Yale GP080VX, GP120VX, GLP080VX, GLP120VX, GDP080VX Parts Manual

...

PARTS MANUAL

GP080-120VX, GLP080-120VX,

GDP080-120VX

VERACITOR

(G813)

Yale Materials Handling Corporation

1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011

524329168

©Yale Corp.

08/2008

MODEL NOMENCLATURE

NOTE: 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 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 MAST-TWO STAGE LIMITED FREE-LIFT

13 MAST-THREE STAGE FULL FREE-LIFT

14 MAST-TWO STAGE FULL FREE-LIFT

15 ATTACHMENTS AND HEADER HOSE GROUP

16 OPTIONS

17 FIELD CONVERSION KITS

This Parts Manual is divided into 19 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.

18 NUMERICAL INDEX

19 USER SUPPORT INFORMATION

GENERAL INFORMATION

TABLE OF CONTENTS

DESCRIPTION PAGE

ACCUMULATOR ............................................................................................................................................. 16-8

AIR CLEANER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-4

GM 4.3L, GASOLINE AND LPG ................................................................................................................. 5-2

AIR FILTER ..................................................................................................................................................... 5-7

AIR INTAKE MANIFOLD

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-70

ASSEMBLED ENGINE

GM 4.3L, GASOLINE AND LPG - SHEET 1 OF 3 ...................................................................................... 2-4

GM 4.3L, GASOLINE AND LPG - SHEET 2 OF 3 ...................................................................................... 2-8

GM 4.3L, GASOLINE AND LPG - SHEET 3 OF 3 ...................................................................................... 2-10

AUDIBLE ALARM KITS ................................................................................................................................... 17-3

AUXILIARY HOSES ........................................................................................................................................ 11-40

AUXILIARY TUBE EXTENSIONS

THREE STAGE FULL FREE-LIFT .............................................................................................................. 15-36

TWO STAGE FULL FREE-LIFT .................................................................................................................. 15-34

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 15-32

BACK-UP ALARM ........................................................................................................................................... 16-6

BATTERY CABLES

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-22

GM 4.3L ....................................................................................................................................................... 6-14

BRAKE AND INCHING PEDAL CONVERSION .............................................................................................. 17-2

BRAKE ASSEMBLY

GP/GLP/GDP100-120VX - DRY BRAKE .................................................................................................... 10-18

GP/GLP/GDP80-90VX - DRY BRAKE ........................................................................................................ 10-16

BRAKE COOLING SYSTEM

SINGLE AND DUAL PEDAL - WET BRAKE ............................................................................................... 10-24

BRAKE LINKAGE

DUAL PEDAL - DRY BRAKE ...................................................................................................................... 10-6

DUAL PEDALS - WET BRAKE ................................................................................................................... 10-12

SINGLE PEDAL - DRY BRAKE .................................................................................................................. 10-2

SINGLE PEDAL - WET BRAKE .................................................................................................................. 10-10

BRAKE MASTER CYLINDER ASSEMBLY ..................................................................................................... 10-22

CAB ASSEMBLY WITH STEEL DOORS

COVERS, SEALS, SHIMS, AND FASTENERS .......................................................................................... 1-28

FAN ............................................................................................................................................................. 1-30

LEFT HAND DOOR COMPONENTS .......................................................................................................... 1-36

RIGHT HAND DOOR COMPONENTS ....................................................................................................... 1-32

RIGHT HAND DOOR HEATER COMPONENTS ........................................................................................ 1-34

SHEET 1 OF 3 ............................................................................................................................................ 1-20

SHEET 2 OF 3 ............................................................................................................................................ 1-22

SHEET 3 OF 3 ............................................................................................................................................ 1-24

WINDOWS .................................................................................................................................................. 1-26

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

CAMSHAFT

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-32

CAMSHAFT AND OIL PAN

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-20

CARRIAGE

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-28

TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-18

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-18

CARRIER ASSEMBLY

DRY BRAKE ................................................................................................................................................ 8-10

COIL ASSEMBLY

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-23

CONTROL LEVER LABELS

MANUAL HYDRAULICS ............................................................................................................................. 1-58

CONTROL VALVE ASSEMBLY ...................................................................................................................... 7-30

ELECTRONIC CONTROL - THREE FUNCTION ........................................................................................ 11-24

ELECTRONIC CONTROL - FOUR FUNCTION .......................................................................................... 11-26

MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 11-16

COOLING

CUMMINS QSB 3.3L ................................................................................................................................... 4-6

GM 4.3L WITH EXTERNAL OIL COOLER AND ELECTRONIC TRANSMISSION - OR WITH WET BRAKE

.................................................................................................................................................................... 4-2

GM 4.3L WITH INTERNAL OIL COOLER - WITH BASIC TRANSMISSION AND DRY BRAKE ................ 4-4

COUNTERWEIGHT ........................................................................................................................................ 1-6

COWL ELECTRICAL ....................................................................................................................................... 6-30

COWL MOUNT ................................................................................................................................................ 1-18

CRANKCASE BREATHER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-62

CRANKSHAFT

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-60

CYLINDER BLOCK

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-42

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-18

CYLINDER HEAD

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-44

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-16

DIFFERENTIAL

DRY BRAKE ................................................................................................................................................ 8-8

WET BRAKE ............................................................................................................................................... 8-16

DIRECTIONAL CONTROL KITS ..................................................................................................................... 17-2

DISTRIBUTOR ASSEMBLY

GM 4.3L GASOLINE AND LPG .................................................................................................................. 6-13

DRIVE AXLE AND ATTACHING PARTS

DRY BRAKE ................................................................................................................................................ 8-2

WET BRAKE ............................................................................................................................................... 8-12

DRIVE AXLE ASSEMBLY

DRY BRAKE ................................................................................................................................................ 8-4

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

DRIVE AXLE HOUSING AND HUB

WET BRAKE ............................................................................................................................................... 8-14

DRIVE TIRE AND WHEEL

DUAL MOUNT ............................................................................................................................................. 8-24

PNEUMATIC RADIAL ................................................................................................................................. 8-25

SINGLE MOUNT WITH STANDARD TREAD ............................................................................................. 8-22

SINGLE MOUNT WITH WIDE TREAD ....................................................................................................... 8-23

DUAL MIRRORS

WITH CAB ................................................................................................................................................... 16-4

E-HYDRAULIC CONTROL CONVERSION KITS ........................................................................................... 17-3

ELECTRICAL SYSTEM

RIGHT HAND CHASSIS ............................................................................................................................. 6-4

ELECTRO HYDRAULIC POPPET VALVE

THREE AND FOUR FUNCTION ................................................................................................................. 11-32

ELECTRONIC CONTROL LEVERS

MINI-LEVER MODULE (FOUR FUNCTION) .............................................................................................. 6-32

MINI-LEVER MODULES (THREE FUNCTION) .......................................................................................... 6-34

ELECTRONIC CONTROL MODULE AND SENSORS

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-18

ELECTRONIC LEVER LABELS

MINI LEVERS .............................................................................................................................................. 1-56

ENGINE ELECTRICAL SYSTEM

GM 4.3L GASOLINE AND LPG .................................................................................................................. 6-8

ENGINE MOUNTING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-38

GM 4.3L, GASOLINE AND LPG ................................................................................................................. 2-14

ENGINE SAFETY ELECTRICAL

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-26

GM 4.3L (GS AND LPS) .............................................................................................................................. 6-10

EXAUST SYSTEM

COUNTERWEIGHT EXHAUST - CUMMINS QSB 3.3L DIESEL ............................................................... 3-10

OVERHEAD EXHAUST - CUMMINS QSB 3.3L DIESEL ........................................................................... 3-8

EXHAUST MANIFOLD

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-72

EXHAUST SYSTEM

GM 4.3L - WITH CATALYTIC CONVERTER .............................................................................................. 3-2

GM 4.3L - WITHOUT CATALYTIC CONVERTER ...................................................................................... 3-4

EXHAUST WRAPS

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 3-12

GM 4.3L GASOLINE AND LPG .................................................................................................................. 3-6

FAN ASSEMBLY

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-34

FAN MOUNT ASSEMBLY

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-12

FENDERS ....................................................................................................................................................... 1-14

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iii

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

FIRE EXTINGUISHER .................................................................................................................................... 16-5

FLOOR PLATES AND COVERS ..................................................................................................................... 1-10

FLYWHEEL AND HOUSING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-30

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-28

FOOT DIRECTIONAL CONTROL PEDAL ...................................................................................................... 5-36

FORKS

POLISHED FORK WITH FULL BOTTOM TAPER - CLASS III AND IV ...................................................... 1-62

STANDARD TAPER - CLASS III ................................................................................................................. 1-60

STANDARD TAPER - CLASS IV ................................................................................................................ 1-61

FORWARD CLUTCH

SINGLE SPEED TRANSMISSION .............................................................................................................. 7-16

FORWARD CLUTCH, HIGH

DUAL SPEED TRANSMISSION ................................................................................................................. 7-26

FORWARD CLUTCH, LOW

DUAL SPEED TRANSMISSION ................................................................................................................. 7-24

FREE-LIFT

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-20

FREE-LIFT CYLINDER

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-24

TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-14

FRONT GEAR HOUSING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-56

FUEL FILTER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-33

FUEL FILTER PLUMBING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-30

FUEL INJECTION PUMP

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-24

FUEL INJECTOR AND INJECTOR PLUMBING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-26

FUEL PUMP PLUMBING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-28

FUEL SYSTEM

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-22

GM 4.3L LPG .............................................................................................................................................. 5-8

GM 4.3L, GASOLINE .................................................................................................................................. 5-10

FULL SUSPENSION SEAT

WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-48

FULL SUSPENSION SWIVEL SEAT

WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-50

GEAR PUMP ................................................................................................................................................... 11-6

GM LPG REGULATOR DRAIN KIT ................................................................................................................ 16-12

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

HAND LEVERS

FOUR FUNCTION - WITH DETENTED LEVERS ....................................................................................... 11-12

FOUR FUNCTION - WITHOUT DETENTED LEVERS ............................................................................... 11-14

THREE FUNCTION - WITH DETENTED LEVERS ..................................................................................... 11-8

THREE FUNCTION - WITHOUT DETENTED LEVERS ............................................................................. 11-10

HEADER HOSE

THREE STAGE FULL FREE-LIFT .............................................................................................................. 15-10

TWO STAGE FULL FREE-LIFT .................................................................................................................. 15-6

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 15-2

HEADER HOSE CONVERSION KITS HEATER HOSE ARRANGEMENT

CUMMINS QSB 3.3L DIESEL - WITH CAB ................................................................................................ 1-40

GM 4.3L GASOLINE - WITH CAB .............................................................................................................. 1-38

GM 4.3L LPG - WITH CAB .......................................................................................................................... 1-42

HOOD ASSEMBLY ......................................................................................................................................... 1-2

HYDRAULIC CONTROL CONVERSIONS ...................................................................................................... 17-3

HYDRAULIC FILTER ...................................................................................................................................... 11-4

HYDRAULIC SUPPLY AND RETURN ............................................................................................................ 11-2

IMPACT SENSOR ........................................................................................................................................... 6-46

INNER MAST

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-10

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-6

INNER MAST AND FREE-LIFT

TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-6

INSTRUMENT CLUSTER ............................................................................................................................... 6-29

INTEGRAL SIDE-SHIFT ASSEMBLY

GP/GLP/GDP080-090VX (48 IN. AND 60 IN.) - TWO STAGE LIMITED FREE-LIFT ................................. 15-14

GP/GLP/GDP080-090VX (48 IN. AND 60 IN.) - TWO AND THREE STAGE FULL FREE-LIFT ................ 15-22

GP/GLP/GDP100-120VX (54 IN. AND 60 IN.) - TWO STAGE LIMITED FREE-LIFT ................................. 15-18

GP/GLP/GDP100-120VX (54 IN. AND 60 IN.) - TWO AND THREE STAGE FULL FREE-LIFT ................ 15-28

INTEGRAL SIDE-SHIFT CARRIAGE

GP/GLP/GDP080-090VX (48 IN. AND 60 IN.) - TWO STAGE LIMITED FREE-LIFT ................................. 15-16

GP/GLP/GDP100-120VX (54 IN. AND 60 IN.) - TWO STAGE LIMITED FREE-LIFT ................................. 15-20

GP/GLP/GDP100-120VX (54 IN. AND 60 IN.) - TWO AND THREE STAGE FULL FREE-LIFT ................ 15-30

GP/GLP/GDP80-90VX (48 IN.) - TWO AND THREE STAGE FULL FREE-LIFT ........................................ 15-24

GP/GLP/GDP80-90VX (60 IN.) - TWO AND THREE STAGE FULL FREE-LIFT ........................................ 15-26

INTERMEDIATE MAST

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-6

LABELS

EXTERIOR .................................................................................................................................................. 1-52

INTERIOR ................................................................................................................................................... 1-54

LIFTING BRACKET

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-37

LIFTING EYES ................................................................................................................................................ 16-10

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

LIGHT KITS ..................................................................................................................................................... 17-9

LOAD BACKREST EXTENSION ..................................................................................................................... 1-64

LOAD WEIGH ELECTRICAL .......................................................................................................................... 6-40

LPG TANK BRACKET

SWING OUT ................................................................................................................................................ 5-18

SWING OUT, DROP DOWN ....................................................................................................................... 5-20

MAIN CYLINDER (GP/GLP/GDP080-090VX)

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-14

MAIN CYLINDER (GP/GLP/GDP100-120VX)

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-16

MAIN LIFT

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-12

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-10

MAIN LIFT CYLINDER

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-16

TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-10

MAST ELECTRICAL ....................................................................................................................................... 6-44

MIRROR .......................................................................................................................................................... 16-3

MISCELLANEOUS CONVERSION KITS ........................................................................................................ 17-9

MUD GUARDS ................................................................................................................................................ 1-16

NON SUSPENSION SEAT .............................................................................................................................. 1-44

OIL FILTER AND COOLER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-48

OIL LEVEL GAUGE

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-52

OIL PAN

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-50

OIL PUMP

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-26

OIL PUMP AND FRONT GEAR COVER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-46

OUTER MAST

THREE STAGE FULL FREE-LIFT .............................................................................................................. 13-2

TWO STAGE LIMITED FREE-LIFT ............................................................................................................ 12-2

OUTER MAST AND MAIN LIFT

TWO STAGE FULL FREE-LIFT .................................................................................................................. 14-2

OVERHEAD GUARD ...................................................................................................................................... 1-8

PARK BRAKE ASSEMBLY ............................................................................................................................. 10-20

PISTON AND CONNECTING ROD

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-54

POWER DISTRIBUTION MODULE ................................................................................................................ 6-28

PRE-CLEANER ............................................................................................................................................... 5-6

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GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

REGULATOR

GM 4.3L LPG .............................................................................................................................................. 5-14

REMOTE KEY SWITCH .................................................................................................................................. 6-6

RETURN TO SET TILT KITS .......................................................................................................................... 17-2

REVERSE CLUTCH

DUAL SPEED TRANSMISSION ................................................................................................................. 7-28

SINGLE SPEED TRANSMISSION .............................................................................................................. 7-18

ROCKER ARM SHAFT

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-36

SEALED ALTERNATOR AND MOUNTING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-20

GM 4.3L, GASOLINE AND LPG ................................................................................................................. 6-16

SEAT CONVERSION KITS ............................................................................................................................. 17-2

SEMI SUSPENSION SEAT

WITH AND WITHOUT ELECTRONIC CONTROLS .................................................................................... 1-46

STARTER AND MOUNT

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-24

STARTER MOTOR

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 6-21

STARTING AID

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-64

STEER AXLE .................................................................................................................................................. 9-10

STEER CONTROL UNIT ................................................................................................................................. 9-6

STEER CYLINDER ......................................................................................................................................... 9-14

STEER TIRE AND WHEEL ............................................................................................................................. 9-16

STEERING COLUMN AND ATTACHING PARTS .......................................................................................... 9-2

STEERING COLUMN ASSEMBLY ................................................................................................................. 9-4

STEERING LINES ........................................................................................................................................... 9-8

STROBE LIGHT

LED ............................................................................................................................................................. 16-2

THERMOSTAT

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-39

THROTTLE BODY ASSEMBLY

GM 4.3L LPG .............................................................................................................................................. 5-12

THROTTLE BODY ASSEMBLY AND FUEL RAIL

GM 4.3L GASOLINE ................................................................................................................................... 5-16

THROTTLE PEDAL AND ATTACHING PARTS ............................................................................................. 5-34

TILT HOSES .................................................................................................................................................... 11-42

TILT CYLINDER AND MAST INSTALLATION ................................................................................................ 11-46

TILT CYLINDERS ............................................................................................................................................ 11-48

TORQUE CONVERTER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 7-3

GM 4.3L, GASOLINE AND LPG ................................................................................................................. 7-4

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vii

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

TRANSMISSION

DUAL SPEED, TWO PIECE HOUSING - SHEET 1 0F 2 ........................................................................... 7-20

DUAL SPEED, TWO PIECE HOUSING - SHEET 2 0F 2 ........................................................................... 7-22

SINGLE SPEED - SHEET 1 0F 2 ................................................................................................................ 7-12

SINGLE SPEED - SHEET 2 0F 2 ................................................................................................................ 7-14

TRANSMISSION COOLING

WITH EXTERNAL OIL COOLER - GM 4.3L AND CUMMINS QSB 3.3L .................................................... 7-10

WITH INTERNAL OIL COOLER - CUMMINS QSB 3.3L DIESEL ............................................................... 7-6

WITH INTERNAL OIL COOLER - GM 4.3L GASOLINE AND LPG ............................................................ 7-8

TRANSMISSION ELECTRICAL SYSTEM ...................................................................................................... 6-42

TRANSMISSION MOUNTING ......................................................................................................................... 7-2

TURBOCHARGER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-66

TURBOCHARGER PLUMBING

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-68

VALVE ASSEMBLY, AUXILIARY ONE AND TWO

MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 11-20

VALVE ASSEMBLY, AUXILIARY ONE SECTION

ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-34

VALVE ASSEMBLY, AUXILIARY TWO SECTION

ELECTRONIC CONTROL VALVE - FOUR FUNCTION ............................................................................. 11-36

VALVE ASSEMBLY, LIFT AND LOWER

ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-28

VALVE ASSEMBLY, LIFT AND TILT

MANUAL CONTROL VALVE - THREE AND FOUR FUNCTION ............................................................... 11-18

VALVE ASSEMBLY, OUTLET SECTION

ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-38

MANUAL CONTROL VALVE ...................................................................................................................... 11-22

VALVE ASSEMBLY, TILT SECTION

ELECTRONIC CONTROL VALVE - THREE AND FOUR FUNCTION ....................................................... 11-30

VALVE COVER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-58

VALVE COVER AND INLET MANIFOLD

GM 4.3L GASOLINE AND LPG .................................................................................................................. 2-24

VENT LINE GROUP ........................................................................................................................................ 11-44

VIBRATION DAMPER

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-65

WATER PUMP AND PULLEY

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 2-40

WATER SEPARATOR

CUMMINS QSB 3.3L DIESEL ..................................................................................................................... 5-32

WEATHER PROTECTION KITS ..................................................................................................................... 17-2

WET BRAKE ASSEMBLY ............................................................................................................................... 8-20

WHEEL CONVERSION KITS .......................................................................................................................... 17-2

viii

G813

GENERAL INFORMATION

TABLE OF CONTENTS (continued)

DESCRIPTION PAGE

WIRE HARNESS

ALTERNATOR - CUMMINS QSB 3.3L DIESEL ......................................................................................... 6-74

COWL WITH FORWARD/REVERSE LEVER ............................................................................................. 6-90

COWL WITH FORWARD/REVERSE LEVER - WITH HYDRAULIC PUMP SOLENOID ............................ 6-94

COWL WITH MONOTROL PEDAL ............................................................................................................. 6-86

ELECTRONIC CONTROL VALVE - THREE FUNCTION ........................................................................... 6-98

ELECTRONIC CONTROL VALVE - FOUR FUNCTION ............................................................................. 6-100

ENGINE - CUMMINS QSB 3.3L DIESEL .................................................................................................... 6-64

ENGINE - GM 4.3L GASOLINE .................................................................................................................. 6-66

ENGINE - GM 4.3L LPG ............................................................................................................................. 6-70

LEFT HAND CHASSIS - GM 4.3L, GASOLINE .......................................................................................... 6-60

LEFT HAND CHASSIS - GM 4.3L LPG ...................................................................................................... 6-62

LIGHTS - WITH OVERHEAD GUARD ........................................................................................................ 6-102

RIGHT HAND CHASSIS - GM 4.3L GASOLINE AND LPG ........................................................................ 6-48

RIGHT HAND CHASSIS - CUMMINS QSB 3.3L ........................................................................................ 6-54

SEALED ALTERNATOR - GM 4.3L ............................................................................................................ 6-76

SEALED ALTERNATOR - CUMMINS QSB 3.3L ........................................................................................ 6-78

TRANSMISSION - SINGLE SPEED ........................................................................................................... 6-82

TRANSMISSION - DUAL SPEED ............................................................................................................... 6-84

WORK, REAR DRIVE, AND BRAKE/TAIL LIGHTS

WITH CAB ................................................................................................................................................... 6-36

WITH OVERHEAD GUARD ........................................................................................................................ 6-38

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GENERAL INFORMATION

ABBREVIATIONS QUICK REFERENCE SHEET

Listed below are abbreviations used in parts manuals to denote the following expressions:

spacer

TERM DEFINITION

Amp Amperes AR As Required BDI Battery Discharge Indicators BWI Brush Wear Indicator CE Communicator End CRE Corrosive Environment D/B Date Break dbA Decibel "A" Scale DE Drive End ECH Empty Container Handler ECH-3 Empty Container Handler - 3 High

Stacking

ECH-4 Empty Container Handler - 4 High

Stacking

ECH-5 Empty Container Handler - 5 High

Stacking

ECH-6 Empty Container Handler - 6 High

Stacking

ECH-7 Empty Container Handler - 7 High

Stacking ECM Electronic Control Module ECN Engineering Change Notice EEPROM Electrically Erasable Programmable

Read Only Memory EPA US Environmental Protection Agency EPROM Electrically Programmable Read Only

Memory

FRE Freezer Environment in. inches LPG Liquefied Petroleum Gas MAP Manifold Absolute Pressure mm millimeters MSTS Microprocessor Spark Timing System NPT National Pipe Threads O/S Oversize PTO Power Take Off RPM Revolutions per Minute S/N Serial Number TMM Truck Management Module UL Type D Diesel-Powered Safety Rating UL Type DS Diesel-Powered Safety Rating UL Type E Battery-Powered Safety Rating UL Type EE Battery-Powered Safety Rating UL Type ES Battery-Powered Safety Rating UL Type G Gasoline-Powered Safety Rating UL Type GS Gasoline-Powered Safety Rating UL Type LP Gas-Powered Safety Rating UL Type LPS LP Gas-Powered Safety Rating U/S Undersize UL Underwriters Laboratory V Volts

G813

HOW TO USE THE ILLUSTRATED PARTS MANUAL

This parts manual describes and illustrates assemblies, subassemblies, and detail parts needed for service replacement.

GENERAL INFORMATION

The different constructions are indicated by keys and footnotes. The callouts correspond to descriptions found on the next page.

G813

GENERAL INFORMATION

HOW TO FIND THE DESIRED PART NUMBER

WHEN THE PART NUMBER AND THE NEXT HIGHER ASSEMBLY IS NOT KNOWN:

previous page, BEARING CAP (Item 2) is a subpart of the major assembly CASE.

1. Determine the function and application of the part

required. Turn to the Sections Page. Choose the general area of reference most likely to include the part.

2. Turn to the section you chose. Use the Section

Table of Contents to determine the assembly which would normally contain the part required. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS NOT KNOWN AND THE NEXT HIGHER ASSEMBLY IS KNOWN:

3. Determine the assembly the required part is used

on. Turn to the Table of Contents (Page i).

4. Locate the assembly the required part is used on

and turn to the page indicated for that assembly. Then locate the part on the assembly breakdown page.

WHEN THE PART NUMBER IS KNOWN:

5. Use the Numerical Index (Page 18-1) to find the

part number. Turn to the page listed and locate the part as indicated by the item number.

GENERAL:

The assembly breakdowns include part numbers, descriptions, quantities required, keys and footnotes to help in selecting correct parts.

6. Five periods in the PART NO. column (. . . . .)

indicate that the part is either Not Serviced Separately or there is a reference to another figure. A figure reference is denoted by a pointing hand followed by a parts page number in the DESCRIPTION column (F7A56)

7. Keys are used to show two or more similar

assemblies, RH and LH assembly parts, etc. Select the appropriate key, "A", "B", "C", "D", or "E" and the corresponding quantity column to find the required parts. Two periods in the QTY column (..) indicate that the part is not used for that assembly.

8. Indented descriptions under the DESCRIPTION

column are used to indicate assemblies and subparts of assemblies. In the example on the

9. Quantities shown are for one assembly. The quantities of the subpart BEARING CAP are indicated as two and two. This means two per CASE assembly.

10. Serial number breaks identify the most current parts information and are shown as follows:

→ S/N A810N2639

Indicates last serial number affected.

S/N A810N2640 →

Indicates the first serial number affected.

S/N A810N1553 ↔ S/N A810N3291

Indicates a range of serial numbers affected.

ECN numbers for pending serial numbers are shown to allow for the inclusion of the most current parts information and are identified as follows:

→ S/N Pending Per ECN 63243

Indicates a pending serial number for last unit affected.

S/N Pending Per ECN 63243 →

Indicates a pending serial number for first unit affected.

Date breaks are used to indicate when a change occurred but a subsequent serial number break was not recorded. This is an arbitrary date usually based on the ECN release and are identified as follows:

→ D/B 3/00

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 →

Indicates that a change occurred sometime within that month for the item affected.

D/B 3/00 ↔ D/B 4/00

Indicates a range of production dates of the item affected.

Contact your local dealer for Yale lift trucks for serial number information for items with a ECN or a date break.

ORDERING PARTS:

When ordering replacement parts, give the unit serial number, part number, name of part and quantity required.

For any further information on parts, service, or ordering, consult your local dealer for Yale lift trucks.

xii

G813

GENERAL INFORMATION

IDENTIFICATION OF TRUCK SERIAL NUMBERS

NOTE: Serial Number breakdown is only for trucks built after 1994.

(1) and (2) The first letter and three numbers indicate the truck unit code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number indicates the production sequence number of the truck. (5) The final letter indicates the year of manufacture starting with "A" in 1957, 1980, and 2003.

The letters "I", "O", and "Q" will not be used.

For pending serial numbers contact your local dealer for Yale lift trucks.

Parts referred to in this book as right or left hand parts are in accordance with the illustration above.

G813

xiii

GENERAL INFORMATION

IDENTIFICATION OF MAST SERIAL NUMBERS

(1) and (2) The first letter and number indicates the mast unit code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number indicates the production sequence number of the mast. (5) Carriage travel in millimeters stamped just below the serial number. Mast Group identification consists of mast unit code (1) and (2) plus carriage travel (5). For pending production sequence numbers contact your local dealer for Yale lift trucks.

LIFT EQUIPMENT IDENTIFICATION

1. Fork part number, capacity rating, plant code letter, and date of manufacture are stamped approximately six inches below the top of most forks.

2. The carriage group number is stamped on the right hand side of the top crossmember (pin type) or on the back of the right hand end of the bottom crossmember (hook type). A date code has two letters in line with or below the carriage group number.

3. The mast identification number has a unit code, a letter indicating the plant of manufacture, and a serial number. Underneath the production sequence number is a four digit number that indicates the carriage travel in millimeters.

4. Tilt and lift cylinder group numbers are stamped on the cylinder shell.

Always refer to the group, serial, or part number when ordering service parts.

Modification of masts and carriages by SPED (Special Products Engineering Department) are identified by a model prefix code beginning with the letter "S". contact your dealer for Yale lift trucks for information on these assemblies.

xiv

G813

IDENTIFICATION OF ATTACHMENT AND SIDE-

SHIFT CARRIAGE SERIAL NUMBERS

(1) and (2) The first letter and three numbers indicate the attachment unit code. (3) The second letter indicates the plant of manufacture. (4) The four or five digit number indicates the production sequence number. For pending production sequence numbers contact your local dealer for Yale lift trucks.

GENERAL INFORMATION

Side-shift carriages and attachments have nameplates. Use the serial number found on the nameplate to identify the attachment.

Always refer to the group, serial, or part number when ordering service parts. Modifications of attachments and side-shift carriages by SPED (Special Products Engineering Department) are

identified by a model prefix code beginning with the letter "S". Contact your dealer for Yale lift trucks for information on these assemblies.

G813

GENERAL INFORMATION

PUBLICATIONS

Every new lift truck is provided with an OPERATING MANUAL. This manual has information that the operator must know for inspection and operation of the lift truck.

SERVICE MAINTENANCE MANUALS, which provide service and overhaul procedures, and PARTS

PUBLICATION YALE PART NUMBER

Operating Manual.................................................................................................................... 524262271

Service Manual (Complete)..................................................................................................... 524329176

Parts Manual........................................................................................................................... 524329168

MANUALS with complete replacement part identification, are available at a nominal fee from your Yale dealer to assist users in effectively maintaining Yale lift trucks in a safe, useful condition. See the list below for information on ordering specific publications for this model lift truck.

xvi

G813

GENERAL INFORMATION

MASTER PART SHEET CROSS-REFERENCE

NOTE: Throughout this manual are references to Part Sheet Numbers. These references are usually found after

the description of a part or assembly. The Part Sheet Number is found on the upper left- or righthand corner of the parts pages.

EXAMPLE:

ITEM PART NO. DESCRIPTION QTY

31 505965530 Steering Cylinder (F6E67 [Figure 4-3]) ..............................................................

32 504224261 Pin........................................................................................................................ 4

Below is a numerical listing of Part Sheet Numbers found in this parts book and what page number they are on.

PART SHEET PAGE

O19804...............................10-24

P19554..................................1-10

P19555....................................1-2

P19556..................................1-14

P19557..................................1-16

P19558..................................1-18

P19559....................................1-6

P19560....................................1-8

P19562..................................1-20

P19563..................................1-22

P19564..................................1-24

P19565..................................1-28

P19566..................................1-30

P19567..................................1-26

P19568..................................1-36

P19569..................................1-32

P19570..................................1-34

P19571..................................1-40

P19572..................................1-42

P19574..................................1-44

P19575..................................1-46

P19576..................................1-48

P19577..................................1-50

P19578..................................1-52

P19579..................................1-54

P19580..................................1-58

P19581..................................1-56

P19585..................................1-60

P19586..................................1-61

P19587..................................1-62

P19588..................................1-64

P19589....................................3-2

P19590....................................3-4

P19591....................................3-6

P19592....................................4-4

P19593....................................4-2

PART SHEET PAGE

P19594....................................4-6

P19595..................................2-14

P19596....................................2-4

P19597....................................2-8

P19598..................................2-10

P19599..................................2-12

P19600..................................2-28

P19601..................................2-16

P19602..................................2-18

P19603..................................2-20

P19604..................................2-23

P19605..................................2-26

P19606..................................2-24

P19607....................................5-2

P19608....................................5-4

P19609....................................5-6

P19610....................................5-7

P19678..................................5-10

P19679..................................5-12

P19680....................................5-8

P19681..................................5-16

P19682..................................5-14

P19706..................................5-20

P19707..................................5-22

P19708..................................5-18

P19709..................................2-34

P19712..................................5-34

P19713..................................5-36

P19714....................................6-4

P19715....................................6-6

P19716....................................6-8

P19717..................................6-10

P19718..................................6-14

P19719..................................6-26

P19720..................................6-22

P19722..................................6-13

PART SHEET PAGE

P19723..................................6-16

P19724..................................6-24

P19725..................................6-28

P19727..................................6-30

P19728..................................6-29

P19730..................................6-34

P19731..................................6-32

P19732..................................6-36

P19733..................................6-38

P19734..................................6-42

P19735..................................6-44

P19736..................................6-46

P19737..................................6-40

P19740..................................6-48

P19741..................................6-54

P19742..................................6-62

P19743..................................6-60

P19744..................................6-66

P19745..................................6-70

P19746..................................6-76

P19747..................................6-78

P19748..................................6-82

P19749..................................6-84

P19750..................................6-86

P19751..................................6-90

P19752..................................6-94

P19753..................................6-98

P19754................................6-100

P19756................................6-102

P19758....................................7-2

P19759....................................7-3

P19760....................................7-4

P19761....................................7-6

P19762....................................7-8

P19763..................................7-10

P19764..................................7-12

xvii

GENERAL INFORMATION

PART SHEET PAGE

P19765..................................7-14

P19766..................................7-16

P19767..................................7-18

P19768..................................7-20

P19769..................................7-22

P19770..................................7-24

P19771..................................7-26

P19772..................................7-28

P19774..................................7-30

P19774....................................8-2

P19775....................................8-4

P19776....................................8-8

P19777..................................8-10

P19778..................................8-12

P19779..................................8-14

P19780..................................8-16

P19781..................................8-20

P19782..................................8-22

P19783..................................8-23

P19784..................................8-24

P19785..................................8-25

P19786....................................9-2

P19787....................................9-4

P19788....................................9-6

P19789....................................9-8

P19790..................................9-10

P19791..................................9-14

P19792..................................9-16

P19794..................................10-2

P19797..................................10-6

P19798................................10-10

P19799................................10-12

P19800................................10-16

P19801................................10-18

P19802................................10-20

P19803................................10-22

P19805..................................11-2

P19806..................................11-4

P19807..................................11-6

P19808..................................11-8

P19809................................11-10

P19810................................11-12

P19811................................11-14

P19812................................11-16

P19813................................11-44

P19814................................11-46

P19815................................11-48

PART SHEET PAGE

P19816................................11-42

P19817..................................12-2

P19818..................................12-6

P19819................................12-10

P19820................................12-14

P19821................................12-16

P19824..................................15-2

P19825................................12-18

P19826................................15-16

P19827................................15-20

P19828..................................14-2

P19829..................................14-6

P19830................................14-10

P19831................................14-14

P19832..................................15-6

P19833................................14-18

P19834..................................13-2

P19835..................................13-6

P19836................................13-10

P19837................................13-12

P19838................................13-16

P19839................................13-20

P19840................................13-24

P19841................................15-10

P19842................................13-28

P19843................................15-14

P19844................................15-18

P19845................................15-24

P19846................................15-26

P19847................................15-28

P19848................................15-30

P19849................................15-32

P19850................................15-34

P19851................................15-36

P19852................................16-12

P19853..................................16-2

P19854..................................16-3

P19855..................................16-4

P19856..................................16-5

P19857..................................16-6

P19858..................................16-8

P19859................................16-10

P19860..................................2-30

P19861..................................2-42

P19862..................................2-44

P19863..................................2-46

P19864..................................2-32

PART SHEET PAGE

P19865..................................2-54

P19866..................................2-36

P19867..................................2-58

P19868..................................2-60

P19870..................................2-38

P19871..................................2-50

P19872..................................1-38

P19873................................11-18

P19874................................11-20

P19875................................11-22

P19876................................11-24

P19877................................11-26

P19878................................11-28

P19879................................11-30

P19880................................11-32

P19881................................11-34

P19882................................11-36

P19883................................11-38

P19884..................................2-66

P19885..................................2-68

P19886..................................2-70

P19887..................................2-72

P19889................................15-22

P19898..................................2-62

P19899..................................5-33

P19900..................................6-74

P19901..................................6-20

P19902..................................2-52

P19903..................................2-56

P19904..................................6-64

P19906..................................6-21

P19907..................................6-18

P19908..................................5-24

P19909..................................5-26

P19910..................................5-28

P19911..................................5-30

P19912..................................5-32

P19913....................................3-8

P19914..................................3-10

P19915..................................3-12

P19924..................................2-37

P19925..................................2-48

P19926..................................2-64

P19927..................................2-39

P19928..................................2-65

P19929..................................2-40

P19931................................11-40

xviii

SECTION 1

1 GENERAL TRUCK

CONTENTS

SECTION 1

GENERAL TRUCK