Yale (D878) GLP70VX, GDP70VX, GLP60VX, GDP60VX Forklift Service Parts Catalogue Manual

GLP/GDP70VX, GLP/GDP60VX (D878) PARTS MANUAL Yale Europe Materials Handling Limited Flagship House, Reading Road North Fleet, Hampshire GU13 8HR United Kingdom Telephone; +44 (0) 1252 810 261 Telefax; +44 (0) 1252 770 702 524329203 ©Yale Corp. 08/2008

SECTIONS 1 GENERAL TRUCK 2 DIESEL ENGINE 3 LPG ENGINES 4 FUEL SYSTEM 5 ELECTRICAL SYSTEM 6 STEERING SYSTEM 7 BRAKE SYSTEM 8 TRANSMISSION 9 HYDRAULIC SYSTEM 10 MAST-TWO STAGE LIMITED FREE-LIFT 11 MAST-THREE STAGE FULL FREE-LIFT 12 FORKS, LOAD BACKREST, AND MAST INSTALLATION 13 ATTACHMENTS AND HEADER HOSE GROUP 14 OPTIONS 15 NUMERICAL INDEX 16 USER SUPPORT INFORMATION This Parts Manual is divided into 16 major sections which are listed above. Quick reference to these sections can be made by placing the right thumb on the tab of the desired section, bending the book back and thumbing the pages to the corresponding tab.

TABLE OF CONTENTS DESCRIPTION PAGE A ACCUMULATOR ............................................................................................................................................. 14-8 AIR FILTER ..................................................................................................................................................... 4-4 AIR INTAKE AND FILTER SYSTEM GM 4.3L LPG .............................................................................................................................................. 4-2 AIR INTAKE MANIFOLD CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-48 ALTERNATOR AND MOUNTING CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-28 ASSEMBLED ENGINE GM 4.3L LPG - SHEET 1 OF 3 ................................................................................................................... 3-12 GM 4.3L LPG - SHEET 2 OF 3 ................................................................................................................... 3-16 GM 4.3L LPG - SHEET 3 OF 3 ................................................................................................................... 3-18 AUXILIARY FUNCTION HOSES TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 13-22 B BACK-UP ALARM ........................................................................................................................................... 14-4 BATTERY CABLES CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-22 GM 4.3L LPG .............................................................................................................................................. 5-20 BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL ....................................................................................................................... 7-12 BRAKE PEDAL LINKAGE DUAL PEDAL .............................................................................................................................................. 7-6 SINGLE PEDAL .......................................................................................................................................... 7-2 C CAB ATTACHING PARTS - SHEET 1 OF 2 ....................................................................................................... 1-16 ATTACHING PARTS - SHEET 2 OF 2 ....................................................................................................... 1-18 LEFT HAND DOOR ASSEMBLY ................................................................................................................ 1-24 MAIN ASSEMBLY ....................................................................................................................................... 1-14 RIGHT HAND DOOR ASSEMBLY .............................................................................................................. 1-22 WINDOW WIPER SYSTEM ........................................................................................................................ 1-26 WINDOWS .................................................................................................................................................. 1-20 CAMSHAFT CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-31 CAMSHAFT AND OIL PAN GM 4.3L LPG .............................................................................................................................................. 3-24 CARRIAGE THREE STAGE FULL FREE-LIFT) ............................................................................................................. 13-4 TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 13-2 CHARGE PUMP .............................................................................................................................................. 8-44 COIL ASSEMBLY GM 4.3L LPG .............................................................................................................................................. 3-30 COMPARTMENT PLATFORM ........................................................................................................................ 1-10 CONTROL LEVER LABELS MANUAL HYDRAULICS ............................................................................................................................. 1-54 GENERAL INFORMATION D878 ©2008 Yale Europe Materials Handling Limited i

TABLE OF CONTENTS (continued) DESCRIPTION PAGE CONTROL VALVE THREE SPEED TRANSMISSION ............................................................................................................... 8-30 TWO SPEED TRANSMISSION .................................................................................................................. 8-42 CONTROL VALVE AND STEERING UNIT ASSEMBLY ELECTRONIC CONTROL - THREE FUNCTION ........................................................................................ 9-30 ELECTRONIC CONTROL - FOUR FUNCTION .......................................................................................... 9-32 MANUAL CONTROL - THREE FUNCTION ................................................................................................ 9-18 MANUAL CONTROL - FOUR FUNCTION .................................................................................................. 9-20 COOLING SYSTEM CUMMINS QSB 3.3L ................................................................................................................................... 2-8 GM 4.3L LPG .............................................................................................................................................. 3-6 COUNTERWEIGHTS AND FENDERS ........................................................................................................... 1-28 COWL ELECTRICAL ELECTRIC HYDRAULIC ............................................................................................................................. 5-8 MANUAL HYDRAULIC ................................................................................................................................ 5-10 COWL MOUNT ................................................................................................................................................ 1-34 CRANKCASE BREATHER CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-40 CRANKSHAFT CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-38 CYLINDER BLOCK CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-18 GM 4.3L LPG .............................................................................................................................................. 3-22 CYLINDER HEAD CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-16 GM 4.3L LPG .............................................................................................................................................. 3-20 D DIFFERENTIAL ............................................................................................................................................... 8-8 DISTRIBUTOR ASSEMBLY GM 4.3L LPG .............................................................................................................................................. 5-18 DRIVE AXLE AND ATTACHING PARTS WET BRAKE ............................................................................................................................................... 8-4 DRIVE AXLE HOUSING AND HUB ................................................................................................................ 8-6 DRIVE TIRE AND WHEEL .............................................................................................................................. 8-2 DUAL MIRRORS WITH CAB ................................................................................................................................................... 14-6 WITH OVERHEAD GUARD ........................................................................................................................ 14-7 E ELECTRICAL SYSTEM RIGHT HAND CHASSIS - GM 4.3L LPG .................................................................................................... 5-4 RIGHT HAND CHASSIS - CUMMINS QSB 3.3L DIESEL .......................................................................... 5-6 ELECTRO HYDRAULIC POPPET VALVE ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 9-38 ELECTRONIC CONTROL LEVERS MINI-LEVER MODULE (FOUR FUNCTION) .............................................................................................. 5-40 MINI-LEVER MODULES (THREE FUNCTION) .......................................................................................... 5-38 GENERAL INFORMATION ii ©2008 Yale Europe Materials Handling Limited D878

TABLE OF CONTENTS (continued) DESCRIPTION PAGE ELECTRONIC CONTROL MODULE AND SENSORS CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-32 ELECTRONIC MINI LEVER LABELS DUAL FUNCTION ....................................................................................................................................... 1-48 SINGLE FUNCTION .................................................................................................................................... 1-46 ENGINE ELECTRICAL SYSTEM CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-16 GM 4.3L LPG .............................................................................................................................................. 5-14 ENGINE MOUNTING GM 4.3L LPG .............................................................................................................................................. 3-8 EXHAUST MANIFOLD CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-46 EXHAUST SYSTEM CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-4 GM 4.3L LPG .............................................................................................................................................. 3-2 F FAN ASSEMBLY CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-10 FAN MOUNT ASSEMBLY GM 4.3L LPG .............................................................................................................................................. 3-4 FLOORPLATES AND COVERS ...................................................................................................................... 1-8 FLYWHEEL AND HOUSING CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-12 GM 4.3L LPG .............................................................................................................................................. 3-10 FOOT DIRECTIONAL CONTROL PEDAL ...................................................................................................... 4-30 FORK POSITIONER ASSEMBLY ................................................................................................................... 13-16 FORK POSITIONER CYLINDER .................................................................................................................... 13-20 FORKS PIN TYPE .................................................................................................................................................... 12-6 STANDARD ................................................................................................................................................. 12-4 FORWARD CLUTCH HIGH AND OUTPUT SHAFT THREE SPEED TRANSMISSION - FWD2 ................................................................................................. 8-26 FORWARD CLUTCH LOW TWO SPEED TRANSMISSION .................................................................................................................. 8-40 FORWARD CLUTCH LOW AND SECOND SHAFT THREE SPEED TRANSMISSION - FWD1, RANGE2 ................................................................................ 8-24 FREE-LIFT THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-16 FREE-LIFT CYLINDER THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-18 FUEL FILTER CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-26 FUEL FILTER PLUMBING CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-24 FUEL INJECTION PUMP CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-18 FUEL INJECTOR AND INJECTOR PLUMBING CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-20 GENERAL INFORMATION D878 ©2008 Yale Europe Materials Handling Limited iii

TABLE OF CONTENTS (continued) DESCRIPTION PAGE FUEL PUMP PLUMBING CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-22 FUEL SUPPLY SYSTEM GM 4.3L LPG WITH OVER HEAD GAURD OR PVC DOOR CAB ............................................................. 4-8 GM 4.3L LPG WITH STEEL DOOR CAB .................................................................................................... 4-6 FUEL SYSTEM CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 4-16 FULL SUSPENSION SEAT WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-38 FULL SUSPENSION SWIVEL SEAT WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-40 G GEAR PUMP ................................................................................................................................................... 9-8 GEAR PUMP ASSEMBLY MANUAL HYDRAULIC ................................................................................................................................ 9-6 GM LPG REGULATOR DRAIN KIT ................................................................................................................ 14-10 H HAND LEVERS FOUR FUNCTION - WITH DETENTED LEVERS ....................................................................................... 9-14 FOUR FUNCTION - WITHOUT DETENTED LEVERS ............................................................................... 9-16 THREE FUNCTION - WITH DETENTED LEVERS ..................................................................................... 9-10 THREE FUNCTION - WITHOUT DETENTED LEVERS ............................................................................. 9-12 HANG-ON SIDE-SHIFT CARRIAGE ............................................................................................................... 13-14 HEADER HOSES AND AUXILIARY TUBE THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-10 TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 13-6 HEATER .......................................................................................................................................................... 1-36 HOIST HOSE AND ATTACHING PARTS ....................................................................................................... 9-53 HOOD ASSEMBLY ......................................................................................................................................... 1-2 HYDRAULIC FILTER ...................................................................................................................................... 9-50 HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 9-2 I IMPACT SENSOR ........................................................................................................................................... 5-46 INNER MAST THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-6 TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-4 INSTRUMENT CLUSTER ............................................................................................................................... 5-12 INTERIOR PANELS AND COVERS ............................................................................................................... 1-4 INTERMEDIATE MAST THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-4 J JOYSTICK LABELS ........................................................................................................................................ 1-50 WITH RETURN TO SET TILT ..................................................................................................................... 1-52 GENERAL INFORMATION iv ©2008 Yale Europe Materials Handling Limited D878

TABLE OF CONTENTS (continued) DESCRIPTION PAGE L LABELS EXTERIOR .................................................................................................................................................. 1-42 INTERIOR ................................................................................................................................................... 1-44 LIFTING BRACKET CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-14 LIGHTS BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE - WITH CAB .................................... 5-24 BRAKE, TAIL, BACKUP, SIDE, TURN SIGNALS, WORK, STROBE - WITH OVERHEAD GUARD ......... 5-26 LOAD BACKREST EXTENSION ..................................................................................................................... 12-8 LOAD WEIGH ELECTRICAL .......................................................................................................................... 5-48 LPG REGULATOR GM 4.3L LPG .............................................................................................................................................. 4-14 M MAIN LIFT THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-8 TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-6 MAIN LIFT CYLINDER TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-10 MAIN LIFT CYLINDERS THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-12 MAST ELECTRICAL ....................................................................................................................................... 5-42 MID INLET SECTION MANUAL AND ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ............................... 9-22 O OIL FILLER ARRANGEMENT CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-30 OIL FILTER AND COOLER CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-26 OIL PAN CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-24 OIL PUMP GM 4.3L LPG .............................................................................................................................................. 3-28 OIL PUMP AND FRONT GEAR COVER CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-28 OUTER MAST THREE STAGE FULL FREE-LIFT .............................................................................................................. 11-2 TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 10-2 OUTPUT SHAFT TWO SPEED TRANSMISSION .................................................................................................................. 8-38 OVERHEAD GUARD ...................................................................................................................................... 1-12 P PARK BRAKE ASSEMBLY ............................................................................................................................. 7-10 PISTON AND CONNECTING ROD CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-36 POWER DISTRIBUTION MODULE ................................................................................................................ 5-44 PUMP DRIVE .................................................................................................................................................. 8-46 GENERAL INFORMATION D878 ©2008 Yale Europe Materials Handling Limited v

TABLE OF CONTENTS (continued) DESCRIPTION PAGE R RADIATOR MOUNTING CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-6 REVERSE CLUTCH TWO SPEED TRANSMISSION .................................................................................................................. 8-36 REVERSE CLUTCH AND FIRST SHAFT THREE SPEED TRANSMISSION - REV1, RANGE 1 ................................................................................ 8-28 ROCKER ARM SHAFT CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-34 S SEAT PAN AND COVERS .............................................................................................................................. 1-6 SIDE-SHIFT ASSEMBLY ................................................................................................................................ 13-18 SIDE-SHIFT CYLINDER ................................................................................................................................. 13-21 SINGLE AND DUAL LPG TANK BRACKETS ................................................................................................. 4-10 SOUND ABATEMENT DIESEL ........................................................................................................................................................ 1-30 LPG ............................................................................................................................................................. 1-32 STARTER MOTOR CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-30 STARTING AID CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-50 STEER AXLE .................................................................................................................................................. 6-8 STEER COLUMN AND ATTACHING PARTS ................................................................................................. 6-2 STEER CYLINDER ......................................................................................................................................... 6-11 STEER TIRE AND WHEEL ............................................................................................................................. 6-14 STEERING COLUMN ASSEMBLY ................................................................................................................. 6-4 STEERING CONTROL UNIT .......................................................................................................................... 6-6 STEERING LINES ........................................................................................................................................... 6-12 STROBE LIGHT LED ............................................................................................................................................................. 14-2 T THERMOSTAT CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-20 THROTTLE BODY ASSEMBLY GM 4.3L LPG .............................................................................................................................................. 4-12 THROTTLE PEDAL AND ATTACHING PARTS ............................................................................................. 4-28 TILT CYLINDER AND MAST INSTALLATION ................................................................................................ 9-46 TILT HYDRAULICS ......................................................................................................................................... 9-48 TORQUE CONVERTER CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 8-16 GM 4.3L LPG .............................................................................................................................................. 8-14 TRANSMISSION ASSEMBLY THREE SPEED - SHEET 1 0F 2 ................................................................................................................. 8-20 THREE SPEED - SHEET 2 OF 2 ................................................................................................................ 8-22 TWO SPEED - SHEET 1 OF 2 .................................................................................................................... 8-32 TWO SPEED - SHEET 2 0F 2 .................................................................................................................... 8-34 GENERAL INFORMATION vi ©2008 Yale Europe Materials Handling Limited D878

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Yale (D878) GLP70VX, GDP70VX, GLP60VX, GDP60VX Forklift Service Parts Catalogue Manual

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