YALE (A910) GLC20VX LIFT TRUCK Service Repair Manual by 16310826

Maintenance

Service Repair GLC20-35VX [A910]

PART NO. 524223778

8000 YRM 1151

Tire Sizes

Lift Truck Lifting Capacity Model

Weight

GLC20VX (GC/GLC040VX) (A910) GLP/GDP20VX (GP/GLP/GDP040VX) (B875)

1814 kg (4000 lb)

GLC25VX (GC/GLC050VX) (A910) GLP/GDP25XV (GP/GLP/GDP050VX) (B875)

2268 kg (5000 lb)

GC/GLC055SVX (A910)

2495 kg (5500 lb)

GLC30VX (GC/GLC060VX) (A910) GLP/GDP30VX (GP/GLP/GDP060VX) (B875)

2722 kg (6000 lb)

GLC35VX (GC/GLC070VX) (A910) GLP/GDP35VX (GP/GLP/GDP070VX) (B875)

3175 kg (7000 lb)

NOTE: Load center at 500 mm (24 in.).

Counterweight Weights Model

Model

GLC20VX (GC/GLC040VX) (A910)

1040 kg (2293 lb)

GLC25VX (GC/GLC050VX) (A910)

1395 kg (3075 lb)

GC/GLC055SVX (A910)

1643 kg (3622 lb)

GLC30VX (GC/GLC060VX) (A910)

1819 kg (4010 lb)

GLC35VX (GC/GLC070VX) (A910)

2153 kg (4747 lb)

GLP/GDP20VX (GP/GLP/GDP040VX) (B875)

996 kg (2196 lb)

GLP/GDP25VX (GP/GLP/GDP050VX) (B875)

1340 kg (2954 lb)

GC/GLC060VX (B875)

1666 kg (3672 lb)

GLP/GDP35VX (GP/GLP/GDP070VX) (B875)

1967 kg (4336 lb)

Tire Sizes Truck

Drive Tires

Steer Tires

GLC20-25VX (GC/GLC040-050VX) (A910)

21 × 7 × 15

16 × 5 × 10.5

GLC30VX (GLC055SVXGLC060VX) (A910)

21 × 8 × 15

16 × 6 × 10.5

GLC35VX (GLC070VX) (A910)

21 × 9 × 15

16 × 6 × 10.5

GLP/GDP20-25VX (GP/GLP/ GDP040-050VX) (B875)

7.00 x 12

6.00 x 9

GLP/GDP20-35VX (GP/GLP/ GDP040-070VX) (B875)

28 x 9

6.50 x 10

Capacities

8000 YRM 1151

Capacities Item

Quantity

Specifications

Fuel Capacity Gas GLC20-35VX (GC040-070VX, GC055SVX) (A910)

40.5 liter (10.7 gal)

86 Octane

Gas GP040-070VX (B875)

52.0 liter (13.7 gal)

86 Octane

29.9 liter (7.9 gal) 15.2 kg (33.5 lb)

LPG-HD 5, HD 10

LPG GLP20-35VX (GLP040-070VX) (B875)

29.9 liter (7.9 gal) 15.2 kg (33.5 lb)

LPG-HD 5, HD 10

Diesel GP040-070VX (B875) Trucks Only

52.0 liter (13.7 gal)

Diesel No. 2

LPG GLC20-35VX GLC055SVX) (A910)

(GLC040-070VX,

Engine Oil (With Oil Filter) 3.9 liter (4.1 qt)

7°C (20°F) and below SAE 5W-20 16°C (60 °F) and below SAE 5W-30

Mazda FE 18°C (0°F) and above SAE 10W-30 API SM ILSAC GF4 SAE J2362 4.2 liter (4.4 qt)

7°C (20°F) and below SAE 5W-20 16°C (60 °F) and below SAE 5W-30

Mazda F2 18°C (0°F) and above SAE 10W-30 API SM ILSAC GF4 SAE J2362

8000 YRM 1151

Capacities Item

Quantity 5.0 liter (5.3 qt)

Specifications 7°C (20°F) and below SAE 5W-20 16°C (60 °F) and below SAE 5W-30

GM 2.4L 18°C (0°F) and above SAE 10W-30 API SM ILSAC GF4 SAE J2362 10.2 liter (10.8 qt)

20°C (68°F) and over SAE 40 10 to 30°C (50 to 86°F) SAE 30 0 to 20°C (32 to 68°F) SAE 20 16 to 40°C (3 to 104°F) SAE 15W-40 20 to 30°C ( 4 to 86°F) SAE 10W-30 10 to 10°C (14 to 50°F) SAE 20W 20 to 10°C ( 4 to 50°F) SAE 10W

Yanmar Diesel

Cooling System 11.0 liter (11.6 qt)

CAUTION

Mazda FE and F2 Serpentine and Square Wave

Additives may damage the cooling system. Before using additives, contact your local Yale dealer. Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water.

Capacities

8000 YRM 1151 Item

Quantity

Specifications

10.6 liter (11.2 qt)

CAUTION

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

Mazda FE and F2 Square Wave with Air Oil Cooler

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water. 10.6 liter (11.2 qt)

CAUTION

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

GM 2.4L

Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50% distilled water or deionized water. 11.5 liter (12.1 qt)

CAUTION

Yanmar Diesel

8000 YRM 1151

Capacities Item

Quantity

Specifications

Hydraulic Tank Oil Capacity GLC20-35VX GLC055SVX) (A910)

(GLC040-070VX,

36.1 liter (38.1 qt) Initial Fill 30.1 liter (32.0 qt) Drain and Fill

CAUTION

Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. ISO VG-46 Hydraulic Oil 15째C (5째F) and above

GLP20-35VX (GLP040-070VX) (B875)

45.8 liter (48.4 qt) Initial Fill 39.8 liter (42.0 qt) Drain and Fill

CAUTION

Additives may damage the hydraulic system. Before using additives, contact your local Yale dealer. ISO VG-46 Hydraulic Oil 15째C (5째F) and above

Transmission Standard Transmission (Iron Housing)

20 liter (21.0 qt)

John Deere JDM J20C

Single Speed PS Transmission (Aluminum Housing)

13 liter (14.0 qt)

John Deere JDM J20C

Techtronix Transmission (Iron Housing)

20 liter (21.0 qt)

John Deere JDM J20C

Techtronix Transmission (Aluminum Housing)

13 liter (14.0 qt)

John Deere JDM J20C

Brake Fluid (Dry Brake) Master Cylinder

0.25 liter (0.53 pt)

SAE J-1703, DOT 3

Brake Oil (Wet Brake) Master Cylinder

0.35 liter (0.74 pt)

Dexron III

Differential and Drive Axle Oil (Dry Brake) GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910)

5.0 liter (5.3 qt)

SAE 80W-90 or 85W-140

Differential and Drive Axle Oil (Dry Brake) GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

6.5 liter (6.9 qt)

SAE 80W-90 or 85W-140

Electrical System

8000 YRM 1151 Item

Quantity

Specifications

Planetary Housing, Left Side GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

0.5 liter (0.5 qt)

SAE 80W-90

Planetary Housing, Right Side GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

2.0 liter (2.1 qt)

SAE 80W-90

Wet Brake Portion Of Drive Axle Center Section GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

1.0 liter (1.1 qt)

John Deere JDM J20C

Drive Axle (Wet Brake)

Electrical System Item

Mazda FE and F2

GM 2.4L

Yanmar

12-volt, negative ground

ND W9EXR-U

NGK BPR6EY

N/A

0.8±0.1 mm (0.031±.0.004 in.)

0.8 to 0.9 mm (0.031 to 0.035 in.)

N/A

Gas

6° BTDC (Orange timing mark)

Not Adjustable

N/A

LPG

6° BTDC (Orange timing mark)

Not Adjustable

N/A

2.6L engine preset @ 4° ATDC 3.3L engine preset @ 6° ATDC

Battery Spark Plugs Spark Plug Gap Ignition Timing:

Diesel

8000 YRM 1151

Electrical System Mazda FE and F2

Alternator Output (14 Volts)

G and LPG

Idle

18 amps @ 800 rpm

High Idle

42 amps @ 2700 rpm GM 2.4L

Alternator Output (14 Volts)

G and LPG

Idle

38 amps @ 800 rpm

High Idle

65 amps @ 2700 rpm Yanmar

Alternator Output (13.5 Volts)

Idle

14 amps @ 825 rpm

High Idle (2.6L)

57 amps @ 2700 rpm

High Idle (3.3L)

56 amps @ 2600 rpm

Transmission Oil Pressures

8000 YRM 1151

Transmission Oil Pressures 1-Speed Transmission - Iron Housing All Pressures at 2000 rpm and Oil at 50 to 65°C (120 to 150°F) Port 1 Transmission Pump

Port 2

Port 3

Port 4

Port 5

***Low Pressure

***High Pressure

Reverse Clutch

Forward Clutch

Torque Converter

Lubrication

1138 ±96* kPa (165 ±14 psi)

1482 ±96* kPa (215 ±15 psi)

983 ±58** kPa (142.5 ±8.5 psi)

738 ±52 kPa (107 ±7.5 psi)

138 ±34.5 kPa (20 ±5 psi)

A. EARLY MODELS B. LATER MODELS *Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***High pressure port is used when the lift truck is equipped with a wet brake system. The low pressure port is used when the lift truck is equipped with a dry brake system.

8000 YRM 1151

Transmission Oil Pressures 1-Speed Transmission - Aluminum Housing All Pressures at 2000 rpm and Oil at 18 to 65°C (65 to 150°F)

Port 1 Transmission Pump

Port 2

Port 3

Port 5

***Low Pressure

High Pressure

Reverse Clutch

Forward Clutch

Lubrication

1089 ±69* kPa (158 ±10 psi)

1241 ±138* kPa (180 ±20 psi)

983 ±58** kPa (142.5 ±8.5 psi)

62 ±41 kPa (9 ±6 psi)

A. TOP VIEW B. RIGHT SIDE VIEW *Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi). ***Low pressure at 800 rpm and oil at 27 to 32°C (80 to 90°F).

Transmission Oil Pressures

8000 YRM 1151

2-Speed Transmission, Lift Trucks Manufactured Before July, 2013 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 Lubrication

***Low Pressure

***High Pressure

Reverse Clutch

Forward Low Clutch

Forward High Clutch

Torque Converter

1138 ±96* kPa (165 ±14 psi)

1482 ±96* kPa (215 ±15 psi)

983 ±58** kPa (142.5 ±8.5 psi)

738 ±52 kPa (107 ±7.5 psi)

138 ±34.5 kPa (20 ±5 psi)

8000 YRM 1151

Transmission Oil Pressures 2-Speed Transmission, Lift Trucks Manufactured After July, 2013 All Pressures at 2500 rpm and Oil at 50 to 65°C (120 to 150°F)

Port 1

Port 2

Port 3

Port 5

Port 6

Transmission Pump

Reverse Clutch

Forward Clutch

Torque Converter

Lubrication

1138 ±96* kPa (165 ±14 psi)

983 ±58** kPa (142.5 ±8.5 psi)

738 ±52 kPa (107 ±7.5 psi)

55 ±28 kPa (8 ±4 psi)

A. REAR VIEW B. FRONT VIEW *Relief Pressure **Clutch pack pressure difference between the forward and reverse packs cannot exceed manufacturing limit of 48 kPa (7 psi) or service limit of 70 kPa (10 psi).

Hydraulic System Relief Pressures

8000 YRM 1151

Hydraulic System Relief Pressures Table 1. Hydraulic Systems With Hydraulic Gear Pump Item Oil Temperature for Setting Relief Pressure

Specification 50 to 65°C (122 to 149°F)

Primary Relief Valve Pressure (High Idle) GLC20-30VX (GC/GLC040-060VX, GLC055SVX) (A910) and GLP/GDP20-30VX (GP/GLP/GDP040060VX) (B875)

21.37 ±0.48 MPa (3099 ±70 psi)

GLC35VX (GC/GLC070VX) (A910) GLP/GDP35VX (GP/GLP/GDP070VX) (B875)

23.44 ±0.48 MPa (3400 ±70 psi)

Secondary Relief Valve Pressure (High Idle)

15.51 ±0.48 MPa (2250 ±70 psi)

Table 2. Hydraulic Systems With Variable Displacement Pump Item Oil Temperature for Setting Relief Pressure

Specification 50 to 65°C (122 to 149°F)

Primary Relief Valve Pressure (High Idle) GLP/GDP20-35VX (B875)

25.0 ±0.50 MPa (3626 ±72.5 psi)

Secondary Relief Valve Pressure (High Idle) GLP/GDP20-35VX (B875)

15.5 ±0.50 MPa (2248 ±72.5 psi)

Maximum Allowable Leakage at 1A Port to Tank GLP/GDP20VX (B875) GLP/GDP25-35VX (B875)

18 cc @ 19.3 MPa (2799 psi) 15.8 cc @ 19.3 MPa (2799 psi)

Variable Displacement Pump used only on lift truck models GLP/GDP20-35VX (B875)

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8000 YRM 1151

Steering System

Steering System Item

Quantity

Oil Temperature for Setting Relief Pressure

50 to 65°C (122 to 149°F)

Steering Relief Pressure at 800 rpms - Lift Trucks with Hydraulic Gear Pump GLC20-30VX (GC/GLC040-060VX, GLC055SVX) (A910) and GLP/GDP20-30VX (GP/GLP/GDP040060VX) (B875)

11.0 ±0.3 MPa (1595 ±43.5 psi)

GLC35VX (GC/GLC070VX) (A910) and GDP35VX (GP/GLP/GDP070VX) (B875)

12.0 ±0.3 MPa (1740 ±43.5 psi)

GLP/

Steering Relief Pressure at 800 rpms - Lift Trucks with Variable Displacement Pump GLP/GDP20-35VX (B875)

12.0 MPa (1740 psi)

Steering Cylinder Stroke GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910) GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875)

170.3 mm (6.70 in.) 161.6 mm (6.4 in.)

Inside Steering Tire Angle

82°

Number of Turns to Lock 3.8 3.7

GLC20-35VX (GC/GLC040-070VX, GLC055SVX) (A910) GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Turning Radius (±50 mm NO LOAD)

Outside

Inside

Cushion Tire Trucks GLC20VX (GC/GLC040VX) (A910)

1935

GLC25VX (GC/GLC050VX) (A910)

2007

GC/GLC055SVX (A910)

1935

GLC30VX (GC/GLC060VX) (A910)

2075

GLC35VX (GC/GLC070VX) (A910)

2105

Pneumatic Tire Trucks GLP/GDP20VX (GP/GLP/GDP040VX) (B875)

2150

GLP/GDP25VX (GP/GLP/GDP050VX) (B875)

2216

GLP/GDP30VX (GP/GLP/GDP060VX) (B875)

2277

GLP/GDP35VX (GP/GLP/GDP070VX) (B875)

2380

Stall Speeds (in RPM ±100 rpm)

8000 YRM 1151

Stall Speeds (in RPM ±100 rpm) MAZDA FE (EXCEPT 2007 EMISSION COMPLIANT ENGINES) Engine

New Engine

Broken-In Engine

Gas

2000

2106

LPG

1875

1974

New Engine

Broken-In Engine

Gas

1875

1900

LPG

1820

1865

New Engine

Broken-In Engine

Gas

2073

2183

LPG

1995

2100

New Engine

Broken-In Engine

Gas

1990

2010

LPG

2010

2050

New Engine

Broken-In Engine

Gas

1914

2015

LPG

1950

2053

MAZDA FE (2007 EMISSION COMPLIANT ENGINES ONLY) Engine

MAZDA F2 (EXCEPT 2007 EMISSION COMPLIANT ENGINES) Engine

MAZDA F2 (2007 EMISSION COMPLIANT ENGINES ONLY) Engine

GM 2.4L Engine

8000 YRM 1151

Mast Speeds

YANMAR 2.6L Engine

New Engine

Broken-In Engine*

1752

1845

Diesel

*30 or more hours.

YANMAR 3.3L Engine

New Engine

Broken-In Engine*

2149

2263

Diesel

*30 or more hours.

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

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

Table 3. Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) Lowering M/Sec Model/ Engine

GLC 20-25VX (GC/GLC 040050VX, GC/GLC 055SVX) Mazda FE/F2 GLC 30-35VX (GC/GLC 060070VX) Mazda FE/F2

Lifting M/Sec

Mast

No Load

Rated Load

No Load

GLC 20VX (GC/ GLC 040 VX)

GLC 25VX (GC/ GLC 050 VX)

GC/GLC 055 SVX

GLC 30VX (GC/ GLC 060 VX)

GLC 35VX (GC/ GLC 070 VX)

2-Stage LFL

0.44

0.55

0.60

0.55

N/A

2-Stage FFL

0.37

0.55

0.60

0.49

N/A

3-Stage FFL

0.37

0.55

0.60

0.52

N/A

4-Stage FFL

0.37

0.55

0.60

0.51

N/A

2-Stage LFL

0.44

0.55

0.60

N/A

0.55

2-Stage FFL

0.37

0.55

0.60

N/A

0.53

3-Stage FFL

0.37

0.55

0.60

N/A

0.58

4-Stage FFL

0.37

0.55

0.60

N/A

Mast Speeds

8000 YRM 1151

Table 3. Lift Truck Models GLC20-35VX (GC/GLC040-070VX, GC/GLC055SVX) (A910) (Continued) Lowering M/Sec Model/ Engine

GLC 20-25VX (GC/GLC 040050VX, GC/GLC 055SVX) GM 2.4L

GLC 30-35VX (GC/GLC 060070VX) GM 2.4L

Lifting M/Sec

Mast

No Load

Rated Load

No Load

GLC 20VX (GC/ GLC 040 VX)

GLC 25VX (GC/ GLC 050 VX)

GC/GLC 055 SVX

GLC 30VX (GC/ GLC 060 VX)

GLC 35VX (GC/ GLC 070 VX)

2-Stage LFL

0.44

0.55

0.60

N/A

2-Stage FFL

0.37

0.55

0.54

N/A

3-Stage FFL

0.37

0.55

0.57

N/A

4-Stage FFL

0.37

0.55

N/A

2-Stage LFL

0.44

0.55

0.53

N/A

0.53

(Gas) 0.48 (LPG) 0.53

2-Stage FFL

0.37

0.55

0.52

N/A

0.52

(Gas) 0.47 (LPG) 0.52

3-Stage FFL

0.37

0.55

0.56

N/A

0.56

(Gas) 0.51 (LPG) 0.56

8000 YRM 1151

Mast Speeds

Table 4. Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) Lowering M/Sec Model/ Engine

Mast

Lifting M/Sec GLP/ GLP/ GLP/ GLP/ GDP20VX GDP25VX GDP30VX GDP35VX (GP/GLP/ (GP/GLP/ (GP/GLP/ (GP/GLP/ GDP40VX) GDP50VX) GDP60VX) GDP70VX)

No Load

Rated Load

No Load

2-Stage LFL

0.42

0.50

0.57

N/A

2-Stage FFL

0.42

0.50

0.51

N/A

3-Stage FFL

0.42

0.50

0.54

N/A

2-Stage LFL

0.42

0.50

N/A

GLP/ GDP3035VX (GP/GLP/ GDP060070VX)

(Gas) 0.50 (LPG) 0.45

(Gas) 0.49 (LPG) 0.36

2-Stage FFL

0.42

0.50

0.49

N/A

0.49

(Gas) 0.49 (LPG) 0.43

Mazda FE

3-Stage FFL

0.42

0.50

0.48

N/A

0.48

(Gas) 0.49 (LPG) 0.43

2-Stage LFL

0.42

0.50

0.57

N/A

2-Stage FFL

0.42

0.50

0.51

N/A

3-Stage FFL

0.42

0.50

0.54

N/A

2-Stage LFL

0.42

0.50

N/A

0.50

2-Stage FFL

0.42

0.50

0.49

N/A

0.49

3-Stage FFL

0.42

0.50

0.48

N/A

0.48

GLP/ GDP2025VX (GP/GLP/ GDP040050VX) Mazda FE

GLP/ GDP2025VX (GP/GLP/ GDP040050VX) Mazda F2 GLP/ GDP3035VX (GP/GLP/ GDP060070VX) Mazda F2

Mast Speeds

8000 YRM 1151

Table 4. Lift Truck Models GLP/GDP20-35VX (GP/GLP/GDP040-070VX) (B875) (Continued) Lowering M/Sec Model/ Engine

GLP/ GDP2025VX (GP/GLP/ GDP040050VX)

Mast

Lifting M/Sec GLP/ GLP/ GLP/ GLP/ GDP20VX GDP25VX GDP30VX GDP35VX (GP/GLP/ (GP/GLP/ (GP/GLP/ (GP/GLP/ GDP40VX) GDP50VX) GDP60VX) GDP70VX)

No Load

Rated Load

No Load

2-Stage LFL

0.42

0.50

0.61

N/A

2-Stage FFL

0.42

0.50

0.55

N/A

3-Stage FFL

0.42

0.50

0.58

N/A

2-Stage LFL

0.42

0.50

0.54

N/A

0.54

2-Stage FFL

0.42

0.50

0.53

N/A

0.53

3-Stage FFL

0.42

0.50

0.52

N/A

0.52

2-Stage LFL

0.42

0.50

0.69

0.67

0.63

N/A

2-Stage FFL

0.42

0.50

0.62

0.61

0.58

N/A

3-Stage FFL

0.42

0.50

0.66

0.63

0.59

N/A

2-Stage LFL

0.42

0.50

0.57

N/A

0.54

0.39

2-Stage FFL

0.42

0.50

0.56

N/A

0.53

0.40

3-Stage FFL

0.42

0.50

0.54

N/A

0.52

0.39

2-Stage LFL

0.42

0.50

0.72

0.71

N/A

2-Stage FFL

0.42

0.50

0.64

0.63

N/A

3-Stage FFL

0.42

0.50

0.68

0.67

N/A

GM 2.4L GLP/ GDP3035VX (GP/GLP/ GDP060070VX) GM 2.4L GLP/ GDP2025VX (GP/GLP/ GDP040050VX) Yanmar 2.6L GLP/ GDP3035VX (GP/GLP/ GDP060070VX) Yanmar 2.6L GLP/ GDP2025VX (GP/GLP/ GDP040050VX) Yanmar 3.3L