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Hydraulic System
Item Specification
Hydraulic System Capacity 50.2 liter (13.3 gal)
Hydraulic Tank Capacity 39.5 liter (10.4 gal) Drain and Refill
Relief Pressures*
Main Control Valve
Lift Circuit 20.88 to 21.20 MPa (3025 to 3075 psi)
Tilt and Auxiliary Circuit 15.34 to 15.68 MPa (2225 to 2275 psi)
Steering Circuit 12.075 MPa (1750 psi)
Brake Booster 2.275 MPa (330 psi)
Hydraulic Pump Capacity 102 liter/min (27.0 gal/min) at 21.0 MPa (3050 psi)
Steering Pump Capacity 19.7 liter/min (5.2 gal/min) at 12.075 MPa (1750 psi)
*Oil temperature 49 C (120 F) and engine speed at 2500 rpm.
Tire Sizes
Model Steering Drive
GC/GLC/GDC135CA 22 × 8 × 16 28 × 12 × 22
GC/GLC/GDC155CA 22 × 8 × 16 28 × 12 × 22
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Engine Specifications 8000 YRM 454
Electrical System
Battery
SAE No. 24-335
Cold Cranking 30 sec. min. at 17.8 C (0 F) to 1.2 volts
Reserve Capacity 85 min. at 26 C (80 F)
Alternator Output
38 amps @ 650 rpm (Hot)
GM V-6
62 amps @ 2500 rpm (Hot)
42 amps @ 650 rpm (Hot)
Perkins
62 amps @ 2500 rpm (Hot)
All models - 12-volt negative ground
Engine Specifications
Item GM V-6 4.3 Perkins 1004-4
Number of Cylinders 6 4
Firing Order 1-6-5-4-3-2 1-3-4-2
Bore 101.6 mm (3.99 in.) 100.00 mm (3.937 in.)
Stroke 88.39 mm (3.48 in.) 127.00 mm (5.00 in.)
3
Displacement 4.3 liter (262.4 in. ) 4.0 liter (244.0 in. 3 )
Compression Ratio 9.3:1 16.5:1
Idle Speed 625 to 675 rpm 725 to 775 rpm
Governor Speed 2400 to 2500 rpm 2400 to 2500 rpm
Stall Speed rpm (Engine at 50 hrs) 1810 (Gas) 1735 (LPG) 2090 rpm
Timing 0 BTDC at 650 rpm 16 BTDC (Static)
Oil Pressure (Minimum) 207 to 308 kPa (30 to 45 psi) 276 kPa (40 psi)
Valve Clearance Not adjustable 0.20 mm (0.008 in.) Cold
Intake Exhaust Not adjustable 0.45 mm (0.018 in.) Cold
2
8000 YRM 454 Upright Speeds
Upright Speeds
Two-Stage Upright
Unit Lifting Lowering
No Load Rated Load No Load Rated Load
m/min ft/min m/min ft/min m/min ft/min m/min ft/min
GC/GLC/ 25.6 84 24.1 79 26.8 88 32.9 108
GDC135CA
GC/GLC/ 25.6 84 24.1 79 26.8 88 33.6 110
GDC155CA
Three-Stage Upright
GC/GLC/ 24.4 80 22.3 73 23.5 77 33.6 110
GDC135CA
GC/GLC/ 24.4 80 22.3 73 23.5 77 33.8 111
GDC155CA
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Torque Specifications 8000 YRM 454
Torque Specifications
FRAME Engine Mount Bolts
122 N•m (90 lbf ft)
Counterweight Capscrew
655 N•m (485 lbf ft) POWERSHIFT TRANSMISSION
ENGINE - GM V-6 Torque Converter Housing Capscrews
31 N•m (23 lbf ft)
Intake Manifold Capscrews
47 N•m (35 lbf ft) Torque Converter Drive Plate Capscrews
44 N•m (32 lbf ft)
Valve Cover Capscrews
10 N•m (7 lbf ft) Engine Mount Capscrews at Torque Converter
110 N•m (80 lbf ft)
Exhaust Manifold Capscrews
35 N•m (25 lbf ft) Universal Joint Capscrews
Center Port 25 N•m (20 lbf ft) 50 N•m (37 lbf ft)
Outer Ports 47 N•m (35 lbf ft)
Transmission Cover Capscrews
Camshaft Sprocket Capscrews 38 N•m (28 lbf ft)
25 N•m (20 lbf ft)
Manifold Block Capscrews
Vibration Damper Capscrew 38 N•m (28 lbf ft)
81 N•m (60 lbf ft)
Oil Pump Capscrews
Main Bearing Cap Capscrews 38 N•m (28 lbf ft)
68 N•m (50 lbf ft)
Torque Converter Housing-to-Transmis-
Connecting Rods sion Capscrews
47 N•m (35 lbf ft) 38 N•m (28 lbf ft)
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8000 YRM 454 Torque Specifications
5
Torque Specifications 8000 YRM 454
6
100 YRM 449 Description
General
This section has the description and repair procedures for the frame and connected parts. Included in this section
are the frame, counterweight, hood, hydraulic and fuel tanks, radiator, and exhaust system. Also included are the
instructions for removal and installation of the engine.
Description
The frame is a one-piece weldment and has mounts for the counterweight, upright, overhead guard, engine and
transmission, axles, and other parts. See Figure 1.
1. HOOD 4. COUNTERWEIGHT
2. FLOOR PLATE 5. FRAME
3. OVERHEAD GUARD
1
Counterweight Repair 100 YRM 449
Counterweight Repair
REMOVE slowly. Fuel leaving the fitting removes heat. Use a
cloth to protect your hands from the cold fitting.
WARNING 2. Use the following procedure to remove the LPG
The lift truck must be put on blocks for some types tank:
of maintenance and repair. The removal of the fol-
lowing assemblies causes large changes in the cen- a. Removable LPG tanks can be removed and re-
ter of gravity: upright, drive axle, engine and trans- placed indoors only if the lift truck is at least 8 m
mission, and the counterweight. When the lift truck (25 ft) from any open flame or ignition source.
is put on blocks, put additional blocks in the follow-
ing positions to maintain stability: b. Move the lift truck to the area where tanks are
a. Before removing the upright and drive axle, put changed.
blocks under the counterweight so that the lift
c. Turn the tank fuel valve clockwise until the valve
truck cannot fall backward.
is completely closed.
b. Before removing the counterweight, put blocks
under the upright assembly so that the lift truck d. Run the engine until it stops, then turn the key
cannot fall forward. switch to the OFF position.
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks
used to support the lift truck are solid, one piece
units.
WARNING
Make sure any lifting devices have the correct ca-
pacity for the parts being moved. See Figure 2.
WARNING
LPG can cause an explosion. Do not cause sparks
or permit flammable material near the LPG system.
LPG fuel systems can be disconnected indoors
only if the lift truck is at least 8 m (25 ft) from any Weight of Counterweights
open flame, motor vehicles, electrical equipment, GLC135CA (GC/GDC/ GLC155CA (GC/GDC/
or ignition source. GLC135CA) GLC155CA)
2873 to 2953 kg 3330 to 3420 kg
Close the fuel valve on the LPG tank before any part
(6335 to 6511 lb) (7343 to 7541 lb)
of the engine fuel system is disconnected. Run the
engine until the fuel in the system is used and the
engine stops. 1. LIFT TRUCK 5. ACCESS DOOR
FRAME 6. TRANSITION
2. COUNTERWEIGHT PLATE
If the engine will not run, close the fuel valve on the 3. GRILL 7. HOOD
LPG tank. Loosen the fitting on the supply hose 4. CAPSCREW
from the LPG tank where it enters the filter unit.
Permit the pressure in the fuel system to decrease Figure 2. Counterweight
2
100 YRM 449 Hood Repair
e. Disconnect the quick disconnect fitting. 5. Lift the counterweight from the frame. Put the coun-
terweight in a position so that it has stability and will
f. Release the LPG tank latch and remove the not fall.
tank from the bracket.
INSTALL
3. Open the access door between the counterweight
and the hood. Remove the LPG tank and tank 1. Connect a lifting device to the lifting eye on the
bracket if the unit has the LPG fuel system. counterweight. Lift the counterweight into position
on the frame. See Figure 2.
4. Install a lifting eye in the hole in the top of the coun-
terweight. Connect a lifting device to the lifting eye. 2. Install the capscrews for the counterweight.
Remove the two vertical capscrews and the cap- Tighten the capscrews to 655 N•m (485 lbf ft).
screw behind the tow pin that hold the counter-
weight to the frame. 3. Close the access door. Install the LPG tank on LPG
units.
Hood Repair
REMOVE 3. Use the following procedure to adjust the hood latch
(see Figure 3):
1. Remove the capscrews that fasten the transition
plate. Do NOT remove the plate. See Figure 2. a. Install the floor plates and tighten the cap-
screws.
2. Open the access door, reach under the transition
plate, and remove the radiator overflow hose from b. Install the latch striker in the highest slot posi-
the two J clamps. tion on the rear floor plate. Check that the latch
striker is in the center of the jaws of the hood
3. Raise the hood and disconnect the gas assist cylin- latch.
der at the hood. Remove the hood, transition plate,
and access door. c. Close the hood to the fully-closed position. The
hood latch has two positions. The hood is fully
INSTALL closed after two clicks of the latch.
1. Install the hood, transition plate, and access door d. Loosen the capscrews for the latch striker just
in position on the lift truck. Install the capscrews for enough to let the striker move. Push the hood
the transition plate. Connect the gas assist cylinder down until the hood just touches the rubber
to the hood. Align the hood for the latch on the bumpers on the frame. Make sure the latch
front cover. Tighten the capscrews for the transition striker is still in the center of the hood latch.
plate. Tighten the capscrews for the latch striker.
2. Install the overflow hose in the J clamps. Close the e. Check the operation of the hood latch. Have
access door. an operator sit in the seat. Make sure the hood
is fully closed (two clicks). Also check that the
WARNING hood touches the rubber bumpers. If neces-
The hood, hood latch, and latch striker must be cor- sary, repeat Step d.
rectly adjusted for the correct operation of the op-
erator restraint system.
3
Overhead Guard Repair 100 YRM 449
4
100 YRM 449 Operator Restraint System Repair
5
Fuel and Hydraulic Tanks Repair 100 YRM 449
The following seat belt operation checks must be per- the hood in the open position, replace the seat belt
formed: assembly.
• With the hood closed and in the locked position, pull
the seat belt slowly from the retractor assembly. Make Make sure the seat rails and latch striker are not loose.
sure the seat belt pulls out and retracts smoothly. if See Figure 3. The seat rails must lock tightly in position,
the seat belt cannot be pulled from the retractor as- but move freely when unlocked. The seat rails must be
sembly or the belt will not retract, replace the seat belt correctly fastened to the mount surface. If the mount
assembly. surface is the hood, the hood must be fastened to the
• With the hood closed and in the locked position, pull floor plate with the latch. The floor plate must be fas-
the seat belt with a sudden jerk. Make sure the seat tened to the lift truck frame. Try to lift the hood to make
belt will not pull from the retractor assembly. If the sure it is fastened correctly and will not move.
seat belt can be pulled from the retractor, when it is
Adjust the hood, hood latch, and latch striker when any
pulled with a sudden jerk, replace the seat belt as-
of the parts of the operator restraint system are installed
sembly.
or replaced. See the Hood Repair section for more de-
• With the hood in the open position, make sure the
tails.
seat belt will not pull from the retractor assembly. If
the seat belt can be pulled from the retractor, with
6
100 YRM 449 Radiator Repair
Radiator Repair
REMOVE 2. Drain the coolant from the radiator. Remove the ra-
diator hoses. Disconnect the oil lines at the radiator.
NOTE: To make radiator removal easier, remove the Put caps on the open lines.
counterweight as described in Counterweight Repair,
Remove. 3. Remove the remote fill assembly and radiator
hoses to the engine. Disconnect the hose to the
1. Open the access door between the hood and the auxiliary coolant reservoir.
counterweight. Remove the cover plate over the
radiator. If installed, remove the LPG tank and 4. Remove the hood and transition plate as described
bracket. in Hood Repair, Remove. Remove the fan shroud
and fan. Loosen the exhaust band clamp on the
7
Exhaust System Repair 100 YRM 449
gasoline and LPG units. Remove the engine water 3. Install the engine water outlet on diesel units.
outlet on diesel units. Tighten the exhaust band clamp on gasoline or
LPG units. Install the fan and fan shroud. Install
5. Remove the muffler and inlet exhaust pipe to the the hood and transition plate as described in the
muffler. Remove the capscrews that fasten the ra- Hood Repair, Install section.
diator. Move the exhaust pipe for clearance of the
radiator flange. 4. Connect the hose to the auxiliary coolant reservoir.
Install the remote fill assembly and radiator hoses
6. Tip the radiator forward over the engine as you lift to the engine. Make sure the hose clamp screws
and remove the radiator. have an access at the wheel wells.
INSTALL 5. Connect the oil lines at the radiator. Install the cover
plate over the radiator and fill the radiator with the
NOTE: The installation of the radiator is easier if the coolant specified in the table in the Periodic Main-
counterweight is removed. See Counterweight Repair, tenance 8000 YRM 393.
Remove in this section.
6. If removed, install the counterweight as described
1. Tip the radiator forward over the engine as you in- in the Counterweight Repair, Install section. If the
stall the radiator in the lift truck. Move the exhaust LPG tank and bracket were removed, install them.
pipe for clearance to the radiator flange.
8
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