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General
The overhead guard is an integral part of operator The operator cab is a separate unit and can be
cab. The operator cab is installed on a platform above removed as a complete unit from module and frame
main frame members. Step plates on both sides of lift of the lift truck. See Figure 1.
truck provide access to operator cab.
Cab Replacement
REMOVE NOTE: On lift trucks equipped with a LPG fuel sys-
tem, move the LPG tank and bracket to side of truck
NOTE: The LPG tank bracket used to mount the LPG before opening the hood.
tank (if equipped) onto the counterweight comes in
two styles. One style of bracket swings out to side of See PSI 2.0L LPG Fuel System 0900YRM1739 for
truck and other swings out to side and drops down. lift truck models
• GLP/GDP16-18VX, GLP/GDP20SVX (D810)
1
Cab Replacement 0100 YRM 1752
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with a Kubota 2.5L LPG en-
gine
Figure 3. Rear Bottom Window for Lift Trucks Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875)
2
0100 YRM 1752 Cab Replacement
WARNING
DO NOT disconnect the heater hoses from the en-
gine when the engine is hot or when the cooling
system is under pressure, to do so could cause
serious injury.
WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator is hot
and the cap is removed, the pressure is released
from the system and the steam and boiling cool-
ant can cause burns. Wait 30 minutes for the en-
gine to cool. Do a touch test by touching the radi-
ator with your hand. If the radiator is still hot to
the touch, wait another 30 minutes before at-
tempting to remove, check, or fix any part of the
cooling system.
3. Turn knobs counterclockwise and remove radiator NOTE: AIR FILTER HOSE FOR LIFT TRUCK MOD-
cover to access radiator cap. Remove radiator ELS GLP/GDP16-18VX, GLP/GDP20SVX (D810)
cap. See Figure 5. SHOWN. AIR FILTER HOSE FOR LIFT TRUCK
MODELS GLP/GDP20-35VX (GP/GLP/
GDP040-070VX) (D875) IS SIMILAR.
1. CLAMP
2. AIR FILTER HOSE
3. BOLTS
4. ELBOW
5. RETAINER
6. GROMMET
3
Cab Replacement 0100 YRM 1752
WARNING 7. Open left side door, remove lock nut and discon-
Replacement, installation and repairs to air condi- nect gas spring from cab mounting bracket. See
tioning units that require discharging and/or refill- Figure 8.
ing of the refrigeration fluid must be performed by 8. Lift left side door up and over hinge pin and set
a certified technician. aside. See Figure 9 .
NOTE: Perform Step 5 and Step 6 for lift truck mod-
els GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875).
NOTE: RADIATOR COVER FOR LIFT TRUCKS EQUIPPED WITH STEEL DOORS SHOWN. RADIATOR
COVER FOR LIFT TRUCKS EQUIPPED WITH PVC DOORS IS SIMILAR.
4
0100 YRM 1752 Cab Replacement
NOTE: KUBOTA 2.5L LPG ENGINE SHOWN. OTHER ENGINES ARE SIMILAR.
5
Cab Replacement 0100 YRM 1752
A. OUTSIDE OF LIFT TRUCK, LIFT TRUCK MOD- C. LIFT TRUCK MODELS GLP/GDP20-35VX
ELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) (GP/GLP/GDP040-070VX) (D875)
B. INSIDE OF LIFT TRUCK, LIFT TRUCK MODELS
GLP/GDP16-18VX, GLP/GDP20SVX (D810)
1. QUICK DISCONNECT FITTING 3. INNER REAR COVER
2. HEATER HOSES
6
0100 YRM 1752 Cab Replacement
NOTE: RIGHT SIDE DOOR HINGE SHOWN. 19. Disconnect rear grab handle horn button connec-
tor from right-hand chassis harness, located in
1. HINGE PIN right rear corner leg of cab frame. See Figure 12.
2. DOOR HINGE
Figure 9. Door Removal
7
Cab Replacement 0100 YRM 1752
20. Disconnect light harness connector from Vehicle 22. Remove front and rear cab capscrews and flange
Systems Manager (VSM) and right-hand chassis nuts from lift truck frame. See Figure 14.
harness connector. See Figure 12.
NOTE: DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP16-18VX, GLP/GDP20SVX (D810) SHOWN.
DASH ASSEMBLY FOR LIFT TRUCK MODELS GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (D875) IS SIMI-
LAR.
8
0100 YRM 1752 Cab Replacement
WARNING CAUTION
Make sure that the lifting device has a minimum Lift the operator cab carefully. Check that all elec-
capacity to lift 500 kg (1100 lb) trical wires and attachments are disconnected
and are not damaged.
23. Connect a lifting device to a spreader bar or lift
strap, that is through door openings at top of op- 24. Carefully lift operator cab away from lift truck. Set
erator's cab (under overhead guard structure). operator cab in a storage area and place blocks
Place material that will be a cushion at top of door under operator cab to make it stable and prevent
opening to prevent damage. Operate lifting device damage to parts still attached.
just enough to correctly position spreader bar or
lifting strap on operator's cab. See Figure 15.
9
Cab Replacement 0100 YRM 1752
A. FRONT VIEW
B. REAR VIEW
1. CAPSCREWS
2. FLANGE NUTS
10
0100 YRM 1752 Cab Replacement
11
Cab Replacement 0100 YRM 1752
Cooling System 0700YRM1756 for lift truck mod- 26. On lift trucks equipped with an air conditioner/
els heater unit, start engine and turn on heater to ON
• GLP/GDP20-35VX (GP/GLP/ position, run engine approximately one to two mi-
GDP040-070VX) (D875) nutes or until heater supply hose is fully purged.
21. Install radiator cap and radiator cover. See Fig- 27. If lift truck is equipped with a LPG engine, swing
ure 5. the LPG tank and bracket back to its original posi-
tion on counterweight and make sure it locks in
22. Connect air filter hose onto rear left corner leg of position.
cab frame. Tighten capscrews to
66 N•m (49 lbf ft). See Figure 4. See PSI 2.0L LPG Fuel System 0900YRM1739
for lift truck models
23. Connect battery and close hood. • GLP/GDP16-18VX, GLP/GDP20SVX (D810)
24. For lift trucks NOT equipped with an AC/Heater See Fuel System PSI 2.4L 0900YRM1757 for lift
unit, start engine and turn on heater to ON posi- truck models
tion, run engine approximately one to two minutes
• GLP/GDP20-35VX (GP/GLP/
or until heater supply hose is fully purged.
GDP040-070VX) (D875) equipped with a
PSI 2.4L LPG engine
WARNING
See LPG Fuel System, Kubota 2.5L Engine
Replacement, installation and repairs to air condi-
0900YRM1677 for lift truck models
tioning units that require discharging and/or refill-
ing of the refrigeration fluid must be performed by • GLP/GDP20-35VX (GP/GLP/
a certified technician. GDP040-070VX) (D875) equipped with a
Kubota 2.5L LPG engine
NOTE: Step 25 and Step 26 apply only to lift truck
models GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(D875) equipped with an air conditioner/heater unit.
Door Assemblies
RIGHT DOOR ASSEMBLY NOTE: Removing radiator cap will help depressurize
cooling system.
Remove
1. Remove radiator cover to access radiator cap.
Remove radiator cap. See Radiator Cover and
WARNING Cap Location.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When radiator cap is re-
moved, the pressure is released from cooling sys- WARNING
tem. If cooling system is hot, the steam and boil- DO NOT disconnect the heater hoses from the
ing coolant can cause burns. quick disconnect fittings (inside operator cab) or
engine when the engine is hot or under pressure.
Wait 30 minutes for the engine to cool. Do a touch Serious injury can occur.
test by touching the radiator with your hand. If the
radiator is still hot to the touch, wait another 30 NOTE: Removing right door assembly requires two
minutes before attempting to remove the radiator people.
cap.
2. Disconnect heater hose quick disconnect fittings.
See Figure 7.
12
0100 YRM 1752 Door Assemblies
a. For lift truck models GLP/GDP16-18VX, GLP/ 7. Disconnect gas spring. See Figure 8.
GDP20SVX (D810), open right door and push
buttons on quick disconnect fittings to discon- 8. Remove right door from cab frame by lifting door
nect heater hoses from heater assembly ho- up and over hinge pin. See Figure 9.
ses. Disconnect heater wire harness connec-
tion. See Figure 7 and Figure 12. Disassemble
b. For lift truck models GLP/GDP20-35VX Door Cover With Heater Unit
(GP/GLP/GDP040-070VX) (D875), open right
side door and remove radiator cover to access NOTE: This section removes the right door cover. To
quick disconnect fittings. Push buttons on quick remove the heater unit from right door, see section
disconnect fittings to disconnect heater hoses Heater and Air Conditioner Replacement.
from heater assembly hoses. Disconnect
1. Remove four screws and washers that attach
heater wire harness connection. See Figure 7
handle to door cover. Remove handle and two
and Figure 12.
handle plates. See Figure 16.
13
Door Assemblies 0100 YRM 1752
14
0100 YRM 1752 Door Assemblies
1. PLUG 9. WASHER
2. FASTENER 10. HEATER/FAN LOUVER
3. GAS SPRING 11. CAPSCREW
4. FAN AND HEATER/AC KNOBS 12. DOOR COVER
5. SCREW 13. PRE-FILTER
6. KNOB PLATE 14. HEATER VALVE AND SWITCH PLATE
7. HANDLE 15. STAR NUT
8. HANDLE PLATES
4. Remove two fasteners from top of door cover. 1. Remove inside lever handle cover. See Figure 18.
5. Remove four capscrews that fasten AC rocker 2. Place inside lever handle in closed position. Re-
switch plate to door cover. Remove AC rocker move lock nut from release bar at inside lever
switch plate from door cover. See Figure 17. handle. Pull inside lever handle to open position.
Remove release bar from inside lever handle.
6. Remove five plugs, washers, and star nuts along
sides and front of door cover. Remove two cap- 3. Remove two capscrews and inside lever handle
screws and washers from bottom of door cover. and mounting plate. See Figure 18.
Remove door cover from door frame. See Fig-
ure 16. 4. Remove lock nut from release bar and release
bar from door lock assembly.
7. Remove pre-filter, located on bottom of door
frame. See Figure 16. 5. Remove two nuts and capscrews from door lock
assembly. Remove door lock assembly from door
frame.
15
Door Assemblies 0100 YRM 1752
16
0100 YRM 1752 Door Assemblies
Inspect
Assemble
Windows
17
Door Assemblies 0100 YRM 1752
Door Cover With Heater Unit 7. Install handle and handle plates on door with four
screws and washers. See Figure 16.
NOTE: This section installs the right door cover. To
install the heater unit to right door, see section Heater Install
and Air Conditioner Replacement.
NOTE: Installing right door assembly requires two
1. Install pre-filter on bottom of door frame. See Fig- people.
ure 16.
1. Install right side door onto cab by lifting door over
2. Align holes on door cover with holes that are on top and bottom hinge pins. See .
door frame. Install five plugs into holes that are
along sides and front of door cover. Secure bot- 2. Connect gas spring and lock nut to mounting
tom of door cover using two capscrews and wash- bracket on operator cab frame. See .
ers. See Figure 16.
3. Connect heater hoses to heater assembly and
3. Install two fasteners into holes on top of door connect heater wire harness connection. See Fig-
cover. See Figure 16. ure 7.
4. Install knob plate on heater valve and switch plate 4. Install radiator cap and radiator cover. See Fig-
with four screws. Install fan and heater knobs on ure 5.
knob plate.
LEFT DOOR ASSEMBLY
5. Install handle and handle plates on door with four
screws and washers. See Figure 16. Remove
Door Cover With Air Conditioner/Heater Unit NOTE: Removing left door assembly requires two
people.
NOTE: This section installs the right door cover. To
install the air conditioner/heater unit to right door, see 1. Open left side door and disconnect gas spring.
section Heater and Air Conditioner Replacement. See .
1. Install pre-filter on bottom of door frame. See Fig- 2. Remove left side door from cab frame by lifting
ure 16. door over hinge pin. See .
4. Install two fasteners into holes on top of door 2. Remove two capscrews that secure handle to
cover. See Figure 16. door lock assembly. Remove handle from door.
5. Install knob plate on heater valve and switch plate 3. Remove two fasteners from top of door cover. Re-
with four screws. Install fan and AC/ heater knobs move five plugs along edges of door cover and
on knob plate. remove door cover from door frame. See Fig-
ure 20.
6. Install hose wrap around AC hoses. See Figure 6.
18
0100 YRM 1752 Door Assemblies
1. FASTENER 5. CAPSCREW
2. PLUG 6. DOOR LOCK COVER
3. COVER 7. HANDLE
4. SCREW 8. DOOR LOCK ASSEMBLY
19
Door Assemblies 0100 YRM 1752
Door Lock Assembly Check door assembly and parts for oil, grease, dirt,
and other debris. Clean door assembly and parts with
1. Remove capscrew and washer from release a clean cloth and soap and water. Compressed air
lever. Remove release lever from door. See Fig- can be used for drying door assembly and parts.
ure 21.
Inspect
2. Remove four capscrews and two washers (right
side only) from rear of outside handle. Remove
Inspect seals around window, door, and door lock as-
outside door handle from door.
sembly and replace if damaged. Check door lock and
3. Remove grip and seal from outside handle. Dis- latch assembly. Make sure it opens, shuts, and locks
card seal. See Figure 19 door securely and there is no rust, grease, oil, or dirt
on door lock and latch assembly parts. Inspect win-
dow for cracks or chips. Replace window if damaged.
Assemble
Windows
20
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