Yale GDP80-280DB (C876), GDP300-360EB (C877) Forklifts OEM Service & Repair Manual

Maintenance FRAME GDP80-120DB (GP170-280DB) [B876, C876]; GDP130-160EB (GP300-360EB) [B877, C877] PART NO. 524150772 100 YRM 927

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • 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. • Alwaysfasten 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.

Frame Table of Contents TABLE OF CONTENTS General ................................................................................................................................................................ 1 Description .......................................................................................................................................................... 1 Counterweight Repair .......................................................................................................................................... 2 Remove ........................................................................................................................................................... 2 Install ............................................................................................................................................................... 2 Fenders ........................................................................................................................................................... 2 Remove....................................................................................................................................................... 2 Install .......................................................................................................................................................... 2 Side Counterweights GDP130-160EB (GP300-360EB) .................................................................................. 4 Side Counterweight, Replace.......................................................................................................................... 4 Hood and Air Cleaner Repair .............................................................................................................................. 4 Remove ........................................................................................................................................................... 4 Install ............................................................................................................................................................... 4 Hydraulic Tank Repair ......................................................................................................................................... 7 Remove ........................................................................................................................................................... 7 Repairs, All Units............................................................................................................................................. 9 Small Leaks ................................................................................................................................................ 9 Large Leaks ................................................................................................................................................ 9 Clean ............................................................................................................................................................... 9 Steam Method ............................................................................................................................................ 9 Chemical Solution Method .......................................................................................................................... 10 Other Methods of Preparation for Repair ........................................................................................................ 10 Install ............................................................................................................................................................... 10 Fuel Tank Repair ................................................................................................................................................. 11 Remove ........................................................................................................................................................... 11 Repairs ............................................................................................................................................................ 11 Install ............................................................................................................................................................... 11 Cooling System and Radiator Repair .................................................................................................................. 13 Remove ........................................................................................................................................................... 13 Install ............................................................................................................................................................... 13 Cab Repair .......................................................................................................................................................... 16 Rear Cab Assembly ........................................................................................................................................ 16 Bottom Cab Assembly ..................................................................................................................................... 17 Raising and Lowering Cab .............................................................................................................................. 17 Raise Cab ................................................................................................................................................... 17 Lower Cab................................................................................................................................................... 18 Cab Repair ...................................................................................................................................................... 18 Remove....................................................................................................................................................... 18 Install .......................................................................................................................................................... 19 Engine and Transmission Repair ......................................................................................................................... 20 Transmission, Remove .................................................................................................................................... 20 Transmission, Install ........................................................................................................................................ 22 TE-10 Transmission ........................................................................................................................................ 23 Remove....................................................................................................................................................... 23 Install .......................................................................................................................................................... 26 Label Replacement.............................................................................................................................................. 28 This section is for the following models: GDP80-120DB (GP170-280DB) [B876, C876]; GDP130-160EB (GP300-360EB) [B877, C877] ©2011 Yale Materials Handling Corp. i

100 YRM 927 Description General This section has the description and repair procedures for the frame and connected parts. Included in this section are the frame, counterweight, fenders, hood, hydraulic and fuel tanks, radiator/cooling section, operator compartment, and cab. The instructions for removal and installation of the engine are included in this section. If the lift truck is fitted with a battery disconnect switch, open the switch if welding on the engine and remove the ECM (Engine Control Module). If welding on the lift truck chassis, verify the ground clamp is placed as close to the welding point as possible and NOT near the ECM. If it is necessary to weld near the ECM, remove the ECM from the engine to avoid damage from welding arc radiation. Description The frame is a one-piece weldment and has mounts for the counterweight, fenders, engine, transmission, axles, hydraulic and fuel tanks, operator’s compartment, and other parts. See Figure 1. 1. MAIN MOUNT 2. COUNTERWEIGHT MOUNT 3. STEERING MOUNT 4. DRIVE AXLE MOUNT 5. TILT CYLINDERS MOUNT 6. CAB CYLINDER MOUNT 7. CAB HINGE 8. MAST MOUNT 9. SIDE COUNTERWEIGHT MOUNT 10. FENDERS 11. CAB LATCH MOUNT Figure 1. Frame 1

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Yale GDP80-280DB (C876), GDP300-360EB (C877) Forklifts OEM Service & Repair Manual

Description

Yale GDP80-280DB (C876), GDP300-360EB (C877) Forklifts OEM Service & Repair Manual

Models covered:

What’s Inside the Yale C876 & C877 Forklift Service Manual

General Information & Technical Specifications

Hydraulic System Diagnostics & Repair

Tilt Cylinder Service

Brake System Service (Wet & Dry Systems)

Steering System & Steering Axle

Planetary Drive Axle & Differential Overhaul

Cooling System Service

Frame & Chassis Maintenance

Preventive Maintenance & Scheduled Service

Troubleshooting & Diagnostic Procedures

Why Choose This Yale Forklift Service Manual?

Format & Compatibility

Download the Yale GDP80-280DB / GDP300-360EB Service & Repair Manual

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