Yale (J813) Forklift GP080VX GP090VX GP100VX GP110VX GP120VX GLP080VX GLP090VX GLP100VX GLP110VX GLP120VX GDP080VX GDP090VX GDP100VX GDP110VX GDP120VX Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Yale Model: GP/GLP/GDP-Series Forklift Trucks (VX Models) Product Type: Workshop Service Repair Manual Generation Covered Model Codes: GP080VX, GP090VX, GP100VX, GP110VX, GP120VX, GLP080VX, GLP090VX, GLP100VX, GLP110VX, GLP120VX, GDP080VX, GDP090VX, GDP100VX, GDP110VX, GDP120VX Codes Manual Identifier: J813 (Implied from product name) 👋 Introduction Market Position Target User: Professional forklift technicians, maintenance departments, and experienced DIY repairers. Value Proposition: Provides authoritative, factory-level diagnostic and repair information essential for maintaining the operational efficiency and longevity of Yale GP/GLP/GDP-VX series forklifts. Competitive Analysis Advantage: As an original factory manual, it offers unparalleled accuracy and completeness compared to generic aftermarket guides. Covers multiple engine options (GM and Kubota) and specific transmission types. Key Features Features: Original factory content, detailed illustrations, circuit diagrams, searchable PDFs, comprehensive system coverage, diagnostic troubleshooting aids. Data Currency: The inclusion of 'Diagnostic Trouble Shooting Updates' implies a commitment to providing up-to-date information for troubleshooting. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Yale GP, GLP, and GDP series VX model forklift trucks. Powertrain Coverage: GM 4.3L V-6 Engines (LPG & Gasoline Fuel Systems), Kubota 3.6L Diesel Engine (Diesel Fuel System). Drivetrain And Chassis Coverage: Frame, Operator's Cab, Cooling System, 1 & 2-Speed PX Transmission, Drive Axle & Differential, Steering Axle, Wet Brakes. Hydraulic System Coverage: Hydraulic Gear Pump, Hydraulic Cleanliness, Main Control Valve, Cylinder Repair, Mast Repairs. Electrical System Coverage: High Voltage Switch (HVS) Ignition, Wire Harness Repair, User Interface, General Electrical System. Diagnostic And Reference Coverage: Diagnostic Trouble Shooting, Diagnostic Troubleshooting Updates (e.g., High Engine Water Temperature), Calibration Procedures, Periodic Maintenance, Capacities & Specifications, Diagrams & Schematics, Metric & Inch Fasteners. Page Count Estimated Page Count: Not explicitly stated, but implied to be extensive given the detailed breakdown of systems. Likely several hundred pages across multiple PDF documents. Manual Type Type: Factory Original Workshop Service Repair Manual Language Language: English Format Delivery Format: ZIP archive containing a set of PDF manuals. File Compatibility: WIN/Mac compatible 📖 Manual Coverage Systems Covered Powertrain Systems: Internal combustion engines (GM 4.3L V6, Kubota 3.6L Diesel), fuel delivery and management (LPG, Gasoline, Diesel), ignition systems, exhaust systems. Drivetrain And Chassis: Transmission (1 & 2 speed PX), drive axles, differentials, steering systems, braking systems (wet brakes), frame construction, operator's cabin components, suspension elements. Hydraulic Systems: Hydraulic pump operation and repair, main control valve servicing, hydraulic cylinder overhaul, mast assembly maintenance and repair, hydraulic fluid management and cleanliness. Electrical Systems: Low and high voltage circuits, ignition systems (HVS), wiring harness diagnostics and repair, user interface components, sensor systems, battery and charging systems. Mast Systems: Specific coverage for mast repairs, including chain adjustments, roller wear, seal replacement, and cylinder rod maintenance. Crucial for forklift functionality. Procedures Included Maintenance: Scheduled maintenance, fluid level checks and changes, filter replacements, lubrication procedures, general inspection routines. Diagnostics And Troubleshooting: Systematic fault finding, diagnostic trouble codes (DTCs) interpretation, common issue diagnosis (e.g., high engine water temperature), component testing procedures. Repair And Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and reinstallation for all major systems. Calibration And Adjustment: Procedures for calibrating sensors, adjusting linkages, and setting system parameters to factory specifications. Troubleshooting Updates: The inclusion of 'Diagnostic Trouble Shooting Updates' signifies that the manual is kept current with solutions for emerging or specific operational faults, such as 'High Engine Water Temperature'. Hydraulic Cleanliness: Dedicated procedures for maintaining hydraulic system cleanliness are essential to prevent component damage. This includes flushing, filtering, and proper handling of hydraulic fluids and components. Technical Depth Depth: Comprehensive, covering everything from basic preventive maintenance and fluid checks to complete engine and transmission rebuilds, hydraulic system overhauls, and in-depth electrical diagnostics. Suitable for trained technicians. Illustrations: Contains high-quality images and diagrams to aid in identification of parts and understanding of procedures. Diagrams And Schematics: Includes detailed electrical schematics, hydraulic circuit diagrams, and mechanical assembly drawings. Searchability: Searchable text within PDF documents, allowing for quick access to specific information. Reference Material: The manual includes essential reference data such as fastener specifications (metric and SAE), calibration procedures for electronic systems, and comprehensive diagrams and schematics for all covered systems. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Packaging: Delivered as a ZIP archive containing multiple PDF files, organized by system or component. Organization: Contained set of PDF manuals, indicating a modular structure for easier navigation and management of information. Print Quality Printability: Printable PDFs, allowing users to create hard copies of sections or the entire manual. Image Quality: High quality images are a key selling point, ensuring clarity for repair and identification tasks. Binding Type Binding Type: Not applicable to digital format, but implies standard workshop manual layout if printed. Paper Type Paper Type: Not applicable to digital format, but original manuals typically use durable, coated paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Gm Engine...

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Tags: BG Series Engines Forklift GDP080VX GDP090VX GDP100VX GDP110VX GDP120VX GLP080VX GLP090VX GLP100VX GLP110VX GLP120VX GP080VX GP090VX GP100VX GP110VX GP120VX Kubota Yale

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

GP/GLP/GDP-Series Forklift Trucks (VX Models)

Product Type:

Workshop Service Repair Manual

Generation

Covered Model Codes:

GP080VX, GP090VX, GP100VX, GP110VX, GP120VX, GLP080VX, GLP090VX, GLP100VX, GLP110VX, GLP120VX, GDP080VX, GDP090VX, GDP100VX, GDP110VX, GDP120VX

Codes

Manual Identifier:

J813 (Implied from product name)

👋 Introduction

Market Position

Target User:

Professional forklift technicians, maintenance departments, and experienced DIY repairers.

Value Proposition:

Provides authoritative, factory-level diagnostic and repair information essential for maintaining the operational efficiency and longevity of Yale GP/GLP/GDP-VX series forklifts.

Competitive Analysis

Advantage:

As an original factory manual, it offers unparalleled accuracy and completeness compared to generic aftermarket guides. Covers multiple engine options (GM and Kubota) and specific transmission types.

Key Features

Features:

Original factory content, detailed illustrations, circuit diagrams, searchable PDFs, comprehensive system coverage, diagnostic troubleshooting aids.

Data Currency:

The inclusion of 'Diagnostic Trouble Shooting Updates' implies a commitment to providing up-to-date information for troubleshooting.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for Yale GP, GLP, and GDP series VX model forklift trucks.

Powertrain Coverage:

GM 4.3L V-6 Engines (LPG & Gasoline Fuel Systems), Kubota 3.6L Diesel Engine (Diesel Fuel System).

Drivetrain And Chassis Coverage:

Frame, Operator's Cab, Cooling System, 1 & 2-Speed PX Transmission, Drive Axle & Differential, Steering Axle, Wet Brakes.

Hydraulic System Coverage:

Hydraulic Gear Pump, Hydraulic Cleanliness, Main Control Valve, Cylinder Repair, Mast Repairs.

Electrical System Coverage:

High Voltage Switch (HVS) Ignition, Wire Harness Repair, User Interface, General Electrical System.

Diagnostic And Reference Coverage:

Diagnostic Trouble Shooting, Diagnostic Troubleshooting Updates (e.g., High Engine Water Temperature), Calibration Procedures, Periodic Maintenance, Capacities & Specifications, Diagrams & Schematics, Metric & Inch Fasteners.

Page Count

Estimated Page Count:

Not explicitly stated, but implied to be extensive given the detailed breakdown of systems. Likely several hundred pages across multiple PDF documents.

Manual Type

Type:

Factory Original Workshop Service Repair Manual

Language

Language:

English

Format

Delivery Format:

ZIP archive containing a set of PDF manuals.

File Compatibility:

WIN/Mac compatible

📖 Manual Coverage

Systems Covered

Powertrain Systems:

Internal combustion engines (GM 4.3L V6, Kubota 3.6L Diesel), fuel delivery and management (LPG, Gasoline, Diesel), ignition systems, exhaust systems.

Drivetrain And Chassis:

Transmission (1 & 2 speed PX), drive axles, differentials, steering systems, braking systems (wet brakes), frame construction, operator's cabin components, suspension elements.

Hydraulic Systems:

Hydraulic pump operation and repair, main control valve servicing, hydraulic cylinder overhaul, mast assembly maintenance and repair, hydraulic fluid management and cleanliness.

Electrical Systems:

Low and high voltage circuits, ignition systems (HVS), wiring harness diagnostics and repair, user interface components, sensor systems, battery and charging systems.

Mast Systems:

Specific coverage for mast repairs, including chain adjustments, roller wear, seal replacement, and cylinder rod maintenance. Crucial for forklift functionality.

Procedures Included

Maintenance:

Scheduled maintenance, fluid level checks and changes, filter replacements, lubrication procedures, general inspection routines.

Diagnostics And Troubleshooting:

Systematic fault finding, diagnostic trouble codes (DTCs) interpretation, common issue diagnosis (e.g., high engine water temperature), component testing procedures.

Repair And Overhaul:

Detailed step-by-step instructions for component removal, disassembly, inspection, repair, assembly, and reinstallation for all major systems.

Calibration And Adjustment:

Procedures for calibrating sensors, adjusting linkages, and setting system parameters to factory specifications.

Troubleshooting Updates:

The inclusion of 'Diagnostic Trouble Shooting Updates' signifies that the manual is kept current with solutions for emerging or specific operational faults, such as 'High Engine Water Temperature'.

Hydraulic Cleanliness:

Dedicated procedures for maintaining hydraulic system cleanliness are essential to prevent component damage. This includes flushing, filtering, and proper handling of hydraulic fluids and components.

Technical Depth

Depth:

Comprehensive, covering everything from basic preventive maintenance and fluid checks to complete engine and transmission rebuilds, hydraulic system overhauls, and in-depth electrical diagnostics. Suitable for trained technicians.

Illustrations:

Contains high-quality images and diagrams to aid in identification of parts and understanding of procedures.

Diagrams And Schematics:

Includes detailed electrical schematics, hydraulic circuit diagrams, and mechanical assembly drawings.

Searchability:

Searchable text within PDF documents, allowing for quick access to specific information.

Reference Material:

The manual includes essential reference data such as fastener specifications (metric and SAE), calibration procedures for electronic systems, and comprehensive diagrams and schematics for all covered systems.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Packaging:

Delivered as a ZIP archive containing multiple PDF files, organized by system or component.

Organization:

Contained set of PDF manuals, indicating a modular structure for easier navigation and management of information.

Print Quality

Printability:

Printable PDFs, allowing users to create hard copies of sections or the entire manual.

Image Quality:

High quality images are a key selling point, ensuring clarity for repair and identification tasks.

Binding Type

Binding Type:

Not applicable to digital format, but implies standard workshop manual layout if printed.

Paper Type

Paper Type:

Not applicable to digital format, but original manuals typically use durable, coated paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine Gm

Engine Model:

GM 4.3L V-6

Engine Type Gm:

V-configuration, 6-cylinder, gasoline or LPG fueled.

Fuel System Gm:

Gasoline (port injection or carbureted, depending on specific model year/variant) and LPG (Liquefied Petroleum Gas) fuel systems covered.

Engine Displacement:

4.3 Liters (262 cubic inches)

Primary Engine Kubota

Engine Model:

Kubota 3.6L Diesel

Engine Type Kubota:

Inline, 4-cylinder, naturally aspirated or turbocharged (variant dependent), diesel.

Fuel System Kubota:

Diesel fuel injection system, high-pressure common rail or older rotary pump systems may be covered depending on specific model years within the series.

Engine Displacement:

3.6 Liters (approx. 219 cubic inches)

Performance

General Notes:

Specific horsepower and torque ratings for these engines in forklift applications vary by model and configuration. The manual would detail these specifications for each covered variant.

🔧 Transmission

Standard

Type:

1 and 2-Speed PowerShift (PX) Transmission

Features:

Automatic shifting between gears, clutch pack engagement, torque converter for smooth power transfer. The manual details repair and overhaul procedures for these components.

Fluid Type:

Likely uses a specialized automatic transmission fluid (ATF) or hydraulic fluid. Manual will specify exact type and specifications (e.g., DEXRON-III, ALLISON TES 295 equivalent).

Service Notes:

The manual provides detailed procedures for transmission fluid and filter changes, troubleshooting shifting issues, and complete internal component repair/rebuild.

📐 Dimensions

Capacities

Engine Oil Capacity:

Specific capacities for GM 4.3L and Kubota 3.6L engines will be detailed in the manual. Typically ranges from 5-8 quarts (4.7-7.5 liters).

Hydraulic System Capacity:

Will be specified in the manual, generally ranging from 15-30 gallons (57-114 liters) depending on the specific forklift model and mast configuration.

Weights

Vehicle Weight:

Gross vehicle weight will vary significantly based on model (e.g., 080VX to 120VX denotes approximate load capacity in hundreds of pounds). The manual will list operating weights and load capacities.

Tire Specifications

Tire Types:

The GP/GLP/GDP designations often imply tire types. GP typically refers to cushion tires (solid rubber), while GLP and GDP often indicate pneumatic tires for various terrains. Manual will specify approved tire sizes and types.

🛡️ Safety Features

Active Features

Braking System:

Wet brake system, providing reliable stopping power in various operating conditions. Manual covers brake fluid specifications, bleeding procedures, and component replacement.

Steering System:

Power steering system for ease of operation. Manual details hydraulic pump, steering gear, and associated components.

Passive Features

Operator Protection:

Operator's cab construction, overhead guard (if fitted), and seatbelt are standard safety features. Manual may cover cab structural integrity checks and adjustments.

💡 Technology Features

Infotainment

Features:

Forklifts of this era typically have minimal 'infotainment' in the automotive sense. Features would include operational displays, warning lights, hour meters, and potentially basic diagnostics readouts on the user interface.

Driver Assistance

Features:

Advanced driver assistance systems are not typical. Focus is on mechanical and hydraulic systems for efficient material handling. Electronic controls for hydraulics and powertrain are covered.

Connectivity

Features:

No telematics or external connectivity is implied for this type of manual. Connectivity refers to internal system wiring and communication between electronic components.

🔧 Maintenance

Service Intervals

Typical Schedule:

The manual provides a detailed periodic maintenance schedule. This typically includes daily checks, weekly inspections, monthly/quarterly servicing (e.g., fluid changes, filter replacements, greasing), and annual major inspections.

Filter Replacements:

Scheduled replacement of engine oil filters, fuel filters (for diesel and gasoline), hydraulic filters, and transmission filters is a critical maintenance item detailed in the manual.

Fluid Specifications

Engine Oil:

Specific API service classifications and viscosity grades for both GM and Kubota engines will be listed (e.g., SAE 15W-40 for diesel, SAE 10W-30 or 10W-40 for gasoline/LPG).

Hydraulic Fluid:

Requires high-quality hydraulic fluid meeting specific viscosity and anti-wear properties. Manual will list approved types (e.g., ISO VG 46).

Transmission Fluid:

As noted, a specific ATF or heavy-duty transmission fluid. Manual will specify type and potentially brand recommendations.

Coolant:

Ethylene glycol-based antifreeze, typically a 50/50 mixture with distilled water, for both engine types. Manual specifies type and capacity.

Known Issues

Common Concerns:

While specific 'known issues' are not listed in the product description, typical forklift concerns addressed in such manuals include hydraulic system leaks, transmission shifting problems, engine overheating (as indicated by the 'High Engine Water Temperature' troubleshooting section), brake wear, and electrical connector corrosion.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yale Materials Handling Corporation, a long-standing and reputable manufacturer of industrial trucks and material handling equipment.

Model Evolution

Series Designation:

The GP (Gasoline/LPG), GLP (Gasoline/LPG Pneumatic), and GDP (Gasoline/LPG Dual Fuel) designations represent different powertrain and tire configurations within Yale's forklift lineup. The 'VX' suffix likely indicates a specific generation or enhanced feature set.

Production

Manufacturing Locations:

Yale forklifts are manufactured globally, with significant production facilities in North America and Europe. Specific production dates for the VX series would be detailed in broader historical resources.