Page 1 OPERATING MANUAL VERACITOR® GC/GLC030-035VX, GC/ GLC040SVX (C809) GP/GLP/ GDP030-035VX, GP/GLP/ GDP040SVX (C810) PART NO. 524239830 2/20 DO NOT REMOVE THIS MANUAL FROM THIS UNIT...
Page 2 STEERING TIRE SIZE SPECIAL EQUIPMENT OR ATTACHMENTS © Yale Material Handling Corporation 2020. All Rights Reserved. YALE and VERACITOR are Registered Trademarks of Hyster-Yale Group, Inc. CSS, PREMIER, and are Trademarks in the United States and certain jurisdictions. is a registered copyright.
Page 3: Foreword
NOTE: A comprehensive operator training program is avail- • Understand the capabilities and limitations of the lift able from Yale Corporation. For further details, contact truck. your 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 ........69 TO OWNERS, USERS, AND OPERATORS: ..... Operator Passwords ..........69 Warning ................ Starting Procedures ..........70 Model Description ............10 Starting Procedures, Trucks With Key Switch ..GENERAL ..............11 Starting Procedures, Trucks With Keyless Start OPERATOR PROTECTION EQUIPMENT ....
Page 6 Contents Load Handling, How to Engage and Disengage a Tires and Wheels ............141 Load ..............95 Safety Labels ............143 Load Handling, Traveling .......... 98 Mast, Carriage, Header Hoses, Lift Chains, and Load Handling, Emergency Load Lowering ....102 Attachment ............
Page 7 Contents Brake Fluid Level ............ 162 Tire Installation, Two-Piece Wheel ......182 Operation, Check ............ 162 Add Air to Pneumatic Tires With Tube ...... 183 Parking Brake ............163 Install the Wheels ............. 184 Engine Oil Pressure ..........164 PNEUMATIC TUBELESS TIRE, REPAIR ....184 Cooling System ............
Page 8 Contents Long-Term Storage ........... 198 Loading ..............200 While the Lift Truck is in Storage ......198 Unloading ..............201 How to Put Batteries in Storage ........ 198 PREPARATION FOR USE ......... 202 Putting a Stored Lift Truck Back Into Service ... 199 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 • HANDLE only stable loads within specified weight and parts must meet or exceed the specifications of the origi- load center.
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 COMPONENTS FOR GP/GLP/GDP30-35VX AND GP/GLP/ GDP40SVX TRUCKS ARE IN SAME LOCATIONS. OVERHEAD GUARD TAIL, BRAKE, AND REVERSE LIGHTS SEAT COUNTERWEIGHT STEERING AXLE SEAT BELT AND HIP RESTRAINT DRIVE AXLE CARRIAGE FORKS LOAD BACKREST EXTENSION PARKING BRAKE STEERING WHEEL MAST OPERATING MANUAL (BEHIND SEAT)
Page 13: General
Model Description Model Description General • A Foot Directional Control (FDC) pedal that controls both the forward and reverse operation of the transmission This Operating Manual is for the following models of lift and the speed of the engine. trucks: •...
Page 14 Model Description If your lift truck is an GC/GLC030VX, GC/GLC035VX, and If your lift truck is equipped with electronic hydraulics, it has GC/GLC040SVS (C809) with manual hydraulics and manu- an emergency lowering valve. factured prior to March, 2009, it is not equipped with an This emergency lowering valve (see Figure 15) allows the emergency lowering valve.
Page 15 Model Description Table 1. Transmissions Operational Transmission Feature Electronic Inching Electronic Control of Direction Changes Auto Deceleration – Controlled Power Reversal – Roll Reduction Feature – Roll Back Feature – Reduced Drive Tire Slippage –...
Page 16: Operator Protection Equipment
Model Description not be considered a substitute for good judgment and care when handling loads. Do not remove the overhead guard. NOTE: The seat belt can be either black or red. The SEAT BELT AND HIP RESTRAINT provide additional means to help the operator keep the head and torso sub- stantially within the confines of the lift truck frame and over- head guard if a tipover occurs.
Page 17: Nameplate
3. If your lift truck has either of these labels, do not tion that affects the safe operation of the truck cannot operate the lift truck. Contact your dealer for lift trucks to be undertaken without the written authorization of Yale obtain a complete and correct Nameplate. Corporation.
Page 18: Safety Labels
Model Description Safety Labels Safety labels are installed on the lift truck to provide infor- mation about possible hazards. It is important that all safety labels are installed on the lift truck and can be read. See Figure 4. All possible label configurations that can be on the lift trucks covered in this Operating Manual are not shown in Figure 4.
Page 19 Model Description LABELS FOR GP/GLP/GDP30-35VX AND GP/GLP/GDP40SVS TRUCKS ARE IN SAME LOCATIONS. Figure 4. Warning and Safety Labels (Sheet 1 of 3)
Page 20 Model Description SEE THE PARTS MANUAL FOR THE PART NUMBER. Figure 4. Warning and Safety Labels (Sheet 2 of 3)
Page 21 Model Description SEE THE PARTS MANUAL FOR THE PART NUMBER. Figure 4. Warning and Safety Labels (Sheet 3 of 3)
Page 22: Display Switch Cluster
Model Description Legend for Figure 4 FLAMMABLE LP-GAS MAST WARNING LPG TANK WARNING TIPOVER WARNING OPTIONAL FIRE SAFETY RATING LOCKING GAS SPRING OVERHEAD GUARD LABEL FAN WARNING HOOD OPENING CAUTION WARNING, OPERATION JOYSTICK LABEL EITHER WARNING (DIESEL ONLY) NO RIDERS DIESEL FUEL LABEL (NOT SHOWN) RADIAL TIRES AND WHEELS WARNING FOR PARKING BRAKE...
Page 23 Model Description LEFT SIDE DISPLAY INPUTS LCD SCREEN RIGHT SIDE DISPLAY INPUTS WARNING AND INDICATOR LIGHTS Figure 5. Display Switch Cluster...
Page 24 Model Description Figure 6. Display Switch Cluster – Right Side Display Inputs...
Page 25 Model Description Table 2. Display Switch Cluster – Right-Side Display Inputs (See Figure 6) 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 26 Model Description Table 2. Display Switch Cluster – Right-Side Display Inputs (See Figure 6) (Continued) Item Item Function #2 Button If the lift truck is equipped with front work lights, the #2 Button and the Front Work Light button will share space on the Display Switch Cluster. When an operator or supervisor are in the main menu for entering and administering passwords, the Front Work Lights function is disabled and the button is enabled to enter the number 2 for password purposes.
Page 27 Model Description Table 2. Display Switch Cluster – Right-Side Display Inputs (See Figure 6) (Continued) Item Item Function Scroll Down This button is used for the following functions: • Decreasing the value of a selected operating function • Scrolling downward through a list of possible menu selections #4 Button The Scroll Down and #4 Button share the same space on the Display Switch Cluster.
Page 28 Model Description Table 2. Display Switch Cluster – Right-Side Display Inputs (See Figure 6) (Continued) Item Item Function Hourmeter On trucks with key switch start, when truck is ON, engine hours will be displayed on LCD screen on right side of second line. When truck is OFF, press hourmeter button to display engine hours.
Page 29: Display Switch Cluster - Lcd Screen And Warning And Indicator Lights
Model Description Display Switch Cluster – LCD Screen and coolant temperature and fuel level displays. If a fault occurs, the fault number will be displayed on the top line. Warning and Indicator Lights The time of day is displayed on the right side of the top line The LCD screen (see Figure 7) shows operator messages at all times during the selection of displayed text.
Page 30 Model Description LCD SCREEN WARNING AND INDICATOR LIGHTS Figure 7. Display Switch Cluster – LCD Screen and Warning and Indicator Lights...
Page 31 Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) Item No. Item Function Indicator Light Left This green indicator will blink on and off when the left turn signal is selected. Not Turn Signal on 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 32 Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (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 Indicator The red brake fluid light will illuminate when the brake fluid level switch indicates a low fluid condition.
Page 33 Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (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...
Page 34 Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (Continued) Item No. Item Function Warning Light, CAUTION Engine Oil Stop the engine immediately if the red light is ON while the engine is run- Pressure ning. Malfunction Indicator The red light will illuminate when the system is not in the OFF state and the oil...
Page 35 Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (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 Malfunction If this red light illuminates while the engine is running, it indicates the engine cool- Indicator ant temperature has reached 110 °C (230 °F) or above.
Page 36 Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (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 Malfunction If the lift truck is equipped with the premium monitoring package, this red warning Indicator...
Page 37 Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (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 con- Indicator verter can result.
Page 38: Operator Controls
Model Description Table 3. Instruments – Warning and Indicator Lights (See Figure 7) (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 (See Table 4 and Figure 8)
Page 39 Model Description SEE FIGURE 9 FOR MORE OPERATOR COMPARTMENT PEDAL CONFIGURATIONS. Figure 8. Operator Controls (Sheet 1 of 2)
Page 40 Model Description Figure 8. Operator Controls (Sheet 2 of 2)
Page 41 Model Description Legend for Figure 8 UNITS WITH FOOT DIRECTIONAL CONTROL PEDAL UNITS BUILT AFTER JANUARY, 2010 WITH E-HYDRAULICS. UNITS WITH DIRECTION CONTROL LEVER...
Page 42 Model Description INCHING/BRAKE PEDAL INCHING/BRAKE PEDAL PEDAL BRAKE PEDAL ACCELERATOR PEDAL Figure 9. Operator Compartment Pedal Configurations...
Page 43 Model Description Table 4. Operator Controls (See Figure 8) 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 44 Model Description Table 4. Operator Controls (See Figure 8) (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 posi- tion.
Page 45 Model Description Table 4. Operator Controls (See Figure 8) (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 46 Model Description Table 4. Operator Controls (See Figure 8) (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 depressing the pedal disengages the transmission and applies the service brakes.
Page 47 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Lift/Lower Control NOTE: Manual hydraulic control levers are standard on the trucks covered in this Lever manual (see Figure 8). Two optional controls are available for the hydraulic func- tions: electronic hydraulic mini-levers (see Figure 8) and a joystick (see Figure 10 and Table 5).
Page 48 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Tilt Control Lever NOTE: Manual hydraulic control levers are standard on the trucks covered in this manual (see Figure 8). Two optional controls are available for the hydraulic func- tions: electronic hydraulic mini-levers (see Figure 8) and a joystick (see Figure 10 and Table 5).
Page 49 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Tilt Control Lever These trucks can be equipped with the Return to Set Tilt (RTST) option if truck (Cont) has electronic hydraulic mini-levers. The RTST option automatically stops the tilt function at a set point.
Page 50 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Manual Control Lever for WARNING 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 lift trucks to get the correct See Figure 8.
Page 51 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Electronic Control Mini-Lever The third electronic control mini-lever is installed to the right of the electronic tilt for Auxiliary Hydraulic Func- control lever. This lever can have two methods of operation, depending on the tions (3rd lever).
Page 52 Model Description Table 4. Operator Controls (See Figure 8) (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 8). Two optional controls are available for the hydraulic func- Functions (4th lever).
Page 53 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Electronic Control Mini-Lever The fourth electronic control lever is installed to the right of the third electronic for Auxiliary Hydraulic Func- control lever. This lever can have two methods of operation, depending on the tions (4th lever).
Page 54 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Direc- NOTE: There is a sensor in the seat that actuates an audible buzzer. If the opera- tion tor leaves the seat with the key switch ON and the lever is not in NEUTRAL, the Con- buzzer will pulse ON and OFF for 10 seconds.
Page 55 Model Description Table 4. Operator Controls (See Figure 8) (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 56 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Foot Directional The Foot Directional Control pedal controls the speed and direction of the lift Control Pedal truck. Pushing on the right side of the pedal causes the lift truck to move in reverse.
Page 57 Model Description Table 4. Operator Controls (See Figure 8) (Continued) Item Item Function Direction The Direction Control Switch for the transmission is next to the auxiliary horn but- Control ton on the armrest. The Direction Control Switch is used on lift trucks without a Switch Foot Directional Control pedal.
Page 58: Operator Controls - Joystick Features
Model Description Operator Controls – Joystick Features (See Table 5 and Figure 10) WARNING If any of the controls, instruments, levers, or pedals do not operate as described in the following tables, report the problem immediately. DO NOT operate the vehicle until the problem is corrected.
Page 59 Model Description Table 5. Operator Controls – Joystick Features (See Figure 10) Item Item Function Lift/Lower NOTE: To operate the joystick, the operator must be on the seat. Function Push the joystick lever forward to lower the carriage and forks. Pull the joystick lever A.
Page 60 Model Description Table 5. Operator Controls – Joystick Features (See Figure 10) (Continued) Item Item Function Tilt Function NOTE: To operate the joystick, the operator must be on the seat. Move the joystick lever to the left to tilt the mast backward. Move the joystick lever to the right to tilt the mast forward.
Page 61 Model Description Table 5. Operator Controls – Joystick Features (See Figure 10) (Continued) Item Item Function 2, 4 Auxiliary This rocker switch will control either Function 3 or Functions 3 and 4, depending on Hydraulic the attachment. Function NOTE: To operate the joystick, the operator must be on the seat. (Left Rocker Switch) NOTE: If the lift truck is equipped with only a three function valve and clamp attach-...
Page 62 Model Description Table 5. Operator Controls – Joystick Features (See Figure 10) (Continued) Item Item Function 3, 4 Auxiliary This rocker switch will control either Function 4 or Functions 4 and 5, depending on Hydraulic the attachment. Function NOTE: To operate the joystick, the operator must be on the seat. (Right Rocker Switch) NOTE: If the truck is equipped with only a four function valve and clamp attachment,...
Page 63 Model Description Table 6. 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 64: 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 65 Operating Procedures combustible dust, fibers, or paper and remove any for- The fork lift truck is designed to pickup, move, and tier eign materials. Contact your local dealer for forklift materials. The basic lift truck has a lift mechanism and modifications that may be appropriate in environments forks on the front to engage the load.
Page 66: Stability And Center Of Gravity
Operating Procedures This basic principle is used for picking up a load. The ability The lift truck has moving parts and therefore has a CG that of the lift truck to handle a load is discussed in terms of moves. The CG moves forward and back as the mast is til- center of gravity and both forward and side stability.
Page 67: Capacity (Weight And Load Center)
Operating Procedures operating on uneven surfaces or on an incline. These fac- Capacity (Weight and Load Center) tors must be considered when traveling with an unloaded The capacity of the lift truck is shown on the Nameplate. truck, as well, because an unloaded truck will tip over to The capacity is listed in terms of weight and load center.
Page 68: Impact Sensor
Operating Procedures the center of gravity of the load. Both the vertical and hori- Impact Detection icon will be displayed on the LCD screen. zontal load centers are specified on the Nameplate. If the time is set to 0 seconds, the lift truck will shut down right after the impact is detected and no alarm will sound.
Page 69: Inspection Before Operation
Operating Procedures only do its job when it is in proper working order. If repairs are required, install a tag in the operator's area stating "DO NOT OPERATE" and remove the key from the key switch if truck is equipped with key switch option.
Page 70: Operator Checklist
Operating Procedures fibers (paper, wood, cotton, agricultural grass/grain, etc). activated. If password function is not activated, operator Remove all foreign materials. checklist appears after lift truck is powered ON. • Coolant level in the cooling system and condition of the The operator checklist can store a maximum of 30 items.
Page 71: Mounting And Dismounting
Operating Procedures messages will continue to appear on the LCD screen until The Operator Passwords are a series of five numbers. lift truck has been reset by either a supervisor or service Each of the five number digits can be the numbers 1 technician.
Page 72: Starting Procedures
Operating Procedures delete Operator, Supervisor, and Service passwords and other lockout conditions, cycling the truck power will not view all truck diagnostic information. Allows access to reset the lockout. truck service parameters within preset limits. Starting Procedures If the optional password feature is enabled and after the Do not start or operate the lift truck, key is moved to the ON position, or the Power ON/OFF but- including any of its functions or attach-...
Page 73: Starting Procedures, Trucks With Key Switch
Operating Procedures Starting Procedures, Trucks With Key Switch equipped with Mazda LPG engine (except Mazda 2007 emission compliant engines). WARNING NOTE: The warm-up/thaw cycle can be bypassed at any- LPG is very flammable. An odor of LPG fuel can indi- time by cranking the engine normally.
Page 74: Starting Procedures, Trucks With Keyless Start Option
Operating Procedures 9. Make sure lift truck hood is closed. Starting Procedures, Trucks With Keyless Start Option 10. Turn the key to the ON position. If lift truck is equipped with a diesel engine and engine is cold, the cold start indi- WARNING cator light will illuminate and the cold start circuit will be energized.
Page 75 Operating Procedures equipped with Mazda LPG engine (except Mazda 2007 9. Make sure lift truck hood is closed. emission compliant engines). 10. Depress and release the Power ON/OFF button. If lift NOTE: The warm-up/thaw cycle can be bypassed at any- truck is equipped with a diesel engine and engine is cold, time by cranking the engine normally.
Page 76: Checks With The Engine Running
Operating Procedures stantially within the confines of the truck frame and over- head guard if a tipover occurs. This protection system is Checks With the Engine Running intended to reduce the risk of the head and torso being trapped between the truck and the ground, but it can not WARNING protect the operator against all possible injury in a tipover.
Page 77: Load Weighing Sensor
Operating Procedures • Check the operation of the steering system. 3. Lower the load 51 mm (2 in.). Stop lowering, wait 1 sec- ond, and read the load weight. This will be the most accu- • Check the oil level in the powershift transmission when rate weight.
Page 78 Operating Procedures Certain faults or sensor measurements can cause the truck Engine Start button. If the Engine Start button is pressed to go into Engine Shutdown mode. The following actions before the Power ON/OFF button, the starter will not oper- occur when truck is in this mode: ate.
Page 79: Operating Techniques
Operating Procedures Take the lift truck to a service technician immediately for Basic Operating Procedures repair if it experiences a decrease in performance. Many people make the mistake of thinking that operating a Operating Techniques lift truck is the same as driving an automobile. This is not true.
Page 80 Operating Procedures absolutely necessary to prepare the new operator for ted on the nameplate of the truck on which the platform proper defensive driving and to expect the unexpected. is used. Before anyone is allowed in the platform, lift and lower WARNING the mast slowly with the platform in place to make sure This lift truck is designed for handling materials.
Page 81 Operating Procedures • The seat swivels 5 degrees to the left to allow an easier exit of the truck. • The neutral position is shown in Figure 12. Seat Adjustment for Operator Weight CAUTION A major cause for high Whole Body Vibration is caused by the operator not adjusting the seat to his/her weight.
Page 82 Operating Procedures Legend for Figure 12 Seat Adjustment for Operator Weight SEAT BELT CAUTION WEIGHT ADJUSTMENT KNOB A major cause for high Whole Body Vibration is caused RIDE POSITION INDICATOR FORWARD/BACKWARD ADJUSTMENT LEVER by the operator not adjusting the seat to his/her weight. BACKREST ANGLE ADJUSTMENT LEVER ARMREST NOTE: It is important to adjust the weight setting for each...
Page 83 Operating Procedures Figure 13. Seat Adjustment - Full Suspension...
Page 84: Driving And Direction Changes
Operating Procedures Legend for Figure 13 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 6.
Page 85 Operating Procedures Table 7. Transmissions Operational Feature 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 – Auto-Speed Hydraulics – –...
Page 86: General
Operating Procedures Normal Operations In normal operating conditions, either at start or while driv- ing, the lift truck can only be maintained at a stopped posi- tion by applying the service brake or parking brake. When moving away from a stop: Select direction while maintaining braking.
Page 87: Optional Operator Presence System
Operating Procedures activated switch will shift the transmission to neutral, seat, to resume travel, the Direction Control Lever must be and sound an alarm for 10 seconds. If the lift truck is moved to the "N" position, then to the desired direction of left on a grade, without the parking brake fully applied, travel.
Page 88: Standard And Powershift 1 Speed Transmission
Operating Procedures will freewheel down the grade, possibly causing injury Standard and Powershift 1 Speed Transmission or property damage. WARNING The lift trucks covered in this manual may be equipped with DO NOT select the travel direction if the accelerator is an Optional Operator Presence System.
Page 89: Techtronix 100 Transmission
Foot Directional Control pedal returns. The factory settings for the Controlled Power Reversal Feature can be changed by a Yale Service Technician The operator should always consider the load that is being when required to meet special application require- carried, and keep the carriage lowered, when making a ments.
Page 90 The factory settings for the Auto-Deceleration Feature injury to personnel. can be changed by a Yale Service Technician when Provides limited transmission braking to stop the lift truck required to meet special application requirements.
Page 91: Inching
Operating Procedures feature is effective on grades up to 10% and limits the pedal is fully applied, the transmission is completely disen- speed to 7.6 cm (3 in.) per second. (The lift truck may roll gaged and the brakes are applied. Use the accelerator faster than 7.6 cm (3 in.) per second until the Roll Back fea- pedal or Foot Directional Control pedal to keep the engine ture slows it down.)
Page 92: Steering (Turning)
Operating Procedures Steering (Turning) ground will aggravate these conditions and cause the fork- lift to become unstable. WARNING WARNING TRAVEL SLOWLY WHEN TURN- Failure to observe the tail swing area when making a ING. Lift trucks can tip over even turn can injure or kill someone.
Page 93: Load Handling, General
Operating Procedures the tail swing area when making a turn can lead to injury or Load Handling, General death. 1. The capacity is the maximum Do not turn on an incline. To reduce load that the lift truck can handle for the possibility of a tipover, a lift truck the load condition shown on the must not be driven across an incline.
Page 94: 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 Do not handle a load if hit a bump. An off-center load will increase the possibility of any loose part of it is the truck tipping over to the side.
Page 95 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 objects. Whether the lift truck is loaded or empty, do not overhead guard and load backrest extension provides rea- travel with the load or carriage in a raised position.
Page 96 Operating Procedures WARNING NEVER put hands, arms, head, or legs through the mast or near the carriage or lift chains. This warning applies not only to the operator but also a helper. A helper must not be near the load or lift mechanism while the operator is attempting to handle a load.
Page 97: Load Handling, How To Engage And Disengage A Load
Operating Procedures IF THE LIFT TRUCK TIPS OVER, DO NOT JUMP OFF! Approach the load carefully. Make sure that the truck is HOLD FIRMLY TO STEERING WHEEL, BRACE YOUR perpendicular to the load. Raise the forks to the proper FEET, AND LEAN FORWARD AND AWAY FROM POINT height for engaging the load.
Page 98 Operating Procedures 3. When a load is put on the floor, tilt the mast forward to a vertical position and lower the load. Tilt the mast forward to permit smooth removal of the forks. Carefully move the lift truck backward to remove the forks from under the load. A.
Page 99 Operating Procedures IF THE LIFT TRUCK TIPS OVER EITHER TO THE SIDE WARNING OR FORWARD, DO NOT JUMP OFF! HOLD FIRMLY TO Move carefully and smoothly when the load is raised STEERING WHEEL, BRACE YOUR FEET, AND LEAN over a stack. When the load is elevated the center of FORWARD AND AWAY FROM THE POINT OF IMPACT.
Page 100: Load Handling, Traveling
Operating Procedures NOTE: Not every load can be lifted using only the forks of a lift truck. Some loads will require a special attachment. 6. When lifting round objects, use a block behind the object. Tilt the mast forward so that the forks can slide along the floor under the object to be lifted.
Page 101 Operating Procedures Always look 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.
Page 102 Operating Procedures 6. Anytime the lift truck is moving 8. Watch clearances, especially forks, mast, overhead keep arms, legs, etc., inside the guard, and tail swing. A lift truck is designed to perform a operator's compartment. Arms and wide variety of functions within limited space. legs outside the machine can be injured when passing obstructions.
Page 103 Operating Procedures 11. Stay away from the edge of the road. Keep the wheels of the lift truck on the roadway. If the wheels are allowed to run off the edge of the travel surface onto soft ground, the lift truck can tip over. 12.
Page 104: 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 con- To use the emergency load lowering valve, follow these trol valve, when the electronic signal to the mini-levers steps:...
Page 105 Operating Procedures EMERGENCY LOAD LOWERING VALVE COWL WELDMENT MAIN CONTROL VALVE KICK PANEL Figure 15. Emergency Load Lowering Valve...
Page 106: 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 specifically designed for opening and closing rail car WARNING doors and the operator is trained in its use.
Page 107: Attachments
Operating Procedures • Make sure that the rail car brakes are set and the wheels are blocked while loading or unloading. Do this check so that the rail car will not move due to the movement of the lift truck in and out of the rail car. •...
Page 108: Disconnecting Attachment Hydraulic Quick-Disconnect Hoses
Operating Procedures Disconnecting Attachment Hydraulic Quick- Disconnect Hoses NOTE: Step 1 through Step 4 is to be used for lift trucks equipped with electro-hydraulics. 1. Turn the key switch or keyless switch to the OFF posi- tion. 2. Disconnect the negative terminal of the battery. NOTE: If the Quick-Disconnect hose connectors cannot be disconnected, repeat Step 3 and Step 4.
Page 109: Connecting Attachment Hydraulic Quick-Disconnect Hoses
Operating Procedures 6. Disconnect the negative terminal of the battery. 5. Connect the Quick-Disconnect hose connectors. 7. Move the manual hydraulic levers forward and backward 6. Connect the negative terminal of the battery. to relieve the system hydraulic pressure. 7. Turn the key switch or keyless switch to the ON position 8.
Page 110: Parking
Operating Procedures Parking 6. Check engine compartment, if operating in areas con- taining combustible material, and remove foreign debris. The operator must never leave a lift truck in a condition so See FIRE HAZARD WARNING at the beginning of this that it can cause damage and injury.
Page 111: Maintenance
Maintenance Maintenance General This section contains a Maintenance Schedule and the instructions for maintenance and inspection. WARNING The Maintenance Schedule has time intervals for inspec- Do not make modifications to the lift truck that affect tion, lubrication, and maintenance for your lift truck. The the safe operation of the lift truck.
Page 112: Serial Number Data
Maintenance inspection, lubrication, and maintenance will help your lift The lift truck must be towed on a slope. truck provide more efficient performance and operate for a If the engine cannot run, there is no power available for longer period of time. the hydraulic steering system.
Page 113: How To Put A Lift Truck On Blocks
Maintenance 3. Using a lift truck or a lifting device that can be attached put additional blocks in the following positions to to the mast (I.E. come-a-long), raise the carriage and forks maintain stability: approximately 30 cm (12 in.) from surface. Install a chain Before removing the mast and drive axle, put around a mast crossmember and the carriage, to prevent blocks under the counterweight so that the lift...
Page 114: How To Raise The Steering Tires
Maintenance 3. Tilt the mast fully forward until the drive tires are raised How to Clean a Lift Truck from the surface. CAUTION 4. Put additional blocks under the frame behind the drive Your lift truck may be damaged if water or cleaning tires.
Page 115: Maintenance Schedule
Maintenance Schedule DRIVE TIRES STEERING TIRES Figure 17. Put a Lift Truck on Blocks Maintenance Schedule...
Page 116 Maintenance Schedule Figure 18. Mazda FE Gas Engine (Except 2007 Emission Compliant Engine) Maintenance and Lubrication Points...
Page 117 Maintenance Schedule Figure 19. Mazda FE Gas Engine (2007 Emission Compliant Engine Only) Maintenance and Lubrication Points...
Page 118 Maintenance Schedule Figure 20. Mazda FE Gas Engine With Aluminum Case Gear Drive Transmission (Prior to January, 2011) Maintenance and Lubrication Points...
Page 119 Maintenance Schedule Figure 21. Mazda FE Gas Engine With Aluminum Case Transmission (After January, 2011) Maintenance and Lubrication Points...
Page 120 Maintenance Schedule Figure 22. Mazda FE LPG Engine (Except 2007 Emission Compliant Engines) Maintenance and Lubrication Points...
Page 121 Maintenance Schedule Figure 23. Mazda FE LPG Engine (2007 Emission Compliant Engines Only) Maintenance and Lubrication Points...
Page 122 Maintenance Schedule Figure 24. Mazda FE LPG Engine With Aluminum Case Transmission (Prior to January, 2011) Maintenance and Lubrication Points...
Page 123 Maintenance Schedule Figure 25. Mazda FE LPG Engine With Aluminum Case Transmission (After January, 2011) Maintenance and Lubrication Points...
Page 124 Maintenance Schedule Figure 26. Yanmar 2.6L Diesel Engine (Prior to January, 2011) Maintenance and Lubrication Points...
Page 125 Maintenance Schedule Figure 27. Yanmar 2.6L Diesel Engine With Aluminum Case (After January, 2011) Transmission Maintenance and Lubrication Points...
Page 126 Maintenance Schedule Maintenance Schedule Table 8. (See Figure 18 through Figure 27) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo TIRES Check Condition.
Page 127 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo HYDRAULIC HOSES Check Condition.
Page 128 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo SERVICE BRAKES Check Operation.
Page 129 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo HYDRAULIC OIL 25.6 liter (26.4 qt) ISO - VG 46 Hydraulic Oil...
Page 130 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo ENGINE OIL 3.9 liter (4.1 qt) –7 °C (20 °F) and Below...
Page 131 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo ENGINE OIL 10.2 liter (10.8 qt) 20 °C (68 °F) and Over...
Page 132 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo AIR FILTER 1 Filter See Parts Manual.
Page 133 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo ENGINE IDLE SPEED See NOTE 5.
Page 134 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo TIMING Adjust as Required.
Page 135 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo FUEL FILTER, Gas 1 Filter See Parts Manual.
Page 136 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo FUEL INJECTOR (LPG) 1 Injector Check and Clean if Required.
Page 137 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo CLEAN DEBRIS FROM See NOTE 5.
Page 138 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo HEADER HOSES Check Condition.
Page 139 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo MAST Check for Wear and 0.76 mm (0.03 in.)
Page 140 Quantity 6 Mo STEERING AXLE Check grease. Multipurpose Grease Wheel Bearings See NOTE 9. PEDALS, LEVERS, Lubricate as Yale Part No. 504236201 SEAT RAILS, CABLES, Necessary. HINGES, LINKAGES, HOOD LATCH SERVICE BRAKES Check Lining 1.0 mm (0.040 in.) Thickness. Minimum Thickness DIFFERENTIAL AND 5.0 liter (5.3 qt)
Page 141 (dust and waste paper); chemical or abrasive compounds; poor ground conditions; intensive usage at high perform- ance 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 142 Maintenance Schedule Table 8. (See Figure 18 through Figure 27) (Continued) 1000 Item 8 Hr/ 250 Hr/ 500 Hr/ 2000 Hr/ 4000 Hr/ Procedure or Item Specification 1 Day 6 Mo 6 Mo 1 Yr 2 Yr Quantity 6 Mo NOTE 13: Replace after 3000 hours.
Page 143: Maintenance Procedures Every 8 Hours Or Daily
Maintenance Maintenance Procedures Every 8 Hours or Daily How to Make Checks With the Engine normal. Clean any oil or fuel spills. Ensure all surfaces are free of oils, lubricants, fuel and organic dust or fibers Stopped (paper, wood, cotton, agricultural grass/grain, etc.). WARNING Tires and Wheels Do not operate a lift truck that needs repairs.
Page 144 Maintenance CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD) MAKE SMOOTH EDGES CHECK THE TIRE PRESSURE (PNEUMATIC TIRES) Figure 28. Check the Tires...
Page 145: 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 damaged, 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 146 Maintenance during operation. Adjust/repair/replace hose/components as necessary. 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 29.
Page 147: Operator Restraint System
Maintenance Operator Restraint System The seat belt, hip restraint, seat, hood, and hood latches are all part of the operator restraint system. See Figure 30. Each item must be checked to make sure it is fastened cor- rectly, functions correctly, and is in good condition. NOTE: NON-SWIVEL SEAT SHOWN.
Page 148: Emergency Locking Retractor (Elr)
Maintenance Emergency Locking Retractor (ELR) pulled from the 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 reposition- •...
Page 149: Engine Compartment
Maintenance Engine Compartment Check for the presence of any combustible material such as paper, leaves etc. Remove any combustible materials. Fuel, Oil, and Coolant Leaks, Check WARNING All fuels are very flammable and can burn or cause an explosion. Do not use an open flame to check the fuel level or to check for leaks in the fuel system.
Page 150: Hydraulic Hoses
Maintenance Also check the condition of the radiator or heater hoses insure that the coolant hoses are not leaking. If any hose is that are not leaking. Soft or cracked hoses need to be leaking, report it to maintenance for repair. replaced before a major leak occurs.
Page 151: 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 152: Engine Oil
Maintenance Engine Oil to ON, if the truck is equipped with a key switch, or when the power ON/OFF button is pressed, if the truck is equip- After the engine has stopped, wait one minute before ped with a keyless option, and will stay illuminated until cor- checking the oil level.
Page 153 Maintenance GAS ENGINE LPG ENGINE DIPSTICK ENGINE OIL ENGINE OIL FILL ENGINE OIL FILTER BATTERY DRIVE BELT PCV VALVE AUXILIARY COOLANT RESERVOIR AIR FILTER SPARK PLUGS RADIATOR CAP FUEL FILTER FUEL INJECTOR Figure 33. Mazda 2.0L and 2.2L Engine Maintenance Points (Except 2007 Emission Compliant Engines)
Page 154 Maintenance LPG ENGINE GAS ENGINE DIPSTICK ENGINE OIL ENGINE OIL FILL ENGINE OIL FILTER BATTERY DRIVE BELT PCV VALVE AUXILIARY COOLANT RESERVOIR AIR FILTER SPARK PLUGS RADIATOR CAP FUEL FILTER FUEL INJECTOR (GAS ONLY) Figure 34. Mazda 2.0L and 2.2L Engine Maintenance Points (2007 Emission Compliant Engines Only)
Page 155 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 35. Yanmar 2.6L Diesel Engine Maintenance Points...
Page 156: Air Filter
Maintenance Air Filter Forks 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. replacement is required when one of the following occurs: The identification of a fork describes how the fork is con- •...
Page 157 Maintenance OUTER FORK CARRIER FORKS INNER FORK CARRIER SIDESHIFT CARRIAGE FORK POSITIONER CAPSCREWS FORK REMOVAL NOTCH Figure 36. Fork Positioner...
Page 158 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 indi- vidually.
Page 159: Forks, Inspect
Maintenance Forks, Inspect 1. Inspect the forks for cracks and wear. Check that the fork tips are aligned as shown in Figure 39. Check that the bottom of the fork is not worn (Item 4 in Figure 39). 2. Replace any damaged or broken parts that are used to keep the forks locked in position.
Page 160: Forks, Adjust
Maintenance Forks, Adjust slot, replace with new pin. Adjust the forks as far apart as possible for maximum support of the load. Hook forks will NOTE: During the adjustment of the forks, the heel of the slide along the carriage bars to adjust for the load to be lif- forks should not be touching the ground.
Page 161 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 162: How To Make Checks With The Engine Running
Maintenance How to Make Checks With the Engine tionary during a check, apply the parking brake and put the transmission in NEUTRAL. Make the checks carefully. Running Indicator Lights, Horn, Fuses, and Relays WARNING If lift truck is equipped with a key switch, turn key to ON DO NOT operate a lift truck that needs repairs.
Page 163 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 164: Service Brakes
Maintenance Service Brakes Operation, Check Check the operation of the service brakes. Push on the Brake Fluid Level inching/brake pedal. The service brakes must be applied before the inching/brake pedal reaches the floor plate. The WARNING pedal must stop firmly and must not move slowly down If the brake system has a power assist (or boost), brak- after the brakes are applied.
Page 165: Parking Brake
Maintenance Parking Brake grade 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 opera- tion of the automatic adjuster mechanism is correct before the parking brake is adjusted. Lift trucks with a pedal: A switch energizes the seat warning circuit when the hand lever is released.
Page 166: Engine Oil Pressure
Maintenance Engine Oil Pressure Cooling System NOTE: The engine will enter shutdown mode after a warn- WARNING ing buzzer sounds and a 30-second countdown if engine oil DO NOT remove the radiator cap from the radiator pressure is less than 34.5 kPa (5 psi) on lift trucks with when the engine is hot.
Page 167 The coolant will expand as it is heated and the level in the auxiliary coolant reservoir will increase. CAUTION Additives may damage the cooling system. Before using additives, contact your local Yale dealer. If coolant is added, use the correct mixture of water and ethylene glycol shown in the Maintenance Schedule. WARNING...
Page 168: 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 steer- weldments and carriage so that they can not move. ing can be difficult if the engine is not running.
Page 169: How To Add Fuel To The Lift Truck
Maintenance 3. The inner weldments and the carriage must lower com- No smoking. pletely. All fuels for internal combustion engines are very flam- 4. Raise the mast 1 m (3 ft) with a capacity load. The inner mable. weldments and the carriage must raise smoothly. Lower Fill the fuel tank only in a designated area with good the mast.
Page 170: Lpg Tank, Remove
Maintenance LPG is extremely flammable. When checking or filling motor vehicles, electrical equipments, or ignition an LPG tank: No smoking. Stop engine. source. Frost on the surface of the tank, the valves or fittings Removable LPG tanks must be removed from the fork and the odor of LPG fuel indicates a leak.
Page 171 Maintenance 3. Run the engine until it stops, then turn the key switch to truck. If your truck is equipped with a swing out and drop the OFF position if truck is equipped with key switch, or down LPG tank bracket , drop the tank down to the side of press the Power ON/OFF button if truck is equipped with the truck for ease of removal.
Page 172 Maintenance Figure 43. LPG Tank and Bracket...
Page 173: Lpg Tank, Fill
Maintenance Legend for Figure 43 SWING OUT BRACKET LPG TANK STOP PIN TANK STRAP BRACKET HANDLE QUICK DISCONNECT FITTING BRACKET PIVOT HYDROSTATIC RELIEF VALVE GAS SPRING () MANIFOLD BLOCK BRACKET RELEASE PIN ALIGNMENT PIN LPG Tank, Fill 2. Open the liquid outlet valve and bypass return valve on the storage tank.
Page 174: Lpg Tank, Install
Maintenance maximum level indicated by the liquid level indicator. Imme- tank. If the pin is damaged, repair it before installing the diately close the valve at the end of the supply hose. tank. Secure the tank strap around the tank and close the strap.
Page 175: Gasoline Or Diesel Fuel
Maintenance d. Frost - If the amount of LPG escaping is sufficient, How to Change a Solid Rubber Tire (GC frost may appear on the fittings. Series) Gasoline or Diesel Fuel WARNING The type of solid rubber tire is shown on the Name- WARNING plate.
Page 176: 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 outer bearings are correctly lubricated with grease.
Page 177 Maintenance STEERING TIRE AND WHEEL DRIVE TIRES AND WHEELS WIDE TREAD OUTSIDE OF SOLID RUBBER TIRE WHEEL OVERHANG Figure 44. Tires and Wheels GC/GLC030-035VX, and GC/GLC040SVX Lift Trucks...
Page 178: Pneumatic Tire With Tube, Repair
Maintenance Pneumatic Tire With Tube, Repair Always wear safety glasses. Never loosen the nuts that hold the inner and outer Remove Wheels From Lift Truck wheel halves together when there is air pressure in the tire. WARNING 1. Put the lift truck on blocks as described in How to Put a A solid rubber tire that is the same shape as a pneu- Lift Truck on Blocks at the beginning of this section.
Page 179 Maintenance TWO-PIECE WHEEL THREE-PIECE WHEEL OPTIONAL RIM ASSEMBLY FOUR-PIECE WHEEL WHEEL RIM LOCK RING SIDE FLANGE FLANGE SEAT Figure 45. Types of Pneumatic Wheels...
Page 180: 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 caus- ing serious injury or death. Keep tire tools in firm contact with the wheel parts.
Page 181: 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 flange. If there is a flange Make sure all of the air pressure is removed from the tire before a wheel is disassembled.
Page 182: Install Wheel In Tire
Maintenance 4. Remove the wheel rim from the • DO NOT mix types of tires, type of tire tread, or tire. wheel assemblies of different manufacturers on any one lift truck. Do not use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together.
Page 183: Tire Installation, Three- Or Four-Piece Wheel
Maintenance • DO NOT mix parts between different types or manu- WARNING facturers of wheels. Do not lubricate the tire bead with antifreeze or petro- • DO NOT mix types of tires, type of tire tread, or leum-based liquid. Vapors from these liquids can wheel assemblies of different manufacturers on any cause an explosion during inflation or use.
Page 184: Tire Installation, Two-Piece Wheel
Maintenance 2. Install the wheel rim in the 4. Put the lock ring in the correct tire. Make sure the stem of the position on the rim. Add air pres- inner tube is aligned with the sure to the tire as described in slot in the rim.
Page 185: Add Air To Pneumatic Tires With Tube
Maintenance 2. Tighten the nuts that hold the 1. Put the tire in a safety cage. See Figure 46. rim halves together to 175 N•m 2. Add 20 kPa (3 psi) of air pressure to the tire. (130 lbf ft). Add air pressure to the tire as described in Add Air 3.
Page 186: Install The Wheels
Maintenance 5. Check that all wheel parts are correctly installed. If instal- Air pressure in the tires can cause the tire and rim lation is not correct, remove all of the air pressure from the parts to explode causing serious injury or death. tire.
Page 187: Remove Tire From Wheel
Maintenance Remove Tire From Wheel 2. Put wheel and tire assem- bly on the press. Position the feet of the press on the loose WARNING flange. Push press down on Make sure all of the air pressure is removed from the loose flange to expose the tire before a wheel is disassembled.
Page 188: Install Tire On Wheel
Maintenance 4. Remove the press and Install Tire on Wheel remove the loose flange lock- ing ring and the advance WARNING band (four-piece wheel only) Damage to the tire and wheel assembly and injury or from the tire and wheel death can occur if you do not do the following proce- assembly.
Page 189 Maintenance 2. Apply lubricant to the nee- WARNING dle valve and the valve hole Do not lubricate the tire bead with antifreeze or petro- that will be used (see NOTE leum-based liquid. Vapors from these liquids can in Step 1), by inserting and cause an explosion during inflation or use.
Page 190 Maintenance band. Slide the tire and TBS onto the wheel. 6. Raise the tire and position the base and threaded stem Line up the valve hole in the of the press through the hole TBS with the valve slot in the in the center of the wheel.
Page 191: Add Air To Pneumatic Tubeless Tire
Maintenance Push down on press to 9. Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet to depress the tire beads until ensure all components are correctly sealed. Remove the the locking ring groove is fully press from wheel and tire assembly. exposed.
Page 192: Install The Wheels
Maintenance Solid Rubber Tires on Pneumatic Wheels, Change WARNING Wheels must be changed and tires repaired by trained personnel only. Always wear safety glasses. 1. Put the lift truck on blocks as described in How to Put a Lift Truck on Blocks at the beginning of this section. 2.
Page 193 Maintenance 2. Put the tire tool into the WARNING slot between the lock ring Wheels must be changed and tires repaired by trained and the wheel rim. Remove personnel only. the lock ring and side flange. Always wear safety glasses. 1.
Page 194: Install Tire On Wheel
Maintenance 4. Put the cage in position on • DO NOT mix parts between different types or manu- the tire. Use the press to facturers of wheels. push the tire from the wheel • DO NOT mix type of tires, type of tire tread, or wheel rim.
Page 195 Maintenance 1. Lubricate the wheel rim 3. Remove the cage and put and the inner surface of the the flange seat (if used), the tire with tire lubricant or side ring, and the lock ring in soap. position on the wheel rim. Install the cage on the tire.
Page 196: 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 lift truck.
Page 197: 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 lift truck.
Page 198: Operating Procedures For A New Or Rebuilt Engine
2. Start and run the engine at approximately one-half throt- tle for 30 minutes for the first operation. Check the gauges See your dealer for Yale lift trucks BEFORE performing and indicators for the correct operation during this first any changes to the overhead guard.
Page 199: Short-Term Storage
Maintenance the forks and tag them with the lift truck serial number. For 2. Fully lower the mast. If lift truck is equipped with forks, tilt best protection, operate your internal combustion engine lift mast FORWARD until the tips of the forks touch the floor. truck for a short period each month.
Page 200: Long-Term Storage
Maintenance 9. If the lift truck is not stored indoors, put a cover over the the fluid level in engine, radiator, hydraulic tank, and brake lift truck to prevent damage from the weather. In wet condi- master cylinder. tions, a cover will not prevent corrosion to the lift truck. NOTE: Do not shut down an engine before it reaches oper- Long-Term Storage ating temperature.
Page 201: Putting A Stored Lift Truck Back Into Service
Maintenance freeze at −7.8 °C (18 °F) A fully-charged battery with a spe- If a greasy film forms on the top of a battery, this is acid cific gravity of 1.280 will freeze at −66 °C (−87 °F). and must be neutralized with the solution described above. This "self-discharge"...
Page 202: How To Move A Lift Truck On Atransport
Maintenance How to Move a Lift Truck on a Transport overpasses, powerlines, and natural barriers can prevent clearance. Removal of the mast can be necessary. WARNING If a trailer is the method of transportation, use blocks in Stay a safe distance from the edge front and back of the trailer tires to prevent movement of of docks, ramps, platforms, and the trailer when the lift truck is loaded and unloaded.
Page 203: Unloading
Maintenance button, if truck is equipped with a keyless option. Check CAUTION that all switches and accessories are turned OFF. Make sure that any straps or chains used to fasten the 5. Put blocks in front and back of the lift truck tires to pre- lift truck to the transport do not contact any tubes, vent any movement of the lift truck.
Page 204: Preparation For Use
Maintenance 3. Disconnect the straps or chains. Preparation After Transport 4. Remove the wheel blocks. 1. Complete the unloading procedures. 5. Check that all switches and accessories are turned OFF. 2. Inspect the lift truck for damage and missing compo- nents.
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Yale VERACITOR GCC030VX Operating Manual

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