YALE G813 GDP80VX LIFT TRUCK Service Repair Manual

GP/GLP/GDP80VX, GP/GLP/GDP90VX, GP/GLPGDP100VX, GP/GLP/
GDP110VX, GP/GLP/GDP120VX (G813)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524262274 0100 YRM 1243 05/14
OPERATOR'S CAB........................................................................................................ 524306203 0100 YRM 1290 04/14
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM (GM 4.3L)...................................................................................... 524262275 0900 YRM 1242 08/12
GASOLINE FUEL SYSTEM (GM 4.3L).......................................................................... 524262276 0900 YRM 1244 06/12
LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14
GASOLINE FUEL SYSTEM............................................................................................ 550048401 0900 YRM 1570 09/13
1 AND 2-SPEED POWERSHIFT TRANSMISSION REPAIR......................................... 524223762 1300 YRM 1129 09/09
POWERSHIFT TRANSMISSION REPAIR...................................................................... 550043436 1300 YRM 1529 08/13
DRIVE AXLE - DRY BRAKE........................................................................................... 524262277 1400 YRM 1245 01/12
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR............................................ 524262278 1400 YRM 1246 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 524223772 2200 YRM 1142 04/14
MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706,
A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749,
B750, B751, B752, B753, B754)................................................................................ 524265342 4000 YRM 1250 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 524262280 8000 YRM 1248 04/13
CAPACITIES AND SPECIFICATIONS........................................................................... 524262281 8000 YRM 1249 08/11
DIAGRAMS AND SCHEMATICS.................................................................................... 524329117 8000 YRM 1387 04/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550001092 8000 YRM 1409 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
9000 YRM 1112 ON CD
PART NO. 524329176 (12/14)

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in
damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Discon-
nect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications
of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.

Cooling System Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Cooling System Checks ...................................................................................................................................... 1
Exhaust Leaks Into Cooling System ............................................................................................................... 1
Water Flow Restrictions in Radiator................................................................................................................ 1
Radiator Hoses ............................................................................................................................................... 1
Water Pump .................................................................................................................................................... 1
Flushing the Cooling System............................................................................................................................... 2
Cooling System, Clean.................................................................................................................................... 2
Radiator Replacement......................................................................................................................................... 3
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809);
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910);
GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX
(GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6,
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) .............................................................................................................................. 3
Radiator, Remove for Lift Trucks Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809);
GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
Equipped with Oil Cooler................................................................................................................................. 19
Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879,
E879, F879) .................................................................................................................................................... 21
Radiator, Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) ....................................................... 24
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809);
GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910);
GLC050LX (A967); GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875); GLP/GDP20-25LX
(GLP/GDP050LX) (A974); GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) .............................................................................................................................. 29
Radiator, Install for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809);
GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
Equipped with Oil Cooler................................................................................................................................. 33
Radiator, Install for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879,
E879, F879) .................................................................................................................................................... 34
Radiator, Install for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) ....................................................... 37
Fan Assembly Replacement................................................................................................................................ 47
Fan Removal ................................................................................................................................................... 47
Inspect............................................................................................................................................................. 62
Fan Installation................................................................................................................................................ 62
©2013 Yale Materials Handling Corp. i

Table of Contents Cooling System
TABLE OF CONTENTS (Continued)
This section is for the following models:
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];
GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];
GLC050LX [A967];
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];
GLP/GDP20-25LX (GLP/GDP050LX) [A974];
GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818];
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813];
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
[C879, D879, E879, F879];
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
[C878, D878, E878];
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) [A909, B909]
ii

700 YRM 1123 Cooling System Checks
General
This section contains the repair and replacement in-
structions for the radiator, coolant level sensor, fan
assembly (pusher type), fan shroud, coolant hoses,
coolant recovery bottle, and optional debris screen.
Cooling System Checks
EXHAUST LEAKS INTO COOLING SYSTEM
WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
To check for exhaust leaks into the cooling system, use
a Combustion Leak Test Kit for this purpose. Follow the
manufacturer’s instructions when doing the test.
WATER FLOW RESTRICTIONS IN
RADIATOR
WARNING
To check for water flow restrictions in the radiator, run
engine until it is warm.
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait an-
other 30 minutes before attempting to check or fix
any part of the cooling system.
Shut engine OFF and feel the radiator. The tempera-
ture must be even across the radiator. (The radiator will
be hotter near the top radiator hose.) Cold spots on ra-
diator indicate restrictions.
If radiator has leaks, either replace the radiator or have
it repaired by trained personnel.
RADIATOR HOSES
WARNING
Inspect all radiator hoses. If they feel spongy or have
visible cracks, replace hoses.
WATER PUMP
WARNING
WARNING
ous injury.
Run engine until it is warm. Check the operation of wa-
ter pump by holding the top radiator hose. If the pump
is operating, there will be pressure surges in the hose.
Check for leaks around the timing belt cover near the
base of the oil pump.
Check the weep hole where coolant that leaks past the
water pump seal can be drained before reaching the
water pump bearings. If there is a drip, check the pump
shaft seal and water pump. Replacement of the pump
shaft seal or water pump may be necessary.
For repair procedures for the GM 2.4L water pump, refer
to the section GM Engine Repair, GM 2.4 Liter Engine
600 YRM 1121.
For repair procedures for the Mazda FE and F2 water
pump, refer to the section Mazda Engine, FE and F2
600 YRM 1122.
For replacement procedures for the Yanmar 2.6L and
3.3L water pump, refer to the section Yanmar Diesel
Engines, 2.6L, 3.0L and 3.3L 600 YRM 1205.
1

Flushing the Cooling System 700 YRM 1123
For replacement procedures for the GM 4.3L water
pump, refer to the section GM Engines, 4.3 Liter V-6
600 YRM 1251.
For replacement procedures for the GM 5.7L water
pump, refer to the section GM Engines, 5.7 Liter V-8
LPG 600 YRM 1432.
For replacement procedures for the Kubota water
pump, refer to the section
• Kubota Diesel 3.8L Engines 600 YRM 1557
• Kubota Diesel 3.6L Engine 600 YRM 1579
• Kubota Diesel 3.8L Engines, with Diesel Particu-
late Filter (DPF) 600 YRM 1590
For replacement procedures for the Cummins 4.5L and
QSB 3.3L water pump, contact your local Yale dealer or
see Yale Axcess Online.
Flushing the Cooling System
COOLING SYSTEM, CLEAN
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is away
from all personnel. Wear protective goggles or a
face shield to prevent injury to the eyes.
WARNING
The radiator fins on the radiator are very sharp and
can cause serious injury. Wear gloves while check-
ing the radiator fins.
1. Check radiator fins. Clean exterior of radiator with
compressed air or water as needed.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
WARNING
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
2. Drain cooling system. Fill cooling system with clean
water. See sections below for more information:
• Radiator, Remove for Lift Trucks Mod-
els GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC20-35VX
(GC/GLC040-070VX, GC/GLC055SVX) (A910);
GLC050LX (A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX) (A974);
GLC40, 45, 55VX, GLC55SVX, (GC/GLC080,
100, 120VX, GC/GLC080, 100VXBCS,
GC/GLC120SVX, GC/GLC120VXPRS)
(E818, F818) and GLP/GDP40VX5/VX6,
GLP/GDP45SVX5, GLP/GDP45VX6,
GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100,
110, 120VX) (F813, G813, H813, J813)
• Radiator, Remove for Lift Truck Models S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024,
F024, G024)GLC/GDC60VX, GLC/GDC60VX,
(GC/GLC/GDC135VX, GC/GLC/GDC135VX)
(C879, D879, E879, F879)
• Radiator, Remove for Lift Truck Models
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878) and GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)
3. Install radiator cap. Run engine until top radiator
hose is hot. Stop engine and let engine cool.
4. Drain water from radiator. If water is dirty, fill sys-
tem with water and repeat procedure until water is
clean.
2

700 YRM 1123 Radiator Replacement
CAUTION
Follow the manufacturer’s instructions when using
a chemical radiator cleaner.
5. If water does not clean system, use a chemical ra-
diator cleaner.
CAUTION
Follow the manufacturer’s instructions when using
special equipment to reverse clean the radiator.
6. If radiator or cooling system is very dirty or has
a restriction, use reverse cleaning method. This
method uses water pressure to force water through
radiator in opposite direction of normal flow.
CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
7. Fill cooling system with ethylene glycol boron-free
antifreeze. Purchase a pre-diluted 50/50 solution;
or mix 50 percent concentrate with 50% distilled
or deionized water. The 50/50 mixture will pro-
tect cooling system to 37°C ( 35°F). Add coolant
as necessary to keep level between the ADD and
FULL marks on the reservoir.
Radiator Replacement
RADIATOR, REMOVE FOR LIFT
TRUCKS MODELS GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
WARNING
1. Turn OFF truck.
2. Remove the hood and seat combination.
See Frame 100 YRM 1120 for lift truck models
• GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
(C810)
• GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)
WARNING
Always disconnect the cable at the negative termi-
nal first. Install a tag on the battery terminals so
that no one connects the cables on the terminals.
3. Disconnect the negative battery cable.
4. Disconnect the positive battery cable.
3

Radiator Replacement 700 YRM 1123
WARNING
can cause burns.
5. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capacity
of the cooling system under radiator. Remove radi-
ator cap.
CAUTION
6. Open the drain plug or loosen hose clamp and dis-
connect the lower hose.
7. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from charge air cooler.
See Figure 6.
8. Lift trucks equipped with a Kubota 3.8L diesel en-
gine: Loosen clamps and disconnect transmission
cooler hoses from transmission cooler. See Fig-
ure 8.
9. Once coolant is drained from engine, loosen hose
clamps and disconnect coolant hoses from radiator.
Cap radiator hoses.
10. Loosen hose clamp and disconnect hose from
reservoir and remove reservoir.
See Figure 1 for lift truck models
GC/GLC040SVX (C809
(C810)
(B875)
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
See Figure 2 or Figure 3 for lift truck models
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813)
See Figure 6 for lift truck models below equipped
with a Cummins QSB 3.3L diesel engine
GDP080, 090, 100, 110, 120VX) (G813
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (D879)
with Yanmar 2.6L diesel engine
• GDP20-25LX (GDP050LX) (A974)
with a Kubota 3.8L diesel engine
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)
11. Remove battery and battery tray.
12. If equipped, disconnect electrical connector to the
coolant level sensor.
NOTE: For Mazda LPG engine, the LPG converter
bracket needs to be moved for clearance of radiator.
13. Remove screws and washers from the shroud and
move shroud out of the way.
14. Place radiator guard shield between radiator and
fan so damage to radiator does not occur during
fan removal.
15. Remove fan, fan spacer, and pulley.
16. Remove radiator guard shield.
17. Remove capscrews and upper radiator bracket.
GC/GLC040SVX (C809
(C810)
4

(B875)
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813)
with a Cummins QSB 3.3L diesel engine
GDP080, 090, 100, 110, 120VX) (G813
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (D879)
with Yanmar 2.6L diesel engine
• GDP20-25LX (GDP050LX) (A974)
with a Kubota 3.8L diesel engine
GDP080, 090, 100, 110, 120VX) (H813, J813)
18. Remove radiator from truck.
19. If necessary, remove the coolant level sensor.
5

Figure 1. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) GLC050LX (A967);
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP20-25LX (GLP050LX) (A974)
6

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

Figure 2. Cooling System for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX;
GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818) Before 2011
8

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

Figure 3. Cooling System for Lift Truck Models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX;
GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) After 2011
10

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

Figure 4. Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6,
GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) Before 2011
12

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

Figure 5. Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6,
GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813) After 2011
14

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

1. RADIATOR
2. RADIATOR CAP
3. HARNESS CLIP
5. INSERT
6. ISOLATOR
7. CAPSCREW
8. CLAMP
9. TUBE
10. UPPER HOSE
11. CLAMP
12. CHARGE AIR COOLER HOSE
13. CLAMP
15. SHROUD
16. CLAMP
18. SCREW
19. WASHER
20. CLIP
21. LOWER HOSE
22. RESERVOIR
23. BUSHING
24. RESERVOIR CAP
26. HOSE
27. TUBE
29. SEAL
Figure 6. Cummins 3.3L Cooling System With Charge Air Cooler for GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)
16

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

1. RADIATOR
2. RADIATOR CAP
4. ISOLATOR
5. CAPSCREW
6. INSERT
7. CLAMP
8. TUBE
9. UPPER HOSE
10. LOWER HOSE
11. TRANSMISSION COOLER RETURN LINE
12. TRANSMISSION COOLER SUPPLY LINE
13. SCREW
14. WASHER
15. SHROUD
16. RESERVOIR
17. BUSHING
18. RESERVOIR CAP
Figure 8. Kubota 3.8L Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)
18

RADIATOR, REMOVE FOR LIFT TRUCKS
MODELS GC/GLC030VX, GC/GLC035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) EQUIPPED
WITH OIL COOLER
WARNING
1. Turn OFF truck.
2. Remove the hood and seat combination.
See section Frame 100 YRM 1120 for lift truck mod-
els
GC/GLC040SVX (C809)
(C810)
els
• GLC050LX (A967)
WARNING
WARNING
can cause burns.
of the cooling system under radiator. Remove radi-
ator cap.
CAUTION
6. Open the drain plug or loosen hose clamp and dis-
connect the lower hose.
7. Loosen clamps and disconnect oil cooler hoses
from oil cooler adapters. See Figure 9.
8. Remove oil cooler adapters and O-rings from radi-
ator. Discard O-rings. See Figure 9.
clamps and disconnect coolant hoses from radiator.
Cap radiator hoses.
10. Loosen hose clamp and disconnect hose from
reservoir and remove reservoir. See Figure 9.
11. Remove battery and battery tray.
12. If equipped, disconnect electrical connector to the
bracket needs to be moved for clearance of radiator.
13. Remove screws and washers from the shroud and
move shroud out of the way.
14. Place radiator guard shield between radiator and
fan so damage to radiator does not occur during
fan removal.
15. Remove fan, fan spacer, and pulley.
17. Remove capscrews and upper radiator bracket.
See Figure 9.
18. Remove radiator from truck.
19. If necessary, remove the coolant level sensor.
19

1. RADIATOR
2. CAP
3. UPPER HOSE
4. LOWER HOSE
5. CLAMP
6. SHROUD
7. O-RING
8. OIL COOLER ADAPTER
9. OIL COOLER HOSE
11. CAPSCREW
12. INSERT
13. ISOLATOR
14. RESERVOIR
15. TUBE
16. OUTLET ASSEMBLY
17. HOSE
19. CAP
20. BUSHING
Figure 9. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974)
20

RADIATOR, REMOVE FOR LIFT TRUCK
MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024, G024)GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879)
WARNING
1. Turn off truck.
WARNING
4. Remove radiator cover. See Figure 10.
5. Remove debris cover.
CAUTION
The counterweight cover is extremely heavy 185 kg
(408 lb). Make sure that the eyebolts and lifting de-
vice have sufficient capacity to lift the weight.
6. Remove two bolts from counterweight cover.
7. Install two eyebolts in the hole on each end of the
counterweight cover. Connect a suitable lifting de-
vice to the eyebolts and carefully remove the coun-
terweight cover from lift truck.
8. Remove four capscrews from upper radiator
bracket. Remove bracket. See Figure 23.
9. If necessary, disconnect electrical connector from
the coolant level sensor.
10. Remove screws, washers, and clip nuts from the
shroud and radiator and move shroud out of the
way.
11. Place a radiator guard shield between radiator and
fan so damage to radiator does not occur during fan
removal.
12. Remove fan. See Fan Removal procedures.
WARNING
can cause burns.
of the cooling system under the radiator. Remove
radiator cap.
CAUTION
15. Open drain plug, loosen clamp and disconnect the
lower radiator hose from radiator to allow coolant to
drain into a suitable container. Install caps on hose.
See Figure 10.
clamp and disconnect upper radiator hose from ra-
diator. Install cap on hose. See Figure 10.
17. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from charge air cooler.
See Figure 11.
18. Loosen clamp and disconnect remote refill hose
from radiator. Install cap on hose.
NOTE: Tag the transmission lines before disconnecting
from oil cooler.
19. Disconnect transmission lines from oil cooler. In-
stall caps on transmission lines. Drain transmission
oil from oil cooler into a suitable container. Install
caps on the oil cooler ports.
NOTE: Removing the radiator from lift truck requires
two people.
20. Remove radiator from lift truck frame.
21. If necessary, remove the coolant level sensor from
radiator. See Figure 23.
21

Figure 10. Radiator Removal for Lift Truck Models
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
(GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,
D879, E879, F879)
Legend for Figure 10
1. DEBRIS COVER
2. COUNTERWEIGHT COVER
3. RADIATOR COVER
4. UPPER BRACKET
5. CAPSCREWS
6. REMOTE FILL HOSE
7. HOSE CLAMPS
8. OIL COOLER
9. TRANSMISSION OIL COOLER LINES
10. FITTINGS
11. UPPER HOSE
12. LOWER HOSE
13. REMOTE FILL
14. RADIATOR CAP
22

1. RADIATOR
2. RADIATOR CAP
3. HARNESS CLIP
5. INSERT
6. ISOLATOR
7. CAPSCREW
8. CLAMP
9. TUBE
10. UPPER HOSE
11. CLAMP
13. CLAMP
15. SHROUD
16. CLAMP
18. SCREW
19. WASHER
20. CLIP
21. LOWER HOSE
22. RESERVOIR
23. BUSHING
24. RESERVOIR CAP
26. HOSE
27. TUBE
29. SEAL
Figure 11. Cummins 3.3L Cooling System With Charge Air Cooler for GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879)
23

RADIATOR, REMOVE FOR LIFT TRUCK
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)
WARNING
1. Turn off truck.
WARNING
NOTE: Perform Step 4 for lift truck models GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878).
4. Open hood and loosen clamp and disconnect inlet
hose that attaches to the hood support. See Fig-
ure 25.
NOTE: Perform Step 5 for lift truck model GDP80VX,
GDP80VX9, GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909).
5. Open hood, loosen clamp, and disconnect dirty air
hose attached to hood support.
with Cummins QSB 3.3L diesel engine
• GDP80VX, GDP80VX9, GDP90VX
GLP/GDP190VX) (A909, B909)
with GM 5.7L LPG engine
• GLP80VX, GLP80VX9, GLP90VX
(GLP/GLP170VX, GLP/GLP175VX36,
GLP/GLP190VX) (A909, B909)
See Figure 28 for lift truck models equipped with
Kubota 3.8L Diesel engine
• GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (B909)
6. Lift trucks equipped with GM 4.3L (Gas/LPG) en-
gine, loosen clamp and disconnect inlet hose from
air filter and remove inlet hose. See Figure 25.
GP/GLP/GDP155VX) (C878, D878, E878).
7. Lift trucks equipped with the Kubota 3.8L, Cummins
4.5L, or QSB 3.3L diesel engine loosen clamp and
disconnect inlet hose from silencer. Remove si-
lencer. See Figure 25.
NOTE: Before lifting the hood assembly from the lift
truck frame, make sure to use a lifting device and lift-
ing straps as shown in Figure 12. The hood assembly
weighs approximately 45.6 kg (101 lb).
8. Remove hood assembly. For hood assembly re-
moval procedures, see
Frame 100 YRM 1321 for lift truck models
• GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36,GLP/GDP190VX) (A909)
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C879, D879)
GDP135VX, GP/GLP/GDP155VX) (E878)
GLP/GDP175VX36, GLP/GDP190VX) (B909)
9. Disconnect and cap auxiliary coolant reservoir
hose. See Figure 25.
10. Remove capscrews from the auxiliary coolant
reservoir bracket and upper bracket. Remove
auxiliary coolant reservoir assembly.
11. Remove the four capscrews from the upper radiator
bracket. Remove bracket.
12. If necessary, disconnect electrical connector from
the coolant level sensor.
13. Remove screws, washers and clip nuts from the
shroud and move shroud out of the way.
24

1. PRE-CLEANER 2. STRAP CLAMP
Figure 12. Hood Assembly Removal
fan so damage to radiator does not occur during fan
removal.
GP/GLP/GDP155VX) (C878, D878, E878).
15. Remove capscrews, washers, fan, fan spacer, and
shroud. See Figure 25.
NOTE: Perform Step 16 for lift truck model GLP
GDP80VX, GLPGDP80VX9, GLPGDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909, B909).
16. Remove capscrews, washer, fan, fan spacers, and
fan shroud.
• GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
GLP175VX36, GLP190VX) (A909 B909)
GDP175VX36, GDP190VX) (B909)
WARNING
can cause burns.
drain pan with a capacity equal to or greater than
the capacity of the cooling system under the radia-
tor. Remove radiator cap.
CAUTION
19. Open drain plug or loosen clamp and disconnect
lower radiator hose to allow coolant to drain.
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
GDP175VX36, GDP190VX) (A909, B909)
GLP175VX36, GLP190VX) (A909, B909)
GLP175VX36, GLP190VX) (B909)
20. Lift trucks equipped with a Cummins QSB 3.3L or
Kubota 3.8L diesel engine, loosen clamps and dis-
connect the charge air cooler hoses from radiator.
See Figure 13 or Figure 15.
25

1. RADIATOR
2. RADIATOR CAP
3. HARNESS CLIP
5. INSERT
6. ISOLATOR
7. CAPSCREW
8. CLAMP
9. TUBE
10. UPPER HOSE
11. CLAMP
13. CLAMP
15. SHROUD
16. CLAMP
18. SCREW
19. WASHER
20. CLIP
21. LOWER HOSE
22. RESERVOIR
23. BUSHING
24. RESERVOIR CAP
26. HOSE
27. TUBE
29. SEAL
Figure 13. Cummins 3.3L Cooling System With Charge Air Cooler for GDP60VX, GDP70VX (GDP135VX,
GDP155VX) (D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)
26

clamps and disconnect radiator hoses from radia-
tor. Cap hoses.
NOTE: Tag the transmission lines before disconnecting
from oil cooler.
22. Disconnect and cap transmission lines from oil
cooler and allow transmission oil to drain from oil
cooler into a suitable container, then cap the oil
cooler ports.
23. For lift trucks equipped with GM 5.7L LPG engine,
remove capscrews from baffles and remove baffles
from radiator assembly. Remove capscrews secur-
ing cooling baffle to radiator assembly. See Fig-
ure 14.
1. BAFFLE
2. ISOLATOR
3. UPPER BRACKET
4. CAP
5. RESERVOIR OUTLET
6. BUSHING
7. HOSE
8. RESERVOIR
9. RADIATOR
10. CAPSCREW
11. SHROUD
12. CLAMP
13. UPPER HOSE
14. LOWER HOSE
15. SEAL
16. COOLING BAFFLE
17. DRAIN HOSE
18. PLASTIC TUBE
Figure 14. GM 5.7L Cooling System, Lift Truck Models GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)
27

Figure 15. Kubota 3.8L Cooling System, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)
28

1. RADIATOR
2. RADIATOR CAP
4. INSERT
5. ISOLATOR
6. CAPSCREW
7. CLAMP
8. TUBE
9. UPPER HOSE
13. LOWER HOSE
14. SHROUD
15. RESERVOIR
16. BUSHING
17. RESERVOIR CAP
19. HOSE
21. SEAL
NOTE: Removing the radiator from lift truck requires
two people.
24. Remove radiator from lift truck frame.
25. If necessary, remove the coolant level sensor from
radiator.
RADIATOR, INSTALL FOR LIFT
TRUCK MODELS GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
1. If removed, install the coolant level sensor.
2. Install radiator into truck.
3. Install upper radiator bracket, using capscrews
taken out during removal.
fan, so damage to radiator does not occur during
fan installation
5. Place shroud in lift truck. DO NOT install on radia-
tor.
NOTE: Pull radiator shroud away from radiator while
installing fan, fan spacer, and pulley.
6. Install fan, fan spacer, and pulley.
8. Install the radiator shroud on radiator using screws
and washers taken out during removal..
9. If equipped, connect the electrical connector to the
bracket and screws must be installed to hold the con-
verter.
10. Uncap radiator and reservoir ports and install the
reservoir.
11. Connect the reservoir hose from reservoir to the
radiator. Tighten hose clamp.
12. Lift trucks equipped with Cummins QSB 3.3L en-
gine, uncap the charge air cooler hoses and con-
nect the hoses to charge air cooler. See Figure 6.
13. Lift trucks equipped with Kubota 3.8L diesel en-
gine: Uncap transmission cooler hoses and con-
nect hoses to transmission cooler. See Figure 8.
14. Uncap the upper hose and connect the hose to ra-
diator. Tighten hose clamp.
15. Close the drain plug or install lower hose. Tighten
hose clamp.
29

WARNING
DO NOT use an alcohol or methanol base an-
tifreeze. They are flammable and could cause
personal injury or damage to the lift truck.
CAUTION
or mix 50% concentrate with 50% distilled or deion-
ized water. The 50/50 mixture will protect cooling
system to 37°C ( 35°F).
17. Use the same coolant mixture and fill the reservoir
between the ADD and FULL marks.
See Figure 16 or Figure 17, for lift truck models
GC/GLC040SVX (C809)
(C810)
(B875
• GLC050LX (A967)
See Figure 18, for lift truck models
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813)
GDP080, 090, 100, 110, 120VX) (H813, J813)
1. RESERVOIR
2. ADD MARK
3. FULL MARK
Figure 16. Reservoir for Lift Truck Models
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX (A967);
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
Before May ’06
30

1. RESERVOIR
2. ADD MARK
3. FULL MARK
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX (A967);
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
After May ’06
1. AUXILIARY COOLANT RESERVOIR
2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-
55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813)
31

2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (H813, J813)
18. Install battery and battery tray.
19. Connect the positive battery cable.
20. Connect negative battery cable.
21. Install the hood and seat combination.
els
GC/GLC040SVX (C809)
(C810)
(B875)
els
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
els
• GLC050LX (A967)
WARNING
WARNING
ous injury.
22. Start and run engine until thermostat opens. (The
upper hose will be warm.)
23. On lift trucks equipped with a GM 2.4L engine,
bleed air from the cooling system by opening the
bleed screw located on the left side behind the
alternator. When the air has been bled from the
system close the bleed screw. See Figure 20.
CAUTION
24. Check coolant level at the reservoir. Add coolant
32

1. MANIFOLD
2. COOLANT HOSES
3. BLEED SCREW
4. RADIATOR HOSE
Figure 20. Bleed Screw, GM 2.4L Engine
RADIATOR, INSTALL FOR LIFT TRUCK
MODELS GC/GLC030VX, GC/GLC035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) EQUIPPED
WITH OIL COOLER
1. If removed, install the coolant level sensor.
2. Install radiator into truck.
3. Install upper radiator bracket, using capscrews
taken out during removal.
fan, so damage to radiator does not occur during
fan installation
5. Place shroud in lift truck. DO NOT install on radia-
tor.
NOTE: Pull radiator shroud away from radiator while
installing fan, fan spacer, and pulley.
6. Install fan, fan spacer, and pulley.
8. Install the radiator shroud on radiator using screws
and washers taken out during removal..
9. If equipped, connect the electrical connector to the
bracket and screws must be installed to hold the con-
verter.
10. Uncap radiator and reservoir ports and install the
reservoir.
11. Connect the reservoir hose from reservoir to the
radiator. Tighten hose clamp. See Figure 9.
12. Install new O-rings on oil cooler connectors. See
Figure 9.
13. Install oil cooler adapters to radiator. Torque
adapters to 14.7 to 17.6 N•m (130 to 156 lbf in).
See Figure 9.
14. Uncap oil cooler hoses and connect hoses to oil
cooler adapters. See Figure 9.
15. Uncap the upper hose and connect the hose to ra-
diator. Tighten hose clamp. See Figure 9.
16. Close the drain plug or install lower hose. Tighten
hose clamp.
WARNING
CAUTION
between the ADD and FULL marks. See Figure 21.
33

1. RESERVOIR
2. ADD MARK
3. FULL MARK
(C810); GLC050LX (A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974)
19. Install battery and battery tray.
20. Connect the positive battery cable.
22. Install the hood and seat combination.
els
GC/GLC040SVX (C809)
(C810)
els
• GLC050LX (A967)
WARNING
WARNING
ous injury.
23. Start and run engine until thermostat opens. (The
upper hose will be warm.)
CAUTION
24. Check coolant level at the reservoir. Add coolant
MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024, G024)GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879)
1. If necessary, install coolant level sensor.
NOTE: Installing the radiator into lift truck frame re-
quires two people.
2. Install radiator into lift truck frame.
3. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler. See Fig-
ure 10.
4. Uncap and connect remote refill hose onto radiator
and tighten hose clamp. See Figure 10.
5. Close drain plug and uncap the upper and lower
radiator hoses and connect hoses onto radiator and
tighten hose clamps. See Figure 10.
6. Uncap the charge air cooler hoses and connect the
hoses to charge air cooler. See Figure 11.
7. Install fan. See Fan Installation procedures.
8. Align shroud to radiator and install two capscrews,
washers and clip nuts. See Figure 23.
34

9. If necessary, connect electrical connector onto the
10. Install upper radiator bracket and four capscrews.
CAUTION
The counterweight cover is extremely heavy 185 kg
(408 lb). Make sure that the eyebolts and lifting de-
vice have sufficient capacity to lift the weight.
11. If removed, install two eyebolts in the hole on each
end of the counterweight cover. Connect a suitable
lifting device to the eyebolts and carefully install the
counterweight cover into the lift truck frame. See
Figure 10.
12. Install two bolts to counterweights cover. Tighten to
38 N•m (28 lbf ft).
13. Install debris cover.
14. Install radiator cover.
15. Connect positive battery cable.
WARNING
CAUTION
using additives, contact you local Yale dealer.
18. Install radiator cap.
between the ADD and FULL marks. See Figure 22.
WARNING
fan, pulleys, or drive belts. contact with these parts
WARNING
may be hot or under pressure and cause serious
injury.
20. Start and run the engine until thermostat opens
(The upper radiator hose will be warm).
CAUTION
21. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reservoir.
22. Shut down the engine for one minute or longer prior
to checking the transmission oil level. If the trans-
mission oil is low, add transmission oil to the trans-
mission at the dipstick tube to the correct level in-
dicated on the dipstick. Oil is specified in Periodic
Maintenance section for your lift truck.
2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
D879, E879, F879)
35

Figure 23. Cooling System for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024,
G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879)
36

A. LOWER HOSE (CUMMINS 4.5L/KUBOTA 3.8L
DIESEL)
B. LOWER HOSE (GAS AND LPG)
C. UPPER HOSE (GAS AND LPG)
D. UPPER HOSE (CUMMINS 4.5L/KUBOTA 3.8L
DIESEL)
1. RADIATOR (WITH EXTERNAL OIL COOLER)
2. SHROUD
3. WASHER
4. SCREW
5. CLIP NUT
6. CLIP SPRING
7. CLAMP
9. CAPSCREW
10. INSERT
11. ISOLATOR
12. RESERVOIR
13. BRACKET (COOLANT FILL)
14. OUTLET ASSEMBLY
15. OUTLET
16. CAP
17. BUSHING
18. HOSE
19. HOSE
20. REMOTE FILL HOSE
21. REMOTE FILL
22. RADIATOR CAP
23. SCREEN
25. DRAIN PLUG
MODELS GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) AND GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
GLP/GDP190VX) (A909, B909)
1. If necessary, install coolant level sensor.
NOTE: Installing the radiator into lift truck frame re-
quires two people.
2. Install radiator into lift truck frame.
3. For lift trucks equipped with GM 5.7L LPG engine,
use capscrews and install baffles to radiator assem-
bly. See Figure 14. Use capscrews and attach ra-
diator assembly to cooling baffle.
4. Install upper radiator bracket and four capscrews.
E878)
GDP175VX36, GDP190VX) (A909, B909)
GLP175VX36, GLP190VX) (A909, B909)
GLP175VX36, GLP190VX) (B909)
5. Install coolant reservoir bracket and coolant reser-
voir assembly onto upper bracket and tighten cap-
screws.
E878)
GDP175VX36, GDP190VX) (A909, B909)
GLP175VX36, GLP190VX) (A909, B909)
GDP175VX36, GDP190VX) (B909)
6. Uncap and connect auxiliary coolant reservoir hose
and tighten clamp.
7. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler.
8. Close drain plug and uncap the lower radiator hose
and connect hose onto radiator and tighten clamp.
37

9. Uncap and connect upper radiator hose and tighten
clamp.
10. Lift trucks equipped with Cummins QSB 3.3L or
Kubota 3.8L diesel engine, uncap the charge air
cooler hoses and connect the hoses to the charge
air cooler. See Figure 13 or Figure 15.
11. Install fan. See Fan Installation procedures.
12. Align shroud to radiator and install capscrews,
washers and clip nuts.
E878)
GDP175VX36, GDP190VX) (A909, B909)
GLP175VX36, GLP190VX) (A909, B909)
GDP175VX36, GDP190VX) (B909)
13. If necessary, connect electrical connector onto the
14. Lift truck equipped GM 4.3L (Gas/LPG) engine, in-
stall air intake hose to air filter and tighten clamp.
15. Lift trucks equipped with Cummins 4.5L or QSB
3.3L diesel engine, install silencer and connect
hose from air filter side and tighten clamp. See
Figure 25.
16. Lift trucks equipped with Cummins QSB 3.3L, Kub-
ota 3.8L diesel engine or GM 5.7L LPG engine, con-
nect dirty air hose to hood support and install and
tighten clamp.
GDP175VX36, GDP190VX) (A909, B909)
GLP175VX36, GLP190VX) (A909, B909)
GDP175VX36, GDP190VX) (B909)
17. Install hood assembly. For hood install procedures,
see section
GLP/GDP175VX36,GLP/GDP190VX) (A909)
GDP135VX, GP/GLP/GDP155VX) (E878)
18. Lift truck equipped GM 4.3L (Gas/LPG) engine,
open hood assembly and connect intake hose to
hood support and tighten clamp. See Figure 25.
19. Lift trucks equipped with Kubota 3.8L, Cummins
4.5L, or QSB 3.3L diesel engine, open hood assem-
bly and connect hose to hood support and tighten
clamp.
E878)
GDP175VX36, GDP190VX) (A909, B909)
GDP175VX36, GDP190VX) (B909)
20. Connect positive battery cable.
38

WARNING
CAUTION
23. Install radiator cap.
24. Use the same coolant mixture and fill the auxil-
iary coolant reservoir between the ADD and FULL
marks. See Figure 24.
WARNING
fan, pulleys, or drive belts. contact with these parts
WARNING
may be hot or under pressure and cause serious
injury.
25. Start and run the engine until thermostat opens
(The upper radiator hose will be warm).
CAUTION
26. Check coolant level at the auxiliary coolant reser-
voir. Add coolant as necessary to keep level be-
tween the ADD and FULL marks on the reservoir.
27. Shut down the engine for one minute or longer prior
to checking the transmission oil level. If the trans-
mission oil is low, add transmission oil at the dipstick
tube at the correct level indicated on the dipstick.
Oil is specified in Periodic Maintenance section for
your lift truck.
2. FULL "HOT" MARK
3. FULL "COLD" MARK
4. ADD "COLD" MARK
Figure 24. Reservoir for Lift Truck Models GLP/
GP/GLP/GDP155VX) (C878, D878, E878) and
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
GLP/GDP190VX) (A909, B909)
39

Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) (Sheet 1 of 3)
40

41

42

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

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

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

Figure 28. Cooling System Kubota 3.8L Diesel Engine for Lift Truck Model GDP80VX, GDP80VX9, GDP90VX
(GDP170VX, GDP175VX36, GDP190VX) (B909)
46

700 YRM 1123 Fan Assembly Replacement
1. PRE-CLEANER
2. CLAMP
3. HOOD SUPPORT
4. HOOD ASSEMBLY
5. DIRTY AIR HOSE
6. CLEAN AIR HOSE
7. AIR FILTER
9. CAPSCREW
10. NUT
13. CAP
14. BUSHING
16. TUBE
18. UPPER BRACKET
20. RADIATOR
21. CAC HOSE
22. CAC TUBE
23. AIR FLOW SENSOR
26. SHROUD AND BAFFLE
27. WASHER
28. FAN
29. SPACER
Fan Assembly Replacement
FAN REMOVAL
WARNING
WARNING
WARNING
can cause serious injury. Wear gloves while remov-
ing fan assembly.
NOTE: The fan that is used is a pusher-type fan. Do
not replace with a puller-type fan.
1. Turn OFF lift truck.
2. If equipped, turn the LPG tank valve to the OFF
position.
3. If equipped, release the LPG tank bracket and
swing tank away from the lift truck.
NOTE: Perform Step 4 through Step 6 for lift truck mod-
els
• GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
• GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
GP/GLP/GDP040SVX) (C810)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
GC/GLC120VXPRS) (E818, F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813, J813)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
D879, E879, F879)
• GLC050LX (A967)
4. Release the steering tilt latch and move the steering
wheel forward.
5. Release the seat latch and move the seat forward.
6. Release hood latch and raise hood to open posi-
tion.
47

Fan Assembly Replacement 700 YRM 1123
NOTE: Perform Step 7 for lift truck models
E878)
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
7. Release hood cover latch on hood cover and swing
hood cover up.
WARNING
To prevent a short circuit during fan belt removal,
disconnect the battery negative cable at the battery
negative terminal. Install a lock or tag on the con-
nector to prevent connection. A tool could cause a
short circuit, the high current flow from the battery
can cause an injury or parts damage.
8. Disconnect the negative battery cable from the neg-
ative battery terminal.
9. Remove screws and washers from the radiator
shroud. Lean radiator shroud toward the fan.
with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar
3.3L engine
(B875)
(C810)
with Yanmar 2.6L engine.
• GDP20-25LX (GDP050LX) (A974)
with Mazda FE and F2 engines
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
• GLP20-35VX (GP/GLP040-070VX) (B875)
GC/GLC040SVX (C809)
• GLP16VX, GLP18VX, GLP20SVX (GP/
GLP030VX, GP/GLP035VX, GP/GLP040SVX)
(C810)
with GM 4.3L engine
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
with Cummins 4.5L engine
GDP080, 090, 100, 110, 120VX) (F813)
with GM 4.3L, Cummins 4.5L, or Kubota 3.8L en-
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
(C879, D879, E879, F879)
with GM 4.3L, Cummins 4.5L, or Kubota engines
GDP135VX, GP/GLP/GDP155VX) (C878, E878)
with Cummins QSB 3.3L diesel engines
• GDC60VX, GDC70VX (GDC135VX,
GDC155VX) (D879)
• GDP60VX, GDP70VX (GDP135VX,
GDP155VX) (D878)
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080, 090, 100, 110, 120VX)
(G813)
GDP175VX36, GDP190VX) (A909, B909)
B909)
48

with Kubota 3.8L diesel engine
GDP080, 090, 100, 110, 120VX) (H813, J813)
1. FAN
2. SPACER
3. WASHER
4. CAPSCREW
5. SCREW
6. RADIATOR SHROUD
7. RADIATOR
Figure 29. Fan Removal for GM 2.4L, Yanmar 2.6L, Yanmar 3.0L and Yanmar 3.3L Engines, Lift Truck Models
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875), and GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
49

1. SPACER
2. FAN
3. WASHER
4. CAPSCREW
5. SHROUD
6. SCREW
7. RADIATOR
Figure 30. Fan Removal for Yanmar 2.6L Engine, Lift Truck Models GDP20-25LX (GDP050LX) (A974)
50

NOTE: MODINE RADIATOR SHOWN, COPAR RADIATOR SIMILAR.
1. SPACER, GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875) AND
GC/GLC030-035VX, GC/GLC040SVX (C809)
LIFT TRUCKS ONLY
2. FAN
3. CAPSCREW
4. WASHER
5. SCREW
6. WASHER
7. RADIATOR SHROUD
8. RADIATOR
Figure 31. Fan Removal for Mazda FE and F2 Engines, Lift Truck Models GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910), GLC050LX (A967), GLP20-25LX (GLP050LX) (A974), GLP20-35VX
(GP/GLP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809), and GLP16VX,
GLP18VX, GLP20SVX (GP/GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810)
51

1. FAN
2. SPACER
3. WASHER
4. CAPSCREW
5. SCREW
6. RADIATOR SHROUD
7. RADIATOR
Figure 32. Fan Removal for GM 4.3L Engine, Lift Truck Models GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and
GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GP/GLP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
52

1. SPACER
2. FAN
3. WASHER
4. CAPSCREW
5. RADIATOR SHROUD
6. SCREW
7. LOCKWASHER
8. CLIP NUT
9. RADIATOR
Figure 33. Fan Removal for Cummins 4.5L Engine, Lift truck Models GDP40VX5/VX6;GDP45SVX5,
GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (F813)
53

A. GM 4.3L AND KUBOTA 3.8L B. CUMMINS 4.5L (DIESEL)
1. FAN
2. FAN SPACER
3. WASHER
4. CAPSCREW
5. SCREW
6. SHROUD
7. RADIATOR
Figure 34. Fan Removal for GM 4.3L, Cummins 4.5L and Kubota 3.8L Engines, Lift truck Models S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879, F879)
54

A. GM 4.3L AND KUBOTA B. CUMMINS 4.5L (DIESEL)
1. FAN
2. FAN SPACER
3. WASHER
4. CAPSCREW
5. SCREW
6. SHROUD
7. RADIATOR
Figure 35. Fan Removal for GM 4.3L, Cummins 4.5L, and Kubota Engines, Lift Truck Models GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)
55

1. SPACER
2. FAN
3. SCREW
4. WASHER
5. WASHER
6. CAPSCREW
7. SHROUD
8. RADIATOR
Figure 36. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models GDP40VX5/VX6; GDP45SVX5,
GDP45VX6, GDP50-55VX (GDP080, 090, 100, 110, 120VX) (G813), GDC60VX, GDC70VX (GDC135VX,
GDC155VX) (D879), and GDP60VX, GDP70VX (GDP135VX, GDP155VX) (D878)
56

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

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

1. FAN
2. FAN SPACER
3. WASHER
4. CAPSCREW
5. SCREW
6. SHROUD
7. RADIATOR
Figure 39. Fan Removal for Kubota 3.8L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)
59

1. FAN SHROUD
2. SCREW
3. WASHER
4. SPACER
5. CAPSCREW
6. FAN
7. RADIATOR ASSEMBLY
Figure 40. Fan Removal for Kubota 3.8L Diesel Engine, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)
10. Remove capscrews, washers, and spacer from the
fan pulley.
3.3L engine
(B875)
(C810)
with Yanmar 2.6L engine
• GDP20-25LX (GDP050LX) (A974)
with GM 4.3L engine
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
60

GDP080, 090, 100, 110, 120VX) (F813)
See Figure 34. for lift truck models below equipped
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
(C879, D879, E879, F879)
with GM 4.3L, Cummins 4.5L, Kubota engines
E878)
GDP080, 090, 100, 110, 120VX) (H813, J813)
NOTE: Perform Step 11 for lift truck model GDP80VX,
GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909) and GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (B909).
11. For lift trucks equipped with Cummins QSB 3.3L
diesel engines, GM 5.7L LPG engines, or Kubota
3.8L diesel engines, remove capscrews, washers,
and spacers from fan.
GDP175VX36, GDP190VX) (A909, B909)
B909)
• GC/GLC030-035VX, GC/GLC040SVX (C809)
(B875)
• GLP20-25LX (GLP050LX) (A974)
.
12. For lift trucks equipped with Mazda FE and F2
engines, remove capscrews, washers, and spacer
from the fan pulley.
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
• GLP20-35VX (GP/GLP040-070VX) (B875)
GC/GLC040SVX (C809)
(C810)
• GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/
GDP030-035VX, GP/GLP/GDP040SVX) (C810)
• GLC050LX (A967)
13. For lift trucks equipped with Mazda FE or F2 en-
gines, remove the capscrews and washers retain-
ing the fan.
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
• GLP20-35VX (GP/GLP040-070VX) (B875)
GC/GLC040SVX (C809)
(C810)
14. Remove the fan.
61

INSPECT
WARNING
DO NOT try to repair a damaged fan. If a fan has a
bent blade or is cracked, install a new fan. A dam-
aged fan can break during use and cause damage
or serious injury.
1. Inspect the fan for any damage.
2. If the fan is damaged, replace the entire fan.
FAN INSTALLATION
WARNING
can cause serious injury. Wear gloves while in-
stalling fan assembly.
1. Install the lower portion of the shroud in the retain-
ing clips and lean the shroud toward the engine.
2. Install the spacer, washers, and capscrews to the
fan. Tighten the capscrews to 52 N•m (38 lbf).
with GM 2.4L, Yanmar 2.6L, Yanmar3.0L or Yanmar
3.3L engine
(B875)
(C810)
with Yanmar 2.6L engine.
• GDP20-25LX (GDP050LX) (A974)
with GM 4.3L engine
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
GDP080, 090, 100, 110, 120VX) (F813)
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
(C879, D879, E879, F879)
E878)
GDP080, 090, 100, 110, 120VX) (H813, J813)
NOTE: Perform Step 3 for lift truck models GDP80VX,
GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909, B909).
3. Install spacers, washers, and capscrews onto fan.
GDP175VX36, GDP190VX) (A909, B909)
B909)
62

(B875)
• GLP20-25LX (GLP050LX) (A974)
fan. Tighten the capscrews to 27 N•m (20 lbf ft).
(C810)
• GLP20-35VX (GP/GLP040-070VX) (B875)
• GLP20-25LX (GLP050LX) (A974)
(C809)
• GLC050LX (A967)
5. Place the fan in position of the pulley and install
capscrews and washers. Tighten the capscrews to
27 N•m (20 lbf ft).
with Mazda FE or F2 engines
GC/GLC040SVX (C809)
• GLC050LX (A967)
fan. Tighten the capscrews to 27 N•m (20 lbf ft).
with GM 4.3L engine
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
(C879, D879, E879, F879)
E878)
7. Lean the radiator shroud back toward the radiator.
Install the screws and washers and install the radi-
ator shroud cover.
3.3L engine
(B875)
(C810)
with Yanmar 2.6L engine
• GDP20-25LX (GDP050LX) (A974)
with Mazda FE or F2 engines
• GLC050LX (A967)
• GLP20-25LX (GLP050LX) (A974)
• GLP20-35VX (GP/GLP040-070VX) (B875)
GC/GLC040SVX (C809)
(C810)
63

with GM 4.3L engine
100, 120VX; GC/GLC080, 100VXBCS;
F818)
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)
GDP080, 090, 100, 110, 120VX) (F813)
gines
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
(C879, D879, E879, F879)
E878)
• GDC60VX, GDC70VX (GDC135VX,
GDC155VX) (D879)
• GDP60VX, GDP70VX (GDP135VX,
GDP155VX) (D878)
• GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080, 090, 100, 110, 120VX)
(G813)
GDP175VX36, GDP190VX) (A909, B909)
GLP175VX36, GLP190VX) (A909, B909)
GDP080, 090, 100, 110, 120VX) (H813, J813)
8. Reconnect the negative battery cable to the nega-
tive terminal of the battery.
NOTE: Perform Step 9 through Step 11 for lift truck
models
(C809)
(B875)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
GC/GLC120VXPRS) (E818, F818)
• GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (F813, G813, H813, J813)
• S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
D879, E879, F879)
• GLC050LX (A967)
9. Lower the hood and ensure that the hood latches.
10. Move the seat back.
11. Release the steering wheel tilt latch and move the
steering wheel back.
• GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
12. Close hood cover.
13. If equipped, swing the LPG tank bracket back to-
ward the truck and re-latch.
14. If equipped, turn the LPG tank valve to the ON po-
sition.
64

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale®
dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

YALE G813 GDP80VX LIFT TRUCK Service Repair Manual

YALE G813 GDP80VX LIFT TRUCK Service Repair Manual

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YALE G813 GDP80VX LIFT TRUCK Service Repair Manual