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GP/GLPO/GDP/GTP040VX, GP/GLPO/GDP/GTP050VX, GP/GLPO/GDP/

GTP060VX, GP/GLPO/GDP/GTP070VX (D875)


SERVICE MANUAL CONTENTS
PART YRM REV
SECTION NUMBER NUMBER DATE
OPERATOR'S CAB........................................................................................................ 550108590 0100 YRM 1752 12/14
FRAME............................................................................................................................ 550108889 0100 YRM 1754 12/14
YANMAR DIESEL ENGINES.......................................................................................... 524240453 0600 YRM 1205 12/14
KUBOTA SPARK IGNITED 2.5L LPG............................................................................ 550096316 0600 YRM 1670 12/14
PSI 2.4L ENGINE............................................................................................................ 550108890 0600 YRM 1755 12/14
COOLING SYSTEM........................................................................................................ 550108891 0700 YRM 1756 12/14
LPG FUEL SYSTEM, KUBOTA 2.5L ENGINE............................................................... 550096320 0900 YRM 1677 12/14
FUEL SYSTEM PSI 2.4L................................................................................................ 550108892 0900 YRM 1757 12/14
SINGLE SPEED PS CHAIN DRIVE PTO........................................................................ 550108495 1300 YRM 1740 12/14
2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... 550109083 1300 YRM 1764 12/14
DRIVE AXLE REPAIR (WET BRAKE)........................................................................... 550096322 1400 YRM 1679 12/14
DRIVE AXLE REPAIR - DRY BRAKE............................................................................ 550108893 1400 YRM 1758 12/14
STEERING AXLE............................................................................................................ 550108894 1600 YRM 1759 12/14
BRAKE SYSTEM............................................................................................................ 550108498 1800 YRM 1743 12/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
HYDRAULIC GEAR PUMPS.......................................................................................... 550108499 1900 YRM 1744 12/14
MAIN CONTROL VALVE................................................................................................ 550108500 2000 YRM 1745 12/14
CYLINDER REPAIR (MAST S/N F507, F508, F562, F563)........................................... 550093750 2100 YRM 1668 12/14
CYLINDER REPAIR (MAST S/N D515, E509, E564)..................................................... 550100651 2100 YRM 1692 12/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 550108895 2200 YRM 1760 12/14
ENGINE ELECTRICAL SYSTEM, PSI 2.4L ENGINE..................................................... 550108896 2200 YRM 1761 12/14
MAST REPAIR (S/N F507, F508, F562, F563)............................................................... 550093755 4000 YRM 1669 12/14
MAST REPAIR (S/N D515, E509, E564)........................................................................ 550100656 4000 YRM 1693 12/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
DIAGRAMS AND SCHEMATICS.................................................................................... 550108507 8000 YRM 1753 12/14
PERIODIC MAINTENANCE............................................................................................ 550108897 8000 YRM 1762 12/14
CAPACITIES AND SPECIFICATIONS........................................................................... 550108898 8000 YRM 1763 12/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

PART NO. 550109093 (12/14)


0100 YRM 1752 General

General
The overhead guard is an integral part of operator The operator cab is a separate unit and can be
cab. The operator cab is installed on a platform above removed as a complete unit from module and frame
main frame members. Step plates on both sides of lift of the lift truck. See Figure 1.
truck provide access to operator cab.

Figure 1. Operator Cab

Cab Replacement
REMOVE NOTE: On lift trucks equipped with a LPG fuel sys-
tem, move the LPG tank and bracket to side of truck
NOTE: The LPG tank bracket used to mount the LPG before opening the hood.
tank (if equipped) onto the counterweight comes in
two styles. One style of bracket swings out to side of See PSI 2.0L LPG Fuel System 0900YRM1739 for
truck and other swings out to side and drops down. lift truck models
• GLP/GDP16-18VX, GLP/GDP20SVX (D810)

See for lift truck models


• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with a PSI 2.4L LPG engine

See for lift truck models

1
Cab Replacement 0100 YRM 1752

• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with a Kubota 2.5L LPG en-
gine

1. For lift truck models GLP/GDP16-18VX, GLP/


GDP20SVX (D810), tilt steering column to UP po-
sition, slide seat assembly forward, open rear
door, and open hood to disconnect battery. See
Figure 2.

For lift truck models GLP/GDP20-35VX (GP/GLP/


GDP040-070VX) (D875), tilt steering column to UP
position, slide seat assembly forward, open rear
sliding window, and open hood to disconnect bat-
tery. See Figure 3.

1. LATCH 3. REAR DOOR


2. HINGE

Figure 2. Rear Door and Latch, Lift Truck Models


GLP/GDP16-18VX, GLP/GDP20SVX (D810)

A. LIFT TRUCKS WITHOUT AIR CONDITIONING


B. LIFT TRUCKS WITH AIR CONDITIONING
1. REAR BOTTOM WINDOW
2. RELEASE LATCH
3. AC HOSE

Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)

2
0100 YRM 1752 Cab Replacement

2. Loosen clamp and disconnect air filter hose from


elbow. Remove bolts, elbow, retainer, and grom-
met from rear left corner leg of cab frame. See
Figure 4.

WARNING
DO NOT disconnect the heater hoses from the en-
gine when the engine is hot or when the cooling
system is under pressure, to do so could cause
serious injury.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator is hot
and the cap is removed, the pressure is released
from the system and the steam and boiling cool-
ant can cause burns. Wait 30 minutes for the en-
gine to cool. Do a touch test by touching the radi-
ator with your hand. If the radiator is still hot to
the touch, wait another 30 minutes before at-
tempting to remove, check, or fix any part of the
cooling system.

NOTE: Removing radiator cap will help depressurize


cooling system.

3. Turn knobs counterclockwise and remove radiator NOTE: AIR FILTER HOSE FOR LIFT TRUCK MOD-
cover to access radiator cap. Remove radiator ELS GLP/GDP16-18VX, GLP/GDP20SVX (D810)
cap. See Figure 5. SHOWN. AIR FILTER HOSE FOR LIFT TRUCK
MODELS GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875) IS SIMILAR.

1. CLAMP
2. AIR FILTER HOSE
3. BOLTS
4. ELBOW
5. RETAINER
6. GROMMET

Figure 4. Air Filter Hose Removal

3
Cab Replacement 0100 YRM 1752

5. Contact a certified air conditioning specialist to


CAUTION have the refrigerant extracted from the air condi-
DO NOT allow any fluid to drain when disconnect- tioning system.
ing the heater hose from the engine. The method
will help when purging the system during installa- 6. If lift truck cab is equipped with an air conditioner/
tion. heater unit, disconnect AC refrigerant hoses from
refrigerant compressor. See Figure 6.
4. Disconnect and cap heater hoses from engine.
See Figure 7. NOTE: Removing door assemblies requires two peo-
ple.

WARNING 7. Open left side door, remove lock nut and discon-
Replacement, installation and repairs to air condi- nect gas spring from cab mounting bracket. See
tioning units that require discharging and/or refill- Figure 8.
ing of the refrigeration fluid must be performed by 8. Lift left side door up and over hinge pin and set
a certified technician. aside. See Figure 9 .
NOTE: Perform Step 5 and Step 6 for lift truck mod-
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875).

NOTE: RADIATOR COVER FOR LIFT TRUCKS EQUIPPED WITH STEEL DOORS SHOWN. RADIATOR
COVER FOR LIFT TRUCKS EQUIPPED WITH PVC DOORS IS SIMILAR.

A. GLP/GDP16-18VX, GLP/GDP20SVX (D810) LIFT B. GLP/GDP20-35VX (GP/GLP/GDP040-070VX)


TRUCKS (D875) LIFT TRUCKS
1. RADIATOR COVER
2. RADIATOR CAP

Figure 5. Radiator Cover and Cap Location

4
0100 YRM 1752 Cab Replacement

NOTE: KUBOTA 2.5L LPG ENGINE SHOWN. OTHER ENGINES ARE SIMILAR.

1. AC REFRIGERANT HOSES 4. ENGINE


2. REFRIGERANT COMPRESSOR 5. HOSE WRAP
3. AC/HEATER UNIT 6. AC WIRE HARNESS

Figure 6. AC Refrigerant Hose and Wire Harness Connections

disconnect fittings to disconnect heater hoses


WARNING from heater assembly (see Figure 7). Discon-
DO NOT disconnect the heater hoses from the nect heater wire harness connections. See Fig-
quick disconnect fittings (inside operator cab) or ure 10.
engine when the engine is hot or under pressure,
to do so could cause serious injury. NOTE: Removing door assemblies requires two peo-
ple.
9. Disconnect heater hose quick disconnect fittings.
10. Open right side door, remove lock nut, and dis-
a. For lift truck models GLP/GDP16-18VX, GLP/ connect gas spring from cab mounting bracket.
GDP20SVX (D810), open right side door and See Figure 8.
push buttons on quick disconnect fittings to dis-
connect heater hoses from heater assembly 11. Lift right side door up and over hinge pin and set
hoses. Disconnect heater wire harness con- aside. See Figure 9 .
nectors. See Figure 7.
NOTE: Wiper motor cover must be removed before
b. For lift truck models GLP/GDP20-35VX dash assembly can be removed.
(GP/GLP/GDP040-070VX) (D875), open right
12. Unclip and remove front wiper motor cover. See
side door and remove radiator cover to access
Figure 11.
quick disconnect fittings. Push buttons on quick

5
Cab Replacement 0100 YRM 1752

NOTE: HOSE SLEEVE REMOVED FOR CLARITY

A. OUTSIDE OF LIFT TRUCK, LIFT TRUCK MOD- C. LIFT TRUCK MODELS GLP/GDP20-35VX
ELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) (GP/GLP/GDP040-070VX) (D875)
B. INSIDE OF LIFT TRUCK, LIFT TRUCK MODELS
GLP/GDP16-18VX, GLP/GDP20SVX (D810)
1. QUICK DISCONNECT FITTING 3. INNER REAR COVER
2. HEATER HOSES

Figure 7. Heater Hose Connection

6
0100 YRM 1752 Cab Replacement

NOTE: MAJOR COMPONENTS OF CAB OMITTED


NOTE: RIGHT SIDE DOOR SHOWN.
FOR CLARITY.
1. GAS SPRING 3. LOCK NUT
2. CAB MOUNTING 1. HEATER WIRE HARNESS CONNECTOR
BRACKET 2. REAR GRAB HANDLE HORN BUTTON CON-
NECTOR (TO RIGHT CHASSIS HARNESS)
Figure 8. Gas Spring Mounting Removal
Figure 10. Heater Wire Harness and Rear Grab
Handle Horn Button Connections, Lift Truck
Models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875)

13. Remove five fasteners securing dash panel to top


of cowl panel. Remove four clips, located under-
neath dash panel, that attach dash panel to the
kick panel. See Figure 11.

14. Remove two capscrews securing cowl panel to


front operator cab legs. See Figure 11.

15. Remove dash assembly from lift truck.

16. Remove floor mat and floor plate.

17. Remove kick panel from seal plate assembly. See


Figure 11.

18. Remove capscrews, clip nuts, and seal plate as-


sembly from lift truck frame. See Figure 11.

NOTE: RIGHT SIDE DOOR HINGE SHOWN. 19. Disconnect rear grab handle horn button connec-
tor from right-hand chassis harness, located in
1. HINGE PIN right rear corner leg of cab frame. See Figure 12.
2. DOOR HINGE
Figure 9. Door Removal

7
Cab Replacement 0100 YRM 1752

20. Disconnect light harness connector from Vehicle 22. Remove front and rear cab capscrews and flange
Systems Manager (VSM) and right-hand chassis nuts from lift truck frame. See Figure 14.
harness connector. See Figure 12.

21. Remove rear panels, front panels, and fender


covers to access cab mounting capscrews and
flange nuts. See Figure 13.

NOTE: DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) SHOWN.
DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) IS SIMI-
LAR.

1. FASTENER 6. KICK PANEL


2. CAPSCREW 7. DASH PANEL
3. CLIP 8. SEAL PLATE
4. CLIP NUT 9. COWL PANEL
5. FRONT WIPER MOTOR COVER
Figure 11. Dash Assembly, Remove/Install

8
0100 YRM 1752 Cab Replacement

NOTE: KICK AND DASH PANELS REMOVED FOR CLARITY.

1. VSM 3. HARNESS CONNECTOR (TO RIGHT CHASSIS


2. LIGHT HARNESS CONNECTOR (TO VSM) HARNESS)
4. REAR GRAB HANDLE HORN BUTTON CON-
NECTOR

Figure 12. Cab Electrical Connections

WARNING CAUTION
Make sure that the lifting device has a minimum Lift the operator cab carefully. Check that all elec-
capacity to lift 500 kg (1100 lb) trical wires and attachments are disconnected
and are not damaged.
23. Connect a lifting device to a spreader bar or lift
strap, that is through door openings at top of op- 24. Carefully lift operator cab away from lift truck. Set
erator's cab (under overhead guard structure). operator cab in a storage area and place blocks
Place material that will be a cushion at top of door under operator cab to make it stable and prevent
opening to prevent damage. Operate lifting device damage to parts still attached.
just enough to correctly position spreader bar or
lifting strap on operator's cab. See Figure 15.

9
Cab Replacement 0100 YRM 1752

NOTE: LEFT DOOR REMOVED FOR CLARITY

1. REAR PANEL (LPG)


2. REAR PANEL (DIESEL)
3. FRONT PANEL
4. FENDER COVER
5. SCREWS
6. CAPSCREW

Figure 13. Front and Rear Panels and Fender


Cover Removal

A. FRONT VIEW
B. REAR VIEW
1. CAPSCREWS
2. FLANGE NUTS

Figure 14. Front and Rear Cab Mounting

10
0100 YRM 1752 Cab Replacement

5. Install fender covers, front and rear panels to


frame. Tighten capscrews to 11 N•m (8 lbf in).
See Figure 13.

6. Connect light harness connector to Vehicle Sys-


tems Manager (VSM) and right-hand chassis har-
ness. See Figure 12.

7. Connect right-hand chassis harness to rear grab


handle horn button connector. See Figure 12.

8. Install seal plate assembly to lift truck frame and


tighten capscrews and clip nuts.

9. Install kick panel onto seal plate assembly. See


Figure 11.

10. Install floor plate and floor mat.

11. Install dash assembly onto kick panel and install


five capscrews to secure dash assembly to cowl
panel. See Figure 11.

12. Install and clip front wiper motor cover.

13. Install right side door onto cab by lifting door up


and over top and bottom hinge pins. See Fig-
ure 9.

14. Connect gas spring and lock nut to cab mounting


bracket. See Figure 8 .
NOTE: ILLUSTRATION FOR REFERENCE PURPO-
SES ONLY. ACTUAL CAB MAY BE SLIGHTLY DIF- 15. If lift truck cab is equipped with an air conditioner/
FERENT. heater unit, connect AC refrigerant hoses to re-
frigerant compressor. See Figure 6.
Figure 15. Lift Strap Connection
16. Connect heater hoses to heater assembly and
connect heater wire harness connection. See Fig-
INSTALL ure 7.
1. Connect a lifting device to a spreader bar or lift 17. Install left side door onto cab by lifting door up
strap, that is through door openings at top of op- and over top and bottom hinge pins. See Fig-
erator's cab (under overhead guard structure). ure 9.
Place material that will be a cushion at top of door
opening to prevent damage. Operate lifting device 18. Connect gas spring and lock nut to cab mounting
just enough to correctly position spreader bar or bracket. See Figure 8.
lifting strap on operator's cab. See Figure 15.
19. Uncap and connect heater hoses at engine. See
2. Carefully lift operator cab onto lift truck frame Figure 7.
making sure that front and rear leg mounting
holes are aligned with frame mounting holes. 20. Check coolant level, fill if necessary. For proce-
dures, see
3. Install capscrews and flange nuts to rear operator
cab legs. Tighten capscrews to 66 N•m (49 lbf ft). Cooling System 0700YRM1737 for lift truck mod-
See Figure 14. els
• GLP/GDP16-18VX, GLP/GDP20SVX (D810)
4. Install capscrews and lock nuts to front operator's
cab legs. Tighten capscrews to 66 N•m (49 lbf ft).

11
Cab Replacement 0100 YRM 1752

Cooling System 0700YRM1756 for lift truck mod- 26. On lift trucks equipped with an air conditioner/
els heater unit, start engine and turn on heater to ON
• GLP/GDP20-35VX (GP/GLP/ position, run engine approximately one to two mi-
GDP040-070VX) (D875) nutes or until heater supply hose is fully purged.

21. Install radiator cap and radiator cover. See Fig- 27. If lift truck is equipped with a LPG engine, swing
ure 5. the LPG tank and bracket back to its original posi-
tion on counterweight and make sure it locks in
22. Connect air filter hose onto rear left corner leg of position.
cab frame. Tighten capscrews to
66 N•m (49 lbf ft). See Figure 4. See PSI 2.0L LPG Fuel System 0900YRM1739
for lift truck models
23. Connect battery and close hood. • GLP/GDP16-18VX, GLP/GDP20SVX (D810)
24. For lift trucks NOT equipped with an AC/Heater See Fuel System PSI 2.4L 0900YRM1757 for lift
unit, start engine and turn on heater to ON posi- truck models
tion, run engine approximately one to two minutes
• GLP/GDP20-35VX (GP/GLP/
or until heater supply hose is fully purged.
GDP040-070VX) (D875) equipped with a
PSI 2.4L LPG engine
WARNING
See LPG Fuel System, Kubota 2.5L Engine
Replacement, installation and repairs to air condi-
0900YRM1677 for lift truck models
tioning units that require discharging and/or refill-
ing of the refrigeration fluid must be performed by • GLP/GDP20-35VX (GP/GLP/
a certified technician. GDP040-070VX) (D875) equipped with a
Kubota 2.5L LPG engine
NOTE: Step 25 and Step 26 apply only to lift truck
models GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with an air conditioner/heater unit.

25. Contact a certified air conditioning specialist to


have the refrigerant refilled into air conditioning
system.

Door Assemblies
RIGHT DOOR ASSEMBLY NOTE: Removing radiator cap will help depressurize
cooling system.
Remove
1. Remove radiator cover to access radiator cap.
Remove radiator cap. See Radiator Cover and
WARNING Cap Location.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When radiator cap is re-
moved, the pressure is released from cooling sys- WARNING
tem. If cooling system is hot, the steam and boil- DO NOT disconnect the heater hoses from the
ing coolant can cause burns. quick disconnect fittings (inside operator cab) or
engine when the engine is hot or under pressure.
Wait 30 minutes for the engine to cool. Do a touch Serious injury can occur.
test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30 NOTE: Removing right door assembly requires two
minutes before attempting to remove the radiator people.
cap.
2. Disconnect heater hose quick disconnect fittings.
See Figure 7.

12
0100 YRM 1752 Door Assemblies

a. For lift truck models GLP/GDP16-18VX, GLP/ 7. Disconnect gas spring. See Figure 8.
GDP20SVX (D810), open right door and push
buttons on quick disconnect fittings to discon- 8. Remove right door from cab frame by lifting door
nect heater hoses from heater assembly ho- up and over hinge pin. See Figure 9.
ses. Disconnect heater wire harness connec-
tion. See Figure 7 and Figure 12. Disassemble

b. For lift truck models GLP/GDP20-35VX Door Cover With Heater Unit
(GP/GLP/GDP040-070VX) (D875), open right
side door and remove radiator cover to access NOTE: This section removes the right door cover. To
quick disconnect fittings. Push buttons on quick remove the heater unit from right door, see section
disconnect fittings to disconnect heater hoses Heater and Air Conditioner Replacement.
from heater assembly hoses. Disconnect
1. Remove four screws and washers that attach
heater wire harness connection. See Figure 7
handle to door cover. Remove handle and two
and Figure 12.
handle plates. See Figure 16.

WARNING 2. Remove fan and heater knobs from knob plate.


Remove four screws that fasten knob plate to
Replacement, installation and repairs to air condi-
heater valve and switch plate. Remove knob plate
tioning units that require discharging and/or refill-
from door cover.
ing of the refrigeration fluid must be performed by
a certified technician. 3. Remove two fasteners from top of door cover.
See Figure 16.
NOTE: Step 3 through Step 6 apply to lift truck mod-
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX) 4. Remove five plugs, washers, and star nuts along
(D875) equipped with a air conditioner/heater unit. sides and front of door cover. Remove two cap-
screws and washers from bottom of door cover.
3. Contact a certified air conditioning specialist to
Remove door cover from door frame. See Fig-
have the refrigerant extracted from the air condi-
ure 16.
tioning system.
5. Remove pre-filter, located on bottom of door
4. Remove fasteners and rear cover. See Figure 5.
frame. See Figure 16.
5. Disconnect air conditioner hoses at bulkhead
bracket. See Figure 6.

6. Disconnect air conditioner wire harness. See Fig-


ure 6.

13
Door Assemblies 0100 YRM 1752

Figure 16. Right Door Cover With Heater Unit

14
0100 YRM 1752 Door Assemblies

Legend for Figure 16

1. PLUG 9. WASHER
2. FASTENER 10. HEATER/FAN LOUVER
3. GAS SPRING 11. CAPSCREW
4. FAN AND HEATER/AC KNOBS 12. DOOR COVER
5. SCREW 13. PRE-FILTER
6. KNOB PLATE 14. HEATER VALVE AND SWITCH PLATE
7. HANDLE 15. STAR NUT
8. HANDLE PLATES

Door Cover With Air Conditioner/Heater Unit


NOTE: This section removes the right door cover. To
remove the air conditioner/heater unit from right door,
see section Heater and Air Conditioner Replacement.

NOTE: The procedures in this section apply only to


lift truck models GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875) equipped with an AC/heater
unit.

1. Remove four screws and washers that attach


handle to door cover. Remove handle and two
handle plates. See Figure 16.
1. CAPSCREWS
2. Remove hose wrap from AC hoses. See Figure 6. 2. AC ROCKER SWITCH
3. FAN AND HEATER/AC KNOBS
3. Remove fan and heater/AC knobs from knob
plate. Remove four screws that fasten knob plate Figure 17. AC Rocker Switch
to heater valve and switch plate. Remove knob
plate and heater valve from door cover. See Fig-
ure 16. Door Lock Assembly

4. Remove two fasteners from top of door cover. 1. Remove inside lever handle cover. See Figure 18.

5. Remove four capscrews that fasten AC rocker 2. Place inside lever handle in closed position. Re-
switch plate to door cover. Remove AC rocker move lock nut from release bar at inside lever
switch plate from door cover. See Figure 17. handle. Pull inside lever handle to open position.
Remove release bar from inside lever handle.
6. Remove five plugs, washers, and star nuts along
sides and front of door cover. Remove two cap- 3. Remove two capscrews and inside lever handle
screws and washers from bottom of door cover. and mounting plate. See Figure 18.
Remove door cover from door frame. See Fig-
ure 16. 4. Remove lock nut from release bar and release
bar from door lock assembly.
7. Remove pre-filter, located on bottom of door
frame. See Figure 16. 5. Remove two nuts and capscrews from door lock
assembly. Remove door lock assembly from door
frame.

15
Door Assemblies 0100 YRM 1752

A. LEVER IN CLOSED POSITION B. LEVER IN OPEN POSITION


1. INSIDE LEVER HANDLE 7. DOOR LOCK ASSEMBLY
2. CAPSCREWS 8. RELEASE LEVER
3. INSIDE LEVER HANDLE COVER 9. NUT
4. CAPSCREW (OUTSIDE HANDLE) 10. MOUNTING PLATE
5. LOCK NUT 11. SCREWS
6. RELEASE BAR 12. WASHER

Figure 18. Door Lock and Lever Disassembly

1. Remove screw and washer from release lever


and release lever from outside door handle as-
sembly. See Figure 18 and Figure 19.

2. Remove four capscrews that fasten outside door


handle to door. Remove outside door handle from
door.

3. Remove seal and grip from outside handle as-


sembly. Discard seal. See Figure 19.

16
0100 YRM 1752 Door Assemblies

Inspect

Inspect all hoses for cracks and wear. Replace dam-


aged hoses. Inspect seals around door window and
door lock assembly and replace if damaged. Check
door lock and latch assembly. Make sure it opens,
shuts, and locks door securely and there is no rust,
grease, oil, or dirt on door lock and latch assembly
parts. Inspect windows for cracks or chips. Replace
windows if damaged.

Assemble

Windows

For procedures to install door windows, see section


Window Replacement.

Door Lock Assembly


1. Install new seal and grip to outside handle assem-
NOTE: RIGHT DOOR SHOWN. LEFT DOOR IS THE bly. See Figure 19.
SAME.
2. Apply Loctite® 242 to threads of four capscrews
1. LATCH STRIKER ASSEMBLY and secure outside door handle to door. See Fig-
2. SEAL
3. OUTSIDE HANDLE ASSEMBLY ure 18. Tighten capscrews to 19 N•m (170 lbf in).
4. GRIP
3. Apply Loctite® 242 to capscrew and install re-
Figure 19. Outside Handle Disassembly lease lever to rear of outside door handle assem-
bly. Tighten capscrew to 5.0 N•m (44 lbf in).
Windows
4. Install door lock assembly onto door frame using
For procedures to remove door windows, see section two capscrews and nuts. Tighten capscrews to
Window Replacement. 19 N•m (170 lbf in). See Figure 18.

5. Install inside lever handle and mounting plate to


Clean door frame. Tighten capscrews to
19 N•m (170 lbf in).
WARNING
6. Place inside lever handle in closed position (see
Compressed air can move particles so that they Figure 18). Insert release bar into door lock as-
cause injury to the user or to other personnel. sembly end and into inside lever handle. Secure
Make sure that the path of the compressed air is release bar with lock nuts.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. 7. Install cover onto inside lever assembly.

Check door assembly and parts for oil, grease, dirt,


and other debris. Clean door assembly and parts with
a clean cloth, soap, and water. Compressed air can
be used to dry door assembly and parts.

17
Door Assemblies 0100 YRM 1752

Door Cover With Heater Unit 7. Install handle and handle plates on door with four
screws and washers. See Figure 16.
NOTE: This section installs the right door cover. To
install the heater unit to right door, see section Heater Install
and Air Conditioner Replacement.
NOTE: Installing right door assembly requires two
1. Install pre-filter on bottom of door frame. See Fig- people.
ure 16.
1. Install right side door onto cab by lifting door over
2. Align holes on door cover with holes that are on top and bottom hinge pins. See .
door frame. Install five plugs into holes that are
along sides and front of door cover. Secure bot- 2. Connect gas spring and lock nut to mounting
tom of door cover using two capscrews and wash- bracket on operator cab frame. See .
ers. See Figure 16.
3. Connect heater hoses to heater assembly and
3. Install two fasteners into holes on top of door connect heater wire harness connection. See Fig-
cover. See Figure 16. ure 7.

4. Install knob plate on heater valve and switch plate 4. Install radiator cap and radiator cover. See Fig-
with four screws. Install fan and heater knobs on ure 5.
knob plate.
LEFT DOOR ASSEMBLY
5. Install handle and handle plates on door with four
screws and washers. See Figure 16. Remove

Door Cover With Air Conditioner/Heater Unit NOTE: Removing left door assembly requires two
people.
NOTE: This section installs the right door cover. To
install the air conditioner/heater unit to right door, see 1. Open left side door and disconnect gas spring.
section Heater and Air Conditioner Replacement. See .

1. Install pre-filter on bottom of door frame. See Fig- 2. Remove left side door from cab frame by lifting
ure 16. door over hinge pin. See .

2. Align holes on door cover with holes that are on Disassemble


door frame. Install five plugs into holes that are
along sides and front of door cover. Secure bot- Door Cover
tom of door cover using two capscrews and wash-
ers. See Figure 16. 1. Remove cover from rear of handle and remove
screw. Remove capscrew from door lock cover
3. Install AC rocker switch plate to door cover using and remove door lock cover from lock assembly.
four capscrews. See Figure 17. See Figure 20.

4. Install two fasteners into holes on top of door 2. Remove two capscrews that secure handle to
cover. See Figure 16. door lock assembly. Remove handle from door.

5. Install knob plate on heater valve and switch plate 3. Remove two fasteners from top of door cover. Re-
with four screws. Install fan and AC/ heater knobs move five plugs along edges of door cover and
on knob plate. remove door cover from door frame. See Fig-
ure 20.
6. Install hose wrap around AC hoses. See Figure 6.

18
0100 YRM 1752 Door Assemblies

1. FASTENER 5. CAPSCREW
2. PLUG 6. DOOR LOCK COVER
3. COVER 7. HANDLE
4. SCREW 8. DOOR LOCK ASSEMBLY

Figure 20. Left Door Cover Removal

19
Door Assemblies 0100 YRM 1752

Door Lock Assembly Check door assembly and parts for oil, grease, dirt,
and other debris. Clean door assembly and parts with
1. Remove capscrew and washer from release a clean cloth and soap and water. Compressed air
lever. Remove release lever from door. See Fig- can be used for drying door assembly and parts.
ure 21.
Inspect
2. Remove four capscrews and two washers (right
side only) from rear of outside handle. Remove
Inspect seals around window, door, and door lock as-
outside door handle from door.
sembly and replace if damaged. Check door lock and
3. Remove grip and seal from outside handle. Dis- latch assembly. Make sure it opens, shuts, and locks
card seal. See Figure 19 door securely and there is no rust, grease, oil, or dirt
on door lock and latch assembly parts. Inspect win-
dow for cracks or chips. Replace window if damaged.

Assemble

Windows

For procedures to install door windows, see section


Window Replacement

Door Lock Assembly


1. Install seal and grip (see Figure 19) onto outside
door handle. Place outside door handle onto door
frame. Apply Loctite® 242 to threads of four cap-
screws and secure outside handle to door frame
using capscrews and washers. The washers go
on right side from inside cab. Tighten capscrews
to 19 N•m (170 lbf in).

2. Apply Loctite® 242 to capscrew and install re-


lease lever to rear of outside door handle. Tighten
capscrew and washer to 5.0 N•m (44 lbf in). See
1. CAPSCREW
2. WASHER Figure 21.
3. RELEASE LEVER
Figure 21. Door Lock Assembly Door Cover
1. Place door cover onto door frame. Install two fas-
Windows teners onto top of door cover and install five plugs
along edges of door cover. See Figure 20.
For procedures to remove door windows, see section
Window Replacement. 2. Install handle to latch assembly with two cap-
screws. Tighten capscrews to 19 N•m (170 lbf in).
Secure lock cover to door lock assembly with cap-
Clean
screw.

WARNING 3. Secure handle to rear of door cover with screw.


Compressed air can move particles so that they Tighten screw to 5.0 N•m (44 lbf in). Push cover
cause injury to the user or to other personnel. into place over screw.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

20
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