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Yale VERACITOR GCC030VX, Operating Manual


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NOTE: 

HOOD REMOVED FOR CLARITY.

1.

BATTERY

2.

POWER DISTRIBUTION MODULE (PDM)

3.

RESISTOR (68 OHM)

4.

START RELAY

5.

STARTER (30 AMP FUSE)

6.

IGNITION 3 RELAY

7.

BACKUP RELAY

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 40. PDM Showing Fuses and Relays

Maintenance

161

Summary of Contents for VERACITOR GCC030VX

Page 1: ...OPERATING MANUAL VERACITOR GC GLC030 035VX GC GLC040SVX C809 GP GLP GDP030 035VX GP GLP GDP040SVX C810 PART NO 524239830 2 20 DO NOT REMOVE THIS MANUAL FROM THIS UNIT...

Page 2: ...L NUMBER GROUP NUMBER GROUP NUMBER STEERING TIRE SIZE SPECIAL EQUIPMENT OR ATTACHMENTS Yale Material Handling Corporation 2020 All Rights Reserved YALE and VERACITOR are Registered Trademarks of Hyste...

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 th...

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 practice...

Page 5: ...ERATION 67 Checks With the Engine Stopped 67 Operator Checklist 68 Mounting and Dismounting 69 Operator Passwords 69 Starting Procedures 70 Starting Procedures Trucks With Key Switch 71 Starting Proce...

Page 6: ...2 HOW TO CLEAN A LIFT TRUCK 112 Maintenance Schedule 113 Maintenance Procedures Every 8 Hours or Daily 141 HOW TO MAKE CHECKS WITH THE ENGINE STOPPED 141 Tires and Wheels 141 Safety Labels 143 Mast Ca...

Page 7: ...180 Tire Installation Three or Four Piece Wheel 181 Tire Installation Two Piece Wheel 182 Add Air to Pneumatic Tires With Tube 183 Install the Wheels 184 PNEUMATIC TUBELESS TIRE REPAIR 184 Remove Tire...

Page 8: ...is in Storage 198 How to Put Batteries in Storage 198 Putting a Stored Lift Truck Back Into Service 199 HOW TO MOVE A LIFT TRUCK ON A TRANSPORT 200 Loading 200 Unloading 201 PREPARATION FOR USE 202 P...

Page 9: ...s 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 fo...

Page 10: ...ionary 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 trail...

Page 11: ...l 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...

Page 12: ...E AND REVERSE LIGHTS 3 SEAT 4 COUNTERWEIGHT 5 STEERING AXLE 6 SEAT BELT AND HIP RESTRAINT 7 DRIVE AXLE 8 CARRIAGE 9 FORKS 10 LOAD BACKREST EXTENSION 11 PARKING BRAKE 12 STEERING WHEEL 13 MAST 14 OPERA...

Page 13: ...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 Clu...

Page 14: ...and manufactured prior to March 2009 it is not equipped with an emergency lowering valve If manufactured after March 2009 it is equipped with an emergency lowering valve If your lift truck is equippe...

Page 15: ...Transmission Electronic 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 Dri...

Page 16: ...at 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...

Page 17: ...acity for the lift truck at full load height must be shown on the Nameplate Special capacities with the load height reduced or with optional load centers may also be shown on the Nameplate The lift tr...

Page 18: ...mportant that all safety labels are installed on the lift truck and can be read See Figure 4 All possible label configurations that can be on the lift trucks covered in this Operating Manual are not s...

Page 19: ...LABELS FOR GP GLP GDP30 35VX AND GP GLP GDP40SVS TRUCKS ARE IN SAME LOCATIONS Figure 4 Warning and Safety Labels Sheet 1 of 3 Model Description 17...

Page 20: ...SEE THE PARTS MANUAL FOR THE PART NUMBER Figure 4 Warning and Safety Labels Sheet 2 of 3 Model Description 18...

Page 21: ...SEE THE PARTS MANUAL FOR THE PART NUMBER Figure 4 Warning and Safety Labels Sheet 3 of 3 Model Description 19...

Page 22: ...BEL ON BOTH SIDES OF TRUCK THIS PARKING BRAKE LABEL SEE SHEET 2 USED ON LIFT TRUCKS MANUFACTURED AFTER JANUARY 2012 THIS LABEL USED ON LIFT TRUCKS MANUFACTURED AFTER JANUARY 2012 Display Switch Cluste...

Page 23: ...1 LEFT SIDE DISPLAY INPUTS 2 LCD SCREEN 3 RIGHT SIDE DISPLAY INPUTS 4 WARNING AND INDICATOR LIGHTS Figure 5 Display Switch Cluster Model Description 21...

Page 24: ...Figure 6 Display Switch Cluster Right Side Display Inputs Model Description 22...

Page 25: ...gine is started by pressing and holding this button Lift truck power must be turned ON pressing Power ON OFF button before starting engine If the lift truck contains a key switch the Engine Start grap...

Page 26: ...s then this button functions only as Password entry 2 6 Enter Button This button is used for menu entry navigation and data entry 7 Rear Work Lights This button controls the rear work lights on lift t...

Page 27: ...entering and administering passwords the Scroll Down function is disabled and the button is enabled to enter the number 4 for password purposes 11 Scroll Up This button is used for the following funct...

Page 28: ...e 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 LCD screen on right side of sec...

Page 29: ...ine 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...

Page 30: ...A LCD SCREEN B WARNING AND INDICATOR LIGHTS Figure 7 Display Switch Cluster LCD Screen and Warning and Indicator Lights Model Description 28...

Page 31: ...art 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 equ...

Page 32: ...tem 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 ill...

Page 33: ...perate the lift truck if the red light is ON The red light will illuminate when the transmission oil temperature reaches the pre set warning level When light illuminates and if truck is equipped with...

Page 34: ...sor 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 En...

Page 35: ...the engine is running it indicates the engine cool ant temperature has reached 110 C 230 F or above When light illuminates lift truck will enter Engine Shutdown mode if equipped with optional powertra...

Page 36: ...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 optiona...

Page 37: ...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 th...

Page 38: ...l illuminate if the fuel water separator sensor indicates that water must be drained Not on at Start Check Operator Controls See Table 4 and Figure 8 WARNING If any of the controls instruments levers...

Page 39: ...SEE FIGURE 9 FOR MORE OPERATOR COMPARTMENT PEDAL CONFIGURATIONS Figure 8 Operator Controls Sheet 1 of 2 Model Description 37...

Page 40: ...Figure 8 Operator Controls Sheet 2 of 2 Model Description 38...

Page 41: ...Legend for Figure 8 A UNITS WITH FOOT DIRECTIONAL CONTROL PEDAL B UNITS WITH DIRECTION CONTROL LEVER C UNITS BUILT AFTER JANUARY 2010 WITH E HYDRAULICS Model Description 39...

Page 42: ...A INCHING BRAKE PEDAL B PEDAL C ACCELERATOR PEDAL D INCHING BRAKE PEDAL E BRAKE PEDAL Figure 9 Operator Compartment Pedal Configurations Model Description 40...

Page 43: ...ator can move the lift truck slowly while a high engine speed is used for lifting loads Completely depressing the pedal disengages the transmission and applies the service brakes The brake lights will...

Page 44: ...l up on the tilt lever and the steering column moves up Release the lever when the steering column reaches the desired posi tion To move the steering column down grab the steering wheel and pull up on...

Page 45: ...er system power 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...

Page 46: ...ile a high engine speed is used for lifting loads Completely depressing the pedal disengages the transmission and applies the service brakes The engine can be started when the inching brake pedal is f...

Page 47: ...ions electronic hydraulic mini levers see Figure 8 and a joystick see Figure 10 and Table 5 NOTE To operate the mini levers the operator must be on the seat and the arm rest must be in the down positi...

Page 48: ...raulic mini levers see Figure 8 and a joystick see Figure 10 and Table 5 NOTE To operate the mini levers the operator must be positioned in the seat and the arm rest must be in the down position The t...

Page 49: ...e 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 at...

Page 50: ...ions electronic hydraulic mini levers see Figure 8 and a joystick see Figure 10 and Table 5 The third manual control lever is installed to the right of the manual tilt control lever This lever can hav...

Page 51: ...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 function...

Page 52: ...able 5 The fourth manual control lever is installed to the right of the third manual control lever This lever can have two methods of operation depending on the attach ment NOTE If truck is equipped w...

Page 53: ...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 Tru...

Page 54: ...Display Switch Cluster The Direction Control Lever is used on lift trucks without a pedal The Direction Control Lever has three positions that are indicated by three green lights on left side of Disp...

Page 55: ...unning The key switch is located on the right side of the Display Switch Cluster The key switch has three positions No 1 Position OFF position De energizes all electric circuits except for the horn an...

Page 56: ...rd The speed of the engine increases as the pedal is depressed The reverse lights and the optional reverse alarm will be on in the reverse position during nor mal operation 15 Accelerator Pedal This p...

Page 57: ...18 Auxiliary Horn Button Auxiliary horn button functions when the key or keyless ignition is in the ON posi tion and up to 20 minutes after the key or keyless ignition is turned to the OFF position B...

Page 58: ...RNING 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 A...

Page 59: ...o Item Function 1 Lift Lower Function A Lower B Lift NOTE To operate the joystick the operator must be on the seat Push the joystick lever forward to lower the carriage and forks Pull the joystick lev...

Page 60: ...cks can be equipped with the Return to Set Tilt RTST option The RTST option automatically stops the tilt function at a set point To override the RTST option press the override button located directly...

Page 61: ...nly a three function valve and clamp attach ment the left rocker switch controls the clamp functions Trucks with clamp attachments To engage the clamp move the left rocker switch forward to clamp To d...

Page 62: ...a four function valve and clamp attachment the right rocker switch controls the clamp functions Trucks with clamp attachments To engage the clamp move the right rocker switch forward to clamp To dise...

Page 63: ...d 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...

Page 64: ...uctive 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...

Page 65: ...sified as hazardous must be identified by signs to show the type of approved lift truck required for operation in the area Modifications or poor maintenance can result in the lift truck being unsuitab...

Page 66: ...he location of its CG or if the truck is loaded the combined CG The lift truck has moving parts and therefore has a CG that moves The CG moves forward and back as the mast is til ted forward and back...

Page 67: ...uck will tip forward If the CG moves outside of the line represented by the lines drawn between the drive wheels and the steer ing axle pivot the lift truck will tip to that side Capacity Weight and L...

Page 68: ...ct sensor option is enabled and an impact has been detected then lift truck will shut down once the Impact Shutdown Timer has expired range is from 0 to 30 seconds During this time an alarm will sound...

Page 69: ...ating DO NOT OPERATE and remove the key from the key switch if truck is equipped with key switch option Checks With the Engine Stopped Inspect the lift truck before use and every eight hours or daily...

Page 70: ...ludes a text description of a system or com ponent the operator is to check The operator is instructed to press button 1 for YES or button 2 for NO on the Dis play Switch Cluster See Figure 6 If any c...

Page 71: ...ies of five numbers Each of the five number digits can be the numbers 1 through 5 If enabled the password number series must be entered into the memory by a technician and assigned to an operator Reme...

Page 72: ...OUT SUPERVISOR REQUIRED is displayed A Lockout Reset Supervisor or Service password is needed to unlock the lift truck System power can be turned OFF while in lockout mode by turning key switch to OFF...

Page 73: ...2 F perform Step 2 through Step 6 below for lift trucks equipped with Mazda LPG engine except Mazda 2007 emission compliant engines NOTE The warm up thaw cycle can be bypassed at any time by cranking...

Page 74: ...the starter will shutdown for 60 seconds to cool off A 60 second countdown timer will appear on the LCD screen showing the time remaining before a restart attempt can be tried To restart engine repea...

Page 75: ...losed 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...

Page 76: ...uard if a tipover occurs This protection system is intended to reduce the risk of the head and torso being trapped between the truck and the ground but it can not protect the operator against all poss...

Page 77: ...t the load 0 6 m 2 ft off the ground but if freelift cylin der is present not more than maximum freelift 3 Lower the load 51 mm 2 in Stop lowering wait 1 sec ond and read the load weight This will be...

Page 78: ...ft truck is equipped with the Power ON OFF button press Power ON OFF but ton twice to cycle the system power and then press the Engine Start button If the Engine Start button is pressed before the Pow...

Page 79: ...e make the mistake of thinking that operating a lift truck is the same as driving an automobile This is not true A lift truck is a special machine designed to do a much different job than an automobil...

Page 80: ...a screen or shield at least 2 m 7 ft high between the people on the platform and the lift mechanism The combined weight of the platform load and person nel is not to exceed one half of the capacity as...

Page 81: ...of 135 kg 298 lb The target 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 operator is se...

Page 82: ...t of the truck The neutral position is shown in Figure 13 Seat Adjustment for Operator Weight CAUTION A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to hi...

Page 83: ...Figure 13 Seat Adjustment Full Suspension Operating Procedures 81...

Page 84: ...at all other personnel leave the elevator 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 com pletely familiar w...

Page 85: ...mission Electronic 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 Ti...

Page 86: ...l operating conditions either at start or while driv ing the lift truck can only be maintained at a stopped posi tion by applying the service brake or parking brake When moving away from a stop 1 Sele...

Page 87: ...ng the parking brake the N indicator light on the Display Switch Cluster will illuminate regardless of the position of the Direction Control Lever When the operator returns to the seat to resume trave...

Page 88: ...perator leaves the seat while the truck is moving or does not apply the parking brake before getting off the seat the seat switch will disengage the transmission and disable the hydraulic mast functio...

Page 89: ...for control of the truck and the stability of the load Operators should be trained and become familiar with these operating fea tures before transporting loads When a direction change is selected the...

Page 90: ...ll 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 transmis sion...

Page 91: ...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 opera...

Page 92: ...ic forces are present In fact the 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 condition...

Page 93: ...as tail swing will permit This 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...

Page 94: ...truck 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 suppo...

Page 95: ...every possible impact A lift truck without an overhead guard provides no such protection and other personnel have no overhead protec tion Avoid hitting objects such as stacked material that could beco...

Page 96: ...loads forward only when directly over the unloading place WARNING The lift truck can tip over forward when the load is raised Forward tipping is even more likely when tilting forward braking when trav...

Page 97: ...truck is perpendicular to the load Raise the forks to the proper height for engaging the load 2 Move forward slowly until the forks are in position under the load The forks must support at least two...

Page 98: ...tion and lower the load Tilt the mast forward to permit smooth removal of the forks Carefully move the lift truck backward to remove the forks from under the load 4 If the load is being removed from a...

Page 99: ...gy Be careful not to damage or move adjacent loads IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE OR FORWARD DO NOT JUMP OFF HOLD FIRMLY TO STEERING WHEEL BRACE YOUR FEET AND LEAN FORWARD AND AWAY FRO...

Page 100: ...mechanism raised only enough to clear the ground or obstacles When the mast carriage or load is in a raised position the stability of the lift truck is reduced This is also critical when the lift truc...

Page 101: ...ted 4 When traveling up or down grades in excess of 5 with a heavily loaded lift truck keep the load upgrade to main tain control When operating an unloaded lift truck on a grade in excess of 5 keep t...

Page 102: ...relatively smooth firm 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...

Page 103: ...locations 11 Stay away 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 c...

Page 104: ...der 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...

Page 105: ...1 EMERGENCY LOAD LOWERING VALVE 2 MAIN CONTROL VALVE 3 COWL WELDMENT 4 KICK PANEL Figure 15 Emergency Load Lowering Valve Operating Procedures 103...

Page 106: ...D AWAY FROM THE POINT OF IMPACT Before operating in a highway 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...

Page 107: ...acity When entering a rail car the operator can enter at an angle if the dock plate or bridge is wide enough This will reduce the turning required after entering Never leave a parked truck on a dock p...

Page 108: ...4 If the hoses still cannot be disconnected notify service personnel 3 Press the plunger button located on the top of the pres sure relief valve and listen for the flow of hydraulic fluid through the...

Page 109: ...sition and start the engine 4 Move the manual hydraulic levers forward and back ward and check the hydraulic system for leaks NOTE Step 5 through Step 8 is to be used for lift trucks equipped with ele...

Page 110: ...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 c...

Page 111: ...on 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 s...

Page 112: ...ere is no power available for the hydraulic steering system 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...

Page 113: ...intenance and repair The removal of the following assemblies will cause large changes in the center of gravity mast drive axle engine and transmission and the counterweight When the lift truck is put...

Page 114: ...total weight of the lift truck as shown 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 Li...

Page 115: ...1 DRIVE TIRES 2 STEERING TIRES Figure 17 Put a Lift Truck on Blocks Maintenance Schedule Maintenance Schedule 113...

Page 116: ...Figure 18 Mazda FE Gas Engine Except 2007 Emission Compliant Engine Maintenance and Lubrication Points Maintenance Schedule 114...

Page 117: ...Figure 19 Mazda FE Gas Engine 2007 Emission Compliant Engine Only Maintenance and Lubrication Points Maintenance Schedule 115...

Page 118: ...Figure 20 Mazda FE Gas Engine With Aluminum Case Gear Drive Transmission Prior to January 2011 Maintenance and Lubrication Points Maintenance Schedule 116...

Page 119: ...Figure 21 Mazda FE Gas Engine With Aluminum Case Transmission After January 2011 Maintenance and Lubrication Points Maintenance Schedule 117...

Page 120: ...Figure 22 Mazda FE LPG Engine Except 2007 Emission Compliant Engines Maintenance and Lubrication Points Maintenance Schedule 118...

Page 121: ...Figure 23 Mazda FE LPG Engine 2007 Emission Compliant Engines Only Maintenance and Lubrication Points Maintenance Schedule 119...

Page 122: ...Figure 24 Mazda FE LPG Engine With Aluminum Case Transmission Prior to January 2011 Maintenance and Lubrication Points Maintenance Schedule 120...

Page 123: ...Figure 25 Mazda FE LPG Engine With Aluminum Case Transmission After January 2011 Maintenance and Lubrication Points Maintenance Schedule 121...

Page 124: ...Figure 26 Yanmar 2 6L Diesel Engine Prior to January 2011 Maintenance and Lubrication Points Maintenance Schedule 122...

Page 125: ...Figure 27 Yanmar 2 6L Diesel Engine With Aluminum Case After January 2011 Transmission Maintenance and Lubrication Points Maintenance Schedule 123...

Page 126: ...See Parts Manual 30 31 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...

Page 127: ...GDP030 35VX GP GLP GDP040SVX C810 CIL 38 4 liter 10 1 gal 85 Octane Gasoline Minimum 18 FUEL TANK GAS GC GLC030 35VX GC GLC040SVX C809 CIL 38 8 liter 10 2 gal 85 Octane Gasoline Minimum 18 FUEL TANK...

Page 128: ...n 24 TRANSMISSION X Check for Leaks Chevron Chevrron 1000THF Deere and Company HYGard Fluid J20C Mobile Oil Company Mobilfluid 424 Shell Oil Company Donax TD 24 TRANSMISSION X Check Operation 3 HYDRAU...

Page 129: ...e NOTE 2 NOTE 3 and NOTE 15 ISO VG 46 Hydraulic Oil Shell Tellus Oil 46 Shell Tellus Premium 46 Texaco Rando HD 46 Exxon Nuto H 46 Mobil DTE 25 15 C 5 F and Above 6 HYDRAULIC OIL FILTER C 1 Filter See...

Page 130: ...NE OIL Mazda FE Gas LPG Engine X CIL C 3 9 liter 4 1 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 Above SAE 10W 30 API SM ILSAC GF4 SAE J2362 21 ENG...

Page 131: ...F and Over SAE 40 10 to 30 C 50 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 2...

Page 132: ...anual 16 DRIVE BELT Mazda Engine X Check for Wear and Damage Adjust as Needed See NOTE 5 16 DRIVE BELT Yanmar 2 6L Engine X Check for Wear and Damage Adjust as Needed See NOTE 5 LPG REGULATOR MAZDA X...

Page 133: ...ie sel X See NOTE 5 2400 25 RPM 17 PCV VALVE X C Replace as Necessary See NOTE 13 See Parts Manual OXYGEN SENSOR X Check Indicator Light 4 VALVE ADJUSTMENT Mazda Engines Only X Adjust as Required Inta...

Page 134: ...da FE LPG X Adjust as Required 6 1 BTDC Orange Mark 19 LPG FUEL FILTER Mazda 2007 Emission Compliant Engines Only C 1 Filter See Parts Manual LPG FUEL REGULATOR FILTER Mazda Except 2007 Emission Compl...

Page 135: ...es C 1 Filter See Parts Manual 19 FUEL FILTER Gas Mazda 2007 Emission Compliant Engines Only C 1 Filter See Parts Manual 19 FUEL WATER SEPARATOR Yanmar 2 6L Diesel Engine C 1 Filter See Parts Manual I...

Page 136: ...zda FE Engine 4 Injectors See NOTE 8 Check and Clean if Required 22 FUEL INJECTORS DIESEL Yanmar 2 6L Engine X 4 Injectors Check and Replace if Required 5 SPARK PLUGS Mazda Engines C Check Plug Wires...

Page 137: ...l Company Mobilfluid 424 Shell Oil Company Donax TD 7 TRANSMISSION OIL Aluminum Case X C 13 liter 14 qt Chevron Chevrron 1000THF Deere and Company HYGard Fluid J20C Mobile Oil Company Mobilfluid 424 S...

Page 138: ...AE 30W MAST Sideshift Carriage X L Lubricate as Required 2 Fittings Multipurpose Grease See NOTE 9 29 INTEGRAL SIDESHIFT CARRIAGE Fork Positioner L Lubricate as Required 2 fittings See NOTE 5 Multipur...

Page 139: ...it TILT CYLINDER ENDS L 4 Fittings Multipurpose Grease See NOTE 9 BRAKE MASTER CYL INDER 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...

Page 140: ...L Check grease Multipurpose Grease See NOTE 9 2 PEDALS LEVERS SEAT RAILS CABLES HINGES LINKAGES HOOD LATCH L Lubricate as Necessary Yale Part No 504236201 1 SERVICE BRAKES X Check Lining Thickness 1 0...

Page 141: ...chemical or abrasive compounds poor ground conditions intensive usage at high perform ance levels or other abnormal conditions will require more frequent servicing At your request your Yale dealer wil...

Page 142: ...illed 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 l...

Page 143: ...riage 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 lubri...

Page 144: ...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 28 Check the Tires Maintenance 142...

Page 145: ...wered and the engine is STOPPED Do not try to correct the alignment of the fork tips by bending the forks or adding shims If either fork is damaged replace the forks as a set Never repair damaged fork...

Page 146: ...ks and worn or turned pins Lift chains must be replaced as a set See Figure 29 8 Inspect the chain anchors and pins for cracks and dam age 9 Make sure the lift chains are adjusted so that they have eq...

Page 147: ...aint system See Figure 30 Each item must be checked to make sure it is fastened cor rectly functions correctly and is in good condition NOTE NON SWIVEL SEAT SHOWN 1 OPERATOR WEIGHT ADJUSTMENT 2 FORWAR...

Page 148: ...ment 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...

Page 149: ...r to check for leaks in the fuel system If there is a leak in the fuel system extra care must be used dur ing the repair Do not operate the lift truck until a leak is repaired Make a visual check for...

Page 150: ...port it to maintenance for repair Coolant Hoses Check the condition of the coolant hoses for serviceability by inspecting for cracks or other obvious damage Check to insure that the coolant hoses are...

Page 151: ...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...

Page 152: ...dicator 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 equip ped with a keyless option...

Page 153: ...Y 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 Figure 33 Mazda 2 0L and 2 2L Engine Maint...

Page 154: ...OLANT 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 34 Mazda 2 0L and 2 2L Engine...

Page 155: ...COOLANT 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 35 Yanmar 2 6L Diesel Engine Maintenance P...

Page 156: ...erate the lift truck until the air filter element has been replaced Forks NOTE Forks must be removed or installed by trained per sonnel only The identification of a fork describes how the fork is con...

Page 157: ...1 OUTER FORK CARRIER 2 FORKS 3 INNER FORK CARRIER 4 SIDESHIFT CARRIAGE 5 FORK POSITIONER 6 CAPSCREWS 7 FORK REMOVAL NOTCH Figure 36 Fork Positioner Maintenance 155...

Page 158: ...a hook fork to the fork removal notch on the carriage See Figure 37 and Fig ure 39 Lower the fork onto blocks so that the bottom hook of the fork moves through the fork removal notch See Fig ure 39 Lo...

Page 159: ...p 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...

Page 160: ...to 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 al...

Page 161: ...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 DIMENS...

Page 162: ...g a check apply the parking brake and put the transmission 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 positi...

Page 163: ...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...

Page 164: ...el 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 the inching brake pedal reaches the f...

Page 165: ...is released before making adjustment To adjust the parking brake do the following 1 Turn the adjustment knob as shown in Figure 41 Do not tighten the adjustment so that the brake is applied when the l...

Page 166: ...e engine and check the oil level See Figure 33 Figure 34 or Figure 35 Do not restart the engine until the low pres sure condition has been corrected Cooling System WARNING DO NOT remove the radiator c...

Page 167: ...ule WARNING Compressed air can move particles so that they cause injury to the user or to other personnel Make sure that the path of the compressed air is away from all person nel Wear protective gogg...

Page 168: ...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...

Page 169: ...r 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 F...

Page 170: ...parks or permit flammable material near the LPG system LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m 26 ft from any open flame motor vehicles electrical equipment...

Page 171: ...ct the quick disconnect fitting on the LPG tank See Figure 43 5 Push in the bracket release pin grab the bracket handle and swing the tank and bracket out to the side of the lift truck If your truck i...

Page 172: ...Figure 43 LPG Tank and Bracket Maintenance 170...

Page 173: ...od 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 l...

Page 174: ...gnment 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...

Page 175: ...rubber tires that look like pneumatic tires These variations in tires also cause a variation in the types of wheels and the disassem bly and assembly procedures How to Change a Solid Rubber Tire GC Se...

Page 176: ...ive wheels are installed on the lift truck tighten the wheel nuts to 155 to 175 N m 114 to 129 lbf ft 3 The steering wheels are fastened to the spindle of the steering axle with a large castle nut Mak...

Page 177: ...STEERING TIRE AND WHEEL B DRIVE TIRES AND WHEELS C WIDE TREAD 1 OUTSIDE OF SOLID RUBBER TIRE 2 WHEEL 3 OVERHANG Figure 44 Tires and Wheels GC GLC030 035VX and GC GLC040SVX Lift Trucks Maintenance 175...

Page 178: ...ls are used deflate both tires Air pressure in the tires can cause the tire and rim parts to explode causing serious injury or death Always wear safety glasses Never loosen the nuts that hold the inne...

Page 179: ...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 45 Types of Pneumatic Wheels Maintenance 177...

Page 180: ...the tire and rim parts to explode caus ing serious 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...

Page 181: ...jury 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 Loosen the tire bead from the side flange 2 Put the tire tool in...

Page 182: ...r 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 clear ance at the en...

Page 183: ...dures Clean and inspect all parts of the wheel before installing 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 asse...

Page 184: ...Put the lock ring in the correct position on the rim Add air pres sure to the tire as described in Add Air to Pneumatic Tires With Tube Tire Installation Two Piece Wheel CAUTION Do not use pneumatic s...

Page 185: ...ation to stand away from the safety cage when air pressure is added to the tire WARNING Do not sit or stand by the safety cage Do not use a hammer to try and correct the position of the side flange or...

Page 186: ...te 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 explode causing serious injury...

Page 187: ...with enough force to cause an injury NOTE There are several types of wheels used on these lift trucks When disassembling wheels see Figure 45 1 If wheel rim is a three or four piece rim turn the valve...

Page 188: ...g proce dures Clean and inspect all parts of the wheel before installing 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 wh...

Page 189: ...fset to ensure the correct positioning of the valve in the valve slot The valve hole that is not used should be sealed with a small plastic plug 2 Apply lubricant to the nee dle valve and the valve ho...

Page 190: ...he valve a 1 4 turn to lock the collar under the edges of the rim valve slot 6 Raise the tire and position the base and threaded stem of the press through the hole in the center of the wheel Insert in...

Page 191: ...aled Remove the press from wheel and tire assembly Add Air to Pneumatic Tubeless Tire WARNING Add air pressure to the tires only in a safety cage See Figure 47 Inspect the safety cage for damage befor...

Page 192: ...and tires repaired by trained personnel only Always wear safety glasses 1 Put the lift truck on blocks as described in How to Put a Lift Truck on Blocks at the beginning of this section 2 Remove the w...

Page 193: ...cage in position on the tire Use the press to push the tire away from the side flange 2 Put the tire tool into the slot between the lock ring and the wheel rim Remove the lock ring and side flange 3...

Page 194: ...NOT mix type 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 pa...

Page 195: ...tire on the wheel rim 3 Remove the cage and put the flange seat if used the side ring and the lock ring in position on the wheel rim Install the cage on the tire Use the press to push the tire onto t...

Page 196: ...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...

Page 197: ...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...

Page 198: ...engine 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...

Page 199: ...ure expected during storage Make sure all caps and dipsticks are installed cor rectly 2 Fully lower the mast If lift truck is equipped with forks tilt mast FORWARD until the tips of the forks touch th...

Page 200: ...gns of deterioration Take corrective action immediately Check the fluid level in engine radiator hydraulic tank and brake master cylinder NOTE Do not shut down an engine before it reaches oper ating t...

Page 201: ...location 4 Check each cell in the battery at least once every 30 days and boost charge when specific gravity falls below 1 240 Hg 5 Protect batteries from ambient contamination If a greasy film forms...

Page 202: ...barriers can prevent clearance Removal of the mast can be necessary If a trailer is the method of transportation use blocks in front and back of the trailer tires to prevent movement of the trailer wh...

Page 203: ...N 4 Turn the key switch to OFF to stop the engine if truck is equipped with a key switch or press the Power ON OFF button if truck is equipped with a keyless option Check that all switches and access...

Page 204: ...r stored the lift truck must be pre pared for use for proper operation All problems must be corrected before use of the lift truck see the Service Man ual for procedures Preparation After Transport 1...

Page 205: ...Spacer 2 20 8 19 8 17 3 14 2 14 4 13 10 12 9 12 12 11 11 11 8 11 10 10 3 10 1 10 9 09 8 09 12 08 7 08 1 08 10 07 7 07 3 07 1 07 10 06 6 06 4 06 7 05 4 05...

Page 206: ...OPERATING MANUAL VERACITOR GC GLC030 035VX GC GLC040SVX C809 GP GLP GDP030 035VX GP GLP GDP040SVX C810 PART NO 524239830 2 20 DO NOT REMOVE THIS MANUAL FROM THIS UNIT...

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