Yale c878 gdp60 vx lift truck service repair manual

GLP/GDP60VX, GLP/GDP70VX (C878)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14
FRAME............................................................................................................................ 524288879 0100 YRM 1321 08/12
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
THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... 524288194 1300 YRM 1317 03/13
TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... 524294873 1300 YRM 1343 03/14
DRIVE AXLE WET BRAKE (SPICER)............................................................................ 524296605 1400 YRM 1344 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 A513, A514, A613, A614, B513, B514)..................... 524294878 2100 YRM 1328 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
DIAGRAMS..................................................................................................................... 524223779 8000 YRM 1152 04/14
CAPACITIES AND SPECIFICATIONS........................................................................... 524288212 8000 YRM 1320 12/12
PERIODIC MAINTENANCE............................................................................................ 524288887 8000 YRM 1322 01/14
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. 524288874 (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
0100 YRM 1290 General
1

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.
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.
See Figure 3 for lift truck models
• 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)
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 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.
4. Remove radiator cover to access radiator cap.
Remove radiator cap. See Figure 5.
1. LATCH
2. HINGE
3. REAR DOOR
Figure 2. Rear Door and Latch for Lift Truck
Models GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX, GLP/GDP030VX (C810)
Cab Replacement 0100 YRM 1290
2

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
2. RELEASE 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)
Figure 4. Air Filter Hose Removal
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
0100 YRM 1290 Cab Replacement
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

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.
5. Disconnect and cap heater hoses from engine.
See Figure 6.
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.
6. Contact a certified air conditioning specialist to
have the refrigerant extracted from the air condi-
tioning 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) (G813, H813, J813) with a
Cummins QSB 3.3L or a Kubota diesel engine.
7. If lift truck cab is equipped with an air conditioner/
heater unit, disconnect AC refrigerant hoses from
refrigerant compressor.
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(G813)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(H813, J813)
NOTE: Removing door assemblies requires two peo-
ple.
8. Open left side door, remove lock nut, and discon-
nect 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. For lift truck models GLP/GDP16VX, GLP/
(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 con-
nection. See Figure 11.
b. For lift truck models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875), open
right side door and remove radiator cover to
access quick disconnect fittings. Push buttons
heater hoses from heater assembly (see Fig-
ure 6). Disconnect heater wire harness con-
nection. 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 discon-
nect heater hoses from heater assembly and
disconnect heater wire harness connection.
See Figure 11.
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/
(C810)
B. LIFT TRUCK MODELS GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875)
C. LIFT TRUCK MODELS GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875)
D. LIFT TRUCK MODELS GLP/GDP40VX5/VX6;
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (F813, G813)
E. LIFT TRUCK MODELS GLP/GDP40VX5/VX6;
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (H813, J813)
1. QUICK DISCONNECT FITTING
2. INNER REAR COVER
3. RADIATOR COVER
4. RIGHT SIDE DOOR ASSEMBLY
5. HEATER HOSES
7

1. HOSE FITTING
2. REFRIGERANT COMPRESSOR
3. AC/HEATER UNIT
4. ENGINE
Figure 7. AC Refrigerant Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) 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
2. REFRIGERANT COMPRESSOR
3. AC/HEATER UNIT
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 SHOWN.
1. GAS SPRING
2. CAB MOUNTING BRACKET
3. LOCK NUT
Figure 9. Gas Spring Mounting Removal
Figure 10. Door Removal
Legend for Figure 10
NOTE: RIGHT SIDE DOOR HINGE SHOWN.
1. HINGE PIN
2. DOOR HINGE
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
10

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, dis-
connect AC hoses.
a. Remove six fasteners and remove rear cover.
(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.
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
(GP/GLP/GDP080, 090, 100, 110,
120VX) (J813)
c. Disconnect air conditioner wire harness.
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
(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/GDP16VX, GLP/GDP18VX, GLP/
GDP040-070VX) (B875, C875)
11

A. FRONT VIEW B. TOP VIEW
1. HOSE WRAP
2. FASTENERS
3. REAR COVER
4. AIR CONDITIONER HOSES
5. BULKHEAD BRACKET
6. RECEIVER/DRIER
7. FITTINGS
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

1. HOSE WRAP
2. FASTENERS
3. REAR COVER
5. BULKHEAD BRACKET
6. RECEIVER/DRIER
7. FITTINGS
GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) With a
Kubota Diesel Engine
13

1. HOSE WRAP
2. FASTENERS
3. REAR COVER
5. BULKHEAD BRACKET
6. RECEIVER/DRIER
7. FITTINGS
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
2. FRONT WIPER MOTOR COVER
3. DASH ASSEMBLY
4. KICK PANEL
5. COWL PANEL
6. FRONT OPERATOR CAB LEGS
7. LOCK NUT
8. FLANGE BOLT
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (F813, G813), remove two lock nuts from
front wiper motor cover. Remove front wiper mo-
tor cover. See Figure 15.
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.
17. Remove five capscrews from top of dash assem-
bly 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

Figure 16. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
17

NOTE: CAB REMOVED FOR CLARITY.
A. GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX, GLP/GDP030VX (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
2. KICK PANEL
3. SEAL PLATE ASSEMBLY
4. SEAL
5. FLOOR PLATE (LEFT SIDE)
6. FLOOR PLATE (RIGHT SIDE)
7. FLOOR PLATE
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,
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 Fig-
ure 18.
26. Remove rear panels, front panels, and fender
covers to access cab mounting capscrews and
flange nuts. 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 HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT-HAND
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 (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)
3. LIGHT HARNESS CONNECTOR (TO VSM)
4. HARNESS CONNECTOR (TO RIGHT-HAND
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 SIDE DOOR REMOVED FOR
CLARITY.
1. REAR PANEL (LPG)
2. REAR PANEL (GAS AND DIESEL)
3. FRONT PANEL
4. FENDER COVER
5. SCREWS
6. CAPSCREWS
Figure 19. Front and Rear Panels and Fender
Cover Removal
19

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
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.
Figure 21. Lift Strap Connection
20

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,
GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813, J813)
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 20.
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 panel, 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 Sys-
tems Manager (VSM) and right-hand chassis har-
ness. See Figure 17.
NOTE: Perform Step 7 and Step 8 for lift truck mod-
els GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (J813) equipped with Diesel
Particulate Filter (DPF).
7. Connect light harness connector to Vehicle Sys-
tems Manager (VSM) and right-hand chassis har-
ness. 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.
10. Install seal plate assembly to lift truck frame and
tighten capscrews. See Figure 16.
11. Install floor plate and floor mat. Tighten cap-
screws 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 oper-
ator cab legs. See Figure 15.
14. Install dash assembly onto kick panel and install
five capscrews to secure dash assembly to cowl
panel.
15. Install and clip front wiper motor cover for lift truck
models
• GLP/GDP16VX, GLP/GDP18VX, GLP/
GDP040-070VX) (B875, C875)
16. Install front wiper motor cover and tighten two
lock nuts for lift truck models GLP/GDP40VX5/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (F813, G813).
17. Install front wiper motor cover and tighten three
lock nuts for lift truck models GLP/GDP40VX5/
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 pins. See Fig-
ure 10.
19. Connect gas spring and lock nut to cab mounting
bracket. See Figure 9.
20. Connect heater hoses to heater assembly and
connect heater wire harness connection. See Fig-
ure 6 and Figure 11.
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.
21

GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (H813, J813) with a Kubota engine and
equipped with an air conditioner/heater unit, con-
nect 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 20 to 27 N•m (177 to
239 lbf in). See Figure 13.
23. Install left side door onto cab by lifting door up
and over top and bottom hinge pins. See Fig-
ure 10.
24. Connect gas spring and lock nut to cab mounting
bracket. See Figure 9.
25. Uncap and connect heater hoses at engine. See
Figure 6.
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (G813, H813, J813) with a Cummins QSB
3.3L or a Kubota diesel engine and equipped with
an air conditioner/heater unit, connect AC refriger-
ant hoses to refrigerant compressor.
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(G813)
See Figure 8 for lift models
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(H813, J813)
27. Check coolant level, fill if necessary.
28. Install radiator cap and radiator cover. See Fig-
ure 5.
29. Connect air filter hose onto rear left corner leg of
cab frame. Tighten capscrews to
66 N•m (49 lbf ft). See Figure 4.
30. Connect battery and close hood.
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.
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.
32. Contact a certified air conditioning specialist to
have the refrigerant refilled into air conditioning
system.
33. On lift trucks equipped with an air conditioner/
heater unit, start engine and turn on heater to ON
position, run engine approximately 1 to 2 minutes
or until heater supply hose is fully purged.
NOTE: The EZ Tank Bracket used on these trucks to
mount LPG tank onto counterweight comes in two
styles. One style of bracket swings out to side of truck
and other swings out to side and drops down.
34. Lift trucks equipped with a LPG engine, swing EZ
Tank Bracket back to its original and locked posi-
tion.
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)
NOTE: Removing door assemblies from operators
cab requires two people.
1. Open right side door and remove hair pin from rod
pin. See Figure 22.
2. Remove rod pin and spacers from link.
3. Remove right side door from cab frame by lifting
door up and over hinge pin and set door aside.
See Figure 23.
4. Repeat Step 1 through Step 3 for removal of left
side door.
5. Remove front floor mat and floor plate. See Fig-
ure 24.
6. Disconnect battery.
22

NOTE: RIGHT SIDE DOOR SHOWN
1. ROD PIN
2. SPACERS
3. HAIR PIN
4. DOOR ASSEMBLY
Figure 22. Door Link Removal
NOTE: RIGHT SIDE DOOR HINGE SHOWN
1. HINGE PIN
2. DOOR HINGE
Figure 23. Door Removal
23

1. DASH ASSEMBLY
2. KICK PANEL
3. SEAL PLATE ASSEMBLY
4. FRONT FLOOR MAT
5. REAR FLOOR MAT
6. FLANGE BOLT
7. REAR FLOOR PLATE
8. FRONT FLOOR PLATE
9. MODULE
Figure 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. RIGHT SIDE REAR COVER
2. RIGHT SIDE FRONT COVER
3. SCREWS
4. REAR FLOOR PLATE
5. FRONT FLOOR PLATE
6. CLIP NUTS
Figure 25. Side Cover Removal
8. Remove two screws holding right side front cover
to frame. Remove right side rear cover.
9. Remove two screws securing right side front
cover to front overhead guard leg. Remove right
side front cover.
10. Repeat Step 7 through Step 9 to remove left side
covers.
NOTE: Perform Step 11 for early model GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878).
11. Remove two lock nuts from front wiper motor
cover. Remove front wiper motor cover. See Fig-
ure 26.
1. CAPSCREWS
3. DASH ASSEMBLY
4. KICK PANEL
5. COWL PANEL
6. FRONT OPERATORS CAB LEGS
7. LOCK NUT
8. FLANGE BOLT
Figure 26. Dash Removal, Early Model GLP/
GP/GLP/GDP155VX) (C878, D878) Lift Trucks
NOTE: Perform Step 12 on later model lift trucks
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909)
12. Remove three lock nuts from front wiper motor
cover. Remove front wiper motor cover. See Fig-
ure 27.
25

1. CAPSCREWS
3. DASH ASSEMBLY
4. KICK PANEL
5. COWL PANEL
6. FRONT OPERATORS CAB LEGS
7. LOCK NUT
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-
bly and cowl panel.
14. Unclip dash assembly from kick panel. Remove
dash assembly.
15. Remove kick panel from seal plate assembly. See
Figure 24.
16. Remove two flange bolts securing cowl panel to
See Figure 26 for early model GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878) lift trucks.
See Figure 27 for later model lift trucks
D878, E878)
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
side front operator cab leg that are connected to
Vehicle System Manager (VSM) and right-hand
chassis harness connectors. See Figure 29.
19. Disconnect Diesel Particulate Filter (DPF) display
ure 29.
20. Remove four flange bolts securing right and left
side of front operator cab legs to module. See
Figure 30.
21. From inside cab, remove six flange bolts securing
right and left side rear operator cab legs to mod-
ule.
22. Open right side hood door and remove both wiper
motor washer tubes from t-fitting and disconnect
washer pump harness connector from washer
fluid reservoir.
23. Disconnect rear grab handle horn button connec-
tor from right hand chassis harness.
24. Remove bottom flange bolt securing right side
rear operator cab leg to module.
25. Open left side hood door and remove bottom
flange bolt securing rear left side operator cab leg
to module.
1. VSM
2. HARNESS CONNECTOR (TO VSM)
3. HARNESS CONNECTOR (TO RIGHT HAND
CHASSIS HARNESS)
Figure 28. Light Harness Connection to Vehicle
System Manager (VSM) for Lift Truck Models GLP/
GP/GLP/GDP155VX) (C878, D878) and GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909)
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/
(B909)
Figure 30. Front and Rear Cab Mounting
28

NOTE: RIGHT SIDE SHOWN. WIPER COVER AND
ASSEMBLY FOR EARLY MODEL GLP/GDP60VX,
GDP155VX) (C878, D878) LIFT TRUCKS SHOWN.
THE FRONT AND REAR CAB MOUNTING IS SAME
FOR LATER MODEL GLP/GDP60VX, GLP/
GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878) LIFT TRUCKS AND
ON GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909) LIFT TRUCK MOD-
ELS.
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).
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
still attached.
INSTALL, FOR LIFT TRUCK MODELS
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
D878, E878), GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
Figure 31. Lift Strap Connection
29

2. Carefully lift operator cab onto lift truck frame
making sure that front and rear leg mounting
holes are aligned with module mounting holes.
3. Open left side hood door and install bottom flange
bolt to secure rear left side operator cab leg to
module. Tighten flange bolt to
165 N•m (122 lbf ft). See Figure 30.
4. Open right side hood door and install bottom
flange bolt to secure rear right side operator cab
leg to module. Tighten flange bolt to
165 N•m (122 lbf ft).
5. Connect rear grab handle horn button harness
connector to right hand chassis harness.
6. Connect both wiper motor washer tubes to t-fitting
and connect washer pump harness connector to
washer fluid reservoir.
7. Install two flange bolts to secure right and left side
front operator cab legs to module. Tighten flange
bolt to 165 N•m (122 lbf ft).
8. From inside cab, install four remaining flange
bolts to right and left side rear operator cab legs
to module. Tighten flange bolt to
165 N•m (122 lbf ft).
9. Connect three harness connectors on front right
side operator cab leg to Vehicle System Manager
(VSM) and right hand chassis harness. See Fig-
ure 28.
NOTE: Perform Step 10 and Step 11 for lift truck
models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
(B909) equipped with Diesel Particulate Filter (DPF).
10. Connect three harness connectors on front right
side operator cab leg to Vehicle System Manager
(VSM) and right-hand chassis harness. See Fig-
ure 29.
11. Connect Diesel Particulate Filter (DPF) display
ure 29.
12. Install two flange bolts to secure cowl panel to
See Figure 26 for early model GLP/GDP60VX,
GDP155VX) (C878, D878) lift trucks.
See Figure 27 for later model lift trucks
D878, E878)
GDP175VX36, GLP/GDP190VX) (A909,
B909)
13. Install kick panel to seal plate assembly. See Fig-
ure 24.
14. Install and clip dash assembly onto kick panel.
See Figure 26.
15. Install five capscrews to top of dash assembly to
secure dash assembly onto cowl panel. Tighten
capscrew to 3.5 N•m (30 lbf in).
NOTE: Perform Step 16 on early model GLP/
GP/GLP/GDP155VX) (C878, D878) lift trucks.
16. Install front wiper motor cover using two lock nuts.
See Figure 26.
NOTE: Perform Step 17 on later model lift trucks
D878, E878)
GDP175VX36, GLP/GDP190VX) (A909, B909)
17. Install front wiper motor cover using three lock
nuts. See Figure 27.
18. Install right side front cover to front overhead
guard leg using two screws. See Figure 25.
19. Install right side rear cover to right side front cover
and install and tighten two screws to frame.
20. Align right side rear cover to rear overhead guard
leg and install and tighten two screws to rear
overhead guard leg and install and tighten two
screws to rear overhead guard leg.
21. Repeat Step 18 through Step 20 to install left side
covers.
22. Connect battery.
23. Install front floor plate and floor mat. See Fig-
ure 24.
30

NOTE: Installing door assemblies onto operator cab
requires two people.
24. Lift door up and over top and bottom hinge pins.
See Figure 23.
25. Align link and spacers into guide and install rod
pin. See Figure 22.
26. Install hair pin into rod pin.
27. Repeat steps Step 24 through Step 26 for installa-
tion of left side door.
Door Assemblies
RIGHT SIDE DOOR ASSEMBLY, LIFT
TRUCK MODELS GLP/GDP16VX, GLP/
GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/
GDP040SVX) (C810); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875);
AND GLP/GDP40VX5/VX6, GLP/
GDP45SVX5, GLP/GDP45VX6, GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813, J813)
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 Figure 32.
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 side door assembly requires
two people.
2. Disconnect heater hose quick disconnect fittings.
See Figure 33.
a. For lift truck models GLP/GDP16VX, GLP/
GDP18VX, GLP/GDP20SVX (GP/GLP/
GDP030VX, GP/GLP/GDP035VX, GP/GLP/
GDP040SVX) (C810), open right side door and
push buttons on quick disconnect fittings to dis-
connect heater hoses from heater assembly
hoses. See Figure 33. Disconnect heater wire
harness connection. See Figure 34.
b. For lift truck models GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875, C875), open
right side door and remove radiator cover to
access quick disconnect fittings. Push buttons
heater hoses from heater assembly hoses. See
Figure 33. Disconnect heater wire harness
connection. See Figure 34.
c. For lift truck models GLP/GDP40VX5/VX6,
GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813, J813) equip-
ped with a heater unit, open right side door and
locate two port holes on inner rear cover. Push
buttons on quick disconnect fittings to discon-
nect heater hoses from heater assembly. See
Figure 33. Disconnect heater wire harness
connection. See Figure 34.
0100 YRM 1290 Door Assemblies
31

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
Door Assemblies 0100 YRM 1290
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
2. INNER REAR COVER
3. RADIATOR COVER
4. RIGHT SIDE DOOR ASSEMBLY
5. HEATER HOSES
Figure 33. Heater Hose Connection
0100 YRM 1290 Door Assemblies
33

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