Yale (c879) gdc155 vx lift truck service repair manual

Service Repair Manual
GC/GLC/GDC135VX, GC/GLC/GDC155VX
C879
PART NO. 524288212 8000 YRM 1320

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in
damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Discon-
nect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications
of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.

Capacities and Specifications Table of Contents
TABLE OF CONTENTS
Lift Truck Lifting Capacity..................................................................................................................................... 1
Counterweight Weights ....................................................................................................................................... 1
Tire Sizes............................................................................................................................................................. 1
Capacities............................................................................................................................................................ 2
Electrical System................................................................................................................................................. 8
Transmission Oil Pressures................................................................................................................................. 10
Hydraulic System Relief Pressures ..................................................................................................................... 14
Steering System .................................................................................................................................................. 14
Stall Speeds (in RPM ±100 rpm)......................................................................................................................... 15
GM 4.3L Gas GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,
D879) .............................................................................................................................................................. 15
GM 4.3L LPG GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,
D879) .............................................................................................................................................................. 15
GM 4.3L Gas GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
D878) .............................................................................................................................................................. 15
GM 4.3L LPG GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
D878) .............................................................................................................................................................. 15
Cummins 4.5L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879) ............................................................................................................................................................. 16
Cummins QSB 3.3L Diesel GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (D879) ......................................................................................................................... 16
Cummins 4.5L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878) ............................................................................................................................................................. 16
Cummins QSB 3.3L Diesel GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (D878).......................................................................................................................... 16
Mast Speeds........................................................................................................................................................ 17
Tilt Angles............................................................................................................................................................ 19
Front End Equipment - Mast Creep..................................................................................................................... 20
Mast Creep...................................................................................................................................................... 20
Engine Specifications .......................................................................................................................................... 21
Torque Specifications .......................................................................................................................................... 23
Frame.............................................................................................................................................................. 23
Mast, Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879, D879)............................................................................................................... 23
Mast, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
(C878, D878)................................................................................................................................................... 23
Hang On Sideshift Carriage With Fork Positioner, Lift Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (D878) Manufactured After August, 2012 ................................ 23
Steering System.............................................................................................................................................. 24
Transmission ................................................................................................................................................... 24
Engine - GM 4.3L............................................................................................................................................ 24
Engine - Cummins 4.5L and QSB 3.3L Diesel ................................................................................................ 25
This section is for the following models:
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) [C879, D879];
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) [C878, D878]
©2012 Yale Materials Handling Corp. i

8000 YRM 1320 Tire Sizes
Lift Truck Lifting Capacity
Model Weight
GLC/GDC60VX (GC/GLC/GDC0135VX) 6123 kg (13,500 lb)
GLC/GDC70VX (GC/GLC/GDC155VX) 7030 kg (15,500 lb)
GLP/GDP60VX (GP/GLP/GDP135VX) 6123 kg (13,500 lb)
GLP/GDP70VX (GP/GLP/GDP155VX) 7030 kg (15,500 lb)
NOTE: Load center at 600 mm (24 in.).
Counterweight Weights
Model Weight
GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX)
2779 kg (6127 lb)
GLP/GDP60VX (GP/GLP/GDP135VX) 2622 kg (5780 lb)
GLP/GDP70VX (GP/GLP/GDP155VX) 3135 kg (6911 lb)
Tire Sizes
Truck Drive Tires Steer Tires
GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX
GC/GLC/GDC155VX)
28 × 12 × 22 22 × 8 × 16
GLP/GDP60VX
GLP/GDP70VX
GP/GLP/GDP135VX
GP/GLP/GDP155VX
8.25 × 15 8.25 × 15
1

Capacities 8000 YRM 1320
Capacities
Table 1. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX)
(C879, D879) Lift Truck Models
Item Quantity Specifications
Fuel Capacity
Gas 65.8 liter (17.4 gal) 87 Octane
LPG 38.6 liter (10.2 gal)
Empty
19.0 kg (41 lb)
Full
38.2 kg (84.51 lb)
LPG-HD 5, HD 10
Diesel 65.8 liter (17.4 gal) Diesel No. 2
Engine Oil
GM 4.3L 4.7 liter (5.0 qt) 7°C ( 20°F) and below
SAE 5W-20
16°C (60 °F) and below
SAE 5W-30
18°C (0°F) and above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
Cummins 4.5L Diesel 13.0 liter (13.7 qt) 0°C (32°F) and below
SAE 0W-30
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
SAE 5W-40 or 15-40
API CH-4 or CI-4
Cummins QSB 3.3L Diesel 7.5 liter (8.0 qt) 0°C (32°F) and below
SAE 0W-30
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
SAE 5W-40 or 15-40
API CH-4 or CI-4
2

8000 YRM 1320 Capacities
(C879, D879) Lift Truck Models (Continued)
Cooling System
GM 4.3L 15.1 liter (15.9 qt)
CAUTION
Additives may damage the
cooling system. Before us-
ing additives, contact your
local Yale dealer.
Use Ethylene Glycol Boron-free
Antifreeze. Purchase a
pre-diluted 50/50 solution; or
mix 50% concentrate with 50%
distilled water or deionized
water.
Cummins 4.5L Diesel 13.5 liter (14.2 qt)
CAUTION
local Yale dealer.
water.
Cummins QSB 3.3L Diesel 10.4 liter (11.0 qt)
CAUTION
local Yale dealer.
water.
3

Hydraulic Tank Oil Capacity
All Trucks 64 liter (68 qt)
Initial Fill
60.5 liter (64 qt)
Drain and Fill
CAUTION
hydraulic system. Before us-
local Yale dealer.
ISO VG-46 Hydraulic Oil
Transmission Oil Capacity
Standard Powershift Transmission
(2-Speed)
24 liter (25.4 qt) John Deere
JDM J20C
Techtronix 332 (3-Speed) 24 liter (25.2 qt) John Deere
JDM J20C
Wet Brake Drive Axle Oil Capacities
Drive Axle Housing Arm Oil
Right Chamber
8.8 liter (9.3 qt) John Deere
JDM J20C
Left Chamber
JDM J20C
Right Wheel Hub Oil 1.6 liter (1.7 qt) John Deere
JDM J20C
Left Wheel Hub Oil 1.6 liter (1.7 qt) John Deere
JDM J20C
Brake Oil (Master Cylinder)
All Lift Truck Models 0.35 liter (0.74 pt)
WARNING
DO NOT use DOT fluid; only
use Dexron III oil from sealed
container to prevent possible
damage to the brake system.
Failure to observe the above
Warning could result in death
or serious injury.
Dexron III From Sealed
Container
Wet Brake Center Section Oil
All Lift Truck Models 4.2 liter (4.4 qt) SAE 80W-90
4

Table 2. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX)
Fuel Capacity
Gas 74.8 liter (19.7 gal) 87 Octane
LPG 38.6 liter (10.2 gal)
Empty
19.0 kg (41 lb)
Full
38.2 kg (84.51 lb)
LPG-HD 5, HD 10
Diesel 74.8 liter (19.7 gal) Diesel No. 2
Engine Oil
GM 4.3L 4.7 liter (5.0 qt) 7°C ( 20°F) and below
SAE 5W-20
16°C (60 °F) and below
SAE 5W-30
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
Cummins 4.5L Diesel 13.0 liter (13.7 qt) 0°C (32°F) and below
SAE 0W-30
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
SAE 5W-40 or 15-40
API CH-4 or CI-4
Cummins QSB 3.3L Diesel 7.5 liter (8.0 qt) 0°C (32°F) and below
SAE 0W-30
25 to 20°C ( 13 to 68°F)
SAE 5W-30
20 to 20°C ( 4 to 68°F)
SAE 10W-30
SAE 5W-40 or 15-40
API CH-4 or CI-4
5

Cooling System
GM 4.3L 15.1 liter (15.9 qt)
CAUTION
local Yale dealer.
water.
Cummins 4.5L Diesel 13.5 liter (14.2 qt)
CAUTION
local Yale dealer.
water.
Cummins QSB 3.3L Diesel 10.4 liter (11.0 qt)
CAUTION
local Yale dealer.
water.
6

Hydraulic Tank Oil Capacity
All Trucks 75 liter (79 qt)
Initial Fill
71.7 liter (75.7 qt)
Drain and Fill
CAUTION
hydraulic system. Before us-
local Yale dealer.
ISO VG-46 Hydraulic Oil
Transmission Oil Level
Standard Powershift Transmission
(2-Speed)
24 liter (25.4 qt) John Deere
JDM J20C
Techtronix 332 (3-Speed) 24 liter (25.4 qt) John Deere
JDM J20C
Wet Brake Drive Axle Oil Capacities
Right Chamber
JDM J20C
Left Chamber
JDM J20C
Right Wheel Hub Oil N/A N/A
Left Wheel Hub Oil N/A N/A
Brake Oil (Master Cylinder)
All Lift Truck Models 0.35 liter (0.74 pt)
WARNING
DO NOT use DOT fluid; only
use Dexron III oil from sealed
container to prevent possible
damage to the brake system.
Failure to observe the above
Warning could result in death
or serious injury.
Dexron III From Sealed
Container
Wet Brake Center Section Oil
All Lift Truck Models 4.6 liter (4.9 qt) SAE 80W-90
7

Electrical System 8000 YRM 1320
Electrical System
Item GM 4.3L Cummins 4.5L and
QSB 3.3L Diesel
Battery 12-volt, negative ground 12-volt, negative ground
Spark Plugs AC 41-993 N/A
Spark Plug Gap 1.5 mm (0.059 in.) N/A
Ignition Timing
Gas Not Adjustable N/A
LPG Not Adjustable N/A
Diesel N/A Not Adjustable
GM 4.3L
Alternator Output (14 Volts) G and LPG GS and LPS
Idle 50 amps @ 750 rpm 38 amps @ 750 rpm
Governed Speed 65 amps @ 2400 rpm 45 amps @ 2400 rpm
Cummins 4.5L (Diesel)
Alternator Output (13.5 Volts) D DS
Low Idle 54 amps @ 800 rpm 28 amps @ 800 rpm
Cummins QSB 3.3L (Diesel)
Low Idle 30 amps @ 800 rpm N/A
Governed Speed 95 amps @ 2230 rpm N/A
8

8000 YRM 1320 Electrical System
Item GM 4.3L Cummins 4.5L
Battery 12-volt, negative ground 12-volt, negative ground
Spark Plugs AC 41-993 N/A
Spark Plug Gap 1.5 mm
(0.059 in.)
N/A
Ignition Timing:
Gas Not Adjustable N/A
LPG Not Adjustable N/A
Diesel N/A 0.90 mm (0.035 in.)
GM 4.3L
Alternator Output (14 Volts) G and LPG GS and LPS
Idle 50 amps @ 750 rpm 38 amps @ 750 rpm
Cummins 4.5L (Diesel)
High Idle 95 amps @ 2225 rpm 45 amps @ 2225 rpm
Cummins QSB 3.3L (Diesel)
9

Transmission Oil Pressures 8000 YRM 1320
Transmission Oil Pressures
Table 5. 3-Speed Transmission, Lift Trucks Manufactured BEFORE October 2009
All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F)
Port 1
Transmission Pump
Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8
Low and High
Pressure
Reverse
Clutch
(R1 and
R2)
Forward
Low
Clutch
(F1 and
F2)
Forward
High
Clutch
(F3)
Torque
Con-
verter
Lubrication
First Test
Port
(F1 and R1)
Second Test
Port
(F2, F3 and
R2)
1793 to 2068* kPa
(260 to 300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
758 kPa
(110 psi)
69 to 276 kPa
(10 to 40 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
*Relief Pressure
10

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8000 YRM 1320 Transmission Oil Pressures
Table 6. 2-Speed Transmission, Lift Trucks Manufactured BEFORE June 2009
Port 1
Transmission Pump
Low and High
Pressure
Reverse
Clutch
(R1 and
R2)
Forward
Low
Clutch
(F1)
Forward
High
Clutch
(F2)
Torque
Con-
verter
Lubrication
First Test
Port
(F1 and R1)
Second Test
Port
(F2, and R2)
1793 to 2068* kPa
(260 to 300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
758 kPa
(110 psi)
69 to 276 kPa
(10 to 40 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
*Relief Pressure
11

Transmission Oil Pressures 8000 YRM 1320
Table 7. 3-Speed Transmission, Lift Trucks Manufactured AFTER October 2009
Port 1
Transmission Pump
Low and High
Pressure
Reverse
Clutch
(R1 and
R2)
Forward
Low
Clutch
(F1 and
F2)
Forward
High
Clutch
(F3)
Torque
Con-
verter
Lubrication
First Test
Port
(F1 and R1)
Second Test
Port
(F2, F3 and
R2)
1793 to 2068* kPa
(260 to 300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
758 kPa
(110 psi)
69 to 276 kPa
(10 to 40 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
*Relief Pressure
12

8000 YRM 1320 Transmission Oil Pressures
Table 8. 2-Speed Transmission, Lift Trucks Manufactured AFTER June 2009
Port 1
Transmission Pump
Low and High
Pressure
Reverse
Clutch
(R1 and
R2)
Forward
Low
Clutch
(F1 and
F2)
Forward
High
Clutch
(F3)
Torque
Con-
verter
Lubrication
First Test
Port
(F1 and R1)
Second Test
Port
(F2, F3 and
R2)
1793 to 2068* kPa
(260 to 300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
758 kPa
(110 psi)
69 to 276 kPa
(10 to 40 psi)
1793 to
2068 kPa
(260 to
300 psi)
1793 to
2068 kPa
(260 to
300 psi)
*Relief Pressure
13

Steering System 8000 YRM 1320
Hydraulic System Relief Pressures
Item Specification
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Primary Relief Valve Pressure (High Idle) 22.1 ±0.48 MPa (3205 ± 70 psi)
Secondary Relief Valve Pressure
(High Idle)
15.51 ±0.48 MPa (2250 ±70 psi)
Steering System
Item Quantity
Oil Temperature for Setting Relief Pressure 50 to 65°C (122 to 149°F)
Steering Relief Pressure at 800 rpms 12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Cylinder Stroke (Each Side) 210.8 mm (8.3 in.)
Inside Steering Tire Angle 80.3°
Number of Turns to Lock 4.07
Turning Radius
(±50 mm NO LOAD)
Outside Inside
All Trucks 2585 107
Item Quantity
Oil Temperature 55 to 65°C (131 to 149°F)
Steering Relief Pressure at 800 rpms 12.4 ±0.3 MPa (1798 ±43.5 psi)
Steering Cylinder Stroke (Each Side) 224.0 mm (8.3 in.)
Inside Steering Tire Angle 74.5°
Number of Turns to Lock 3.50
Turning Radius (±76 mm NO LOAD) Outside Inside
GLP/GDP60VX (GP/GLP/GDP135VX) 3319 293
GLP/GDP70VX (GP/GLP/GDP155VX) 3376 293
14

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