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Maintenance

Maintenance

COOLING SYS TEM

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]

( G L P / G D P 1 7 0 V X , GLP/GDP175VX36, GLP/GDP190VX)

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:

and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which,

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); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, 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); 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)

29

Radiator, Install 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 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

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]

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

Cooling System Checks EXHAUST LEAKS INTO COOLING SYSTEM WARNING During engine operation, be careful not to

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

WARNINGwhen doing the test. WATER FLOW RESTRICTIONS IN RADIATOR D u r i n g e

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

To check fo r water flow restrictions in the radiator, run engine until it is warm.

restrictions in the radiator, run engine until it is warm. WARNING T h e r a

WARNING

The radiator or other parts of the cooling system may be hot or under pressure and can cause seri- ous injur y. 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.

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.

Inspect all radiator hoses. If they feel spongy or have visible cracks, replace hoses.

WATER PUMP

WARNINGspongy or have visible cracks, replace hoses. WATER PUMP During engine operation, be careful not to

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNINGbelts. Contact with these parts can cause serious injury. The radiator or other parts of the

The radiator or other parts of the cooling system may be hot or under pressure and can cause seri- 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.

If

radiator has leaks, either replace the radiator or have

it

repaired by trained personnel.

RADIATOR HOSES

e p a i r e d by trained personnel. RADIATOR HOSES WARNING The radiator or

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.

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.

Flushing the Cooling System

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.

700 YRM 1123

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

Online . Flushing the Cooling System COOLING SYSTEM, CLEAN WARNING Compressed air can move particles so

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.

WARNINGgoggles or a face shield to prevent injury to the eyes. The radiator fins on the

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.

exterior of radiator with compressed air or water as needed. WARNING DO NOT remove the radiator

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.

is hot, the steam and boiling coolant can cause burns. WARNING The radiator or other parts

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.

attempting to check or fix any part of the cooling system. CAUTION Disposal of lubricants and

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.

700 YRM 1123 CAUTION
700 YRM 1123
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.

CAUTIONdoes not clean system, use a chemical ra- diator cleaner. Follow the manufacturer’s instructions when using

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

Radiator Replacement

method uses water pressure to force water through radiator in opposite direction of normal flow.

CAUTIONwater through radiator in opposite direction of normal flow. Additives may damage the cooling system. Before

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)

090, 100, 110, 120VX) (F813, G813, H813, J813) WARNING The radiator or other parts of the

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.

1. Turn OFF truck.

See Frame 100 YRM 1120 for lift truck models

GC/GLC030VX,

GC/GLC035VX,

GC/GLC040SVX (C809)

GLP/GDP16VX,

GLP/GDP20SVX

GP/GLP/GDP035VX,

(C810)

GLC20-35VX

GLP/GDP18VX,

(GP/GLP/GDP030VX,

GP/GLP/GDP040SVX)

(GC/GLC040-070VX,

GC/GLC055SVX) (A910)

GLP/GDP20-35VX

(GP/GLP/GDP040-070VX)

(B875)

See Frame 100 YRM 1243 for lift truck models

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)

See Frame 100 YRM 1423 for lift truck models

GLC050LX (A967)

GLP/GDP20-25LX (GLP/GDP050LX) (A974)

WARNINGGLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) Always disconnect the cable at the negative termi- nal

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.

2. Remove the hood and seat combination.

Radiator Replacement

WARNINGRadiator Replacement D O N O T r e m o v e t h e

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.

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.

CAUTIONl i n g system under radiator. Remove radi- ator cap. Disposal of lubricants and fluids

Disposal of lubricants and fluids must meet local environmental regulations.

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/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)

700 YRM 1123

GC/GLC120SVX;

GC/GLC120VXPRS)

(E818,

F818)

See Figure 4 or Figure 5 for lift truck models

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)

See Figure 6 for lift truck models below equipped with a Cummins QSB 3.3L diesel engine

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879)

See Figure 7 for lift truck models below equipped with Yanmar 2.6L diesel engine

GDP20-25LX (GDP050LX) (A974)

See Figure 8 for lift truck models below equipped with a Kubota 3.8L diesel engine

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, 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.

See Figure 1 for lift truck models

GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

GC/GLC030VX,

GC/GLC035VX,

(B875)

GC/GLC040SVX (C809

GLC050LX (A967)

GLP/GDP16VX,

GLP/GDP18VX,

GLP20-25LX (GLP050LX) (A974)

See Figure 2 or Figure 3 for lift truck models

GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;

GLP/GDP20SVX

GP/GLP/GDP035VX,

(C810)

GLC20-35VX

GC/GLC055SVX) (A910)

(GP/GLP/GDP030VX,

GP/GLP/GDP040SVX)

(GC/GLC040-070VX,

700 YRM 1123

GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

(B875)

GLC050LX (A967)

GLP20-25LX (GLP050LX) (A974)

See Figure 2 or Figure 3 for lift truck models

GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818,

F818)

See Figure 4 or Figure 5 for lift truck models

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)

See Figure 6 for lift truck models below equipped with a Cummins QSB 3.3L diesel engine

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813

Radiator Replacement

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879)

See Figure 7 for lift truck models below equipped with Yanmar 2.6L diesel engine

GDP20-25LX (GDP050LX) (A974)

See Figure 8 for lift truck models below equipped with a Kubota 3.8L diesel engine

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813)

18. Remove radiator from truck.

19. If necessary, remove the coolant level sensor.

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 1. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX

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)

700 YRM 1123

Legend for Figure 1

Radiator Replacement

A. RADIATOR WITH EXTERNAL COOLER

C.

RESERVOIR BEFORE MAY ’06

B. RADIATOR WITH INTERNAL COOLER, MODINE SHOWN

D.

RESERVOIR AFTER MAY ’06

1. RADIATOR

15.

NUT-CLIP, GC/GLC040-070VX, GC/GLC055SVX

2. CAP

[A910] AND GLC050LX (A967)

3. UPPER HOSE

16.

ISOLATOR

4. LOWER HOSE

17.

COOLANT LEVEL SENSOR

5. CLAMP

18.

RESERVOIR

6. SHROUD

19.

TUBE

7. CLIP

20.

OUTLET ASSEMBLY

8. WASHER

21.

HOSE

9. SCREW

22.

RESERVOIR OUTLET

10. CLIP

23.

CAP

11. UPPER RADIATOR BRACKET

24.

BUSHING

12. CAPSCREW, GC/GLC040-070VX,

25.

SCREEN ASSEMBLY (OPTIONAL)

GC/GLC055SVX [A910] AND GLC050LX

26.

HEAT SHIELD

(A967)

27.

RESERVOIR BRACKET

13. INSERT

28.

HEAT SHIELD, GLP/GDP20-35VX

14. LOWER BRACKET, GC/GLC040-070VX, GC/GLC055SVX [A910] AND GLC050LX (A967)

(GP/GLP/GDP040-070VX) [B875] AND GLP20-25LX (GLP050LX) (A974)

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 2. Cooling System for Lift Truck Models GLC40, 45, 55VX;

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

700 YRM 1123

Legend for Figure 2

Radiator Replacement

A. RADIATOR WITH EXTERNAL COOLER

B.

RADIATOR WITH INTERNAL COOLER

1. RADIATOR

15.

RESERVOIR BRACKET

2. SHROUD

16.

OUTLET ASSEMBLY

3. WASHER

17.

OUTLET

4. SCREW

18.

CAP

5. CLIP NUT

19.

BUSHING

6. CLIP

20.

HOSE

7. UPPER HOSE

21.

TUBE

8. LOWER HOSE

22.

STRAP

9. CLAMP

23.

NUT

10. UPPER RADIATOR BRACKET

24.

SCREEN

11. INSERT

25.

BAFFLE (RH AND LH)

12. CAPSCREW

26.

RADIATOR CAP

13. ISOLATOR

27.

COOLANT LEVEL SENSOR

14. RESERVOIR

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 3. Cooling System for Lift Truck Models GLC40, 45, 55VX;

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

700 YRM 1123

Legend for Figure 3

Radiator Replacement

A. RADIATOR WITH EXTERNAL COOLER

B.

RADIATOR WITH INTERNAL COOLER

1. RADIATOR

14.

RESERVOIR

2. SHROUD

15.

OUTLET ASSEMBLY

3. WASHER

16.

OUTLET

4. SCREW

17.

CAP

5. CLIP NUT

18.

BUSHING

6. CLIP

19.

HOSE

7. UPPER HOSE

20.

TUBE

8. LOWER HOSE

21.

NUT

9. CLAMP

22.

SCREEN

10. UPPER RADIATOR BRACKET

23.

BAFFLE (RH AND LH)

11. INSERT

24.

RADIATOR CAP

12. CAPSCREW

25.

COOLANT LEVEL SENSOR

13. ISOLATOR

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 4. Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,

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

700 YRM 1123

Legend for Figure 4

Radiator Replacement

A. RADIATOR WITH INTERNAL COOLER

B.

RADIATOR WITH EXTERNAL COOLER

1. CAPSCREW

14.

WASHER

2. INSERT

15.

SCREEN

3. UPPER RADIATOR BRACKET

16.

STRAP

4. RADIATOR CAP

17.

RESERVOIR BRACKET

5. ISOLATOR

18.

RESERVOIR

6. CLIP NUT

19.

OUTLET ASSEMBLY

7. COOLANT LEVEL SENSOR

20.

OUTLET

8. RADIATOR

21.

CAP

9. CLIP

22.

BUSHING

10. RADIATOR SHROUD

23.

TUBE

11. CLAMP

24.

UPPER HOSE

12. LOWER HOSE

25.

DRAIN PLUG

13. SCREW

26.

OIL COOLER

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 5. Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,

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

700 YRM 1123

Legend for Figure 5

Radiator Replacement

A. RADIATOR WITH INTERNAL COOLER

B.

RADIATOR WITH EXTERNAL COOLER

1. CAPSCREW

13.

SCREW

2. INSERT

14.

WASHER

3. UPPER RADIATOR BRACKET

15.

SCREEN

4. RADIATOR CAP

16.

RESERVOIR

5. ISOLATOR

17.

OUTLET ASSEMBLY

6. CLIP NUT

18.

OUTLET

7. COOLANT LEVEL SENSOR

19.

CAP

8. RADIATOR

20.

BUSHING

9. CLIP

21.

TUBE

10. RADIATOR SHROUD

22.

UPPER HOSE

11. CLAMP

23.

DRAIN PLUG

12. LOWER HOSE

24.

OIL COOLER

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 1. 2. RADIATOR CAP 3. HARNESS CLIP 4. UPPER RADIATOR BRACKET

1.

2. RADIATOR CAP

3. HARNESS CLIP

4. UPPER RADIATOR BRACKET

5.

6. ISOLATOR

7.

8.

9. TUBE

10. UPPER HOSE

11.

12. CHARGE AIR COOLER HOSE

13. CLAMP

14. CHARGE AIR COOLER HOSE

15. SHROUD

RADIATOR

INSERT

CAPSCREW

CLAMP

CLAMP

16.

17. CHARGE AIR COOLER HOSE

18. SCREW

19. WASHER

20.

21. LOWER HOSE

22.

23.

24. RESERVOIR CAP

25. RESERVOIR OUTLET

26.

27. TUBE

28. COOLANT LEVEL SENSOR

29. SEAL

CLAMP

CLIP

RESERVOIR

BUSHING

HOSE

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)

700 YRM 1123

Radiator Replacement

700 YRM 1123 Radiator Replacement 1. LOWER HOSE 2. CLAMP 3. UPPER HOSE 4. RESERVOIR 5.

1. LOWER HOSE

2. CLAMP

3. UPPER HOSE

4. RESERVOIR

5. OUTLET ASSEMBLY

6.

7.

8. RESERVOIR OUTLET

HOSE

CAPSCREW

INSERT

12. RADIATOR CAP

11.

10.

9.

BUSHING

CAP

13. ISOLATOR

14. UPPER RADIATOR BRACKET

15. RADIATOR

16. PLUG - COOLANT LEVEL SENSOR

17. HEAT SHIELD

18.

19.

20. SCREW

21.

22.

23.

CLIP NUT

WASHER

DRAIN PLUG

SHROUD

TUBE

Figure 7. Yanmar 2.6L Cooling System for Lift Truck Models GDP20-25LX (GDP050LX) (A974)

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 1. RADIATOR 2. RADIATOR CAP 3. UPPER RADIATOR BRACKET 4. 5.

1. RADIATOR

2. RADIATOR CAP

3. UPPER RADIATOR BRACKET

4.

5.

6.

7.

8. TUBE

9. UPPER HOSE

10. LOWER HOSE

ISOLATOR

CAPSCREW

INSERT

CLAMP

11. TRANSMISSION COOLER RETURN LINE

12. TRANSMISSION COOLER SUPPLY LINE

13. SCREW

14.

15.

16.

17.

18. RESERVOIR CAP

19. RESERVOIR OUTLET

20. COOLANT LEVEL SENSOR

WASHER

SHROUD

RESERVOIR

BUSHING

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)

700 YRM 1123

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); GLC050LX (A967) AND GLP/GDP20-25LX (GLP/GDP050LX) (A974) EQUIPPED WITH OIL COOLER

(GLP/GDP050LX) (A974) EQUIPPED WITH OIL COOLER WARNING The radiator or other parts of the cooling system

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.

1. Turn OFF truck.

2. Remove the hood and seat combination.

See section Frame 100 YRM 1120 for lift truck mod- els

GC/GLC030VX,

GC/GLC035VX,

GC/GLC040SVX (C809)

GLP/GDP16VX,

GLP/GDP20SVX

GP/GLP/GDP035VX,

(C810)

GLP/GDP18VX,

(GP/GLP/GDP030VX,

GP/GLP/GDP040SVX)

See section Frame 100 YRM 1423 for lift truck mod- els

GLC050LX (A967)

GLP/GDP20-25LX (GLP/GDP050LX) (A974)

WARNINGGLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) Always disconnect the cable at the negative termi- nal

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.

battery cable. 4. Disconnect the positive battery cable. WARNING DO NOT remove the radiator cap from

WARNING

DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is

Radiator Replacement

removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant 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.

of the cooling system under radiator. Remove radi- ator cap. CAUTION Disposal of lubricants and fluids

CAUTION

Disposal of lubricants and fluids must meet local environmental regulations.

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.

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 9.

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. See Figure 9.

18. Remove radiator from truck.

19. If necessary, remove the coolant level sensor.

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 1. 2. 3. UPPER HOSE 4. LOWER HOSE 5. 6. SHROUD

1.

2.

3. UPPER HOSE

4. LOWER HOSE

5.

6. SHROUD

7.

8. OIL COOLER ADAPTER

9. OIL COOLER HOSE

10. UPPER RADIATOR BRACKET

RADIATOR

CAP

CLAMP

O-RING

11.

12.

13. ISOLATOR

14. RESERVOIR

15.

16. OUTLET ASSEMBLY

17.

18. RESERVOIR OUTLET

19. CAP

20. BUSHING

CAPSCREW

INSERT

TUBE

HOSE

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)

700 YRM 1123

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
F879)
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.

1. Turn off truck.

WARNINGor fix any part of the cooling system. 1. Turn off truck. Always disconnect the cable

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.

2. Disconnect the negative battery cable.

3. Disconnect the positive battery cable.

4. Remove radiator cover. See Figure 10.

5. Remove debris cover.

radiator cover. See Figure 10. 5. Remove debris cover. CAUTION The counterweight cover is extremely heavy

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.

Radiator Replacement

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.

13. Remove radiator guard shield.

WARNINGFan Removal procedures. 13. Remove radiator guard shield. DO NOT remove the radiator cap from the

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.

14. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under the radiator. Remove radiator cap.

CAUTIONthe cooling system under the radiator. Remove radiator cap. Disposal of lubricants and fluids must meet

Disposal of lubricants and fluids must meet local environmental regulations.

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.

16. Once coolant is drained from engine, loosen hose 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.

Radiator Replacement

Radiator Replacement Figure 10. Radiator Removal for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,

Figure 10. Radiator Removal 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)

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

700 YRM 1123 Radiator Replacement 1. 2. RADIATOR CAP 3. HARNESS CLIP 4. UPPER RADIATOR BRACKET

1.

2. RADIATOR CAP

3. HARNESS CLIP

4. UPPER RADIATOR BRACKET

5.

6. ISOLATOR

7.

8.

9. TUBE

10. UPPER HOSE

11.

12. CHARGE AIR COOLER HOSE

13. CLAMP

14. CHARGE AIR COOLER HOSE

15. SHROUD

RADIATOR

INSERT

CAPSCREW

CLAMP

CLAMP

16.

17. CHARGE AIR COOLER HOSE

18. SCREW

19. WASHER

20.

21. LOWER HOSE

22.

23.

24. RESERVOIR CAP

25. RESERVOIR OUTLET

26.

27. TUBE

28. COOLANT LEVEL SENSOR

29. SEAL

CLAMP

CLIP

RESERVOIR

BUSHING

HOSE

Figure 11. Cummins 3.3L Cooling System With Charge Air Cooler for GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879)

Radiator Replacement

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(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) The radiator or other parts of the cooling system may be

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.

1. Turn off truck.

WARNINGor fix any part of the cooling system. 1. Turn off truck. Always disconnect the cable

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.

2. Disconnect the negative battery cable.

3. Disconnect the positive battery cable.

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.

See Figure 26 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)

See Figure 27 for lift truck models below equipped with GM 5.7L LPG engine

GLP80VX, GLP80VX9, GLP90VX (GLP/GLP170VX, GLP/GLP175VX36, GLP/GLP190VX) (A909, B909)

700 YRM 1123

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.

NOTE: Perform Step 7 for lift truck models GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, 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)

Frame 100 YRM 1581 for lift truck models

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, 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.

700 YRM 1123

700 YRM 1123 1. PRE-CLEANER 2. STRAP CLAMP Figure 12. Hood Assembly Removal 14. Place a

1.

PRE-CLEANER

2.

STRAP CLAMP

Figure 12. Hood Assembly Removal

14. Place a radiator guard shield between radiator and fan so damage to radiator does not occur during fan removal.

NOTE: Perform Step 15 for lift truck models GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, 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, GLP\GDP80VX9, GLP\GDP90VX (GLP/ GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909).

16. Remove capscrews, washer, fan, fan spacers, and fan shroud.

See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

Radiator Replacement

See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909 B909)

See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909)

17. Remove radiator guard shield.

WARNINGGDP190VX) (B909) 17. Remove radiator guard shield. DO NOT remove the radiator cap from the radiator

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.

18. Let coolant cool to ambient temperature. Place a drain pan with a capacity equal to or greater than the capacity of the cooling system under the radia- tor. Remove radiator cap.

CAUTIONcooling system under the radia- tor. Remove radiator cap. Disposal of lubricants and fluids must meet

Disposal of lubricants and fluids must meet local environmental regulations.

19. Open drain plug or loosen clamp and disconnect lower radiator hose to allow coolant to drain.

See Figure 25 for lift truck models

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878,

E878)

See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, 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.

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 1. 2. RADIATOR CAP 3. HARNESS CLIP 4. UPPER RADIATOR BRACKET

1.

2. RADIATOR CAP

3. HARNESS CLIP

4. UPPER RADIATOR BRACKET

5.

6. ISOLATOR

7.

8.

9. TUBE

10. UPPER HOSE

11.

12. CHARGE AIR COOLER HOSE

13. CLAMP

14. CHARGE AIR COOLER HOSE

15. SHROUD

RADIATOR

INSERT

CAPSCREW

CLAMP

CLAMP

16.

17. CHARGE AIR COOLER HOSE

18. SCREW

19. WASHER

20.

21. LOWER HOSE

22.

23.

24. RESERVOIR CAP

25. RESERVOIR OUTLET

26.

27. TUBE

28. COOLANT LEVEL SENSOR

29. SEAL

CLAMP

CLIP

RESERVOIR

BUSHING

HOSE

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)

700 YRM 1123

21. Once coolant is drained from engine, loosen hose 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

Radiator Replacement

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.

ing cooling baffle to radiator assembly. See Fig- ure 14. 1. 2. 3. UPPER BRACKET 4.

1.

2.

3. UPPER BRACKET

4. CAP

5. RESERVOIR OUTLET

6.

7. HOSE

8.

9. RADIATOR

BAFFLE

ISOLATOR

BUSHING

RESERVOIR

10.

11.

12. CLAMP

13. UPPER HOSE

14. LOWER HOSE

15.

16. COOLING BAFFLE

17. DRAIN HOSE

18. PLASTIC TUBE

CAPSCREW

SHROUD

SEAL

Figure 14. GM 5.7L Cooling System, Lift Truck Models GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 15. Kubota 3.8L Cooling System, Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9,

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

700 YRM 1123

Legend for Figure 15

Radiator Replacement

1. RADIATOR

12.

CHARGE AIR COOLER HOSE

2. RADIATOR CAP

13.

LOWER HOSE

3. UPPER RADIATOR BRACKET

14.

SHROUD

4. INSERT

15.

RESERVOIR

5. ISOLATOR

16.

BUSHING

6. CAPSCREW

17.

RESERVOIR CAP

7. CLAMP

18.

RESERVOIR OUTLET

8. TUBE

19.

HOSE

9. UPPER HOSE

20.

COOLANT LEVEL SENSOR

10. CHARGE AIR COOLER HOSE

21.

SEAL

11. CHARGE AIR COOLER HOSE

NOTE: Removing the radiator from lift truck requires two people.

5.

Place shroud in lift truck. DO NOT install on radia- tor.

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 (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)

1. If removed, install the coolant level sensor.

2. Install radiator into truck.

3. Install upper radiator bracket, using capscrews taken out during removal.

4. Place a radiator guard shield between radiator and fan, so damage to radiator does not occur during fan installation

NOTE: Pull radiator shroud away from radiator while installing fan, fan spacer, and pulley.

6. Install fan, fan spacer, and pulley.

7. Remove radiator guard shield.

8. Install the radiator shroud on radiator using screws and washers taken out during removal

9. If equipped, connect the electrical connector to the coolant level sensor.

NOTE: For Mazda LPG engine, the LPG converter 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.

Radiator Replacement

WARNINGRadiator Replacement DO NOT use an alc ohol or methanol base an- t i f r

DO NOT use an alcohol or methanol base an- tifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTIONn a l i n j u r y or damage to the lift truck. Additives

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

16. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; 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/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)

GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

(B875

GLC050LX (A967)

GLP/GDP20-25LX (GLP/GDP050LX) (A974)

See Figure 18, for lift truck models

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)

See Figure 19 for lift truck models

GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813)

700 YRM 1123

GDP080, 090, 100, 110, 120VX) (H813, J813) 700 YRM 1123 1. 2. ADD MARK RESERVOIR 3.

1.

2. ADD MARK

RESERVOIR

3.

FULL MARK

Figure 16. Reservoir 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 GLP/GDP20-25LX (GLP/GDP050LX) (A974) Before May ’06

700 YRM 1123

700 YRM 1123 1. 2. ADD MARK RESERVOIR 3. FULL MARK Figure 17. Reservoir for Lift

1.

2. ADD MARK

RESERVOIR

3.

FULL MARK

Figure 17. Reservoir 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 GLP/GDP20-25LX (GLP/GDP050LX) (A974) After May ’06

Radiator Replacement

(GLP/GDP050LX) (A974) After May ’06 Radiator Replacement 1. AUXILIARY COOLANT RESERVOIR 2. FULL "HOT" MARK 3.

1. AUXILIARY COOLANT RESERVOIR

2. FULL "HOT" MARK

3. FULL "COLD" MARK

4. ADD "COLD" MARK

Figure 18. Reservoir for Lift Truck Models 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)

Radiator Replacement

Radiator Replacement 1. AUXILIARY COOLANT RESERVOIR 2. FULL "HOT" MARK 3. FULL "COLD" MARK 4. ADD

1. AUXILIARY COOLANT RESERVOIR

2. FULL "HOT" MARK

3. FULL "COLD" MARK

4. ADD "COLD" MARK

Figure 19. Reservoir 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 battery and battery tray.

19. Connect the positive battery cable.

20. Connect negative battery cable.

21. Install the hood and seat combination.

See section Frame 100 YRM 1120 for lift truck mod- els

GC/GLC030VX,

GC/GLC035VX,

GC/GLC040SVX (C809)

GLP/GDP16VX,

GLP/GDP20SVX

GP/GLP/GDP035VX,

(C810)

GLC20-35VX

GC/GLC055SVX) (A910)

GLP/GDP18VX,

(GP/GLP/GDP030VX,

GP/GLP/GDP040SVX)

(GC/GLC040-070VX,

GLP/GDP20-35VX

(GP/GLP/GDP040-070VX)

(B875)

700 YRM 1123

See section Frame 100 YRM 1243 for lift truck mod- els

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)

See section Frame 100 YRM 1423 for lift truck mod- els

GLC050LX (A967)

GLP/GDP20-25LX (GLP/GDP050LX) (A974)

GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) WARNING During engine operation, be careful not to touch the

WARNING

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNINGbelts. Contact with these parts can cause serious injury. T h e r a d i

The radiator or other parts of the cooling system may be hot or under pressure and can cause seri- 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.

t e m c l o s e the bleed screw. See Figure 20. CAUTION Additives

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

24. Check coolant level at the reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

700 YRM 1123

700 YRM 1123 1. MANIFOLD 2. COOLANT HOSES 3. BLEED SCREW 4. RADIATOR HOSE Figure 20.

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, GC/GLC040SVX (C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, 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.

4. Place a radiator guard shield between radiator and 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.

Radiator Replacement

6. Install fan, fan spacer, and pulley.

7. Remove radiator guard shield.

8. Install the radiator shroud on radiator using screws and washers taken out during removal

9. If equipped, connect the electrical connector to the coolant level sensor.

NOTE: For Mazda LPG engine, the LPG converter 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.

WARNINGthe drain plug or install lower hose. Tighten hose clamp. DO NOT use an alcohol or

DO NOT use an alcohol or methanol base an- tifreeze. They are flammable and could cause personal injury or damage to the lift truck.

CAUTIONand could cause personal injury or damage to the lift truck. Additives may damage the cooling

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

17. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deion- ized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F).

18. Use the same coolant mixture and fill the reservoir between the ADD and FULL marks. See Figure 21.

Radiator Replacement

Radiator Replacement 1. 2. ADD MARK RESERVOIR 3. FULL MARK Figure 21. Reservoir for Lift Truck

1.

2. ADD MARK

RESERVOIR

3.

FULL MARK

Figure 21. Reservoir 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 GLP/GDP20-25LX (GLP/GDP050LX) (A974)

19. Install battery and battery tray.

20. Connect the positive battery cable.

21. Connect negative battery cable.

22. Install the hood and seat combination.

See section Frame 100 YRM 1120 for lift truck mod- els

GC/GLC030VX,

GC/GLC035VX,

GC/GLC040SVX (C809)

GLP/GDP16VX,

GLP/GDP20SVX

GP/GLP/GDP035VX,

(C810)

GLP/GDP18VX,

(GP/GLP/GDP030VX,

GP/GLP/GDP040SVX)

See section Frame 100 YRM 1423 for lift truck mod- els

GLC050LX (A967)

GLP/GDP20-25LX (GLP/GDP050LX) (A974)

GLC050LX (A967) • GLP/GDP20-25LX (GLP/GDP050LX) (A974) WARNING 700 YRM 1123 During engine operation, be careful not

WARNING

700 YRM 1123

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNINGbelts. Contact with these parts can cause serious injury. The radiator or other parts of the

The radiator or other parts of the cooling system may be hot or under pressure and can cause seri- ous injury.

23. Start and run engine until thermostat opens. (The upper hose will be warm.)

until thermostat opens. (The upper hose will be warm.) CAUTION Additives may damage the cooling system.

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

24. Check coolant level at the reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

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)

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.

700 YRM 1123

9. If necessary, connect electrical connector onto the coolant level sensor.

10. Install upper radiator bracket and four capscrews.

10. Install upper radiator bracket and four capscrews. CAUTION The counterweight cover is extremely heavy 185

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.

16. Connect negative battery cable.

WARNINGpositive battery cable. 16. Connect negative battery cable. DO NOT use an alcohol or methanol base

DO NOT use an alcohol or methanol base an- tifreeze. They are flammable and could cause personal injury or damage to the lift truck.

and could cause personal injury or damage to the lift truck. CAUTION Additives may damage the

CAUTION

Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

17. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deion- ized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F).

18. Install radiator cap.

19. Use the same coolant mixture and fill the reservoir between the ADD and FULL marks. See Figure 22.

reservoir between the ADD and FULL marks. See Figure 22. WARNING During engine operation, be careful

WARNING

During engine operation, be careful not to touch the fan, pulleys, or drive belts. contact with these parts can cause serious injury.

Radiator Replacement

WARNINGthese parts can cause serious injury. Radiator Replacement T h e r a d i a

The radiator or other parts of the cooling system 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).

CAUTIONthermostat opens (The upper radiator hose will be warm). Additives may damage the cooling system. Before

Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

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.

in Periodic Maintenance section for your lift truck. 1. AUXILIARY COOLANT RESERVOIR 2. FULL "HOT" MARK

1. AUXILIARY COOLANT RESERVOIR

2. FULL "HOT" MARK

3. FULL "COLD" MARK

4. ADD "COLD" MARK

Figure 22. Reservoir 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 Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 23. Cooling System for Lift Truck Models S6.0FT, S7.0FT (S135FT,

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)

700 YRM 1123

Radiator Replacement

Legend for Figure 23

A. LOWER HOSE (CUMMINS 4.5L/KUBOTA 3.8L DIESEL)

B. LOWER HOSE (GAS AND LPG)

1. RADIATOR (WITH EXTERNAL OIL COOLER)

2. SHROUD

3. WASHER

4. SCREW

5. CLIP NUT

6. CLIP SPRING

7. CLAMP

8. UPPER RADIATOR BRACKET

9. CAPSCREW

10. INSERT

11. ISOLATOR

12. RESERVOIR

13. BRACKET (COOLANT FILL)

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)

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.

See Figure 25 for lift truck models

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878,

E878)

See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

C.

UPPER HOSE (GAS AND LPG)

D.

UPPER HOSE (CUMMINS 4.5L/KUBOTA 3.8L DIESEL)

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

24.

COOLANT LEVEL SENSOR

25.

DRAIN PLUG

See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (B909)

5.

Install coolant reservoir bracket and coolant reser- voir assembly onto upper bracket and tighten cap- screws.

See Figure 25 for lift truck models

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878,

 

E878)

 

See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, 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.

Radiator Replacement

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.

See Figure 25 for lift truck models

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878,

E878)

See Figure 13 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

See Figure 14 for lift truck models below equipped with GM 5.7L LPG engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

See Figure 15 for lift truck models equipped with Kubota 3.8L Diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909)

13. If necessary, connect electrical connector onto the coolant level sensor.

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.

See Figure 26 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

700 YRM 1123

See Figure 27 for lift truck models below equipped with GM 5.7L LPG engine

GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

See Figure 28 for lift truck models equipped with Kubota 3.8L Diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909)

17. Install hood assembly. For hood install procedures, see section

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)

Frame 100 YRM 1581 for lift truck models

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (E878)

GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)

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.

See Figure 25 for lift truck models

GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878,

E878)

See Figure 26 for lift truck models below equipped with Cummins QSB 3.3L diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

See Figure 28 for lift truck models equipped with Kubota 3.8L Diesel engine

GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (B909)

20. Connect positive battery cable.

21. Connect negative battery cable.

700 YRM 1123 WARNING
700 YRM 1123
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.

CAUTIONn a l i n j u r y or damage to the lift truck. Additives

Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

22. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled or deion- ized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F).

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.

reservoir between the ADD and FULL marks. See Figure 24. WARNING During engine operation, be careful

WARNING

During engine operation, be careful not to touch the fan, pulleys, or drive belts. contact with these parts can cause serious injury.

belts. contact with these parts can cause serious injury. WARNING The radiator or other parts of

WARNING

The radiator or other parts of the cooling system 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).

thermostat opens (The upper radiator hose will be warm). CAUTION A d d i t i

CAUTION

Additives may damage the cooling system. Before using additives, contact you local Yale dealer.

Radiator Replacement

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.

in Periodic Maintenance section for your lift truck. 1. AUXILIARY COOLANT RESERVOIR 2. FULL "HOT" MARK

1. AUXILIARY COOLANT RESERVOIR

2. FULL "HOT" MARK

3. FULL "COLD" MARK

4. ADD "COLD" MARK

Figure 24. Reservoir 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)

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX

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)

700 YRM 1123

Radiator Replacement

700 YRM 1123 Radiator Replacement Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX

Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) (Sheet 2 of 3)

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 25. Cooling System for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX

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

700 YRM 1123

Legend for Figure 25

Radiator Replacement

A. GM 4.3L (GAS/LPG)

C.

KUBOTA (DIESEL)

B. CUMMINS 4.5L

(DIESEL)

1. AIR INTAKE (WITHOUT PRE-CLEANER)

17.

SCREW

2. PRE-CLEANER

18.

SHROUD

3. HOOD ASSEMBLY

19.

FAN

4. CLAMP

20.

FAN SPACER

5. INLET HOSE

21.

TRANSMISSION LINES

6. SILENCER (DIESEL)

22.

AUXILIARY COOLANT RESERVOIR AND

7. AIR FILTER

BRACKET ASSEMBLY

8. UPPER RADIATOR BRACKET

23.

OUTLET

9. ISOLATOR

24.

CAP

10. INSERT

25.

BUSHING

11. CAPSCREW

26.

HOSE

12. RADIATOR (WITH EXTERNAL OIL COOLER)

27.

AUXILIARY COOLANT RESERVOIR HOSE

13. UPPER HOSE

28.

DRAIN PLUG

14. LOWER HOSE

29.

RADIATOR CAP

15. CLIP NUT

30.

HOOD SUPPORT

16. WASHER

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 1. PRE-CLEANER 2. CLAMP 3. HOOD SUPPORT 4. HOOD ASSEMBLY 5.

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

11. AUXILIARY COOLANT RESERVOIR HOSE

12. RESERVOIR OUTLET

13.

14. BUSHING

15. COOLANT RECOVERY RESERVOIR

16. TUBE

CAP

17. COOLANT LEVEL SENSOR

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.

30. AUXILIARY COOLANT RESERVOIR ASSEMBLY

31. CLIP NUT

SPACER

Figure 26. Cooling System Cummins QSB 3.3L Diesel Engine for Lift Truck Model GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

700 YRM 1123

Radiator Replacement

700 YRM 1123 Radiator Replacement 1. PRE-CLEANER 2. 3. HOOD SUPPORT 4. HOOD 5. DIRTY AIR

1. PRE-CLEANER

2.

3. HOOD SUPPORT

4. HOOD

5. DIRTY AIR HOSE

6. CLEAN AIR HOSE

7.

8. AIR CLEANER BRACKET

9.

10.

11. RADIATOR ISOLATOR

12. UPPER BRACKET

CLAMP

AIR FILTER

CAPSCREW

NUT

13. RADIATOR

14.

15. COOLANT RECOVERY RESERVOIR

16. LOWER RADIATOR HOSE

17. UPPER RADIATOR HOSE

18. SEAL

19.

20. FAN SHROUD

21.

22.

23. FAN MOUNTING SCREWS

BAFFLE

BAFFLE

FAN

SPACER

Figure 27. Cooling System GM 5.7L LPG Engine for Lift Truck Model GLP80VX, GLP80VX9, GLP90VX (GLP170VX, GLP175VX36, GLP190VX) (A909, B909)

Radiator Replacement

700 YRM 1123

Radiator Replacement 700 YRM 1123 Figure 28. Cooling System Kubota 3.8L Diesel Engine for Lift Truck

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

700 YRM 1123

Fan Assembly Replacement

Legend for Figure 28

1. PRE-CLEANER

2. CLAMP

3. HOOD SUPPORT

4. HOOD ASSEMBLY

5. DIRTY AIR HOSE

6. CLEAN AIR HOSE

7.

8. AIR CLEANER BRACKET

9. CAPSCREW

10. NUT

11. AUXILIARY COOLANT RESERVOIR HOSE

12. RESERVOIR OUTLET

13.

14.

15. COOLANT RECOVERY RESERVOIR

AIR FILTER

CAP

BUSHING

16. TUBE

17. COOLANT LEVEL SENSOR

18. UPPER BRACKET

19. RADIATOR ISOLATOR

20. RADIATOR

21. CAC HOSE

22. CAC TUBE

23. AIR FLOW SENSOR

24. LOWER RADIATOR HOSE

25. UPPER RADIATOR HOSE

26. SHROUD AND BAFFLE

27. WASHER

28.

29.

FAN

SPACER

Fan Assembly Replacement

FAN REMOVAL

28. 29. FAN SPACER Fan Assembly Replacement FAN REMOVAL WARNING During engine operation, be careful not

WARNING

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNINGbelts. Contact with these parts can cause serious injury. The radiator or other parts of the

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.

attempting to check or fix any part of the cooling system. WARNING The radiator fins on

WARNING

The radiator fins on the radiator are very sharp and 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/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)

GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

(B875)</