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Yale Veracitor GCC040VX, Operating Manual

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Engine Oil

There is an indicator light for the engine oil pressure on the
Display Switch Cluster. During normal operation the 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

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Summary of Contents for Veracitor GCC040VX

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: ...ER 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 Materi...

Page 3: ...re 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...

Page 4: ...nizations 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...

Page 5: ...h 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 Key...

Page 6: ...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 Car...

Page 7: ...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 Wh...

Page 8: ...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 P...

Page 9: ...or 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 forwa...

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: ...D 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 Componen...

Page 13: ...VERHEAD 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 Ma...

Page 14: ...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...

Page 15: ...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...

Page 16: ...meplate 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 inst...

Page 17: ...ll 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 sh...

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: ...RNING 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 B...

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: ...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...

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: ...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...

Page 29: ...urposes 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 th...

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...

Page 31: ...swords 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 displ...

Page 32: ...eld 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...

Page 33: ...gine 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 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: ...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 36: ...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 37: ...perate 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 o...

Page 38: ...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 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 powertrai...

Page 40: ...minate 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...

Page 41: ...hen 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...

Page 42: ...l 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...

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: ...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...

Page 46: ...l 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...

Page 47: ...wer 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 yo...

Page 48: ...ile 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...

Page 49: ...al 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 firs...

Page 50: ...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...

Page 51: ...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 52: ...anual 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 e...

Page 53: ...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...

Page 54: ...rd 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 funct...

Page 55: ...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 four levers and clamp attachment the last 4th lever controls clamp functions Truc...

Page 56: ...witch 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 le...

Page 57: ...ghts 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 sta...

Page 58: ...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 Direc...

Page 59: ...onnect 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 th...

Page 60: ...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 61: ...ductive 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 se...

Page 62: ...k 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...

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 li...

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 Th...

Page 65: ...tdown 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 tr...

Page 66: ...ore 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...

Page 67: ...d 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 start...

Page 68: ...igned 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 prese...

Page 69: ...r 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 f...

Page 70: ...ed 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...

Page 71: ...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 Depr...

Page 72: ...ips 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 o...

Page 73: ...r 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...

Page 74: ...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...

Page 75: ...ck 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 sho...

Page 76: ...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...

Page 77: ...ducation 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 desig...

Page 78: ...xit 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...

Page 79: ...ment 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...

Page 80: ...t 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 8...

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

Page 82: ...n 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 o...

Page 83: ...nching 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 ST...

Page 84: ...ravel 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 witho...

Page 85: ...action 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 a...

Page 86: ...tects 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 transmissio...

Page 87: ...anged 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 sele...

Page 88: ...e 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 con...

Page 89: ...ING 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 l...

Page 90: ...e 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 beco...

Page 91: ...ction 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...

Page 92: ...ck 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 t...

Page 93: ...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 Whe...

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 e...

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...

Page 96: ...wly 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 carefu...

Page 97: ...wer 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 t...

Page 98: ...ity 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 i...

Page 99: ...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 cou...

Page 100: ...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...

Page 101: ...y 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 a...

Page 102: ...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 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: ...hway 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...

Page 105: ...ating 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 install...

Page 106: ...chment 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 t...

Page 107: ...til 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 lef...

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...

Page 109: ...m 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 Neve...

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...

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 d...

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: ...tion 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 RE...

Page 118: ...ust 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 H...

Page 119: ...EL 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 Chec...

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 HYDR...

Page 121: ...ngine 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...

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...

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...

Page 124: ...L 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 SP...

Page 125: ...e 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 TIMI...

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...

Page 127: ...t 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 Par...

Page 128: ...UGS 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 I...

Page 129: ...0 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 C...

Page 130: ...EADER 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...

Page 131: ...urpose 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...

Page 132: ...n 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 Multipurpo...

Page 133: ...L 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 T...

Page 134: ...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 J...

Page 135: ...te 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 de...

Page 136: ...ol 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 Hydr...

Page 137: ...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 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 a...

Page 140: ...hains 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 replace...

Page 141: ...t 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 i...

Page 142: ...WARD 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 Maintenan...

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 t...

Page 144: ...re 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 WARN...

Page 145: ...ssed 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 Cle...

Page 146: ...uck 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...

Page 147: ...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 148: ...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...

Page 149: ...ANT 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 Maintenan...

Page 150: ...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...

Page 151: ...UXILIARY 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...

Page 152: ...RATOR 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 Point...

Page 153: ...t 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 u...

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: ...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 Low...

Page 156: ...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 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...

Page 158: ...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 159: ...g 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...

Page 160: ...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 161: ...ster 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 e...

Page 162: ...rking 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 applie...

Page 163: ...m 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 Engin...

Page 164: ...e 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...

Page 165: ...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 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 Fil...

Page 167: ...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 re...

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...

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

Page 170: ...s 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 tan...

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...

Page 172: ...es 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 proce...

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 M...

Page 174: ...ND 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 Truck...

Page 175: ...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 tr...

Page 176: ...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 F...

Page 177: ...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 Pn...

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...

Page 179: ...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...

Page 180: ...pect 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 a...

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...

Page 182: ...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 1...

Page 183: ...s 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...

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 ca...

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 T...

Page 186: ...el 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 us...

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 appr...

Page 188: ...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 val...

Page 189: ...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...

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 Inst...

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...

Page 192: ...im 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...

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 lu...

Page 194: ...er 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...

Page 195: ...s 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 p...

Page 196: ...e 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 oper...

Page 197: ...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 c...

Page 198: ...TE 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 engi...

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 preservati...

Page 200: ...mp 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 liftin...

Page 201: ...locks 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 an...

Page 202: ...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...

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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