YALE (D879) GDC135VX LIFT TRUCK Service Repair Manual by 1637912

Maintenance

6HUYLFH 5HSDLU GC/GLC/GDC135VX, GC/GLC/GDC155V D879

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]

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

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

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)

10.4 liter (11.0 qt)

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

4.2 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

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)

13.5 liter (14.2 qt)

10.4 liter (11.0 qt)

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

Left Wheel Hub Oil

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)

4.6 liter (4.9 qt)

SAE 80W-90

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

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)

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)

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

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)

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)

Low Idle

30 amps @ 800 rpm

20 amps @ 800 rpm

Governed Speed

95 amps @ 2230 rpm

45 amps @ 2230 rpm

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)

*Relief Pressure

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)

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)

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

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)

*Relief Pressure

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)

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)

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)

*Relief Pressure

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

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

8000 YRM 1320

Stall Speeds (in RPM ±100 rpm)

Stall Speeds (in RPM ±100 rpm) GM 4.3L GAS GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

2160

2210

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

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

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

2070

2170

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

GM 4.3L GAS GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

2160

2210

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

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

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

2070

2170

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

Stall Speeds (in RPM Â±100 rpm)

8000 YRM 1320

CUMMINS 4.5L DIESEL GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879) Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

1900

2050

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

CUMMINS QSB 3.3L DIESEL GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (D879) Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

1935

1950

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

CUMMINS 4.5L DIESEL GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878) Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

1900

2050

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

CUMMINS QSB 3.3L DIESEL GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) Transmission

New Engine

Broken-In Engine (30 hrs)

Standard Powershift

1935

1950

Techtronix 332

N/A*

*Techtronix 332 transmission has torque limiting feature.

8000 YRM 1320

Mast Speeds

Mast Speeds NOTE: Lift speed is measured in meters/sec (inch/sec) at governed engine RPM with full open valve and 65째C (149째F) oil temperature.

Lowering speed is measured in meters/sec (inch/sec) with full open valve and 65째C (149째F) oil temperature. Plus or minus 10% acceptable lifting or lowering.

Table 11. Lift Truck Models GLC/GDC60VX (GC/GLC/GDC135VX) (C879, D879)

Engine

Mast

GM 4.3L

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.52 (20.0)

0.51 (20.0)

Table 12. Lift Truck Models GLC/GDC70VX (GC/GLC/GDC155VX) (C879, D879)

Engine

Mast

GM 4.3L

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.52 (20.0)

0.51 (20.0)

Table 13. Lift Truck Models GLC/GDC60VX (GC/GLC/GDC135VX) (C879, D879)

Engine

Mast

Cummins 4.5L and QSB 3.3L

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.50 (20.0)

0.49 (19.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.48 (19.0)

0.47 (19.0)

Table 14. Lift Truck Models GLC/GDC70VX (GC/GLC/GDC155VX) (C879, D879)

Engine

Cummins 4.5L and QSB 3.3L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.46 (18.0)

0.45 (18.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.44 (17.0)

0.43 (17.0)

Mast Speeds

8000 YRM 1320

Table 15. Lift Truck Models GLP/GDP60VX (GP/GLP/GDP135VX) (C878, D878)

Engine

Mast

GM 4.3L

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.52 (20.0)

0.51 (20.0)

Table 16. Lift Truck Models GLP/GDP70VX (GP/GLP/GDP155VX) (C878, D878)

Engine

Mast

GM 4.3L

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.54 (21.0)

0.53 (21.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.52 (20.0)

0.51 (20.0)

Table 17. Lift Truck Models GLP/GDP60VX (GP/GLP/GDP135VX) (C878, D878)

Engine

Mast

Cummins 4.5L

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.50 (20.0)

0.49 (19.0)

3-Stage FFL

0.41 (16.0)

0.53 (21.0)

0.48 (19.0)

0.47 (19.0)

Table 18. Lift Truck Models GLP/GDP70VX (GP/GLP/GDP155VX) (C878, D878)

Engine

Cummins 4.5L

Mast

Lowering M/Sec (Inch/Sec)

Lifting M/Sec (Inch/Sec)

No Load

Rated Load

No Load

Rated Load

2-Stage LFL

0.53 (21.0)

0.58 (23.0)

0.46 (18.0)

0.45 (18.0)

3-Stage FFL

0.41 (16.0)

0.55 (22.0)

0.44 (17.0)

0.43 (17.0)

8000 YRM 1320

Tilt Angles

Tilt Angles Lift truck should be on level ground and in unloaded condition.

Table 19. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Lift Truck Models Mast Type

Forward

Tolerance

Back

Tolerance

2-Stage FFL, 3-Stage FFL, 3-Stage LFL

6°

+1°,

0.5°

6°

+0°,

0.5°

2-Stage LFL

6°

+1°,

0.5°

10°

+0°,

0.5°

Table 20. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Truck Models Mast Type

Forward

Tolerance

Back

Tolerance

2-Stage FFL, 3-Stage FFL, 3-Stage LFL

5°

+1°,

0.5°

6°

+0°,

0.5°

2-Stage LFL

5°

+1°,

0.5°

10°

+0°,

0.5°

Front End Equipment - Mast Creep

8000 YRM 1320

Front End Equipment - Mast Creep MAST CREEP

NOTE: Mast should be 90° vertical prior to test.

Measure with rated load at 2.5 m (8.0 ft) high and with the lift, tilt, and auxiliary control levers in neutral position.

Table 21. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Lift Truck Models Hydraulic Oil Temperature

Maximum Vertical Creep at Carriage

Maximum Tilt Creep Mast Angle

Cylinder Stroke

°C

°F

mm/Min

in./Min

°/Min

mm/Min

in./Min

2.2

0.086

0.11

1.24

0.054

3.3

0.130

0.16

1.80

0.071

104

6.3

0.247

0.31

3.50

0.137

122

10.0

0.394

0.50

5.62

0.221

140

14.6

0.575

0.73

8.20

0.323

Table 22. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Lift Truck Models Hydraulic Oil Temperature

Maximum Vertical Creep at Carriage

Maximum Tilt Creep Mast Angle

Cylinder Stroke

°C

°F

mm/Min

in./Min

°/Min

mm/Min

in./Min

2.2

0.086

0.11

1.30

0.051

3.3

0.130

0.16

1.90

0.075

104

6.3

0.247

0.31

3.67

0.145

122

10.0

0.394

0.50

5.92

0.233

140

14.6

0.575

0.73

8.65

0.341

8000 YRM 1320

Engine Specifications

Engine Specifications Item

GM 4.3L

No. of Cylinders

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 Control 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)

Engine Specifications

8000 YRM 1320

Item

Cummins 4.5L Diesel

No. of Cylinders

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)

Item

Cummins QSB 3.3L Diesel

No. of Cylinders Firing Order Bore and Stroke Displacement Compression Ratio

4 1-3-4-2 95 mm × 115 mm (3.74 in. × 4.53 in.) 3261 cc 17.3:1

Horsepower/rpm (basic transmission)

80 @ 2200 rpm

Horsepower/rpm (Duramatch transmission)

99 @ 2200 rpm

Oil Pressure

49 kPa (7 psi)

Valve Clearance Intake

0.35 mm (0.014 in.)

Exhaust

0.50 mm (0.02 in.)

Idle Speed

800 ±25 rpm

8000 YRM 1320

Torque Specifications

Item

Cummins QSB 3.3L Diesel 2230 ±25 rpm

Governed Speed High Idle (No Load) Thermostat Range START TO OPEN

82°C (180°F)

FULL OPEN

95°C (203°F)

Cooling System Pressure

103 kPa (15 psi)

Torque Specifications FRAME Overhead Guard Mount Capscrews 66 N•m (49 lbf ft) Cowl-to-Overhead Guard Legs 66 N•m (49 lbf ft) Steering Column Nut 40 to 54 N•m (30 to 40 lbf ft) Counterweight Capscrews 1020 N•m (750 lbf ft)

MAST, LIFT TRUCK MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) Mast Mounting Capscrews Mast to Drive Axle 320 N•m (236 lbf ft) Tilt/Cylinder Adjust 90 N•m (66 lbf ft) Pivot Pin Retainer 68 N•m (50 lbf ft) Chain Anchor Nut 370 N•m (273 lbf ft) Retainer Plate (Pin Type Forks) 70 to 80 N•m (56 to 60 lbf ft) Hang On Sideshift Assembly Lower Hook Capscrews 155 to 170 N•m (115 to 125 lbf ft) Fork Positioner Installation Capscrews 155 to 170 N•m (115 to 125 lbf ft) Load Backrest to Carriage Assembly Nuts (Without Fork Positioner) 70 to 80 N•m (56 to 60 lbf ft)

MAST, LIFT TRUCK MODELS GLP/GDP60VX, GLP/GDP70VX

(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) Mast Mounting Capscrews Mast to Drive Axle 755 to 830 N•m (557 to 612 lbf ft) Tilt/Cylinder Adjust 90 to 99 N•m (66 to 73 lbf ft) Pivot Pin Retainer 68 N•m (50 lbf ft) Chain Anchor Nut 370 N•m (273 lbf ft) Hang On Sideshift Assembly Lower Hook Capscrews 155 to 170 N•m (115 to 125 lbf ft) Fork Positioner Installation Capscrews 155 to 170 N•m (115 to 125 lbf ft) Load Backrest to Carriage Assembly Nuts (Without Fork Positioner) 70 to 80 N•m (56 to 60 lbf ft)

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 Fork Carrier Block Capscrews 80 N•m (60 lbf ft) Retainer Capscrew 100 N•m (75 lbf ft) Cylinder Retainer 65 N•m (120 lbf ft) Hang On Sideshift Assembly Lower Hook Capscrews 320 N•m (236 lbf ft)

Torque Specifications Fork Positioner Frame to Hang On Sideshift Frame Capscrews 145 N•m (110 lbf ft) Fork Positioner to Sideshift Frame Capscrews 225 N•m (166 lbf ft)

8000 YRM 1320

TRANSMISSION Transmission Mounting Bracket to Differential Housing Capscrew 225 to 255 N•m (166 to 188 lbf ft)

Side Retainer to Fork Carrier Capscrews 80 N•m (60 lbf ft)

Torque Converter Housing to Transmission Case Capscrews 38 N•m (28 lbf ft)

Lift Chain Anchor Nuts 210 N•m (155 lbf ft)

Torque Converter Access Bolts 55 N•m (41 lbf ft)

Load Backrest to Carriage Assembly Capscrews 225 N•m (166 lbf ft)

Drive Shaft to Output Yoke Capscrews 55 to 63 N•m (41 to 47 lbf ft)

STEERING SYSTEM

Control Valve Mounting Capscrews 20 to 25 N•m (15 to 18 lbf ft)

Hub Nut (Slotted Nut), Lift Truck Models GLC/ GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879) 203 N•m (150 lbf ft) initial 35 N•m (26 lbf in) final Hub Nut (Slotted Nut), Lift Truck Models GLP/ GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878) 203 N•m (150 lbf ft) initial 34 N•m (25 lbf in) final Steering Axle Mounting Bolts and Nuts, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) 250 to 275 N•m (184 to 203 lbf ft) Steering Axle Mounting Bolts and Nuts, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) 270 N•m (199 lbf ft) Spindle Bearing Cap Capscrew, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (C879, D879) 52 N•m (38 lbf ft) Spindle Bearing Cap Capscrew, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878) 47 N•m (35 lbf ft) Steering Cylinder Mounting Bolts 225 N•m (166 lbf ft)

Engine Mounting Bracket to Frame Bolts 320 N•m (236 lbf ft)

ENGINE - GM 4.3L Alternator Pulley 61 N•m (45 lbf ft) Balance Shaft Gear Capscrew 20 N•m (177 lbf in) Plus 35 Degrees Balance Shaft Retainer Capscrews 12 N•m (106 lbf in) Camshaft Retainer Screws 12 N•m (106 lbf in) Camshaft Sprocket Capscrews 28 N•m (21 lbf ft) Camshaft Sprocket Nut 25 N•m (18 lbf ft) Chain Control Block for Hydraulic Pump Drive 19 N•m (168 lbf in) with Adhesive Sealant Connecting Rod Cap 27 N•m (240 lbf in) After this step, tighten nuts an additional 70 degrees. Coolant Pump to Engine Block 41 N•m (30 lbf ft) Cooling Fan to Pulley 24 N•m (212 lbf in)

8000 YRM 1320

Torque Specifications

Cylinder Head See the section GM Engines, 4.3 Liter V-6 600 YRM 1251 for torque value and tightening sequence to use.

Oil Pan to Crankcase Capscrews 25 N•m (18 lbf ft) Nuts 25 N•m (18 lbf ft)

Distributor Mount Capscrew 25 N•m (18 lbf ft)

Rear Oil Seal Retainer Screws and Nut 15 N•m (133 lbf in)

Exhaust Manifold 15 N•m (133 lbf in) - first step 30 N•m (22 lbf ft) - second step

Rocker Arm Cover 12 N•m (106 lbf in)

Flywheel 100 N•m (74 lbf ft) Flywheel Housing 48 N•m (35 lbf ft) Inlet Manifold to Cylinder Head 3 N•m (27 lbf in) - first step 12 N•m (106 lbf ft) - second step 15 N•m (133 lbf in) - third step (final)

Rocker Arm Nuts 25 N•m (18 lbf ft) Rocker Arm Studs 47 N•m (35 lbf ft) Rocker Arm Bolts 30 N•m (22 lbf ft) Thermostat Housing 25 N•m (18 lbf ft)

Main Bearing Cap 105 N•m (77 lbf ft)

Timing Cover 12 N•m (106 lbf in)

Motor Mount to Engine 31 N•m (23 lbf ft)

Valve Lifter Retainer Capscrews 16 N•m (142 lbf in)

Oil Pump Cover 12 N•m (106 lbf in)

Vibration Damper 95 N•m (70 lbf ft)

Oil Pump to Crankcase 90 N•m (66 lbf ft)

ENGINE - CUMMINS 4.5L AND QSB 3.3L DIESEL

Oil Pressure Switch 27 N•m (20 lbf ft)

For torque instructions for the Cummins 4.5L and QSB 3.3L diesel engine, contact your local Yale dealer or see Yale Axcess Online.

Oil Screen Support to Crankcase 50 N•m (37 lbf ft)

700 YRM 1123

Cooling System Checks

General This section contains the repair and replacement instructions for the radiator, coolant level sensor, fan

assembly (pusher type), fan shroud, coolant hoses, coolant recovery bottle, and optional debris screen.

Cooling System Checks EXHAUST LEAKS INTO COOLING SYSTEM WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system. Inspect all radiator hoses. If they feel spongy or have visible cracks, replace hoses.

To check for exhaust leaks into the cooling system, use a Combustion Leak Test Kit for this purpose. Follow the manufacturerâ&#x20AC;&#x2122;s instructions when doing the test.

WATER PUMP

WATER FLOW RESTRICTIONS IN RADIATOR

During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury.

WARNING

WARNING During engine operation, be careful not to touch the fan, pulleys, or drive belts. Contact with these parts can cause serious injury. To check for water flow restrictions in the radiator, run engine until it is warm.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.

WARNING The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Run engine until it is warm. Check the operation of water pump by holding the top radiator hose. If the pump is operating, there will be pressure surges in the hose. Check for leaks around the timing belt cover near the base of the oil pump. Check the weep hole where coolant that leaks past the water pump seal can be drained before reaching the water pump bearings. If there is a drip, check the pump shaft seal and water pump. Replacement of the pump shaft seal or water pump may be necessary.

Shut engine OFF and feel the radiator. The temperature must be even across the radiator. (The radiator will be hotter near the top radiator hose.) Cold spots on radiator indicate restrictions.

For repair procedures for the GM 2.4L water pump, refer to the section GM Engine Repair, GM 2.4 Liter Engine 600 YRM 1121.

If radiator has leaks, either replace the radiator or have it repaired by trained personnel.

For repair procedures for the Mazda FE and F2 water pump, refer to the section Mazda Engine, FE and F2 600 YRM 1122.

RADIATOR HOSES WARNING

For replacement procedures for the Yanmar 2.6L and 3.3L water pump, refer to the section Yanmar Diesel 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 serious injury. Wait 30 minutes for the radiator to cool.

Flushing the Cooling System

700 YRM 1123

For replacement procedures for the GM 4.3L water pump, refer to the section GM Engines, 4.3 Liter V-6 600 YRM 1251. For replacement procedures for the GM 5.7L water pump, refer to the section GM Engines, 5.7 Liter V-8 LPG 600 YRM 1432.

For replacement procedures for the Kubota water pump, refer to the section • Kubota Diesel 3.8L Engines 600 YRM 1557 • Kubota Diesel 3.6L Engine 600 YRM 1579 • Kubota Diesel 3.8L Engines, with Diesel Particulate Filter (DPF) 600 YRM 1590 For replacement procedures for the Cummins 4.5L and QSB 3.3L water pump, contact your local Yale dealer or see Yale Axcess Online.

Flushing the Cooling System COOLING SYSTEM, CLEAN WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure the path of the compressed air is away from all personnel. Wear protective goggles or a face shield to prevent injury to the eyes.

WARNING The radiator fins on the radiator are very sharp and can cause serious injury. Wear gloves while checking the radiator fins. 1. Check radiator fins. Clean exterior of radiator with compressed air or water as needed.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations.

2. Drain cooling system. Fill cooling system with clean water. See sections below for more information: • Radiator, Remove for Lift Trucks 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); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) and GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) • Radiator, Remove for Lift Truck Models S6.0FT, S7.0FT (S135FT, S155FT) (D024, E024, F024, G024)GLC/GDC60VX, GLC/GDC60VX, (GC/GLC/GDC135VX, GC/GLC/GDC135VX) (C879, D879, E879, F879) • Radiator, Remove for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/ GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLP/GDP80VX, GLP/ GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909) 3. Install radiator cap. Run engine until top radiator hose is hot. Stop engine and let engine cool. 4. Drain water from radiator. If water is dirty, fill system with water and repeat procedure until water is clean.

700 YRM 1123

Radiator Replacement method uses water pressure to force water through radiator in opposite direction of normal flow.

CAUTION Follow the manufacturer’s instructions when using a chemical radiator cleaner. 5. If water does not clean system, use a chemical radiator cleaner.

CAUTION Follow the manufacturer’s instructions when using special equipment to reverse clean the radiator. 6. If radiator or cooling system is very dirty or has a restriction, use reverse cleaning method. This

CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. 7. Fill cooling system with ethylene glycol boron-free antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50 percent concentrate with 50% distilled or deionized water. The 50/50 mixture will protect cooling system to 37°C ( 35°F). Add coolant as necessary to keep level between the ADD and FULL marks on the reservoir.

Radiator Replacement RADIATOR, REMOVE FOR LIFT TRUCKS 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); GLP/GDP20-25LX (GLP/GDP050LX) (A974); GLC40, 45, 55VX, GLC55SVX, (GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, GC/GLC120SVX, GC/GLC120VXPRS) (E818, F818) AND GLP/GDP40VX5/VX6, GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/GDP080, 090, 100, 110, 120VX) (F813, G813, H813, J813) WARNING

See Frame 100 YRM 1120 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) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) See Frame 100 YRM 1243 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (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)

The radiator or other parts of the cooling system may be hot or under pressure and can cause serious injury. Wait 30 minutes for the radiator to cool. Do a touch test by touching the radiator with your hand. If the radiator is still hot to the touch, wait another 30 minutes before attempting to check or fix any part of the cooling system.

Always disconnect the cable at the negative terminal first. Install a tag on the battery terminals so that no one connects the cables on the terminals.

1. Turn OFF truck.

4. Disconnect the positive battery cable.

WARNING

3. Disconnect the negative battery cable.

2. Remove the hood and seat combination.

Radiator Replacement

WARNING DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 5. Let coolant cool to ambient temperature. Place a drain pan with a capacity greater than the capacity of the cooling system under radiator. Remove radiator cap.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 6. Open the drain plug or loosen hose clamp and disconnect the lower hose. 7. Lift trucks equipped with a Cummins QSB 3.3L diesel engine: Loosen clamps and disconnect the charge air cooler hoses from charge air cooler. See Figure 6. 8. Lift trucks equipped with a Kubota 3.8L diesel engine: Loosen clamps and disconnect transmission cooler hoses from transmission cooler. See Figure 8. 9. Once coolant is drained from engine, loosen hose clamps and disconnect coolant hoses from radiator. Cap radiator hoses. 10. Loosen hose clamp and disconnect hose from reservoir and remove reservoir. See Figure 1 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) • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) See Figure 2 or Figure 3 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;

700 YRM 1123 GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 4 or Figure 5 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813) See Figure 6 for lift truck models below equipped with a Cummins QSB 3.3L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813 • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879) See Figure 7 for lift truck models below equipped with Yanmar 2.6L diesel engine • GDP20-25LX (GDP050LX) (A974) See Figure 8 for lift truck models below equipped with a Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813) 11. Remove battery and battery tray. 12. If equipped, disconnect electrical connector to the coolant level sensor. NOTE: For Mazda LPG engine, the LPG converter bracket needs to be moved for clearance of radiator. 13. Remove screws and washers from the shroud and move shroud out of the way. 14. Place radiator guard shield between radiator and fan so damage to radiator does not occur during fan removal. 15. Remove fan, fan spacer, and pulley. 16. Remove radiator guard shield. 17. Remove capscrews and upper radiator bracket. See Figure 1 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)

700 YRM 1123 • GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) • GLC050LX (A967) • GLP20-25LX (GLP050LX) (A974) See Figure 2 or Figure 3 for lift truck models • GLC40, 45, 55VX; GLC55SVX; (GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS) (E818, F818) See Figure 4 or Figure 5 for lift truck models • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (F813, G813)

Radiator Replacement • GLC/GDC60VX, GLC/GDC70VX (GC/GLC/ GDC135VX, GC/GLC/GDC155VX) (D879) See Figure 7 for lift truck models below equipped with Yanmar 2.6L diesel engine • GDP20-25LX (GDP050LX) (A974) See Figure 8 for lift truck models below equipped with a Kubota 3.8L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6; GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (H813, J813) 18. Remove radiator from truck. 19. If necessary, remove the coolant level sensor.

See Figure 6 for lift truck models below equipped with a Cummins QSB 3.3L diesel engine • GLP/GDP40VX5/VX6; GLP/GDP45SVX5, GLP/GDP45VX6, GLP/GDP50-55VX (GP/GLP/ GDP080, 090, 100, 110, 120VX) (G813

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)

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