YALE (C879) GLC155VX LIFT TRUCK Service Repair Manual

Service Repair Manual

GC/GLC/GDC135VX, GC/GLC/GDC155VX C879

PART NO. 524288212

8000 YRM 1320

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.

Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

• 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.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect 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.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• 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.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• 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 Lift Truck Lifting Capacity.....................................................................................................................................

Counterweight Weights .......................................................................................................................................

Tire Sizes.............................................................................................................................................................

Capacities............................................................................................................................................................

Electrical System .................................................................................................................................................

Transmission Oil Pressures .................................................................................................................................

Hydraulic System Relief Pressures .....................................................................................................................

Steering System ..................................................................................................................................................

Stall Speeds (in RPM ±100 rpm).........................................................................................................................

GM 4.3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) ..............................................................................................................................................................

GM 4.3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) ..............................................................................................................................................................

GM 4.3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) ..............................................................................................................................................................

GM 4.3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) ..............................................................................................................................................................

Cummins 4.5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) .............................................................................................................................................................

Cummins QSB 3.3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) .........................................................................................................................

Cummins 4.5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) .............................................................................................................................................................

Cummins QSB 3.3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) ..........................................................................................................................

Mast Speeds........................................................................................................................................................

Tilt Angles............................................................................................................................................................

Front End Equipment - Mast Creep .....................................................................................................................

Mast Creep......................................................................................................................................................

Engine Specifications ..........................................................................................................................................

Torque Specifications ..........................................................................................................................................

Frame ..............................................................................................................................................................

Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879)...............................................................................................................

Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878)...................................................................................................................................................

Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) Manufactured After August, 2012 ................................

Steering System..............................................................................................................................................

Transmission ...................................................................................................................................................

Engine - GM 4.3L ............................................................................................................................................

Engine - Cummins 4.5L and QSB 3.3L Diesel ................................................................................................

1 1 1 2 8 10 14 14 15 15 15 15 15 16 16 16 16 17 19 20 20 21 23 23 23 23 23 24 24 24 25

This section is for the following models: GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/ GDC155VX) [C879, D879]; GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/ GDP155VX) [C878, D878]

©2012 Yale Materials Handling Corp.

i

8000 YRM 1320

Tire Sizes

Lift Truck Lifting Capacity Model

Weight

GLC/GDC60VX (GC/GLC/GDC0135VX)

6123 kg (13,500 lb)

GLC/GDC70VX (GC/GLC/GDC155VX)

7030 kg (15,500 lb)

GLP/GDP60VX (GP/GLP/GDP135VX)

6123 kg (13,500 lb)

GLP/GDP70VX (GP/GLP/GDP155VX)

7030 kg (15,500 lb)

NOTE: Load center at 600 mm (24 in.).

Counterweight Weights Model

Weight

GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)

2779 kg (6127 lb)

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 (GC/GLC/GDC135VX GC/GLC/GDC155VX)

28 × 12 × 22

22 × 8 × 16

GLP/GDP60VX GLP/GDP70VX GP/GLP/GDP135VX GP/GLP/GDP155VX

8.25 × 15

8.25 × 15

1

Capacities

8000 YRM 1320

Capacities Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Lift Truck Models Item

Quantity

Specifications

Fuel Capacity Gas

65.8 liter (17.4 gal)

87 Octane

LPG

38.6 liter (10.2 gal) Empty 19.0 kg (41 lb) Full 38.2 kg (84.51 lb)

LPG-HD 5, HD 10

Diesel

65.8 liter (17.4 gal)

Diesel No. 2

Engine Oil GM 4.3L

4.7 liter (5.0 qt)

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

Cummins 4.5L Diesel

13.0 liter (13.7 qt)

0°C (32°F) and below SAE 0W-30 25 to 20°C ( 13 to 68°F) SAE 5W-30 20 to 20°C ( 4 to 68°F) SAE 10W-30 15°C (5°F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

Cummins QSB 3.3L Diesel

7.5 liter (8.0 qt)

0°C (32°F) and below SAE 0W-30 25 to 20°C ( 13 to 68°F) SAE 5W-30 20 to 20°C ( 4 to 68°F) SAE 10W-30 15°C (5°F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

2

8000 YRM 1320

Capacities

Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Lift Truck Models (Continued) Item

Quantity

Specifications

Cooling System GM 4.3L

15.1 liter (15.9 qt)

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

Cummins 4.5L Diesel

13.5 liter (14.2 qt)

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

Cummins QSB 3.3L Diesel

10.4 liter (11.0 qt)

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

3

Capacities

8000 YRM 1320

Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Lift Truck Models (Continued) Item

Quantity

Specifications

Hydraulic Tank Oil Capacity All Trucks

64 liter (68 qt) Initial Fill 60.5 liter (64 qt) Drain and Fill

CAUTION

Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer.

ISO VG-46 Hydraulic Oil 15°C (5°F) and above Transmission Oil Capacity Standard Powershift Transmission (2-Speed)

24 liter (25.4 qt)

John Deere JDM J20C

Techtronix 332 (3-Speed)

24 liter (25.2 qt)

John Deere JDM J20C

Drive Axle Housing Arm Oil Right Chamber

8.8 liter (9.3 qt)

John Deere JDM J20C

Drive Axle Housing Arm Oil Left Chamber

8.8 liter (9.3 qt)

John Deere JDM J20C

Right Wheel Hub Oil

1.6 liter (1.7 qt)

John Deere JDM J20C

Left Wheel Hub Oil

1.6 liter (1.7 qt)

John Deere JDM J20C

Wet Brake Drive Axle Oil Capacities

Brake Oil (Master Cylinder) All Lift Truck Models

0.35 liter (0.74 pt)

WARNING

DO NOT use DOT fluid; only use Dexron III oil from sealed container to prevent possible damage to the brake system.

Failure to observe the above Warning could result in death or serious injury.

Dexron III From Sealed Container Wet Brake Center Section Oil All Lift Truck Models

4

4.2 liter (4.4 qt)

SAE 80W-90

8000 YRM 1320

Capacities

Table 2. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Truck Models Item

Quantity

Specifications

Fuel Capacity Gas

74.8 liter (19.7 gal)

87 Octane

LPG

38.6 liter (10.2 gal) Empty 19.0 kg (41 lb) Full 38.2 kg (84.51 lb)

LPG-HD 5, HD 10

Diesel

74.8 liter (19.7 gal)

Diesel No. 2

Engine Oil GM 4.3L

4.7 liter (5.0 qt)

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

Cummins 4.5L Diesel

13.0 liter (13.7 qt)

0°C (32°F) and below SAE 0W-30 25 to 20°C ( 13 to 68°F) SAE 5W-30 20 to 20°C ( 4 to 68°F) SAE 10W-30 15°C (5°F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

Cummins QSB 3.3L Diesel

7.5 liter (8.0 qt)

0°C (32°F) and below SAE 0W-30 25 to 20°C ( 13 to 68°F) SAE 5W-30 20 to 20°C ( 4 to 68°F) SAE 10W-30 15°C (5°F) and above SAE 5W-40 or 15-40 API CH-4 or CI-4

5

Capacities

8000 YRM 1320

Table 2. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Truck Models (Continued) Item

Quantity

Specifications

Cooling System GM 4.3L

15.1 liter (15.9 qt)

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

Cummins 4.5L Diesel

13.5 liter (14.2 qt)

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

Cummins QSB 3.3L Diesel

10.4 liter (11.0 qt)

CAUTION

Additives may damage the cooling system. Before using additives, contact your local Yale dealer.

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

6

8000 YRM 1320

Capacities

Table 2. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Truck Models (Continued) Item

Quantity

Specifications

Hydraulic Tank Oil Capacity All Trucks

75 liter (79 qt) Initial Fill 71.7 liter (75.7 qt) Drain and Fill

CAUTION

Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer.

ISO VG-46 Hydraulic Oil 15°C (5°F) and above Transmission Oil Level Standard Powershift Transmission (2-Speed)

24 liter (25.4 qt)

John Deere JDM J20C

Techtronix 332 (3-Speed)

24 liter (25.4 qt)

John Deere JDM J20C

7.8 liter (8.25 qt)

John Deere JDM J20C

7.8 liter (8.25 qt)

John Deere JDM J20C

Right Wheel Hub Oil

N/A

N/A

Left Wheel Hub Oil

N/A

N/A

Wet Brake Drive Axle Oil Capacities Drive Axle Housing Arm Oil Right Chamber Drive Axle Housing Arm Oil Left Chamber

Brake Oil (Master Cylinder) All Lift Truck Models

0.35 liter (0.74 pt)

WARNING

DO NOT use DOT fluid; only use Dexron III oil from sealed container to prevent possible damage to the brake system.

Failure to observe the above Warning could result in death or serious injury.

Dexron III From Sealed Container Wet Brake Center Section Oil All Lift Truck Models

4.6 liter (4.9 qt)

SAE 80W-90

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 Item

GM 4.3L

Cummins 4.5L and QSB 3.3L Diesel

Battery

12-volt, negative ground

12-volt, negative ground

Spark Plugs

AC 41-993

N/A

Spark Plug Gap

1.5 mm (0.059 in.)

N/A

Gas

Not Adjustable

N/A

LPG

Not Adjustable

N/A

Diesel

N/A

Not Adjustable

Ignition Timing

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)

8

Alternator Output (13.5 Volts)

D

DS

Low Idle

30 amps @ 800 rpm

N/A

Governed Speed

95 amps @ 2230 rpm

N/A

8000 YRM 1320

Electrical System

Table 4. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Truck Models Item

GM 4.3L

Cummins 4.5L

Battery

12-volt, negative ground

12-volt, negative ground

Spark Plugs

AC 41-993

N/A

Spark Plug Gap

1.5 mm (0.059 in.)

N/A

Gas

Not Adjustable

N/A

LPG

Not Adjustable

N/A

Diesel

N/A

0.90 mm (0.035 in.)

Ignition Timing:

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

Transmission Oil Pressures Table 5. 3-Speed Transmission, Lift Trucks Manufactured BEFORE October 2009 All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1 and F2)

Forward High Clutch (F3)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

*Relief Pressure

10

Port 6

Port 7

Port 8

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, F3 and R2)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

8000 YRM 1320

Transmission Oil Pressures Table 6. 2-Speed Transmission, Lift Trucks Manufactured BEFORE June 2009 All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F)

Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Port 6

Port 7

Port 8

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1)

Forward High Clutch (F2)

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, and R2)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

*Relief Pressure

11

Transmission Oil Pressures

8000 YRM 1320

Table 7. 3-Speed Transmission, Lift Trucks Manufactured AFTER October 2009 All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1 and F2)

Forward High Clutch (F3)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

*Relief Pressure

12

Port 6

Port 7

Port 8

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, F3 and R2)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

8000 YRM 1320

Transmission Oil Pressures Table 8. 2-Speed Transmission, Lift Trucks Manufactured AFTER June 2009 All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F)

Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

Low and High Pressure

Reverse Clutch (R1 and R2)

Forward Low Clutch (F1 and F2)

Forward High Clutch (F3)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068* kPa (260 to 300 psi)

Port 6

Port 7

Port 8

Torque Converter

Lubrication

First Test Port (F1 and R1)

Second Test Port (F2, F3 and R2)

758 kPa (110 psi)

69 to 276 kPa (10 to 40 psi)

1793 to 2068 kPa (260 to 300 psi)

1793 to 2068 kPa (260 to 300 psi)

*Relief Pressure

13

Steering System

8000 YRM 1320

Hydraulic System Relief Pressures Item

Specification

Oil Temperature for Setting Relief Pressure

50 to 65°C (122 to 149°F)

Primary Relief Valve Pressure (High Idle)

22.1 ±0.48 MPa (3205 ± 70 psi)

Secondary Relief Valve Pressure (High Idle)

15.51 ±0.48 MPa (2250 ±70 psi)

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 (±50 mm NO LOAD)

Outside

Inside

All Trucks

2585

107

Table 10. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Truck Models

14

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

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