GDP170VX, GDP175VX36, GDP190VX (A909) SERVICE MANUAL CONTENTS SECTION OPERATOR'S CAB................. CAB............................. ........................ ....................... ....................... ....................... ....................... ........................ ................. ..... FRAME................ FRAME........................... ....................... ....................... ....................... ........................ ....................... ....................... ....................... ....................... ................ .... GM ENGINES 5.7 LITER V-8 LPG................... LPG............................... ........................ ....................... ....................... ....................... ............... .... COOLING SYSTEM............... SYSTEM........................... ....................... ....................... ........................ ....................... ....................... ....................... ................... ........ LPG FUEL SYSTEM GM 5.7L ENGINE............... ENGINE.......................... ....................... ........................ ....................... ....................... ............ THREE-SPEED THREE-SPEED POWERSHIFT TRANSMISSION TRANSMISSION REPAIR............. REPAIR........................ ....................... ................... ....... DRIVE AXLE WET BRAKE BRAKE (SPICER)............... (SPICER).......................... ....................... ........................ ....................... ....................... ............... ... STEERING AXLE.................. AXLE.............................. ....................... ....................... ....................... ....................... ........................ ....................... .................... ......... BRAKE SYSTEM............... SYSTEM........................... ....................... ....................... ........................ ....................... ....................... ....................... ....................... ............ HYDRAULIC HYDRAULIC GEAR PUMP.................. PUMP............................. ....................... ....................... ....................... ....................... ....................... .................. ...... HYDRAULIC HYDRAULIC CLEANLINESS CLEANLINESS PROCEDURES........ PROCEDURES................... ....................... ....................... ....................... ..................... ......... MAIN CONTROL VALVE............... VALVE........................... ....................... ....................... ....................... ....................... ........................ ....................... ........... CYLINDER REPAIR (MAST S/N A513, A514, A514, A613, A614, B513, B513, B514)............ B514)..................... ......... HIGH VOLTAGE SWITCH (HVS) IGNITION............. IGNITION......................... ....................... ....................... ....................... .................. ....... WIRE HARNESS REPAIR............ REPAIR........................ ....................... ....................... ........................ ....................... ....................... ....................... ............. USER INTERFACE.......... INTERFACE...................... ....................... ....................... ....................... ....................... ........................ ....................... ....................... ................ USER INTERFACE.......... INTERFACE...................... ....................... ....................... ....................... ....................... ........................ ....................... ....................... ................ ELECTRICAL ELECTRICAL SYSTEM............... SYSTEM.......................... ....................... ....................... ....................... ........................ ....................... ....................... ................ MAST REPAIR (S/N A513, A513, A514, A613, A614, A643, A643, A644, A683, A684)........... A684)................... ........ METRIC AND INCH (SAE) FASTENERS.......... FASTENERS...................... ....................... ....................... ....................... ....................... ............... ... CALIBRATION CALIBRATION PROCEDURES........ PROCEDURES................... ....................... ........................ ....................... ....................... ....................... .................... ......... PERIODIC MAINTENANCE..... MAINTENANCE................. ....................... ....................... ....................... ....................... ....................... ....................... .................. ...... CAPACITIES CAPACITIES AND SPECIFICATIONS... SPECIFICATIONS............... ........................ ....................... ....................... ....................... ....................... ................ DIAGRAMS AND SCHEMATICS........ SCHEMATICS................... ....................... ....................... ....................... ....................... ....................... ................... ....... DIAGNOSTIC DIAGNOSTIC TROUBLESHOOTING TROUBLESHOOTING MANUAL............. MANUAL......................... ....................... ....................... ....................... .............
PART NUMBER
YRM NUMBER
REV DATE
524306203 524288879 550021072 524223757 550021077 524288194 524296605 524223764 524262279 524223766 550073240 524223767 524294878 524208014 524223769 524223770 524223771 524223772 550000873 524150797 524223780 550000874 550000875 550001092 524221866
0100 YRM 1290 0100 YRM 1321 0600 YRM 1432 0700 YRM 1123 0900 YRM 1433 1300 YRM 1317 1400 YRM 1344 1600 YRM 1133 1800 YRM 1247 1900 YRM 1136 1900 YRM 1620 2000 YRM 1137 2100 YRM 1328 2200 YRM 1097 2200 YRM 1128 2200 YRM 1130 2200 YRM 1131 2200 YRM 1142 4000 YRM 1406 8000 YRM 0231 8000 YRM 1134 8000 YRM 1407 8000 YRM 1408 8000 YRM 1409 9000 YRM 1112
04/14 08/12 07/12 03/13 07/12 03/13 12/13 07/13 03/13 04/14 12/14 04/14 02/14 05/14 12/14 12/14 12/14 04/14 02/14 10/13 12/14 10/14 08/12 04/14 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center . 9000 YRM 1112 ON CD PART NO. 550000865 (12/14)
0100 YRM 1290
General
0100 YRM 1290
General
General The overhead guard is an integral part of operator cab. The operator cab is installed on a platform above main frame members. Step plates on both sides of lift truck provide access to operator cab. The operator
cab is a separate unit and can be removed as a complete unit from module and frame of the lift truck. See Figure 1.
Figure 1. Operator Cab
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Cab Replacement
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Cab Replacement
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Cab Replacement REMOVE, FOR LIFT TRUCK MODELS GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) NOTE: The EZ Tank Bracket used on these trucks to mount LPG tank onto counterweight come in two styles. One style of bracket swings out to side of truck and other swings out to side and drops down. NOTE: On lift trucks equipped with LPG, make sure to release EZ Tank Bracket before opening hood.
WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator is hot and the cap is removed, the pressure is released from the system and the steam and boiling coolant can cause burns. Wait 30 minutes for the engine to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to remove, check, or fix any part of the cooling system. NOTE: Removing radiator cap will help depressurize cooling system. 4.
Remove radiator cover to access radiator cap. Remove radiator cap. See Figure 5.
1. 2.
LATCH HINGE
1. For lift truck models GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810), tilt steering column to UP UP position, slide seat assembly forward, open rear door, and open hood to disconnect battery. battery. See Figure Figure 2. 2. Tilt steering column to UP position, UP position, slide seat assembly forward, open rear sliding window, and open hood to disconnect battery. See Figure 3 for lift truck models •
GLP/ GLP/GD GDP2 P200-35 35VX VX GDP040-070VX) (B875, C875)
(GP/ (GP/GL GLP/ P/
•
GLP/GDP40VX5/VX6; GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)
3. Disconnect air filter hose from rear left corner leg of cab frame. See Figure 4.
WARNING DO NOT disconnect the heater hoses from the engine when the engine is hot or when the cooling system is under pressure, to do so could cause serious injury.
3. REAR DOOR
Figure 2. Rear Door and Latch for Lift Truck Models GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810)
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0100 YRM 1290
Cab Replacement
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/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) WITHOUT AIR CONDITIONING. CONDITIONING. B. LIFT TRUCKS MODELS GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) WITH AIR CONDITIONING. 1. REAR REAR BOTT BOTTOM OM WIND WINDOW OW 2. RELEA LEASE LAT LATCH
3. AC HOSE
Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) Legend for Figure 4 NOTE: AIR FILTER HOSE FOR GLP/GDP40VX5/ 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 AIR FILT FILTER ER HOSE HOSE
Figure 4. Air Filter Hose Removal
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Cab Replacement
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Cab Replacement
0100 YRM 1290
A. GLP/GDP16VX, GLP/GDP16VX, GLP/GDP18VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (GP/GLP/GDP040-070VX) (B875, C875) C. GLP/GDP40VX5/VX6; 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/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
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Cab Replacement
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CAUTION DO NOT allow any fluid to drain when disconnecting the heater hose from the engine. The method will help when purging the system during installation. 5.
Disconnect and cap heater hoses from engine. See Figure 6.
WARNING Replacement, installation installation and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid must be performed by a certified technician. 6.
8. Open left side door, remove lock nut, and disconnect gas spring from cab mounting bracket. See Figure 9. 9. Lift left side door up and over hinge pin and set aside. See Figure 10.
WARNING DO NOT disconnect the heater hoses from the quick disconnect fittings (inside operator cab) or engine when the engine is hot or under pressure, to do so could cause serious injury. 10. Disconnect heater hose quick disconnect fittings. a.
Contact a certified air conditioning specialist to have the refrigerant extracted from the air conditioning system.
NOTE: Step 7 is for lift truck models GLP/ GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) 120VX) (G813, (G813, H813, J813) with a Cummins QSB 3.3L or a Kubota diesel engine. 7.
Cab Replacement
If lift truck cab is equipped with an air conditioner/ heater unit, disconnect AC refrigerant hoses from refrigerant compressor. See Figure 7 for lift truck models •
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)
See Figure 8 for lift truck models •
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 100, 110, 120VX) (H813, J813)
For lift truck models GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810), open right side door and push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly hoses (see Figure 6). Disconnect heater wire harness connection. See Figure 11.
b. For lift truck models models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (GP/GLP/GDP040-070VX) (B875, C875), open right side door and remove radiator cover to access quick disconnect fittings. Push buttons on quick disconnect fittings to disconnect heater hoses from heater assembly (see Figure 6). Disconnect Disconnect heater heater wire harness connection. See Figure 11. c.
For lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813), open right side door and located on inner rear cover there are two port holes (see Figure 6). Push buttons on quick disconnect fittings to disconnect heater hoses fr om om heater heater assembly and disconnect heater wire harness connection. See Figure 11.
NOTE: Removing door assemblies requires two people.
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Cab Replacement
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Cab Replacement
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Figure 6. Heater Hose Connection
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0100 YRM 1290
Cab Replacement
0100 YRM 1290
Cab Replacement
Legend for Figure 6 SHOWN MAY NOT NOT REFLECT ENGINE IN LIFT TRUCK. TRUCK. NOTE: ART NOTE: ART SHOWN NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. LIFT TRUCK MODELS GLP/GDP16VX, GLP/ GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (C810) B. LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (GP/GLP/GDP040-070VX) (B875, C875) C. LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (GP/GLP/GDP040-070VX) (B875, C875)
D. LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) E. LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)
1. QUICK QUICK DISCO DISCONN NNECT ECT FITTI FITTING NG 2. INNE INNER R REAR REAR COVE COVER R 3. RADI RADIAT ATOR OR COVE COVER R
4. RIGH RIGHT T SIDE SIDE DOO DOOR R ASSE ASSEMB MBLY LY 5. HEAT EATER HOSES
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Cab Replacement
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Cab Replacement
0100 YRM 1290
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 1. HOS HOSE FITTING ING 2. REFR REFRIG IGER ERAN ANT T COMP COMPRE RESS SSOR OR
3. AC/H AC/HEA EATE TER R UNIT UNIT 4. ENGINE
Figure 7. AC Refrigerant Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with Cummins QSB 3.3L Engine
8
0100 YRM 1290
Cab Replacement
0100 YRM 1290
Cab Replacement
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. KUBOTA 3.8L DIESEL ENGINE SHOWN, 3.6L DIESEL ENGINE SIMILAR. A. LIFT TRUCK MODELS GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, (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, (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) 1. HOSE FITT ITTING 2. REFR REFRIG IGER ERAN ANT T COMP COMPRE RESS SSOR OR
3. AC/H AC/HEA EATE TER R UNIT UNIT 4. ENGINE
Figure 8. AC Refrigerant Hose Connection, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813) with Kubota Diesel Engine
9
Cab Replacement
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Cab Replacement
0100 YRM 1290
Legend for Figure 10 NOTE: RIGHT SIDE DOOR HINGE SHOWN. 1. 2.
HINGE PIN DOOR HI HINGE
NOTE: RIGHT SIDE DOOR SHOWN. 1. GAS SPRING 2. CAB CAB MOU MOUNT NTIN ING G BRA BRACK CKET ET 3. LOCK NUT Figure 9. Gas Spring Mounting Removal NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 1. HEAT HEATER ER WIRE WIRE HARNE HARNESS SS CONN CONNEC ECTOR TOR 2. REAR REAR GRAB GRAB HANDLE HANDLE HORN HORN BUTTO BUTTON N CONCONNECTOR (TO RIGHT-HAND CHASSIS HARNESS) Figure 11. Heater Wire Harness and Rear Grab Handle Horn Button Connectors
Figure 10. Door Removal
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Cab Replacement
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11. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813, H813, J813) with a Cummins QSB 3.3L or Kubota diesel engine, if lift truck cab is equipped with an air conditioner/heater unit, disconnect AC hoses. a.
Remove six fasteners and remove rear cover.
Cab Replacement
See Figure 14 for lift truck models •
c.
Disconnect air conditioner wire harness. See Figure 12 for lift truck models •
See Figure 12 for lift truck models •
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)
•
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
b. Disconnect air conditioner hoses at bulkhead bracket and at receiver/drier. receiver/drier. See Figure 12 for lift truck models •
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)
See Figure 13 for lift truck models •
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813)
See Figure 14 for lift truck models •
See Figure 14 for lift truck models •
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)
See Figure 13 for lift truck models
See Figure 13 for lift truck models •
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
GLP/ GLP/GD GDP4 P40V 0VX5 X5/V /VX6 X6;; GLP/ GLP/GD GDP4 P45S 5SVX VX5, 5, GLP/GDP45VX6; GLP/GDP45V X6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813)
12. Remove lock nut and disconnect gas spring from cab mounting bracket. See Figure 9. 13. Lift door up and over hinge pin and set aside. See Figure 10. NOTE: Wiper motor cover must be removed before dash assembly can be removed. 14. Unclip and remove front wiper motor cover. See Figure 15 for lift truck models •
GLP/ GLP/GD GDP1 P16V 6VX, X, GLP/ GLP/GD GDP1 P18V 8VX, X, GLP/ GLP/ GDP20SVX, GLP/GDP030VX (C810)
•
GLP/ GLP/GD GDP2 P200-35 35VX VX GDP040-070VX) (B875, C875)
(GP/ (GP/GL GLP/ P/
11
Cab Replacement
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Cab Replacement
0100 YRM 1290
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW
B. TOP VIEW
1. 2. 3. 4.
5. 6. 7. 8.
HOSE WRAP FASTENERS REAR COVER AIR AIR CON CONDI DITI TION ONER ER HOSE HOSES S
BULK BULKHE HEAD AD BRAC BRACKE KET T RECE RECEIV IVER ER/D /DRI RIER ER FITTINGS AIR CONDIT CONDITION IONER ER WIRE WIRE HAR HARNE NESS SS
Figure 12. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) With a Cummins QSB 3.3L Diesel Engine
12
0100 YRM 1290
Cab Replacement
0100 YRM 1290
Cab Replacement
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW
B. TOP VIEW
1. 2. 3. 4.
5. 6. 7. 8.
HOSE WRAP FASTENERS REAR COVER AIR AIR CON CONDI DITI TION ONER ER HOSE HOSES S
BULK BULKHE HEAD AD BRA BRACK CKET ET RECE RECEIV IVER ER/D /DRI RIER ER FITTINGS AIR CONDI CONDITIO TIONE NER R WIRE WIRE HAR HARNES NESS S
Figure 13. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) With a Kubota Diesel Engine
13
Cab Replacement
0100 YRM 1290
Cab Replacement
0100 YRM 1290
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. FRONT VIEW
B. TOP VIEW
1. 2. 3. 4.
5. 6. 7. 8.
HOSE WRAP FASTENERS REAR COVER AIR AIR CON CONDI DITI TION ONER ER HOSE HOSES S
BULK BULKHE HEAD AD BRAC BRACKE KET T RECE RECEIV IVER ER/D /DRI RIER ER FITTINGS AIR CONDIT CONDITION IONER ER WIRE WIRE HAR HARNE NESS SS
Figure 14. AC System Arrangement and Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) With a Kubota Diesel Engine
14
0100 YRM 1290
Cab Replacement
0100 YRM 1290
Cab Replacement
Figure 15. Dash Installation
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Cab Replacement
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Cab Replacement
0100 YRM 1290
Legend for Figure 15 NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. A. GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/ GDP040SVX) (C810) AND GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (GP/GLP/GDP040-070VX) (B875, C875) B. GLP/GDP40VX5/VX6; GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 1. 2. 3. 4.
CAPSCREWS FRON FRONT T WIPE WIPER R MOTO MOTOR R COVE COVER R DAS DASH AS ASSEMBLY MBLY KICK PANEL
15. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813), remove two lock nuts from front wiper motor cover. Remove front wiper motor cover. See Figure 15. 16. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813), remove three lock nuts from front wiper motor cover. Remove front wiper motor cover.
5. 6. 7. 8.
COWL PA PANEL FRON FRONT T OPER OPERAT ATOR OR CAB CAB LEG LEGS S LOCK NUT FLANGE BOLT
17. Remove five capscrews from top of dash assembly and cowl panel. 18. Remove two flange bolts securing cowl panel to front operator cab legs. 19. Unclip dash assembly from kick panel. Remove dash assembly. 20. Remove kick panel from seal plate assembly. See Figure 16.
16
0100 YRM 1290
Cab Replacement
0100 YRM 1290
Cab Replacement
Figure 16. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
17
Cab Replacement
0100 YRM 1290
Cab Replacement
0100 YRM 1290
Legend for Figure 16 NOTE: CAB REMOVED FOR CLARITY. A. GLP/GDP16VX, GLP/GDP16VX, GLP/GDP18VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810) AND GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (GP/GLP/GDP040-070VX) (B875, C875)
B. GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813)
1. 2. 3. 4.
5. FLOO FLOOR R PLA PLATE TE (LEF (LEFT T SIDE SIDE)) 6. FLOO FLOOR R PLAT PLATE E (RIG (RIGHT HT SID SIDE) E) 7. FLOOR PLATE
CAPSCREWS KICK PANEL SEAL SEAL PLAT PLATE E ASSE ASSEMB MBLY LY SEAL
21. Remove capscrews and seal plate assembly from lift truck frame. 22. Disconnect rear grab handle horn button connector from right-hand chassis harness, located in right rear corner leg of cab frame. See Figure 11. 23. Disconnect light harness connector from Vehicle Systems Manager (VSM) and right-hand chassis harness connector. See Figure 17. NOTE: Perform Step 24 and Step 25 for lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (J813) equipped with Diesel Particulate Filter (DPF). 24. Disconnect light harness connector from Vehicle Systems Manager (VSM) and right-hand chassis harness connector. See Figure 18. 25. Disconnect Diesel Particulate Filter (DPF) display harness connector from cowl harness. See Figure 18. 26. Remove rear panels, front panels, and fender covers to access cab mounting capscrews and flange nuts. nuts. See See Figure 19. 27. Remove front and rear cab capscrews and flange nuts from lift truck frame. See Figure 20.
NOTE: KICK PANEL REMOVED FOR CLARITY. 1. VSM 2. LIGHT LIGHT HAR HARNE NESS SS CONN CONNEC ECTOR TOR (TO (TO VSM) VSM) 3. HARNE HARNESS SS CONNE CONNECT CTOR OR (TO (TO RIGHTRIGHT-HAN HAND D CHASSIS HARNESS) Figure 17. Light Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models GLP/ GDP16VX, GLP/GDP18VX, GLP/GDP20SVX, GLP/ GDP030VX (C810), GLP/GDP20- 35VX 35VX (GP /GLP/ GDP040-070VX) (B875, C875) and GLP/GDP40VX5/ GLP/GDP40VX5/ VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813)
18
0100 YRM 1290
Cab Replacement
0100 YRM 1290
Cab Replacement
NOTE: KICK PANEL REMOVED FOR CLARITY. 1. VSM 2. DPF DPF DISPLA DISPLAY Y HARNE HARNESS SS CONN CONNEC ECTOR TOR (TO (TO COWL HARNESS) 3. LIGHT LIGHT HARN HARNES ESS S CONNE CONNECT CTOR OR (TO (TO VSM) VSM) 4. HARNE HARNESS SS CONN CONNECT ECTOR OR (TO (TO RIGHT RIGHT-HA -HAND ND CHASSIS HARNESS) Figure 18. Electrical Harness Connection to Vehicle System Manager (VSM) for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (J813)
NOTE: LEFT CLARITY. 1. 2. 3. 4. 5. 6.
SIDE
DOOR
REMOVED
FOR
REAR REAR PANE PANEL L (LP (LPG) G) REAR REAR PAN PANEL EL (GAS (GAS AND DIESE DIESEL) L) FRONT PA PANEL FENDE NDER COVER SCREWS CAPSCREWS Figure 19. Front and Rear Panels and Fender Cover Removal
19
Cab Replacement
0100 YRM 1290
Cab Replacement
0100 YRM 1290
WARNING Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb). 28. Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 21.
CAUTION Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected and are not damaged. 29. Carefully lift operator cab away from lift truck. Set operator cab in a storage area and place blocks under operator cab to make it stable and prevent damage to parts still attached.
NOTE: ILLUSTRATION FOR REFERENCE PURPOSES ONLY. ACTUAL LIFT TRUCK MAY BE SLIGHTLY DIFFERENT. A. FRONT VIEW B. REAR VIEW 1. CAPSCREWS 2. FLANGE NU NUTS Figure 20. Front and Rear Cab Mounting Figure 21. Lift Strap Connection
20
0100 YRM 1290
Cab Replacement
0100 YRM 1290
INSTALL, FOR LIFT TRUCK MODELS GLP/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810); GLP/ GDP20-35VX (GP/GLP/GDP040-070VX) (B875, C875); AND GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) 1.
2.
Connect a lifting device to a spreader bar or lift strap, that is through door openings at top of operator's cab (under overhead guard structure). Place material that will be a cushion at top of door opening to prevent damage. Operate lifting device just enough to correctly position spreader bar or lifting strap on operator's cab. See Figure 21. Carefully lift operator cab cab onto lift lift truck frame making sure that front and rear leg mounting holes are aligned with frame mounting holes.
3.
Install capscrews and flange nuts to rear operator cab legs. Tighten capscrews to 66 N•m (49 lbf ft). See Figure 20.
4.
Install capscrews and lock nuts to front operator's cab legs. Tighten capscrews to to 66 N•m N•m (49 (49 lbf ft). ft).
5.
Install fender covers, front panel, and and rear panels to frame. See Figure 19. Tighten capscrews to 10.8 N•m (7.96 lbf ft).
6.
Connect light harness connector to Vehicle Systems Manager (VSM) and right-hand right-hand chassis chassis harness. See Figure 17.
NOTE: Perform Step 7 and Step 8 for lift truck models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/ GDP45VX6; GLP/GDP50-55VX GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) equipped with Diesel Particulate Filter (DPF). 7.
Connect light harness connector to Vehicle Systems Manager (VSM) and right-hand chassis harness. See Figure 18.
8.
Connect Diesel Particulate Filter (DPF) harness connector to cowl harness. See Figure 18.
9.
Connect right-hand chassis harness to rear grab handle horn button connector. See Figure 11.
Cab Replacement
11. Install floor plate and floor mat. Tighten capscrews to 10.8 N•m (7.96 lbf ft). 12. Install kick panel onto seal plate assembly. 13. Install two flange bolts securing cowl to front operator cab legs. See Figure 15. 14. Install dash assembly onto kick panel and install five capscrews to secure dash assembly assembly to cowl panel. 15. Install and clip front wiper motor cover for lift truck models •
GLP/ GLP/GD GDP1 P16V 6VX, X, GLP/ GLP/GD GDP1 P18V 8VX, X, GLP/ GLP/ GDP20SVX, GLP/GDP030VX (C810)
•
GLP/ GLP/GD GDP2 P200-35 35VX VX GDP040-070VX) (B875, (B875, C875) C875)
(GP/ (GP/GL GLP/ P/
16. Install front wiper motor cover and tighten two lock nuts for lift truck models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813). 17. Install front wiper motor cover cov er and and tighten tighten three three lock nuts for lift truck models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP45VX6, GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813). 18. Install right side door onto cab by lifting door up and over top and bottom hinge hinge pins. See See Figure 10. 19. Connect gas spring and lock nut to cab mounting bracket. See Figure 9. 20. Connect heater hoses hoses to heater heater assembly and connect heater wire harness connection. See Figure 6 and Figure 11. 21. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with a Cummins QSB 3.3L engine and equipped with an air conditioner/heater unit, connect AC hoses. Tighten AC hose at bulkhead bracket to 29 to 37 N•m (21 to 27 lbf ft) and AC hose to receiver/drier to 15 to 18 N•m (133 to 159 lbf in). See Figure 12.
10. Install seal plate assembly to lift truck frame and tighten capscrews. See Figure 16.
21
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