Yale (d875) glpo070 vx lift truck service repair manual

GP/GLPO/GDP/GTP040VX, GP/GLPO/GDP/GTP050VX, GP/GLPO/GDP/
GTP060VX, GP/GLPO/GDP/GTP070VX (D875)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
OPERATOR'S CAB........................................................................................................ 550108590 0100 YRM 1752 12/14
FRAME............................................................................................................................ 550108889 0100 YRM 1754 12/14
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
KUBOTA SPARK IGNITED 2.5L LPG............................................................................ 550096316 0600 YRM 1670 12/14
PSI 2.4L ENGINE............................................................................................................ 550108890 0600 YRM 1755 12/14
COOLING SYSTEM........................................................................................................ 550108891 0700 YRM 1756 12/14
LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14
FUEL SYSTEM PSI 2.4L................................................................................................ 550108892 0900 YRM 1757 12/14
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550108495 1300 YRM 1740 12/14
2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... 550109083 1300 YRM 1764 12/14
DRIVE AXLE REPAIR (WET BRAKE)........................................................................... 550096322 1400 YRM 1679 12/14
DRIVE AXLE REPAIR - DRY BRAKE............................................................................ 550108893 1400 YRM 1758 12/14
STEERING AXLE............................................................................................................ 550108894 1600 YRM 1759 12/14
BRAKE SYSTEM............................................................................................................ 550108498 1800 YRM 1743 12/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
HYDRAULIC GEAR PUMPS.......................................................................................... 550108499 1900 YRM 1744 12/14
MAIN CONTROL VALVE................................................................................................ 550108500 2000 YRM 1745 12/14
CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 12/14
CYLINDER REPAIR (MAST S/N D515, E509, E564)..................................................... 550100651 2100 YRM 1692 12/14
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.................................................................................................. 550108895 2200 YRM 1760 12/14
ENGINE ELECTRICAL SYSTEM, PSI 2.4L ENGINE..................................................... 550108896 2200 YRM 1761 12/14
MAST REPAIR (S/N F507, F508, F562, F563)............................................................... 550093755 4000 YRM 1669 12/14
MAST REPAIR (S/N D515, E509, E564)........................................................................ 550100656 4000 YRM 1693 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550108507 8000 YRM 1753 12/14
PERIODIC MAINTENANCE............................................................................................ 550108897 8000 YRM 1762 12/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550108898 8000 YRM 1763 12/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
PART NO. 550109093 (12/14)

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
Cab Replacement
REMOVE
NOTE: The LPG tank bracket used to mount the LPG
tank (if equipped) onto the counterweight comes 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 a LPG fuel sys-
tem, move the LPG tank and bracket to side of truck
before opening the hood.
See PSI 2.0L LPG Fuel System 0900YRM1739 for
lift truck models
• GLP/GDP16-18VX, GLP/GDP20SVX (D810)
See for lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with a PSI 2.4L LPG engine
See for lift truck models
0100 YRM 1752 General
1

• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with a Kubota 2.5L LPG en-
gine
1. For lift truck models GLP/GDP16-18VX, GLP/
GDP20SVX (D810), tilt steering column to UP po-
sition, slide seat assembly forward, open rear
door, and open hood to disconnect battery. See
Figure 2.
For lift truck models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875), tilt steering column to UP
position, slide seat assembly forward, open rear
sliding window, and open hood to disconnect bat-
tery. See Figure 3.
1. LATCH
2. HINGE
3. REAR DOOR
Figure 2. Rear Door and Latch, Lift Truck Models
GLP/GDP16-18VX, GLP/GDP20SVX (D810)
A. LIFT TRUCKS WITHOUT AIR CONDITIONING
B. LIFT TRUCKS WITH AIR CONDITIONING
1. REAR BOTTOM WINDOW
2. RELEASE LATCH
3. AC HOSE
Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
Cab Replacement 0100 YRM 1752
2

2. Loosen clamp and disconnect air filter hose from
elbow. Remove bolts, elbow, retainer, and grom-
met from rear left corner leg of cab frame. See
Figure 4.
WARNING
DO NOT disconnect the heater hoses from the en-
gine when the engine is hot or when the cooling
system is under pressure, to do so could cause
serious injury.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator is hot
and the cap is removed, the pressure is released
from the system and the steam and boiling cool-
ant can cause burns. Wait 30 minutes for the en-
gine to cool. Do a touch test by touching the radi-
ator with your hand. If the radiator is still hot to
the touch, wait another 30 minutes before at-
tempting to remove, check, or fix any part of the
cooling system.
NOTE: Removing radiator cap will help depressurize
cooling system.
3. Turn knobs counterclockwise and remove radiator
cover to access radiator cap. Remove radiator
cap. See Figure 5.
NOTE: AIR FILTER HOSE FOR LIFT TRUCK MOD-
ELS GLP/GDP16-18VX, GLP/GDP20SVX (D810)
SHOWN. AIR FILTER HOSE FOR LIFT TRUCK
MODELS GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875) IS SIMILAR.
1. CLAMP
2. AIR FILTER HOSE
3. BOLTS
4. ELBOW
5. RETAINER
6. GROMMET
Figure 4. Air Filter Hose Removal
0100 YRM 1752 Cab Replacement
3

CAUTION
DO NOT allow any fluid to drain when disconnect-
ing the heater hose from the engine. The method
will help when purging the system during installa-
tion.
4. Disconnect and cap heater hoses from engine.
See Figure 7.
WARNING
Replacement, installation and repairs to air condi-
tioning units that require discharging and/or refill-
ing of the refrigeration fluid must be performed by
a certified technician.
NOTE: Perform Step 5 and Step 6 for lift truck mod-
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875).
5. Contact a certified air conditioning specialist to
have the refrigerant extracted from the air condi-
tioning system.
6. If lift truck cab is equipped with an air conditioner/
heater unit, disconnect AC refrigerant hoses from
refrigerant compressor. See Figure 6.
NOTE: Removing door assemblies requires two peo-
ple.
7. Open left side door, remove lock nut and discon-
nect gas spring from cab mounting bracket. See
Figure 8.
8. Lift left side door up and over hinge pin and set
aside. See Figure 9 .
NOTE: RADIATOR COVER FOR LIFT TRUCKS EQUIPPED WITH STEEL DOORS SHOWN. RADIATOR
COVER FOR LIFT TRUCKS EQUIPPED WITH PVC DOORS IS SIMILAR.
A. GLP/GDP16-18VX, GLP/GDP20SVX (D810) LIFT
TRUCKS
B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) LIFT TRUCKS
1. RADIATOR COVER
2. RADIATOR CAP
Figure 5. Radiator Cover and Cap Location
4

NOTE: KUBOTA 2.5L LPG ENGINE SHOWN. OTHER ENGINES ARE SIMILAR.
1. AC REFRIGERANT HOSES
2. REFRIGERANT COMPRESSOR
3. AC/HEATER UNIT
4. ENGINE
5. HOSE WRAP
6. AC WIRE HARNESS
Figure 6. AC Refrigerant Hose and Wire Harness Connections
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.
9. Disconnect heater hose quick disconnect fittings.
a. For lift truck models GLP/GDP16-18VX, GLP/
GDP20SVX (D810), open right side door and
push buttons on quick disconnect fittings to dis-
connect heater hoses from heater assembly
hoses. Disconnect heater wire harness con-
nectors. See Figure 7.
b. For lift truck models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (D875), 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 7). Discon-
nect heater wire harness connections. See Fig-
ure 10.
NOTE: Removing door assemblies requires two peo-
ple.
10. Open right side door, remove lock nut, and dis-
connect gas spring from cab mounting bracket.
See Figure 8.
11. Lift right side door up and over hinge pin and set
aside. See Figure 9 .
NOTE: Wiper motor cover must be removed before
dash assembly can be removed.
12. Unclip and remove front wiper motor cover. See
Figure 11.
5

NOTE: HOSE SLEEVE REMOVED FOR CLARITY
A. OUTSIDE OF LIFT TRUCK, LIFT TRUCK MOD-
ELS GLP/GDP16-18VX, GLP/GDP20SVX (D810)
B. INSIDE OF LIFT TRUCK, LIFT TRUCK MODELS
GLP/GDP16-18VX, GLP/GDP20SVX (D810)
C. LIFT TRUCK MODELS GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (D875)
1. QUICK DISCONNECT FITTING
2. HEATER HOSES
3. INNER REAR COVER
Figure 7. Heater Hose Connection
6

NOTE: RIGHT SIDE DOOR SHOWN.
1. GAS SPRING
2. CAB MOUNTING
BRACKET
3. LOCK NUT
Figure 8. Gas Spring Mounting Removal
NOTE: RIGHT SIDE DOOR HINGE SHOWN.
1. HINGE PIN
2. DOOR HINGE
Figure 9. Door Removal
NOTE: MAJOR COMPONENTS OF CAB OMITTED
FOR CLARITY.
1. HEATER WIRE HARNESS CONNECTOR
2. REAR GRAB HANDLE HORN BUTTON CON-
NECTOR (TO RIGHT CHASSIS HARNESS)
Figure 10. Heater Wire Harness and Rear Grab
Handle Horn Button Connections, Lift Truck
Models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
13. Remove five fasteners securing dash panel to top
of cowl panel. Remove four clips, located under-
neath dash panel, that attach dash panel to the
kick panel. See Figure 11.
14. Remove two capscrews securing cowl panel to
front operator cab legs. See Figure 11.
15. Remove dash assembly from lift truck.
16. Remove floor mat and floor plate.
17. Remove kick panel from seal plate assembly. See
Figure 11.
18. Remove capscrews, clip nuts, and seal plate as-
sembly from lift truck frame. See Figure 11.
19. Disconnect rear grab handle horn button connec-
tor from right-hand chassis harness, located in
right rear corner leg of cab frame. See Figure 12.
7

20. Disconnect light harness connector from Vehicle
Systems Manager (VSM) and right-hand chassis
harness connector. See Figure 12.
21. Remove rear panels, front panels, and fender
covers to access cab mounting capscrews and
flange nuts. See Figure 13.
22. Remove front and rear cab capscrews and flange
nuts from lift truck frame. See Figure 14.
NOTE: DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) SHOWN.
DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) IS SIMI-
LAR.
1. FASTENER
2. CAPSCREW
3. CLIP
4. CLIP NUT
5. FRONT WIPER MOTOR COVER
6. KICK PANEL
7. DASH PANEL
8. SEAL PLATE
9. COWL PANEL
Figure 11. Dash Assembly, Remove/Install
8

NOTE: KICK AND DASH PANELS REMOVED FOR CLARITY.
1. VSM
2. LIGHT HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT CHASSIS
HARNESS)
4. REAR GRAB HANDLE HORN BUTTON CON-
NECTOR
Figure 12. Cab Electrical Connections
WARNING
Make sure that the lifting device has a minimum
capacity to lift 500 kg (1100 lb)
23. 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 15.
CAUTION
Lift the operator cab carefully. Check that all elec-
trical wires and attachments are disconnected
and are not damaged.
24. 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.
9

NOTE: LEFT DOOR REMOVED FOR CLARITY
1. REAR PANEL (LPG)
2. REAR PANEL (DIESEL)
3. FRONT PANEL
4. FENDER COVER
5. SCREWS
6. CAPSCREW
Figure 13. Front and Rear Panels and Fender
Cover Removal
A. FRONT VIEW
B. REAR VIEW
1. CAPSCREWS
2. FLANGE NUTS
Figure 14. Front and Rear Cab Mounting
10

NOTE: ILLUSTRATION FOR REFERENCE PURPO-
SES ONLY. ACTUAL CAB MAY BE SLIGHTLY DIF-
FERENT.
Figure 15. Lift Strap Connection
INSTALL
1. 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 15.
2. Carefully lift operator cab onto 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 14.
4. Install capscrews and lock nuts to front operator's
cab legs. Tighten capscrews to 66 N•m (49 lbf ft).
5. Install fender covers, front and rear panels to
frame. Tighten capscrews to 11 N•m (8 lbf in).
See Figure 13.
6. Connect light harness connector to Vehicle Sys-
tems Manager (VSM) and right-hand chassis har-
ness. See Figure 12.
7. Connect right-hand chassis harness to rear grab
handle horn button connector. See Figure 12.
8. Install seal plate assembly to lift truck frame and
tighten capscrews and clip nuts.
9. Install kick panel onto seal plate assembly. See
Figure 11.
10. Install floor plate and floor mat.
11. Install dash assembly onto kick panel and install
five capscrews to secure dash assembly to cowl
panel. See Figure 11.
12. Install and clip front wiper motor cover.
13. Install right side door onto cab by lifting door up
and over top and bottom hinge pins. See Fig-
ure 9.
14. Connect gas spring and lock nut to cab mounting
bracket. See Figure 8 .
15. If lift truck cab is equipped with an air conditioner/
heater unit, connect AC refrigerant hoses to re-
frigerant compressor. See Figure 6.
16. Connect heater hoses to heater assembly and
connect heater wire harness connection. See Fig-
ure 7.
17. Install left side door onto cab by lifting door up
and over top and bottom hinge pins. See Fig-
ure 9.
18. Connect gas spring and lock nut to cab mounting
bracket. See Figure 8.
19. Uncap and connect heater hoses at engine. See
Figure 7.
20. Check coolant level, fill if necessary. For proce-
dures, see
Cooling System 0700YRM1737 for lift truck mod-
els
11

Cooling System 0700YRM1756 for lift truck mod-
els
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)
21. Install radiator cap and radiator cover. See Fig-
ure 5.
22. Connect air filter hose onto rear left corner leg of
cab frame. Tighten capscrews to
66 N•m (49 lbf ft). See Figure 4.
23. Connect battery and close hood.
24. For lift trucks NOT equipped with an AC/Heater
unit, start engine and turn on heater to ON posi-
tion, run engine approximately one to two minutes
or until heater supply hose is fully purged.
WARNING
NOTE: Step 25 and Step 26 apply only to lift truck
models GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with an air conditioner/heater unit.
have the refrigerant refilled into air conditioning
system.
26. On lift trucks equipped with an air conditioner/
heater unit, start engine and turn on heater to ON
position, run engine approximately one to two mi-
nutes or until heater supply hose is fully purged.
27. If lift truck is equipped with a LPG engine, swing
the LPG tank and bracket back to its original posi-
tion on counterweight and make sure it locks in
position.
See PSI 2.0L LPG Fuel System 0900YRM1739
for lift truck models
See Fuel System PSI 2.4L 0900YRM1757 for lift
truck models
GDP040-070VX) (D875) equipped with a
PSI 2.4L LPG engine
See LPG Fuel System, Kubota 2.5L Engine
0900YRM1677 for lift truck models
GDP040-070VX) (D875) equipped with a
Kubota 2.5L LPG engine
Door Assemblies
RIGHT DOOR ASSEMBLY
Remove
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When radiator cap is re-
moved, the pressure is released from cooling sys-
tem. If cooling system is hot, the steam and boil-
ing 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 the radiator
cap.
NOTE: Removing radiator cap will help depressurize
cooling system.
1. Remove radiator cover to access radiator cap.
Remove radiator cap. See Radiator Cover and
Cap Location.
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.
NOTE: Removing right door assembly requires two
people.
2. Disconnect heater hose quick disconnect fittings.
See Figure 7.
12

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a. For lift truck models GLP/GDP16-18VX, GLP/
GDP20SVX (D810), open right door and push
buttons on quick disconnect fittings to discon-
nect heater hoses from heater assembly ho-
ses. Disconnect heater wire harness connec-
tion. See Figure 7 and Figure 12.
b. For lift truck models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (D875), 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 hoses. Disconnect
heater wire harness connection. See Figure 7
and Figure 12.
WARNING
NOTE: Step 3 through Step 6 apply to lift truck mod-
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with a air conditioner/heater unit.
have the refrigerant extracted from the air condi-
tioning system.
4. Remove fasteners and rear cover. See Figure 5.
5. Disconnect air conditioner hoses at bulkhead
bracket. See Figure 6.
6. Disconnect air conditioner wire harness. See Fig-
ure 6.
7. Disconnect gas spring. See Figure 8.
8. Remove right door from cab frame by lifting door
up and over hinge pin. See Figure 9.
Disassemble
Door Cover With Heater Unit
NOTE: This section removes the right door cover. To
remove the heater unit from right door, see section
Heater and Air Conditioner Replacement.
1. Remove four screws and washers that attach
handle to door cover. Remove handle and two
handle plates. See Figure 16.
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.
See Figure 16.
4. Remove five plugs, washers, and star nuts along
sides and front of door cover. Remove two cap-
screws and washers from bottom of door cover.
Remove door cover from door frame. See Fig-
ure 16.
5. Remove pre-filter, located on bottom of door
frame. See Figure 16.
0100 YRM 1752 Door Assemblies
13

Figure 16. Right Door Cover With Heater Unit
Door Assemblies 0100 YRM 1752
14

Legend for Figure 16
1. PLUG
2. FASTENER
3. GAS SPRING
4. FAN AND HEATER/AC KNOBS
5. SCREW
6. KNOB PLATE
7. HANDLE
8. HANDLE PLATES
9. WASHER
10. HEATER/FAN LOUVER
11. CAPSCREW
12. DOOR COVER
13. PRE-FILTER
14. HEATER VALVE AND SWITCH PLATE
15. STAR NUT
Door Cover With Air Conditioner/Heater Unit
NOTE: This section removes the right door cover. To
remove the air conditioner/heater unit from right door,
see section Heater and Air Conditioner Replacement.
NOTE: The procedures in this section apply only to
lift truck models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875) equipped with an AC/heater
unit.
1. Remove four screws and washers that attach
handle to door cover. Remove handle and two
handle plates. See Figure 16.
2. Remove hose wrap from AC hoses. See Figure 6.
3. Remove fan and heater/AC knobs from knob
plate. Remove four screws that fasten knob plate
to heater valve and switch plate. Remove knob
plate and heater valve from door cover. See Fig-
ure 16.
4. Remove two fasteners from top of door cover.
5. Remove four capscrews that fasten AC rocker
switch plate to door cover. Remove AC rocker
switch plate from door cover. See Figure 17.
6. Remove five plugs, washers, and star nuts along
sides and front of door cover. Remove two cap-
screws and washers from bottom of door cover.
Remove door cover from door frame. See Fig-
ure 16.
7. Remove pre-filter, located on bottom of door
frame. See Figure 16.
1. CAPSCREWS
2. AC ROCKER SWITCH
3. FAN AND HEATER/AC KNOBS
Figure 17. AC Rocker Switch
Door Lock Assembly
1. Remove inside lever handle cover. See Figure 18.
2. Place inside lever handle in closed position. Re-
move lock nut from release bar at inside lever
handle. Pull inside lever handle to open position.
Remove release bar from inside lever handle.
3. Remove two capscrews and inside lever handle
and mounting plate. See Figure 18.
4. Remove lock nut from release bar and release
bar from door lock assembly.
5. Remove two nuts and capscrews from door lock
assembly. Remove door lock assembly from door
frame.
15

A. LEVER IN CLOSED POSITION B. LEVER IN OPEN POSITION
1. INSIDE LEVER HANDLE
2. CAPSCREWS
3. INSIDE LEVER HANDLE COVER
4. CAPSCREW (OUTSIDE HANDLE)
5. LOCK NUT
6. RELEASE BAR
7. DOOR LOCK ASSEMBLY
8. RELEASE LEVER
9. NUT
10. MOUNTING PLATE
11. SCREWS
12. WASHER
Figure 18. Door Lock and Lever Disassembly
1. Remove screw and washer from release lever
and release lever from outside door handle as-
sembly. See Figure 18 and Figure 19.
2. Remove four capscrews that fasten outside door
handle to door. Remove outside door handle from
door.
3. Remove seal and grip from outside handle as-
sembly. Discard seal. See Figure 19.
Door Assemblies 0100 YRM 1752
16

NOTE: RIGHT DOOR SHOWN. LEFT DOOR IS THE
SAME.
1. LATCH STRIKER ASSEMBLY
2. SEAL
3. OUTSIDE HANDLE ASSEMBLY
4. GRIP
Figure 19. Outside Handle Disassembly
Windows
For procedures to remove door windows, see section
Window Replacement.
Clean
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
Check door assembly and parts for oil, grease, dirt,
and other debris. Clean door assembly and parts with
a clean cloth, soap, and water. Compressed air can
be used to dry door assembly and parts.
Inspect
Inspect all hoses for cracks and wear. Replace dam-
aged hoses. Inspect seals around door window and
door lock assembly and replace if damaged. Check
door lock and latch assembly. Make sure it opens,
shuts, and locks door securely and there is no rust,
grease, oil, or dirt on door lock and latch assembly
parts. Inspect windows for cracks or chips. Replace
windows if damaged.
Assemble
Windows
For procedures to install door windows, see section
Window Replacement.
Door Lock Assembly
1. Install new seal and grip to outside handle assem-
bly. See Figure 19.
2. Apply Loctite® 242 to threads of four capscrews
and secure outside door handle to door. See Fig-
ure 18. Tighten capscrews to 19 N•m (170 lbf in).
3. Apply Loctite® 242 to capscrew and install re-
lease lever to rear of outside door handle assem-
bly. Tighten capscrew to 5.0 N•m (44 lbf in).
4. Install door lock assembly onto door frame using
two capscrews and nuts. Tighten capscrews to
19 N•m (170 lbf in). See Figure 18.
5. Install inside lever handle and mounting plate to
door frame. Tighten capscrews to
19 N•m (170 lbf in).
6. Place inside lever handle in closed position (see
Figure 18). Insert release bar into door lock as-
sembly end and into inside lever handle. Secure
release bar with lock nuts.
7. Install cover onto inside lever assembly.
17

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