Yale Veracitor GCC040VX User manual

OPERATING MANUAL
Veracitor®
GC/GLC040VX, GC/GLC050VX, GC/GLC060VX, GC/GLC070VX,
GC/GLC055SVX (C910);
GP/GLP/GDP040-070VX (D875)
PART NO. 550108846 5/15
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 2015. All right reserved.
YALE and VERACITOR are Registered Trademarks of NACCO Materials Handling Group, Inc. CSS, PREMIER, and are Trademarks in the United States
and certain jurisdictions.
is a registered copyright.
Spacer

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, instructions,
and operating procedures in this manual.
In addition, a qualified person, experienced in lift truck oper-
ation, must guide a new operator through several driving 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. 2015 550108846 - 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 pro-
grams 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 ................................................................... 12
OPERATOR PROTECTION EQUIPMENT ................. 13
NAMEPLATE .............................................................. 14
SAFETY LABELS ....................................................... 15
DISPLAY SWITCH CLUSTER .................................... 23
Display Switch Cluster – Right-Side Display
Inputs .................................................................... 23
Display Switch Cluster – LCD Screen and Warning
and Indicator Lights .............................................. 31
OPERATOR CONTROLS ........................................... 40
Operating Procedures ................................................ 59
GENERAL ................................................................... 59
Know Your Lift Truck ................................................ 59
Stability and Center of Gravity .................................. 61
Capacity (Weight and Load Center) ......................... 62
Impact Sensor ........................................................... 63
INSPECTION BEFORE OPERATION ........................ 64
Checks With the Engine Stopped ............................. 64
Operator Checklist .................................................... 65
Mounting and Dismounting ....................................... 65
Operator Passwords ................................................. 66
Starting Procedures .................................................. 67
Starting Procedures, Trucks With Key Switch .......... 67
Starting Procedures, Trucks With Keyless Start
Option ................................................................... 68
Checks With the Engine Running ............................. 70
Load Weighing Sensor ............................................. 71
Set Load Weight to Zero ........................................... 72
Engine Shutdown ...................................................... 72
Engine Modes (Generation 2 ECO-eLo) ................... 73
OPERATING TECHNIQUES ...................................... 74
Basic Operating Procedures ..................................... 74
Driving and Direction Changes ................................. 80
Seat Switch Sensor ................................................ 82
Standard Operator Presence System ..................... 83
Optional Operator Presence System ...................... 84
Standard Transmission ........................................... 84
Techtronix 100 Transmission .................................. 85
Inching ...................................................................... 87
Steering (Turning) ..................................................... 88
Load Handling, General ............................................ 89
Load Handling, Lifting, Lowering, and Tilting ............ 90
Contents
3

Load Handling, How to Engage and Disengage a
Load ...................................................................... 93
Load Handling, Traveling .......................................... 96
Load Handling, Emergency Load Lowering .............. 100
HIGHWAY TRUCKS, RAIL CARS, AND DOCKS ....... 102
ATTACHMENTS ......................................................... 103
Disconnecting Attachment Hydraulic Quick-
Disconnect Hoses ................................................. 103
Connecting Attachment Hydraulic Quick-Disconnect
Hoses .................................................................... 104
STOPPING ................................................................. 105
PARKING .................................................................... 105
Maintenance ................................................................ 106
GENERAL ................................................................... 106
Serial Number Data .................................................. 107
HOW TO MOVE A DISABLED LIFT TRUCK .............. 107
How to Tow the Lift Truck ......................................... 107
HOW TO PUT A LIFT TRUCK ON BLOCKS .............. 108
How to Raise the Drive Tires .................................... 108
How to Raise the Steering Tires ............................... 109
HOW TO CLEAN A LIFT TRUCK ............................... 109
Maintenance Schedule ............................................... 110
Maintenance Procedures Every 8 Hours or Daily .... 135
HOW TO MAKE CHECKS WITH THE ENGINE
STOPPED ................................................................. 135
Tires and Wheels ...................................................... 135
Safety Labels ............................................................ 137
Mast, Carriage, Header Hoses, Lift Chains, and
Attachment ............................................................ 137
Operator Restraint System ....................................... 139
Emergency Locking Retractor (ELR) ...................... 141
Hood and Seat Latches ............................................ 141
Engine Compartment ................................................ 142
Paper Application ...................................................... 142
Fuel, Oil, and Coolant Leaks, Check ........................ 144
Hydraulic Hoses ........................................................ 144
Coolant Hoses .......................................................... 144
Steering Column Gas Cylinder ................................. 144
Transmission ............................................................ 144
Hydraulic System Oil ................................................ 145
Engine Oil ................................................................. 146
Air Filter .................................................................... 151
Forks ......................................................................... 151
Forks, Remove ......................................................... 151
Forks, Inspect ........................................................... 154
Forks, Install ............................................................. 154
Forks, Adjust ............................................................. 155
HOW TO MAKE CHECKS WITH THE ENGINE
RUNNING ................................................................. 157
Indicator Lights, Horn, Fuses, and Relays ................ 157
Contents
4

Service Brakes .......................................................... 159
Brake Fluid Level .................................................... 159
Operation, Check .................................................... 159
Parking Brake ........................................................... 160
Engine Oil Pressure .................................................. 161
Cooling System ......................................................... 161
Steering System ....................................................... 163
Control Levers and Pedals ....................................... 163
Lift System Operation ............................................... 163
HOW TO ADD FUEL TO THE LIFT TRUCK .............. 164
Liquefied Petroleum Gas (LPG) ................................ 164
LPG Tank, Remove ................................................ 165
LPG Tank, Fill ......................................................... 168
LPG Tank, Install .................................................... 169
Gasoline or Diesel Fuel ............................................ 170
WHEELS AND TIRES ................................................. 170
General ..................................................................... 170
How to Change a Solid Rubber Tire (GC/GLC
Series) .................................................................. 170
Remove and Install the Tire on the Wheel ................ 171
PNEUMATIC TIRE WITH TUBE, REPAIR ................. 173
Remove Wheels From Lift Truck .............................. 173
Remove Tire From Wheel ......................................... 174
Tire Removal, Two-Piece Wheel ............................ 176
Tire Removal, Three- and Four-Piece Wheels ....... 177
Install Wheel in Tire .................................................. 177
Tire Installation, Three- or Four-Piece Wheel ......... 179
Tire Installation, Two-Piece Wheel ......................... 180
Add Air to Pneumatic Tires With Tube ...................... 180
Install the Wheels ..................................................... 182
PNEUMATIC TUBELESS TIRE, REPAIR .................. 182
Remove Tire From Lift Truck .................................... 182
Remove Tire From Wheel ......................................... 183
Install Tire on Wheel ................................................. 184
Add Air to Pneumatic Tubeless Tire ......................... 188
Install the Wheels ..................................................... 188
SOLID RUBBER TIRES ON PNEUMATIC WHEELS,
CHANGE .................................................................. 189
Remove Tire From Wheel ......................................... 189
Install Tire on Wheel ................................................. 190
DUAL DRIVE WHEELS, INSTALL ............................. 192
JUMP-STARTING THE LIFT TRUCK ......................... 193
Jump-Starting Using a Battery Charger .................... 193
Jump-Starting Using Another Lift Truck .................... 193
OPERATING PROCEDURES FOR A NEW OR
REBUILT ENGINE .................................................... 194
CHANGES TO THE OVERHEAD GUARD ................. 194
HOW TO PUT INTERNAL COMBUSTION ENGINE
(ICE) TRUCKS IN STORAGE .................................. 194
Short-Term Storage .................................................. 195
Contents
5

Long-Term Storage ................................................... 196
While the Lift Truck is in Storage .............................. 196
How to Put Batteries in Storage ................................ 196
Putting a Stored Lift Truck Back Into Service ........... 197
HOW TO MOVE A LIFT TRUCK ON A
TRANSPORT ............................................................ 197
Loading ..................................................................... 198
Unloading .................................................................. 199
PREPARATION FOR USE ......................................... 200
Preparation After Transport ...................................... 200
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 Operating Manual.
• DO NOT operate or repair truck unless trained and author-
ized.
•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 original
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
1. COUNTERWEIGHT
2. OPERATING MANUAL (BEHIND SEAT)
3. TAIL, BRAKE, AND REVERSE LIGHTS
4. OVERHEAD GUARD
5. SEAT BELT AND HIP RESTRAINT
6. STEERING WHEEL
7. PARKING BRAKE
8. MAST
9. LOAD BACKREST EXTENSION
10. FORKS
11. CARRIAGE
12. DRIVE AXLE
13. SEAT
14. STEERING AXLE
Figure 1. Model View Showing Major Components for Lift Truck Models GC/GLC040VX, GC/GLC050VX, GC/
GLC055SVX, GC/GLC060VX, GC/GLC070VX (C910)
Model Description
10

1. COUNTERWEIGHT
2. OPERATING MANUAL (BEHIND SEAT)
3. TAIL, BRAKE, AND REVERSE LIGHTS
4. OVERHEAD GUARD
5. SEAT BELT AND HIP RESTRAINT
6. STEERING WHEEL
7. PARKING BRAKE
8. MAST
9. LOAD BACKREST EXTENSION
10. FORKS
11. CARRIAGE
12. DRIVE AXLE
13. SEAT
14. STEERING AXLE
Figure 2. Model View Showing Major Components for Lift Truck Models GP/GLP/GDP040-070VX (D875)
Model Description
11

Model Description
General
This Operating Manual is for the following models of lift
trucks:
GC/GLC040VX, GC/GLC050VX, GC/GLC055SVX, GC/
GLC060VX, GC/GLC070VX (C910)
Lift trucks available with the following engines:
•PSI 2.4L engine which uses gasoline and LPG fuel
•Kubota 2.5L engine which uses LPG fuel
GP/GLP/GDP040-070VX (D875)
Lift trucks available with the following engines:
•PSI 2.4L engine which uses gasoline and LPG fuel
•Kubota 2.5L engine which uses LPG fuel
•Yanmar 2.6L engine which uses diesel fuel
•Yanmar 3.3L engine which uses diesel fuel
•Kubota 2.4L engine which uses diesel fuel
Lift trucks in this manual will be equipped with a Standard or
Techtronix 100 transmission These lift trucks can be equip-
ped 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 GC/GLC040VX, GC/GLC050VX, GC/GLC055SVX, GC/
GLC060VX, GC/GLC070VX lift trucks are equipped with
solid rubber tires. The GP040-070VX, GLP40-70VX, and
GDP40-70VXGP/GLP/GDP040-070VX are equipped with
pneumatic tires or solid pneumatic tires. See Wheels and
Tires in the Maintenance Section for a description of these
tires.
Model Description
12

This emergency lowering valve (see Figure 14) 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.
Operator Protection Equipment
The LOAD BACKREST EXTENSION is installed to keep
loose parts of the load from falling back toward the operator.
It must be high enough, with vertical openings small enough,
to prevent the parts of the load from falling backwards. If a
load backrest extension that is different from the one installed
on your lift truck is required, contact your Yale 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 trap-
ped 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 movement. 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 con-
figurations.
•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 Operator
Presence System.
Model Description
13

Nameplate
WARNING
DO NOT add to or modify the lift truck. Any modification
that affects the safe operation of the truck cannot be
undertaken without the written authorization of Yale Cor-
poration.
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 han-
dle 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.
NOTE: The image in Figure 3 is a sample only. Reference
the actual nameplate installed on the truck for actual truck
specifications.
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 oper-
ate the lift truck. Contact your dealer for Yale lift trucks to
obtain a complete and correct Nameplate.
Model Description
14

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 informa-
tion about possible hazards. It is important that all safety
labels are installed on the lift truck and can be read. See Fig-
ure 4 and Figure 5.
All possible label configurations that can be on the lift trucks
covered in this Operating Manual are not shown in Fig-
ure 4 and Figure 5. See the Parts Manual for label part num-
bers and a complete listing of all labels that are available for
the lift trucks covered in this Operating Manual.
Model Description
15

Figure 4. Warning and Safety Labels for Lift Truck Models GC/GLC040VX, GC/GLC050VX, GC/GLC060VX, GC/
GLC070VX, GC/GLC055SVX (C910) (Sheet 1 of 3)
Model Description
16

SEE THE PARTS MANUAL FOR THE PART NUMBER.
Figure 4. Warning and Safety Labels for Lift Truck Models GC/GLC040VX, GC/GLC050VX, GC/GLC060VX, GC/
GLC070VX, GC/GLC055SVX (C910) (Sheet 2 of 3)
Model Description
17

SEE THE PARTS MANUAL FOR THE PART NUMBER.
Figure 4. Warning and Safety Labels for Lift Truck Models GC/GLC040VX, GC/GLC050VX, GC/GLC060VX, GC/
GLC070VX, GC/GLC055SVX (C910) (Sheet 3 of 3)
Model Description
18