Yale Ale G813 GDP100VX

GP/GLP/GDP80VX, GP/GLP/GDP90VX, GP/GLPGDP100VX, GP/GLP/
GDP110VX, GP/GLP/GDP120VX (G813)

SERVICE MANUAL CONTENTS
PART YRM REV
SECTION NUMBER NUMBER DATE
FRAME............................................................................................................................ 524262274 0100 YRM 1243 05/14
OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM (GM 4.3L)...................................................................................... 524262275 0900 YRM 1242 08/12
GASOLINE FUEL SYSTEM (GM 4.3L).......................................................................... 524262276 0900 YRM 1244 06/12
LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14
GASOLINE FUEL SYSTEM............................................................................................ 550048401 0900 YRM 1570 09/13
1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... 524223762 1300 YRM 1129 09/09
POWERSHIFT TRANSMISSION REPAIR...................................................................... 550043436 1300 YRM 1529 08/13
DRIVE AXLE - DRY BRAKE........................................................................................... 524262277 1400 YRM 1245 01/12
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 524262278 1400 YRM 1246 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
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).......................................................................................................................... 524223768 2100 YRM 1139 02/14
HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 524223772 2200 YRM 1142 04/14
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)................................................................................ 524265342 4000 YRM 1250 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 524262280 8000 YRM 1248 04/13
CAPACITIES AND SPECIFICATIONS........................................................................... 524262281 8000 YRM 1249 08/11
DIAGRAMS AND SCHEMATICS.................................................................................... 524329117 8000 YRM 1387 04/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550001092 8000 YRM 1409 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
9000 YRM 1112 ON CD
PART NO. 524329176 (12/14)
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. 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. Discon-
nect 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................................................................................................................................................................ 1
Cooling System Checks ...................................................................................................................................... 1
Exhaust Leaks Into Cooling System ............................................................................................................... 1
Water Flow Restrictions in Radiator ................................................................................................................ 1
Radiator Hoses ............................................................................................................................................... 1
Water Pump .................................................................................................................................................... 1
Flushing the Cooling System............................................................................................................................... 2
Cooling System, Clean.................................................................................................................................... 2
Radiator Replacement......................................................................................................................................... 3
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) .............................................................................................................................. 3
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809);
GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
Equipped with Oil Cooler................................................................................................................................. 19
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) .................................................................................................................................................... 21
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) ....................................................... 24
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809);
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) .............................................................................................................................. 29
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809);
GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
Equipped with Oil Cooler................................................................................................................................. 33
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) .................................................................................................................................................... 34
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) ....................................................... 37
Fan Assembly Replacement................................................................................................................................ 47
Fan Removal ................................................................................................................................................... 47
Inspect............................................................................................................................................................. 62
Fan Installation ................................................................................................................................................ 62
©2013 Yale Materials Handling Corp. i

Table of Contents Cooling System
TABLE OF CONTENTS (Continued)

This section is for the following models:
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];

GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLC050LX [A967];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLP/GDP20-25LX (GLP/GDP050LX) [A974];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813];
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
[C879, D879, E879, F879];
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
[C878, D878, E878];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) [A909, B909]
ii
700 YRM 1123 Cooling System Checks
General
This section contains the repair and replacement in- assembly (pusher type), fan shroud, coolant hoses,
structions for the radiator, coolant level sensor, fan coolant recovery bottle, and optional debris screen.
Cooling System Checks

EXHAUST LEAKS INTO COOLING SYSTEM Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait an-
WARNING other 30 minutes before attempting to check or fix
any part of the cooling system.
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts Inspect all radiator hoses. If they feel spongy or have
can cause serious injury. visible cracks, replace hoses.
To check for exhaust leaks into the cooling system, use
a Combustion Leak Test Kit for this purpose. Follow the
WATER PUMP
manufacturer’s instructions when doing the test.
WARNING
WATER FLOW RESTRICTIONS IN During engine operation, be careful not to touch the
RADIATOR fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
WARNING
During engine operation, be careful not to touch the WARNING
fan, pulleys, or drive belts. Contact with these parts The radiator or other parts of the cooling system
can cause serious injury. may be hot or under pressure and can cause seri-
ous injury.
To check for water flow restrictions in the radiator, run
engine until it is warm. Run engine until it is warm. Check the operation of wa-
ter pump by holding the top radiator hose. If the pump
is operating, there will be pressure surges in the hose.
WARNING
The radiator or other parts of the cooling system Check for leaks around the timing belt cover near the
may be hot or under pressure and can cause seri- base of the oil pump.
ous injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your Check the weep hole where coolant that leaks past the
hand. If the radiator is still hot to the touch, wait an- water pump seal can be drained before reaching the
other 30 minutes before attempting to check or fix water pump bearings. If there is a drip, check the pump
any part of the cooling system. 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 tempera-
ture must be even across the radiator. (The radiator will For repair procedures for the GM 2.4L water pump, refer
be hotter near the top radiator hose.) Cold spots on ra- to the section GM Engine Repair, GM 2.4 Liter Engine
diator indicate restrictions. 600 YRM 1121.
If radiator has leaks, either replace the radiator or have For repair procedures for the Mazda FE and F2 water
it repaired by trained personnel. pump, refer to the section Mazda Engine, FE and F2
600 YRM 1122.
RADIATOR HOSES
For replacement procedures for the Yanmar 2.6L and
3.3L water pump, refer to the section Yanmar Diesel
WARNING 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 seri-
1
Flushing the Cooling System 700 YRM 1123
For replacement procedures for the GM 4.3L water For replacement procedures for the Kubota water
pump, refer to the section GM Engines, 4.3 Liter V-6 pump, refer to the section
600 YRM 1251. • Kubota Diesel 3.8L Engines 600 YRM 1557
• Kubota Diesel 3.6L Engine 600 YRM 1579
For replacement procedures for the GM 5.7L water • Kubota Diesel 3.8L Engines, with Diesel Particu-
pump, refer to the section GM Engines, 5.7 Liter V-8 late Filter (DPF) 600 YRM 1590
LPG 600 YRM 1432.
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 2. Drain cooling system. Fill cooling system with clean
water. See sections below for more information:
• Radiator, Remove for Lift Trucks Mod-
WARNING
els GC/GLC030VX, GC/GLC035VX,
Compressed air can move particles so that they GC/GLC040SVX (C809); GLP/GDP16VX,
cause injury to the user or to other personnel. GLP/GDP18VX, GLP/GDP20SVX
Make sure the path of the compressed air is away (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
from all personnel. Wear protective goggles or a GP/GLP/GDP040SVX) (C810); GLC20-35VX
face shield to prevent injury to the eyes. (GC/GLC040-070VX, GC/GLC055SVX) (A910);
GLC050LX (A967); GLP/GDP20-35VX
WARNING (GP/GLP/GDP040-070VX) (B875);
The radiator fins on the radiator are very sharp and GLP/GDP20-25LX (GLP/GDP050LX) (A974);
can cause serious injury. Wear gloves while check- GLC40, 45, 55VX, GLC55SVX, (GC/GLC080,
ing the radiator fins. 100, 120VX, GC/GLC080, 100VXBCS,
GC/GLC120SVX, GC/GLC120VXPRS)
1. Check radiator fins. Clean exterior of radiator with (E818, F818) and GLP/GDP40VX5/VX6,
compressed air or water as needed. GLP/GDP45SVX5, GLP/GDP45VX6,
GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
WARNING 110, 120VX) (F813, G813, H813, J813)
• Radiator, Remove for Lift Truck Models S6.0FT,
DO NOT remove the radiator cap from the radiator
S7.0FT (S135FT, S155FT) (D024, E024,
when the engine is hot. When the radiator cap is
F024, G024)GLC/GDC60VX, GLC/GDC60VX,
removed, the pressure is released from the system.
(GC/GLC/GDC135VX, GC/GLC/GDC135VX)
If the system is hot, the steam and boiling coolant
(C879, D879, E879, F879)
can cause burns.
• Radiator, Remove for Lift Truck Models
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
WARNING GDP135VX, GP/GLP/GDP155VX) (C878,
The radiator or other parts of the cooling system D878, E878) and GLP/GDP80VX, GLP/
may be hot or under pressure and can cause seri- GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
ous injury. Wait 30 minutes for the radiator to cool. GLP/GDP175VX36, GLP/GDP190VX) (A909,
Do a touch test by touching the radiator with your B909)
other 30 minutes before attempting to check or fix 3. Install radiator cap. Run engine until top radiator
any part of the cooling system. hose is hot. Stop engine and let engine cool.
4. Drain water from radiator. If water is dirty, fill sys-

CAUTION tem with water and repeat procedure until water is
Disposal of lubricants and fluids must meet local clean.
environmental regulations.
2
700 YRM 1123 Radiator Replacement
method uses water pressure to force water through

CAUTION radiator in opposite direction of normal flow.
Follow the manufacturer’s instructions when using
a chemical radiator cleaner.
CAUTION
5. If water does not clean system, use a chemical ra- Additives may damage the cooling system. Before
diator cleaner. using additives, contact your local Yale dealer.
7. Fill cooling system with ethylene glycol boron-free

CAUTION antifreeze. Purchase a pre-diluted 50/50 solution;
Follow the manufacturer’s instructions when using or mix 50 percent concentrate with 50% distilled
special equipment to reverse clean the radiator. or deionized water. The 50/50 mixture will pro-
tect cooling system to 37°C ( 35°F). Add coolant
6. If radiator or cooling system is very dirty or has
as necessary to keep level between the ADD and
a restriction, use reverse cleaning method. This
FULL marks on the reservoir.
Radiator Replacement
RADIATOR, REMOVE FOR LIFT See Frame 100 YRM 1120 for lift truck models
TRUCKS MODELS GC/GLC030VX, • GC/GLC030VX, GC/GLC035VX,
GC/GLC035VX, GC/GLC040SVX GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)
(C810); GLC20-35VX (GC/GLC040-070VX, • GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX GC/GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(A967); GLP/GDP20-35VX (B875)
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX) See Frame 100 YRM 1243 for lift truck models
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
(A974); GLC40, 45, 55VX, GLC55SVX,
100, 120VX; GC/GLC080, 100VXBCS;
(GC/GLC080, 100, 120VX, GC/GLC080, GC/GLC120SVX; GC/GLC120VXPRS) (E818,
100VXBCS, GC/GLC120SVX, F818)
GC/GLC120VXPRS) (E818, F818) AND • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
GLP/GDP45VX6, GLP/GDP50-55VX
H813, J813)
(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)
WARNING
may be hot or under pressure and can cause seri- WARNING
ous injury. Wait 30 minutes for the radiator to cool. Always disconnect the cable at the negative termi-
Do a touch test by touching the radiator with your nal first. Install a tag on the battery terminals so
hand. If the radiator is still hot to the touch, wait an- that no one connects the cables on the terminals.
other 30 minutes before attempting to check or fix
any part of the cooling system. 3. Disconnect the negative battery cable.
1. Turn OFF truck. 4. Disconnect the positive battery cable.
2. Remove the hood and seat combination.
3
Radiator Replacement 700 YRM 1123
GC/GLC120SVX; GC/GLC120VXPRS) (E818,

WARNING F818)
when the engine is hot. When the radiator cap is See Figure 4 or Figure 5 for lift truck models
removed, the pressure is released from the system. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
If the system is hot, the steam and boiling coolant GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
can cause burns. GDP080, 090, 100, 110, 120VX) (F813, G813)
5. Let coolant cool to ambient temperature. Place a See Figure 6 for lift truck models below equipped
drain pan with a capacity greater than the capacity with a Cummins QSB 3.3L diesel engine
of the cooling system under radiator. Remove radi- • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
ator cap. GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (G813
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
CAUTION GDC135VX, GC/GLC/GDC155VX) (D879)
Disposal of lubricants and fluids must meet local
environmental regulations. See Figure 7 for lift truck models below equipped
with Yanmar 2.6L diesel engine
6. Open the drain plug or loosen hose clamp and dis- • GDP20-25LX (GDP050LX) (A974)
connect the lower hose.
See Figure 8 for lift truck models below equipped
7. Lift trucks equipped with a Cummins QSB 3.3L with a Kubota 3.8L diesel engine
diesel engine: Loosen clamps and disconnect the • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
charge air cooler hoses from charge air cooler. GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
See Figure 6. GDP080, 090, 100, 110, 120VX) (H813, J813)
8. Lift trucks equipped with a Kubota 3.8L diesel en- 11. Remove battery and battery tray.
gine: Loosen clamps and disconnect transmission
cooler hoses from transmission cooler. See Fig- 12. If equipped, disconnect electrical connector to the
ure 8. coolant level sensor.
9. Once coolant is drained from engine, loosen hose NOTE: For Mazda LPG engine, the LPG converter
clamps and disconnect coolant hoses from radiator. bracket needs to be moved for clearance of radiator.
Cap radiator hoses.
13. Remove screws and washers from the shroud and
10. Loosen hose clamp and disconnect hose from move shroud out of the way.
reservoir and remove reservoir.
14. Place radiator guard shield between radiator and
See Figure 1 for lift truck models fan so damage to radiator does not occur during
• GC/GLC030VX, GC/GLC035VX, fan removal.
GC/GLC040SVX (C809
• GLP/GDP16VX, GLP/GDP18VX, 15. Remove fan, fan spacer, and pulley.
GLP/GDP20SVX (GP/GLP/GDP030VX,
16. Remove radiator guard shield.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810) 17. Remove capscrews and upper radiator bracket.
• GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910) See Figure 1 for lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GC/GLC030VX, GC/GLC035VX,
(B875) GC/GLC040SVX (C809
• GLC050LX (A967) • GLP/GDP16VX, GLP/GDP18VX,
• GLP20-25LX (GLP050LX) (A974) GLP/GDP20SVX (GP/GLP/GDP030VX,
See Figure 2 or Figure 3 for lift truck models (C810)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLC20-35VX (GC/GLC040-070VX,
100, 120VX; GC/GLC080, 100VXBCS; GC/GLC055SVX) (A910)
4
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/

(B875) GDC135VX, GC/GLC/GDC155VX) (D879)
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974) See Figure 7 for lift truck models below equipped
with Yanmar 2.6L diesel engine
See Figure 2 or Figure 3 for lift truck models • GDP20-25LX (GDP050LX) (A974)
100, 120VX; GC/GLC080, 100VXBCS; See Figure 8 for lift truck models below equipped
GC/GLC120SVX; GC/GLC120VXPRS) (E818, with a Kubota 3.8L diesel engine
F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
See Figure 4 or Figure 5 for lift truck models GDP080, 090, 100, 110, 120VX) (H813, J813)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ 18. Remove radiator from truck.
GDP080, 090, 100, 110, 120VX) (F813, G813)
19. If necessary, remove the coolant level sensor.
with a Cummins QSB 3.3L diesel engine
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (G813
5
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
Legend for Figure 1

A. RADIATOR WITH EXTERNAL COOLER C. RESERVOIR BEFORE MAY ’06
B. RADIATOR WITH INTERNAL COOLER, MODINE D. RESERVOIR AFTER MAY ’06
SHOWN
1. RADIATOR 15. NUT-CLIP, GC/GLC040-070VX, GC/GLC055SVX
2. CAP [A910] AND GLC050LX (A967)
3. UPPER HOSE 16. ISOLATOR
4. LOWER HOSE 17. COOLANT LEVEL SENSOR
5. CLAMP 18. RESERVOIR
6. SHROUD 19. TUBE
7. CLIP 20. OUTLET ASSEMBLY
8. WASHER 21. HOSE
9. SCREW 22. RESERVOIR OUTLET
10. CLIP 23. CAP
11. UPPER RADIATOR BRACKET 24. BUSHING
12. CAPSCREW, GC/GLC040-070VX, 25. SCREEN ASSEMBLY (OPTIONAL)
GC/GLC055SVX [A910] AND GLC050LX 26. HEAT SHIELD
(A967) 27. RESERVOIR BRACKET
13. INSERT 28. HEAT SHIELD, GLP/GDP20-35VX
14. LOWER BRACKET, GC/GLC040-070VX, (GP/GLP/GDP040-070VX) [B875] AND
GC/GLC055SVX [A910] AND GLC050LX (A967) GLP20-25LX (GLP050LX) (A974)
7
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
Legend for Figure 2

A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER
1. RADIATOR 15. RESERVOIR BRACKET
2. SHROUD 16. OUTLET ASSEMBLY
3. WASHER 17. OUTLET
4. SCREW 18. CAP
5. CLIP NUT 19. BUSHING
6. CLIP 20. HOSE
7. UPPER HOSE 21. TUBE
8. LOWER HOSE 22. STRAP
9. CLAMP 23. NUT
10. UPPER RADIATOR BRACKET 24. SCREEN
11. INSERT 25. BAFFLE (RH AND LH)
12. CAPSCREW 26. RADIATOR CAP
13. ISOLATOR 27. COOLANT LEVEL SENSOR
14. RESERVOIR
9
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
Legend for Figure 3

A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER
1. RADIATOR 14. RESERVOIR
3. WASHER 16. OUTLET
4. SCREW 17. CAP
5. CLIP NUT 18. BUSHING
6. CLIP 19. HOSE
7. UPPER HOSE 20. TUBE
8. LOWER HOSE 21. NUT
9. CLAMP 22. SCREEN
10. UPPER RADIATOR BRACKET 23. BAFFLE (RH AND LH)
11. INSERT 24. RADIATOR CAP
12. CAPSCREW 25. COOLANT LEVEL SENSOR
13. ISOLATOR
11
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
Legend for Figure 4

A. RADIATOR WITH INTERNAL COOLER B. RADIATOR WITH EXTERNAL COOLER
1. CAPSCREW 14. WASHER
2. INSERT 15. SCREEN
3. UPPER RADIATOR BRACKET 16. STRAP
4. RADIATOR CAP 17. RESERVOIR BRACKET
5. ISOLATOR 18. RESERVOIR
6. CLIP NUT 19. OUTLET ASSEMBLY
7. COOLANT LEVEL SENSOR 20. OUTLET
8. RADIATOR 21. CAP
9. CLIP 22. BUSHING
10. RADIATOR SHROUD 23. TUBE
11. CLAMP 24. UPPER HOSE
12. LOWER HOSE 25. DRAIN PLUG
13. SCREW 26. OIL COOLER
13
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
Legend for Figure 5

A. RADIATOR WITH INTERNAL COOLER B. RADIATOR WITH EXTERNAL COOLER
1. CAPSCREW 13. SCREW
2. INSERT 14. WASHER
3. UPPER RADIATOR BRACKET 15. SCREEN
4. RADIATOR CAP 16. RESERVOIR
5. ISOLATOR 17. OUTLET ASSEMBLY
6. CLIP NUT 18. OUTLET
7. COOLANT LEVEL SENSOR 19. CAP
8. RADIATOR 20. BUSHING
9. CLIP 21. TUBE
10. RADIATOR SHROUD 22. UPPER HOSE
11. CLAMP 23. DRAIN PLUG
12. LOWER HOSE 24. OIL COOLER
15
1. RADIATOR 16. CLAMP

2. RADIATOR CAP 17. CHARGE AIR COOLER HOSE
3. HARNESS CLIP 18. SCREW
4. UPPER RADIATOR BRACKET 19. WASHER
5. INSERT 20. CLIP
6. ISOLATOR 21. LOWER HOSE
7. CAPSCREW 22. RESERVOIR
8. CLAMP 23. BUSHING
9. TUBE 24. RESERVOIR CAP
10. UPPER HOSE 25. RESERVOIR OUTLET
11. CLAMP 26. HOSE
12. CHARGE AIR COOLER HOSE 27. TUBE
13. CLAMP 28. COOLANT LEVEL SENSOR
14. CHARGE AIR COOLER HOSE 29. SEAL
15. SHROUD
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
1. LOWER HOSE 13. ISOLATOR

2. CLAMP 14. UPPER RADIATOR BRACKET
3. UPPER HOSE 15. RADIATOR
4. RESERVOIR 16. PLUG - COOLANT LEVEL SENSOR
5. OUTLET ASSEMBLY 17. HEAT SHIELD
6. BUSHING 18. CLIP NUT
7. CAP 19. WASHER
8. RESERVOIR OUTLET 20. SCREW
9. HOSE 21. DRAIN PLUG
10. CAPSCREW 22. SHROUD
11. INSERT 23. TUBE
12. RADIATOR CAP
Figure 7. Yanmar 2.6L Cooling System for Lift Truck Models GDP20-25LX (GDP050LX) (A974)
17
1. RADIATOR 11. TRANSMISSION COOLER RETURN LINE

2. RADIATOR CAP 12. TRANSMISSION COOLER SUPPLY LINE
3. UPPER RADIATOR BRACKET 13. SCREW
4. ISOLATOR 14. WASHER
5. CAPSCREW 15. SHROUD
6. INSERT 16. RESERVOIR
10. LOWER HOSE 20. 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
RADIATOR, REMOVE FOR LIFT TRUCKS removed, the pressure is released from the system.
MODELS GC/GLC030VX, GC/GLC035VX, If the system is hot, the steam and boiling coolant
GC/GLC040SVX (C809); GLP/GDP16VX, can cause burns.
GLP/GDP18VX, GLP/GDP20SVX 5. Let coolant cool to ambient temperature. Place a
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, drain pan with a capacity greater than the capacity
GP/GLP/GDP040SVX) (C810); GLC050LX of the cooling system under radiator. Remove radi-
ator cap.
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) EQUIPPED
WITH OIL COOLER CAUTION
WARNING
The radiator or other parts of the cooling system 6. Open the drain plug or loosen hose clamp and dis-
may be hot or under pressure and can cause seri- connect the lower hose.
Do a touch test by touching the radiator with your 7. Loosen clamps and disconnect oil cooler hoses
hand. If the radiator is still hot to the touch, wait an- from oil cooler adapters. See Figure 9.
any part of the cooling system. 8. Remove oil cooler adapters and O-rings from radi-
ator. Discard O-rings. See Figure 9.
1. Turn OFF truck.
9. Once coolant is drained from engine, loosen hose
2. Remove the hood and seat combination. clamps and disconnect coolant hoses from radiator.
Cap radiator hoses.
See section Frame 100 YRM 1120 for lift truck mod-
els 10. Loosen hose clamp and disconnect hose from
• GC/GLC030VX, GC/GLC035VX, reservoir and remove reservoir. See Figure 9.
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, 11. Remove battery and battery tray.
GLP/GDP20SVX (GP/GLP/GDP030VX, 12. If equipped, disconnect electrical connector to the
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) coolant level sensor.
(C810)
NOTE: For Mazda LPG engine, the LPG converter
See section Frame 100 YRM 1423 for lift truck mod- bracket needs to be moved for clearance of radiator.
els
• GLC050LX (A967) 13. Remove screws and washers from the shroud and
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) move shroud out of the way.
14. Place radiator guard shield between radiator and

WARNING fan so damage to radiator does not occur during
Always disconnect the cable at the negative termi- fan removal.
nal first. Install a tag on the battery terminals so
that no one connects the cables on the terminals. 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 18. Remove radiator from truck.
when the engine is hot. When the radiator cap is 19. If necessary, remove the coolant level sensor.
19
1. RADIATOR 11. CAPSCREW

2. CAP 12. INSERT
3. UPPER HOSE 13. ISOLATOR
4. LOWER HOSE 14. RESERVOIR
5. CLAMP 15. TUBE
7. O-RING 17. HOSE
8. OIL COOLER ADAPTER 18. RESERVOIR OUTLET
9. OIL COOLER HOSE 19. CAP
10. UPPER RADIATOR BRACKET 20. 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
RADIATOR, REMOVE FOR LIFT TRUCK 11. Place a radiator guard shield between radiator and
MODELS S6.0FT, S7.0FT (S135FT, S155FT) fan so damage to radiator does not occur during fan
(D024, E024, F024, G024)GLC/GDC60VX, removal.
GLC/GDC60VX, (GC/GLC/GDC135VX, 12. Remove fan. See Fan Removal procedures.
GC/GLC/GDC135VX) (C879, D879, E879,
F879)
WARNING
WARNING
Do a touch test by touching the radiator with your
can cause burns.
other 30 minutes before attempting to check or fix 14. Let coolant cool to ambient temperature. Place a
any part of the cooling system. drain pan with a capacity greater than the capacity
of the cooling system under the radiator. Remove
1. Turn off truck.
radiator cap.
WARNING
Always disconnect the cable at the negative termi-
CAUTION
nal first. Install a tag on the battery terminals so Disposal of lubricants and fluids must meet local
that no one connects the cables on the terminals. environmental regulations.
2. Disconnect the negative battery cable. 15. Open drain plug, loosen clamp and disconnect the
lower radiator hose from radiator to allow coolant to
3. Disconnect the positive battery cable. drain into a suitable container. Install caps on hose.
See Figure 10.
4. Remove radiator cover. See Figure 10.
16. Once coolant is drained from engine, loosen hose
5. Remove debris cover. clamp and disconnect upper radiator hose from ra-
diator. Install cap on hose. See Figure 10.
CAUTION
17. Lift trucks equipped with a Cummins QSB 3.3L
The counterweight cover is extremely heavy 185 kg
diesel engine: Loosen clamps and disconnect the
(408 lb). Make sure that the eyebolts and lifting de-
charge air cooler hoses from charge air cooler.
vice have sufficient capacity to lift the weight.
See Figure 11.
6. Remove two bolts from counterweight cover.
18. Loosen clamp and disconnect remote refill hose
7. Install two eyebolts in the hole on each end of the from radiator. Install cap on hose.
counterweight cover. Connect a suitable lifting de-
NOTE: Tag the transmission lines before disconnecting
vice to the eyebolts and carefully remove the coun-
from oil cooler.
terweight cover from lift truck.
19. Disconnect transmission lines from oil cooler. In-
8. Remove four capscrews from upper radiator
stall caps on transmission lines. Drain transmission
bracket. Remove bracket. See Figure 23.
oil from oil cooler into a suitable container. Install
9. If necessary, disconnect electrical connector from caps on the oil cooler ports.
the coolant level sensor.
NOTE: Removing the radiator from lift truck requires
10. Remove screws, washers, and clip nuts from the two people.
shroud and radiator and move shroud out of the
20. Remove radiator from lift truck frame.
way.
21. If necessary, remove the coolant level sensor from
radiator. See Figure 23.
21
Legend for Figure 10

1. DEBRIS COVER
2. COUNTERWEIGHT COVER
3. RADIATOR COVER
4. UPPER BRACKET
5. CAPSCREWS
6. REMOTE FILL HOSE
7. HOSE CLAMPS
8. OIL COOLER
9. TRANSMISSION OIL COOLER LINES
10. FITTINGS
11. UPPER HOSE
12. LOWER HOSE
13. REMOTE FILL
14. RADIATOR CAP
Figure 10. Radiator Removal for Lift Truck Models

S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
(GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,
D879, E879, F879)
22

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
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, REMOVE FOR LIFT TRUCK See Figure 28 for lift truck models equipped with
MODELS GLP/GDP60VX, GLP/GDP70VX Kubota 3.8L Diesel engine
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) • GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (B909)
(C878, D878, E878) AND GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX 6. Lift trucks equipped with GM 4.3L (Gas/LPG) en-
(GLP/GDP170VX, GLP/GDP175VX36, gine, loosen clamp and disconnect inlet hose from
air filter and remove inlet hose. See Figure 25.
GLP/GDP190VX) (A909, B909)
NOTE: Perform Step 7 for lift truck models GLP/
WARNING GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
The radiator or other parts of the cooling system 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
Do a touch test by touching the radiator with your
disconnect inlet hose from silencer. Remove si-
lencer. See Figure 25.
any part of the cooling system. NOTE: Before lifting the hood assembly from the lift
truck frame, make sure to use a lifting device and lift-
1. Turn off truck.
ing straps as shown in Figure 12. The hood assembly
weighs approximately 45.6 kg (101 lb).
WARNING
Always disconnect the cable at the negative termi- 8. Remove hood assembly. For hood assembly re-
nal first. Install a tag on the battery terminals so moval procedures, see
that no one connects the cables on the terminals.
Frame 100 YRM 1321 for lift truck models
2. Disconnect the negative battery cable. • GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX,
3. Disconnect the positive battery cable. GLP/GDP175VX36,GLP/GDP190VX) (A909)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
NOTE: Perform Step 4 for lift truck models GLP/ GDP135VX, GP/GLP/GDP155VX) (C879, D879)
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878). Frame 100 YRM 1581 for lift truck models
4. Open hood and loosen clamp and disconnect inlet GDP135VX, GP/GLP/GDP155VX) (E878)
hose that attaches to the hood support. See Fig- • GLP/GDP80VX, GLP/GDP80VX9,
ure 25. GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (B909)
NOTE: Perform Step 5 for lift truck model GDP80VX,
GDP80VX9, GDP90VX (GLP/GDP170VX, GLP/ 9. Disconnect and cap auxiliary coolant reservoir
GDP175VX36, GLP/GDP190VX) (A909, B909). hose. See Figure 25.
5. Open hood, loosen clamp, and disconnect dirty air 10. Remove capscrews from the auxiliary coolant
hose attached to hood support. reservoir bracket and upper bracket. Remove
auxiliary coolant reservoir assembly.
with Cummins QSB 3.3L diesel engine 11. Remove the four capscrews from the upper radiator
• GDP80VX, GDP80VX9, GDP90VX bracket. Remove bracket.
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) 12. If necessary, disconnect electrical connector from
the coolant level sensor.
with GM 5.7L LPG engine 13. Remove screws, washers and clip nuts from the
• GLP80VX, GLP80VX9, GLP90VX shroud and move shroud out of the way.
(GLP/GLP170VX, GLP/GLP175VX36,
GLP/GLP190VX) (A909, B909)
24

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)
WARNING
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 radia-
tor. Remove radiator cap.
CAUTION
19. Open drain plug or loosen clamp and disconnect

1. PRE-CLEANER 2. STRAP CLAMP
lower radiator hose to allow coolant to drain.
Figure 12. Hood Assembly Removal
See Figure 25 for lift truck models
14. Place a radiator guard shield between radiator and • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
fan so damage to radiator does not occur during fan GDP135VX, GP/GLP/GDP155VX) (C878, D878,
removal. E878)
NOTE: Perform Step 15 for lift truck models GLP/ See Figure 13 for lift truck models below equipped
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, with Cummins QSB 3.3L diesel engine
GP/GLP/GDP155VX) (C878, D878, E878). • GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
15. Remove capscrews, washers, fan, fan spacer, and
shroud. See Figure 25. See Figure 14 for lift truck models below equipped
NOTE: Perform Step 16 for lift truck model GLP\ • GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GDP80VX, GLP\GDP80VX9, GLP\GDP90VX (GLP/ GLP175VX36, GLP190VX) (A909, B909)
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909, B909). See Figure 15 for lift truck models equipped with
16. Remove capscrews, washer, fan, fan spacers, and • GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
fan shroud. GLP175VX36, GLP190VX) (B909)
See Figure 13 for lift truck models below equipped 20. Lift trucks equipped with a Cummins QSB 3.3L or
with Cummins QSB 3.3L diesel engine Kubota 3.8L diesel engine, loosen clamps and dis-
• GDP80VX, GDP80VX9, GDP90VX (GDP170VX, connect the charge air cooler hoses from radiator.
GDP175VX36, GDP190VX) (A909, B909) See Figure 13 or Figure 15.
25

5. INSERT 20. CLIP
11. CLAMP 26. HOSE
15. SHROUD
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
21. Once coolant is drained from engine, loosen hose cooler into a suitable container, then cap the oil
clamps and disconnect radiator hoses from radia- cooler ports.
tor. Cap hoses.
23. For lift trucks equipped with GM 5.7L LPG engine,
NOTE: Tag the transmission lines before disconnecting remove capscrews from baffles and remove baffles
from oil cooler. from radiator assembly. Remove capscrews secur-
ing cooling baffle to radiator assembly. See Fig-
22. Disconnect and cap transmission lines from oil ure 14.
cooler and allow transmission oil to drain from oil
1. BAFFLE 10. CAPSCREW

2. ISOLATOR 11. SHROUD
3. UPPER BRACKET 12. CLAMP
4. CAP 13. UPPER HOSE
5. RESERVOIR OUTLET 14. LOWER HOSE
6. BUSHING 15. SEAL
7. HOSE 16. COOLING BAFFLE
8. RESERVOIR 17. DRAIN HOSE
9. RADIATOR 18. PLASTIC TUBE
Figure 14. GM 5.7L Cooling System, Lift Truck Models GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)
27
Figure 15. Kubota 3.8L Cooling System, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)
28

1. RADIATOR 12. CHARGE AIR COOLER HOSE
2. RADIATOR CAP 13. LOWER HOSE
3. UPPER RADIATOR BRACKET 14. SHROUD
4. INSERT 15. RESERVOIR
5. ISOLATOR 16. BUSHING
6. CAPSCREW 17. RESERVOIR CAP
7. CLAMP 18. RESERVOIR OUTLET
8. TUBE 19. HOSE
9. UPPER HOSE 20. COOLANT LEVEL SENSOR
11. CHARGE AIR COOLER HOSE
NOTE: Removing the radiator from lift truck requires 5. Place shroud in lift truck. DO NOT install on radia-
two people. tor.
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. 6. Install fan, fan spacer, and pulley.
RADIATOR, INSTALL FOR LIFT 7. Remove radiator guard shield.

TRUCK MODELS GC/GLC030VX, 8. Install the radiator shroud on radiator using screws
GC/GLC035VX, GC/GLC040SVX and washers taken out during removal..
(C809); GLP/GDP16VX, GLP/GDP18VX,
9. If equipped, connect the electrical connector to the
coolant level sensor.
(C810); GLC20-35VX (GC/GLC040-070VX, NOTE: For Mazda LPG engine, the LPG converter
GC/GLC055SVX) (A910); GLC050LX bracket and screws must be installed to hold the con-
verter.
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875); 10. Uncap radiator and reservoir ports and install the
GLP/GDP20-25LX (GLP/GDP050LX) reservoir.
(A974); GLC40, 45, 55VX; GLC55SVX; 11. Connect the reservoir hose from reservoir to the
(GC/GLC080, 100, 120VX; GC/GLC080, radiator. Tighten hose clamp.
100VXBCS; GC/GLC120SVX;
12. Lift trucks equipped with Cummins QSB 3.3L en-
GC/GLC120VXPRS) (E818, F818) AND
gine, uncap the charge air cooler hoses and con-
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, nect the hoses to charge air cooler. See Figure 6.
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) 13. Lift trucks equipped with Kubota 3.8L diesel en-
gine: Uncap transmission cooler hoses and con-
(F813, G813, H813, J813) nect hoses to transmission cooler. See Figure 8.
1. If removed, install the coolant level sensor.
14. Uncap the upper hose and connect the hose to ra-
2. Install radiator into truck. diator. Tighten hose clamp.
3. Install upper radiator bracket, using capscrews 15. Close the drain plug or install lower hose. Tighten
taken out during removal. hose clamp.
4. Place a radiator guard shield between radiator and

fan, so damage to radiator does not occur during
fan installation
29
WARNING
DO NOT use an alcohol or methanol base an-
tifreeze. 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.

antifreeze. Purchase a pre-diluted 50/50 solution;
or mix 50% concentrate with 50% distilled or deion-
ized 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)
(C810)
GC/GLC055SVX) (A910)
(B875
• GLC050LX (A967)
See Figure 18, for lift truck models

• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 1. RESERVOIR 3. FULL MARK
100, 120VX; GC/GLC080, 100VXBCS; 2. ADD MARK
F818) Figure 16. Reservoir for Lift Truck Models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ (C809); GLP/GDP16VX, GLP/GDP18VX,
GDP080, 090, 100, 110, 120VX) (F813, G813) GLP/GDP20SVX (GP/GLP/GDP030VX,
See Figure 19 for lift truck models (C810); GLC20-35VX (GC/GLC040-070VX,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GC/GLC055SVX) (A910); GLC050LX (A967);
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
GDP080, 090, 100, 110, 120VX) (H813, J813) and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
Before May ’06
30
1. RESERVOIR 3. FULL MARK

2. ADD MARK 1. AUXILIARY COOLANT RESERVOIR
2. FULL "HOT" MARK
Figure 17. Reservoir for Lift Truck Models 3. FULL "COLD" MARK
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX 4. ADD "COLD" MARK
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX, Figure 18. Reservoir for Lift Truck Models
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
(C810); GLC20-35VX (GC/GLC040-070VX, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC055SVX) (A910); GLC050LX (A967); GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6;
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-
and GLP/GDP20-25LX (GLP/GDP050LX) (A974) 55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
After May ’06 (F813, G813)
31
els
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
els
• GLC050LX (A967)
WARNING
fan, pulleys, or drive belts. Contact with these parts
1. AUXILIARY COOLANT RESERVOIR
2. FULL "HOT" MARK can cause serious injury.
3. FULL "COLD" MARK
4. ADD "COLD" MARK
WARNING
Figure 19. Reservoir for Lift Truck Models The radiator or other parts of the cooling system
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ may be hot or under pressure and can cause seri-
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, ous injury.
090, 100, 110, 120VX) (H813, J813)
22. Start and run engine until thermostat opens. (The
18. Install battery and battery tray. upper hose will be warm.)
19. Connect the positive battery cable. 23. On lift trucks equipped with a GM 2.4L engine,
bleed air from the cooling system by opening the
20. Connect negative battery cable. bleed screw located on the left side behind the
alternator. When the air has been bled from the
21. Install the hood and seat combination. system close the bleed screw. See Figure 20.
els CAUTION
• GC/GLC030VX, GC/GLC035VX, Additives may damage the cooling system. Before
GC/GLC040SVX (C809) using additives, contact your local Yale dealer.
GLP/GDP20SVX (GP/GLP/GDP030VX, 24. Check coolant level at the reservoir. Add coolant
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) as necessary to keep level between the ADD and
(C810) FULL marks on the reservoir.
(B875)
32
6. Install fan, fan spacer, and pulley.
8. Install the radiator shroud on radiator using screws

and washers taken out during removal..
9. If equipped, connect the electrical connector to the

NOTE: For Mazda LPG engine, the LPG converter

bracket and screws must be installed to hold the con-
verter.
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 3. BLEED SCREW
2. COOLANT HOSES 4. RADIATOR HOSE 13. Install oil cooler adapters to radiator. Torque
adapters to 14.7 to 17.6 N•m (130 to 156 lbf in).
Figure 20. Bleed Screw, GM 2.4L Engine See Figure 9.
RADIATOR, INSTALL FOR LIFT TRUCK 14. Uncap oil cooler hoses and connect hoses to oil
cooler adapters. See Figure 9.
MODELS GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX, 15. Uncap the upper hose and connect the hose to ra-
GLP/GDP18VX, GLP/GDP20SVX diator. Tighten hose clamp. See Figure 9.
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, 16. Close the drain plug or install lower hose. Tighten
GP/GLP/GDP040SVX) (C810); GLC050LX hose clamp.
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) EQUIPPED WARNING
WITH OIL COOLER DO NOT use an alcohol or methanol base an-
1. If removed, install the coolant level sensor.
2. Install radiator into truck.
CAUTION
3. Install upper radiator bracket, using capscrews
taken out during removal. Additives may damage the cooling system. Before
4. Place a radiator guard shield between radiator and
fan, so damage to radiator does not occur during 17. Fill cooling system with ethylene glycol boron-free
fan installation antifreeze. Purchase a pre-diluted 50/50 solution;
5. Place shroud in lift truck. DO NOT install on radia- ized water. The 50/50 mixture will protect cooling
tor. system to 37°C ( 35°F).
NOTE: Pull radiator shroud away from radiator while 18. Use the same coolant mixture and fill the reservoir
installing fan, fan spacer, and pulley. between the ADD and FULL marks. See Figure 21.
33
WARNING
WARNING
ous injury.
23. Start and run engine until thermostat opens. (The

upper hose will be warm.)
CAUTION
1. RESERVOIR 3. FULL MARK 24. Check coolant level at the reservoir. Add coolant
2. ADD MARK as necessary to keep level between the ADD and
FULL marks on the reservoir.
Figure 21. Reservoir for Lift Truck Models
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX RADIATOR, INSTALL FOR LIFT TRUCK
(C809); GLP/GDP16VX, GLP/GDP18VX, MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024, G024)GLC/GDC60VX,
(C810); GLC050LX (A967) and GLP/GDP20-25LX GLC/GDC60VX, (GC/GLC/GDC135VX,
(GLP/GDP050LX) (A974) GC/GLC/GDC135VX) (C879, D879, E879,
F879)
19. Install battery and battery tray.
1. If necessary, install coolant level sensor.
20. Connect the positive battery cable.
NOTE: Installing the radiator into lift truck frame re-
21. Connect negative battery cable. quires 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 mod- 3. Remove caps from the oil cooler and transmission
els lines and connect lines into oil cooler. See Fig-
• GC/GLC030VX, GC/GLC035VX, ure 10.
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX, 4. Uncap and connect remote refill hose onto radiator
GLP/GDP20SVX (GP/GLP/GDP030VX, and tighten hose clamp. See Figure 10.
(C810) 5. Close drain plug and uncap the upper and lower
radiator hoses and connect hoses onto radiator and
See section Frame 100 YRM 1423 for lift truck mod- tighten hose clamps. See Figure 10.
els
• GLC050LX (A967) 6. Uncap the charge air cooler hoses and connect the
• GLP/GDP20-25LX (GLP/GDP050LX) (A974) 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
9. If necessary, connect electrical connector onto the

coolant level sensor. WARNING
10. Install upper radiator bracket and four capscrews. may be hot or under pressure and cause serious
injury.
CAUTION 20. Start and run the engine until thermostat opens
The counterweight cover is extremely heavy 185 kg (The upper radiator hose will be warm).
(408 lb). Make sure that the eyebolts and lifting de-
vice have sufficient capacity to lift the weight.
CAUTION
11. If removed, install two eyebolts in the hole on each Additives may damage the cooling system. Before
end of the counterweight cover. Connect a suitable using additives, contact you local Yale dealer.
lifting device to the eyebolts and carefully install the
counterweight cover into the lift truck frame. See 21. Check coolant level at the auxiliary coolant reser-
Figure 10. voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reservoir.
12. Install two bolts to counterweights cover. Tighten to
38 N•m (28 lbf ft). 22. Shut down the engine for one minute or longer prior
to checking the transmission oil level. If the trans-
13. Install debris cover. mission oil is low, add transmission oil to the trans-
mission at the dipstick tube to the correct level in-
14. Install radiator cover. dicated on the dipstick. Oil is specified in Periodic
Maintenance section for your lift truck.
15. Connect positive battery cable.
16. Connect negative battery cable.
WARNING
DO NOT use an alcohol or methanol base an-
CAUTION
using additives, contact you local Yale dealer.

18. Install radiator cap.
19. Use the same coolant mixture and fill the reservoir 1. AUXILIARY COOLANT RESERVOIR
between the ADD and FULL marks. See Figure 22. 2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
WARNING
Figure 22. Reservoir for Lift Truck Models
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
fan, pulleys, or drive belts. contact with these parts
(GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,
D879, E879, F879)
35
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

A. LOWER HOSE (CUMMINS 4.5L/KUBOTA 3.8L C. UPPER HOSE (GAS AND LPG)
DIESEL) D. UPPER HOSE (CUMMINS 4.5L/KUBOTA 3.8L
B. LOWER HOSE (GAS AND LPG) DIESEL)
1. RADIATOR (WITH EXTERNAL OIL COOLER) 14. OUTLET ASSEMBLY
2. SHROUD 15. OUTLET
3. WASHER 16. CAP
4. SCREW 17. BUSHING
5. CLIP NUT 18. HOSE
6. CLIP SPRING 19. HOSE
7. CLAMP 20. REMOTE FILL HOSE
8. UPPER RADIATOR BRACKET 21. REMOTE FILL
9. CAPSCREW 22. RADIATOR CAP
10. INSERT 23. SCREEN
11. ISOLATOR 24. COOLANT LEVEL SENSOR
12. RESERVOIR 25. DRAIN PLUG
13. BRACKET (COOLANT FILL)
RADIATOR, INSTALL FOR LIFT TRUCK See Figure 15 for lift truck models equipped with
MODELS GLP/GDP60VX, GLP/GDP70VX Kubota 3.8L Diesel engine
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) • GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (B909)
(C878, D878, E878) AND GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX 5. Install coolant reservoir bracket and coolant reser-
(GLP/GDP170VX, GLP/GDP175VX36, voir assembly onto upper bracket and tighten cap-
screws.
GLP/GDP190VX) (A909, B909)
1. If necessary, install coolant level sensor.
NOTE: Installing the radiator into lift truck frame re- GDP135VX, GP/GLP/GDP155VX) (C878, D878,
quires two people. E878)
2. Install radiator into lift truck frame. See Figure 13 for lift truck models below equipped
with Cummins QSB 3.3L diesel engine
3. For lift trucks equipped with GM 5.7L LPG engine, • GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
use capscrews and install baffles to radiator assem- GDP175VX36, GDP190VX) (A909, B909)
bly. See Figure 14. Use capscrews and attach ra-
diator assembly to cooling baffle. See Figure 14 for lift truck models below equipped
4. Install upper radiator bracket and four capscrews. • GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ See Figure 15 for lift truck models equipped with
GDP135VX, GP/GLP/GDP155VX) (C878, D878, Kubota 3.8L Diesel engine
E878) • GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (B909)
with Cummins QSB 3.3L diesel engine 6. Uncap and connect auxiliary coolant reservoir hose
• GDP80VX, GDP80VX9, GDP90VX (GDP170VX, and tighten clamp.
GDP175VX36, GDP190VX) (A909, B909)
7. Remove caps from the oil cooler and transmission
See Figure 14 for lift truck models below equipped lines and connect lines into oil cooler.
• GLP80VX, GLP80VX9, GLP90VX (GLP170VX, 8. Close drain plug and uncap the lower radiator hose
GLP175VX36, GLP190VX) (A909, B909) and connect hose onto radiator and tighten clamp.
37
9. Uncap and connect upper radiator hose and tighten See Figure 27 for lift truck models below equipped
clamp. with GM 5.7L LPG engine
10. Lift trucks equipped with Cummins QSB 3.3L or GLP175VX36, GLP190VX) (A909, B909)
Kubota 3.8L diesel engine, uncap the charge air
cooler hoses and connect the hoses to the charge See Figure 28 for lift truck models equipped with
air cooler. See Figure 13 or Figure 15. Kubota 3.8L Diesel engine
11. Install fan. See Fan Installation procedures. GDP175VX36, GDP190VX) (B909)
12. Align shroud to radiator and install capscrews, 17. Install hood assembly. For hood install procedures,
washers and clip nuts. see section
See Figure 25 for lift truck models Frame 100 YRM 1321 for lift truck models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GLP/GDP80VX, GLP/GDP80VX9,
GDP135VX, GP/GLP/GDP155VX) (C878, D878, GLP/GDP90VX (GLP/GDP170VX,
E878) GLP/GDP175VX36,GLP/GDP190VX) (A909)
GDP135VX, GP/GLP/GDP155VX) (C879, D879)
• GDP80VX, GDP80VX9, GDP90VX (GDP170VX, Frame 100 YRM 1581 for lift truck models
GDP175VX36, GDP190VX) (A909, B909) • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (E878)
• GLP/GDP80VX, GLP/GDP80VX9,
GLP175VX36, GLP190VX) (A909, 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.
GDP175VX36, GDP190VX) (B909) 19. Lift trucks equipped with Kubota 3.8L, Cummins
4.5L, or QSB 3.3L diesel engine, open hood assem-
13. If necessary, connect electrical connector onto the
bly and connect hose to hood support and tighten
clamp.
14. Lift truck equipped GM 4.3L (Gas/LPG) engine, in-
stall air intake hose to air filter and tighten clamp.
15. Lift trucks equipped with Cummins 4.5L or QSB GDP135VX, GP/GLP/GDP155VX) (C878, D878,
3.3L diesel engine, install silencer and connect E878)
hose from air filter side and tighten clamp. See
Figure 25.
16. Lift trucks equipped with Cummins QSB 3.3L, Kub- • GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
ota 3.8L diesel engine or GM 5.7L LPG engine, con- GDP175VX36, GDP190VX) (A909, B909)
nect dirty air hose to hood support and install and
tighten clamp.
See Figure 26 for lift truck models below equipped • GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
with Cummins QSB 3.3L diesel engine GDP175VX36, GDP190VX) (B909)
20. Connect positive battery cable.
GDP175VX36, GDP190VX) (A909, B909)
21. Connect negative battery cable.
38
26. Check coolant level at the auxiliary coolant reser-

WARNING voir. Add coolant as necessary to keep level be-
DO NOT use an alcohol or methanol base an- tween the ADD and FULL marks on the reservoir.
personal injury or damage to the lift truck. 27. Shut down the engine for one minute or longer prior
to checking the transmission oil level. If the trans-
mission oil is low, add transmission oil at the dipstick
CAUTION tube at the correct level indicated on the dipstick.
Additives may damage the cooling system. Before Oil is specified in Periodic Maintenance section for
using additives, contact you local Yale dealer. your lift truck.
23. Install radiator cap.
24. Use the same coolant mixture and fill the auxil-
iary coolant reservoir between the ADD and FULL
marks. See Figure 24.
WARNING
fan, pulleys, or drive belts. contact with these parts
WARNING
may be hot or under pressure and cause serious 1. AUXILIARY COOLANT RESERVOIR
injury. 2. FULL "HOT" MARK
3. FULL "COLD" MARK
25. Start and run the engine until thermostat opens 4. ADD "COLD" MARK
(The upper radiator hose will be warm).
Figure 24. Reservoir for Lift Truck Models GLP/
CAUTION GP/GLP/GDP155VX) (C878, D878, E878) and
Additives may damage the cooling system. Before GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
using additives, contact you local Yale dealer. (GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909)
39
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
41
42

A. GM 4.3L (GAS/LPG) C. KUBOTA (DIESEL)
B. CUMMINS 4.5L (DIESEL)
1. AIR INTAKE (WITHOUT PRE-CLEANER) 17. SCREW
2. PRE-CLEANER 18. SHROUD
3. HOOD ASSEMBLY 19. FAN
4. CLAMP 20. FAN SPACER
5. INLET HOSE 21. TRANSMISSION LINES
6. SILENCER (DIESEL) 22. AUXILIARY COOLANT RESERVOIR AND
7. AIR FILTER BRACKET ASSEMBLY
8. UPPER RADIATOR BRACKET 23. OUTLET
9. ISOLATOR 24. CAP
10. INSERT 25. BUSHING
11. CAPSCREW 26. HOSE
12. RADIATOR (WITH EXTERNAL OIL COOLER) 27. AUXILIARY COOLANT RESERVOIR HOSE
13. UPPER HOSE 28. DRAIN PLUG
14. LOWER HOSE 29. RADIATOR CAP
15. CLIP NUT 30. HOOD SUPPORT
16. WASHER
43
1. PRE-CLEANER 17. COOLANT LEVEL SENSOR

2. CLAMP 18. UPPER BRACKET
3. HOOD SUPPORT 19. RADIATOR ISOLATOR
4. HOOD ASSEMBLY 20. RADIATOR
5. DIRTY AIR HOSE 21. CAC HOSE
6. CLEAN AIR HOSE 22. CAC TUBE
7. AIR FILTER 23. INSULATED CLAMP
8. AIR CLEANER BRACKET 24. LOWER RADIATOR HOSE
9. CAPSCREW 25. UPPER RADIATOR HOSE
10. NUT 26. SHROUD AND BAFFLE
11. AUXILIARY COOLANT RESERVOIR HOSE 27. WASHER
12. RESERVOIR OUTLET 28. FAN
13. CAP 29. SPACER
14. BUSHING 30. AUXILIARY COOLANT RESERVOIR ASSEMBLY
15. COOLANT RECOVERY RESERVOIR 31. CLIP NUT
16. TUBE
Figure 26. Cooling System Cummins QSB 3.3L Diesel Engine for Lift Truck Model GDP80VX, GDP80VX9,
GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)
44
1. PRE-CLEANER 13. RADIATOR

2. CLAMP 14. BAFFLE
3. HOOD SUPPORT 15. COOLANT RECOVERY RESERVOIR
4. HOOD 16. LOWER RADIATOR HOSE
5. DIRTY AIR HOSE 17. UPPER RADIATOR HOSE
6. CLEAN AIR HOSE 18. SEAL
7. AIR FILTER 19. BAFFLE
8. AIR CLEANER BRACKET 20. FAN SHROUD
9. CAPSCREW 21. FAN
10. NUT 22. SPACER
11. RADIATOR ISOLATOR 23. FAN MOUNTING SCREWS
12. UPPER BRACKET
Figure 27. Cooling System GM 5.7L LPG Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX
(GLP170VX, GLP175VX36, GLP190VX) (A909, B909)
45
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

1. PRE-CLEANER 16. TUBE
3. HOOD SUPPORT 18. UPPER BRACKET
4. HOOD ASSEMBLY 19. RADIATOR ISOLATOR
5. DIRTY AIR HOSE 20. RADIATOR
6. CLEAN AIR HOSE 21. CAC HOSE
7. AIR FILTER 22. CAC TUBE
8. AIR CLEANER BRACKET 23. AIR FLOW SENSOR
9. CAPSCREW 24. LOWER RADIATOR HOSE
10. NUT 25. UPPER RADIATOR HOSE
11. AUXILIARY COOLANT RESERVOIR HOSE 26. SHROUD AND BAFFLE
12. RESERVOIR OUTLET 27. WASHER
13. CAP 28. FAN
14. BUSHING 29. SPACER
15. COOLANT RECOVERY RESERVOIR
Fan Assembly Replacement

FAN REMOVAL NOTE: Perform Step 4 through Step 6 for lift truck mod-
els
WARNING • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810)
WARNING GC/GLC055SVX) (A910)
The radiator or other parts of the cooling system • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
may be hot or under pressure and can cause seri- (B875)
ous injury. Wait 30 minutes for the radiator to cool. • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
Do a touch test by touching the radiator with your 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
hand. If the radiator is still hot to the touch, wait an- GC/GLC120VXPRS) (E818, F818)
other 30 minutes before attempting to check or fix • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
any part of the cooling system. GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813, J813)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
WARNING
The radiator fins on the radiator are very sharp and (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,
can cause serious injury. Wear gloves while remov- D879, E879, F879)
ing fan assembly. • GLC050LX (A967)
NOTE: The fan that is used is a pusher-type fan. Do • GLP/GDP20-25LX (GLP/GDP050LX) (A974)
not replace with a puller-type fan. 4. Release the steering tilt latch and move the steering
1. Turn OFF lift truck. wheel forward.
2. If equipped, turn the LPG tank valve to the OFF 5. Release the seat latch and move the seat forward.
position. 6. Release hood latch and raise hood to open posi-
3. If equipped, release the LPG tank bracket and tion.
swing tank away from the lift truck.
47
Fan Assembly Replacement 700 YRM 1123
NOTE: Perform Step 7 for lift truck models See Figure 32 for lift truck models below equipped
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ with GM 4.3L engine
GDP135VX, GP/GLP/GDP155VX) (C878, D878, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
E878) 100, 120VX; GC/GLC080, 100VXBCS;
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX GC/GLC120SVX; GC/GLC120VXPRS) (E818,
(GLP/GDP170VX, GLP/GDP175VX36, GLP/ F818)
GDP190VX) (A909, B909) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
7. Release hood cover latch on hood cover and swing GDP080, 090, 100, 110, 120VX) (F813, G813,
hood cover up. H813, J813)

WARNING
with Cummins 4.5L engine
To prevent a short circuit during fan belt removal, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
disconnect the battery negative cable at the battery GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
negative terminal. Install a lock or tag on the con- GDP080, 090, 100, 110, 120VX) (F813)
nector to prevent connection. A tool could cause a
short circuit, the high current flow from the battery See Figure 34 for lift truck models below equipped
can cause an injury or parts damage. with GM 4.3L, Cummins 4.5L, or Kubota 3.8L en-
gines
8. Disconnect the negative battery cable from the neg- • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
ative battery terminal. F024, G024)GLC/GDC60VX, GLC/GDC60VX,
9. Remove screws and washers from the radiator (GC/GLC/GDC135VX, GC/GLC/GDC135VX)
shroud. Lean radiator shroud toward the fan. (C879, D879, E879, F879)
See Figure 29 for lift truck models below equipped See Figure 35 for lift truck models below equipped
with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar with GM 4.3L, Cummins 4.5L, or Kubota engines
3.3L engine • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
• GLC20-35VX (GC/GLC040-070VX, GDP135VX, GP/GLP/GDP155VX) (C878, E878)
GC/GLC055SVX) (A910) See Figure 36 for lift truck models below equipped
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) with Cummins QSB 3.3L diesel engines
(B875) • GDC60VX, GDC70VX (GDC135VX,
• GLP/GDP16VX, GLP/GDP18VX, GDC155VX) (D879)
GLP/GDP20SVX (GP/GLP/GDP030VX, • GDP60VX, GDP70VX (GDP135VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GDP155VX) (D878)
(C810) • GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
See Figure 30 for lift truck models below equipped GDP50-55VX (GDP080, 090, 100, 110, 120VX)
with Yanmar 2.6L engine. (G813)
• GDP20-25LX (GDP050LX) (A974) See Figure 37 for lift truck models below equipped
See Figure 31 for lift truck models below equipped with Cummins QSB 3.3L diesel engines
with Mazda FE and F2 engines • GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
• GLC20-35VX (GC/GLC040-070VX, GDP175VX36, GDP190VX) (A909, B909)
GC/GLC055SVX) (A910) See Figure 38 for lift truck models below equipped
• GLC050LX (A967) with GM 5.7L LPG engine
• GLP20-25LX (GLP050LX) (A974) • GLP/GDP80VX, GLP/GDP80VX9,
• GLP20-35VX (GP/GLP040-070VX) (B875) GLP/GDP90VX (GLP/GDP170VX,
• GC/GLC030VX, GC/GLC035VX, GLP/GDP175VX36, GLP/GDP190VX) (A909,
GC/GLC040SVX (C809) B909)
• GLP16VX, GLP18VX, GLP20SVX (GP/
GLP030VX, GP/GLP035VX, GP/GLP040SVX)
(C810)
48
with Kubota 3.8L diesel engine with Kubota 3.8L diesel engine
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, • GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GLP/GDP90VX (GLP/GDP170VX,
GDP080, 090, 100, 110, 120VX) (H813, J813) GLP/GDP175VX36, GLP/GDP190VX) (B909)
1. FAN 5. SCREW
2. SPACER 6. RADIATOR SHROUD
3. WASHER 7. RADIATOR
4. CAPSCREW
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
1. SPACER 5. SHROUD
2. FAN 6. SCREW
4. CAPSCREW
Figure 30. Fan Removal for Yanmar 2.6L Engine, Lift Truck Models GDP20-25LX (GDP050LX) (A974)
50
NOTE: MODINE RADIATOR SHOWN, COPAR RADIATOR SIMILAR.

1. SPACER, GLP/GDP20-35VX 4. WASHER
(GP/GLP/GDP040-070VX) (B875) AND 5. SCREW
GC/GLC030-035VX, GC/GLC040SVX (C809) 6. WASHER
LIFT TRUCKS ONLY 7. RADIATOR SHROUD
2. FAN 8. RADIATOR
3. CAPSCREW
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
1. FAN 5. SCREW
2. SPACER 6. RADIATOR SHROUD
4. CAPSCREW
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
1. SPACER 6. SCREW
2. FAN 7. LOCKWASHER
3. WASHER 8. CLIP NUT
4. CAPSCREW 9. RADIATOR
5. RADIATOR SHROUD
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
A. GM 4.3L AND KUBOTA 3.8L B. CUMMINS 4.5L (DIESEL)

1. FAN 5. SCREW
2. FAN SPACER 6. SHROUD
4. 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
A. GM 4.3L AND KUBOTA B. CUMMINS 4.5L (DIESEL)

1. FAN 5. SCREW
4. 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
1. SPACER 5. WASHER
2. FAN 6. CAPSCREW
3. SCREW 7. SHROUD
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
1. RADIATOR SHROUD 5. CAPSCREW

2. SCREW 6. FAN
4. SPACER
Figure 37. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models GDP80VX, GDP80VX9, GDP90VX
(GDP170VX, GDP175VX36, GDP190VX) (A909, B909)
57
1. FAN SHROUD 5. CAPSCREW

2. SCREW 6. FAN
3. WASHER 7. RADIATOR ASSEMBLY
4. SPACER
Figure 38. Fan Removal for GM 5.7L LPG Engine, Lift Truck Models GDP80VX, GDP80VX9, GDP90VX
(GDP170VX, GDP175VX36, GDP190VX) (A909, B909)
58
1. FAN 5. SCREW
4. CAPSCREW
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
1. FAN SHROUD 5. CAPSCREW

2. SCREW 6. FAN
3. WASHER 7. RADIATOR ASSEMBLY
4. SPACER
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 See Figure 30 for lift truck models below equipped
fan pulley. with Yanmar 2.6L engine
• GDP20-25LX (GDP050LX) (A974)
with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar See Figure 32 for lift truck models below equipped
3.3L engine with GM 4.3L engine
• GLC20-35VX (GC/GLC040-070VX, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GC/GLC055SVX) (A910) 100, 120VX; GC/GLC080, 100VXBCS;
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) GC/GLC120SVX; GC/GLC120VXPRS) (E818,
(B875) F818)
• GLP/GDP16VX, GLP/GDP18VX, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP20SVX (GP/GLP/GDP030VX, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GDP080, 090, 100, 110, 120VX) (F813, G813,
(C810) H813, J813)
60
See Figure 33 for lift truck models below equipped NOTE: Perform Step 12 for lift truck models
with Cummins 4.5L engine • GC/GLC030-035VX, GC/GLC040SVX (C809)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ (B875)
GDP080, 090, 100, 110, 120VX) (F813) • GLP20-25LX (GLP050LX) (A974)
.
See Figure 34. for lift truck models below equipped
with GM 4.3L, Cummins 4.5L, or Kubota 3.8L en- 12. For lift trucks equipped with Mazda FE and F2
gines engines, remove capscrews, washers, and spacer
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, from the fan pulley.
(GC/GLC/GDC135VX, GC/GLC/GDC135VX) See Figure 31 for lift truck models below equipped
(C879, D879, E879, F879) with Mazda FE and F2 engines
See Figure 35 for lift truck models below equipped GC/GLC055SVX) (A910)
with GM 4.3L, Cummins 4.5L, Kubota engines • GLC050LX (A967)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ • GLP20-25LX (GLP050LX) (A974)
GDP135VX, GP/GLP/GDP155VX) (C878, D878, • GLP20-35VX (GP/GLP040-070VX) (B875)
E878) • GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
See Figure 39 for lift truck models below equipped • GLP16VX, GLP18VX, GLP20SVX (GP/
with Kubota 3.8L diesel engine GLP030VX, GP/GLP035VX, GP/GLP040SVX)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, (C810)
GDP080, 090, 100, 110, 120VX) (H813, J813) NOTE: Perform Step 13 for lift truck models
• GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/
NOTE: Perform Step 11 for lift truck model GDP80VX, GDP030-035VX, GP/GLP/GDP040SVX) (C810)
GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, • GLC20-35VX (GC/GLC040-070VX,
GDP190VX) (A909) and GLP/GDP80VX, GLP/ GC/GLC055SVX) (A910)
GDP80VX9, GLP/GDP90VX (B909). • GLC050LX (A967)
11. For lift trucks equipped with Cummins QSB 3.3L 13. For lift trucks equipped with Mazda FE or F2 en-
diesel engines, GM 5.7L LPG engines, or Kubota gines, remove the capscrews and washers retain-
3.8L diesel engines, remove capscrews, washers, ing the fan.
and spacers from fan.
See Figure 37 for lift truck models below equipped with Mazda FE and F2 engines
with Cummins QSB 3.3L diesel engines • GLC20-35VX (GC/GLC040-070VX,
• GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GC/GLC055SVX) (A910)
GDP175VX36, GDP190VX) (A909, B909) • GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
• GLP20-35VX (GP/GLP040-070VX) (B875)
GC/GLC040SVX (C809)
GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)
(C810)
14. Remove the fan.
with Kubota 3.8L diesel engine
61
INSPECT See Figure 33 for lift truck models below equipped

with Cummins 4.5L engine
WARNING • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
DO NOT try to repair a damaged fan. If a fan has a
GDP080, 090, 100, 110, 120VX) (F813)
bent blade or is cracked, install a new fan. A dam-
aged fan can break during use and cause damage See Figure 34. for lift truck models below equipped
or serious injury. with GM 4.3L, Cummins 4.5L, or Kubota 3.8L en-
gines
1. Inspect the fan for any damage.
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
2. If the fan is damaged, replace the entire fan. F024, G024)GLC/GDC60VX, GLC/GDC60VX,
(GC/GLC/GDC135VX, GC/GLC/GDC135VX)
FAN INSTALLATION (C879, D879, E879, F879)

WARNING with GM 4.3L, Cummins 4.5L, or Kubota engines
The radiator fins on the radiator are very sharp and • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
can cause serious injury. Wear gloves while in- GDP135VX, GP/GLP/GDP155VX) (C878, D878,
stalling fan assembly. E878)
1. Install the lower portion of the shroud in the retain- See Figure 39 for lift truck models below equipped
ing clips and lean the shroud toward the engine. with Kubota 3.8L diesel engine
2. Install the spacer, washers, and capscrews to the
fan. Tighten the capscrews to 52 N•m (38 lbf).
GDP080, 090, 100, 110, 120VX) (H813, J813)
NOTE: Perform Step 3 for lift truck models GDP80VX,
with GM 2.4L, Yanmar 2.6L, Yanmar3.0L or Yanmar
GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,
3.3L engine
GDP190VX) (A909, B909).
GC/GLC055SVX) (A910) 3. Install spacers, washers, and capscrews onto fan.
(B875) See Figure 37 for lift truck models below equipped
• GLP/GDP16VX, GLP/GDP18VX, with Cummins QSB 3.3L diesel engines
GLP/GDP20SVX (GP/GLP/GDP030VX, • GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) GDP175VX36, GDP190VX) (A909, B909)
(C810)
See Figure 30 for lift truck models below equipped with GM 5.7L LPG engine
with Yanmar 2.6L engine. • GLP/GDP80VX, GLP/GDP80VX9,
• GDP20-25LX (GDP050LX) (A974) GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909,
See Figure 32 for lift truck models below equipped B909)
with GM 4.3L engine
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, See Figure 40 for lift truck models below equipped
100, 120VX; GC/GLC080, 100VXBCS; with Kubota 3.8L diesel engine
GC/GLC120SVX; GC/GLC120VXPRS) (E818, • GLP/GDP80VX, GLP/GDP80VX9,
F818) GLP/GDP90VX (GLP/GDP170VX,
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP175VX36, GLP/GDP190VX) (B909)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
62
NOTE: Perform Step 4 for lift truck models See Figure 34 for lift truck models below equipped
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX with GM 4.3L, Cummins 4.5L, or Kubota 3.8L en-
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, gines
GP/GLP/GDP040SVX) (C810) • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) F024, G024)GLC/GDC60VX, GLC/GDC60VX,
(B875) (GC/GLC/GDC135VX, GC/GLC/GDC135VX)
• GLP20-25LX (GLP050LX) (A974) (C879, D879, E879, F879)
4. Install the spacer, washers, and capscrews to the See Figure 35 for lift truck models below equipped
fan. Tighten the capscrews to 27 N•m (20 lbf ft). with GM 4.3L, Cummins 4.5L, or Kubota engines
See Figure 31 for lift truck models below equipped GDP135VX, GP/GLP/GDP155VX) (C878, D878,
with Mazda FE and F2 engines E878)
GLP030VX, GP/GLP035VX, GP/GLP040SVX) 7. Lean the radiator shroud back toward the radiator.
(C810) Install the screws and washers and install the radi-
• GLP20-35VX (GP/GLP040-070VX) (B875) ator shroud cover.
• GLP20-25LX (GLP050LX) (A974)
NOTE: Perform Step 5 for lift truck models with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX 3.3L engine
(C809) • GLC20-35VX (GC/GLC040-070VX,
• GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)
GC/GLC055SVX) (A910) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
• GLC050LX (A967) (B875)
5. Place the fan in position of the pulley and install GLP/GDP20SVX (GP/GLP/GDP030VX,
capscrews and washers. Tighten the capscrews to GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
27 N•m (20 lbf ft). (C810)
with Mazda FE or F2 engines with Yanmar 2.6L engine
• GC/GLC030VX, GC/GLC035VX, • GDP20-25LX (GDP050LX) (A974)
GC/GLC040SVX (C809)
• GLC20-35VX (GC/GLC040-070VX, See Figure 31 for lift truck models below equipped
GC/GLC055SVX) (A910) with Mazda FE or F2 engines
• GLC050LX (A967) • GLC20-35VX (GC/GLC040-070VX,
6. Install the spacer, washers, and capscrews to the • GLC050LX (A967)
fan. Tighten the capscrews to 27 N•m (20 lbf ft). • GLP20-25LX (GLP050LX) (A974)
• GLP20-35VX (GP/GLP040-070VX) (B875)
with GM 4.3L engine
GC/GLC040SVX (C809)
100, 120VX; GC/GLC080, 100VXBCS;
(C810)
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
63
with GM 4.3L engine with Kubota 3.8L diesel engine
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLP/GDP80VX, GLP/GDP80VX9,
100, 120VX; GC/GLC080, 100VXBCS; GLP/GDP90VX (GLP/GDP170VX,
GC/GLC120SVX; GC/GLC120VXPRS) (E818, GLP/GDP175VX36, GLP/GDP190VX) (B909)
F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, 8. Reconnect the negative battery cable to the nega-
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ tive terminal of the battery.
GDP080, 090, 100, 110, 120VX) (F813, G813,
NOTE: Perform Step 9 through Step 11 for lift truck
H813, J813)
models
See Figure 33 for lift truck models below equipped • GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
with Cummins 4.5L engine (C809)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, • GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GDP080, 090, 100, 110, 120VX) (F813) GP/GLP/GDP040SVX) (C810)
See Figure 34. for lift truck models below equipped GC/GLC055SVX) (A910)
with GM 4.3L, Cummins 4.5L, or Kubota 3.8L en- • GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
gines (B875)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
F024, G024)GLC/GDC60VX, GLC/GDC60VX, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
(GC/GLC/GDC135VX, GC/GLC/GDC135VX) GC/GLC120VXPRS) (E818, F818)
(C879, D879, E879, F879) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
See Figure 35 for lift truck models below equipped 090, 100, 110, 120VX) (F813, G813, H813, J813)
with GM 4.3L, Cummins 4.5L, or Kubota engines • S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ F024, G024)GLC/GDC60VX, GLC/GDC60VX,
GDP135VX, GP/GLP/GDP155VX) (C878, D878, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,
E878) D879, E879, F879)
• GLC050LX (A967)
with Cummins QSB 3.3L diesel engines
• GDC60VX, GDC70VX (GDC135VX, 9. Lower the hood and ensure that the hood latches.
GDC155VX) (D879)
• GDP60VX, GDP70VX (GDP135VX, 10. Move the seat back.
GDP155VX) (D878)
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6, 11. Release the steering wheel tilt latch and move the
GDP50-55VX (GDP080, 090, 100, 110, 120VX) steering wheel back.
(G813)
NOTE: Perform Step 12 for lift truck models
See Figure 37 for lift truck models below equipped • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
with Cummins QSB 3.3L diesel engines GDP135VX, GP/GLP/GDP155VX) (C878, D878)
• GDP80VX, GDP80VX9, GDP90VX (GDP170VX, • GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
GDP175VX36, GDP190VX) (A909, B909) (GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
with GM 5.7L LPG engine 12. Close hood cover.
13. If equipped, swing the LPG tank bracket back to-
GLP175VX36, GLP190VX) (A909, B909)
ward the truck and re-latch.
14. If equipped, turn the LPG tank valve to the ON po-
with Kubota 3.8L diesel engine
sition.
GDP080, 090, 100, 110, 120VX) (H813, J813)
64
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 con-
tained 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 re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Cab Replacement ..................................................................................................................................................... 2
Remove, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/
GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/
GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813, J813)................................................................................................2
Install, for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/
GDP030VX (C810); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/
GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813, J813)..............................................................................................21
Remove, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) and , GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).......................................... 22
Install, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)..................................................................... 29
Door Assemblies .....................................................................................................................................................31
Right Side Door Assembly, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/
GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); and GLP/GDP40VX5/VX6, GLP/
GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)...................................................................................................................................31
Remove ..........................................................................................................................................................31
Disassemble ...................................................................................................................................................38
Door Cover With Heater Unit ..................................................................................................................... 38
Door Cover With Air Conditioner/Heater Unit ............................................................................................ 40
Heater Assembly ........................................................................................................................................42
Air Conditioner and Heater Unit Assembly ................................................................................................ 42
Door Lock Assembly ..................................................................................................................................45
Windows .................................................................................................................................................... 46
Clean ..............................................................................................................................................................46
Inspect ............................................................................................................................................................46
Assemble ....................................................................................................................................................... 46
Windows .................................................................................................................................................... 46
Heater Assembly ........................................................................................................................................47
Air Conditioner and Heater Unit Assembly ................................................................................................ 47
Door Cover With Heater Unit ..................................................................................................................... 47
Door Cover With Air Conditioner and Heater Unit ..................................................................................... 48
Install ..............................................................................................................................................................48
Left Side Door Assembly, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810); GLP/
(F813, G813, H813, J813)...................................................................................................................................49
Remove ..........................................................................................................................................................49
Disassemble ...................................................................................................................................................49
Door Cover .................................................................................................................................................49
Windows .................................................................................................................................................... 50
©2014 Yale Materials Handling Corp. i

Table of Contents
Clean ..............................................................................................................................................................50
Inspect ............................................................................................................................................................50
Assemble ....................................................................................................................................................... 50
Windows .................................................................................................................................................... 50
Door Cover .................................................................................................................................................50
Install ..............................................................................................................................................................51
Right and Left Side Door Assemblies, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)............. 51
Remove ..........................................................................................................................................................51
Disassemble ...................................................................................................................................................52
Door Cover .................................................................................................................................................52
Windows .................................................................................................................................................... 54
Clean ..............................................................................................................................................................54
Inspect ............................................................................................................................................................54
Assemble ....................................................................................................................................................... 54
Windows .................................................................................................................................................... 54
Door Cover .................................................................................................................................................55
Install ..............................................................................................................................................................55
Window Wipers Replacement .................................................................................................................................55
General ...............................................................................................................................................................55
Front Wiper Assembly and Motor ....................................................................................................................... 55
Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) and GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875)....................................................................................................... 55
Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810) and GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875)....................................................................................................... 57
Remove, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6,
GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813),
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909)............................................................................................. 57
Install, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878), and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909)............................................................................................. 61
Rear Wiper Assembly and Motor ........................................................................................................................62
Remove, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)................................................................ 62
Install, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)................................................................ 62
Remove, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)............................ 64
Install, Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)................................ 64
Remove, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6,
GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)........................... 67
ii
Table of Contents
Install, Lift Truck Models GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/

GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)................................... 67
Remove, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)......................................69
Install, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)....................................................... 69
Window Replacement .............................................................................................................................................71
General ...............................................................................................................................................................71
Remove Door Window, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(F813, G813, H813, J813)...................................................................................................................................71
Install Door Windows, Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(F813, G813, H813, J813)...................................................................................................................................72
Remove Door Window, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) .................................72
Install Door Window, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/
Heater Replacement ...............................................................................................................................................74
Remove, for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/
Install, for Lift truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)............................................................77
Heater and Air Conditioner Assembly .....................................................................................................................78
Air Conditioner Condenser Unit ..........................................................................................................................78
Remove ..........................................................................................................................................................78
Install ..............................................................................................................................................................79
Air Conditioner Receiver/Drier Unit .................................................................................................................... 80
Remove ..........................................................................................................................................................80
Install ..............................................................................................................................................................81
Air Conditioner Compressor ............................................................................................................................... 81
Light Replacement ..................................................................................................................................................82
Work Lights (Front and Rear) ............................................................................................................................. 82
Remove ..........................................................................................................................................................82
Install ..............................................................................................................................................................82
Strobe Light ........................................................................................................................................................ 84
Remove ..........................................................................................................................................................84
Install ..............................................................................................................................................................85
Turn, Stop, Tail, and Backup Light ..................................................................................................................... 85
Remove ..........................................................................................................................................................85
iii
Table of Contents
Install ..............................................................................................................................................................85
Front Marker/Turn Signal Lights ......................................................................................................................... 86
Remove ..........................................................................................................................................................86
Install ..............................................................................................................................................................86
Display Switches .....................................................................................................................................................87
Electrical Schematics ..............................................................................................................................................91
Optional Equipment ................................................................................................................................................ 91
Heavy Duty Pre-Cleaner .....................................................................................................................................91
Remove ..........................................................................................................................................................91
Clean ..............................................................................................................................................................92
Inspect ............................................................................................................................................................92
Install ..............................................................................................................................................................92
Fan ..................................................................................................................................................................... 93
Remove ..........................................................................................................................................................93
Install ..............................................................................................................................................................93
Mirror .................................................................................................................................................................. 93
Remove ..........................................................................................................................................................93
Install ..............................................................................................................................................................93
Label Replacement .................................................................................................................................................95
This section is for the following models:
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX [C810];

GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875, C875];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813];
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
[C878, D878, E878];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) [A909, B909]
iv
0100 YRM 1290 General
General
The overhead guard is an integral part of operator cab is a separate unit and can be removed as a
cab. The operator cab is installed on a platform above complete unit from module and frame of the lift truck.
main frame members. Step plates on both sides of lift See Figure 1.
truck provide access to operator cab. The operator
Figure 1. Operator Cab
1
Cab Replacement 0100 YRM 1290
Cab Replacement
REMOVE, FOR LIFT TRUCK MODELS
GLP/GDP16VX, GLP/GDP18VX, GLP/ WARNING
GDP20SVX, GLP/GDP030VX (C810); GLP/ DO NOT remove the radiator cap from the radiator
GDP20-35VX (GP/GLP/GDP040-070VX) when the engine is hot. When the radiator is hot
(B875, C875); AND GLP/GDP40VX5/VX6, and the cap is removed, the pressure is released
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ from the system and the steam and boiling cool-
GDP50-55VX (GP/GLP/GDP080, 090, 100, ant can cause burns. Wait 30 minutes for the en-
110, 120VX) (F813, G813, H813, J813) gine to cool. Do a touch test by touching the radi-
ator with your hand. If the radiator is still hot to
NOTE: The EZ Tank Bracket used on these trucks to the touch, wait another 30 minutes before at-
mount LPG tank onto counterweight come in two tempting to remove, check, or fix any part of the
styles. One style of bracket swings out to side of truck cooling system.
and other swings out to side and drops down.
NOTE: Removing radiator cap will help depressurize
NOTE: On lift trucks equipped with LPG, make sure cooling system.
to release EZ Tank Bracket before opening hood.
4. Remove radiator cover to access radiator cap.
Remove radiator cap. See Figure 5.
1. For lift truck models GLP/GDP16VX, GLP/
GDP18VX, GLP/GDP20SVX, GLP/GDP030VX
(C810), tilt steering column to UP position, slide
seat assembly forward, open rear door, and open
hood to disconnect battery. See Figure 2.
2. Tilt steering column to UP position, slide seat as-

sembly forward, open rear sliding window, and
open hood to disconnect battery.

• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875, C875)
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
3. Disconnect air filter hose from rear left corner leg

of cab frame. See Figure 4.
WARNING 1. LATCH 3. REAR DOOR

DO NOT disconnect the heater hoses from the en- 2. HINGE
gine when the engine is hot or when the cooling
Figure 2. Rear Door and Latch for Lift Truck
system is under pressure, to do so could cause
Models GLP/GDP16VX, GLP/GDP18VX, GLP/
serious injury.
GDP20SVX, GLP/GDP030VX (C810)
2
0100 YRM 1290 Cab Replacement
A. LIFT TRUCKS MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) AND GLP/GDP40VX5/

VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) WITHOUT AIR CONDITIONING.
B. LIFT TRUCKS MODELS GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) WITH AIR CONDITIONING.
1. REAR BOTTOM WINDOW 3. AC HOSE
2. RELEASE LATCH
Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875,
C875) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813, J813)
Legend for Figure 4

NOTE: AIR FILTER HOSE FOR GLP/GDP40VX5/
VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (F813) SHOWN. AIR FILTER HOSE FOR
OTHER LIFT TRUCK MODELS ARE SIMILAR.
1. CAPSCREW
2. AIR FILTER HOSE
Figure 4. Air Filter Hose Removal
3
A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810)

B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)
C. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813)
D. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (J813)
1. RADIATOR COVER 2. RADIATOR CAP
Figure 5. Radiator Cover and Cap Location
4
8. Open left side door, remove lock nut, and discon-

CAUTION nect gas spring from cab mounting bracket. See
DO NOT allow any fluid to drain when disconnect- Figure 9.
ing the heater hose from the engine. The method
will help when purging the system during installa- 9. Lift left side door up and over hinge pin and set
tion. aside. See Figure 10.
5. Disconnect and cap heater hoses from engine.

WARNING
See Figure 6.
DO NOT disconnect the heater hoses from the
quick disconnect fittings (inside operator cab) or
WARNING engine when the engine is hot or under pressure,
Replacement, installation and repairs to air condi- to do so could cause serious injury.
tioning units that require discharging and/or refill-
ing of the refrigeration fluid must be performed by 10. Disconnect heater hose quick disconnect fittings.
a certified technician. a. For lift truck models GLP/GDP16VX, GLP/
6. Contact a certified air conditioning specialist to GDP18VX, GLP/GDP20SVX, GLP/GDP030VX
have the refrigerant extracted from the air condi- (C810), open right side door and push buttons
tioning system. on quick disconnect fittings to disconnect
heater hoses from heater assembly hoses (see
NOTE: Step 7 is for lift truck models GLP/ Figure 6). Disconnect heater wire harness con-
GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ nection. See Figure 11.
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (G813, H813, J813) with a b. For lift truck models GLP/GDP20-35VX
Cummins QSB 3.3L or a Kubota diesel engine. (GP/GLP/GDP040-070VX) (B875, C875), open
right side door and remove radiator cover to
7. If lift truck cab is equipped with an air conditioner/ access quick disconnect fittings. Push buttons
heater unit, disconnect AC refrigerant hoses from on quick disconnect fittings to disconnect
refrigerant compressor. heater hoses from heater assembly (see Fig-
ure 6). Disconnect heater wire harness con-
See Figure 7 for lift truck models nection. See Figure 11.
c. For lift truck models GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
(GP/GLP/GDP080, 090, 100, 110, 120VX)
GDP50-55VX (GP/GLP/GDP080, 090, 100,
(G813)
110, 120VX) (F813, G813, H813, J813), open
See Figure 8 for lift truck models right side door and located on inner rear cover
there are two port holes (see Figure 6). Push
buttons on quick disconnect fittings to discon-
nect heater hoses from heater assembly and
(GP/GLP/GDP080, 090, 100, 110, 120VX)
disconnect heater wire harness connection.
(H813, J813)
See Figure 11.
NOTE: Removing door assemblies requires two peo-
ple.
5
Figure 6. Heater Hose Connection
6
Legend for Figure 6

NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK.
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
A. LIFT TRUCK MODELS GLP/GDP16VX, GLP/ D. LIFT TRUCK MODELS GLP/GDP40VX5/VX6;

GDP18VX, GLP/GDP20SVX, GLP/GDP030VX GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
(C810) GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
B. LIFT TRUCK MODELS GLP/GDP20-35VX 120VX) (F813, G813)
(GP/GLP/GDP040-070VX) (B875, C875) E. LIFT TRUCK MODELS GLP/GDP40VX5/VX6;
C. LIFT TRUCK MODELS GLP/GDP20-35VX GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
(GP/GLP/GDP040-070VX) (B875, C875) GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (H813, J813)
1. QUICK DISCONNECT FITTING 4. RIGHT SIDE DOOR ASSEMBLY
2. INNER REAR COVER 5. HEATER HOSES
3. RADIATOR COVER
7
1. HOSE FITTING 3. AC/HEATER UNIT

2. REFRIGERANT COMPRESSOR 4. ENGINE
Figure 7. AC Refrigerant Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,

GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with Cummins QSB
3.3L Engine
8
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. KUBOTA 3.8L DIESEL EN-
GINE SHOWN, 3.6L DIESEL ENGINE SIMILAR.
A. LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX

(GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)
B. LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
1. HOSE FITTING 3. AC/HEATER UNIT
2. REFRIGERANT COMPRESSOR 4. ENGINE
Figure 8. AC Refrigerant Hose Connection, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813) with Kubota
Diesel Engine
9

NOTE: RIGHT SIDE DOOR HINGE SHOWN.
1. HINGE PIN
2. DOOR HINGE
NOTE: RIGHT SIDE DOOR SHOWN.
1. GAS SPRING
2. CAB MOUNTING BRACKET
3. LOCK NUT
Figure 9. Gas Spring Mounting Removal
NOTE: MAJOR COMPONENTS OF CAB HAVE

BEEN REMOVED FOR CLARITY.
1. HEATER WIRE HARNESS CONNECTOR

2. REAR GRAB HANDLE HORN BUTTON CON-
NECTOR (TO RIGHT-HAND CHASSIS HAR-
NESS)
Figure 11. Heater Wire Harness and Rear Grab

Handle Horn Button Connectors
Figure 10. Door Removal
10
11. For lift truck models GLP/GDP40VX5/VX6; GLP/ See Figure 14 for lift truck models
GDP45SVX5, GLP/GDP45VX6; GLP/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, GLP/GDP45VX6; GLP/GDP50-55VX
120VX) (G813, H813, J813) with a Cummins QSB (GP/GLP/GDP080, 090, 100, 110,
3.3L or Kubota diesel engine, if lift truck cab is 120VX) (J813)
equipped with an air conditioner/heater unit, dis-
connect AC hoses. c. Disconnect air conditioner wire harness.
a. Remove six fasteners and remove rear cover. See Figure 12 for lift truck models
See Figure 12 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,

• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, (GP/GLP/GDP080, 090, 100, 110,
GLP/GDP45VX6; GLP/GDP50-55VX 120VX) (G813)
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813) See Figure 13 for lift truck models
GLP/GDP45VX6; GLP/GDP50-55VX 120VX) (H813)
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813) See Figure 14 for lift truck models

GLP/GDP45VX6; GLP/GDP50-55VX 120VX) (J813)
(GP/GLP/GDP080, 090, 100, 110,
120VX) (J813) 12. Remove lock nut and disconnect gas spring from
cab mounting bracket. See Figure 9.
b. Disconnect air conditioner hoses at bulkhead
bracket and at receiver/drier. 13. Lift door up and over hinge pin and set aside. See
Figure 10.
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, NOTE: Wiper motor cover must be removed before
GLP/GDP45VX6; GLP/GDP50-55VX dash assembly can be removed.
(GP/GLP/GDP080, 090, 100, 110,
14. Unclip and remove front wiper motor cover. See
120VX) (G813)
Figure 15 for lift truck models
See Figure 13 for lift truck models • GLP/GDP16VX, GLP/GDP18VX, GLP/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GDP20SVX, GLP/GDP030VX (C810)
GLP/GDP45VX6; GLP/GDP50-55VX • GLP/GDP20-35VX (GP/GLP/
(GP/GLP/GDP080, 090, 100, 110, GDP040-070VX) (B875, C875)
120VX) (H813)
11
A. FRONT VIEW B. TOP VIEW

1. HOSE WRAP 5. BULKHEAD BRACKET
2. FASTENERS 6. RECEIVER/DRIER
3. REAR COVER 7. FITTINGS
4. AIR CONDITIONER HOSES 8. AIR CONDITIONER WIRE HARNESS
Figure 12. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/
GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) With a
Cummins QSB 3.3L Diesel Engine
12

GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) With a
Kubota Diesel Engine
13

GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) With a
Kubota Diesel Engine
14
Figure 15. Dash Installation
15

A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/

GDP040SVX) (C810) AND GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875)
B. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813, J813)
1. CAPSCREWS 5. COWL PANEL
2. FRONT WIPER MOTOR COVER 6. FRONT OPERATOR CAB LEGS
3. DASH ASSEMBLY 7. LOCK NUT
4. KICK PANEL 8. FLANGE BOLT
15. For lift truck models GLP/GDP40VX5/VX6; GLP/ 17. Remove five capscrews from top of dash assem-
GDP45SVX5, GLP/GDP45VX6; GLP/ bly and cowl panel.
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (F813, G813), remove two lock nuts from 18. Remove two flange bolts securing cowl panel to
front wiper motor cover. Remove front wiper mo- front operator cab legs.
tor cover. See Figure 15.
19. Unclip dash assembly from kick panel. Remove
16. For lift truck models GLP/GDP40VX5/VX6; GLP/ dash assembly.
GDP45SVX5, GLP/GDP45VX6; GLP/
20. Remove kick panel from seal plate assembly. See
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
Figure 16.
120VX) (H813, J813), remove three lock nuts
from front wiper motor cover. Remove front wiper
motor cover.
16
Figure 16. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
17

NOTE: CAB REMOVED FOR CLARITY.
A. GLP/GDP16VX, GLP/GDP18VX, GLP/ B. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/

GDP20SVX, GLP/GDP030VX (C810) AND GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP20-35VX (GP/GLP/GDP040-070VX) (B875, GDP080, 090, 100, 110, 120VX) (F813, G813,
C875) H813, J813)
1. CAPSCREWS 5. FLOOR PLATE (LEFT SIDE)
2. KICK PANEL 6. FLOOR PLATE (RIGHT SIDE)
3. SEAL PLATE ASSEMBLY 7. FLOOR PLATE
4. SEAL
21. Remove capscrews and seal plate assembly from

lift truck frame.
22. Disconnect rear grab handle horn button connec-

tor from right-hand chassis harness, located in
right rear corner leg of cab frame. See Figure 11.
23. Disconnect light harness connector from Vehicle

Systems Manager (VSM) and right-hand chassis
harness connector. See Figure 17.
NOTE: Perform Step 24 and Step 25 for lift truck

models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GDP080, 090, 100, 110, 120VX) (J813) equipped with
Diesel Particulate Filter (DPF).
24. Disconnect light harness connector from Vehicle

Systems Manager (VSM) and right-hand chassis
harness connector. See Figure 18.
25. Disconnect Diesel Particulate Filter (DPF) display

NOTE: KICK PANEL REMOVED FOR CLARITY.
harness connector from cowl harness. See Fig-
ure 18. 1. VSM
2. LIGHT HARNESS CONNECTOR (TO VSM)
26. Remove rear panels, front panels, and fender 3. HARNESS CONNECTOR (TO RIGHT-HAND
covers to access cab mounting capscrews and CHASSIS HARNESS)
flange nuts. See Figure 19.
Figure 17. Light Harness Connection to Vehicle
27. Remove front and rear cab capscrews and flange System Manager (VSM) for Lift Truck Models GLP/
nuts from lift truck frame. See Figure 20. GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/
GDP030VX (C810), GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875, C875) and GLP/GDP40VX5/
VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (F813, G813, H813)
18
1. VSM
2. DPF DISPLAY HARNESS CONNECTOR (TO
COWL HARNESS) NOTE: LEFT SIDE DOOR REMOVED FOR
3. LIGHT HARNESS CONNECTOR (TO VSM) CLARITY.
4. HARNESS CONNECTOR (TO RIGHT-HAND
CHASSIS HARNESS) 1. REAR PANEL (LPG)
2. REAR PANEL (GAS AND DIESEL)
Figure 18. Electrical Harness Connection to 3. FRONT PANEL
Vehicle System Manager (VSM) for Lift Truck 4. FENDER COVER
Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, 5. SCREWS
6. CAPSCREWS
GDP080, 090, 100, 110, 120VX) (J813) Figure 19. Front and Rear Panels and Fender
Cover Removal
19
WARNING
Make sure that the lifting device has a minimum
capacity to lift 500 kg (1100 lb).
28. Connect a lifting device to a spreader bar or lift

strap, that is through door openings at top of op-
erator's cab (under overhead guard structure).
Place material that will be a cushion at top of door
opening to prevent damage. Operate lifting device
just enough to correctly position spreader bar or
lifting strap on operator's cab. See Figure 21.
CAUTION
Lift the operator cab carefully. Check that all elec-
trical wires and attachments are disconnected
and are not damaged.
29. Carefully lift operator cab away from lift truck. Set
operator cab in a storage area and place blocks
under operator cab to make it stable and prevent
damage to parts still attached.
NOTE: ILLUSTRATION FOR REFERENCE PURPO-

SES ONLY. ACTUAL LIFT TRUCK MAY BE
SLIGHTLY DIFFERENT.
A. FRONT VIEW
B. REAR VIEW
1. CAPSCREWS
2. FLANGE NUTS
Figure 20. Front and Rear Cab Mounting
Figure 21. Lift Strap Connection
20
INSTALL, FOR LIFT TRUCK MODELS 11. Install floor plate and floor mat. Tighten cap-
GLP/GDP16VX, GLP/GDP18VX, GLP/ screws to 10.8 N•m (7.96 lbf ft).
GDP20SVX, GLP/GDP030VX (C810); GLP/
GDP20-35VX (GP/GLP/GDP040-070VX) 12. Install kick panel onto seal plate assembly.
(B875, C875); AND GLP/GDP40VX5/VX6, 13. Install two flange bolts securing cowl to front oper-
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ ator cab legs. See Figure 15.
GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813, J813) 14. Install dash assembly onto kick panel and install
five capscrews to secure dash assembly to cowl
panel.
erator's cab (under overhead guard structure). 15. Install and clip front wiper motor cover for lift truck
Place material that will be a cushion at top of door models
• GLP/GDP16VX, GLP/GDP18VX, GLP/
lifting strap on operator's cab. See Figure 21. GDP20SVX, GLP/GDP030VX (C810)
• GLP/GDP20-35VX (GP/GLP/
2. Carefully lift operator cab onto lift truck frame GDP040-070VX) (B875, C875)
making sure that front and rear leg mounting
holes are aligned with frame mounting holes. 16. Install front wiper motor cover and tighten two
lock nuts for lift truck models GLP/GDP40VX5/
3. Install capscrews and flange nuts to rear operator VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
cab legs. Tighten capscrews to 66 N•m (49 lbf ft). GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
See Figure 20. 120VX) (F813, G813).
4. Install capscrews and lock nuts to front operator's 17. Install front wiper motor cover and tighten three
cab legs. Tighten capscrews to 66 N•m (49 lbf ft). lock nuts for lift truck models GLP/GDP40VX5/
VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
5. Install fender covers, front panel, and rear panels GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
to frame. See Figure 19. Tighten capscrews to 120VX) (H813, J813).
10.8 N•m (7.96 lbf ft).
18. Install right side door onto cab by lifting door up
6. Connect light harness connector to Vehicle Sys- and over top and bottom hinge pins. See Fig-
tems Manager (VSM) and right-hand chassis har- ure 10.
ness. See Figure 17.
19. Connect gas spring and lock nut to cab mounting
NOTE: Perform Step 7 and Step 8 for lift truck mod- bracket. See Figure 9.
els GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 20. Connect heater hoses to heater assembly and
090, 100, 110, 120VX) (J813) equipped with Diesel connect heater wire harness connection. See Fig-
Particulate Filter (DPF). ure 6 and Figure 11.
7. Connect light harness connector to Vehicle Sys- 21. For lift truck models GLP/GDP40VX5/VX6; GLP/
tems Manager (VSM) and right-hand chassis har- GDP45SVX5, GLP/GDP45VX6; GLP/
ness. See Figure 18. GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (G813) with a Cummins QSB 3.3L engine
8. Connect Diesel Particulate Filter (DPF) harness and equipped with an air conditioner/heater unit,
connector to cowl harness. See Figure 18. connect AC hoses. Tighten AC hose at bulkhead
9. Connect right-hand chassis harness to rear grab bracket to 29 to 37 N•m (21 to 27 lbf ft) and AC
handle horn button connector. See Figure 11. hose to receiver/drier to 15 to 18 N•m (133 to
159 lbf in). See Figure 12.
10. Install seal plate assembly to lift truck frame and
tighten capscrews. See Figure 16.
21
22. For lift truck models GLP/GDP40VX5/VX6; GLP/

GDP45SVX5, GLP/GDP45VX6; GLP/ WARNING
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, Replacement, installation and repairs to air condi-
120VX) (H813, J813) with a Kubota engine and tioning units that require discharging and/or refill-
equipped with an air conditioner/heater unit, con- ing of the refrigeration fluid must be performed by
nect AC hoses. Tighten AC hose at bulkhead a certified technician.
bracket to 29 to 37 N•m (21 to 27 lbf ft) and AC
hose to receiver/drier to 20 to 27 N•m (177 to 32. Contact a certified air conditioning specialist to
239 lbf in). See Figure 13. have the refrigerant refilled into air conditioning
system.
23. Install left side door onto cab by lifting door up
and over top and bottom hinge pins. See Fig- 33. On lift trucks equipped with an air conditioner/
ure 10. heater unit, start engine and turn on heater to ON
position, run engine approximately 1 to 2 minutes
24. Connect gas spring and lock nut to cab mounting or until heater supply hose is fully purged.
bracket. See Figure 9.
NOTE: The EZ Tank Bracket used on these trucks to
25. Uncap and connect heater hoses at engine. See mount LPG tank onto counterweight comes in two
Figure 6. styles. One style of bracket swings out to side of truck
and other swings out to side and drops down.
GDP45SVX5, GLP/GDP45VX6; GLP/ 34. Lift trucks equipped with a LPG engine, swing EZ
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, Tank Bracket back to its original and locked posi-
120VX) (G813, H813, J813) with a Cummins QSB tion.
3.3L or a Kubota diesel engine and equipped with
an air conditioner/heater unit, connect AC refriger- REMOVE, FOR LIFT TRUCK MODELS
ant hoses to refrigerant compressor. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878,
See Figure 7 for lift truck models D878, E878) AND , GLP/GDP80VX, GLP/
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GDP80VX9, GLP/GDP90VX (GLP/
GLP/GDP45VX6; GLP/GDP50-55VX GDP170VX, GLP/GDP175VX36, GLP/
(GP/GLP/GDP080, 090, 100, 110, 120VX) GDP190VX) (A909, B909)
(G813)
NOTE: Removing door assemblies from operators
See Figure 8 for lift models cab requires two people.
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, 1. Open right side door and remove hair pin from rod
GLP/GDP45VX6; GLP/GDP50-55VX pin. See Figure 22.
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(H813, J813) 2. Remove rod pin and spacers from link.
27. Check coolant level, fill if necessary. 3. Remove right side door from cab frame by lifting
door up and over hinge pin and set door aside.
28. Install radiator cap and radiator cover. See Fig- See Figure 23.
ure 5.
4. Repeat Step 1 through Step 3 for removal of left
29. Connect air filter hose onto rear left corner leg of side door.
cab frame. Tighten capscrews to
66 N•m (49 lbf ft). See Figure 4. 5. Remove front floor mat and floor plate. See Fig-
ure 24.
30. Connect battery and close hood.
6. Disconnect battery.
31. Start engine and turn on heater to ON position,
run engine approximately 1 to 2 minutes or until
heater supply hose is fully purged.
22
NOTE: RIGHT SIDE DOOR SHOWN NOTE: RIGHT SIDE DOOR HINGE SHOWN
1. ROD PIN 1. HINGE PIN
2. SPACERS 2. DOOR HINGE
3. HAIR PIN
4. DOOR ASSEMBLY Figure 23. Door Removal
Figure 22. Door Link Removal
23
1. DASH ASSEMBLY 6. FLANGE BOLT

2. KICK PANEL 7. REAR FLOOR PLATE
3. SEAL PLATE ASSEMBLY 8. FRONT FLOOR PLATE
4. FRONT FLOOR MAT 9. MODULE
5. REAR FLOOR MAT
Figure 24. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
24
7. Remove two screws holding right side rear cover

to rear overhead guard leg. See Figure 25.
NOTE: RIGHT SIDE VIEW SHOWN.

1. CAPSCREWS
1. RIGHT SIDE REAR COVER 2. FRONT WIPER MOTOR COVER
2. RIGHT SIDE FRONT COVER 3. DASH ASSEMBLY
3. SCREWS 4. KICK PANEL
4. REAR FLOOR PLATE 5. COWL PANEL
5. FRONT FLOOR PLATE 6. FRONT OPERATORS CAB LEGS
6. CLIP NUTS 7. LOCK NUT
Figure 25. Side Cover Removal 8. FLANGE BOLT
Figure 26. Dash Removal, Early Model GLP/

8. Remove two screws holding right side front cover GP/GLP/GDP155VX) (C878, D878) Lift Trucks
to frame. Remove right side rear cover.
9. Remove two screws securing right side front

cover to front overhead guard leg. Remove right NOTE: Perform Step 12 on later model lift trucks
side front cover. • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
10. Repeat Step 7 through Step 9 to remove left side D878, E878)
covers.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
NOTE: Perform Step 11 for early model GLP/ GDP90VX (GLP/GDP170VX, GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GDP175VX36, GLP/GDP190VX) (A909, B909)
GP/GLP/GDP155VX) (C878, D878).
12. Remove three lock nuts from front wiper motor
11. Remove two lock nuts from front wiper motor cover. Remove front wiper motor cover. See Fig-
cover. Remove front wiper motor cover. See Fig- ure 27.
ure 26.
25
1. CAPSCREWS 5. COWL PANEL

2. FRONT WIPER MOTOR COVER 6. FRONT OPERATORS CAB LEGS
3. DASH ASSEMBLY 7. LOCK NUT
4. KICK PANEL 8. FLANGE BOLT
Figure 27. Dash Removal, Later Model GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878) Lift Trucks and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) Lift Truck Models
26
13. Remove five capscrews from top of dash assem- 22. Open right side hood door and remove both wiper
bly and cowl panel. motor washer tubes from t-fitting and disconnect
washer pump harness connector from washer
14. Unclip dash assembly from kick panel. Remove fluid reservoir.
dash assembly.
23. Disconnect rear grab handle horn button connec-
15. Remove kick panel from seal plate assembly. See tor from right hand chassis harness.
Figure 24.
24. Remove bottom flange bolt securing right side
16. Remove two flange bolts securing cowl panel to rear operator cab leg to module.
front operator cab legs.
25. Open left side hood door and remove bottom
See Figure 26 for early model GLP/GDP60VX, flange bolt securing rear left side operator cab leg
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ to module.
GDP155VX) (C878, D878) lift trucks.
See Figure 27 for later model lift trucks

D878, E878)
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909,
B909)
17. Disconnect three harness connectors from right

side front operator cab leg that are connected to
Vehicle Systems Manager (VSM) and right hand
chassis harness connectors. See Figure 28.
NOTE: PerformStep 18 and Step 19 for lift truck

models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (E878) and GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36,GLP/GDP190VX)
(B909) equipped with Diesel Particulate Filter (DPF).
18. Disconnect three harness connectors from right
1. VSM
side front operator cab leg that are connected to 2. HARNESS CONNECTOR (TO VSM)
Vehicle System Manager (VSM) and right-hand 3. HARNESS CONNECTOR (TO RIGHT HAND
chassis harness connectors. See Figure 29. CHASSIS HARNESS)
19. Disconnect Diesel Particulate Filter (DPF) display Figure 28. Light Harness Connection to Vehicle
harness connector from cowl harness. See Fig- System Manager (VSM) for Lift Truck Models GLP/
ure 29. GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878) and GLP/
20. Remove four flange bolts securing right and left GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
side of front operator cab legs to module. See GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
Figure 30. (A909)
21. From inside cab, remove six flange bolts securing
right and left side rear operator cab legs to mod-
ule.
27
1. VSM
2. DPF DISPLAY HARNESS CONNECTOR (TO
COWL)
3. HARNESS CONNECTOR (TO VSM)
4. HARNESS CONNECTOR (TO RIGHT HAND
CHASSIS HARNESS)
Figure 29. Electrical Harness Connection to

Vehicle System Manager (VSM) for Lift Truck
Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36,GLP/GDP190VX)
(B909)
Figure 30. Front and Rear Cab Mounting
28
Legend for Figure 30 INSTALL, FOR LIFT TRUCK MODELS

NOTE: RIGHT SIDE SHOWN. WIPER COVER AND
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
ASSEMBLY FOR EARLY MODEL GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
D878, E878), GLP/GDP80VX, GLP/
GDP155VX) (C878, D878) LIFT TRUCKS SHOWN.
GDP80VX9, GLP/GDP90VX (GLP/
THE FRONT AND REAR CAB MOUNTING IS SAME
GDP170VX, GLP/GDP175VX36, GLP/
FOR LATER MODEL GLP/GDP60VX, GLP/
GDP190VX) (A909, B909)
GDP70VX (GP/GLP/GDP135VX, GP/GLP/ 1. Connect a lifting device to a spreader bar or lift
GDP155VX) (C878, D878, E878) LIFT TRUCKS AND strap, that is through door openings at top of op-
ON GLP/GDP80VX, GLP/GDP80VX9, GLP/ erator's cab (under overhead guard structure).
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, Place material that will be a cushion at top of door
GLP/GDP190VX) (A909, B909) LIFT TRUCK MOD- opening to prevent damage. Operate lifting device
ELS. just enough to correctly position spreader bar or
A. REAR VIEW B. FRONT 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
WARNING
Make sure that the lifting device has a minimum
capacity to lift 500 kg (1100 lb).

erator's cab (under overhead guard structure).
Place material that will be a cushion at top of door
CAUTION
Lift the operator cab carefully. Check that all elec-
trical wires and attachments are disconnected
correctly and are not damaged.
27. Carefully lift operator cab up and away from lift

truck. Set operator cab in a storage area and
place blocks under operator cab to make it stable
and prevent damage to wire harness and parts Figure 31. Lift Strap Connection
still attached.
29
2. Carefully lift operator cab onto lift truck frame See Figure 27 for later model lift trucks
making sure that front and rear leg mounting • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
holes are aligned with module mounting holes. GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878)
3. Open left side hood door and install bottom flange
bolt to secure rear left side operator cab leg to • GLP/GDP80VX, GLP/GDP80VX9, GLP/
module. Tighten flange bolt to GDP90VX (GLP/GDP170VX, GLP/
165 N•m (122 lbf ft). See Figure 30. GDP175VX36, GLP/GDP190VX) (A909,
B909)
4. Open right side hood door and install bottom
flange bolt to secure rear right side operator cab 13. Install kick panel to seal plate assembly. See Fig-
leg to module. Tighten flange bolt to ure 24.
165 N•m (122 lbf ft).
14. Install and clip dash assembly onto kick panel.
5. Connect rear grab handle horn button harness See Figure 26.
connector to right hand chassis harness.
15. Install five capscrews to top of dash assembly to
6. Connect both wiper motor washer tubes to t-fitting secure dash assembly onto cowl panel. Tighten
and connect washer pump harness connector to capscrew to 3.5 N•m (30 lbf in).
washer fluid reservoir.
NOTE: Perform Step 16 on early model GLP/
7. Install two flange bolts to secure right and left side GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
front operator cab legs to module. Tighten flange GP/GLP/GDP155VX) (C878, D878) lift trucks.
bolt to 165 N•m (122 lbf ft).
16. Install front wiper motor cover using two lock nuts.
8. From inside cab, install four remaining flange See Figure 26.
bolts to right and left side rear operator cab legs
to module. Tighten flange bolt to NOTE: Perform Step 17 on later model lift trucks
165 N•m (122 lbf ft). • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
9. Connect three harness connectors on front right D878, E878)
side operator cab leg to Vehicle System Manager
(VSM) and right hand chassis harness. See Fig-
GDP90VX (GLP/GDP170VX, GLP/
ure 28.
GDP175VX36, GLP/GDP190VX) (A909, B909)
NOTE: Perform Step 10 and Step 11 for lift truck
17. Install front wiper motor cover using three lock
models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
nuts. See Figure 27.
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ 18. Install right side front cover to front overhead
GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) guard leg using two screws. See Figure 25.
(B909) equipped with Diesel Particulate Filter (DPF).
19. Install right side rear cover to right side front cover
10. Connect three harness connectors on front right and install and tighten two screws to frame.
side operator cab leg to Vehicle System Manager
(VSM) and right-hand chassis harness. See Fig- 20. Align right side rear cover to rear overhead guard
ure 29. leg and install and tighten two screws to rear
overhead guard leg and install and tighten two
11. Connect Diesel Particulate Filter (DPF) display screws to rear overhead guard leg.
harness connector from cowl harness. See Fig-
ure 29. 21. Repeat Step 18 through Step 20 to install left side
covers.
12. Install two flange bolts to secure cowl panel to
front operator cab legs. 22. Connect battery.
See Figure 26 for early model GLP/GDP60VX, 23. Install front floor plate and floor mat. See Fig-
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ ure 24.
GDP155VX) (C878, D878) lift trucks.
30
0100 YRM 1290 Door Assemblies
NOTE: Installing door assemblies onto operator cab 26. Install hair pin into rod pin.
requires two people.
27. Repeat steps Step 24 through Step 26 for installa-
24. Lift door up and over top and bottom hinge pins. tion of left side door.
See Figure 23.
25. Align link and spacers into guide and install rod
pin. See Figure 22.
Door Assemblies
RIGHT SIDE DOOR ASSEMBLY, LIFT NOTE: Removing right side door assembly requires
TRUCK MODELS GLP/GDP16VX, GLP/ two people.
GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/ 2. Disconnect heater hose quick disconnect fittings.
GDP040SVX) (C810); GLP/GDP20-35VX See Figure 33.
(GP/GLP/GDP040-070VX) (B875, C875); a. For lift truck models GLP/GDP16VX, GLP/
AND GLP/GDP40VX5/VX6, GLP/ GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP45SVX5, GLP/GDP45VX6, GLP/ GDP030VX, GP/GLP/GDP035VX, GP/GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, GDP040SVX) (C810), open right side door and
110, 120VX) (F813, G813, H813, J813) push buttons on quick disconnect fittings to dis-
connect heater hoses from heater assembly
Remove
hoses. See Figure 33. Disconnect heater wire
harness connection. See Figure 34.
WARNING
b. For lift truck models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875), open
when the engine is hot. When radiator cap is re-
right side door and remove radiator cover to
moved, the pressure is released from cooling sys-
access quick disconnect fittings. Push buttons
tem. If cooling system is hot, the steam and boil-
on quick disconnect fittings to disconnect
ing coolant can cause burns.
heater hoses from heater assembly hoses. See
Wait 30 minutes for the engine to cool. Do a touch Figure 33. Disconnect heater wire harness
test by touching the radiator with your hand. If the connection. See Figure 34.
radiator is still hot to the touch, wait another 30
c. For lift truck models GLP/GDP40VX5/VX6,
minutes before attempting to remove the radiator
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
cap.
GDP50-55VX (GP/GLP/GDP080, 090, 100,
NOTE: Removing radiator cap will help depressurize 110, 120VX) (F813, G813, H813, J813) equip-
cooling system. ped with a heater unit, open right side door and
locate two port holes on inner rear cover. Push
1. Remove radiator cover to access radiator cap. buttons on quick disconnect fittings to discon-
Remove radiator cap. See Figure 32. nect heater hoses from heater assembly. See
Figure 33. Disconnect heater wire harness
connection. See Figure 34.
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.
Serious injury can occur.
31
Door Assemblies 0100 YRM 1290

C. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813)
D. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (J813)
1. RADIATOR COVER 2. RADIATOR CAP
Figure 32. Radiator Cover and Cap Location
32
NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK.

C. GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813)
D. GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (H813, J813)
1. QUICK DISCONNECT FITTING 4. RIGHT SIDE DOOR ASSEMBLY
2. INNER REAR COVER 5. HEATER HOSES
3. RADIATOR COVER
Figure 33. Heater Hose Connection
33

(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)

(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)

(GP/GLP/GDP080, 090, 100, 110,
120VX) (J813)
b. Disconnect air conditioner hoses at bulkhead

bracket and at receiver/drier.
NOTE: MAJOR COMPONENTS OF CAB HAVE
BEEN REMOVED FOR CLARITY. See Figure 35 for lift truck models
1. HEATER WIRE HARNESS CONNECTOR
2. REAR GRAB HANDLE HORN BUTTON CON- GLP/GDP45VX6; GLP/GDP50-55VX
NECTOR (TO RIGHT-HAND CHASSIS HAR- (GP/GLP/GDP080, 090, 100, 110,
NESS) 120VX) (G813)
Figure 34. Heater Wire Harness and Rear Grab See Figure 36 for lift truck models
Handle Horn Button Connectors • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
WARNING
Replacement, installation and repairs to air condi- See Figure 37 for lift truck models
tioning units that require discharging and/or refill-
ing of the refrigerant fluid must be performed by a
certified technician.
(GP/GLP/GDP080, 090, 100, 110,
3. Contact a certified air conditioning specialist to 120VX) (J813)
have the refrigerant extracted from air condition-
c. Disconnect air conditioner wire harness.
ing system.
GDP45SVX5, GLP/GDP45VX6; GLP/ • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, GLP/GDP45VX6; GLP/GDP50-55VX
120VX) (G813, H813, J813) with a Cummins QSB (GP/GLP/GDP080, 090, 100, 110,
3.3L or Kubota diesel engine, if lift truck cab is 120VX) (G813)
equipped with an air conditioner/heater unit, dis-
connect AC hoses.
a. Remove six fasteners and remove rear cover.
34
See Figure 36 for lift truck models See Figure 37 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, (GP/GLP/GDP080, 090, 100, 110,
120VX) (H813) 120VX) (J813)

GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)
35

GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)
36

GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
37
5. Disconnect gas spring. See Figure 38. 2. Remove fan and heater knobs from knob plate.
Remove four screws that fasten knob plate to
heater valve and switch plate. Remove knob plate
from door cover.
3. Remove two fasteners from top of door cover.
4. Remove five plugs along sides and front of door

cover. Remove two capscrews and washers from
bottom of door cover. Remove door cover from
door frame.
5. Remove prefilter, located on bottom of door

frame.
NOTE: RIGHT SIDE DOOR SHOWN.
1. GAS SPRING
2. MOUNTING BRACKET
3. LOCK NUT
Figure 38. Gas Spring Mounting Installation
6. Remove right side door from cab frame by lifting

door up and over hinge pin. See Figure 39.
Disassemble
NOTE: RIGHT SIDE DOOR HINGE SHOWN.
Door Cover With Heater Unit
1. HINGE PIN 2. DOOR HINGE
1. Remove four screws and washers that attach
handle to door cover. Remove handle and two Figure 39. Door Removal
handle plates. See Figure 40.
38
Figure 40. Right Side Door Cover Removal, Heater Unit
39
1. PLUG 9. WASHER
2. FASTENER 10. HEATER/FAN LOUVER
3. GAS SPRING 11. CAPSCREW
4. FAN AND HEATER KNOBS 12. DOOR COVER
5. SCREW 13. PRE-FILTER
6. KNOB PLATE 14. HEATER VALVE AND SWITCH PLATE
7. HANDLE 15. STAR NUT
8. HANDLE PLATES
Door Cover With Air Conditioner/Heater Unit See Figure 37 for lift truck models
NOTE: Only lift truck models GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
(GP/GLP/GDP080, 090, 100, 110, 120VX)
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
(J813)
120VX) (G813, H813, J813) with a Cummins QSB
3.3L or Kubota diesel engine may be equipped with 3. Remove fan and heater/AC knobs from knob
an air conditioner/heater unit. plate. Remove four screws that fasten knob plate
to heater valve and switch plate. Remove knob
NOTE: The procedures in this section remove air
plate and heater valve from door cover. See Fig-
conditioner/heater unit assembly door cover from right
ure 41.
side door. For procedures to remove or replace other
components of air conditioner/heater unit assembly, 4. Remove two fasteners from top of door cover.
go to Heater and Air Conditioner Assembly section.
5. Remove four capscrews that fasten AC rocker
1. Remove four screws and washers that attach switch plate to door cover. Remove AC rocker
handle to door cover. Remove handle. See Fig- switch plate from door cover. See Figure 41.
ure 41.
6. Remove five plugs, washers, and star nuts along
2. Remove hose wrap from AC hoses. sides and front of door cover. Remove two cap-
screws and washers from bottom of door cover.
Remove door cover from door frame.
GLP/GDP45VX6; GLP/GDP50-55VX 7. Remove prefilter, located on bottom of door
(GP/GLP/GDP080, 090, 100, 110, 120VX) frame. See Figure 41.
(G813)

(GP/GLP/GDP080, 090, 100, 110, 120VX)
(H813)
40
1. CAPSCREW 8. HEATER, FAN, AND AC LOUVER

2. AC ROCKER SWITCH PLATE 9. PRE-FILTER
3. AC ROCKER SWITCH 10. DOOR COVER
4. HEATER/AC KNOBS 11. WASHER
5. HANDLE 12. PLUG
6. HEATER VALVE AND SWITCH PLATE 13. WASHER
7. FASTENER 14. STAR NUT
Figure 41. Right Side Door Cover Removal, Air Conditioner/Heater Unit
41
Heater Assembly Air Conditioner and Heater Unit Assembly

NOTE: The heater assembly is non-repairable, re- NOTE: Only lift truck models GLP/GDP40VX5/VX6;
place as a complete unit. See Parts Manual. GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
1. Remove lock nut from heater valve and switch 120VX) (G813, H813, J813) with a Cummins QSB
plate. See Figure 42. 3.3L or Kubota diesel engine may be equipped with
an air conditioner/heater unit.
2. Disconnect heater switch connector from heater
switch.
NOTE: The procedures in this section remove air
3. Remove two screws from heater valve and switch conditioner/heater unit assembly from right side door.
plate and remove plate. For procedures to remove or replace other compo-
nents of air conditioner/heater unit assembly, go to
4. Disconnect supply hose at heater valve and dis-
Heater and Air Conditioner Assembly section.
connect return hose from heater coil.
5. Remove two nuts and washers from heater as-

sembly bracket. Remove heater assembly and
bracket from door frame.
1. LOCK NUT 7. HEATER VALVE AND SWITCH PLATE

2. NUT 8. HEATER VALVE
3. WASHER 9. HEATER SWITCH
4. HEATER ASSEMBLY BRACKET 10. RETURN HOSE
5. SUPPLY HOSE 11. SCREWS
6. HEATER ASSEMBLY 12. HEATER COIL
Figure 42. Heater Assembly Removal
42
NOTE: The air conditioner and heater assembly is See Figure 44 for lift truck models
non-repairable, replace as a complete unit. See Parts • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
Manual. GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
1. Remove lock nut from heater valve and switch
(J813)
plate.

(GP/GLP/GDP080, 090, 100, 110, 120VX)
(G813, H813)
1. HEATER RETURN HOSE 7. CAPSCREW

2. HEATER SUPPLY HOSE 8. AC/HEATER UNIT
3. AC HOSES 9. HEATER VALVE
4. HEATER VALVE AND SWITCH PLATE 10. AC ROCKER SWITCH
5. LOCKNUT 11. HEATER COIL
6. MOUNTING BRACKET 12. AC EXPANSION VALVE
Figure 43. Air Conditioner/Heater Unit Assembly Removal, Lift Truck Models GLP/GDP40VX5/VX6; GLP/
GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813)
43
2. Disconnect heater switch connector from heater 5. Disconnect supply hose at heater valve and dis-
switch plate. connect return hose from heater coil.
3. Remove four screws from heater valve and switch See Figure 43 for lift truck models
plate and remove plate. • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
4. Disconnect AC rocker switch.
(GP/GLP/GDP080, 090, 100, 110, 120VX)
See Figure 43 for lift truck models (G813, H813)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, See Figure 44 for lift truck models
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(G813, H813)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
See Figure 44 for lift truck models (J813)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(J813)
1. SCREW 7. AC HOSES
2. AC ROCKER SWITCH 8. HEATER SUPPLY HOSE
3. HEATER VALVE 9. HEATER RETURN HOSE
4. LOCKNUT 10. HEATER COIL
5. SWITCH PLATE 11. AC EXPANSION VALVE
6. AC/ HEATER UNIT 12. MOUNTING BRACKET
Figure 44. Air Conditioner/Heater Unit Assembly Removal, Lift Truck Models GLP/GDP40VX5/VX6; GLP/
GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
44
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GP/GLP/GDP80VX, GP/GLP/GDP90VX, GP/GLPGDP100VX, GP/GLP/

GDP110VX, GP/GLP/GDP120VX (G813)

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

©2013 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];

Cooling System Checks

Flushing the Cooling System

4. Drain water from radiator. If water is dirty, fill sys-

method uses water pressure to force water through

7. Fill cooling system with ethylene glycol boron-free

1. Turn OFF truck. 4. Disconnect the positive battery cable.

2. Remove the hood and seat combination.

GC/GLC120SVX; GC/GLC120VXPRS) (E818,

• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/

Legend for Figure 1

Legend for Figure 2

Legend for Figure 3

Legend for Figure 4

Legend for Figure 5

1. RADIATOR 16. CLAMP

1. LOWER HOSE 13. ISOLATOR

1. RADIATOR 11. TRANSMISSION COOLER RETURN LINE

14. Place radiator guard shield between radiator and

1. RADIATOR 11. CAPSCREW

Legend for Figure 10

Figure 10. Radiator Removal for Lift Truck Models

1. RADIATOR 16. CLAMP

See Figure 14 for lift truck models below equipped

See Figure 15 for lift truck models equipped with

17. Remove radiator guard shield.

18. Let coolant cool to ambient temperature. Place a

19. Open drain plug or loosen clamp and disconnect

1. RADIATOR 16. CLAMP

1. BAFFLE 10. CAPSCREW

Legend for Figure 15

RADIATOR, INSTALL FOR LIFT 7. Remove radiator guard shield.

4. Place a radiator guard shield between radiator and

16. Fill cooling system with ethylene glycol boron-free

See Figure 16 or Figure 17, for lift truck models

See Figure 18, for lift truck models

1. RESERVOIR 3. FULL MARK

6. Install fan, fan spacer, and pulley.

7. Remove radiator guard shield.

8. Install the radiator shroud on radiator using screws

9. If equipped, connect the electrical connector to the

NOTE: For Mazda LPG engine, the LPG converter

10. Uncap radiator and reservoir ports and install the

11. Connect the reservoir hose from reservoir to the

12. Install new O-rings on oil cooler connectors. See

23. Start and run engine until thermostat opens. (The

7. Install fan. See Fan Installation procedures.

8. Align shroud to radiator and install two capscrews,

9. If necessary, connect electrical connector onto the

16. Connect negative battery cable.

17. Fill cooling system with ethylene glycol boron-free

18. Install radiator cap.

Legend for Figure 23

26. Check coolant level at the auxiliary coolant reser-