Yale Forklift Periodic Maintenance

8000 YRM 1248 Maintenance program
Table 1. Maintenance program

Item no. Element 8 250 500 2000 4000 Procedure or Specification
hours/ hours/ hours/ 1000 hours/ 1 hours/ 2 quantity
1 day 6 hours/ 6 year years
6
month months months
s
25 x
Tires and wheels Check status See nameplate
x Change if
Security labels See Parts Manual
necessary
28, 29 x Check condition See Parts Manual
Mast, board, and lubrication
collector hoses,
lifting chains and
accessory
x Check condition
Seat belt, hip and operation
restraint and seat
rails
Hood and seat x

latches Check condition
and operation
engine compartment x Remove

combustible
materials See
NOTE 5.
x Check condition
Clean as
Paper Application:
necessary
Engine
Replace as
Compartment;
necessary See
Wheelbarrow
NOTE 8.
components;
Exhaust pipe wraps;
Radiator; Radiator
screen, if equipped;
lower fairing, if
equipped
x Check for leaks
See NOTE 1.
Check for leaks -
Fuel, oil, water
x
Hydraulic hoses Check status See Parts Manual
13 x
coolant hoses Check status See Parts Manual
16 Fuel bottle (LPG) CIL GPL- HD 5, HD 10

15.1 - 20.4 kg
(33.5 - 45.0 lb)
complete
X=Check C=Replace L=Lubricate CIL=Check indicator light during operation
1
0
Maintenance program 8000 YRM 1248
Table 1. Maintenance program (Continued)

6
month months months
s
16 CIL 44.7 liters 86 octane -
(11.8 gal) minimumgasoline
GM Fuel Tank 4.3L
Gasoline [GC080,
100, 120VX;] GC080,
100VXBCS;
GC120SVX;
GC120VXPRS
(E818)
USA only
16 CIL 79 liters (20.8 gal) Minimum 86 octane
Fuel tank (short

wheelbase) GM 4.3L
(Petrol) (GP080, 090,
100, 110, 120VX
(F813, G813)
USA only
16 CIL 100.3 liters (26.5 Minimum 86 octane

gal)
Fuel tank (long
wheelbase) GM 4.3L
(gasoline)
GP 080, 090, 100,
110, 120VX (F813,
G813)
USA only
16 CIL 79 liters (20.8 gal) Diesel No. 2
Fuel Tank (Short

Wheelbase)
Cummins 4.5L and
QSB 3.3L (Diesel)
GDP080, 090, 100,
110, 120VX (F813,
G813)
1
1

6
month months months
s
16 CIL 100.3 liters (26.5 Diesel No. 2
gal)
Fuel tank (long
wheelbase)
Cummins 4.5L and
QSB 3.3L (Diesel)
GDP080, 090, 100,
110, 120VX (F813,
G813)
x Check operation
Horn, lights, alarms,
fuses and relays
1 Service brakes x
Check operation
23 x
Parking break Check operation
x Check condition
Steering column gas and operation
cylinder and steering
controls
22 x
oil temperature Check for leaks John Deere JDM J20C
22 x
oil temperature Check operation
3 x x c 39.4 liter (41.6 qt) Hydraulic oil ISO VG 46

See NOTE 2 and -15 0 C (5°F) and higher
GM Hydraulic Oil
NOTE 3.
4.3L [GC/GLC080,
100, 120VX;]
GC/GLC080,
100VXBCS;
GC/GLC120SVX;
GC/GLC120VXPRS
(E818)
See NOTE 2 and -15 0 C (5°F) and higher
NOTE 3
Hydraulic oil (short
wheelbase)
GP/GLP/GDP080,
090, 100, 110,
120VX (F813, G813)
1
2

6
month months months
s
See NOTE 2 and 15 0 C (5 0 F) and
NOTE 3 above
Hydraulic oil (long
wheelbase)
GP/GLP/GDP080,
090, 100, 110,
120VX (F813, G813)
6 c 1 filter See NOTE
Hydraulic oil filter See Parts Manual
4.
10 Hydraulic tank x c See Parts Manual
breather Inspect and clean
as necessary See
NOTE 5.
8 Battery and cable x Clean

terminals
9 Motor oil GM 4.3L C X IL c
4.7 liter (5.0 qt) 7° C (20 0 F) and
engine See NOTE 5. below SAE 5W-20
(gasoline/LPG) 16 0 C (60 0 F) and
below SAE 5W-30
18 0 C (0 0 F) and
above SAE 10W-
30
API SL
ILSAC GF3 SAE
c
J2362
19
engine oil filter 1 Filter See NOTE See Parts Manual
GM 4.3L engine 4 and NOTE 5.
9 Engine oil Cummins X CYL c 13.0 liter (13.7 qt) 0 0 C (32 0 F) and below
engine See NOTE 5. SAE 0W-30
4.5L (diesel) 25 to 20°C
(13 to 68° F) SAE 5W-
30
20 to 20°C
(4 to 68 0 F) SAE 10-30
15° C (5 0 F) and
above SAE 5W-40 or
15W-40
API CH-4 or CI-4
1
3

6
month months months
s
9 Engine oil Cummins X CYL c 7.5 liter (8 qt) See 0° C (32°F) and below
QSB 3.3L Engine NOTE 5. SAE 0W-30
(Diesel) 25 to 20 0 C
(13 to 68 0 F) SAE 5W-
30
20 to 20°C
(4 to 68 0 F) SAE 10-30
15°C (5 0 F) and
above SAE 5W-40 or
15W-40
API CH-4 or CI-4
19 c 1 Filter See NOTE See Parts Manual
4 and NOTE 5.
engine oil filter
Cummins 4.5L
and QSB 3.3L
(Diesel)
18 Air filter CIL c See Parts Manual
1 filter See NOTE
5, NOTE 6 and
NOTE 12.
18 Air filter x c See Parts Manual

1 filter See NOTE
5, NOTE 6 and
NOTE 12.
Engine oil pressure CIL Check oil pressure
GM engine 207 to 380

kPa (30 to 55 psi)
Cummins 4.5L Diesel
engine at high idle 207
kPa (30 psi) at low idle
69 kPa (10 psi)
Cummins QSB 3.3L
Diesel engine 49 kPa (7
psi) Minimum
15 transmission band x
GM engine Check for damage
and wear. No
adjustment is
necessary. See
NOTE 5.
1
4

6
month months months
s
15 transmission band x
Cummins 4.5L Check for damage
and QSB 3.3L and wear. No
(Diesel) adjustment is
necessary. See
NOTE 5.
LPG regulator GM x Drain tar See

4.3L engine NOTE 5.
x 750 ±25 rpm
Engine speed at idle
GM 4.3L
(gasoline/LPG)
x 2400 ±25 rpm
Regulated engine
speed
GM 4.3L
(gasoline/LPG)
x 770 ±50 rpm
Engine speed at idle Coolant
cold engine temperature Less
Cummins 4.5L than 77°C (170 0
(Diesel) F)
x 800 ±50 rpm
Engine speed at idle Coolant
hot engine temperature
Cummins 4.5L greater than 77 0
(Diesel) C (170 0 F)
x 2250 ±50 rpm
Regulated Engine
Speed (No Load)
Cummins 4.5L
(Diesel)
x Coolant 1000 ±25 rpm
temperature less
Engine speed at idle than 30 0 C (86 0
cold engine F)
Cummins QSB
3.3L)
(diesel)
x Coolant 800 ±25 rpm
temperature
Engine speed at idle greater than 30°C
hot engine (86° F)
Cummins QSB
3.3L)
(diesel)
1
5

6
month months months
s
x 2230 ±25rpm
Regulated engine
speed
Cummins QSB
3.3L diesel)
Oxygen Sensor GM Change if
X CYL
4.3L Engine necessary
GM 4.3L Engine
4 Not adjustable
Valve Adjustment
4 Valve adjustment x Adjust as needed
Cum Engines
mins 4.5L diesel Intake 0.254 mm (0.010
in.) Cold Exhaust 0.508
mm (0.020 in.) Cold
4 x Adjust as
Valve adjustment necessary See
NOTE 13. Intake 0.35 mm (0.014
Engines
in.) Cold Exhaust 0.50
Cummins QSB
mm (0.02 in.) Cold
3.3L diesel
17 c 1 Filter See Parts Manual

Fuel filter, LPG
(GM)
Fuel filter
Gasoline (GM)
17 Fuel and water CIL c 1 filter Drain water See Parts Manual
separator filter from filter as
Cummins engine needed
4.5L
and QSB 3.3L
Diesel
Pipe fuel filter

Cummins engine
4.5L diesel
Final fuel filter

Cummins QSB
3.3l diesel engine
1
6

6
month months months
s
20 x
Check and
fuel injectors replace if
GM 4.3L necessary 6
gasoline/LPG injectors
5 Plugs c See NOTE 9.
GM 4.3L engine
Check spark plug
wires 6 spark
plugs
12, 14 Refrigeration system X CYL c 15.1 liter (15.9 qt) 50% water and 50%
GM 4.3L engine boron-free ethylene
glycol antifreeze
12, 14 X CYL c 13.5 liter (14.2 qt) 50% water and 50%
Refrigeration system boron-free ethylene
Cummins 4.5L glycol antifreeze
diesel engine
12, 14 X CYL c 10.4 liter (11 qt) 50% water and 50%
Refrigeration system boron-free ethylene
Engine glycol antifreeze
Cummins QSB
3.3l diesel
x See NOTE 5.
Cleaning debris from
the radiator panel
7 x c 20 liter (21 qt) John Deere JDM J20C

Transmission oil Dry
brake
21 c 1 filter See Parts Manual

Transmission oil filter
1 vent
and breather
See NOTE 4
26 Forks x x x
Check status
26 l Lubricate as Multi-purpose grease

Rod closures
necessary See NOTE 7.
x Check operation
Lifting system,
operation
1
7

6
month months months
s
27 l Lubricate as Multi-purpose
necessary. See grease
mast See NOTE 7.
NOTE 10 and
Sliding surfaces
NOTE 11
and surfaces of
the
loading rollers
27 x
Collector hoses Check status
28 lifting chains x SAE 30W motor oil

Check lubrication.
See NOTE 11.
28 lifting chains l L,X SAE 30W motor oil

Check wear.
Lubricate as
necessary.
mast l 2 fittings Multi-purpose

Joints grease
See NOTE 7.
mast Sliding deck x l x Lubricate as Multi-purpose
surfaces with necessary. grease
integrated lateral 8 Fittings See NOTE 7
movement 4 support bands
l 4 fittings Multi-purpose
Tilt Cylinder Ends grease
See NOTE 7
l
Brake master SAE 10W-30 API SL
cylinder rod end pin ILSAC GF3 SAE J2362
Hydraulic manual l
levers SAE 10W-30 API SL
ILSAC GF3 SAE J2362
24 CIL x c 0.35 liter (0.74 pt)

Brake oil (brake Dexron III sealed
pump) container
11 Steering shaft l 4 fittings Multi-purpose
Bearings of grease
spindle See NOTE 7.
1
8

6
month months months
s
11 l 2 fittings Multi-purpose
grease
Steering axle Tie See NOTE 7.
rods
[GC/GLC080,
100, 120VX;]
GC/GLC080,
100VXBCS; GC/
GLC120SVX;
GC/GLC120VX-
PRS (E818)
11 l 4 fittings Multi-purpose
grease
Steering axle Tie See NOTE 7.
rods GP/GLP/
GDP080, 090,
100, 110, 120VX
(F813, G813)
2 l Lubricate as Use silicone sprayer
necessary part no. Yale
Pedals, levers, seat
504236201
rails, cables, hinges,
connections, hood
lock
1 Service brakes (dry x Check the 1.0 mm (0.040 in.)
brake) thickness of the minimum
linings
23 Parking break l Lubricate as
necessary
Use a silicone sprayer
(Yale part number
504236201)
30 x c 6.0 liter (6.3 qt) SAE 80W-90 or 85W-
140
Differential and
propeller shaft oil
(dry brake)
7/30 x c 28.8 liter (30.4 qt) John Deere JDM J20C
Oil bath disc brake

planetary carrier
housing oil and
transmission
GC/GLC080VX,
VXBCS (E818)
1
9

6
month months months
s
7/30 x c 29.8 liters (31.4 John Deere JDM J20C
qt)
Oil bath disc brake

planetary carrier
housing oil and
transmission
GC/GLC100VX,
VXBCS
GC/GLC120VX,
SVX, VXPRS (E818)
7/30 x c 31.3 liter (33.0 qt) John Deere JDM J20C
GP/GLP/GDP080,
090, 100, 110,
120VX (F813, G813)
Wet Brake &
Transmission
Planetary Carrier
Housing Oil
30 x c 2.0 liter (2.1 qt) John Deere JDM J20C
Disc brake center

section oil in oil bath
[GC/GLC080, 100,
120VX;]
GC/GLC080,
100VXBCS;
GC/GLC120SVX;
GC/GLC120VXPRS
(E818)
30 x c 2.0 liter (2.1 qt) John Deere JDM J20C
Brake center section

oil in oil bath
GP/GLP/GDP080,
090, 100, 110,
120VX (F813, G813)
x
System inspection
engine electrical
connectors
x
Inspect engine
vacuum, fuel lines
and fittings
2
0

6
month months months
s
x
Inspect
the possible
existence of leaks in
the lock and make
sure the lock
is closed
x
Check the
LPG/GASOLINE
regulator pressure
x
Check for leaks in
the air induction
system
x
Check for vacuum
leaks in the manifold
x
Check that the
throttle shaft is not
sticking
x
Check for leaks in
the injectors and rails
x
Inspect manifold and
exhaust pipes for
leaks
x
Inspect the catalyst
inlet and outlet
31 c Replace
Ignition system
distributor, rotor and
spark plug wires
NOTE 1: Check the fuel system for leaks before any service or maintenance activities.
NOTE 2: Operation in difficult conditions or at high temperatures requires more frequent checks.
NOTE 3: Heavy or contaminating applications will require changing the hydraulic oil at 2,000 hours.
NOTE 4: Change the engine oil and filter, and other fluid filters, after the first 100 hours of operation.
2
1
8000 YRM 1248 Maintenance procedures every 8 hours or daily

6
month months months
s
NOTE 5: Recommended maintenance intervals are based on normal use in a clean environment. In case of use in a contaminated
environment, uneven ground, intensive use in demanding conditions or other abnormal conditions, it will be necessary to increase
the frequency of maintenance work. Upon request, your Yale truck supplier will recommend appropriate maintenance intervals
based on a study of your application.
NOTE 6: In dirty or dusty environments, replace at 1,000 hours or as necessary.

NOTE 7: Multipurpose grease with 2 to 4% molybdenum disulfide.
NOTE 8: Vehicles used in paper applications require regular inspection and cleaning to minimize the risk of fire. This should be
done at least every 8 hours or more frequently depending on the work environment. Use compressed air and steam clean as
necessary.
NOTE 9: Refer to Capacities and Specifications 8000 YRM 1249 for the correct spark plug gap and type of spark plugs to use.
NOTE 10: Lubricate the mast every three months if the unit has less than 1000 hours.
NOTE 11: Lubricate at the first sign of rust.
NOTE 12: Do not open the air filter cartridge except to change the air filter element. See Maintenance Procedures every 2,000
hours or annually to change the air filter element.
NOTE 13: The initial adjustment of the valve clearance is after 250 hours or 3 months. Subsequent adjustments must be made at
intervals of 2000 hours/2 years, whichever comes first.
Maintenance procedures every 8 hours or daily

HOW TO PERFORM CHECKS and check for leaks or abnormalities. Wipe away any oil
WITH THE ENGINE STOPPED or fuel stains. Be sure to remove any remaining oil,
lubricant, etc. fuel and organic fibers or dusts (paper,
▲ WARNING wood, cotton, grass/grain, etc.).
Do not use any forklift that requires repair.
Immediately communicate the need repair time. If Tires and wheels
repair is necessary, post a sign at the operator's
station indicating "OUT OF SERVICE" dam. If the Check the tires for damage (see Figure 7). Inspect the
truck is equipped with an ignition key, remove the tread and remove any objects that could cause damage.
key from the ignition. Check that the rims are not deformed or damaged.
Check if any screws or nuts are missing or loose.
Place the forklift on a level surface lada. Lower the Remove any wire, straps or other materials wrapped
dashboard and forks, stop the engine, and apply the around the shaft.
parking brake. open the hood
2
2
Maintenance procedures every 8 hours or daily 8000 YRM 1248
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. ELIMINATE EDGE EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC WHEELS)
Figura 7. Checking the tires

Security labels which the rollers move. Inspect the rollers for wear
or damage.
A WARNING
3. Inspect the load support rack for cracks or damage.
Safety labels are installed on the forklift to provide
information about the operation. ization and 4. If the forklift is equipped with an ac cessory or a
possible dangers. It is important that all safety board with internal lateral movement grade, inspect
labels are installed on the forklift and are legible. its components for possible They feel cracks or
wear. Make sure the components securing the
Check that all safety labels are They are installed in
accessory or integrated lateral movement board to
their correct position on the forklift. Refer to the Parts
the board are in good condition.
Manual , the Model Description section of the User
Manual , or the Frame 100 YRM 1243 section for the 5. Visually inspect hoses/fittings for hydraulic leaks;
correct location of the safety labels. With See Parts the hose cover for cuts, cracks, or exposed
Manual for Part Number ence of security labels. reinforcements; Defective/broken fixing devices or
pulleys; and correct guidance du during operation.
Mast, board, lifting chains, collector hoses, Adjust/repair/replace hose/components as
accessory necessary.
▲ WARNING 6. Check that the lifting chains are properly lubricated.

Fully lower the lifting mechanism. Never allow Use SAE 30 motor oil, as necessary, to lubricate
anyone to stand under a raised board. Do not place the housings. lifting pressures.
any part of your body on the lifting mechanism
7. Inspect lift chains for cracks or broken links and
unless all mast parts are fully lowered and the
worn or bent pins. See Figure 8.
engine is OFF. Don't try to cor govern the alignment
of the rod tips by bending the rods or adding shims. 8. Inspect chain anchors and pins in case of cracks
and damage.
Never repair damaged forks as they become hot.
doling or welding them. The rods are made of 9. Be sure to adjust the lift chains so that they have
special steel by es specials. If any of the rods are the same tension. Adjustment or replacement of
damaged, replace them as a set. lifting chains must be carried out by authorized
personnel.
1. Inspect the mast and deck profiles for cracks. Make
sure the cap screws and nuts are tight.
2. Inspect channels for wear ted in the areas over
2
3
The following seat belt function checks must be carried

out:
• With the hood closed and in the locked position, pull
the seat belt slowly out of the tensioner assembly.
Make sure the seat belt extends and retracts
smoothly. If the belt does not come out of the
tensioner assembly or retract, replace the seat belt
assembly.
• With the hood closed and in the locked position, pull
the seat belt with a sharp snap. Make sure the belt
does not come out of the tensioner assembly. If you
can remove the seat belt from the tensioner when it
pulls with a snap, replace the seat belt assembly.
• With the hood in the open position, make sure the
seat belt does not come out of the tensioner
assembly. If you can remove the seat belt from the
tensioner, with the hood in the open position, replace
the next to the seat belt.
1. WORN PIN
2. CRACKS
3. EDGE WEAR
4. HOLE WEAR
5. LOOSE LEAVES
6. CROWN PIN
7. CORROSION
Figura 8. Checking the lifting chain
Operator restraint system

Components of the operator restraint system These are:
the seat belt, the lap restraints, the seat, the hood and
the hood latch. See Figure 9. Each of these elements
must be checked. ments to verify that they are securely
fastened, that they function function correctly and are in
good condition. ted.
Emergency Lock Tensioner (ELR)
NOTE: Trucks produced after November 2005 models

are equipped with emergency locking tensioner (ELR)
type seat belts.
When the ELR-type seat belt is properly buckled over

the operator, the belt will allow the operator to reposition
himself slightly without activating the locking
mechanism. If the truck tilts, rides on a spring, or stops
suddenly, the locking mechanism will activate and
secure the operator's torso in the seat.
A damaged or worn seat belt does not protect will

provide adequate protection when necessary sary. The
end of the seat belt must be properly attached to the
buckle. The seat belt ity must be in good condition.
Replace the seat belt at the slightest sign of damage or
wear. spend. See Figure 9.
2
4
NOTE: THE SWIVEL SEAT IS A FEATURE OPTIONAL

THERISTICS
1. FORWARD/BACKWARD ADJUSTMENT
2. SWIVEL ADJUSTMENT
3. OPERATOR WEIGHT ADJUSTMENT
4. SEAT POSITION ADJUSTMENT (SEAT RAIL)
5. SEAT BELT
Hood and seat latches

Make sure the seat rails and interlock are not loose. The
seat rails should be firmly locked in position, but should
move freely when unlocked. quedos (see Figure 9 and
Figure 10). The seat rails must be properly attached to
the hood and the hood properly attached to the frame
hinges. Try lifting the hood to make sure it is securely
fastened and does not move. If adjustment is
necessary, go to Checking the Hood Latch.
1. CLOSURE INTERLOCK
2. HOOD CLOSURE engine compartment
3. FORWARD/BACKWARD ADJUSTMENT
4. HOOD Check for the presence of combustible materials such
5. OPERATOR WEIGHT ADJUSTMENT as paper, leaves, etc. Remove materials fuels.
6. SEAT RAIL
7. ARMREST
8. SEAT BELT Paper application
9. SEAT
10. HIP SUPPORT Vehicles used in re paper applications want regular
11. HOOD HINGE inspection and cleaning for mini reduce the risk of fire.
Legend to figure 10 This should be done at least every 8 hours or more
Figure 9. Checking the hood and seat frequently depending on tion of the work environment.
The application of paper with It will help limit contact of
paper or tissue scraps with hot surfaces under the hood,
but frequent maintenance is required.
WARNING
Engine and exhaust system components are hot to
the touch. Make sure the com components of the
forklift to cool before beginning inspection and
cleaning, otherwise personal injury could occur.
Make sure the truck engine cools down properly. directly

leaving it idling for a few minutes. When you turn off the
truck when it is hot, the engine will not be able to start.
cool quickly due to loss of coolant circulation. Heat
trapped under the hood can actually increase engine
temperature. due to the absence of heat transfer in the
radii adore With the engine off and forklift components
cooled, check and clean the ra radiator and, if equipped,
the radiator screen. Com test the engine manifold,
exhaust pipes, muffler and catalytic converter for tro
pieces of paper. Clean as necessary. Check and clean
components in the engine compartment, transmission,
Figure 10. Swivel seat controls fan cowl, lower fairing, and inner frame bosses to
prevent buildup of paper, dust, and oil. Check the shaft
and hood openings for paper and polling cable buildup.
2
5
Remove your city. Fuel, oil and coolant leaks, check

A WARNING ▲ WARNING
Compressed air can move particles in such a way
All fuels are highly flammable and can cause burns
that they can cause injury to the user and others.
and explosions. Do not use open flames to check
Make sure that the compressed air outlet cannot
fuel level or fuel system leaks. If there is a leak in
reach other people. Wear protective glasses or a
the fuel system, use extreme caution during repair.
mask to avoid cause eye injuries.
Do not use the truck until the leak has been
repaired.
A CAUTION
Air pressure, nozzle or extension tube can cause Visually check for leaks in the car. lift gate or below it. If
damage to the exhaust pipe wraps and radiator fins. possible, find the leak and report it for maintenance and
Make sure the air pressure, nozzle or exhaust tube repair. Leaks often indicate the need to repair damaged
tension does not cause damage to the exhaust pipe or missing components. spent. LPG fuel system leaks
wraps or radiator fins. are usually not visible unless ice is present. However,
there is usually a strong smell. Fuel leaks MUST be
Paper removal can normally be accomplished using repaired IMMEDIATELY.
using a compressed air line and a nozzle. An extension
may be useful to reach difficult places. Remove the floor Check the possible existence of leaks and the condition
plates and lat covers Erasers for better access to the of the parts in the fuel system. To add fuel to the truck,
car compartment tor. Open or remove the lower fairing, see the procedures section of the HOW TO FILL THE
if equipped. Clean components with compressed air. FORKLIFT TANK WITH FUEL section of the
Take care to maintain the integrity of the exhaust pipe Operator's Manual .
wraps when cleaning with compressed air. gone and be
careful not to get dirt into the openings. Check the Also check the condition of the radiator hoses. radiator
condition of the exhaust pipe wraps for wear, proper fit, or heater to see if there are any leaks. Hoses that are
oil contamination, or antifreeze. front, gaps in the cover soft or have cracks should be replaced before a
and defective fastening elements and replace as significant leak occurs.
necessary. Do not reuse wrappers if they have been
removed by another operation if necessary. vice. Hydraulic hoses
▲ WARNING Check the condition of the hydraulic hoses for usability,

Be careful with steam cleaning. Steam can cause inspecting for cracks or other obvious damage. Check to
serious burns. Bring clothing protective clothing, make sure the hydraulic hoses do not leak. If any hose
gloves and eye protection. Always avoid skin leaks, notify maintenance personnel for repair.
contact with steam.
coolant hoses
If the compressed air does not properly remove the su
Check the condition of the coolant hoses for usability,
dirt, steam clean to remove any buildup. Persistent
inspect checking if there are cracks or any other obvious
contamination of material or oil. Protect the com
damage. Check to make sure the coolant hoses are not
electrical components from moisture when steam
leaking. If any hose leaks, notify maintenance personnel
cleaning. Do not spray exhaust wraps directly with high
for repair.
pressure steam. Allow the truck to lift machine to dry
before working on it again. contaminated lathe. Dust
Steering column gas cylinder
and paper scraps will stick to wet surfaces.
Make sure the steering column gas cylinder is working
Check the condition of the exhaust pipe wraps for wear, properly. The cylinder should NOT allow the column to
proper fit straight, contamination with oil or antifreeze, move unless the tilt lever is released. See Figure 11.
hue Check the cover and defective fixing elements and
replace as necessary. Do not reuse wrappers if they
have been removed for another service operation.
2
6
1. LEVER 2. GAS CYLINDER

INCLINATION
Figure 11. Gas cylinder column

steering and tilt lever
2
7
oil temperature
Check the transmission for leaks and damaged or loose
components. Use in difficult conditions or at high
temperatures may require more frequent checks.
Hydraulic system oil

A WARNING
At operating temperature, hydraulic oil is HOT.
Avoid letting hot oil come into contact with your
skin and cause a burn.
(N CAUTION
Do not allow dirt to enter the hydraulic system when CAUTION
checking the hydraulic oil level or changing the
filter.
Never operate the hydraulic pump without oil in the

hydraulic system. Operating the hydraulic pump
without oil will damage the pump.
After stopping the engine, wait one minute before

checking the oil level. Keep the hydraulic oil at the
correct level indicated on the dipstick. Use the correct
type of oil indicated on the Pro maintenance schedule.
Check for leaks, damage or compo Loose connections

in the hydraulic system. Use in difficult conditions or at
high temperatures may result in want more frequent
checks.
engine oil
A WARNING
At operating temperature, engine oil is HOT. Avoid
letting hot oil come into contact with the skin and
causing it to mature.
Avoid dust entering the engine when checking the
oil level or changing the filter.
Never run the engine without oil. Operating the

engine without oil causes damage to it.
After stopping the engine, wait one minute before

checking the oil level. See Figure 12, Figure 13 and
Figure 14. Keep the oil at the correct level straight line
indicated on the dipstick. Use the correct type of oil
indicated in the Maintenance Schedule iment.
2
8
Legend of figure 12
A. TOP VIEW
B. RIGHT SIDE SHOWN
1. BATTERY
2. AUXILIARY REFRIGERANT LIQUID TANK
3. RADIATOR CAP
4. WATER SEPARATOR
5. AIR FILTER
6. LIFT PUMP
7. FUEL INJECTION PUMP
8. ENGINE OIL FILLER CAP
9. FUEL FILTER IN THE PIPE
10. ENGINE OIL DIPSTICK
11. FUEL INJECTOR
12. TRANSMISSION BAND
Figure 12. Engine maintenance points
Cummins 4.5L diesel truck models
elevator (GP/GLP/GDP080, 090, 100, 110, 120VX)
(F813)
2
9
TO. FRONT VIEW OF THE RIGHT SIDE

1. LEVEL DIPSTICK
2. TURBOCHARGER
3. OIL FILLER CAP
4. AIR INTAKE HOUSING
5. FUEL PRIMER PUMP
6. FUEL AND WATER SEPARATOR
7. NDE
8. FUEL FILTER
9. STARTING MOTOR
10. FUEL DISTRIBUTION MANIFOLD
11. ELECTRONIC FUEL PUMP
12. WATER PUMP
13. CRANKSHAFT POSITIONING SENSOR
14. TREE POSITIONING SENSOR
CAM
15. ALTERNATOR
16. ALTERNATOR BELT ADJUSTMENT
b. FRONT VIEW OF THE LEFT SIDE
Figure 13. Cummins QSB 3.3L diesel engine maintenance points on forklift models
elevators (GP/GLP/GDP080, 090, 100, 110, 120VX) (G813)
17. TEMPERATURE TRANSMISSION UNIT

18. WATER INLET / THERMOSTAT HOUSING
19. TURBOCHARGER AIR INLET INTAKE
20. TURBOCHARGER DISCHARGE DOOR
21. TURBOCHARGER EXHAUST
22. TURBOCHARGER EXHAUST MANIFOLD
23. OIL FILTER
24. TURBOCHARGER OIL DRAIN DUCT
25. TURBOCHARGER OIL FEED DUCT
26. OIL COLLECTION PAN
27. OIL PAN DRAIN PLUG
3
0
TO. GASOLINE ENGINE b. LPG ENGINE
2. BATTERY
3. AUXILIARY LIQUID TANK
REFRIGERANT
4. RADIATOR CAP
5. FILLING ENGINE OIL
7. AIR FILTER
8. FUEL FILTER
9. ENGINE OIL FILTER
10. PLUGS
11. FUEL INJECTOR
3
1
Figure 14. GM Engine Maintenance Points
Air filter
The air filter cartridge should not be opened until
replacement of the air filter element is necessary.
Replacement of the filter element is necessary air
supply when one of the following occurs:
• Optional dashboard airflow restriction indicator light
illuminates
• Optional manual airflow indicator button protrudes
• The specified number of hours has passed since the
last filter element change.
Do not operate the forklift until the filter element has

been replaced.
Forks
Fork identification describes how to attach the fork to
the board. These forklifts These machines have hook
forks.
Withdrawal
A WARNING
Do not attempt to move the forks without a lifting
device. Each hook fork for these cars Lifting bars
can weigh from 45 to 115 kg (99 to 253 lb).
NOTE: Forks must be replaced as a unit and not

individually.
Forks can be removed from the board for replacement

or other maintenance procedures iment. Raise the
locking pin and slide a hook rod into the rod removal
slot in the dash. See Figure 15 and Figure 16. Lower
the fork onto the blocks so that the lower hook of the
fork moves through the removal slot. fork cut. See
Figure 16. Continue lowering the board so that the top
hook of the fork disengages from the top bar of the
board. Remove the board to separate it from the fork or
separate the fork from the board with a lifting device.
3
2
1. BARS OF THE 3. BLOCKS

BOARD
2. FORK
HOOK
Figure 15. Removal of hook forks
Inspection
1. Inspect the forks for soreness. tattered or worn out.

Check that the tips of the rods are aligned as
shown in Figure 16. Check the bottom of the forks Fork Tip Alignment
for wear (4, Figure 16). Rods length 3% dimension
2. Replace any damaged or broken parts that are
915 mm (36 in.) 27 mm (1.10 in.)
used ice to keep the rods in position.
1067 mm (42 in.) 32mm (1.26 in.)
Facility 1220 mm (48 in.) 37mm (1.46 in.)
1,372 mm (54 in.) 41 mm (1.61 in.)
Move the fork and board so that the gan The upper part 1524 mm (60 in.) 46 mm (1.81 in.)
of the fork can be hooked to the upper bar of the 1830 mm (72 in.) 55mm (2.17 in.)
dashboard. Raise board for intro Slide the lower hook
1. TOE ALIGNMENT
through the fork removal slot. Slide the fork onto the (MUST BE LESS THAN 3%
board so that the top and bottom hooks engage the FORK LENGTH)
board. Attach the pin to a slot in the top bar of the dash. 2. CRACKS
3. CLOSURE DAMAGE
4. FORK HEEL
(MUST BE 90% OF THE
DIMENSION
5. BOARD
6. LOAD SUPPORT GRILL
7. MAXIMUM ANGLE 93 0
8. ROD REMOVAL SLOT
Figure 16. Checking the forks
3
3
Adjustment
NOTE: When adjusting the forks, the heel of the forks

should not touch the ground.
The forks are attached to the board using hooks and

pins. See Figure 15 and Figure 17. These pins are
mounted through the upper hooks of the fork and are
housed in slots in situ. adas on the top bar of the board.
If the pin does not stay engaged in the slot in the board,
replace it with a new pin. Adjust the forks so you know
as possible to provide maximum support to the load.
The hook forks will slide along the deck bars to
accommodate the load to be lifted. Lift the pin on each
fork to slide the fork onto the dash bar. Make sure the
pin is engaged in the dash bar to lock the rod in the
1. CAP SCREWS
desired position once the width adjustment is 2. LOWER HOOK
completed. 3. GARRISON
4. LOWER SUPPORT PLATES
5. UPPER SUPPORT PLATES
6. GREASE FITTERS
7. CYLINDER STEM
8. ELASTIC RING
9. STEM SCRAPER
10. STEM BUSHINGS
11. WATERTIGHT CLOSURE
12. FIXED FRAME
Figure 18. Board with lateral movement

integrated
▲ WARNING
FASTEN THE SEAT BELT! The seat belt is used to
5. CRADLE keep the operator inside the forklift in case it
6. COMMAND
7. PIN ASSEMBLY overturns. IT CAN ONLY BE USEFUL IF IT IS
BUTTONED.
1. FORK Figure 17. Rod Pin Assembly
2. BARRETTE Make sure the area around the truck is clear before
3. DOCK
4. WASHER Board with integrated starting the engine or performing any operational
lateral movement checks. Be careful when carrying out checks tions. If
the forklift must be stopped during a check, apply the
Check for cracks, wear and damage. If there is damage, parking brake and put the transmission in NEUTRAL
see Mast Repairs , 2 and 3 Stage Masts 4000 YRM position. Carry out checks carefully.
1250 for procedures. repair procedures. If necessary,
lubricate the sliding surfaces on the grease nipples with Indicator lights, horn, fuses and relays
the multi-purpose grease shown in Maintenance
Program. maintenance. See Figure 18. If the truck is equipped with an ignition key, turn it to the
ON position. If the truck is equipped with on/off button
HOW TO PERFORM CHECKS at (Power ON/OFF ), press the button to turn on turn on
WITH THE ENGINE RUNNING the system. All warning and indicator lights will
illuminate for two seconds (com initial testing) when the
A WARNING system power is turned on . See Figure 19. Check the
DO NOT use any truck that requires repair. fun correct operation of all indicator lights as explained
Immediately communicate the need repair time. If in the Operator's Manual . Com test the horn
repair is necessary, post an "OUT OF SERVICE" operation. Start the engine by turning the ignition key to
sign at the operator's station. If the truck is the start position. start , if the truck is equipped with a
equipped with an ignition key, remove the key. key
3
4
contact or press the engine start button, if the truck is power distribution (PDM) which is located under the
equipped with it. If any indicator light does not work hood and near the battery, on the right. See Figure 20.
properly, check the fuses. The fuses are located in the
Power Module.
Element Warning and indicator light
1 Warning light, engine fault light

2 Warning light, system fault light
3 Indicator light, air filter clogging
4 Indicator lights, steering and transmission
5 Warning light, brake oil level failure indicator
6 Warning light, seat belt closure failure indicator
7 Warning light, parking brake failure indicator
8 Warning light, alternator failure indicator
9 Warning light, transmission oil temperature fault indicator
10 Warning light, engine oil pressure fault indicator
11 Warning light, engine coolant temperature fault indicator
12 Warning light, radiator coolant level failure indicator
13 Warning light, fuel level gauge failure indicator
14 Indicator light, 1st gear lock (Techtronix 200X transmissions)
15 Water separator indicator light (Diesel only)
16 Indicator light, cold start (Diesel only)
Figure 19. Warning and indicator lights
3
5
NOTE: HOOD REMOVED FOR GREATER CLARITY.

1. BATTERY
2. PDM
3. RESISTOR (68 OHMS)
4. STARTER MOTOR RELAY
5. STARTER MOTOR (30 AMP FUSE)
6. ON RELAY 3
7. REVERSE RELAY
8. REVERSE (20 AMP FUSE)
9. IGNITION (30 AMP FUSE)
10. REPLACEMENT FUEL PUMP (20 AMP FUSE)
11. FUEL PUMP REPLACEMENT RELAY
12. BATTERY (25 AMP FUSE)
13. FRONT WORK LIGHT (FUEL FUSE)
20 AMPS)
14. WORK LIGHT RELAYS
FRONT REAR
16. REAR WORK LIGHT (20 FUSE
AMPERES)
17. IGNITION 1 (20 AMP FUSE)
18. RELAY ON
3
6
Figure 20. PDM showing fuses and relays

Service brakes Parking break
Brake oil level Be sure to adjust the service brakes and that the
automatic adjusting mechanism is operating correctly so
▲ WARNING that you can adjust the brake on this ing.
Small amounts of water in the brake system can
result in reduced braking performance if the water Forklifts with directional control pedal. The switch
reaches the wheel cylinder area. Do not allow water activates the seat warning circuit when the manual lever
to enter. Make sure the sealed reservoir cap is is released. This switch puts the transmission in
replaced correctly. NEUTRAL and disengages going the steering solenoid.
There is also an inter breaker on the left side of the
If the brake system has a power-assisted master bracket. This switch prevents the engine from starting
cylinder, it will be more difficult to brake if the unless the parking brake is applied.
engine is not running.
NOTE: Make sure the parking brake is released before
Loss of oil from the brake oil reservoir indicates a making adjustment.
leak. Repair the brake system before using the truck
1. Turn the adjusting knob to raise the equalizing rod
on evadora. If there is dirt or water in the system,
and tighten the brake cables on it. operation shown
change the brake oil.
in Figure 21. Do not tighten the adjustment knob so
DO NOT use "DOT" fluid, only use Dexron III oil much that the brake is applied when the lever is
from a sealed container to avoid possible damage to released. The parking brake lever has a lock.
the brake system. Not respecting the warnings
Use your thumb or other finger to unlock the lever
Failure to do so may result in serious injury or
when releasing the parking brake.
death.
There is an on-screen light on the instrument panel. 2. For polished brakes, check parking brake operation.
indicator corresponding to brake oil. The red light is ON The ele wheelbarrow The machine with a rated load
when the ignition key is in the START position or the must not move when the parking brake is applied
power ON/OFF button is pressed and should be OFF on a slope. between 15%, that is, a slope that rises
when the engine is running. If the light stays on with the 1.5 m in 10 m (1.5 feet in 10 ft).
engine running, this means that the brake oil level in the
engine is tank is too low.
Operation, check
Check the operation of the service brakes. Depress the

slow speed/brake pedal. The brakes of being vice must
be applied before the slow/brake pedal reaches the floor
plate. The pedal should stop firmly and not move slowly
until down once the brakes are applied. Service brakes
must be applied equally to both drive wheels. When
applying the service brakes, they must not pull the truck
towards either side. two of the direction of travel. The
service brakes adjust automatically when the trans
mission is in reverse, the truck is moving and the brakes
are firmly applied When the slow/brake pedal is fully
depressed, the service brakes are applied and the
transmission is shifted into position. NEUTRAL tion.
Forklifts with directional control pedal. When the

slow/brake pedal is fully depressed, a switch in the
ignition circuit closes. crank, which allows the engine to
start.
3
7
2. DISCONNECT POSITION
3. CONNECTION POSITION
4. ADJUSTMENT KNOB
Figure 21. Parking break
Engine oil pressure

NOTE: The engine will go into shutdown mode After an
audible warning signal and a 30-second countdown, if
the engine oil pressure tor is less than 34.5 kPa (5 psi)
on lift trucks machines with transmission train protection
system mission. Forklifts equipped with a Cummins
diesel engine will enter shutdown mode ged when
engine oil pressure is less than 49 kPa (7 psi) on
forklifts with drivetrain protection issue. See engine
shutdown procedures in the Man ual of the User .
There is an indicator light for the engine oil pressure. tor

on the on-screen instrument panel. During normal
operation, the red indicator light illuminates when the
ignition key is turned to the ON position, if the truck is
equipped with an ignition key, or when the power
ON/OFF button is pressed, if the truck is equipped with
an ignition key. The truck is equipped with the keyless
start option, and will remain on until the correct oil
1. UNLOCK BUTTON
pressure is achieved, at which time the light will go out.
3
8
If the light remains on with the engine running, this that they can cause injury to the user and others.
means that the engine oil pressure is low. Stop the Make sure that the compressed air outlet cannot
engine and check the oil level. See Figure 14 for reach other people. Wear protective glasses or a
GC/GLC080, 100, 120VX forklifts; GC/GLC080, mask to avoid cause eye injuries.
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS
(E818)Figure 12 and Figure 14 for elevated trucks (for Check the radiator fins. Clean the radiator with
GP/GLP/GDP080, 090, 100, 110, 120VX) models compressed air or water as necessary. Check for debris
(F813, G813) Do not restart the engine until the low in the radii core. adore and remove them. If the indicator
pressure situation has been corrected. ruled. light comes on again when restarting, turn off the
forklift. machine and do not operate it again until the
Refrigeration system problem has been corrected.
A WARNING
DO NOT remove the radiator cap while the engine is
hot. When the radiator cap is removed, system
pressure is released. If the system is hot, steam and
boiling coolant can cause burns.
NOTE: The engine will go into shutdown mode After a

warning chime and a 30-second countdown, if the
coolant temperature reaches 118°C (245°F) or higher,
on GM 4.3L forklifts with protection system tion of the
drive train. Forklifts equipped with a Cummins 4.5L or
QSB 3.3L diesel engine will enter shutdown mode when
the coolant temperature reaches 114 0 C (238 0 F) or
higher, for forklifts with drive train protection system .
See Engine Shutdown Procedures in the Owner's
Manual .
There is an on-screen light on the instrument panel.

indicator corresponding to the coolant temperature. The
red light is ON when the ignition key is in the on
position. START or power ON/OFF button is pressed
and should turn OFF when the engine is running. If the 1. FILLER CAP
light comes on with the engine at sea cha, this means 2. HOT FILLED BRAND.
that the coolant and the engine are too hot. Stop the 3. COLD FULL MARK
4. MARK ADD "COLD
engine and check the coolant level in the tank. coolant
recovery tank. Figure 22. Auxiliary coolant tank
Make sure the coolant level is between the "ADD" and Direction system
"FULL" marks on the auxiliary coolant reservoir (see
Figure 22). The coolant expands when heated and its ▲ WARNING
level in the auxiliary coolant tank increases. The forklift is equipped with hydraulic power
steering. Direction may be difficult cil if the engine
A CAUTION is not running.
Additives can damage the cooling system. eration.
Before using additives, contact your local Yale Make sure the steering system operates smoothly and
distributor. allows good steering control. Make sure the steering
column can be adjusted and the gas cylinder works
If you add coolant, use the correct mixture of water and properly mind.
ethylene glycol indicated in the Maintenance Schedule.
Control levers and pedals
A WARNING
Compressed air can move particles in such a way Check that the transmission control levers mission, mast
3
9
and accessories operate as described in the Operator's 1. Check for leaks in the hydraulic system. Check the
Manual . Check that the pedals operate correctly as condition of the hydraulic system hoses and tubes.
shown. written in the Operator's Manual .
NOTE: Some parts of the mast move at speed different
Lifting system, operation speeds during lifting and lowering.
2. Slowly raise and lower the mast several times

▲ WARNING without load. Raise the mast to its maximum stop at
When working on or near the mast, see Safety
least once. The mast pieces should rise and fall
Procedures When Working Near the Mast at the end
smoothly in the proper order. The hose must be
of this section.
correctly guided during during operation.
Lower the lifting mechanism completely. Never
3. The interior profiles and the board must be
allow anyone to stand under a raised board. Do not
completely lowered.
place any part of your body on the lifting
mechanism unless all mast parts are fully lowered 4. Raise the mast 1 m (3 ft) with a rated load. The
and the engine is OFF. interior profiles and the board should be raised
gently. Lower the mast. All components Moving
If you cannot lower the mast, use chains on the objects should descend smoothly.
mast and deck profiles to prevent it from moving.
go. Make sure moving parts are in place. face to an 5. Lower the load to approximately 0.3 m (1 ft). Tilt the
immobilized piece. mast back and forth. The mast should tilt smoothly
and both tilt cylinders should stop at the same time.
Do not try to find hydraulic leaks by putting your
hands on hydraulic components with pre Zion. 6. Check that the controls on the accio accessory nen
Hydraulic oil could be injected into the body due to the functions of the accessory. See the symbols
the effect of pressure. those of each of the controls. Make sure all
hydraulic lines are connected. correctly and do not
Carry out the following checks and inspections: present leaks.
4
0
First service inspection after the first 100 hours of operation 8000 YRM 1248
First service inspection after the first

100 hours of operation
GM 4.3L ENGINE OIL FILTER CUMMINS 4.5LY QSB 3.3L ENGINE OIL
NOTE: The engine oil filter must also be changed
FILTER
changed after the first 100 hours of operation of a newly Change the engine oil filter See Figure 24. Apply clean
installed engine. oil to the new filter gasket. Install a new filter. Rotate the
Change the engine oil filter See Figure 23. Apply clean filter until it touches the gasket and then tighten 1/2 - 3/4
oil to the new filter gasket. Install a new filter. Rotate the turn by hand. Start the engine. Examine the area around
filter until it touches the gasket and then tighten 1/2 - 3/4 the oil filter for leaks.
turn by hand. Start the engine. Examine the area around
the oil filter for leaks.
NOTE: LEFT SIDE OF MO SHOWN TOR

NOTE: BACK SIDE SHOWN
1. OIL FILTER
2. DRAIN PLUG LEFT
3. ENGINE OIL OIL DIPSTICK 1. OIL FILTER 2. DRAIN PLUG
Figure 24. Change engine oil filter, Cummins 4.5L
Figure 23. GM Engine Oil and Filter Change
4.3L diesel (shown)
4
1
8000 YRM 1248 First service inspection after the first 100 hours of operation
HYDRAULIC SYSTEM To change the hydraulic oil, see Hydraulic oil,

replacement.
Hydraulic filter, replacement
▲ WARNING
At operating temperature, hydraulic oil is HOT.
A CAUTION
Do not allow dirt to enter the hydraulic system when
filter. Dust could damage hydraulic system parts.

A CAUTION
Removal of lubricants and other fluids Two must be
carried out in accordance with local environmental
regulations.
1. Place the forklift on a level surface and lower the

board. Unscrew and remove the filter cap and head
spring. See Figure 25. Raise the hydraulic filter
element enough to allow the hydraulic oil to drain.
NOTE: Have a container large enough to hold the filter

element and allow the hydraulic oil to finish draining.
2. Remove the hydraulic filter element and O-ring from

the bowl and place it in a container. Cover the head
to prevent foreign bodies from entering the
hydraulic tank.
3. Lubricate the new O-ring with hydraulic oil and

install it on the bottom of the filter element. Install
the new filter element into the bowl.
4. Install the spring and filter cap on the head.

6. FITTING
A CAUTION 7. STAR RING
Additives can damage the hydraulic system. Before 8. FILTERING ELEMENT
9. FILTER BUCKET
using additives, contact your local Yale distributor.
Figure 25. hydraulic filter
5. Start the truck and let it run for 30 seconds. Check
for leaks. Stop the engine and check the hydraulic 1. TOP
2. DOCK
oil level. Add oil, if necessary. Use the type of 3. O-RING
hydraulic oil indicated in the Maintenance Schedule. 4. SCREW
SKULLCAP
5. HEAD
4
2
First service inspection after the first 100 hours of operation 8000 YRM 1248
TRANSMISSION OIL FILTER, REPLACEMENT

A WARNING
At operating temperature, transmission oil is HOT.
( CAUTION
Prevent dust from entering the transmission when
checking the oil level or changing the filter. Dirt can
cause damage to components. transmission lenses.
AN CAUTION
regulations.
NOTE: The transmission oil filter must also be changed

after the first 100 hours of operation. operation of a
newly installed transmission.
NOTE: Before removing the oil filter, perform an ori NOTE: ALL COMPOS ARE SHOWN MAIN LENS AND
place on top of the filter and allow five minutes cough to FRAME COMPONENTS REMOVED FOR GREATER
drain the oil in the transmission. See Figure 26. This will CLEARANCE DAD
reduce the oil that will come out of the filter and into the 1. TRANSMISSION
transmission when the filter is removed. 2. TRANSMISSION DRAIN PLUG
3. DOCK
1. Remove and discard the trans oil filter mission. 4. SIEVE
Apply clean oil to the new transmission oil filter 5. TRANSMISSION OIL FILTER
6. TRANSMISSION DIP DIPS
gasket. Install the new transmission oil filter and 7. TRANSMISSION BREATHER
hand tighten. See Figure 26.
Figure 26. Changing the oil filter
2. Check the oil level in the var tube level island. If
transmission
necessary, add additional oil as shown in
Maintenance Schedule iment. Check for leaks
during operation.
4
3
8000 YRM 1248 Maintenance procedures every 1000 hours or every 6 months
Maintenance procedures every 250 hours or every 6 months

NOTE: Perform the 8-hour checks before performing the TRANSMISSION BAND
procedures in this section.
GM 4.3L engine
GM 4.3L ENGINE OIL AND FILTER
Fan and alternator drive belt
NOTE: Replace the engine oil filter after the first 100
hours of operation on new lift trucks. Check for wear and possible damage to the cor
transmission area. See Figure 28. A few small cracks
Change the engine oil and engine oil filter. See Figure running through the strap are acceptable. Belts with
27. Use the correct type of oil according to the cracks that extend the entire length of the belt and belts
Maintenance Schedule. Apply clean oil to the new filter with pieces missing are not acceptable. See Figure 29
gasket. Install a new filter. Rotate the filter until it for drive belt layout.
touches the gasket and then tighten 1/2 - 3/4 turn by
hand. Start the engine. Examine the area around the oil
filter for leaks.
1. ACCEPTABLE CRACKS
2. UNACCEPTABLE CRACKS AND DAMAGES
Figure 28. Drive Belt Inspection
NOTE: LEFT SIDE OF MO SHOWN TOR

1. OIL FILTER
2. DRAIN PLUG
3. ENGINE OIL OIL DIPSTICK
Figure 27. GM 4.3L Engine Oil Change
Figure 29. Installing the drive belt

GM 4.3L
4
4
Maintenance procedures every 1000 hours or every 6 months 8000 YRM 1248
Legend of figure 29
NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTABLE

TENSIONERS.
1. FAN PULLEY
2. WATER PUMP PULLEY
3. CRANK PULLEY
4. SERPENTINE BELT
5. TENSIONER CENTERING PULLEY
6. ALTERNATOR PULLEY
EMPTY TAR FROM LPG REGULATOR

1. Warm the engine to operating temperature.
2. Close the fuel valve and run the engine until it runs
out of gas and stops.
3. Raise the hood.
4. Remove the engine tar drain screw. ulator. Drain the

1. TAR DRAIN SCREW
tar from the regulator. When the tar has completely
drained, install the tar drain screw into the regulator. Figure 30. GM LPG Regulator
See and Figure 30.
Maintenance procedures every 500 hours or every 6 months

NOTE: Perform the 8 and 250 hour checks before HYDRAULIC TANK VENT
performing the procedures in this section.
Inspection
HYDRAULIC SYSTEM OIL
NOTE: Do not remove the breather when inspecting it.
A WARNING The breather element is not a serviceable part. If the
At operating temperature, hydraulic oil is HOT. element is damaged, replace it with a new breather
Avoid letting hot oil come into contact with your element.
1. Raise the hood and remove the right rear side
panel cho See Figure 31.
A CAUTION
Do not allow dirt to enter the hydraulic system when A WARNING
checking the hydraulic oil level or changing the Compressed air can move particles in such a way
filter. that they can cause injury to the user and others.
( CAUTION A CAUTION
Additives can damage the hydraulic system. Before Direct air pressure on the filter element may cause
using additives, contact your local Yale distributor. damage. Direct air pressure away from the filter
element.
Check the hydraulic oil level with the oil at normal
2. Using compressed air, remove dirt and debris from
operating temperature, mast upright, deck lowered and
the frame cavity around the breather. See Figure
engine stopped. See Figure 38. Add only the necessary
31.
hydraulic oil. If the oil level exceeds the FULL mark, oil
will leak from the breather during operation. The oil 3. If necessary, unscrew and replace the res leak if oil
level, indicated by the dipstick, is most accurate when has accumulated in the cavity or breather, or if dirt
the oil temperature is 53 to 93°C (130 to 200°F).
4
5
has accumulated side into the vent ducts located at CUMMINS ENGINE OIL AND FILTER
the bottom of the vent. 4.5LY QSB 3.3L
4. Install the right rear side panel and close the hood. NOTE: Replace the engine oil filter after the first 100
See Figure 31. hours of operation on new lift trucks.
Change the engine oil and engine oil filter. See Figure
32. Use the correct type of oil according to the
Maintenance Schedule. Apply clean oil to the new filter
gasket. Install a new filter. Rotate the filter until it
touches the gasket and then tighten 1/2 - 3/4 turn by
hand. Start the engine. Examine the area around the oil
filter for leaks.
Figure 31. Hydraulic tank breather

Legend of figure 31
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK VENT
BATTERY
▲ WARNING
The acid in the electrolyte can cause injury. If
electrolyte is spilled, use water to clean the area.
Use a baking soda solution to neutralize the acid. If
acid gets into your eyes, rinse them immediately
with water. Wear eye protection.
A WARNING NOTE: LEFT BACK SIDE.

Batteries generate explosive vapors. Man Keep the
plug vents clean. Avoid sparks or flames in the 1. OIL FILTER 2. PLUG
battery area. Do not cause sparks at the battery SEWER SYSTEM
connections. When performing maintenance,
Figure 32. Cummins engine oil change
disconnect the battery ground cable.
4.5L diesel (as shown)
Disconnect the negative and positive battery terminals.
REPLACING THE SEPARATOR FILTER
Using a damp cloth, clean the battery case. If the
FUEL/WATER, ENGINE
terminals are corroded, clean them with a wire brush.
Connect the negative and positive cables to their CUMMINS 4.5LY QSB 3.3L
respective terminals.
( CAUTION
4
6
regulations.
Replace the fuel filter at specified intervals. cos to

prevent contaminants from adversely affecting the flow
of diesel fuel.
Withdrawal
1. Stop the engine and allow it to cool.
2. Disconnect the air inlet elbow for ac yield to the fuel

filter element. See Figure 33.
3. Disconnect the fuel filter sensor connector. fuel filter

element fuel.
A CAUTION
Drain the water/fuel into a container and dispose of
in accordance with local environmental regulations.
4. Open the drain valve by turning the valve

counterclockwise approximately 3 and a half turns
until it begins to drain. Drain until the fuel filter
element is empty.
5. Remove and discard the fuel filter element. fuel.
Facility
1. Clean the mounting surface of the fuel filter head
and apply a small amount of diesel fuel to the
gasket of the new fuel filter element. See Figure 33
and Figure 34.
2. Before installing the filter element, fill it with diesel

fuel. This method will help in purging the sys fuel
issue.
A CAUTION
Do not overtighten the filter element. If you tighten
the filter element too much, threads may form.
3. Install the new fuel filter element until it contacts the

mounting surface. fuel filter head fitting. Tighten one
more turn.
4. Connect the fuel sensor connector to the fuel filter

element.
5. Connect the hose to the air inlet elbow.
6. Open the fuel supply valve.
7. Prime the fuel system. See Priming the Fuel System

(Cummins 4.5L and QSB 3.3L).
8. Check for fuel leaks.
4
7
Figure 33. Cummins 4.5L Engine Fuel System
4
8
Legend of figure 33
TO RIGHT SIDE VIEW b. FRONT VIEW
.
1. FUEL FILTER ELEMENT 7. FUEL TRANSMITTER UNIT
2. PURGE COCK 8. FILTER SENSOR CONNECTOR
3. LIFT PUMP FUEL
4. FUEL FEED PUMP 9. AIR INLET ELBOW
5. FUEL FILTER PIPE 10. IN-LINE INJECTOR FITTINGS
6. FUEL SUPPLY VALVE FUEL (4)
4
9
Legend of figure 34
A. RIGHT VIEW
B. TOP VIEW
1. TURBO
2. HEAD
3. ELBOWED HOUSING
4. STEERING WHEEL
5. OIL COLLECTION PAN
6. ENGINE BLOCK
7. ELECTRONIC FUEL PUMP
8. FUEL FILTER
9. WATER OUTLET HOUSING
10. WATER PUMP BELT
11. WATER INLET HOUSING
12. OIL FILLER CAP
13. WATER DOOR
14. TURBO
15. AIR INTAKE HOUSING
16. OIL DIPSTICK
17. MANIFOLD
18. EXHAUST OUTLET
19. ENGINE ECM
20. STARTING MOTOR
21. FUEL AND WATER SEPARATOR
22. PRIMER PUMP
23. INTAKE MANIFOLD
24. FUEL FILTER
25. AIR ENTRANCE
26. INJECTOR DUCT
FINAL REPLACEMENT OF THE FUEL

FILTER (CUMMINS QSB 3.3L)
A CAUTION
regulations.

prevent contaminants from adversely affecting the flow
of diesel fuel.
1. Close any OEM fuel valves (if applicable) to prevent

fuel from escaping.
2. Clean the area around the fuel filter head.
A CAUTION
Drain the fuel into a container and dispose of in
Figure 34. engine fuel system accordance with local environmental regulations.
Cummins QSB 3.3L
3. Remove the fuel filter.
4. Clean the gasket surface.
5
0
5. Fill the new fuel filter with com clean fuel and 3. Tighten the fuel line to the injector pump to 9 N•m
lubricate the gasket with clean engine oil. (80 lbf in). See Figure 33.
6. Install a fuel filter. 4. Open crack in one or more of the hydraulic

passages located in the cylinder head.
7. Start the engine and check for leaks around fuel
filter cover. ▲ WARNING
The jet of pressure released by the fuel injectors can
PRIMING THE FUEL SYSTEM (CUMMINS penetrate the skin and cause injury. serious
4.5LY personal injuries Wear protective clothing and
QSB 3.3L) accessories
Controlled ventilation 5. Move the engine until fuel comes out of the loose
fittings. Tighten the injector line fittings while moving
(N CAUTION the engine. The engine must start
When using the starter motor to vent the system, do
not engage the starter motor for more than 30 A CAUTION
seconds or the system may be damaged. Wait 2 Removal of lubricants and other fluids Two must be
minutes before engaging the starter motor again. carried out in accordance with local environmental
regulations.
Controlled ventilation is provided at the injection pump
through the fuel drain manifold. fuel. The small amounts 6. Wipe up any fuel that may have spilled Clean and
of air introduced Changes made when changing filters or dispose of fuel and rags according to local
the injection pump supply line will automatically vent if directives.
the fuel filter element is changed and filled prior to
installation. TRANSMISSION BAND
manual purge Cummins 4.5L and QSB 3.3L diesel engine
Manual purging will be necessary if one of the following Fan and alternator drive belt
conditions exists.
Check for wear and possible damage to the cor
• The fuel filter is not filled prior to installation.
transmission area. See Figure 35. A few small cracks
• The injection pump is replaced.
running through the strap are acceptable. Belts with
• Comm duct connections loosen high pressure fuel, or
cracks that extend the entire length of the belt and belts
the leads are replaced cough.
with pieces missing are not acceptable. See Figure 36
• It is the initial start of the engine after a prolonged
and Figure 37 for drive belt layout.
period long without working.
If equipped with electronic fuel pump (Cummins QSB

3.3L), with the pedal or throttle lever in the idle position,
turn the ignition key touch to the ON position. Wait for
the “Wait to Start” light to turn off. Start the forklift.
If the engine does not start after 3 attempts, contact Test

the fuel supply system. The absence of blue or white
smoke indicates that you are missing sum fuel injection
to the engine.
1. Open crack in the fuel line to the injector pump. See

Figure 33.
2. Operate the manual lever until it comes out fuel due 1. ACCEPTABLE CRACKS
to loose fitting. 2. UNACCEPTABLE CRACKS AND DAMAGES
5
1
Figure 35. Drive Belt Inspection
1. ALTERNATOR BELT ADJUSTMENT BRACKET

NOTE: CUMMINS 4.5L ENGINES HAVE TEN SELF- 3. CAMSHAFT PULLEY
4. CRANK PULLEY
ADJUSTABLE SOURCES. 5. ALTERNATOR PULLEY
1. ALTERNATOR PULLEY
2. CAMSHAFT PULLEY Figure 37. Drive belt arrangement
3. WATER PUMP PULLEY Cummins QSB 3.3L diesel engine
4. CRANK PULLEY
5. TENSIONER CENTERING PULLEY CLEANING RESIDUES FROM THE RADIATOR
PANEL
Figure 36. Drive belt arrangement
Cummins 4.5L diesel engine Check the radiator core for blockages and remove any
blocking or obstructing material.
A WARNING
Compressed air can move particles in such a way
that they can cause injury to the user and others.
Clean with compressed air, set to max output ima of 103

kPa (15 psi), and blow any debris out of the radiator
core and bell.
5
2
TRANSMISSION OIL LEVEL If the engine has been running, it should remain off for a
minute or more before performing the oil level check
▲ WARNING (see Figure 38). If the transmission oil is low, add
At operating temperature, transmission oil is HOT. transmission oil through the dipstick tube to the correct
Avoid letting hot oil come into contact with your level as indicated on the dipstick. Use the correct type of
skin and cause a burn. oil indicated in the Maintenance Schedule.
(N CAUTION
Prevent dust from entering the transmission during
checking the oil level or changing the filter.
1. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL DIPSTICK
Figure 38. Checking hydraulic and transmission oil
5
3
CHECKING THE OIL LEVEL OF THE WET 1. Remove the fill/level plug from the central body. tral.
BRAKE CENTRAL BODY See Figure 39 for elevated trucks flush with models
GC/GLC080, 100, 120VX; GC/GLC080,
A WARNING 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS
At operating temperature, the center section oil is (E818) and Figure 40 for forklifts of models
HOT. Avoid letting hot oil come into contact with GP/GLP/ GDP080, 090, 100, 110, 120VX (F813,
your skin and cause a burn. G813).
2. Visually check the oil level. If necessary, add oil

( CAUTION through the filler/level hole until it overflows. The
Do not allow dirt to enter the center body when
type of oil straight is indicated in the Maintenance
checking the oil level. her This will contaminate the
Program iment.
oil and cause damage to the central body of the
axle. 3. Install the center body fill/level hole plug and tighten
to 30 to 50 N•m (22 to 37 lbf ft).
5
4
A. BACK VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN PLUGS
3. CENTER SECTION DRAIN PLUG
4. CENTER SECTION FILLER CAP/LEVEL
5. PLANETARY CARRIER HOUSING (RIGHT)
6. PLANETARY CARRIER HOUSING (LEFT)
7. CENTRAL SECTION A. BACK VIEW SHOWN
B. FRONT VIEW SHOWN
Figure 39. Location of the drain plug and 1. PLANETARY CARRIER HOUSING FILL/LEVEL
disc brake drive shaft filling/level PLUGS
in oil bath for forklift models 2. PLANETARY CARRIER HOUSING DRAIN PLUGS
elevator GC/GLC080, 100, 120VX; GC/GLC080, 3. CENTER SECTION FILLER CAP/LEVEL
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS 4. CENTER SECTION DRAIN PLUG
(E818) 6. PLANETARY CARRIER HOUSING (LEFT)
7. CENTRAL SECTION
Figure 40. Location of the drain plug and

filling/level of propeller shaft with brake on
oil bath for forklifts
GP/GLP/GDP080, 090, 100, 110, 120VX models
(F813)
5
5
FORKS ROLLERS
3. SUPPORT ROLLER
▲ WARNING Figure 41. Mast lubrication
Never repair damaged forks. Do not heat, weld or
bend the forks. The forks They are made of special NOTE: When lubricating the mast supports/knuckle
steel using special methods. Replace damaged rods pins, the load must be removed from the normal mating
as a complete assembly. surface to allow the grease to properly lubricate the
mating surfaces. normal feel of the mast bushings.
Measure the thickness of the forks with a fork arm
gauge (Yale part # 150021700) in a vertical section 2. Raise the deck about 61 cm (2 ft) and tilt the mast
where there is no wear. This thickness is dimension X. all the way back. Place blocks under the outer mast
Next, measure the thickness at the butt of the rod (see channels 13 mm (0.5 in.) from the channels See
Figure 16). If the thickness of the bead is not greater Figure 42.
than 90% of dimension X, replace the rod.
3. Tilt the mast fully forward. See Figure 42.
MAST LUBRICATION
▲ WARNING
When working on or near the mast, see Safety
Procedures When Working. Go down near the mast
in this section.
NOTE: Load rollers and pulleys have co Sealed riders

and do not need additional lubrication.
1. Lubricate sliding surfaces and surfaces fices of the

charge rollers along the entire length of the
channels, as shown in Figure 41.
A. TOP LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATION OF THE SURFACE OF THE
SUPPORT PLATES
2. LUBRICATION OF THE SURFACE OF THE LOAD
5
6
4. Lubricate the article pin bushings. mast connection

at the outer mast grease fittings. See Figure 43 and
Figure 44. Use the multi-purpose grease shown in
Maintenance Schedule.
5. Tilt the mast all the way back. Removal of blocks

from under the channels
6. If installing a side-moving tabletop, lubricate the

sliding surfaces on the greasers with the multi-
purpose grease shown in Maintenance Schedule.
See Figure 45.
A. FULLY TILTED BACKWARDS MAST
B. MAST TILTED FORWARD
1 BLOCK 2. MAST
Figure 42. Mast lock
5
7
1. MAST SUSPENSION HOOK BUSHINGS 7. CAP SCREW

2. LUBRICATION FITTINGS 8. NUT
3. MAST BEARING PLUGS 9. WASHER
4. TILT PIN 10. STEM END BEARING
5. STEM END 11. TILT CYLINDER ASSEMBLY
6. ANCHOR PIN 12. MAST SUPPORT COVER
Figure 43. Mast support suspension hook, lubrication
5
8
1. OUTER MAST
2. MAST JOINT BUSHING
3. GREASE FITTING
Figure 44. Joint Pin Lubrication

LOWER 8. ELASTIC RING
3. GARRISON 9. SCRAPER
4. PLATINUMS STEM
SUPPORT 10.
LOWER STEM BUSHING
5. PLATINUMS 11. WATERTIGHT
SUPPORT 12. FIXED FRAME
SUPERIORS
UPPER TANK HOSE CHECKS

Daily inspection plus; bent hose, flat tada or twisted; stiff
or burnt hose; slipping of the hose fitting; correct hose
tension Adjust/repair/replace hose/components as
necessary.
Figure 45. Board with lateral movement

integrated
Legend of figure 45
1. SCREWS 6. GREASE FITTERS
SKULLCAP 7. STEM OF THE
2. HOOK CYLINDER
5
9
LUBRICATION OF LIFT CHAINS hour/6 month lifting chain lubrication.

the forklift and immerse them in engine oil. Be sure to
A WARNING clean any dirt or grease from the ca before lubricating
When working on or near the mast, see Safety them. DO NOT USE STEAM TO CLEAN LIFT CHAINS.
Procedures When Working. Go down near the mast
in this section. TILT CYLINDER LUBRICATION
Do not repair lifting chains that are broken. worn or NOTE: The floor plate must be removed to lubricate the
damaged. If there is a chain of elements vation worn tilt cylinder rear lubrication fittings. nation.
or damaged, both lift chains will need to be
Lubricate the ends of the tilt cylinder. Use the all-
replaced.
purpose grease shown in Manual Program.
NOTE: Lubrication of 500 hour/6 month lift chains maintenance. There are four lubrication fittings. See
should not be done in combination. nation with 1000 Figure 46.
Lubricate the chains with SAE 30 motor oil. The best procedure is to remove the chains
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR GREATER CLARITY.

1. CAP SCREW 3. ANCHOR PIN 5. SPACER
2. RETAINER 4. LUBRICATION FITTING INCLINATION
Figure 46. Tilt Cylinder Lubrication
6
0
BRAKE MASTER CYLINDER ROD END PIN LUBRICATION OF THE HYDRAULIC

LUBRICATION MANUAL LEVERS
Lubricate the cylinder rod end pin. brake master Lubricate the bushings of the hydraulic manual levers
cylinder. Use moose oil tor indicated in the Maintenance cas. Use the spray lubricant indicated in the
Schedule. See Figure 47. Maintenance Schedule. See Figure 48.
1. STEM END PIN

2. KEY PIN (LOCK)
Figure 47. Brake Master Cylinder Rod End Pin
Lubrication
NOTE: FOUR-FUNCTION LEVERS WITH HOLD ARE

SHOWN.
1. BUSHINGS
2. STEM END PIN
3. HYDRAULIC LEVERS
4. CLOSING RING (COTT PIN)
Figure 48. Lubrication of manual levers

hydraulic
6
1
BRAKE OIL Legend of figure 49
A WARNING 1. TANK CAP

2. BRAKE OIL TANK
Small amounts of water in the brake 3. TANK MOUNTING BRACKET
system can result in reduced braking 4. HOOD
performance if the water reaches the 5. UPPER BRAKE OIL SUPPLY HOSE
wheel cylinder area. Do not allow water 6. CYLINDRICAL BLOCK OUTLET
FITTING
to enter. Make sure the sealed reservoir 7. LOWER BRAKE OIL SUPPLY HOSE
cap is replaced correctly. 8. NOZZLE
9. BRAKE MASTER CYLINDER
If there is dirt or water in the system, 10. CYLINDRICAL BLOCK DRAIN
change the brake oil. PLUG
11. CYLINDRICAL BLOCK
12. CYLINDRICAL BLOCK MOUNTING
A CAUTION BRACKET SCREW
DO NOT use "DOT" fluid, only use
Dexron III oil from a sealed container to LUBRICATION OF THE LINKS
avoid possible damage to the brake FOR FORKLIFT MODELS
system.
GC/GLC080, 100, 120VX;
Remove the dashboard from the hood. GC/GLC080, 100VXBCS;
The brake oil reservoir is located on the GC/GLC120SVX;
hood, on the brake master cylinder. See GC/GLC120VXPRS (E818)
Figure 49. Add oil as necessary. Use the
brake fluid indicated in the Maintenance Lubricate the tie rods. Use the multi-
Schedule. purpose grease shown in Maintenance
Schedule. There is a lubrication fitting on
each tie rod. See Figure 50.
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
Figure 49. Brake oil reservoir 3. LUBRICATION FITTING (SPINDLE)
Figure 50. Lubrication of the tie rods

forklift models GC/GLC080, 100,
6
2
120VX; GC/GLC080, 100VXBCS;

GC/GLC120SVX;
GC/GLC120VXPRS (E818)
6
3
LUBRICATION OF THE LINKS each tie rod. See Figure 51. filler hole to
FOR FORKLIFT MODELS check if the fluid level is at the lower end
of the filler hole. See Figure 52 and Figure
GP/GLP/GDP080, 090, 100, 110,
53. If the oil level is low, add oil as shown
120VX (F813, G813) in Maintenance Schedule until the oil level
Lubricate the tie rods. Use the multi- is between 0 to 10 mm (0 to 0.4 in.) at the
purpose grease shown in Maintenance bottom of the filler hole. Install the filler
Schedule. There is a lubrication fitting on cap and check for leaks.
1.
PROPELLER SHAFT
2. CHECK/FILLER CAP
3. DRAIN PLUG
1. LUBRI Figure 52. Filling the propeller shaft
CATION FITTING (TIE ROD) with fluid
2. LUBRICATION FITTING (SPINDLE) (dry brake) for forklift models
3. STEERING AXLE elevator GC/GLC080, 100, 120VX;
GC/GLC080,
Figure 51. Tie rod lubrication 100VXBCS; GC/GLC120SVX;
for forklift models GC/GLC120VXPRS
GP/GLP/GDP080, 090, 100, 110, 120VX (E818)
(F813, G813)
DIFFERENTIAL AND DRIVE AXLE OIL, FORKLIFT MODELS
The differential and drive axle use the same sum oil injection. The oil level should be
between 0 to 10 mm (0 to 0.40 in.) at the bottom of the filler hole. The filler hole for
checking the oil level is located at the front of the differential housing. Remove the filler
cap and check the fluid level by sticking a finger into the filler cap.
6
4
Legend of figure 53
1. CHECK/FILLER CAP
2. DRAIN PLUG
3. DRIVE AXLE
Figure 53. Filling the propeller shaft with fluid
(dry brake) for forklifts
(F813, G813)
Maintenance procedures every

1000 hours or every 6 months
NOTE: LPG FUEL FILTER ELEMENT
Perform the REPLACEMENT, GM 4.3L ENGINE
8, 250, and
500 hour Withdrawal
checks before performing the procedures
in this sec. tion. A WARNING
LPG can cause an explosion. Do not
VALVE CLEARANCE, CHECKING allow sparks or open flames to occur in
AND ADJUSTING the work area.
The GM 4.3L engine incorporates 1. Close the fuel tank valve.
hydraulic valve lifters cos and does not Run the engine until it stops.
require valve clearance adjustment during
normal maintenance. 2. Disconnect the negative battery cable.
See Maintenance Schedule for valve A WARNING

clearance. A small amount of fuel may be found in
the fuel line. Useful wear gloves to
You will find additional information about
avoid burns and wear protection ocular
the engines in the following sections:
tion. If fuel continues to leak from the
• GM engines , 4.3 liter V-6 600 YRM
connections after loosening, check that
1251
the manual valve is fully closed.
•
3. Remove the bolt and sealing washer
IGNITION SYSTEM that your Seal the upper section of the
fuel filter housing. Discard the sealing
GM 4.3L engine washer. See Figure 54.
GM 4.3L gasoline and LPG engines have
an electronic control unit (ECU) that
controls the ignition timing. There is no
type of adjustment. Change the spark
plugs every 1,000 hours. The air gap
straight of the spark plugs is 0.9 mm
(0.035 in.).
6
5
3. Install the new housing O-ring.
4. Install the upper section of the fuel

filter housing.
5. Install the bolt and new sealing

washer. Tighten the bolt to 13 N•m
(115 lbf in).
NOTE: Opening the fuel valve too quickly

can cause the internal overflow valve to
close, obstructing fuel flow. If this
happens, close the fuel valve, wait a few
seconds, and then slowly open the fuel
valve again. This will reset the excess fuel
valve.
6. Slowly open the fuel valve on the

cylinder.
7. Turn the ignition key to the on

position ON and back to OFF to
pressurize the fuel system. Check for
leaks.
8. Check for leaks at the uti connections

using a soapy solution or an electronic
1. CAP SCREW
leak detector. If leaks are detected,
2. SEALING WASHER
3. FUEL FILTER HOUSING UPPER make necessary repairs.
SECTION
4. FUEL FILTER
5. FUEL FILTER O-RING
6. HOUSING O-RING
7. FUEL FILTER HOUSING LOWER
SECTION
Figure 54. Filter removal and

installation
fuel
4. Remove the upper section of the fuel

filter housing.
5. Remove and discard the housing O-

ring.
6. Remove the fuel filter and fuel filter O-

ring.
Facility
1. Clean and inspect the fuel filter
housing. fuel to check for
contamination or damage.
2. Install the new fuel filter and fuel filter

O-ring. See Figure 54.
6
6
PIPE FILTER REPLACEMENT, CUMMINS ( CAUTION

4.5L ENGINE Drain the fuel into a container and dispose of in
accordance with local environmental regulations.
(N CAUTION 3. Loosen the clamps and disconnect two leads fuel
Removal of lubricants and other fluids Two must be leak from the fuel filter pipe. Remove and discard
carried out in accordance with local environmental the fuel filter from the line.
regulations.
Facility
prevent contaminants from adversely affecting the flow 1. Install the fuel filter pipe by connecting the two fuel
of diesel fuel. lines and tighten the clamps. See Figure 55.
Withdrawal 2. Open the fuel supply valve.
1. Stop the engine and allow it to cool. 3. Check for fuel leaks.
2. Close the fuel supply valve located on the fuel

sending unit. See Figure 55.
6
7
Figure 55. Cummins 4.5L Engine Fuel System
6
8
Legend of figure 55
A. RIGHT SIDE VIEW
1. FUEL FILTER ELEMENT
2. PURGE COCK
3. LIFT PUMP
4. FUEL FEED PUMP 5. FUEL FILTER PIPE 6. FUEL
SUPPLY VALVE
CHECKING THE WEAR OF THE LIFT CHAINS

If the length of a section of chain exceeds that of a
similar section on a new chain by 3%, the chain in
question is worn and should be replaced. tuida Measure
the chain for wear where it moves on the pulleys. Using
a chain scale, ref. no. Yale 518096869 Check the lift
chains as indicated in Figure 56.
B. FRONT VIEW
7. FUEL TRANSMITTER UNIT
8. FUEL FILTER SENSOR CONNECTOR
9. AIR INLET ELBOW
10. FUEL LINE INJECTOR FITTINGS (4)
Advance
Total length of
E E5
20 links
(advance) of the Wear limit
new chain Maximum length
of 20 links)
12.7mm 254.0mm 261.6mm
(0.50 in.) (10 in.) (10.3 in.)
15.9mm 317.5mm 327.0mm
(0.63 in.) (12.5 in.) (12.9 in.)
19.1mm 381.0mm 392.4mm
(0.75 in.) (15 in.) (15.4 in.)
25.4mm 508.0mm 523.3mm
(1.00 in.) (20 in.) (20.6 in.)
1. CHAIN WEAR SCALE
Figure 56. Checking the chains

elevation
6
9
LUBRICATION OF LIFT CHAINS 6. GREASE FITTERS

7. STEM OF THE
CYLINDER
▲ WARNING 8. ELASTIC RING
Cleaning solvents can be flammable and toxic and 9. STEM SCRAPER
cause skin irritation. When useful ice solvents for 10. STEM BUSHING
cleaning, always follow the manufacturer's 11. WATERTIGHT CLOSURE
recommendations. 12. FIXED FRAME
Compressed air can displace particles that can

cause injury to the user or other hazards. jadores. Figure 57. Board with lateral movement
Make sure that the air outlet pressed cannot reach integrated
other people. Useful Wear protective goggles or a
mask to prevent eye injuries.
Remove the lifting chains. Clean the chains by

immersing them in a petroleum-based solvent for at
least 30 minutes. Use compressed air, set to a
maximum output of 103 kPa (15 psi), to completely dry
the chains when they are clean.
Lubricate the lift chains by soaking them in 30W 1. SCREWS

motor oil for at least 30 minutes. Remove the chains SKULLCAP
2. LOWER HOOK
from the oil. Hang them for an hour to lose excess oil. 3. GARRISON
4. PLATINUMS
BOARD WITH INTEGRATED LATERAL LOWER
MOVEMENT, CHECKING SLIDING SUPPORT
5. PLATINUMS
SURFACES SUPERIOR
SUPPORT
1. Check the sliding surfaces of the board with lateral
movement and, if necessary, lubricate the sliding
surfaces in the slots. greasers with the multi-
purpose grease shown in Maintenance Schedule.
See Figure 57.
7
0
STEERING SHAFT (SCINDLE BEARINGS) FOR CONTROL LEVERS AND PEDALS

FORKLIFT MODELS GC/GLC080, 100, 120VX; Lubricate the connections, pedal shafts, control cables
GC/GLC080, 100VXBCS; (throttle, hood, parking brake), and seat rails. Use
GC/GLC120SVX; GC/GLC120VXPRS (E818) silicone spray lubricant, Yale part number 504236201.
Lubricate the steering shaft spindle bearings. There are

four lubrication fittings, two on each side of the steering
shaft. See Figure 58. Use the multi-purpose grease shown
in Maintenance Schedule.
I1! B) 8=
6 2
V ) - BLgg5
3, 3 /X
3
, b ( ,-64 — “<, ) J
e yég / A$~(B
A) )/ \ <2^21 and / or
BM210469
U— 1
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD) 1-- - - -2
3. LUBRICATION FITTING (SCINDLE BEARINGS) BM210542
Figure 58. Spindle bearing lubrication for forklift

1. LUBRICATION FITTING (TIE ROD)
models GC/GLC080, 100, 120VX; GC/GLC080, 2. LUBRICATION FITTING (SCINDLE BEARINGS)
100VXBCS; 3. STEERING AXLE
GC/GLC120SVX; GC/GLC120VXPRS (E818)
Figure 59. Lubrication of spindle bearings for
STEERING SHAFT (BEARINGS forklift models GP/GLP/GDP080, 090, 100, 110,
SPINDLE) FOR FORKLIFT MODELS 120VX (F813, G813)
GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
INSPECTION OF ENGINE ELECTRICAL
G813)
SYSTEM, CONNECTORS
Lubricate the steering shaft spindle bearings. There are
When inspecting the electrical system, check the
four lubrication fittings, two on each side of the steering
following ient:
shaft. See Figure 59. Use the multi-purpose grease shown
in Maintenance Schedule. • Check and clean the battery connection.
Make sure connections are tight.
• Check for possible damage to the battery or leaks in
the case. Replace if necessary.
• Check for corrosion, friction and rubbing on the
positive and negative cables. Tighten the connections
at both ends.
• Check for friction, rubbing, pinching, cracks or breaks
in the wiring.
7
1
8000 YRM 1248 Maintenance procedures every 2,000 hours or annually
• Check the engine wiring connectors. Check that the Replace the bu jigs at the recommended intervals as
connectors are threaded and lock stuck putting the shown Go to Maintenance Program.
connectors together. Pull on the connector halves to • Check that all electrical components are securely
make sure they are locked. mounted and secured to the engine or chassis.
• Check for hardening, cracks, abom bulging, pinching, • Check the operation of the MIL, charge and oil
separation, split covers, and proper adjustment of the pressure lights by starting the engine and checking
ignition coil wiring. ignition and spark plug wires. that the light illuminates before shutting off.
Maintenance procedures every 2,000 hours or annually

NOTE: Perform the 8, 250, 500, and 1000 hour checks hydraulic tank.
before performing the procedures in this section.
3. Lubricate the new O-ring with hydraulic oil and
HYDRAULIC SYSTEM install it on the bottom of the filter element. Install
the new filter element into the bowl.
Hydraulic filter, replacement
4. Install the spring and filter cap on the head.
A WARNING
At operating temperature, hydraulic oil is HOT. A CAUTION
Avoid letting hot oil come into contact with your Additives can damage the hydraulic system. Before
skin and cause a burn. using additives, contact your local Yale distributor.
5. Start the truck and let it run for 30 seconds. Check

CAUTION for leaks. Stop the engine and check the hydraulic
Do not allow dirt to enter the hydraulic system when oil level. Add oil, if necessary. Use the type of
checking the hydraulic oil level or changing the hydraulic oil indicated in the Maintenance Schedule.
filter. Dust could damage hydraulic system parts. To change the hydraulic oil, see Hydraulic oil,
replacement.
A CAUTION
regulations.
1. Place the forklift on a level surface and lower the

board. Unscrew and remove the filter cap and head
spring. See Figure 60. Raise the hydraulic filter
element enough to allow the hydraulic oil to drain.
NOTE: Have a container large enough to hold the filter

element and allow the hydraulic oil to finish draining.
2. Remove the hydraulic filter element and O-ring from

the bowl and place it in a container. Cover the head
to prevent foreign bodies from entering the
7
2
Maintenance procedures every 2,000 hours or annually 8000 YRM 1248
Hydraulic tank breather, replacement

1. Raise the hood and remove the right rear side
panel cho. See Figure 61.
2. Unscrew and remove the old breather from the

hydraulic reservoir and replace with the new
breather hydraulic tank drain.
3. Install the right rear side panel and close the hood.
See Figure 61.
1. HOOD/SEAT ASSEMBLY
2. SIDE PANEL
3. HYDRAULIC TANK VENT
Figure 61. Hydraulic tank breather
1. TOP 6. FITTING IGNITION SYSTEM; DISTRIBUTOR COVER,

2. DOCK 7. ROTOR AND SPARK PLUG WIRES
3. O-RING STAR RING
4. SCREW 8. ELEMENT
SKULLCAP FILTER NOTE: Make sure the ignition key is in the OFF position
5. HEAD 9. BUCKET OF and the negative battery cable has been removed from
THE the battery before removing the ignition system.
Figure 60. hydraulic filter Remove and discard the spark plug wire assembly, coil
wire, spark plugs, distributor cap, and rotor. For
7
3
procedures, see In switching on high voltage switch suitable coolant mixture. mixture of 50% water and
(HVS) , Mo GM 4.3L engines comply with EPA 2200 50% boron-free ethylene glycol antifreeze. Fill the
YRM 1097 for Spark Plug Wire Removal/Installation, auxiliary tank to a level between the ADD and FULL
Distributor Cap Removal/Installation, and Rotor marks on the tank.
Removal, Ignition Coil Wire Removal, and Spark Plug
Replacement. 5. Install the radiator cap. Start the engine. Check for
leaks. Add the liquid re necessary coolant to the
COOLING SYSTEM, GM 4.3LY CUMMINS auxiliary coolant tank. The coolant level should be
between the ADD and FULL marks on the
4.5LY QSB 3.3L ENGINES.
reservoir.
1. Place the forklift on a level surface. Stop the engine.
Place a container with a minimum capacity of 15.1 AIR FILTER
liter (15.9 qt) under the radiator drain valve which The air filter cartridge should not be opened until
may be located on the left or right rear of the replacement of the air filter element is necessary.
radiator, on the engine side of the radiator. Replacement of the filter element is necessary air
supply when one of the following occurs:
A WARNING • Optional dashboard airflow restriction indicator light
DO NOT remove the radiator cap while the engine is illuminates
hot. When the radiator cap is removed, system • Optional manual airflow indicator button protrudes
pressure is released. If the system is hot, steam and • The specified number of hours has passed since the
boiling coolant can cause burns. DO NOT remove last filter element change.
the radiator cap ador with the engine running.
A CAUTION
A CAUTION Do not allow dirt to enter the engine air intake while
Removal of lubricants and other fluids Two must be changing the air filter element. A small amount of
carried out in accordance with local environmental dirt could cause engine damage.
regulations.
1. Turn off the motor. Never open the air filter cartridge
2. Open the drain valve and remove the radiator cap to remove the filter element with the engine running.
adore Empty the coolant into the container. Flush
the cooling system. Check the hoses for damage. 2. Unlatch and remove the lid. To remove the filter
Replace with new hoses if necessary. element, press and turn it counterclockwise until it is
free. bre. To facilitate removal, gently move the end
3. Disconnect the hose that goes to the aux tank iliary back and forth to help break the plug. See Figure
to the fitting at the top of the radiator, under the 62.
radiator cap, and drain the reservoir into the same
container used for the coolant. engine source. 3. Gently remove the filter elements from the car.
Check the tank for contaminants and wash it if tucho. Prevent contaminants from falling from the
necessary. Reconnect the hose to the fitting on the ele ment or hit it against the cartridge.
top of the radiator.
4. Using a clean, soft cloth, wipe the inside surface of
A CAUTION the cartridge. Remove the liner assembly for easy
Additives can damage the cooling system. eration. cleaning. Clean thoroughly around the locking tabs
Before using additives, contact your local Yale that secure the element. Clean tabs make it easier
distributor. to install the new filter element. Be careful not to
introduce contaminants into the engine outlet pipe.
4. Close the drain valve. Fill the cooling system with a
7
4
5. Inspect the liner and O-ring assembly for damage. If

damaged, replace the liner and O-ring assembly.
7
5
BM210144
1. CARTRIDGE 4. FILTERING ELEMENT

2. DUST EVACUATION VALVE 5. TOP
3. LINING ASSEMBLY
Figure 62. Air filter

6. Install the new filter element into the cartridge by
pushing it in. Make sure the liner assembly is
properly seated in the cartridge. It will fit snugly and
be centered on the cartridge.
If your air filter assembly is equipped with a

secondary element instead of the liner assembly,
replace the secondary element with every 2 to 3
primary element replacements.
7. Inspect the new filter element for holes, cuts,

scratches or gouges in the urethane sealing
surfaces. Do not use if damage is detected.
2. INWARDS
A CAUTION TO BLOCK
The element must be correctly installed to ensure
adequate protection of the motor. tor. An incorrectly 1. PUSH THE Figure 63. Air filter label
installed element can allow dirt to enter and cause CLOSING
engine damage. A CAUTION
During cap installation, do not force the cap onto
NOTE: Correct installation of the element is necessary. the cartridge. Doing so will damage the filter
ment to allow the cover to be installed correctly mind. element. cover, cap and possibly the cartridge.
Never reinstall a used item. Never install a damaged
item. Always use a Yale approved filter element. NOTE: If the filter element is correctly in Installed, the
cap will fit easily onto the cartridge with no gap between
8. Install the new filter element into the cartridge. the cap and the cartridge. If the lid does not fit box
Press and rotate the filter element clockwise until it easily, the filter element has not been installed correctly.
is fully engaged in the cartridge. See Figure 63. Do not use a lid that is bent, damaged, or has missing
latches.
9. Install the cap on the cartridge and make sure the IN

LET arrow is in line with the cartridge entrance.
NOTE: Do not use the latches to press the lid with after
the cartridge. If the cap does not fit completely against
the cartridge without gaps, the element has not been
installed correctly.
7
6
10. Tighten the latches to secure the lid to the cartridge.
Make sure the closures penetrate the ra damage to
both the cartridge and the cap.
11. Inspect the entire air intake system for leaks. Inspect
all tighten the clamps to check if they are tight and
tighten if necessary. Inspect all Check the hoses for
damage. Replace damaged hoses. Inspect the dust
evacuation valve to see if it pre feel damage. If
damaged, replace the dust evacuation valve.
OXYGEN SENSOR
Check that the oxygen sensor electrical connector is
seated and locked. Check for possible leaks,
separations, friction or burns on the cables. If
necessary, repair them. See, Figure 64, and Figure 65.
1. OXYGEN SENSOR (POSTCATALYTIC)

2. MUFFLER
3. OXYGEN SENSOR (PRECATALYTIC)
Figure 65. Oxygen sensor (BCS only) for

Forklift models GC/GLC080,
100VXBCS (E818)
FUEL FILTER
LPG REGULATOR, GM ENGINE
Withdrawal
1. Close the cylinder shut-off valve. Run the engine
Figure 64. Oxygen sensor status
until it stops.
for forklift models
GP/GLP/GDP080, 090, 100, 110, 120VX (F813, 2. Disconnect the hose from the inlet fitting.
G813) and GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS 3. Remove the LPG regulator inlet fitting. Discard the
(E818) O-ring. See Figure 66.
Legend of figure 64 4. Remove and discard the plastic cap, the es filter
puma, the paper filter and the rubber washer of the
1. OXYGEN SENSOR
2. ELECTRIC CONNECTOR LPG regulator.
3. EXHAUST PIPES TO THE EXHAUST MANIFOLD
5. Disconnect the hose from the outlet fitting. Remove
the three screws and the LPG regulator outlet
fitting. Discard the O-ring.
6. Remove and discard the LPG regulator screen.
7
7
GASOLINE FUEL FILTER
1. Raise the hood and disconnect the negative battery
terminal.
Removal and
replacement
2. Remove and discard the fuel filter. See Figure 67.
3. Install the new fuel filter and tighten the mounting

bolts to 2.45 - 2.77 N•m (22 - 25 lbf in).
4. Connect the negative battery terminal and close the

hood.
1. FUEL FILTER
2. FUEL PUMP/UNIT
TRANSMITTER
1. LPG REGULATOR 6.
PAPER FILTER
2. INLET FITTING 7.
WASHER
3. O-RING ERASER
4. PLASTIC CAP 8. SCREWS
5. FOAM FILTER 9. OUTLET FITTING
10. LCD
Figure 66. GM LPG Regulator
Facility Figure 67. Replacing the fuel filter

(GM 4.3L)
1. Install a new screen on the LPG regulator.
LPG FUEL INJECTOR, GM ENGINES
2. Install a new O-ring on the outlet fitting. Using three
screws, install the outlet fitting on the LPG For removal and cleaning instructions, click See section
regulator. LPG Fuel System , Mo tor GM 4.3L 900 YRM 1242.
3. Install the new rubber washer, paper filter, foam GASOLINE FUEL INJECTOR, GM ENGINES
filter and plastic cap on the LPG regulator.
For removal and cleaning instructions, click See
4. Install a new O-ring on the inlet fitting. trada. Install Gasoline Fuel System section, GM 4.3L 900 YRM
the inlet fitting on the LPG regulator and connect 1244 Engine .
the hose to the inlet fitting.
FUEL INJECTOR, CUMMINS 4.5LY QSB 3.3L
5. Open the shut-off valve on the LPG cylinder and ENGINE
check for leaks.
For disassembly and cleaning instructions for GP/GLP/
GDP080, 090, 100, 110, 120VX (F813, G813) forklifts
equipped with a Cummins 4.5L or QSB 3.3L diesel
7
8
engine, contact your dealer. local Yale dealer or consult
Yale Axcess Online .
FORKS
A WARNING
Never repair damaged forks. Do not heat, weld, cut,
drill or bend forks. the. The forks are made of
special steel using special methods. Replace
damaged forks as a set.
Check the heel and fork attachment points by inspecting

with penis fluid trante or magnetic particles.
TRANSMISSION OIL AND FILTER (DRY

BRAKE), REPLACEMENT
A WARNING
At operating temperature, transmission oil is HOT.
NOTE: ALL COMPOS ARE SHOWN MAIN LENS AND
FRAME COMPONENTS REMOVED FOR GREATER
CAUTION CLEARANCE DAD
Prevent dust from entering the transmission when
checking the oil level or changing the filter. 1. TRANSMISSION
Dirt can cause damage to transmission 2. TRANSMISSION DRAIN PLUG
components. 3. DOCK
4. SIEVE
A CAUTION 5. TRANSMISSION OIL FILTER
Removal of lubricants and other fluids Two must be 7. TRANSMISSION BREATHER
regulations. Figure 68. Transmission oil change
NOTE: Replace the transmission oil filter after the first 2. Clean the screen with cleaning solvent and dry with
100 hours of operation on new lift trucks. See Figure 68. compressed air, set to a maximum output of 103
Before removing the oil filter, cut a hole in the top of the kPa (15 psi).
filter and allow five minutes for the oil in the
3. Once the oil is drained, install the screen first, then
transmission to drain. This will reduce the oil that will
the spring and drain plug.
come out of the filter and into the transmission when the
filter is removed. 4. Remove and discard the transmission breather.
Install the new transmission breather and hand
1. The transmission drain plug is located on the lower
tighten.
right side of the trans cover mission, towards the
back of the truck. Re throw away the drain plug, 5. Remove and discard the old oil filter. Apply clean oil
spring and screen. See Figure 68. Drain the oil into to the new filter gasket. Install the new filter and
a container. Once all the oil has drained, replace hand tighten.
the drain plug.
6. Add transmission oil to the dipstick tube. The
A WARNING correct type of oil is indicated in the Maintenance
Cleaning solvents can be flammable and toxic and Schedule.
cause skin irritation. When using cleaning solvents,
always follow the safety procedures recommended 7. Start and run the engine for approx. imly 5 minutes
by the solvent manufacturer. after filling to allow transmission components to
lubricate. mission and the wet brake part of the
Compressed air can displace particles that can center section of the drive axle. With the truck in the
cause injury to the user or other hazards. jadores. ON position, refer to Maintenance Schedule to add
Make sure that the air outlet pressed cannot reach additional oil to the transmission rod tube that will
other people. Useful Wear protective goggles or a need to be added to properly fill the wet brake
mask to prevent eye injuries. portion of the center section of the drive axle and
7
9
transmission. .
8. Turn the ignition key to the OFF position and check

for leaks and oil level.
9. Turn the ignition key to the off position. turned OFF

and check the oil level. If necessary, top up with oil.
TRANSMISSION HOUSING AND WET BRAKE

PLANETARY CARRIER OIL CHANGE
▲ WARNING
The oil used for the wet brake drive axle or
transmission must not be contaminated. I swim. If
the oil in the transmission housing and/or wet brake
planetary carrier becomes contaminated, it must be
drained and replaced with new oil.
▲ WARNING
At operating temperature, the transmission case oil
and carrier plane Wet brake fluid is HOT. Avoid
letting hot oil come into contact with your skin and NOTE: ALL COMPOS ARE SHOWN MAIN LENS AND
cause a burn. FRAME COMPONENTS REMOVED FOR GREATER
CLEARANCE DAD.
A CAUTION 1. TRANSMISSION
Prevent dust from entering the transaxle housing 2. TRANSMISSION DRAIN PLUG
mission and of the wet brake planetary carrier 3. DOCK
during checking the oil level or changing the filter. 4. SIEVE
Dirt will contaminate the oil and cause This will 5. TRANSMISSION OIL FILTER
cause damage to the transmission housing and wet 7. TRANSMISSION BREATHER
brake planetary carrier components.
Figure 69. Transmission oil change
A CAUTION
Removal of lubricants and other fluids Two must be 2. Remove the drain plug and fill/level plug from the plan
carried out in accordance with local environmental carrier housing age. Drain the oil into a suitable
regulations. container cuado When all the oil has drained,
reinstall the drain plug and fill/level plug. Tighten to
NOTE: Replace the transmission oil filter after the first a torque of 30 - 50 N•m (22 - 37 lbf ft). For forklift
100 hours of operation on new lift trucks. See Figure 69. models GC/GLC080, 100, 120VX; GC/GLC080,
Before removing the oil filter, cut a hole in the top of the 100VXBCS; GC/GLC120SVX; GC/GLC120VX-
filter and allow five minutes for the oil in the PRS (E818) see Figure 70. For forklifts of models
transmission to drain. This will reduce the oil that will GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
come out of the filter and into the transmission when the G813) see Figure 71.
filter is removed.
1. The transmission drain plug is located on the lower

right side of the trans cover mission, towards the
back of the truck. Re throw away the drain plug,
spring and screen. See Figure 69. Drain the oil into
a container, when all the oil has drained, install the
drain plug.
8
0
A. BACK VIEW SHOWN

B. FRONT VIEW SHOWN
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN PLUGS
3. CENTER BODY DRAIN PLUG
4. FILLER CAP/CENTER BODY LEVEL
7. CENTRAL BODY A. BACK VIEW SHOWN
B. FRONT VIEW SHOWN
disc brake drive shaft filling/level
PLUGS
in oil bath for forklift models 2. PLANETARY CARRIER HOUSING DRAIN PLUGS
elevator GC/GLC080, 100, 120VX; GC/GLC080, 3. FILLER CAP/CENTER BODY LEVEL
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS 4. CENTER BODY DRAIN PLUG
(E818) 5. PLANETARY CARRIER HOUSING (RIGHT)
7. CENTRAL BODY

filling/level of propeller shaft with brake on
oil bath for forklifts
(F813)
8
1
▲ WARNING OIL CHANGE OF THE WET BRAKE CENTER
Cleaning solvents can be flammable and toxic and SECTION
cause skin irritation. When using cleaning solvents,
always follow the safety procedures recommended Withdrawal
by the solvent manufacturer.
1. Remove the fill/level plug from the center body.
Compressed air can displace particles that can Removing the filler/level plug will allow the oil to
cause injury to the user or other hazards. jadores. drain out faster. For forklift models GC/GLC080,
Make sure that the air outlet pressed cannot reach 100, 120VX; GC/GLC080, 100VXBCS;
other people. Useful Wear protective goggles or a GC/GLC120SVX; GC/GLC120VXPRS (E818) see
mask to prevent eye injuries. Figure 70. For forklifts of models GP/GLP/GDP080,
090, 100, 110, 120VX (F813, G813) see Figure 71.
3. Clean the screen with cleaning solvent and dry with
compressed air, set to a maximum output of 103 2. Place an empty container under the center body
kPa (15 psi). drain plug.
4. Once the oil is drained, install the screen first, then 3. Remove the drain plug from the center body and it
the spring and drain plug. is Pere until the oil has completely drained.
5. Remove and discard the transmission breather.
Facility
Install the new transmission breather and hand
tighten. 1. Install the body drain plug tral. Tighten to a torque of
30 - 50 N•m (22 - 37 lbf ft). For ele truck models
6. Remove and discard the old oil filter. Apply clean oil
machine GC/GLC080, 100, 120VX; GC/GLC080,
to the new filter gasket. Install the new filter and
100VXBCS; GC/GLC120SVX; GC/GLC120VX-
hand tighten.
PRS (E818), see Figure 70. For GP/GLP/GDP080,
7. Add transmission oil to the dipstick tube. The 090, 100, 110, 120VX (F813, G813) forklifts, see
correct type of oil is indicated in the Maintenance Figure 71.
Schedule.
Before adding oil, make sure the charge
8. Start and run the engine for approximately 5 retilla is parked and on level ground.
minutes after filling to allow the transmission
CAUTION
components and plan carrier housings to lubricate.
wet brake age. With the truck in the ON position, 2. Add oil through the filler/level hole in the center
see Pro maintenance schedule to add additional oil body until the filler/level hole overflows. The correct
to the trans rod tube mission to be added to fill type of oil is indicated in the Maintenance Schedule.
correct ly the planetary carrier housings and For forklift models GC/GLC080, 100, 120VX;
transmission. For ele truck models machine GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC080, 100, 120VX; GC/GLC080, GC/GLC120VXPRS (E818) see Figure 70. For
100VXBCS; GC/GLC120SVX; GC/GLC120VX- forklifts of models GP/GLP/GDP080, 090, 100, 110,
PRS (E818) see Figure 70. For forklifts of models 120VX (F813, G813) see Figure 71.
GP/GLP/GDP080, 090, 100, 110, 120VX (F813, 3. Install the fill/level plug. Tighten to a torque of 30 -
G813) see Figure 71. 50 N•m (22 - 37 lbf ft).
9. Turn the ignition key to the OFF position and check
for leaks and oil level.
8
2
BRAKE OIL (MASTER CYLINDER), CHANGE A CAUTION
DO NOT use "DOT" fluid, only use Dexron III oil
1. Remove the dashboard from the hood. from a sealed container to avoid possible damage to
the brake system.
A CAUTION
Removal of lubricants and other fluids Two must be 3. Remove the brake oil reservoir cap and drain plug
carried out in accordance with local environmental from the cylinder block. Pour the liquid into a
regulations. suitable container with a ca Minimum capacity of
0.35 liter (0.74 pt). Install the cylinder block drain
2. Remove the brake oil reservoir from the hood plug. Fill the tank with clean oil from a seal
bracket. See Figure 72. container. ado and install the reservoir cap. The
correct type of oil is indicated in the Maintenance
Schedule iment.
4. Install the reservoir into the bracket located on the

hood.
BRAKE OIL (DRY BRAKES), WITHDRAWAL

Perform the following procedure to remove used brake
oil from the rest of the brake system.
1. Make sure the brake master cylinder reservoir is full

of brake oil.
NOTE: This procedure cannot be performed by one

person.
2. Place one end of a rubber hose on the wheel

cylinder's bleed screw. Place the other end of the
hose into a con empty fork.
3. Loosen the wheel cylinder bleed screw one turn to

be able to extract the brake oil. adjustment of the
brake system. Slowly depress the brake pedal and
keep it depressed at the end of its travel. ridicule
Close the bleed screw. Release the brake pedal.
NOTE: New brake oil will be easily recognized mind,

1. TANK CAP since the color will be lighter than that of the used oil
2. BRAKE OIL TANK
3. TANK MOUNTING BRACKET which will be darker.
4. HOOD
5. UPPER BRAKE OIL SUPPLY HOSE 4. Repeat Step 1 to Step 3 until new brake oil comes
6. CYLINDRICAL BLOCK OUTLET FITTING out into the container.
7. LOWER BRAKE OIL SUPPLY HOSE
8. NOZZLE 5. Check the brake oil level in the brake master
9. BRAKE MASTER CYLINDER cylinder reservoir during the pro yield. Be sure to
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK keep the brake oil at the correct level.
12. CYLINDRICAL BLOCK MOUNTING BRACKET
SCREW 6. Repeat the procedure for the other wheel cylinder.
A WARNING SERVICE BRAKES (DRY BRAKE)

Small amounts of water in the brake system can Check the brake linings and brake assembly parts for
result in reduced braking performance if the water wear and damage. two. The minimum acceptable brake
reaches the wheel cylinder area. Do not allow water lining thickness is 1.0 mm (0.040 in.). If the brake linings
Figure 72. Brake oil change have worn below specifications, replace them. Refer to
the 1800 SRM 1247 Brake System section for removal
and installation procedures for drive wheels and brake
to enter. Make sure the sealed reservoir cap is drums. If the brake linings or shoes are worn or
replaced correctly. damaged, replace them. Brake shoes must be replaced
8
3
in complete sets cough. Inspect the brake drums for any 3. The filling hole is located on the side of front of the
cracks or damage. Replace any damaged parts. differential housing. Add oil as shown in
Maintenance Schedule until the oil level is at the
▲ WARNING bottom of the filler hole. Install the fill plug and turn
Brake linings may contain dangerous fibers. thick the drive wheels to pump the oil into the axle.
Inhaling dust from these brake linings causes the Remove the filler cap and check the oil level. Add
risk of cancer or lung diseases. Avoid raising dust! oil as necessary. Install the filler cap and check for
Do not clean brake components with compressed leaks. See Figure 73 and Figure 74.
air or a brush. Follow the individual cleaning
procedure fallen in this section. Avoid raising dust
when removing brake drums.
Do not sand, brush, grind, hammer or modify the

for so that they produce dust. Any mod ification of
the linings must be carried out within a restricted
area with special ventilation. Useful ice protective
clothing and a beef mask piration
The following procedures are for cleaning the brakes:
A CAUTION
Do not use oil solvent to clean the cylinder wheel
drive Use an approved solvent to clean brake
components. Avoid getting oil or grease into the
brake fluid or brake linings.
1. Avoid raising dust from the brake linings while

removing the brake drum.
2. Use a solvent suitable for cleaning brakes to

moisten the dust on the linings. Follow the
instructions instructions and take the precautions 1. PROPELLER SHAFT
indicated by the manufacturer for the use of the 2. CHECK/FILL CAP
solvent. If using a spray solvent, do not spray dust 3. DRAIN PLUG
on the liners.
Figure 73. Shaft Fluid Fill
3. Once the brake lining dust has been moistened, traction (dry brake) for models
clean the parts. Place cloths or towels in a plastic of forklift GC/GLC/GDC080,
bag or inside a vacuum container while they are still 100, 120VX; GC/GLC/GDC080, 100VXBCS;
damp. Place a HAZARDOUS FIBERS warning label GC/GLC/GDC120SVX; GC/GLC/GDC120VXPRS
on the plastic bag or airtight container. (E818)
4. All cleaning cloths to be washed should be cleaned

in such a way that they do not release fibers into the
air.
DIFFERENTIAL (DRY BRAKE)

NOTE: Additional information on the differential can be
found in the Drive Shaft and Differential Assembly
Repair section, (Dry Brake) 1400 YRM 1245.
1. Place the forklift on blocks. With See How to Raise

Drive Tires in this manual.
2. The differential and drive axle use the same oil

supply. Place a container with a minimum capacity
of 5 liters (5.3 qt) under the differential. Remove the
drain plug located at the bottom of the differential
and drain the oil from the differential completely.
Install the va plug ciated.
8
4
Figure 74. Filling the propeller shaft with fluid Check valve clearance and make any necessary
(dry brake) for forklifts adjustments. To adjust the valve clearances do the
GP/GLP/GDP080, 090, 100, 110, 120VX models following:
(F813, G813)
1. Align the top dead center (TDC) mark on the
Legend of figure 74 crankshaft pulley with the engraved mark on the
block. See Figure 75.
1. CHECK/FILL CAP
2. DRAIN PLUG
3. DRIVE AXLE
CHECK THE LPG/GASOLINE REGULATOR

PRESSURE
If you would like additional information about the
pretest For LPG/gasoline regulator information, see
LPG Fuel System , GM 4.3L Engine 900 YRM 1242
and Gasoline Fuel System , GM 4.3L 900 YRM 1244
Engine .
CHECK THE THROTTLE SHAFT IS NOT

STICKING
Check the return action of the throttle body erator to
ensure that the throttle shaft does not stick. Repair if
necessary.
INSPECT FOR POSSIBLE LEAKS IN THE

MANIFOLD AND EXHAUST PIPES 1. CRANK PULLEY
To check the manifold and exhaust pipes for leaks, do 3. ENGRAVED MARK OF THE DISTRIBUTION
the following:
Figure 75. TDC brand of Cummins QSB engine
• Check the exhaust manifold cylinder head for leaks. 3.3L
Make sure all personnel noses and protectors are in
2. Adjust ONLY the valves shown in Figure 76 by
place.
loosening the locknut with a wrench and adjusting
• Check if there are leaks in the elements of your
the valve clearance with a screwdriver. side or with
Connect the exhaust pipe to the manifold and make
an Allen wrench.
sure they are tight. Repair if necessary.
• Check all exhaust extension connectors for leaks and
tighten if necessary.
• Perform a visual inspection of the converter to verify
proper mounting of the muffler and tail pipe.
• Check for possible leaks at the inlet and outlet of the
converter.
VALVE CLEARANCE, CHECKING AND

ADJUSTING FOR
THE CUMMINS QSB 3.3L DIESEL ENGINE
The Cummins QSB 3.3L engine does not require valve
clearance adjustments during normal operation. See
Maintenance Schedule for valve clearance.
Maintenance procedures every 8 hours or daily22

HOW TO PERFORM CHECKS
8
5
WITH THE ENGINE STOPPED
▲ WARNING 22
WITH THE ENGINE STOPPED 22
▲ WARNING 22
Tires and wheels 22
Security labels 23
A WARNING 23
Mast, board, lifting chains, collector hoses, accessory 23
▲ WARNING 23
Operator restraint system 24
Hood and seat latches 25
engine compartment 25
Paper application 25
WARNING 25
A WARNING 26
A CAUTION 26
▲ WARNING 26
Fuel, oil and coolant leaks, check 26
▲ WARNING 26
Hydraulic hoses 26
coolant hoses 26
Steering column gas cylinder 26
oil temperature 28
Hydraulic system oil 28
A WARNING 28
(N CAUTION 28
engine oil 28
A WARNING 28
Air filter 31
Forks 31
A WARNING 31
Board with integrated lateral movement 33
HOW TO PERFORM CHECKS 33
WITH THE ENGINE RUNNING 33
A WARNING 33
8
6
▲ WARNING 33
Indicator lights, horn, fuses and relays 33
Service brakes 35
▲ WARNING 35
Parking break 36
Engine oil pressure 36
Refrigeration system 37
A WARNING 37
A CAUTION 37
A WARNING 37
Direction system 37
▲ WARNING 37
Control levers and pedals 37
Lifting system, operation 38
▲ WARNING 38
First service inspection after the first 100 hours of operation 39
GM 4.3L ENGINE OIL FILTER 39
CUMMINS 4.5LY QSB 3.3L ENGINE OIL FILTER 39
HYDRAULIC SYSTEM 40
Hydraulic filter, replacement 40
▲ WARNING 40
A CAUTION 40
A CAUTION 40
A CAUTION 40
TRANSMISSION OIL FILTER, REPLACEMENT 40
A WARNING 40
( CAUTION 41
AN CAUTION 41
Maintenance procedures every 250 hours or every 6 months42
GM 4.3L ENGINE OIL AND FILTER 42
TRANSMISSION BAND 42
GM 4.3L engine 42
EMPTY TAR FROM LPG REGULATOR 43
HYDRAULIC SYSTEM OIL 43
A WARNING 43
8
7
A CAUTION 43
( CAUTION 43
HYDRAULIC TANK VENT 43
Inspection 43
A WARNING 43
A CAUTION 43
BATTERY 44
▲ WARNING 44
A WARNING 44
CUMMINS ENGINE OIL AND FILTER 44
4.5LY QSB 3.3L 44
REPLACING THE SEPARATOR FILTER 44
FUEL/WATER, ENGINE 44
CUMMINS 4.5LY QSB 3.3L 44
( CAUTION 44
Withdrawal 45
A CAUTION 45
Facility 45
A CAUTION 45
FINAL REPLACEMENT OF THE FUEL FILTER (CUMMINS QSB 3.3L) 48
A CAUTION 48
A CAUTION 48
PRIMING THE FUEL SYSTEM (CUMMINS 4.5LY 49
QSB 3.3L) 49
Controlled ventilation 49
(N CAUTION 49
manual purge 49
▲ WARNING 49
A CAUTION 49
Cummins 4.5L and QSB 3.3L diesel engine 49
CLEANING RESIDUES FROM THE RADIATOR PANEL 50
A WARNING 50
TRANSMISSION OIL LEVEL 51
▲ WARNING 51
(N CAUTION 51
8
8
CHECKING THE OIL LEVEL OF THE WET BRAKE CENTRAL BODY 52
A WARNING 52
( CAUTION 52
FORKS 54
▲ WARNING 54
MAST LUBRICATION 54
▲ WARNING 54
UPPER TANK HOSE CHECKS 57
LUBRICATION OF LIFT CHAINS 58
A WARNING 58
TILT CYLINDER LUBRICATION 58
BRAKE MASTER CYLINDER ROD END PIN LUBRICATION 59
LUBRICATION OF THE HYDRAULIC MANUAL LEVERS 59
Maintenance procedures every 1000 hours or every 6 months 62
VALVE CLEARANCE, CHECKING AND ADJUSTING 62
IGNITION SYSTEM 62
GM 4.3L engine 62
LPG FUEL FILTER ELEMENT REPLACEMENT, GM 4.3L ENGINE 62
Withdrawal 62
A WARNING 62
A WARNING 62
Facility 63
PIPE FILTER REPLACEMENT, CUMMINS 4.5L ENGINE 64
(N CAUTION 64
Withdrawal 64
( CAUTION 64
Facility 64
CHECKING THE WEAR OF THE LIFT CHAINS 66
▲ WARNING 67
BOARD WITH INTEGRATED LATERAL MOVEMENT, CHECKING SLIDING SURFACES
67
Maintenance procedures every 2,000 hours or annually 69
HYDRAULIC SYSTEM 69
A WARNING 69
8
9
CAUTION 69
A CAUTION 69
A CAUTION 69
Hydraulic tank breather, replacement 70
IGNITION SYSTEM; DISTRIBUTOR COVER, ROTOR AND SPARK PLUG WIRES 70
COOLING SYSTEM, GM 4.3LY CUMMINS 4.5LY QSB 3.3L ENGINES. 70
A WARNING 71
A CAUTION 71
A CAUTION 71
AIR FILTER 71
A CAUTION 71
A CAUTION 72
A CAUTION 72
OXYGEN SENSOR 73
FUEL FILTER 73
LPG REGULATOR, GM ENGINE 73
Withdrawal 73
Facility 74
GASOLINE FUEL FILTER 74
A WARNING 75
TRANSMISSION HOUSING AND WET BRAKE PLANETARY CARRIER OIL CHANGE 76
▲ WARNING 76
▲ WARNING 76
A CAUTION 76
A CAUTION 76
▲ WARNING 78
OIL CHANGE OF THE WET BRAKE CENTER SECTION 78
Withdrawal 78
Facility 78
BRAKE OIL (MASTER CYLINDER), CHANGE 79
A CAUTION 79
A WARNING 79
A CAUTION 79
BRAKE OIL (DRY BRAKES), WITHDRAWAL79
SERVICE BRAKES (DRY BRAKE) 79
▲ WARNING 80
9
0
A CAUTION 80
DIFFERENTIAL (DRY BRAKE) 80
Maintenance procedures every 4000 hours or every 2 years 90
HYDRAULIC OIL, REPLACEMENT 90
A WARNING 90
A CAUTION 90
VALVE CLEARANCE, CHECKING AND ADJUSTING FOR 91
THE CUMMINS 4.5L DIESEL ENGINE 91
Safety procedures when working near the mast104
A WARNING 104
Removing water from the fuel filter 107
A CAUTION 107
( CAUTION 107
Checking the hood closure 107
A WARNING 107
1. 2. Tighten the locknut to 24 N•m (18 lbf in) and
measure the valve clearance.
Figure 76. Engine valve adjustment
Cummins 3. Check the vibration damper and rotate the
crankshaft 360 degrees. See Figure 77.
9
1
1. PIN 2. SHOCK ABSORBER

ADJUSTMENT OF VIBRATIONS
Figure 77. Cummins vibration damper
4. Perform Step 2 to Step 3 to adjust SOLA MIND the

valves shown in Figure 78. With See Maintenance
Schedule for valve clearance.

▲ WARNING..............................................22
WITH THE ENGINE STOPPED.................22
▲ WARNING..............................................22
Tires and wheels...........................................22
Security labels..............................................23
A WARNING...............................................23
▲ WARNING..............................................23
Operator restraint system..............................24
Hood and seat latches...................................25
engine compartment.....................................25
Paper application..........................................25
WARNING...................................................25
A WARNING...............................................26
A CAUTION................................................26
▲ WARNING..............................................26
9
2
Fuel, oil and coolant leaks, check.................26

▲ WARNING..............................................26
Hydraulic hoses............................................26
coolant hoses................................................26
Steering column gas cylinder.......................26
oil temperature..............................................28
Hydraulic system oil.....................................28
A WARNING...............................................28
(N CAUTION................................................28
engine oil......................................................28
A WARNING...............................................28
Air filter........................................................31
Forks.............................................................31
A WARNING...............................................31
Board with integrated lateral movement......33
HOW TO PERFORM CHECKS..................33
WITH THE ENGINE RUNNING...............33
A WARNING...............................................33
▲ WARNING..............................................33
Indicator lights, horn, fuses and relays.........33
Service brakes...............................................35
▲ WARNING..............................................35
Parking break................................................36
Engine oil pressure.......................................36
Refrigeration system.....................................37
A WARNING...............................................37
A CAUTION................................................37
A WARNING...............................................37
Direction system...........................................37
▲ WARNING..............................................37
Control levers and pedals.............................37
Lifting system, operation..............................38
▲ WARNING..............................................38
9
3

GM 4.3L ENGINE OIL FILTER.................39
HYDRAULIC SYSTEM..............................40
Hydraulic filter, replacement........................40
▲ WARNING..............................................40
A CAUTION................................................40
A CAUTION................................................40
A CAUTION................................................40
A WARNING...............................................40
( CAUTION..................................................41
AN CAUTION.............................................41
GM 4.3L ENGINE OIL AND FILTER.......42
TRANSMISSION BAND............................42
GM 4.3L engine...........................................42
EMPTY TAR FROM LPG REGULATOR. 43
HYDRAULIC SYSTEM OIL......................43
A WARNING................................................43
A CAUTION................................................43
( CAUTION..................................................43
HYDRAULIC TANK VENT.......................43
Inspection.....................................................43
A WARNING...............................................43
A CAUTION................................................43
BATTERY....................................................44
▲ WARNING..............................................44
A WARNING...............................................44
CUMMINS ENGINE OIL AND FILTER...44
4.5LY QSB 3.3L..........................................44
9
4
FUEL/WATER, ENGINE............................44
CUMMINS 4.5LY QSB 3.3L......................44
( CAUTION..................................................44
Withdrawal...................................................45
A CAUTION.................................................45
Facility..........................................................45
A CAUTION................................................45
A CAUTION.................................................48
A CAUTION................................................48
QSB 3.3L)....................................................49
Controlled ventilation...................................49
(N CAUTION...............................................49
manual purge................................................49
▲ WARNING..............................................49
A CAUTION................................................49
A WARNING...............................................50
TRANSMISSION OIL LEVEL...................51
▲ WARNING..............................................51
(N CAUTION...............................................51
A WARNING...............................................52
( CAUTION..................................................52
FORKS.........................................................54
▲ WARNING..............................................54
MAST LUBRICATION...............................54
▲ WARNING..............................................54
UPPER TANK HOSE CHECKS.................57
LUBRICATION OF LIFT CHAINS...........58
9
5
A WARNING...............................................58
TILT CYLINDER LUBRICATION............58
IGNITION SYSTEM...................................62
GM 4.3L engine...........................................62
Withdrawal...................................................62
A WARNING...............................................62
A WARNING...............................................62
Facility..........................................................63
(N CAUTION................................................64
Withdrawal...................................................64
( CAUTION..................................................64
Facility..........................................................64
LUBRICATION OF LIFT CHAINS...........67
▲ WARNING..............................................67
......................................................................67
A WARNING...............................................69
CAUTION....................................................69
A CAUTION................................................69
A CAUTION................................................69
Hydraulic tank breather, replacement..........70
9
6
A WARNING................................................71
A CAUTION................................................71
A CAUTION................................................71
AIR FILTER.................................................71
A CAUTION................................................71
A CAUTION................................................72
A CAUTION.................................................72
OXYGEN SENSOR.....................................73
FUEL FILTER.............................................73
LPG REGULATOR, GM ENGINE.............73
Withdrawal...................................................73
Facility..........................................................74
GASOLINE FUEL FILTER........................74
A WARNING...............................................75
▲ WARNING..............................................76
▲ WARNING..............................................76
A CAUTION................................................76
A CAUTION................................................76
▲ WARNING..............................................78
Withdrawal...................................................78
Facility..........................................................78
A CAUTION................................................79
A WARNING...............................................79
A CAUTION.................................................79
SERVICE BRAKES (DRY BRAKE)..........79
▲ WARNING..............................................80
A CAUTION................................................80
DIFFERENTIAL (DRY BRAKE)...............80
9
7

HYDRAULIC OIL, REPLACEMENT........90
A WARNING...............................................90
A CAUTION................................................90
THE CUMMINS 4.5L DIESEL ENGINE...91
A WARNING.............................................104
Removing water from the fuel filter..............107
A CAUTION..............................................107
( CAUTION................................................107
Checking the hood closure.............................107
A WARNING.............................................107
1.

Cummins
9
8
Maintenance procedures every 4000 hours or every 2 years 8000 YRM 1248
Maintenance procedures every 4000 hours or every 2 years

NOTE: Perform the 8, 250, 500, 1000 and 2500 hour regulations.
checks before performing the procedures. cough of this NOTE: Change the hydraulic oil filter at the same time
section. as changing the oil.
HYDRAULIC OIL, REPLACEMENT 1. Place a container with a minimum capacity of 39.4

liters (42 qt) under the drain plug on the bottom of
A WARNING the hydraulic tank. To drain the oil, remove the drain
At operating temperature, hydraulic oil is HOT. plug from the inside bottom of the hydraulic tank.
Avoid letting hot oil come into contact with your See Figure 79. When the tank is empty, inspect the
skin and cause a burn. in inside of it to check if there are foreign bodies or
fungi. If necessary, clean the inside of the tank
Do not allow dirt to enter the hydraulic system when
according to the instructions. tions contained in the
section Frame 100 YRM 1243. When the reservoir
CAUTION inspection or cleaning is complete, install the drain
plug into the bottom of the hydraulic reservoir.
filter. Dust could damage hydraulic system parts. Additives can damage the hydraulic system. Before
Never operate the hydraulic pump without oil in the CAUTION

using additives, contact your local Yale distributor.
2. Fill the hydraulic reservoir with the specified oil.
A CAUTION fallen into the Maintenance Program.
carried out in accordance with local environmental 3. When the oil level is correct, operate the system
and check for leaks.
NOTE: Heavy or contaminating applications require They will want the hydraulic oil changed at 2,000 hours ras.
9
9
8000 YRM 1248 Maintenance procedures every 4000 hours or every 2 years
1. HYDRAULIC SYSTEM TANK 2. DRAIN PLUG

Figure 79. Hydraulic oil change
VALVE CLEARANCE, CHECKING AND the valve clearance with a screwdriver. side or with
ADJUSTING FOR an Allen wrench.
THE CUMMINS 4.5L DIESEL ENGINE 3. Tighten the locknut to 24 N•m (18 lbf in) and
measure the valve clearance.
The Cummins 4.5L engine does not require valve
clearance adjustments during normal operation. See 4. Remove the adjustment pin. See Figure 80.
Maintenance Schedule for valve clearance.
5. Check the vibration damper and rotate the
Check valve clearance and make any necessary crankshaft 360 degrees. See Figure 82.
adjustments. To adjust the valve clearances do the
following: 6. Perform Step 2 and Step 3 to adjust ONLY the
valves shown in Figure 83.
1. Turn the engine until it is in neutral. (TDC) for
cylinder number one (intake and exhaust valves
closed). Insert the adjusting pin. See Figure 80.
2. Adjust ONLY the valves shown in Figure 81 by

loosening the locknut with a wrench and adjusting
1
0
0
1. INSERT ADJUSTMENT PIN HERE

2. WATER/FUEL SEPARATOR FILTER
3. TIMING BELT
Figure 80. Timing pin location, Cummins 4.5L diesel engine

▲ WARNING..............................................22
▲ WARNING..............................................22
Tires and wheels...........................................22
Security labels...............................................23
A WARNING...............................................23
1
0
1
▲ WARNING..............................................23
Operator restraint system..............................24
Hood and seat latches...................................25
engine compartment.....................................25
Paper application..........................................25
WARNING...................................................25
A WARNING...............................................26
A CAUTION................................................26
▲ WARNING..............................................26
Fuel, oil and coolant leaks, check.................26
▲ WARNING..............................................26
Hydraulic hoses............................................26
coolant hoses.................................................26
Steering column gas cylinder.......................26
oil temperature..............................................28
Hydraulic system oil.....................................28
A WARNING...............................................28
(N CAUTION................................................28
engine oil......................................................28
A WARNING...............................................28
Air filter........................................................31
Forks.............................................................31
A WARNING...............................................31
Board with integrated lateral movement......33
HOW TO PERFORM CHECKS..................33
WITH THE ENGINE RUNNING................33
A WARNING...............................................33
▲ WARNING..............................................33
Indicator lights, horn, fuses and relays.........33
Service brakes...............................................35
▲ WARNING..............................................35
Parking break................................................36
Engine oil pressure.......................................36
Refrigeration system.....................................37
A WARNING...............................................37
1
0
2
A CAUTION................................................37
A WARNING...............................................37
Direction system...........................................37
▲ WARNING..............................................37
Control levers and pedals.............................37
Lifting system, operation..............................38
▲ WARNING..............................................38
GM 4.3L ENGINE OIL FILTER.................39
▲ WARNING..............................................40
A CAUTION................................................40
A CAUTION................................................40
A CAUTION................................................40
A WARNING...............................................40
( CAUTION..................................................41
AN CAUTION.............................................41
GM 4.3L ENGINE OIL AND FILTER........42
GM 4.3L engine............................................42
EMPTY TAR FROM LPG REGULATOR..43
HYDRAULIC SYSTEM OIL......................43
A WARNING................................................43
A CAUTION................................................43
( CAUTION..................................................43
HYDRAULIC TANK VENT.......................43
Inspection......................................................43
A WARNING...............................................43
A CAUTION................................................43
BATTERY....................................................44
▲ WARNING..............................................44
1
0
3
A WARNING...............................................44
CUMMINS ENGINE OIL AND FILTER.. .44
4.5LY QSB 3.3L...........................................44
FUEL/WATER, ENGINE............................44
CUMMINS 4.5LY QSB 3.3L.......................44
( CAUTION..................................................44
Withdrawal...................................................45
A CAUTION.................................................45
Facility..........................................................45
A CAUTION................................................45
A CAUTION.................................................48
A CAUTION................................................48
QSB 3.3L).....................................................49
Controlled ventilation...................................49
(N CAUTION...............................................49
manual purge................................................49
▲ WARNING..............................................49
A CAUTION................................................49
A WARNING...............................................50
TRANSMISSION OIL LEVEL...................51
▲ WARNING..............................................51
(N CAUTION...............................................51
A WARNING...............................................52
( CAUTION..................................................52
FORKS.........................................................54
▲ WARNING..............................................54
MAST LUBRICATION...............................54
▲ WARNING..............................................54
UPPER TANK HOSE CHECKS.................57
1
0
4
LUBRICATION OF LIFT CHAINS............58
A WARNING...............................................58
TILT CYLINDER LUBRICATION............58
IGNITION SYSTEM...................................62
GM 4.3L engine............................................62
Withdrawal...................................................62
A WARNING...............................................62
A WARNING...............................................62
Facility..........................................................63
(N CAUTION................................................64
Withdrawal...................................................64
( CAUTION..................................................64
Facility..........................................................64
LUBRICATION OF LIFT CHAINS............67
▲ WARNING..............................................67
......................................................................67
A WARNING...............................................69
CAUTION....................................................69
A CAUTION................................................69
A CAUTION................................................69
Hydraulic tank breather, replacement...........70
A WARNING................................................71
A CAUTION................................................71
1
0
5
A CAUTION................................................71
AIR FILTER.................................................71
A CAUTION................................................71
A CAUTION................................................72
A CAUTION.................................................72
OXYGEN SENSOR.....................................73
FUEL FILTER..............................................73
LPG REGULATOR, GM ENGINE.............73
Withdrawal...................................................73
Facility..........................................................74
GASOLINE FUEL FILTER.........................74
A WARNING...............................................75
▲ WARNING..............................................76
▲ WARNING..............................................76
A CAUTION................................................76
A CAUTION................................................76
▲ WARNING..............................................78
Withdrawal...................................................78
Facility..........................................................78
A CAUTION................................................79
A WARNING...............................................79
A CAUTION.................................................79
SERVICE BRAKES (DRY BRAKE)..........79
▲ WARNING..............................................80
A CAUTION................................................80
DIFFERENTIAL (DRY BRAKE)...............80
HYDRAULIC OIL, REPLACEMENT........90
A WARNING...............................................90
A CAUTION................................................90
1
0
6
THE CUMMINS 4.5L DIESEL ENGINE...91
A WARNING.............................................104
Removing water from the fuel filter...............107
A CAUTION..............................................107
( CAUTION................................................107
Checking the hood closure.............................107
A WARNING.............................................107
1.
ADMISSION
2. CYLINDER 1

Cummins
1. ADJUSTMENT PIN
2. VIBRATION DAMPER
Figure 82. Cummins vibration damper
1
0
7
8000 YRM 1248 Safety procedures when working near the mast
Legend of figure 83
Maintenance procedures every 8 hours or

daily 22
▲ WARNING 22
▲ WARNING 22
Tires and wheels 22
Security labels 23
A WARNING 23
Mast, board, lifting chains, collector
hoses, accessory 23
▲ WARNING 23
Operator restraint system 24
Hood and seat latches 25
engine compartment 25
Paper application 25
WARNING 25
A WARNING 26
A CAUTION 26
▲ WARNING 26
Fuel, oil and coolant leaks, check 26
▲ WARNING 26
Hydraulic hoses 26
coolant hoses 26
Steering column gas cylinder 26
oil temperature 28
Hydraulic system oil 28
A WARNING 28
(N CAUTION 28
engine oil 28
1
0
8
Safety procedures when working near the mast 8000 YRM 1248
A WARNING 28
Air filter 31
Forks 31
A WARNING 31
Board with integrated lateral movement
33
HOW TO PERFORM CHECKS 33
WITH THE ENGINE RUNNING 33
A WARNING 33
▲ WARNING 33
Indicator lights, horn, fuses and relays
33
Service brakes 35
▲ WARNING 35
Parking break 36
Engine oil pressure 36
Refrigeration system 37
A WARNING 37
A CAUTION 37
A WARNING 37
Direction system 37
▲ WARNING 37
Control levers and pedals 37
Lifting system, operation 38
▲ WARNING 38
First service inspection after the first 100
hours of operation 39
GM 4.3L ENGINE OIL FILTER 39
CUMMINS 4.5LY QSB 3.3L ENGINE
OIL FILTER 39
HYDRAULIC SYSTEM 40
▲ WARNING 40
1
0
9
A CAUTION 40
A CAUTION 40
A CAUTION 40
TRANSMISSION OIL FILTER,
REPLACEMENT 40
A WARNING 40
( CAUTION 41
AN CAUTION 41
Maintenance procedures every 250 hours
or every 6 months 42
GM 4.3L ENGINE OIL AND FILTER
42
GM 4.3L engine 42
EMPTY TAR FROM LPG
REGULATOR 43
Maintenance procedures every 500 hours
or every 6 months 43
HYDRAULIC SYSTEM OIL 43
A WARNING 43
A CAUTION 43
( CAUTION 43
HYDRAULIC TANK VENT 43
Inspection 43
A WARNING 43
A CAUTION 43
BATTERY 44
▲ WARNING 44
A WARNING 44
CUMMINS ENGINE OIL AND
FILTER 44
4.5LY QSB 3.3L 44
REPLACING THE SEPARATOR
FILTER 44
1
1
0
FUEL/WATER, ENGINE 44
CUMMINS 4.5LY QSB 3.3L 44
( CAUTION 44
Withdrawal 45
A CAUTION 45
Facility 45
A CAUTION 45
FINAL REPLACEMENT OF THE
FUEL FILTER (CUMMINS QSB
3.3L) 48
A CAUTION 48
A CAUTION 48
PRIMING THE FUEL SYSTEM
(CUMMINS 4.5LY 49
QSB 3.3L) 49
Controlled ventilation 49
(N CAUTION 49
manual purge 49
▲ WARNING 49
A CAUTION 49
Cummins 4.5L and QSB 3.3L diesel
engine 49
CLEANING RESIDUES FROM THE
RADIATOR PANEL 50
A WARNING 50
TRANSMISSION OIL LEVEL 51
▲ WARNING 51
(N CAUTION 51
CHECKING THE OIL LEVEL OF
THE WET BRAKE CENTRAL BODY
52
A WARNING 52
( CAUTION 52
1
1
1
FORKS 54
▲ WARNING 54
MAST LUBRICATION 54
▲ WARNING 54
UPPER TANK HOSE CHECKS 57
A WARNING 58
TILT CYLINDER LUBRICATION 58
BRAKE MASTER CYLINDER ROD
END PIN LUBRICATION 59
LUBRICATION OF THE
HYDRAULIC MANUAL LEVERS 59
Maintenance procedures every 1000
hours or every 6 months 62
VALVE CLEARANCE, CHECKING
AND ADJUSTING 62
IGNITION SYSTEM 62
GM 4.3L engine 62
LPG FUEL FILTER ELEMENT
REPLACEMENT, GM 4.3L ENGINE
62
Withdrawal 62
A WARNING 62
A WARNING 62
Facility 63
PIPE FILTER REPLACEMENT,
CUMMINS 4.5L ENGINE 64
(N CAUTION 64
Withdrawal 64
( CAUTION 64
Facility 64
CHECKING THE WEAR OF THE
LIFT CHAINS 66
1
1
2
▲ WARNING 67
BOARD WITH INTEGRATED
LATERAL MOVEMENT,
CHECKING SLIDING SURFACES 67
Maintenance procedures every 2,000
hours or annually 69
HYDRAULIC SYSTEM 69
A WARNING 69
CAUTION 69
A CAUTION 69
A CAUTION 69
Hydraulic tank breather, replacement70
IGNITION SYSTEM; DISTRIBUTOR
COVER, ROTOR AND SPARK
PLUG WIRES 70
COOLING SYSTEM, GM 4.3LY
CUMMINS 4.5LY QSB 3.3L
ENGINES. 70
A WARNING 71
A CAUTION 71
A CAUTION 71
AIR FILTER 71
A CAUTION 71
A CAUTION 72
A CAUTION 72
OXYGEN SENSOR 73
FUEL FILTER 73
LPG REGULATOR, GM ENGINE 73
Withdrawal 73
Facility 74
GASOLINE FUEL FILTER 74
A WARNING 75
TRANSMISSION HOUSING AND
1
1
3
WET BRAKE PLANETARY

CARRIER OIL CHANGE 76
▲ WARNING 76
▲ WARNING 76
A CAUTION 76
A CAUTION 76
▲ WARNING 78
OIL CHANGE OF THE WET BRAKE
CENTER SECTION 78
Withdrawal 78
Facility 78
BRAKE OIL (MASTER CYLINDER),
CHANGE 79
A CAUTION 79
A WARNING 79
A CAUTION 79
BRAKE OIL (DRY BRAKES),
WITHDRAWAL 79
SERVICE BRAKES (DRY BRAKE)
79
▲ WARNING 80
A CAUTION 80
DIFFERENTIAL (DRY BRAKE) 80
Maintenance procedures every 4000
hours or every 2 years 90
HYDRAULIC OIL, REPLACEMENT
90
A WARNING 90
A CAUTION 90
VALVE CLEARANCE, CHECKING
AND ADJUSTING FOR 91
THE CUMMINS 4.5L DIESEL
1
1
4
ENGINE 91
Safety procedures when working near the
mast 104
A WARNING 104
Removing water from the fuel filter 107
A CAUTION 107
( CAUTION 107
Checking the hood closure 107
A WARNING 107
1.
ADMISSION
2. CYLINDER 1

Cummins
Safety procedures when working near the mast

When inspecting the the body suffers the
mast or working near im damage to the
the mast the following mast or deck, serious
instructions should be or even fatal injuries
followed. Additional may occur.
precautions and
procedures may be • Never put any part
necessary to repair or of your body or
remove the mast. See under the mast or
cor section section of deck unless all
the Service Manual mast parts are
corresponding to the completely lowered
specific mast you are or a safety chain
repairing. has been
attached. security.
A WARNING Also make sure the
The mast parts are truck is turned off
heavy and can be and the key is
moved. The removed. Place a
distances between DO NOT USE label
the pieces are pe in the operator
queñas If any part of compartment.
1
1
5
• Be careful with make sure there is

hairpins. When the no movement in
mast is raised, the the mast. Make
forks may be too sure all moving
high and cause parts of the mast
injury. are fully lowered.
• DO NOT ever climb
the mast or truck. O WELL
Useful Use a ladder 2. If the parts of the
or man lift to work mast are to be in
on the mast. position When
• DO NOT use raised, attach a
blocks to support safety chain to
the mast profiles or retain the moving
limit their parts of the mast.
movement. Attach the moving
• Repairing the mast parts to a part that
requires cannot move.
disassembly and Follow these
removal of parts, instructions:
and may require
removal of the a. Put the mast
mast or board. upright.
Follow the repair
procedures listed b. Raise the
in the applicable mast to align
section. tooth in the bottom
the Mast Service cross member
Manual. of the profile
that moves
NOTE: If there is no inside the
power to lower the outer profile
mast on trucks with a cross
equipped with an member of the
electronic hydraulic outer profile.
system, there is an In the two-
emergency load stage mast
lowering valve located and the free-
in the lift/lower valve lift mast, the
section of the main moving part is
control valve. Refer to the inner
the Operator's profile. In the
Manual for load three-stage
lowering procedures mast it is the
using the emergency intermediate
load lowering valve. profile. See
Figure 84.
1. Completely lower
the mast and c. Use a 3/8 in.
board. Push the safety chain
raise/lower control ged with at
lever forward and least one hook
1
1
6
to join the is running,

crossbars stop it.
together, so Apply the
that the parking
moving brake.
element Install an
cannot eti DO NOT
descend. REMOVE
Attach the note on the
hook to the chain or
back of the chain safety
mast. Make nets.
sure the hook
is fully and. Install
engaged with another
a chain link. safety chain
Make sure the (minimum
safety chain 3/8 inch)
does not between the
touch the top and
lifting chains bottom
or chain rails. rior of
pulleys, pipes, the board
hoses, fittings and a
or other mast crossbar of
parts. the exterior
profile.
d. Lower the
mast until the 3. Apply the parking
safety chain brake. After
tension and raising or
the lift cylinder securing the
mast, turn off
is free (free
the engine and
lift, three-
remove the key.
stage masts
Place a DO
only).
NOT USE label
legend of in the operator's
cabin.
A. ELL MAST IN
TWO STAGES figure 84
B. LIFTING MAST IN
TWO STAGES C. LIFTING MAST
1. OUTER MAST IN THREE STAGES
2. INNER MAST D. ELC MAST IN
3. INTERMEDIATE FOUR STAGES
MAST 5. FREE LIFT
4. HOOK
CYLINDER
and four 6. DASHBOARD
stages) is BAR
7. CROSSBAR
fully 8. FIRST
collected. If INTERMEDIATE
the engine MAST
1
1
7
1
1
8
Figure 84. Double, free lift, triple and quad masts
1
1
9
Checking the hood closure 8000 YRM 1248
Removing water from the fuel filter

NOTE: The following procedure only applies to car lift
gates equipped with Cum engines mins 4.5L and QSB
3.3L diesel.
1. Turn off the motor.
NOTE: The drain valve is located on the back inside the

fuel filter element.
2. To access the fuel filter element and drain valve,

remove the air inlet elbow. See Figure 85.
A CAUTION
Drain the water/fuel into a container and dispose of
in accordance with local environmental regulations.
3. Turn the drain valve clockwise approximately 3

turns and day. Drain the fuel filter until clean fuel is
visible.
( CAUTION
Do not overtighten when closing the drain valve.
Overtightening can damage threads.
1. AIR INLET ELBOW
Close the drain valve by lifting and turning clockwise 2. FUEL FILTER ELEMENT
until it is hand tight. 3. PURGE COCK
Figure 85. Location of the drain valve

engine fuel filter (shown)
Cummins 4.5L engine)
Checking the hood closure

A WARNING the latch cap screws.
The hood, hood latch, and interlock must be
adjusted correctly for the operator restraint system 5. Check the operation of the hood latch. Have an
to function properly. operator sit in the seat. Make sure the hood is fully
closed (two clicks). Also check that the hood
1. Install the hood latch to the hood frame. See Figure touches the rubber bumper. If necessary, repeat
86. Tighten the cap screws so that the hood latch Step 4.
can still move when the hood is closed.
2. Install the latch interlock in the highest slot position.

Check that the latch is in the center of the hood
latch jaws when closing the hood.
3. Carefully close the hood in the full position closed

mind. The hood closure has two positions. tions.
The hood latch is completely closed after two clicks
of the latch.
4. Push down until the hood touches the rubber

bumper. Make sure the latch interlock is still in the
center of the hood latch. Open the hood and tighten
1
2
0

Yale Forklift Periodic Maintenance

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Yale Forklift Periodic Maintenance

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8000 YRM 1248 Maintenance program

Table 1. Maintenance program

Hood and seat x

engine compartment x Remove

16 Fuel bottle (LPG) CIL GPL- HD 5, HD 10

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

16 CIL 79 liters (20.8 gal) Minimum 86 octane

Fuel tank (short

16 CIL 100.3 liters (26.5 Minimum 86 octane

16 CIL 79 liters (20.8 gal) Diesel No. 2

Fuel Tank (Short

Table 1. Maintenance program (Continued)

3 x x c 39.4 liter (41.6 qt) Hydraulic oil ISO VG 46

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

8 Battery and cable x Clean

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

18 Air filter x c See Parts Manual

Engine oil pressure CIL Check oil pressure

GM engine 207 to 380

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

LPG regulator GM x Drain tar See

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

17 c 1 Filter See Parts Manual

Pipe fuel filter

17 c 1 Filter See Parts Manual

Final fuel filter

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

7 x c 20 liter (21 qt) John Deere JDM J20C

21 c 1 filter See Parts Manual

26 l Lubricate as Multi-purpose grease

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

28 lifting chains x SAE 30W motor oil

28 lifting chains l L,X SAE 30W motor oil

mast l 2 fittings Multi-purpose

24 CIL x c 0.35 liter (0.74 pt)

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

Oil bath disc brake

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

Oil bath disc brake

Disc brake center

Brake center section

X=Check C=Replace L=Lubricate CIL=Check indicator light during operation

Table 1. Maintenance program (Continued)

Table 1. Maintenance program (Continued)

NOTE 6: In dirty or dusty environments, replace at 1,000 hours or as necessary.

Maintenance procedures every 8 hours or daily

Figura 7. Checking the tires

▲ WARNING 6. Check that the lifting chains are properly lubricated.

2. Inspect channels for wear ted in the areas over

The following seat belt function checks must be carried

Figura 8. Checking the lifting chain

Operator restraint system

Emergency Lock Tensioner (ELR)

NOTE: Trucks produced after November 2005 models