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GLP/GP/GTP20VX, GLP/GDP/GTP25VXP, GLP/GDP/GTP30VX, GLP/GDP/
GTP35VX (C875)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14
FRAME............................................................................................................................ 550096314 0100 YRM 1672 04/14
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
KUBOTA SPARK IGNITED 2.5L LPG............................................................................ 550096316 0600 YRM 1670 12/14
MAZDA 2.2L ENGINE..................................................................................................... 550096315 0600 YRM 1673 04/14
COOLING SYSTEM........................................................................................................ 550096317 0700 YRM 1674 03/14
LPG FUEL SYSTEM, MAZDA 2.2L ENGINE................................................................. 550096318 0900 YRM 1675 03/14
LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550096321 1300 YRM 1678 04/14
2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... 550096632 1300 YRM 1690 04/14
DRIVE AXLE REPAIR (WET BRAKE)........................................................................... 550096322 1400 YRM 1679 12/14
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 550096323 1400 YRM 1680 04/14
STEERING AXLE............................................................................................................ 550096324 1600 YRM 1681 04/14
BRAKE SYSTEM............................................................................................................ 550096325 1800 YRM 1682 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
HYDRAULIC GEAR PUMPS.......................................................................................... 550096326 1900 YRM 1683 04/14
MAIN CONTROL VALVE................................................................................................ 550096327 2000 YRM 1684 04/14
MAIN CONTROL VALVE WITH VARIABLE DISPLACEMENT PUMP......................... 550096637 2000 YRM 1691 04/14
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.................................................................................................. 550096328 2200 YRM 1685 04/14
ELECTRICAL SYSTEM, MAZDA 2.2L ENGINE............................................................ 550096329 2200 YRM 1686 04/14
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
PERIODIC MAINTENANCE............................................................................................ 550096309 8000 YRM 1687 05/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550096330 8000 YRM 1688 04/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550096331 8000 YRM 1689 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
9000 YRM 1112 ON CD
PART NO. 550096627 (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
Cab Replacement 0100 YRM 1290
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.
See Figure 7 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(G813)
See Figure 8 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(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/
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 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
on quick disconnect fittings to disconnect
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.
0100 YRM 1290 Cab Replacement
5
Figure 6. Heater Hose Connection
Cab Replacement 0100 YRM 1290
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/
GDP18VX, GLP/GDP20SVX, GLP/GDP030VX
(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;
GLP/GDP45SVX5, GLP/GDP45VX6; GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100, 110,
120VX) (F813, G813)
E. LIFT TRUCK MODELS 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
0100 YRM 1290 Cab Replacement
7
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
1. HOSE FITTING
2. REFRIGERANT COMPRESSOR
3. AC/HEATER UNIT
4. ENGINE
Figure 7. AC Refrigerant Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with Cummins QSB
3.3L Engine
Cab Replacement 0100 YRM 1290
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
0100 YRM 1290 Cab Replacement
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
Cab Replacement 0100 YRM 1290
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.
See Figure 12 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
See Figure 13 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
See Figure 14 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
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.
See Figure 12 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
See Figure 13 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
See Figure 14 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (J813)
c. Disconnect air conditioner wire harness.
See Figure 12 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
See Figure 13 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
See Figure 14 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; 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/GDP16VX, GLP/GDP18VX, GLP/
GDP20SVX, GLP/GDP030VX (C810)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875, C875)
0100 YRM 1290 Cab Replacement
11
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
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
Cab Replacement 0100 YRM 1290
12
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
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 13. 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) (H813) With a
Kubota Diesel Engine
0100 YRM 1290 Cab Replacement
13
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
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 14. 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) (J813) With a
Kubota Diesel Engine
Cab Replacement 0100 YRM 1290
14
Figure 15. Dash Installation
0100 YRM 1290 Cab Replacement
15
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) (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
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 mo-
tor 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.
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.
Cab Replacement 0100 YRM 1290
16
Figure 16. Seal Plate Assembly, Kick Panel, and Floor Plate Removal
0100 YRM 1290 Cab Replacement
17
Legend for Figure 16
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)
Cab Replacement 0100 YRM 1290
18
NOTE: KICK PANEL REMOVED FOR CLARITY.
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
0100 YRM 1290 Cab Replacement
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
Cab Replacement 0100 YRM 1290
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,
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813, J813)
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 21.
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/
GDP20SVX, GLP/GDP030VX (C810)
• GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (B875, C875)
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 and tighten three
lock nuts for lift truck models GLP/GDP40VX5/
VX6, GLP/GDP45SVX5, 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 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.
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.
0100 YRM 1290 Cab Replacement
21
22. For lift truck models GLP/GDP40VX5/VX6; GLP/
GDP45SVX5, GLP/GDP45VX6; GLP/
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.
26. 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 and equipped with
an air conditioner/heater unit, connect AC refriger-
ant hoses to refrigerant compressor.
See Figure 7 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(G813)
See Figure 8 for lift models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(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.
Cab Replacement 0100 YRM 1290
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
0100 YRM 1290 Cab Replacement
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
Cab Replacement 0100 YRM 1290
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
2. FRONT WIPER MOTOR COVER
3. DASH ASSEMBLY
4. KICK PANEL
5. COWL PANEL
6. FRONT OPERATORS CAB LEGS
7. LOCK NUT
8. FLANGE BOLT
Figure 26. Dash Removal, Early Model GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878) Lift Trucks
NOTE: Perform Step 12 on later model lift trucks
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909)
12. Remove three lock nuts from front wiper motor
cover. Remove front wiper motor cover. See Fig-
ure 27.
0100 YRM 1290 Cab Replacement
25
1. CAPSCREWS
2. FRONT WIPER MOTOR COVER
3. DASH ASSEMBLY
4. KICK PANEL
5. COWL PANEL
6. FRONT OPERATORS CAB LEGS
7. LOCK NUT
8. FLANGE BOLT
Figure 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
Cab Replacement 0100 YRM 1290
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
front operator cab legs.
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
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909,
B909)
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
harness connector from cowl harness. See Fig-
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.
NOTE: KICK PANEL REMOVED FOR CLARITY.
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/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878) and GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909)
0100 YRM 1290 Cab Replacement
27
NOTE: KICK PANEL REMOVED FOR CLARITY.
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/
GDP135VX, GP/GLP/GDP155VX) (E878) and GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36,GLP/GDP190VX)
(B909)
Figure 30. Front and Rear Cab Mounting
Cab Replacement 0100 YRM 1290
28
Legend for Figure 30
NOTE: RIGHT SIDE SHOWN. WIPER COVER AND
ASSEMBLY FOR EARLY MODEL GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878) LIFT TRUCKS SHOWN.
THE FRONT AND REAR CAB MOUNTING IS 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).
26. 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 31.
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/
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878), GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
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 31.
Figure 31. Lift Strap Connection
0100 YRM 1290 Cab Replacement
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/
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).
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
harness connector from cowl harness. See Fig-
ure 29.
12. Install two flange bolts to secure cowl panel to
front operator cab legs.
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
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909,
B909)
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/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
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
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909)
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.
Cab Replacement 0100 YRM 1290
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
on quick disconnect fittings to disconnect
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,
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/
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
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 32. Radiator Cover and Cap Location
Door Assemblies 0100 YRM 1290
32
NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK.
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
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)
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
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 34. Heater Wire Harness and Rear Grab
Handle Horn Button Connectors
WARNING
Replacement, installation and repairs to air condi-
tioning units that require discharging and/or refill-
ing of the refrigerant fluid must be performed by a
certified technician.
3. Contact a certified air conditioning specialist to
have the refrigerant extracted from air condition-
ing system.
4. 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.
See Figure 35 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
See Figure 36 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
See Figure 37 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
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.
See Figure 35 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
See Figure 36 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
See Figure 37 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (J813)
c. Disconnect air conditioner wire harness.
See Figure 35 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (G813)
Door Assemblies 0100 YRM 1290
34
See Figure 36 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (H813)
See Figure 37 for lift truck models
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110,
120VX) (J813)
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
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 35. 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)
0100 YRM 1290 Door Assemblies
35
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
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 36. 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) (H813)
Door Assemblies 0100 YRM 1290
36
NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY.
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 37. 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) (J813)
0100 YRM 1290 Door Assemblies
37
5. Disconnect gas spring. See Figure 38.
NOTE: RIGHT SIDE DOOR SHOWN.
1. GAS SPRING
2. MOUNTING BRACKET
3. LOCK NUT
Figure 38. Gas Spring Mounting Installation
6. Remove right side door from cab frame by lifting
door up and over hinge pin. See Figure 39.
Disassemble
Door Cover With Heater Unit
1. Remove four screws and washers that attach
handle to door cover. Remove handle and two
handle plates. See Figure 40.
2. Remove fan and heater knobs from knob plate.
Remove four screws that fasten knob plate to
heater valve and switch plate. Remove knob plate
from door cover.
3. Remove two fasteners from top of door cover.
4. Remove five plugs along sides and front of door
cover. Remove two capscrews and washers from
bottom of door cover. Remove door cover from
door frame.
5. Remove prefilter, located on bottom of door
frame.
NOTE: RIGHT SIDE DOOR HINGE SHOWN.
1. HINGE PIN 2. DOOR HINGE
Figure 39. Door Removal
Door Assemblies 0100 YRM 1290
38
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for your reading.
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Yale c875 gdp30 vx lift truck service repair manual

  • 1. GLP/GP/GTP20VX, GLP/GDP/GTP25VXP, GLP/GDP/GTP30VX, GLP/GDP/ GTP35VX (C875) SERVICE MANUAL CONTENTS SECTION PART NUMBER YRM NUMBER REV DATE OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14 FRAME............................................................................................................................ 550096314 0100 YRM 1672 04/14 YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14 KUBOTA SPARK IGNITED 2.5L LPG............................................................................ 550096316 0600 YRM 1670 12/14 MAZDA 2.2L ENGINE..................................................................................................... 550096315 0600 YRM 1673 04/14 COOLING SYSTEM........................................................................................................ 550096317 0700 YRM 1674 03/14 LPG FUEL SYSTEM, MAZDA 2.2L ENGINE................................................................. 550096318 0900 YRM 1675 03/14 LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14 SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550096321 1300 YRM 1678 04/14 2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... 550096632 1300 YRM 1690 04/14 DRIVE AXLE REPAIR (WET BRAKE)........................................................................... 550096322 1400 YRM 1679 12/14 DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 550096323 1400 YRM 1680 04/14 STEERING AXLE............................................................................................................ 550096324 1600 YRM 1681 04/14 BRAKE SYSTEM............................................................................................................ 550096325 1800 YRM 1682 04/14 HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14 HYDRAULIC GEAR PUMPS.......................................................................................... 550096326 1900 YRM 1683 04/14 MAIN CONTROL VALVE................................................................................................ 550096327 2000 YRM 1684 04/14 MAIN CONTROL VALVE WITH VARIABLE DISPLACEMENT PUMP......................... 550096637 2000 YRM 1691 04/14 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.................................................................................................. 550096328 2200 YRM 1685 04/14 ELECTRICAL SYSTEM, MAZDA 2.2L ENGINE............................................................ 550096329 2200 YRM 1686 04/14 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 PERIODIC MAINTENANCE............................................................................................ 550096309 8000 YRM 1687 05/14 CAPACITIES AND SPECIFICATIONS........................................................................... 550096330 8000 YRM 1688 04/14 DIAGRAMS AND SCHEMATICS.................................................................................... 550096331 8000 YRM 1689 04/14 DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14 9000 YRM 1112 ON CD PART NO. 550096627 (12/14)
  • 2. 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
  • 3. 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
  • 4. 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
  • 5. 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 Cab Replacement 0100 YRM 1290 4
  • 6. 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. See Figure 7 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) See Figure 8 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (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/ 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 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 on quick disconnect fittings to disconnect 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. 0100 YRM 1290 Cab Replacement 5
  • 7. Figure 6. Heater Hose Connection Cab Replacement 0100 YRM 1290 6
  • 8. 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/ GDP18VX, GLP/GDP20SVX, GLP/GDP030VX (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; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/ GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) E. LIFT TRUCK MODELS 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 0100 YRM 1290 Cab Replacement 7
  • 9. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 1. HOSE FITTING 2. REFRIGERANT COMPRESSOR 3. AC/HEATER UNIT 4. ENGINE Figure 7. AC Refrigerant Hose Connections, Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) with Cummins QSB 3.3L Engine Cab Replacement 0100 YRM 1290 8
  • 10. 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 0100 YRM 1290 Cab Replacement 9
  • 11. 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 Cab Replacement 0100 YRM 1290 10
  • 12. 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. See Figure 12 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) See Figure 13 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) See Figure 14 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, 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. See Figure 12 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) See Figure 13 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) See Figure 14 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) c. Disconnect air conditioner wire harness. See Figure 12 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) See Figure 13 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) See Figure 14 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; 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/GDP16VX, GLP/GDP18VX, GLP/ GDP20SVX, GLP/GDP030VX (C810) • GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875, C875) 0100 YRM 1290 Cab Replacement 11
  • 13. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 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 Cab Replacement 0100 YRM 1290 12
  • 14. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 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 13. 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) (H813) With a Kubota Diesel Engine 0100 YRM 1290 Cab Replacement 13
  • 15. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 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 14. 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) (J813) With a Kubota Diesel Engine Cab Replacement 0100 YRM 1290 14
  • 16. Figure 15. Dash Installation 0100 YRM 1290 Cab Replacement 15
  • 17. 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) (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 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 mo- tor 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. 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. Cab Replacement 0100 YRM 1290 16
  • 18. Figure 16. Seal Plate Assembly, Kick Panel, and Floor Plate Removal 0100 YRM 1290 Cab Replacement 17
  • 19. Legend for Figure 16 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) Cab Replacement 0100 YRM 1290 18
  • 20. NOTE: KICK PANEL REMOVED FOR CLARITY. 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 0100 YRM 1290 Cab Replacement 19
  • 21. 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 Cab Replacement 0100 YRM 1290 20
  • 22. 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. 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. 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/ GDP20SVX, GLP/GDP030VX (C810) • GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875, C875) 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 and tighten three lock nuts for lift truck models GLP/GDP40VX5/ VX6, GLP/GDP45SVX5, 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 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. 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. 0100 YRM 1290 Cab Replacement 21
  • 23. 22. For lift truck models GLP/GDP40VX5/VX6; GLP/ GDP45SVX5, GLP/GDP45VX6; GLP/ 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. 26. 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 and equipped with an air conditioner/heater unit, connect AC refriger- ant hoses to refrigerant compressor. See Figure 7 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) See Figure 8 for lift models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (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. Cab Replacement 0100 YRM 1290 22
  • 24. 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 0100 YRM 1290 Cab Replacement 23
  • 25. 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 Cab Replacement 0100 YRM 1290 24
  • 26. 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 2. FRONT WIPER MOTOR COVER 3. DASH ASSEMBLY 4. KICK PANEL 5. COWL PANEL 6. FRONT OPERATORS CAB LEGS 7. LOCK NUT 8. FLANGE BOLT Figure 26. Dash Removal, Early Model GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Trucks NOTE: Perform Step 12 on later model lift trucks • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 12. Remove three lock nuts from front wiper motor cover. Remove front wiper motor cover. See Fig- ure 27. 0100 YRM 1290 Cab Replacement 25
  • 27. 1. CAPSCREWS 2. FRONT WIPER MOTOR COVER 3. DASH ASSEMBLY 4. KICK PANEL 5. COWL PANEL 6. FRONT OPERATORS CAB LEGS 7. LOCK NUT 8. FLANGE BOLT Figure 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 Cab Replacement 0100 YRM 1290 26
  • 28. 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 front operator cab legs. 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 • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 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 harness connector from cowl harness. See Fig- 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. NOTE: KICK PANEL REMOVED FOR CLARITY. 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/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909) 0100 YRM 1290 Cab Replacement 27
  • 29. NOTE: KICK PANEL REMOVED FOR CLARITY. 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/ GDP135VX, GP/GLP/GDP155VX) (E878) and GLP/ GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (B909) Figure 30. Front and Rear Cab Mounting Cab Replacement 0100 YRM 1290 28
  • 30. Legend for Figure 30 NOTE: RIGHT SIDE SHOWN. WIPER COVER AND ASSEMBLY FOR EARLY MODEL GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) (C878, D878) LIFT TRUCKS SHOWN. THE FRONT AND REAR CAB MOUNTING IS 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). 26. 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 31. 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/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878), GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/ GDP190VX) (A909, B909) 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 31. Figure 31. Lift Strap Connection 0100 YRM 1290 Cab Replacement 29
  • 31. 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/ 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). 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 harness connector from cowl harness. See Fig- ure 29. 12. Install two flange bolts to secure cowl panel to front operator cab legs. 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 • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 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/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, 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 • GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) • GLP/GDP80VX, GLP/GDP80VX9, GLP/ GDP90VX (GLP/GDP170VX, GLP/ GDP175VX36, GLP/GDP190VX) (A909, B909) 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. Cab Replacement 0100 YRM 1290 30
  • 32. 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 on quick disconnect fittings to disconnect 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, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/ 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
  • 33. 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 32. Radiator Cover and Cap Location Door Assemblies 0100 YRM 1290 32
  • 34. NOTE: ART SHOWN MAY NOT REFLECT ENGINE IN LIFT TRUCK. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 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) 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
  • 35. 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 34. Heater Wire Harness and Rear Grab Handle Horn Button Connectors WARNING Replacement, installation and repairs to air condi- tioning units that require discharging and/or refill- ing of the refrigerant fluid must be performed by a certified technician. 3. Contact a certified air conditioning specialist to have the refrigerant extracted from air condition- ing system. 4. 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. See Figure 35 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) See Figure 36 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) See Figure 37 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, 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. See Figure 35 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) See Figure 36 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) See Figure 37 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) c. Disconnect air conditioner wire harness. See Figure 35 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813) Door Assemblies 0100 YRM 1290 34
  • 36. See Figure 36 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813) See Figure 37 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (J813) NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 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 35. 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) 0100 YRM 1290 Door Assemblies 35
  • 37. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 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 36. 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) (H813) Door Assemblies 0100 YRM 1290 36
  • 38. NOTE: MAJOR COMPONENTS OF CAB HAVE BEEN REMOVED FOR CLARITY. 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 37. 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) (J813) 0100 YRM 1290 Door Assemblies 37
  • 39. 5. Disconnect gas spring. See Figure 38. NOTE: RIGHT SIDE DOOR SHOWN. 1. GAS SPRING 2. MOUNTING BRACKET 3. LOCK NUT Figure 38. Gas Spring Mounting Installation 6. Remove right side door from cab frame by lifting door up and over hinge pin. See Figure 39. Disassemble Door Cover With Heater Unit 1. Remove four screws and washers that attach handle to door cover. Remove handle and two handle plates. See Figure 40. 2. Remove fan and heater knobs from knob plate. Remove four screws that fasten knob plate to heater valve and switch plate. Remove knob plate from door cover. 3. Remove two fasteners from top of door cover. 4. Remove five plugs along sides and front of door cover. Remove two capscrews and washers from bottom of door cover. Remove door cover from door frame. 5. Remove prefilter, located on bottom of door frame. NOTE: RIGHT SIDE DOOR HINGE SHOWN. 1. HINGE PIN 2. DOOR HINGE Figure 39. Door Removal Door Assemblies 0100 YRM 1290 38
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