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Maintenance

COOLING SYSTEM
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]

PART NO. 524223757

700 YRM 1123

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

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

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.

Cooling System

Table of Contents

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

2013 Yale Materials Handling Corp.

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Table of Contents

Cooling System

TABLE OF CONTENTS (Continued)


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

ii

700 YRM 1123

Cooling System Checks

General
This section contains the repair and replacement instructions for the radiator, coolant level sensor, fan

assembly (pusher type), fan shroud, coolant hoses,


coolant recovery bottle, and optional debris screen.

Cooling System Checks


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

Do a touch test by touching the radiator with your


hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.
Inspect all radiator hoses. If they feel spongy or have
visible cracks, replace hoses.

To check for exhaust leaks into the cooling system, use


a Combustion Leak Test Kit for this purpose. Follow the
manufacturers instructions when doing the test.

WATER PUMP

WATER FLOW RESTRICTIONS IN


RADIATOR

During engine operation, be careful not to touch the


fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.

WARNING

WARNING
During engine operation, be careful not to touch the
fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.
To check for water flow restrictions in the radiator, run
engine until it is warm.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury.
Run engine until it is warm. Check the operation of water pump by holding the top radiator hose. If the pump
is operating, there will be pressure surges in the hose.
Check for leaks around the timing belt cover near the
base of the oil pump.
Check the weep hole where coolant that leaks past the
water pump seal can be drained before reaching the
water pump bearings. If there is a drip, check the pump
shaft seal and water pump. Replacement of the pump
shaft seal or water pump may be necessary.

Shut engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will
be hotter near the top radiator hose.) Cold spots on radiator indicate restrictions.

For repair procedures for the GM 2.4L water pump, refer


to the section GM Engine Repair, GM 2.4 Liter Engine
600 YRM 1121.

If radiator has leaks, either replace the radiator or have


it repaired by trained personnel.

For repair procedures for the Mazda FE and F2 water


pump, refer to the section Mazda Engine, FE and F2
600 YRM 1122.

RADIATOR HOSES
WARNING

For replacement procedures for the Yanmar 2.6L and


3.3L water pump, refer to the section Yanmar Diesel
Engines, 2.6L, 3.0L and 3.3L 600 YRM 1205.

The radiator or other parts of the cooling system


may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.

Flushing the Cooling System

700 YRM 1123

For replacement procedures for the GM 4.3L water


pump, refer to the section GM Engines, 4.3 Liter V-6
600 YRM 1251.
For replacement procedures for the GM 5.7L water
pump, refer to the section GM Engines, 5.7 Liter V-8
LPG 600 YRM 1432.

For replacement procedures for the Kubota water


pump, refer to the section
Kubota Diesel 3.8L Engines 600 YRM 1557
Kubota Diesel 3.6L Engine 600 YRM 1579
Kubota Diesel 3.8L Engines, with Diesel Particulate Filter (DPF) 600 YRM 1590
For replacement procedures for the Cummins 4.5L and
QSB 3.3L water pump, contact your local Yale dealer or
see Yale Axcess Online.

Flushing the Cooling System


COOLING SYSTEM, CLEAN
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure the path of the compressed air is away
from all personnel. Wear protective goggles or a
face shield to prevent injury to the eyes.

WARNING
The radiator fins on the radiator are very sharp and
can cause serious injury. Wear gloves while checking the radiator fins.
1. Check radiator fins. Clean exterior of radiator with
compressed air or water as needed.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

2. Drain cooling system. Fill cooling system with clean


water. See sections below for more information:
Radiator, Remove for Lift Trucks 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)
Radiator, Remove for Lift Truck Models S6.0FT,
S7.0FT (S135FT, S155FT) (D024, E024,
F024, G024)GLC/GDC60VX, GLC/GDC60VX,
(GC/GLC/GDC135VX,
GC/GLC/GDC135VX)
(C879, D879, E879, F879)
Radiator, Remove for Lift Truck Models
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX,
GP/GLP/GDP155VX)
(C878,
D878, E878) and GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)
3. Install radiator cap. Run engine until top radiator
hose is hot. Stop engine and let engine cool.
4. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is
clean.

700 YRM 1123

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

CAUTION
Follow the manufacturers instructions when using
a chemical radiator cleaner.
5. If water does not clean system, use a chemical radiator cleaner.

CAUTION
Follow the manufacturers instructions when using
special equipment to reverse clean the radiator.
6. If radiator or cooling system is very dirty or has
a restriction, use reverse cleaning method. This

CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
7. Fill cooling system with ethylene glycol boron-free
antifreeze. Purchase a pre-diluted 50/50 solution;
or mix 50 percent concentrate with 50% distilled
or deionized water. The 50/50 mixture will protect cooling system to 37C ( 35F). Add coolant
as necessary to keep level between the ADD and
FULL marks on the reservoir.

Radiator Replacement
RADIATOR, REMOVE FOR LIFT
TRUCKS MODELS GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX, GLC55SVX,
(GC/GLC080, 100, 120VX, GC/GLC080,
100VXBCS, GC/GLC120SVX,
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6, GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
WARNING

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)

The radiator or other parts of the cooling system


may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.

Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so
that no one connects the cables on the terminals.

1. Turn OFF truck.

4. Disconnect the positive battery cable.

WARNING

3. Disconnect the negative battery cable.

2. Remove the hood and seat combination.

Radiator Replacement

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
5. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capacity
of the cooling system under radiator. Remove radiator cap.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
6. Open the drain plug or loosen hose clamp and disconnect the lower hose.
7. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from charge air cooler.
See Figure 6.
8. Lift trucks equipped with a Kubota 3.8L diesel engine: Loosen clamps and disconnect transmission
cooler hoses from transmission cooler. See Figure 8.
9. Once coolant is drained from engine, loosen hose
clamps and disconnect coolant hoses from radiator.
Cap radiator hoses.
10. Loosen hose clamp and disconnect hose from
reservoir and remove reservoir.
See Figure 1 for lift truck models
GC/GLC030VX,
GC/GLC035VX,
GC/GLC040SVX (C809
GLP/GDP16VX,
GLP/GDP18VX,
GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX)
(C810)
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
GLC050LX (A967)
GLP20-25LX (GLP050LX) (A974)
See Figure 2 or Figure 3 for lift truck models
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100,
120VX;
GC/GLC080,
100VXBCS;

700 YRM 1123


GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
See Figure 4 or Figure 5 for lift truck models
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
See Figure 6 for lift truck models below equipped
with a Cummins QSB 3.3L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (G813
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (D879)
See Figure 7 for lift truck models below equipped
with Yanmar 2.6L diesel engine
GDP20-25LX (GDP050LX) (A974)
See Figure 8 for lift truck models below equipped
with a Kubota 3.8L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)
11. Remove battery and battery tray.
12. If equipped, disconnect electrical connector to the
coolant level sensor.
NOTE: For Mazda LPG engine, the LPG converter
bracket needs to be moved for clearance of radiator.
13. Remove screws and washers from the shroud and
move shroud out of the way.
14. Place radiator guard shield between radiator and
fan so damage to radiator does not occur during
fan removal.
15. Remove fan, fan spacer, and pulley.
16. Remove radiator guard shield.
17. Remove capscrews and upper radiator bracket.
See Figure 1 for lift truck models
GC/GLC030VX,
GC/GLC035VX,
GC/GLC040SVX (C809
GLP/GDP16VX,
GLP/GDP18VX,
GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX)
(C810)
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)

700 YRM 1123


GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
GLC050LX (A967)
GLP20-25LX (GLP050LX) (A974)
See Figure 2 or Figure 3 for lift truck models
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100,
120VX; GC/GLC080,
100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
See Figure 4 or Figure 5 for lift truck models
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)

Radiator Replacement
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (D879)
See Figure 7 for lift truck models below equipped
with Yanmar 2.6L diesel engine
GDP20-25LX (GDP050LX) (A974)
See Figure 8 for lift truck models below equipped
with a Kubota 3.8L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)
18. Remove radiator from truck.
19. If necessary, remove the coolant level sensor.

See Figure 6 for lift truck models below equipped


with a Cummins QSB 3.3L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (G813

Radiator Replacement

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

Legend for Figure 1


A. RADIATOR WITH EXTERNAL COOLER
B. RADIATOR WITH INTERNAL COOLER, MODINE
SHOWN

C. RESERVOIR BEFORE MAY 06


D. RESERVOIR AFTER MAY 06

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

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


[A910] AND GLC050LX (A967)
16. ISOLATOR
17. COOLANT LEVEL SENSOR
18. RESERVOIR
19. TUBE
20. OUTLET ASSEMBLY
21. HOSE
22. RESERVOIR OUTLET
23. CAP
24. BUSHING
25. SCREEN ASSEMBLY (OPTIONAL)
26. HEAT SHIELD
27. RESERVOIR BRACKET
28. HEAT SHIELD, GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) [B875] AND
GLP20-25LX (GLP050LX) (A974)

RADIATOR
CAP
UPPER HOSE
LOWER HOSE
CLAMP
SHROUD
CLIP
WASHER
SCREW
CLIP
UPPER RADIATOR BRACKET
CAPSCREW, GC/GLC040-070VX,
GC/GLC055SVX [A910] AND GLC050LX
(A967)
13. INSERT
14. LOWER BRACKET, GC/GLC040-070VX,
GC/GLC055SVX [A910] AND GLC050LX (A967)

Radiator Replacement

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

Legend for Figure 2


A. RADIATOR WITH EXTERNAL COOLER

B. RADIATOR WITH INTERNAL COOLER

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.

RADIATOR
SHROUD
WASHER
SCREW
CLIP NUT
CLIP
UPPER HOSE
LOWER HOSE
CLAMP
UPPER RADIATOR BRACKET
INSERT
CAPSCREW
ISOLATOR
RESERVOIR

RESERVOIR BRACKET
OUTLET ASSEMBLY
OUTLET
CAP
BUSHING
HOSE
TUBE
STRAP
NUT
SCREEN
BAFFLE (RH AND LH)
RADIATOR CAP
COOLANT LEVEL SENSOR

Radiator Replacement

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

Legend for Figure 3


A. RADIATOR WITH EXTERNAL COOLER

B. RADIATOR WITH INTERNAL COOLER

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

RADIATOR
SHROUD
WASHER
SCREW
CLIP NUT
CLIP
UPPER HOSE
LOWER HOSE
CLAMP
UPPER RADIATOR BRACKET
INSERT
CAPSCREW
ISOLATOR

RESERVOIR
OUTLET ASSEMBLY
OUTLET
CAP
BUSHING
HOSE
TUBE
NUT
SCREEN
BAFFLE (RH AND LH)
RADIATOR CAP
COOLANT LEVEL SENSOR

11

Radiator Replacement

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

Legend for Figure 4


A. RADIATOR WITH INTERNAL COOLER

B. RADIATOR WITH EXTERNAL COOLER

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

CAPSCREW
INSERT
UPPER RADIATOR BRACKET
RADIATOR CAP
ISOLATOR
CLIP NUT
COOLANT LEVEL SENSOR
RADIATOR
CLIP
RADIATOR SHROUD
CLAMP
LOWER HOSE
SCREW

WASHER
SCREEN
STRAP
RESERVOIR BRACKET
RESERVOIR
OUTLET ASSEMBLY
OUTLET
CAP
BUSHING
TUBE
UPPER HOSE
DRAIN PLUG
OIL COOLER

13

Radiator Replacement

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

Legend for Figure 5


A. RADIATOR WITH INTERNAL COOLER

B. RADIATOR WITH EXTERNAL COOLER

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

CAPSCREW
INSERT
UPPER RADIATOR BRACKET
RADIATOR CAP
ISOLATOR
CLIP NUT
COOLANT LEVEL SENSOR
RADIATOR
CLIP
RADIATOR SHROUD
CLAMP
LOWER HOSE

SCREW
WASHER
SCREEN
RESERVOIR
OUTLET ASSEMBLY
OUTLET
CAP
BUSHING
TUBE
UPPER HOSE
DRAIN PLUG
OIL COOLER

15

Radiator Replacement

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

RADIATOR
RADIATOR CAP
HARNESS CLIP
UPPER RADIATOR BRACKET
INSERT
ISOLATOR
CAPSCREW
CLAMP
TUBE
UPPER HOSE
CLAMP
CHARGE AIR COOLER HOSE
CLAMP
CHARGE AIR COOLER HOSE
SHROUD

700 YRM 1123

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

CLAMP
CHARGE AIR COOLER HOSE
SCREW
WASHER
CLIP
LOWER HOSE
RESERVOIR
BUSHING
RESERVOIR CAP
RESERVOIR OUTLET
HOSE
TUBE
COOLANT LEVEL SENSOR
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

700 YRM 1123

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

LOWER HOSE
CLAMP
UPPER HOSE
RESERVOIR
OUTLET ASSEMBLY
BUSHING
CAP
RESERVOIR OUTLET
HOSE
CAPSCREW
INSERT
RADIATOR CAP

Radiator Replacement

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

ISOLATOR
UPPER RADIATOR BRACKET
RADIATOR
PLUG - COOLANT LEVEL SENSOR
HEAT SHIELD
CLIP NUT
WASHER
SCREW
DRAIN PLUG
SHROUD
TUBE

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

17

Radiator Replacement

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

RADIATOR
RADIATOR CAP
UPPER RADIATOR BRACKET
ISOLATOR
CAPSCREW
INSERT
CLAMP
TUBE
UPPER HOSE
LOWER HOSE

700 YRM 1123

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

TRANSMISSION COOLER RETURN LINE


TRANSMISSION COOLER SUPPLY LINE
SCREW
WASHER
SHROUD
RESERVOIR
BUSHING
RESERVOIR CAP
RESERVOIR OUTLET
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

700 YRM 1123

RADIATOR, REMOVE FOR LIFT TRUCKS


MODELS GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) EQUIPPED
WITH OIL COOLER
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.
1. Turn OFF truck.
2. Remove the hood and seat combination.
See section Frame 100 YRM 1120 for lift truck models
GC/GLC030VX,
GC/GLC035VX,
GC/GLC040SVX (C809)
GLP/GDP16VX,
GLP/GDP18VX,
GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX)
(C810)
See section Frame 100 YRM 1423 for lift truck models
GLC050LX (A967)
GLP/GDP20-25LX (GLP/GDP050LX) (A974)

WARNING
Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so
that no one connects the cables on the terminals.

Radiator Replacement
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
5. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capacity
of the cooling system under radiator. Remove radiator cap.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
6. Open the drain plug or loosen hose clamp and disconnect the lower hose.
7. Loosen clamps and disconnect oil cooler hoses
from oil cooler adapters. See Figure 9.
8. Remove oil cooler adapters and O-rings from radiator. Discard O-rings. See Figure 9.
9. Once coolant is drained from engine, loosen hose
clamps and disconnect coolant hoses from radiator.
Cap radiator hoses.
10. Loosen hose clamp and disconnect hose from
reservoir and remove reservoir. See Figure 9.
11. Remove battery and battery tray.
12. If equipped, disconnect electrical connector to the
coolant level sensor.
NOTE: For Mazda LPG engine, the LPG converter
bracket needs to be moved for clearance of radiator.
13. Remove screws and washers from the shroud and
move shroud out of the way.
14. Place radiator guard shield between radiator and
fan so damage to radiator does not occur during
fan removal.
15. Remove fan, fan spacer, and pulley.

3. Disconnect the negative battery cable.

16. Remove radiator guard shield.

4. Disconnect the positive battery cable.

17. Remove capscrews and upper radiator bracket.


See Figure 9.

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

18. Remove radiator from truck.


19. If necessary, remove the coolant level sensor.

19

Radiator Replacement

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

RADIATOR
CAP
UPPER HOSE
LOWER HOSE
CLAMP
SHROUD
O-RING
OIL COOLER ADAPTER
OIL COOLER HOSE
UPPER RADIATOR BRACKET

700 YRM 1123

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

CAPSCREW
INSERT
ISOLATOR
RESERVOIR
TUBE
OUTLET ASSEMBLY
HOSE
RESERVOIR OUTLET
CAP
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

700 YRM 1123

RADIATOR, REMOVE FOR LIFT TRUCK


MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024, G024)GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879)
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.
1. Turn off truck.

WARNING
Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so
that no one connects the cables on the terminals.
2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.

Radiator Replacement
11. Place a radiator guard shield between radiator and
fan so damage to radiator does not occur during fan
removal.
12. Remove fan. See Fan Removal procedures.
13. Remove radiator guard shield.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
14. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capacity
of the cooling system under the radiator. Remove
radiator cap.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
15. Open drain plug, loosen clamp and disconnect the
lower radiator hose from radiator to allow coolant to
drain into a suitable container. Install caps on hose.
See Figure 10.

4. Remove radiator cover. See Figure 10.


5. Remove debris cover.

CAUTION
The counterweight cover is extremely heavy 185 kg
(408 lb). Make sure that the eyebolts and lifting device have sufficient capacity to lift the weight.
6. Remove two bolts from counterweight cover.
7. Install two eyebolts in the hole on each end of the
counterweight cover. Connect a suitable lifting device to the eyebolts and carefully remove the counterweight cover from lift truck.
8. Remove four capscrews from upper radiator
bracket. Remove bracket. See Figure 23.
9. If necessary, disconnect electrical connector from
the coolant level sensor.
10. Remove screws, washers, and clip nuts from the
shroud and radiator and move shroud out of the
way.

16. Once coolant is drained from engine, loosen hose


clamp and disconnect upper radiator hose from radiator. Install cap on hose. See Figure 10.
17. Lift trucks equipped with a Cummins QSB 3.3L
diesel engine: Loosen clamps and disconnect the
charge air cooler hoses from charge air cooler.
See Figure 11.
18. Loosen clamp and disconnect remote refill hose
from radiator. Install cap on hose.
NOTE: Tag the transmission lines before disconnecting
from oil cooler.
19. Disconnect transmission lines from oil cooler. Install caps on transmission lines. Drain transmission
oil from oil cooler into a suitable container. Install
caps on the oil cooler ports.
NOTE: Removing the radiator from lift truck requires
two people.
20. Remove radiator from lift truck frame.
21. If necessary, remove the coolant level sensor from
radiator. See Figure 23.

21

Radiator Replacement

700 YRM 1123

Legend for Figure 10


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Figure 10. Radiator Removal for Lift Truck Models


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

22

DEBRIS COVER
COUNTERWEIGHT COVER
RADIATOR COVER
UPPER BRACKET
CAPSCREWS
REMOTE FILL HOSE
HOSE CLAMPS
OIL COOLER
TRANSMISSION OIL COOLER LINES
FITTINGS
UPPER HOSE
LOWER HOSE
REMOTE FILL
RADIATOR CAP

700 YRM 1123

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

RADIATOR
RADIATOR CAP
HARNESS CLIP
UPPER RADIATOR BRACKET
INSERT
ISOLATOR
CAPSCREW
CLAMP
TUBE
UPPER HOSE
CLAMP
CHARGE AIR COOLER HOSE
CLAMP
CHARGE AIR COOLER HOSE
SHROUD

Radiator Replacement

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

CLAMP
CHARGE AIR COOLER HOSE
SCREW
WASHER
CLIP
LOWER HOSE
RESERVOIR
BUSHING
RESERVOIR CAP
RESERVOIR OUTLET
HOSE
TUBE
COOLANT LEVEL SENSOR
SEAL

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

23

Radiator Replacement

RADIATOR, REMOVE FOR LIFT TRUCK


MODELS GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) AND GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909)
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.
1. Turn off truck.

WARNING
Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so
that no one connects the cables on the terminals.
2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
NOTE: Perform Step 4 for lift truck models GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878).
4. Open hood and loosen clamp and disconnect inlet
hose that attaches to the hood support. See Figure 25.
NOTE: Perform Step 5 for lift truck model GDP80VX,
GDP80VX9, GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909).
5. Open hood, loosen clamp, and disconnect dirty air
hose attached to hood support.
See Figure 26 for lift truck models below equipped
with Cummins QSB 3.3L diesel engine
GDP80VX,
GDP80VX9,
GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909)
See Figure 27 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX,
GLP80VX9,
GLP90VX
(GLP/GLP170VX,
GLP/GLP175VX36,
GLP/GLP190VX) (A909, B909)

24

700 YRM 1123


See Figure 28 for lift truck models equipped with
Kubota 3.8L Diesel engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (B909)
6. Lift trucks equipped with GM 4.3L (Gas/LPG) engine, loosen clamp and disconnect inlet hose from
air filter and remove inlet hose. See Figure 25.
NOTE: Perform Step 7 for lift truck models GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878).
7. Lift trucks equipped with the Kubota 3.8L, Cummins
4.5L, or QSB 3.3L diesel engine loosen clamp and
disconnect inlet hose from silencer. Remove silencer. See Figure 25.
NOTE: Before lifting the hood assembly from the lift
truck frame, make sure to use a lifting device and lifting straps as shown in Figure 12. The hood assembly
weighs approximately 45.6 kg (101 lb).
8. Remove hood assembly. For hood assembly removal procedures, see
Frame 100 YRM 1321 for lift truck models
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36,GLP/GDP190VX) (A909)
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C879, D879)
Frame 100 YRM 1581 for lift truck models
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (E878)
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (B909)
9. Disconnect and cap auxiliary coolant reservoir
hose. See Figure 25.
10. Remove capscrews from the auxiliary coolant
reservoir bracket and upper bracket. Remove
auxiliary coolant reservoir assembly.
11. Remove the four capscrews from the upper radiator
bracket. Remove bracket.
12. If necessary, disconnect electrical connector from
the coolant level sensor.
13. Remove screws, washers and clip nuts from the
shroud and move shroud out of the way.

700 YRM 1123

Radiator Replacement
See Figure 14 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909 B909)
See Figure 15 for lift truck models equipped with
Kubota 3.8L Diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (B909)
17. Remove radiator guard shield.

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
can cause burns.
18. Let coolant cool to ambient temperature. Place a
drain pan with a capacity equal to or greater than
the capacity of the cooling system under the radiator. Remove radiator cap.

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
1. PRE-CLEANER

2. STRAP CLAMP

Figure 12. Hood Assembly Removal


14. Place a radiator guard shield between radiator and
fan so damage to radiator does not occur during fan
removal.
NOTE: Perform Step 15 for lift truck models GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878).
15. Remove capscrews, washers, fan, fan spacer, and
shroud. See Figure 25.
NOTE: Perform Step 16 for lift truck model GLP\
GDP80VX, GLP\GDP80VX9, GLP\GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909, B909).

19. Open drain plug or loosen clamp and disconnect


lower radiator hose to allow coolant to drain.
See Figure 25 for lift truck models
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 13 for lift truck models below equipped
with Cummins QSB 3.3L diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 14 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)

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


fan shroud.

See Figure 15 for lift truck models equipped with


Kubota 3.8L Diesel engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (B909)

See Figure 13 for lift truck models below equipped


with Cummins QSB 3.3L diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)

20. Lift trucks equipped with a Cummins QSB 3.3L or


Kubota 3.8L diesel engine, loosen clamps and disconnect the charge air cooler hoses from radiator.
See Figure 13 or Figure 15.

25

Radiator Replacement

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

RADIATOR
RADIATOR CAP
HARNESS CLIP
UPPER RADIATOR BRACKET
INSERT
ISOLATOR
CAPSCREW
CLAMP
TUBE
UPPER HOSE
CLAMP
CHARGE AIR COOLER HOSE
CLAMP
CHARGE AIR COOLER HOSE
SHROUD

700 YRM 1123

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

CLAMP
CHARGE AIR COOLER HOSE
SCREW
WASHER
CLIP
LOWER HOSE
RESERVOIR
BUSHING
RESERVOIR CAP
RESERVOIR OUTLET
HOSE
TUBE
COOLANT LEVEL SENSOR
SEAL

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

26

700 YRM 1123


21. Once coolant is drained from engine, loosen hose
clamps and disconnect radiator hoses from radiator. Cap hoses.
NOTE: Tag the transmission lines before disconnecting
from oil cooler.
22. Disconnect and cap transmission lines from oil
cooler and allow transmission oil to drain from oil

1.
2.
3.
4.
5.
6.
7.
8.
9.

BAFFLE
ISOLATOR
UPPER BRACKET
CAP
RESERVOIR OUTLET
BUSHING
HOSE
RESERVOIR
RADIATOR

Radiator Replacement
cooler into a suitable container, then cap the oil
cooler ports.
23. For lift trucks equipped with GM 5.7L LPG engine,
remove capscrews from baffles and remove baffles
from radiator assembly. Remove capscrews securing cooling baffle to radiator assembly. See Figure 14.

10.
11.
12.
13.
14.
15.
16.
17.
18.

CAPSCREW
SHROUD
CLAMP
UPPER HOSE
LOWER HOSE
SEAL
COOLING BAFFLE
DRAIN HOSE
PLASTIC TUBE

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

27

Radiator Replacement

700 YRM 1123

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

28

700 YRM 1123

Radiator Replacement

Legend for Figure 15


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

RADIATOR
RADIATOR CAP
UPPER RADIATOR BRACKET
INSERT
ISOLATOR
CAPSCREW
CLAMP
TUBE
UPPER HOSE
CHARGE AIR COOLER HOSE
CHARGE AIR COOLER HOSE

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

CHARGE AIR COOLER HOSE


LOWER HOSE
SHROUD
RESERVOIR
BUSHING
RESERVOIR CAP
RESERVOIR OUTLET
HOSE
COOLANT LEVEL SENSOR
SEAL

NOTE: Removing the radiator from lift truck requires


two people.

5. Place shroud in lift truck. DO NOT install on radiator.

24. Remove radiator from lift truck frame.

NOTE: Pull radiator shroud away from radiator while


installing fan, fan spacer, and pulley.

25. If necessary, remove the coolant level sensor from


radiator.

RADIATOR, INSTALL FOR LIFT


TRUCK MODELS GC/GLC030VX,
GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX
(A967); GLP/GDP20-35VX
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX)
(A974); GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818, F818) AND
GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813)
1. If removed, install the coolant level sensor.

6. Install fan, fan spacer, and pulley.


7. Remove radiator guard shield.
8. Install the radiator shroud on radiator using screws
and washers taken out during removal..
9. If equipped, connect the electrical connector to the
coolant level sensor.
NOTE: For Mazda LPG engine, the LPG converter
bracket and screws must be installed to hold the converter.
10. Uncap radiator and reservoir ports and install the
reservoir.
11. Connect the reservoir hose from reservoir to the
radiator. Tighten hose clamp.
12. Lift trucks equipped with Cummins QSB 3.3L engine, uncap the charge air cooler hoses and connect the hoses to charge air cooler. See Figure 6.
13. Lift trucks equipped with Kubota 3.8L diesel engine: Uncap transmission cooler hoses and connect hoses to transmission cooler. See Figure 8.

2. Install radiator into truck.

14. Uncap the upper hose and connect the hose to radiator. Tighten hose clamp.

3. Install upper radiator bracket, using capscrews


taken out during removal.

15. Close the drain plug or install lower hose. Tighten


hose clamp.

4. Place a radiator guard shield between radiator and


fan, so damage to radiator does not occur during
fan installation

29

Radiator Replacement

700 YRM 1123

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

CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
16. Fill cooling system with ethylene glycol boron-free
antifreeze. Purchase a pre-diluted 50/50 solution;
or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling
system to 37C ( 35F).
17. Use the same coolant mixture and fill the reservoir
between the ADD and FULL marks.
See Figure 16 or Figure 17, for lift truck models
GC/GLC030VX,
GC/GLC035VX,
GC/GLC040SVX (C809)
GLP/GDP16VX,
GLP/GDP18VX,
GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX)
(C810)
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875
GLC050LX (A967)
GLP/GDP20-25LX (GLP/GDP050LX) (A974)
See Figure 18, for lift truck models
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
100,
120VX;
GC/GLC080,
100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813)
See Figure 19 for lift truck models
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)

30

1. RESERVOIR
2. ADD MARK

3. FULL MARK

Figure 16. Reservoir for Lift Truck Models


GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX (A967);
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
Before May 06

700 YRM 1123

1. RESERVOIR
2. ADD MARK

Radiator Replacement

3. FULL MARK

Figure 17. Reservoir for Lift Truck Models


GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX (A967);
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)
and GLP/GDP20-25LX (GLP/GDP050LX) (A974)
After May 06

1.
2.
3.
4.

AUXILIARY COOLANT RESERVOIR


FULL "HOT" MARK
FULL "COLD" MARK
ADD "COLD" MARK

Figure 18. Reservoir for Lift Truck Models


GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100,
120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS) (E818), GLP/GDP40VX5/VX6;
GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP5055VX (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813)

31

Radiator Replacement

700 YRM 1123


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

WARNING
1.
2.
3.
4.

AUXILIARY COOLANT RESERVOIR


FULL "HOT" MARK
FULL "COLD" MARK
ADD "COLD" MARK

Figure 19. Reservoir for Lift Truck Models


GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/
GDP45VX6; GLP/GDP50-55VX (GP/GLP/GDP080,
090, 100, 110, 120VX) (H813, J813)
18. Install battery and battery tray.
19. Connect the positive battery cable.
20. Connect negative battery cable.
21. Install the hood and seat combination.
See section Frame 100 YRM 1120 for lift truck 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)

32

During engine operation, be careful not to touch the


fan, pulleys, or drive belts. Contact with these parts
can cause serious injury.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury.
22. Start and run engine until thermostat opens. (The
upper hose will be warm.)
23. On lift trucks equipped with a GM 2.4L engine,
bleed air from the cooling system by opening the
bleed screw located on the left side behind the
alternator. When the air has been bled from the
system close the bleed screw. See Figure 20.

CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
24. Check coolant level at the reservoir. Add coolant
as necessary to keep level between the ADD and
FULL marks on the reservoir.

700 YRM 1123

Radiator Replacement
6. Install fan, fan spacer, and pulley.
7. Remove radiator guard shield.
8. Install the radiator shroud on radiator using screws
and washers taken out during removal..
9. If equipped, connect the electrical connector to the
coolant level sensor.
NOTE: For Mazda LPG engine, the LPG converter
bracket and screws must be installed to hold the converter.
10. Uncap radiator and reservoir ports and install the
reservoir.
11. Connect the reservoir hose from reservoir to the
radiator. Tighten hose clamp. See Figure 9.
12. Install new O-rings on oil cooler connectors. See
Figure 9.

1. MANIFOLD
2. COOLANT HOSES

3. BLEED SCREW
4. RADIATOR HOSE

Figure 20. Bleed Screw, GM 2.4L Engine

RADIATOR, INSTALL FOR LIFT TRUCK


MODELS GC/GLC030VX, GC/GLC035VX,
GC/GLC040SVX (C809); GLP/GDP16VX,
GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC050LX
(A967) AND GLP/GDP20-25LX
(GLP/GDP050LX) (A974) EQUIPPED
WITH OIL COOLER
1. If removed, install the coolant level sensor.

13. Install oil cooler adapters to radiator. Torque


adapters to 14.7 to 17.6 Nm (130 to 156 lbf in).
See Figure 9.
14. Uncap oil cooler hoses and connect hoses to oil
cooler adapters. See Figure 9.
15. Uncap the upper hose and connect the hose to radiator. Tighten hose clamp. See Figure 9.
16. Close the drain plug or install lower hose. Tighten
hose clamp.

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

2. Install radiator into truck.


3. Install upper radiator bracket, using capscrews
taken out during removal.
4. Place a radiator guard shield between radiator and
fan, so damage to radiator does not occur during
fan installation

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

5. Place shroud in lift truck. DO NOT install on radiator.

17. Fill cooling system with ethylene glycol boron-free


antifreeze. Purchase a pre-diluted 50/50 solution;
or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling
system to 37C ( 35F).

NOTE: Pull radiator shroud away from radiator while


installing fan, fan spacer, and pulley.

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

33

Radiator Replacement

700 YRM 1123

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

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury.
23. Start and run engine until thermostat opens. (The
upper hose will be warm.)

CAUTION
Additives may damage the cooling system. Before
using additives, contact your local Yale dealer.
1. RESERVOIR
2. ADD MARK

3. FULL MARK

Figure 21. Reservoir for Lift Truck Models


GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX,
GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810); GLC050LX (A967) and GLP/GDP20-25LX
(GLP/GDP050LX) (A974)
19. Install battery and battery tray.
20. Connect the positive battery cable.

24. Check coolant level at the reservoir. Add coolant


as necessary to keep level between the ADD and
FULL marks on the reservoir.

RADIATOR, INSTALL FOR LIFT TRUCK


MODELS S6.0FT, S7.0FT (S135FT, S155FT)
(D024, E024, F024, G024)GLC/GDC60VX,
GLC/GDC60VX, (GC/GLC/GDC135VX,
GC/GLC/GDC135VX) (C879, D879, E879,
F879)
1. If necessary, install coolant level sensor.

21. Connect negative battery cable.

NOTE: Installing the radiator into lift truck frame requires two people.

22. Install the hood and seat combination.

2. Install radiator into lift truck frame.

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

3. Remove caps from the oil cooler and transmission


lines and connect lines into oil cooler. See Figure 10.
4. Uncap and connect remote refill hose onto radiator
and tighten hose clamp. See Figure 10.
5. Close drain plug and uncap the upper and lower
radiator hoses and connect hoses onto radiator and
tighten hose clamps. See Figure 10.
6. Uncap the charge air cooler hoses and connect the
hoses to charge air cooler. See Figure 11.
7. Install fan. See Fan Installation procedures.
8. Align shroud to radiator and install two capscrews,
washers and clip nuts. See Figure 23.

34

700 YRM 1123

Radiator Replacement

9. If necessary, connect electrical connector onto the


coolant level sensor.
10. Install upper radiator bracket and four capscrews.

CAUTION
The counterweight cover is extremely heavy 185 kg
(408 lb). Make sure that the eyebolts and lifting device have sufficient capacity to lift the weight.
11. If removed, install two eyebolts in the hole on each
end of the counterweight cover. Connect a suitable
lifting device to the eyebolts and carefully install the
counterweight cover into the lift truck frame. See
Figure 10.
12. Install two bolts to counterweights cover. Tighten to
38 Nm (28 lbf ft).
13. Install debris cover.
14. Install radiator cover.
15. Connect positive battery cable.

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and cause serious
injury.
20. Start and run the engine until thermostat opens
(The upper radiator hose will be warm).

CAUTION
Additives may damage the cooling system. Before
using additives, contact you local Yale dealer.
21. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.
22. Shut down the engine for one minute or longer prior
to checking the transmission oil level. If the transmission oil is low, add transmission oil to the transmission at the dipstick tube to the correct level indicated on the dipstick. Oil is specified in Periodic
Maintenance section for your lift truck.

16. Connect negative battery cable.

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

CAUTION
Additives may damage the cooling system. Before
using additives, contact you local Yale dealer.
17. Fill cooling system with ethylene glycol boron-free
antifreeze. Purchase a pre-diluted 50/50 solution;
or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling
system to 37C ( 35F).
18. Install radiator cap.
19. Use the same coolant mixture and fill the reservoir
between the ADD and FULL marks. See Figure 22.

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

1.
2.
3.
4.

AUXILIARY COOLANT RESERVOIR


FULL "HOT" MARK
FULL "COLD" MARK
ADD "COLD" MARK

Figure 22. Reservoir for Lift Truck Models


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

35

Radiator Replacement

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

Legend for Figure 23


A. LOWER HOSE (CUMMINS 4.5L/KUBOTA 3.8L
DIESEL)
B. LOWER HOSE (GAS AND LPG)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

RADIATOR (WITH EXTERNAL OIL COOLER)


SHROUD
WASHER
SCREW
CLIP NUT
CLIP SPRING
CLAMP
UPPER RADIATOR BRACKET
CAPSCREW
INSERT
ISOLATOR
RESERVOIR
BRACKET (COOLANT FILL)

RADIATOR, INSTALL FOR LIFT TRUCK


MODELS GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878, E878) AND GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909)
1. If necessary, install coolant level sensor.
NOTE: Installing the radiator into lift truck frame requires 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 assembly. See Figure 14. Use capscrews and attach radiator assembly to cooling baffle.
4. Install upper radiator bracket and four capscrews.
See Figure 25 for lift truck models
GLP/GDP70VX
(GP/GLP/
GLP/GDP60VX,
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 13 for lift truck models below equipped
with Cummins QSB 3.3L diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 14 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)

C. UPPER HOSE (GAS AND LPG)


D. UPPER HOSE (CUMMINS 4.5L/KUBOTA 3.8L
DIESEL)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

OUTLET ASSEMBLY
OUTLET
CAP
BUSHING
HOSE
HOSE
REMOTE FILL HOSE
REMOTE FILL
RADIATOR CAP
SCREEN
COOLANT LEVEL SENSOR
DRAIN PLUG
See Figure 15 for lift truck models equipped with
Kubota 3.8L Diesel engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (B909)

5. Install coolant reservoir bracket and coolant reservoir assembly onto upper bracket and tighten capscrews.
See Figure 25 for lift truck models
(GP/GLP/
GLP/GDP60VX,
GLP/GDP70VX
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 13 for lift truck models below equipped
with Cummins QSB 3.3L diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 14 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)
See Figure 15 for lift truck models equipped with
Kubota 3.8L Diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (B909)
6. Uncap and connect auxiliary coolant reservoir hose
and tighten clamp.
7. Remove caps from the oil cooler and transmission
lines and connect lines into oil cooler.
8. Close drain plug and uncap the lower radiator hose
and connect hose onto radiator and tighten clamp.

37

Radiator Replacement
9. Uncap and connect upper radiator hose and tighten
clamp.
10. Lift trucks equipped with Cummins QSB 3.3L or
Kubota 3.8L diesel engine, uncap the charge air
cooler hoses and connect the hoses to the charge
air cooler. See Figure 13 or Figure 15.
11. Install fan. See Fan Installation procedures.

700 YRM 1123


See Figure 27 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)
See Figure 28 for lift truck models equipped with
Kubota 3.8L Diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (B909)

12. Align shroud to radiator and install capscrews,


washers and clip nuts.

17. Install hood assembly. For hood install procedures,


see section

See Figure 25 for lift truck models


GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)

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)

See Figure 13 for lift truck models below equipped


with Cummins QSB 3.3L diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 14 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)
See Figure 15 for lift truck models equipped with
Kubota 3.8L Diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (B909)
13. If necessary, connect electrical connector onto the
coolant level sensor.
14. Lift truck equipped GM 4.3L (Gas/LPG) engine, install air intake hose to air filter and tighten clamp.
15. Lift trucks equipped with Cummins 4.5L or QSB
3.3L diesel engine, install silencer and connect
hose from air filter side and tighten clamp. See
Figure 25.
16. Lift trucks equipped with Cummins QSB 3.3L, Kubota 3.8L diesel engine or GM 5.7L LPG engine, connect dirty air hose to hood support and install and
tighten clamp.
See Figure 26 for lift truck models below equipped
with Cummins QSB 3.3L diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)

Frame 100 YRM 1581 for lift truck models


GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (E878)
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (B909)
18. Lift truck equipped GM 4.3L (Gas/LPG) engine,
open hood assembly and connect intake hose to
hood support and tighten clamp. See Figure 25.
19. Lift trucks equipped with Kubota 3.8L, Cummins
4.5L, or QSB 3.3L diesel engine, open hood assembly and connect hose to hood support and tighten
clamp.
See Figure 25 for lift truck models
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 26 for lift truck models below equipped
with Cummins QSB 3.3L diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 28 for lift truck models equipped with
Kubota 3.8L Diesel engine
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (B909)
20. Connect positive battery cable.
21. Connect negative battery cable.

38

700 YRM 1123

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

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

Radiator Replacement
26. Check coolant level at the auxiliary coolant reservoir. Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.
27. Shut down the engine for one minute or longer prior
to checking the transmission oil level. If the transmission oil is low, add transmission oil at the dipstick
tube at the correct level indicated on the dipstick.
Oil is specified in Periodic Maintenance section for
your lift truck.

22. Fill cooling system with ethylene glycol boron-free


antifreeze. Purchase a pre-diluted 50/50 solution;
or mix 50% concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling
system to 37C ( 35F).
23. Install radiator cap.
24. Use the same coolant mixture and fill the auxiliary coolant reservoir between the ADD and FULL
marks. See Figure 24.

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

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and cause serious
injury.
25. Start and run the engine until thermostat opens
(The upper radiator hose will be warm).

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

1.
2.
3.
4.

AUXILIARY COOLANT RESERVOIR


FULL "HOT" MARK
FULL "COLD" MARK
ADD "COLD" MARK

Figure 24. Reservoir for Lift Truck Models GLP/


GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878) and
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909)

39

Radiator Replacement

700 YRM 1123

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

700 YRM 1123

Radiator Replacement

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

41

Radiator Replacement

700 YRM 1123

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

42

700 YRM 1123

Radiator Replacement

Legend for Figure 25


A. GM 4.3L (GAS/LPG)
B. CUMMINS 4.5L (DIESEL)

C. KUBOTA (DIESEL)

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

17.
18.
19.
20.
21.
22.

AIR INTAKE (WITHOUT PRE-CLEANER)


PRE-CLEANER
HOOD ASSEMBLY
CLAMP
INLET HOSE
SILENCER (DIESEL)
AIR FILTER
UPPER RADIATOR BRACKET
ISOLATOR
INSERT
CAPSCREW
RADIATOR (WITH EXTERNAL OIL COOLER)
UPPER HOSE
LOWER HOSE
CLIP NUT
WASHER

23.
24.
25.
26.
27.
28.
29.
30.

SCREW
SHROUD
FAN
FAN SPACER
TRANSMISSION LINES
AUXILIARY COOLANT RESERVOIR AND
BRACKET ASSEMBLY
OUTLET
CAP
BUSHING
HOSE
AUXILIARY COOLANT RESERVOIR HOSE
DRAIN PLUG
RADIATOR CAP
HOOD SUPPORT

43

Radiator Replacement

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.

PRE-CLEANER
CLAMP
HOOD SUPPORT
HOOD ASSEMBLY
DIRTY AIR HOSE
CLEAN AIR HOSE
AIR FILTER
AIR CLEANER BRACKET
CAPSCREW
NUT
AUXILIARY COOLANT RESERVOIR HOSE
RESERVOIR OUTLET
CAP
BUSHING
COOLANT RECOVERY RESERVOIR
TUBE

700 YRM 1123

17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.

COOLANT LEVEL SENSOR


UPPER BRACKET
RADIATOR ISOLATOR
RADIATOR
CAC HOSE
CAC TUBE
INSULATED CLAMP
LOWER RADIATOR HOSE
UPPER RADIATOR HOSE
SHROUD AND BAFFLE
WASHER
FAN
SPACER
AUXILIARY COOLANT RESERVOIR ASSEMBLY
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

700 YRM 1123

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

PRE-CLEANER
CLAMP
HOOD SUPPORT
HOOD
DIRTY AIR HOSE
CLEAN AIR HOSE
AIR FILTER
AIR CLEANER BRACKET
CAPSCREW
NUT
RADIATOR ISOLATOR
UPPER BRACKET

Radiator Replacement

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.

RADIATOR
BAFFLE
COOLANT RECOVERY RESERVOIR
LOWER RADIATOR HOSE
UPPER RADIATOR HOSE
SEAL
BAFFLE
FAN SHROUD
FAN
SPACER
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

Radiator Replacement

700 YRM 1123

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 28


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

PRE-CLEANER
CLAMP
HOOD SUPPORT
HOOD ASSEMBLY
DIRTY AIR HOSE
CLEAN AIR HOSE
AIR FILTER
AIR CLEANER BRACKET
CAPSCREW
NUT
AUXILIARY COOLANT RESERVOIR HOSE
RESERVOIR OUTLET
CAP
BUSHING
COOLANT RECOVERY RESERVOIR

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

TUBE
COOLANT LEVEL SENSOR
UPPER BRACKET
RADIATOR ISOLATOR
RADIATOR
CAC HOSE
CAC TUBE
AIR FLOW SENSOR
LOWER RADIATOR HOSE
UPPER RADIATOR HOSE
SHROUD AND BAFFLE
WASHER
FAN
SPACER

Fan Assembly Replacement


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

WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool.
Do a touch test by touching the radiator with your
hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix
any part of the cooling system.

WARNING
The radiator fins on the radiator are very sharp and
can cause serious injury. Wear gloves while removing fan assembly.
NOTE: The fan that is used is a pusher-type fan. Do
not replace with a puller-type fan.
1. Turn OFF lift truck.
2. If equipped, turn the LPG tank valve to the OFF
position.
3. If equipped, release the LPG tank bracket and
swing tank away from the lift truck.

NOTE: Perform Step 4 through Step 6 for lift truck 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)
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 position.

47

Fan Assembly Replacement


NOTE: Perform Step 7 for lift truck models
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36,
GLP/
GDP190VX) (A909, B909)
7. Release hood cover latch on hood cover and swing
hood cover up.

WARNING
To prevent a short circuit during fan belt removal,
disconnect the battery negative cable at the battery
negative terminal. Install a lock or tag on the connector to prevent connection. A tool could cause a
short circuit, the high current flow from the battery
can cause an injury or parts damage.
8. Disconnect the negative battery cable from the negative battery terminal.
9. Remove screws and washers from the radiator
shroud. Lean radiator shroud toward the fan.
See Figure 29 for lift truck models below equipped
with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar
3.3L engine
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
GLP/GDP16VX,
GLP/GDP18VX,
GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX)
(C810)
See Figure 30 for lift truck models below equipped
with Yanmar 2.6L engine.
GDP20-25LX (GDP050LX) (A974)
See Figure 31 for lift truck models below equipped
with 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)

48

700 YRM 1123


See Figure 32 for lift truck models below equipped
with GM 4.3L engine
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 Figure 33 for lift truck models below equipped
with 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 equipped
with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines
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 equipped
with 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 equipped
with Cummins QSB 3.3L diesel engines
GDC60VX,
GDC70VX
(GDC135VX,
GDC155VX) (D879)

GDP60VX,
GDP70VX
(GDP135VX,
GDP155VX) (D878)
GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080, 090, 100, 110, 120VX)
(G813)
See Figure 37 for lift truck models below equipped
with Cummins QSB 3.3L diesel engines
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 38 for lift truck models below equipped
with GM 5.7L LPG engine
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)

700 YRM 1123


See Figure 39 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)

1.
2.
3.
4.

FAN
SPACER
WASHER
CAPSCREW

Fan Assembly Replacement


See Figure 40 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (B909)

5. SCREW
6. RADIATOR SHROUD
7. RADIATOR

Figure 29. Fan Removal for GM 2.4L, Yanmar 2.6L, Yanmar 3.0L and Yanmar 3.3L Engines, Lift Truck Models
GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910), GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875), and GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810)

49

Fan Assembly Replacement

1.
2.
3.
4.

SPACER
FAN
WASHER
CAPSCREW

700 YRM 1123

5. SHROUD
6. SCREW
7. RADIATOR

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

50

700 YRM 1123

Fan Assembly Replacement

NOTE: MODINE RADIATOR SHOWN, COPAR RADIATOR SIMILAR.


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

4.
5.
6.
7.
8.

WASHER
SCREW
WASHER
RADIATOR SHROUD
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

Fan Assembly Replacement

1.
2.
3.
4.

FAN
SPACER
WASHER
CAPSCREW

700 YRM 1123

5. SCREW
6. RADIATOR SHROUD
7. RADIATOR

Figure 32. Fan Removal for GM 4.3L Engine, Lift Truck Models GLC40, 45, 55VX; GLC55SVX;
(GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) and
GLP40VX5/VX6; GLP45SVX5, GLP45VX6; GLP50-55VX (GP/GLP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)

52

700 YRM 1123

1.
2.
3.
4.
5.

SPACER
FAN
WASHER
CAPSCREW
RADIATOR SHROUD

Fan Assembly Replacement

6.
7.
8.
9.

SCREW
LOCKWASHER
CLIP NUT
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

Fan Assembly Replacement

700 YRM 1123

A. GM 4.3L AND KUBOTA 3.8L

B. CUMMINS 4.5L (DIESEL)

1.
2.
3.
4.

5. SCREW
6. SHROUD
7. RADIATOR

FAN
FAN SPACER
WASHER
CAPSCREW

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

700 YRM 1123

Fan Assembly Replacement

A. GM 4.3L AND KUBOTA

B. CUMMINS 4.5L (DIESEL)

1.
2.
3.
4.

5. SCREW
6. SHROUD
7. RADIATOR

FAN
FAN SPACER
WASHER
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

Fan Assembly Replacement

1.
2.
3.
4.

SPACER
FAN
SCREW
WASHER

700 YRM 1123

5.
6.
7.
8.

WASHER
CAPSCREW
SHROUD
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

700 YRM 1123

1.
2.
3.
4.

RADIATOR SHROUD
SCREW
WASHER
SPACER

Fan Assembly Replacement

5. CAPSCREW
6. FAN
7. RADIATOR

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

57

Fan Assembly Replacement

1.
2.
3.
4.

FAN SHROUD
SCREW
WASHER
SPACER

700 YRM 1123

5. CAPSCREW
6. FAN
7. RADIATOR ASSEMBLY

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

58

700 YRM 1123

1.
2.
3.
4.

FAN
FAN SPACER
WASHER
CAPSCREW

Fan Assembly Replacement

5. SCREW
6. SHROUD
7. RADIATOR

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

59

Fan Assembly Replacement

1.
2.
3.
4.

FAN SHROUD
SCREW
WASHER
SPACER

700 YRM 1123

5. CAPSCREW
6. FAN
7. RADIATOR ASSEMBLY

Figure 40. Fan Removal for Kubota 3.8L Diesel Engine, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)
10. Remove capscrews, washers, and spacer from the
fan pulley.
See Figure 29 for lift truck models below equipped
with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar
3.3L engine
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
GLP/GDP16VX,
GLP/GDP18VX,
GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX)
(C810)

60

See Figure 30 for lift truck models below equipped


with Yanmar 2.6L engine
GDP20-25LX (GDP050LX) (A974)
See Figure 32 for lift truck models below equipped
with GM 4.3L engine
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)

700 YRM 1123


See Figure 33 for lift truck models below equipped
with 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 equipped
with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines
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 equipped
with GM 4.3L, Cummins 4.5L, Kubota engines
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 39 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)
NOTE: Perform Step 11 for lift truck model GDP80VX,
GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909) and GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (B909).
11. For lift trucks equipped with Cummins QSB 3.3L
diesel engines, GM 5.7L LPG engines, or Kubota
3.8L diesel engines, remove capscrews, washers,
and spacers from fan.
See Figure 37 for lift truck models below equipped
with Cummins QSB 3.3L diesel engines
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 38 for lift truck models below equipped
with GM 5.7L LPG engine
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)
See Figure 40 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (B909)

Fan Assembly Replacement


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 F2
engines, remove capscrews, washers, and spacer
from the fan pulley.
See Figure 31 for lift truck models below equipped
with 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)
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 engines, remove the capscrews and washers retaining the fan.
See Figure 31 for lift truck models below equipped
with 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)
14. Remove the fan.

61

Fan Assembly Replacement

INSPECT
WARNING
DO NOT try to repair a damaged fan. If a fan has a
bent blade or is cracked, install a new fan. A damaged fan can break during use and cause damage
or serious injury.
1. Inspect the fan for any damage.
2. If the fan is damaged, replace the entire fan.

FAN INSTALLATION
WARNING
The radiator fins on the radiator are very sharp and
can cause serious injury. Wear gloves while installing fan assembly.
1. Install the lower portion of the shroud in the retaining clips and lean the shroud toward the engine.
2. Install the spacer, washers, and capscrews to the
fan. Tighten the capscrews to 52 Nm (38 lbf).
See Figure 29 for lift truck models below equipped
with GM 2.4L, Yanmar 2.6L, Yanmar3.0L or Yanmar
3.3L engine
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
GLP/GDP18VX,
GLP/GDP16VX,
(GP/GLP/GDP030VX,
GLP/GDP20SVX
GP/GLP/GDP040SVX)
GP/GLP/GDP035VX,
(C810)
See Figure 30 for lift truck models below equipped
with Yanmar 2.6L engine.
GDP20-25LX (GDP050LX) (A974)
See Figure 32 for lift truck models below equipped
with GM 4.3L engine
GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
GC/GLC080,
100VXBCS;
100,
120VX;
GC/GLC120SVX; GC/GLC120VXPRS) (E818,
F818)
GLP/GDP45SVX5,
GLP/GDP40VX5/VX6;
GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
H813, J813)

62

700 YRM 1123


See Figure 33 for lift truck models below equipped
with 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 equipped
with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines
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 equipped
with GM 4.3L, Cummins 4.5L, or Kubota engines
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 39 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)
NOTE: Perform Step 3 for lift truck models GDP80VX,
GDP80VX9, GDP90VX (GDP170VX, GDP175VX36,
GDP190VX) (A909, B909).
3. Install spacers, washers, and capscrews onto fan.
See Figure 37 for lift truck models below equipped
with Cummins QSB 3.3L diesel engines
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 38 for lift truck models below equipped
with GM 5.7L LPG engine
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)
See Figure 40 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (B909)

700 YRM 1123

Fan Assembly Replacement

NOTE: Perform Step 4 for lift truck models


GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810)
GLP/GDP20-35VX
(GP/GLP/GDP040-070VX)
(B875)
GLP20-25LX (GLP050LX) (A974)

See Figure 34 for lift truck models below equipped


with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines
S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024,
F024, G024)GLC/GDC60VX, GLC/GDC60VX,
(GC/GLC/GDC135VX,
GC/GLC/GDC135VX)
(C879, D879, E879, F879)

4. Install the spacer, washers, and capscrews to the


fan. Tighten the capscrews to 27 Nm (20 lbf ft).

See Figure 35 for lift truck models below equipped


with GM 4.3L, Cummins 4.5L, or Kubota engines
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)

See Figure 31 for lift truck models below equipped


with Mazda FE and F2 engines
GLP16VX,
GLP18VX,
GLP20SVX
(GP/
GLP030VX, GP/GLP035VX, GP/GLP040SVX)
(C810)
GLP20-35VX (GP/GLP040-070VX) (B875)
GLP20-25LX (GLP050LX) (A974)
NOTE: Perform Step 5 for lift truck models
GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809)
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLC050LX (A967)
5. Place the fan in position of the pulley and install
capscrews and washers. Tighten the capscrews to
27 Nm (20 lbf ft).
See Figure 31 for lift truck models below equipped
with Mazda FE or F2 engines
GC/GLC030VX,
GC/GLC035VX,
GC/GLC040SVX (C809)
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLC050LX (A967)
6. Install the spacer, washers, and capscrews to the
fan. Tighten the capscrews to 27 Nm (20 lbf ft).
See Figure 32 for lift truck models below equipped
with GM 4.3L engine
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)

7. Lean the radiator shroud back toward the radiator.


Install the screws and washers and install the radiator shroud cover.
See Figure 29 for lift truck models below equipped
with GM 2.4L, Yanmar 2.6L, Yanmar 3.0L or Yanmar
3.3L engine
GLC20-35VX
(GC/GLC040-070VX,
GC/GLC055SVX) (A910)
GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(B875)
GLP/GDP16VX,
GLP/GDP18VX,
GLP/GDP20SVX
(GP/GLP/GDP030VX,
GP/GLP/GDP035VX,
GP/GLP/GDP040SVX)
(C810)
See Figure 30 for lift truck models below equipped
with Yanmar 2.6L engine
GDP20-25LX (GDP050LX) (A974)
See Figure 31 for lift truck models below equipped
with Mazda FE or 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)

63

Fan Assembly Replacement


See Figure 32 for lift truck models below equipped
with GM 4.3L engine
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 Figure 33 for lift truck models below equipped
with 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 equipped
with GM 4.3L, Cummins 4.5L, or Kubota 3.8L engines
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 equipped
with GM 4.3L, Cummins 4.5L, or Kubota engines
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
See Figure 36 for lift truck models below equipped
with Cummins QSB 3.3L diesel engines
GDC60VX,
GDC70VX
(GDC135VX,
GDC155VX) (D879)

GDP60VX,
GDP70VX
(GDP135VX,
GDP155VX) (D878)
GDP40VX5/VX6; GDP45SVX5, GDP45VX6,
GDP50-55VX (GDP080, 090, 100, 110, 120VX)
(G813)
See Figure 37 for lift truck models below equipped
with Cummins QSB 3.3L diesel engines
GDP80VX, GDP80VX9, GDP90VX (GDP170VX,
GDP175VX36, GDP190VX) (A909, B909)
See Figure 38 for lift truck models below equipped
with GM 5.7L LPG engine
GLP80VX, GLP80VX9, GLP90VX (GLP170VX,
GLP175VX36, GLP190VX) (A909, B909)
See Figure 39 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP40VX5/VX6;
GLP/GDP45SVX5,
GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (H813, J813)

64

700 YRM 1123


See Figure 40 for lift truck models below equipped
with Kubota 3.8L diesel engine
GLP/GDP80VX,
GLP/GDP80VX9,
GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (B909)
8. Reconnect the negative battery cable to the negative terminal of the battery.
NOTE: Perform Step 9 through Step 11 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)
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)
9. Lower the hood and ensure that the hood latches.
10. Move the seat back.
11. Release the steering wheel tilt latch and move the
steering wheel back.
NOTE: Perform Step 12 for lift truck models
GLP/GDP60VX,
GLP/GDP70VX
(GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878)
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX,
GLP/GDP175VX36,
GLP/
GDP190VX) (A909, B909)
12. Close hood cover.
13. If equipped, swing the LPG tank bracket back toward the truck and re-latch.
14. If equipped, turn the LPG tank valve to the ON position.

Yale Europe Materials Handling Limited


Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom

700 YRM 1123

3/13 (11/12)(9/12)(7/12) (1/12)(8/11)(7/11)(8/10)(5/10) Printed in the United Kingdom

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