Page 2 STEERING TIRE SIZE SPECIAL EQUIPMENT OR ATTACHMENTS © Yale Material Handling Corporation 2015. All right reserved. YALE and VERACITOR are Registered Trademarks of NACCO Materials Handling Group, Inc. CSS, PREMIER, and are Trademarks in the United States and certain jurisdictions.
Page 3: Foreword
NOTE: A comprehensive operator training program is avail- • Understand the capabilities and limitations of the lift truck. able from Yale Corporation. For further details, contact your • Become familiar with the construction of the lift truck and dealer for Yale lift trucks.
Page 4 Operating Manual will NOT be installed on your unit. If you for Yale lift trucks (Yale Part No. 2106-2/03-0). have a question about any item described, contact your NOTE: Yale lift trucks are not intended for use on public dealer for Yale lift trucks. roads.
Page 5: Table Of Contents
Contents Contents Foreword ..............Mounting and Dismounting ........65 TO OWNERS, USERS, AND OPERATORS: ..... Operator Passwords ..........66 Warning ................ Starting Procedures ..........67 Model Description ............10 Starting Procedures, Trucks With Key Switch ..67 GENERAL ..............12 Starting Procedures, Trucks With Keyless Start OPERATOR PROTECTION EQUIPMENT ....
Page 6 Contents Load Handling, How to Engage and Disengage a Tires and Wheels ............135 Load ..............93 Safety Labels ............137 Load Handling, Traveling .......... 96 Mast, Carriage, Header Hoses, Lift Chains, and Load Handling, Emergency Load Lowering ....100 Attachment ............
Page 7 Contents Service Brakes ............159 Install Wheel in Tire ..........177 Brake Fluid Level ............ 159 Tire Installation, Three- or Four-Piece Wheel ..179 Operation, Check ............ 159 Tire Installation, Two-Piece Wheel ......180 Parking Brake ............160 Add Air to Pneumatic Tires With Tube ...... 180 Engine Oil Pressure ..........
Page 8 Contents Long-Term Storage ........... 196 Loading ..............198 While the Lift Truck is in Storage ......196 Unloading ..............199 How to Put Batteries in Storage ........ 196 PREPARATION FOR USE ......... 200 Putting a Stored Lift Truck Back Into Service ... 197 Preparation After Transport ........
Page 9: Warning
• INSPECT truck before use. • WATCH clearances, especially overhead. • DO NOT operate if truck needs repair. Tag truck and remove key. Repair truck before use. Always use Yale KNOW YOUR LOADS: Approved parts when making repairs. Replacement parts •...
Page 10 Warning WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH! AUTHORIZED, TRAINED OPERATOR ONLY! USE COMMON SENSE: • WHEN PARKING, also shut off power, close LPG fuel valve, block wheels on inclines. • DO NOT use truck to lift people unless there is no other practical option.
Page 11 Warning WARNING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH! AUTHORIZED, TRAINED OPERATOR ONLY! PROTECT YOURSELF FASTEN YOUR SEAT BELT! • TRAVEL with carriage as low as possible and tilted back. • AVOID bumps, holes, and loose materials. •...
Page 12: Model Description
Model Description Model Description COUNTERWEIGHT OPERATING MANUAL (BEHIND SEAT) TAIL, BRAKE, AND REVERSE LIGHTS OVERHEAD GUARD SEAT BELT AND HIP RESTRAINT STEERING WHEEL PARKING BRAKE MAST LOAD BACKREST EXTENSION FORKS CARRIAGE DRIVE AXLE SEAT STEERING AXLE Figure 1. Model View Showing Major Components for Lift Truck Models GC/GLC040VX, GC/GLC050VX, GC/ GLC055SVX, GC/GLC060VX, GC/GLC070VX (C910)
Page 13 Model Description COUNTERWEIGHT OPERATING MANUAL (BEHIND SEAT) TAIL, BRAKE, AND REVERSE LIGHTS OVERHEAD GUARD SEAT BELT AND HIP RESTRAINT STEERING WHEEL PARKING BRAKE MAST LOAD BACKREST EXTENSION FORKS CARRIAGE DRIVE AXLE SEAT STEERING AXLE Figure 2. Model View Showing Major Components for Lift Truck Models GP/GLP/GDP040-070VX (D875)
Page 14: General
Model Description Model Description General Lift trucks in this manual will be equipped with a Standard or Techtronix 100 transmission These lift trucks can be equip- This Operating Manual is for the following models of lift ped with three types of controls: trucks: •...
Page 15: Operator Protection Equipment
• Seat belt with no operation interlock. on your lift truck is required, contact your Yale lift truck dealer. • Seat belt with operation interlock. Seat belt must be fas- The OVERHEAD GUARD is intended to offer reasonable tened for lift truck to start or to travel.
Page 16: Nameplate
3. If your lift truck has either of these labels, do not oper- Any change to the lift truck, the tires, or its equipment ate the lift truck. Contact your dealer for Yale lift trucks to can change the lifting capacity. The lift truck must be obtain a complete and correct Nameplate.
Page 17: Safety Labels
Model Description Safety Labels Safety labels are installed on the lift truck to provide informa- tion about possible hazards. It is important that all 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 shown in Fig- ure 4 and Figure 5.
Page 18 Model Description 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)
Page 19 Model Description 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)
Page 20 Model Description 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)
Page 21 Model Description Legend for Figure 4 LPG TANK WARNING TIPOVER WARNING STABILITY SYSTEM LABEL (ON BOTH FLAMMABLE LP-GAS NAMEPLATE SIDES OF TRUCK)** WARNING, OPERATION DRIVE TRAIN PROTECTION CAUTION LIFT AND TILT LABEL OVERHEAD GUARD LABEL PINCH POINT WARNING FAN WARNING MAST WARNING TRANSMISSION LABEL (EXAMPLE ANTIFREEZE WARNING...
Page 22 Model Description Figure 5. Warning and Safety Labels for Lift Truck Models GP/GLP/GDP040-070VX (D875) (Sheet 1 of 3)
Page 23 Model Description 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)
Page 24 Model Description 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)
Page 25: Display Switch Cluster
Model Description Legend for Figure 5 LPG TANK WARNING RADIAL TIRES AND WHEELS LIFT AND TILT LABEL FLAMMABLE LP-GAS (PNEUMATIC TIRES ONLY) NO RIDERS EITHER WARNING (DIESEL ONLY) NO ONE ON OR UNDER FORKS STABILITY SYSTEM LABEL (ON BOTH OVERHEAD GUARD LABEL UNLEADED FUEL LABEL (NOT SHOWN) SIDES OF TRUCK)** WARNING, OPERATION...
Page 26 Model Description LEFT SIDE DISPLAY INPUTS LCD SCREEN RIGHT SIDE DISPLAY INPUTS WARNING AND INDICATOR LIGHTS Figure 6. Display Switch Cluster...
Page 27 Model Description LEFT SIDE DISPLAY – CAB OPTION GC/GLC040VX, GC/ RIGHT SIDE DISPLAY GLC050VX, GC/GLC055SVX, GC/GLC060VX,-GC/GLC070VX AND GP/GLP/GDP040-070VX ONLY Figure 7. Display Switch Cluster...
Page 28 Model Description Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 7) Item Item Function Power ON/OFF If the lift truck is equipped with the keyless start option, lift truck system power is turned ON by pressing this button. To turn the lift truck system power and engine OFF, press the Power ON/OFF button again.
Page 29 Model Description Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 7) (Continued) Item Item Function #1 Button When an operator or supervisor is in the main menu for entering and administering passwords, this button is used to enter the number 1 for password purposes. If the lift truck is equipped with a Techtronix 200X Transmission, the 1st Gear Locking function and the #1 button will share space on the Display Switch Cluster.
Page 30 Model Description Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 7) (Continued) Item Item Function Rear Work Lights This button controls the rear work lights on lift trucks equipped with this option. #3 Button If the lift truck is equipped with rear work lights, the #3 Button and the Rear Work Light button will share space on the Display Switch Cluster.
Page 31 Model Description Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 7) (Continued) Item Item Function Scroll Up This button is used for the following functions: • Increasing the value of a selected operating function • Scrolling upward through a list of possible menu selections #5 Button The Scroll Up and #5 Button share the same space on the Display Switch Cluster.
Page 32 Model Description Table 1. Display Switch Cluster – Right-Side Display Inputs (See Figure 7) (Continued) Item Item Function Windshield Washer On lift trucks with the cab option, press this button to wash the front windshield. Wind- shield wipers will turn on and off automatically. Front Windshield On lift trucks with cab option, press this switch to turn the front windshield wiper ON.
Page 33: Display Switch Cluster - Lcd Screen And Warning And Indicator Lights
Model Description Display Switch Cluster – LCD Screen and 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 Warning and Indicator Lights the right side of the top line at all times during the selection The LCD screen (see Figure 8) shows operator messages of displayed text.
Page 34 Model Description LCD SCREEN WARNING AND INDICATOR LIGHTS Figure 8. Display Switch Cluster – LCD Screen and Warning and Indicator Lights...
Page 35 Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) Item No. Item Function Indicator Light Left This green indicator will blink on and off when the left turn signal is selected. Not on Turn Signal at Start Check. Warning Light, This amber indicator is on when the system is in the ON state, and turns off as the Engine...
Page 36 Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) (Continued) Item No. Item Function Warning Light, CAUTION Brake Fluid Level Do not continue to operate the lift truck if the light is on during operation. Malfunction The red brake fluid light will illuminate when the brake fluid level switch indicates a Indicator low fluid condition.
Page 37 Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) (Continued) Item No. Item Function Indicator Light This green indicator will blink on and off when the right turn signal is selected. Not Right Turn Signal on at Start Check. Warning Light, CAUTION Transmission Oil...
Page 38 Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) (Continued) Item No. Item Function Warning Light, CAUTION Engine Oil Stop the engine immediately if the red light is ON while the engine is running. Pressure The red light will illuminate when the system is not in the OFF state and the oil pres- Malfunction sure sensor indicates an insufficient pressure.
Page 39 Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) (Continued) Item No. Item Function Warning Light, CAUTION Engine Coolant Do not continue to operate the lift truck if the light is on during operation. Temperature If this red light illuminates while the engine is running, it indicates the engine coolant Malfunction temperature has reached 110 °C (230 °F) or above.
Page 40 Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) (Continued) Item No. Item Function Warning Light, CAUTION Coolant Level Do not continue to operate the lift truck if the light is on during operation. in Radiator If the lift truck is equipped with the premium monitoring package, this red warning Malfunction light will illuminate when the radiator coolant level switch indicates that the level of...
Page 41 Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) (Continued) Item No. Item Function Warning Light, CAUTION Fuel Level Do not allow the lift truck to run out of LPG. Damage to the catalytic converter Indicator can result.
Page 42: Operator Controls
Model Description Table 2. Instruments – Warning and Indicator Lights (See Figure 8) (Continued) Item No. Item Function Indicator Light This amber indicator light will illuminate if the fuel-water separator sensor indicates Water Separator that water must be drained. Not on at Start Check. (Diesel Only) Operator Controls the problem immediately.
Page 43 Model Description SEE FIGURE 10 FOR MORE OPERATOR COMPARTMENT PEDAL CONFIGURATIONS. Figure 9. Operator Controls...
Page 44 Model Description INCHING/BRAKE PEDAL INCHING/BRAKE PEDAL FOOT DIRECTIONAL CONTROL PEDAL BRAKE PEDAL ACCELERATOR PEDAL Figure 10. Operator Compartment Pedal Configurations...
Page 45 Model Description Table 3. Operator Controls (See Figure 9) Item Item Function Steering Wheel The steering wheel controls the position of the steer tires. Inching/Brake Pedal By varying the position of the inching/brake pedal, the operator can move the lift truck slowly while a high engine speed is used for lifting loads.
Page 46 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Lever For Steering Column Tilt To move the steering column up, pull 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 the lever.
Page 47 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Parking Brake Lever WARNING Correct adjustment is necessary to provide adequate braking. See the Main- tenance section for adjustment procedures. Always apply the parking brake when leaving the lift truck. NOTE: There is a sensor in the seat that actuates an audible alarm.
Page 48 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Inching/Brake By varying the position of the inching/brake pedal, the operator can move the lift Pedal 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.
Page 49 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Lift/Lower Control NOTE: Manual hydraulic control levers are standard on the trucks covered in this Lever manual (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.
Page 50 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Tilt Control Lever NOTE: Manual hydraulic control levers are standard on the trucks covered in this manual (see Figure 9). NOTE: To operate the mini-levers, the operator must be positioned in the seat and the arm rest must be in the down position.
Page 51 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Tilt Control Lever These trucks can be equipped with the Return to Set Tilt (RTST) option if truck has (Cont) electronic hydraulic mini-levers. The RTST option automatically stops the tilt function at a set point.
Page 52 Auxiliary Hydraulic A manual control lever with a detent must be installed when an attachment Functions (3rd lever). with a clamp is installed. See your dealer for Yale lift trucks to get the correct See Figure 9. control lever. NOTE: Manual hydraulic control levers are standard on the trucks covered in this manual (see Figure 9).
Page 53 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Electronic Control Mini-Lever for The third electronic control mini-lever is installed to the right of the electronic tilt Auxiliary Hydraulic Functions control lever. This lever can have two methods of operation, depending on the (3rd lever).
Page 54 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Manual Control Lever for NOTE: Manual hydraulic control levers are standard on the trucks covered in this Auxiliary Hydraulic manual (see Figure 9). Functions (4th lever). The fourth manual control lever is installed to the right of the third manual control See Figure 9.
Page 55 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Electronic Control Mini-Lever for The fourth electronic control lever is installed to the right of the third electronic control Auxiliary Hydraulic Functions lever. This lever can have two methods of operation, depending on the attachment. (4th lever).
Page 56 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function NOTE: There is a sensor in the seat that actuates an audible buzzer. If the operator leaves the seat with the key switch ON and the lever is not in NEUTRAL, the buzzer will pulse ON and OFF for 10 seconds.
Page 57 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Key Switch NOTE: There is no mechanical lockout that prevents the key switch from being returned to the START position without first being returned to the OFF position. However, the Vehicle System Manager (VSM) software prevents the starter motor from being energized while the engine is running.
Page 58 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Accelerator Pedal This pedal controls the speed of the engine and is operated by the operator's right foot. It is used on units that have a Direction Control Lever. Direction The Direction Control Switch for the transmission is next to the auxiliary horn button Control...
Page 59 Model Description Table 3. Operator Controls (See Figure 9) (Continued) Item Item Function Battery This switch is only on units with the GS or LPS fire safety rating. The operator can Disconnect shut off all electrical power to the lift truck by pulling up on the T-handle that is located Switch (Not between the steering wheel and the parking brake.
Page 60 Model Description Table 4. Auxiliary Control Levers Direction of Movement Function Load or Equipment Control Lever 1. REACH Retract/Extend Backward/Forward 2. SIDESHIFT Right/Left Backward/Forward 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.
Page 61: Operating Procedures
Operating Procedures Operating Procedures General If engines are operated in confined spaces, maintain adequate ventilation or vent exhaust to the outside. Do Know Your Lift Truck not exceed applicable air contaminant limits (see 29 CFR 1910.1000 Table Z-1). WARNING Follow the inspection and maintenance schedule and Always make sure the parking brake is fully applied procedures in this manual.
Page 62 The fork lift truck is designed to pickup, move, and tier mate- eign materials. Contact your local Yale dealer for forklift rials. The basic lift truck has a lift mechanism and forks on modifications that may be appropriate in environments the front to engage the load.
Page 63: Stability And Center Of Gravity
Operating Procedures Stability and Center of Gravity forward and back. The CG moves up and down as the mast moves up and down. The center of gravity (CG) of any object is the single point about which the object is balanced in all directions.
Page 64: Capacity (Weight And Load Center)
Operating Procedures unloaded truck will tip over to the side easier than a loa- Capacity (Weight and Load Center) ded truck with its load in the lowered position. The capacity of the lift truck is shown on the Nameplate. The In order for the lift truck to be stable (not tip over forward or capacity is listed in terms of weight and load center.
Page 65: Impact Sensor
Operating Procedures center of gravity of the load. Both the vertical and horizontal icon will be displayed on the LCD screen. If the time is set to load centers are specified on the Nameplate. 0 seconds, the lift truck will shut down right after the impact is detected and no alarm will sound.
Page 66: Inspection Before Operation
Operating Procedures Inspection Before Operation • Seat is correctly fastened to its mounts. Hood is correctly latched. WARNING • Condition of the engine compartment. Ensure all surfaces Report damage or faulty operation immediately. Do not are free of oils, lubricants, fuel, and organic dusts or fibers operate a lift truck that needs repair.
Page 67: Operator Checklist
Operating Procedures Operator Checklist 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 If your lift truck is equipped with the optional operator check- (starter, engine outputs, transmission and hydraulic functions list, it can be enabled or disabled by a supervisor or service disabled) if any item in the checklist is answered with a NO...
Page 68: Operator Passwords
Operating Procedures hands free of any obstacles such as food, beverages, or • Supervisor: Has all rights assigned to Operator and Lock- tools. out Reset passwords. Can add, edit, and delete Operator or Supervisor passwords and view all truck diagnostic Operator Passwords information.
Page 69: Starting Procedures
Operating Procedures If the truck is locked out, the message PASSWORD LOCK- • Operator must be in seat OUT, SUPERVISOR REQUIRED is displayed. A Lockout • Seat belt must be fastened Reset, Supervisor, or Service password is needed to unlock the lift truck.
Page 70: Starting Procedures, Trucks With Keyless Start Option
Operating Procedures 3. The Engine Control Unit (ECU) will automatically begin a 12. On trucks equipped with a LPG or gasoline engine, turn warm-up/thaw cycle which preheats select fuel system com- the key to the START position to engage the starter. The ponents.
Page 71 Operating Procedures 7. Make sure the parking brake is applied or push on the WARNING inching/brake pedal. Gasoline is extremely flammable. Do not start the engine if a gas leak is detected. 8. If equipped, put the direction control lever for the trans- mission in the NEUTRAL (N) position.
Page 72: Checks With The Engine Running
Operating Procedures For all engine types, if engine fails to start after 30 seconds, the starter will shutdown for 60 seconds to cool off. A 60- Checks With the Engine Running second countdown timer will appear on the LCD screen showing the time remaining before a restart attempt can be WARNING tried.
Page 73: Load Weighing Sensor
Operating Procedures THE SEAT BELT AND HIP RESTRAINT bracket provides a • Check the operation of the service brakes and parking means to help the operator keep the head and torso sub- brake. stantially within the confines of the truck frame and overhead •...
Page 74: Set Load Weight To Zero
Operating Procedures 2. Lift the load 0.6 m (2 ft) off the ground, but if freelift cylinder Certain faults or sensor measurements can cause the truck is present, not more than maximum freelift. to go into Engine Shutdown mode. The following actions occur when truck is in this mode: 3.
Page 75: Engine Modes (Generation 2 Eco-Elo)
Operating Procedures button. If the Engine Start button is pressed before the Power Take the lift truck to a service technician immediately for ON/OFF button, the starter will not operate. See Starting repair if it experiences a decrease in performance. Procedures, Trucks With Keyless Start Option in this sec- Engine Modes (Generation 2 ECO-eLo) tion, if starter becomes disabled.
Page 76: Operating Techniques
Operating Procedures Operating Techniques WARNING Before operating the lift truck, FASTEN YOUR SEAT BELT. There are a number of operations, if not performed carefully, that can cause the lift truck to tip. If you have not read the WARN- ING page in the front of this Operating Manual, do so NOW.
Page 77 Operating Procedures A lift truck is a special machine designed to do a much dif- WARNING ferent job than an automobile. Because of the close areas in This lift truck is designed for handling materials. A lift which a lift truck operates and its other operating character- truck is not designed to lift people.
Page 78 Operating Procedures Before anyone is allowed in the platform, lift and lower Seat Adjustment for Operator Weight the mast slowly with the platform in place to make sure CAUTION the mast functions properly. Apply the parking brake. Do A major cause for high Whole Body Vibration is caused not travel with people in the platform.
Page 79 Operating Procedures Legend for Figure 11 SEAT BELT WEIGHT ADJUSTMENT KNOB RIDE POSITION INDICATOR FORWARD/BACKWARD ADJUSTMENT LEVER BACKREST ANGLE ADJUSTMENT LEVER ARMREST SWIVEL LATCH RELEASE LEVER 4. ADJUST SEAT - FULL SUSPENSION. Seat Position Adjustment (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.
Page 80 Operating Procedures Seat Adjustment for Operator Weight feet positioned on the pedals. This ensures that the oper- ator is set at the midpoint of the 80 mm (3.5 in.) suspen- CAUTION sion. A major cause for high Whole Body Vibration is caused •...
Page 81 Operating Procedures Figure 12. Seat Adjustment - Full Suspension...
Page 82: Driving And Direction Changes
Operating Procedures Legend for Figure 12 STANDARD, NON-SWIVEL SEAT FULL SUSPENSION SWIVEL SEAT SEAT BELT BACKREST ANGLE ADJUSTMENT LEVER WEIGHT ADJUSTMENT KNOB ARMREST RIDE POSITION INDICATOR SWIVEL LATCH RELEASE LEVER FORWARD/BACKWARD ADJUSTMENT LEVER 5. Do not drive a lift truck into an elevator unless authorized power.
Page 83 Operating Procedures Table 5. Transmissions Operational Feature StandardTransmission Techtronix 100 Transmission Electronic Inching Electronic Control of Direction Changes Auto Deceleration – Controlled Power Reversal – Roll Reduction Feature – Roll Back Feature – Reduced Drive Tire Slippage – STANDARD TRANSMISSION TECHTRONIX 100 TRANSMISSION Figure 13.
Page 84: Seat Switch Sensor
Operating Procedures Seat Switch Sensor A switch in the operator's seat will automatically shift the transmission to neutral within 1-2 seconds when the operator WARNING leaves the seat of the lift truck with the engine running and without applying the parking brake. Always make sure the parking brake is fully applied before leaving the lift truck.
Page 85: Standard Operator Presence System
Operating Procedures Standard Operator Presence System A switch in the operator's seat will automatically shift the transmission to neutral within 1-2 seconds when the operator WARNING leaves the seat of the lift truck with the engine running and without applying the parking brake. Always make sure the parking brake is fully applied before leaving the lift truck.
Page 86: Optional Operator Presence System
Operating Procedures Optional Operator Presence System disengage the transmission and disable the hydraulic mast functions. WARNING When the operator returns to the seat, if it was not set, the ALWAYS make sure the parking brake is fully applied parking brake must be applied and released. before leaving the lift truck.
Page 87: Techtronix 100 Transmission
Operating Procedures be changed by a Yale Service Technician when required CAUTION to meet special application requirements. The drive train can be damaged if the lift truck is traveling too fast when the controls are changed to the opposite The Techtronix 100 transmission allows the operator to direction of travel.
Page 88 Auto-Deceleration Feature can be stop. Failure to use the service or parking brakes could changed by a Yale Service Technician when required to result in damage to the lift truck and/or injury to person- meet special application requirements.
Page 89: Inching
Operating Procedures Roll Back Feature The inching/brake pedal is used to control the inching oper- ation. When the inching/brake pedal is initially applied, the If the operator uses the brakes to bring the lift truck, regard- clutch in the transmission is partially disengaged and the less of direction selected, to a stop on a grade;...
Page 90: Steering (Turning)
Operating Procedures Steering (Turning) aggravate these conditions and cause the forklift to become unstable. WARNING WARNING TRAVEL SLOWLY WHEN TURN- Failure to observe the tail swing area when making a turn ING. Lift trucks can tip over even can injure or kill someone. at very slow speeds.
Page 91: Load Handling, General
Operating Procedures Load Handling, General Do not turn on an incline. To reduce the possibility of a tipover, a lift truck 1. The capacity is the maximum load must not be driven across an incline. that the lift truck can handle for the When possible, keep both hands on load condition shown on the Name- the steering wheel.
Page 92: Load Handling, Lifting, Lowering, And Tilting
Operating Procedures If the weight of the load is not centered between the forks, WARNING the load can fall from the forks when you turn a corner or hit a bump. An off-center load will increase the possibility of the Do not handle a load if any truck tipping over to the side.
Page 93 Do not lift or hit anything that can fall on the operator or a The operator must exercise care while working near such bystander. Remember, a lift truck equipped with a Yale over- objects. Whether the lift truck is loaded or empty, do not travel head guard and load backrest extension provides reasonable with the load or carriage in a raised position.
Page 94 Operating Procedures not only to the operator but also a helper. A helper must braking when traveling forward, or accelerating in not be near the load or lift mechanism while the operator reverse. is attempting to handle a load. The lift mechanism has If the lift mechanism is raised to pick up or deposit a load, moving parts with close clearances that can cause seri- keep the tilt angle in either direction to a minimum.
Page 95: Load Handling, How To Engage And Disengage A Load
Operating Procedures Load Handling, How to Engage and Disengage Make sure that the load is centered between the forks. Make sure that the forks do not extend past the load so that loads a Load or equipment that are behind the load being lifted are not damaged.
Page 96 Operating Procedures as low as possible and tilted backward. Lowering speed is controlled by the position of the control lever. Lower slowly 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.
Page 97 Operating Procedures Move forward slowly. When the load is in position, lower the IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE OR load on to the stack or the rack. Lower the forks just enough FORWARD, DO NOT JUMP OFF! HOLD FIRMLY TO to remove them from under the load.
Page 98: Load Handling, Traveling
Operating Procedures under the object to be lifted. Tilt the mast fully backward to help keep the load on the forks. 2. Travel with the lift mechanism raised only enough to clear the ground or obstacles. When the mast, carriage, or load is in a raised position, the stability of the lift truck is reduced.
Page 99 Operating Procedures in the direction of travel to avoid damage to something or injury to someone. 3. For better visibility with large loads, travel with the load trailing, but always keep a proper lookout in the direction of travel. Normally, direction of travel is determined by the best visibility available to the operator.
Page 100 Operating Procedures 8. Watch clearances, especially forks, mast, overhead guard, 6. Anytime the lift truck is moving and tail swing. A lift truck is designed to perform a wide variety keep arms, legs, etc., inside the of functions within limited space. operator's compartment.
Page 101 Operating Procedures 10. Do not pass another lift truck traveling in the same direc- 12. Under all travel conditions, oper- tion at intersections, blind spots, or at other dangerous loca- ate the lift truck at a speed that will tions. permit it to be brought to a stop in a safe manner.
Page 102: Load Handling, Emergency Load Lowering
Operating Procedures Load Handling, Emergency Load Lowering NOTE: The emergency load lowering valve is to be used ONLY if the electrical signal to the main control valve has been disrupted and there is a load lifted. WARNING On trucks equipped with an electronic hydraulic control To use the emergency load lowering valve, follow these valve, when the electronic signal to the mini-levers or steps:...
Page 103 Operating Procedures EMERGENCY LOAD LOWERING VALVE COWL WELDMENT MAIN CONTROL VALVE KICK PANEL Figure 14. Emergency Load Lowering Valve...
Page 104: Highway Trucks, Rail Cars, And Docks
Operating Procedures Highway Trucks, Rail Cars, and Docks • 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 specifi- cally designed for opening and closing rail car doors and WARNING the operator is trained in its use.
Page 105: Attachments
Operating Procedures that the rail car will not move due to the movement of the operating the attachment. For the operation of attachment lift truck in and out of the rail car. control levers, see Figure 9, Figure 10, and Table 3. •...
Page 106: Connecting Attachment Hydraulic Quick-Disconnect Hoses
Operating Procedures 7. Move the manual hydraulic levers forward and backward to relieve the system hydraulic pressure. 8. Disconnect the Quick-Disconnect hose connectors. Connecting Attachment Hydraulic Quick- Disconnect Hoses NOTE: Step 1 through Step 4 is to be used for lift trucks equipped with manual hydraulics.
Page 107: Stopping
Operating Procedures 8. Move the mini-levers forward and backward, and check 2. Fully lower the forks or carriage. Tilt mast forward until the the hydraulic system for leaks. tips of the forks touch the ground. Stopping 3. If equipped, move the Direction Control Lever to the NEU- TRAL position.
Page 108: Maintenance
Disposal of lubricants and fluids must meet local envi- mal conditions will require more frequent servicing. ronmental regulations. Your dealer for Yale lift trucks has the equipment and trained NOTE: Unless otherwise noted, overhead views of lift trucks service personnel to do a complete program of inspection, on the following pages are equipped with iron case trans- lubrication, and maintenance.
Page 109: Serial Number Data
Schedule. Service Manuals are available from Never lift and move a disabled lift truck unless the disa- your dealer for Yale lift trucks to help users who do their own bled lift truck MUST be moved and cannot be towed. A maintenance.
Page 110: How To Put A Lift Truck On Blocks
Maintenance approximately 30 cm (12 in.) from surface. Install a chain Before removing the mast and drive axle, put blocks around a mast crossmember and the carriage, to prevent under the counterweight so that the lift truck cannot carriage and mast channels from moving. fall backward.
Page 111: How To Raise The Steering Tires
Maintenance 4. Put additional blocks under the frame behind the drive How to Clean a Lift Truck tires. CAUTION 5. If the hydraulic system will not operate, use a hydraulic jack Your lift truck may be damaged if water or cleaning under the side of the frame near the front.
Page 112: Maintenance Schedule
Maintenance Schedule DRIVE TIRES STEERING TIRES Figure 16. Put a Lift Truck on Blocks Maintenance Schedule...
Page 113 Maintenance Schedule Figure 17. Kubota 2.5L LPG Engine Maintenance and Lubrication Points...
Page 114 Maintenance Schedule Figure 18. PSI 2.4L Dual Fuel Engine Maintenance and Lubrication Points...
Page 115 Maintenance Schedule Figure 19. Yanmar 2.6L and 3.3L Diesel Engine Maintenance and Lubrication Points...
Page 116 Maintenance Schedule Figure 20. Kubota 2.4L Diesel Engine Maintenance and Lubrication Points...
Page 117 Maintenance Schedule Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity TIRES Check...
Page 118 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity ENGINE COMPARTMENT Remove...
Page 119 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity FUEL TANK (GAS) 52 liter...
Page 120 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity TRANSMISSION Check...
Page 121 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity ENGINE OIL 4.9 liter...
Page 122 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity ENGINE OIL 10.2 liter...
Page 123 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity ENGINE OIL FILTER 1 Filter...
Page 124 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity ENGINE GOVERNED 2600 ±25 RPM...
Page 125 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity DRIVE BELT Check for...
Page 126 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity PCV VALVE Check Only.
Page 127 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity VAPORIZER REGULATOR Drain Oil.
Page 128 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity FUEL/WATER 1 Filter...
Page 129 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity 10,11 COOLING SYSTEM...
Page 130 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity MAST Lubricate as...
Page 131 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity MAST Lubricate as...
Page 132 Spindle Bearings See NOTE 8. GLC040-70VX, GLC055SVX (C910) PEDALS, LEVERS, SEAT Lubricate as Yale Part No. 504236201 RAILS, CABLES, HINGES, Necessary. LINKAGES, HOOD LATCH X = Check C = Change L = Lubricate CIL = Check indicator light during operation...
Page 133 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity SERVICE BRAKES Check Lining...
Page 134 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity WET BRAKE AXLE 2.0 liter...
Page 135 (dust and waste 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 dealer will advise you of the appropriate service intervals based on an application survey.
Page 136 Maintenance Schedule Table 6. (See Figure 17 Through Figure 20) (Continued) 8 Hr/ 250 Hr/ 500 Hr/ 1000 Hr/ 2000 Hr/ 4000 Hr/ Procedure Item No. Item Specification 1 Day 6 Mo 6 Mo 6 Mo 1 Yr 2 Yr or Quantity NOTE 12: Replace after 3000 hours.
Page 137: Maintenance Procedures Every 8 Hours Or Daily
Maintenance Maintenance Procedures Every 8 Hours or Daily How to Make Checks With the Engine Stopped Clean any oil or fuel spills. Ensure all surfaces are free of oils, lubricants, fuel and organic dust or fibers (paper, wood, cot- ton, agricultural grass/grain, etc.). WARNING Do not operate a lift truck that needs repairs.
Page 138 Maintenance CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD) MAKE SMOOTH EDGES CHECK THE TIRE PRESSURE (PNEUMATIC TIRES) Figure 21. Check the Tires...
Page 139: Safety Labels
Maintenance Safety Labels 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. WARNING Safety labels are installed on the lift truck to give infor- Never repair damaged forks by heating or welding.
Page 140 Maintenance 6. Check that the lift chains are correctly lubricated. Use SAE 30 engine oil to lubricate the lift chains. 7. Inspect the lift chains for cracks or broken links and worn or turned pins. Lift chains must be replaced as a set. See Figure 22.
Page 141: Operator Restraint System
Maintenance Operator Restraint System item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition. The seat belt, hip restraint, seat, hood, and hood latches are all part of the operator restraint system (see Figure 23). Each...
Page 142 Maintenance BACKWARD ANGLE ADJUSTMENT LEVER HOOD SEAT BELT HIP RESTRAINTS SEAT FORWARD/BACKWARD ADJUSTMENT LEVER SEAT RAIL OPERATOR WEIGHT ADJUSTMENT HOOD LATCH Figure 23. Hood and Seat Check...
Page 143: Emergency Locking Retractor (Elr)
Maintenance Emergency Locking Retractor (ELR) retractor assembly or the belt will not retract, replace the seat belt assembly. When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning • With the hood closed and in the locked position, pull the without activating the locking mechanism.
Page 144: Engine Compartment
Maintenance Engine Compartment Check for the presence of any combustible material such as paper, leaves etc. Remove any combustible materials. Paper Application Vehicles used in paper applications require regular inspec- tion and cleaning to minimize the risk of fire. This should be done at least once every 8 hours or more frequently depend- ing upon operating environment.
Page 145 Maintenance With engine OFF and lift truck components cooled, check and access hard to reach places. Remove floor plates and side clean the radiator and if equipped, radiator screen. Check covers for better access to engine compartment. Open or engine manifold, exhaust pipes, muffler, and catalytic con- remove belly pan, if equipped.
Page 146: Fuel, Oil, And Coolant Leaks, Check
Maintenance Fuel, Oil, and Coolant Leaks, Check Hydraulic Hoses Check the condition of the hydraulic hoses for serviceability WARNING by inspecting for cracks or other obvious damage. Check to All fuels are very flammable and can burn or cause an insure that the hydraulic hoses are not leaking.
Page 147: Hydraulic System Oil
Maintenance Hydraulic System Oil WARNING At operating temperature the hydraulic oil is HOT. Do not permit the hot oil to touch the skin and cause a 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.
Page 148: Engine Oil
Maintenance Engine Oil 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 There is an indicator light for the engine oil pressure on the a keyless option, and will stay illuminated until correct oil Display Switch Cluster.
Page 149 Maintenance BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP DRIVE BELT AIR FILTER ENGINE OIL FILTER DIPSTICK ENGINE OIL FUEL FILTER FUEL INJECTOR ENGINE OIL FILL Figure 26. Yanmar 2.6L and 3.3L Diesel Engine Maintenance Points...
Page 150 Maintenance DIPSTICK ENGINE OIL BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP ENGINE OIL FILL DRIVE BELT AIR FILTER FUEL FILTER ENGINE OIL FILTER PCV VALVE SPARK PLUGS Figure 27. Kubota 2.5L Engine Maintenance Points...
Page 151 Maintenance DIPSTICK ENGINE OIL BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP ENGINE OIL FILL DRIVE BELT AIR FILTER FUEL FILTER ENGINE OIL FILTER PCV VALVE SPARK PLUGS FUEL INJECTOR (GAS ONLY) Figure 28. PSI 2.4L Engine Maintenance Points...
Page 152 Maintenance FUEL/WATER SEPARATOR ENGINE OIL FILTER AIR FILTER ENGINE OIL FILL DIPSTICK ENGINE OIL BATTERY AUXILIARY COOLANT RESERVOIR RADIATOR CAP DRIVE BELT Figure 29. Kubota 2.4L Diesel Engine Maintenance Points...
Page 153: Air Filter
Maintenance Air Filter can occur if fork latch pins are not removed prior to using attachment. The air filter canister should not be opened until an air filter NOTE: Forks must be removed or installed by trained per- element replacement is required. An air filter element sonnel only.
Page 154 Maintenance OUTER FORK CARRIER FORKS INNER FORK CARRIER SIDESHIFT CARRIAGE FORK POSITIONER CAPSCREWS FORK REMOVAL NOTCH Figure 30. Fork Positioner...
Page 155 Maintenance WARNING Do not try to move a fork without a lifting device. Each hook fork for these lift trucks can weigh 45 to 115 kg (99 to 253 lb). NOTE: Forks are to be replaced only in sets and not individ- ually.
Page 156: Forks, Inspect
Maintenance Forks, Inspect 1. Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 33. Check that the bottom of the fork is not worn (Item 4 in Figure 33). 2. Replace any damaged or broken parts that are used to keep the forks locked in position.
Page 157: Forks, Adjust
Maintenance Forks, Adjust bar. If pin does not remain engaged in carriage slot, replace with new pin. Adjust the forks as far apart as possible for NOTE: During the adjustment of the forks, the heel of the maximum support of the load. Hook forks will slide along the forks should not be touching the ground.
Page 158 Maintenance Fork Tip Alignment Length of Forks 3% Dimension 915 mm (36 in) 27 mm (1.10 in) 1067 mm (42 in) 32 mm (1.26 in) 1220 mm (48 in) 37 mm (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)
Page 159: How To Make Checks With The Engine Running
Maintenance How to Make Checks With the Engine Running Indicator Lights, Horn, Fuses, and Relays If lift truck is equipped with a key switch, turn key to ON posi- WARNING tion. If lift truck is equipped with a Power ON/OFF button, DO NOT operate a lift truck that needs repairs.
Page 160 Maintenance NOTE: HOOD REMOVED FOR CLARITY. BATTERY POWER DISTRIBUTION MODULE (PDM) RESISTOR (68 OHM) START RELAY STARTER (30 AMP FUSE) IGNITION 3 RELAY BACKUP RELAY BACKUP (20 AMP FUSE) IGNITION (30 AMP FUSE) SPARE FUEL PUMP (20 AMP FUSE) SPARE FUEL PUMP RELAY BATTERY (25 AMP FUSE) FRONT WORK LIGHT (20 AMP FUSE) FRONT/REAR WORK LIGHT RELAYS...
Page 161: Service Brakes
Maintenance Service Brakes There is an indicator light on the Display Switch Cluster for the brake fluid. The red light is ON when the key switch is in Brake Fluid Level the START position or the Power ON/OFF button is pressed, and must go OFF when the engine is running.
Page 162: Parking Brake
Maintenance Parking Brake is a slope that increases 1.5 m in 10 m (1.5 ft increase in 10 ft). Make sure the service brakes are adjusted and the operation of the automatic adjuster mechanism is correct before the parking brake is adjusted. Lift trucks with a Foot Directional Control pedal: A switch energizes the seat warning circuit when the hand lever is released.
Page 163: Engine Oil Pressure
Additives may damage the cooling system. Before using NOTE: The engine will enter shutdown mode after a warning additives, contact your local Yale dealer. buzzer sounds and a 30-second countdown if coolant tem- perature reaches 121 °C (250 °F) or above, on lift trucks with If coolant is added, use the correct mixture of water and eth- powertrain protection system.
Page 164 Maintenance WARNING Compressed air can move particles so that they cause injury to the user or to other personnel. Make sure that the path of the compressed air is away from all person- nel. Wear protective goggles or a face shield to prevent injury to the eyes.
Page 165: Steering System
Maintenance Steering System parts of the mast are completely lowered and the engine is STOPPED. WARNING If the mast cannot be lowered, use chains on the mast The lift truck has hydraulic power steering. The steering weldments and carriage so that they can not move. Make can be difficult if the engine is not running.
Page 166: How To Add Fuel To The Lift Truck
Maintenance 3. The inner weldments and the carriage must lower com- All fuels for internal combustion engines are very flam- pletely. mable. 4. Raise the mast 1 m (3 ft) with a capacity load. The inner Fill the fuel tank only in a designated area with good weldments and the carriage must raise smoothly.
Page 167: Lpg Tank, Remove
Maintenance LPG is extremely flammable. When checking or filling an Removable LPG tanks must be removed from the fork lift LPG tank: No smoking. Stop engine. before filling. If the lift truck is equipped with a non- removable LPG tank, make sure all components (engine, Frost on the surface of the tank, the valves or fittings and transmission, muffler, catalytic muffler) have surface the odor of LPG fuel indicates a leak.
Page 168 Maintenance 4. Disconnect the quick-disconnect fitting on the LPG tank. tank bracket (EZ Tank Bracket), drop the tank down to the See Figure 37. side of the truck for ease of removal. 5. Push in the bracket release pin, grab the bracket handle, 6.
Page 169 Maintenance Figure 37. LPG Tank and Bracket...
Page 170: Lpg Tank, Fill
Maintenance Legend for Figure 37 SWING OUT BRACKET (EZ TANK BRACKET) LPG TANK STOP PIN TANK STRAP BRACKET HANDLE QUICK DISCONNECT FITTING BRACKET PIVOT HYDROSTATIC RELIEF VALVE GAS SPRING (EZ TANK BRACKET) MANIFOLD BLOCK BRACKET RELEASE PIN ALIGNMENT PIN LPG Tank, Fill so that the liquid level indicator will always be in the vapor space above the liquid level.
Page 171: Lpg Tank, Install
Maintenance 8. Watch for a discharge from the vent valve on the liquid quickly and with enough force to cause injury to the fin- level indicator. When a cloud of visible vapor appears, the gers and hand. LPG tank is full. Do not fill the LPG tank to more than the 1.
Page 172: Gasoline Or Diesel Fuel
Maintenance fuel cannot be heard, apply soapy water to the fittings and tires also cause a variation in the types of wheels and the observe for bubbles. disassembly and assembly procedures. d. Frost - If the amount of LPG escaping is sufficient, frost How to Change a Solid Rubber Tire (GC/GLC may appear on the fittings.
Page 173: Remove And Install The Tire On The Wheel
Maintenance Remove and Install the Tire on the Wheel 3. The steering wheels are fastened to the spindle of the steering axle with a large castle nut. Make sure inner and NOTE: Make sure the tires are installed on the wheels so that outer bearings are correctly lubricated with grease.
Page 174 Maintenance STEERING TIRE AND WHEEL DRIVE TIRES AND WHEELS WIDE TREAD OUTSIDE OF SOLID RUBBER TIRE WHEEL OVERHANG Figure 38. Tires and Wheels GC/GLC040VX, GC/GLC050VX, GC/GLC060VX, GC/GLC070VX, GC/GLC055SVX (C910) Lift Trucks...
Page 175: Pneumatic Tire With Tube, Repair
Nameplate listed ply rating may be acceptable. Check 1. Put the lift truck on blocks as described in How to Put a with your dealer whether a specific bias-ply tire is Lift Truck on Blocks at the beginning of this section. approved for use on Yale trucks.
Page 176: Remove Tire From Wheel
Maintenance 2. Remove the air from the tire. Remove the valve core to Remove Tire From Wheel make sure that all of the air is out of the inner tube. Push a When disassembling wheels, see Figure 39. There are sev- wire through the valve stem to make sure that the valve stem eral types of wheels used on this series of lift trucks.
Page 177 Maintenance NOTE: TUBELESS TIRES ARE MOUNTED ON WHEEL TYPES SHOWN IN ILLUSTRATIONS B OR D. TWO-PIECE WHEEL THREE-PIECE WHEEL OPTIONAL RIM ASSEMBLY FOUR-PIECE WHEEL WHEEL RIM LOCK RING SIDE FLANGE FLANGE SEAT Figure 39. Types of Pneumatic Wheels...
Page 178: Tire Removal, Two-Piece Wheel
Maintenance Tire Removal, Two-Piece Wheel WARNING Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the tires can cause the tire and rim parts to explode causing seri- ous injury or death. Keep tire tools in firm contact with the wheel parts.
Page 179: Tire Removal, Three- And Four-Piece Wheels
Maintenance Tire Removal, Three- and Four-Piece Wheels 2. Put the tire tool into the slot between the lock ring and wheel WARNING rim. Remove the lock ring and side Make sure all of the air pressure is removed from the tire flange.
Page 180 Maintenance • DO NOT use any damaged or repaired wheel parts. WARNING • Make sure that all parts of the wheel are the correct Do not lubricate the tire bead with antifreeze or petro- parts for that wheel assembly. leum-based liquid. Vapors from these liquids can cause an explosion during inflation or use.
Page 181: Tire Installation, Three- Or Four-Piece Wheel
Maintenance Tire Installation, Three- or Four-Piece Wheel 25 mm (0.5 to 1.0 in.) after it is installed. If the clearance is wrong, the wrong part has been used. WARNING 1. Install the inner tube and the rubber flap Damage to the tire and wheel assembly and injury or in the tire.
Page 182: Tire Installation, Two-Piece Wheel
Maintenance 3. Turn over the rim and tire. Put 1. Install the inner tube and the blocks under the rim so that the rim rubber flap in the tire. Install both is 8 to 10 cm (3 to 4 in.) above the halves of the wheel rim in the tire.
Page 183 Maintenance WARNING Do not sit or stand by the safety cage. Do not use a ham- mer to try and correct the position of the side flange or lock ring when the tire has air pressure greater than 20 kPa (3 psi) of air pressure to the tire. 1.
Page 184: Install The Wheels
Maintenance 13 to 25 mm (0.5 to 1.0 in.) when the tire has the correct air Never loosen the nuts that hold the inner and outer pressure. wheels halves together when there is air pressure in the tire. Install the Wheels WARNING Install the wheel on the hub.
Page 185: Remove Tire From Wheel
Maintenance 2. Remove the valve cap and core to remove all air from the 1. If the tire is equipped with a tire. Tubeless Bead Seal (TBS) 3. Remove the wheel nuts and remove the wheel and tire style rubber sealing ring with a from the lift truck.
Page 186: Install Tire On Wheel
Maintenance 3. Remove the loose flange 5. Push the TBS or TSR locking ring and the advance toward the inside of the tire to band (four-piece wheel only) remove it. using a tire tool. Install Tire on Wheel 4. Remove the press and WARNING remove the loose flange lock- Damage to the tire and wheel...
Page 187 Maintenance WARNING 1. Clean interior and exterior Do not use a steel hammer on the wheel. Use a rubber, bead area of the tire. Lubri- lead, plastic, or brass hammer to put parts together. cate tire beads and the inside of the tire, up to the WARNING tire shoulders.
Page 188 Maintenance 4. Apply lubricant to the rim. If a four-piece wheel is being 2. For TBS, apply lubricant to used, lubricate the advance band. Slide the tire and rubber the needle valve and the valve sealing ring onto the wheel. hole that will be used (see NOTE in Step 1), by inserting For TSR, use a lever to push...
Page 189 Maintenance 5. For TBS, with separate CAUTION valve stems, place the wheel DO NOT compress the bead and tire assembly on a flat sur- too far and cause the rubber face. Turn the valve a 1/4 turn sealing ring to become dis- to lock the collar under the torted and damage the valve edges of the rim valve slot.
Page 190: Add Air To Pneumatic Tubeless Tire
Maintenance Add Air to Pneumatic Tubeless Tire WARNING Add air pressure to the tires only in a safety cage. See Figure 41. Inspect the safety cage for damage before use. When air pressure is added, use a chuck that fastens onto the valve stem.
Page 191: Solid Rubber Tires On Pneumatic Wheels, Change
Maintenance Solid Rubber Tires on Pneumatic Wheels, WARNING Change Wheels must be changed and tires repaired by trained personnel only. WARNING Always wear safety glasses. Wheels must be changed and tires repaired by trained personnel only. 1. Put the wheel rim on the Always wear safety glasses.
Page 192: Install Tire On Wheel
Maintenance 2. Put the tire tool into the slot 3. Put the cage in position on between the lock ring and the the tire. Use the press to push wheel rim. Remove the lock the tire from the wheel rim. ring and side flange.
Page 193 Maintenance Do not use a steel hammer on the wheel. Use a rubber, 2. Put the wheel rim on the bed lead, plastic, or brass hammer to put parts together. of the press. Put the tire over Make sure that the lock ring is in the correct position. the wheel rim.
Page 194: Dual Drive Wheels, Install
Maintenance wheel nuts. If the wheels are the two-piece rims, make sure 4. While the cage is holding the nuts that fasten the rim halves together are toward the the tire on the wheel rim, brake drum when they are installed. install the lock ring.
Page 195: Jump-Starting The Lift Truck
Maintenance Jump-Starting the Lift Truck Jump-Starting Using Another Lift Truck Jump-Starting Using a Battery Charger WARNING To prevent possible arcing between the two lift trucks, CAUTION make sure that the lift trucks are not touching. DO NOT try to start the engine by pushing or towing the CAUTION lift truck.
Page 196: Operating Procedures For A New Or Rebuilt Engine
2. Start and run the engine at approximately one-half throttle for 30 minutes for the first operation. Check the gauges and See your dealer for Yale lift trucks BEFORE performing indicators for the correct operation during this first operating any changes to the overhead guard.
Page 197: Short-Term Storage
Maintenance and tag them with the lift truck serial number. For best pro- Apply a thin coat of fresh, high grade SAE 30 or 40 weight tection, operate your internal combustion engine lift truck for engine oil to the exposed cylinder rods. If the forks are a short period each month.
Page 198: Long-Term Storage
Maintenance Long-Term Storage NOTE: Do not shut down an engine before it reaches oper- ating temperature. Do the following steps to prepare the lift truck for storage for Each month set the park brake, start engine, and run until 6 months or longer: normal operating temperature is reached.
Page 199: Putting A Stored Lift Truck Back Into Service
Maintenance This "self-discharge" is due to a chemical reaction; therefore, Putting a Stored Lift Truck Back Into Service that chemical reaction can be accelerated by heat resulting 1. Remove all tape, covers, and preservation materials. in more rapid "self-discharge." The rate of discharge can amount to an average of about 0.001 point drop in specific 2.
Page 200: Loading
Maintenance lift truck away from the edge of the dock, the rear will If the lift truck is equipped with lifting eyes, use a crane to load swing toward the edge. This can cause the lift truck to and unload the lift truck from the transport. If the truck is not fall off the dock.
Page 201: Unloading
Maintenance The operator must never leave a lift truck in a condition so parked outside or the LPG tank must be removed and stored that it can cause damage and injury. When the lift truck is outside. loaded on the transport, do the following operations: If the lift truck is transported in severe weather or any other 1.
Page 202: Preparation For Use
Maintenance Preparation for Use Preparation After Transport After being transported or stored, the lift truck must be pre- 1. Complete the unloading procedures. pared for use for proper operation. All problems must be cor- 2. Inspect the lift truck for damage and missing components. rected before use of the lift truck, see the Service Manual for procedures.
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