Capacidades y Especificaciones

Maintenance
CAPACITIES AND
SPECIFICATIONS
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 fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have 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 THE
LIFT 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 fuels
and when working on these fuel systems.
Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!
Capacities and Specifications
Table of Contents
TABLE OF CONTENTS
Lift Truck Weights ................................................................................................................................................
Electrical System .................................................................................................................................................
Stall Speeds ........................................................................................................................................................
Capacities............................................................................................................................................................
Tire Pressure .......................................................................................................................................................
Engine Specifications ..........................................................................................................................................
Transmission Oil Pressures .................................................................................................................................
Hydraulic System.................................................................................................................................................
Mast Speeds........................................................................................................................................................
Torque Specifications ..........................................................................................................................................
Brake System ..................................................................................................................................................
Differential .......................................................................................................................................................
Drive Axle........................................................................................................................................................
Engine, GM V-6 4.3 Liter.................................................................................................................................
Engine, Perkins 1004-42 .................................................................................................................................
Frame ..............................................................................................................................................................
Lift Cylinders ...................................................................................................................................................
Main Control Valve ..........................................................................................................................................
Masts...............................................................................................................................................................
Powershift Transmission..................................................................................................................................
Steering System..............................................................................................................................................
Tilt Cylinders ...................................................................................................................................................
Hydrostatic Components.................................................................................................................................
1
1
1
2
2
3
4
5
6
6
6
6
7
7
8
8
8
8
8
9
9
9
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
5940
13,095
6120
13,490
GLP/GDP4.5MJ (GP/GLP/GDP100MJ)
6830
15,060
7130
15,720
7330
16,160
NOTE: Lift trucks equipped with overhead guard, two-stage mast, carriage, load backrest, forks, gas engine, powershift transmission, and operator.
Electrical System
Item
GM V-6 4.3 Liter
All Models
Perkins 1004-42 Diesel
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
0 BTDC
0 BTDC
16 BTDC (Static)
AC R48TS
0.89 mm (0.035 in.)
Ignition Timing
Gas @ 725 rpm
Ignition Timing
LPG @ 725 rpm
Ignition Timing
Perkins Diesel
Spark Plugs
Spark Plug Gap
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

53.0 liter (14.0 qt)
75.0 liter (19.8 gal)
Hydraulic System Hydrostatic Transmission

78.0 liter (20.6 qt)
100.0 liter (26.4 gal)
Powershift Transmission
17.0 liter (18.0 qt)
Differential and Drive Axle
8.5 liter (9.0 qt)
Fuel Tank
69.0 liter (18.2 gal)
103.0 liter (27.2 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
8000 YRM 738
Engine Specifications
Engine Specifications
Item
Number of Cylinders
Firing Order
Bore and Stroke
Displacement
Compression Ratio
Oil Pressure
Valve Clearance
GM V-6 4.3 Liter
Perkins 1004-42
1-6-5-4-3-2
1-3-4-2
101.6 mm 88.39 mm
(4.00 in. 3.48 in.)
100 mm 127 mm
(3.94 in. 5.00 in.)
4.3 liter (262.4 in. 3 )
4.06 liter (247.8 in. 3 )
9.3:1
16.5:1
207 to 380 kPa (30 to 55 psi)

@ 2000 rpm
280 kPa (40 psi) min. @ 2200 rpm
Not Adjustable
0.20 mm (0.008 in.) Cold
Intake
Valve Clearance
Not Adjustable
Exhaust
Idle Speed
Governed Speed @ No Load
Thermostat Range
Cooling System Pressure
Fuel Pump Pressure
0.45 mm (0.018 in.) Cold

675 to 725 rpm
725 to 775 rpm
2200 rpm
2200 rpm
82 C (180 F)
71 to 86 C (160 to 187 F)
103 kPa (15 psi)
103 kPa (15 psi)
--
42 to 70 kPa (6 to 10 psi)
Transmission Oil Pressures
8000 YRM 738
Transmission Oil Pressures

Table 1. Single-Speed
Port No.
Transmission Pressures*
Transmission
Pump
1310 to 1476 kPa

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

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

(125 to 152 psi)
Torque Converter
765 to 903 kPa

(111 to 131 psi)
Lubrication Circuit
61 to 111 kPa
(9 to 16 psi)
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
Port No.
Transmission
Pump
1310 to 1476 kPa

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

(125 to 152 psi)
Forward-Low
Clutch
862 to 1048 kPa

(125 to 152 psi)
Forward-High
Clutch
862 to 1048 kPa

(125 to 152 psi)
Torque Converter
765 to 903 kPa

(111 to 131 psi)
Lubrication Circuit
61 to 111 kPa
(9 to 16 psi)
Modulator
Pressure Variation
8000 YRM 738
Hydraulic System
Table 3. Hydrostatic Transmission

Port No.
Charge
16 to 17 bar
(230 to 240 psi)
@2200 RPM
Pilot Supply
41 to 48 bar
(600 to 700 psi)
@2200 RPM
Forward Loop M B
460 to 480 bar

(6670 to 6960 psi)
@2200 RPM
Reverse Loop M A
460 to 480 bar

(6670 to 6960 psi)
@2200 RPM
If using Translink, see the section Hydrostatic Transmission, Troubleshooting and Repairs 1300 YRM 801.
Hydraulic System
Item
Specification
Hydraulic Pump*
Type
Priority Flow (Steering)
Gear
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 Valve
116 liter/min (30.6 gal/min) @ 2200 rpm No Load

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

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

121 liter/min (32.0 gal/min) @ 2200 rpm Rated Load
*Pressures with oil at 50 to 80 C (120 to 180 F).
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
Unit
Lifting
No Load
m/sec
GLP/GDP3.5-4.0LJ
(GP/GLP/GDP70-90LJ)
GM V-6 Engine
ft/min
Lowering
Rated Load
m/sec
ft/min
No Load
m/sec
Rated Load
ft/min
m/sec
ft/min
93
0.55
108
100
0.52
102
93
0.56
110
100
0.52
102
83
0.50
98
79
0.47
93
83
0.50
98
79
0.47
93
Two-Stage Mast
0.63
124
0.57
112
0.47
Three-Stage Mast
0.59
GLP/GDP3.5-4.0LJ
(GP/GLP/GDP70-90LJ)
Perkins Engine
116
0.54
106
0.51
Two-Stage Mast
0.66
130
0.60
118
0.47
Three-Stage Mast
0.59
GLP/GDP4.5-5.5MJ
(GP/GLP/GDP100-120MJ
GM V-6 Engine
116
0.55
108
0.51
Two-Stage Mast
0.50
98
0.49
96
0.42
Three-Stage Mast
0.48
GLP/GDP4.5-5.5MJ
(GP/GLP/GDP100-120MJ
Perkins Engine
94
0.47
93
0.40
Two-Stage Mast
0.49
96
0.42
83
0.42
Three-Stage Mast
0.47
93
0.40
79
0.40
BRAKE SYSTEM
Backplate Nuts
340 to 375 Nm (251 to 277 lbf ft)
DIFFERENTIAL
Ring Gear Bolts
140 Nm (103 lbf ft)
Differential Case Half Capscrews

140 Nm (103 lbf ft)
Differential Bearing Caps
225 Nm (166 lbf ft)
Thrust Bolt Lock Nut
75 to 95 Nm (55 to 70 lbf ft)
8000 YRM 738

Adjustment Nut Retainers
19 Nm (14 lbf ft)
Pinion Nut (Output Gear)
1100 Nm (811 lbf ft)
DRIVE AXLE
Drive Axle Hangers to Frame Bolts
320 to 350 Nm (236 to 258 lbf ft)
Axle Shaft Capscrews
225 to 250 Nm (166 to 184 lbf ft)
Wheel Bearing Adjustment Nut
200 to 225 Nm (148 to 166 lbf ft) Initial
34 Nm (25 lbf ft) Final
Wheel Bearing Lock Nut
135 to 150 Nm (100 to 110 lbf ft)
Wheel Nuts
610 to 680 Nm (450 to 502 lbf ft)
ENGINE, GM V-6 4.3 LITER

Alternator Pulley
61 Nm (45 lbf ft)
Balance Shaft Gear Capscrew
20 Nm (15 lbf ft) Plus 35 Degrees
Balance Shaft Retainer Capscrews
14 Nm (10 lbf ft)
Camshaft Retainer Capscrews
14 Nm (10 lbf ft)
Camshaft Sprocket Capscrews
28 Nm (21 lbf ft)
Camshaft Sprocket Nut
28 Nm (21 lbf ft)
Exhaust Manifold
Center Two Bolts: 36 Nm (27 lbf ft)
All Other Bolts: 28 Nm (21 lbf ft)
Flywheel
80 Nm (59 lbf ft)
Flywheel Housing
48 Nm (35 lbf ft)
Inlet Manifold to Cylinder Head
48 Nm (35 lbf ft)
Main Bearing Cap
106 Nm (78 lbf ft)
Oil Pump Cover
14 Nm (10 lbf ft)
Oil Pump to Crankcase
30 Nm (22 lbf ft)
Oil Pressure Switch
27 Nm (20 lbf ft)
Oil Screen Support to Crankcase
50 Nm (37 lbf ft)
Oil Sump to Crankcase
25 Nm (18 lbf ft)
Rear Oil Seal Retainer Screws and Nuts
15 Nm (11 lbf ft)
Rocker Arm Cover
10 Nm (7 lbf ft)
Rocker Arm Nuts
25 Nm (18 lbf ft)
Rocker Arm Studs
47 Nm (35 lbf ft)
Connecting Rod Cap See Engine Manual
Thermostat Housing
25 Nm (18 lbf ft)
Coolant Pump to Engine Block

40 Nm (30 lbf ft)
Timing Cover
27 Nm (20 lbf ft)
Cooling Fan to Pulley

24 Nm (18 lbf ft)
Valve Lifter Retainer Bolts

16 Nm (12 lbf ft)
Cylinder Head See Engine Manual
Vibration Damper
95 Nm (70 lbf ft)
Distributor Mount Capscrew

34 Nm (25 lbf ft)
ENGINE, PERKINS 1004-42

Camshaft Gear Capscrew
95 Nm (70 lbf ft)
Connecting Rod Capscrews
155 Nm (114 lbf ft)
Connecting Rod Nuts
125 Nm (92 lbf ft)
Crankshaft Pulley
115 Nm (85 lbf ft)
Cylinder Head See Engine Manual
Damper on Crankshaft Pulley
75 Nm (55 lbf ft)
Exhaust Manifold Nuts
44 Nm (32 lbf ft)
Flywheel Capscrews
105 Nm (77 lbf ft)
Flywheel Housing Capscrews
75 Nm (55 lbf ft)
Fuel Injection Pump Gear
28 Nm (21 lbf ft)
Fuel Injection Pump Mount
22 Nm (16 lbf ft)
8000 YRM 738

Rocker Arm Brackets, Cast Iron
75 Nm (55 lbf ft)
Timing Case Capscrews - M8
22 Nm (16 lbf ft)
Timing Case Capscrews - M10
44 Nm (32 lbf ft)
Timing Case Cover
22 Nm (16 lbf ft)
Valve Cover
44 Nm (32 lbf ft)
FRAME
Counterweight Capscrews
555 Nm (409 lbf ft)
Engine Mount Nuts
165 Nm (122 lbf ft)
Overhead Capscrews
90 Nm (66 lbf ft)
Radiator Support Capscrews, Outer
66 Nm (49 lbf ft)
Radiator Support Capscrews, Inner
38 Nm (28 lbf ft)
LIFT CYLINDERS
Idler Gear Capscrews

44 Nm (32 lbf ft)
Main Lift Cylinder Retainer Cap

340 to 410 Nm (251 to 302 lbf ft)
Intake Manifold Capscrews

44 Nm (32 lbf ft)
Free-Lift Cylinder Retainer Cap

400 to 475 Nm (295 to 350 lbf ft)
Main Bearing Capscrews

265 Nm (195 lbf ft)
Free-Lift Cylinder Mount Capscrews

121 Nm (89 lbf ft)
Oil Pump
22 Nm (16 lbf ft)
MAIN CONTROL VALVE
Oil Pump Cover

28 Nm (21 lbf ft)
Through Bolt Nuts (5/16 in.)

19 Nm (14 lbf ft)
Oil Pump to Bearing Cap

22 Nm (16 lbf ft)
Through Bolt Nuts (3/8 in.)

45 Nm (33 lbf ft)
Rear Oil Seal Housing

22 Nm (16 lbf ft)
MASTS
Rocker Arm Brackets, Aluminum

40 Nm (30 lbf ft)
Pivot Pin Capscrews

550 Nm (406 lbf ft)
Sideshift Carriage (Internal)
Lower Hook Capscrews 78 Nm (58 lbf ft)
8000 YRM 738
POWERSHIFT TRANSMISSION
Rod End Lock Capscrews
66 to 73 Nm (49 to 54 lbf ft)
Control Valve Capscrews

19 Nm (14 lbf ft)
HYDROSTATIC COMPONENTS
Front Cover Capscrews

38 Nm (28 lbf ft)
Axle Valve Socket Head Capscrew

52 to 57 Nm (38 to 42 lbf ft)
Oil Pump Capscrews

38 Nm (28 lbf ft)
Left Axle Hangar Bolts

320 to 350 Nm (236 to 258 lbf ft)
Torque Converter Housing Capscrews

38 Nm (28 lbf ft)
Pump Mounting Screw

320 Nm (236 lbf ft)
Torque Converter Housing to Flywheel

Housing Capscrews
38 Nm (28 lbf ft)
Pump Mounting Front Bracket To Axle

38 Nm (28 lbf ft)
Torque Converter Drive Plate Capscrews

38 Nm (28 lbf ft)
Transmission to Drive Axle Capscrews
66 Nm (50 lbf ft)
Pump Mounting Front Bracket To Pump

66 Nm (49 lbf ft)
Coupler Hub
90 Nm (66 lbf ft)
STEERING SYSTEM
Plastic Adapter To Flywheel Drive Plate

52 Nm (38 lbf ft)
Axle Mount Capscrews

72 to 80 Nm (53 to 59 lbf ft)
Loop Tube To Hose

136 Nm (100 lbf ft)
Bearing Cap for Spindle

45 to 50 Nm (33 to 37 lbf ft)
Loop Tube To Pump

110 Nm (81 lbf ft)
Steering Cylinder Mount Capscrews

245 to 270 Nm (181 to 199 lbf ft)
Loop Tube To Clamp

38 Nm (28 lbf ft)
Wheel Bearings
200 Nm (148 lbf ft) Initial
34 Nm (25 lbf ft) Final
Loop Hose To Axle

71 Nm (52 lbf ft)
Wheel Nuts
610 to 680 Nm (450 to 502 lbf ft)
Left Axle Hanger Pins

555 to 610 Nm (409 to 450 lbf ft)
TILT CYLINDERS
Pump Valve Capscrews

8 Nm (70 lbf in)
Piston Nut
400 to 440 Nm (295 to 325 lbf ft)
Charge Pump Socket Head Capscrews

24 Nm (212 lbf in)
Retainer
400 to 500 Nm (295 to 369 lbf ft)
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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Maintenance

PART NO. 524173815

8000 YRM 738

Capacities and Specifications

This section is for the following models:

2004 Yale Materials Handling Corp.

8000 YRM 738

Lift Truck Weights

GM V-6 4.3 Liter

Perkins 1004-42 Diesel

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

0.89 mm (0.035 in.)

Engine With 50 Hours

1700 rpm +300/ 50 rpm

1950 rpm +300/ 50 rpm

1900 rpm +300/ 50 rpm

1950 rpm +300/ 50 rpm

Perkins (1004-42, 1104C-44)

1950 rpm 50 rpm

2050 rpm 50 rpm

8000 YRM 738

4.7 liter (5.0 qt)

8.0 liter (8.5 qt)

17.0 liter (18.0 qt)

17.0 liter (18.0 qt)

Hydraulic Tank (Powershift and Hydrostatic)

45.0 liter (11.8 gal)

67.0 liter (17.7 gal)

Hydraulic System Powershift Transmission

53.0 liter (14.0 qt)

75.0 liter (19.8 gal)

Hydraulic System Hydrostatic Transmission

78.0 liter (20.6 qt)

100.0 liter (26.4 gal)

17.0 liter (18.0 qt)

Differential and Drive Axle

8.5 liter (9.0 qt)

69.0 liter (18.2 gal)

103.0 liter (27.2 gal)

0.2 liter (0.4 pt)

8000 YRM 738

GM V-6 4.3 Liter

4.3 liter (262.4 in. 3 )

4.06 liter (247.8 in. 3 )

207 to 380 kPa (30 to 55 psi)

280 kPa (40 psi) min. @ 2200 rpm

0.45 mm (0.018 in.) Cold

725 to 775 rpm

103 kPa (15 psi)

103 kPa (15 psi)

Transmission Oil Pressures

8000 YRM 738

Transmission Oil Pressures

1310 to 1476 kPa

862 to 1048 kPa

862 to 1048 kPa

765 to 903 kPa