Yale GDP040-070VX Operating Manual Download | Manualshive

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Jump-Starting the Lift Truck

Jump-Starting Using a Battery Charger

CAUTION

DO NOT try to start the engine by pushing or towing the
lift truck. Damage to the transmission can occur if engine
is started by pushing or towing lift truck.

If the battery becomes discharged and requires a booster
battery to start the engine, follow these procedures carefully
when connecting the jumper cables:

1.

Disconnect the negative battery terminal of the lift truck

being started.

2.

Always connect positive jumper cable to positive terminal

of discharged battery and negative jumper cable to negative
terminal.

3.

Always connect jumper cable, that is the ground cables,

last.

4.

Always connect jumper cables to discharged battery

before connecting them to booster battery.

Jump-Starting Using Another Lift Truck

WARNING

To prevent possible arcing between the two lift trucks,
make sure that the lift trucks are not touching.

CAUTION

DO NOT try to start the engine by pushing or towing the
lift truck. Damage to the transmission can occur if engine
is started by pushing or towing lift truck.

1.

Always connect positive jumper cable to positive terminal

of discharged battery and negative jumper cable to negative
terminal.

2.

Always connect jumper cable, that is the ground cable,

last.

3.

Always connect jumper cables to discharge lift truck bat-

tery before connecting them to the fully charged lift truck bat-
tery.

Maintenance

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Summary of Contents for GDP040-070VX

Page 1: ...OPERATING MANUAL Veracitor GC GLC040VX GC GLC050VX GC GLC060VX GC GLC070VX GC GLC055SVX C910 GP GLP GDP040 070VX D875 PART NO 550108846 5 15 DO NOT REMOVE THIS MANUAL FROM THIS UNIT ...

Page 2: ...BER GROUP NUMBER GROUP NUMBER STEERING TIRE SIZE SPECIAL EQUIPMENT OR ATTACHMENTS Yale Material Handling Corporation 2015 All right reserved YALE and VERACITOR are Registered Trademarks of NACCO Materials Handling Group Inc CSS PREMIER and are Trademarks in the United States and certain jurisdictions is a registered copyright Spacer ...

Page 3: ...ore the new operator attempts to operate the lift truck alone It is the responsibility of the employer to make sure that the operator can see hear and has the physical and mental ability to operate the equipment safely Various laws and regulations require the employer to train lift truck operators These laws and regulations include Occupational Safety and Health Act USA Canada Material Handling Re...

Page 4: ...anizations Example Accident Prevention Manual for Industrial Operations from the National Safety Council Guide for Users of Industrial Lift Trucks describes lift truck safety good maintenance practices and training pro grams and is available from your dealer for Yale lift trucks Yale Part No 504295733 Forklift Pedestrian Accidents Available from your dealer for Yale lift trucks Yale Part No 2106 2...

Page 5: ...th the Engine Stopped 64 Operator Checklist 65 Mounting and Dismounting 65 Operator Passwords 66 Starting Procedures 67 Starting Procedures Trucks With Key Switch 67 Starting Procedures Trucks With Keyless Start Option 68 Checks With the Engine Running 70 Load Weighing Sensor 71 Set Load Weight to Zero 72 Engine Shutdown 72 Engine Modes Generation 2 ECO eLo 73 OPERATING TECHNIQUES 74 Basic Operati...

Page 6: ...9 HOW TO CLEAN A LIFT TRUCK 109 Maintenance Schedule 110 Maintenance Procedures Every 8 Hours or Daily 135 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED 135 Tires and Wheels 135 Safety Labels 137 Mast Carriage Header Hoses Lift Chains and Attachment 137 Operator Restraint System 139 Emergency Locking Retractor ELR 141 Hood and Seat Latches 141 Engine Compartment 142 Paper Application 142 Fuel Oil and...

Page 7: ...l Three and Four Piece Wheels 177 Install Wheel in Tire 177 Tire Installation Three or Four Piece Wheel 179 Tire Installation Two Piece Wheel 180 Add Air to Pneumatic Tires With Tube 180 Install the Wheels 182 PNEUMATIC TUBELESS TIRE REPAIR 182 Remove Tire From Lift Truck 182 Remove Tire From Wheel 183 Install Tire on Wheel 184 Add Air to Pneumatic Tubeless Tire 188 Install the Wheels 188 SOLID RU...

Page 8: ...k is in Storage 196 How to Put Batteries in Storage 196 Putting a Stored Lift Truck Back Into Service 197 HOW TO MOVE A LIFT TRUCK ON A TRANSPORT 197 Loading 198 Unloading 199 PREPARATION FOR USE 200 Preparation After Transport 200 Contents 6 ...

Page 9: ...for intended pur pose only VERIFY truck is equipped with overhead guard and load backrest adequate for the load LOOK WHERE YOU ARE GOING IF YOU CAN T SEE DON T GO TRAVEL in reverse if load blocks forward vision MAKE SURE tail swing area is clear SOUND horn at intersections or where vision is blocked WATCH clearances especially overhead KNOW YOUR LOADS HANDLE only stable loads within specified weig...

Page 10: ...tionary object BEFORE DISMOUNTING neutralize travel control lower carriage and set brake WHEN PARKING also shut off power close LPG fuel valve block wheels on inclines KNOW THE AREA NEVER enter a trailer or railroad car unless its wheels are blocked CONFIRM floor strength FILL fuel tank or charge battery only in designated area TURN OFF engine when fueling AVOID sparks or open flame Provide ventil...

Page 11: ...al or tilted slightly back Use minimum tilt when stacking elevated loads TRAVEL with carriage as low as possible and tilted back SLOW DOWN before turning especially without load FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE THE LIFT TRUCK TO TIP DO NOT JUMP off if the truck tips over HOLD steering wheel firmly BRACE your feet LEAN FORWARD and AWAY from point of impact Warning WARNING FAILURE TO F...

Page 12: ...RD 5 SEAT BELT AND HIP RESTRAINT 6 STEERING WHEEL 7 PARKING BRAKE 8 MAST 9 LOAD BACKREST EXTENSION 10 FORKS 11 CARRIAGE 12 DRIVE AXLE 13 SEAT 14 STEERING AXLE Figure 1 Model View Showing Major Components for Lift Truck Models GC GLC040VX GC GLC050VX GC GLC055SVX GC GLC060VX GC GLC070VX C910 Model Description 10 ...

Page 13: ...OVERHEAD GUARD 5 SEAT BELT AND HIP RESTRAINT 6 STEERING WHEEL 7 PARKING BRAKE 8 MAST 9 LOAD BACKREST EXTENSION 10 FORKS 11 CARRIAGE 12 DRIVE AXLE 13 SEAT 14 STEERING AXLE Figure 2 Model View Showing Major Components for Lift Truck Models GP GLP GDP040 070VX D875 Model Description 11 ...

Page 14: ...h three types of controls A Foot Directional Control FDC pedal that controls both the forward and reverse operation of the transmission and the speed of the engine A Direction Control Lever on the left side of the Display Switch Cluster that controls the forward neutral and reverse operation of the transmission A separate accel erator pedal controls the engine speed A directional control switch in...

Page 15: ...d judgment and care when handling loads Do not remove the overhead guard NOTE The seat belt can be either black or red The SEAT BELT AND HIP RESTRAINT provide additional means to help the operator keep the head and torso sub stantially within the confines of the lift truck frame and over head guard if a tipover occurs This restraint system is intended to reduce the risk of the head and torso being...

Page 16: ...ameplate Special capacities with the load height reduced or with optional load centers may also be shown on the Nameplate NOTE The image in Figure 3 is a sample only Reference the actual nameplate installed on the truck for actual truck specifications The lift truck serial number code is on the Nameplate The serial number code is also stamped on the right hand side of the lift truck frame under th...

Page 17: ...all safety labels are installed on the lift truck and can be read See Fig ure 4 and Figure 5 All possible label configurations that can be on the lift trucks covered in this Operating Manual are not shown in Fig ure 4 and Figure 5 See the Parts Manual for label part num bers and a complete listing of all labels that are available for the lift trucks covered in this Operating Manual Model Descripti...

Page 18: ...Figure 4 Warning and Safety Labels for Lift Truck Models GC GLC040VX GC GLC050VX GC GLC060VX GC GLC070VX GC GLC055SVX C910 Sheet 1 of 3 Model Description 16 ...

Page 19: ...SEE THE PARTS MANUAL FOR THE PART NUMBER Figure 4 Warning and Safety Labels for Lift Truck Models GC GLC040VX GC GLC050VX GC GLC060VX GC GLC070VX GC GLC055SVX C910 Sheet 2 of 3 Model Description 17 ...

Page 20: ...SEE THE PARTS MANUAL FOR THE PART NUMBER Figure 4 Warning and Safety Labels for Lift Truck Models GC GLC040VX GC GLC050VX GC GLC060VX GC GLC070VX GC GLC055SVX C910 Sheet 3 of 3 Model Description 18 ...

Page 21: ...ARNING 10 NAMEPLATE 11 DRIVE TRAIN PROTECTION CAUTION 12 PINCH POINT WARNING 13 TRANSMISSION LABEL EXAMPLE ONLY 14 LOCKING GAS SPRING 15 HOOD OPENING CAUTION 16 NO RIDERS 17 STABILITY SYSTEM LABEL ON BOTH SIDES OF TRUCK 18 LIFT AND TILT LABEL 19 FAN WARNING 20 ANTIFREEZE WARNING 21 BORON FREE LABEL 22 OPTIONAL FIRE SAFETY RATING NOT SHOWN 23 UNLEADED FUEL LABEL NOT SHOWN Model Description 19 ...

Page 22: ...Figure 5 Warning and Safety Labels for Lift Truck Models GP GLP GDP040 070VX D875 Sheet 1 of 3 Model Description 20 ...

Page 23: ...SEE THE PARTS MANUAL FOR THE PART NUMBER Figure 5 Warning and Safety Labels for Lift Truck Models GP GLP GDP040 070VX D875 Sheet 2 of 3 Model Description 21 ...

Page 24: ...SEE THE PARTS MANUAL FOR THE PART NUMBER Figure 5 Warning and Safety Labels for Lift Truck Models GP GLP GDP040 070VX D875 Sheet 3 of 3 Model Description 22 ...

Page 25: ...G 26 ANTIFREEZE WARNING 27 BORON FREE LABEL 28 OPTIONAL FIRE SAFETY RATING NOT SHOWN 29 SOOT TRAP WARNING DIESEL ONLY NOT SHOWN Display Switch Cluster WARNING If any of the instruments levers or pedals do not operate as described in the following tables report the problem immediately DO NOT operate the lift truck until the prob lem is corrected NOTE On the lift truck models covered in this manual ...

Page 26: ...1 LEFT SIDE DISPLAY INPUTS 2 LCD SCREEN 3 RIGHT SIDE DISPLAY INPUTS 4 WARNING AND INDICATOR LIGHTS Figure 6 Display Switch Cluster Model Description 24 ...

Page 27: ...A LEFT SIDE DISPLAY CAB OPTION GC GLC040VX GC GLC050VX GC GLC055SVX GC GLC060VX GC GLC070VX AND GP GLP GDP040 070VX ONLY B RIGHT SIDE DISPLAY Figure 7 Display Switch Cluster Model Description 25 ...

Page 28: ...F symbol is replaced with the Hourmeter symbol 2 Engine Start This button is used when the lift truck is equipped with the keyless start option The engine is started by pressing and holding this button Lift truck power must be turned ON press ing Power ON OFF button before starting engine If the lift truck contains a key switch the Engine Start graphic is covered and the function disabled 3 1st Ge...

Page 29: ...purposes If the lift truck is not equipped with a Techtronix 200X Trans mission then this button functions only as Password entry 1 5 Front Work Lights This button controls the front work lights and the marker lights on lift trucks equipped with this option 6 2 Button If the lift truck is equipped with front work lights the 2 Button and the Front Work Light button will share space on the Display S...

Page 30: ... is disabled and the button is enabled to enter the number 3 for password purposes If the lift truck is not equipped with rear work lights then this button functions only as Password entry 3 10 Scroll Down This button is used for the following functions Decreasing the value of a selected operating function Scrolling downward through a list of possible menu selections 11 4 Button The Scroll Down an...

Page 31: ...sswords the Scroll Up function is disabled and the button is enabled to enter the number 5 for password purposes 14 Hourmeter On trucks with key switch start when truck is ON engine hours will be displayed on LCD screen on right side of second line When truck is OFF press hourmeter button to display engine hours On trucks with keyless start option when truck is ON engine hours will be displayed on...

Page 32: ...ield wipers will turn on and off automatically 16 Front Windshield Wiper On lift trucks with cab option press this switch to turn the front windshield wiper ON Press the switch again to turn the front windshield wiper OFF 17 Rear Windshield Wiper On lift trucks with cab option press this switch to turn the rear windshield wiper ON Press the switch again to turn the rear windshield wiper OFF Model ...

Page 33: ...ngine coolant temperature and fuel level displays If a fault occurs the fault number will be displayed on the top line The time of day is displayed on the right side of the top line at all times during the selection of displayed text HYD TEMP FUNCTION REDUCED is displayed when the hydraulic oil temperature is higher or lower than specified limits The warning lights and indicator symbols shown in F...

Page 34: ...A LCD SCREEN B WARNING AND INDICATOR LIGHTS Figure 8 Display Switch Cluster LCD Screen and Warning and Indicator Lights Model Description 32 ...

Page 35: ...tart Check 3 Warning Light System Malfunction Indicator This amber light will illuminate when a fault that is not engine related occurs 4 Indicator Light Air Filter Restriction If the lift truck is equipped with the premium monitoring package this amber Air Filter Restriction light will illuminate when the air filter restriction switch senses a restriction in the air filter 5 Indicator Lights Dire...

Page 36: ...stem power is turned ON Not on at Start Check 8 Warning Light Parking Brake Malfunction Indicator WARNING Always apply the parking brake when leaving the lift truck The red parking brake light will illuminate any time the system power is ON and the parking brake lever is moved into the applied position The indicator light will flash any time the Parking Brake Warning alarm is active Not on at Star...

Page 37: ...operate the lift truck if the red light is ON The red light will illuminate when the transmission oil temperature reaches the preset warning level When light illuminates and if truck is equipped with optional powertrain protection truck performance will decrease Turn truck OFF and notify service person immedi ately for repair If truck is not equipped with optional powertrain protection and light i...

Page 38: ...nsor indicates an insufficient pressure This includes illuminating at System Power ON until the normal operating minimum is reached Not on at Start Check When light illuminates lift truck will enter Engine Shutdown mode if equipped with optional powertrain protection See Operating Procedures section for Engine Shut down procedures If truck is not equipped with optional powertrain protection and li...

Page 39: ... the engine is running it indicates the engine coolant temperature has reached 110 C 230 F or above When light illuminates lift truck will enter Engine Shutdown mode if equipped with optional powertrain protection See Operating Procedures section for Engine Shut down procedures If truck is not equipped with optional powertrain protection and light is illuminated when engine is running turn engine ...

Page 40: ...uminate when the radiator coolant level switch indicates that the level of coolant in the radiator is too low When light illuminates lift truck will enter Engine Shutdown mode if equipped with optional powertrain protection See Operating Procedures section for Engine Shut down procedures If truck not equipped with optional powertrain protection and light is illuminated when engine is running turn ...

Page 41: ...when there is 1 16th of fuel left in the tank For LPG Trucks with LPG pressure switch The light illuminates when there is 30 seconds to 3 minutes of operation remaining For LPG trucks equipped with the Premium Low Fuel Sensor The light illuminates when there is 10 to 20 minutes of operation remaining An audible alarm will sound every 4 minutes when the red light is illuminated 16 Indicator Light C...

Page 42: ...ll illuminate if the fuel water separator sensor indicates that water must be drained Not on at Start Check Operator Controls See Table 3 and Figure 9 WARNING If any of the controls instruments levers or pedals do not operate as described in the following tables report the problem immediately DO NOT operate the vehicle until the problem is corrected Model Description 40 ...

Page 43: ...SEE FIGURE 10 FOR MORE OPERATOR COMPARTMENT PEDAL CONFIGURATIONS Figure 9 Operator Controls Model Description 41 ...

Page 44: ...A INCHING BRAKE PEDAL B FOOT DIRECTIONAL CONTROL PEDAL C ACCELERATOR PEDAL D INCHING BRAKE PEDAL E BRAKE PEDAL Figure 10 Operator Compartment Pedal Configurations Model Description 42 ...

Page 45: ...e the lift truck slowly while a high engine speed is used for lifting loads Completely depress ing the pedal disengages the transmission and applies the service brakes The brake lights will be on when the brake pedal is depressed during normal operation On units with a Foot Directional Control pedal the engine can be started when the inching brake pedal is fully depressed or when the parking brake...

Page 46: ...ll up on the tilt lever and the steering column moves up Release the lever when the steering column reaches the desired position To move the steering column down grab the steering wheel and pull up on the lever Pull the steering column to the desired position 4 Horn The horn button controls the operation of the horn Model Description 44 ...

Page 47: ...ower ON or OFF without applying the parking brake the alarm will sound for 10 seconds The lift truck is equipped with a lever to apply the parking brake Pull the lever to apply the parking brake Use your thumb to release the button on the lever when the lever is moved to release the parking brake On units with a Foot Directional Control pedal applying the parking brake puts the transmission in NEU...

Page 48: ...hile a high engine speed is used for lifting loads Completely depress ing the pedal disengages the transmission and applies the service brakes The engine can be started when the inching brake pedal is fully depressed and Direction Control Lever is in neutral 7 Brake Pedal This pedal controlled by the operator s right foot controls the application of the service brakes Model Description 46 ...

Page 49: ...ual see Figure 9 NOTE To operate the mini levers the operator must be on the seat and the arm rest must be in the down position The lift lower control lever can be either the first manual lever or first mini lever to the right of the operator s seat Pull backward toward the operator to raise the car riage and forks Push forward to lower the carriage and forks Model Description 47 ...

Page 50: ...E To operate the mini levers the operator must be positioned in the seat and the arm rest must be in the down position The tilt control lever can be either the second manual lever or second mini lever to the right of the operator s seat Push the lever forward to tilt the mast and forks forward Pull the lever backward toward the operator to tilt the mast and forks back ward Model Description 48 ...

Page 51: ...he RTST option press the override button located directly behind the tilt mini lever and push the tilt mini lever forward or pull backward RTST is intended as an operator aid in positioning forks or attachments for their application to minimize product damage and facilitate load handling Care should be taken to operate the truck in accordance with load handling instructions as described in Operati...

Page 52: ...manual see Figure 9 The third manual control lever is installed to the right of the manual tilt control lever This lever can have two methods of operation depending on the attachment NOTE If truck is equipped with only three levers and clamp attachment the last 3rd lever controls clamp functions Control Lever with a Detent Attachments with a clamp action The lever is spring loaded toward the opera...

Page 53: ...i levers the operator must be on the seat and the arm rest must be in the down position NOTE If truck is equipped with only three levers and clamp attachment the last 3rd lever controls clamp functions Trucks with Clamp Attachment To engage the clamp move the mini lever back ward To disengage the clamp press the override button located directly behind the mini lever and push the mini lever forward...

Page 54: ...ird manual control lever This lever can have two methods of operation depending on the attachment NOTE If truck is equipped with four levers and clamp attachment the last 4th lever controls clamp functions Control Lever with a Detent Attachments with a clamp action The lever is spring loaded toward the operator The lever is operated by moving it to the right then forward and back Control Lever wit...

Page 55: ...ni levers the operator must be on the seat and the arm rest must be in the down position NOTE If truck is equipped with four levers and clamp attachment the last 4th lever controls clamp functions Trucks with Clamp Attachment To engage the clamp move the mini lever back ward To disengage the clamp press the override button located directly behind the mini lever and push the mini lever forward Truc...

Page 56: ...Switch Cluster The Direction Control Lever is used on lift trucks without a Foot Directional Control pedal The Direction Control Lever has three positions that are indicated by three green lights on left side of Display Switch Cluster see Figure 8 and Table 2 NEUTRAL N and REVERSE Move the lever to one of the direction positions for travel The Direction Control Lever must be in the NEUTRAL N posi ...

Page 57: ...ights No 2 Position ON position Energizes all electric circuits except the starter circuit The key switch will be in this position during normal operation No 3 Position START position Energizes the starter motor for starting the engine A spring returns the key to position No 2 ON position when the key is released 14 Foot Directional Control Pedal The Foot Directional Control pedal controls the spe...

Page 58: ...6 Direction Control Switch The Direction Control Switch for the transmission is next to the auxiliary horn button on the armrest The Direction Control Switch is used on lift trucks without a Foot Directional Control pedal 17 Auxiliary Horn Button Auxiliary horn button functions when the key or keyless ignition is in the ON position and up to 20 minutes after the key or keyless ignition is turned t...

Page 59: ...connect Switch Not Shown In Figure 9 This switch is only on units with the GS or LPS fire safety rating The operator can shut off all electrical power to the lift truck by pulling up on the T handle that is located between the steering wheel and the parking brake Model Description 57 ...

Page 60: ...rd 3 PUSH PULL Backward Forward Backward Forward 4 ROTATE Clockwise Counterclockwise Backward Forward 5 UPENDER Up Down Backward Forward 6 SCOOP Up Down Backward Forward 7 LOAD STABILIZER Down Clamp Up Release Backward Forward 8 SWING FORKS Right Left Backward Forward 9 FORK SPREAD Together Apart Backward Forward 10 CLAMP Clamp Release Backward Forward Model Description 58 ...

Page 61: ...oductive harm Avoid exposure to engine exhaust If engines are operated in confined spaces maintain adequate ventilation or vent exhaust to the outside Do not exceed applicable air contaminant limits see 29 CFR 1910 1000 Table Z 1 Follow the inspection and maintenance schedule and procedures in this manual Do not alter exhaust ignition or fuel systems WARNING FIRE HAZARD The hot engine surfaces and...

Page 62: ...ck required for operation in the area Modifications or poor maintenance can result in the lift truck being unsuitable for operation in areas classified as hazard ous The fork lift truck is designed to pickup move and tier mate rials The basic lift truck has a lift mechanism and forks on the front to engage the load The lift mechanism lifts the load so that it can be moved and stacked In order to u...

Page 63: ... back as the mast is tilted forward and back The CG moves up and down as the mast moves up and down A CG LOAD B COMBINED CG C CG TRUCK The center of gravity and therefore the stability of the loaded lift truck is affected by a number of factors such as size weight shape and position of the load the height to which the load is raised the amount of forward and backward tilt tire pressure and the dyn...

Page 64: ... by the lines drawn between the drive wheels and the steering axle pivot the lift truck will tip to that side Capacity Weight and Load Center The capacity of the lift truck is shown on the Nameplate The capacity is listed in terms of weight and load center The weight is specified in kilograms and pounds The load center is specified in millimeters and inches The capacity is the maximum load that th...

Page 65: ...utdown Timer has expired range is from 0 to 30 seconds During this time an alarm will sound and the Impact Detection icon will be displayed on the LCD screen If the time is set to 0 seconds the lift truck will shut down right after the impact is detected and no alarm will sound The Impact Shutdown Timer and other Impact related setup parameters can be set by either a service technician or supervis...

Page 66: ...fore using the lift truck make the following checks Condition of forks carriage chains header hoses mast attachment and overhead guard Condition of wheels and tires Seat belt fastens correctly Seat is correctly fastened to its mounts Hood is correctly latched Condition of the engine compartment Ensure all surfaces are free of oils lubricants fuel and organic dusts or fibers paper wood cotton agric...

Page 67: ...nd all items were answered with YES the operator can start the lift truck If there were any NO answered to checklist items the truck may or may not start The lift truck can be set up to not start starter engine outputs transmission and hydraulic functions disabled if any item in the checklist is answered with a NO response If lift truck is configured this way the message Truck Disabled will appear...

Page 68: ...signed to Operator and Lock out Reset passwords Can add edit and delete Operator or Supervisor passwords and view all truck diagnostic information Allows access to truck service parameters within preset limits Service Has all rights assigned to Operator Lockout Reset and Supervisor passwords Can add edit and delete Operator Supervisor and Service passwords and view all truck diagnostic information...

Page 69: ...or s position If equipped be sure cab door is secured in the closed position or removed before start ing lift truck operations If lift truck is equipped with the optional operator presence system the following sequence must be followed for engine to start Operator must be in seat Seat belt must be fastened Make sure park brake is applied Starting Procedures Trucks With Key Switch WARNING LPG is ve...

Page 70: ...ped with Operator Password feature enter correct operator supervisor or service password 12 On trucks equipped with a LPG or gasoline engine turn the key to the START position to engage the starter The word Cranking and a 30 second countdown timer will appear on the LCD screen when the key is in the START position On lift trucks equipped with a diesel engine if cold start delay is required the col...

Page 71: ...e parking brake is applied or push on the inching brake pedal 8 If equipped put the direction control lever for the trans mission in the NEUTRAL N position 9 Make sure lift truck hood is closed 10 Depress and release the Power ON OFF button If lift truck is equipped with a diesel engine and engine is cold the cold start indicator light will illuminate and the cold start circuit will be energized 1...

Page 72: ...Tips Over Do Not Jump Stay On Truck Hold Firmly To Steering Wheel Brace Feet Lean Forward And Away From Impact The seat belt is installed to help the operator stay on the truck if the lift truck tips over IT CAN ONLY HELP IF IT IS FASTENED The operator must be aware that the lift truck can tip over There is a great risk that the operator or someone else can be killed or injured if trapped or hit b...

Page 73: ...or correct operation of the mast carriage and attach ments Check the operation of the Foot Directional Control pedal or the optional direction control lever and accelerator pedal Check the operation of the service brakes and parking brake Check the operation of the steering system Check the oil level in the powershift transmission when the oil is at operating temperature 50 C 120 F Turn the truck ...

Page 74: ...y service technician immediately for repair Certain faults or sensor measurements can cause the truck to go into Engine Shutdown mode The following actions occur when truck is in this mode The VSM will have a coolant over temperature light come on at 110 C 230 F At 110 C 230 F the engine will be limited to 75 power A linear power regression will be applied between 110 and 116 C 230 and 240 F At 11...

Page 75: ...uck s hydraulic functions When this occurs the following actions take place The fault number is displayed on the top line of the LCD screen and a description of truck performance being decreased is shown on bottom line The Engine Malfunction icon illuminates see Figure 7 and Table 1 An alarm will sound for 10 seconds Take the lift truck to a service technician immediately for repair if it experien...

Page 76: ...t read the WARN ING page in the front of this Operating Manual do so NOW As you study the following information about how to properly operate a lift truck remember the WARN INGS NOTE The lift trucks in this manual are equipped with the Emergency Locking Retractor ELR style seat belt When the ELR seat belt is properly buckled across the operator the belt will permit slight operator repositioning wi...

Page 77: ...education in proper driving and load handling techniques is absolutely necessary to prepare the new oper ator for proper defensive driving and to expect the unexpec ted WARNING This lift truck is designed for handling materials A lift truck is not designed to lift people Do not use a lift truck to lift people unless it has been determined that there is no other practical option scaffolds elevated ...

Page 78: ...exit of the truck The neutral position is shown in Figure 11 Seat Adjustment for Operator Weight CAUTION A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to his her weight NOTE It is important to adjust the weight setting for each operator NOTE The seat is designed for a maximum weight of 135 kg 298 lb The target is for the ride indicator to fall between...

Page 79: ...tment Standard Seat Fore and aft adjustment it is recommended that the seat be adjusted so that the thigh is horizontal to the ground so that the best ergonomic position is achieved See Fig ure 12 Seat Position Adjustment Swivel Seat The seat swivels 12 degrees to the right to allow the oper ator a more ergonomic position when driving in reverse The seat swivels 5 degrees to the left to allow an e...

Page 80: ...et is for the ride indicator to fall between the arrows when the operator sits upright in the seat with the feet positioned on the pedals This ensures that the oper ator is set at the midpoint of the 80 mm 3 5 in suspen sion The handle can be turned as shown to increase or decrease the weight resistance pull handle out before turning As the handle is turned the stiffness of the sus pension can be ...

Page 81: ...Figure 12 Seat Adjustment Full Suspension Operating Procedures 79 ...

Page 82: ...in the elevator set the brakes put the controls in NEUTRAL and shut off the power It is advisable that all other personnel leave the ele vator before the lift truck enters or leaves 6 Drive carefully observe traffic rules and be in full control of the lift truck at all times Be completely familiar with all the driving and load handling techni ques contained in this Operating Manual Driving and Dir...

Page 83: ...Inching Yes Yes Electronic Control of Direction Changes Yes Yes Auto Deceleration Yes Controlled Power Reversal Yes Roll Reduction Feature Yes Roll Back Feature Yes Reduced Drive Tire Slippage Yes 1 STANDARD TRANSMISSION 2 TECHTRONIX 100 TRANSMISSION Figure 13 Transmission Labels Operating Procedures 81 ...

Page 84: ...travel mode A switch in the operator s seat will automatically shift the transmission to neutral within 1 2 seconds when the operator leaves the seat of the lift truck with the engine running and without applying the parking brake If the lift truck is equipped with a Direction Control Lever and the operator leaves the seat without engaging the parking brake the N indicator light on the Display Swi...

Page 85: ...raction travel mode A switch in the operator s seat will automatically shift the transmission to neutral within 1 2 seconds when the operator leaves the seat of the lift truck with the engine running and without applying the parking brake If the lift truck is equipped with a Direction Control Lever and the operator leaves the seat without engaging the parking brake the N indicator light on the Dis...

Page 86: ...etects when the seat belt is fastened This system is designed with a slight delay in the seat switch and seat belt switch to allow the operator to reposition himself without disengaging the transmission and disabling the hydraulic mast functions The operator must be on the seat and the seat belt must be fastened before engaging the starter If the operator leaves the seat while the truck is moving ...

Page 87: ...hanged by a Yale Service Technician when required to meet special application requirements The Techtronix 100 transmission allows the operator to change travel direction When a direction change is selected the lift truck s Vehicle Management System automatically reduces engine speed to idle and activates transmission braking The operator con trols the level of transmission braking or deceleration ...

Page 88: ...he operator should always consider the load that is being carried and keep the carriage lowered when using transmission braking Roll Reduction Feature WARNING The lift truck is only considered at a controlled stop when the truck is not rolling and the service or parking brake is applied The operator cannot rely on transmission braking alone to bring the lift truck to a full controlled stop Failure...

Page 89: ...NING Inching requires coordinated movement of the inching brake pedal and the accelerator or the Foot Directional Control pedal New operators must practice this proce dure before attempting to handle loads Inching is the movement of a lift truck that allows a slow travel speed while keeping the engine speed high for fast operation of the lift mechanism The inching brake pedal is used to control th...

Page 90: ...he lift truck will actually tip over easier when empty than when loaded with the load lowered Mast tilt off center loads and uneven ground will aggravate these conditions and cause the forklift to become unstable WARNING Failure to observe the tail swing area when making a turn can injure or kill someone A TAIL SWING Because lift trucks are designed to work in a relatively small space they can tur...

Page 91: ...action permits the lift truck to enter the narrow aisle going straight ahead Load Handling General 1 The capacity is the maximum load that the lift truck can handle for the load condition shown on the Name plate The operator must know whether or not a load is within the maximum capacity of the lift truck before the load is handled However factors such as weak floors or uneven terrain loads with a ...

Page 92: ...uck tipping over to the side Make sure the pins that keep the forks in position are engaged so that the forks cannot move 4 Check the condition of the driving surface Make sure the floor will support the weight of the lift truck and the load Load Handling Lifting Lowering and Tilting NOTE The lift trucks covered in this manual can be equipped with either standard manual hydraulic levers or Electro...

Page 93: ...n and other personnel have no overhead protection Avoid hitting objects such as stacked material that could become dislodged and fall The operator must exercise care while working near such objects Whether the lift truck is loaded or empty do not travel with the load or carriage in a raised position WARNING Keep yourself and all others clear of the lift mechanism Never allow anyone under or on the...

Page 94: ... Forward tipping is even more likely when tilting forward braking when traveling forward or accelerating in reverse If the lift mechanism is raised to pick up or deposit a load keep the tilt angle in either direction to a minimum Backward and forward tilt are helpful but they affect side and forward stability Do not tilt in either direction more than necessary when handling a load that is raised T...

Page 95: ... centered between the forks Make sure that the forks do not extend past the load so that loads or equipment that are behind the load being lifted are not damaged Lift the load a small distance from the floor to make sure the lift truck has the capacity to lift the load A BE CAREFUL OF FORKS BEYOND THE LOAD If the forks are longer than the load move the forks under the load so that the tips of the ...

Page 96: ...owly and smoothly Slowly return the control lever to the neutral position so that the load is not dropped or that the lift truck is not tipped over due to the rapid stop of the load WARNING Move carefully and smoothly when the load is raised over a stack When the load is elevated the center of gravity of the lift truck and the load is much higher The lift truck can tip over when the load is raised...

Page 97: ...ower the forks so that they will drag on the surface under the load Tilt the mast forward just enough to permit smooth removal of the forks from under the load Carefully move the lift truck back ward to remove the forks from under the load Lower the forks when traveling NOTE Not every load can be lifted using only the forks of a lift truck Some loads will require a special attachment 6 When liftin...

Page 98: ...lity of the lift truck is reduced This is also critical when the lift truck is not carrying a load The ability of the lift truck to resist side tipping can be less on a lift truck without a load than it is on a lift truck with a load in the lowered travel posi tion Therefore a lift truck without a load is more likely to tip sideways especially in a turn than a lift truck with a load carried in the...

Page 99: ...4 When traveling up or down grades in excess of 5 with a heavily loaded lift truck keep the load upgrade to maintain control When operating an unloaded lift truck on a grade in excess of 5 keep the counterweight upgrade 5 Watch out for pedestrians at all times Do not drive up to anyone standing in front of an object Use extra care at cross aisles doorways and other locations where pedestrians can ...

Page 100: ...m surfaces Lift trucks with pneumatic tires can adapt to more uneven ground Always make sure you pick the smoothest route for your lift truck 8 Watch clearances especially forks mast overhead guard and tail swing A lift truck is designed to perform a wide variety of functions within limited space The operator must be aware that the forks can sometimes extend beyond the front of the load If the for...

Page 101: ...ay from the edge of the road Keep the wheels of the lift truck on the roadway If the wheels are allowed to run off the edge of the travel surface onto soft ground the lift truck can tip over 12 Under all travel conditions oper ate the lift truck at a speed that will permit it to be brought to a stop in a safe manner Operating Procedures 99 ...

Page 102: ...nder the load WARNING Always lower the mast assembly when leaving the lift truck unattended NOTE The emergency load lowering valve is to be used ONLY if the electrical signal to the main control valve has been disrupted and there is a load lifted To use the emergency load lowering valve follow these steps 1 Move seat all the way forward and raise the steering col umn to its highest position and op...

Page 103: ...1 EMERGENCY LOAD LOWERING VALVE 2 MAIN CONTROL VALVE 3 COWL WELDMENT 4 KICK PANEL Figure 14 Emergency Load Lowering Valve Operating Procedures 101 ...

Page 104: ...ghway truck or rail car observe the following DO NOT use a lift truck to move a rail car DO NOT use a lift truck to open or close the door on a rail car unless the lift truck has an attachment that is specifi cally designed for opening and closing rail car doors and the operator is trained in its use Check to make sure that the brakes on the highway truck are set and that wheel blocks have been pl...

Page 105: ...rating instructions are available and understood before operating the attachment For the operation of attachment control levers see Figure 9 Figure 10 and Table 3 Attachments must be removed or installed by trained per sonnel only Disconnecting Attachment Hydraulic Quick Disconnect Hoses NOTE Step 1 through Step 4 is to be used for lift trucks equipped with electro hydraulics 1 Turn the key switch...

Page 106: ...achment Hydraulic Quick Disconnect Hoses NOTE Step 1 through Step 4 is to be used for lift trucks equipped with manual hydraulics 1 Connect the Quick Disconnect hose connectors 2 Connect the negative terminal of the battery 3 Turn the key switch or keyless switch to the ON position and start the engine 4 Move the manual hydraulic levers forward and backward and check the hydraulic system for leaks...

Page 107: ...ntil the tips of the forks touch the ground 3 If equipped move the Direction Control Lever to the NEU TRAL position 4 Turn the key to the OFF position to stop the engine 5 If the lift truck must be left on an incline put blocks on the down hill side of the wheels so that the lift truck can not move 6 Check engine compartment if operating in areas contain ing combustible material and remove foreign...

Page 108: ... contains a Maintenance Schedule and the instructions for maintenance and inspection The Maintenance Schedule has time intervals for inspec tion lubrication and maintenance for your lift truck The serv ice intervals are provided in both operating hours recorded on the lift truck hour meter and in calendar time Use the interval that occurs first The recommendation for the time intervals are for eig...

Page 109: ...em This condition can make the lift truck difficult to steer Poor traction can cause the disabled lift truck or towing vehicle to slide A slope will also make the lift truck more difficult to stop Never lift and move a disabled lift truck unless the disa bled lift truck MUST be moved and cannot be towed A lift truck used to move a disabled lift truck MUST have a capacity rating equal to or greater...

Page 110: ... of gravity mast drive axle engine and transmission and the counterweight When the lift truck is put on blocks put additional blocks in the following positions to main tain stability 1 Before removing the mast and drive axle put blocks under the counterweight so that the lift truck cannot fall backward 2 Before removing the counterweight put blocks under the mast assembly so that the lift truck ca...

Page 111: ... on the Nameplate 3 Put the jack under the steering axle or frame to raise the lift truck Put blocks under the frame to support the lift truck How to Clean a Lift Truck CAUTION Your lift truck may be damaged if water or cleaning agents come in contact with electrical components DO NOT directly spray any electrical components espe cially connectors switches electro hydraulic controls battery area a...

Page 112: ...1 DRIVE TIRES 2 STEERING TIRES Figure 16 Put a Lift Truck on Blocks Maintenance Schedule Maintenance Schedule 110 ...

Page 113: ...Figure 17 Kubota 2 5L LPG Engine Maintenance and Lubrication Points Maintenance Schedule 111 ...

Page 114: ...Figure 18 PSI 2 4L Dual Fuel Engine Maintenance and Lubrication Points Maintenance Schedule 112 ...

Page 115: ...Figure 19 Yanmar 2 6L and 3 3L Diesel Engine Maintenance and Lubrication Points Maintenance Schedule 113 ...

Page 116: ...Figure 20 Kubota 2 4L Diesel Engine Maintenance and Lubrication Points Maintenance Schedule 114 ...

Page 117: ...ition See Nameplate SAFETY LABELS X Replace as Necessary See Parts Manual 27 28 MAST CARRIAGE HEADER HOSES LIFT CHAINS AND ATTACHMENT X Check Condition and Lubrication See Parts Manual SEAT BELT HIP RESTRAINTS AND SEAT RAILS X Check Condition and Operation HOOD AND SEAT LATCHES X Check Condition and Operation X Check C Change L Lubricate CIL Check indicator light during operation Maintenance Sched...

Page 118: ...aust Wraps Radia tor Radiator Screen if equipped Belly Pan if equipped X X Check Condition Clean as Required Replace as Required See NOTE 9 CHECK FOR LEAKS FUEL OIL WATER X Check for Leaks See NOTE 1 HYDRAULIC HOSES X Check Condition See Parts Manual COOLANT HOSES X Check Condition See Parts Manual 14 FUEL TANK GAS GLC040 070VX GLC055SVX C910 CIL 40 5 liter 10 7 gal 86 Octane Gasoline Minimum X Ch...

Page 119: ...UEL TANK LPG CIL 29 9 liter 7 9 gal 15 2 kg 33 5 lb LPG HD 5 HD 10 14 FUEL TANK DIESEL GLP GDP20 35VX D875 CIL 52 liter 13 7 gal Diesel No 2 HORN LIGHTS ALARMS X Check Operation 1 SERVICE BRAKES X Check Operation 24 PARKING BRAKE X Check Operation STEERING CONTROLS AND STEERING COLUMN GAS CYLINDER X Check Condition and Operation 21 TRANSMISSION X Check for Leaks X Check C Change L Lubricate CIL Ch...

Page 120: ... 3 and NOTE 15 ISO VG 46 Hydraulic Oil 15 C 5 F and above 6 HYDRAULIC OIL GP GLP GDP040 070VX D875 X X C 39 8 liter 42 qt See NOTE 2 NOTE 3 and NOTE 15 ISO VG 46 Hydraulic Oil 15 C 5 F and Above 5 HYDRAULIC OIL FILTER C 1 Filter See NOTE 15 See Parts Manual 8 HYDRAULIC TANK BREATHER X C Inspect and Replace as Required See NOTE 15 See Parts Manual 7 BATTERY AND CABLE TERMINALS X Clean X Check C Cha...

Page 121: ...Engine Dual Fuel X CIL C 4 9 liter 5 2 qt See NOTE 4 and NOTE 5 7 C 20 F and Below SAE 5W 20 16 C 60 F and Below SAE 5W 30 18 C 0 F and Below SAE 10W 30 API SL ILSAC GF3 SAE J2362 16 ENGINE OIL Kubota 2 5L Engine LPG X CIL C 6 6 liter 7 0 qt See NOTE 4 and NOTE 5 SAE 10W 30 ILSAC GF3 API SL SAE J2362 X Check C Change L Lubricate CIL Check indicator light during operation Maintenance Schedule 119 ...

Page 122: ... to 86 F SAE 30 0 to 20 C 32 to 68 F SAE 20 16 to 40 C 3 to 103 F SAE 15W 40 20 to 30 C 4 to 86 F SAE 10W 30 10 to 10 C 14 to 50 F SAE 20W 20 to 10 C 4 to 50 F SAE 10W API CG 4 or better 16 ENGINE OIL Kubota 2 4L Engines GDP040 070VX D875 X CIL C 9 5 liter 10 0 qt See NOTE 4 and NOTE 5 Above 10 C 14 F SAE 15W 40 Below 10 C 14 F SAE 10W 30 API CJ 4 Only 17 ENGINE OIL FILTER PSI 2 4L Engine C 1 Filt...

Page 123: ... 6L and 3 3L Engines GDP040 070VX D875 C 1 Filter See NOTE 4 and NOTE 5 See Parts Manual 17 ENGINE OIL FILTER Kubota 2 4L Engines GDP040 070VX D875 C 1 Filter See NOTE 4 and NOTE 5 See Parts Manual 19 AIR FILTER X CIL C 1 Filter See NOTE 5 NOTE 6 and NOTE 13 See Parts Manual ENGINE IDLE SPEED Yanmar 2 6L and 3 3L Engines X 825 25 RPM ENGINE GOVERNED SPEED Yanmar 2 6L Diesel Engine X 2700 25 RPM X ...

Page 124: ...3L Engine Diesel X 2600 25 RPM ENGINE IDLE SPEED Kubota 2 5L Engine X 800 25 RPM ENGINE GOVERNED SPEED Kubota 2 5L Engine X 2400 25 RPM ENGINE IDLE SPEED PSI 2 4L Engine X 800 25 RPM ENGINE GOVERNED SPEED PSI 2 4L Engine X 2400 25 RPM 12 DRIVE BELT PSI 2 4L Engine X Check for Wear and Damage Adjust as Needed X Check C Change L Lubricate CIL Check indicator light during operation Maintenance Schedu...

Page 125: ...ge Adjust as Needed 12 DRIVE BELT Yanmar 2 6L and 3 3L Engines X Check for Wear and Damage Adjust as Needed 12 DRIVE BELT Kubota 2 4L Diesel Engines X Check for Wear and Damage Adjust as Needed 13 TIMING BELT PSI 2 4L Engine C Replace as Necessary 20 PCV VALVE PSI 2 4L X C Replace as Necessary See NOTE 12 and NOTE 15 See Parts Manual X Check C Change L Lubricate CIL Check indicator light during op...

Page 126: ... Diesel Engines X Adjust as Required Intake 0 20 mm 0 008 in Cold Exhaust 0 20 mm 0 008 in Cold 30 VALVE ADJUSTMENT Kubota 2 5L LPG X Adjust as Required Intake and Exhaust Cold 0 18 to 22 mm 0 007 to 0 0086 in 30 VALVE ADJUSTMENT Kubota 2 4L Diesel X Adjust as Required Intake and Exhaust Cold 0 18 to 22 mm 0 007 to 0 0086 in 4 DIRECT ELECTRONIC PRESSURE REGULATOR DEPR PSI 2 4L Engine X Check Condi...

Page 127: ...ot Shown C 1 Filter See Parts Manual 15 IN LINE FUEL FILTER PSI 2 4L ENGINE DUAL FUEL PSI 2 4L Engine Dual Fuel C 1 Filter See Parts Manual 15 LPG FUEL FILTER Kubota 2 5L Engines LPG C 1 Filter See Parts Manual 15 FUEL WATER SEPARATOR Yanmar 2 6L and 3 3L Engines Diesel C 1 Filter See Parts Manual 15 IN LINE FUEL FILTER Yanmar 2 6L and 3 3L Engines Diesel C 1 Filter See Parts Manual X Check C Chan...

Page 128: ...LUGS PSI 2 4L Engines C Check Plug Wires 4 Spark Plugs See Parts Manual 0 9 mm 0 035 in 18 SPARK PLUGS Kubota 2 5L Engines LPG C 4 Spark Plugs See Parts Manual 0 7 to 0 8 mm 0 028 to 0 032 in 31 FUEL INJECTORS Yanmar 2 6L and 3 3L Engines Diesel X 4 Injectors Check and Replace if Required 31 FUEL INJECTORS PSI 2 4L Engines X 4 Injectors Check and Replace if Required 10 11 COOLING SYSTEM PSI 2 4L E...

Page 129: ...10 6 liter 11 2 qt See NOTE 14 10 11 COOLING SYSTEM Yanmar 2 6L and 3 3L Engines X CIL C 11 5 liter 12 1 qt See NOTE 14 10 11 COOLING SYSTEM Kubota 2 4L Engines X CIL C 10 5 liter 11 1 qt See NOTE 14 CLEAN DEBRIS FROM RADIATOR CORE X See NOTE 5 3 TRANSMISSION OIL Dry Brakes Aluminum Case X C 13 liter 14 qt John Deere JDM J20C 22 TRANSMISSION OIL FILTER C 1 Filter See NOTE 4 See Parts Manual 26 FOR...

Page 130: ...HEADER HOSES X Check Condition 28 LIFT CHAINS X L L X Check Lubri cation Lubricate as Required Check for Wear See NOTE 11 Engine Oil SAE 30W MAST Sideshift Carriage X L Lubricate as Required 2 Fittings Multipurpose Grease See NOTE 8 INTEGRAL SIDESHIFT CARRIAGE Fork Positioner L Lubricate as Required See NOTE 5 Multipurpose Grease See NOTE 8 MAST Pivots L 2 Fittings Multipurpose Grease See NOTE 8 X...

Page 131: ...purpose Grease See NOTE 8 2 5 mm 3 32 in MAST Integral Sideshift Carriage Lower Mounting Hook X Check for Wear and Clearance See NOTE 2 and NOTE 5 0 76 mm 0 03 in Minimum Wear Limit TILT CYLINDER ENDS L 4 Fittings Multipurpose Grease See NOTE 8 BRAKE MASTER CYLINDER ROD END PIN L SAE 10W 30 API SM ILSAC GF4 SAE J2362 MANUAL HYDRAULIC HAND LEVERS L SAE 10W 30 API SM ILSAC GF4 SAE J2362 X Check C Ch...

Page 132: ...on III from Sealed Container 9 STEERING AXLE Tire Rod Ends GP GLP GDP040 070VX D875 L 4 Fittings Multipurpose Grease See NOTE 8 9 STEERING AXLE King Pin GP GLP GDP040 070VX D875 L 2 Fittings Multipurpose Grease See NOTE 8 9 STEERING AXLE Spindle Bearings GLC040 70VX GLC055SVX C910 L 4 Fittings Multipurpose Grease See NOTE 8 2 PEDALS LEVERS SEAT RAILS CABLES HINGES LINKAGES HOOD LATCH L Lubricate a...

Page 133: ...IL Dry Brakes GLC040 70VX GLC055SVX C910 X C 5 0 liter 5 3 qt SAE 80W 90 or 85W 140 29 DIFFERENTIAL AND DRIVE AXLE OIL Dry Brakes GP GLP GDP040 070VX D875 X C 6 5 liter 6 9 qt SAE 80W 90 or 85W 140 3 TRANSMISSION OIL Wet Brakes Aluminum Case GP GLP GDP040 070VX D875 X C 13 liter 14 qt John Deere JDM J20C 32 WET BRAKE AXLE PLANETARY HOUSING OIL LEFT SIDE X C 0 5 liter 0 5 qt SAE 80W 90 X Check C Ch...

Page 134: ...0 Hr 1 Yr 4000 Hr 2 Yr Procedure or Quantity Specification 32 WET BRAKE AXLE PLANETARY HOUSING OIL RIGHT SIDE X C 2 0 liter 2 1 qt SAE 80W 90 32 WET BRAKE AXLE CENTER SECTION OIL X C 1 0 liter 1 1 qt John Deere JDM J20C X Check C Change L Lubricate CIL Check indicator light during operation Maintenance Schedule 132 ...

Page 135: ...ste paper chemical or abrasive compounds poor ground conditions intensive usage at high performance levels or other abnormal conditions will require more frequent servicing At your request your Yale dealer will advise you of the appropriate service intervals based on an application survey NOTE 6 In dirty or dusty environments replace at 1000 hours or as needed NOTE 7 Check fuel injectors at 5000 h...

Page 136: ...col Boron free Antifreeze Purchase a pre diluted 50 50 solution or mix 50 concentrate with 50 distilled or deionized water NOTE 15 Hydraulic oil sampling and analysis is a recommended practice See Hydraulic Cleanliness Procedures 1900 YRM 1620 for oil cleanliness and water content guidelines For lift trucks operating in heavy duty applications or highly contaminated environments take oil samples e...

Page 137: ...rriage and forks stop the engine and apply the parking brake Open the hood and check for leaks and conditions that are not normal Clean any oil or fuel spills Ensure all surfaces are free of oils lubricants fuel and organic dust or fibers paper wood cot ton agricultural grass grain etc Tires and Wheels Check the tires for damage see Figure 21 Check the tread and remove any objects that will cause ...

Page 138: ...1 CHECK FOR DAMAGE REMOVE NAILS GLASS AND OTHER OBJECTS FROM THE TREAD 2 MAKE SMOOTH EDGES 3 CHECK THE TIRE PRESSURE PNEUMATIC TIRES Figure 21 Check the Tires Maintenance 136 ...

Page 139: ... Do not try to correct the alignment of the fork tips by bending the forks or adding shims If either fork is dam aged replace the forks as a set Never repair damaged forks by heating or welding Forks are made of special steel using special procedures If either fork is damaged replace the forks as a set 1 Inspect the welds on the mast cylinders and carriage for cracks Make sure that the capscrews a...

Page 140: ...chains must be replaced as a set See Figure 22 8 Inspect the chain anchors and pins for cracks and damage 9 Make sure the lift chains are adjusted so that they have equal tension Adjustments or replacement of the lift chains must be done by authorized personnel 1 WORN PIN 2 CRACKS 3 EDGE WEAR 4 HOLE WEAR 5 LOOSE LEAVES 6 DAMAGED PIN 7 CORROSION Figure 22 Lift Chain Check Maintenance 138 ...

Page 141: ...at belt hip restraint seat hood and hood latches are all part of the operator restraint system see Figure 23 Each item must be checked to make sure it is fastened correctly functions correctly and is in good condition Maintenance 139 ...

Page 142: ...KWARD ANGLE ADJUSTMENT LEVER 2 HOOD 3 SEAT BELT 4 HIP RESTRAINTS 5 SEAT 6 FORWARD BACKWARD ADJUSTMENT LEVER 7 SEAT RAIL 8 OPERATOR WEIGHT ADJUSTMENT 9 HOOD LATCH Figure 23 Hood and Seat Check Maintenance 140 ...

Page 143: ... moment to remove slack from the belt in the retractor Release the seat belt Seat belt will retract and the internal latch will unlock If the seat belt cannot be pulled from the retractor assembly or the belt will not retract replace the seat belt assembly With the hood closed and in the locked position pull the seat belt with a sudden jerk Make sure the seat belt will not pull from the retractor ...

Page 144: ...ore frequently depend ing upon operating environment The paper application will help limit the contact of paper or tissue scraps to hot surfaces under the hood but frequent maintenance is required WARNING Engine and exhaust system components are hot to the touch Be sure lift truck components are cool before starting inspection and cleaning or personal injury may occur Ensure the truck engine cools...

Page 145: ...essed air line and nozzle An extension may be helpful to access hard to reach places Remove floor plates and side covers for better access to engine compartment Open or remove belly pan if equipped Clean components with com pressed air Take care to maintain the integrity of the exhaust wraps when cleaning with compressed air and use caution to not force debris into openings WARNING Be careful when...

Page 146: ...ruck see the section How to Add Fuel to the Lift Truck Also check the condition of the radiator or heater hoses that are not leaking Soft or cracked hoses need to be replaced before a major leak occurs Hydraulic Hoses Check the condition of the hydraulic hoses for serviceability by inspecting for cracks or other obvious damage Check to insure that the hydraulic hoses are not leaking If any hose is...

Page 147: ...a burn CAUTION Do not permit dirt to enter the hydraulic system when the oil level is checked or the filter is changed Never operate the hydraulic pump without oil in the hydraulic system The operation of the hydraulic pump without oil will damage the pump Check the hydraulic system for leaks and damaged or loose components Heavy duty or high temperature operations can require more frequent checks...

Page 148: ...e red indi cator light will illuminate when the key switch is turned to ON if the truck is equipped with a key switch or when the power ON OFF button is pressed if the truck is equipped with a keyless option and will stay illuminated until correct oil pressure is obtained at which time the light will go off Maintenance 146 ...

Page 149: ...LANT RESERVOIR 3 RADIATOR CAP 4 DRIVE BELT 5 AIR FILTER 6 ENGINE OIL FILTER 7 DIPSTICK ENGINE OIL 8 FUEL FILTER 9 FUEL INJECTOR 10 ENGINE OIL FILL Figure 26 Yanmar 2 6L and 3 3L Diesel Engine Maintenance Points Maintenance 147 ...

Page 150: ...2 BATTERY 3 AUXILIARY COOLANT RESERVOIR 4 RADIATOR CAP 5 ENGINE OIL FILL 6 DRIVE BELT 7 AIR FILTER 8 FUEL FILTER 9 ENGINE OIL FILTER 10 PCV VALVE 11 SPARK PLUGS Figure 27 Kubota 2 5L Engine Maintenance Points Maintenance 148 ...

Page 151: ...AUXILIARY COOLANT RESERVOIR 4 RADIATOR CAP 5 ENGINE OIL FILL 6 DRIVE BELT 7 AIR FILTER 8 FUEL FILTER 9 ENGINE OIL FILTER 10 PCV VALVE 11 SPARK PLUGS 12 FUEL INJECTOR GAS ONLY Figure 28 PSI 2 4L Engine Maintenance Points Maintenance 149 ...

Page 152: ...ARATOR 2 ENGINE OIL FILTER 3 AIR FILTER 4 ENGINE OIL FILL 5 DIPSTICK ENGINE OIL 6 BATTERY 7 AUXILIARY COOLANT RESERVOIR 8 RADIATOR CAP 9 DRIVE BELT Figure 29 Kubota 2 4L Diesel Engine Maintenance Points Maintenance 150 ...

Page 153: ...ht 45 to 115 kg 99 to 253 lb CAUTION Remove fork latch pins if adding a fork positioner attach ment Damage to forks and other carriage components can occur if fork latch pins are not removed prior to using attachment NOTE Forks must be removed or installed by trained per sonnel only Forks are to be replaced only in sets The identification of a fork describes how the fork is connec ted to the carri...

Page 154: ...1 OUTER FORK CARRIER 2 FORKS 3 INNER FORK CARRIER 4 SIDESHIFT CARRIAGE 5 FORK POSITIONER 6 CAPSCREWS 7 FORK REMOVAL NOTCH Figure 30 Fork Positioner Maintenance 152 ...

Page 155: ...a hook fork to the fork removal notch on the carriage See Figure 31 and Fig ure 33 Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch See Fig ure 33 Lower the carriage further so that the top hook of the fork is disengaged from the top carriage bar Move the car riage away from the fork or use a lifting device to move the fork away from the carriage ...

Page 156: ...ep the forks locked in position Forks Install 1 Move the fork and carriage so that the top hook on the fork can engage the upper carriage bar Raise the carriage to move the lower hook through the fork removal notch Slide the fork on the carriage so that both upper and lower hooks engage the carriage Engage the lock pin with a notch in the upper carriage bar See Figure 32 2 If lift truck is equippe...

Page 157: ... into slots in the top carriage bar If pin does not remain engaged in carriage slot replace with new pin Adjust the forks as far apart as possible for maximum support of the load Hook forks will slide along the carriage bars to adjust for the load to be lifted Raise the lock pin in each fork to slide the fork on the carriage bar Make sure the lock pin is engaged in the carriage bar to lock the for...

Page 158: ...m 1 46 in 1372 mm 54 in 41 mm 1 61 in 1524 mm 60 in 46 mm 1 81 in 1830 mm 72 in 55 mm 2 17 in 1 TIP ALIGNMENT MUST BE WITHIN 3 OF FORK LENGTH 2 CRACKS 3 LATCH DAMAGE 4 HEEL OF FORK MUST BE 90 OF DIMENSION X 5 CARRIAGE 6 LOAD BACKREST EXTENSION 7 MAXIMUM ANGLE 93 8 FORK REMOVAL NOTCH Figure 33 Forks Check Maintenance 156 ...

Page 159: ...ng a check apply the parking brake and put the trans mission in NEUTRAL Make the checks carefully Indicator Lights Horn Fuses and Relays If lift truck is equipped with a key switch turn key to ON posi tion If lift truck is equipped with a Power ON OFF button press button to turn system power on Check all indicator lights for correct operation as described in Table 3 Check the operation of the horn...

Page 160: ...8 BACKUP 20 AMP FUSE 9 IGNITION 30 AMP FUSE 10 SPARE FUEL PUMP 20 AMP FUSE 11 SPARE FUEL PUMP RELAY 12 BATTERY 25 AMP FUSE 13 FRONT WORK LIGHT 20 AMP FUSE 14 FRONT REAR WORK LIGHT RELAYS 15 BATTERY 25 AMP FUSE 16 REAR WORK LIGHT 20 AMP FUSE 17 IGNITION 1 20 AMP FUSE 18 IGNITION RELAY 19 BATTERY 25 AMP FUSE Figure 34 PDM Showing Fuses and Relays Maintenance 158 ...

Page 161: ...uster for the brake fluid The red light is ON when the key switch is in the START position or the Power ON OFF button is pressed and must go OFF when the engine is running If the light is ON when the engine is running the brake fluid level in the reservoir is too low Operation Check Check the operation of the service brakes Push on the inching brake pedal The service brakes must be applied before ...

Page 162: ...arking brake is released before making adjustment To adjust the parking brake do the following 1 Turn the adjustment knob as shown in Figure 35 Do not tighten the adjustment so that the brake is applied when the lever is released The lever for the parking brake has a lock Use your thumb or finger to release the lock on the lever when the parking brake is released 2 For burnished brakes test the op...

Page 163: ...em Lift trucks equipped with a Yanmar diesel engine will enter the shutdown mode when the coolant temperature reaches 110 C 230 F or above on lift trucks with powertrain protection system See the Engine Shutdown procedures in the Operating Proce dures section in this manual There is an indicator light on the Display Switch Cluster for the coolant temperature The red light is ON when the key switch...

Page 164: ...he eyes With the engine off check the radiator fins Clean the radiator with compressed air or water as needed Check for and remove any debris on the radiator core If the indicator light turns on again after restarting shut down the lift truck and do not operate the lift truck until the problem is corrected 1 FILL CAP 2 AUXILIARY COOLANT RESERVOIR 3 FULL MARK 4 ADD MARK 5 RADIATOR CAP Figure 36 Aux...

Page 165: ...e lift mechanism unless all parts of the mast are completely lowered and the engine is STOPPED If the mast cannot be lowered use chains on the mast weldments and carriage so that they can not move Make sure the moving parts are attached to a part that does not move See the Periodic Maintenance section of the service manual for additional information Do not try to find hydraulic leaks by putting ha...

Page 166: ... ON OFF button if truck is equipped with keyless start option The operator must be off of the lift truck while fuel is added No smoking All fuels for internal combustion engines are very flam mable Fill the fuel tank only in a designated area with good ventilation Have a fire extinguisher available Never fill the fuel tank near an open flame or near equip ment that can create sparks Never check fu...

Page 167: ...t 8 m 26 ft from any open flame motor vehicles electrical equipments or ignition source Removable LPG tanks must be removed from the fork lift before filling If the lift truck is equipped with a non removable LPG tank make sure all components engine transmission muffler catalytic muffler have surface temperatures that have cooled to below 427 C 800 F LPG Tank Remove NOTE The LPG tank bracket used ...

Page 168: ... bracket handle and swing the tank and bracket out to the side of the lift truck If your truck is equipped with a swing out and drop down LPG tank bracket EZ Tank Bracket drop the tank down to the side of the truck for ease of removal 6 Unlatch the tank strap and remove the LPG tank from the bracket Maintenance 166 ...

Page 169: ...Figure 37 LPG Tank and Bracket Maintenance 167 ...

Page 170: ...es and regulations for filling LPG tanks Make sure these rules and regulations are available and understood 1 Check the gauge on tank to make sure it needs filling During the fill operation the LPG tank must be in a position so that the liquid level indicator will always be in the vapor space above the liquid level 2 Open the liquid outlet valve and bypass return valve on the storage tank 3 Start ...

Page 171: ... quickly and with enough force to cause injury to the fin gers and hand 1 Place the LPG tank into the bracket Be sure alignment pin on tank bracket is properly aligned with the hole in the tank If the pin is damaged repair it before installing the tank Secure the tank strap around the tank and close the strap 2 Pull the stop pin and swing the LPG tank bracket into the resting position on the count...

Page 172: ...ies lift trucks have pneumatic tires or solid rub ber tires that look like pneumatic tires These variations in tires also cause a variation in the types of wheels and the disassembly and assembly procedures How to Change a Solid Rubber Tire GC GLC Series WARNING The type of solid rubber tire is shown on the Nameplate Make sure the Nameplate is correct for the type of tires on the lift truck Wheels...

Page 173: ... drive wheels are installed on the lift truck tighten the wheel nuts to 340 to 380 N m 251 to 280 lbf ft 3 The steering wheels are fastened to the spindle of the steering axle with a large castle nut Make sure inner and outer bearings are correctly lubricated with grease Install inner bearing assembly and wheel on spindle Install outer bearing cone and castle nut Tighten castle nut up to 68 N m 50...

Page 174: ...AND WHEEL B DRIVE TIRES AND WHEELS C WIDE TREAD 1 OUTSIDE OF SOLID RUBBER TIRE 2 WHEEL 3 OVERHANG Figure 38 Tires and Wheels GC GLC040VX GC GLC050VX GC GLC060VX GC GLC070VX GC GLC055SVX C910 Lift Trucks Maintenance 172 ...

Page 175: ...l to the Nameplate listed ply rating may be acceptable Check with your dealer whether a specific bias ply tire is approved for use on Yale trucks WARNING Wheels must be changed and tires repaired by trained personnel only Deflate tire completely before removing the wheel from the lift truck If dual wheels are used deflate both tires Air pressure in the tires can cause the tire and rim parts to exp...

Page 176: ...e stem does not have a restriction 3 Remove the wheel nuts and remove the wheel and tire from the lift truck Lift truck tires and wheels are heavy Remove Tire From Wheel When disassembling wheels see Figure 39 There are sev eral types of wheels used on this series of lift trucks See Tire Removal Two Piece Wheel and Tire Removal Three and Four Piece Wheels Maintenance 174 ...

Page 177: ...D ON WHEEL TYPES SHOWN IN ILLUSTRATIONS B OR D A TWO PIECE WHEEL B OPTIONAL RIM ASSEMBLY C THREE PIECE WHEEL D FOUR PIECE WHEEL 1 WHEEL RIM 2 SIDE FLANGE 3 LOCK RING 4 FLANGE SEAT Figure 39 Types of Pneumatic Wheels Maintenance 175 ...

Page 178: ... the tire and rim parts to explode causing seri ous injury or death Keep tire tools in firm contact with the wheel parts If the tool slips it can move with enough force to cause an injury 1 Remove the nuts that fasten the wheel rims together 2 Loosen the tire bead from the wheel rim 3 Remove the wheel rims from tire Remove the inner tube and flap Maintenance 176 ...

Page 179: ...e an injury 1 Loosen the tire bead from the side flange 2 Put the tire tool into the slot between the lock ring and wheel rim Remove the lock ring and side flange If there is a flange seat remove it 3 Loosen the bead from the other side of the wheel rim Remove the valve stem from the wheel 4 Remove the wheel rim from the tire Install Wheel in Tire WARNING Damage to the tire and wheel assembly and ...

Page 180: ...spect all parts of the wheel Paint any parts that have rust or corrosion 2 Install a new inner tube in the tire Used tubes and flaps can cause tire failure WARNING Do not lubricate the tire bead with antifreeze or petro leum based liquid Vapors from these liquids can cause an explosion during inflation or use 3 Apply a rubber lubricant or a soap solution to the tire bead and tube 4 Install a new t...

Page 181: ... of tires type of tire tread or wheel assemblies of different manufacturers on any one lift truck Do not use a steel hammer on the wheel Use a rubber lead plastic or brass hammer to put parts together Make sure that the side ring is in the correct position The ends of the side ring must not touch The clearance at the ends of the side rings will be approximately 13 to 25 mm 0 5 to 1 0 in after it i...

Page 182: ...p in the tire Install both halves of the wheel rim in the tire Make sure the stem of the inner tube is aligned with the slot in the rim 2 Tighten the nuts that hold the rim halves together to 175 N m 130 lbf ft Add air pressure to the tire as described in Add Air to Pneumatic Tires With Tube Add Air to Pneumatic Tires With Tube WARNING Add air pressure to the tires only in a safety cage See Figure...

Page 183: ...ts are correctly installed Hit the lock ring lightly to make sure that it is in the seat Figure 40 Add Air to Tires With Tube 4 If installation is correct add air pressure to the tire to the specified pressure See Nameplate 5 Check that all wheel parts are correctly installed If instal lation is not correct remove all of the air pressure from the tire Remove the valve core to make sure all of the ...

Page 184: ... the inner and outer wheels halves together when there is air pressure in the tire WARNING DO NOT mix brands of rubber sealing rings and tires Serious injury to personnel or damage to the lift truck can occur if the rubber sealing rings are not compatible with the tire brand Specially designed rubber sealing rings enable tubeless tires to be used on wheel rims that were designed to be used with a ...

Page 185: ... move with enough force to cause an injury NOTE There are several types of wheels used on these lift trucks When disassembling wheels see Figure 39 1 If the tire is equipped with a Tubeless Bead Seal TBS style rubber sealing ring with a separate valve stem turn the valve stem 1 4 turn and remove valve stem from wheel as shown in illustration If the tire is equipped with a Tubeless Sealing Ring TSR...

Page 186: ...eel WARNING Damage to the tire and wheel assembly and injury or death can occur if you do not do the following proce dures Clean and inspect all parts of the wheel before instal ling the tire DO NOT use any damaged or repaired wheel parts Make sure that all parts of the wheel are the correct parts for that wheel assembly DO NOT mix parts between different types or manu facturers of wheels DO NOT m...

Page 187: ... 1 Clean interior and exterior bead area of the tire Lubri cate tire beads and the inside of the tire up to the tire shoulders Apply lubri cant to entire underside of the TBS or TSR Use lubri cant approved by the tire manufacturer NOTE If the wheel rim width is less than six inches the TBS will contain one valve hole to accommodate the needle valve If the wheel rim width is greater than six inches...

Page 188: ...e the wings are not folded over For the TBS rub ber sealing ring with separate valve stem make a mark on the tire to note the position of the valve hole For TSR rubber sealing ring with an integral valve stem align valve slot in the rim with the TSR valve stem 4 Apply lubricant to the rim If a four piece wheel is being used lubricate the advance band Slide the tire and rubber sealing ring onto the...

Page 189: ...o far and damage the valve Position the arms of the press onto the loose flange CAUTION DO NOT compress the bead too far and cause the rubber sealing ring to become dis torted and damage the valve stem Push down on press to depress the tire beads until the locking ring groove is fully exposed 8 Insert tire tool into the lock ing ring groove and a vise grip on other end Remove vise grip Release the...

Page 190: ... not sit or stand by the safety cage Add air to tire to the recommended pressure that is shown on the Nameplate Install valve cap to ensure air stays in the tire Figure 41 Add Air to Tubeless Tire Install the Wheels Install the wheel on the hub Tighten the nuts in a cross pat tern and torque to 450 to 500 N m 332 to 369 lbf ft for drive wheel nuts and 155 to 175 N m 114 to 129 lbf ft for steer whe...

Page 191: ... tires and wheels are heavy Remove Tire From Wheel WARNING Keep tire tools in firm contact with the wheel If the tool slips it can move with enough force to cause serious injury NOTE When disassembling wheels see Figure 39 There are several types of wheels used on these series of lift trucks WARNING Wheels must be changed and tires repaired by trained personnel only Always wear safety glasses 1 Pu...

Page 192: ...rim Install Tire on Wheel WARNING Damage to tire and wheel assembly and injury or death can occur if you do not do the following proce dures Clean and inspect all parts of the wheel before instal ling the tire DO NOT use any damaged or repaired wheel parts Make sure that all parts of the wheel are the correct parts for the wheel assembly DO NOT mix parts between different types or manu facturers o...

Page 193: ... wheels used on these series of lift trucks CAUTION Too much lubricant can cause the tire to slide and move around the wheel rim 1 Lubricate the wheel rim and the inner surface of the tire with tire lubricant or soap 2 Put the wheel rim on the bed of the press Put the tire over the wheel rim Put the cage in position on the tire Use the press to install the tire on the wheel rim 3 Remove the cage a...

Page 194: ...eer wheel nuts If two piece wheels are installed make sure the nuts that fasten the rim halves together are toward the brake drum when they are installed 2 Install the spacer to the axle shaft Tighten the nuts to 98 N m 72 lbf ft 3 Install the outer wheel on the spacer Tighten the nuts to a torque of 450 to 500 N m 332 to 369 lbf ft for the drive wheel nuts and 155 to 175 N m 114 to 129 lbf ft for...

Page 195: ...ys connect jumper cable that is the ground cables last 4 Always connect jumper cables to discharged battery before connecting them to booster battery Jump Starting Using Another Lift Truck WARNING To prevent possible arcing between the two lift trucks make sure that the lift trucks are not touching CAUTION DO NOT try to start the engine by pushing or towing the lift truck Damage to the transmissio...

Page 196: ...ne speeds with a light load during the first 50 hours of operation High engine speeds with a light load can cause damage to the cylinders in the engine Changes to the Overhead Guard WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck Do not make changes to the overhead guard by welding Changes that are made by welding or by drilling holes that are ...

Page 197: ...y lower the mast If lift truck is equipped with forks tilt mast FORWARD until the tips of the forks touch the floor Apply a thin coat of fresh high grade SAE 30 or 40 weight engine oil to the exposed cylinder rods If the forks are removed tilt mast BACKWARD until cylinders are com pletely retracted This protects the cylinder rods 3 Check that all switches and accessories are in the OFF position 4 ...

Page 198: ...OTE Do not shut down an engine before it reaches oper ating temperature Each month set the park brake start engine and run until normal operating temperature is reached This will coat the internal engine components with a film of oil and rid the engine of built up condensation Each month all hydraulic cylinders must be cycled several times to keep the seals active and to coat the interior walls wi...

Page 199: ... a greasy film forms on the top of a battery this is acid and must be neutralized with the solution described above Putting a Stored Lift Truck Back Into Service 1 Remove all tape covers and preservation materials 2 Check the lift truck for damage and missing components Repair damage and or replace missing components NOTE If the lift truck has been stored longer than one year all lubricants and fl...

Page 200: ...amp is the correct design and capacity If the lift truck is equipped with lifting eyes use a crane to load and unload the lift truck from the transport If the truck is not equipped with approved lifting eyes do not lift the truck by attaching a lifting device to any other part of the lift truck for the purposes of loading or unloading Loading WARNING The straps or chains used to fasten the lift tr...

Page 201: ...blocks in front and back of the lift truck tires to prevent any movement of the lift truck Make sure the blocks are attached to the load surface If the lift truck is equipped with an LPG fuel system and is not in active use close the fuel valve at the tank If the lift truck is going to be left overnight or longer the truck must be parked outside or the LPG tank must be removed and stored outside I...

Page 202: ...n All problems must be cor rected before use of the lift truck see the Service Manual for procedures Preparation After Transport 1 Complete the unloading procedures 2 Inspect the lift truck for damage and missing components 3 Follow the steps in the section How to Make Checks With the Engine Stopped Maintenance 200 ...

Page 203: ...Spacer 5 15 4 15 2 15 1 15 11 14 ...

Page 204: ...OPERATING MANUAL Veracitor GC GLC040VX GC GLC050VX GC GLC060VX GC GLC070VX GC GLC055SVX C910 GP GLP GDP040 070VX D875 PART NO 550108846 5 15 DO NOT REMOVE THIS MANUAL FROM THIS UNIT ...

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