900YRM1136

HYDRAULIC GEAR PUMP

10-2011

2000YRM1137

MAIN CONTROL VALVE

08-2011

2100YRM1328

CYLINDERS REPAIR

06-2010

2200YRM1097

HIGH VOLTAGE SWITCH IGNITION (HVS) GM 3.0L AND 4.3L

06-2010

2200YRM1128

WIRE HARNESS REPAIR

12-2011

2200YRM1130

USER INTERFACE - SUPERVISOR

06-2011

2200YRM1131

USER INTERFACE - SERVICE

06-2011

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Yale Axcess Online

2200YRM1142

ELECTRICAL SYSTEM

08-2011

4000YRM1250

MAST REPAIR

05-2011

8000YRM0231

METRIC AND INCH (SAE) FASTENERS

12-2004

8000YRM1134

CALIBRATIONS

09-2011

8000YRM1320

CAPACITIES AND SPECIFICATIONS

08-2011

8000YRM1322

PERIODIC MAINTENANCE

10-2011

8000YRM1387

DIAGRAMS AND SCHEMATICS

06-2011

8000YRM1409

SCHEMATICS/DIAGRAMS

06-2011

9000YRM1112

DIAGNOSTICS TROUBLESHOOTING

08-2011

©2011 Yale Axcess Online

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Operator’s Cab GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX [C810]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878]; GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) [A909]

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Safety Precautions Maintenance and Repair • 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 http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (2 of 121)21.12.2011 11:37:29

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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.

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General Cab Replacement Remove, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); and GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Install, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Remove, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Install, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Door Assemblies Right Side Door Assembly, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/ GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875); and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Remove Disassemble Door Cover With Heater Unit Door Cover With Air Conditioner/Heater Unit Heater Assembly Air Conditioner and Heater Unit Assembly Door Lock Assembly Windows Clean Inspect Assemble Windows Door Lock Assembly Heater Assembly Air Conditioner and Heater Unit Assembly Door Cover With Heater Unit Door Cover With Air Conditioner and Heater Unit Install Left Side Door Assembly, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875); and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/ GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (4 of 121)21.12.2011 11:37:29

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Remove Disassemble Door Cover Door Lock Assembly Windows Clean Inspect Assemble Windows Door Lock Assembly Door Cover Install Right and Left Side Door Assemblies, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Remove Disassemble Door Cover Door Lock Assembly Windows Clean Inspect Assemble Windows Door Lock Assembly Door Cover Install Window Wipers Replacement General Front Wiper Assembly and Motor Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875) Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/ GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Remove, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813), GLP/GDP60VX, GLP/GDP70VX (GP/ GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Install, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813), GLP/GDP60VX, GLP/GDP70VX (GP/ GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/

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GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Rear Wiper Assembly and Motor Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/ GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) Remove, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Install, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Remove, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Install, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Window Replacement General Remove Door Window, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875); and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/ GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Install Door Windows, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/GDP20-35VX (GP/GLP/GDP040070VX) (B875); and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/ GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Remove Door Window, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/ GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Install Door Window, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Heater Replacement Remove, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Install, for Lift truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Heater and Air Conditioner Assembly Air Conditioner Condenser Unit

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Remove Install Air Conditioner Receiver/Drier Unit Remove Install Air Conditioner Compressor Light Replacement Work Lights (Front and Rear) Remove Install Strobe Light Remove Install Turn, Stop, Tail, and Backup Light Remove Install Front Marker/Turn Signal Lights Remove Install Display Switches Electrical Schematics Optional Equipment Heavy Duty Pre-Cleaner Remove Clean Inspect Install Fan Remove Install Mirror Remove Install Label Replacement This section is for the following models: GLP/GDP16VX, GLP/GDP18VX,GLP/GDP20SVX, GLP/GDP030VX [C810]; GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875]; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) [F813, G813]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878]; GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36,

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GDP190VX) [A909]

General The overhead guard is an integral part of the operator cab. The operator cab is installed on a platform above the main frame members. Step plates on both sides of the lift truck provide access to the operator cab. The operator cab is a separate unit and can be removed as a complete unit from the module and frame of the lift truck. See Figure 1.

Figure 1. Operator Cab http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (8 of 121)21.12.2011 11:37:29

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Cab Replacement Remove, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/ GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); and GLP/ GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) NOTE: The EZ Tank Bracket™ used on these trucks to mount the LPG tank onto the counterweight come in two styles. One style of bracket swings out to the side of the truck and the other swings out to the side and drops down.

NOTE: On lift trucks equipped with LPG, make sure to release the EZ Tank Bracket™ before opening the hood.

1. For lift truck models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810), tilt the steering column to the UP position, slide seat assembly forward, open rear door, and open hood to disconnect battery. See Figure 2.

2. Tilt the steering column to the UP position, slide seat assembly forward, open rear sliding window, and open the hood to disconnect battery. See Figure 3 for lift truck models: • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) 3. Disconnect the air filter hose from the rear left corner leg of the cab frame. See Figure 4.

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

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

NOTE: Removing the radiator cap will help depressurize the cooling system.

4. Remove radiator cover to access radiator cap. Remove radiator cap. See Figure 5.

CAUTION DO NOT allow any fluid to drain when disconnecting the heater hose from the engine. The method will help when purging the system during installation. http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (9 of 121)21.12.2011 11:37:29

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5. Disconnect and cap the heater hoses from engine. See Figure 6.

1. Latch 2. hinge 3. rear door Figure 2. Rear Door and Latch for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810)

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A. Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) without air conditioning.

B. Lift Trucks Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with air conditioning.

1. Rear bottom Window 2. release latch 3. ac hose Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) 6. For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with a Cummins QSB 3.3L engine, if lift truck cab is equipped with an air conditioner/heater unit, disconnect the AC refrigerant hoses from the refrigerant compressor. See Figure 7.

Legend for Figure 4 1. capscrew 2. air filter hose

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Figure 4. Air Filter Hose Removal

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Figure 5. Radiator Cover and Cap Location Legend for Figure 5 A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) C. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (13 of 121)21.12.2011 11:37:29

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090, 100, 110, 120VX) (F813, G813) 1. radiator cover 2. radiator cap

Figure 6. Heater Hose Connection Legend for Figure 6 http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (14 of 121)21.12.2011 11:37:29

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NOTE: Major components of the cab have been removed for clarity.

A. lift truck models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) C. lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/ GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) 1. quick disconnect fitting 2. inner rear cover 3. radiator cover 4. right side door assembly 5. heater hoses

NOTE: Major components of the cab have been removed for clarity.

1. hose fitting 2. refrigerant compressor 3. ac/heater unit 4. engine Figure 7. AC Refrigerant Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (15 of 121)21.12.2011 11:37:29

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NOTE: Removing the door assemblies requires two people.

7. Open left side door, remove lock nut, and disconnect gas spring from the cab mounting bracket. See Figure 8.

NOTE: Right side door shown.

1. Gas Spring 2. CAB Mounting bracket 3. lock nut Figure 8. Gas Spring Mounting Removal

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8. Lift left side door up and over hinge pin and set aside. See Figure 9.

WARNING DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator cab) or engine when the engine is hot or under pressure, to do so could cause serious injury.

CAUTION Disconnecting the right-hand gas spring and fully opening the door without disconnecting the heater hoses may cause the hoses to pull loose from the quick disconnect fittings.

9. Disconnect heater hose quick disconnect fittings. a. For Lift truck models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810), open right side door and push the buttons on quick disconnect fittings to disconnect the heater hoses from the heater assembly hoses (see Figure 6). Disconnect the heater wire harness connection.

See Figure 10. b. For lift truck models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875), open right side door and remove radiator cover to access the quick disconnect fittings. Push the buttons on the quick disconnect fittings to disconnect the heater hoses from heater assembly (see Figure 6). Disconnect the heater wire harness connection. See Figure 10. c. For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813), open right side door and located on inner rear cover there are two port holes (see Figure 6). Push the buttons on the quick disconnect fittings to disconnect the heater hoses from heater assembly and disconnect the heater wire harness connection. See Figure 10.

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NOTE: Right side door hinge shown.

1. hinge 2. door pin hinge Figure 9. Door Removal

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NOTE: Major components of cab have been removed for clarity.

1. heater wire harness connector 2. rear grab handle horn button connector (to Right-hand chassis harness) Figure 10. Heater Wire Harness and Rear Grab Handle Horn Button Connectors

CAUTION Disconnecting the right-hand gas spring and fully opening the door without disconnecting the air conditioner hoses may cause the hoses to pull loose from the fittings and cause damage.

10. For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with a Cummins QSB 3.3L engine, if lift truck cab is equipped with an air conditioner/heater unit, disconnect the AC hoses.

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a. Remove six fasteners and remove rear cover. See Figure 11. b. Disconnect the air conditioner hoses at the bulkhead bracket and at the receiver/drier. See Figure 11. c. Disconnect the air conditioner wire harness. See Figure 11.

CAUTION Disconnecting the right-hand gas spring and fully opening the door without disconnecting the heater hoses or air conditioner hoses, may cause the hoses to pull loose from the quick disconnect fittings or fittings and cause damage to hoses.

11. Remove lock nut and disconnect gas spring from cab mounting bracket. See Figure 8.

12. Lift door up and over hinge pin and set aside. See Figure 9.

NOTE: Wiper motor cover must be removed before the dash assembly can be removed.

13. Unclip and remove front wiper motor cover. See Figure 12 for lift truck models: • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

NOTE: Major components of the cab have been removed for clarity.

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4. air conditioner hoses 5. bulkhead bracket 6. receiver/drier 7. fittings 8. air conditioner wire harness Figure 11. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) Legend for Figure 12 NOTE: Major Components of cab have been removed for clarity.

A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/ GLP/GDP040SVX) (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) B. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) 1. capscrews 2. front wiper motor cover 3. dash assembly 4. Kick panel 5. cowl panel 6. front operator cab legs 7. lock nut 8. flange bolt

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Figure 12. Dash Installation 14. For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813), remove two lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 12.

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16. Remove two flange bolts securing the cowl panel to the front operator cab legs.

17. Unclip the dash assembly from kick panel. Remove dash assembly.

18. Remove kick panel from seal plate assembly. See Figure 13.

19. Remove capscrews and seal plate assembly from lift truck frame.

20. Disconnect rear grab handle horn button connector from right-hand chassis harness, located in right rear corner leg of the cab frame. See Figure 10.

21. Disconnect the light harness connector from the Vehicle Systems Manager (VSM) and right-hand chassis harness connector. See Figure 14.

22. Remove rear panels, front panels, and fender covers to access the cab mounting capscrews and flange nuts. See Figure 15.

23. Remove front and rear cab capscrews and flange nuts from lift truck frame. See Figure 16.

WARNING Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb).

24. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator’s cab (under the overhead guard structure). Place material that will be a cushion at the top of the door opening to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lifting strap on the operator’s cab. See Figure 17.

CAUTION Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected and are not damaged.

25. Carefully lift the operator cab away from the lift truck. Set the operator cab in a storage area and place blocks under the operator cab to make it stable and prevent damage to parts still attached.

Legend for Figure 13 NOTE: Cab removed for clarity.

A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) and GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) B. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) 1. capscrews 2. kick panel 3. seal plate assembly 4. seal 5. floor plate (Left side) 6. floor plate (Right side) 7. floor plate

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Figure 13. Seal Plate Assembly, Kick Panel, and Floor Plate Removal

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NOTE: Kick panel removed for clarity.

1. VSM 2. LIGHT harness connector (To VSM) 3. harness connector (to right-hand chassis harness) Figure 14. Light Harness Connection to Vehicle System Manager (VSM)

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NOTE: Left side door removed for clarity.

1. rear panel (LPG) 2. rear panel (gas and diesel) 3. front panel

4. fender cover 5. screws 6. capscrews

Figure 15. Front and Rear Panels and Fender Cover Removal

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A. front view

B. rear view

1. capscrews

2. flange nuts Figure 16. Front and Rear Cab Mounting

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Figure 17. Lift Strap Connection

Install, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/ GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); and GLP/ GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) 1. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator’s cab (under the overhead guard structure). Place material that will be a cushion at the top of the door opening to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lifting strap on the operator’s cab. See Figure 17.

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

3. Install the capscrews and flange nuts to the rear operator cab legs. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 16.

4. Install the capscrews and lock nuts to the front operator’s cab legs. Tighten capscrews to 66 N•m (49 lbf ft).

5. Install the fender covers, front panel, and rear panels to the frame. See Figure 15. Tighten capscrews to 10.8 N•m (7.96 lbf ft).

6. Connect light harness connector to the VSM (Vehicle Systems Manager) and right-hand chassis harness. See Figure 14.

7. Connect the right-hand chassis harness to rear grab handle horn button connector. See Figure 10.

8. Install seal plate assembly to the lift truck frame and tighten capscrews. See Figure 13.

9. Install floor plate and floor mat. Tighten capscrews to 10.8 N•m (7.96 lbf ft).

10. Install kick panel onto seal plate assembly.

11. Install two flange bolts securing the cowl to the front operator cab legs. See Figure 12.

12. Install dash assembly onto kick panel and install five capscrews to secure dash assembly to cowl panel.

13. Install and clip front wiper motor cover for lift truck models: • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875).

14. Install front wiper motor cover and tighten two lock nuts for lift truck models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813).

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15. Install right side door onto cab by lifting door up and over the top and bottom hinge pins. See Figure 9.

16. Connect gas spring and lock nut to cab mounting bracket. See Figure 8.

17. Connect the heater hoses to the heater assembly and connect the heater wire harness connection.

See Figure 6 and Figure 10.

18. For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with a Cummins QSB 3.3L engine and equipped with an air conditioner/heater unit, connect the AC hoses. Tighten the AC hose at the bulkhead bracket to 29 to 37 N•m (21 to 27 lbf ft) and the AC hose to the receiver/drier to 15 to 18 N•m (133 to 159 lbf in). See Figure 11.

19. Install left side door onto cab by lifting door up and over the top and bottom hinge pins. See Figure 9.

20. Connect gas spring and lock nut to cab mounting bracket. See Figure 8.

21. Uncap and connect heater hoses at the engine. See Figure 6.

22. For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with a Cummins QSB 3.3L engine and equipped with an air conditioner/heater unit, connect the AC refrigerant hoses to the refrigerant compressor. See Figure 7.

23. Check coolant level, fill if necessary.

24. Install radiator cap and radiator cover. See Figure 5.

25. Connect the air filter hose onto the rear left corner leg of the cab frame. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 4.

26. Connect battery and close hood.

27. Start engine and turn on the heater to the ON position, run engine approximately 1 to 2 minutes or until heater supply hose is fully purged.

WARNING Contact an authorized technician or company to charge the AC system. DO NOT charge the AC system if you don’t have the experience or authorization. To do so can result in serious injury.

28. On lift trucks equipped with an air conditioner/heater unit, start engine and turn on the heater to the ON position, run engine approximately 1 to 2 minutes or until heater supply hose is fully purged.

NOTE: The EZ Tank Bracket™ used on these trucks to mount the LPG tank onto the counterweight comes in two styles. One style of bracket swings out to the side of the truck and the other swings out to the side and drops down.

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position.

Remove, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/ GLP/GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) NOTE: Removing the door assemblies from operators cab requires two people.

1. Open right side door and remove hair pin from rod pin. See Figure 18.

2. Remove rod pin and spacers from link.

3. Remove right side door from cab frame by lifting door up and over the hinge pin and set door aside.

See Figure 19.

4. Repeat Step 1 through Step 3 for the removal of left side door.

5. Remove front floor mat and floor plate. See Figure 20.

6. Disconnect battery.

7. Remove two screws holding the right side rear cover to the rear overhead guard leg. See Figure 21.

8. Remove two screws holding the right side front cover to frame. Remove right side rear cover.

9. Remove two screws securing the right side front cover to the front overhead guard leg. Remove right side front cover.

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NOTE: Right side door shown 1. rod pin 2. spacers 3. hair pin 4. door assembly

5. gas spring 6. lock nut 7. washer 8. link Figure 18. Door Link Removal

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NOTE: Right side door hinge shown 1. hinge 2. door pin hinge Figure 19. Door Removal 10. Repeat Step 7 through Step 9 to remove the left side covers.

NOTE: Perform Step 11 for early model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878).

11. Remove two lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 22.

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NOTE: Perform Step 12 on later model lift trucks: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 12. Remove three lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 23.

13. Remove five capscrews from top of dash assembly and cowl panel.

14. Unclip the dash assembly from kick panel. Remove dash assembly.

15. Remove kick panel from seal plate assembly. See Figure 20.

16. Remove two flange bolts securing cowl panel to front operator cab legs. See Figure 22 for early model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) lift trucks.

See Figure 23 for later model lift trucks: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 17. Disconnect three harness connectors from right side front operator cab leg that are connected to the Vehicle Systems Manager (VSM) and right hand chassis harness connectors. See Figure 24.

18. Remove four flange bolts securing right and left side of the front operator cab legs to module. See Figure 25.

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

20. Open right side hood door and remove both wiper motor washer tubes from t-fitting and disconnect washer pump harness connector from washer fluid reservoir.

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1. dash assembly 2. kick panel 3. seal plate assembly 4. front floor mat 5. rear floor mat 6. flange bolt 7. rear floor plate 8. front floor plate 9. module Figure 20. Seal Plate Assembly, Kick Panel, and Floor Plate Removal

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NOTE: Right side view shown.

1. right side rear cover 2. right side front cover 3. screws

4. rear floor plate 5. front floor plate 6. clip nuts Figure 21. Side Cover Removal

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1. capscrews 2. front wiper motor cover 3. dash assembly 4. kick panel 5. cowl panel

6. front operators cab legs 7. lock nut 8. flange bolt

Figure 22. Dash Removal, Early Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) Lift Trucks http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (38 of 121)21.12.2011 11:37:29

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1. capscrews 2. front wiper motor cover 3. dash assembly 4. kick panel 5. cowl panel 6. front operators cab legs 7. lock nut 8. flange bolt Figure 23. Dash Removal, Later Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) Lift Trucks and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) Lift Truck Models

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NOTE: Kick panel removed for clarity.

1. VSM 2. harness connector (to VSM) 3. harness connector (to right hand chassis harness) Figure 24. Light Harness Connection to Vehicle System Manager (VSM) Legend for Figure 25 NOTE: Right Side Shown. Wiper cover and assembly for early model GLP/GDP60VX, GLP/GDP70VX (GP/ GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) lift trucks shown. The front and rear cab mounting is the same for later model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) lift trucks and on GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) lift truck models. http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (40 of 121)21.12.2011 11:37:29

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A. Rear B. Front View View 1. Flange Bolts 2. rear operator cab leg 3. rear light harness 4. washer pump harness connector 5. washer fluid reservoir 6. module 7. cowl panel

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Figure 25. Front and Rear Cab Mounting 21. Disconnect rear grab handle horn button connector from right hand chassis harness.

22. Remove the bottom flange bolt securing right side rear operator cab leg to module.

23. Open left side hood door and remove the bottom flange bolt securing rear left side operator cab leg to module.

WARNING Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb).

24. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator’s cab (under the overhead guard structure). Place material that will be a cushion at the top of the door opening to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lifting strap on the operator’s cab. See Figure 26.

CAUTION Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected correctly and are not damaged.

25. Carefully lift the operator cab up and away from the lift truck. Set the operator cab in a storage area and place blocks under the operator cab to make it stable and prevent damage to the wire harness and http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM1290.html (42 of 121)21.12.2011 11:37:29

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parts still attached.

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Figure 26. Lift Strap Connection

Install, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 1. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator’s cab (under the overhead guard structure). Place material that will be a cushion at the top of the door opening to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lifting strap on the operator’s cab. See Figure 26.

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

3. Open left side hood door and install the bottom flange bolt to secure rear left side operator cab leg to module. Tighten flange bolt to 165 N•m (122 lbf ft). See Figure 25.

4. Open right side hood door and install bottom flange bolt to secure rear right side operator cab leg to module. Tighten flange bolt to 165 N•m (122 lbf ft).

5. Connect rear grab handle horn button harness connector to right hand chassis harness.

6. Connect both wiper motor washer tubes to t-fitting and connect washer pump harness connector to washer fluid reservoir.

7. Install two flange bolts to secure right and left side front operator cab legs to module. Tighten flange bolt to 165 N•m (122 lbf ft).

8. From inside the cab, install the four remaining flange bolts to right and left side rear operator cab legs to module. Tighten flange bolt to 165 N•m (122 lbf ft).

9. Connect the three harness connectors on the front right side operator cab leg to Vehicle System Manager (VSM) and right hand chassis harness. See Figure 24.

10. Install two flange bolts to secure cowl panel to front operator cab legs. See Figure 22 for early model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) lift trucks.

See Figure 23 for later model lift trucks: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 11. Install kick panel to seal plate assembly. See Figure 20.

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12. Install and clip dash assembly onto kick panel. See Figure 22.

13. Install five capscrews to top of dash assembly to secure dash assembly onto the cowl panel. Tighten capscrew to 3.5 N•m (30 lbf in).

NOTE: Perform Step 14 on early model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) lift trucks.

14. Install front wiper motor cover using two lock nuts. See Figure 22.

NOTE: Perform Step 15 on later model lift trucks: • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909) 15. Install front wiper motor cover using three lock nuts. See Figure 23.

16. Install right side front cover to front overhead guard leg using two screws. See Figure 21.

17. Install right side rear cover to right side front cover and install and tighten two screws to frame.

18. Align right side rear cover to rear overhead guard leg and install and tighten two screws to rear overhead guard leg and install and tighten two screws to rear overhead guard leg.

19. Repeat Step 16 through Step 18 to install left side covers.

20. Connect battery.

21. Install front floor plate and floor mat. See Figure 20.

NOTE: Installing the door assemblies onto operator cab requires two people.

22. Lift door up and over the top and bottom hinge pins. See Figure 19.

23. Align link and spacers into guide and install rod pin. See Figure 18.

24. Install hair pin into rod pin.

25. Repeat steps Step 22 through Step 24 for installation of left side door.

Door Assemblies Right Side Door Assembly, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875); and GLP/GDP40VX5/VX6, GLP/ GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Remove

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