This is the Highly Detailed factory service repair manual for theYALE F876 GDP120DC LIFT TRUCK, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.YALE F876 GDP120DC LIFT TRUCK Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: 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 File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveYALE F876 GDP120DC LIFT TRUCK Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!

1. 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........................................................................................................ 550033400 0100 YRM 1390 11/13
CAB HEATER................................................................................................................. 550033398 0100 YRM 1459 08/12
FRAME............................................................................................................................ 550061801 0100 YRM 1594 08/12
CUMMINS ENGINE FAULT CODE GUIDE.................................................................... 524211827 0600 YRM 1101 07/14
COOLING SYSTEM........................................................................................................ 550061806 0700 YRM 1595 09/13
ZF TRANSMISSION OPERATION AND DIAGNOSTICS............................................... 550035502 1300 YRM 1455 09/13
TRANSMISSION REPAIR (ZF-WG161)......................................................................... 550035503 1300 YRM 1456 08/12
DIFFERENTIAL............................................................................................................... 524150779 1400 YRM 0046 08/12
PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. 524150780 1400 YRM 0944 08/12
STEERING SYSTEM...................................................................................................... 550035504 1600 YRM 1479 08/12
BRAKE AND HYDRAULIC COOLING SYSTEM........................................................... 550035505 1800 YRM 1498 03/13
HYDRAULIC SYSTEM.................................................................................................... 550035506 1900 YRM 1478 11/14
HYDRAULIC CONTROL SYSTEM................................................................................. 550035498 2200 YRM 1481 08/12
ELECTRICAL SYSTEM.................................................................................................. 550061811 2200 YRM 1592 09/13
2-STAGE MAST.............................................................................................................. 550088524 4000 YRM 1647 05/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
ASSEMBLY GUIDE........................................................................................................ 524230692 8000 YRM 1181 12/14
DIAGRAMS..................................................................................................................... 550061816 8000 YRM 1591 10/13
PERIODIC MAINTENANCE............................................................................................ 550061821 8000 YRM 1593 07/12
CAPACITIES AND SPECIFICATIONS........................................................................... 550061826 8000 YRM 1596 07/13
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 550061831 (12/14)

2. SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• 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 con-
tained 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 re-
move 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 man-
ual:
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 back-
ground. The CAUTION symbol and word are on yellow background.

3. ©2014 Yale Materials Handling Corp.
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
i

4. 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
ii

5. 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
Table of Contents
iii

6. 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
iv

7. 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]
Table of Contents
v

8. 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.
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.
The remove and replace instructions for the cab as an
assembly are in the frame YRM specific to each
model lift truck.
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:
1. Place the lift truck on a solid, level surface.
2. Lower the mast completely and tilt forward.
3. Place the shift lever in NEUTRAL.
4. Apply the parking brake.
5. Shut down the engine.
0100 YRM 1390 General
1

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10. 1. HEATER SECTION
2. INCHING PEDAL
3. BRAKE PEDAL
4. ACCELERATOR PEDAL
5. STEERING COLUMN
6. FRONT, REAR, AND TOP WINDOWS
7. 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
Description of Operation 0100 YRM 1390
2

11. Description of Operation
CAB STRUCTURE
The cab frame is a welded structure. The overhead
guard is an integral part of the cab frame. See Fig-
ure 1. In order to maintain maximum overhead protec-
tion, changes to the cab frame and integrated over-
head guard are not allowed. There are two cab op-
tions: 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 inte-
rior 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 po-
sition 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.
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 direc-
tional 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 op-
erated. See Raising and Lowering Cab, Raise Cab,
Figure 8.
NOTE: If the optional electrical cab tilt pump is inop-
erable, the cab can be raised or lowered by using the
manually operated cab tilt hand pump.
A. PULL DIRECTION OF THE TILT LATCH RE-
LEASE
1. CAB SUPPORT FRAME
2. CAB TILT HAND PUMP
3. CAB LATCH
4. CAB TILT CYLINDER
Figure 2. Cab Tilt System
A. LOWER
B. RAISE
1. PUMP LEVER CONNECTION
2. PUMP DIRECTIONAL VALVE
Figure 3. Cab Tilt Hand Pump
0100 YRM 1390 Description of Operation
3

12. 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, move-
ment 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 cylin-
der. 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 deter-
mined by a retaining ring in the cab tilt cylinder.
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 pres-
sure, the cylinder check valve will raise to allow the oil
at the piston side of the cylinder to return to the reser-
voir. The cylinder cannot lower when there is insuffi-
cient 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.
Description of Operation 0100 YRM 1390
4