Capacidades y Especificaciones

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Maintenance

CAPACITIES ANDSPECIFICATIONS

GLP/GDP3.5-5.5LJ/MJ

(GP/GLP/GDP70-120LJ/MJ) [C813, E813]

PART NO. 524173815 8000 YRM 738



SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-

tened, and that the load being lifted is balanced. Make sure the crane, cables, and chainshave the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THELIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet

or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using

force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or

if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are

flammable. Be sure to follow the necessary safety precautions when handling these fuelsand when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks awayfrom the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNINGIndicates a condition that can cause immediate death or injury!

CAUTIONIndicates a condition that can cause property damage!



Capacities and Specifications Table of Contents

TABLE OF CONTENTS

Lift Truck Weights ................................................................................................................................................

Electrical System .................................................................................................................................................Stall Speeds ........................................................................................................................................................

Capacities............................................................................................................................................................ 2

Tire Pressure ....................................................................................................................................................... 2Engine Specifications .......................................................................................................................................... 3

Transmission Oil Pressures ................................................................................................................................. 4Hydraulic System................................................................................................................................................. 5

Mast Speeds........................................................................................................................................................ 6Torque Specifications .......................................................................................................................................... 6

Brake System .................................................................................................................................................. 6Differential ....................................................................................................................................................... 6

Drive Axle........................................................................................................................................................ 7Engine, GM V-6 4.3 Liter................................................................................................................................. 7Engine, Perkins 1004-42 ................................................................................................................................. 8

Frame .............................................................................................................................................................. 8

Lift Cylinders ................................................................................................................................................... 8Main Control Valve .......................................................................................................................................... 8Masts............................................................................................................................................................... 8

Powershift Transmission.................................................................................................................................. 9Steering System.............................................................................................................................................. 9Tilt Cylinders ................................................................................................................................................... 9

Hydrostatic Components................................................................................................................................. 9

This section is for the following models:

GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) [C813, E813]

©2004 Yale Materials Handling Corp.





8000 YRM 738 Stall Speeds

Lift Truck Weights

Model kg lb

GLP/GDP3.5LJ (GP/GLP/GDP70LJ) 5660 12,480



GLP/GDP4.5MJ (GP/GLP/GDP100MJ) 6830 15,060



NOTE: Lift trucks equipped with overhead guard, two-stage mast, carriage, load backrest, forks, gas engine, pow-ershift transmission, and operator.

Electrical System

Item GM V-6 4.3 Liter Perkins 1004-42 DieselAll Models 12 volt, negative ground

Alternator Output (Idle) 45 amps @ 800 rpm 38 amps @ 800 rpm

Alternator Output (High Idle) 68 amps @ 2200 rpm 65 amps @ 2200 rpm

Ignition Timing

Gas @ 725 rpm 0 BTDC -

Ignition Timing

LPG @ 725 rpm 0 BTDC -

Ignition Timing

Perkins Diesel - 16 BTDC (Static)

Spark Plugs AC R48TS -

Spark Plug Gap 0.89 mm (0.035 in.) -

Stall Speeds

Engine New Engine Engine With 50 Hours

GM V-6 Gas 1700 rpm +300/ 50 rpm 1950 rpm +300/ 50 rpm

GM V-6 LPG 1900 rpm +300/ 50 rpm 1950 rpm +300/ 50 rpm

Perkins (1004-42, 1104C-44) 1950 rpm ±50 rpm 2050 rpm ±50 rpm



Tire Pressure 8000 YRM 738

Capacities

Item Quantity

Engine Oil

GM V-6 4.7 liter (5.0 qt)

Perkins 1004-42 8.0 liter (8.5 qt)

Cooling System

GM V-6 17.0 liter (18.0 qt)

Perkins 1004-42 17.0 liter (18.0 qt)

Hydraulic Tank (Powershift and Hydrostatic)

GLP/GDP3.5-4.0LJ (GP/GLP/GDP70-90LJ) 45.0 liter (11.8 gal)

GLP/GDP4.5-5.5MJ (GP/GLP/GDP100-120MJ) 67.0 liter (17.7 gal)

Hydraulic System Powershift Transmission

GLP/GDP3.5-4.0LJ (GP/GLP/GDP70-90LJ) 53.0 liter (14.0 qt)


Hydraulic System Hydrostatic Transmission

GLP/GDP3.5-4.0LJ (GP/GLP/GDP70-90LJ) 78.0 liter (20.6 qt)


Powershift Transmission 17.0 liter (18.0 qt)

Differential and Drive Axle 8.5 liter (9.0 qt)

Fuel Tank

GLP/GDP3.5-4.0LJ (GP/GLP/GDP70-90LJ) 69.0 liter (18.2 gal)


Brake Fluid 0.2 liter (0.4 pt)

Tire Pressure

Bias Ply Tires

Tire Size kPa psi

7.00 × 12 - 12 Ply 862 125

300 × 15 - 18 Ply 862 125

250 × 15 - 16 Ply 862 125

250 × 15 - 18 Ply 965 140

7.00 × 15 - 12 Ply 862 125

8.25 × 15 - 12 Ply 690 100

2



8000 YRM 738 Engine Specifications

Engine Specifications

Item GM V-6 4.3 Liter Perkins 1004-42

Number of Cylinders 6 4

Firing Order 1-6-5-4-3-2 1-3-4-2

Bore and Stroke 101.6 mm × 88.39 mm(4.00 in. × 3.48 in.)

100 mm × 127 mm(3.94 in. × 5.00 in.)

Displacement 4.3 liter (262.4 in.3) 4.06 liter (247.8 in.3)

Compression Ratio 9.3:1 16.5:1

Oil Pressure 207 to 380 kPa (30 to 55 psi)@ 2000 rpm

280 kPa (40 psi) min. @ 2200 rpm

Valve Clearance Not Adjustable

Intake 0.20 mm (0.008 in.) Cold

Valve Clearance Not Adjustable

Exhaust 0.45 mm (0.018 in.) Cold

Idle Speed 675 to 725 rpm 725 to 775 rpm

Governed Speed @ No Load 2200 rpm 2200 rpm

Thermostat Range 82 C (180 F) 71 to 86 C (160 to 187 F)

Cooling System Pressure 103 kPa (15 psi) 103 kPa (15 psi)

Fuel Pump Pressure -- 42 to 70 kPa (6 to 10 psi)

3



Transmission Oil Pressures 8000 YRM 738

Transmission Oil Pressures

Table 1. Single-Speed

Port No. Transmission Pressures*

1 Transmission

Pump

1310 to 1476 kPa

(190 to 214 psi)

2 Reverse Clutch 862 to 1048 kPa

(125 to 152 psi)

3 Forward Clutch 862 to 1048 kPa(125 to 152 psi)

4 Torque Converter 765 to 903 kPa(111 to 131 psi)

5 Lubrication Circuit 61 to 111 kPa

(9 to 16 psi)

6 Modulator Pressure Variation

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.

Table 2. Two-Speed


1 Transmission

Pump

1310 to 1476 kPa

(190 to 214 psi)2 Reverse Clutch 862 to 1048 kPa

(125 to 152 psi)

3 Forward-LowClutch

862 to 1048 kPa(125 to 152 psi)

4 Forward-HighClutch

862 to 1048 kPa(125 to 152 psi)

5 Torque Converter 765 to 903 kPa

(111 to 131 psi)

6 Lubrication Circuit 61 to 111 kPa

(9 to 16 psi)

7 Modulator Pressure Variation

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.

4



8000 YRM 738 Hydraulic System

Table 3. Hydrostatic Transmission


1 Charge 16 to 17 bar

(230 to 240 psi)@2200 RPM

2 Pilot Supply 41 to 48 bar(600 to 700 psi)

@2200 RPM

3 Forward Loop MB 460 to 480 bar(6670 to 6960 psi)

@2200 RPM

4 Reverse Loop M A 460 to 480 bar

(6670 to 6960 psi)@2200 RPM

*Oil temperature at least 50 to 65 C (120 to 150 F) and engine speed at 2000 rpm.If using Translink ® , see the section Hydrostatic Transmission, Troubleshooting and Repairs 1300 YRM 801.

Hydraulic System

Item Specification

Hydraulic Pump*

Type Gear

Priority Flow (Steering) 17 to 19 liter/min (4.5 to 5.0 gal/min) at 9.6 MPa(1400 psi) and 800 engine rpm

Hydraulic Pump*

Hydraulic Pump Flow to Main Control ValveGLP/GDP3.5-4.0LJ (GP/GLP/GDP70-90LJ)

116 liter/min (30.6 gal/min) @ 2200 rpm No Load

Hydraulic Pump Flow to Main Control Valve

GLP/GDP3.5-4.0LJ (GP/GLP/GDP70-90LJ)

112 liter/min (29.6 gal/min) @ 2200 rpm Rated Load

Hydraulic Pump Flow to Main Control Valve

GLP/GDP4.5-5.5MJ (GP/GLP/GDP100-120MJ)

125 liter/min (33.0 gal/min) @ 2200 rpm No Load

Hydraulic Pump Flow to Main Control ValveGLP/GDP4.5-5.5MJ (GP/GLP/GDP100-120MJ)

121 liter/min (32.0 gal/min) @ 2200 rpm Rated Load

*Pressures with oil at 50 to 80 C (120 to 180 F).

5



Torque Specifications 8000 YRM 738

Item Specification

Relief Pressures*

Steering Circuit 10.7 MPa (1550 psi)

Tilt and Auxiliary Circuit 15.5 MPa (2250 psi)

Lift Circuit 22.0 MPa (3200 psi)

*Pressures with oil at 50 to 80 C (120 to 180 F).

Mast Speeds

Lifting Lowering

No Load Rated Load No Load Rated Load

Unit

m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min

Two-Stage Mast

0.63 124 0.57 112 0.47 93 0.55 108

Three-Stage Mast

GLP/GDP3.5-4.0LJ

(GP/GLP/GDP70-90LJ)GM V-6 Engine

0.59 116 0.54 106 0.51 100 0.52 102

Two-Stage Mast

0.66 130 0.60 118 0.47 93 0.56 110

Three-Stage Mast

GLP/GDP3.5-4.0LJ(GP/GLP/GDP70-90LJ)

Perkins Engine

0.59 116 0.55 108 0.51 100 0.52 102

Two-Stage Mast

0.50 98 0.49 96 0.42 83 0.50 98

Three-Stage Mast

GLP/GDP4.5-5.5MJ

(GP/GLP/GDP100-120MJ

GM V-6 Engine

0.48 94 0.47 93 0.40 79 0.47 93

Two-Stage Mast

0.49 96 0.42 83 0.42 83 0.50 98

Three-Stage Mast

GLP/GDP4.5-5.5MJ(GP/GLP/GDP100-120MJ

Perkins Engine

0.47 93 0.40 79 0.40 79 0.47 93

Torque Specifications

BRAKE SYSTEM

Backplate Nuts340 to 375 N•m (251 to 277 lbf ft)

DIFFERENTIAL

Ring Gear Bolts

140 N•m (103 lbf ft)

Differential Case Half Capscrews140 N•m (103 lbf ft)

Differential Bearing Caps

225 N•m (166 lbf ft)

Thrust Bolt Lock Nut

75 to 95 N•m (55 to 70 lbf ft)

6



8000 YRM 738 Torque Specifications

Adjustment Nut Retainers19 N•m (14 lbf ft)

Pinion Nut (Output Gear)1100 N•m (811 lbf ft)

DRIVE AXLEDrive Axle Hangers to Frame Bolts

320 to 350 N•m (236 to 258 lbf ft)

Axle Shaft Capscrews225 to 250 N•m (166 to 184 lbf ft)

Wheel Bearing Adjustment Nut200 to 225 N•m (148 to 166 lbf ft) Initial

34 N•m (25 lbf ft) Final

Wheel Bearing Lock Nut

135 to 150 N•m (100 to 110 lbf ft)

Wheel Nuts610 to 680 N•m (450 to 502 lbf ft)

ENGINE, GM V-6 4.3 LITER

Alternator Pulley

61 N•m (45 lbf ft)

Balance Shaft Gear Capscrew

20 N•m (15 lbf ft) Plus 35 Degrees

Balance Shaft Retainer Capscrews14 N•m (10 lbf ft)

Camshaft Retainer Capscrews14 N•m (10 lbf ft)

Camshaft Sprocket Capscrews28 N•m (21 lbf ft)

Camshaft Sprocket Nut

28 N•m (21 lbf ft)

Connecting Rod Cap See Engine Manual

Coolant Pump to Engine Block

40 N•m (30 lbf ft)

Cooling Fan to Pulley

24 N•m (18 lbf ft)

Cylinder Head See Engine Manual

Distributor Mount Capscrew

34 N•m (25 lbf ft)

Exhaust ManifoldCenter Two Bolts: 36 N•m (27 lbf ft)

All Other Bolts: 28 N•m (21 lbf ft)

Flywheel

80 N•m (59 lbf ft)

Flywheel Housing

48 N•m (35 lbf ft)

Inlet Manifold to Cylinder Head48 N•m (35 lbf ft)

Main Bearing Cap106 N•m (78 lbf ft)

Oil Pump Cover14 N•m (10 lbf ft)

Oil Pump to Crankcase

30 N•m (22 lbf ft)

Oil Pressure Switch

27 N•m (20 lbf ft)

Oil Screen Support to Crankcase

50 N•m (37 lbf ft)

Oil Sump to Crankcase25 N•m (18 lbf ft)

Rear Oil Seal Retainer Screws and Nuts15 N•m (11 lbf ft)

Rocker Arm Cover10 N•m (7 lbf ft)

Rocker Arm Nuts

25 N•m (18 lbf ft)

Rocker Arm Studs

47 N•m (35 lbf ft)

Thermostat Housing25 N•m (18 lbf ft)

Timing Cover27 N•m (20 lbf ft)

Valve Lifter Retainer Bolts16 N•m (12 lbf ft)

Vibration Damper

95 N•m (70 lbf ft)

7



Torque Specifications 8000 YRM 738

ENGINE, PERKINS 1004-42

Camshaft Gear Capscrew

95 N•m (70 lbf ft)

Connecting Rod Capscrews155 N•m (114 lbf ft)

Connecting Rod Nuts125 N•m (92 lbf ft)

Crankshaft Pulley115 N•m (85 lbf ft)

Cylinder Head See Engine Manual

Damper on Crankshaft Pulley75 N•m (55 lbf ft)

Exhaust Manifold Nuts

44 N•m (32 lbf ft)

Flywheel Capscrews

105 N•m (77 lbf ft)

Flywheel Housing Capscrews

75 N•m (55 lbf ft)

Fuel Injection Pump Gear28 N•m (21 lbf ft)

Fuel Injection Pump Mount22 N•m (16 lbf ft)

Idler Gear Capscrews44 N•m (32 lbf ft)

Intake Manifold Capscrews

44 N•m (32 lbf ft)

Main Bearing Capscrews

265 N•m (195 lbf ft)

Oil Pump22 N•m (16 lbf ft)

Oil Pump Cover28 N•m (21 lbf ft)

Oil Pump to Bearing Cap22 N•m (16 lbf ft)

Rear Oil Seal Housing

22 N•m (16 lbf ft)

Rocker Arm Brackets, Aluminum

40 N•m (30 lbf ft)

Rocker Arm Brackets, Cast Iron75 N•m (55 lbf ft)

Timing Case Capscrews - M822 N•m (16 lbf ft)

Timing Case Capscrews - M1044 N•m (32 lbf ft)

Timing Case Cover

22 N•m (16 lbf ft)

Valve Cover

44 N•m (32 lbf ft)

FRAME

Counterweight Capscrews555 N•m (409 lbf ft)

Engine Mount Nuts165 N•m (122 lbf ft)

Overhead Capscrews

90 N•m (66 lbf ft)

Radiator Support Capscrews, Outer66 N•m (49 lbf ft)

Radiator Support Capscrews, Inner38 N•m (28 lbf ft)

LIFT CYLINDERS

Main Lift Cylinder Retainer Cap340 to 410 N•m (251 to 302 lbf ft)

Free-Lift Cylinder Retainer Cap400 to 475 N•m (295 to 350 lbf ft)

Free-Lift Cylinder Mount Capscrews121 N•m (89 lbf ft)

MAIN CONTROL VALVE

Through Bolt Nuts (5/16 in.)

19 N•m (14 lbf ft)

Through Bolt Nuts (3/8 in.)45 N•m (33 lbf ft)

MASTS

Pivot Pin Capscrews

550 N•m (406 lbf ft)

Sideshift Carriage (Internal)

Lower Hook Capscrews 78 N•m (58 lbf ft)

8



8000 YRM 738 Torque Specifications

POWERSHIFT TRANSMISSION

Control Valve Capscrews

19 N•m (14 lbf ft)

Front Cover Capscrews38 N•m (28 lbf ft)

Oil Pump Capscrews38 N•m (28 lbf ft)

Torque Converter Housing Capscrews38 N•m (28 lbf ft)

Torque Converter Housing to Flywheel

Housing Capscrews38 N•m (28 lbf ft)

Torque Converter Drive Plate Capscrews38 N•m (28 lbf ft)

Transmission to Drive Axle Capscrews66 N•m (50 lbf ft)

STEERING SYSTEM

Axle Mount Capscrews72 to 80 N•m (53 to 59 lbf ft)

Bearing Cap for Spindle45 to 50 N•m (33 to 37 lbf ft)

Steering Cylinder Mount Capscrews245 to 270 N•m (181 to 199 lbf ft)

Wheel Bearings

200 N•m (148 lbf ft) Initial34 N•m (25 lbf ft) Final

Wheel Nuts610 to 680 N•m (450 to 502 lbf ft)

TILT CYLINDERS

Piston Nut

400 to 440 N•m (295 to 325 lbf ft)

Retainer

400 to 500 N•m (295 to 369 lbf ft)

Rod End Lock Capscrews66 to 73 N•m (49 to 54 lbf ft)

HYDROSTATIC COMPONENTS

Axle Valve Socket Head Capscrew

52 to 57 N•m (38 to 42 lbf ft)Left Axle Hangar Bolts

320 to 350 N•m (236 to 258 lbf ft)

Pump Mounting Screw320 N•m (236 lbf ft)

Pump Mounting Front Bracket To Axle38 N•m (28 lbf ft)

Pump Mounting Front Bracket To Pump66 N•m (49 lbf ft)

Coupler Hub90 N•m (66 lbf ft)

Plastic Adapter To Flywheel Drive Plate

52 N•m (38 lbf ft)

Loop Tube To Hose136 N•m (100 lbf ft)

Loop Tube To Pump110 N•m (81 lbf ft)

Loop Tube To Clamp38 N•m (28 lbf ft)

Loop Hose To Axle

71 N•m (52 lbf ft)

Left Axle Hanger Pins

555 to 610 N•m (409 to 450 lbf ft)

Pump Valve Capscrews

8 N•m (70 lbf in)

Charge Pump Socket Head Capscrews24 N•m (212 lbf in)

9



NOTES

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10





Yale Materials Handling Corp.1400 Sullivan Dr., Greenville, NC 27834-2011

8000 YRM 738 5/04 (9/03)(1/03)(8/02) Printed in U S A

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Capacidades y Especificaciones