524223757-0700YRM1123-(03-2013)-UK-EN

Maintenance

COOLING SYSTEMGC/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]

PART NO. 524223757 700 YRM 1123

SAFETY PRECAUTIONSMAINTENANCE 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 Manualsprovide 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 indamage 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 beinglifted 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 BLOCKSin 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 specificationsof 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 tofollow 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 surethe area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNINGIndicates a hazardous situation which, if not avoided, could result in death orserious injury.

CAUTIONIndicates a hazardous situation which, if not avoided, could result in minoror 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................................................................................................................................................................ 1Cooling System Checks ...................................................................................................................................... 1

Exhaust Leaks Into Cooling System ............................................................................................................... 1Water Flow Restrictions in Radiator ................................................................................................................ 1Radiator Hoses ............................................................................................................................................... 1Water Pump .................................................................................................................................................... 1

Flushing the Cooling System............................................................................................................................... 2Cooling System, Clean.................................................................................................................................... 2

Radiator Replacement......................................................................................................................................... 3Radiator, 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) .............................................................................................................................. 3Radiator, 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................................................................................................................................. 19Radiator, 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) .................................................................................................................................................... 21Radiator, 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) ....................................................... 24Radiator, 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) .............................................................................................................................. 29Radiator, 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................................................................................................................................. 33Radiator, 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) .................................................................................................................................................... 34Radiator, 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................................................................................................................................ 47Fan Removal ................................................................................................................................................... 47Inspect............................................................................................................................................................. 62Fan Installation ................................................................................................................................................ 62

2013 Yale Materials Handling Corp. i

Table of Contents Cooling System

TABLE OF CONTENTS (Continued)This section is for the following models:

GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX [C809];GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,

GP/GLP/GDP035VX, GP/GLP/GDP040SVX) [C810];GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) [A910];

GLC050LX [A967];GLP/GDP20-35VX (GP/GLP/GDP040-070VX) [B875];

GLP/GDP20-25LX (GLP/GDP050LX) [A974];GLC40, 45, 55VX; GLC55SVX (GC/GLC080, 100, 120VX; GC/GLC080,

100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) [E818, F818];GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX

(GP/GLP/GDP080, 090, 100, 110, 120VX) [F813, G813, H813, J813];GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)

[C879, D879, E879, F879];GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)

[C878, D878, E878];GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,

GLP/GDP175VX36, GLP/GDP190VX) [A909, B909]

ii

700 YRM 1123 Cooling System Checks

GeneralThis 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 ChecksEXHAUST LEAKS INTO COOLING SYSTEM

WARNINGDuring engine operation, be careful not to touch thefan, pulleys, or drive belts. Contact with these partscan cause serious injury.To check for exhaust leaks into the cooling system, usea Combustion Leak Test Kit for this purpose. Follow themanufacturers instructions when doing the test.

WATER FLOW RESTRICTIONS INRADIATOR

WARNINGDuring engine operation, be careful not to touch thefan, pulleys, or drive belts. Contact with these partscan cause serious injury.To check for water flow restrictions in the radiator, runengine until it is warm.

WARNINGThe radiator or other parts of the cooling systemmay 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 yourhand. If the radiator is still hot to the touch, wait an-other 30 minutes before attempting to check or fixany part of the cooling system.

Shut engine OFF and feel the radiator. The tempera-ture must be even across the radiator. (The radiator willbe hotter near the top radiator hose.) Cold spots on ra-diator indicate restrictions.

If radiator has leaks, either replace the radiator or haveit repaired by trained personnel.

RADIATOR HOSES

WARNINGThe radiator or other parts of the cooling systemmay 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 yourhand. If the radiator is still hot to the touch, wait an-other 30 minutes before attempting to check or fixany part of the cooling system.

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

WATER PUMP

WARNINGDuring engine operation, be careful not to touch thefan, pulleys, or drive belts. Contact with these partscan cause serious injury.

WARNINGThe radiator or other parts of the cooling systemmay 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 pumpis operating, there will be pressure surges in the hose.

Check for leaks around the timing belt cover near thebase of the oil pump.

Check the weep hole where coolant that leaks past thewater pump seal can be drained before reaching thewater pump bearings. If there is a drip, check the pumpshaft seal and water pump. Replacement of the pumpshaft seal or water pump may be necessary.

For repair procedures for the GM 2.4L water pump, referto the section GM Engine Repair, GM 2.4 Liter Engine600 YRM 1121.

For repair procedures for the Mazda FE and F2 waterpump, refer to the section Mazda Engine, FE and F2600 YRM 1122.

For replacement procedures for the Yanmar 2.6L and3.3L water pump, refer to the section Yanmar DieselEngines, 2.6L, 3.0L and 3.3L 600 YRM 1205.

1

Flushing the Cooling System 700 YRM 1123

For replacement procedures for the GM 4.3L waterpump, refer to the section GM Engines, 4.3 Liter V-6600 YRM 1251.

For replacement procedures for the GM 5.7L waterpump, refer to the section GM Engines, 5.7 Liter V-8LPG 600 YRM 1432.

For replacement procedures for the Kubota waterpump, 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 1590For replacement procedures for the Cummins 4.5L andQSB 3.3L water pump, contact your local Yale dealer orsee Yale Axcess Online.

Flushing the Cooling SystemCOOLING SYSTEM, CLEAN

WARNINGCompressed air can move particles so that theycause injury to the user or to other personnel.Make sure the path of the compressed air is awayfrom all personnel. Wear protective goggles or aface shield to prevent injury to the eyes.

WARNINGThe radiator fins on the radiator are very sharp andcan cause serious injury. Wear gloves while check-ing the radiator fins.

1. Check radiator fins. Clean exterior of radiator withcompressed air or water as needed.

WARNINGDO NOT remove the radiator cap from the radiatorwhen the engine is hot. When the radiator cap isremoved, the pressure is released from the system.If the system is hot, the steam and boiling coolantcan cause burns.


CAUTIONDisposal of lubricants and fluids must meet localenvironmental regulations.

2. Drain cooling system. Fill cooling system with cleanwater. 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 ModelsGLP/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 radiatorhose 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 isclean.

2

700 YRM 1123 Radiator Replacement

CAUTIONFollow the manufacturers instructions when usinga chemical radiator cleaner.

5. If water does not clean system, use a chemical ra-diator cleaner.

CAUTIONFollow the manufacturers instructions when usingspecial equipment to reverse clean the radiator.

6. If radiator or cooling system is very dirty or hasa restriction, use reverse cleaning method. This

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

CAUTIONAdditives may damage the cooling system. Beforeusing additives, contact your local Yale dealer.

7. Fill cooling system with ethylene glycol boron-freeantifreeze. Purchase a pre-diluted 50/50 solution;or mix 50 percent concentrate with 50% distilledor deionized water. The 50/50 mixture will pro-tect cooling system to 37C ( 35F). Add coolantas necessary to keep level between the ADD andFULL marks on the reservoir.

Radiator ReplacementRADIATOR, REMOVE FOR LIFTTRUCKS 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) ANDGLP/GDP40VX5/VX6, GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX(GP/GLP/GDP080, 090, 100, 110, 120VX)(F813, G813, H813, J813)


1. Turn OFF truck.

2. Remove the hood and seat combination.

See Frame 100 YRM 1120 for lift truck models GC/GLC030VX, GC/GLC035VX,

GC/GLC040SVX (C809) GLP/GDP16VX, GLP/GDP18VX,

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)

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)

WARNINGAlways disconnect the cable at the negative termi-nal first. Install a tag on the battery terminals sothat no one connects the cables on the terminals.

3. Disconnect the negative battery cable.

4. Disconnect the positive battery cable.

3

Radiator Replacement 700 YRM 1123


5. Let coolant cool to ambient temperature. Place adrain pan with a capacity greater than the capacityof the cooling system under radiator. Remove radi-ator cap.


6. Open the drain plug or loosen hose clamp and dis-connect the lower hose.

7. Lift trucks equipped with a Cummins QSB 3.3Ldiesel engine: Loosen clamps and disconnect thecharge 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 transmissioncooler hoses from transmission cooler. See Fig-ure 8.

9. Once coolant is drained from engine, loosen hoseclamps and disconnect coolant hoses from radiator.Cap radiator hoses.

10. Loosen hose clamp and disconnect hose fromreservoir and remove reservoir.

See Figure 1 for lift truck models GC/GLC030VX, GC/GLC035VX,

GC/GLC040SVX (C809 GLP/GDP16VX, GLP/GDP18VX,




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 equippedwith 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 equippedwith Yanmar 2.6L diesel engine GDP20-25LX (GDP050LX) (A974)See Figure 8 for lift truck models below equippedwith 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 thecoolant level sensor.

NOTE: For Mazda LPG engine, the LPG converterbracket needs to be moved for clearance of radiator.

13. Remove screws and washers from the shroud andmove shroud out of the way.

14. Place radiator guard shield between radiator andfan so damage to radiator does not occur duringfan 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 GC/GLC030VX, GC/GLC035VX,

GC/GLC040SVX (C809 GLP/GDP16VX, GLP/GDP18VX,



4



GLC050LX (A967) GLP20-25LX (GLP050LX) (A974)See Figure 2 or Figure 3 for lift truck models GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,


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 equippedwith 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 equippedwith Yanmar 2.6L diesel engine GDP20-25LX (GDP050LX) (A974)See Figure 8 for lift truck models below equippedwith a Kubota 3.8L diesel engine GLP/GDP40VX5/VX6; GLP/GDP45SVX5,


18. Remove radiator from truck.

19. If necessary, remove the coolant level sensor.

5


Figure 1. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,

GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) GLC050LX (A967);GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP20-25LX (GLP050LX) (A974)

6


Legend for Figure 1A. RADIATOR WITH EXTERNAL COOLERB. RADIATOR WITH INTERNAL COOLER, MODINE

SHOWN

C. RESERVOIR BEFORE MAY 06D. RESERVOIR AFTER MAY 06

1. RADIATOR2. CAP3. UPPER HOSE4. LOWER HOSE5. CLAMP6. SHROUD7. CLIP8. WASHER9. SCREW10. CLIP11. UPPER RADIATOR BRACKET12. CAPSCREW, GC/GLC040-070VX,

GC/GLC055SVX [A910] AND GLC050LX(A967)

13. INSERT14. LOWER BRACKET, GC/GLC040-070VX,

GC/GLC055SVX [A910] AND GLC050LX (A967)

15. NUT-CLIP, GC/GLC040-070VX, GC/GLC055SVX[A910] AND GLC050LX (A967)

16. ISOLATOR17. COOLANT LEVEL SENSOR18. RESERVOIR19. TUBE20. OUTLET ASSEMBLY21. HOSE22. RESERVOIR OUTLET23. CAP24. BUSHING25. SCREEN ASSEMBLY (OPTIONAL)26. HEAT SHIELD27. RESERVOIR BRACKET28. HEAT SHIELD, GLP/GDP20-35VX

(GP/GLP/GDP040-070VX) [B875] ANDGLP20-25LX (GLP050LX) (A974)

7


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

8


Legend for Figure 2A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER

1. RADIATOR2. SHROUD3. WASHER4. SCREW5. CLIP NUT6. CLIP7. UPPER HOSE8. LOWER HOSE9. CLAMP10. UPPER RADIATOR BRACKET11. INSERT12. CAPSCREW13. ISOLATOR14. RESERVOIR

15. RESERVOIR BRACKET16. OUTLET ASSEMBLY17. OUTLET18. CAP19. BUSHING20. HOSE21. TUBE22. STRAP23. NUT24. SCREEN25. BAFFLE (RH AND LH)26. RADIATOR CAP27. COOLANT LEVEL SENSOR

9


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

10


Legend for Figure 3A. RADIATOR WITH EXTERNAL COOLER B. RADIATOR WITH INTERNAL COOLER

1. RADIATOR2. SHROUD3. WASHER4. SCREW5. CLIP NUT6. CLIP7. UPPER HOSE8. LOWER HOSE9. CLAMP10. UPPER RADIATOR BRACKET11. INSERT12. CAPSCREW13. ISOLATOR

14. RESERVOIR15. OUTLET ASSEMBLY16. OUTLET17. CAP18. BUSHING19. HOSE20. TUBE21. NUT22. SCREEN23. BAFFLE (RH AND LH)24. RADIATOR CAP25. COOLANT LEVEL SENSOR

11


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

12


Legend for Figure 4A. RADIATOR WITH INTERNAL COOLER B. RADIATOR WITH EXTERNAL COOLER

1. CAPSCREW2. INSERT3. UPPER RADIATOR BRACKET4. RADIATOR CAP5. ISOLATOR6. CLIP NUT7. COOLANT LEVEL SENSOR8. RADIATOR9. CLIP10. RADIATOR SHROUD11. CLAMP12. LOWER HOSE13. SCREW

14. WASHER15. SCREEN16. STRAP17. RESERVOIR BRACKET18. RESERVOIR19. OUTLET ASSEMBLY20. OUTLET21. CAP22. BUSHING23. TUBE24. UPPER HOSE25. DRAIN PLUG26. OIL COOLER

13


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

14


Legend for Figure 5A. RADIATOR WITH INTERNAL COOLER B. RADIATOR WITH EXTERNAL COOLER

1. CAPSCREW2. INSERT3. UPPER RADIATOR BRACKET4. RADIATOR CAP5. ISOLATOR6. CLIP NUT7. COOLANT LEVEL SENSOR8. RADIATOR9. CLIP10. RADIATOR SHROUD11. CLAMP12. LOWER HOSE

13. SCREW14. WASHER15. SCREEN16. RESERVOIR17. OUTLET ASSEMBLY18. OUTLET19. CAP20. BUSHING21. TUBE22. UPPER HOSE23. DRAIN PLUG24. OIL COOLER

15


1. RADIATOR2. RADIATOR CAP3. HARNESS CLIP4. UPPER RADIATOR BRACKET5. INSERT6. ISOLATOR7. CAPSCREW8. CLAMP9. TUBE10. UPPER HOSE11. CLAMP12. CHARGE AIR COOLER HOSE13. CLAMP14. CHARGE AIR COOLER HOSE15. SHROUD

16. CLAMP17. CHARGE AIR COOLER HOSE18. SCREW19. WASHER20. CLIP21. LOWER HOSE22. RESERVOIR23. BUSHING24. RESERVOIR CAP25. RESERVOIR OUTLET26. HOSE27. TUBE28. COOLANT LEVEL SENSOR29. SEAL

Figure 6. Cummins 3.3L Cooling System With Charge Air Cooler for GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)

16


1. LOWER HOSE2. CLAMP3. UPPER HOSE4. RESERVOIR5. OUTLET ASSEMBLY6. BUSHING7. CAP8. RESERVOIR OUTLET9. HOSE10. CAPSCREW11. INSERT12. RADIATOR CAP

13. ISOLATOR14. UPPER RADIATOR BRACKET15. RADIATOR16. PLUG - COOLANT LEVEL SENSOR17. HEAT SHIELD18. CLIP NUT19. WASHER20. SCREW21. DRAIN PLUG22. SHROUD23. TUBE

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

17


1. RADIATOR2. RADIATOR CAP3. UPPER RADIATOR BRACKET4. ISOLATOR5. CAPSCREW6. INSERT7. CLAMP8. TUBE9. UPPER HOSE10. LOWER HOSE

11. TRANSMISSION COOLER RETURN LINE12. TRANSMISSION COOLER SUPPLY LINE13. SCREW14. WASHER15. SHROUD16. RESERVOIR17. BUSHING18. RESERVOIR CAP19. RESERVOIR OUTLET20. COOLANT LEVEL SENSOR

Figure 8. Kubota 3.8L Cooling System for Lift Truck Models GLP/GDP40VX5/VX6; GLP/GDP45SVX5,GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)

18


RADIATOR, REMOVE FOR LIFT TRUCKSMODELS 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) EQUIPPEDWITH OIL COOLER


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,



See section Frame 100 YRM 1423 for lift truck mod-els GLC050LX (A967) GLP/GDP20-25LX (GLP/GDP050LX) (A974)




WARNINGDO NOT remove the radiator cap from the radiatorwhen 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 coolantcan cause burns.

5. Let coolant cool to ambient temperature. Place adrain pan with a capacity greater than the capacityof the cooling system under radiator. Remove radi-ator cap.


6. Open the drain plug or loosen hose clamp and dis-connect the lower hose.

7. Loosen clamps and disconnect oil cooler hosesfrom 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 hoseclamps and disconnect coolant hoses from radiator.Cap radiator hoses.

10. Loosen hose clamp and disconnect hose fromreservoir and remove reservoir. See Figure 9.

11. Remove battery and battery tray.

12. If equipped, disconnect electrical connector to thecoolant level sensor.

NOTE: For Mazda LPG engine, the LPG converterbracket needs to be moved for clearance of radiator.

13. Remove screws and washers from the shroud andmove shroud out of the way.

14. Place radiator guard shield between radiator andfan so damage to radiator does not occur duringfan removal.

15. Remove fan, fan spacer, and pulley.


17. Remove capscrews and upper radiator bracket.See Figure 9.

18. Remove radiator from truck.

19. If necessary, remove the coolant level sensor.

19


1. RADIATOR2. CAP3. UPPER HOSE4. LOWER HOSE5. CLAMP6. SHROUD7. O-RING8. OIL COOLER ADAPTER9. OIL COOLER HOSE10. UPPER RADIATOR BRACKET

11. CAPSCREW12. INSERT13. ISOLATOR14. RESERVOIR15. TUBE16. OUTLET ASSEMBLY17. HOSE18. RESERVOIR OUTLET19. CAP20. BUSHING

Figure 9. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,

GP/GLP/GDP040SVX) (C810); GLC050LX (A967) and GLP20-25LX (GLP050LX) (A974)

20


RADIATOR, REMOVE FOR LIFT TRUCKMODELS 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. Turn off truck.




4. Remove radiator cover. See Figure 10.

5. Remove debris cover.

CAUTIONThe 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 thecounterweight 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 radiatorbracket. Remove bracket. See Figure 23.

9. If necessary, disconnect electrical connector fromthe coolant level sensor.

10. Remove screws, washers, and clip nuts from theshroud and radiator and move shroud out of theway.

11. Place a radiator guard shield between radiator andfan so damage to radiator does not occur during fanremoval.

12. Remove fan. See Fan Removal procedures.



14. Let coolant cool to ambient temperature. Place adrain pan with a capacity greater than the capacityof the cooling system under the radiator. Removeradiator cap.


15. Open drain plug, loosen clamp and disconnect thelower radiator hose from radiator to allow coolant todrain into a suitable container. Install caps on hose.See Figure 10.

16. Once coolant is drained from engine, loosen hoseclamp and disconnect upper radiator hose from ra-diator. Install cap on hose. See Figure 10.

17. Lift trucks equipped with a Cummins QSB 3.3Ldiesel engine: Loosen clamps and disconnect thecharge air cooler hoses from charge air cooler.See Figure 11.

18. Loosen clamp and disconnect remote refill hosefrom radiator. Install cap on hose.

NOTE: Tag the transmission lines before disconnectingfrom oil cooler.

19. Disconnect transmission lines from oil cooler. In-stall caps on transmission lines. Drain transmissionoil from oil cooler into a suitable container. Installcaps on the oil cooler ports.

NOTE: Removing the radiator from lift truck requirestwo people.

20. Remove radiator from lift truck frame.

21. If necessary, remove the coolant level sensor fromradiator. See Figure 23.

21


Figure 10. Radiator Removal for Lift Truck ModelsS6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,

F024, G024)GLC/GDC60VX, GLC/GDC60VX,(GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,

D879, E879, F879)

Legend for Figure 101. DEBRIS COVER2. COUNTERWEIGHT COVER3. RADIATOR COVER4. UPPER BRACKET5. CAPSCREWS6. REMOTE FILL HOSE7. HOSE CLAMPS8. OIL COOLER9. TRANSMISSION OIL COOLER LINES10. FITTINGS11. UPPER HOSE12. LOWER HOSE13. REMOTE FILL14. RADIATOR CAP

22




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

23


RADIATOR, REMOVE FOR LIFT TRUCKMODELS 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. Turn off truck.




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 equippedwith 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 equippedwith GM 5.7L LPG engine GLP80VX, GLP80VX9, GLP90VX

(GLP/GLP170VX, GLP/GLP175VX36,GLP/GLP190VX) (A909, B909)

See Figure 28 for lift truck models equipped withKubota 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 fromair 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 anddisconnect inlet hose from silencer. Remove si-lencer. See Figure 25.

NOTE: Before lifting the hood assembly from the lifttruck frame, make sure to use a lifting device and lift-ing straps as shown in Figure 12. The hood assemblyweighs 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 reservoirhose. See Figure 25.

10. Remove capscrews from the auxiliary coolantreservoir bracket and upper bracket. Removeauxiliary coolant reservoir assembly.

11. Remove the four capscrews from the upper radiatorbracket. Remove bracket.

12. If necessary, disconnect electrical connector fromthe coolant level sensor.

13. Remove screws, washers and clip nuts from theshroud and move shroud out of the way.

24


1. PRE-CLEANER 2. STRAP CLAMP

Figure 12. Hood Assembly Removal

14. Place a radiator guard shield between radiator andfan so damage to radiator does not occur during fanremoval.

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 equippedwith Cummins QSB 3.3L diesel engine GDP80VX, GDP80VX9, GDP90VX (GDP170VX,

GDP175VX36, GDP190VX) (A909, B909)

See Figure 14 for lift truck models below equippedwith GM 5.7L LPG engine GLP80VX, GLP80VX9, GLP90VX (GLP170VX,

GLP175VX36, GLP190VX) (A909 B909)See Figure 15 for lift truck models equipped withKubota 3.8L Diesel engine GDP80VX, GDP80VX9, GDP90VX (GDP170VX,

GDP175VX36, GDP190VX) (B909)17. Remove radiator guard shield.


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


19. Open drain plug or loosen clamp and disconnectlower 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)


GDP175VX36, GDP190VX) (A909, B909)See Figure 14 for lift truck models below equippedwith GM 5.7L LPG engine GLP80VX, GLP80VX9, GLP90VX (GLP170VX,

GLP175VX36, GLP190VX) (A909, B909)See Figure 15 for lift truck models equipped withKubota 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.

25




Figure 13. Cummins 3.3L Cooling System With Charge Air Cooler for GDP60VX, GDP70VX (GDP135VX,GDP155VX) (D878), GDP80VX, GDP80VX9, GDP90VX (GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

26


21. Once coolant is drained from engine, loosen hoseclamps and disconnect radiator hoses from radia-tor. Cap hoses.

NOTE: Tag the transmission lines before disconnectingfrom oil cooler.

22. Disconnect and cap transmission lines from oilcooler and allow transmission oil to drain from oil

cooler into a suitable container, then cap the oilcooler ports.

23. For lift trucks equipped with GM 5.7L LPG engine,remove capscrews from baffles and remove bafflesfrom radiator assembly. Remove capscrews secur-ing cooling baffle to radiator assembly. See Fig-ure 14.

1. BAFFLE2. ISOLATOR3. UPPER BRACKET4. CAP5. RESERVOIR OUTLET6. BUSHING7. HOSE8. RESERVOIR9. RADIATOR

10. CAPSCREW11. SHROUD12. CLAMP13. UPPER HOSE14. LOWER HOSE15. SEAL16. COOLING BAFFLE17. DRAIN HOSE18. PLASTIC TUBE

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

27


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

28


Legend for Figure 151. RADIATOR2. RADIATOR CAP3. UPPER RADIATOR BRACKET4. INSERT5. ISOLATOR6. CAPSCREW7. CLAMP8. TUBE9. UPPER HOSE10. CHARGE AIR COOLER HOSE11. CHARGE AIR COOLER HOSE

12. CHARGE AIR COOLER HOSE13. LOWER HOSE14. SHROUD15. RESERVOIR16. BUSHING17. RESERVOIR CAP18. RESERVOIR OUTLET19. HOSE20. COOLANT LEVEL SENSOR21. SEAL

NOTE: Removing the radiator from lift truck requirestwo people.

24. Remove radiator from lift truck frame.

25. If necessary, remove the coolant level sensor fromradiator.

RADIATOR, INSTALL FOR LIFTTRUCK 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) ANDGLP/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 capscrewstaken out during removal.

4. Place a radiator guard shield between radiator andfan, so damage to radiator does not occur duringfan installation

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

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

6. Install fan, fan spacer, and pulley.


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

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

NOTE: For Mazda LPG engine, the LPG converterbracket and screws must be installed to hold the con-verter.

10. Uncap radiator and reservoir ports and install thereservoir.

11. Connect the reservoir hose from reservoir to theradiator. 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. Tightenhose clamp.

29


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


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

17. Use the same coolant mixture and fill the reservoirbetween the ADD and FULL marks.

See Figure 16 or Figure 17, for lift truck models GC/GLC030VX, GC/GLC035VX,




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,


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,


1. RESERVOIR2. ADD MARK

3. FULL MARK

Figure 16. Reservoir for Lift Truck ModelsGC/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

30



3. FULL MARK



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

1. AUXILIARY COOLANT RESERVOIR2. FULL "HOT" MARK3. FULL "COLD" MARK4. ADD "COLD" MARK

Figure 18. Reservoir for Lift Truck ModelsGLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6;GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX)

(F813, G813)

31



Figure 19. Reservoir for Lift Truck ModelsGLP/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 1243 for lift truck mod-els GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,





WARNINGThe radiator or other parts of the cooling systemmay 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 thebleed screw located on the left side behind thealternator. When the air has been bled from thesystem close the bleed screw. See Figure 20.


24. Check coolant level at the reservoir. Add coolantas necessary to keep level between the ADD andFULL marks on the reservoir.

32


1. MANIFOLD2. COOLANT HOSES

3. BLEED SCREW4. RADIATOR HOSE

Figure 20. Bleed Screw, GM 2.4L Engine

RADIATOR, INSTALL FOR LIFT TRUCKMODELS 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) EQUIPPEDWITH OIL COOLER1. If removed, install the coolant level sensor.

2. Install radiator into truck.

3. Install upper radiator bracket, using capscrewstaken out during removal.

4. Place a radiator guard shield between radiator andfan, so damage to radiator does not occur duringfan installation

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

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

6. Install fan, fan spacer, and pulley.


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

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

NOTE: For Mazda LPG engine, the LPG converterbracket and screws must be installed to hold the con-verter.

10. Uncap radiator and reservoir ports and install thereservoir.

11. Connect the reservoir hose from reservoir to theradiator. Tighten hose clamp. See Figure 9.

12. Install new O-rings on oil cooler connectors. SeeFigure 9.

13. Install oil cooler adapters to radiator. Torqueadapters to 14.7 to 17.6 Nm (130 to 156 lbf in).See Figure 9.

14. Uncap oil cooler hoses and connect hoses to oilcooler 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. Tightenhose clamp.




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

33



3. FULL MARK



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.


22. Install the hood and seat combination.






WARNINGThe radiator or other parts of the cooling systemmay 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.)


24. Check coolant level at the reservoir. Add coolantas necessary to keep level between the ADD andFULL marks on the reservoir.

RADIATOR, INSTALL FOR LIFT TRUCKMODELS 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 transmissionlines and connect lines into oil cooler. See Fig-ure 10.

4. Uncap and connect remote refill hose onto radiatorand tighten hose clamp. See Figure 10.

5. Close drain plug and uncap the upper and lowerradiator hoses and connect hoses onto radiator andtighten hose clamps. See Figure 10.

6. Uncap the charge air cooler hoses and connect thehoses to charge air cooler. See Figure 11.

7. Install fan. See Fan Installation procedures.

8. Align shroud to radiator and install two capscrews,washers and clip nuts. See Figure 23.

34


9. If necessary, connect electrical connector onto thecoolant level sensor.

10. Install upper radiator bracket and four capscrews.

CAUTIONThe 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 eachend of the counterweight cover. Connect a suitablelifting device to the eyebolts and carefully install thecounterweight cover into the lift truck frame. SeeFigure 10.

12. Install two bolts to counterweights cover. Tighten to38 Nm (28 lbf ft).

13. Install debris cover.

14. Install radiator cover.

15. Connect positive battery cable.



CAUTIONAdditives may damage the cooling system. Beforeusing additives, contact you local Yale dealer.


18. Install radiator cap.

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

WARNINGDuring engine operation, be careful not to touch thefan, pulleys, or drive belts. contact with these partscan cause serious injury.

WARNINGThe radiator or other parts of the cooling systemmay be hot or under pressure and cause seriousinjury.20. Start and run the engine until thermostat opens

(The upper radiator hose will be warm).


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 priorto 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 PeriodicMaintenance section for your lift truck.


Figure 22. Reservoir for Lift Truck ModelsS6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,

F024, G024)GLC/GDC60VX, GLC/GDC60VX,(GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,

D879, E879, F879)

35


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

36


Legend for Figure 23A. LOWER HOSE (CUMMINS 4.5L/KUBOTA 3.8L

DIESEL)B. LOWER HOSE (GAS AND LPG)

C. UPPER HOSE (GAS AND LPG)D. UPPER HOSE (CUMMINS 4.5L/KUBOTA 3.8L

DIESEL)1. RADIATOR (WITH EXTERNAL OIL COOLER)2. SHROUD3. WASHER4. SCREW5. CLIP NUT6. CLIP SPRING7. CLAMP8. UPPER RADIATOR BRACKET9. CAPSCREW10. INSERT11. ISOLATOR12. RESERVOIR13. BRACKET (COOLANT FILL)

14. OUTLET ASSEMBLY15. OUTLET16. CAP17. BUSHING18. HOSE19. HOSE20. REMOTE FILL HOSE21. REMOTE FILL22. RADIATOR CAP23. SCREEN24. COOLANT LEVEL SENSOR25. DRAIN PLUG

RADIATOR, INSTALL FOR LIFT TRUCKMODELS 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.





GLP175VX36, GLP190VX) (A909, B909)

See Figure 15 for lift truck models equipped withKubota 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.





GLP175VX36, GLP190VX) (A909, B909)See Figure 15 for lift truck models equipped withKubota 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 transmissionlines and connect lines into oil cooler.

8. Close drain plug and uncap the lower radiator hoseand connect hose onto radiator and tighten clamp.

37


9. Uncap and connect upper radiator hose and tightenclamp.

10. Lift trucks equipped with Cummins QSB 3.3L orKubota 3.8L diesel engine, uncap the charge aircooler hoses and connect the hoses to the chargeair 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.






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 QSB3.3L diesel engine, install silencer and connecthose from air filter side and tighten clamp. SeeFigure 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 andtighten clamp.


GDP175VX36, GDP190VX) (A909, B909)

See Figure 27 for lift truck models below equippedwith GM 5.7L LPG engine GLP80VX, GLP80VX9, GLP90VX (GLP170VX,


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,


18. Lift truck equipped GM 4.3L (Gas/LPG) engine,open hood assembly and connect intake hose tohood support and tighten clamp. See Figure 25.

19. Lift trucks equipped with Kubota 3.8L, Cummins4.5L, or QSB 3.3L diesel engine, open hood assem-bly and connect hose to hood support and tightenclamp.




GDP175VX36, GDP190VX) (A909, B909)See Figure 28 for lift truck models equipped withKubota 3.8L Diesel engine GDP80VX, GDP80VX9, GDP90VX (GDP170VX,

GDP175VX36, GDP190VX) (B909)20. Connect positive battery cable.


38





23. Install radiator cap.

24. Use the same coolant mixture and fill the auxil-iary coolant reservoir between the ADD and FULLmarks. See Figure 24.

WARNINGDuring engine operation, be careful not to touch thefan, pulleys, or drive belts. contact with these partscan cause serious injury.

WARNINGThe radiator or other parts of the cooling systemmay be hot or under pressure and cause seriousinjury.25. Start and run the engine until thermostat opens

(The upper radiator hose will be warm).


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 priorto checking the transmission oil level. If the trans-mission oil is low, add transmission oil at the dipsticktube at the correct level indicated on the dipstick.Oil is specified in Periodic Maintenance section foryour lift truck.


Figure 24. Reservoir for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,

GP/GLP/GDP155VX) (C878, D878, E878) andGLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX

(GLP/GDP170VX, GLP/GDP175VX36,GLP/GDP190VX) (A909, B909)

39


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

40



41



42


Legend for Figure 25A. GM 4.3L (GAS/LPG)B. CUMMINS 4.5L (DIESEL)

C. KUBOTA (DIESEL)

1. AIR INTAKE (WITHOUT PRE-CLEANER)2. PRE-CLEANER3. HOOD ASSEMBLY4. CLAMP5. INLET HOSE6. SILENCER (DIESEL)7. AIR FILTER8. UPPER RADIATOR BRACKET9. ISOLATOR10. INSERT11. CAPSCREW12. RADIATOR (WITH EXTERNAL OIL COOLER)13. UPPER HOSE14. LOWER HOSE15. CLIP NUT16. WASHER

17. SCREW18. SHROUD19. FAN20. FAN SPACER21. TRANSMISSION LINES22. AUXILIARY COOLANT RESERVOIR AND

BRACKET ASSEMBLY23. OUTLET24. CAP25. BUSHING26. HOSE27. AUXILIARY COOLANT RESERVOIR HOSE28. DRAIN PLUG29. RADIATOR CAP30. HOOD SUPPORT

43


1. PRE-CLEANER2. CLAMP3. HOOD SUPPORT4. HOOD ASSEMBLY5. DIRTY AIR HOSE6. CLEAN AIR HOSE7. AIR FILTER8. AIR CLEANER BRACKET9. CAPSCREW10. NUT11. AUXILIARY COOLANT RESERVOIR HOSE12. RESERVOIR OUTLET13. CAP14. BUSHING15. COOLANT RECOVERY RESERVOIR16. TUBE

17. COOLANT LEVEL SENSOR18. UPPER BRACKET19. RADIATOR ISOLATOR20. RADIATOR21. CAC HOSE22. CAC TUBE23. INSULATED CLAMP24. LOWER RADIATOR HOSE25. UPPER RADIATOR HOSE26. SHROUD AND BAFFLE27. WASHER28. FAN29. SPACER30. AUXILIARY COOLANT RESERVOIR ASSEMBLY31. CLIP NUT

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

44


1. PRE-CLEANER2. CLAMP3. HOOD SUPPORT4. HOOD5. DIRTY AIR HOSE6. CLEAN AIR HOSE7. AIR FILTER8. AIR CLEANER BRACKET9. CAPSCREW10. NUT11. RADIATOR ISOLATOR12. UPPER BRACKET

13. RADIATOR14. BAFFLE15. COOLANT RECOVERY RESERVOIR16. LOWER RADIATOR HOSE17. UPPER RADIATOR HOSE18. SEAL19. BAFFLE20. FAN SHROUD21. FAN22. SPACER23. FAN MOUNTING SCREWS

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

45


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

46

700 YRM 1123 Fan Assembly Replacement

Legend for Figure 281. PRE-CLEANER2. CLAMP3. HOOD SUPPORT4. HOOD ASSEMBLY5. DIRTY AIR HOSE6. CLEAN AIR HOSE7. AIR FILTER8. AIR CLEANER BRACKET9. CAPSCREW10. NUT11. AUXILIARY COOLANT RESERVOIR HOSE12. RESERVOIR OUTLET13. CAP14. BUSHING15. COOLANT RECOVERY RESERVOIR

16. TUBE17. COOLANT LEVEL SENSOR18. UPPER BRACKET19. RADIATOR ISOLATOR20. RADIATOR21. CAC HOSE22. CAC TUBE23. AIR FLOW SENSOR24. LOWER RADIATOR HOSE25. UPPER RADIATOR HOSE26. SHROUD AND BAFFLE27. WASHER28. FAN29. SPACER

Fan Assembly ReplacementFAN REMOVAL



WARNINGThe radiator fins on the radiator are very sharp andcan cause serious injury. Wear gloves while remov-ing fan assembly.

NOTE: The fan that is used is a pusher-type fan. Donot replace with a puller-type fan.

1. Turn OFF lift truck.

2. If equipped, turn the LPG tank valve to the OFFposition.

3. If equipped, release the LPG tank bracket andswing 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)



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)

S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,F024, G024)GLC/GDC60VX, GLC/GDC60VX,(GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879,D879, E879, F879)

GLC050LX (A967) GLP/GDP20-25LX (GLP/GDP050LX) (A974)4. Release the steering tilt latch and move the steering

wheel forward.

5. Release the seat latch and move the seat forward.

6. Release hood latch and raise hood to open posi-tion.

47

Fan Assembly Replacement 700 YRM 1123

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


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

7. Release hood cover latch on hood cover and swinghood cover up.

WARNINGTo prevent a short circuit during fan belt removal,disconnect the battery negative cable at the batterynegative terminal. Install a lock or tag on the con-nector to prevent connection. A tool could cause ashort circuit, the high current flow from the batterycan cause an injury or parts damage.8. Disconnect the negative battery cable from the neg-

ative battery terminal.

9. Remove screws and washers from the radiatorshroud. Lean radiator shroud toward the fan.

See Figure 29 for lift truck models below equippedwith GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar3.3L engine GLC20-35VX (GC/GLC040-070VX,

GC/GLC055SVX) (A910) GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

(B875) GLP/GDP16VX, GLP/GDP18VX,


See Figure 30 for lift truck models below equippedwith Yanmar 2.6L engine. GDP20-25LX (GDP050LX) (A974)See Figure 31 for lift truck models below equippedwith Mazda FE and F2 engines GLC20-35VX (GC/GLC040-070VX,

GC/GLC055SVX) (A910) GLC050LX (A967) GLP20-25LX (GLP050LX) (A974) GLP20-35VX (GP/GLP040-070VX) (B875) GC/GLC030VX, GC/GLC035VX,

GC/GLC040SVX (C809) GLP16VX, GLP18VX, GLP20SVX (GP/

GLP030VX, GP/GLP035VX, GP/GLP040SVX)(C810)

See Figure 32 for lift truck models below equippedwith GM 4.3L engine GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,



See Figure 33 for lift truck models below equippedwith Cummins 4.5L engine GLP/GDP40VX5/VX6; GLP/GDP45SVX5,

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

See Figure 34 for lift truck models below equippedwith GM 4.3L, Cummins 4.5L, or Kubota 3.8L en-gines S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,

F024, G024)GLC/GDC60VX, GLC/GDC60VX,(GC/GLC/GDC135VX, GC/GLC/GDC135VX)(C879, D879, E879, F879)

See Figure 35 for lift truck models below equippedwith GM 4.3L, Cummins 4.5L, or Kubota engines GLP/GDP60VX, GLP/GDP70VX (GP/GLP/

GDP135VX, GP/GLP/GDP155VX) (C878, E878)See Figure 36 for lift truck models below equippedwith Cummins QSB 3.3L diesel engines GDC60VX, GDC70VX (GDC135VX,

GDC155VX) (D879) GDP60VX, GDP70VX (GDP135VX,

GDP155VX) (D878) GDP40VX5/VX6; GDP45SVX5, GDP45VX6,

GDP50-55VX (GDP080, 090, 100, 110, 120VX)(G813)

See Figure 37 for lift truck models below equippedwith Cummins QSB 3.3L diesel engines GDP80VX, GDP80VX9, GDP90VX (GDP170VX,

GDP175VX36, GDP190VX) (A909, B909)See Figure 38 for lift truck models below equippedwith GM 5.7L LPG engine GLP/GDP80VX, GLP/GDP80VX9,

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

48


See Figure 39 for lift truck models below equippedwith Kubota 3.8L diesel engine GLP/GDP40VX5/VX6; GLP/GDP45SVX5,


See Figure 40 for lift truck models below equippedwith Kubota 3.8L diesel engine GLP/GDP80VX, GLP/GDP80VX9,


1. FAN2. SPACER3. WASHER4. CAPSCREW

5. SCREW6. RADIATOR SHROUD7. RADIATOR

Figure 29. Fan Removal for GM 2.4L, Yanmar 2.6L, Yanmar 3.0L and Yanmar 3.3L Engines, Lift Truck ModelsGLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX)(B875), and GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,

GP/GLP/GDP040SVX) (C810)

49


1. SPACER2. FAN3. WASHER4. CAPSCREW

5. SHROUD6. SCREW7. RADIATOR

Figure 30. Fan Removal for Yanmar 2.6L Engine, Lift Truck Models GDP20-25LX (GDP050LX) (A974)

50


NOTE: MODINE RADIATOR SHOWN, COPAR RADIATOR SIMILAR.

1. SPACER, GLP/GDP20-35VX(GP/GLP/GDP040-070VX) (B875) ANDGC/GLC030-035VX, GC/GLC040SVX (C809)LIFT TRUCKS ONLY

2. FAN3. CAPSCREW

4. WASHER5. SCREW6. WASHER7. RADIATOR SHROUD8. RADIATOR

Figure 31. Fan Removal for Mazda FE and F2 Engines, Lift Truck Models GLC20-35VX (GC/GLC040-070VX,GC/GLC055SVX) (A910), GLC050LX (A967), GLP20-25LX (GLP050LX) (A974), GLP20-35VX

(GP/GLP040-070VX) (B875), GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX (C809), and GLP16VX,GLP18VX, GLP20SVX (GP/GLP030VX, GP/GLP035VX, GP/GLP040SVX) (C810)

51


1. FAN2. SPACER3. WASHER4. CAPSCREW

5. SCREW6. RADIATOR SHROUD7. RADIATOR

Figure 32. Fan Removal for GM 4.3L Engine, Lift Truck Models GLC40, 45, 55VX; GLC55SVX;(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) andGLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GP/GLP080, 090, 100, 110, 120VX) (F813, G813,

H813, J813)

52


1. SPACER2. FAN3. WASHER4. CAPSCREW5. RADIATOR SHROUD

6. SCREW7. LOCKWASHER8. CLIP NUT9. RADIATOR

Figure 33. Fan Removal for Cummins 4.5L Engine, Lift truck Models GDP40VX5/VX6;GDP45SVX5,GDP45VX6; GDP50-55VX (GDP080, 090, 100, 110, 120VX) (F813)

53


A. GM 4.3L AND KUBOTA 3.8L B. CUMMINS 4.5L (DIESEL)1. FAN2. FAN SPACER3. WASHER4. CAPSCREW

5. SCREW6. SHROUD7. RADIATOR

Figure 34. Fan Removal for GM 4.3L, Cummins 4.5L and Kubota 3.8L Engines, Lift truck Models S6.0FT,S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX,

GC/GLC/GDC135VX) (C879, D879, E879, F879)

54


A. GM 4.3L AND KUBOTA B. CUMMINS 4.5L (DIESEL)1. FAN2. FAN SPACER3. WASHER4. CAPSCREW


Figure 35. Fan Removal for GM 4.3L, Cummins 4.5L, and Kubota Engines, Lift Truck Models GLP/GDP60VX,GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878)

55


1. SPACER2. FAN3. SCREW4. WASHER

5. WASHER6. CAPSCREW7. SHROUD8. RADIATOR

Figure 36. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models GDP40VX5/VX6; GDP45SVX5,GDP45VX6, GDP50-55VX (GDP080, 090, 100, 110, 120VX) (G813), GDC60VX, GDC70VX (GDC135VX,

GDC155VX) (D879), and GDP60VX, GDP70VX (GDP135VX, GDP155VX) (D878)

56


1. RADIATOR SHROUD2. SCREW3. WASHER4. SPACER

5. CAPSCREW6. FAN7. RADIATOR

Figure 37. Fan Removal for Cummins QSB 3.3L Engine, Lift Truck Models GDP80VX, GDP80VX9, GDP90VX(GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

57


1. FAN SHROUD2. SCREW3. WASHER4. SPACER

5. CAPSCREW6. FAN7. RADIATOR ASSEMBLY

Figure 38. Fan Removal for GM 5.7L LPG Engine, Lift Truck Models GDP80VX, GDP80VX9, GDP90VX(GDP170VX, GDP175VX36, GDP190VX) (A909, B909)

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1. FAN2. FAN SPACER3. WASHER4. CAPSCREW


Figure 39. Fan Removal for Kubota 3.8L Diesel Engine for Lift Truck Models GLP/GDP40VX5/VX6;GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (H813, J813)

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1. FAN SHROUD2. SCREW3. WASHER4. SPACER

5. CAPSCREW6. FAN7. RADIATOR ASSEMBLY

Figure 40. Fan Removal for Kubota 3.8L Diesel Engine, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9,GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)

10. Remove capscrews, washers, and spacer from thefan pulley.

See Figure 29 for lift truck models below equippedwith GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar3.3L engine GLC20-35VX (GC/GLC040-070VX,




See Figure 30 for lift truck models below equippedwith Yanmar 2.6L engine GDP20-25LX (GDP050LX) (A974)See Figure 32 for lift truck models below equippedwith GM 4.3L engine GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,



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See Figure 34. for lift truck models below equippedwith GM 4.3L, Cummins 4.5L, or Kubota 3.8L en-gines S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,


See Figure 35 for lift truck models below equippedwith GM 4.3L, Cummins 4.5L, Kubota engines GLP/GDP60VX, GLP/GDP70VX (GP/GLP/




NOTE: Perform Step 11 for lift truck model GDP80VX,GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,GDP190VX) (A909) and GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (B909).11. For lift trucks equipped with Cummins QSB 3.3L

diesel engines, GM 5.7L LPG engines, or Kubota3.8L diesel engines, remove capscrews, washers,and spacers from fan.






NOTE: Perform Step 12 for lift truck models GC/GLC030-035VX, GC/GLC040SVX (C809) GLP/GDP20-35VX (GP/GLP/GDP040-070VX)

(B875) GLP20-25LX (GLP050LX) (A974).

12. For lift trucks equipped with Mazda FE and F2engines, remove capscrews, washers, and spacerfrom the fan pulley.

See Figure 31 for lift truck models below equippedwith Mazda FE and F2 engines GLC20-35VX (GC/GLC040-070VX,




NOTE: Perform Step 13 for lift truck models GLP/GDP16-18VX, GLP/GDP20SVX (GP/GLP/

GDP030-035VX, GP/GLP/GDP040SVX) (C810) GLC20-35VX (GC/GLC040-070VX,

GC/GLC055SVX) (A910) GLC050LX (A967)13. For lift trucks equipped with Mazda FE or F2 en-

gines, remove the capscrews and washers retain-ing the fan.

See Figure 31 for lift truck models below equippedwith Mazda FE and F2 engines GLC20-35VX (GC/GLC040-070VX,




14. Remove the fan.

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INSPECT

WARNINGDO NOT try to repair a damaged fan. If a fan has abent blade or is cracked, install a new fan. A dam-aged fan can break during use and cause damageor serious injury.1. Inspect the fan for any damage.

2. If the fan is damaged, replace the entire fan.

FAN INSTALLATION

WARNINGThe radiator fins on the radiator are very sharp andcan cause serious injury. Wear gloves while in-stalling fan assembly.

1. Install the lower portion of the shroud in the retain-ing clips and lean the shroud toward the engine.

2. Install the spacer, washers, and capscrews to thefan. Tighten the capscrews to 52 Nm (38 lbf).See Figure 29 for lift truck models below equippedwith GM 2.4L, Yanmar 2.6L, Yanmar3.0L or Yanmar3.3L engine GLC20-35VX (GC/GLC040-070VX,




See Figure 30 for lift truck models below equippedwith Yanmar 2.6L engine. GDP20-25LX (GDP050LX) (A974)See Figure 32 for lift truck models below equippedwith GM 4.3L engine GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,





See Figure 34. for lift truck models below equippedwith GM 4.3L, Cummins 4.5L, or Kubota 3.8L en-gines S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,


See Figure 35 for lift truck models below equippedwith GM 4.3L, Cummins 4.5L, or Kubota engines GLP/GDP60VX, GLP/GDP70VX (GP/GLP/




NOTE: Perform Step 3 for lift truck models GDP80VX,GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,GDP190VX) (A909, B909).3. Install spacers, washers, and capscrews onto fan.






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NOTE:

524223757-0700YRM1123-(03-2013)-UK-EN

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