YALE E879 GDC60VX LIFT TRUCK Service Repair Manual

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Text of YALE E879 GDC60VX LIFT TRUCK Service Repair Manual

  • GLC/GDC60VX, GLC/GDC70VX (E879)SERVICE MANUAL CONTENTS

    SECTIONPART

    NUMBERYRM

    NUMBERREV

    DATEFRAME............................................................................................................................ 524288189 0100 YRM 1316 08/13GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14KUBOTA ENGINE REPAIR............................................................................................ 550048607 0600 YRM 1557 03/13COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... 524288194 1300 YRM 1317 03/13TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... 524294873 1300 YRM 1343 03/14DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)................... 524288199 1400 YRM 1318 12/13STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... 524294878 2100 YRM 1328 02/14HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14ELECTRICAL SYSTEM.................................................................................................. 524223772 2200 YRM 1142 04/14MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706,

    A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749,B750, B751, B752, B753, B754)................................................................................ 524265342 4000 YRM 1250 02/14

    METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14PERIODIC MAINTENANCE............................................................................................ 550048616 8000 YRM 1571 11/13CAPACITIES AND SPECIFICATIONS........................................................................... 550048609 8000 YRM 1572 04/13DIAGRAMS AND SCHEMATICS.................................................................................... 550055283 8000 YRM 1585 04/14DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14

    Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.9000 YRM 1112 ON CD

    PART NO. 550048594 (12/14)

  • General

    This section contains repair procedures for tilt cylinders, main lift cylinder, and free-lift cylinders. The number andthe design of the parts can be different, but the operation of the cylinders is the same.

    Safety Procedures When Working Near MastThe following procedures MUST be used when in-specting or working near the mast. Additional precau-tions and procedures can be required when repairingor removing the mast.

    WARNING Mast parts are heavy and can move. Distances be-tween parts are small. Serious injury or death canresult if part of the body is hit by parts of the mastor the carriage.

    Never put any part of the body into or underthe mast or carriage unless all parts arecompletely lowered or a safety chain is in-stalled. Also make sure that the power isOFF and the key is removed. Put a DO NOTOPERATE tag in the operator's compart-ment. Disconnect the battery and put a tagor lock on the battery connector.

    Be careful of the forks. When the mast israised, the forks can be at a height to causean injury.

    DO NOT climb on the mast or lift truck atany time. Use a ladder or personnel lift towork on the mast.

    DO NOT use blocks to support the mastweldments nor to restrain their movement.

    Mast repairs require disassembly and re-moval of parts and can require removal ofthe mast or carriage. Follow the repair pro-cedures in this section.

    WHEN WORKING NEAR THE MAST ALWAYS: Lower the mast and carriage completely.

    Push the lift/lower control lever forward andmake sure there is no movement in themast. Make sure that all parts of the mastthat move are fully lowered.

    OR

    If parts of the mast must be in a raised posi-tion, install a safety chain to restrain themoving parts of the mast. Connect movingparts to a part that does not move. Followthese procedures:

    1. Put mast in vertical position.

    2. Raise mast to align bottom crossmember of weld-ment that moves in outer weldment with cross-member on outer weldment. On the two-stageand free-lift mast, the moving part is the innerweldment. On the three-stage mast, it is the inter-mediate weldment. On the four-stage mast, it isthe first intermediate weldment. See Figure 1.

    3. Use a 3/8-inch minimum safety chain with a hookto fasten the crossmembers together so the mov-able member cannot lower. Put hook on back sideof mast. Make sure hook is completely engagedwith a link in the chain. Make sure safety chaindoes not touch lift chains or chain sheaves, tubes,hoses, fittings, or other parts on the mast.

    4. Lower mast until there is tension in safety chainand free-lift cylinder (two-stage full free-lift, three-stage, and four-stage) is completely retracted. Ifrunning, turn the power OFF. Apply the parkingbrake. Install a DO NOT REMOVE tag on thesafety chain(s).

    5. Install another safety chain (3/8-in. minimum) be-tween the top or bottom crossmember of the car-riage bar and a crossmember on the outer weld-ment.

    6. After lowering or restraining the mast, shut off thepower, and remove key.

    NOTE: Place a DO NOT OPERATE tag in the opera-tor's compartment.

    7. Disconnect battery and put a tag or lock on bat-tery connector.

    2100 YRM 1328 General

    1

  • A. TWO-STAGE LFL MASTB. TWO-STAGE FFL MAST

    C. THREE-STAGE FFL MASTD. FOUR-STAGE FFL MAST

    1. OUTER WELDMENT2. INNER WELDMENT3. INTERMEDIATE WELDMENT4. HOOK

    5. FREE-LIFT CYLINDER6. CARRIAGE BAR7. CROSSMEMBER8. FIRST INTERMEDIATE WELDMENT

    Figure 1. Two-Stage LFL, Two-Stage FFL, Three-Stage FFL, and Four-Stage FFL Masts

    Safety Procedures When Working Near Mast 2100 YRM 1328

    2

  • Tilt Cylinder RepairREMOVE

    WARNING Before removing the tilt cylinder(s), tilt the mastforward. Use a chain to hold the mast to the frameand prevent the mast from moving forward orbackwards.

    WARNING DO NOT push the tilt pins out of the rod end withyour fingers. DO NOT permit the tilt cylinders todrop and cause damage.

    NOTE: Insure that the parking brake is applied be-fore starting the procedure below.

    NOTE: Perform Step 1 and Step 2 if mast is installedon the lift truck.

    1. At the mast end mount, remove the capscrew andanchor pin from the tilt pin. Using a brass drift orsimilar tool, push the tilt pin out of the rod end.Remove lube fitting from tilt pin.

    See Figure 2 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/

    GDP135VX, GP/GLP/GDP155VX) (C878,D878, E878)

    GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,D879, E879, F879)

    See Figure 3 for lift truck model GLP/GDP80VX, GLP/GDP80VX9, GLP/

    GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909,B909)

    2. Stroke cylinder to the full back tilt position.

    3. Remove floor mats, floor plates and side coversto access the frame end mount of tilt cylinder. SeeSide Covers Remove procedures in

    Frame 0100YRM1321 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/

    GDP135VX, GP/GLP/GDP155VX) (C878,D878)

    GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909)

    Frame 0100YRM1316 for lift truck models GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/

    GDC135VX, GC/GLC/GDC155VX) (C879,D879, E879, F879)

    Frame 0100YRM1581 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/

    GDP135VX, GP/GLP/GDP155VX) (E878) GLP/GDP80VX, GLP/GDP80VX9, GLP/

    GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (B909)

    4. Disconnect the hydraulic lines at the cylinder hoseports. Install caps on the hydraulic lines and in thecylinder hose ports.

    See Figure 2 for lift truck models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/

    GDP135VX, GP/GLP/GDP155VX) (C878,D878, E878)

    GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,D879, E879, F879)

    See Figure 3 for lift truck model GLP/GDP80VX, GLP/GDP80V