Yale Forklift GDP80DB, GDP90DB, GDP100DB, GDP120DB (D876) Parts Manual PDF

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Yale Forklift GDP80DB, GDP90DB, GDP100DB, GDP120DB (D876) Parts Manual – PDF DOWNLOAD

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Yale Forklift GDP80DB, GDP90DB, GDP100DB, GDP120DB (D876) Parts Manual – PDF DOWNLOAD

Language : English
Pages : 864
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Yale Forklift GDP80DB, GDP90DB, GDP100DB, GDP120DB (D876) Parts Manual – PDF DOWNLOAD

GENERAL TRUCK 23
FLOORPLATES 28
HOODS AND COVERS 32
COUNTERWEIGHT 35
COUNTERWEIGHT AND OPTIONAL LIFTING EYES 36
OVERHEAD GUARD WIRE MESH 38
CAB ATTACHING PARTS 40
EXTERIOR MIRRORS 42
CAB DOOR ATTACHING PARTS 44
CAB DOOR RIGHT HAND (→ S/N D876E01667G (Closed Cab With Heater/Closed Cab With Air Conditioning and Insulation)) (→ S/N D876E01666G (Closed Cab With Insulation)) 46
CAB DOOR RIGHT HAND (S/N D876E01668G → (Closed Cab With Heater/Closed Cab With Air Conditioning and Insulation)) (S/N D876E01667G → (Closed Cab With Insulation)) 50
CAB DOOR LEFT HAND (→ S/N D876E01666G (Closed Cab With Insulation)) (→ S/N D876E01667G (Closed Cab With Heater/Closed Cab With Air Conditioning and Insulation)) 54
CAB DOOR LEFT HAND (S/N D876E01667G → (Closed Cab With Insulation)) (S/N D876E01668G → (Closed Cab With Heater/Closed Cab With Air Conditioning and Insulation)) 58
CAB FLOORMATS 61
HANDHOLD AND UNDERFLOOR COVER OPEN CAB 62
CAB WINDOWS INSTALLATION 64
MAIN WINDOW ASSEMBLY 66
WINDOW WIPER SYSTEM WASHER BOTTLE KIT 68
WINDOW WIPER SYSTEM REAR AND ROOF WIPER KITS – AND FRONT WIPER OPTIONS 70
CAB SUNSHADES 72
DASH DISPLAY 74
RADIO PREPARATION 76
RADIO CONSOLE 78
REAR DUCT AND CONSOLE 80
CAB RECIRCULATING FAN 82
INDICATOR DISPLAY AND CONTROLS 84
CAB ELECTRONIC CONTROLS AND PANELS 86
CAB AND TILT CYLINDER MOUNTING 88
TILT CYLINDER CAB 92
TILT PLATFORM ASSEMBLY 94
CAB TILT PUMP ASSEMBLY ELECTRIC 95
HAND PUMP 96
ELECTRIC PUMP 98
CONDENSER AND ATTACHING PARTS THREE-FAN SYSTEM (→ S/N D876E01612F) 100
AIR CONDITIONING COMPRESSOR AND ATTACHING PARTS DIESEL ENGINE 102
AIR CONDITIONING COMPRESSOR AND ATTACHING PARTS LPG ENGINE 104
COMPRESSOR ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 106
HEATER AND AIR CONDITIONER MOUNTING WITH THREE-FAN CONDENSER SYSTEM 108
HEATER ASSEMBLY WITH THREE-FAN CONDENSER SYSTEM 110
HEATER AND AIR CONDITIONER ASSEMBLY WITH THREE-FAN CONDENSER SYSTEM 112
HEATER AND AIR DUCT ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM 114
AIR DUCT ASSEMBLY HEATER – WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 116
HEATER ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 118
HEATER SYSTEM WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 120
HEATING AND AIR CONDITIONING SYSTEM FILTER 121
AIR CONDITIONER SYSTEM ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 122
CONDENSER SYSTEM TWO-FAN SYSTEM (S/N D876E01613F →) 124
CONDENSER TWO-FAN SYSTEM (S/N D876E01613F →) 126
AIR CONDITIONER SYSTEM WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 128
AIR CONDITIONER ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 130
AIR DUCT ASSEMBLY AIR CONDITIONING – WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 132
CONTROL PANEL ASSEMBLY WITH TWO-FAN CONDENSER SYSTEM (S/N D876E01613F →) 134
HEATER HOSES DIESEL ENGINE 136
HEATER HOSES LPG ENGINE 138
TRAINING SEAT 140
DELUXE SUSPENSION SEAT 142
SEAT SUSPENSION ASSEMBLY AIR 144
SEAT SUSPENSION ASSEMBLY MECHANICAL 148
SEAT SUSPENSION MOUNTING 152
SEAT ASSEMBLY 156
PIVOT ARM ASSEMBLY 160
LABELS MAIN 162
LABELS LPG FUEL TRUCK 164
LABELS HYDRAULIC CONTROL – JOYSTICK 166
LABELS HYDRAULIC CONTROL – LEVERS 167
ARMREST ASSEMBLY 168
LOUVER CLIMATE CONTROL CAB 170
AIR DUCT LOUVER, CLIMATE CONTROL CAB 172
SEAT ASSEMBLY CLIMATE CONTROL CAB 174
CLIMATE CONTROL SYSTEM 176
AIR CONDITIONER SYSTEM CLIMATE CONTROL CAB 178
AIR CONDITIONER CLIMATE CONTROL CAB 180
CAB ASSEMBLY CLIMATE CONTROL CAB 182
ENGINE ASSEMBLY – DIESEL 185
RADIATOR ASSEMBLY 190
COOLING SYSTEM 192
EXHAUST SYSTEM 194
AIR COMPRESSOR 196
AIR COMPRESSOR MOUNTING 198
AIR COMPRESSOR COOLANT PLUMBING 200
AIR HEATER 202
AIR INTAKE CONNECTION 204
AIR INTAKE HOSE 206
AIR INTAKE MANIFOLD 207
AIR TRANSFER CONNECTION 208
ALTERNATOR SUPPORT AND WATER INLET 209
ALTERNATOR SUPPORT AND WATER INLET 210
BELT TENSIONER 211
CAMSHAFT 212
CONNECTING RODS AND PISTONS 214
CONNECTING RODS AND PISTONS 216
COOLANT HEATER STARTING AID 218
CRANKCASE BREATHER 219
CRANKSHAFT AND BEARINGS 220
CRANKSHAFT AND BEARINGS 222
CYLINDER BLOCK 224
CYLINDER BLOCK 226
CYLINDER HEAD 228
ENGINE ASSEMBLY 230
ENGINE CONTROL MODULE 232
ENGINE COOLANT VENT 234
ENGINE MOUNT 235
ENGINE OIL COOLER 236
ETR MODULE WIRING 237
EXHAUST MANIFOLD 238
FAN DRIVE AND MOUNTING 240
FLYWHEEL AND MOUNTING 242
FLYWHEEL HOUSING 243
FLYWHEEL HOUSING 244
FLYWHEEL HOUSING 246
FRONT GEAR COVER 248
LIFTING BRACKETS AND MOUNTING 249
LIFTING BRACKETS AND MOUNTING 250
LUBRICATING OIL PUMP 252
OIL FILLER 253
OIL FILTER 254
OIL LEVEL GAUGE 255
OIL PAN 256
REAR GEAR HOUSING 258
ROCKER LEVERS 260
THERMOSTAT 262
TORQUE CONVERTER COOLER PLUGS 263
TURBOCHARGER 264
TURBOCHARGER PLUMBING 265
TURBOCHARGER PLUMBING 266
VALVE COVER 268
VALVE TAPPETS 269
VIBRATION DAMPER 270
VIBRATION DAMPER 271
WATER OUTLET CONNECTION 272
WATER PUMP 273
WATER PUMP DRIVE 274
ENGINE BLOCK HEATER 276
ENGINE ASSEMBLY – LPG 279
RADIATOR ASSEMBLY 282
COOLING SYSTEM 284
EXHAUST SYSTEM 286
ACCESSORY DRIVE BELT AND TENSIONER 288
ACCESSORY HOLE COVER 289
AIR COMPRESSOR COOLANT PLUMBING 290
AIR COMPRESSOR INLET CONNECTION 292
AIR INTAKE CONNECTION 294
CAM FOLLOWER COVER 295
CAMSHAFT 296
CRANKCASE BREATHER 298
CRANKSHAFT AND MAIN BEARINGS 300
CYLINDER BLOCK 304
CYLINDER HEAD 306
ENGINE ASSEMBLY 308
ENGINE MOUNT 310
ENGINE OIL COOLER 312
EXHAUST GAS SENSOR PLUMBING 314
EXHAUST MANIFOLD 315
EXHAUST OUTLET CONNECTION 316
FAN DRIVE 317
FLYWHEEL 318
FLYWHEEL HOUSING 320
FRONT GEAR COVER AND HOUSING 322
FRONT GEAR TRAIN ACCESSORY DRIVE 324
INTAKE MANIFOLD 326
LIFTING BRACKET 328
OIL LEVEL GAUGE 330
OIL PAN 332
OIL PUMP 334
PISTON AND CONNECTING ROD 336
ROCKER LEVERS 338
THERMOSTAT 340
THERMOSTAT HOUSING 341
TURBOCHARGER 342
TURBOCHARGER COMPRESSOR OUTLET CONNECTION 344
TURBOCHARGER PLUMBING 346
TURBOCHARGER ASSEMBLY 348
VALVE COVER 350
VALVE TAPPET 352
VIBRATION DAMPER 354
WATER INLET CONNECTION 356
WATER OUTLET CONNECTION 357
WATER PUMP 358
FUEL SYSTEM 359
FUEL SYSTEM LPG 362
FUEL SYSTEM DIESEL 366
AIR INTAKE SYSTEM LPG 368
AIR INTAKE SYSTEM DIESEL – DRY BRAKE 370
AIR INTAKE SYSTEM DIESEL – WET BRAKE 372
AIR CLEANER ASSEMBLY 374
FOOT DIRECTIONAL CONTROL PEDAL ASSEMBLY 376
THROTTLE PEDAL LINKAGE 378
FUEL SYSTEM ACCESSORIES CUMMINS LPG 380
REMOTE FUEL FILTER CUMMINS DIESEL (→ S/N D876E01613F (Wet Brakes)) (→ S/N D876E01630F (Dry Brakes)) 381
REMOTE FUEL FILTER CUMMINS DIESEL (S/N D876E01614F → (Wet Brakes)) (S/N D876E01631F → (Dry Brakes)) 382
FUEL CONTROL MODULE CUMMINS LPG 384
FUEL FILTER CUMMINS LPG 387
FUEL INJECTOR PLUMBING CUMMINS DIESEL 388
FUEL INJECTION PUMP CUMMINS DIESEL 390
FUEL INJECTOR CUMMINS DIESEL 392
FUEL FILTER PLUMBING CUMMINS DIESEL 393
FUEL FILTER CUMMINS DIESEL 394
FUEL INLET FITTING CUMMINS DIESEL 395
FUEL RAIL SYSTEM CUMMINS DIESEL (→ S/N D876E01613F (Wet Brakes)) (→ S/N D876E01630F (Dry Brakes)) 396
FUEL RAIL SYSTEM CUMMINS DIESEL (S/N D876E01631F → (Dry Brakes)) (S/N D876E01614F → (Wet Brakes)) 398
ELECTRICAL SYSTEM 401
ELECTRICAL SYSTEM DIESEL ENGINE 406
ELECTRICAL SYSTEM LPG ENGINE 410
BATTERY DISCONNECT 414
LIGHT SWITCHES 416
DC-DC CONVERTER AND ATTACHING PARTS 417
RELAYS AND FUSES 418
JOYSTICK ASSEMBLY TWISTLOCKS 422
CONTROL PANEL AIR CONDITIONER 424
CONTROL PANEL HEATER 426
ENGINE CONTROL SYSTEM CUMMINS DIESEL (→ S/N D876E01613F (Wet Brakes)) (→ S/N D876E01630F (Dry Brakes)) 428
ENGINE CONTROL SYSTEM CUMMINS DIESEL (S/N D876E01614F → (Wet Brakes)) (S/N D876E01631F → (Dry Brakes)) 430
ENGINE CONTROL SYSTEM CUMMINS LPG 432
STARTER MOTOR CUMMINS DIESEL 434
STARTER MOTOR CUMMINS LPG 435
ALTERNATOR AND MOUNTING CUMMINS DIESEL (→ S/N D876E01613F (Wet Brakes)) (→ S/N D876E01630F (Dry Brakes)) 436
ALTERNATOR AND MOUNTING CUMMINS DIESEL (S/N D876E01614F → (Wet Brakes)) (S/N D876E01631F → (Dry Brakes)) 438
ALTERNATOR AND MOUNTING CUMMINS LPG 439
ENGINE IGNITION SYSTEM CUMMINS LPG 442
WIRE HARNESS CHASSIS, LPG – SHEET 1 0F 2 444
WIRE HARNESS CHASSIS, LPG – SHEET 2 0F 2 448
WIRE HARNESS CHASSIS, DIESEL – SHEET 1 0F 2 452
WIRE HARNESS CHASSIS, DIESEL – SHEET 2 0F 2 456
WIRE HARNESS CAB SIDE CONSOLE – SHEET 1 OF 3 460
WIRE HARNESS CAB SIDE CONSOLE – SHEET 2 OF 3 464
WIRE HARNESS CAB SIDE CONSOLE – SHEET 3 OF 3 468
WIRE HARNESS CLOSED CAB 470
WIRE HARNESS OPEN CAB 474
WIRE HARNESS WINDOW WASH PUMPS 476
WIRE HARNESS BRAKE TEMPERATURE 477
WIRE HARNESS BACK-UP ALARM 478
WIRE HARNESS REAR DRIVE LIGHT EXTENSION 480
WIRE HARNESS CAB LIGHTS 482
WIRE HARNESS FRONT LIGHTS – WITH FRONT FENDER AND MAST WORKLIGHTS 484
WIRE HARNESS FRONT LIGHTS 486
WIRE HARNESS MAST WORKLIGHT EXTENSION 488
WIRE HARNESS MAST LIGHT EXTENSION – RIGHT HAND 489
WIRE HARNESS MAST LIGHT EXTENSION – LEFT HAND 490
WIRE HARNESS REAR WORK LIGHTS 491
WIRE HARNESS STROBE LIGHT 492
WIRE HARNESS AIR DRYER 493
WIRE HARNESS CAB UNDERFLOOR 494
WIRE HARNESS CAB TILT 496
WIRE HARNESS ARMREST – OPEN CAB 498
WIRE HARNESS ARMREST – CLOSED CAB 500
WIRE HARNESS REAR WIPER 502
WIRE HARNESS STEERING COLUMN 504
WIRE HARNESS HYDRAULIC OIL TEMPERATURE 506
WIRE HARNESS FRONT END 507
WIRE HARNESS TWO STAGE LIMITED FREE-LIFT 509
WIRE HARNESS SHIFT LEVER 510
WIRE HARNESS TAIL LIGHTS 511
SECOND 12V SOCKET OPTION CLIMATE CONTROL CAB 512
ELECTRIC HORN 513
STEERING SYSTEM 515
STEERING COLUMN ASSEMBLY 518
STEERING COLUMN AND ATTACHING PARTS 520
STEER CYLINDER 522
STEER AXLE 524
BRAKE SYSTEM 527
PARK BRAKE SOLENOID VALVE 530
WET BRAKE SYSTEM LPG ENGINE 532
WET BRAKE SYSTEM DIESEL ENGINE 536
DRY BRAKE SYSTEM 540
BRAKE ASSEMBLY WET BRAKE – 425 SERIES DRIVE AXLE 544
BRAKE ASSEMBLY WET BRAKE – 475 SERIES DRIVE AXLE 546
BRAKE ASSEMBLY DRY BRAKE 548
DRAIN VALVE DRY BRAKE 552
BRAKE VALVE WET BRAKE 554
BRAKE VALVE DRY BRAKE 556
BRAKE VALVE (AIR BRAKE) 558
AIR DRYER SYSTEM DIESEL ENGINE – DRY BRAKE 560
AIR DRYER SYSTEM LPG ENGINE – DRY BRAKE 562
AIR DRYER ASSEMBLY 564
HYDRAULIC GEAR PUMP LPG ENGINE – WET BRAKE 566
HYDRAULIC GEAR PUMP DIESEL ENGINE – WET BRAKE 567
BRAKE ACCUMULATOR 568
ACCUMULATOR CHARGE VALVE 570
BRAKE AND INCHING PEDAL LINKAGE 572
TRANSMISSION 575
TRANSMISSION MOUNT AND ATTACHING PARTS LPG ENGINE 578
TRANSMISSION MOUNT AND ATTACHING PARTS DIESEL ENGINE 580
TORQUE CONVERTER HOUSING AND ATTACHING PARTS 582
TORQUE CONVERTER ASSEMBLY 584
UNIVERSAL SHAFT 586
TRANSMISSION CASE 588
AUXILIARY PUMP DRIVE 590
CHARGE PUMP AND FILTER ASSEMBLY 592
TRANSMISSION CONTROL VALVE 594
DRIVE GEAR 598
DRIVE PLATE 600
FORWARD CLUTCH 602
FORWARD CLUTCH 604
GEAR CLUTCH INSTALLATION 606
REVERSE IDLER SHAFT 608
LOW CLUTCH 610
LOW CLUTCH 612
OUTPUT FLANGE 614
OUTPUT SHAFT 616
OUTPUT SHAFT 618
REVERSE AND SECOND CLUTCH 620
THIRD CLUTCH 622
TURBINE SHAFT AND STATOR SUPPORT 624
DRIVE AXLE HOUSING AND ATTACHING PARTS 626
DIFFERENTIAL AND CARRIER DRY BRAKE 628
DIFFERENTIAL AND CARRIER WET BRAKE – 425 AND 475 SERIES 632
HUB AND SHAFT ASSEMBLY DRY BRAKE 636
HUB AND SHAFT ASSEMBLY WET BRAKE – 425 SERIES 638
HUB AND SHAFT ASSEMBLY WET BRAKE – 475 SERIES 640
PARK BRAKE WET BRAKE 642
HYDRAULIC SYSTEM 645
HYDRAULIC SUPPLY AND RETURN SHEET 1 OF 3 648
HYDRAULIC SUPPLY AND RETURN SHEET 2 OF 3 652
HYDRAULIC SUPPLY AND RETURN SHEET 3 OF 3 654
HYDRAULIC TANK AND ATTACHING PARTS 656
HYDRAULIC TANK AND ATTACHING PARTS 658
HYDRAULIC CONTROL VALVE ASSEMBLY 660
HYDRAULIC CONTROL VALVE AND ATTACHING PARTS SHEET 1 OF 2 664
HYDRAULIC CONTROL VALVE AND ATTACHING PARTS SHEET 2 OF 2 666
PILOT VALVE ASSEMBLY 668
END CAP PARTS LIFT SECTION 670
HYDRAULIC CONTROLS LEVERS 672
HYDRAULIC CONTROLS JOYSTICK 675
HYDRAULIC PUMP 676
LIFT ACCUMULATOR ASSEMBLY 678
LIFT ACCUMULATOR AND ATTACHING PARTS 679
TILT CYLINDER ASSEMBLY 680
TILT CYLINDER AND ATTACHING PARTS 682
ELECTRONIC LEVER ASSEMBLY 684
ELECTRONIC LEVER ASSEMBLY WITH CLAMP ATTACHMENT 686
MAST INSTALLATION 688
Mast-Two Stage Limited Free-Lift 691
CARRIAGE INDIVIDUAL FORK POSITIONER (FOUR FUNCTION) 694
CARRIAGE SIMULTANEOUS FORK POSITIONER 698
CARRIAGE THREE FUNCTION, (WITHOUT HOSE GROUP) 702
CARRIAGE WITH HOSE GROUP 704
INNER MAST 708
LIFT 710
MAIN LIFT CYLINDER 714
OUTER MAST TWO STAGE LIMITED FREE-LIFT 718
Mast-Three Stage Full Free-Lift 721
CARRIAGE FOUR, FIVE, AND SIX FUNCTION 724
STANDARD PIN CARRIAGE THREE STAGE – FOUR, FIVE, AND SIX FUNCTION 726
STANDARD PIN CARRIAGE INDIVIDUAL FORK POSITIONER (FOUR FUNCTION) 728
CARRIAGE SIMULTANEOUS FORK POSITIONER (THREE FUNCTION) 730
CARRIAGE THREE FUNCTION 732
FREE-LIFT CYLINDER 734
MAIN LIFT CYLINDER 736
MAST ASSEMBLY SHEET 1 OF 3 738
MAST ASSEMBLY SHEET 2 OF 3 740
MAST ASSEMBLY SHEET 3 OF 3 742
ATTACHMENTS AND HEADER HOSE GROUP 745
DIRECTIONAL CONTROL VALVE 748
FORK POSITIONER CYLINDER 750
FORKS IDENTIFY BY PART NUMBER 752
HEADER HOSE THREE STAGE FULL FREE-LIFT 754
HEADER HOSE TWO STAGE LIMITED FREE-LIFT 756
SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT – FOUR, FIVE, AND SIX FUNCTION 760
SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT – INDIVIDUAL FORK POSITIONER (FIVE FUNCTION) 764
SIDE-SHIFT CARRIAGE THREE STAGE FULL FREE-LIFT – SIMULTANEOUS FORK POSITIONER (FOUR FUNCTION) 768
SIDE-SHIFT CARRIAGE THREE FUNCTION – THREE STAGE FULL FREE-LIFT 772
SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – INDIVIDUAL FORK POSITIONER (FIVE FUNCTION) 774
SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – SIMULTANEOUS FORK POSITIONER (FOUR FUNCTION) 778
SIDE-SHIFT CARRIAGE TWO STAGE LIMITED FREE-LIFT – WITH HOSE GROUP 782
SIDE-SHIFT CYLINDER TWO STAGE LIMITED FREE-LIFT AND THREE STAGE FULL FREE-LIFT 786
OPTIONS 789
DIRECTIONAL MARKER 792
FRONT FENDER LIGHTS 793
TAIL LIGHT ASSEMBLY 794
ALARM 795
CAB-MOUNTED DRIVE LIGHTS 796
STROBE LIGHT 798
MAST WORKLIGHTS TWO AND THREE STAGE MAST 800
REAR WORK LIGHTS 802
STEER TIRES AND WHEELS BERGOUGNAN – SOLID TIRE 803
STEER TIRES AND WHEELS BRIDGESTONE 804
STEER TIRES AND WHEELS MICHELIN 805
STEER TIRES AND WHEELS TRELLEBORG 806
DRIVE TIRES AND WHEELS BERGOUGNAN – SOLID TIRE 807
DRIVE TIRES AND WHEELS BRIDGESTONE 808
DRIVE TIRES AND WHEELS MICHELIN 809
DRIVE TIRES AND WHEELS TRELLEBORG 810
SOUND REDUCTION HOOD 811
LIFTING EYES 812
HEATED TOP WINDOW CLIMATE CONTROL CAB 814
NUMERICAL INDEX 815
USER SUPPORT INFORMATION 859

S.V 07/24