Yale (B875) GP/GLP/GDP040VX-GP/GLP/GDP070VX Forklift Service Parts Catalogue Manual

PARTS MANUAL GP/GLP/GDP040VX-GP/GLP/GDP070VX (B875)

MODEL NOMENCLATURE NOTE: This parts manual contains alternate pages for certain assemblies. The truck model code can be used to determine many of the assemblies on your lift truck (power, tire type, mast type). The complete truck model and serial number are stamped into the nameplate. See Identification of Truck Serial Number on Page xix for further information.

SECTIONS 1 GENERAL TRUCK 2 ENGINE ASSEMBLY 3 EXHAUST SYSTEM 4 COOLING SYSTEM 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TRANSMISSION 8 DRIVE AXLE 9 STEERING SYSTEM 10 BRAKE SYSTEM 11 HYDRAULIC SYSTEM 12 LIFTING MECHANISM 13 ATTACHMENTS AND HEADER HOSE GROUP 14 OPTIONS 15 FIELD CONVERSION KITS 16 NUMERICAL INDEX This Parts Manual is divided into 17 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.

GENERAL INFORMATION ALPHABETICAL INDEX DESCRIPTION PAGE NO. A ABBREVIATIONS QUICK REFERENCE SHEET ................................................................................................. xvi ACCUMULATOR AND ATTACHING PARTS..................................................................................................... 14-12 ADD ON OPTIONS LIGHT KITS ........................................................................................................................ 15-8 AIR INTAKE SYSTEM AIR FILTER ASSEMBLY ................................................................................................................................. 5-66 GASOLINE MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 5-28 GM 2.4L GASOLINE AND LPG ........................................................................................................................ 5-4 LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 5-36 MAZDA 2.0L AND 2.2L GASOLINE ⇒PENDING PER ECN 104248 ............................................................................................................... 5-16 MAZDA 2.0L AND 2.2L LPG ⇒PENDING PER ECN 104248 .................................................................................................................. 5-22 PRE-CLEANER AND DUCT ........................................................................................................................... 5-64 YANMAR 2.6 AND 3.3L DIESEL ⇒PENDING PER ECN 10402532 ........................................................................................................... 5-60 YANMAR 2.6L AND 3.3L, DIESEL PENDING PER ECN 10402532⇒ .............................................................................................................. 5-62 ALPHABETICAL INDEX............................................................................................................................................ i ALTERNATOR AND MOUNTING GM 2.4L GASOLINE AND LPG ................................................................................................................................. 2-92 YANMAR 2.6 AND 3.3L DIESEL........................................................................................................................................................ 6-45 ASSEMBLED ENGINE GASOLINE AND LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 2-40 GM 2.4L, GASOLINE AND LPG SHEET 1 OF 4 ............................................................................................................................................ 2-68 SHEET 2 OF 4 ............................................................................................................................................ 2-70 SHEET 3 OF 4 ............................................................................................................................................ 2-72 SHEET 4 OF 4 ............................................................................................................................................ 2-74 AUDIBLE ALARM KITS ...................................................................................................................................... 15-9 AUXILIARY HYDRAULIC COOLER ................................................................................................................... 11-6 AUXILIARY ONE AND TWO MANUAL CONTROL VALVE THREE AND FOUR FUNCTION ............................................................................................................... 11-26 AUXILIARY ONE SECTION ELECTRONIC CONTROL THREE AND FOUR FUNCTION ............................................................................................................... 11-28 AUXILIARY TUBE EXTENSION KITS................................................................................................................ 15-8 i

GENERAL INFORMATION DESCRIPTION PAGE NO. A (continued) AUXILIARY TUBE EXTENSIONS TWO AND THREE STAGE FULL FREE-LIFT .............................................................................................. 13-28 TWO STAGE LIMITED FREE-LIFT............................................................................................................... 13-26 AUXILIARY TWO SECTION ELECTRONIC CONTROL FOUR FUNCTION..................................................................................................................................... 11-30 AXLE HOUSING WET BRAKE ..................................................................................................................................................... 8-4 B BACK-UP ALARM .............................................................................................................................................. 14-6 BATTERY CABLES GM 2.4L GASOLINE AND LPG ................................................................................................................................. 6-40 BEVEL GEAR WET BRAKE ..................................................................................................................................................... 8-6 BRAKE AND INCHING PEDAL CONVERSION................................................................................................. 15-2 BRAKE ASSEMBLY DRY BRAKE ................................................................................................................................................. 10-14 BRAKE COOLING SYSTEM SINGLE AND DUAL PEDAL WET BRAKE PENDING PER ECN 10402574⇒......................................................................................................... 10-20 ⇒PENDING PER ECN 10402574 ......................................................................................................... 10-18 BRAKE LINKAGE DUAL PEDAL DRY BRAKE.............................................................................................................................................. 10-12 WET BRAKE ............................................................................................................................................... 10-8 SINGLE PEDAL DRY BRAKE................................................................................................................................................ 10-6 WET BRAKE ............................................................................................................................................... 10-2 C CAB ASSEMBLY AND ATTACHING PARTS ........................................................................................................... 1-16 FRAME AND ATTACHING PARTS ................................................................................................................. 1-18 INTERIOR PANELS ........................................................................................................................................ 1-20 LH DOOR........................................................................................................................................................ 1-22 RH DOOR AND HEATER ASSEMBLY ........................................................................................................... 1-24 WINDOWS AND WINDOW WIPER SYSTEM ................................................................................................ 1-30 CAB DOORS PVC................................................................................................................................................................. 1-28 CAMSHAFT AND DRIVE GEAR YANMAR 2.6L AND 3.3L DIESEL...................................................................................................................................................... 2-106 CAMSHAFT AND VALVES GASOLINE AND LPG MAZDA 2.0L AND 2.2L ii

GENERAL INFORMATION DESCRIPTION PAGE NO. C (continued) PENDING PER ECN 104248⇒............................................................................................................... 2-46 MAZDA 2.0L AND 2.2L GASOLINE AND LPG ⇒PENDING PER ECN 104248 ............................................................................................................... 2-22 CAMSHAFT, CYLINDER HEAD AND MANIFOLDS GM 2.4L GASOLINE AND LPG ⇒S/N B875B04790D ............................................................................................................................... 2-80 GM 2.4L, GASOLINE AND LPG S/N B875B04791D⇒ .................................................................................................................................. 2-84 CARBURETOR MAZDA 2.0L AND 2.2L LPG S/N B875B08413D⇒............................................................................................................................... 2-66 CARRIAGE THREE STAGE FULL FREE-LIFT ................................................................................................................ 13-10 TWO STAGE FULL FREE-LIFT ...................................................................................................................... 13-6 TWO STAGE LIMITED FREE-LIFT................................................................................................................. 13-2 CONTROL LEVER LABELS............................................................................................................................... 1-56 CONTROL VALVE TRANSMISSION............................................................................................................................................. 7-68 CONTROL VALVE ASSEMBLY ELECTRONIC CONTROL THREE AND FOUR FUNCTION ............................................................................................................... 11-24 MANUAL CONTROL THREE AND FOUR FUNCTION ............................................................................................................... 11-22 COOLING MANIFOLD AND ATTACHING PARTS GM 2.4L GASOLINE AND LPG ................................................................................................................................. 4-18 COOLING SYSTEM GM 2.4L, GASOLINE AND LPG, SQUARE WAVE RADIATOR WITH EXTERNAL OIL COOLER ................................................................................................................ 4-14 WITH INTERNAL OIL COOLER ................................................................................................................. 4-16 MAZDA 2.0L AND 2.2L, GASOLINE AND LPG, SERPENTINE RADIATOR BASIC POWERSHIFT TRANSMISSION PENDING PER ECN 10402518⇒............................................................................................................. 4-4 ⇒PENDING PER ECN 10402518 ............................................................................................................. 4-2 MAZDA 2.0L AND 2.2L, GASOLINE AND LPG, SQUARE WAVE RADIATOR BASIC POWERSHIFT TRANSMISSION PENDING PER ECN 10402518⇒............................................................................................................. 4-8 ⇒PENDING PER ECN 10402518 ............................................................................................................. 4-6 ELECTRONIC CONTROL TRANSMISSION, WITH INTERNAL OIL COOLER ⇒PENDING PER ECN 10402518 ........................................................................................................... 4-10 ELECTRONIC TRANSMISSION, EXTERNAL OIL COOLER, OR WET BRAKE PENDING PER ECN 10402518⇒........................................................................................................... 4-12 YANMAR 2.6L AND 3.3L, DIESEL, SQUARE WAVE RADIATOR WITH EXTERNAL OIL COOLER ................................................................................................................ 4-22 WITH INTERNAL OIL COOLER ................................................................................................................. 4-20 iii

GENERAL INFORMATION DESCRIPTION PAGE NO. C (continued) COUNTERWEIGHTS ......................................................................................................................................... 1-12 COWL ELECTRICAL............................................................................................................................................ 6-4 COWL MOUNT................................................................................................................................................... 1-10 CRANKSHAFT AND PISTONS MAZDA 2.0L AND 2.2L GASOLINE AND LPG PENDING PER ECN 104248⇒............................................................................................................... 2-54 ⇒PENDING PER ECN 104248 ............................................................................................................... 2-24 YANMAR 2.6L AND 3.3L DIESEL...................................................................................................................................................... 2-108 CRANKSHAFT, PISTONS AND OIL PAN GM 2.4L GASOLINE AND LPG ................................................................................................................................. 2-88 CYLINDER BLOCK GASOLINE AND LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 2-48 MAZDA 2.0L AND 2.2L GASOLINE AND LPG ⇒PENDING PER ECN 104248 ............................................................................................................... 2-18 YANMAR 2.6L AND 3.3L DIESEL...................................................................................................................................................... 2-110 CYLINDER HEAD MAZDA 2.0L AND 2.2L GASOLINE AND LPG ⇒PENDING PER ECN 104248 ............................................................................................................... 2-20 YANMAR 2.6L AND 3.3L DIESEL...................................................................................................................................................... 2-102 CYLINDER HEAD AND COVER GASOLINE AND LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 2-44 D DELAY VALVE MAZDA 2.0L AND 2.2L LPG S/N B875B08414D⇒ S/N PENDING PER ECN 104248 ........................................................................ 2-38 DIFFERENTIAL WET BRAKE ..................................................................................................................................................... 8-8 DIRECTIONAL CONTROL ................................................................................................................................. 15-2 DIRECTIONAL CONTROL PEDAL ASSEMBLY ................................................................................................ 5-80 DISTRIBUTOR MAZDA 2.0L AND 2.2L GASOLINE AND LPG ................................................................................................................................. 6-37 DRIVE AXLE AND ATTACHING PARTS WET BRAKE ..................................................................................................................................................... 8-2 DRIVE AXLE ASSEMBLY iv

GENERAL INFORMATION DESCRIPTION PAGE NO. D (continued) DRY BRAKE ................................................................................................................................................... 8-16 DRIVE TIRE AND WHEEL PNEUMATIC RADIAL ..................................................................................................................................... 8-20 SINGLE ........................................................................................................................................................... 8-22 WIDE TREAD ................................................................................................................................................. 8-24 DUAL DRIVE WHEELS AND TIRES.................................................................................................................. 8-26 E ELECTRICAL SYSTEM CHASSIS .......................................................................................................................................................... 6-8 ELECTRO HYDRAULIC POPPET VALVE ELECTRONIC CONTROL LIFT AND LOWER .................................................................................................................................... 11-32 ELECTRONIC LEVER LABELS AUXILIARY DUAL FUNCTION ....................................................................................................................... 1-60 AUXILIARY SINGLE FUNCTION.................................................................................................................... 1-58 ELECTRONIC PRESSURE REGULATOR ASSEMBLY LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 5-44 ELECTRONIC PRESSURE REGULATOR KIT LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 5-46 EMISSION CONTROL SYSTEM MAZDA 2.0L AND 2.2L, GASOLINE PENDING PER ECN 104248⇒ .................................................................................................................. 2-50 MAZDA 2.0L AND 2.2L, LPG PENDING PER ECN 104248⇒ .................................................................................................................. 2-52 ENGINE CONTROL MODULE GASOLINE MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 6-18 LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 6-19 ENGINE COOLING MAZDA 2.0L AND 2.2L GASOLINE AND LPG ⇒PENDING PER ECN 104248 ............................................................................................................... 2-26 YANMAR 2.6 AND 3.3L DIESEL...................................................................................................................................................... 2-112 ENGINE COOLING SYSTEM MAZDA 2.0L AND 2.2L GASOLINE AND LPG PENDING PER ECN 104248⇒............................................................................................................... 2-64 ENGINE ELECTRICAL COMPONENTS GASOLINE AND LPG v

GENERAL INFORMATION DESCRIPTION PAGE NO. E (continued) MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 6-14 MAZDA 2.0L AND 2.2L GASOLINE AND LPG ⇒PENDING PER ECN 104248 ............................................................................................................... 6-24 ENGINE ELECTRICAL SYSTEM GASOLINE AND LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 6-16 MAZDA 2.0L AND 2.2L GASOLINE ⇒PENDING PER ECN 104248 ............................................................................................................... 6-26 LPG ⇒PENDING PER ECN 104248 ............................................................................................................... 6-30 YANMAR 2.6L AND 3.3L, DIESEL WITH OVERHEAD GUARD ........................................................................................................................ 6-42 ENGINE FUEL SYSTEM GASOLINE AND LPG MAZDA 2.0L AND 2.2L PENDING PER ECN 104248⇒............................................................................................................... 2-42 ENGINE FUEL SYSTEM AND INTAKE MANIFOLD MAZDA 2.0L AND 2.2L GASOLINE ⇒PENDING PER ECN 104248 ............................................................................................................... 2-14 ENGINE MOUNTING ........................................................................................................................................... 2-4 ENGINE SAFETY ELECTRICAL SYSTEM GM 2.4L GASOLINE AND LPG ................................................................................................................................. 6-38 MAZDA 2.0L AND 2.2L GASOLINE AND LPG ................................................................................................................................. 6-34 EXHAUST MANIFOLD GASOLINE AND LPG MAZDA 2.0 L AND 2.2 L PENDING PER ECN 104248⇒............................................................................................................... 2-53 MAZDA 2.0 L AND 2.2 L ⇒PENDING PER ECN 104248 .................................................................................................................. 2-16 EXHAUST SYSTEM GM 2.4L GASOLINE AND LPG ................................................................................................................................... 3-2 MAZDA 2.0L AND 2.2L GASOLINE AND LPG PENDING PER ECN 104248⇒................................................................................................................. 3-6 ⇒PENDING PER ECN 104248 ................................................................................................................. 3-4 YANMAR 2.6 AND 3.3L DIESEL.......................................................................................................................................................... 3-8 vi

Yale (B875) GP/GLP/GDP040VX-GP/GLP/GDP070VX Forklift Service Parts Catalogue Manual

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