Yale VERACITOR GCC030VX User manual

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

LIFT TRUCK MODEL
ENGINE MODEL
TRANSMISSION TYPE
MAST LIFT HEIGHT
CARRIAGE TYPE
DRIVE TIRE SIZE
SERIAL NUMBER
SERIAL NUMBER
SERIAL NUMBER
GROUP NUMBER
GROUP NUMBER
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.
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Foreword
To OWNERS, USERS, and OPERATORS:
The safe and efficient operation of a lift truck requires
skill and alertness on the part of the operator. To develop
the skill required the operator must:
•Receive training in the proper operation of THIS lift truck.
•Understand any potential hazards that may exist in the
work place where the lift truck is intended to be used.
•Understand the capabilities and limitations of the lift
truck.
•Become familiar with the construction of the lift truck and
see that it is maintained in good condition.
•Read and properly understand the warnings, instruc-
tions, and operating procedures in this manual.
In addition, a qualified person, experienced in lift truck
operation, must guide a new operator through several driv-
ing and load handling operations before the new operator
attempts to operate the lift truck alone.
It is the responsibility of the employer to make sure that the
operator can see, hear, and has the physical and mental
ability to operate the equipment safely.
Various laws and regulations require the employer to train
lift truck operators. These laws and regulations include:
•Occupational Safety and Health Act (USA)
•Canada Material Handling Regulations
NOTE: A comprehensive operator training program is avail-
able from Yale Corporation. For further details, contact
your dealer for Yale lift trucks.
This Operating Manual is the original instruction and con-
tains information necessary for the operation and mainte-
nance of a basic lift truck. Optional equipment is sometimes
installed that can change some operating characteristics
described in this manual. Make sure the necessary instruc-
tions are available and understood before operating the lift
truck.
Foreword
©YALE MATERIALS HANDLING CORP. 2020 524239830 - ENGLISH-US 1

Some of the components and systems described in this
Operating Manual will NOT be installed on your unit. If you
have a question about any item described, contact your
dealer for Yale lift trucks.
Additional information that describes safe operation and
use of lift trucks is available from the following sources:
•Employment safety and health standards or regulations
(Examples: "Occupational Safety and Health Standards
(USA)", "Canada Material Handling Regulations".
•Safety codes and standards (Example: Industrial Truck
Standards Development Foundation, ANSI/ITSDF
B56.1, Safety Standard for Low Lift and High Lift
Trucks).
•Publications from government safety agencies, govern-
ment insurers, private insurers and private organizations
(Example: Accident Prevention Manual for Industrial
Operations, from the National Safety Council).
•Guide for Users of Industrial Lift Trucks describes lift
truck safety, good maintenance practices, and training
programs and is available from your dealer for Yale lift
trucks (Yale Part No. 504295733).
•Forklift/Pedestrian Accidents. Available from your dealer
for Yale lift trucks (Yale Part No. 2106-2/03-0).
NOTE: Yale lift trucks are not intended for use on public
roads.
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.
Foreword
2

Contents
Foreword ...................................................................... 1
TO OWNERS, USERS, AND OPERATORS: ............. 1
Warning ........................................................................ 7
Model Description ....................................................... 10
GENERAL ................................................................... 11
OPERATOR PROTECTION EQUIPMENT ................. 14
NAMEPLATE .............................................................. 15
SAFETY LABELS ....................................................... 16
DISPLAY SWITCH CLUSTER .................................... 20
Display Switch Cluster – Right-Side Display Inputs .. 20
Display Switch Cluster – LCD Screen and Warning
and Indicator Lights .............................................. 27
OPERATOR CONTROLS ........................................... 36
OPERATOR CONTROLS – JOYSTICK FEATURES . 56
Operating Procedures ................................................ 62
GENERAL ................................................................... 62
Know Your Lift Truck ................................................ 62
Stability and Center of Gravity .................................. 64
Capacity (Weight and Load Center) ......................... 65
Impact Sensor ........................................................... 66
INSPECTION BEFORE OPERATION ........................ 67
Checks With the Engine Stopped ............................. 67
Operator Checklist .................................................... 68
Mounting and Dismounting ....................................... 69
Operator Passwords ................................................. 69
Starting Procedures .................................................. 70
Starting Procedures, Trucks With Key Switch .......... 71
Starting Procedures, Trucks With Keyless Start
Option ................................................................... 72
Checks With the Engine Running ............................. 74
Load Weighing Sensor ............................................. 75
Set Load Weight to Zero ........................................... 75
Engine Shutdown ...................................................... 75
OPERATING TECHNIQUES ...................................... 77
Basic Operating Procedures ..................................... 77
Driving and Direction Changes ................................. 82
General ................................................................... 84
Normal Operations .................................................. 84
Standard Operator Presence System ..................... 84
Optional Operator Presence System ...................... 85
Standard and Powershift 1 Speed Transmission .... 86
Techtronix 100 Transmission .................................. 87
Inching ...................................................................... 89
Steering (Turning) ..................................................... 90
Load Handling, General ............................................ 91
Load Handling, Lifting, Lowering, and Tilting ............ 92
Contents
3

Load Handling, How to Engage and Disengage a
Load ...................................................................... 95
Load Handling, Traveling .......................................... 98
Load Handling, Emergency Load Lowering .............. 102
HIGHWAY TRUCKS, RAIL CARS, AND DOCKS ....... 104
ATTACHMENTS ......................................................... 105
Disconnecting Attachment Hydraulic Quick-
Disconnect Hoses ................................................. 106
Connecting Attachment Hydraulic Quick-Disconnect
Hoses .................................................................... 107
STOPPING ................................................................. 107
PARKING .................................................................... 108
Maintenance ................................................................ 109
GENERAL ................................................................... 109
Serial Number Data .................................................. 110
HOW TO MOVE A DISABLED LIFT TRUCK .............. 110
How to Tow the Lift Truck ......................................... 110
HOW TO PUT A LIFT TRUCK ON BLOCKS .............. 111
How to Raise the Drive Tires .................................... 111
How to Raise the Steering Tires ............................... 112
HOW TO CLEAN A LIFT TRUCK ............................... 112
Maintenance Schedule ............................................... 113
Maintenance Procedures Every 8 Hours or Daily .... 141
HOW TO MAKE CHECKS WITH THE ENGINE
STOPPED ................................................................. 141
Tires and Wheels ...................................................... 141
Safety Labels ............................................................ 143
Mast, Carriage, Header Hoses, Lift Chains, and
Attachment ............................................................ 143
Operator Restraint System ....................................... 145
Emergency Locking Retractor (ELR) ...................... 146
Hood and Seat Latches ............................................ 146
Engine Compartment ................................................ 147
Fuel, Oil, and Coolant Leaks, Check ........................ 147
Hydraulic Hoses ........................................................ 148
Coolant Hoses .......................................................... 148
Steering Column Gas Cylinder ................................. 148
Transmission ............................................................ 148
Hydraulic System Oil ................................................ 149
Engine Oil ................................................................. 150
Air Filter .................................................................... 154
Forks ......................................................................... 154
Forks, Remove ......................................................... 154
Forks, Inspect ........................................................... 157
Forks, Install ............................................................. 157
Forks, Adjust ............................................................. 158
HOW TO MAKE CHECKS WITH THE ENGINE
RUNNING ................................................................. 160
Indicator Lights, Horn, Fuses, and Relays ................ 160
Service Brakes .......................................................... 162
Contents
4

Brake Fluid Level .................................................... 162
Operation, Check .................................................... 162
Parking Brake ........................................................... 163
Engine Oil Pressure .................................................. 164
Cooling System ......................................................... 164
Steering System ....................................................... 166
Control Levers and Pedals ....................................... 166
Lift System Operation ............................................... 166
HOW TO ADD FUEL TO THE LIFT TRUCK .............. 167
Liquefied Petroleum Gas (LPG) ................................ 167
LPG Tank, Remove ................................................ 168
LPG Tank, Fill ......................................................... 171
LPG Tank, Install .................................................... 172
Gasoline or Diesel Fuel ............................................ 173
WHEELS AND TIRES ................................................. 173
General ..................................................................... 173
How to Change a Solid Rubber Tire (GC Series) ..... 173
Remove and Install the Tire on the Wheel ................ 174
PNEUMATIC TIRE WITH TUBE, REPAIR ................. 176
Remove Wheels From Lift Truck .............................. 176
Remove Tire From Wheel ......................................... 176
Tire Removal, Two-Piece Wheel ............................ 178
Tire Removal, Three- and Four-Piece Wheels ....... 179
Install Wheel in Tire .................................................. 180
Tire Installation, Three- or Four-Piece Wheel ......... 181
Tire Installation, Two-Piece Wheel ......................... 182
Add Air to Pneumatic Tires With Tube ...................... 183
Install the Wheels ..................................................... 184
PNEUMATIC TUBELESS TIRE, REPAIR .................. 184
Remove Tire From Lift Truck .................................... 184
Remove Tire From Wheel ......................................... 185
Install Tire on Wheel ................................................. 186
Add Air to Pneumatic Tubeless Tire ......................... 189
Install the Wheels ..................................................... 190
SOLID RUBBER TIRES ON PNEUMATIC WHEELS,
CHANGE .................................................................. 190
Remove Tire From Wheel ......................................... 190
Install Tire on Wheel ................................................. 192
JUMP-STARTING THE LIFT TRUCK ......................... 194
Jump-Starting Using a Battery Charger .................... 194
Jump-Starting Using Another Lift Truck .................... 194
JUMP-STARTING THE LIFT TRUCK ......................... 195
Jump-Starting Using a Battery Charger .................... 195
Jump-Starting Using Another Lift Truck .................... 195
OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE .................................................... 196
CHANGES TO THE OVERHEAD GUARD ................. 196
HOW TO PUT INTERNAL COMBUSTION ENGINE
(ICE) TRUCKS IN STORAGE .................................. 196
Short-Term Storage .................................................. 197
Contents
5

Long-Term Storage ................................................... 198
While the Lift Truck is in Storage .............................. 198
How to Put Batteries in Storage ................................ 198
Putting a Stored Lift Truck Back Into Service ........... 199
HOW TO MOVE A LIFT TRUCK ON A
TRANSPORT ............................................................ 200
Loading ..................................................................... 200
Unloading .................................................................. 201
PREPARATION FOR USE ......................................... 202
Preparation After Transport ...................................... 202
Contents
6

KNOW THE EQUIPMENT:
•ALWAYS use 3 points of contact when getting on and off
the truck.
•KNOW operating, inspection, and maintenance instruc-
tions in this Operating Manual.
•DO NOT operate or repair truck unless trained and
authorized.
•INSPECT truck before use.
• DO NOT operate if truck needs repair. Tag truck and
remove key. Repair truck before use. Always use Yale
Approved parts when making repairs. Replacement
parts must meet or exceed the specifications of the origi-
nal equipment manufacturer.
•USE auxiliary equipment (attachments) for intended pur-
pose only.
•VERIFY truck is equipped with overhead guard and load
backrest adequate for the load.
LOOK WHERE YOU ARE GOING:
•IF YOU CAN'T SEE, DON'T GO.
•TRAVEL in reverse if load blocks forward vision.
•MAKE SURE tail swing area is clear.
•SOUND horn at intersections or where vision is blocked.
•WATCH clearances, especially overhead.
KNOW YOUR LOADS:
•HANDLE only stable loads within specified weight and
load center. See Nameplate on truck.
• DO NOT handle loose loads higher than load backrest.
•SPACE forks as far apart as load allows and center load
between forks. Keep load against load backrest.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
7

USE COMMON SENSE:
•DO NOT use truck to lift people unless there is no other
practical option. Then, use only a securely attached spe-
cial work platform. Follow instructions in this Operating
Manual.
•OBEY traffic rules. Yield right-of-way to pedestrians.
•BE in complete control at all times.
•ALLOW NO ONE under or near lift mechanism or load.
•OPERATE truck only from operator's seat.
•KEEP arms, legs, and head inside operator's compart-
ment.
• DO NOT move truck if anyone is between truck and sta-
tionary object.
•BEFORE DISMOUNTING, neutralize travel control,
lower carriage, and set brake.
•WHEN PARKING, also shut off power, close LPG fuel
valve, block wheels on inclines.
KNOW THE AREA:
•NEVER enter a trailer or railroad car unless its wheels
are blocked.
•CONFIRM floor strength.
•FILL fuel tank or charge battery only in designated area.
•TURN OFF engine when fueling.
•AVOID sparks or open flame. Provide ventilation.
• DO NOT start if fuel is leaking.
•KEEP vent caps clear when charging battery.
•DISCONNECT battery during servicing.
•CHECK dockboard width, capacity, and security.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
8

PROTECT YOURSELF FASTEN YOUR SEAT BELT!
•AVOID bumps, holes, and loose materials.
•AVOID sudden starts or stops.
•NEVER turn on or angle across an incline.
•TRAVEL on inclines with load uphill or when unloaded
with lift mechanism downhill.
•TILT mast slowly and smoothly. LIFT or LOWER with
upright vertical or tilted slightly back. Use minimum tilt
when stacking elevated loads.
•TRAVEL with carriage as low as possible and tilted
back.
•SLOW DOWN before turning, especially without load.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN
CAUSE THE LIFT TRUCK TO TIP.
DO NOT JUMP off if the truck tips over. HOLD steering
wheel firmly. BRACE your feet. LEAN FORWARD and
AWAY from point of impact.
Warning
WARNING
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH!
AUTHORIZED, TRAINED OPERATOR ONLY!
9

Model Description
COMPONENTS FOR GP/GLP/GDP30-35VX AND GP/GLP/
GDP40SVX TRUCKS ARE IN SAME LOCATIONS.
1. OVERHEAD GUARD
2. TAIL, BRAKE, AND REVERSE LIGHTS
3. SEAT
4. COUNTERWEIGHT
5. STEERING AXLE
6. SEAT BELT AND HIP RESTRAINT
7. DRIVE AXLE
8. CARRIAGE
9. FORKS
10. LOAD BACKREST EXTENSION
11. PARKING BRAKE
12. STEERING WHEEL
13. MAST
14. OPERATING MANUAL (BEHIND SEAT)
Figure 1. Model View Showing Major Components of GC/GLC030-035VX, GC/GLC040SVX Series
Model Description
10

Model Description
General
This Operating Manual is for the following models of lift
trucks:
GC/GLC030VX, GC/GLC035VX, and
GC/GLC040SVS (C809)
GP/GLP/GDP030VX, GP/GLP/GDP035VX, and
GP/GLP/GDP040SVX (C810)
These lift trucks are available with the following engines:
•Mazda 2.2L engine which uses gasoline or LPG fuel
•Yanmar 2.6L engine which uses diesel fuel
Prior to January, 2011, these lift truck models can be
equipped with a Standard (iron case), Powershift 1 Speed
(aluminum case gear drive) or Techtronix 100 transmission
(see Table 1 and Figure 2). After January, 2011, these lift
truck models will be equipped with a Powershift 1 Speed
(aluminum case chain drive) or Techtronix 100 transmis-
sion (see Table 1 and Figure 2), and can be equipped with
three types of controls:
•A Foot Directional Control (FDC) pedal that controls both
the forward and reverse operation of the transmission
and the speed of the engine.
•A Direction Control Lever on the left side of the Display
Switch Cluster that controls the forward, neutral, and
reverse operation of the transmission. A separate accel-
erator pedal controls the engine speed.
•A directional control switch integrated into the armrest on
units equipped with E-hydraulics controls both forward
and reverse operation of the transmission. A separate
accelerator pedal controls engine speed.
The GP/GLP/GDP030VX, GP/GLP/GDP035VX, and
GP/GLP/GDP040SVX lift trucks are equipped with pneu-
matic tires or solid rubber tires that look like pneumatic tires
and the GC/GLC030VX, GC/GLC035VX, and GC/
GLO040SVX lift trucks are equipped with solid rubber tires
(often called cushion tires) that are pressed onto the rim.
See Wheels and Tires in the Maintenance Section for a
description of these tires.
Model Description
11

If your lift truck is an GC/GLC030VX, GC/GLC035VX, and
GC/GLC040SVS (C809) with manual hydraulics and manu-
factured prior to March, 2009, it is not equipped with an
emergency lowering valve. If manufactured after March,
2009, it is equipped with an emergency lowering valve.
If your lift is an GP/GLP/GDP030VX, GP/GLP/GDP035VX,
and GP/GLP/GDP040SVX (C810) with manual hydraulics
and manufactured prior to March, 2009, it is not equipped
with an emergency lowering valve. If manufactured after
March, 2009, it is equipped with an emergency lowering
valve.
If your lift truck is equipped with electronic hydraulics, it has
an emergency lowering valve.
This emergency lowering valve (see Figure 15) allows the
operator or service technician to lower the lift truck's mast
assembly if the electrical signal to the main control valve is
disrupted. See the section Load Handling, Emergency
Load Lowering in the Operating Procedures section.
Model Description
12

Table 1. Transmissions
Operational
Feature Transmission
Electronic Inching Yes Yes
Electronic Control of
Direction Changes
Yes Yes
Auto Deceleration – Yes
Controlled Power Reversal – Yes
Roll Reduction Feature – Yes
Roll Back Feature – Yes
Reduced Drive Tire Slippage – Yes
Model Description
13

1. STANDARD TRANSMISSION
2. TECHTRONIX 100 TRANSMISSION
3. POWERSHIFT 1 SPEED TRANSMISSION
Figure 2. Transmission Labels
Operator Protection Equipment
The LOAD BACKREST EXTENSION is installed to keep
loose parts of the load from falling back toward the opera-
tor. It must be high enough, with vertical openings small
enough, to prevent the parts of the load from falling back-
wards. If a load backrest extension that is different from the
one installed on your lift truck is required, contact your lift
truck dealer.
The OVERHEAD GUARD is intended to offer reasonable
protection to the operator from falling objects, but cannot
protect against every possible impact. Therefore, it must
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. This restraint system is
intended to reduce the risk of the head and torso being
trapped between the lift truck and the ground, but it cannot
protect the operator against all possible injury in a tipover.
The hip restraint will help the operator resist side move-
ment. It is not a substitute for the seat belt. Always fasten
the seat belt.
This lift truck is equipped with one of the three seat belt
configurations.
•Seat belt with no operation interlock.
•Seat belt with operation interlock. Seat belt must be fas-
tened for lift truck to start or to travel.
•Seat belt with sequencing interlock. Operator must be in
the seat, then the seat belt fastened before lift truck will
operate. This seat belt is used with the Optional Opera-
tor Presence System.
Model Description
14

Nameplate
WARNING
DO NOT add to or modify the lift truck. Any modifica-
tion that affects the safe operation of the truck cannot
be undertaken without the written authorization of Yale
Corporation.
Any change to the lift truck, the tires, or its equipment
can change the lifting capacity. The lift truck must be
rated as equipped and the Nameplate must show the
new capacity rating.
The capacity is specified in kilograms (kg) and pounds (lb).
The capacity is the maximum load that the lift truck can
handle for the load condition shown on the Nameplate.
The maximum capacity for the lift truck, at full load height,
must be shown on the Nameplate. Special capacities with
the load height reduced or with optional load centers, may
also be shown on the Nameplate.
The lift truck serial number code is on the Nameplate. The
serial number code is also stamped on the right-hand side
of the lift truck frame, under the floorplate.
When a lift truck is shipped incomplete from the factory, the
Nameplate is covered by an INCOMPLETE label as shown
in Figure 3. If the equipment on the truck is changed, the
Nameplate is covered by a NOTICE label as shown in Fig-
ure 3. If your lift truck has either of these labels, do not
operate the lift truck. Contact your dealer for lift trucks to
obtain a complete and correct Nameplate.
Model Description
15

A. NAMEPLATE
B. NOTICE LABEL
C. INCOMPLETE LABEL
Figure 3. Nameplate and Labels
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. See the Parts Manual for label part numbers and
a complete listing of all labels that are available for the lift
trucks covered in this Operating Manual.
Model Description
16

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)
Model Description
17

SEE THE PARTS MANUAL FOR THE PART NUMBER.
Figure 4. Warning and Safety Labels (Sheet 2 of 3)
Model Description
18