YALE F876 GDP100DCS LIFT TRUCK (EUROPE) Service Repair Manual by 16310553

GDP80DC, GDP90DC, GDP100DC, GDP100DCS, GDP120DC (GDP190DC, GDP210DC, GDP230DC, GDP230DCS, GDP250DC, GDP280DC) (F876); GDP130EC, GDP140EC, GDP160EC (GDP300EC, GDP330EC, GDP360EC) (F877) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

OPERATOR'S CAB........................................................................................................ CAB HEATER................................................................................................................. FRAME............................................................................................................................ CUMMINS ENGINE FAULT CODE GUIDE.................................................................... COOLING SYSTEM........................................................................................................ ZF TRANSMISSION OPERATION AND DIAGNOSTICS............................................... TRANSMISSION REPAIR (ZF-WG161)......................................................................... DIFFERENTIAL............................................................................................................... PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. STEERING SYSTEM...................................................................................................... BRAKE AND HYDRAULIC COOLING SYSTEM........................................................... HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC CONTROL SYSTEM................................................................................. ELECTRICAL SYSTEM.................................................................................................. 2-STAGE MAST.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... ASSEMBLY GUIDE........................................................................................................ DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS...........................................................................

550033400 550033398 550061801 524211827 550061806 550035502 550035503 524150779 524150780 550035504 550035505 550035506 550035498 550061811 550088524 524150797 524230692 550061816 550061821 550061826

0100 YRM 1390 0100 YRM 1459 0100 YRM 1594 0600 YRM 1101 0700 YRM 1595 1300 YRM 1455 1300 YRM 1456 1400 YRM 0046 1400 YRM 0944 1600 YRM 1479 1800 YRM 1498 1900 YRM 1478 2200 YRM 1481 2200 YRM 1592 4000 YRM 1647 8000 YRM 0231 8000 YRM 1181 8000 YRM 1591 8000 YRM 1593 8000 YRM 1596

11/13 08/12 08/12 07/14 09/13 09/13 08/12 08/12 08/12 08/12 03/13 11/14 08/12 09/13 05/14 10/13 12/14 10/13 07/12 07/13

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 550061831 (12/14)

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR •

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The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death. 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. Always fasten 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.

Table of Contents

TABLE OF CONTENTS General ..................................................................................................................................................................... 1 Description of Operation ........................................................................................................................................... 3 Cab Structure ....................................................................................................................................................... 3 Cab Tilt System .................................................................................................................................................... 3 Cab Tilt System, Raise .....................................................................................................................................4 Cab Tilt System, Lower .................................................................................................................................... 4 Oil Filling for Cab Tilt System ....................................................................................................................................6 Raising and Lowering Cab ........................................................................................................................................7 Raise Cab .............................................................................................................................................................7 Lower Cab ............................................................................................................................................................ 8 Cab Door Assembly ..................................................................................................................................................8 Cab Door .............................................................................................................................................................. 8 Remove ............................................................................................................................................................8 Install ................................................................................................................................................................8 Door Hinge ........................................................................................................................................................... 9 Remove ............................................................................................................................................................9 Install ................................................................................................................................................................9 Door Striker Pin .................................................................................................................................................. 10 Door Striker Pin Adjustment ...........................................................................................................................10 Door Latch .......................................................................................................................................................... 10 Remove ..........................................................................................................................................................10 Install ..............................................................................................................................................................10 Door Handle ....................................................................................................................................................... 11 Remove ..........................................................................................................................................................11 Install ..............................................................................................................................................................11 Door Release ......................................................................................................................................................11 Remove ..........................................................................................................................................................11 Install ..............................................................................................................................................................12 Door Push Button ............................................................................................................................................... 12 Remove ..........................................................................................................................................................12 Install ..............................................................................................................................................................12 Cab Tilt System .......................................................................................................................................................12 Electric Tilt Pump ................................................................................................................................................12 Remove ..........................................................................................................................................................12 Install ..............................................................................................................................................................13 Hand Pump .........................................................................................................................................................13 Remove ..........................................................................................................................................................13 Install ..............................................................................................................................................................13 Cab Tilt Cylinder ................................................................................................................................................. 15 Remove ..........................................................................................................................................................15 Disassemble ...................................................................................................................................................15 Clean ..............................................................................................................................................................16 Inspect ............................................................................................................................................................16 Assemble ....................................................................................................................................................... 17 Install ..............................................................................................................................................................17 Latch ...................................................................................................................................................................17 Remove ..........................................................................................................................................................17 Install ..............................................................................................................................................................18 Brake and Inching Pedals .......................................................................................................................................19 Remove .............................................................................................................................................................. 19

Table of Contents

TABLE OF CONTENTS (Continued) Install .................................................................................................................................................................. 19 Brake Pedal Adjustment ..................................................................................................................................... 19 Dry Brake ....................................................................................................................................................... 19 Wet Brake ...................................................................................................................................................... 19 Inching Pedal Adjustment ...................................................................................................................................20 Inching Pedal Sensor Adjustment Using Dana Dashboard Software .................................................................20 Inching Pedal Sensor Calibration Procedure Using Dana Dashboard Software ................................................ 21 Inching Pedal Sensor Adjustment Using the APC200 Display ........................................................................... 21 Inching Pedal Sensor Calibration Procedure Using the APC200 Display .......................................................... 22 Inching Sensor Adjustment for trucks with ZF Transmission ..............................................................................22 Inching Pedal Calibration for trucks with ZF Transmission .................................................................................23 Accelerator Pedal and Sensor ................................................................................................................................ 23 Accelerator Pedal ............................................................................................................................................... 23 Remove ..........................................................................................................................................................23 Install ..............................................................................................................................................................23 Accelerator Pedal Sensor ...................................................................................................................................23 Adjust ............................................................................................................................................................. 23 Seat Assembly ........................................................................................................................................................24 Seat .................................................................................................................................................................... 24 Remove ..........................................................................................................................................................24 Install ..............................................................................................................................................................24 Seat Cushion ...................................................................................................................................................... 25 Remove ..........................................................................................................................................................25 Install ..............................................................................................................................................................25 Back Cushion ..................................................................................................................................................... 26 Remove ..........................................................................................................................................................26 Install ..............................................................................................................................................................26 Seat Suspension Replacement .......................................................................................................................... 26 Boot Replacement .............................................................................................................................................. 26 Suspension Scissor and Shock Absorber .......................................................................................................... 27 Remove ..........................................................................................................................................................27 Install ..............................................................................................................................................................32 Compressor ........................................................................................................................................................ 39 Remove ..........................................................................................................................................................39 Install ..............................................................................................................................................................43 Power Assist Armrest ..............................................................................................................................................49 Release Cable .................................................................................................................................................... 49 Remove ..........................................................................................................................................................49 Install ..............................................................................................................................................................49 Gas Spring ..........................................................................................................................................................50 Remove ..........................................................................................................................................................50 Install ..............................................................................................................................................................50 Joystick ...............................................................................................................................................................50 Remove ..........................................................................................................................................................50 Install ..............................................................................................................................................................50 Electrical Levers ................................................................................................................................................. 51 Remove ..........................................................................................................................................................51 Install ..............................................................................................................................................................51 Armrest Rocker Switches ................................................................................................................................... 51 Remove ..........................................................................................................................................................51

Table of Contents

TABLE OF CONTENTS (Continued) Install ..............................................................................................................................................................51 Armrest Top Cover ............................................................................................................................................. 52 Remove ..........................................................................................................................................................52 Install ..............................................................................................................................................................52 Instrument Panel .....................................................................................................................................................52 Key Switch ..........................................................................................................................................................52 Remove ..........................................................................................................................................................52 Install ..............................................................................................................................................................52 12V Power Socket .............................................................................................................................................. 52 Remove ..........................................................................................................................................................52 Install ..............................................................................................................................................................53 Electric-Operated Heat Control and Air Recirculation Control (Airco Only) ........................................................53 Remove ..........................................................................................................................................................53 Install ..............................................................................................................................................................53 Cable-Operated Heater Control (Heater Only) ................................................................................................... 53 Remove ..........................................................................................................................................................53 Install ..............................................................................................................................................................54 Air Conditioning Switch Replacement ................................................................................................................ 54 Instrument Panel Rocker Switches Replacement .............................................................................................. 55 Parking Brake Switch ......................................................................................................................................... 55 Remove ..........................................................................................................................................................55 Install ..............................................................................................................................................................55 Indicator Display Replacement ...........................................................................................................................55 Instrument Panel Top Console ........................................................................................................................... 56 Remove ..........................................................................................................................................................56 Install ..............................................................................................................................................................56 Steering Wheel and Column Assembly .................................................................................................................. 57 Steering Wheel and Horn ................................................................................................................................... 57 Remove ..........................................................................................................................................................57 Install ..............................................................................................................................................................57 Steering Column Assembly ................................................................................................................................ 57 Remove ..........................................................................................................................................................57 Install ..............................................................................................................................................................57 Adjustment Handle ............................................................................................................................................. 60 Remove ..........................................................................................................................................................60 Install ..............................................................................................................................................................60 Main Warning Lights ...........................................................................................................................................60 Remove ..........................................................................................................................................................60 Install ..............................................................................................................................................................60 Shift Lever .......................................................................................................................................................... 60 Remove ..........................................................................................................................................................60 Install ..............................................................................................................................................................61 Turn Signal Lever ............................................................................................................................................... 61 Remove ..........................................................................................................................................................61 Install ..............................................................................................................................................................61 Window Wipers Replacement .................................................................................................................................61 Window Wiper Assembly, Replace .....................................................................................................................61 Remove ..........................................................................................................................................................61 Install ..............................................................................................................................................................62 Window Wiper Motor Replacement ........................................................................................................................ 62

iii

Table of Contents

TABLE OF CONTENTS (Continued) Front Window Wiper Motor Assembly ................................................................................................................ 62 Remove ..........................................................................................................................................................62 Install ..............................................................................................................................................................62 Rear Window Wiper Motor Assembly .................................................................................................................63 Remove ..........................................................................................................................................................63 Install ..............................................................................................................................................................63 Top Window Wiper Motor Assembly .................................................................................................................. 63 Remove ..........................................................................................................................................................63 Install ..............................................................................................................................................................63 Window Washer System .........................................................................................................................................64 Window Washer Reservoir and Pumps ..............................................................................................................64 Remove ..........................................................................................................................................................64 Install ..............................................................................................................................................................64 Window Washer Hoses ...................................................................................................................................... 65 Hoses for Top and Rear Window ................................................................................................................... 65 Remove ......................................................................................................................................................65 Install ..........................................................................................................................................................65 Hoses for Front Window .................................................................................................................................66 Remove ......................................................................................................................................................66 Install ..........................................................................................................................................................66 Window Washer Spray Nozzles ......................................................................................................................... 67 Front ...............................................................................................................................................................67 Remove ......................................................................................................................................................67 Install ..........................................................................................................................................................67 Rear ............................................................................................................................................................... 67 Remove ......................................................................................................................................................67 Install ..........................................................................................................................................................67 Top ................................................................................................................................................................. 67 Remove ......................................................................................................................................................67 Install ..........................................................................................................................................................67 Window Replacement .............................................................................................................................................68 Front Window ..................................................................................................................................................... 69 Remove ..........................................................................................................................................................69 Install ..............................................................................................................................................................69 Rear Window ...................................................................................................................................................... 69 Remove ..........................................................................................................................................................69 Install ..............................................................................................................................................................69 Top Window ........................................................................................................................................................70 Remove ..........................................................................................................................................................70 Install ..............................................................................................................................................................70 Door Window ...................................................................................................................................................... 71 Upper/Lower Window .....................................................................................................................................71 Remove ......................................................................................................................................................71 Install ..........................................................................................................................................................71 Sliding Window and Sliding Tracks .................................................................................................................... 71 Remove ..........................................................................................................................................................71 Install ..............................................................................................................................................................73 Weather Strip Replacement ........................................................................................................................... 73 Window Stopper Replacement .......................................................................................................................73 Window Seal Replacement ............................................................................................................................ 73

Table of Contents

TABLE OF CONTENTS (Continued) Sliding Window Frame ................................................................................................................................... 73 Remove ......................................................................................................................................................73 Install ..........................................................................................................................................................74 Floor Mat .................................................................................................................................................................74 Front Floor Mat ................................................................................................................................................... 74 Remove ..........................................................................................................................................................74 Install ..............................................................................................................................................................75 Rear Floor Mat ....................................................................................................................................................75 Remove ..........................................................................................................................................................75 Install ..............................................................................................................................................................75 Radio Console ........................................................................................................................................................ 76 Remove .............................................................................................................................................................. 76 Install .................................................................................................................................................................. 76 Air Duct Replacement .............................................................................................................................................77 Front ................................................................................................................................................................... 77 Rear ....................................................................................................................................................................77 Remove ..........................................................................................................................................................77 Install ..............................................................................................................................................................77 Accessories ............................................................................................................................................................ 78 Mirror Replacement ............................................................................................................................................ 78 Sunshade Replacement ..................................................................................................................................... 78 Top ................................................................................................................................................................. 78 Rear ............................................................................................................................................................... 79 Map Light Replacement ......................................................................................................................................79 Interior Fan Replacement ................................................................................................................................... 79 Remove ..........................................................................................................................................................79 Training Seat ...................................................................................................................................................... 79 Field Installation ............................................................................................................................................. 79 Remove ..........................................................................................................................................................79 Label Replacement .................................................................................................................................................80 This section is for the following models: GDP/GLP80-120DB (GDP170-280DB) [D876]; GDP/GLP130-160EB (GDP/GLP300-360EB) [D877]; GDP80DC, GDP90DC, GDP100DC, GDP100DCS, GDP120DC (GDP190DC, GDP210DC, GDP230DC, GDP230DCS, GDP250DC, GDP280DC) [E876]; GDP130EC, GDP140EC, GDP160EC (GDP300EC, GDP330EC, GDP360EC) [E877]; GDP80-120DC, GDP100DCS (GDP190-280DC, GDP230DCS) [F876]; GDP130-160EC (GDP360-360EC) [F877]

0100 YRM 1390

General

General This YRM describes the functions of the cab and the replacement instructions for the cab components. See Figure 1. Some of the described components are options that may not be present on each cab. The operation of the various switches and controls can be found in the Operating Manual.

Information on systems that are related to the cab are in YRM for the Electrical System, Hydraulic System, Brake System, Steering System and Diagrams specific to each model lift truck. Before making any repairs to the lift truck, complete the following procedures:

The description and repair instructions for the heater assembly are in Cab Heater (Prior to Oct. 2008) 0100YRM1458 for lift trucks built prior to October, 2008, and in Cab Heater 0100YRM1459 for lift trucks built after October, 2008.

1. Place the lift truck on a solid, level surface.

The remove and replace instructions for the cab as an assembly are in the frame YRM specific to each model lift truck.

5. Shut down the engine.

2. Lower the mast completely and tilt forward. 3. Place the shift lever in NEUTRAL. 4. Apply the parking brake.

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Description of Operation

1. 2. 3. 4. 5. 6. 7.

0100 YRM 1390

HEATER SECTION INCHING PEDAL BRAKE PEDAL ACCELERATOR PEDAL STEERING COLUMN FRONT, REAR, AND TOP WINDOWS FRONT, REAR, AND TOP WIPER ASSEMBLIES

8. INTEGRATED OVERHEAD GUARD 9. OPERATOR'S CONSOLE, CONTROLS, AND ARMREST 10. AIR CONDITIONING CONDENSER, DRYER, AND FAN ASSEMBLY (OPTIONAL) 11. SEAT

Figure 1. Operator's Cab

0100 YRM 1390

Description of Operation

Description of Operation CAB STRUCTURE The cab frame is a welded structure. The overhead guard is an integral part of the cab frame. See Figure 1. In order to maintain maximum overhead protection, changes to the cab frame and integrated overhead guard are not allowed. There are two cab options: an open cab and a closed cab. The closed cab features windows and wipers, doors, a heater, and optional air conditioning. Both cab types feature interior components.

CAB TILT SYSTEM On lift trucks with a cab tilt system, the cab can tilt to the right-hand side, providing service access to the engine compartment and components under the cab. The cab tilt system consists of a cab support frame, cab tilt cylinder, cab tilt hand pump assembly, cab latches, and an optional electrical cab tilt pump. See Figure 2. The cab is attached to the lift truck in the lowered position by the cab support pivots on the right-hand frame channel, the two cab latches on the left-hand frame channel, and the cab tilt cylinder.

A. PULL DIRECTION OF THE TILT LATCH RELEASE 1. 2. 3. 4.

CAB SUPPORT FRAME CAB TILT HAND PUMP CAB LATCH CAB TILT CYLINDER Figure 2. Cab Tilt System

Hydraulic pressure is required to unlock the cab latches and extend the cab tilt cylinder. The cab can be raised by rotating the cab tilt hand pump directional valve clockwise and operating the cab tilt hand pump. See Figure 3. To lower the cab from the raised position, rotate the cab tilt hand pump directional valve counterclockwise and operating the cab tilt hand pump. The cab tilt cylinder retracts to lower the cab. The optional electrical cab tilt pump is push-button operated. See Raising and Lowering Cab, Raise Cab, Figure 8. NOTE: If the optional electrical cab tilt pump is inoperable, the cab can be raised or lowered by using the manually operated cab tilt hand pump. A. LOWER B. RAISE 1. PUMP LEVER CONNECTION 2. PUMP DIRECTIONAL VALVE Figure 3. Cab Tilt Hand Pump

Description of Operation When the cab has been raised to the partially open position, the safety latch will engage with a retainer plate that is welded to the frame. To raise or lower the cab after the safety latch has engaged, pull and hold the tilt latch release and raise or lower the cab until the safety latch has passed the retainer plate. Just before the fully open position is reached, movement becomes gravity-controlled by the weight of the cab. The cab is in the fully open position when the cab tilt cylinder is fully extended.

Cab Tilt System, Raise When the directional valve is in the raise position, the pump push port and pump pull port are connected to each other. See Figure 4. Hydraulic pressure is transferred to the cab latches and both the piston and rod side of the cab tilt cylinder. Hydraulic oil extruded at the rod side enters the piston side of the cylinder through the directional valve in the hand pump. The end of stroke is determined by a retaining ring in the cab tilt cylinder.

0100 YRM 1390

Cab Tilt System, Lower When the directional valve is in the lower position, the pump push port is connected to the pump reservoir through a reservoir check valve. The reservoir check valve retains enough pressure to keep the cab locks open. The pump pull port is connected to the hand pump. While the hand pump provides sufficient pressure, the cylinder check valve will raise to allow the oil at the piston side of the cylinder to return to the reservoir. The cylinder cannot lower when there is insufficient pressure at the pull connection. When the piston has reached the free fall area, the oil at the piston side will escape to the rod side and the cab will drop under the influence of its own weight. When the cab drops, the oil in the cab lock cylinders is pushed out through the reservoir check valve. After the cab has dropped, the cab is locked into position by the cab latches.

0100 YRM 1390

1. 2. 3. 4. 5. 6. 7. 8.

Description of Operation

ROD AREA CAB TILT CYLINDER FREE FALL INTERCONNECTION CHECK VALVE PULL ELECTRIC CAB TILT PUMP (OPTIONAL) RESERVOIR RELIEF VALVE

9. 10. 11. 12. 13. 14. 15.

CAB TILT HAND PUMP RESERVOIR CHECK VALVE LOWER PUMP DIRECTIONAL VALVE RAISE LATCH PUSH

Figure 4. Cab Tilt System