Professional Documents
Culture Documents
6HUYLFH5HSDLU
GC/GLC/GDC135VX, GC/GLC/GDC155V
D879
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Discon-
nect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications
of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Capacities and Specifications Table of Contents
TABLE OF CONTENTS
Counterweight Weights
Model Weight
GLC/GDC60VX, GLC/GDC70VX
2779 kg (6127 lb)
(GC/GLC/GDC135VX, GC/GLC/GDC155VX)
GLP/GDP60VX (GP/GLP/GDP135VX) 2622 kg (5780 lb)
GLP/GDP70VX (GP/GLP/GDP155VX) 3135 kg (6911 lb)
Tire Sizes
Truck Drive Tires Steer Tires
GLC/GDC60VX, GLC/GDC70VX 28 × 12 × 22 22 × 8 × 16
(GC/GLC/GDC135VX
GC/GLC/GDC155VX)
GLP/GDP60VX 8.25 × 15 8.25 × 15
GLP/GDP70VX
GP/GLP/GDP135VX
GP/GLP/GDP155VX
1
Capacities 8000 YRM 1320
Capacities
Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879) Lift Truck Models
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
2
8000 YRM 1320 Capacities
3
Capacities 8000 YRM 1320
4
8000 YRM 1320 Capacities
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
5
Capacities 8000 YRM 1320
6
8000 YRM 1320 Capacities
7
Electrical System 8000 YRM 1320
Electrical System
Table 3. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879) Lift Truck Models
GM 4.3L
Alternator Output (14 Volts) G and LPG GS and LPS
Idle 50 amps @ 750 rpm 38 amps @ 750 rpm
Governed Speed 65 amps @ 2400 rpm 45 amps @ 2400 rpm
Cummins 4.5L (Diesel)
Alternator Output (13.5 Volts) D DS
Low Idle 54 amps @ 800 rpm 28 amps @ 800 rpm
Governed Speed 95 amps @ 2225 rpm 45 amps @ 2225 rpm
Cummins QSB 3.3L (Diesel)
Alternator Output (13.5 Volts) D DS
Low Idle 30 amps @ 800 rpm N/A
Governed Speed 95 amps @ 2230 rpm N/A
8
8000 YRM 1320 Electrical System
GM 4.3L
Alternator Output (14 Volts) G and LPG GS and LPS
Idle 50 amps @ 750 rpm 38 amps @ 750 rpm
Governed Speed 65 amps @ 2400 rpm 45 amps @ 2400 rpm
Cummins 4.5L (Diesel)
Alternator Output (13.5 Volts) D DS
Low Idle 54 amps @ 800 rpm 32 amps @ 800 rpm
High Idle 95 amps @ 2225 rpm 45 amps @ 2225 rpm
Cummins QSB 3.3L (Diesel)
Alternator Output (13.5 Volts) D DS
Low Idle 30 amps @ 800 rpm 20 amps @ 800 rpm
Governed Speed 95 amps @ 2230 rpm 45 amps @ 2230 rpm
9
Transmission Oil Pressures 8000 YRM 1320
*Relief Pressure
10
8000 YRM 1320 Transmission Oil Pressures
*Relief Pressure
11
Transmission Oil Pressures 8000 YRM 1320
*Relief Pressure
12
8000 YRM 1320 Transmission Oil Pressures
*Relief Pressure
13
Steering System 8000 YRM 1320
Steering System
Table 9. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879) Lift Truck Models
Item Quantity
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Steering Relief Pressure at 800 rpms 12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Cylinder Stroke (Each Side) 210.8 mm (8.3 in.)
Inside Steering Tire Angle 80.3°
Number of Turns to Lock 4.07
Turning Radius Outside Inside
(±50 mm NO LOAD)
All Trucks 2585 107
Item Quantity
Oil Temperature 55 to 65°C (131 to 149°F)
Steering Relief Pressure at 800 rpms 12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Cylinder Stroke (Each Side) 224.0 mm (8.3 in.)
Inside Steering Tire Angle 74.5°
Number of Turns to Lock 3.50
Turning Radius (±76 mm NO LOAD) Outside Inside
GLP/GDP60VX (GP/GLP/GDP135VX) 3319 293
GLP/GDP70VX (GP/GLP/GDP155VX) 3376 293
14
8000 YRM 1320 Stall Speeds (in RPM ±100 rpm)
15
Stall Speeds (in RPM ±100 rpm) 8000 YRM 1320
16
8000 YRM 1320 Mast Speeds
Mast Speeds
NOTE: Lift speed is measured in meters/sec (inch/sec) Lowering speed is measured in meters/sec (inch/sec)
at governed engine RPM with full open valve and 65°C with full open valve and 65°C (149°F) oil temperature.
(149°F) oil temperature.
Plus or minus 10% acceptable lifting or lowering.
Cummins 4.5L and 2-Stage LFL 0.53 (21.0) 0.58 (23.0) 0.50 (20.0) 0.49 (19.0)
QSB 3.3L 3-Stage FFL 0.41 (16.0) 0.53 (21.0) 0.48 (19.0) 0.47 (19.0)
Cummins 4.5L and 2-Stage LFL 0.53 (21.0) 0.58 (23.0) 0.46 (18.0) 0.45 (18.0)
QSB 3.3L 3-Stage FFL 0.41 (16.0) 0.55 (22.0) 0.44 (17.0) 0.43 (17.0)
17
Mast Speeds 8000 YRM 1320
18
8000 YRM 1320 Tilt Angles
Tilt Angles
Lift truck should be on level ground and in unloaded
condition.
19
Front End Equipment - Mast Creep 8000 YRM 1320
Measure with rated load at 2.5 m (8.0 ft) high and with
the lift, tilt, and auxiliary control levers in neutral posi-
tion.
20
8000 YRM 1320 Engine Specifications
Engine Specifications
Item GM 4.3L
No. of Cylinders 6
Firing Order 1-6-5-4-3-2
Bore 101.6 mm (3.9 in.)
Stroke 88.4 mm
(3.48 in.)
Displacement 4.3 liter (262.4 in. 3 )
Horsepower (Gasoline) 100 @ 2400 rpm
Horsepower (LPG) 93 @ 2400 rpm
Engine Timing Timing is controlled by the Electronic Con-
trol Module (ECM)
Compression Ratio
Gas 9.4:1
LPG 9.4:1
Oil Pressure With GFI Installed 207-380 ± 30 kPa (30-55 ± 4.4 psi)
@ 2000 rpm 80°C (176°F)
Oil Pressure With PSI Installed 124 kPa (18 psi)
@ 2000 80°C (176°F)
Valve Clearance
Intake Not Adjustable
Exhaust Not Adjustable
Idle Speed - Gas 750 ±25 rpm
Idle Speed - LPG 750 ±25 rpm
Governed Speed High Idle (No Load) 2400 ±25 rpm
Thermostat Range
STARTS TO OPEN 82 ±1.5°C (180 ±35°F)
FULL OPEN 128 ±1.5°C (260 ±35°F)
Cooling System Pressure 103 kPa (15 psi)
21
Engine Specifications 8000 YRM 1320
No. of Cylinders 4
Firing Order 1-3-4-2
Bore and Stroke 102 mm × 138 mm
(4.01 in. × 5.43 in.)
Displacement 4506 cc
Compression Ratio 17.6:1
Horsepower/rpm 78 @ 2050 rpm
Oil Pressure @ 80°C (176°F) at low idle 69 kPa (10 psi) @ 800 rpm
at high idle 207 kPa (30 psi) @ 2250 rpm
Valve Clearance
Intake 0.254 mm (0.010 in.)
(COLD)
Exhaust 0.508 mm (0.020 in.)
(COLD)
Idle Speed (Cold Engine) 770 ±50 rpm
Idle Speed (Hot Engine) 800 ±50 rpm
Governed Speed High Idle (No Load) 2250 ±50 rpm
Thermostat Range
STARTS TO OPEN 82°C (180°F)
FULL OPEN 95°C (203°F)
Cooling System Pressure 103 kPa (15 psi)
22
8000 YRM 1320 Torque Specifications
Torque Specifications
FRAME (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878)
Overhead Guard Mount Capscrews
66 N•m (49 lbf ft) Mast Mounting Capscrews
Mast to Drive Axle 755 to 830 N•m (557 to 612 lbf ft)
Cowl-to-Overhead Guard Legs
Tilt/Cylinder Adjust 90 to 99 N•m (66 to 73 lbf ft)
66 N•m (49 lbf ft)
Pivot Pin Retainer 68 N•m (50 lbf ft)
Steering Column Nut
Chain Anchor Nut
40 to 54 N•m (30 to 40 lbf ft)
370 N•m (273 lbf ft)
Counterweight Capscrews
Hang On Sideshift Assembly Lower
1020 N•m (750 lbf ft)
Hook Capscrews
155 to 170 N•m (115 to 125 lbf ft)
MAST, LIFT TRUCK MODELS
GLC/GDC60VX, GLC/GDC70VX Fork Positioner Installation Capscrews
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) 155 to 170 N•m (115 to 125 lbf ft)
(C879, D879) Load Backrest to Carriage Assembly Nuts
Mast Mounting Capscrews (Without Fork Positioner)
Mast to Drive Axle 320 N•m (236 lbf ft) 70 to 80 N•m (56 to 60 lbf ft)
Tilt/Cylinder Adjust 90 N•m (66 lbf ft)
Pivot Pin Retainer 68 N•m (50 lbf ft) HANG ON SIDESHIFT CARRIAGE
WITH FORK POSITIONER, LIFT TRUCK
Chain Anchor Nut MODELS GLP/GDP60VX, GLP/GDP70VX
370 N•m (273 lbf ft)
(GP/GLP/GDP135VX, GP/GLP/GDP155VX)
Retainer Plate (Pin Type Forks) (D878) MANUFACTURED AFTER AUGUST,
70 to 80 N•m (56 to 60 lbf ft) 2012
Hang On Sideshift Assembly Lower Fork Carrier Block Capscrews
Hook Capscrews 80 N•m (60 lbf ft)
155 to 170 N•m (115 to 125 lbf ft)
Retainer Capscrew
Fork Positioner Installation Capscrews 100 N•m (75 lbf ft)
155 to 170 N•m (115 to 125 lbf ft)
Cylinder Retainer
Load Backrest to Carriage Assembly Nuts 65 N•m (120 lbf ft)
(Without Fork Positioner)
70 to 80 N•m (56 to 60 lbf ft) Hang On Sideshift Assembly Lower
Hook Capscrews
MAST, LIFT TRUCK MODELS 320 N•m (236 lbf ft)
GLP/GDP60VX, GLP/GDP70VX
23
Torque Specifications 8000 YRM 1320
Load Backrest to Carriage Assembly Capscrews Drive Shaft to Output Yoke Capscrews
225 N•m (166 lbf ft) 55 to 63 N•m (41 to 47 lbf ft)
Hub Nut (Slotted Nut), Lift Truck Models GLP/ Alternator Pulley
GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, 61 N•m (45 lbf ft)
GP/GLP/GDP155VX) (C878, D878)
Balance Shaft Gear Capscrew
203 N•m (150 lbf ft) initial
20 N•m (177 lbf in) Plus 35 Degrees
34 N•m (25 lbf in) final
Balance Shaft Retainer Capscrews
Steering Axle Mounting Bolts and Nuts, Lift Truck
12 N•m (106 lbf in)
Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879) Camshaft Retainer Screws
250 to 275 N•m (184 to 203 lbf ft) 12 N•m (106 lbf in)
Steering Axle Mounting Bolts and Nuts, Lift Truck Camshaft Sprocket Capscrews
Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ 28 N•m (21 lbf ft)
GDP135VX, GP/GLP/GDP155VX) (C878, D878)
270 N•m (199 lbf ft) Camshaft Sprocket Nut
25 N•m (18 lbf ft)
Spindle Bearing Cap Capscrew, Lift Truck
Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ Chain Control Block for Hydraulic Pump Drive
GDC135VX, GC/GLC/GDC155VX) (C879, D879) 19 N•m (168 lbf in) with Adhesive Sealant
52 N•m (38 lbf ft)
Connecting Rod Cap
Spindle Bearing Cap Capscrew, Lift Truck 27 N•m (240 lbf in)
Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ After this step, tighten nuts an additional 70 degrees.
GDP135VX, GP/GLP/GDP155VX) (C878, D878)
47 N•m (35 lbf ft) Coolant Pump to Engine Block
41 N•m (30 lbf ft)
Steering Cylinder Mounting Bolts
225 N•m (166 lbf ft) Cooling Fan to Pulley
24 N•m (212 lbf in)
24
8000 YRM 1320 Torque Specifications
Distributor Mount Capscrew Rear Oil Seal Retainer Screws and Nut
25 N•m (18 lbf ft) 15 N•m (133 lbf in)
25
700 YRM 1123 Cooling System Checks
General
This section contains the repair and replacement in- assembly (pusher type), fan shroud, coolant hoses,
structions for the radiator, coolant level sensor, fan coolant recovery bottle, and optional debris screen.
If radiator has leaks, either replace the radiator or have For repair procedures for the Mazda FE and F2 water
it repaired by trained personnel. pump, refer to the section Mazda Engine, FE and F2
600 YRM 1122.
RADIATOR HOSES
For replacement procedures for the Yanmar 2.6L and
3.3L water pump, refer to the section Yanmar Diesel
WARNING Engines, 2.6L, 3.0L and 3.3L 600 YRM 1205.
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri-
ous injury. Wait 30 minutes for the radiator to cool.
1
Flushing the Cooling System 700 YRM 1123
For replacement procedures for the GM 4.3L water For replacement procedures for the Kubota water
pump, refer to the section GM Engines, 4.3 Liter V-6 pump, refer to the section
600 YRM 1251. • Kubota Diesel 3.8L Engines 600 YRM 1557
• Kubota Diesel 3.6L Engine 600 YRM 1579
For replacement procedures for the GM 5.7L water • Kubota Diesel 3.8L Engines, with Diesel Particu-
pump, refer to the section GM Engines, 5.7 Liter V-8 late Filter (DPF) 600 YRM 1590
LPG 600 YRM 1432.
For replacement procedures for the Cummins 4.5L and
QSB 3.3L water pump, contact your local Yale dealer or
see Yale Axcess Online.
2
700 YRM 1123 Radiator Replacement
Radiator Replacement
RADIATOR, REMOVE FOR LIFT See Frame 100 YRM 1120 for lift truck models
TRUCKS MODELS GC/GLC030VX, • GC/GLC030VX, GC/GLC035VX,
GC/GLC035VX, GC/GLC040SVX GC/GLC040SVX (C809)
• GLP/GDP16VX, GLP/GDP18VX,
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX,
GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
GP/GLP/GDP035VX, GP/GLP/GDP040SVX) (C810)
(C810); GLC20-35VX (GC/GLC040-070VX, • GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910); GLC050LX GC/GLC055SVX) (A910)
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX)
(A967); GLP/GDP20-35VX (B875)
(GP/GLP/GDP040-070VX) (B875);
GLP/GDP20-25LX (GLP/GDP050LX) See Frame 100 YRM 1243 for lift truck models
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080,
(A974); GLC40, 45, 55VX, GLC55SVX,
100, 120VX; GC/GLC080, 100VXBCS;
(GC/GLC080, 100, 120VX, GC/GLC080, GC/GLC120SVX; GC/GLC120VXPRS) (E818,
100VXBCS, GC/GLC120SVX, F818)
GC/GLC120VXPRS) (E818, F818) AND • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (F813, G813,
GLP/GDP45VX6, GLP/GDP50-55VX
H813, J813)
(GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813, G813, H813, J813) See Frame 100 YRM 1423 for lift truck models
• GLC050LX (A967)
• GLP/GDP20-25LX (GLP/GDP050LX) (A974)
WARNING
The radiator or other parts of the cooling system
may be hot or under pressure and can cause seri- WARNING
ous injury. Wait 30 minutes for the radiator to cool. Always disconnect the cable at the negative termi-
Do a touch test by touching the radiator with your nal first. Install a tag on the battery terminals so
hand. If the radiator is still hot to the touch, wait an- that no one connects the cables on the terminals.
other 30 minutes before attempting to check or fix
any part of the cooling system. 3. Disconnect the negative battery cable.
3
Radiator Replacement 700 YRM 1123
5. Let coolant cool to ambient temperature. Place a See Figure 6 for lift truck models below equipped
drain pan with a capacity greater than the capacity with a Cummins QSB 3.3L diesel engine
of the cooling system under radiator. Remove radi- • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
ator cap. GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/
GDP080, 090, 100, 110, 120VX) (G813
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
CAUTION GDC135VX, GC/GLC/GDC155VX) (D879)
Disposal of lubricants and fluids must meet local
environmental regulations. See Figure 7 for lift truck models below equipped
with Yanmar 2.6L diesel engine
6. Open the drain plug or loosen hose clamp and dis- • GDP20-25LX (GDP050LX) (A974)
connect the lower hose.
See Figure 8 for lift truck models below equipped
7. Lift trucks equipped with a Cummins QSB 3.3L with a Kubota 3.8L diesel engine
diesel engine: Loosen clamps and disconnect the • GLP/GDP40VX5/VX6; GLP/GDP45SVX5,
charge air cooler hoses from charge air cooler. GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/
See Figure 6. GDP080, 090, 100, 110, 120VX) (H813, J813)
8. Lift trucks equipped with a Kubota 3.8L diesel en- 11. Remove battery and battery tray.
gine: Loosen clamps and disconnect transmission
cooler hoses from transmission cooler. See Fig- 12. If equipped, disconnect electrical connector to the
ure 8. coolant level sensor.
9. Once coolant is drained from engine, loosen hose NOTE: For Mazda LPG engine, the LPG converter
clamps and disconnect coolant hoses from radiator. bracket needs to be moved for clearance of radiator.
Cap radiator hoses.
13. Remove screws and washers from the shroud and
10. Loosen hose clamp and disconnect hose from move shroud out of the way.
reservoir and remove reservoir.
14. Place radiator guard shield between radiator and
See Figure 1 for lift truck models fan so damage to radiator does not occur during
• GC/GLC030VX, GC/GLC035VX, fan removal.
GC/GLC040SVX (C809
• GLP/GDP16VX, GLP/GDP18VX, 15. Remove fan, fan spacer, and pulley.
GLP/GDP20SVX (GP/GLP/GDP030VX,
16. Remove radiator guard shield.
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
(C810) 17. Remove capscrews and upper radiator bracket.
• GLC20-35VX (GC/GLC040-070VX,
GC/GLC055SVX) (A910) See Figure 1 for lift truck models
• GLP/GDP20-35VX (GP/GLP/GDP040-070VX) • GC/GLC030VX, GC/GLC035VX,
(B875) GC/GLC040SVX (C809
• GLC050LX (A967) • GLP/GDP16VX, GLP/GDP18VX,
• GLP20-25LX (GLP050LX) (A974) GLP/GDP20SVX (GP/GLP/GDP030VX,
GP/GLP/GDP035VX, GP/GLP/GDP040SVX)
See Figure 2 or Figure 3 for lift truck models (C810)
• GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, • GLC20-35VX (GC/GLC040-070VX,
100, 120VX; GC/GLC080, 100VXBCS; GC/GLC055SVX) (A910)
4
700 YRM 1123 Radiator Replacement
5
Radiator Replacement 700 YRM 1123
Figure 1. Cooling System for Lift Truck Models GC/GLC030VX, GC/GLC035VX, GC/GLC040SVX
(C809); GLP/GDP16VX, GLP/GDP18VX, GLP/GDP20SVX (GP/GLP/GDP030VX, GP/GLP/GDP035VX,
GP/GLP/GDP040SVX) (C810); GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) GLC050LX (A967);
GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) and GLP20-25LX (GLP050LX) (A974)
6
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