Periodi

Maintenance
PERIODIC
MAINTENANCE
GP/GLP/GDP135VX, GP/GLP/GDP155VX
[C878, D878]
PART NO. 524288884 8000 YRM 1322

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General ..................................................................................................................................................................... 1
Serial Number Data .............................................................................................................................................. 1
How to Move Disabled Lift Truck ..........................................................................................................................2
How to Tow Lift Truck ...................................................................................................................................... 2
How to Put Lift Truck on Blocks ............................................................................................................................3
How to Raise Drive Tires ................................................................................................................................. 3
How to Raise Steering Tires ............................................................................................................................ 3
How to Clean a Lift Truck ..................................................................................................................................... 4
Maintenance Schedule ............................................................................................................................................. 5
Maintenance Procedures Every 8 Hours or Daily ...................................................................................................32
How to Make Checks With Engine Stopped .......................................................................................................32
Tires and Wheels ........................................................................................................................................... 32
Safety Labels ................................................................................................................................................. 32
Mast, Carriage, Lift Chains, Header Hoses, Attachment ............................................................................... 33
Operator Restraint System .............................................................................................................................34
Emergency Locking Retractor (ELR) ......................................................................................................... 34
Adjust Seat - Full Suspension ....................................................................................................................34
Adjust Seat - Internal Suspension ..............................................................................................................35
Seat Plate and Seat Rails .............................................................................................................................. 36
Engine Compartment ..................................................................................................................................... 36
Paper Application ........................................................................................................................................... 36
Fuel, Oil, and Coolant Leaks, Check ..............................................................................................................37
Hydraulic Hoses ............................................................................................................................................. 38
Coolant Hoses ................................................................................................................................................38
Steering Column Gas Cylinder .......................................................................................................................38
Transmission ..................................................................................................................................................38
Hydraulic System Oil ......................................................................................................................................38
Engine Oil .......................................................................................................................................................40
Air Filter ..........................................................................................................................................................46
Forks .............................................................................................................................................................. 46
Remove ......................................................................................................................................................46
Inspect ....................................................................................................................................................... 46
Install ..........................................................................................................................................................47
Adjust .........................................................................................................................................................47
Hang On Sideshift Carriage ........................................................................................................................... 48
How to Make Checks With Engine Running .......................................................................................................49
Indicator Lights, Horn, Fuses, and Relays ..................................................................................................... 49
Service Brakes ............................................................................................................................................... 52
Brake Oil Level ...........................................................................................................................................52
Operation, Check .......................................................................................................................................52
Parking Brake .................................................................................................................................................52
Engine Oil Pressure ....................................................................................................................................... 52
Cooling System .............................................................................................................................................. 53
Steering System .............................................................................................................................................54
Control Levers and Pedals .............................................................................................................................54
Lift System, Operate ...................................................................................................................................... 54
Air Filter ..........................................................................................................................................................55
Fuel/Water Separator Filter, Cummins 4.5L and QSB 3.3L Diesel Engine ....................................................55
First Service After First 100 Hours of Operation .....................................................................................................56
GM 4.3L Engine Oil and Oil Filter .......................................................................................................................56
©2013 Yale Materials Handling Corp. i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter ......................................................................................56
Maintenance Procedures Every 250 Hours or 6 Months ........................................................................................ 57
GM 4.3L Engine Oil and Oil Filter Change ......................................................................................................... 57
Drive Belt ............................................................................................................................................................ 57
GM 4.3L Engine ............................................................................................................................................. 57
Fan and Alternator Drive Belt .....................................................................................................................57
Drain Tar From LPG Regulator .......................................................................................................................... 58
Drain Tar From LPG Converter .......................................................................................................................... 58
Maintenance Procedures Every 500 Hours or 6 Months ........................................................................................ 60
Hydraulic System Oil .......................................................................................................................................... 60
Hydraulic Tank Breather .....................................................................................................................................63
Inspect ............................................................................................................................................................63
Battery ................................................................................................................................................................ 63
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter ......................................................................................64
Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine ............................................. 64
Remove ..........................................................................................................................................................64
Install ..............................................................................................................................................................64
Final Fuel Filter Replacement (Cummins QSB 3.3L Engine) ............................................................................. 65
Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine) ...................................................................... 65
Controlled Venting ..........................................................................................................................................65
Manual Bleeding ............................................................................................................................................ 65
Low Idle Speed Adjustment, Cummins 4.5L Engine Only .................................................................................. 68
Drive Belt ............................................................................................................................................................ 68
Cummins 4.5L and QSB 3.3L Diesel Engine ................................................................................................. 68
Fan and Alternator Drive Belt .....................................................................................................................68
Clean Debris From Radiator Core ...................................................................................................................... 70
Transmission Oil, Breather, and Wet Brake Axle Oil Level Check ..................................................................... 70
Wet Brake Center Body Oil Level Check ............................................................................................................71
Forks ...................................................................................................................................................................73
Mast Lubrication ................................................................................................................................................. 73
Header Hose Checks ......................................................................................................................................... 79
Lift Chain Lubrication ..........................................................................................................................................79
Tilt Cylinder Lubrication ...................................................................................................................................... 80
Master Brake Cylinder Rod End Pin Lubrication ................................................................................................ 81
Manual Hydraulic Levers Lubrication ................................................................................................................. 81
Brake Oil .............................................................................................................................................................82
Tie Rod Lubrication ............................................................................................................................................ 83
Parking Brake Adjustment .................................................................................................................................. 83
Maintenance Procedures Every 1000 Hours or 6 Months ...................................................................................... 84
Valve Clearance, Check and Adjust ................................................................................................................... 84
Ignition System ................................................................................................................................................... 84
GM 4.3L Engine ............................................................................................................................................. 84
LPG Fuel Filter Element Replace, GM 4.3L Engine ........................................................................................... 84
Remove ..........................................................................................................................................................84
Install ..............................................................................................................................................................85
In-Line Filter Replacement, Cummins 4.5L Engine ............................................................................................ 85
Remove ..........................................................................................................................................................85
Install ..............................................................................................................................................................86
Lift Chains Wear Check ......................................................................................................................................86
Lift Chain Lubrication ..........................................................................................................................................86
ii
Periodic Maintenance Table of Contents
Hang On Sideshift Carriage, Check Sliding Surfaces ........................................................................................ 87

Steering Axle Spindle Bearings .......................................................................................................................... 91
Control Levers and Pedals ................................................................................................................................. 91
Inspect Engine Electrical System, Connectors ...................................................................................................91
Transmission Oil, Filter, Breather Change and Wet Brake Drive Axle Oil Change ............................................ 92
Parking Brake Lever Lubrication, Wet Brake Axle ..............................................................................................95
Normal Operating Environment ......................................................................................................................96
Heavy Duty or Contaminated Environment ....................................................................................................97
Remove ......................................................................................................................................................97
Clean and Inspect ......................................................................................................................................98
Install ..........................................................................................................................................................98
Maintenance Procedures Every 2000 Hours or Annually ....................................................................................... 99
Hydraulic System ................................................................................................................................................99
Hydraulic Filter Assembly, Replace ............................................................................................................... 99
Install ..............................................................................................................................................................99
Hydraulic Tank Breather, Replace ................................................................................................................. 99
Ignition System: Distributor Cap, Rotor, and Spark Plug Wires ....................................................................... 100
Cooling System Check ..................................................................................................................................... 100
Air Filter ............................................................................................................................................................ 105
Oxygen Sensor, GM 4.3L Engine Equipped With GFI Installed ....................................................................... 107
LPG Regulator Fuel Filter, GM 4.3L Engines with GFI Installed ...................................................................... 108
Remove ........................................................................................................................................................108
Install ............................................................................................................................................................108
Gasoline Fuel Filter .......................................................................................................................................... 109
Remove and Replace ...................................................................................................................................109
LPG Fuel Injector, GM 4.3L Engines with GFI Installed ................................................................................... 109
Gasoline Fuel Injector, GM Engines .................................................................................................................109
Fuel Injector, Cummins 4.5L and QSB 3.3L Engine .........................................................................................109
Forks .................................................................................................................................................................109
Brake Oil (Master Cylinder), Change ................................................................................................................110
Test Regulator Pressure LPG/GAS...................................................................................................................110
Check Throttle Shaft for Sticking ...................................................................................................................... 110
Inspect Exhaust Manifold and Piping for Leaks ................................................................................................111
Transmission Automatic Clutch Calibration ......................................................................................................111
Brake System Accumulator .............................................................................................................................. 111
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine ....................................................111
Wheel Bearings ................................................................................................................................................ 112
Steer Wheels, Lubrication ............................................................................................................................ 112
Maintenance Procedures Every 4000 Hours or 2 Years ...................................................................................... 112
Hydraulic Oil, Replace ...................................................................................................................................... 112
Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine ............................................................ 115
Safety Procedures When Working Near Mast ...................................................................................................... 117
Fuel Filter Water Removal .................................................................................................................................... 119
Lift Chain Adjustments ..........................................................................................................................................120
Jump-Starting the Lift Truck ..................................................................................................................................121
Jump-Starting Using a Battery Charger ............................................................................................................121
Jump-Starting a Lift Truck Using Another Lift Truck .........................................................................................121
Welding Repairs ................................................................................................................................................... 122
Overhead Guard Changes ....................................................................................................................................122
Wheel and Tire Replacement ............................................................................................................................... 123
iii
Table of Contents Periodic Maintenance
General .............................................................................................................................................................123
Pneumatic Tire With Tube, Repair ................................................................................................................... 123
Remove Wheels From Lift Truck ..................................................................................................................123
Remove Tire From Wheel ............................................................................................................................ 123
Remove Tire From Two-Piece Wheel ......................................................................................................125
Remove Tire From Three- and Four-Piece Wheels .................................................................................126
Install Wheel in Tire ......................................................................................................................................127
Install Three-Piece or Four-Piece Wheel in Tire ...................................................................................... 128
Install Tire on Two-Piece Wheel .............................................................................................................. 129
Install Two-Piece Wheel in Tire ............................................................................................................... 130
Add Air to Pneumatic Tires With Tube ............................................................................................................. 130
Install the Wheels .........................................................................................................................................131
Dual Drive Wheels, Install ............................................................................................................................ 131
Pneumatic Tubeless Tire, Repair ..................................................................................................................... 132
Remove Wheels From Lift Truck ..................................................................................................................132
Install Tire on Wheel .................................................................................................................................... 134
Add Air to Pneumatic Tubeless Tire .............................................................................................................137
Wheels, Install ..............................................................................................................................................137
Solid Rubber Tires on Pneumatic Wheels, Change ......................................................................................... 137
Install Tire on Wheel .................................................................................................................................... 139
Adhesives and Sealants ....................................................................................................................................... 141
This section is for the following models:
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878]
iv
8000 YRM 1322 General
General
The time intervals must be decreased from the
WARNING recommendations in the Maintenance Schedule for
DO NOT make repairs or adjustments unless you the following conditions:
have both authorization and training. Repairs and • The lift truck is used more than eight hours per
adjustments that are not correct can make a day.
dangerous operating condition.
• The lift truck must work in dirty operating
conditions.
WARNING • Poor ground conditions.
DO NOT operate a lift truck that needs repairs.
• Intensive usage at high performance levels or
Report the need for repairs immediately. If repair
other abnormal conditions will require more
is necessary, put a DO NOT OPERATE tag in the
frequent servicing.
operator's area. Remove the key from the key
switch.
Your dealer for Yale lift trucks has the equipment and
trained service personnel to do a complete program of
CAUTION inspection, lubrication, and maintenance. A regular
Disposal of lubricants and fluids must meet local program of inspection, lubrication, and maintenance
environmental regulations. will help your lift truck provide more efficient
performance and operate for a longer period of time.
This section contains a Maintenance Schedule and
the instructions for maintenance and inspection. Some users have service personnel and equipment to
do the inspection, lubrication, and maintenance
The Maintenance Schedule has time intervals for shown in the Maintenance Schedule. Service
inspection, lubrication, and maintenance of your lift Manuals are available from your dealer for Yale lift
truck. The service intervals are provided in both trucks to help users who do their own maintenance.
operating hours recorded on the lift truck hourmeter
and in calendar time. The recommendation is to use SERIAL NUMBER DATA
the interval that comes first.
The serial number for the lift truck is on the
The recommendations for the time intervals provided Nameplate. It is also on the right side of the frame,
is for eight hours of operation per day. under the floor plate.
1
General 8000 YRM 1322
HOW TO MOVE DISABLED LIFT TRUCK 1. The towed lift truck must have an operator.
How to Tow Lift Truck 2. Tow truck slowly.
3. Using a lift truck or a lifting device that can be

WARNING attached to the mast (I.E. come-a-long), raise
Use extra caution when towing a lift truck if any of carriage and forks approximately 30 cm (12 in.)
the following conditions exist: from surface. Install chain around a mast
crossmember and the carriage to prevent carriage
• Brakes do not operate correctly. and mast channels from moving.
• Steering does not operate correctly.
4. If another lift truck is used to tow the disabled lift
• Tires are damaged.
truck, that lift truck must have an equal or larger
• Traction conditions are bad. capacity than the disabled lift truck. Install
• The lift truck must be towed on a slope. approximately 1/2 of a capacity load on forks of lift
truck that is being used to tow disabled lift truck.
If the engine cannot run, there is no power This 1/2 capacity load will increase traction of lift
available for the hydraulic steering system and truck. Keep load as low as possible.
the service brakes. This condition can make the
lift truck difficult to steer and stop. If the lift truck 5. Use a towing link made of steel that fastens to
uses power from the engine to help apply the tow pins in counterweights of both lift trucks.
brakes, the application of the brakes will be more Slowly and carefully remove the slack out of the
difficult. Poor traction can cause the disabled lift towing link. See Figure 1.
truck or towing vehicle to slide. A slope will also
make the lift truck more difficult to stop.
Never lift and move a disabled lift truck unless the

disabled lift truck MUST be moved and cannot be
towed. A lift truck used to move a disabled lift
truck MUST have a capacity rating equal to or
greater than the weight of the disabled lift truck.
The capacity of the lift truck used to move a
disabled lift truck must have a load center equal
to half the width of the disabled lift truck. See the
Nameplate of the disabled lift truck for the
approximate total weight. The forks must extend
the full width of the disabled lift truck. Put the
weight center of the disabled lift truck on load
center of the forks. Be careful to not damage the
underside of the lift truck.
CAUTION
To prevent damage to the transmission during
towing, lift the drive wheels off the ground or
disconnect the drive shaft. 1. STEEL TOW LINK
2. TOW PIN
CAUTION Figure 1. Towing the Lift Truck

DO NOT try to start the engine by pushing or
towing the lift truck. Damage to the hydraulic
system can occur if engine is started by pushing
or towing lift truck.
2
8000 YRM 1322 General
HOW TO PUT LIFT TRUCK ON BLOCKS 2. Put mast in vertical position. Put a block under
each outer mast channel.
How to Raise Drive Tires
3. Tilt mast fully forward until drive tires are raised
from surface.
WARNING
The lift truck must be put on blocks for some 4. Put additional blocks under frame behind drive
types of maintenance and repair. The removal of tires.
the following assemblies will cause large changes
5. If hydraulic system will not operate, use a
in the center of gravity: mast, drive axle, engine,
hydraulic jack under the side of the frame near
transmission, and counterweight. When the lift
the front. Make sure jack has a capacity equal to
truck is put on blocks, put additional blocks in the
at least half the weight of the lift truck. See
following positions to maintain stability:
Nameplate.
• Before removing the mast and drive axle,
put blocks under the counterweight so the How to Raise Steering Tires
lift truck cannot fall backward.
NOTE: Some lift trucks are equipped with lifting eyes
• Before removing the counterweight, put
for the purpose of lifting the entire lift truck. If the lift
blocks under the mast assembly so the lift
truck is equipped with this type of lifting eyes, the lift
truck cannot fall forward.
truck can be lifted and blocks installed.
The surface must be solid, even, and level when
1. Apply parking brake. Put blocks on both sides
the lift truck is put on blocks. Make sure any
(front and back) of drive tires to prevent
blocks used to support the lift truck are solid,
movement of lift truck. See Figure 2.
one-piece units.
2. Use hydraulic jack to raise steering tires. Make
CAUTION sure jack has a capacity of at least 2/3 of total
weight of lift truck as shown on the nameplate.
These lift trucks are equipped with cowl lifting
eyes. The cowl lifting eyes are to be used to lift 3. Put jack under steering axle or frame to raise lift
the front of the lift truck only. Lifting more than truck. Put blocks under frame to support lift truck.
the front of the lift truck with the cowl lifting eyes
will damage the cowl section.
1. Put blocks on each side (front and back) of

steering tires to prevent movement of lift truck.
See Figure 2.
3
General 8000 YRM 1322
1. DRIVE TIRES 2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
HOW TO CLEAN A LIFT TRUCK If it becomes necessary to clean the fork lift, follow the
guidelines listed below.
WARNING 1. Assure truck components are cool before starting
Engine, exhaust system components and other the cleaning procedure.
components are hot to the touch. Be sure lift
truck components are cool before starting 2. Disconnect the battery. If an electric truck,
inspection and cleaning, or personal injury may remove the traction battery.
occur.
3. Remove accumulated debris using a compressed
air line and nozzle.
WARNING
Compressed air can move particles so that they 4. Lightly spray a non-corrosive cleaning agent onto
cause injury to the user or to other personnel. the areas to be cleaned. This will help loosen
Make sure that the path of the compressed air is grime, so close contact direct spraying will not be
away from all personnel. Wear protective goggles necessary.
or a face shield to prevent injury to the eyes.
5. Be sure to avoid directing the spray into electrical
panel compartment. Ensure overspray does not
CAUTION come in contact with electrical components; do
Units may be washed with a non-heated pressure not spray water directly at electrical components,
washer. Steam cleaning is not recommended in wiring connectors or electrical enclosures. Even
most instances, as condensation may form in sealed connectors may allow water egress under
electrical components causing damage or erratic pressure or if connector is damaged.
behavior. 6. Avoid spraying in areas containing electrical
NOTE: Lift trucks used in paper applications may components such as:
need cleaning beyond what is described here. Please • Floor Plates
refer to Paper Application section in the applicable • Battery Compartment
Operating Manual and to available Service Gram/
Bulletin for more detail. • Dash/cowl assembly
• Armrests with electrical components
4
8000 YRM 1322 Maintenance Schedule
7. Clean the battery compartment by using a clean 9. DO NOT pressure wash lift chains, sheaves or
cloth to wash the battery with water. Dry with load rollers in the mast assembly. Refer to the
compressed air. Care should be taken to keep Chains, Sheaves and Load Rollers maintenance
moisture at a minimum as some units have a section in the Service Manual for proper cleaning
traction or hydraulic motor directly below the procedures.
battery compartment.
10. After cleaning, immediately start and run the lift
8. DO NOT pressure wash the battery. Do not use truck to dry out components.
hot water. For cleaning traction batteries, refer to
the Battery section of the Service Manual.
Maintenance Schedule
NOTE: The 250-hour, 500-hour, and 1000-hour/6-month maintenance services are performed either at the
specified hours or at 6 months whichever occurs first.
5
Maintenance Schedule 8000 YRM 1322
Figure 3. GM 4.3L LPG Trucks With GFI Installed
6
Figure 4. GM 4.3L LPG Trucks With PSI Installed
7
Figure 5. GM 4.3L Gas Trucks With GFI Installed
8
Figure 6. GM 4.3L Gas Trucks With PSI Installed
9
Figure 7. Cummins 4.5L Diesel Trucks
10
Figure 8. Cummins QSB 3.3L Diesel Trucks
11
Figure 9. GM 4.3L LPG Trucks, Trucks With Two-Speed Transmission Manufactured After June 2009, or
Three-Speed Transmission Manufactured After October 2009
12
Figure 10. GM 4.3L Gas Trucks, Trucks With Two-Speed Transmission Manufactured After June 2009, or
Three-Speed Transmission Manufactured After October 2009
13
Figure 11. Cummins QSB 3.3L Diesel Trucks, Trucks With Two-Speed Transmission Manufactured After
June 2009, or Three-Speed Transmission Manufactured After October 2009
14
Table 1. Maintenance Schedule
Item Item 8 hr/ 250 500 1000 2000 4000 hr/ Procedure or Specification
No. 1 day hr/ hr/ hr/ hr/ 2 yr Quantity
6 mo 6 mo 6 mo 1 yr
25 Tires and Wheels X Check Condi- See Nameplate
tion
Safety Labels X Replace as See Parts Manual
Necessary
27, Mast, Carriage, X Check Condi- See Parts Manual
28, Header Hoses, tion and Lubri-
29, Lift Chains, At- cation
38 tachment
Seat Belt, Hip Re- X Check Condi-
straints, and Seat tion and Opera-
Rails tion
Engine Compart- X Remove Com-
ment bustible Materi-
als
See NOTE 5
Paper Applica- X Check Condi-
tion: Engine Com- tion Clean as
partment, Truck Required Re-
Components, Ex- place as Re-
haust Wraps, Ra- quired
diator, Radiator See NOTE 8
Screen if equip-
ped, Belly Pan if
equipped
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condi- See Parts Manual
tion
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
15
Table 1. Maintenance Schedule (Continued)
6 mo 6 mo 6 mo 1 yr
13 Coolant Hoses X Check Condi- See Parts Manual
tion
16 Fuel Tank CIL Dual Tanks LPG - HD 5, HD 10
LPG (GM 29.9 liter
4.3L) (7.9 gal) Per
Tank
Single Tank
38.8 li-
ter (10.25 gal)
16 Fuel Tank CIL 74.8 liter 87 Octane Gasoline
GM 4.3L (19.7 gal) Minimum
(Gasoline)
16 Fuel Tank CIL 74.8 liter Diesel No. 2

Cummins (19.7 gal)
4.5L
and QSB
3.3L
(Diesel)
Horn, Lights, X Check Opera-
Alarms, Fuses, tion
and Relays
1 Service Brakes X Check Opera-
tion
23 Parking Brake X Check Opera-
tion
Steering Controls X Check Condi-
and Steering Col- tion and Opera-
umn Gas Cylinder tion
16
6 mo 6 mo 6 mo 1 yr
22 Transmission X Check for Leaks John Deere
JDM J20C
22 Transmission X Check Opera-
tion
7 Transmission Oil X Check Oil Level John Deere
JDM J20C
39 Transmission Oil X Check Oil Level John Deere
Breather/Dipstick JDM J20C
(Trucks With
Two-Speed
Transmission
Manufactured Af-
ter June 2009, or
Three-Speed
Transmission
Manufactured Af-
ter October 2009)
40 Transmission Oil C 24 liter (25.4 qt) John Deere
JDM J20C
21 Transmission Oil C 1 Filter See Parts Manual
Filter See NOTE 4.
37 Transmission Oil C 1 Breather See Parts Manual
Breather
39 Transmission Oil X Check Breather See Parts Manual
Breather/Dipstick 1 Breather
(Trucks With
Two-Speed
Transmission
Manufactured Af-
ter June 2009, or
Three-Speed
Transmission
Manufactured Af-
ter October 2009)
17
6 mo 6 mo 6 mo 1 yr
22 Transmission X Perform Auto- See Calibration
matic Clutch Procedures
Calibration 8000YRM1134 for
Calibration Proce-
dures
3 Hydraulic Oil X X C 71.5 liter ISO VG 46 Hydraulic
(75.5 qt) Oil
See NOTE 2, -15°C (5°F) and
NOTE 3 and Above
NOTE 16.
6 Hydraulic Oil Fil- C 1 Filter. See See Parts Manual
ter NOTE 16.
10 Hydraulic Tank X C Inspect and Re- See Parts Manual
Breather place as Re-
quired
See NOTE 5.
18
6 mo 6 mo 6 mo 1 yr
8 Battery and Cable X Clean
Terminals
9, 33 Engine Oil Fill/ X C 4.7 liter (5.0 qt) -7°C (20°F) and be-
Dipstick CIL See NOTE 4 low
GM 4.3L and NOTE 5. SAE 5W-20
Engine 16°C (60°F) and be-
(Gasoline/ low
LPG) SAE 5W-30
-18°C (0°F) and
Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
9, 33 Engine Oil Fill/ X C 13 liter (13.7 qt) 0°C (32°F) and be-
Cummins and NOTE 5. SAE 0W-30
4.5L En- -25 to 20°C (-13 to
gine 68°F)
(Diesel) SAE 5W-30
-20 to 20°C (-4 to
68°F)
SAE 10-30
-15°C (5°F) and
above
SAE 5W-40 or
15W-40
API CH-4 or CI-4
9, 33 Engine Oil Fill/ X C 7.5 liter (8 qt) 0°C (32°F) and be-
Cummins and NOTE 5 SAE 0W-30
QSB -25 to 20°C (-13 to
3.3L En- 68°F)
gine SAE 5W-30
(Diesel) -20 to 20°C (-4 to
68°F)
SAE 10-30
-15°C (5°F) and
above
SAE 5W-40 or
15W-40
API CH-4 or CI-4
19
6 mo 6 mo 6 mo 1 yr
19 Engine Oil Filter C 1 Filter See Parts Manual
GM 4.3L See NOTE 4
Engine and NOTE 5.
19 Engine Oil Filter C 1 Filter See Parts Manual

Cummins See NOTE 4
4.5L and NOTE 5.
and QSB
3.3L
Diesel En-
gine
18 Air Filter (With CIL C 1 Filter See Parts Manual
Premium Monitor- See NOTE 5,
ing) NOTE 6, and
NOTE 11.
18 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 11.
20
6 mo 6 mo 6 mo 1 yr
Engine Oil Pres- CIL Check Oil Pres- GM Engine
sure sure 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) Mini-
mum
15 Drive Belt X Check for Wear
GM Engine and Damage.
No Adjustment
Needed.
See NOTE 5.
15 Drive Belt X Check for Wear
Cummins and Damage.
4.5L No Adjustment
and QSB Needed.
3.3L See NOTE 5.
(Diesel)
32 LPG Regulator X Drain Tar
GM 4.3L Engine See NOTE 5.
With GFI Installed
21
6 mo 6 mo 6 mo 1 yr
32 LPG Converter X Drain Tar
GM 4.3L Engine See NOTE 5.
With PSI Installed
Engine Idle X 750 ±25 rpm
Speed
GM 4.3L
(Gasoline/
LPG)
Engine Governed X 2400 ±25 rpm
Speed
GM 4.3L
(Gasoline/
LPG)
(No Load)
PCV Valve X Replace as See Parts Manual
GM 4.3L Necessary
Engine See NOTE 13
With GFI
Installed
22
6 mo 6 mo 6 mo 1 yr
Engine Idle X Coolant Tem- 770 ±50 rpm
Speed perature
Cold En- Less than
gine 77°C (170°F)
Cummins
4.5L
(Diesel)
Speed perature
Hot En- Greater than
gine 77°C (170°F)
Cummins
4.5L
(Diesel)
Speed perature Less
Cold En- than
gine 30°C (86°F)
Cummins
QSB
3.3L (Die-
sel)
Speed perature
Hot En- Greater than
gine 30°C (86°F)
Cummins
QSB
3.3L (Die-
sel)
23
6 mo 6 mo 6 mo 1 yr
Speed
Cummins
4.5L
(Diesel)
(No Load)
Speed
Cummins
QSB
3.3L (Die-
sel)
Oxygen Sensor X Replace as
GM 4.3L CIL Necessary
Engine
With GFI
Installed
4 Valve Adjustment Not Adjustable
GM 4.3L
Engine
4 Valve Adjustment X Adjust as Re- Intake
Cummins quired 0.254 mm (0.010 in.)
4.5L Cold
Diesel En- Exhaust
gines 0.508 mm (0.020 in.)
Cold
4 Valve Adjustment X Adjust as Re- Intake
Cummins quired 0.35 mm (0.014 in.)
QSB See NOTE 12. Cold
3.3L Diesel Exhaust
Engines 0.50 mm (0.02 in.)
Cold
17 Fuel Filter, LPG C 1 Filter See Parts Manual
(GM)
17 Fuel Filter C 1 Filter See Parts Manual
Gasoline
(GM)
24
6 mo 6 mo 6 mo 1 yr
36 Fuel Water Sepa- CIL C 1 Filter See Parts Manual
rator Filter Drain Water
Cummins from Filter as
4.5L Required
and QSB
3.3L
Diesel En-
gine
17 In-Line Fuel Filter C 1 Filter See Parts Manual
Cummins
4.5L
Diesel En-
gine
17 Final Fuel Filter C 1 Filter See Parts Manual
Cummins
QSB
3.3L Diesel
Engine
20 Fuel Injectors X Check and Re-
GM 4.3L place If Re-
LPG With quired
GFI Instal- 6 Injectors
led
GM 4.3L place If Re-
Gas quired
6 Injectors
Cummins place If Re-
4.5L quired
and QSB 4 Injectors
3.3L
Diesel En-
gines
5 Spark Plugs C Change Spark 1.5 mm (0.0059 in.)
GM 4.3L Plugs AC41-993
Engine 6 Plugs
12, Cooling System X C 15.1 liter See NOTE 14

14 GM 4.3L CIL (15.9 qt)
Engine
25
6 mo 6 mo 6 mo 1 yr
12, Cooling System X C 13.5 liter See NOTE 14
14 Cummins CIL (14.2 qt)
4.5L
Diesel En-
gine
12, Cooling System X C 10.4 liter (11 qt) See NOTE 14
14 Cummins CIL
QSB
3.3L Diesel
Engine
Clean Debris X See NOTE 5.
From Radiator
Core
26 Forks X X X Check Condi-
tion
Fork Latches L Lubricate as Multipurpose Grease
Necessary See NOTE 7.
Lift System, Oper- X Check Opera-
ate tion
27 Mast L Lubricate As Multipurpose Grease
Sliding Required See NOTE 7.
Surfaces See NOTE 9.
and Load
Roller Sur-
faces
38 Header Hoses X Check Condi-
tion
26
6 mo 6 mo 6 mo 1 yr
28 Lift Chains X Check Condi- Engine Oil
tion/ Lube if SAE 30W
Necessary.
See NOTE 10.
28 Lift Chains L X, L Check for Wear SAE 30W
Lube as Re- Engine Oil
quired
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
Mast (Before Au- X L X Lube as Re- Multipurpose Grease

gust, 2012) quired See NOTE 7 and
Hang-On (2 fittings for NOTE 15.
Sideshift Upper Bearings) 1.5 mm (0.06 in.)
Carriage and Minimum Thickness.
Sliding (4 Lower Bear-
Surfaces ing Strips)
(Upper and Check Bearings
Lower For Wear.
Bearings)
27
6 mo 6 mo 6 mo 1 yr
Mast (After Au- X L X Lube as Re- Multipurpose Grease
gust, 2012) quired See NOTE 7 and
Hang-On (4 fittings for NOTE 15.
Sideshift Upper Bearings) 2.5 mm (0.10 in.)
Carriage and Minimum Thickness.
Sliding (3 Lower Bear-
Surfaces ing Strips)
(Upper and Check Bearings
Lower For Wear.
Bearings)
Mast X L X Lube as Re- Multipurpose Grease
Fork Posi- quired See NOTE 7 and
tioner 2 Fittings NOTE 15.
Mast X L X Lube as Re- Multipurpose Grease

Fork Posi- quired See NOTE 7 and
tioner 2 Anchors NOTE 15.
Cylinder
Rod
Anchors
Mast X Check Torque See NOTE 15.
Fork Posi- 8 Capscrews
tioner
and Lower
Hook
Capscrews
Mast L Lube as Re- See NOTE 15.
Fork Car- quired
rier
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 7.
Brake Master Cyl- L SAE 10W-30
inder Rod API SM
End Pin ILSAC GF4
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SM
ILSAC GF4
SAE J2362
28
6 mo 6 mo 6 mo 1 yr
24 Brake Oil CIL X C 0.35 liter Dexron® III from
Master (0.74 pt) Sealed Container
Cylinder
Brake System Ac- X Check Pre- Pre-charge Pressure
cumulator charge Pres- 4 ±0.35 bar (58
sure ±5 psi)
11 Steering Axle L 4 Fittings Multipurpose Grease
Spindle See NOTE 7.
Bearings
11 Steering Axle L 4 Fittings Multipurpose Grease
Tie Rods See NOTE 7.
41 Wheel Bearings L Check Grease. Multipurpose Grease

Steer See NOTE 7.
Wheels
2 Pedals, Levers, L Lubricate as Use Silicone Spray
Seat Rails, Ca- Necessary Yale Part No.
bles, Hinges, 504236201)
Linkages
23 Parking Brake X Adjust as Nec- Must Hold a Full Ca-
Adjustment essary. pacity Load on a
15% Grade.
23 Parking Brake L Lubricate as Use Silicone Spray
Necessary (Yale Part Number
504236201)
29
6 mo 6 mo 6 mo 1 yr
30 Wet Brake Drive C Change Oil John Deere
Axle Housing Arm 7.8 liter (8.3 qt) JDM J20C
Oil
(Left
Chamber)
35 Wet Brake Drive C Change Oil John Deere
Axle Housing Arm 7.8 liter (8.3 qt) JDM J20C
Oil
(Right
Chamber)
34 Wet Brake Center X C Change Oil SAE 80W-90
Section Oil 4.6 liter (4.9 qt)
42 Parking Brake X Check and Lu- Normal Operating
Levers (Wet bricate as Nec- Environment: Spray
Brake Axle) essary Lubricant Heavy
Duty or Contamina-
ted Environment:
Multipurpose Grease
See NOTE 7.
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel
Lines, and Fit-
tings
Inspect X
Lock-Off for
Leaks, and En-
sure Lock-Off
Closing
Test LPG/GAS X
Regulator Pres-
sure (with GFI In-
stalled)
30
6 mo 6 mo 6 mo 1 yr
Check X
Air Induction Sys-
tem for Leaks
Check X
Manifold for Vac-
uum Leaks
Check X
Throttle Shaft
for Sticking
Check X
Injectors and
Rails for Leaks
Inspect X
Exhaust Mani-
folds and Piping
for Leaks
Inspect X
Catalyst Inlet
and Outlet
31 Ignition System: C Replace
Distributor Cap,
Rotor, and Spark
Plug Wires
Inspect Muffler In- X Replace as Re-
let and Outlet quired
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500
hours of operation.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications
involving contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or
abrasive compounds; poor ground conditions; intensive usage at high performance levels; or other abnormal con-
ditions will require more frequent servicing. At your request your dealer will advise you of the appropriate service
intervals based on an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: Vehicles used in paper applications require regular inspections and cleaning to minimize risk of fire. This
should be done at least once every 8 hours or more frequently depending upon operating environment. Use com-
pressed air and steam as necessary.
31
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1322
6 mo 6 mo 6 mo 1 yr
NOTE 9: Lubricate mast every three months if units has less than 1000 hours.
NOTE 10: Lubricate if dry or at first sign of visible surface rust.
NOTE 11: Do not open the air filter canister except to change the air filter element. See Maintenance Procedures
Every 2000 Hours or Annually to change air filter element.
NOTE 12: Initial valve adjustment is at 250 hours or 3 months. Subsequent adjustments must be performed at
2000-hour/2-year intervals, whichever comes first.
NOTE 13: Replace after 3000 hours. Use hour interval only.
NOTE 14: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concen-
trate with 50% distilled water or deionized water.
NOTE 15: For lift trucks equipped with Hang On Sideshift Carriage (with or without Fork Positioner) see Mainte-
nance Procedures Every 500 hours or 6 months, Mast Lubrication section in this manual.
NOTE 16: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Proce-
dures 1900YRM1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty appli-
cations or highly contaminated environments, take oil samples every 500 hours. Normal Operating conditions may
allow for less frequent oil sampling. Oil sampling should be done just prior to all oil and filter changes.
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE Tires and Wheels
STOPPED
Check tires for damage. Check the tread and remove
any objects that will cause damage. Check for bent or
WARNING damaged rims. Check for loose or missing hardware.
DO NOT operate a lift truck that needs repairs. Re- Remove any wire, strapping, or other material wrap-
port the need for repairs immediately. If repair is ped around the axle. See Figure 12.
necessary, put a DO NOT OPERATE tag in the op-
erator's area. If the lift truck is equipped with a Safety Labels
key switch, remove the key from the key switch.
If a lift truck that needs repairs is operated, dam- WARNING

age to lift truck and injury to personnel can occur. Safety labels are installed on the lift truck to pro-
vide information about operation and possible
Put lift truck on a level surface. Lower carriage and hazards. It is important that all safety labels are
forks, stop engine, and apply parking brake. Open installed on the lift truck and can be read to avoid
both hood door assemblies and check for leaks and damage to lift truck and injury to personnel.
conditions that are not normal. Clean any oil or fuel
spills. Ensure all surfaces are free of oils, lubricants, Check that all safety labels are installed in the correct
fuel, and organic dust or fibers (paper, wood, cotton, location on lift truck. See the Parts Manual, Model
agricultural grass/grain, etc.). Description section in the Operating Manual or sec-
tion Frame 0100YRM1321 for the correct location of
the safety labels. See the Parts Manual for the part
numbers of the safety labels.
32
8000 YRM 1322 Maintenance Procedures Every 8 Hours or Daily
Make sure the parts that fasten the hang on side-

shift carriage or attachment to the carriage are in
good condition.
6. Visually inspect hoses/fittings for hydraulic leaks;

hose cover for cuts, cracks or exposed reinforce-
ment; defective/broken clamping devices or
sheaves; proper tracking during operation. Adjust/
repair/replace hose/components as necessary.
See Mast Repairs 4000YRM1250 for quick dis-
connect procedures.
7. Check that lift chains are correctly lubricated. Use

1. CHECK FOR DAMAGE (REMOVE NAILS,
GLASS, AND OTHER OBJECTS FROM THE SAE 30W engine oil as necessary to lubricate lift
TREAD) chains.
2. CHECK EDGES FOR WEAR
3. CHECK TIRE PRESSURE 8. Inspect lift chains for cracks or broken links, and
worn or turned pins. See Figure 13.
Figure 12. Tire and Wheel Check
9. Inspect chain anchors and pins for cracks and
damage.
Mast, Carriage, Lift Chains, Header Hoses, 10. Make sure lift chains are adjusted so that they
Attachment have equal tension. Adjustments or replace-
ment of the lift chains must be done by au-
WARNING thorized personnel.
To avoid serious injury to personnel, always lower
the lift mechanism completely. Never allow any
person under a raised carriage. Do not put any
part of your body in or through the lift mechanism
unless all parts of the mast are completely low-
ered and the engine is STOPPED.
DO NOT operate fork lift without lateral fork stops

in place. Forks may disengage from fork carriage.
1. Inspect welds on the mast and carriage for

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

Fork stops prevent forks from laterally disengag-
ing from the carriage.
3. Inspect channels for wear in areas where rollers

travel. Inspect rollers for wear or damage.
1. WORN PIN 5. LOOSE LEAVES
4. Inspect load backrest extension for cracks and 2. CRACKS 6. TURNED PIN
damage. 3. EDGE WEAR 7. CORROSION
4. HOLE WEAR
5. If lift truck is equipped with a hang on sideshift
carriage or attachment, inspect the parts for Figure 13. Lift Chain Check
cracks and wear.
33
Operator Restraint System • The seat swivels 5 degrees to the left to allow
an easier exit of the truck.
NOTE: The seat belt can be either black or red.
• The neutral position is shown in Figure 15.
The seat, seat belt, seat rails, hip restraint, and seat
Seat Adjustment for Operator Weight
plate are all part of the operator restraint system.
Each item must be checked to make sure it is fas-
tened correctly, functions correctly, and is in good
condition. See Figure 14.
CAUTION
A major cause for high Whole Body Vibration is
Emergency Locking Retractor (ELR) caused by the operator not adjusting the seat to
his/her weight.
When the ELR style seat belt is properly buckled
NOTE: It is important to adjust the weight setting for
across the operator, the belt will permit slight operator
each operator.
repositioning without activating the locking mecha-
nism. If the truck tips, travels off a dock, or comes to a NOTE: The seat is designed for maximum weight of
sudden stop, the locking mechanism will be activated 135 kg (298 lb).
and hold the operator's lower torso in the seat.
A seat belt that is damaged, worn, or does not oper-

ate properly will not provide protection when it is nee-
ded. The end of the belt must fasten correctly in the
latch. The seat belt must be in good condition. Re-
place the seat belt if damage or wear is seen. See
Figure 14.
NOTE: The following seat belt operation checks must

be performed three times before replacing the seat
belt assembly.
• Pull the seat belt slowly from the retractor as-

sembly. Make sure the seat belt pulls out and
retracts smoothly. If the seat belt cannot be
pulled from the retractor assembly or the belt
will not retract, replace the seat belt assembly.
• Pull the seat belt with a sudden jerk. Make sure
the seat belt will not pull from the retractor as-
sembly. If the seat belt can be pulled from the NOTE: NON-SWIVEL SEAT SHOWN.
retractor, when it is pulled with a sudden jerk,
1. FLANGE NUT
replace the seat belt assembly. 2. SEAT PLATE
3. FORWARD/BACKWARD ADJUSTMENT
Adjust Seat - Full Suspension 4. SEAT RAIL
5. SEAT BELT
Seat Position Adjustment (Standard Seat) 6. HIP RESTRAINT
7. OPERATOR WEIGHT ADJUSTMENT
• Fore and aft adjustment - It is recommended 8. SEAT
that the seat be adjusted so that the thigh is
horizontal to the ground in order to achieve the Figure 14. Seat, Seat Rail, Seat Plate, and Seat
best ergonomic position. See Figure 14. Belt Check
Seat Position Adjustment (Swivel Seat)

• The seat swivels 12 degrees to the right to al-
low the operator a more ergonomic position
when driving in reverse.
34
• The target is for the "ride indicator" to fall be- pedals. This ensures that the operator is set at
tween the arrows when the operator sits up- the midpoint of the 40 mm (1.57 in.) suspen-
right in the seat with the feet positioned on the sion.
pedals. This ensures that the operator is set at • The weight adjustment knob can be turned left
the midpoint of the 80 mm (3.15 in.) suspen- or right to increase or decrease the weight re-
sion. sistance. As the weight adjustment knob is
• The handle can be turned as shown to in- turned, the "stiffness" of the suspension can be
crease or decrease the weight resistance. Pull felt to increase or decrease on which way the
handle out before turning. As the handle is weight adjustment knob is turned.
turned, the "stiffness" of the suspension can be
felt to increase or decrease on which way the
handle is turned.
Adjust Seat - Internal Suspension
Seat Position Adjustment (Swivel Seat)

• The seat swivels 10.5 degrees to the right to
allow the operator a more ergonomic position
when driving in reverse.
• The seat swivels 5 degrees to the left to allow
an easier exit of the truck.
• The neutral position is shown in Figure 16.
Seat Adjustment for Operator Weight
CAUTION
A major cause for high Whole Body Vibration is
caused by the operator not adjusting the seat to
his/her weight. NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE.
NOTE: It is important to adjust the weight setting for 1. BACKREST ANGLE ADJUSTMENT LEVER
each operator. 2. SWIVEL ADJUSTMENT
3. OPERATOR WEIGHT ADJUSTMENT
NOTE: The seat is designed for maximum weight of 4. FORWARD/BACKWARD ADJUSTMENT HAN-
135 kg (298 lb). DLE
5. SEAT BELT
• The target is for the "ride indicator" to fall be- Figure 15. Swivel Seat Controls
tween the arrows when the operator sits up-
right in the seat with the feet positioned on the
35
NOTE: OPTIONAL SWIVEL SEAT SHOWN.
A. STANDARD, NON SUSPENSION SEAT B. FULL SUSPENSION SEAT

1. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
2. WEIGHT ADJUSTMENT KNOB 6. ARMREST
3. RIDE POSITION INDICATOR 7. SWIVEL LATCH RELEASE LEVER
4. FORWARD/BACKWARD ADJUSTMENT LEVER
Figure 16. Seat Adjustment
Seat Plate and Seat Rails Paper Application
Make sure the seat rails are not loose. The seat rails Vehicles used in paper applications require regular in-
must lock tightly in position, but move freely when un- spection and cleaning to minimize the risk of fire. This
locked. See Figure 14. The seat rails must be cor- should be done at least once every eight hours or
rectly fastened to the seat plate and the seat plate more frequently depending upon operating environ-
must be fastened to the frame. ment. The paper application option will help limit the
contact of paper or tissue scraps to hot surfaces un-
Engine Compartment der the hooddoors, but frequent maintenance is re-
quired.
Check for the presence of any combustible material
such as paper, leaves, etc. Remove any combustible
materials.
36
WARNING WARNING
Engine and exhaust system components are hot Be careful when cleaning with steam. Steam can
to touch. Be sure lift truck components are cool cause serious burns. Wear protective clothing,
before starting inspection and cleaning or per- gloves, and eye protection. Never expose your
sonal injury may occur. skin to steam.
Ensure truck engine cools properly by allowing it to If compressed air did not adequately remove debris,
idle for several minutes. Shutting truck down while hot steam clean to remove any persistent accumulation of
will not allow the engine to cool quickly due to the loss material or oil. Protect electrical components from
of coolant circulation. The heat trapped under the moisture when steam cleaning. DO NOT spray ex-
hood doors may actually increase the engine temper- haust wraps directly with high pressure steam. Allow
ature because of no heat transfer through the radia- lift truck to air dry before returning to work in a conta-
tor. With engine off and lift truck components cooled, minated environment. Paper dust and scraps will ad-
check and clean the radiator and if equipped, radiator here to wet surfaces.
screen. Check engine manifold, exhaust pipes, muf-
fler and catalytic converter for paper scraps. Clean as Check the condition of exhaust wraps for wear, proper
required. Check and clean the engine compartment fit, contamination with oil or antifreeze, gaps in cover-
components, transmission, fan shroud, belly pan if age, failed fasteners and replace as necessary. DO
equipped, and inside frame ledges to avoid paper, NOT reuse wraps if they have been removed for
dust and oil accumulation. Check axle and cowl open- some other service operation.
ings for paper buildup and bailing wire. Remove any
debris. Fuel, Oil, and Coolant Leaks, Check
WARNING WARNING
Compressed air can move particles so that they All fuels are very flammable and can burn or
cause injury to the user or to other personnel. cause an explosion. DO NOT use an open flame to
Make sure that the path of the compressed air is check the fuel level or to check for leaks in the
away from all personnel. Wear protective goggles fuel system. If there is a leak in the fuel system,
or a face shield to prevent injury to the eyes. extra care must be used during the repair. DO
NOT operate the lift truck until a leak is repaired.
CAUTION Make a visual check for leaks on and under the lift
Air pressure, nozzle or extension tube may cause truck. If possible, find and report the leak to mainte-
damage to exhaust wraps and radiator fins. As- nance for repair. Leaks often indicate a need for re-
sure that air pressure, nozzle or extension tube pair of damaged or worn components. Leaks in the
does not damage exhaust wraps or radiator fins. LPG fuel system are usually not visible unless ice is
present. There is however, usually a strong odor. Fuel
Paper removal can generally be accomplished using leaks MUST be repaired IMMEDIATELY.
a compressed air line and nozzle. An extension may
be helpful to access hard to reach places. Remove Check fuel system for leaks and the condition of
floor plates and both hood doors for access to engine parts. When fuel is added to the lift truck, see section
compartment. Open or remove belly pan, if equipped. How to Add Fuel to the Lift Truck in the Operating
Clean components with compressed air. Take care to Manual.
maintain the integrity of the exhaust wraps when
cleaning with compressed air and use caution to not Also check the condition of the radiator or heater ho-
force debris into openings. ses that are not leaking. Soft or cracked hoses need
to be replaced before a major leak occurs.
37
Hydraulic Hoses Check the transmission for leaks and damaged or

loose components. Heavy-duty or high temperature
Check condition of hydraulic hoses for serviceability operations can require more frequent checks.
by inspecting for cracks or other obvious damage.
Check to insure that hydraulic hoses are not leaking. See Figure 18 for lift truck models equipped with two-
If any hose is leaking, report it to maintenance for re- speed transmission manufactured before June, 2009
pair. or a three-speed transmission manufactured before
October, 2009.
Coolant Hoses
See Figure 19 for lift truck models equipped with two-
Check condition of coolant hoses for serviceability by speed transmission manufactured after June, 2009 or
inspecting for cracks or other obvious damage. Check a three-speed transmission manufactured after Octo-
to insure that the coolant hoses are not leaking. If any ber, 2009.
hose is leaking, report it to maintenance for repair.
Hydraulic System Oil
Steering Column Gas Cylinder
Make sure the gas cylinder for the steering column WARNING
operates correctly. The cylinder must NOT allow the At operating temperature, the hydraulic oil is HOT.
column to move unless the tilt lever is released. See Do not permit the hot oil to touch the skin and
Figure 17. cause a burn.
Transmission CAUTION
NOTE: On lift trucks equipped with two-speed trans- Do not permit dirt to enter the hydraulic system
mission manufactured after June, 2009 or a three- when the oil level is checked or the filter is
speed transmission manufactured after October, 2009 changed. Damage to the lift truck and hydraulic
the transmission oil dipstick and transmission oil system can occur if dirt enters the hydraulic sys-
breather are one unit. See Figure 19. tem.
Never operate the hydraulic pump without oil in

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

checking the oil level. Keep the hydraulic oil at the
correct level as indicated on the dipstick. Use the cor-
rect oil as shown in the Maintenance Schedule.

speed transmission manufactured before June, 2009
or a three-speed transmission manufactured before
October, 2009.

speed transmission manufactured after June, 2009 or
1. TILT LEVER a three-speed transmission manufactured after Octo-
2. GAS CYLINDER ber, 2009.
Figure 17. Steering Column Gas Cylinder and Tilt Check the hydraulic system for leaks and damaged or
Lever loose components. Heavy-duty or high-temperature
operations can require more frequent checks.
38
NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED BEFORE JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED BEFORE OCTOBER 2009 SHOWN.
1. TRANSMISSION BREATHER 4. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL DIPSTICK 5. HYDRAULIC TANK BREATHER
3. HYDRAULIC OIL FILTER 6. HYDRAULIC DRAIN PLUG
Figure 18. Transmission and Hydraulic Oil Checks
39
NOTE: LIFT TRUCKS WITH TWO-SPEED TRANSMISSION MANUFACTURED AFTER JUNE 2009, OR
THREE-SPEED TRANSMISSION MANUFACTURED AFTER OCTOBER 2009 SHOWN.
1. TRANSMISSION OIL DIPSTICK/BREATHER 5. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL FILTER 6. HYDRAULIC TANK
3. HYDRAULIC TANK BREATHER 7. HYDRAULIC OIL DRAIN PLUG
4. HYDRAULIC OIL FILTER 8. TRANSMISSION OIL DRAIN PLUG
Engine Oil See Figure 20 for lift truck models equipped with GM
4.3L engine and GFI fuel system.
WARNING See Figure 21for lift truck models equipped with GM
At operating temperature, the engine oil is HOT. 4.3L engine and PSI fuel system.
Do not permit the hot oil to touch the skin and
cause a burn. See Figure 22 for lift trucks equipped with GM 4.3L
gas engine.
CAUTION
See Figure 23 for lift truck models equipped with
DO NOT permit dirt to enter the engine when the Cummins 4.5L diesel engine.
oil level is checked or the filter is changed. Dam-
age to the engine can occur if dirt enters the en- See Figure 24 for lift truck models equipped with
gine. Cummins QSB 3.3L diesel engine.
Never operate the engine without oil. The opera-
tion of the engine without oil will damage the en-
gine.
After engine has stopped, wait one minute before

checking the oil level.
40
1. BATTERY 8. SPARK PLUGS

2. POWER DISTRIBUTION MODULE (PDM) 9. DRIVE BELT
3. FUEL INJECTOR 10. RADIATOR CAP
4. LPG FUEL FILTER ASSEMBLY 11. AUXILIARY COOLANT RESERVOIR
5. ENGINE OIL FILL 12. AIR FILTER PRECLEANER
6. ENGINE OIL DIPSTICK 13. LPG REGULATOR ASSEMBLY
7. AIR FILTER 14. COOLANT HOSES
Figure 20. GM 4.3L LPG Engine Maintenance Points With GFI Installed
41
1. BATTERY 8. DRIVE BELT

2. POWER DISTRIBUTION MODULE (PDM) 9. RADIATOR CAP
3. LPG FUEL FILTER ASSEMBLY 10. AUXILIARY COOLANT RESERVOIR
5. ENGINE OIL DIPSTICK 12. LPG CONVERTER ASSEMBLY
6. AIR FILTER 13. COOLANT HOSES
7. SPARK PLUGS 14. ENGINE LABEL
Figure 21. GM 4.3L LPG Engine Maintenance Points With PSI Installed
42
1. BATTERY 8. SPARK PLUGS

2. POWER DISTRIBUTION MODULE (PDM) 9. DRIVE BELT
3. FUEL INJECTOR 10. RADIATOR CAP
4. FUEL FILTER 11. AUXILIARY COOLANT RESERVOIR
6. ENGINE OIL DIPSTICK 13. COOLANT HOSES
7. AIR FILTER 14. FUEL PUMP ASSEMBLY
Figure 22. GM 4.3L Gasoline Engine Maintenance Points
43
Figure 23. Cummins 4.5L Diesel Engine Maintenance Points
44
Legend for Figure 23
A. TOP VIEW B. RIGHT SIDE VIEW

1. BATTERY 8. AUXILIARY COOLANT RESERVOIR
2. FUEL INJECTION PUMP 9. RADIATOR CAP
3. FUEL INJECTORS 10. FUEL/WATER SEPARATOR FILTER
4. INLINE FUEL FILTER 11. DRIVE BELT
5. AIR FILTER 12. FUEL TRANSFER PUMP
6. ENGINE OIL DIPSTICK 13. POWER DISTRIBUTION MODULE (PDM)
7. ENGINE OIL CAP 14. SILENCER
A. RIGHT SIDE FRONT VIEW B. LEFT SIDE FRONT VIEW

1. DIPSTICK 15. ALTERNATOR
2. TURBOCHARGER 16. ALTERNATOR BELT ADJUSTMENT
3. OIL FILL CAP 17. TEMPERATURE SENDING UNIT
4. AIR INLET HOUSING 18. WATER INLET/THERMOSTAT HOUSING
5. FUEL PRIMER PUMP 19. TURBOCHARGER AIR INLET
6. FUEL/WATER SEPARATOR 20. TURBOCHARGER WASTEGATE
7. ECM 21. TURBOCHARGER EXHAUST
8. FUEL FILTER 22. TURBOCHARGER EXHAUST MANIFOLD
9. STARTER 23. OIL FILTER
10. FUEL RAIL 24. TURBOCHARGER OIL DRAIN LINE
11. ELECTRONIC FUEL PUMP 25. TURBOCHARGER OIL FEEL LINE
12. WATER PUMP 26. OIL PAN
13. CRANK POSITIONING SENSOR 27. OIL PAN DRAIN PLUG
14. CAM POSITIONING SENSOR 28. DRIVE BELT
Figure 24. Cummins QSB 3.3L Diesel Engine Maintenance Points
45
Air Filter
The air filter canister should not be opened until an air

filter element replacement is required. An air filter ele-
ment replacement is required when one of the follow-
ing occurs:
• The optional air flow restriction indicator light
on the dash illuminates.
• If equipped, the manual air flow indicator is red.
• The specified number of hours has passed
since the last filter element replacement.
Do not operate the lift truck until the air filter element
has been replaced.
Forks
NOTE: Forks must be removed or installed by trained
personnel only. 1. CARRIAGE BARS 3. BLOCKS
2. HOOK FORK
The identification of a fork describes how the fork is Figure 25. Hook Fork Removal
connected to the carriage. These lift trucks have hook
forks.
Inspect
Remove
WARNING
WARNING
DO NOT try to correct the alignment of the fork
DO NOT try to move a fork without a lifting device.
tips by bending the forks or adding shims. Never
Each hook fork for these lift trucks can weigh 66
repair damaged forks by heating or welding.
to 183 kg (145 to 402 lb).
Forks are made of special steel using special pro-
NOTE: Forks are to be replaced only in sets and not cedures. If either fork is damaged, replace the
individually. forks as a set.
1. Inspect the forks for cracks and wear. Check that

A fork can be removed from the carriage for replace-
fork tips are aligned as shown in Figure 26.
ment of the fork or other maintenance. Lift the lock pin
and slide a hook fork to the fork removal notch on car- 2. Check that the bottom of the fork is not worn. See
riage. See Figure 25 and Figure 26. Figure 26, item 4.
Lower fork onto blocks so that the bottom hook of the 3. Replace any damaged or broken parts that are
fork moves through the fork removal notch. Lower used to keep forks locked in position.
carriage further so that the top hook of the fork is dis-
engaged from the top carriage bar. Move the carriage
away from the fork, or use a lifting device to move the
fork away from the carriage. See Figure 26.
46
Install
Move fork and carriage so that the top hook on the

fork can engage the upper carriage bar. Raise the
carriage to move the lower hook through the fork re-
moval notch. Slide the fork on the carriage so that
both upper and lower hooks engage the carriage. En-
gage the lock pin with a notch in the upper carriage
bar.
Adjust
NOTE: During the adjustment of the forks, the heel of
the forks should not be touching the ground.
The forks are connected to the carriage by hooks and

lock pins. See Figure 25 and Figure 27. The lock pins
are installed through the top fork hooks and fit into
slots in the top carriage bar. If pin does not remain en-
gaged in carriage slot, replace with new pin. Adjust
the forks as far apart as possible for maximum sup-
port of the load. Hook forks will slide along the car-
riage bars to adjust for the load to be lifted. Raise the
lock pin in each fork to slide the fork on the carriage
Fork Tip Alignment bar. Make sure the lock pin is engaged in the carriage
Length of Forks 3% Dimension bar to lock the fork in position after the width adjust-
ment is made.
915 mm (36 in.) 27 mm (1.10 in.)
1067 mm (42 in.) 32 mm (1.26 in.)
1220 mm (48 in.) 37 mm (1.46 in.)
1372 mm (54 in.) 41 mm (1.61 in.)
1524 mm (60 in.) 46 mm (1.81 in.)
1830 mm (72 in.) 55 mm (2.17 in.)
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF

FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93° 1. FORK 5. WEDGE
8. FORK REMOVAL NOTCH 2. LOCK PIN 6. KNOB
3. SPRING 7. LOCK PIN ASSEM-
Figure 26. Forks Check 4. WASHER BLY
Figure 27. Fork Lock Pin Assembly
47
Hang On Sideshift Carriage
Check for cracks, wear and damage. If damaged, see

Mast Repairs 4000YRM1250 for repair procedures. If
necessary, lubricate sliding surfaces (upper bearings)
at grease fittings and lower bearing strips with multi-
purpose grease shown in the Maintenance Schedule.
See Figure 28.
If lift truck is equipped with a fork positioner, lubricate

fork positioner carrier at grease fittings and the fork
cylinder rod anchors with multipurpose grease shown
in the Maintenance Schedule.
See Figure 28 for fork lift trucks manufactured before

August, 2012.
See Figure 29 for fork lift trucks manufactured after

August, 2012.
1. BACKREST
2. FORK CARRIER RETAINER CAPSCREWS
3. CYLINDER ANCHOR BAR CAPSCREWS
4. CYLINDERS AND HOSES
5. FORKS
6. LOWER HOOKS
7. MOUNTING FLANGE CAPSCREWS
8. BACKREST CAPSCREWS
Figure 29. Hang On Sideshift Carriage, Fork Lift

Trucks Manufactured After August, 2012
1. UPPER BEARINGS GREASE FITTINGS

2. GREASE FITTINGS FOR FORK POSITIONER
CARRIER AND FORK CYLINDER ROD AN-
CHORS
3. FORK POSITIONERS
4. FORK POSITIONER MOUNTING CAPSCREWS
5. LOWER HOOK CAPSCREWS
6. LOWER BEARING STRIPS
Trucks Manufactured Before August, 2012
48
HOW TO MAKE CHECKS WITH ENGINE the lift truck is stationary during a check, apply the
RUNNING parking brake and put the transmission in NEUTRAL.
Make the checks carefully.
WARNING Indicator Lights, Horn, Fuses, and Relays
DO NOT operate a lift truck that needs repairs. Re-
port the need for repair immediately. If repair is If lift truck is equipped with a key switch, turn key to
necessary, put a DO NOT OPERATE tag in the op- ON position. If lift truck is equipped with a Power
erator's area. If lift truck is equipped with a key ON/OFF button, press button to turn system power
switch, remove the key. ON. All warning light and indicator lights will light up
for two seconds (start check) when system power is
If a lift truck that needs repairs is operated, dam-
turned ON. See Figure 30. Check all indicator lights
age to lift truck and injury to personnel can occur.
for correct operation as described in the Operating
Manual. Check the operation of the horn. Start the
WARNING engine by turning the key switch to the Start position,
FASTEN YOUR SEAT BELT! The seat belt is in- if truck is equipped with a key switch, or press the en-
stalled to help the operator stay on the truck if the gine start button, if lift truck is equipped with this but-
lift truck tips over. IT CAN ONLY HELP IF IT IS ton. If any indicator lights do not operate correctly,
FASTENED. check the fuses.
Make sure that the area around the lift truck is clear
before starting the engine or making any checks of
the operation. Be careful when making the checks. If
49
Item Warning and Indicator Light

1 Warning Light, Engine Malfunction Light
2 Warning Light, System Malfunction Light
3 Indicator Light, Air Filter Restriction
4 Indicators Light, Direction and Transmission
5 Warning Light, Brake Oil Level Malfunction Indicator
6 Warning Light, Fasten Seat Belt Malfunction Indicator
7 Warning Light, Parking Brake Malfunction Indicator
8 Warning Light, Alternator Malfunction Indicator
9 Warning Light, Transmission Oil Temperature Malfunction Indicator
10 Warning Light, Engine Oil Pressure Malfunction Indicator
11 Warning Light, Engine Coolant Temperature Malfunction Indicator
12 Warning Light, Coolant Level in Radiator Malfunction Indicator
13 Warning Light, Fuel Level Indicator Malfunction Indicator
14 Indicator Light, 1st Gear Locking
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 30. Warning and Indicator Lights
50
NOTE: FLOOR PLATES REMOVED FOR CLARITY.
1. BATTERY 11. SPARE FUEL PUMP RELAY

2. PDM 12. BATTERY (20-AMP FUSE)
3. RESISTOR (68 OHM) 13. FRONT WORK LIGHT (20-AMP FUSE)
4. START RELAY 14. FRONT/REAR WORK LIGHT RELAYS
5. STARTER (30-AMP FUSE) 15. BATTERY (25-AMP FUSE)
6. IGNITION 3 RELAY 16. REAR WORK LIGHT (20-AMP FUSE)
7. BACKUP RELAY 17. IGNITION 1 (20-AMP FUSE)
8. BACKUP (20-AMP FUSE) 18. IGNITION RELAY
9. IGNITION (30-AMP FUSE) 19. BATTERY (25-AMP FUSE)
10. SPARE FUEL PUMP (20-AMP FUSE) 20. SEMICONDUCTOR TRANSZORB
Figure 31. PDM Showing Fuses and Relays
51
Service Brakes Lift trucks with a Foot Directional Control pedal:

When the inching/brake pedal is fully applied, a switch
Brake Oil Level in the starting circuit is closed so that the engine can
be started.
WARNING Parking Brake
Small amounts of water in the brake system can
cause reduced braking performance if the water There is an indicator icon on the display panel for the
reaches the wheel cylinder areas. DO NOT allow parking brake. This icon is illuminated as describe in
water entry. Ensure that the sealed reservoir lid is the Operating Manual. There is a sensor in the seat
properly replaced. that actuates an audible alarm. If the operator leaves
the seat, with system power OFF, without applying
The brake system has a boosted master cylinder,
the parking brake, the alarm will sound for 10 seconds
braking will be more difficult if the engine is not
until the parking brake is applied or the operator sits
running and can result in injury to personnel.
back on the seat. If system power is ON or the engine
Loss of oil from the brake oil reservoir indicates a is running, and the operator leaves the seat, without
leak and can cause damage to the brake system applying the parking brake, the alarm will sound con-
and lift truck. Repair the brake system before us- tinuously until parking brake is applied or the operator
ing the lift truck. Replace the brake oil in the sys- sits back on the seat.
tem if there is dirt or water in the system.
Make sure the service brakes operate correctly before
DO NOT use DOT fluid, only use Dexron III oil checking the operation of the parking brake. Check
from sealed container to prevent possible damage the operation of the parking brake. The parking brake,
to the brake system. Failure to observe the above when in good condition and correctly adjusted, will
Warning could result in death or serious injury. hold a lift truck with a full capacity load on a 15%
grade [a slope that increases 1.5 meters in 10 meters
There is an indicator light on the Display Switch Clus- (1.5 feet increase in 10 feet)]. If parking brake re-
ter for the brake oil. See Figure 30. The red light is quires adjustment, notify service personnel.
ON when the key switch is in the START position or
the Power ON/OFF button is pressed, and must go Engine Oil Pressure
OFF when the engine is running. If the light is ON
when the engine is running, the brake fluid oil in the NOTE: The engine will enter shutdown mode after a
reservoir is too low. warning buzzer sounds and a 30-second countdown,
if engine oil pressure is less than 34.5 kPa (5 psi) on
Operation, Check lift trucks with powertrain protection system and GM
engine. Lift trucks equipped with a Cummins QSB
Check the operation of the service brakes. Push on 3.3L diesel engine will enter the shutdown mode
the inching/brake pedal. The service brakes must be when the engine oil pressure is less than
applied before the inching/brake pedal reaches the 49 kPa (7 psi) on lift trucks with powertrain protection
floor plate. The pedal must stop firmly and must not system. Lift trucks equipped with a Cummins 4.5L die-
move slowly down after the brakes are applied. The sel engine will enter the shutdown mode when the en-
service brakes must apply equally to both drive gine oil pressure is less than 69 kPa (10 psi) on lift
wheels. The service brakes must not pull the lift truck trucks with powertrain protection system. See the En-
to either side of the direction of travel when they are gine Shutdown procedures in the Operating Man-
applied. The service brakes are automatically adjus- ual.
ted when the lift truck is moving and the brakes are
firmly applied. Full application of the inching/brake
pedal applies the service brakes and puts the trans-
mission in NEUTRAL.
52
There is an indicator light for the engine oil pressure There is an indicator light on the Display Switch Clus-
on the Display Switch Cluster. See Figure 30. During ter for the coolant temperature. The red light is ON
normal operation, the red indicator light will illuminate when the key switch is in the START position or the
when the key switch is turned to ON, if the truck is Power ON/OFF button is pressed, and must go OFF
equipped with a key switch, or when the Power when the engine is running. If the light is ON when the
ON/OFF button is pressed, if the truck is equipped engine is running, the coolant and engine are too hot.
with a Power ON/OFF option, and will stay illuminated Stop the engine and check the coolant level in the
until correct oil pressure is obtained, at which time the auxiliary coolant reservoir. See Figure 30.
light will go off.
Make sure the coolant level is between the ADD and
If the light continues to stay ON when engine is run- FULL marks on the auxiliary coolant reservoir. The
ning, the engine oil pressure is low. Stop the engine coolant will expand as it is heated and the level in the
and check the oil level. auxiliary coolant reservoir will increase. See Fig-
ure 32.
See Figure 20 for lift truck models equipped with GM
4.3L engine and GFI fuel system.
CAUTION
See Figure 21 for lift truck models equipped with GM Additives may damage the cooling system. Before
4.3L engine and PSI fuel system. using additives, contact your local Yale dealer.
See Figure 22 for lift truck models equipped with GM If coolant is added, see Maintenance Schedule for
4.3L gasoline engine. correct solution.
See Figure 23 for lift trucks equipped with Cummins

4.5L diesel engine. WARNING
Compressed air can move particles so that they
See Figure 24 for lift trucks equipped with Cummins cause injury to the user or to other personnel.
QSB 3.3L diesel engine. Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
Do not restart the engine until the low pressure condi- or a face shield to prevent injury to the eyes.
tion has been corrected.
Turn lift truck engine OFF and check the radiator fins.
Cooling System Clean the radiator with compressed air or water as
needed. Check for and remove any debris on the radi-
ator core. If the indicator light turns on again after re-
WARNING
starting, shut down the lift truck and do not operate
DO NOT remove the radiator cap from the radiator the lift truck until the problem is corrected.
when the engine is hot. When the radiator cap is
removed, the pressure is released from the sys-
tem. If the system is hot, the steam and boiling
coolant can cause burns.
NOTE: The engine will enter shutdown mode after a

warning buzzer sounds and a 30-second countdown,
if coolant temperature reaches 121°C (250°F) or
above on lift trucks with GM engine and powertrain
protection system. Lift trucks equipped with a Cum-
mins diesel engine will enter the shutdown mode
when the coolant temperature reaches 110°C (230°F)
or above on lift trucks with powertrain protection sys-
tem. See the ENGINE SHUTDOWN procedures in the
Operating Manual.
53
Lift System, Operate
WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast at the end
of this section.
Lower the lift mechanism completely. Never allow

any person under a raised carriage. DO NOT put
any part of your body in or through the lift mecha-
nism unless all parts of the mast are completely
lowered and the engine is STOPPED. Serious in-
jury to personnel can result if lift mechanism is
not lowered completely.
If the mast cannot be lowered, use chains on the

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

1. RADIATOR CAP hands on pressurized hydraulic components. Hy-
2. FILL CAP draulic oil can be injected into the body by the
3. AUXILIARY COOLANT RESERVOIR
4. ADD MARK pressure and cause serious injury to personnel.
5. FULL COLD MARK
6. FULL HOT MARK Perform the following checks and inspections:
Figure 32. Auxiliary Coolant Reservoir 1. Turn lift truck engine OFF and check for leaks in
the hydraulic system. Check the condition of the
hydraulic hoses and tubes.
Steering System
NOTE: Some parts of the mast move at different
speeds during raising and lowering.
WARNING
The lift truck has hydraulic power steering. The 2. Slowly raise and lower the mast several times
steering can be difficult if the engine is not run- without a load. Raise mast to its full height at least
ning. once. The mast components must raise and lower
smoothly in the correct sequence. Hose must
Make sure the steering system operates smoothly track properly during operation.
and provides good steering control. Make sure the
steering column can be adjusted and the gas cylinder 3. The inner weldments and carriage must lower
function is correct. completely.
4. Raise the mast 1 m (3 ft) with a capacity load.

Control Levers and Pedals The inner weldments and the carriage must raise
smoothly. Lower the mast. All moving compo-
Check that the control levers for the transmission, nents must lower smoothly.
mast, and attachment operate as described in Oper-
ating Manual. Check that the pedals operate cor- 5. Lower the load to approximately 0.3 m (1 ft). Tilt
rectly as described in Operating Manual. mast forward and backward. Mast must tilt
smoothly and both tilt cylinders must stop evenly.
54
6. Check that the controls for the attachment oper-

ate the functions of the attachment. See symbols
by each of the controls. Make sure all hydraulic
lines are connected correctly and do not leak.
Air Filter
There is an indicator light on the Display Switch Clus-

ter (see Figure 30) for the air filter. The amber light is
ON when the key switch is in the START position or
the Power ON/OFF button is pressed, and must go
OFF when the engine is running. If the light is ON
when the engine is running, there is a restriction in the
air filter. Turn engine OFF and remove restriction from
air filter. See Figure 33.
1. AIR FILTER COVER
Fuel/Water Separator Filter, Cummins 4.5L 2. RESTRICTION INDICATOR PORT
3. AIR OUTLET
and QSB 3.3L Diesel Engine 4. DUST DISCHARGE VALVE
5. AIR INLET
This amber indicator light (see Figure 30) will illumi- 6. COVER LATCHES
nate if the sensor on the fuel/water separator filter in-
dicates that water must be drained from the filter. Figure 33. Air Filter

4.5L diesel engine.

QSB 3.3L diesel engine.
55
First Service After First 100 Hours of Operation 8000 YRM 1322
First Service After First 100 Hours of Operation

GM 4.3L ENGINE OIL AND OIL FILTER CUMMINS 4.5L AND QSB 3.3L ENGINE
OIL AND OIL FILTER
1. Change engine oil and oil filter. Apply clean oil to
gasket of new filter. Install new filter. Turn filter 1. Change engine oil and oil filter. Apply clean oil to
until gasket touches, then tighten 1/2 to 3/4 turn gasket of new filter. Install new filter. Turn filter
with your hand. Fill engine with oil as specified in until gasket touches, then tighten 1/2 to 3/4 turn
Maintenance Schedule. See Figure 34. with your hand. Fill engine with oil as specified in
Maintenance Schedule. See Figure 35.
2. Check engine oil at the dipstick tube. If neces-
sary, add additional oil shown in the Maintenance 2. Check engine oil at the dipstick tube. If neces-
Schedule. Start engine. Check area around oil fil- sary, add additional oil shown in the Maintenance
ter for leaks. See Figure 34. Schedule. Start engine. Check area around oil fil-
ter for leaks. See Figure 35.
NOTE: CUMMINS 4.5L DIESEL ENGINE SHOWN.

NOTE: ALL OIL FILL COMPONENTS LISTED IN
CUMMINS QSB 3.3L DIESEL ENGINE SIMILAR.
LEGEND FOR GM 4.3L ENGINES EQUIPPED WITH
GFI OR PSI ARE LOCATED IN THE SAME AREA. 1. OIL FILTER 3. OIL DIPSTICK
2. DRAIN PLUG
1. OIL FILTER
2. DRAIN PLUG Figure 35. Oil Filter Change (Cummins 4.5L
3. ENGINE OIL DIPSTICK Engine)
4. ENGINE OIL FILL
Figure 34. GM 4.3L Engine Oil Filter Change
56
8000 YRM 1322 Maintenance Procedures Every 250 Hours or 6 Months
Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform the Maintenance Procedures Every 8 DRIVE BELT
Hours or Daily prior to performing the procedures in
this section. GM 4.3L Engine
GM 4.3L ENGINE OIL AND OIL FILTER Fan and Alternator Drive Belt
CHANGE
Check drive belt for wear and damage. See Fig-
NOTE: Change the oil and oil filter for the engine at
ure 37. A few small cracks that run across belt are ac-
the first 100 hours of operation on new lift trucks.
ceptable. A belt with cracks that run length of belt or a
belt with missing pieces is not acceptable. See Fig-
Change engine oil and engine oil filter. Use the cor-
ure 38 for the drive belt arrangement.
rect oil shown in the Maintenance Schedule. Apply
clean oil to gasket of new filter. Install new filter. Turn
filter until gasket touches, then tighten 1/2 to 3/4 turn
with your hand. Start engine. Check area around oil
filter for leaks. See Figure 36.
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 37. Drive Belt Inspection
1. OIL FILTER
2. DRAIN PLUG
3. ENGINE OIL DIPSTICK
4. ENGINE OIL FILL
Figure 36. GM 4.3L Engine Oil Change
57
Maintenance Procedures Every 250 Hours or 6 Months 8000 YRM 1322
NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING 1. TAR DRAIN SCREW

TENSIONERS.
Figure 39. GM LPG Regulator
1. FAN PULLEY
2. WATER PUMP PULLEY
3. CRANKSHAFT PULLEY DRAIN TAR FROM LPG CONVERTER
4. SERPENTINE BELT
5. TENSIONER CENTERING PULLEY 1. Move the lift truck to a well ventilated area, and
6. ALTERNATOR PULLEY ensure no external ignition sources are present.
Figure 38. GM 4.3L Drive Belt Arrangement
2. Start the engine.
3. Close the valve on the LPG tank.

DRAIN TAR FROM LPG REGULATOR
4. When engine runs out of fuel, turn key switch to
NOTE: The following procedure is to be used on lift OFF position or press Power ON/OFF button
trucks equipped with a GM 4.3L LPG Engine with GFI OFF, if equipped, and disconnect the negative
installed. terminal on the battery.
1. Warm engine to operating temperature.
CAUTION
2. Shut fuel valve off and run engine until dead.
A small amount of fuel may remain in the fuel line.
3. Raise the hood doors. To prevent the possibility of burns wear gloves
and eye protection. If fuel continues to flow check
4. Remove tar drain screw from regulator. Allow tar to make sure the LPG tank valve is completely
to drain from regulator. When tar has completely closed.
drained, install tar drain screw in regulator. See
Figure 39. 5. Disconnect the inlet line and outlet hose from the
LPG converter. See Figure 40.
58
6. Remove the mounting bolts and LPG converter 12. Start the engine and recheck for leaks at the con-
from the mounting bracket. verter.
CAUTION
Engine components may be hot. Use gloves when
handling the LPG Converter to prevent the possi-
bility of burns.
CAUTION
Drain the tar into a container and dispose in ac-
cordance with local environmental regulations.
7. Rotate the LPG converter sightly so that outlet

opening is pointing toward the container and allow
tar to drain from LPG converter. If LPG converter
cannot be rotated a sufficient amount to drain the
tar, disconnect the two cooling hoses.
8. Using mounting bolts, install the LPG converter 1. LPG CONVERTER

on the mounting bracket. 2. INLET LINE
3. OUTLET HOSE
4. MOUNTING BOLTS
9. Connect the inlet line and outlet hose to the LPG 5. COOLANT HOSE
converter. If disconnected, connect the two cool-
ing hoses. Figure 40. LPG Converter Removal
10. Connect the negative terminal on the battery.
11. Open the valve on the LPG tank and check for
leaks on the LPG converter using soapy water or
a leak detector. If any leaks are found, tighten fit-
tings or replace hose clamps as applicable.
59

NOTE: Perform the 8-hour and 250-hour checks prior Check the hydraulic oil level when the oil is at operat-
to performing the procedures in this section. ing temperature and with the mast in a vertical posi-
tion, the carriage lowered, and the engine stopped.
HYDRAULIC SYSTEM OIL Add hydraulic oil only as needed. If hydraulic oil is
above the FULL level, the hydraulic oil will leak from
WARNING the breather during operation. The oil level indicated
by the dipstick is most accurate when the oil tempera-
At operating temperature, the hydraulic oil is HOT.
ture is 53 to 93°C (130 to 200°F).
DO NOT permit the hot oil to touch the skin and
cause a burn.
speed transmission manufactured before June, 2009
CAUTION or a three-speed transmission manufactured before
DO NOT permit dirt to enter the hydraulic system October, 2009.
when the oil level is checked or the filter is
changed. Damage to the lift truck and hydraulic See Figure 42 for lift truck models equipped with two-
system can occur if dirt enters the hydraulic sys- speed transmission manufactured after June, 2009 or
tem. a three-speed transmission manufactured after Octo-
ber, 2009.
Never operate the hydraulic pump without oil in
the hydraulic system. The operation of the hy-
draulic pump without oil will damage the pump.
CAUTION
Additives may damage the hydraulic system. Be-
fore using additives, contact your local Yale
dealer.
60
1. TRANSMISSION BREATHER 4. HYDRAULIC OIL FILL/DIPSTICK

2. TRANSMISSION OIL FILL/DIPSTICK 5. HYDRAULIC TANK BREATHER
61

62
HYDRAULIC TANK BREATHER

CAUTION
Inspect Direct air pressure on the filter element can cause
damage. Direct air pressure away from filter ele-
NOTE: When inspecting the breather, do not disas- ment.
semble it. The breather element is a non serviceable
part. If it is damaged, replace with a new breather ele- 2. Using compressed air, remove any dirt and debris
ment. in the frame cavity around the breather.
1. Remove floor mat, front and rear floor plates, and See Figure 41 for lift truck models equipped with
right side rear cover to access hydraulic tank two-speed transmission manufactured before June,
breather. See Figure 43. 2009 or a three-speed transmission manufactured
before October, 2009.
WARNING See Figure 42 for lift truck models equipped with
Compressed air can move particles so that they two-speed transmission manufactured after June,
cause injury to the user or to other personnel. 2009 or a three-speed transmission manufactured
Make sure that the path of the compressed air is after October, 2009.
or a face shield to prevent injury to the eyes. 3. If necessary, unscrew and replace the breather if
oil has accumulated in the cavity or on the
breather, or if dirt has accumulated at the
breather passages at the bottom of the breather.
4. Install right side rear cover, front and rear floor

plates, and floor mat. See Figure 43.
BATTERY
WARNING
The acid in the electrolyte can cause injury. If the
electrolyte is spilled, use water to flush the area.
Use a solution of sodium bicarbonate (soda) to
make the acid neutral. Acid in the eyes must be
flushed with water immediately. Wear eye protec-
tion.
WARNING
Batteries generate explosive fumes. Keep the
NOTE: RIGHT SIDE VIEW vents in the caps clean. Keep sparks or open
1. RIGHT SIDE REAR COVER flame away from the battery area. DO NOT make
2. RIGHT SIDE FRONT COVER sparks from the battery connections. Disconnect
3. SCREWS the battery ground cable when doing mainte-
4. REAR FLOOR PLATE nance.
5. FRONT FLOOR PLATE
6. CLIP NUTS
Disconnect the negative and positive terminals of the
Figure 43. Side Cover Removal battery. Using a damp cloth clean the case of the bat-
tery. If the terminals are corroded, clean the terminals
with a wire brush. Connect the negative and positive
cables to their respective terminals.
63
CUMMINS 4.5L AND QSB 3.3L ENGINE Replace the fuel filter at specified intervals to prevent
OIL AND OIL FILTER contaminants from adversely affecting the diesel fuel
flow.
NOTE: Change the oil and oil filter for the engine at
the first 100 hours of operation on new lift trucks. Remove
Change engine oil and engine oil filter. Use the cor- 1. Stop Engine and allow it to cool.
rect oil shown in Maintenance Schedule. Apply clean
oil to gasket of new filter. Install new filter. Turn filter 2. Disconnect air inlet elbow to access the fuel filter
until gasket touches, then tighten 1/2 to 3/4 turn with element.
your hand. Start engine. Check area around oil filter
See Figure 45 for Cummins 4.5L diesel engine.
for leaks. See Figure 44.
See Figure 46 for Cummins QSB 3.3L diesel en-
gine.
3. Disconnect fuel filter sensor connector from the

fuel filter element.
CAUTION
Drain the water/fuel into a container and dispose
in accordance with local environmental regula-
tions.
4. Open the drain valve by turning the valve counter-

clockwise approximately 3 1/2 turns until draining
occurs. Drain until fuel filter element is empty.
5. Remove and discard Fuel filter element.
Install
1. Clean the fuel filter head mounting surface and
apply a small amount of diesel fuel to the gasket
on the new fuel filter element.
NOTE: BOTTOM LEFT SIDE ILLUSTRATED. CUM-
MINS 4.5L DIESEL ENGINE SHOWN. CUMMINS See Figure 45 for Cummins 4.5L diesel engine.
QSB 3.3L DIESEL ENGINE SIMILAR.
See Figure 46 for Cummins QSB 3.3L diesel en-
1. OIL FILTER 3. OIL DIPSTICK gine.
2. DRAIN PLUG
2. Before installing the filter element, fill the filter ele-
Figure 44. Engine Oil Change Cummins 4.5L
ment with diesel fuel. This method will aid in
Diesel
bleeding the fuel system.
FUEL/WATER SEPARATOR FILTER CAUTION

REPLACEMENT, CUMMINS 4.5L AND DO NOT overtighten the filter element. Overtight-
QSB 3.3L ENGINE ening the filter element may distort the threads.
3. Install the new fuel filter element until it contacts

CAUTION the fuel filter head mounting surface. Tighten one
Disposal of lubricants and fluids must meet local additional turn.
environmental regulations.
4. Connect the fuel sensor connector to fuel filter el-
ement
64
5. Connect air inlet elbow hose. PRIMING THE FUEL SYSTEM (CUMMINS
4.5L AND QSB 3.3L ENGINE)
6. Open the fuel supply valve.
Controlled Venting
7. Prime the fuel system. See Priming the Fuel Sys-
tem (Cummins 4.5L and QSB 3.3L Engine).
CAUTION
8. Check for fuel leaks.
When using the starting motor to vent the system,
FINAL FUEL FILTER REPLACEMENT DO NOT engage it for more than 30 seconds, or
(CUMMINS QSB 3.3L ENGINE) starter motor damage will occur. Wait 2 minutes
before engaging the starter again.
CAUTION Controlled venting is provided at the injection pump

Disposal of lubricants and fluids must meet local through the fuel drain manifold. Small amounts of air
environmental regulations. introduced by changing the filters or injection pump
supply line will be vented automatically if the fuel filter
Replace the fuel filter at specified intervals to prevent element is changed and filled prior to installation.
contaminants from adversely affecting the diesel fuel
flow. Manual Bleeding
1. Close any OEM fuel valves (if applicable) to pre- Manual Bleeding will be required if one of the follow-
vent fuel from draining. ing conditions exist.
• The fuel filter is not filled prior to installation.
2. Clean the area around the fuel filter head.
• The fuel injection pump is replaced.
• The high pressure fuel line connections are
CAUTION
loosened, or lines are replaced.
Drain the fuel into a container and dispose in ac-
cordance with local environmental regulations. • It is an initial engine start up after an extended
period of no engine operation.
3. Remove the fuel filter. See Figure 46.
1. Crack open the fuel line to the injector pump.
4. Clean the gasket surface.
See Figure 45 for Cummins 4.5L diesel engine.
CAUTION See Figure 46 for Cummins QSB 3.3L diesel en-

DO NOT pour fuel directly into the center of the fil- gine.
ter, since this will allow unfiltered fuel to enter the
system and may cause damage to fuel system 2. Operate the hand lever until fuel is expelled from
components. the loosened fitting.
5. Pre-fill new filters, both pressure side and suction 3. Tighten the fuel line to the injector pump to
side, with clean fuel prior to assembly. Use the 9 N•m (80 lbf in).
clean side block off plug packed with the filter. See Figure 45 for Cummins 4.5L diesel engine.
6. Lubricate the gasket with clean engine oil. See Figure 46 for Cummins QSB 3.3L diesel en-
7. Install fuel filter. Tighten filter until gasket contacts gine.
filter head surface. Tighten filter an additional 3/4 4. Crack open one or more of the injector lines loca-
turn after contact. ted on the cylinder head.
8. Start engine and check for leaks around the fuel
filter.
65
A. RIGHT SIDE VIEW

B. FRONT VIEW
1. FUEL FILTER ELEMENT
2. DRAIN VALVE
3. LIFT PUMP
4. FUEL PUMP
5. IN-LINE FUEL FILTER
6. FUEL SUPPLY VALVE
7. FUEL SENDING UNIT
8. FUEL FILTER SENSOR CONNECTOR
9. AIR INLET ELBOW
10. FUEL LINE INJECTOR FITTINGS (4)
Figure 45. Cummins 4.5L Engine Fuel System
66
A. RIGHT VIEW
B. TOP VIEW
1. TURBO
2. HEAD
3. BELL HOUSING
4. FLYWHEEL
5. OIL 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 FILL CAP
13. WATERGATE
14. TURBORCHARGER AIR INLET
15. OIL DIPSTICK
16. EXHAUST MANIFOLD
17. EXHAUST OUTLET
18. ENGINE ECM
19. STARTER
20. FUEL/WATER SEPARATOR
21. PRIMER PUMP
22. INTAKE MANIFOLD
23. AIR INLET HOUSING
24. INJECTOR LINE
WARNING
The pressure spray released by the fuel injectors
can penetrate the skin and cause serious per-
sonal injury. Wear protective clothing.
5. Crank the engine until fuel is expelled from the

loose fittings. If fuel is present at the injectors,
tighten the injector line fittings, and then crank en-
gine. The engine should start.
CAUTION
Disposal of lubricants and fluids must meet local
6. Wipe up any fuel that may have spilled and dis-

pose of the fuel and rags in accordance with local
directives.
Figure 46. Cummins QSB 3.3L Engine Fuel

System
67
LOW IDLE SPEED ADJUSTMENT, DRIVE BELT

CUMMINS 4.5L ENGINE ONLY
Cummins 4.5L and QSB 3.3L Diesel Engine
CAUTION Fan and Alternator Drive Belt
DO NOT attempt to adjust high idle speed limit
screws. This may impair the safety and perform- Check drive belt for wear and damage. See Fig-
ance of the lift truck and shorten the life of the en- ure 48. A few small cracks that run across belt are ac-
gine. If the high idle speed limit screws require ceptable. A belt with cracks that run the length of belt
adjustment, see your authorized Cummins indus- or a belt with missing pieces is not acceptable.
trial engine dealer or distributor.
See Figure 49 for Cummins 4.5L diesel engine drive
NOTE: Make sure the engine is running prior to mak- belt arrangement.
ing the low idle adjustment.
1. Loosen lock nut. See Figure 47. See Figure 50 for Cummins QSB 3.3L diesel engine
drive belt arrangement.
2. Turn the adjustment screw until correct RPM
identified in the Maintenance Schedule has been
set.
3. After the RPM has been set. Use a screw driver

to hold the adjustment screw in place and tighten
lock nut.
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 48. Drive Belt Inspection
1. TPS
2. LOW IDLE STOP
3. TURNBUCKLE NUT
4. TURNBUCKLE
5. CLEVIS
6. LOCK NUT
7. ADJUSTING SCREW (LOW IDLE)
8. ROD ENDS
Figure 47. Low Idle and Pull Actuator Adjustment

Location
68
1. ALTERNATOR BELT ADJUSTMENT BRACKET

NOTE: CUMMINS 4.5L DIESEL ENGINES HAVE 2. DRIVE BELT
SELF-ADJUSTING TENSIONERS. NO ADJUST- 3. CAMSHAFT PULLEY
MENT NEEDED. 4. CRANKSHAFT PULLEY
5. ALTERNATOR PULLEY
1. ALTERNATOR PULLEY
2. CAMSHAFT PULLEY Figure 50. Cummins QSB 3.3L Diesel Engine Drive
3. WATER PUMP PULLEY Belt Arrangement
4. CRANKSHAFT PULLEY
5. TENSIONER PULLEY
Figure 49. Cummins 4.5L Diesel Engine Drive Belt
Arrangement
69
CLEAN DEBRIS FROM RADIATOR CORE See Figure 42 for lift truck models equipped with
two-speed transmission manufactured after June,
Check the radiator core for restrictions and remove 2009 or a three-speed transmission manufactured
material causing radiator core to be plugged or re- after October, 2009.
stricted.
WARNING
WARNING Cleaning solvents can be flammable and toxic,
Compressed air can move particles so that they and can cause skin irritation. When using clean-
cause injury to the user or to other personnel. ing solvents, always follow the recommendations
Make sure that the path of the compressed air is of the manufacturer.
or a face shield to prevent injury to the eyes. WARNING
Compressed air can move particles so that they
Clean with compressed air, adjusted to a maximum
cause injury to the user or to other personnel.
output of 103 kPa (15 psi), and blow debris from core
Make sure that the path of the compressed air is
and fan shroud.
or a face shield to prevent injury to the eyes.
TRANSMISSION OIL, BREATHER, AND
WET BRAKE AXLE OIL LEVEL CHECK NOTE: The information in Step 2 applies to lift trucks
with a two-speed transmission manufactured After
WARNING June 2009, or a three-speed transmission manufac-
tured After October 2009. On these trucks, the trans-
At operating temperature, the transmission oil is
mission oil dipstick and breather are one unit.
HOT. DO NOT permit the hot oil to touch the skin
and cause a burn. 2. Check the transmission oil breather. See Fig-
ure 51. If breather is dirty or plugged up, clean
transmission oil breather with a grease cleaning
CAUTION
solvent and use compressed air to dry. If trans-
DO NOT permit dirt to enter the transmission mission oil breather is worn or damaged, replace
when the oil level is checked or the filter is with new transmission breather. See Parts Man-
changed and cause damage to the transmission. ual.
NOTE: The transmission and wet brake drive axle 3. Start and run the engine for approximately one
housing arms share oil. By checking the transmission minutes after adding oil to allow oil to lubricate
oil level and adding oil if necessary, the oil level in the parts within the wet brake drive axle housing
wet brake drive axle housing arms is also checked arms.
and filled when oil is added.
4. Turn lift tuck OFF and let it cool for one minute.
1. If engine has been running, the engine must be Check oil level at the transmission dipstick and
shut down for one minute or longer prior to check- add additional oil at the transmission dipstick tube
ing the oil level. If the transmission oil is low, add to properly fill the transmission. The correct oil
oil to transmission at the dipstick tube at the cor- and quantity needed are shown in the Mainte-
rect level as indicated on the dipstick. Use the nance Schedule.
correct oil as shown in the Maintenance Sched-
ule.
See Figure 41 for lift truck models equipped with

two-speed transmission manufactured before June,
2009 or a three-speed transmission manufactured
before October, 2009.
70
WET BRAKE CENTER BODY OIL LEVEL

CHECK
WARNING
At operating temperature, the center section oil is
HOT. DO NOT permit the hot oil to touch the skin
and cause a burn.
CAUTION
DO NOT permit dirt to enter the center body when
the oil level is checked. Dirt will contaminate the
oil and cause damage to the center body of the
axle.
1. Remove the center body fill plug. See Figure 52.
2. Visually check oil level. If necessary, add oil at the

fill port until the oil/fill level port has overflowed.
The Correct oil is shown in the Maintenance
Schedule or Figure 53. NOTE: LIFT TRUCKS WITH A TWO-SPEED TRANS-
MISSION MANUFACTURED AFTER JUNE 2009, OR
3. Install center body fill plug and tighten to 30 to
A THREE-SPEED TRANSMISSION MANUFAC-
50 N•m (22 to 37 lbf ft).
TURED AFTER OCTOBER 2009.
NOTE: THREE-SPEED TRANSMISSION SHOWN.
1. TRANSMISSION OIL DRAIN PLUG

2. TRANSMISSION OIL DIPSTICK/BREATHER
3. TRANSMISSION OIL FILL HOLE
4. TRANSMISSION OIL FILTER
5. TRANSMISSION
Figure 51. Transmission Oil Dipstick and Breather
71
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE
Figure 52. Wet Brake Drive Axle Drain and Fill/Level Plug Location
72
A. RIGHT PLANETARY HOUSING - USE JDM J20C C. CENTER SECTION HOUSING - USE SAE
B. LEFT PLANETARY HOUSING - USE JDM J20C 80W/90
1. HUB FILL/DRAIN PLUG 4. CENTER SECTION FILL/LEVEL PLUG
2. PLANETARY DRAIN PLUG 5. CENTER SECTION DRAIN PLUG
3. PLANETARY FILL PLUG
Figure 53. Oil Application Diagram
FORKS 1. Lubricate sliding surfaces and load roller surfaces

along full length of channels as shown in Fig-
ure 55.
WARNING
Never repair damaged forks. DO NOT heat, weld, NOTE: When lubricating the mast mounting/pivot
or bend the forks. Forks are made of special steel pins, the load must be removed from the normal con-
using special methods. Replaced damaged forks tact surface to allow grease to properly lubricate the
as a complete set. normal contact surfaces of the mast bushings.
Measure thickness of forks with a fork arm caliper 2. Raise the carriage about 61 cm (2 ft), and tilt the
(Yale Part No. 150021700) at a vertical section where mast fully back. Place blocks under the outer
there is no wear. This thickness is dimension X. Now, mast channels to within 13 mm (0.5 in.) of the
measure thickness at heel of fork. If the thickness of channels. See Figure 56.
the heel is not greater than 90% of dimension X, re-
3. Tilt the mast fully forward. See Figure 56.
place fork. See Figure 54.
4. Lubricate the mast pivot bushings at grease fit-
MAST LUBRICATION tings on outer mast. Use multipurpose grease
shown in the Maintenance Schedule. See Fig-
WARNING ure 57.
When working on or near the mast, see Safety 5. Tilt mast fully back. Remove the blocks from un-
Procedures When Working Near Mast in this sec- der the channels
tion.
NOTE: The load rollers and sheaves have sealed

bearings and do not need additional lubrication.
73
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES
2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 55. Mast Lubrication

1. TIP ALIGNMENT (MUST BE WITHIN 3%
OF FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Figure 54. Forks Check
74
NOTE: Perform Step 6 and Step 7 for lift trucks man-

ufactured before August, 2012.
6. If a hang on sideshift carriage is installed, lubri-

cate sliding surfaces (upper bearings) at grease
fittings and lower bearing strips with multipurpose
grease shown in the Maintenance Schedule. See
Figure 58.
If lift truck is equipped with a fork positioner, lubri-

cate fork positioner carrier at grease fittings and the
fork cylinder rod anchors with multipurpose grease
shown in the Maintenance Schedule. See Fig-
ure 58.
7. Check the torque for the fork positioner mounting

capscrews, if lift truck is equipped with a fork posi-
tioner, and lower hook capscrews on the hang on
sideshift carriage. The torque values for these
capscrews are 155 to 170 N•m (115 to 125 lbf ft).
NOTE: Perform Step 8 through Step 17 for lift trucks

manufactured after August, 2012.
8. If lift truck is equipped with a hang on sideshift

carriage with fork positioner, lubricate sliding sur-
faces (upper bearing) at grease fittings and side-
shifter lower bearings. See Figure 59.
9. Lubricate fork carrier arm as required. Use graph-

ite dry lube.
10. Check for loose or missing capscrews, worn or

damaged hoses and hydraulic leaks.
11. Inspect frame lower hooks for wear and proper

A. MAST TILTED FULLY BACK clearance. Adjust if necessary. See Mast Repairs
B. MAST TILTED FORWARD 4000YRM1250 for adjustment procedures.
1. BLOCK 2. MAST 12. Tighten fork positioner mounting flange cap-
Figure 56. Blocking the Mast screws to 165 N•m (120 lbf ft). See Figure 59.
75
1. OUTER MAST 3. LUBRICATION FITTING

2. MAST PIVOT BUSHING
Figure 57. Pivot Pin Lubrication
76
13. Tighten fork carrier retainer capscrews to

66 N•m (50 lbf ft). See Figure 59.
14. Tighten cylinder anchor bar capscrews to

15. Tighten fork positioner cylinder rod anchor plugs

to 135 N•m (100 lbf ft). See Figure 59.
16. Tighten backrest capscrews to

17. Inspect carrier arm bars and bearings for wear or

damage. If bearing thickness is less than
2.5 mm (0.10 in.) replace both bearings.
1. UPPER BEARINGS GREASE FITTINGS

2. GREASE FITTINGS FOR FORK POSITIONER
CARRIER AND FORK CYLINDER ROD AN-
CHORS
3. FORK POSITIONERS
5. LOWER HOOK CAPSCREWS
6. LOWER BEARING STRIPS

Trucks Manufactured Before August, 2012
77
A. REAR VIEW
1. BACKREST 6. FORK CARRIER
2. CYLINDERS AND HOSES 7. MOUNTING FLANGE CAPSCREWS
3. FORKS 8. FORK CARRIER RETAINER CAPSCREW
4. BACKREST CAPSCREW 9. CYLINDER ANCHOR BAR CAPSCREWS
5. WASHER 10. FRAME-LOWER HOOKS
Figure 59. Hang On Sideshift Carriage With Fork Positioner, Fork Lift Trucks Manufactured After August,
2012
78
HEADER HOSE CHECKS DO NOT repair worn or damaged lift chains. If a

lift chain is worn or damaged, both lift chains
NOTE: Also inspect header hoses every 8 hours or must be replaced.
daily.
NOTE: The 500 Hour/6 Months Lift Chain Lubrication
Inspect for kinked, crushed, flattened, or twisted ho- should not be performed in combination with the 1000
ses; hard, stiff, or charred hoses. Inspect hose fittings Hour/6 Months Lift Chain Lubrication.
and for hose slippage and proper hose tensioning.
Adjust/repair/replace hose/components as necessary. Lubricate lift chains with SAE 30W engine oil. The
See Mast Repairs 4000YRM1250. best procedure is to remove the chains from the lift
truck and soak them in engine oil. Be sure to clean
LIFT CHAIN LUBRICATION any dirt or grease from chains before lubricating. DO
NOT USE STEAM TO CLEAN THE LIFT CHAINS.
WARNING
Procedures When Working Near Mast in this sec-
tion.
79
TILT CYLINDER LUBRICATION Lubricate the tilt cylinder ends. Use multipurpose
grease shown in the Maintenance Schedule. There
NOTE: The floor plate must be removed in order to are four lubrication fittings. See Figure 60.
lubricate the rear tilt cylinder lubrication fittings.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 6. MAST END MOUNT
2. LOCK NUT 7. CYLINDER HOSE PORTS
3. ANCHOR PIN 8. ROD END
4. TILT PIN 9. LUBE FITTINGS
5. FRAME END MOUNT
Figure 60. Tilt Cylinder Lubrication
80
MASTER BRAKE CYLINDER ROD END MANUAL HYDRAULIC LEVERS

PIN LUBRICATION LUBRICATION
Lubricate the master brake cylinder rod end pin. Use Lubricate the bushings for the manual hydraulic lev-
lubricant shown in the Maintenance Schedule. See ers. Use spray lubricant as listed in the Maintenance
Figure 61. Schedule. See Figure 62.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 61. Master Brake Cylinder Rod End Pin

Lubrication
NOTE: FOUR FUNCTION LEVERS WITH DETENT

SHOWN.
1. BUSHINGS
2. ROD END PIN
3. HYDRAULIC LEVERS
4. LOCKING RING (COTTER PIN)
Figure 62. Manual Hydraulic Levers Lubrication
81
BRAKE OIL
WARNING
cause reduced braking performance if the water
reaches the wheel cylinder areas. DO NOT allow
water entry. Ensure that the sealed reservoir lid is
properly replaced.
Replace the brake oil in the system if there is dirt

or water in the system.
CAUTION
DO NOT use DOT fluid, only use Dexron III oil
from sealed container to prevent possible damage
to the brake system.
Remove the dash and kick panel from the cowl. The
brake oil reservoir is located on the cowl, at the mas-
ter cylinder. See Figure 63. Add brake oil, as neces-
sary. Use Dexron III brake oil shown in the Mainte-
nance Schedule.
1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR
3. RESERVOIR MOUNTING BRACKET
4. COWL
5. UPPER BRAKE OIL SUPPLY HOSE
6. CYLINDRICAL BLOCK OUTLET FITTING
7. LOWER BRAKE OIL SUPPLY HOSE
8. NIPPLE
9. MASTER CYLINDER
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK
12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
Figure 63. Brake Oil Reservoir
82
TIE ROD LUBRICATION NOTE: Make sure parking brake is released before
making adjustment.
Lubricate the tie rods. Use multipurpose grease
shown in the Maintenance Schedule. There are two 1. Turn the adjustment knob to raise the equalized
lubrication fittings on each tie rod. See Figure 64. link and tighten the parking brake cables shown in
Figure 65. DO NOT tighten the adjustment so that
PARKING BRAKE ADJUSTMENT the brake is applied when the lever is released.
The lever for the parking brake has a lock. Use
Make sure the service brakes are adjusted and the your thumb or finger to release the lock on the
operation of the automatic adjuster mechanism is cor- lever when the parking brake is released.
rect before the parking brake is adjusted.
2. For burnished brakes, test the operation of the
parking brake. The lift truck with a capacity load
Lift trucks with a Foot Directional Control pedal.
must not move when parking brake is applied on
The switch energizes the seat warning circuit when
a 15 percent grade [a slope that increases 1.5 m
hand lever is released. This switch puts the transmis-
in 10 m (1.5 ft in 10 ft)].
sion in NEUTRAL by de-energizing the direction sole-
noid. There is also a switch on the left-hand side of
bracket. This switch prevents engine from starting un-
less parking brake is applied.
1. SPINDLE BEARINGS LUBE FITTINGS 3. STEERING AXLE

2. TIE RODS LUBE FITTINGS
Figure 64. Tie Rod Lubrication
83
1. LOCK BUTTON RELEASE

2. OFF POSITION
3. ON POSITION
4. ADJUSTMENT KNOB
Figure 65. Parking Brake

NOTE: Perform the 8-hour, 250-hour, and 500-hour LPG FUEL FILTER ELEMENT REPLACE,
checks prior to performing the procedures in this sec- GM 4.3L ENGINE
tion.
Remove
VALVE CLEARANCE, CHECK AND
ADJUST
WARNING
The GM 4.3L engine has hydraulic valve lifters and LPG can cause an explosion and serious injury to
does not require valve clearance adjustments during personnel. DO NOT permit any sparks or open
normal service. Additional engine information is avail- flames in the work area.
able in the following section: GM Engines
0600YRM1251. 1. Close fuel valve on tank. Run engine until it stops.
2. Disconnect negative battery cable.

IGNITION SYSTEM
GM 4.3L Engine WARNING
A small amount of fuel may still be present in the
The GM 4.3L gasoline and LPG engines have an fuel line. Use gloves to prevent burns and wear
electronic control unit (ECU) that controls the ignition eye protection. If liquid fuel continues to flow
timing. There are no adjustments. Change the spark from the connections when loosened, check to
plugs every 1000 hours. See the section Capacities make sure the manual valve is fully closed.
and Specifications 8000YRM1320 for the correct
spark plug gap and type of plugs to use.
84
4. Install top section of fuel filter housing.
5. Install bolt and new seal washer. Tighten bolt to

13 N•m (115 lbf in).
NOTE: Opening the fuel valve too quickly can cause

the internal excessive flow valve to close, restricting
the flow of fuel. 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 tank.
7. Turn the key to the ON position and back to the

OFF position or press Power ON/OFF button ON
and then OFF if lift truck is equipped with this op-
tion, to pressurize the fuel system. Check for
leaks.
8. Check for leaks at connections by using soapy

solution or electronic leak detector. If leaks are
detected, make proper repairs.
See LPG Fuel System 0900YRM1242 for lift

trucks equipped with GFI fuel system.
See LPG Fuel System 0900YRM1556 for lift

1. BOLT trucks equipped with PSI fuel system.
2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION IN-LINE FILTER REPLACEMENT,
4. FUEL FILTER
5. FUEL FILTER O-RING CUMMINS 4.5L ENGINE
6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION
CAUTION
Figure 66. LPG Fuel Filter Removal and Disposal of lubricants and fluids must meet local
Installation environmental regulations.
3. Remove the bolt and seal washer retaining the Replace the fuel filter at specified intervals to prevent
top section of the fuel filter housing. Discard seal contaminants from adversely affecting the diesel fuel
washer. See Figure 66. flow.
4. Remove top section of fuel filter housing. Remove

5. Remove and discard housing O-ring. 1. Stop engine and allow it to cool.
6. Remove fuel filter and fuel filter O-ring. 2. Close fuel supply valve located on the fuel send-
ing unit. See Figure 67.
Install
1. Clean and inspect the fuel filter housing for con- CAUTION
tamination or damage. Drain the fuel into a container and dispose in ac-
cordance with local environmental regulations.
2. Install the new fuel filter and fuel filter O-ring. See
Figure 66. 3. Loosen clamps and disconnect two fuel lines from
the inline fuel filter. Remove and discard the inline
3. Install new housing O-ring.
fuel filter.
85
A. RIGHT SIDE VIEW

B. FRONT VIEW
1. FUEL FILTER ELEMENT
2. DRAIN VALVE
3. LIFT PUMP
4. FUEL PUMP
5. INLINE FUEL FILTER
6. FUEL SUPPLY VALVE
7. FUEL SENDING UNIT
8. FUEL FILTER SENSOR CONNECTOR
9. AIR INLET ELBOW
10. FUEL LINE INJECTOR FITTINGS (4)
Install
1. Install inline fuel filter by connecting the two fuel
lines and tighten clamps. See Figure 67.
2. Open the fuel supply valve.
3. Check for fuel leaks.
LIFT CHAINS WEAR CHECK

If a section of chain is 3% longer than a similar sec-
tion of new chain, the chain is worn and must be re-
placed. Measure chain for wear where it moves over
sheaves. Using a chain scale, (Yale P/N 518096869)
check lift chains as shown in Figure 68.
LIFT CHAIN LUBRICATION
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the recommendations of
the manufacturer.
Compressed air can move particles so they cause

injury to the user or to other personnel. Make sure
that the path of the compressed air is away from
all personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.
Figure 67. Cummins 4.5L Engine Fuel System
86
HANG ON SIDESHIFT CARRIAGE, CHECK

SLIDING SURFACES
1. Check the sideshift carriage sliding surfaces. If
necessary, lubricate sliding surfaces (upper bear-
ings) at grease fittings and lower bearing strips
with multipurpose grease shown in the Mainte-
nance Schedule. See Figure 69.
2. If lift truck is equipped with a fork positioner, lubri-

cate fork positioner carrier at grease fittings and
the fork cylinder rod anchors with multipurpose
grease shown in the Maintenance Schedule.
See Figure 69 for fork lift trucks manufactured be-

fore August, 2012.
See Figure 71 for lift trucks manufactured after Au-

gust, 2012.
Pitch Wear Limit

Total Length of
(The Maximum
20 Links (Pitch)
Length of 20
of New Chain
Links)
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
19.1 mm 381.0 mm 392.4 mm
(0.75 in.) (15.0 in.) (15.4 in.)
25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
1. CHAIN WEAR SCALE
Figure 68. Lift Chains Check
Remove the lift chains. Clean the lift chains by soak-

ing them in a solvent that has a petroleum base for at
least 30 minutes. Use compressed air, adjusted to a 1. UPPER BEARINGS GREASE FITTINGS
maximum output of 103 kPa (15 psi), to completely 2. GREASE FITTINGS FOR FORK POSITIONER
dry the chains when they are clean. CARRIER AND FORK CYLINDER ROD AN-
CHORS
Lubricate the lift chains by soaking them in 30W en- 3. FORK POSITIONERS
gine oil for at least 30 minutes. Remove the chains 5. LOWER HOOK CAPSCREWS
from the oil. Hang the chains for one hour so excess 6. LOWER BEARING STRIPS
oil will drain from the chains.
Figure 69. Hang On Sideshift Carriage, Lubricate,
Lift Trucks Manufactured Before August, 2012
87
NOTE: Perform Step a and Step b for lift trucks NOTE: Perform Step c and Step d for lift trucks man-
equipped with hang on sideshift carriage with fork po- ufactured after August, 2012
sitioner manufactured before August, 2012.
c. Remove upper bearings from the upper car-
3. Clean the bearing areas. Inspect the hang on riage bar. If any upper bearings are worn to
sideshift bearings for wear as follows: less than 2.5 mm (0.10 in.) thickness, replace
all upper bearings by driving upper bearings
a. Remove upper bearings from the upper car- from upper carriage bar. Install new upper
riage bar. If any upper bearings are worn to bearings into upper carriage bar. See Fig-
less than 1.5 mm (0.06 in.) thickness, replace ure 71.
all upper bearings by driving upper bearings
from upper carriage bar. Install new upper d. Remove lower bearings from the lower car-
bearings into upper carriage bar. See Fig- riage bar. If any lower bearings are worn to
ure 70. less than 2.5 mm (0.10 in.) thickness, replace
all lower bearings by prying lower bearings
b. Remove lower bearings from the lower car- from the lower carriage bar. Install new lower
riage bar. If any lower bearings are worn to bearings onto lower carriage bar. See Fig-
less than 1.5 mm (0.06 in.) thickness, replace ure 71.
all lower bearings by prying lower bearings
from the lower carriage bar. Install new lower
bearings onto lower carriage bar. See Fig-
ure 70.
88
Figure 70. Hang On Sideshift Carriage, Check Bearings, Lift Trucks Manufactured Before August, 2012
89
A. HANG ON SIDESHIFT CARRIAGE FOR LIFT TRUCKS MANUFACTURED BEFORE JANUARY, 2011.
B. HANG ON SIDESHIFT CARRIAGE FOR LIFT TRUCKS MANUFACTURED AFTER JANUARY, 2011.
1. GREASE FITTING 9. LOWER HOOK
2. UPPER BEARING 10. CAPSCREW
3. ANCHOR BRACKET 11. WASHER
4. SIDESHIFT CYLINDER 12. UPPER CARRIAGE BAR
5. CLEVIS PIN 13. PIN
6. COTTER PIN 14. PLUG
7. LOWER BEARING 15. LOWER CARRIAGE BAR
8. NUT
1. UPPER CARRIAGE BAR 7. WASHER

2. LOWER BEARINGS 8. LOWER HOOK
3. RESTRICTOR WASHER 9. CAPSCREW
4. SIDESHIFT CYLINDER 10. GREASE FITTING
5. UPPER BEARING 11. LOWER CARRIAGE BAR
6. ROLL PIN
Figure 71. Hang On Sideshift Carriage, Check Bearings, Lift Trucks manufactured After August, 2012
90
STEERING AXLE SPINDLE BEARINGS • Check engine wire harness for rubbing, chaff-
ing, pinching, and cracks or breaks in the wir-
Lubricate the spindle bearings on the steering axle. ing.
There are four lubrication fittings, two on each side of • Check engine harness connectors. Check to
the steering axle. Use multipurpose grease as shown ensure connectors are fitted and locked by
in the Maintenance Schedule. See Figure 72. pushing the connectors together. Pull on the
connector halves to make sure they are locked.
CONTROL LEVERS AND PEDALS
• Check ignition coil wire and spark plug wires
Lubricate linkages, pedal shafts, control cables (throt- for hardening, cracking, arching, chaffing, sep-
tle, hood hinges, parking brake), and seat rails. Use a aration, split boot covers, and proper fit. Re-
silicone spray lubricant, Yale Part No. 504236201. place spark plugs at the recommended interval
as shown in the Maintenance Schedule.
INSPECT ENGINE ELECTRICAL SYSTEM, • Check that all electrical components are se-
CONNECTORS curely mounted and retained to the engine or
chassis.
When inspecting the electrical system, check the fol- • Check the Malfunctioning Indicator Light (MIL),
lowing: charging, and oil pressure lights for operation
by starting the engine and checking that the
• Check and clean battery connection. Ensure light illuminates before turning out.
that connections are tight.
• Check battery for damage or cracks to the
case. Replace if necessary.
• Check positive and negative cables for corro-
sion, rubbing, and chaffing. Tighten connec-
tions at both ends.
1. SPINDLE BEARINGS LUBE FITTINGS 3. STEERING AXLE

2. TIE RODS LUBE FITTINGS
Figure 72. Steering Axle Tie Rods and Spindle Bearings
91
TRANSMISSION OIL, FILTER, BREATHER Schedule for wet brake axle oil quantity. When oil
CHANGE AND WET BRAKE DRIVE AXLE has completely drained, install all drain plugs.
OIL CHANGE Tighten the left and right chamber drive axle
housing arm and center section drain plugs to 30
to 50 N•m (22 to 37 lbf ft). See Figure 75.
WARNING
At operating temperature, the transmission and 3. Remove and discard old transmission oil filter.
wet brake axle oil is HOT. DO NOT permit the hot Apply clean oil to gasket of new filter. Install new
oil to touch the skin and cause a burn. filter and hand tighten.
CAUTION CAUTION
The oil used for the wet brake drive axle or trans- Before adding oil, ensure the truck is parked and
mission should not be contaminated. If either the on level ground.
wet brake drive axle and/or transmission oil be-
comes contaminated, the oil must be drained and 4. Turn the wheel hub to the 90 degree position and
replaced with new oil. fill hub with the correct oil and quantity as shown
in the Maintenance Schedule and Figure 76 until
oil reaches the bottom of the drain/fill plug hole.
CAUTION Tighten the left and right chamber drive axle
DO NOT permit dirt to enter the transmission or housing arm and center section drain plugs to 30
wet brake drive axle when the oil level is checked to 50 N•m (22 to 37 lbf ft). Tighten the right and
or the transmission filter is changed. Dirt will con- left wheel hub drain/fill plugs to 90 N•m (66 lbf ft).
taminate the oil and cause damage to the trans- See Figure 75.
mission and wet brake drive axle components.
5. Fill wet brake drive axle center section until oil
reaches the fill hole. The correct oil and quantity
CAUTION needed are shown in the Maintenance Schedule
Disposal of lubricants and fluids must meet local or Figure 76. Install fill plug and tighten to 48 to
environmental regulations. 60 N•m (35 to 44 lbf ft).
NOTE: Change the transmission oil filter at the first 6. Add oil to transmission above the FULL mark on
500 hours of operation on new lift trucks. the dipstick tube. The correct oil and quantity nee-
ded is shown in the Maintenance Schedule.
1. The drain plug for the transmission is located on
the bell housing side of the transmission sump. See Figure 73 for lift trucks with two-speed trans-
Remove drain plug. Drain oil into a container. Be mission manufactured before June 2009, or three-
sure container is large enough to hold all the oil. speed transmission manufactured before October
See Maintenance Schedule for transmission oil 2009.
quantity. Once oil is completely drained, reinstall
See Figure 74 for lift trucks with two-speed trans-
drain plug.
mission manufactured after June 2009, or three-
See Figure 73 for lift trucks with two-speed trans- speed transmission manufactured after October
mission manufactured before June 2009, or three- 2009.
speed transmission manufactured before October
2009.
CAUTION
See Figure 74 for lift trucks with two-speed trans- DO NOT run the engine for more than two mi-
mission manufactured after June 2009, or three- nutes. Damage to the transmission bearings can
speed transmission manufactured after October occur if engine runs longer than two minutes and
2009. oil level is not at the full mark.
7. Start and run the engine for approximately 1 to 2

2. Remove all drain plugs from the wet brake axle minutes after fill to allow oil to lubricate parts
and drain oil into a container. Be sure container is within the wet brake drive axle housing arms and
large enough to hold all the oil. See Maintenance center section.
92
NOTE: LIFT TRUCKS WITH TWO-SPEED TRANS- NOTE: LIFT TRUCKS WITH TWO-SPEED TRANS-
MISSION MANUFACTURED BEFORE JUNE 2009, MISSION MANUFACTURED AFTER JUNE 2009, OR
OR THREE-SPEED TRANSMISSION MANUFAC- THREE-SPEED TRANSMISSION MANUFACTURED
TURED BEFORE OCTOBER 2009 SHOWN. AFTER OCTOBER 2009 SHOWN.
NOTE: ALL MAJOR COMPONENTS AND FRAME NOTE: ALL MAJOR COMPONENTS AND FRAME
COMPONENTS REMOVED FOR THE SAKE OF COMPONENTS REMOVED FOR THE SAKE OF
CLARITY. CLARITY.
1. TRANSMISSION 1. TRANSMISSION OIL DRAIN PLUG

2. TRANSMISSION BREATHER 2. TRANSMISSION OIL DIPSTICK/BREATHER
3. TRANSMISSION DIPSTICK 3. TRANSMISSION OIL FILL HOLE
4. TRANSMISSION OIL FILTER 4. TRANSMISSION OIL FILTER
5. TRANSMISSION DRAIN PLUG 5. TRANSMISSION
Figure 73. Transmission Oil Change Figure 74. Transmission Oil Change
93
1. DRIVE AXLE MAIN HOUSING CENTER DRAIN 5. OIL DRAIN PLUG, LEFT SIDE
PLUG 6. DRIVE AXLE MAIN HOUSING CENTER FILL/
2. OIL FILL PLUG, RIGHT SIDE LEVEL PLUG
3. O-RING 7. OIL DRAIN PLUG, RIGHT SIDE
4. OIL FILL PLUG, LEFT SIDE
Figure 75. Wet Brake Drive Axle Drain and Fill/Level Plug Location
94
A. RIGHT PLANETARY HOUSING - USE JDM J20C

B. LEFT PLANETARY HOUSING - USE JDM J20C
C. CENTER SECTION HOUSING - USE SAE 80W/90
1. HUB FILL/DRAIN PLUG 4. CENTER SECTION FILL/LEVEL PLUG
2. PLANETARY DRAIN PLUG 5. CENTER SECTION DRAIN PLUG
3. PLANETARY FILL PLUG
Figure 76. Oil Application Diagram
NOTE: Transmission oil temperature should be at 1. Block lift truck wheels to prevent lift truck from
least 50°C (120°F) when checking oil level. moving when parking brake is released.
8. Turn lift tuck OFF. Check oil level at the transmis- 2. Have one person sit in the lift truck seat and apply
sion dipstick and add additional oil at the trans- the service brake and release the parking brake.
mission dipstick tube to properly fill the transmis-
sion. The correct oil and quantity needed are 3. Have another person observe the parking brake
shown in the Maintenance Schedule. See Fig- lever(s) on top of the drive axle while the other
ure 75. person turns the parking brake adjustment knob
counterclockwise. See Figure 65. The spring on
9. Repeat Step 6, Step 7, and Step 8 until transmis- the cable(s) should have enough force to cause
sion oil level is at the correct level. the lever(s) to move forward as the parking brake
adjustment cable is slackened.
NOTE: Perform Step 10 on lift trucks with two-speed
transmission manufactured before June 2009, or 4. If lever(s) move freely and lift truck operates in a
three-speed transmission manufactured before Octo- normal operating environment, go to Normal Op-
ber 2009. erating Environment. If lever(s) do not move or if
lift truck operates in a heavy duty or contaminated
10. Replace transmission breather with a new environment, go to Heavy Duty or Contaminated
breather. See Figure 73. Environment.
PARKING BRAKE LEVER LUBRICATION,
WET BRAKE AXLE
Before lubricating the parking brake levers on the wet
brake axle, perform the following:
95
Normal Operating Environment 6. Wait a few minutes to allow solvent to evaporate.

Once solvent has evaporated, spray the area a
1. Clean area around parking brake lever and thrust second time.
bushing to remove dirt and debris. See Figure 77.
7. After second application of grease has evapora-
2. Remove socket head screw and spacer from ted, check parking brake lever for free movement.
parking brake lever. See Figure 77.
8. Install the spacer and socket head screw onto
3. Lift parking brake lever approximately 1 mm (. parking brake lever. Tighten socket head screw to
040 in.) up from thrust lever and away from drive 24 to 26 N•m (17 to 19 lbf ft).
axle housing. See Figure 77.
9. Adjust the parking brake lever(s) using parking
4. Use spray grease, shown in Maintenance Sched- brake adjustment screw (see Figure 77). See
ule, with an extension tube and insert tube in Drive Axle and Differential Assembly Repair
space between parking brake lever and thrust 1400YRM1344 for procedures.
lever.
10. After adjusting parking brake lever(s), adjust park-
5. Spray a generous amount of grease in space being brake. See Maintenance Procedures Every
tween parking brake lever and thrust lever. See 500 Hours or 6 Months for procedures.
Figure 77.
1. SOCKET HEAD SCREW

2. SPACER
3. PARKING BRAKE LEVER
4. THRUST LEVER
5. THRUST BUSHING
6. PARKING BRAKE LEVER ADJUSTMENT SCREW
Figure 77. Lubricate Parking Brake Lever, Normal Operating Environment
96
Heavy Duty or Contaminated Environment
Remove
1. Clean area around parking brake lever and thrust
bushing to remove dirt and debris. See Figure 77.
2. Remove parking brake cable from parking brake

lever.
3. Remove socket head screw securing parking

brake lever to thrust lever. See Figure 77.
NOTE: Mark parking brake lever in relation to the

thrust lever to help install parking brake lever in cor-
rect position during installation. See Figure 78. 1. SOCKET HEAD SCREW
2. THRUST BUSHING
4. Remove spacer and parking brake lever from 3. THRUST LEVER
thrust lever.
Figure 79. Remove Thrust Bushing
NOTE: CIRCLE INDICATES WHERE TO MARK

PARKING BRAKE LEVER.
1. O-RING (OUTSIDE)
1. SPACER 2. O-RING (INSIDE)
2. SOCKET HEAD SCREW 3. BORE (APPLY GREASE HERE)
Figure 78. Remove Parking Brake Lever 4. THRUST BUSHING
Figure 80. Remove O-Rings From Thrust Bushing

5. Remove socket head screws and thrust bushing
from drive axle. See Figure 79.
6. Remove O-rings from inside and outside of thrust

bushing. See Figure 80.
97
Clean and Inspect 7. Install spacer and socket head screw and secure
parking brake lever to thrust lever. Tighten socket
1. Inspect inside bore of thrust bushing. Remove head screws to 24 to 26 N•m (17 to 19 lbf ft). See
any rust or debris. See Figure 80. Figure 77.
NOTE: Before removing rust and debris from thrust 8. Attach parking brake cable to parking brake lever.
lever, cover the opening in the top of the drive axle,
as well as the edges, so that rust and debris do not 9. Adjust the parking brake lever(s) using parking
get into the drive axle trumpet arms. brake adjustment screw (see Figure 77). See
Drive Axle and Differential Assembly Repair
2. Inspect thrust lever and remove any rust or debris 1400YRM1344 for procedures.
as necessary. See Figure 81.
10. After adjusting parking brake lever(s), adjust park-
Install ing brake. See Maintenance Procedures Every
500 Hours or 6 Months for procedures.
1. Apply thin coat of multipurpose grease (see Main-
tenance Schedule) to thrust lever from the bottom
of the spline down to where the O-ring contacts
the thrust lever when the thrust bushing is instal-
led. See Figure 81.
2. Lubricate new O-ring (inside) with lithium based

grease and install the O-ring inside the bore on
the thrust bushing. See Figure 80.
3. Pack area above the O-ring, inside the bore, with

multipurpose grease, as shown in the Mainte-
nance Schedule, prior to installing thrust bushing
onto thrust lever. See Figure 80.
4. Lubricate new O-ring (outside) with lithium based

grease and install the O-ring on outside of thrust 1. THRUST LEVER
bushing. See Figure 80. 2. APPLY MULTIPURPOSE GREASE HERE
3. COVER OPENINGS AND EDGES
5. Apply Loctite® 242 to socket head screws and in- Figure 81. Inspect and Clean Thrust Lever
stall thrust bushing to drive axle. Tighten socket
head screws to 24 to 26 N•m (17 to 19 lbf ft). See
Figure 79.
6. Install parking brake lever in same position as no-

ted during Remove procedure. See Figure 78.
98
8000 YRM 1322 Maintenance Procedures Every 2000 Hours or Annually
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and 5. If present, clean contaminants from inside of
1000-hour checks prior to performing the procedures bowl.
in this section.
Install
HYDRAULIC SYSTEM
1. Lubricate new seal with clean hydraulic oil and in-
Hydraulic Filter Assembly, Replace stall it on bottom of new hydraulic filter. Install
new filter into bowl. See Figure 82.
WARNING 2. Install hydraulic filter and bowl into hydraulic tank.
At operating temperature, the hydraulic oil is HOT.
DO NOT permit the hot oil to touch the skin and 3. Install new O-ring, spring, and lid onto head.
cause a burn.
CAUTION
CAUTION Additives may damage the hydraulic system. Be-
DO NOT permit dirt to enter the hydraulic system fore using additives, contact your local Yale
when the oil level is checked or the filter is dealer.
changed. Dirt can cause damage to the compo-
4. Start the truck, and allow it to run for 30 seconds.
nents of the hydraulic system.
Check for leaks. Stop engine and check hydraulic
Never operate the hydraulic pump without oil in oil level. Add oil, if necessary. Use hydraulic oil
the hydraulic system. The operation of the hy- shown in the Maintenance Schedule. To change
draulic pump without oil will damage the pump. the hydraulic oil, see Hydraulic Oil, Replace.
Hydraulic Tank Breather, Replace

CAUTION
Disposal of lubricants and fluids must meet local 1. Remove floor mat, front and rear floor plates, and
environmental regulations. right side rear cover to access the hydraulic tank
breather. See Figure 83.
1. Put lift truck on a level surface and lower the car-
riage. 2. Unscrew and remove old hydraulic tank breather,
and replace with new hydraulic tank breather.
NOTE: Have a container large enough to hold the hy-
draulic filter assembly and allow for hydraulic oil drain- See Figure 84 for lift truck models with two-speed
ing. transmission manufactured before June 2009, or
three-speed transmission manufactured before Oc-
2. Unscrew and remove lid, spring, and O-ring from tober 2009.
head. See Figure 82.
See Figure 85 for lift truck models with two-speed
3. Remove filter, seal, O-ring, and bowl from hy- transmission manufactured after June 2009, or
draulic tank and place into container to drain oil. three-speed transmission manufactured after Octo-
Cover the head to prevent any foreign materials ber 2009.
from getting into the hydraulic tank.
3. Install right side rear cover, front and rear floor
4. Remove filter and seal from bowl. See Figure 82. plates, and floor mat. See Figure 83.
99
Maintenance Procedures Every 2000 Hours or Annually 8000 YRM 1322
IGNITION SYSTEM: DISTRIBUTOR CAP, 2. Open drain valve and remove radiator cap. See
ROTOR, AND SPARK PLUG WIRES Figure 86. Drain coolant into the container. Flush
cooling system. Check hoses for damage. Re-
NOTE: Make sure the key is in the OFF position or place any damaged hoses with new hoses, as
the Power ON/OFF button has been pressed OFF, if needed.
lift truck is equipped with this option, and the negative
battery cable has been removed from the battery be- 3. Disconnect the hose leading from the auxiliary
fore removing the ignition system. reservoir to fitting at the top of the radiator under
the radiator cap, and drain the reservoir into the
Remove and discard spark plug wire assembly, coil same container used for the radiator coolant.
wire, spark plugs, distributor cap, and rotor. For pro- Check the reservoir for contaminants and flush,
cedures see High Voltage Switch (HVS) Ignition as necessary. Connect the hose back on the fit-
2200YRM1097. ting at the top of the radiator.
COOLING SYSTEM CHECK

CAUTION
1. Put lift truck on a level surface. Stop engine. Additives may damage the cooling system. Before
Place a container with a minimum capacity of using additives, contact your local Yale dealer.
15.1 liter (15.9 qt) under the radiator drain valve
which could be located on either the lower left or 4. Close drain valve. Fill cooling system with the cor-
right side of the radiator on the engine side of the rect coolant, use Ethylene Glycol Boron-free Anti-
radiator. freeze. Purchase a pre-diluted 50/50 solution; or
mix 50% concentrate with 50% distilled water or
deionized water. Fill the auxiliary reservoir to a
WARNING level between the ADD and FULL marks on the
DO NOT remove the radiator cap from the radiator reservoir. See Figure 87.
when the engine is hot. When the radiator cap is
removed, the pressure is released from the sys- 5. Install radiator cap. Start engine. Check for leaks.
tem. If the system is hot, the steam and boiling Add coolant to auxiliary coolant reservoir as nee-
coolant can cause burns. DO NOT remove the ded. Coolant level should be between the ADD
cover for the radiator when the engine is running. and FULL marks on the reservoir.
CAUTION
Disposal of lubricants and fluids must meet local
100
1. LID 5. SEAL
2. SPRING 6. BOWL
3. O-RING 7. FITTING
4. FILTER 8. HEAD
Figure 82. Hydraulic Filter Assembly
101

NOTE: RIGHT SIDE VIEW
1. RIGHT SIDE REAR COVER

2. RIGHT SIDE FRONT COVER
3. SCREWS
4. REAR FLOOR PLATE
5. FRONT FLOOR PLATE
6. CLIP NUTS
Figure 83. Side Cover Removal
1. TRANSMISSION BREATHER 4. HYDRAULIC OIL FILL/DIPSTICK

2. TRANSMISSION OIL FILL/DIPSTICK 5. HYDRAULIC TANK BREATHER
Figure 84. Hydraulic Tank Breather Location
102

103
NOTE: GM 4.3L ENGINE COOLING SYSTEM AR- 1. RADIATOR CAP

RANGEMENT SHOWN. 2. FILL CAP
3. AUXILIARY COOLANT RESERVOIR
1. DRAIN VALVE 4. ADD MARK
2. AUXILIARY RESERVOIR 5. FULL COLD MARK
3. HOSE 6. FULL HOT MARK
4. RADIATOR CAP
Figure 87. Auxiliary Coolant Reservoir
Figure 86. Cooling System Check
104
AIR FILTER 3. Gently pull filter element from canister. Avoid dis-
lodging contaminants from the element or knock-
The air filter canister should not be opened until an air ing it against the canister.
filter element replacement is required. An air filter ele-
ment replacement is required when one of the follow- 4. With a clean, soft rag, clean the inside surface of
ing occurs: the canister. Remove the liner assembly to make
cleaning easier. Clean well around the locking
• The optional air flow restriction indicator light tabs that retain the element. Clean tabs make
on the dash illuminates. new filter element installation easier. Be careful
• The optional manual air flow indicator button not to knock any contaminants into the outlet tube
pops up. to the engine.
• The specified number of hours has passed
5. Inspect the liner and O-ring assembly for damage.
since the last filter element replacement.
If damaged, replace the liner and O-ring assem-
bly.
CAUTION 6. Install the liner assembly into the canister by
DO NOT to allow dirt to enter the engine air intake pushing in. Make sure the liner assembly is prop-
when replacing the air filter element. A small erly seated in the canister. It will fit snugly into
amount of dirt could cause engine damage. and be centered in the canister.
1. Shut off engine. Never open the air filter canister If your air filter assembly is equipped with a secon-
or remove filter element with engine running. dary element in place of the liner assembly, replace
the secondary element with every 2 to 3 primary el-
2. Unlatch and remove the cover. To remove filter ement replacements.
element, press and rotate filter element counter-
clockwise about 1/8 turn until the filter element is 7. Inspect the new filter element for voids, cuts,
free. To assist removal, gently move the end back tears or indentations in the urethane-sealing sur-
and forth to help break the seal. See Figure 88. faces. Do not use if damage is detected.
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 88. Air Filter
105
NOTE: Do not use the latches to pull the cover down

CAUTION against the canister. If the cover does not fit com-
The element must be properly installed to ensure pletely against the canister with no gaps, the element
adequate engine protection. An improperly instal- is not installed correctly.
led element may allow dirt and dust to enter and
damage the engine. 10. Fasten latches to secure the cover to the canister.
Make sure the latches penetrate the slots in both
NOTE: Proper element installation is required to al- the canister and the cover.
low the cover to be installed correctly. Never reinstall
a used element. Never install a damaged element. Al- 11. Inspect the entire air intake system for leaks. In-
ways use a Yale-approved filter element. spect all clamps for tightness and tighten if neces-
sary. Inspect all hoses for damage. Replace dam-
8. Install new filter element into canister. Press and aged hoses. Inspect the dust evacuation valve for
rotate filter element 1/8 turn clockwise until fully damage. If damaged, replace the dust evacuation
engaged in the canister. See Figure 89. valve.
CAUTION
During cover installation, DO NOT force the cover
on the canister. To do so will result in damage to
the filter element, cover, and possibly the canis-
ter.
NOTE: If the filter element is properly installed, the

cover will fit easily into the canister with no gap be-
tween the cover and the canister. If the cover does
not fit easily, the filter element is not installed prop-
erly. Do not use a cover that is bent, damaged, or
missing latches.
1. PUSH IN
9. Install cover into the canister and ensure the IN- 2. TWIST TO LOCK
LET arrow is in line with the canister inlet.
Figure 89. Air Filter Label
106
OXYGEN SENSOR, GM 4.3L ENGINE Figure 90. If the oxygen sensors need to be replaced,
EQUIPPED WITH GFI INSTALLED see the section Electrical System 2200YRM1142 for
the procedures.
Check that the oxygen sensor electrical connectors
are seated and locked. Check wires for cracks, splits,
chaffing, or burn through and repair if necessary. See
NOTE: OVERHEAD EXHAUST IS AN OPTIONAL FEATURE.

1. OXYGEN SENSOR 3. EXHAUST PIPES TO EXHAUST MANIFOLD
2. ELECTRICAL CONNECTOR
Figure 90. Oxygen Sensor Check
107
LPG REGULATOR FUEL FILTER, GM 4.3L

ENGINES WITH GFI INSTALLED
Remove
1. Close shutoff valve on tank. Run engine until it
stops.
2. Disconnect the hose from the inlet fitting.
3. Remove the inlet fitting from the LPG regulator.

Discard the O-ring. See Figure 91.
4. Remove and discard the plastic cap, foam filter,

paper filter, and rubber washer from the LPG reg-
ulator.
5. Disconnect the hose from the outlet fitting. Re-

move three screws and the outlet fitting from the
LPG regulator. Discard the O-ring.
6. Remove and discard the screen from the LPG

regulator.
Install
1. LPG REGULATOR
1. Install a new screen in the LPG regulator. 2. INLET FITTING
3. O-RING
2. Install a new O-ring on the outlet fitting. Using 4. PLASTIC CAP
three screws, install the outlet fitting on the LPG 5. FOAM FILTER
6. PAPER FILTER
regulator. 7. RUBBER WASHER
8. SCREWS
3. Install new rubber washer, paper filter, foam filter, 9. OUTLET FITTING
and plastic cap in the LPG regulator. 10. SCREEN
4. Install new O-ring on the inlet fitting. Install inlet Figure 91. GM LPG Regulator
fitting into the LPG regulator and connect hose to
the inlet fitting.
5. Open shutoff valve on LPG tank and check for

leaks.
108
GASOLINE FUEL FILTER FUEL INJECTOR, CUMMINS 4.5L AND

QSB 3.3L ENGINE
Remove and Replace
For removal and cleaning instructions for lift truck
1. Remove floor mat and floor plates to disconnect models equipped with the Cummins 4.5L and QSB
the negative terminal of the battery. 3.3L diesel engines, contact your local YALE dealer
or see Yale Axcess Online.
2. Remove and discard the fuel filter. See Figure 92.
3. Install the new fuel filter and tighten the clamp FORKS
screws to 2.45 to 2.77 N•m (22 to 25 lbf in).
4. Connect the negative terminal of the battery and WARNING

close the hood. Never repair damaged forks. DO NOT heat, weld,
cut, drill, or bend forks. Forks are made of special
LPG FUEL INJECTOR, GM 4.3L ENGINES steel using special methods. Replace damaged
WITH GFI INSTALLED forks as a set.
For removal and cleaning instructions, see the section Check the heel and attachments points of forks with a
LPG Fuel System 0900YRM1242. penetrant or by magnetic particle inspection.
GASOLINE FUEL INJECTOR, GM Inspect forks for:

ENGINES • Surface cracks.
For removal and cleaning instructions, see the section • Straightness of blade and shank.
Gasoline Fuel System 0900YRM1244. • Fork angle.
• Difference in height of fork tips.
• Positioning lock.
• Wear on fork hooks.
• Legibility of marking.
If forks need to be replaced, replace as a set.
1. FUEL FILTER
2. FUEL PUMP/SENDER UNIT
Figure 92. Fuel Filter Replacement (GM 4.3L)
109
BRAKE OIL (MASTER CYLINDER),

CHANGE WARNING
1. Remove the dash and kick panel from the cowl. cause reduced braking performance if the water
See the section Frame 0100YRM1321 for the re- reaches the wheel cylinder areas. DO NOT allow
moval procedures. water entry. Ensure that the sealed reservoir lid is
properly replaced.
2. Disconnect and cap lower brake oil supply hose
from nipple. See Figure 93.
CAUTION
3. Remove the reservoir and cylindrical block from
their mounting brackets and remove the reservoir Disposal of lubricants and fluids must meet local
and cylindrical block as a unit from the cowl. See environmental regulations.
Figure 93. 4. Remove reservoir cap and cylindrical block drain
plug. Discard O-ring. See Figure 93. Drain oil
from the reservoir and cylindrical block. Lower
brake oil supply hose into a suitable container.
5. Install cylindrical block drain plug and new O-ring

into cylindrical block. Tighten cylindrical block
drain plug to 90 to 100 N•m (66 to 74 lbf ft).
6. Install the reservoir and cylindrical block onto their

mounting brackets located the cowl. See Fig-
ure 93.
CAUTION
DO NOT use DOT fluid, only use Dexron III oil
from a sealed container to prevent possible dam-
age to the brake system.
7. Fill the reservoir with Dexron III oil until brake oil
flows from the lower brake oil supply hose and
connect hose onto nipple. Install reservoir cap.
8. Bleed the brake lines and axle cylinders. See the

section Brake System 1800YRM1247 for the pro-
cedures.
TEST LPG/GAS REGULATOR PRESSURE

1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR For more information regarding the Test LPG/GAS
3. RESERVOIR MOUNTING BRACKET Regulator Pressure, see the section LPG Fuel Sys-
4. COWL tem 0900YRM1242 and
5. UPPER BRAKE OIL SUPPLY HOSE
6. CYLINDRICAL BLOCK OUTLET FITTING
7. LOWER BRAKE OIL SUPPLY HOSE CHECK THROTTLE SHAFT FOR
8. NIPPLE STICKING
9. MASTER CYLINDER
10. CYLINDRICAL BLOCK DRAIN PLUG Check Throttle body return action to ensure throttle
11. CYLINDRICAL BLOCK shaft is not sticking. Repair if necessary.
12. CYLINDRICAL BLOCK MOUNTING BRACKET
CAPSCREW
Figure 93. Brake Oil Change
110
INSPECT EXHAUST MANIFOLD AND 1. Align the TDC mark on the crankshaft pulley with
PIPING FOR LEAKS the engraved mark on the block. See Figure 94.
To check the exhaust manifold and piping for leaks,

perform the following:
• Check the exhaust manifold at the cylinder

head for leaks. Ensure that all bolts and shields
are in place.
• Check exhaust pipe fasteners to manifold for
leaks to ensure they are tight. Repair if neces-
sary.
• Check all exhaust pipe extension connectors
for leaks and tighten, if necessary.
• Visually inspect converter for correct muffler
mounting and tail pipe mounting.
• Check for any leaks at the inlet and outlet of
the converter.
TRANSMISSION AUTOMATIC CLUTCH

CALIBRATION
1. CRANKSHAFT PULLEY
NOTE: Transmission clutch calibration is performed 2. DRIVE BELT
only on electronic, 3-speed transmissions (Duramatch 3. ENGRAVE TIMING MARK
and Duramatch Plus transmissions).
Figure 94. Cummins QSB 3.3L TDC Mark
Calibrate the transmission clutches every 2000 hours
or annually. See the section Calibration Procedures
2. Adjust ONLY the valves shown in Figure 95, by
8000YRM1134 for the procedures to calibrate the
loosening the locknut with a wrench and adjusting
transmission clutches.
the valve clearance using a screwdriver or Allen
wrench.
BRAKE SYSTEM ACCUMULATOR
Check the precharge pressure in the brake system
accumulator. If the precharge pressure is not within 4
±0.35 bar (58 ±5 psi), recharge the accumulator with
nitrogen gas. See the section Brake System
1800YRM1247 for the procedures on checking the
precharge pressure in the accumulator.
VALVE CLEARANCE, CHECK AND

ADJUST FOR CUMMINS QSB 3.3L
DIESEL ENGINE
The Cummins QSB 3.3L engine does not require
valve clearance adjustments during normal service.
See the Maintenance Schedule for valve clearances. 1. EXHAUST VALVE 4. CYLINDER 2
2. INTAKE VALVE 5. CYLINDER 3
3. CYLINDER 1 6. CYLINDER 4
Check the valve clearance and make adjustments as
needed. To adjust the valve clearances do the follow- Figure 95. Cummins Valve Adjustment
ing:
111
Maintenance Procedures Every 4000 Hours or 2 Years 8000 YRM 1322
3. Tighten the lock nut to 24 N•m (212 lbf in) and

measure valve lash.
4. Mark the vibration damper and rotate the crank-

shaft 360 degrees. See Figure 96.
1. EXHAUST VALVE 4. CYLINDER 2

2. INTAKE VALVE 5. CYLINDER 3
Figure 97. Cummins Valve Adjustment
WHEEL BEARINGS
1. TIMING PIN Steer Wheels, Lubrication
2. VIBRATION DAMPER
Figure 96. Cummins Vibration Damper Lubricate the wheel bearings in the hubs for the steer
wheels with multipurpose grease as shown in the
Maintenance Schedule. See Steering Axle
5. Perform Step 2 and Step 3 to adjust ONLY the 1600YRM1133 for the procedures.
valves shown in Figure 97. See the Maintenance
Schedule for valve clearances.
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 250-hour, 500-hour,
1000-hour, and 2000-hour checks prior to performing CAUTION
the procedures in this section. Disposal of lubricants and fluids must meet local
HYDRAULIC OIL, REPLACE
NOTE: Heavy-duty or contaminated applications will
require hydraulic oil change at 2000 hours.
WARNING
At operating temperature the hydraulic oil is HOT. NOTE: Replace the hydraulic oil filter at the same
DO NOT permit the hot oil to touch the skin and time the oil is changed.
cause a burn.
1. Replace the hydraulic oil as described below:
CAUTION a. Place a container with a minimum capacity of

DO NOT permit dirt to enter the hydraulic system 60.5 liter (64 qt) under the drain plug at the bot-
when the oil level is checked or the filter is tom of the hydraulic tank. To drain the oil, re-
changed. Dirt can cause damage to the compo- move the drain plug from the bottom of the hy-
nents of the hydraulic system. draulic tank.
Never operate the hydraulic pump without oil in See Figure 98 for lift truck models with two-
the hydraulic system. The operation of the hy- speed transmission manufactured before June
draulic pump without oil will damage the pump. 2009, or three-speed transmission manufactured
before October 2009.
112
8000 YRM 1322 Maintenance Procedures Every 4000 Hours or 2 Years
See Figure 99 for lift truck models with two-

speed transmission manufactured after June CAUTION
2009, or three-speed transmission manufactured Additives may damage the hydraulic system. Be-
after October 2009. fore using additives, contact your local Yale
dealer.
b. When the tank is empty, inspect the inside of
the tank for any foreign matter or possible fun- 2. Fill hydraulic tank with oil specified in the Mainte-
gus. If necessary, clean the inside of the tank nance Schedule.
in accordance with the instructions found in the
section Frame 0100YRM1321. 3. When the oil level is correct, operate system and
check for leaks.
c. When either the inspection or the cleaning of
the tank is completed, install the drain plug in
the bottom of the hydraulic tank. Tighten drain
plug to 38 N•m (28 lbf ft).
1. TRANSMISSION BREATHER 4. HYDRAULIC OIL DIPSTICK

2. TRANSMISSION OIL DIPSTICK 5. HYDRAULIC TANK BREATHER
Figure 98. Hydraulic Oil Change
113

114
8000 YRM 1322 Maintenance Procedures Every 4000 Hours or 2 Years
VALVE CLEARANCE, CHECK AND 2. Adjust ONLY the valves shown in Figure 101, by
ADJUST FOR CUMMINS 4.5L DIESEL loosening the locknut with a wrench and adjusting
ENGINE the valve clearance using a screwdriver or Allen
wrench.
The Cummins 4.5L engine does not require valve
clearance adjustments during normal service. See the 3. Tighten the lock nut to 24 N•m (18 lbf in) and
Maintenance Schedule for valve clearances. measure valve lash.
4. Remove the timing pin. See Figure 100.

Check the valve clearance and make adjustments as
needed. To adjust the valve clearances do the follow- 5. Mark the vibration damper and rotate the crank-
ing: shaft 360 degrees. See Figure 102.
1. Rotate the engine until it is at TDC for cylinder 6. Perform Step 2 and Step 3 to adjust ONLY the
number one (intake and exhaust valves closed). valves shown in Figure 103. See the Maintenance
Insert timing pin. See Figure 100. Schedule for valve clearances.
1. INSERT TIMING PIN HERE 3. TIMING BELT

2. FUEL/WATER SEPARATOR FILTER
Figure 100. Timing Pin Location, Cummins 4.5L Diesel Engine
115
1. EXHAUST VALVE 4. CYLINDER 2

1. EXHAUST VALVE 4. CYLINDER 2 2. INTAKE VALVE 5. CYLINDER 3
2. INTAKE VALVE 5. CYLINDER 3 3. CYLINDER 1 6. CYLINDER 4
Figure 101. Cummins Valve Adjustment Figure 103. Cummins Valve Adjustment
1. TIMING PIN
2. VIBRATION DAMPER
Figure 102. Cummins Vibration Damper
116
8000 YRM 1322 Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast

The following procedures must be used when inspect- OR
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re- 2. If parts of the mast must be in a raised position,
moving the mast. See the correct Service Manual install a safety chain to restrain the moving parts
section for the specific mast being repaired. of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
WARNING a. Put mast in vertical position.

Mast parts are heavy and can move. Distances be- b. Raise mast to align bottom crossmember of
tween parts are small. Serious injury or death can weldment that moves in outer weldment with a
result if part of the body is hit by parts of the mast crossmember on outer weldment. On the two-
or the carriage. stage and free-lift mast, the moving part is the
inner weldment. On the three-stage mast, it is
• Never put any part of the body into or under
the intermediate weldment. See Figure 104.
the mast or carriage unless all parts of the
mast are completely lowered or a safety c. Use a 3/8-in. minimum safety chain with a hook
chain is installed. Also make sure that the to fasten the crossmembers together so the
power is off and the key is removed. Put a movable member cannot lower. Put the hook
DO NOT OPERATE tag in the operator's on the back side of the mast. Make sure the
compartment. hook is completely engaged with a link in the
• Be careful of the forks. When the mast is chain. Make sure the safety chain does not
raised, the forks can be at a height to cause touch lift chains or chain sheaves, tubes, ho-
an injury. ses, fittings, or other parts on the mast.
• DO NOT climb on the mast or lift truck at d. Lower the mast until there is tension in the
any time. Use a ladder or personnel lift to safety chain and the free-lift cylinder (free-lift,
work on the mast. three-stage, and four-stage masts only) is com-
• DO NOT use blocks to support the mast pletely retracted. If running, stop engine. Apply
weldments nor to restrain their movement. parking brake. Install a DO NOT REMOVE tag
• Mast repairs require disassembly and re- on the safety chain(s).
moval of parts and can require removal of e. Install another safety chain (3/8-in. minimum)
the mast or carriage. Follow the repair pro- between the top or bottom crossmember of the
cedures in the correct Service Manual for carriage and a crossmember on the outer
the mast. weldment.
NOTE: If there is no power to lower the mast on lift 3. Apply parking brake. After lowering or restraining
trucks equipped with Electronic Hydraulic System, the mast, shut off power and remove key. Put a
there is an emergency load lowering valve located on DO NOT OPERATE tag in the operator's com-
the hoist/lower valve section of the main control valve. partment.
See the Operating Manual for the procedures to
lower a load using the emergency load lowering
valve.
1. Lower mast and carriage completely. Push lift/

lower control lever forward and make sure there is
no movement in the mast. Make sure all parts of
the mast that move are fully lowered.
117
Safety Procedures When Working Near Mast 8000 YRM 1322
A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST

B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE MAST
Figure 104. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
118
8000 YRM 1322 Fuel Filter Water Removal
Fuel Filter Water Removal

NOTE: The following procedure only pertains to lift
trucks equipped with a Cummins 4.5L and QSB 3.3L
diesel engine.
1. Shut engine off.
NOTE: The drain valve is located on the bottom of

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

remove the air inlet elbow. See Figure 105.
CAUTION
Drain water/fuel into a container and dispose in
accordance with local environmental regulations.
3. Turn the drain valve counterclockwise approxi-

mately 3 1/2 turns. Drain fuel filter until clear fuel
is visible.
CAUTION
DO NOT overtighten when closing the drain valve. 1. AIR INLET ELBOW
Overtightening can damage the threads. 2. FUEL FILTER ELEMENT
3. DRAIN VALVE
Close the drain valve by lifting and turning clockwise
Figure 105. Engine Fuel Filter Drain Valve
until it is hand-tight.
Location (Cummins 4.5L Shown)
119
Lift Chain Adjustments 8000 YRM 1322
Lift Chain Adjustments

WARNING
Procedures When Working Near Mast in this sec-
tion.
Never allow anyone under a raised carriage. DO

NOT put any part of your body in or through the
lift mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
DO NOT try to find hydraulic leaks by putting your

hand on hydraulic components under pressure.
Hydraulic oil can be injected into the body by the
pressure.
During test procedures for the hydraulic system,

fasten the load to the carriage with chains to pre-
1. MAST
vent it from falling. Keep all personnel away from 2. CARRIAGE
the lift truck during the tests. 3. FORK
4. HEEL OF FORK IS 12 +3.0/−6.0 mm (0.47
When lift chains are correctly adjusted: +0.12/−0.24 in.) ABOVE THE FLOOR LEVEL.
• Tension will be the same on each chain of Figure 106. Lift Chain Adjustments With Forks
chain set. Check tension by pushing on both Installed
chains at the same time.
• Chain length will be correct.
• Chains must travel freely through complete cy-
cle.
1. When adjusting lift chains on forklift trucks equip-

ped with the forks installed, go to Step 2. If forklift
truck is equipped with an attachment without
forks, go to Step 3.
NOTE: Prior to performing adjustment procedures,

make sure forklift truck is parked on a level surface
and the mast is in the vertical position.
2. Adjust chain anchors which support the carriage

until bottom of the fork heel is 12
+3.0/−6.0 mm (0.47 +0.12/−0.24 in.) above floor
level. See Figure 106.
3. Adjust chain anchors which support carriage until

the bottom of lower carriage bar is above the floor 1. MAST
level as shown in Table 2. See Figure 107. 2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER CAR-
RIAGE BAR
Figure 107. Lift Chain Adjustment Without Forks

Installed
120
8000 YRM 1322 Jump-Starting the Lift Truck
In Table 2, the masts are divided by class. Each

class is determined by the lifting capability of the lift Table 2. Carriage Chain Adjustment, Forks Not In-
cylinders. The Class II mast would have the lift ca- stalled
pability of 2.5-3.5 tons, Class III has the lift capabil-
ity of 3.5-4.0 tons, and Class IV has the lift capabil- 82.5 ±3 mm (3.25
Class II and Class III
ity of 4.0-7.0 tons. ±0.12 in.)
133.5 ±3 mm (5.26
Class IV
±0.12 in.)
Jump-Starting the Lift Truck

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

booster battery to start the engine, follow these proce- DO NOT try to start the engine by pushing or tow-
dures carefully when connecting the jumper cables. ing the lift truck. Damage to the hydraulic system
can occur if engine is started by pushing or tow-
1. Disconnect the negative battery terminal of the lift ing lift truck.
truck being started.
1. Always connect positive jumper cable to positive
2. Always connect positive jumper cable to positive terminal of discharged battery and negative
terminal of discharged battery and negative jumper cable to negative terminal.
jumper cable to negative terminal.
2. Always connect jumper cable, that is the ground
3. Always connect jumper cable, that is the ground cable, last.
cable, last.
3. Always connect jumper cables to discharged lift
4. Always connect jumper cables to discharged bat- truck battery before connecting them to the fully-
tery before connecting them to booster battery. charged lift truck battery.
121
Welding Repairs 8000 YRM 1322
Welding Repairs
industrial hygiene practices including removal of
WARNING all paint (prime and finish coats) to the metal
Welding can cause a fire or an explosion. Always around the area to be welded, local ventilation,
follow the instructions in the Frame section if a and/or supplied-air respiratory protection.
fuel or hydraulic tank must be welded. Make sure
there is no fuel, oil, or grease near the weld area.
Make sure there is good ventilation in the area CAUTION
where the welding must be done. When an arc welder is used, always disconnect
the ground cable from the battery in the lift truck.
DO NOT heat, weld, or bend forks. Forks are made This action will prevent damage to the alternator
of special steel using special methods. The or the battery.
strength of the overhead guard can be reduced by
welding or heating. Get information from your Connect the ground clamp for the arc welder as
dealer for Yale lift trucks before welding on a close as possible to the weld area. This action will
mast. prevent damage to a bearing from the large cur-
rent from the welder.
Forklift frames and components may be painted
with a catalyzed paint such as polyurethane or a Some repairs require welding. If an acetylene or arc
two-part primer. Welding, burning, or other heat welder is used, make sure procedures in previous
sufficient to cause thermal decomposition of the WARNING and CAUTION are done.
paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory See the American National Standard Safety in Weld-
tract and overexposure may occur without odor ing and Cutting, AWS Z 49.1 - 1999.
warning. Should work be performed, utilize good
Overhead Guard Changes

See your dealer for Yale lift trucks BEFORE per-
WARNING forming any changes to the overhead guard.
DO NOT weld mounts for lights or accessories to
the legs of the overhead guard. Changes that are No welding or drilling on legs of overhead guard is
made by welding or by drilling holes that are too permitted as per previous WARNING.
big or in the wrong location can reduce the
strength of the overhead guard.
122
8000 YRM 1322 Wheel and Tire Replacement
Wheel and Tire Replacement

GENERAL Deflate tire completely before removing the wheel
from the lift truck. If dual wheels are used, deflate
The GP/GLP/GDP series lift trucks have pneumatic both tires. Air pressure in the tires can cause the
tires or solid rubber tires that look like pneumatic tires. tire and rim parts to explode, causing serious in-
These variations in tires also cause a variation in the jury or death.
types of wheels and the disassembly and assembly
procedures. Always wear safety glasses.
Never loosen the nuts that hold the inner and

PNEUMATIC TIRE WITH TUBE, REPAIR outer wheel halves together when there is air
pressure in the tire.
Remove Wheels From Lift Truck
Lift truck tires and wheels are heavy. Use caution
WARNING when removing or installing lift truck tires and
wheels or personal injury can occur.
A solid rubber tire that is the same shape as a
pneumatic tire can be installed on a three-piece or 1. Put lift truck on blocks as described in How to Put
four-piece wheel for a pneumatic tire. DO NOT Lift Truck on Blocks at the beginning of this sec-
make changes in the parts of the rim if this type of tion.
solid rubber tire is installed instead of a pneu-
matic tire. Changes to the parts of the rim can 2. Remove air from tire. Remove valve core to make
cause a failure of the wheel and cause an acci- sure all air is out of inner tube. Push a wire
dent. through valve stem to make sure valve stem does
not have a restriction.
WARNING 3. Remove wheel nuts and remove wheel and tire
The type of tire and the tire pressure (pneumatic from lift truck.
tires) are shown on the Nameplate. Make sure the
Nameplate is correct for the type of tires on the lift Remove Tire From Wheel
truck.
NOTE: When you disassemble the wheels, see Fig-
ure 108. There are several types of wheels used on
WARNING this series of lift trucks.
Wheels must be changed and tires repaired by
trained personnel only.
123
Wheel and Tire Replacement 8000 YRM 1322
A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL
1. WHEEL RIM 3. LOCK RING
2. SIDE FLANGE 4. FLANGE SEAT
Figure 108. Types of Pneumatic Wheels
124
Remove Tire From Two-Piece Wheel
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the
tires can cause the tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause an injury.
STEP 1.
Remove nuts that fasten wheel rims together.
STEP 2.
Loosen tire bead from wheel rim.
STEP 3.
Remove wheel rims from tire. Remove inner tube
and flap.
125
Remove Tire From Three- and Four-Piece Wheels
WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the
tires can cause the tire and rim parts to explode, causing serious injury or death.
cause an injury.
STEP 1.
Loosen tire bead from side flange.
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange. If there is a
flange seat, remove it.
STEP 3.
Loosen bead from other side of wheel rim. Remove
valve stem from wheel.
126
STEP 4.
Remove wheel from tire.
Install Wheel in Tire will be approximately 13 to 25 mm (0.5 to 1.0 in.)

after it is installed. If the clearance is wrong, the
wrong part has been used.
WARNING
Damage to the tire and wheel assembly and injury 1. Clean and inspect all parts of wheel. Paint any
or death can occur if you do not do the following parts that have rust or corrosion.
procedures:
2. Install new inner tube in tire. Used tubes and flaps
• Clean and inspect all parts of the wheel be- can cause tire failure.
fore installing the tire.
• DO NOT use any damaged or repaired
wheel parts. WARNING
DO NOT lubricate tire bead with antifreeze or pe-
• Make sure all parts of the wheel are the cor-
troleum-based liquid. Vapors from these liquids
rect parts for that wheel assembly.
can cause an explosion during inflation or use.
• DO NOT mix parts between different types
or manufacturers of wheels. 3. Apply a rubber lubricant or a soap solution to the
tire bead and tube.
• DO NOT mix types of tires, type of tire
tread, or wheel assemblies of different man- 4. Install new tire flap.
ufacturers on any one lift truck.
5. Make sure rim is the correct size for tire. Lubricate
DO NOT use a steel hammer on the wheel. Use a part of wheel that contacts bead and flap.
rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct 6. Install the three-piece or four piece wheel in the
position. The ends of the side ring must not tire as shown in Install Three-Piece or Four-Piece
touch. The clearance at the ends of the lock ring Wheel in Tire.
7. Install the two-piece wheel in the tire as shown in

Install Tire on Two-Piece Wheel.
127
Install Three-Piece or Four-Piece Wheel in Tire
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the following pro-
cedures:
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any
one lift truck.
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts to-
gether. Make sure the side ring is in the correct position. The ends of the side ring must not touch. The
clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed.
If the clearance is wrong, the wrong part has been used.
STEP 1.
Install inner tube and rubber flap in tire.
STEP 2.
Install wheel rim in tire. Make sure stem of inner tube
is aligned with slot in rim.
STEP 3.
Turn over rim and tire. Put blocks under rim so rim is
8 to 10 cm (3 to 4 in.) above floor. Install flange seat
(if used) and lock ring.
128
STEP 4.
Put lock ring in the correct position on rim. Add air
pressure to tire as described in Install Wheel in Tire.
Install Tire on Two-Piece Wheel will be approximately 13 to 25 mm (0.5 to 1.0 in.)

after it is installed. If the clearance is wrong, the
wrong part has been used.
WARNING
Wheels can explode and cause injury or death if
the following procedures are not followed: CAUTION
• Clean and inspect all parts of the wheel be- DO NOT use pneumatic-shaped solid tires on two-
fore installing the tire. piece bolt together drive wheels. Spinning may
occur.
• DO NOT use any damaged or repaired
wheel parts. 1. Clean and inspect all parts of wheel. Paint any
• Make sure all parts of the wheel are the cor- parts that have rust or corrosion.
rect parts for that wheel assembly.
2. Install new inner tube in tire. Used tubes and flaps
• DO NOT mix parts between different types can cause tire failure.
or manufacturers of wheels.
• DO NOT mix types of tires, type of tire
tread, or wheel assemblies of different man-
WARNING
ufacturers on any one lift truck. DO NOT lubricate the tire bead with antifreeze or
petroleum-based liquid. Vapors from these liquids
DO NOT use a steel hammer on the wheel. Use a can cause an explosion during inflation or use.
rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct 3. Apply a rubber lubricant or a soap solution to tire
position. The ends of the side ring must not bead and tube.
touch. The clearance at the ends of the lock ring
4. Install new tire flap.
5. Make sure rim is the correct size for tire. Lubricate

part of wheel that contacts bead and flap.
129
Install Two-Piece Wheel in Tire

STEP 1.
Install inner tube and rubber flap in tire. Install both
halves of wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.
STEP 2.
Tighten nuts that hold rim halves together to
175 N•m (130 lbf ft). Add air pressure to tire (see
Nameplate).
ADD AIR TO PNEUMATIC TIRES WITH 5. Check that all wheel parts are correctly installed.
TUBE If installation is not correct, remove all air pres-
sure from tire. Remove valve core to make sure
all air pressure has been removed and then make
WARNING adjustments. The clearance at the ends of the
Add air pressure to the tires only in a safety cage. lock ring will be approximately 13 to 25 mm (0.5
Inspect the safety cage for damage before use. to 1.0 in.) when the tire has the correct air pres-
When air pressure is added, use a chuck that fas- sure.
tens onto the valve stem of the inner tube. Make
sure there is enough hose to permit the operator
to stand away from the safety cage when air pres-
sure is added to the tire.
DO NOT sit or stand by the safety cage. DO NOT

use a hammer to try and correct the position of
the side flange or lock ring when the tire has air
pressure greater than 20 kPa (3 psi).
1. Put tire in a safety cage.
2. Add 20 kPa (3 psi) of air pressure to tire. See Fig-

ure 109.
3. Check that all wheel parts are correctly installed.

Hit lock ring lightly to make sure it is in the seat.
4. If installation is correct, add air pressure to tire to

Figure 109. Add Air to Tires
the specified pressure.
130
Install the Wheels 4. Install the valve extension bracket and tighten the
attaching nut to 8 N•m (70 lbf in). Install the valve
extension hose into the bracket. See Figure 110.
WARNING
when removing and installing lift truck tires and
Install wheel on hub. Tighten nuts in a cross pattern to

610 to 680 N•m (450 to 502 lbf ft) for both drive
wheels nuts steer wheels nuts. If the wheels are the
two-piece rims, make sure nuts that fasten rim halves
together are toward brake drum when they are instal-
led.
Dual Drive Wheels, Install
WARNING
NOTE: Some lift trucks have dual drive wheels. The

following procedures describe the steps to install the
dual sets of wheels.
1. Install inner wheel on hub. If the wheels are the

two-piece rims, make sure nuts that fasten rim
halves together are toward brake drum when they
are installed. 1. TIRE
2. DUAL HUB ASSEMBLY
2. Install wheel adapter spacers on the inner wheel 3. WHEEL NUT
studs and tighten spacers to 100 to 125 N•m (74 4. WHEEL
to 92 lbf ft). Install the dual hub assembly and in- 5. WHEEL ADAPTER SPACER
ner wheel nuts on the spacers and tighten the 6. VALVE EXTENSION
7. BRACKET
wheel nuts to 610 to 680 N•m (450 to 500 lbf ft).
See Figure 110. Figure 110. Dual Drive Wheels Installation
3. Install outer wheel on dual hub assembly. Tighten
nuts to a torque value of 610 to 680 N•m (450 to
500 lbf ft). If the wheels are the two-piece rims,
make sure nuts that fasten rim halves together
are toward brake drum when they are installed.
131
PNEUMATIC TUBELESS TIRE, REPAIR Lift truck tires and wheels are heavy. Use caution
Remove Wheels From Lift Truck wheels or personal injury can occur.
The Tubeless Bead Seal (TBS) enables tubeless tires

WARNING to be used on wheel rims that were designed to be
Wheels must be changed and tires repaired by used with a tube.
The main component of a TBS is a special rubber ring
Deflate tire completely before removing the wheel
that fits inside the tire between the tire beads to en-
from the lift truck. If dual wheels are used, deflate
sure the air tightness of the existing wheel and the
both tires. Air pressure in tires can cause the tire
tubeless tire assembly. See Figure 108.
and rim parts to explode causing serious injury or
death.
1. Put lift truck on blocks as described in How to Put
Always wear safety glasses. Lift Truck on Blocks at beginning of this section.
Never loosen the nuts that hold the inner and 2. Remove the valve cap and core to remove all air
outer wheels halves together when there is air from the tire.
pressure in the tire.
3. Remove the wheel nuts and remove the wheel
and tire from the lift truck.
Remove Tire From Wheel
WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air pressure in
the tires can cause the tire and rim parts to explode causing serious injury or death.
cause injury.
NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 108.
STEP 1.
If wheel rim is a three- or four-piece rim, turn the
valve 1/4 turn and remove valve from wheel.
132
STEP 2.
Put wheel and tire assembly on the press. Position
the feet of the press on the loose flange. Press down
on loose flange to expose the locking ring.
STEP 3.
Remove the loose flange locking ring and the ad-
vance band (four-piece wheel only) using a tire tool.
STEP 4.
Remove the press and remove the loose flange lock-
ing ring and the advance band (four-piece wheel
only) from the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to remove
it.
133
Install Tire on Wheel
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow proce-
dures:
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
one lift truck.
WARNING
gether.
WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can
cause an explosion during inflation or use.
STEP 1.
Clean interior and exterior bead of the tire. Lubricate
tire beads and the inside of the tire, up to the tire
shoulders. Apply lubricant to the entire underside of
the TBS.
NOTE: If the wheel rim width is less than 152 mm (6 in.), the TBS will contain one valve hole to accommodate
the needle valve. If the wheel rim width is greater than 152 mm (6 in.), the TBS will have two holes for the needle
valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve slot.
The valve hole that is not used should be sealed with a small plastic plug.
134
STEP 2.
Apply lubricant to the needle valve and the valve
hole that will be used (see NOTE) by inserting and
removing the lubricated valve several times. If a
three- or four-piece wheel is being used, remove the
valve. If a two-piece wheel is being used, leave
valve in valve hole.
If the TBS has two-valve holes, lubricate the plastic

plug and insert into valve hole that will not be used.
STEP 3.
Place the TBS inside the tire, making sure that the
wings of the TBS are not folded over. Make a mark
on the tire to note the position of the valve hole in
the TBS.
STEP 4.
Apply lubricant to the rim. If a four-piece wheel is be-
ing used, lubricate the advance band. Slide the tire
and the TBS onto the wheel.
Line up the valve hole in the TBS with the valve slot in
the wheel. Lubricate and insert the valve into the
valve hole. Make sure it is fully inserted.
STEP 5.
Place the wheel and tire assembly on a flat surface.
Turn the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.
135
STEP 6.
Raise the tire and position the base and threaded
stem of the press through the hole in the center of
the wheel. Insert in wheel assembly, the following
parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring
STEP 7.
Position the advance band. Ensure that it does not
go in too far and damage the valve. Position the
arms of the press onto the loose flange.
Push down on the press to depress the tire beads un-

til locking ring groove is fully exposed.
STEP 8.
Insert tire tool into the locking ring groove, and a vise
grip on other end. Remove vise grip. Release the
press and check that all component parts are cor-
rectly positioned. Replace the valve core.
STEP 9.
Inflate tire to 103 kPa (15 psi). Tap wheel with a mallet to ensure all components are correctly sealed. Remove
the press from wheel and tire assembly.
136
Add Air to Pneumatic Tubeless Tire Wheels, Install
WARNING WARNING
Add air pressure to tires only in safety cage. In- Lift truck tires and wheels are heavy. Use caution
spect safety cage for damage before use. When when removing and installing lift truck tires and
air pressure is added, use a chuck that fastens wheels or personal injury can occur.
onto valve stem. Make sure there is enough hose
to permit operator to stand away from safety cage Install wheel on hub. Tighten nuts in a cross pattern to
when air pressure is added to tire. 610 to 680 N•m (450 to 500 lbf ft) for both drive
wheels nuts and steer wheels nuts. If the wheels are
DO NOT sit or stand by safety cage. the two-piece rims, make sure nuts that fasten rim
halves together are toward brake drum when they are
1. Put tire in safety cage. See Figure 111.
installed.
2. Add air to tire to the recommended air pressure
that is shown on the Nameplate. Install valve cap SOLID RUBBER TIRES ON PNEUMATIC
to ensure air stays in the tire. WHEELS, CHANGE
WARNING
Wheels must be changed and tires repaired by
Always wear safety glasses.

1. Put lift truck on blocks as described in How to Put

Lift Truck on Blocks at the beginning of this sec-
tion.
2. Remove wheel nuts and remove wheel and tire

from lift truck.
Figure 111. Add Air to Tires
137
Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Figure 108. There are several types of wheels used on these
series of lift trucks.
WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to cause
serious injury. Always wear safety glasses.
STEP 1.
Put wheel rim on bed of press. Put cage in position
on tire. Use press to push tire away from side flange.
STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange.
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
138
STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.
Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 108. There are several types of wheels used on these series
of lift trucks. DO NOT use a two-piece pneumatic wheel for solid rubber tires.
WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following proce-
dures.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
one lift truck.
gether. Make sure the side ring is in the correct position. The ends of the side ring must not touch. The
clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed.
If the clearance is wrong, the wrong part has been used.
CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.
139
STEP 1.
Lubricate wheel rim and inner surface of tire with tire
lubricant or soap.
STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to install
tire on wheel rim.
STEP 3.
Remove cage and put flange seat (if used), side
ring, and lock ring in position on wheel rim. Install
cage on tire. Use press to push tire onto wheel rim
so side flange and lock ring can be installed.
STEP 4.
While the cage is holding the tire on the wheel rim,
install lock ring. Use a tire tool to make sure lock ring
is in the correct position.
140
8000 YRM 1322 Adhesives and Sealants
Adhesives and Sealants
Loctite® Part
Yale Part No. Description Size
No.
501702901 222 Small Screw Threadlock (Purple) 50 ml
505965518 242 Removable Threadlock (Blue) 10 ml
580012519 271 High Strength Threadlock (Red) 10 ml
501702904 290 Low Viscosity Threadlock (Green) 50 ml
518806679 422 SuperBonder® Adhesive 3 ml
500009917 515 Gasket Eliminator (Purple) 50 ml
518795676 567 Pipe Sealant with Teflon ® 50 ml
502058904 595 Super Flex® Silicone 100 ml
504226218 767 Antiseize Compound 1 lb
150015825 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz
Loctite®, Super Flex®, and Super Bonder® are registered trademarks of the Loctite Corporation.
Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.
141
NOTES
142
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
8000 YRM 1322 12/13 (4/13)(12/12)(8/12)(3/12)(2/12)

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Maintenance

PART NO. 524288884 8000 YRM 1322

©2013 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

Hang On Sideshift Carriage, Check Sliding Surfaces ........................................................................................ 87

TABLE OF CONTENTS (Continued)

This section is for the following models:

(GP/GLP/GDP135VX, GP/GLP/GDP155VX) [C878, D878]

How to Tow Lift Truck 2. Tow truck slowly.

3. Using a lift truck or a lifting device that can be

Never lift and move a disabled lift truck unless the

CAUTION Figure 1. Towing the Lift Truck

1. Put blocks on each side (front and back) of

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

Figure 3. GM 4.3L LPG Trucks With GFI Installed

Figure 4. GM 4.3L LPG Trucks With PSI Installed

Figure 5. GM 4.3L Gas Trucks With GFI Installed

Figure 6. GM 4.3L Gas Trucks With PSI Installed

Figure 7. Cummins 4.5L Diesel Trucks

Figure 8. Cummins QSB 3.3L Diesel Trucks

Table 1. Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

16 Fuel Tank CIL 74.8 liter Diesel No. 2

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

19 Engine Oil Filter C 1 Filter See Parts Manual

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

12, Cooling System X C 15.1 liter See NOTE 14

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Mast (Before Au- X L X Lube as Re- Multipurpose Grease

Table 1. Maintenance Schedule (Continued)

Mast X L X Lube as Re- Multipurpose Grease

Table 1. Maintenance Schedule (Continued)

41 Wheel Bearings L Check Grease. Multipurpose Grease

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Maintenance Procedures Every 8 Hours or Daily

If a lift truck that needs repairs is operated, dam- WARNING

Make sure the parts that fasten the hang on side-

6. Visually inspect hoses/fittings for hydraulic leaks;

7. Check that lift chains are correctly lubricated. Use

DO NOT operate fork lift without lateral fork stops

1. Inspect welds on the mast and carriage for

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

3. Inspect channels for wear in areas where rollers

A seat belt that is damaged, worn, or does not oper-

NOTE: The following seat belt operation checks must

• Pull the seat belt slowly from the retractor as-

Seat Position Adjustment (Swivel Seat)

Adjust Seat - Internal Suspension