Periodic - Maintenance Us

Maintenance
PERIODIC
MAINTENANCE
GLC050LX [A967];
GLP/GDP050LX [A974]
PART NO. 550013979 8000 YRM 1424

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in
damage to the products, personal injury, property damage or death.
• 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. Discon-
nect 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 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.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Serial Number Data......................................................................................................................................... 1
How to Move Disabled Lift Truck ..................................................................................................................... 1
How to Tow Lift Truck .................................................................................................................................. 1
How to Put Lift Truck on Blocks....................................................................................................................... 2
How to Raise Drive Tires ............................................................................................................................ 2
How to Raise Steering Tires ....................................................................................................................... 3
How to Clean a Lift Truck ................................................................................................................................ 4
Maintenance Schedule ........................................................................................................................................ 4
Maintenance Procedures Every 8 Hours or Daily................................................................................................ 15
How to Make Checks With Engine Stopped.................................................................................................... 15
Tires and Wheels ........................................................................................................................................ 15
Safety Labels .............................................................................................................................................. 15
Mast, Carriage, Lift Chains, Header Hoses, Attachment ............................................................................ 16
Operator Restraint System ......................................................................................................................... 17
Emergency Locking Retractor (ELR) ...................................................................................................... 19
Hood and Seat Latches .............................................................................................................................. 19
Engine Compartment.................................................................................................................................. 19
Ground Static Strap .................................................................................................................................... 19
Fuel, Oil, and Coolant Leaks, Check .......................................................................................................... 20
Hydraulic Hoses.......................................................................................................................................... 20
Coolant Hoses ............................................................................................................................................ 21
Steering Column Gas Cylinder ................................................................................................................... 21
Transmission ............................................................................................................................................... 21
Hydraulic System Oil................................................................................................................................... 21
Engine Oil ................................................................................................................................................... 22
Air Filter ...................................................................................................................................................... 25
Forks ........................................................................................................................................................... 25
Remove .................................................................................................................................................. 25
Inspect .................................................................................................................................................... 26
Install ...................................................................................................................................................... 26
Adjust...................................................................................................................................................... 27
How To Make Checks With Engine Running................................................................................................... 27
Indicator Lights, Horn, Fuses, and Relays .................................................................................................. 27
Service Brakes............................................................................................................................................ 30
Brake Fluid Level .................................................................................................................................... 30
Operation, Check.................................................................................................................................... 30
Parking Brake ............................................................................................................................................. 30
Engine Oil Pressure .................................................................................................................................... 30
Cooling System........................................................................................................................................... 31
Steering System ......................................................................................................................................... 31
Control Levers and Pedals.......................................................................................................................... 31
Lift System, Operate ................................................................................................................................... 32
First Service After First 100 Hours of Operation ................................................................................................. 33
Mazda FE and F2 Engine Oil and Oil Filter Change ....................................................................................... 33
Yanmar 2.6L Engine Oil and Oil Filter Change................................................................................................ 33
Hydraulic System ............................................................................................................................................ 33
Hydraulic Filter Element, Replace............................................................................................................... 33
Remove .................................................................................................................................................. 33
Install ...................................................................................................................................................... 34
Maintenance Procedures Every 250 Hours or 6 Months..................................................................................... 36
©2013 Yale Materials Handling Corp. i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)

Mazda FE and F2 Engine Oil and Oil Filter Change ....................................................................................... 36
Mazda FE and F2 Engine Drive Belt Check.................................................................................................... 36
Fan and Alternator Drive Belt...................................................................................................................... 36
Drain Tar From Electronic Pressure Regulator (EPR)..................................................................................... 37
Maintenance Procedures Every 500 Hours or 6 Months..................................................................................... 38
Hydraulic System Oil....................................................................................................................................... 38
Hydraulic Tank Breather .................................................................................................................................. 38
Inspect ........................................................................................................................................................ 38
Battery............................................................................................................................................................. 40
Yanmar 2.6L Engine Oil and Oil Filter Change................................................................................................ 40
Yanmar 2.6L Engine Drive Belt ....................................................................................................................... 40
PCV Valve ....................................................................................................................................................... 41
Clean Debris From Radiator Core................................................................................................................... 41
Transmission Oil Level .................................................................................................................................... 41
Forks ............................................................................................................................................................... 42
Mast Lubrication.............................................................................................................................................. 42
Header Hose Checks ...................................................................................................................................... 46
Lift Chain Lubrication ...................................................................................................................................... 46
Tilt Cylinder Lubrication................................................................................................................................... 46
Master Cylinder Rod End Pin Lubrication ....................................................................................................... 46
Manual Hydraulic Levers Lubrication .............................................................................................................. 46
Brake Fluid ...................................................................................................................................................... 46
Parking Brake Adjustment............................................................................................................................... 47
Tie Rod Lubrication ......................................................................................................................................... 50
Differential and Drive Axle Oil ......................................................................................................................... 50
Maintenance Procedures Every 1000 Hours or 6 Months................................................................................... 51
Valve Clearance, Check and Adjust ................................................................................................................ 51
Ignition System - Mazda FE and F2 Engine.................................................................................................... 51
LPG Fuel Filter Replace - Mazda FE and F2 Engine...................................................................................... 51
Remove....................................................................................................................................................... 51
Clean/Inspect .............................................................................................................................................. 51
Install .......................................................................................................................................................... 51
Fuel Filter Replacement - Yanmar 2.6L Engine............................................................................................... 52
Priming the Fuel System (Yanmar) ................................................................................................................. 54
Lift Chains Wear Check................................................................................................................................... 54
Lift Chain Lubrication ...................................................................................................................................... 54
Integral Sideshift Carriage, Check Bearings ................................................................................................... 54
Steering Axle................................................................................................................................................... 55
Control Levers and Pedals .............................................................................................................................. 55
Maintenance Procedures Every 2000 Hours or Annually.................................................................................... 57
Hydraulic System ............................................................................................................................................ 57
Hydraulic Oil Filter Element, Replace ......................................................................................................... 57
Remove .................................................................................................................................................. 57
Clean and Inspect................................................................................................................................... 57
Install ...................................................................................................................................................... 57
Hydraulic Tank Breather, Replace............................................................................................................... 58
Air Filter........................................................................................................................................................... 59
PCV Valve ....................................................................................................................................................... 61
Oxygen Sensor ............................................................................................................................................... 61
Timing Belt ...................................................................................................................................................... 61
Forks ............................................................................................................................................................... 61
ii
Periodic Maintenance Table of Contents

Fuel Injector, Yanmar Engines ........................................................................................................................ 61
Integral Sideshift Carriage............................................................................................................................... 61
Bearings, Replace ...................................................................................................................................... 61
Transmission Oil and Oil Filter, Replace ......................................................................................................... 63
Remove....................................................................................................................................................... 63
Clean and Inspect ....................................................................................................................................... 66
Install .......................................................................................................................................................... 66
Brake Fluid Change ........................................................................................................................................ 67
Service Brakes ................................................................................................................................................ 68
Drive Axle and Differential Oil, Change........................................................................................................... 68
Wheel Bearings............................................................................................................................................... 69
Steer Wheels, Lubrication........................................................................................................................... 69
Maintenance Procedures Every 4000 Hours or 2 Years...................................................................................... 71
Hydraulic Oil, Change ..................................................................................................................................... 71
Cooling System ............................................................................................................................................... 73
Safety Procedures When Working Near Mast ..................................................................................................... 75
Hood Latch Check ............................................................................................................................................... 77
Lift Chain Adjustments......................................................................................................................................... 78
Jump-Starting the Lift Truck................................................................................................................................. 80
Jump-Starting Using a Battery Charger .......................................................................................................... 80
Jump-Starting a Lift Truck Using Another Lift Truck ........................................................................................ 80
Welding Repairs .................................................................................................................................................. 80
Overhead Guard Changes .................................................................................................................................. 81
Wheels and Tires Replacement .......................................................................................................................... 81
General ........................................................................................................................................................... 81
How to Change Solid Rubber Tire ................................................................................................................. 81
Remove and Install Tire on Wheel.............................................................................................................. 81
Pneumatic Tire With Tube, Repair .................................................................................................................. 82
Remove Wheels From Lift Truck ................................................................................................................. 82
Remove Tire From Wheel ........................................................................................................................... 83
Remove Tire From Two-Piece Wheel ..................................................................................................... 83
Remove Tire From Three- and Four-Piece Wheels................................................................................ 84
Install Wheel in Tire .................................................................................................................................... 85
Install Two-Piece Wheel in Tire .............................................................................................................. 86
Install Three- or Four-Piece Wheel in Tire.............................................................................................. 87
Add Air to Pneumatic Tires With Tube ........................................................................................................ 88
Wheels, Install............................................................................................................................................. 88
Pneumatic Tubeless Tire, Repair .................................................................................................................... 89
Remove Wheels From Lift Truck ................................................................................................................. 89
Install Tire on Wheel ................................................................................................................................... 91
Add Air to Pneumatic Tubeless Tire............................................................................................................ 93
Wheels, Install............................................................................................................................................. 94
Solid Rubber Tires on Pneumatic Wheels, Change ........................................................................................ 94
Install Tire on Wheel ................................................................................................................................... 96
Adhesives and Sealants ...................................................................................................................................... 98
iii
Table of Contents Periodic Maintenance

This section is for the following models:
GLC050LX [A967];
GLP/GDP050LX [A974]
iv
8000 YRM 1424 General
General
SERIAL NUMBER DATA
WARNING
DO NOT make repairs or adjustments unless you The serial number for the lift truck is on the nameplate.
have both authorization and training. Repairs and It is also on the right side of the frame, under the floor
adjustments that are not correct can make a dan- plate.
gerous operating condition.
HOW TO MOVE DISABLED LIFT TRUCK
WARNING How to Tow Lift Truck
DO NOT operate a lift truck that needs repairs. Re-
port the need for repairs immediately. If repair is
WARNING
necessary, put a DO NOT OPERATE tag in the oper-
ator’s area. Remove the key from the key switch. Use extra caution when towing a lift truck if any of
the following conditions exist:
• Brakes do not operate correctly.
CAUTION • Steering does not operate correctly.
Disposal of lubricants and fluids must meet local • Tires are damaged.
environmental regulations. • Traction conditions are bad.
• The lift truck must be towed on a slope.
This section contains a Maintenance Schedule and the
instructions for maintenance and inspection. If the engine cannot run, there is no power available
for the hydraulic steering system and the service
The Maintenance Schedule has time intervals for in- brakes. This condition can make the lift truck dif-
spection, lubrication, and maintenance of your lift truck. ficult to steer and stop. If the lift truck uses power
The service intervals are given in both operating hours from the engine to help apply the brakes, the ap-
recorded on the lift truck hourmeter and in calendar plication of the brakes will be more difficult. Poor
time. The recommendation is to use the interval that traction can cause the disabled lift truck or towing
comes first. vehicle to slide. A slope will also make the lift truck
more difficult to stop.
The recommendations for the time intervals given is for
eight hours of operation per day. The time intervals Never lift and move a disabled lift truck unless the
must be decreased from the recommendations in the disabled lift truck MUST be moved and cannot be
Maintenance Schedule for the following conditions: towed. A lift truck used to move a disabled lift truck
• The lift truck is used more than eight hours per day. MUST have a capacity rating equal to or greater
• The lift truck must work in dirty operating conditions. than the weight of the disabled lift truck. The ca-
• Poor ground conditions. pacity of the lift truck used to move a disabled lift
• Intensive usage at high performance levels or other truck must have a load center equal to half the width
abnormal conditions will require more frequent ser- of the disabled lift truck. See the Nameplate of the
vicing. disabled lift truck for the approximate total weight.
The forks must extend the full width of the disabled
Your dealer for Yale lift trucks has the equipment and
lift truck. Put the weight center of the disabled lift
trained service personnel to do a complete program
truck on load center of the forks. Be careful to not
of inspection, lubrication, and maintenance. A regular
damage the underside of the lift truck.
program of inspection, lubrication, and maintenance will
help your lift truck provide more efficient performance 1. The towed lift truck must have an operator.
and operate for a longer period of time.
2. Tow truck slowly.
Some users have service personnel and equipment to
do the inspection, lubrication, and maintenance shown
in the Maintenance Schedule. Service Manuals are
available from your dealer for Yale lift trucks to help
users who do their own maintenance.
1
General 8000 YRM 1424
3. Using a lift truck or a lifting device that could be used to support the lift truck are solid, one-piece
attached to the mast (I.E. come-a-long), raise car- units.
riage and forks approximately 30 cm (12 in.) from
surface. Install chain around a mast crossmember CAUTION
and the carriage to prevent carriage and mast chan-
These lift trucks are equipped with cowl lifting eyes.
nels from moving.
The cowl lifting eyes are to be used to lift the front
4. If another lift truck is used to tow the disabled lift of the lift truck only. Lifting more than the front of
truck, that lift truck must have an equal or larger the lift truck with the cowl lifting eyes will damage
capacity than the disabled lift truck. Install approx- the cowl section.
imately 1/2 of a capacity load on forks of lift truck
that is being used to tow disabled lift truck. This 1/2
capacity load will increase traction of lift truck. Keep
load as low as possible.
5. Use a towing link made of steel that fastens to tow

pins in counterweights of both lift trucks. Slowly and
carefully remove the slack out of the towing link.
See Figure 1.
HOW TO PUT LIFT TRUCK ON BLOCKS

How to Raise Drive Tires
WARNING
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the fol-
lowing assemblies will cause large changes in the
center of gravity: mast, drive axle, engine, trans-
mission, and counterweight. When the lift truck is
put on blocks, put additional blocks in the following
positions to maintain stability:
• Before removing the mast and drive axle, put
blocks under the counterweight so the lift truck
cannot fall backward.
• Before removing the counterweight, put blocks 1. STEEL TOW LINK
under the mast assembly so the lift truck cannot 2. TOW PIN
fall forward. 3. COUNTERWEIGHT
The surface must be solid, even, and level when the Figure 1. Towing the Lift Truck
lift truck is put on blocks. Make sure any blocks
2
8000 YRM 1424 General
1. Put blocks on each side (front and back) of steering How to Raise Steering Tires
tires to prevent movement of lift truck. See Figure 2.
NOTE: Some lift trucks are equipped with lifting eyes for
2. Put mast in vertical position. Put a block under each the purpose of lifting the entire lift truck. If the lift truck is
outer mast channel. equipped with this type of lifting eyes, the lift truck can
be lifted and blocks installed.
3. Tilt mast fully forward until drive tires are raised from
surface. 1. Apply parking brake. Put blocks on both sides (front
and back) of drive tires to prevent movement of lift
4. Put additional blocks under frame behind drive tires. truck. See Figure 2.
5. If hydraulic system will not operate, use a hydraulic 2. Use hydraulic jack to raise steering tires. Make sure
jack under the side of the frame near the front. jack has a capacity of at least 2/3 of total weight of
Make sure jack has a capacity equal to at least half lift truck as shown on the Nameplate.
the weight of the lift truck. See Nameplate.
3. Put jack under steering axle or frame to raise lift
truck. Put blocks under frame to support lift truck.
NOTE: COMPONENTS SHOWN ON LIFT TRUCK MAY NOT BE ON YOUR LIFT TRUCK. ILLUSTRATION USED
FOR GENERAL PURPOSES.
1. DRIVE TIRES 2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
3
Maintenance Schedule 8000 YRM 1424
HOW TO CLEAN A LIFT TRUCK 4. Lightly spray a non-corrosive cleaning agent onto
the areas to be cleaned. This will help loosen
WARNING grime, so close contact direct spraying will not be
necessary.
Engine, exhaust system components and other
components are hot to the touch. Be sure lift truck 5. Be sure to avoid directing the spray into electrical
components are cool before starting inspection panel compartment. Ensure overspray does not
and cleaning, or personal injury may occur. come in contact with electrical components; do not
spray water directly at electrical components, wiring
WARNING connectors or electrical enclosures. Even sealed
Compressed air can move particles so that they connectors may allow water egress under pressure
cause injury to the user or to other personnel. or if connector is damaged.
Make sure that the path of the compressed air is
6. Avoid spraying in areas containing electrical com-
away from all personnel. Wear protective goggles
ponents such as:
or a face shield to prevent injury to the eyes.
• Floor Plates
• Battery Compartment
CAUTION • Dash/cowl assembly
Units may be washed with a non-heated pressure • Armrests with electrical components
washer. Steam cleaning is not recommended in
7. Clean the battery compartment by using a clean
most instances, as condensation may form in elec-
cloth to wash the battery with water. Dry with com-
trical components causing damage or erratic be-
pressed air. Care should be taken to keep mois-
havior.
ture at a minimum as some units have a traction or
NOTE: Lift trucks used in paper applications may need hydraulic motor directly below the battery compart-
cleaning beyond what is described here. Please refer ment.
to Paper Application section in the applicable Operating
8. DO NOT pressure wash the battery. Do not use
Manual and to available Service Gram/Bulletin for more
hot water. For cleaning traction batteries, refer to
detail.
the Battery section of the Service Manual.
If it becomes necessary to clean the fork lift, follow the
9. DO NOT pressure wash lift chains, sheaves or
guidelines listed below.
load rollers in the mast assembly. Refer to the
1. Assure truck components are cool before starting Chains, Sheaves and Load Rollers maintenance
the cleaning procedure. section in the Service Manual for proper cleaning
procedures.
2. Disconnect the battery. If an electric truck, remove
the traction battery. 10. After cleaning, immediately start and run the lift
truck to dry out components.
3. Remove accumulated debris using a compressed
air line and nozzle.
Maintenance Schedule
NOTE: The 250-hour, 500-hour, and 1000-hour main-
tenance services are performed either at the specified
hours or 6 months whichever occurs first.
4
8000 YRM 1424 Maintenance Schedule
Figure 3. Maintenance Points - Mazda FE LPG Engine, Lift Trucks Manufactured Before January 2011
5
Figure 4. Maintenance Points - Mazda FE LPG Engine, Lift Trucks Manufactured After January 2011
6
Figure 5. Maintenance Points - Mazda F2 LPG Engine
7
Figure 6. Maintenance Points - Yanmar 2.6L Engine
8
Table 1. Maintenance Schedule
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
26 Tires X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
29, Mast, Carriage, X Check Condition See Parts Manual
30 Header Hoses, Lift and Lubrication
Chains, Attachment
Seat Belt, Hip X Check Condition
Restraints, and Seat and Operation
Rails
Hood and Seat X Check Condition
Latches and Operation
Engine Compartment X Remove
Combustible
Materials
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condition See Parts Manual
Ground Static Strap X Check Condition
(If Equipped) and Replace if
Necessary.
13 Coolant Hoses X Check Condition See Parts Manual
18 Fuel Tank (LPG) CIL 38.4 liter (10.1 gal) LPG - HD 5, HD 10
15.2 kg (33.5 lb)
18 Fuel Tank (Diesel) CIL 38.4 liter (10.1 gal) Diesel No. 2
Horn, Lights, Alarms X Check Operation
1 Service Brakes X Check Operation
24 Parking Brake X L Check Operation Use Silicone Spray
Lubricate As (Yale P/N 504236201)
Needed
Steering Controls and X Check Condition
Steering Column Gas and Operation
Cylinder
23 Transmission X Check for Leaks John Deere
Check Operation JDM J20C
3 Hydraulic Oil X X C 29.9 liter (31.6 qt) ISO VG 46
GLC050LX (A967) Lift Drain and Fill Hydraulic Oil
Trucks See NOTE 2, 15°C (5°F) and
NOTE 3 and Above
NOTE 13.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
9
Table 1. Maintenance Schedule (Continued)
3 Hydraulic Oil X X C 39.2 liter (41.4 qt) ISO VG 46
GLP/GDP050LX Drain and Fill Hydraulic Oil
(A974) Lift Trucks See NOTE 2, 15°C (5°F) and
NOTE 3 and Above
NOTE 13.
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
Element See NOTE 4 and
NOTE 13.
10 Hydraulic Tank X C Inspect and Clean See Parts Manual
Breather as Required.
See NOTE 5.
8 Battery and Cable X Clean.
Terminals See NOTE 5.
9 Engine Oil X C 3.9 liter (4.1 qt) 7°C (20°F)
Mazda FE Engine CIL See NOTE 4 and and Below
NOTE 5 SAE 5W-20
16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
9 Engine Oil X C 4.2 liter (4.4 qt) 7°C (20°F)
Mazda F2 Engine CIL See NOTE 4 and and Below
NOTE 5 SAE 5W-20
16°C (60°F)
and Below
SAE 5W-30
18°C (0°F)
and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
10
9 Engine Oil Yanmar X CIL C 10.2 liter (10.8 qt) 20°C (68°F)
2.6L Engine NOTE 4 and and Above
NOTE 5 SAE 40
10 to 30°C
(50 to 86°F)
SAE 30
0 to 20°C (32 to 68°F)
SAE 20
16 to 40°C
(3 to 103°F)
SAE 15W-40
20 to 30°C
( 4 to 86°F)
SAE 10W-30
10 to 10°C
(14 to 50°F)
SAE 20W
20 to 10°C
( 4 to 50°F)
SAE 10W
21 Engine Oil Filter C 1 Filter See Parts Manual

See NOTE 4 and
NOTE 5.
21 Engine Oil Filter C 1 Filter See Parts Manual
Yanmar 2.6L Engine See NOTE 4 and
NOTE 5
20 Air Filter CIL C 1 Filter See Parts Manual
X See NOTE 5,
NOTE 6, and
NOTE 11.
16 Drive Belt X Check for Wear and
Damage. Adjust
as Needed. See
NOTE 5.
16 Drive Belt Yanmar X Check for Wear and
2.6L Engine Damage. Adjust
as Needed. See
NOTE 5.
Electronic Pressure X Drain Tar. See
Regulator (EPR) NOTE 5.
Engine Idle Speed X See NOTE 5. 800 ±25 rpm
Mazda FE and F2 (No Load)
Engine
Engine Governed X See NOTE 5. 2400 ±25 rpm
Speed (No Load)
11
Engine Governed X See NOTE 5. 2600 ±25 rpm
Speed (No Load)
Engine Idle Speed X See NOTE 5 825 ±25 rpm
Yanmar 2.6L Engine (No Load)
Engine Governed X See NOTE 5 2400 ±25 rpm
Speed Yanmar 2.6L (No Load)
Engine
17 PCV Valve X C Replace. See Parts Manual
Oxygen Sensor X Check Indicator Light
4 Valve Adjustment X Adjust as Required Intake
0.15 mm (0.006 in.)
Cold
Exhaust
0.35 mm (0.014 in.)
Cold
4 Valve Adjustment X Adjust as Required Intake
Yanmar 2.6L Engine 0.20 mm (0.008 in.)
Cold
Exhaust
0.20 mm (0.008 in.)
Cold
Timing X Adjust as Required 6° BTDC
(Orange Mark)
Mazda FE and F2
Engine
19 LPG Fuel Filter C 1 Filter See Parts Manual
Mazda FE and F2
Engine
15 Timing Belt Replace See Parts Manual
Mazda FE and F2 See NOTE 7.
Engine
5 Spark Plugs C Check Plug Wires See Parts Manual
Mazda FE and F2 4 Plugs 0.8 +0.0/ 0.1 mm
Engine (0.032 +0.0/
0.004 in.)
12, Cooling System X C 11.0 liter (11.6 qt) See NOTE 12
14 Mazda FE and F2 CIL
Engine
12, Cooling System X C 11.5 liter (12.1 qt) See NOTE 12
14 Yanmar 2.6L Engine CIL
Clean Debris From X See NOTE 5
Radiator Core
7 Transmission Oil X C 13 liter (14 qt) John Deere
JDM J20C
12
22 Transmission Oil Filter C 1 Filter See Parts Manual
See NOTE 4.
27 Forks X X X Check Condition
28 Mast L Lubricate Multipurpose Grease
Sliding Surfaces As Required See NOTE 8.
and Load Roller See NOTE 9.
Surfaces
28 Header Hoses X Check Condition
29 Lift Chains X Check Condition/ SAE 30W
Lube if Necessary. Engine Oil
See NOTE 10.
29 Lift Chains L X, L Lube as Required SAE 30W
Check for Wear Engine Oil
Mast X L Lube as Required Multipurpose Grease
Sideshift 2 Fittings See NOTE 8.
Carriage
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 8.
Mast L X C Lube as Required Multipurpose Grease
Integral 2 Fittings See NOTE 8.
Sideshift 4 Bearings 2.5 mm (3/32 in.)
Carriage Minimum Thickness
(Upper/Lower
Bearings)
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 8.
Brake Master Cylinder L Lubricate As SAE 10W-30
Rod End Pin Required API SM
ILSAC GF4
SAE J2362
Manual Hydraulic L Lubricate As SAE 10W-30
Hand Levers Required API SM
ILSAC GF4
SAE J2362
25 Brake Fluid CIL X C 0.25 liter (0.26 qt) SAE J-1703 (DOT 3)
11 Steering Axle L 4 Fittings Multipurpose Grease
Tie Rod Ends See NOTE 8.
11 Steering Axle L 2 Fittings Multipurpose Grease
King Pins See NOTE 8.
2 Pedals, Levers, Seat L Lubricate as Yale Part No.
Rails, Cables, Hinges, Necessary 504236201
Linkages, Hood Latch
13
24 Parking Brake X Adjust as Must Hold a Full
Adjustment Necessary Capacity Load on a
15% Grade.
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
Thickness Minimum
34 Wheel Bearings L Check Grease Multipurpose Grease
Steer Wheels See NOTE 8.
31 Differential and Drive X C 5.0 liter (5.3 qt) SAE 80W-90 or
Axle Oil 85W-140
32 Fuel/Water Separator C 1 Filter See Part Manual.
Yanmar 2.6L Diesel
Engine
In-line Filter Yanmar C 1 Filter See Part Manual.
2.6L Diesel Engine
33 Fuel Injectors Yanmar X 4 Injectors Check and Replace
2.6L Diesel Engine if Required.
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and oil filter, transmission fluid filter, and hydraulic oil filter, after first 100 hours of operation.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving
contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive compounds;
poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require more frequent
servicing. At your request, your Yale dealer will advise you of the appropriate service intervals, based on an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Replace timing belt on Mazda engines every 3500 hours. Use only hour interval.
NOTE 8: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 9: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 10: Lubricate if dry or at first sign of visible surface rust.
NOTE 11: DO NOT open the air filter canister except to change the air filter element. See Maintenance Procedures Every 2000
Hours or Annually to change air filter element.
NOTE 12: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50%
distilled water or deionized water.
NOTE 13: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures 1900 YRM
1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or highly contaminated
environments, take oil samples every 500 hours. Normal Operating conditions may allow for less frequent oil sampling. Oil
sampling should be done just prior to all oil and filter changes.
14
8000 YRM 1424 Maintenance Procedures Every 8 Hours or Daily
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE or missing hardware. Remove any wire, strapping, or
STOPPED other material that is wrapped around the axle.
Safety Labels
WARNING
port the need for repairs immediately. If repair is WARNING
necessary, put a DO NOT OPERATE tag in the oper- Safety labels are installed on the lift truck to provide
ator’s area and remove the key from the key switch. information about operation and possible hazards.
It is important that all safety labels are installed on
Put the lift truck on a level surface. Lower the carriage the lift truck and can be read.
and forks, stop the engine, and apply the parking brake.
Open the hood and check for leaks and conditions that Check that all safety labels are installed in the correct
are not normal. Clean any oil or fuel spills. Ensure all location on the lift truck. See the Parts Manual, Model
surfaces are free of oils, lubricants, fuel, and organic Description section in the Operating Manual or the
dust or fibers (paper, wood, cotton, agricultural grass/ section Frame 100 YRM 1423 for the correct location
grain, etc.). of the safety labels. See the Parts Manual for the part
numbers of the safety labels.
Tires and Wheels
Check the tires for damage. See Figure 7. Check
the tread and remove any objects that will cause dam-
age. Check for bent or damaged rims. Check for loose
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 7. Tire Check
15
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1424
Mast, Carriage, Lift Chains, Header Hoses, 5. Inspect the load backrest extension for cracks and
Attachment damage.
6. If the lift truck is equipped with an integral sideshift

WARNING carriage or attachment, inspect the parts for cracks
Lower the lift mechanism completely. Never allow and wear. Make sure the parts that fasten the inte-
any person under a raised carriage. DO NOT put gral sideshift carriage or attachment to the carriage
any part of your body in or through the lift mech- are in good condition.
anism unless all parts of the mast are completely
lowered and the engine is STOPPED. DO NOT try
to correct the alignment of the fork tips by bending
the forks or adding shims. Never repair damaged
forks by heating or welding. Forks are made of spe-
cial steel using special procedures. If either fork is
damaged, replace the forks as a set.
WARNING
DO NOT operate fork lift without lateral fork stops
in place. Forks may disengage from fork carriage.
1. Inspect the welds on the mast and carriage for

cracks. Make sure that the capscrews and nuts
are tight.
2. Inspect the carriage to be sure fork stops are in

place. Fork stops prevent forks from laterally dis- NOTE: MAST IS DIFFERENT, BUT LUBRICATION AR-
engaging from the carriage. EAS ARE THE SAME.
3. Inspect the channels for wear in the areas where A. UPPER LOAD ROLLERS
B. LOWER LOAD ROLLERS
the rollers travel. Inspect the rollers for wear or
damage. 1. LUBRICATE STRIP BEARINGS SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
4. Check mast lubrication. If necessary, lubricate the 3. LOAD ROLLER
sliding surfaces and the load roller surfaces along
the full length of the channels as shown in Figure 8. Figure 8. Mast Lubrication
Only apply lubricant to surfaces that are clean and
dry. Only apply lubricant to the darker areas as
indicated by (1) and (2) in Figure 8.
16
Operator Restraint System

WARNING
Always wear the proper protective equipment in- NOTE: The seat belt can be either black or red.
cluding eye protection and petroleum-resistant
gloves when handling hydraulic oil. Thoroughly The seat belt, hip restraint, seat, hood, and hood latch
wash oil from exposed areas of skin as soon as are all part of the operator restraint system. See Fig-
possible. ure 10 and Figure 11. Each item must be checked to
make sure it is fastened correctly, functions correctly,
and is in good condition.
WARNING
Never check for leaks by putting hands on hydraulic
lines or components under pressure. Hydraulic oil
under pressure can be injected into the skin.
7. Visually inspect hoses/fittings for hydraulic leaks;

hose cover for cuts, cracks or exposed rein-
forcement; defective/broken clamping devices
or sheaves; proper tracking during operation. Ad-
just/repair/replace hose/components as necessary.
8. Check that the lift chains are correctly lubricated.

Use SAE 30 engine oil as necessary to lubricate
the lift chains.
9. Inspect the lift chains for cracks or broken links, and

worn or turned pins. See Figure 9.
10. Inspect the chain anchors and pins for cracks and
damage.
1. WORN PIN 5. LOOSE LEAVES
11. Make sure the lift chains are adjusted so that they 2. CRACKS 6. TURNED PIN
have equal tension. Adjustments or replacement 3. EDGE WEAR 7. CORROSION
of the lift chains must be done by authorized 4. HOLE WEAR
personnel.
Figure 9. Lift Chain Check
17
1. LATCH STRIKER 4. HOOD RELEASE HANDLE

2. BUMPER 5. HOOD LATCH
3. HOOD 6. LIFT TRUCK FRAME
Figure 10. Hood and Hood Latch Check
18
Emergency Locking Retractor (ELR) seat belt can be pulled from the retractor, when it is
pulled with a sudden jerk, replace the seat belt as-
When the ELR style seat belt is properly buckled across sembly.
the operator, the belt will permit slight operator reposi- • With the hood in the open position, make sure the
tioning without activating the locking mechanism. If the seat belt will not pull from the retractor assembly. If
truck tips over, travels off a dock, or comes to a sudden the seat belt can be pulled from the retractor, with
stop, the locking mechanism will be activated and hold the hood in the open position, replace the seat belt
the operator’s lower torso in the seat. assembly.
A seat belt that is damaged worn or does not operate
Hood and Seat Latches
properly will not provide protection when it is needed.
The end of the belt must fasten correctly in the latch. Make sure the seat rails and latch striker are not loose.
The seat belt must be in good condition. Replace the The seat rails must lock tightly in position, but move
seat belt if it is worn or damaged. See Figure 11. freely when unlocked. See Figure 10. The seat rails
must be correctly fastened to the hood and the hood
NOTE: The following seat belt operation checks must
fastened to the hinges on the frame. Try to lift the hood
be performed at least three times before replacing the
to make sure it is fastened correctly and will not move.
seat belt assembly:
If adjustment is required, go to Hood Latch Check.
• With the hood closed and in the locked position, pull
the seat belt slowly from the retractor assembly. Make Engine Compartment
sure the seat belt pulls out and retracts smoothly. If Check for the presence of any combustible material
the seat belt does not pull out of the retractor assem- such as paper, leaves, etc. Remove any combustible
bly, the internal latch may be locked. Pull firmly on materials.
the seat belt and hold for a moment to remove slack
from the belt in the retractor. Release the seal belt. Ground Static Strap
Seat belt will retract and the internal latch will unlock.
If the seat belt cannot be pulled from the retractor as- If lift truck is equipped with a Ground Static Strap (see
sembly or the belt will not retract, replace the seat belt Figure 12), check to be sure Ground Static Strap is se-
assembly. curely in place and in contact with the ground. Check
• With the hood closed and in the locked position, pull attaching hardware. If worn, missing or not in contact
the seat belt with a sudden jerk. Make sure the seat with the ground, replace strap and mounting hardware
belt will not pull from the retractor assembly. If the as required.
19
A. STANDARD, NON SUSPENSION SEAT B. FULL SUSPENSION SEAT

1. SEAT BELT 4. FORWARD/BACKWARD ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 5. BACKREST ANGLE ADJUSTMENT LEVER
3. RIDE POSITION INDICATOR 6. ARMREST
Figure 11. Seat Belt and Seat Check
Fuel, Oil, and Coolant Leaks, Check Check the fuel system for leaks and the condition of
parts. When fuel is added to the lift truck, see the sec-
tion HOW TO ADD FUEL TO THE LIFT TRUCK in the
WARNING
Operating Manual.
All fuels are very flammable and can burn or cause
an explosion. Do not use an open flame to check Also check the condition of the radiator or heater hoses
the fuel level or to check for leaks in the fuel system. that are not leaking. Soft or cracked hoses need to be
If there is a leak in the fuel system, extra care must replaced before a major leak occurs.
be used during the repair. Do not operate the lift
truck until a leak is repaired. Hydraulic Hoses
Make a visual check for leaks on and under the lift truck. Check the condition of the hydraulic hoses for service-
If possible, find and report the leak to maintenance for ability by inspecting for cracks or other obvious damage.
repair. Leaks often indicate a need for repair of dam- Check to ensure that the hydraulic hoses are not leak-
aged or worn components. Leaks in the LPG fuel sys- ing. If any hose is leaking, report it to maintenance for
tem are usually not visible unless ice is present. There repair.
is however, usually a strong odor. Fuel leaks MUST be
repaired IMMEDIATELY.
20
Coolant Hoses
Check the condition of the coolant hoses for service-
ability by inspecting for cracks or other obvious dam-
age. Check to ensure that the coolant hoses are not
leaking. If any hose is leaking, report it to maintenance
for repair.
Steering Column Gas Cylinder

Make sure the gas cylinder for the steering column op-
erates correctly. The cylinder must NOT allow the col-
umn to move unless the tilt lever is released. See Fig-
ure 13.
Transmission
Check the transmission for leaks and damaged or loose
components. Heavy-duty or high temperature opera-
tions can require more frequent checks. 1. GROUND STATIC STRAP
2. FRAME
Hydraulic System Oil 3. PDM
4. BATTERY
WARNING Figure 12. Ground Static Strap
At operating temperature, the hydraulic oil is HOT.
DO NOT permit the hot oil to touch the skin and
cause a burn.
CAUTION
DO NOT permit dirt to enter the hydraulic system
when the oil level is checked or the filter is changed.
Never operate the hydraulic pump without oil in the

hydraulic system. The operation of the hydraulic
pump without oil will damage the pump.
After the engine has stopped, wait one minute before

checking the oil level. Keep the hydraulic oil at the cor-
rect level as indicated on the dipstick, located on top of
right frame channel. See Figure 14. Use the correct oil
as shown in the Maintenance Schedule.
1. TILT LEVER 2. GAS CYLINDER
Check the hydraulic system for leaks and damaged or
loose components. Heavy-duty or high-temperature Figure 13. Steering Column Gas Cylinder and Tilt
operations can require more frequent checks. Lever
21
Never operate the engine without oil. The operation

of the engine without oil will damage the engine.
After the engine has stopped, wait one minute before

checking the oil level. Keep the oil at the correct level as
indicated on the dipstick. Use the correct oil as shown
in the Maintenance Schedule.
See Figure 15 for lift truck equipped with Mazda FE LPG

engine.
See Figure 16 for lift truck equipped with Mazda F2 LPG

engine.
See Figure 17 for lift trucks equipped with Yanmar 2.6L

engine.
There is an indicator light for the engine oil pressure on

the Display Switch Cluster. During normal operation,
the red indicator light will illuminate when the key switch
is turned to ON, and will stay illuminated until correct oil
1. HYDRAULIC OIL FILTER pressure is obtained, at which time the light will go off.
2. HYDRAULIC OIL DIPSTICK
3. HYDRAULIC TANK BREATHER If the light continues to stay on when engine is running,
4. RIGHT FRAME CHANNEL the engine oil pressure is low. Stop the engine and
check the oil level. DO NOT restart the engine until the
Figure 14. Hydraulic System Oil Check low pressure condition has been corrected.
Engine Oil See Figure 15 for lift trucks equipped with Mazda FE
LPG engine.
WARNING See Figure 16 for lift truck equipped with Mazda F2 LPG
At operating temperature, the engine oil is HOT. DO engine.
NOT permit the hot oil to touch the skin and cause
a burn. See Figure 17 for lift trucks equipped with Yanmar 2.6L
engine.
CAUTION
DO NOT permit dirt to enter the engine when the oil
level is checked or the filter is changed.
Legend for Figure 15

A. TOP VIEW B. LEFT SIDE VIEW
1. ENGINE OIL DIPSTICK 7. PCV VALVE
2. BATTERY 8. AIR FILTER
3. AUXILIARY COOLANT RESERVOIR 9. SPARK PLUG
4. RADIATOR CAP 10. LPG FUEL FILTER
5. ENGINE OIL FILL 11. ENGINE OIL FILTER
6. DRIVE BELT 12. OIL DRAIN PLUG
22
Figure 15. Engine Maintenance Points - Mazda FE LPG Engine
23
1. ENGINE OIL DIPSTICK

2. BATTERY
3. AUXILIARY COOLANT RESERVOIR
4. RADIATOR CAP 1. BATTERY
5. ENGINE OIL FILL
6. DRIVE BELT 3. RADIATOR CAP
7. PCV VALVE 4. DRIVE BELT
5. AIR FILTER
8. AIR FILTER
9. SPARK PLUG 6. ENGINE OIL FILTER
10. LPG FUEL FILTER 7. DIPSTICK ENGINE OIL
8. FUEL FILTER
11. ENGINE OIL FILTER
12. OIL DRAIN PLUG 9. FUEL INJECTOR
10. ENGINE OIL FILL
Figure 16. Engine Maintenance Points - Mazda F2 Figure 17. Engine Maintenance Points - Yanmar
LPG Engine 2.6L Diesel Engine
24
Air Filter NOTE: Forks are to be replaced only in sets and not
individually.
The air filter canister should not be opened until an air
filter element replacement is required. An air filter ele- A fork can be removed from the carriage for replace-
ment replacement is required when one of the following ment of the fork or other maintenance.
occurs:
• If equipped, the manual air flow indicator is red 1. Lift the lock pin and slide a hook fork to the fork re-
• The specified number of hours has passed since the moval notch on the carriage. See Figure 18 and
last filter element replacement Figure 19. Lower the fork onto blocks so that the
bottom hook of the fork moves through the fork re-
DO NOT operate the lift truck until the air filter element moval notch. See Figure 19. Lower the carriage
has been replaced. further so that the top hook of the fork is disengaged
from the top carriage bar. Move the carriage away
See Figure 15 for lift trucks equipped with Mazda FE from the fork, or use a lifting device to move the fork
LPG engine. away from the carriage.
See Figure 16 for lift truck equipped with Mazda F2 LPG
engine.

engine.
Forks
The identification of a fork describes how the fork is
connected to the carriage. These lift trucks have hook
forks.
Remove
WARNING 1. CARRIAGE BARS 3. BLOCKS

DO NOT try to move a fork without a lifting device. 2. HOOK FORK
Each hook fork for these lift trucks can weigh 45 to
115 kg (99 to 253 lb). Figure 18. Hook Fork Removal
25
Inspect Legend for Figure 19
1. Inspect the forks for cracks and wear. Check that Fork Tip Alignment
the fork tips are aligned as shown in Figure 19.
Length of Forks 3% Dimension
Check that the bottom of the fork is not worn. See
Figure 19, item 4. 915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
2. Replace any damaged or broken parts that are 1220 mm (48 in.) 37 mm (1.46 in.)
used to keep the forks locked in position. 1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
1830 mm (72 in.) 55 mm (2.17 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Install
1. Move the fork and carriage so that the top hook on

the fork can engage the upper carriage bar. Raise
the carriage to move the lower hook through the fork
removal notch. Slide the fork on the carriage so that
both upper and lower hooks engage the carriage.
Engage the lock pin with a notch in the upper car-
riage bar.
Figure 19. Forks Check
26
Adjust brake and put the transmission in NEUTRAL. Make the

checks carefully.
NOTE: During the adjustment of the forks, the heel of
the forks should not be touching the ground. Indicator Lights, Horn, Fuses, and Relays
The forks are connected to the carriage by hooks and Turn key to the ON position. All warning light and indica-
lock pins. See Figure 18 and Figure 20. The lock pins tor lights will light up for two seconds (start check) when
are installed through the top fork hooks and fit into slots system power is turned ON. See Figure 21. Check all
in the top carriage bar. If pin does not remain engaged indicator lights for correct operation as described in the
in carriage slot, replace with new pin. Adjust the forks Operating Manual. Check the operation of the horn.
as far apart as possible for maximum support of the Start the engine by turning the key switch to the Start
load. Hook forks will slide along the carriage bars to position. If any indicator lights do not operate correctly,
adjust for the load to be lifted. Raise the lock pin in each check the fuses. The fuses are located in the Power
fork to slide the fork on the carriage bar. Make sure the Distribution Module (PDM) which is under the hood next
lock pin is engaged in the carriage bar to lock the fork to the battery on the right side. See Figure 22.
in position after the width adjustment is made.
HOW TO MAKE CHECKS WITH ENGINE

RUNNING
WARNING
port the need for repair immediately. If repair is nec-
essary, put a DO NOT OPERATE tag in the operators
area and remove the key.
WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed 1. FORK
to help the operator stay on the truck if the lift truck 2. LOCK PIN
3. SPRING
tips over. IT CAN ONLY HELP IF IT IS FASTENED. 4. WASHER
5. WEDGE
Make sure that the area around the lift truck is clear 6. KNOB
before starting the engine or making any checks of the 7. LOCK PIN ASSEMBLY
operation. Be careful when making the checks. If the
lift truck is stationary during a check, apply the parking Figure 20. Fork Lock Pin Assembly
27
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Indicator
2 Warning Light, System Malfunction Indicator
3 Indicators Light, Direction and Transmission Lights
4 Warning Light, Brake Fluid Level Malfunction Indicator
5 Warning Light, Fasten Seat Belt Malfunction Indicator
6 Warning Light, Parking Brake Malfunction Indicator
7 Warning Light, Alternator Malfunction Indicator
8 Warning Light, Transmission Oil Temperature Malfunction Indicator Light
9 Warning Light, Engine Oil Pressure Malfunction Indicator
10 Warning Light, Engine Coolant Temperature Malfunction Indicator
11 Warning Light, Fuel Level Indicator
12 Indicator Light Cold Start (Diesel Only)
13 Indicator Light Water Separator (Diesel Only)
Figure 21. Warning and Indicator Lights
28
NOTE: HOOD REMOVED FOR CLARITY.

1. BATTERY 12. TRANZORB
2. PDM 13. IGNITION 3 RELAY
3. START RELAY 14. IGNITION 3+ (20 AMP)
4. BATTERY (25 AMP) 15. IGNITION 1 RELAY
5. STARTER (30 AMP) 16. IGNITION 1+ (20 AMP)
6. FUEL/RUN RELAY 17. REAR WORKLIGHT RELAY
7. FUEL/RUN (30 AMP) 18. REAR WORKLIGHT (20 AMP)
8. FRONT WORKLIGHT RELAY 19. (20 AMP)
9. BACKUP RELAY 20. RESISTOR (68 OHM)
10. BACKUP (20 AMP) 21. FRONT WORKLIGHT (20 AMP)
11. BATTERY (20 AMP)
Figure 22. PDM Showing Fuses and Relays
29
Service Brakes Parking Brake

Brake Fluid Level There is an indicator icon on the display panel for the
parking brake. The icon is illuminated as described in
WARNING the Operating Manual. If the operator leaves the seat
without setting the parking brake and the key in the ON
If the brake system has a power assist (or boosted
position, an audible alarm will sound for 1 minute. If
master cylinder), braking will be more difficult if the
the operator leaves the seat without setting the parking
engine is not running.
brake and the key is in the OFF position for a period
Loss of fluid from the brake fluid reservoir indicates of 10 minutes or less, an audible alarm will sound for 1
a leak. Repair the brake system before using the lift minute.
truck. Replace the brake fluid in the system if there
Make sure the service brakes operate correctly before
is dirt or water in the system.
checking the operation of the parking brake. Check
There is an indicator light on the Display Switch Cluster the operation of the parking brake. The parking brake,
for the brake fluid. The red light is ON when the key when in good condition and correctly adjusted, will hold
switch is in the START position, and must go OFF when a lift truck with a full capacity load on a 15% grade [a
the engine is running. If the light is on when the engine slope that increases 1.5 meters in 10 meters (1.5 feet
is running, the brake fluid level in the reservoir is too increase in 10 feet)]. If parking brake requires adjust-
low. See the section Maintenance Procedures Every ment, notify service personnel.
500 Hours or 6 Months for procedures to add brake fluid
if necessary. Engine Oil Pressure
Operation, Check There is an indicator light for the engine oil pressure on
the Display Switch Cluster. See Figure 21. During nor-
Check the operation of the service brakes. Push on the mal operation, the red indicator light will illuminate when
inching/brake pedal. The service brakes must be ap- the key switch is turned to ON, and will stay illuminated
plied before the inching/brake pedal reaches the floor until correct oil pressure is obtained, at which time the
plate. The pedal must stop firmly and must not move light will go off.
slowly down after the brakes are applied. The service
brakes must apply equally to both drive wheels. The If the light continues to stay on when engine is running,
service brakes must not pull the lift truck to either side the engine oil pressure is low. Stop the engine and
of the direction of travel when they are applied. The ser- check the oil level.
vice brakes are automatically adjusted when the trans-
See Figure 15 for lift trucks equipped with Mazda FE
mission is in reverse and the lift truck is moving and the
LPG engine.
brakes are firmly applied. Full application of the inch-
ing/brake pedal applies the service brakes and puts the
transmission in NEUTRAL.
30
See Figure 16 for lift truck equipped with Mazda F2 LPG If coolant is added, see Maintenance Schedule for cor-
engine. rect solution.

engine.
WARNING
Compressed air can move particles so that they
DO NOT restart the engine until the low pressure con- cause injury to the user or to other personnel.
dition has been corrected. Make sure that the path of the compressed air is
Cooling System or a face shield to prevent injury to the eyes.
Check the radiator fins. Clean the radiator with com-

WARNING pressed air or water as needed. Check for and remove
DO NOT remove the radiator cap from the radiator any debris on the radiator core. If the indicator light
when the engine is hot. When the radiator cap is turns on again after restarting, shut down the lift truck
removed, the pressure is released from the system. and do not operate the lift truck until the problem is cor-
If the system is hot, the steam and boiling coolant rected.
can cause burns.
Steering System
There is an indicator light on the Display Switch Cluster
for the coolant temperature. See Figure 21. The red
light is on when the key switch is in the START position, WARNING
and must go off when the engine is running. If the light is The lift truck has hydraulic power steering. The
on when the engine is running, the coolant and engine steering can be difficult if the engine is not running.
are too hot. Stop the engine and check the coolant level
in the auxiliary coolant reservoir. Make sure the steering system operates smoothly and
provides good steering control. Make sure the steering
Make sure the coolant level is between the ADD and column can be adjusted and the gas cylinder function
FULL marks on the auxiliary coolant reservoir. See Fig- is correct.
ure 23. The coolant will expand as it is heated and the
level in the auxiliary coolant reservoir will increase. Control Levers and Pedals
Check that the control levers for the transmission, mast,
CAUTION and attachment operate as described in the Operating
Additives may damage the cooling system. Before Manual. Check that the pedals operate correctly as
using additives, contact your local Yale dealer. described in the Operating Manual.
31
Lift System, Operate
WARNING
When working on or near the mast, see Safety Pro-
cedures When Working Near Mast at the end of this
section.
Lower the lift mechanism completely. Never allow

any person under a raised carriage. DO NOT put
any part of your body in or through the lift mech-
anism unless all parts of the mast are completely
lowered and the engine is STOPPED.
If the mast cannot be lowered, use chains on the

mast weldments and carriage so that they cannot
move. Make sure the moving parts are attached to
a part that does not move.
DO NOT try to find hydraulic leaks by putting hands

on pressurized hydraulic components. Hydraulic
oil can be injected into the body by the pressure.
Perform the following checks and inspections:
1. Check for leaks in the hydraulic system. Check the

condition of the hydraulic hoses and tubes.
NOTE: Some parts of the mast move at different speeds

during raising and lowering. 1. FILL CAP
3. FULL MARK
2. Slowly raise and lower the mast several times with- 4. ADD MARK
out a load. Raise the mast to its full height at least 5. COOLANT HOSES
once. The mast components must raise and lower 6. RADIATOR
smoothly in the correct sequence. Hose must track 7. RADIATOR CAP
properly during operation.
Figure 23. Auxiliary Coolant Reservoir
3. The inner weldments and the carriage must lower
completely. 5. Lower the load to approximately 0.3 m (1 ft). Tilt
the mast forward and backward. The mast must tilt
4. Raise the mast 1 m (3 ft) with a capacity load. smoothly and both tilt cylinders must stop evenly.
The inner weldments and the carriage must raise
smoothly. Lower the mast. All moving components 6. Check that the controls for the attachment oper-
must lower smoothly. ate the functions of the attachment. See the sym-
bols by each of the controls. Make sure all of the
hydraulic lines are connected correctly and do not
leak.
32
8000 YRM 1424 First Service After First 100 Hours of Operation
First Service After First 100 Hours of Operation

MAZDA FE AND F2 ENGINE OIL AND OIL
FILTER CHANGE
NOTE: The engine oil and oil filter must be changed
after the first 100 hours of operation for a newly installed
engine.
Change the engine oil and oil filter. See Figure 24. Ap-
ply clean oil to gasket of new filter. Install new filter.
Turn filter until gasket touches, then tighten 1/2 to 3/4
turn with your hand. Start engine. Check area around
oil filter for leaks.
YANMAR 2.6L ENGINE OIL AND OIL

FILTER CHANGE
Change the engine oil and oil filter. See Figure 25. Ap-
ply clean oil to gasket of new filter. Install new filter.
Turn filter until gasket touches, then tighten 1/2 to 3/4
turn with your hand. Fill engine with oil, as specified in
NOTE: BOTTOM VIEW OF ENGINE SHOWN.
Maintenance Schedule, until full mark reached on the
dipstick. Start engine. Check area around oil filter for 1. OIL FILTER 2. DRAIN PLUG
leaks, shut engine off and check oil dipstick, if low add
oil. Figure 24. Engine Oil and Oil Filter Change - Mazda
FE and F2
HYDRAULIC SYSTEM
Hydraulic Filter Element, Replace
Remove
WARNING
DO NOT permit the hot oil to touch the skin and
cause a burn.
NOTE: BOTTOM VIEW OF ENGINE SHOWN.

1. OIL FILTER 2. DRAIN PLUG
Figure 25. Engine Oil and Oil Filter Change -

Yanmar 2.6L
33
First Service After First 100 Hours of Operation 8000 YRM 1424
Install
CAUTION
DO NOT permit dirt to enter the hydraulic system 1. Lubricate sealing surfaces on filter housing head
when the oil level is checked or the filter is changed. with clean hydraulic oil.
Dirt can cause damage to the components of the
2. Lubricate new quad ring with clean hydraulic oil and
hydraulic system.
install onto head. See Figure 26.
3. Lubricate new O-ring with clean hydraulic oil and
install onto top of filter housing. See Figure 26.
4. Lubricate new O-ring with clean hydraulic oil and in-
CAUTION stall on bottom of new filter element. See Figure 26.
Disposal of lubricants and fluids must meet local 5. Install new filter element into bowl as noted during
environmental regulations. removal. See Figure 26.
1. Put lift truck on a level surface and lower carriage. 6. Lubricate new O-ring with clean hydraulic oil and
2. Unscrew and remove lid and spring from head. Re- install on lid. See Figure 26.
move and discard O-ring from lid. See Figure 26. 7. Install spring and lid onto head. See Figure 26.
NOTE: Use a container large enough to hold the filter Tighten lid to 14 N•m (124 lbf in).
element and allow for final hydraulic oil draining.
CAUTION
NOTE: Note placement of filter element and handle
prior to removal to aid in installation. Additives may damage the hydraulic system. Be-
fore using additives, contact your local Yale dealer.
3. Remove filter element from filter housing and place
in container. Cover head to prevent any foreign 8. Start the truck, and allow it to run for 30 seconds.
material from getting into the hydraulic tank. See Check for leaks. Stop engine and check hydraulic
Figure 26. oil level. Add oil, if necessary. Use hydraulic oil
shown in the Maintenance Schedule. To change
4. After filter element has drained, discard filter ele- the hydraulic oil, see Maintenance Procedures Ev-
ment and O-ring. ery 4000 Hours or 2 Years.
5. Remove and discard quad ring from head. See

Figure 26.
34
8000 YRM 1424 First Service After First 100 Hours of Operation

1. LID
2. SPRING
3. O-RING
4. FILTER ELEMENT
5. NUTS
6. CAPSCREW
7. FILTER HOUSING
8. QUAD RING
9. PLUG
10. HEAD
Figure 26. Hydraulic Oil Filter
35
Maintenance Procedures Every 250 Hours or 6 Months 8000 YRM 1424
Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform the Maintenance Procedures Every 8 Legend for Figure 27
Hours or Daily checks prior to performing the proce-
dures in this section. NOTE: BOTTOM VIEW OF ENGINE SHOWN.
1. OIL FILTER
MAZDA FE AND F2 ENGINE OIL AND OIL 2. DRAIN PLUG
FILTER CHANGE
MAZDA FE AND F2 ENGINE DRIVE BELT
CAUTION CHECK
Disposal of lubricants and fluids must meet local
environmental regulations. Fan and Alternator Drive Belt
NOTE: Change the oil and oil filter for the engine at the Check the drive belt for the fan and alternator for wear
first 100 hours of operation on new lift trucks. and damage.
Change the engine oil and engine oil filter. See Fig- Check tension by pushing on drive belt to check deflec-
ure 27. Remove drain plug and allow oil to drain into tion. See Figure 28. When pressure is 98 N (22 lbf), the
container. When oil is done draining, install drain plug. correct deflection is approximately 7 to 8 mm (0.3 in.).
Tighten drain plug to 30 to 41 N•m (22 to 30 lbf ft). Apply Loosen alternator support bracket to adjust tension of
clean oil to gasket of new filter. Install new filter. Turn fil- belt.
ter until gasket touches, then tighten 1/2 to 3/4 turn with
your hand. Fill engine oil, see Maintenance Schedule
for correct quantity and oil type. Start engine. Check
area around oil filter for leaks.
1. CHECK TENSION HERE

2. ALTERNATOR SUPPORT BRACKET
Figure 28. Drive Belt Check and Adjustment

Figure 27. Engine Oil and Oil Filter Change
36
8000 YRM 1424 Maintenance Procedures Every 250 Hours or 6 Months
DRAIN TAR FROM ELECTRONIC 12. Connect wire harness to fuel temperature sensor.
PRESSURE REGULATOR (EPR)
13. Connect negative battery cable and close hood.
NOTE: Draining the Electronic Pressure Regulator
14. Fill fuel tank with LPG fuel. See the Operating
(EPR) when engine is warm will help the oils flow freely
Manual for procedures.
from the regulator.
1. Warm engine to operating temperature.
2. Close fuel valve on tank and run engine until it runs

out of fuel and stops. Try to restart engine 2-3 times
until it no longer starts.
3. Turn the key to the OFF position.
4. Raise hood and disconnect negative battery cable.
5. Disconnect wire harness from fuel temperature

sensor.
6. Remove the electronic pressure regulator assem-

bly, see for procedures.
7. Remove the retaining pin in the fuel temperature

sensor and remove fuel temperature sensor from
the electronic pressure regulator. See Figure 29.
8. Using a suitable container, rotate the electronic

pressure regulator 90° so that the fuel temperature
sensor outlet fitting is pointing down and drain the
electronic pressure regulator.
9. Inspect and remove any tar or debris from the sec-

ondary chamber. 1. FUEL TEMPERATURE SENSOR
2. RETAINING PIN
10. Install fuel temperature sensor and retaining pin 3. ELECTRONIC PRESSURE REGULATOR (EPR)
into EPR. See Figure 29.
Figure 29. Mazda Emission Compliant EPR
11. Install the electronic pressure regulator assembly, Assembly
see for procedures.
37

NOTE: Perform the Maintenance Procedures Every 8 HYDRAULIC TANK BREATHER
Hours or Daily and the Maintenance Procedures Every
250 Hours or 6 Months prior to performing the proce- Inspect
dures in this section.
NOTE: When inspecting the breather, DO NOT remove
HYDRAULIC SYSTEM OIL it. If it is damaged, replace with a new breather element.
See Parts Manual for replacement part number.
WARNING 1. Remove right rear side panel. See Figure 30. See
At operating temperature, the hydraulic oil is HOT. service manual Frame 100 YRM 1423 for proce-
DO NOT permit the hot oil to touch the skin and dures.
cause a burn.
WARNING
CAUTION Compressed air can move particles so that they
DO NOT permit dirt to enter the hydraulic system cause injury to the user or to other personnel.
when the oil level is checked or the filter is changed. Make sure that the path of the compressed air is
Never operate the hydraulic pump without oil in the or a face shield to prevent injury to the eyes.
CAUTION
Direct air pressure on the filter element can cause
CAUTION damage. Direct air pressure away from filter ele-
Additives may damage the hydraulic system. Be- ment.
2. Using compressed air, remove any dirt and debris
Check the hydraulic oil level when the oil is at operat- in the frame cavity around the breather. See Fig-
ing temperature with the mast in a vertical position, the ure 30.
carriage lowered, and the engine stopped. See Fig-
ure 30. Add hydraulic oil only as needed. If hydraulic oil 3. Replace the breather if oil has accumulated in the
is above the FULL level, the hydraulic oil will leak from cavity or on the breather, or if dirt has accumu-
the breather during operation. The oil level indicated by lated at the breather passages at the bottom of the
the dipstick is most accurate when the oil temperature breather.
is 53 to 93°C (130 to 200°F).
4. Install right rear side panel. See service manual
Frame 100 YRM 1423 for procedures.
38
1. RIGHT REAR SIDE PANEL 3. HYDRAULIC OIL DIPSTICK

2. HYDRAULIC TANK BREATHER 4. HYDRAULIC OIL FILTER
Figure 30. Hydraulic Oil and Breather Check
39
BATTERY
WARNING
The acid in the electrolyte can cause injury. If the
electrolyte is spilled, use water to flush the area.
Use a solution of sodium bicarbonate (soda) to
make the acid neutral. Acid in the eyes must be
flushed with water immediately. Wear eye protec-
tion.
WARNING
Batteries generate explosive fumes. Keep the vents
in the caps clean. Keep sparks or open flame away
from the battery area. DO NOT make sparks from NOTE: BOTTOM VIEW OF ENGINE SHOWN.
the battery connections. Disconnect the battery
ground cable when doing maintenance. 1. OIL FILTER 2. DRAIN PLUG
Disconnect the negative and positive terminals of the Figure 31. Engine Oil and Oil Filter Change -
battery. Using a damp cloth clean the case of the bat- Yanmar 2.6L
tery. If the terminals are corroded, clean the terminals
with a wire brush. Connect the negative and positive YANMAR 2.6L ENGINE DRIVE BELT
cables to their respective terminals.
NOTE: The drive belt tension may be checked at any
YANMAR 2.6L ENGINE OIL AND OIL of the three positions A, B, or C shown in Figure 32
whichever is most easily accessible.
FILTER CHANGE
Check the drive belt for the fan and alternator for wear
NOTE: Change the oil and oil filter for the engine at the
and damage. Check tension by pushing on drive belt
first 100 hours of operation on new lift trucks.
with a force of 98 N (22 lbf) to check deflection at any
Change engine oil and engine oil filter. See Figure 31. one of three possible positions. See Figure 32. Check
Use the correct oil according to the Maintenance Table 2 for the correct deflection of the V-belt. Loosen
Schedule. Apply clean oil to gasket of new filter. Install alternator support bracket bolt to adjust tension of belt.
new filter. Turn filter until gasket touches, then tighten See Figure 33. When the tension of the V-belt is cor-
1\2 to 3\4 turn with your hand. Start engine. Check rect, tighten the alternator support bracket bold, and
area around oil filter for leaks. check the belt tension again.
Table 2. V-Belt Deflection Table
Used V-Belt Tension New V-Belt Tension

A B C A B C
10 to 13 mm 7 to 10 mm 8 to 13 mm 8 to 11 mm 5 to 8 mm 7 to 11 mm
(0.375 to 0.5 in.) (0.250 to (0.3125 to (0.3125 to (0.1875 to (0.250 to
0.375 in.) 0.5 in.) 0.4375 in.) 0.3125 in.) 0.4375 in.)
40
PCV VALVE
Remove the PCV valve (positive crankcase ventilation
valve) from the valve cover. See Figure 34. Check the
operation of the PCV valve by shaking the PCV valve
and listen for the check ball rattling inside. If the check
ball does not rattle, replace the PCV valve.
NOTE: RIGHT SIDE SHOWN.

1. PCV VALVE 2. ENGINE OIL FILL
Figure 34. PCV Valve Check

Figure 32. Yanmar Diesel Engine Drive Belt
CLEAN DEBRIS FROM RADIATOR CORE
Check the radiator core for restrictions and remove ma-
terial causing radiator core to be plugged or restricted.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
or a face shield to prevent injury to the eyes.
Clean with compressed air, adjusted to a maximum out-

put of 103 kPa (15 psi), and blow debris from core and
fan shroud.
TRANSMISSION OIL LEVEL

Run engine until it reaches operating temperature
1. SUPPORT BRACKET BOLT of 50°C (120°F). Shut down engine for one minute or
2. ALTERNATOR longer before checking the oil level. If transmission oil is
3. PRY BAR low, add oil to transmission at the dipstick to the correct
level as indicated on the dipstick. See Figure 35. Use
Figure 33. Yanmar Diesel Engine Drive Belt the correct oil as shown in the Maintenance Schedule.
Adjustment
41
1. TRANSMISSION 2. TRANSMISSION OIL DIPSTICK
Figure 35. Transmission Oil Level Check
FORKS NOTE: The load rollers and sheaves have sealed bear-
ings and do not need additional lubrication.
WARNING 1. Lubricate sliding surfaces and load roller surfaces
Never repair damaged forks. DO NOT heat, weld, along full length of channels as shown in Figure 37.
or bend the forks. Forks are made of special steel
using special methods. Replace damaged forks as NOTE: When lubricating the mast mounting, the load
a complete set. must be removed from the normal contact surface to
allow grease to properly lubricate the normal contact
Measure thickness of forks with a fork arm caliper (Yale surfaces of the mast bushings.
Part No. 150021700) at a vertical section where there is
no wear. This thickness is dimension X. Now measure 2. Raise the carriage about 61 cm (2 ft), and tilt the
thickness at heel of fork. See Figure 36. If the thick- mast fully back. Place blocks under the outer mast
ness of the heel is not greater than 90% of dimension channels to within 13 mm (0.5 in.) of the channels.
X, replace fork. See Figure 38.
MAST LUBRICATION 3. Tilt the mast fully forward. See Figure 38.
WARNING
When working on or near the mast, see Safety Pro-
cedures When Working Near Mast in this section.
42
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 37. Mast Lubrication

Fork Tip Alignment
Length of Forks 3% Dimension
915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.)
1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
1830 mm (72 in.) 55 mm (2.17 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Figure 36. Forks Check
43

A. MAST TILTED FULLY BACK
B. MAST TILTED FORWARD
1. BLOCK 2. MAST
4. Lubricate the mast pivot bushings at grease fittings

on outer mast. See Figure 39. Use multipurpose
grease shown in the Maintenance Schedule.
5. Tilt mast fully back. Remove the blocks from under

the channels.
6. If a sideshift carriage is installed, lubricate slid-

ing surfaces at grease fittings with multipurpose
grease shown in the Maintenance Schedule. See
Figure 40.
Figure 38. Blocking the Mast
44
1. LUBE FITTINGS 3. MAST HANGER BUSHINGS

2. OUTER BOTTOM CROSSMEMBER 4. MAST MOUNTING CAP
Figure 39. Mast Mounting Hanger Lubrication
45
NOTE: The 500 Hour/6 Months Lift Chain Lubrication

should not be performed in combination with the 1000
Hour/6 Months Lift Chain Lubrication.
Lubricate lift chains with SAE 30W engine oil. The best
procedure is to remove the chains from the lift truck and
soak them in engine oil. Be sure to clean any dirt or
grease from chains before lubricating. DO NOT USE
STEAM TO CLEAN THE LIFT CHAINS.
TILT CYLINDER LUBRICATION

NOTE: The floor plate and floor mat must be removed in
order to lubricate the rear tilt cylinder lubrication fittings.
Lubricate the tilt cylinder ends. Use multipurpose

grease shown in the Maintenance Schedule. There are
four lubrication fittings. See Figure 41.
1. UPPER BEARING MASTER CYLINDER ROD END PIN

2. LOWER HOOK LUBRICATION
3. LOAD ROLLER
4. SNAP RING Lubricate the master brake cylinder rod end pin. Use
5. SIDESHIFT CYLINDER engine oil as shown in the Maintenance Schedule. See
6. LOWER BEARING
7. SHIMS Figure 42.
8. INNER CARRIAGE
9. LUBE FITTING MANUAL HYDRAULIC LEVERS
10. OUTER FRAME LUBRICATION
Figure 40. Sideshift Carriage Lubricate the bushings for the manual hydraulic levers.
Use spray lubricant as listed in the Maintenance Sched-
HEADER HOSE CHECKS ule. See Figure 43.
Daily inspection plus; kinked, crushed flattened or
twisted hose; hard, stiff or charred hose; hose fitting BRAKE FLUID
slippage; proper hose tensioning. Adjust/repair/replace Remove the dashboard from the cowl. See service
hose/components as necessary. manual Frame 100 YRM 1423 for removal procedures.
The brake fluid reservoir is located on the cowl, at the
LIFT CHAIN LUBRICATION master cylinder. See Figure 44. Add brake fluid, as
necessary. Use the brake fluid specified in the Main-
WARNING tenance Schedule. After correct brake fluid has been
When working on or near the mast, see Safety Pro- added, install dashboard to cowl. See service manual
cedures When Working Near Mast in this section. Frame 100 YRM 1423 for installation procedures.
DO NOT repair worn or damaged lift chains. If a lift

chain is worn or damaged, both lift chains must be
replaced.
46
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 4. LUBRICATION FITTING
2. RETAINER 5. TILT SPACER
3. ANCHOR PIN
Figure 41. Tilt Cylinder Lubrication
PARKING BRAKE ADJUSTMENT

Before adjusting the parking brake, make sure the ser-
vice brakes are adjusted and the operation of the auto-
matic adjuster mechanism is correct. See Brake Sys-
tem 1800 YRM 1135 for procedures.
1. Turn the adjustment knob to raise the equalized link

and tighten the parking brake cables shown in Fig-
ure 45. DO NOT tighten the adjustment so that the
brake is applied when the lever is released. The
lever for the parking brake has a lock. Use your
thumb or finger to release the lock on the lever when
the parking brake is released.
2. For burnished brakes, test the operation of the park-

ing brake. The lift truck with a capacity load must
not move when parking brake is applied on a 15
percent grade [a slope that increases 1.5 m in 10 m
(1.5 ft in 10 ft)]. 1. ROD END PIN
2. COTTER PIN (LOCKING)
Figure 42. Master Brake Cylinder Rod End Pin

Lubrication
47
1. BRAKE FLUID RESERVOIR

1. BUSHING 2. MOUNTING BRACKET
2. LOCKING RING (COTTER PIN) 3. COWL
3. ROD END PIN
4. HYDRAULIC LEVERS Figure 44. Brake Fluid Reservoir
Figure 43. Manual Hydraulic Levers Lubrication
48

1. LOCK BUTTON RELEASE
2. OFF POSITION
3. ON POSITION
4. ADJUSTMENT KNOB
Figure 45. Parking Brake Adjustment
49
TIE ROD LUBRICATION Legend for Figure 46
Lubricate the tie rods. Use multipurpose grease speci- 1. STEERING AXLE
fied in the Maintenance Schedule. There are two lubri- 2. LUBRICATION FITTING
cation fittings on each tie rod. See Figure 46.
DIFFERENTIAL AND DRIVE AXLE OIL
The differential and drive axle use the same oil supply.
The oil level must be between 0 to 10 mm (0 to 0.40 in.)
below the bottom edge of fill hole. The fill hole for check-
ing the oil level is on the left side of differential cover.
See Figure 47. Remove fill plug and check fluid level by
sticking a finger into the fill hole to feel if the fluid level
is at the bottom edge of the fill hole. If oil is low, add oil
shown in the Maintenance Schedule until the oil level is
between 0 to 10 mm (0 to 0.40 in.) below the bottom
edge of fill hole. Install fill plug and check for leaks.
Figure 46. Tie Rod Lubrication
NOTE: DRIVE AXLE AND DIFFERENTIAL FOR LIFT TRUCK MODEL GLC050LX (A967) SHOWN. THE CHECK/
FILL PLUG AND DRAIN PLUG ARE IN SAME LOCATION ON DRIVE AXLE AND DIFFERENTIAL FOR LIFT TRUCK
MODEL GLP/GDP050LX (A974).
1. CHECK/FILL PLUG 3. DIFFERENTIAL COVER
2. DRAIN PLUG
Figure 47. Differential and Drive Axle Oil Check
50

NOTE: Perform the Maintenance Procedures Every 8 3. Remove the bolt and seal washer from the fuel filter
Hours or Daily, Maintenance Procedures Every 250 housing top section. Discard seal washer. See
Hours or 6 Months, and Maintenance Procedures Figure 48.
Every 500 Hours or 6 Months prior to performing the
procedures in this section. 4. Remove fuel filter housing top section from fuel filter
housing bottom section.
VALVE CLEARANCE, CHECK AND
5. Remove and discard housing O-ring.
ADJUST
6. Remove and discard fuel filter and fuel filter O-ring.
See the Maintenance Schedule for valve clearances.
Additional engine information can be found in the ser- Clean/Inspect
vice manual Mazda Engine, FE and F2 600 YRM 1122.
1. Clean and inspect the fuel filter housing top section
IGNITION SYSTEM - MAZDA FE AND F2 for contamination or damage. If damaged, replace
ENGINE the housing.
The Mazda engine used on lift trucks covered in this ser- 2. Clean and inspect the fuel filter housing bottom sec-
vice manual has an electronic ignition system. Change tion for contamination or damage. If damaged, re-
the spark plugs and check the timing every 1000 hours. place the housing.
The correct spark plug gap is shown in the Maintenance
Schedule. Install
The correct timing for the Mazda engine is shown in 1. Install the new fuel filter and fuel filter O-ring. See
the Maintenance Schedule. See the service manual Figure 48.
Mazda Engine, FE and F2 600 YRM 1122 for proce-
dures to adjust the timing. 2. Install new housing O-ring.
3. Install fuel filter housing top section onto fuel filter

LPG FUEL FILTER REPLACE - MAZDA FE housing bottom section.
AND F2 ENGINE
4. Install bolt and new seal washer. Tighten bolt to
Remove 13 N•m (115 lbf in).
NOTE: Opening the fuel valve too quickly can cause

WARNING the internal excess flow valve to close, restricting the
LPG can cause an explosion. DO NOT permit any flow of fuel. If this happens, close the fuel valve, wait a
sparks or open flames in the work area. few seconds, and then slowly open the fuel valve again.
This will reset the excess flow valve.
1. Close fuel valve on tank and run engine until it runs
out of fuel and stops. Try to restart engine 2-3 times 5. Slowly open the fuel valve on tank.
until it no longer starts.
6. Connect the negative battery cable.
2. Disconnect negative battery cable.
7. Turn the key to the ON position and back to the OFF
WARNING position to pressurize the fuel system. Check for
leaks.
A small amount of fuel may still be present in the
fuel line. Use gloves to prevent burns and wear eye 8. Check for leaks at connections by using soapy solu-
protection. If liquid fuel continues to flow from the tion or electron leak detector. If leaks are detected,
connections when loosened, check to make sure make proper repairs.
the manual valve is fully closed.
51
1. BOLT* 5. FUEL FILTER O-RING

2. SEAL WASHER 6. HOUSING O-RING
3. FUEL FILTER HOUSING TOP SECTION* 7. FUEL FILTER HOUSING BOTTOM SECTION*
4. FUEL FILTER 8. LOW PRESSURE SWITCH
*NOT SERVICED SEPARATELY
Figure 48. Mazda LPG Fuel Filter Removal/Installation
FUEL FILTER REPLACEMENT - YANMAR 3. Disconnect fuel filter sensor connector.

2.6L ENGINE
4. Place an approved container under the fuel filter.
CAUTION 5. Open the drain plug to drain fuel from the fuel filter.
6. Remove the fuel filter from the fuel filter head. Wipe
environmental regulations.
up any spilled fuel immediately.
Replace the fuel filter as specified intervals to prevent
7. Remove the drain plug from the fuel filter. Discard
contaminants from adversely affecting the diesel fuel
the O-ring.
flow.
8. Remove the fuel filter sensor from the fuel filter el-
NOTE: See Figure 49 for all steps in the following pro-
ement and discard the O-ring.
cedure.
9. Remove the inline fuel filter from the inlet nipple that
1. Stop the engine and allow it to cool.
goes to the fuel injection pump. See Figure 50.
2. Close all cocks in the line.
10. Dispose of the fuel, fuel filters, and O-ring in accor-
NOTE: Tag connectors prior to disconnecting to aid in dance with local directives.
reconnecting.
52

1. FUEL FILTER ASSEMBLY
2. FUEL FILTER ELEMENT
3. FUEL FILTER SENSOR CONNECTOR
4. FUEL FILTER HEAD
5. O-RING
6. DRAIN PLUG
7. FUEL FILTER SENSOR
8. INLINE FUEL FILTER
9. INLET NIPPLE
1. INLINE FUEL FILTER

2. FUEL LINE
3. WATER SEPARATOR/FUEL FILTER
4. FUEL SUPPLY VALVE
Figure 50. In-Line Fuel Filter Replacement
Figure 49. Yanmar Fuel Filter Replacement
53
11. Install the new inline fuel filter into the inlet nipple. LIFT CHAINS WEAR CHECK
12. Install the fuel filter sensor assembly in the new fuel If a section of chain is 3% longer than a similar sec-
filter using the new O-ring supplied with the fuel tion of new chain, the chain is worn and must be re-
filter. placed. Measure chain for wear where it moves over
sheaves. Using a chain scale, Yale P/N 518096869,
13. Install the new O-ring on the drain plug, and install check lift chains as shown in Figure 52.
the drain plug on the new fuel filter element. Hand
tighten only. LIFT CHAIN LUBRICATION
14. Clean the fuel filter head mounting surface and ap-
ply a small amount of diesel fuel to the gasket on WARNING
the new fuel filter element. Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
15. Install the new fuel filter element until it contacts vents, always follow the recommendations of the
the fuel filter head mounting surface. Tighten one manufacturer.
additional turn.
Compressed air can move particles so they cause
16. Open all the fuel cocks in the fuel line. injury to the user or to other personnel. Make sure
that the path of the compressed air is away from all
17. Reconnect the fuel filter sensor connector. personnel. Wear protective goggles or a face shield
18. Prime the fuel system. See Priming the Fuel Sys- to prevent injury to the eyes.
tem (Yanmar). Remove the lift chains. Clean the lift chains by soaking
19. Check for fuel leaks. them in a solvent that has a petroleum base for at least
30 minutes. Use compressed air, adjusted to a maxi-
PRIMING THE FUEL SYSTEM (YANMAR) mum output of 103 kPa (15 psi), to completely dry the
chains when they are clean.
1. Place an approved container under the air bleed
port. See Figure 51. Lubricate the lift chains by soaking them in SAE 30W
engine oil for at least 30 minutes. Remove the chains
2. Loosen the air bleed port 2 or 3 turns. from the oil. Hang the chains for one hour so excess oil
will drain from the chains.
CAUTION INTEGRAL SIDESHIFT CARRIAGE, CHECK
NEVER use the starter motor to crank the engine in BEARINGS
order to prime the fuel system. This may cause the
starter to overhead and damage the coils and/or the 1. Lower carriage completely and remove forks.
ring gear.
2. Remove backrest and the lower mounting hooks
3. Operate the fuel priming pump (see Figure 51) until from sideshift carriage. See Figure 53.
the fuel coming out of the air bleed port is free of
bubbles. 3. Use a lifting device with a capacity of at least 450 kg
(1000 lb) to lift outer frame away from inner car-
4. Tighten the air bleed port. riage.
5. Wipe up any fuel that may have spilled, and dispose
of the fuel and rags in accordance with local direc-
tives.
54
4. Clean bearing areas. Inspect sideshift bearings for Legend for Figure 51
wear as follows:
1. AIR BLEED PORT
a. If either upper bearing is worn to less than 2. FUEL PRIMING PUMP
2.5 mm (3/32 in.) thickness, replace both up-
per bearings by driving upper bearings out of
carriage bar.
b. If either lower bearing is worn to less than

2.5 mm (3/32 in.) thickness, replace both lower
bearings by prying lower bearings from lower
carriage bar.
STEERING AXLE
Lubricate the spindle bearings on the steering axle.
There are two lubrication fittings, one on each side of
the steering axle. See Figure 54. Use multipurpose
grease as shown in the Maintenance Schedule.
CONTROL LEVERS AND PEDALS

Lubricate linkages, pedal shafts, control cables (throttle,
hood, parking brake), rod end pins and seat rails. Use
a silicone spray lubricant, Yale Part No. 504236201.
Pitch Wear Limit
Total Length of
(The Maximum
20 Links (Pitch)
Length of 20
of New Chain
Links)
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.75 in.) (15.0 in.) (15.4 in.)
25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
1. CHAIN WEAR SCALE
Figure 52. Lift Chains Check
Figure 51. Priming the Fuel System
55
1. UPPER BEARING
2. LOWER HOOK
3. LOAD ROLLER
4. SNAP RING
5. SIDESHIFT CYLINDER
6. LOWER BEARING
7. SHIMS
8. INNER CARRIAGE
9. LUBE FITTING
10. OUTER FRAME
Figure 53. Integral Sideshift Carriage
A. GLC050LX (A967)
B. GLP/GDP050LX (A974)
1. STEERING AXLE
2. LUBRICATION FITTING
Figure 54. Lubricate Spindle Bearings
56
8000 YRM 1424 Maintenance Procedures Every 2000 Hours or Annually
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the Maintenance Procedures Every 8 NOTE: Use a container large enough to hold the filter
Hours or Daily, Maintenance Procedures Every 250 element and allow for final hydraulic oil draining.
Hours or 6 Months, Maintenance Procedures Every
500 Hours or 6 Months, and Maintenance Procedures NOTE: Note placement of filter element and handle
Every 1000 Hours or 6 Months prior to performing the prior to removal to aid in installation.
procedures in this section.
3. Remove filter element from filter housing and place
in container. Cover head to prevent any foreign
HYDRAULIC SYSTEM
material from getting into the hydraulic tank. See
Hydraulic Oil Filter Element, Replace Figure 55.
NOTE: The hydraulic oil filter element must be changed 4. After filter element has drained, discard filter ele-
after the first 100 hours of operation on new lift trucks. ment and O-ring.
Remove 5. Remove and discard quad ring from head. See

Figure 55.
WARNING Clean and Inspect

DO NOT permit the hot oil to touch the skin and 1. Clean housing and cover plate as necessary.
cause a burn.
2. Inspect filter housing, especially sealing surfaces,
for damage. Replace if damaged.
CAUTION
DO NOT permit dirt to enter the hydraulic system 3. Inspect dipstick plug. Replace O-ring and dipstick
when the oil level is checked or the filter is changed. plug as necessary.
Dirt can cause damage to the components of the
Install
hydraulic system.
1. Lubricate sealing surfaces on filter housing head
with clean hydraulic oil.
pump without oil will damage the pump. 2. Lubricate new quad ring with clean hydraulic oil and
install onto head. See Figure 55.
CAUTION 3. Lubricate new O-ring with clean hydraulic oil and
Disposal of lubricants and fluids must meet local install onto top of filter housing. See Figure 55.
4. Lubricate new O-ring with clean hydraulic oil and in-
1. Put lift truck on a level surface and lower carriage. stall on bottom of new filter element. See Figure 55.
2. Unscrew and remove lid and spring from head. Re- 5. Install new filter element into bowl as noted during
move and discard O-ring from lid. See Figure 55. removal. See Figure 55.
57
Maintenance Procedures Every 2000 Hours or Annually 8000 YRM 1424
6. Lubricate new O-ring with clean hydraulic oil and

install on lid. See Figure 55.
7. Install spring and lid onto head. See Figure 55.

Tighten lid to 14 N•m (124 lbf in).
CAUTION
Additives may damage the hydraulic system. Be-
8. Start the truck, and allow it to run for 30 seconds.

Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
shown in the Maintenance Schedule. To change
the hydraulic oil, see Maintenance Procedures Ev-
ery 4000 Hours or 2 Years.
Hydraulic Tank Breather, Replace

1. Raise the hood and remove the right rear side
panel. See service manual Frame 100 YRM 1423
for procedures to remove right rear side panel. See
Figure 56.
2. Unscrew and remove old hydraulic tank breather,

and replace with new hydraulic tank breather.
3. Install right rear side panel. See service manual

Frame 100 YRM 1423 for procedures to install right
rear side panel. Close hood. See Figure 56.
1. LID
2. SPRING
3. O-RING
4. FILTER ELEMENT
5. NUTS
6. CAPSCREW
7. FILTER HOUSING
8. QUAD RING
9. PLUG
10. HEAD
Figure 55. Hydraulic Filter
58
1. RIGHT REAR SIDE PANEL 3. HYDRAULIC OIL DIPSTICK

2. HYDRAULIC TANK BREATHER 4. HYDRAULIC OIL FILTER
Figure 56. Hydraulic Tank Breather
AIR FILTER 1. Shut off the engine. Never open the air filter can-
ister or remove the filter element with the engine
The air filter canister should not be opened until an air running.
filter element replacement is required. An air filter ele-
ment replacement is required when one of the following 2. Unlatch and remove the cover. See Figure 57. To
occurs: remove filter element, press and rotate filter ele-
• The optional manual air flow indicator button pops up ment counterclockwise about 1/8 turn until the filter
• The specified number of hours has passed since the element is free. To assist removal, gently move the
last filter element replacement end back and forth to help break the seal.
3. Gently pull the filter element from the canister.

CAUTION Avoid dislodging contaminants from the element or
DO NOT to allow dirt to enter the engine air in- knocking it against the canister.
take when replacing the air filter element. A small
amount of dirt could cause engine damage.
59
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 57. Air Filter
4. With a clean, soft rag, clean the inside surface of NOTE: Proper element installation is required to allow
the canister. Remove the liner assembly to make the cover to be installed correctly. Never reinstall a used
cleaning easier. Clean well around the locking tabs element. Never install a damaged element. Always use
that retain the element. Clean tabs make new filter a Yale approved filter element.
element installation easier. Be careful not to knock
any contaminants into the outlet tube to the engine. 8. Install the new filter element into the canister. Press
and rotate the filter element 1/8 turn clockwise until
5. Inspect the liner and O-ring assembly for damage. fully engaged in the canister. See Figure 58.
If damaged, replace the liner and O-ring assembly.
6. Install the liner assembly into the canister by push- CAUTION

ing in. Make sure the liner assembly is properly During cover installation, DO NOT force the cover
seated in the canister. It will fit snugly into and be on the canister. To do so will result in damage to
centered in the canister. the filter element, cover, and possibly the canister.
If your air filter assembly is equipped with a sec- NOTE: If the filter element is properly installed, the
ondary element in place of the liner assembly, re- cover will fit easily into the canister with no gap between
place the secondary element with every 2 to 3 pri- the cover and the canister. If the cover does not fit
mary element replacements. easily, the filter element is not installed properly. DO
NOT use a cover that is bent, damaged, or missing
7. Inspect the new filter element for voids, cuts, tears latches.
or indentations in the urethane-sealing surfaces.
Do not use if damage is detected. 9. Install the cover into the canister and ensure the
INLET arrow is in line with the canister inlet.
CAUTION NOTE: DO NOT use the latches to pull the cover down
The element must be properly installed to ensure against the canister. If the cover does not fit completely
adequate engine protection. An improperly in- against the canister with no gaps, the element is not
stalled element may allow dirt and dust to enter installed correctly.
and damage the engine.
60
FORKS
WARNING
Never repair damaged forks. DO NOT heat, weld,
cut, drill, or bend the forks. Forks are made of spe-
cial steel using special methods. Replace damaged
forks as a set.
Check heel and attachment points of forks with a pen-

etrant or by magnetic particle inspection.
FUEL INJECTOR, YANMAR ENGINES

1. PUSH IN 2. TWIST TO LOCK For removal and cleaning instructions, see the section
Yanmar Diesel Engines, 2.6L, 3.0L and 3.3L 600
Figure 58. Air Filter Label YRM 1205.
10. Fasten the latches to secure the cover to the can-
ister. Make sure the latches penetrate the slots in
INTEGRAL SIDESHIFT CARRIAGE
both the canister and the cover.
Bearings, Replace
11. Inspect the entire air intake system for leaks. In-
Replace all four bearings regardless of wear. See the
spect all clamps for tightness and tighten if neces-
section, Maintenance Procedures Every 1000 Hours or
sary. Inspect all hoses for damage. Replace dam-
6 Months for the procedure.
aged hoses. Inspect the dust evacuation valve for
damage. If damaged, replace the dust evacuation
valve.
PCV VALVE
Install a new PCV valve. See Figure 59.
OXYGEN SENSOR
Check the oxygen sensor electrical connector to ensure
it is seated and locked. Check wires for cracks, splits,
chaffing, or burn through. If necessary, repair or replace
with new oxygen sensor. See Figure 60.
TIMING BELT
Change timing belt after 3500 hours of operation. The 1. PCV VALVE 2. ENGINE OIL FILL
cover for the timing belt must be removed for checks
and adjustments. See Mazda Engine, FE and F2 600 Figure 59. PCV Valve Replacement
YRM 1122 for more information on the timing belt.
61
1. MUFFLER
2. POST-CATALYTIC CONVERTER OXYGEN SENSOR
3. PRE-CATALYTIC CONVERTER OXYGEN SENSOR
4. EXHAUST PIPE (EXHAUST MANIFOLD TO CATALYTIC CONVERTER)
5. EXHAUST PIPE (CATALYTIC CONVERTER TO MUFFLER)
6. CATALYTIC CONVERTER
Figure 60. Oxygen Sensors
62
TRANSMISSION OIL AND OIL FILTER, See Figure 61 for lift trucks manufactured before
REPLACE July, 2013
Remove See Figure 62 for lift trucks manufactured after July,

2013
WARNING See Figure 63 for lift trucks manufactured before
At operating temperature, the transmission oil is July, 2013
HOT. DO NOT permit the hot oil to touch the skin
and cause a burn. See Figure 64 for lift trucks manufactured after July,
2013
CAUTION 3. Remove suction screen spring and suction screen.

DO NOT permit dirt to enter the transmission when
the oil level is checked or the filter is changed. Dirt See Figure 61 for lift trucks manufactured before
can cause damage to the transmission compo- July, 2013
nents. See Figure 62 for lift trucks manufactured after July,
2013
CAUTION
Disposal of lubricants and fluids must meet local See Figure 63 for lift trucks manufactured before
environmental regulations. July, 2013
NOTE: Change the transmission oil filter at the first 500 See Figure 64 for lift trucks manufactured after July,
hours of operation on new lift trucks. 2013
1. Remove drain plug. and . When oil is completely 4. Remove flange head capscrews and hydraulic gear
drained, install drain plug. pump.
See Figure 61 for lift trucks manufactured before See Figure 61 for lift trucks manufactured before
July, 2013 July, 2013
See Figure 62 for lift trucks manufactured after July, See Figure 62 for lift trucks manufactured after July,
2013 2013
See Figure 63 for lift trucks manufactured before See Figure 63 for lift trucks manufactured before
July, 2013 July, 2013
See Figure 64 for lift trucks manufactured after July, See Figure 64 for lift trucks manufactured after July,
2013 2013
2. Remove capscrews, lock washers, charge pump, 5. Remove and discard transmission oil filter.
and charge pump gasket. Discard gasket.
63
1. TRANSMISSION
1. TRANSMISSION 2. TRANSMISSION OIL FILTER
2. TRANSMISSION OIL FILTER 3. TRANSMISSION DIPSTICK
3. TRANSMISSION DIPSTICK 4. TRANSMISSION BREATHER
4. TRANSMISSION BREATHER 5. TRANSMISSION DRAIN PLUG
5. TRANSMISSION DRAIN PLUG 6. SUCTION SCREEN
6. SUCTION SCREEN 7. SUCTION SCREEN SPRING
7. SUCTION SCREEN SPRING 8. CHARGE PUMP GASKET
8. CHARGE PUMP GASKET 9. CHARGE PUMP
9. CHARGE PUMP 10. WASHER
10. WASHER 11. CAPSCREW
11. CAPSCREW 12. FLANGE HEAD CAPSCREW
12. FLANGE HEAD CAPSCREW 13. HYDRAULIC GEAR PUMP
13. HYDRAULIC GEAR PUMP
Figure 62. Transmission Oil Filter Change -
Figure 61. Transmission Oil Filter Change - Aluminum Gear Drive, Lift Trucks Manufactured
Aluminum Gear Drive, Lift Trucks Manufactured After July, 2013
Before July, 2013
64
1. TRANSMISSION 1. TRANSMISSION
2. TRANSMISSION OIL FILTER 2. TRANSMISSION OIL FILTER
3. TRANSMISSION DIPSTICK 3. TRANSMISSION DIPSTICK
4. TRANSMISSION BREATHER 4. TRANSMISSION BREATHER
5. TRANSMISSION DRAIN PLUG 5. TRANSMISSION DRAIN PLUG
6. SUCTION SCREEN 6. SUCTION SCREEN
7. SUCTION SCREEN SPRING 7. SUCTION SCREEN SPRING
8. CHARGE PUMP GASKET 8. CHARGE PUMP GASKET
9. CHARGE PUMP 9. CHARGE PUMP
10. WASHER 10. WASHER
11. CAPSCREW 11. CAPSCREW
12. FLANGE HEAD CAPSCREW 12. FLANGE HEAD CAPSCREW
13. HYDRAULIC GEAR PUMP 13. HYDRAULIC GEAR PUMP
Figure 63. Transmission Oil Filter Change - Figure 64. Transmission Oil Filter Change -
Aluminum Chain Drive, Lift Trucks Manufactured Aluminum Chain Drive, Lift Trucks Manufactured
Before July, 2013 After July, 2013
65
Clean and Inspect 2. Using seven washers and seven capscrews in-
stall new charge pump gasket and charge pump.
Tighten capscrews to 19 N•m (168 lbf in).
WARNING
Cleaning solvents can be flammable and toxic and 3. Apply a 3 to 5 mm (0.12 to 0.20 in.) bead of sealant
can cause skin irritation. When using cleaning to either hydraulic gear pump or transmission
solvents, always follow the solvent manufacturer’s housing face. Hold pump in the correct position on
recommended safety procedures. the transmission. Install flange head capscrews
into pump and transmission housing. Tighten cap-
Compressed air can move particles so they cause screws to 38 N•m (28 lbf ft).
injury to the user or to other personnel. Make sure
the path of the compressed air is away from all per- See Figure 61 for lift trucks manufactured before
sonnel. Wear protective goggles or a face shield to July, 2013
prevent injury to the eyes.
See Figure 62 for lift trucks manufactured after July,
1. Clean suction screen spring and suction screen 2013
with cleaning solvent and dry with compressed air.
Inspect spring and screen for damage. Replace if See Figure 63 for lift trucks manufactured before
damaged. July, 2013
2. Wipe exterior surfaces of transmission housing, hy- See Figure 64 for lift trucks manufactured after July,
draulic gear pump, and charge pump with solvent 2013
soaked cloth and dry with a lint-free cloth. Inspect
housing and pumps for damage. Replace if dam- 4. Apply clean oil to gasket of new transmission oil
aged. filter and install filter onto transmission.
3. Clean metal threaded components with solvent and See Figure 61 for lift trucks manufactured before
dry with compressed air. Clean plastic threaded July, 2013
components with warm soapy water and dry with See Figure 62 for lift trucks manufactured after July,
a lint-free cloth. Inspect components for damage. 2013
Replace if damaged.
See Figure 63 for lift trucks manufactured before
4. Clean and inspect transmission oil breather. If July, 2013
breather is worn or damaged, replace with new
breather. See Parts Manual. See Figure 64 for lift trucks manufactured after July,
2013
Install
5. Add oil to transmission at dipstick tube. The correct
1. Install suction screen and suction screen spring. oil is shown in the Maintenance Schedule.
See Figure 61 for lift trucks manufactured before 6. Start and run engine for approximately five minutes
July, 2013 after fill to allow oil to lubricate parts within trans-
mission.
2013 NOTE: Transmission oil temperature should be at least
50°C (120°F) when checking oil level.
See Figure 63 for lift trucks manufactured before
July, 2013 7. Turn key to OFF position, check for leaks, and
check oil level. Top off oil, if necessary.
2013
66
BRAKE FLUID CHANGE Legend for Figure 65
1. Remove the dashboard from the cowl. See service 1. BRAKE FLUID RESERVOIR
manual Frame 100 YRM 1423 for removal proce- 2. RESERVOIR HOLDER
3. COWL
dures. 4. COVER
5. BRAKE HOSE
CAUTION 6. MASTER CYLINDER
7. BRAKE FLUID SWITCH
Disposal of lubricants and fluids must meet local 8. MOUNTING BRACKET
3. Remove the brake fluid reservoir cover and cylin-
2. Disconnect brake fluid switch from chassis wire har- drical block drain plug. Pour the fluid into a suitable
ness. Disconnect brake hose from master cylin- container with a 0.25 liter (0.53 pt) minimum capac-
der. Remove the brake fluid reservoir from mount- ity. Install the cylindrical block drain plug. Refill the
ing bracket on the cowl. See Figure 65. reservoir with clean fluid from a sealed container
and install the cover on the reservoir. The correct
fluid is shown in the Maintenance Schedule.
4. Install the brake fluid reservoir onto mounting

bracket located on cowl. Connect brake hose and
switch. See Figure 65.
5. Connect brake hose to master cylinder. Connect

brake fluid switch to chassis wire harness.
6. Install the dashboard to the cowl. See service man-

ual Frame 100 YRM 1423 for installation proce-
dures.
7. Put one end of a rubber hose on the bleeder screw

of the wheel cylinder. See Figure 66. Put the other
end of the hose into a empty container.
8. Loosen the bleeder screw at the wheel cylinder one

turn so that the used brake fluid can be removed
from the brake system. Slowly push the brake pedal
and hold it at the end of its stroke. Close the bleeder
screw. Release the brake pedal.
NOTE: The new brake fluid will be easily recognized,

as the color will be more clear than the used fluid which
will be darker.
9. Repeat Step 7 and Step 8 until there is new brake

fluid in the container.
10. Check the level of the brake fluid in the brake fluid
reservoir for the master cylinder during the proce-
dure. Make sure to keep the brake fluid at the cor-
rect level.
11. Repeat the procedure for the other wheel cylinder.
Figure 65. Brake Fluid Change
67
to brake linings must be done in a restricted area

with special ventilation. Protective clothing and a
respirator must be used.
Brake cleaning procedures are as follows:
CAUTION
DO NOT use an oil solvent to clean the wheel cylin-
der. Use a solvent approved for cleaning of brake
parts. DO NOT permit oil or grease in the brake fluid
or on the brake linings.
1. DO NOT release brake lining dust from brake lin-

ings into the air when brake drum is removed.
2. Use a solvent approved for cleaning of brake parts

to wet lining dust. Follow the instructions and cau-
tions of the manufacturer for the use of the solvent.
1. BLEEDER SCREW If a solvent spray is used, DO NOT create brake lin-
2. BRAKE TUBE ASSEMBLY
ing dust with the spray.
Figure 66. Brake Fluid Removal
3. When the brake lining dust is wet, clean parts. Put
any cloth or towels in a plastic bag or an airtight
SERVICE BRAKES
container while they are still wet. Put a DANGER-
Check brake lining and parts of the brake assembly for OUS FIBERS warning label on the plastic bag or
wear or damage. The minimum acceptable brake lining airtight container.
thickness is 1.0 mm (0.040 in.). If the brake linings are
4. Any cleaning cloths that will be washed must be
worn thinner than the specification, replace the brake
cleaned so that fibers are not released into the air.
linings. See Brake System 1800 YRM 1135 for pro-
cedures. If the brake linings or brake shoes are worn
DRIVE AXLE AND DIFFERENTIAL OIL,
or damaged, they must be replaced. Brake shoes must
be replaced in complete sets. Inspect brake drums for CHANGE
cracks or damage. Replace any damaged parts.
NOTE: Additional information on the drive axle and dif-
ferential can be found in the section Drive Axle and
WARNING Differential Assembly Repair 1400 YRM 1426.
Brake linings can contain dangerous fibers.
Breathing the dust from these brake linings is 1. Place the lift truck on blocks. See the General sec-
a cancer or lung disease hazard. DO NOT create tion in this manual for procedures.
dust! DO NOT clean brake parts with compressed 2. Place a container with a minimum capacity of 5 liter
air or by brushing. Follow the cleaning procedure (5.3 qt) under the differential. Remove the drain
in this section. When the brake drums are removed, plug located in the bottom of the differential and
DO NOT create dust. drain the oil from the differential completely. Install
DO NOT sand, grind, chisel, hammer, or change lin- the drain plug. See Figure 67.
ings in any way that will create dust. Any changes
68
1. CHECK/FILL PLUG 3. DIFFERENTIAL

2. DRAIN PLUG
Figure 67. Drive Axle and Differential Oil Change
3. The fill hole for checking the oil level is on the left WHEEL BEARINGS
side of differential cover. See Figure 67 and Fig-
ure 68. Add oil shown in the Maintenance Schedule Steer Wheels, Lubrication
until the oil level is 0 to 10 mm (0 to 0.39 in.) below
bottom edge of the fill hole. See Figure 68. Install Lubricate the wheel bearings in the hubs for the steer
fill plug and rotate the drive wheels in order to get wheels with multipurpose grease as shown in the Main-
oil pumped into the axle. Remove the fill plug and tenance Schedule. See Steering Axle 1600 YRM 1425
check the oil level. Add oil, as necessary. Install for procedures.
the fill plug and check for leaks.
69

A. LEFT SIDE VIEW
B. FRONT VIEW
1. OIL FILL PLUG
2. OIL FILL LEVEL
3. DRIVE AXLE CENTER SECTION
Figure 68. Drive Axle and Differential Oil Fill Level
70
8000 YRM 1424 Maintenance Procedures Every 4000 Hours or 2 Years
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the Maintenance Procedures Every 8 NOTE: Replace the hydraulic oil filter at the same time
Hours or Daily, Maintenance Procedures Every 250 the oil is changed.
Hours or 6 Months, Maintenance Procedures Every
500 Hours or 6 Months, Maintenance Procedures 1. Replace the hydraulic oil as described below:
Every 1000 Hours or 6 Months, and Maintenance
a. Place a container with a minimum capacity of
Procedures Every 2000 Hours or Annually before per-
30.1 liter (32 qt) under the drain plug at the
forming the procedures in this section.
bottom of the hydraulic tank. To drain the oil,
remove the drain plug from the bottom of the
HYDRAULIC OIL, CHANGE
hydraulic tank. See Figure 69.
WARNING b. When the tank is empty, inspect the inside of

At operating temperature the hydraulic oil is HOT. the tank for any foreign matter or possible fun-
DO NOT permit the hot oil to touch the skin and gus. If necessary, clean the inside of the tank
cause a burn. in accordance with the instructions found in the
section Frame 100 YRM 1423.
CAUTION c. When either the inspection or the cleaning of
DO NOT permit dirt to enter the hydraulic system the tank is completed, install the drain plug in
when the oil level is checked or the filter is changed. the bottom of the hydraulic tank. Tighten drain
Dirt can cause damage to the components of the plug to 38 N•m (28 lbf ft).
hydraulic system.
Never operate the hydraulic pump without oil in the CAUTION

hydraulic system. The operation of the hydraulic Additives may damage the hydraulic system. Be-
pump without oil will damage the pump. fore using additives, contact your local Yale dealer.
2. Fill hydraulic tank with oil specified in the Mainte-

CAUTION nance Schedule.
environmental regulations. 3. When the oil level is correct, operate system and
check for leaks.
NOTE: Heavy-duty or contaminated applications will re-
quire hydraulic oil change at 2000 hours.
71
Maintenance Procedures Every 4000 Hours or 2 Years 8000 YRM 1424
1. DRAIN PLUG 3. HYDRAULIC TANK BREATHER

2. HYDRAULIC TANK
Figure 69. Hydraulic Oil Change
72
8000 YRM 1424 Maintenance Procedures Every 4000 Hours or 2 Years
COOLING SYSTEM 5. Disconnect the hose leading from the auxiliary

reservoir to fitting at the top of the radiator un-
1. Put lift truck on a level surface. Stop engine. Place der the radiator cap, and drain the reservoir into
a container with a minimum capacity of 30.1 liter the same container used for the radiator coolant.
(32 qt) under the radiator drain valve which is lo- Check the reservoir for contaminants and flush, as
cated on the lower left side of the radiator on the necessary. Connect the hose back on the fitting at
engine side of the radiator. See Figure 70. the top of the radiator. See Figure 70.
WARNING CAUTION
DO NOT remove the radiator cap from the radiator Additives may damage the cooling system. Before
when the engine is hot. When the radiator cap is using additives, contact your local Yale dealer.
removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant 6. Close drain valve. Fill cooling system with the cor-
can cause burns. DO NOT remove the cover for the rect coolant mixture, use Ethylene Glycol Boron-
radiator when the engine is running. free Antifreeze. Purchase a pre-diluted 50/50 so-
lution; or mix 50% concentrate with 50% distilled
water or deionized water. Fill the auxiliary reservoir
CAUTION
to a level between the ADD and FULL marks on the
Disposal of lubricants and fluids must meet local reservoir.
7. Install radiator cap. Start engine. Check for
2. Open drain valve and remove radiator cap. Drain leaks. Add coolant to auxiliary coolant reservoir as
coolant into the container. needed. Coolant level should be between the ADD
3. Flush cooling system. See service manual Cooling and FULL marks on the reservoir. See Figure 70.
System 700 YRM 1123 for procedures.
4. Check hoses for damage. Replace with new hoses,

as needed.
73
Maintenance Procedures Every 4000 Hours or 2 Years 8000 YRM 1424
NOTE: COOLING SYSTEM FOR LIFT TRUCK MODELS GLC050LX (A967) SHOWN. COOLING SYSTEM FOR
LIFT TRUCK MODELS GLP/GDP050LX (A974) IS THE SAME.
1. DRAIN VALVE 5. FULL MARK
2. RADIATOR 6. AUXILIARY RESERVOIR
3. AUXILIARY RESERVOIR HOSE 7. ADD MARK
4. RADIATOR CAP
Figure 70. Radiator Coolant Change
74
8000 YRM 1424 Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast

The following procedures must be used when inspect- OR
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re- 2. If parts of the mast must be in a raised position,
moving the mast. See the service manual section Mast install a safety chain to restrain the moving parts of
Repair 4000 YRM 1431 for more information. the mast. Connect moving parts to a part that does
not move. Follow these procedures:
WARNING a. Put mast in vertical position.

Mast parts are heavy and can move. Distances be-
tween parts are small. Serious injury or death can b. Raise mast to align bottom crossmember of
result if part of the body is hit by parts of the mast weldment that moves in outer weldment with
or the carriage. a crossmember on outer weldment. On the
two-stage and free-lift mast, the moving part is
• Never put any part of the body into or under the the inner weldment. On the three-stage mast,
mast or carriage unless all parts of the mast are it is the intermediate weldment. See Figure 71.
completely lowered or a safety chain is installed.
Also make sure that the power is off and the key c. Use a 3/8-in. minimum safety chain with a
is removed. Put a DO NOT OPERATE tag in the hook to fasten the crossmembers together so
operator’s compartment. the movable member cannot lower. Put the
• Be careful of the forks. When the mast is raised, hook on the back side of the mast. Make sure
the forks can be at a height to cause an injury. the hook is completely engaged with a link in
• DO NOT climb on the mast or lift truck at any time. the chain. Make sure the safety chain does
Use a ladder or personnel lift to work on the mast. not touch lift chains or chain sheaves, tubes,
• DO NOT use blocks to support the mast weld- hoses, fittings, or other parts on the mast.
ments nor to restrain their movement. d. Lower the mast until there is tension in the
• Mast repairs require disassembly and removal of safety chain and the free-lift cylinder (free-lift,
parts and can require removal of the mast or car- three-stage, and four-stage masts only) is com-
riage. Follow the repair procedures in the correct pletely retracted. If running, stop engine. Apply
Service Manual for the mast. parking brake. Install a DO NOT REMOVE tag
NOTE: If there is no power to lower the mast, there is on the safety chain(s).
an emergency load lowering valve located on the hoist/ e. Install another safety chain (3/8-in. minimum)
lower valve section of the main control valve. See the between the top or bottom crossmember of the
Operating Manual for the procedures to lower a load carriage and a crossmember on the outer weld-
using the emergency load lowering valve. ment.
1. Lower mast and carriage completely. Push lift/lower 3. Apply parking brake. After lowering or restraining
control lever forward and make sure there is no the mast, shut off power and remove key. Put a DO
movement in the mast. Make sure all parts of the NOT OPERATE tag in the operator’s compartment.
mast that move are fully lowered.
75
Safety Procedures When Working Near Mast 8000 YRM 1424
A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST

B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST
Figure 71. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
76
8000 YRM 1424 Hood Latch Check
Hood Latch Check

3. Carefully close hood to fully-closed position. The
WARNING hood latch has two positions. The hood latch is fully
The hood, hood latch, and latch striker must be cor- closed after two clicks of the latch.
rectly adjusted for the correct operation of the op-
erator restraint system. 4. Push down until hood just touches rubber bumper.
Make sure latch striker is still in center of hood latch.
1. Install hood latch on frame of hood. See Figure 72. Open hood and tighten capscrews for latch.
Tighten capscrews so that hood latch can still move
when hood is closed. 5. Check operation of hood latch. Have an opera-
tor sit in the seat. Make sure hood is fully closed
2. Install latch striker in highest slot position. Check (two clicks). Also check that hood touches rubber
that latch striker is in center of jaws of hood latch bumper. If necessary, repeat Step 4.
when hood closes.
1. LATCH STRIKER 4. HOOD RELEASE HANDLE

2. BUMPER 5. HOOD LATCH
3. HOOD 6. FRAME
Figure 72. Hood Latch Check
77
Lift Chain Adjustments 8000 YRM 1424
Lift Chain Adjustments

fully lowering (see Safety Procedures When Working
WARNING Near Mast). With slack chain(s), check locknut torque.
When working on or near the mast, see Safety Pro- If 2.5 N•m (22.1 lbf in) for 1/2-20, 4.5 N•m (39.8 lbf in)
cedures When Working Near Mast in this section. for 5/8-18 nuts, 6.0 N•m (53.1 lbf in) for 3/4-16 of torque
cannot be reached; replace locknut. The chain an-
Never allow anyone under a raised carriage. DO
chors, after adjustment, must be able to move on their
NOT put any part of your body in or through the lift
mountings.
mechanism unless all parts of the mast are com-
pletely lowered and the engine is STOPPED. 1. When adjusting lift chains on forklift trucks
equipped with the forks installed, go to Step 2.
DO NOT try to find hydraulic leaks by putting your
If forklift truck is equipped with an attachment with-
hand on hydraulic components under pressure.
out forks, go to Step 3.
Hydraulic oil can be injected into the body by the
pressure. NOTE: Prior to performing adjustment procedures,
make sure forklift truck is parked on a level surface and
During test procedures for the hydraulic system,
the mast is in the vertical position.
fasten the load to the carriage with chains to pre-
vent it from falling. Keep all personnel away from 2. Adjust chain anchors which support the carriage
the lift truck during the tests. until bottom of the fork heel is 12 +3.0/ 6.0 mm
(0.47 +0.12/ 0.24 in.) above floor level. See Fig-
When lift chains are correctly adjusted:
ure 73.
• Tension will be the same on each chain of chain set.
Check tension by pushing on both chains at the same 3. Adjust chain anchors which support carriage until
time. the bottom of lower carriage bar is above the floor
• Chain length will be correct. level as shown in Table 3. See Figure 74.
• Chains must travel freely through complete cycle.
In Table 3, the masts are divided by class. Each
NOTE: When the lift chain adjustments are complete, class is determined by the lifting capability of the
make sure the threads on the nuts of the chain anchors lift cylinders. The Class II mast would have the
are completely engaged. Inspect the torque of the pre- lift capability of 2.5-3.5 tons, Class III has the lift
vailing torque nut (locknut) used to adjust the chain an- capability of 3.5-4.0 tons, and Class IV has the lift
chor with every lift chain adjustment. After carriage and capability of 4.0-7.0 tons.
or mast section(s) are adjusted for proper ground clear-
ance, prevent the carriage and or mast section(s) from
78
8000 YRM 1424 Lift Chain Adjustments
1. MAST
2. CARRIAGE 1. MAST
3. FORK 2. CARRIAGE
4. HEEL OF FORK IS 12 +3.0/ 6.0 mm (0.47 3. DISTANCE FROM FLOOR TO LOWER
+0.12/ 0.24 in.) ABOVE THE FLOOR LEVEL. CARRIAGE BAR
Figure 73. Lift Chain Adjustments With Forks Figure 74. Lift Chain Adjustment Without Forks
Installed Installed
Table 3. Carriage Chain Adjustment,

Forks Not Installed
82.5 ±3 mm
Class II and Class III
(3.25 ±0.12 in.)
133.5 ±3 mm
Class IV
(5.26 ±0.12 in.)
79
Welding Repairs 8000 YRM 1424
Jump-Starting the Lift Truck

JUMP-STARTING USING A BATTERY JUMP-STARTING A LIFT TRUCK USING
CHARGER ANOTHER LIFT TRUCK
CAUTION WARNING
DO NOT try to start the engine by pushing or towing To prevent possible arcing between the two lift
the lift truck. Damage to the hydraulic system can trucks, make sure that the lift trucks are not touch-
occur if engine is started by pushing or towing lift ing.
truck.
If the battery becomes discharged and requires a CAUTION

booster battery to start the engine, follow these proce- DO NOT try to start the engine by pushing or towing
dures carefully when connecting the jumper cables. the lift truck. Damage to the hydraulic system can
occur if engine is started by pushing or towing lift
1. Disconnect the negative battery terminal of the lift truck.
truck being started.
1. Always connect positive jumper cable to positive
2. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper
terminal of discharged battery and negative jumper cable to negative terminal.
cable to negative terminal.
2. Always connect jumper cable, that is the ground
3. Always connect jumper cable, that is the ground cable, last.
cable, last.
3. Always connect jumper cables to discharged
4. Always connect jumper cables to discharged bat- lift truck battery before connecting them to the
tery before connecting them to booster battery. fully-charged lift truck battery.
Welding Repairs
Forklift frames and components may be painted
WARNING with a catalyzed paint such as polyurethane or a
Welding can cause a fire or an explosion. Always two-part primer. Welding, burning, or other heat
follow the instructions in the Frame section if a fuel sufficient to cause thermal decomposition of the
or hydraulic tank must be welded. Make sure there paint may release isocyanates. These chemicals
is no fuel, oil, or grease near the weld area. Make are allergic sensitizers to the skin and respiratory
sure there is good ventilation in the area where the tract and overexposure may occur without odor
welding must be done. warning. Should work be performed, utilize good
industrial hygiene practices including removal
DO NOT heat, weld, or bend forks. Forks are
of all paint (prime and finish coats) to the metal
made of special steel using special methods. The
around the area to be welded, local ventilation,
strength of the overhead guard can be reduced
and/or supplied-air respiratory protection.
by welding or heating. Get information from your
dealer for Yale lift trucks before welding on a mast.
80
8000 YRM 1424 Wheels and Tires Replacement
prevent damage to a bearing from the large current

CAUTION from the welder.
When an arc welder is used, always disconnect the
ground cable from the battery in the lift truck. This Some repairs require welding. If an acetylene or arc
action will prevent damage to the alternator or the welder is used, make sure procedures in previous
battery. WARNING and CAUTION are done.
Connect the ground clamp for the arc welder as See the American National Standard Safety in Welding
close as possible to the weld area. This action will and Cutting, AWS Z 49.1 - 1999.
Overhead Guard Changes

See your dealer for Yale lift trucks BEFORE perform-
WARNING ing any changes to the overhead guard.
DO NOT weld mounts for lights or accessories to
the legs of the overhead guard. Changes that are No welding or drilling on legs of overhead guard is per-
made by welding or by drilling holes that are too big mitted as per previous WARNING.
or in the wrong location can reduce the strength of
the overhead guard.
Wheels and Tires Replacement

GENERAL it can have lugs. DO NOT mix types of tires or tread on
lift truck.
The GC series lift trucks covered in this manual have
solid rubber tires (often called cushion tires) that are 1. Raise lift truck as described in How to Put Lift Truck
pressed onto the rim. The series lift trucks covered in on Blocks in this manual.
this manual have pneumatic tires or solid rubber tires
that look like pneumatic tires. These variations in the 2. Remove wheel nuts and remove wheel from lift
tires also cause a variation in the types of wheels and truck. Lift truck wheels are heavy.
the disassembly and assembly procedures.
Remove and Install Tire on Wheel
HOW TO CHANGE SOLID RUBBER TIRE
1. The correct tools, equipment, and a press ring must
be used for each size of wheel. Use a press to push
WARNING wheel from rim and tire. The capacity of the press
The type of solid rubber tire is shown on the Name- must be approximately 355 to 1779 kN (80,000 to
plate. Make sure the Nameplate is correct for type 400,000 lb). For the tire sizes, see Nameplate.
of tires on lift truck.
NOTE: Make sure tires are installed on wheels so out-
Wheels must be changed and tires repaired by side edges of tire and wheel are as shown in Figure 75.
trained personnel only. Also, check Nameplate of lift truck for correct tire size
and tread width.
Always wear safety glasses.
2. When drive wheels are installed on lift truck, tighten
NOTE: Solid rubber tires made from softer or harder wheel nuts in a cross pattern to a torque value of
material can be installed as optional equipment. The 155 to 175 N•m (114 to 129 lbf ft).
tread on the solid rubber tires can be either smooth or
81
Wheels and Tires Replacement 8000 YRM 1424
A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS

1. OUTSIDE OF SOLID RUBBER TIRE 3. OVERHANG
2. WHEEL
Figure 75. Tires and Wheels Lift Trucks
3. The steering wheels are fastened to the spindle Type of tire and tire pressure (pneumatic tires) are
of the steering axle with a large castle nut. Make shown on the Nameplate. Make sure Nameplate is
sure inner and outer bearings are correctly lubri- correct for type of tires on lift truck.
cated with grease. Install inner bearing assembly
and wheel on spindle. Install outer bearing cone
WARNING
and castle nut. Tighten castle nut up to 200 N•m
(148 lbf ft) while wheel is rotated. Loosen castle Wheels must be changed and tires repaired by
nut until hub turns freely with no end play. Tighten trained personnel only.
castle nut to 12 N•m (106 lbf in). Install cotter pin Deflate tire completely before removing wheel from
in castle nut. If the cotter pin cannot be installed, lift truck. If dual wheels are used, deflate both tires.
loosen the castle nut to the first position where the Air pressure in tires can cause tire and rim parts to
cotter pin can be installed. Install cap for bearings. explode, causing serious injury or death.
PNEUMATIC TIRE WITH TUBE, REPAIR Always wear safety glasses.
Remove Wheels From Lift Truck Never loosen nuts that hold inner and outer wheel
halves together when there is air pressure in tire.
WARNING 1. Put lift truck on blocks as described in How to Put
A solid rubber tire that is the same shape as a Lift Truck on Blocks at beginning of this section.
pneumatic tire can be installed on a three-piece
or four-piece wheel for a pneumatic tire. DO NOT 2. Remove air from tire. Remove valve core to make
make changes in parts of rim if this type of solid sure that all air is out of inner tube. Push a wire
rubber tire is installed instead of a pneumatic tire. through valve stem to make sure that valve stem
Changes to parts of rim can cause a failure of does not have a restriction.
wheel and can cause an accident.
82
3. Remove wheel nuts and remove wheel and tire from Remove Tire From Wheel
lift truck. Lift truck tires and wheels are heavy.
NOTE: When disassembling wheels, see Figure 76.
There are several types of wheels used on this series
of lift trucks.
A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT
Figure 76. Types of Pneumatic Wheels
Remove Tire From Two-Piece Wheel
WARNING
Make sure all air pressure is removed from tire before wheel is disassembled. Air pressure in tires can cause
tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with wheel parts. If tool slips, it can move with enough force to cause an
injury.
STEP 1.
Remove nuts that fasten wheel rims together.
83
STEP 2.
Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove inner tube and
flap.
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all air pressure is removed from tire before wheel is disassembled. Air pressure in tires can cause
tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with wheel parts. If tool slips, it can move with enough force to cause an
injury.
STEP 1.
Loosen tire bead from side flange.
84
STEP 2.
Put tire tool into slot between lock ring and wheel rim.
Remove lock ring and side flange. If there is a flange
seat, remove it.
STEP 3.
Loosen bead from outer side of wheel rim. Remove
valve stem from wheel.
STEP 4.
Remove wheel from tire.
Install Wheel in Tire together. Make sure that side ring is in correct posi-
tion. Ends of side ring must not touch. Clearance at
WARNING ends of lock ring will be approximately 13 to 25 mm
(0.5 to 1.0 in.) after it is installed. If clearance is
Damage to the tire and wheel assembly and injury
wrong, the wrong part has been used.
or death can occur if you do not do the following
procedures: 1. Clean and inspect all parts of wheel. Paint any
• Clean and inspect all parts of wheel before in- parts that have rust or corrosion.
stalling tire.
• DO NOT use any damaged or repaired wheel 2. Install a new inner tube in tire. Used tubes and flaps
parts. can cause tire failure.
• Make sure that all parts of wheel are correct parts
for that wheel assembly. WARNING
• DO NOT mix parts between different types or
DO NOT lubricate tire bead with antifreeze or petro-
manufacturers of wheels.
leum-based liquid. Vapors from these liquids can
• DO NOT mix types of tires, type of tire tread, or
cause an explosion during inflation or use.
wheel assemblies of different manufacturers on
any one lift truck. 3. Apply rubber lubricant or soap solution to tire bead
and tube.
DO NOT use a steel hammer on the wheel. Use a
rubber, lead, plastic, or brass hammer to put parts 4. Install new tire flap.
85
5. Make sure rim is correct size for tire. Lubricate part piece wheel in tire as shown in Install Three- or
of wheel that contacts bead and flap. Four-Piece Wheel in Tire.
6. Install two-piece wheel in tire as shown in Install

Two-Piece Wheel in Tire. Install three-piece or four-
Install Two-Piece Wheel in Tire
WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following procedures:
• Clean and inspect all parts of wheel before installing tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of wheel are correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or types of wheel assemblies of different manufacturers on
any one lift truck.
DO NOT use a steel hammer on wheel. Use a rubber, lead, plastic, or brass hammer to put parts together.
Make sure that side ring is in correct position. Ends of side ring must not touch. Clearance at ends of lock
ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed. If clearance is wrong, the wrong
part has been used.
CAUTION
DO NOT use pneumatic-shaped solid tires on two-piece bolt together drive wheels. Spinning may occur.
STEP 1.
Install inner tube and rubber flap in tire. Install both
halves of wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
STEP 2.
Tighten nuts that hold rim halves together to 175 N•m
(129 lbf ft). Add air pressure to tire. (See Nameplate.)
86
Install Three- or Four-Piece Wheel in Tire
WARNING
any one lift truck.
part has been used.
STEP 1.
Install inner tube and rubber flap in tire.
STEP 2.
Install wheel rim in tire. Make sure stem of inner tube is
aligned with slot in rim.
STEP 3.
Turn over rim and tire. Put blocks under rim so rim is 8
to 10 cm (3 to 4 in.) above floor. Install flange seat (if
used) and lock ring.
87
STEP 4.
Put lock ring in correct position on rim. Add air pressure
to tire as described in Add Air to Pneumatic Tires With
Tube.
Add Air to Pneumatic Tires With Tube 2. Add 20 kPa (3 psi) of air pressure to tire.
3. Check that all wheel parts are correctly installed.

WARNING Hit lock ring lightly to make sure that it is in seat.
Add air pressure to tires only in safety cage. In-
spect safety cage for damage before use. When air 4. If installation is correct, add air pressure to tire to
pressure is added, use a chuck that fastens onto specified pressure.
valve stem of inner tube. Make sure there is enough
hose to permit operator to stand away from safety 5. Check that all wheel parts are correctly installed.
cage when air pressure is added to tire. If installation is not correct, remove all air pressure
from tire. Remove valve core to make sure all air
DO NOT sit or stand by safety cage. DO NOT use pressure has been removed and then make adjust-
a hammer to try to correct position of side flange ments. Clearance at ends of lock ring will be ap-
or lock ring when tire has air pressure greater than proximately 13 to 25 mm (0.5 to 1.0 in.) when tire
20 kPa (3 psi). has correct air pressure.
1. Put tire in safety cage. See Figure 77. Wheels, Install

Install wheel on hub. On drive wheels tighten nuts in a
cross pattern to a torque value of 155 to 175 N•m (114
to 129 lbf ft). If wheels are two-piece rims, make sure
nuts that fasten rim halves together are toward brake
drum when they are installed.
The steering wheels are fastened to the spindle of the

steering axle with a large castle nut. Make sure inner
and outer bearings are correctly lubricated with grease.
Install inner bearing assembly and wheel on spindle.
Install outer bearing cone and castle nut. Tighten castle
nut up to 200 N•m (148 lbf ft) while wheel is rotated.
Loosen castle nut until hub turns freely with no end play.
Tighten castle nut to 12 N•m (106 lbf in). Install cotter
pin in castle nut. If the cotter pin cannot be installed,
loosen the castle nut to the first position where the cotter
Figure 77. Add Air to Tires pin can be installed. Install cap for bearings.
88
PNEUMATIC TUBELESS TIRE, REPAIR The Tubeless Bead Seal (TBS) enables tubeless tires
to be used on wheel rims that were designed to be used
Remove Wheels From Lift Truck with a tube.
The main component of a TBS is a special rubber ring

WARNING
that fits inside the tire between the tire beads to ensure
Wheels must be changed and tires repaired by the air tightness of the existing wheel and the tubeless
trained personnel only. tire assembly. See Figure 76.
Deflate tire completely before removing the wheel 1. Put lift truck on blocks as described in How to Put
from the lift truck. If dual wheels are used, deflate Lift Truck on Blocks at beginning of this section.
both tires. Air pressure in tires can cause the tire
and rim parts to explode causing serious injury or 2. Remove the valve cap and core to remove all air
death. from the tire.
Always wear safety glasses. 3. Remove the wheel nuts and remove the wheel and
tire from the lift truck. Lift truck tires and wheels are
Never loosen the nuts that hold the inner and outer heavy.
wheels halves together when there is air pressure
in the tire.
Remove Tire From Wheel
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air pressure in
the tires can cause the tire and rim parts to explode causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to cause
injury.
NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 76.
STEP 1.
If wheel rim is a three- or four-piece rim, turn the valve
1/4 turn and remove valve from wheel.
89
STEP 2.
Put wheel and tire assembly on the press. Position the
feet of the press on the loose flange. Press down on
loose flange to expose the locking ring.
STEP 3.
Remove the loose flange locking ring and the advance
band (four-piece wheel only) using a tire tool.
STEP 4.
Remove the press and remove the loose flange locking
ring and the advance band (four-piece wheel only) from
the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to remove it.
90
Install Tire on Wheel
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any one
lift truck.
WARNING
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts together.
WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can
cause an explosion during inflation or use.
STEP 1.
Clean interior and exterior bead of the tire. Lubricate
tire beads and the inside of the tire, up to the tire shoul-
ders. Apply lubricant to the entire underside of the TBS.
NOTE: If the wheel rim width is less than 152 mm (6 in.), the TBS will contain one valve hole to accommodate the
needle valve. If the wheel rim width is greater than 152 mm (6 in.), the TBS will have two holes for the needle valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve slot.
The valve hole that is not used should be sealed with a small plastic plug.
STEP 2.
Apply lubricant to the needle valve and the valve hole
that will be used (see NOTE), by inserting and removing
the lubricated valve several times. If a three- or four-
piece wheel is being used, remove the valve. If a two-
piece wheel is being used, leave valve in valve hole.
If the TBS has two-valve holes, lubricate the plastic plug

and insert into valve hole that will not be used.
91
STEP 3.
Place the TBS inside the tire, making sure that the wings
of the TBS are not folded over. Make a mark on the tire
to note the position of the valve hole in the TBS.
STEP 4.
Apply lubricant to the rim. If a four-piece wheel is being
used, lubricate the advance band. Slide the tire and the
TBS onto the wheel.
Line up the valve hole in the TBS with the valve slot in
the wheel. Lubricate and insert the valve into the valve
hole. Make sure it is fully inserted.
STEP 5.
Place the wheel and tire assembly on a flat surface.
Turn the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.
STEP 6.
Raise the tire and position the base and threaded stem
of the press through the hole in the center of the wheel.
Insert in wheel assembly, the following parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring
92
STEP 7.
Position the advance band. Ensure that it does not go
in too far and damage the valve. Position the arms of
the press onto the loose flange.
Push down on the press to depress the tire beads until

locking ring groove is fully exposed.
STEP 8.
Insert tire tool into the locking ring groove, and a vise
grip on other end. Remove vise grip. Release the press
and check that all component parts are correctly posi-
tioned. Replace the valve core.
STEP 9.
Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet
to ensure all components are correctly sealed. Remove
the press from wheel and tire assembly.
Add Air to Pneumatic Tubeless Tire
WARNING
Add air pressure to tires only in safety cage. In-
spect safety cage for damage before use. When air
pressure is added, use a chuck that fastens onto
valve stem. Make sure there is enough hose to per-
mit operator to stand away from safety cage when
air pressure is added to tire.
DO NOT sit or stand by safety cage.
1. Put tire in safety cage. See Figure 78.
2. Add air to tire to the recommended air pressure that

is shown on the Nameplate. Install valve cap to
ensure air stays in the tire. Figure 78. Add Air to Tires
93
Wheels, Install SOLID RUBBER TIRES ON PNEUMATIC

WHEELS, CHANGE
Install wheel on hub. On drive wheels tighten nuts in a
cross pattern to a torque value of 155 to 175 N•m (114
to 129 lbf ft). If wheels are two-piece rims, make sure WARNING
nuts that fasten rim halves together are toward brake Wheels must be changed and tires repaired by
drum when they are installed. trained personnel only.
The steering wheels are fastened to the spindle of the Always wear safety glasses.
steering axle with a large castle nut. Make sure inner
and outer bearings are correctly lubricated with grease. 1. Put lift truck on blocks as described in How to Put
Install inner bearing assembly and wheel on spindle. Lift Truck on Blocks at beginning of this section.
Install outer bearing cone and castle nut. Tighten castle
2. Remove wheel nuts and remove wheel and tire from
nut up to 200 N•m (148 lbf ft) while wheel is rotated.
lift truck. Lift truck tires and wheels are heavy.
Loosen castle nut until hub turns freely with no end play.
Tighten castle nut to 12 N•m (106 lbf in). Install cotter
pin in castle nut. If the cotter pin cannot be installed,
loosen the castle nut to the first position where the cotter
pin can be installed. Install cap for bearings.
Remove Tire From Wheel
WARNING
Keep tire tools in firm contact with wheel. If tool slips, it can move with enough force to cause serious injury.
When disassembling wheels, see Figure 76. There are several types of wheels used on these series of lift trucks.
WARNING
Wheels must be changed and tires repaired by trained personnel only.
Always wear safety glasses.
STEP 1.
Put wheel rim on bed of press. Put cage in position on
tire. Use press to push tire away from side flange.
94
STEP 2.
Put tire tool into slot between lock ring and wheel rim.
Remove lock ring and side flange.
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
STEP 4.
Put cage in position on tire. Use press to push tire from
wheel rim.
95
Install Tire on Wheel
WARNING
any one lift truck.
part has been used.
When assembling wheels, see Figure 76. There are several types of wheels used on these series of lift trucks. DO
NOT use a two-piece pneumatic wheel for solid rubber tires.
CAUTION
Too much lubricant can cause tire to slide and move around wheel rim.
STEP 1.
Lubricate wheel rim and inner surface of tire with tire
lubricant or soap.
96
STEP 2.
Put wheel rim on bed of press. Put tire over wheel rim.
Put cage in position on tire. Use press to install tire on
wheel rim.
STEP 3.
Remove cage and put flange seat (if used), side ring,
and lock ring in position on wheel rim. Install cage on
tire. Use press to push tire onto wheel rim so side flange
and lock ring can be installed.
STEP 4.
While cage is holding tire on wheel rim, install lock ring.
Use tire tool to make sure lock ring is in correct position.
97
Adhesives and Sealants 8000 YRM 1424
Adhesives and Sealants

Loctite® Part
Yale Part No. Description Size
No.
501702901 222 Small Screw Threadlock (Purple) 50 ml
505965518 242 Removable Threadlock (Blue) 10 ml
580012519 271 High Strength Threadlock (Red) 10 ml
501702904 290 Low Viscosity Threadlock (Green) 50 ml
518806679 422 SuperBonder® Adhesive 3 ml
500009917 515 Gasket Eliminator (Purple) 50 ml
518795676 567 Pipe Sealant with Teflon® 50 ml
502058904 595 Super Flex® Silicone 100 ml
504226218 767 Antiseize Compound 1 lb
150015825 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz
Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation.
Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.
98
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
8000 YRM 1424 8/13 (4/13)(12/12)(8/12)(3/12)(11/11)(7/11)(11/10)(8/10)(5/10) Printed in U.S.A.

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Maintenance

PART NO. 550013979 8000 YRM 1424

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2013 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

5. Use a towing link made of steel that fastens to tow

HOW TO PUT LIFT TRUCK ON BLOCKS

Figure 2. Put Lift Truck on Blocks

Figure 5. Maintenance Points - Mazda F2 LPG Engine

Figure 6. Maintenance Points - Yanmar 2.6L Engine

Table 1. Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

21 Engine Oil Filter C 1 Filter See Parts Manual

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Maintenance Procedures Every 8 Hours or Daily

Figure 7. Tire Check

6. If the lift truck is equipped with an integral sideshift

1. Inspect the welds on the mast and carriage for

2. Inspect the carriage to be sure fork stops are in

Operator Restraint System

7. Visually inspect hoses/fittings for hydraulic leaks;

8. Check that the lift chains are correctly lubricated.

9. Inspect the lift chains for cracks or broken links, and

1. LATCH STRIKER 4. HOOD RELEASE HANDLE

Figure 10. Hood and Hood Latch Check

A. STANDARD, NON SUSPENSION SEAT B. FULL SUSPENSION SEAT

Figure 11. Seat Belt and Seat Check

Steering Column Gas Cylinder

Never operate the hydraulic pump without oil in the

After the engine has stopped, wait one minute before

Never operate the engine without oil. The operation

After the engine has stopped, wait one minute before

See Figure 15 for lift truck equipped with Mazda FE LPG

See Figure 16 for lift truck equipped with Mazda F2 LPG

See Figure 17 for lift trucks equipped with Yanmar 2.6L

There is an indicator light for the engine oil pressure on

Legend for Figure 15

Figure 15. Engine Maintenance Points - Mazda FE LPG Engine

1. ENGINE OIL DIPSTICK

See Figure 17 for lift trucks equipped with Yanmar 2.6L

WARNING 1. CARRIAGE BARS 3. BLOCKS

Inspect Legend for Figure 19

1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

1. Move the fork and carriage so that the top hook on

Figure 19. Forks Check

Adjust brake and put the transmission in NEUTRAL. Make the

HOW TO MAKE CHECKS WITH ENGINE

Item Warning and Indicator Light

Figure 21. Warning and Indicator Lights

NOTE: HOOD REMOVED FOR CLARITY.

Figure 22. PDM Showing Fuses and Relays

Service Brakes Parking Brake

See Figure 17 for lift trucks equipped with Yanmar 2.6L

Check the radiator fins. Clean the radiator with com-