Plano de Manutencao Yale

Maintenance
PERIODIC
MAINTENANCE
GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS [E818];
GP/GLP/GDP080, 090, 100, 110, 120VX [F813, G813]
PART NO. 524262280 8000 YRM 1248

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product.
Updated technical service information may be available from your local authorized Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in
damage to the products, personal injury, property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being
lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Discon-
nect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS
in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications
of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to
follow the necessary safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure
the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Periodic Maintenance Table of Contents
TABLE OF CONTENTS
General.................................................................................................................................................................. 1
Serial Number Data........................................................................................................................................... 1
How to Move Disabled Lift Truck ....................................................................................................................... 2
How to Tow Lift Truck .................................................................................................................................... 2
How to Put Lift Truck on Blocks......................................................................................................................... 4
How to Raise Drive Tires .............................................................................................................................. 4
How to Raise Steering Tires ......................................................................................................................... 4
How to Clean a Lift Truck .................................................................................................................................. 5
Maintenance Schedule .......................................................................................................................................... 6
Maintenance Procedures Every 8 Hours or Daily................................................................................................ 25
How to Make Checks With Engine Stopped.................................................................................................... 25
Tires and Wheels ........................................................................................................................................ 25
Safety Labels .............................................................................................................................................. 25
Mast, Carriage, Lift Chains, Header Hoses, Attachment ............................................................................ 26
Operator Restraint System ......................................................................................................................... 27
Emergency Locking Retractor (ELR) ...................................................................................................... 27
Adjust Seat - Full Suspension ................................................................................................................ 27
Adjust Seat - Internal Suspension .......................................................................................................... 28
Hood and Seat Latches .............................................................................................................................. 29
Engine Compartment.................................................................................................................................. 29
Paper Application........................................................................................................................................ 29
Fuel, Oil, and Coolant Leaks, Check .......................................................................................................... 30
Hydraulic Hoses.......................................................................................................................................... 30
Coolant Hoses ............................................................................................................................................ 30
Steering Column Gas Cylinder ................................................................................................................... 31
Transmission ............................................................................................................................................... 31
Hydraulic System Oil................................................................................................................................... 31
Engine Oil ................................................................................................................................................... 31
Air Filter ...................................................................................................................................................... 31
Forks ........................................................................................................................................................... 37
Remove .................................................................................................................................................. 37
Inspect .................................................................................................................................................... 37
Install ...................................................................................................................................................... 37
Adjust...................................................................................................................................................... 37
Integral Sideshift Carriage .......................................................................................................................... 39
How to Make Checks With Engine Running.................................................................................................... 39
Indicator Lights, Horn, Fuses, and Relays .................................................................................................. 39
Service Brakes............................................................................................................................................ 41
Brake Oil Level ....................................................................................................................................... 41
Operation, Check.................................................................................................................................... 42
Parking Brake ............................................................................................................................................. 42
Engine Oil Pressure .................................................................................................................................... 42
Cooling System........................................................................................................................................... 42
Steering System ......................................................................................................................................... 43
Control Levers and Pedals.......................................................................................................................... 43
Lift System, Operate ................................................................................................................................... 43
First Service After First 100 Hours of Operation ................................................................................................. 44
GM 4.3L Engine Oil and Oil Filter ................................................................................................................... 44
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter .................................................................................. 45
Maintenance Procedures Every 250 Hours or 6 Months..................................................................................... 45
GM 4.3L Engine Oil and Oil Filter ................................................................................................................... 45
©2013 Yale Materials Handling Corp. i

Table of Contents Periodic Maintenance
TABLE OF CONTENTS (Continued)

Drive Belt......................................................................................................................................................... 45
GM 4.3L Engine .......................................................................................................................................... 45
Fan and Alternator Drive Belt ................................................................................................................. 45
Drain Tar From LPG Converter ....................................................................................................................... 47
Maintenance Procedures Every 500 Hours or 6 Months..................................................................................... 48
Hydraulic System Oil....................................................................................................................................... 48
Hydraulic Tank Breather .................................................................................................................................. 48
Inspect ........................................................................................................................................................ 48
Battery............................................................................................................................................................. 49
Cummins 4.5L and QSB 3.3L Engine Oil and Oil Filter .................................................................................. 49
Fuel/Water Separator Filter Replacement, Cummins 4.5L and QSB 3.3L Engine.......................................... 50
Remove....................................................................................................................................................... 50
Install .......................................................................................................................................................... 50
Final Fuel Filter Replacement (Cummins QSB 3.3L Engine).......................................................................... 52
Priming the Fuel System (Cummins 4.5L and QSB 3.3L Engine)................................................................... 53
Controlled Venting....................................................................................................................................... 53
Manual Bleeding ......................................................................................................................................... 53
Drive Belt......................................................................................................................................................... 54
Cummins 4.5L and QSB 3.3L Diesel Engine .............................................................................................. 54
Fan and Alternator Drive Belt ................................................................................................................. 54
Clean Debris From Radiator Core................................................................................................................... 55
Transmission Oil Level .................................................................................................................................... 55
Wet Brake Center Body Oil Level Check......................................................................................................... 56
Forks ............................................................................................................................................................... 58
Mast Lubrication.............................................................................................................................................. 58
Header Hose Checks ...................................................................................................................................... 61
Lift Chain Lubrication ...................................................................................................................................... 61
Tilt Cylinder Lubrication................................................................................................................................... 61
Master Brake Cylinder Rod End Pin Lubrication ............................................................................................. 62
Manual Hydraulic Levers Lubrication .............................................................................................................. 62
Brake Oil ......................................................................................................................................................... 63
Tie Rod Lubrication for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS (E818) ............................................................................................... 64
Tie Rod Lubrication for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813)................ 64
Differential and Drive Axle Oil, Lift Truck Models With Dry Brakes ................................................................. 65
Parking Brake Adjustment............................................................................................................................... 66
Maintenance Procedures Every 1000 Hours or 6 Months................................................................................... 66
Valve Clearance, Check and Adjust ................................................................................................................ 66
Ignition System................................................................................................................................................ 66
GM 4.3L Engine .......................................................................................................................................... 66
LPG Fuel Filter Element Replace, GM 4.3L Engine........................................................................................ 67
Remove....................................................................................................................................................... 67
Install .......................................................................................................................................................... 67
In-Line Filter Replacement, Cummins 4.5L Engine......................................................................................... 68
Remove....................................................................................................................................................... 68
Install .......................................................................................................................................................... 68
Lift Chains Wear Check................................................................................................................................... 70
Lift Chain Lubrication ...................................................................................................................................... 70
Integral Sideshift Carriage, Check Sliding Surfaces........................................................................................ 70
Steering Axle (Spindle Bearings) for Lift Truck Models GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818) ........................................................................... 71
ii
Periodic Maintenance Table of Contents

Steering Axle (Spindle Bearings) for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX
(F813, G813)................................................................................................................................................... 71
Control Levers and Pedals .............................................................................................................................. 72
Inspect Engine Electrical System, Connectors ............................................................................................... 72
Maintenance Procedures Every 2000 Hours or Annually.................................................................................... 72
Hydraulic System ............................................................................................................................................ 72
Hydraulic Filter, Replace ............................................................................................................................. 72
Hydraulic Tank Breather, Replace............................................................................................................... 74
Ignition System; Distributor Cap, Rotor, and Spark Plug Wires ...................................................................... 74
Cooling System ............................................................................................................................................... 74
Air Filter........................................................................................................................................................... 74
Oxygen Sensor GM 4.3L LPG Engines with GFI Installed.............................................................................. 76
LPG Regulator Fuel Filter, GM 4.3L Engines With GFI Installed .................................................................... 77
Remove....................................................................................................................................................... 77
Install .......................................................................................................................................................... 77
Gasoline Fuel Filter ......................................................................................................................................... 78
Remove and Replace for Lift Trucks Equipped with GFI............................................................................. 78
Remove and Replace for Lift Trucks Equipped with PSI............................................................................. 78
LPG Fuel Injector, GM 4.3L Engines With GFI Installed ................................................................................. 79
Gasoline Fuel Injector, GM Engines................................................................................................................ 79
Fuel Injector, Cummins 4.5L and QSB 3.3L Engine........................................................................................ 79
Forks ............................................................................................................................................................... 79
Transmission Oil and Filter (Dry Brake), Replace ........................................................................................... 79
Transmission and Wet Brake Planetary Carrier Housing Oil Change ............................................................. 81
Wet Brake Center Section Oil Change............................................................................................................ 83
Remove....................................................................................................................................................... 83
Install .......................................................................................................................................................... 83
Brake Oil (Master Cylinder), Change .............................................................................................................. 84
Brake Oil (Dry Brake), Remove....................................................................................................................... 85
Service Brakes (Dry Brake)............................................................................................................................. 85
Differential (Dry Brake).................................................................................................................................... 86
Test LPG/GAS Regulator Pressure................................................................................................................. 87
Check Throttle Shaft for Sticking..................................................................................................................... 87
Inspect Exhaust Manifold and Piping for Leaks .............................................................................................. 87
Valve Clearance, Check and Adjust for Cummins QSB 3.3L Diesel Engine ................................................... 87
Wheel Bearings............................................................................................................................................... 88
Steer Wheels, Lubrication........................................................................................................................... 88
Maintenance Procedures Every 4000 Hours or 2 Years...................................................................................... 88
Hydraulic Oil, Replace..................................................................................................................................... 88
Valve Clearance, Check and Adjust for Cummins 4.5L Diesel Engine............................................................ 89
Weld Inspection............................................................................................................................................... 91
Safety Procedures When Working Near Mast ..................................................................................................... 93
Fuel Filter Water Removal ................................................................................................................................... 95
Hood Latch Check ............................................................................................................................................... 96
Lift Chain Adjustments......................................................................................................................................... 97
Jump-Starting the Lift Truck................................................................................................................................. 98
Jump-Starting Using a Battery Charger .......................................................................................................... 98
Jump-Starting a Lift Truck Using Another Lift Truck ........................................................................................ 98
Welding Repairs .................................................................................................................................................. 99
Overhead Guard Changes .................................................................................................................................. 99
Wheel and Tire Replacement .............................................................................................................................. 99
iii
Table of Contents Periodic Maintenance

General ........................................................................................................................................................... 99
Solid Rubber Tire, Change (GC/GLC Series) ................................................................................................. 99
Remove and Install Tire on Wheel............................................................................................................ 100
Pneumatic Tire With Tube, Repair ................................................................................................................ 101
Remove Wheels From Lift Truck ............................................................................................................... 101
Remove Tire From Wheel ......................................................................................................................... 101
Remove Tire From Two-Piece Wheel ................................................................................................... 102
Remove Tire From Three- and Four-Piece Wheels.............................................................................. 103
Install Wheel in Tire .................................................................................................................................. 104
Install Three-Piece or Four-Piece Wheel in Tire................................................................................... 105
Install Tire on Two-Piece Wheel ........................................................................................................... 106
Install Two-Piece Wheel in Tire ............................................................................................................ 107
Add Air to Pneumatic Tires With Tube .......................................................................................................... 107
Install the Wheels ..................................................................................................................................... 108
Dual Drive Wheels, Install......................................................................................................................... 108
Pneumatic Tubeless Tire, Repair .................................................................................................................. 109
Remove Wheels From Lift Truck ............................................................................................................... 109
Install Tire on Wheel ................................................................................................................................. 111
Add Air to Pneumatic Tubeless Tire.......................................................................................................... 113
Wheels, Install........................................................................................................................................... 114
Solid Rubber Tires on Pneumatic Wheels, Change ...................................................................................... 114
Install Tire on Wheel ................................................................................................................................. 116
Adhesives and Sealants .................................................................................................................................... 118
This section is for the following models:
GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;

GC/GLC120VXPRS [E818];
GP/GLP/GDP080, 090, 100, 110, 120VX [F813, G813]
iv
8000 YRM 1248 General
General
must be decreased from the recommendations in the
WARNING Maintenance Schedule for the following conditions:
DO NOT make repairs or adjustments unless you • The lift truck is used more than eight hours per day.
have both authorization and training. Repairs and • The lift truck must work in dirty operating conditions.
adjustments that are not correct can make a dan- • Poor ground conditions.
gerous operating condition. • Intensive usage at high performance levels or other
abnormal conditions will require more frequent ser-
WARNING vicing.
DO NOT operate a lift truck that needs repairs. Re- Your dealer for Yale lift trucks has the equipment and
port the need for repairs immediately. If repair is trained service personnel to do a complete program
necessary, put a DO NOT OPERATE tag in the oper- of inspection, lubrication, and maintenance. A regular
ator’s area. Remove the key from the key switch. program of inspection, lubrication, and maintenance will
help your lift truck provide more efficient performance
CAUTION and operate for a longer period of time.
Disposal of lubricants and fluids must meet local Some users have service personnel and equipment to
environmental regulations. do the inspection, lubrication, and maintenance shown
This section contains a Maintenance Schedule and the in the Maintenance Schedule. Service manuals are
instructions for maintenance and inspection. available from your dealer for Yale lift trucks to help
users who do their own maintenance.
The Maintenance Schedule has time intervals for in-
spection, lubrication, and maintenance of your lift truck. SERIAL NUMBER DATA
The service intervals are provided in both operating
hours recorded on the lift truck hourmeter and in cal- The serial number for the lift truck is on the Nameplate.
endar time. The recommendation is to use the interval It is also on the right side of the frame, under the floor
that comes first. plate.
The recommendations for the time intervals provided is

for eight hours of operation per day. The time intervals
1
General 8000 YRM 1248
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 could be

WARNING attached to the mast (I.E. come-a-long), raise car-
Use extra caution when towing a lift truck if any of riage and forks approximately 30 cm (12 in.) from
the following conditions exist: surface. Install chain around a mast crossmember
• Brakes do not operate correctly. and carriage to prevent carriage and mast channels
• Steering does not operate correctly. from moving.
• Tires are damaged.
• Traction conditions are bad. 4. If another lift truck is used to tow the disabled lift
• The lift truck must be towed on a slope. truck, that lift truck must have an equal or larger
capacity than the disabled lift truck. Install approx-
If the engine cannot run, there is no power available imately 1/2 of a capacity load on forks of lift truck
for the hydraulic steering system and the service that is being used to tow disabled lift truck. This 1/2
brakes. This condition can make the lift truck dif- capacity load will increase traction of lift truck. Keep
ficult to steer and stop. If the lift truck uses power load as low as possible.
from the engine to help apply the brakes, the ap-
plication of the brakes will be more difficult. Poor 5. If lift trucks are equipped with a tow pin in the coun-
traction can cause the disabled lift truck or towing terweight (standard counterweight), use a towing
vehicle to slide. A slope will also make the lift truck link made of steel that fastens to the tow pins in
more difficult to stop. the counterweights of both lift trucks. See Figure 1.
Slowly and carefully remove the slack out of the
Never lift and move a disabled lift truck unless the towing link.
disabled lift truck MUST be moved and cannot be
towed. A lift truck used to move a disabled lift truck 6. If lift trucks are equipped with a leaded counter-
MUST have a capacity rating equal to or greater weight without a tow pin (see Figure 1), use a tow-
than the weight of the disabled lift truck. The ca- ing link made of steel that fastens to the two center
pacity of the lift truck used to move a disabled lift grill bars of both lift trucks. Slowly and carefully re-
truck must have a load center equal to half the width move the slack out of the towing link.
of the disabled lift truck. See the Nameplate of the
disabled lift truck for the approximate total weight. Lift truck models that are equipped with a leaded
The forks must extend the full width of the disabled counterweight, that are covered in this YRM
lift truck. Put the weight center of the disabled lift are GC/GLC080VXBCS, GC/GLC100VXBCS,
truck on load center of the forks. Be careful to not GC/GLC120SVX, and GC/GLC120VXPRS (E818).
damage the underside of the lift truck.
2
A. COUNTERWEIGHT WITHOUT TOW PIN B. COUNTERWEIGHT WITH TOW PIN (STANDARD

(LEADED COUNTERWEIGHT) COUNTERWEIGHT)
1. TOWING LINK 3. TOW PIN
2. CENTER GRILL BARS
Figure 1. Counterweight Types
3
General 8000 YRM 1248
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 types 4. Put additional blocks under frame behind drive tires.
of maintenance and repair. The removal of the fol-
lowing assemblies will cause large changes in the 5. If hydraulic system will not operate, use a hydraulic
center of gravity: mast, drive axle, engine, trans- jack under the side of the frame near the front.
mission, and counterweight. When the lift truck is Make sure jack has a capacity equal to at least half
put on blocks, put additional blocks in the following the weight of the lift truck. See Nameplate.
positions to maintain stability:
• Before removing the mast and drive axle, put How to Raise Steering Tires
blocks under the counterweight so the lift truck
NOTE: Some lift trucks are equipped with lifting eyes
cannot fall backward.
for the purpose of lifting the entire lift truck. If lift truck
• Before removing the counterweight, put blocks
is equipped with these type of lifting eyes, the lift truck
under the mast assembly so the lift truck cannot
can be lifted and blocks installed.
fall forward.
1. Apply parking brake. Put blocks on both sides (front
The surface must be solid, even, and level when the
and back) of drive tires to prevent movement of lift
lift truck is put on blocks. Make sure any blocks
truck. See Figure 2.
used to support the lift truck are solid, one-piece
units. 2. Use hydraulic jack to raise steering tires. Make sure
jack has a capacity of at least 2/3 of total weight of
CAUTION lift truck as shown on the Nameplate.
These lift trucks are equipped with cowl lifting eyes.
3. Put jack under steering axle or frame to raise lift
The cowl lifting eyes are to be used to lift the front
truck. Put blocks under frame to support lift truck.
of the lift truck only. Lifting more than 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.
4
1. DRIVE TIRES 2. STEERING TIRES
Figure 2. Put Lift Truck on Blocks
HOW TO CLEAN A LIFT TRUCK NOTE: Lift trucks used in paper applications may need
cleaning beyond what is described here. Please refer to
WARNING Paper Application section in the applicable Operating
Manual and to available Service Gram/Bulletin for more
Engine, exhaust system components and other
detail.
components are hot to the touch. Be sure lift truck
components are cool before starting inspection If it becomes necessary to clean the fork lift, follow the
and cleaning, or personal injury may occur. guidelines listed below.
WARNING 1. Assure truck components are cool before starting

the cleaning procedure.
Compressed air can move particles so that they
cause injury to the user or to other personnel. 2. Disconnect the battery. If an electric truck, remove
Make sure that the path of the compressed air is the traction battery.
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes. 3. Remove accumulated debris using a compressed
air line and nozzle.
CAUTION 4. Lightly spray a non-corrosive cleaning agent onto
Units may be washed with a non-heated pressure the areas to be cleaned. This will help loosen
washer. Steam cleaning is not recommended in grime, so close contact direct spraying will not be
most instances, as condensation may form in elec- necessary.
trical components causing damage or erratic be-
havior.
5
Maintenance Schedule 8000 YRM 1248
5. Be sure to avoid directing the spray into electrical hydraulic motor directly below the battery compart-
panel compartment. Ensure overspray does not ment.
come in contact with electrical components; do not
spray water directly at electrical components, wiring 8. DO NOT pressure wash the battery. Do not use
connectors or electrical enclosures. Even sealed hot water. For cleaning traction batteries, refer to
connectors may allow water egress under pressure the Battery section of the Service Manual.
or if connector is damaged.
9. DO NOT pressure wash lift chains, sheaves or
6. Avoid spraying in areas containing electrical com- load rollers in the mast assembly. Refer to the
ponents such as: Chains, Sheaves and Load Rollers maintenance
• Floor Plates section in the Service Manual for proper cleaning
• Battery Compartment procedures.
• Dash/cowl assembly
10. After cleaning, immediately start and run the lift
• Armrests with electrical components
truck to dry out components.
7. Clean the battery compartment by using a clean
cloth to wash the battery with water. Dry with com-
pressed air. Care should be taken to keep mois-
ture at a minimum as some units have a traction or
Maintenance Schedule
NOTE: The lift trucks shown in Figure 3 and Figure 4, the specified hours or at 6 months whichever occurs
represent all lift trucks covered in this manual that are first.
equipped with a GM 4.3L LPG engine.
NOTE: The 250-hour, 500-hour, and 1000-hour/6-

month maintenance services are performed either at
6
8000 YRM 1248 Maintenance Schedule
Figure 3. GM 4.3L LPG Trucks With GFI Installed
7
Figure 4. GM 4.3L LPG Trucks With PSI Installed
8
Figure 5. GM 4.3L Gasoline Trucks With GFI Installed for Lift Truck Models GC/GLC080, 100, 120VX;
GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818)
9
Figure 6. GM 4.3L Gasoline Trucks With GFI Installed for Lift Truck Models GP/GLP/GDP080, 090, 100,
110, 120VX (F813, G813)
10
Figure 7. GM 4.3L Gasoline Trucks With PSI Installed for Lift Truck Models GC/GLC080, 100, 120VX;
GC/GLC080, 100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS (E818)
11
Figure 8. GM 4.3L Gasoline Trucks With PSI Installed for Lift Truck Models GP/GLP/GDP080, 090, 100,
110, 120VX (F813, G813)
12
Figure 9. Cummins 4.5L Diesel for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (F813)
13
Figure 10. Cummins QSB 3.3L Diesel for Lift Truck Models GP/GLP/GDP080, 090, 100, 110, 120VX (G813)
14
Table 1. Maintenance Schedule
Item Item 8 hr/ 250 hr/ 500 hr/ 1000 hr/ 2000 hr/ 4000 hr/ Procedure or Specification
No. 1 day 6 mo 6 mo 6 mo 1 yr 2 yr Quantity
25 Tires and Wheels X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
28, Mast, Carriage, X Check Condition See Parts Manual
29 Header Hoses, Lift and Lubrication
Chains, Attachment
Seat Belt, Hip X Check Condition
Restraints, and Seat and Operation
Rails
Hood and Seat X Check Condition
Latches and Operation
Engine X Remove
Compartment Combustible
Materials
See NOTE 5.
Paper Application: X Check Condition
Engine Clean as
Compartment, Required Replace
Truck Components, as Required
Exhaust Wraps, See NOTE 8.
Radiator, Radiator
Screen if equipped,
Belly Pan if equipped
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condition See Parts Manual
13 Coolant Hoses X Check Condition See Parts Manual
16 Fuel Tank (LPG) CIL 15.1 - 20.4 kg LPG - HD 5, HD 10
(33.5 - 45.0 lb)
Full
16 Fuel Tank CIL 44.7 liter 86 Octane - Gasoline
GM 4.3L (11.8 gal) Minimum
(Gasoline)
GC080, 100, 120VX;
GC080, 100VXBCS;
GC120SVX;
GC120VXPRS
(E818)
16 Fuel Tank (Short CIL 79 liter 86 Octane Minimum
Wheel Base) (20.8 gal)
GM 4.3L
(Gasoline)
GP080, 090, 100,
110, 120VX (F813,
G813)
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation
15
Table 1. Maintenance Schedule (Continued)
16 Fuel Tank (Long CIL 100.3 liter 86 Octane Minimum
GM 4.3L
(Gasoline)
GP080, 090, 100,
110, 120VX (F813,
G813)
16 Fuel Tank (Short CIL 79 liter Diesel No. 2
Cummins 4.5L and
QSB 3.3L (Diesel)
GDP080, 090, 100,
110, 120VX (F813,
G813)
16 Fuel Tank (Long CIL 100.3 liter Diesel No. 2
Cummins 4.5L and
QSB 3.3L (Diesel)
GDP080, 090, 100,
110, 120VX (F813,
G813)
Horn, Lights, X Check Operation
Alarms, Fuses,
and Relays
1 Service Brakes X Check Operation
23 Parking Brake X Check Operation
Steering Controls X Check Condition
and Steering and Operation
Column Gas
Cylinder
22 Transmission X Check for Leaks John Deere
JDM J20C
22 Transmission X Check Operation
3 Hydraulic Oil GM X X C 39.4 liter (41.6 qt) ISO VG 46 Hydraulic Oil
4.3L [GC/GLC080, See NOTE 2, 15°C (5°F) and Above
100, 120VX;] NOTE 3 and
GC/GLC080, NOTE 17.
100VXBCS;
GC/GLC120SVX;
GC/GLC120VXPRS
(E818)
3 Hydraulic Oil X X C 62.0 liter (65.5 qt) ISO VG 46 Hydraulic Oil
(Short Wheel Base) See NOTE 2, 15°C (5°F) and Above
GP/GLP/GDP080, NOTE 3, and
090, 100, 110, NOTE 17.
120VX (F813, G813)
16
3 Hydraulic Oil X X C 78.0 liter (82.4 qt) ISO VG 46 Hydraulic Oil
(Long Wheel Base) See NOTE 2, 15°C (5°F) and Above
GP/GLP/GDP080, NOTE 3 and
090, 100, 110, NOTE 17.
120VX (F813, G813)
6 Hydraulic Oil Filter C 1 Filter See Parts Manual
. See NOTE 17.
10 Hydraulic Tank X C Inspect and See Parts Manual
Breather Replace as
Required
See NOTE 5.
8 Battery and Cable X Clean
Terminals
9 Engine Oil X C 4.7 liter (5.0 qt) 7°C (20°F) and Below
GM 4.3L Engine CIL See NOTE 4 and SAE 5W-20
(Gasoline/LPG) NOTE 5. 16°C (60°F) and Below
SAE 5W-30
18°C (0°F) and Above
SAE 10W-30
API SM
ILSAC GF4
SAE J2362
19 Engine Oil Filter C 1 Filter See Parts Manual
GM 4.3L Engine See NOTE 4
and NOTE 5.
9 Engine Oil X C 13.0 liter (13.7 qt) 0°C (32°F) and Below
Cummins 4.5L CIL See NOTE 4 and SAE 0W-30
Engine (Diesel) NOTE 5. 25 to 20°C
( 13 to 68°F)
SAE 5W-30
20 to 20°C
( 4 to 68°F)
SAE 10-30
SAE 5W-40 or 15W-40
API CH-4 or CI-4
9 Engine Oil X C 7.5 liter (8 qt) 0°C (32°F) and Below
Cummins CIL See NOTE 4 and SAE 0W-30
QSB 3.3L NOTE 5. 25 to 20°C
Engine (Diesel) ( 13 to 68°F)
SAE 5W-30
20 to 20°C
( 4 to 68°F)
SAE 10-30
SAE 5W-40 or 15W-40
API CH-4 or CI-4
17
19 Engine Oil Filter C 1 Filter See Parts Manual
Cummins 4.5L See NOTE 4
and QSB 3.3L and NOTE 5.
(Diesel)
18 Air Filter CIL C 1 Filter See Parts Manual
(with premium See NOTE 5,
monitoring) NOTE 6, and
NOTE 12.
18 Air Filter X C 1 Filter See Parts Manual
See NOTE 5,
NOTE 6, and
NOTE 12.
Engine Oil CIL Check Oil GM Engine
Pressure Pressure 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
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 4.5L and Damage.
and QSB 3.3L No Adjustment
(Diesel) Needed.
See NOTE 5.
LPG Regulator X Drain Tar
GM 4.3L Engine See NOTE 5.
With GFI Installed
33 LPG Converter 4.3L X Drain Tar
LPG Engine With See NOTE 5.
PSI Installed
Engine Idle Speed X 750 ±25 rpm
GM 4.3L
(Gasoline/LPG)
Engine Governed X 2400 ±25 rpm
Speed
GM 4.3L
(Gasoline/LPG)
18
Engine Idle Speed X Coolant 770 ±50 rpm
Cold Engine Temperature
Cummins 4.5L Less than
(Diesel) 77°C (170°F)
Hot Engine Temperature
Cummins 4.5L Greater than
(Diesel) 77°C (170°F)
Speed (No Load)
Cummins 4.5L
Diesel
PCV Valve X Replace as See Parts Manual
GM 4.3L Engine Necessary
with GFI Installed See NOTE 14.
Cold Engine Temperature Less
Cummins QSB than 30°C (86°F)
3.3L (Diesel)
Hot Engine Temperature
Cummins QSB Greater than
3.3L (Diesel) 30°C (86°F)
Speed
Cummins QSB
3.3L (Diesel)
Oxygen Sensor X Replace as
GM 4.3L Engine CIL Necessary
With GFI Installed
4 Valve Adjustment Not Adjustable
GM 4.3L Engine
4 Valve Adjustment X Adjust as Intake
Cummins 4.5L Required 0.254 mm (0.010 in.)
Diesel Engines Cold
Exhaust
0.508 mm (0.020 in.)
Cold
4 Valve Adjustment X Adjust as Intake
Cummins QSB Required 0.35 mm (0.014 in.)
3.3L Diesel See NOTE 13. Cold
Engines Exhaust
0.50 mm (0.02 in.)
Cold
17 Fuel Filter, LPG C 1 Filter See Parts Manual
(GM)
19
17 Fuel Filter C 1 Filter See Parts Manual
Gasoline (GM)
17 Fuel Water CIL C 1 Filter See Parts Manual
Separator Filter Drain Water from
Cummins 4.5L Filter as Required
and QSB 3.3L
Diesel Engine
17 In-Line Fuel Filter C 1 Filter See Parts Manual
Cummins 4.5L
Diesel Engine
17 Final Fuel Filter C 1 Filter See Parts Manual
Cummins QSB
3.3L Diesel
Engine
20 Fuel Injectors X Check and
GM 4.3L Gas Replace If
Required
6 Injectors
20 Fuel Injectors X Check and
GM 4.3L LPG Replace If
With GFI Installed Required
6 Injectors
5 Spark Plugs C Check Plug Wires See NOTE 9.
GM 4.3L Engine 6 Plugs
12, Cooling System X C 15.1 liter (15.9 qt) See NOTE 15.
14 GM 4.3L CIL
Engine
12, Cooling System X C 13.5 liter (14.2 qt) See NOTE 15.
14 Cummins 4.5L CIL
Diesel Engine
12, Cooling System X C 10.4 liter (11 qt) See NOTE 15.
14 Cummins QSB CIL
3.3L Diesel
Engine
Clean Debris From X See NOTE 5.
Radiator Core
7 Transmission Oil X C 20 liter (21 qt) John Deere
Dry Brake JDM J20C
21 Transmission Oil C 1 Filter See Parts Manual
Filter and Breather 1 Breather
See NOTE 4.
26 Forks X X X Check Condition
26 Fork Latches L Lubricate as Multipurpose Grease
Necessary See NOTE 7.
20
Lift System, Operate X Check Operation
27 Mast L Lubricate Multipurpose Grease
Sliding Surfaces as Required See NOTE 7.
and Load Roller See NOTE 10
Surfaces and NOTE 11.
27 Header Hoses X Check Condition
28 Lift Chains X Check Condition/ SAE 30W
Lube if Engine Oil
Necessary.
See NOTE 11.
28 Lift Chains L L, X Check for Wear. SAE 30W
Lube as Required. Engine Oil
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
Mast X L X Lube as Required. Multipurpose Grease
Integral 8 Fittings See NOTE 7
Sideshift 4 Bearing Strips 2.0 mm (0.08 in.)
Carriage Check Bearing Minimum Thickness.
Sliding Surfaces Strips for Wear.
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease

See NOTE 7
Brake Master L SAE 10W-30
Cylinder Rod End API SM
Pin ILSAC GF4
SAE J2362
Manual Hydraulic L SAE 10W-30
Hand Levers API SM
ILSAC GF4
SAE J2362
24 Brake Oil CIL X C 0.35 liter (0.74 pt) Dexron III from Sealed
(Master Cylinder) Container
11 Steering Axle L 4 Fittings Multipurpose Grease
Spindle Bearings See NOTE 7.
Tie Rods See NOTE 7.
GC/GLC080,
100, 120VX;
GC/GLC080,
100VXBCS;
GC/GLC120SVX;
GC/GLC120VX-
PRS (E818)
21
Tie Rods See NOTE 7.
GP/GLP/
GDP080, 090,
100, 110, 120VX
(F813, G813)
34 Wheel Bearings L Check Grease. Multipurpose Grease
Steer Wheels See NOTE 7.
2 Pedals, Levers, L Lubricate as Use Silicone Spray
Seat Rails, Cables, Necessary Yale Part No.
Hinges, Linkages, 504236201
Hood Latch
1 Service Brakes X Check Lining 1.0 mm (0.040 in.)
(Dry Brake) Thickness Minimum
23 Parking Brake X Adjust as Must Hold a Full
Adjustment Necessary. Capacity Load on a
15% Grade.
23 Parking Brake L Lubricate as Use Silicone Spray
Necessary (Yale Part Number
504236201)
30 Differential and Drive X C 6.0 liter (6.3 qt) SAE 80W-90 or
Axle Oil 85W-140
(Dry Brake)
7/30 Transmission and X C 28.8 liter (30.4 qt) John Deere
Planetary Carrier JDM J20C
Housing Oil
GC/GLC080VX,
VXBCS (E818)
Housing Oil
GC/GLC100VX,
VXBCS
GC/GLC120VX,
SVX, VXPRS (E818)
Housing Oil
GP/GLP/GDP080,
090, 100, 110,
120VX (F813, G813)
22
30 Planetary Carrier X C 2.0 liter (2.1 qt) SAE 80W/90
Housing Oil
GC/GLC080,
100, 120VX;
GC/GLC080,
100VXBCS;
GC/GLC120SVX;
GC/GLC120VXPRS
(E818)
30 Planetary Carrier X C 2.0 liter (2.1 qt) SAE 80W-90
Housing Oil
GP/GLP/GDP080,
090, 100, 110,
120VX (F813, G813)
Inspect Engine X
Electrical System,
Connectors
Inspect Engine X
Vacuum, Fuel Lines,
and Fittings
Inspect X
Lock-Off for Leaks,
and Ensure
Lock-Off Closing
Test LPG/GAS X
Regulator Pressure
- GFI equipped
engines
Check X
Air Induction System
for Leaks
Check X
Manifold for Vacuum
Leaks
Check X
Throttle Shaft for
Sticking
Check X
Injectors and Rails
for leaks
Inspect X
Exhaust Manifolds
and Piping for Leaks
Inspect X
Catalyst Inlet
and Outlet
23
31 Ignition System: C Replace
Distributor Cap,
Rotor, and Spark
Plug Wires
Inspect Muffler Inlet X Replace as
and Outlet Required
Mast and Carriage X Inspect Dye Penetrant
with Paper Roll See NOTE 16
Clamp
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 - see 2000 Hr/1 Yr service procedures.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving
contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive compounds;
poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require more frequent
servicing. At your request your Yale dealer will advise you of the appropriate service intervals based on an application survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: Vehicles used in paper application require regular inspection 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 compressed air and steam clean
as necessary.
NOTE 9: See Capacities and Specifications 8000 YRM 1249 for spark plug gap and type of spark plugs to use.
NOTE 10: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 11: Lubricate if dry or at first sign of visible surface rust.
NOTE 12: 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 13: 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 14: Replace after 3000 hours. Use hour interval only.
NOTE 15: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with 50%
distilled or deionized water.
NOTE 16: Inspect after an impact likely to cause damage. In large diameter paper-roll production applications, inspect at first
4000 hours with subsequent inspection at 2000 hour intervals. At your request, your Yale dealer will advise you of the appropriate
service intervals based on an application survey.
NOTE 17: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures 1900 YRM
1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or highly contaminated
environments, take oil samples every 500 hours. Normal Operating conditions may allow for less frequent oil sampling. Oil
sampling should be done just prior to all oil and filter changes.
24
8000 YRM 1248 Maintenance Procedures Every 8 Hours or Daily
Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE damaged rims. Check for loose or missing hardware.
STOPPED Remove any wire, strapping, or other material that is
wrapped around the axle. See Figure 11.
WARNING Safety Labels
DO NOT operate a lift truck that needs repairs. Re-
port the need for repairs immediately. If repair is
necessary, put a DO NOT OPERATE tag in the op- WARNING
erator’s area. If the lift truck is equipped with a key Safety labels are installed on the lift truck to provide
switch, remove the key from the key switch. information about operation and possible hazards.
It is important that all safety labels are installed on
Put lift truck on a level surface. Lower carriage and the lift truck and can be read.
forks, stop the engine, and apply parking brake. Open
hood and check for leaks and conditions that are not Check that all safety labels are installed in the correct
normal. Clean any oil or fuel spills. Ensure all sur- location on lift truck. See the Parts Manual, Model De-
faces are free of oils, lubricants, fuel, and organic dust scription section in the Operating Manual or section
or fibers (paper, wood, cotton, agricultural grass/grain, Frame 100 YRM 1243 for correct location of safety la-
etc.). bels. See Parts Manual for part numbers of the safety
labels.
Tires and Wheels
Check tires for damage. Check tread and remove any
objects that will cause damage. Check for bent or
1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)
Figure 11. Tire Check
25
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 1248
Mast, Carriage, Lift Chains, Header Hoses, See Mast Repairs, 2- and 3-Stage Masts 4000
Attachment YRM 1250 for quick disconnect procedures.
7. Check that lift chains are correctly lubricated. Use

WARNING SAE 30W engine oil as necessary to lubricate lift
Lower the lift mechanism completely. Never allow chains.
any person under a raised carriage. DO NOT put
any part of your body in or through the lift mech- 8. Inspect lift chains for cracks or broken links, and
anism unless all parts of the mast are completely worn or turned pins. See Figure 12.
lowered and the engine is STOPPED. DO NOT try
to correct the alignment of the fork tips by bending 9. Inspect chain anchors and pins for cracks and dam-
the forks or adding shims. Never repair damaged age.
forks by heating or welding. Forks are made of spe- 10. Make sure lift chains are adjusted so that they have
cial steel using special procedures. If either fork is equal tension. Adjustments or replacement of
damaged, replace the forks as a set. the lift chains must be done by authorized per-
DO NOT operate fork lift without lateral fork stops sonnel.
in place. Forks may disengage from fork carriage.
1. Inspect welds on mast and carriage for cracks.

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

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

travel. Inspect rollers for wear or damage.
4. Inspect load backrest extension for cracks and

damage.
5. If lift truck is equipped with an integral sideshift car-

riage or attachment, inspect the parts for cracks
and wear. Make sure the parts that fasten the in-
tegral sideshift carriage or attachment to carriage
are in good condition.
1. WORN PIN 5. LOOSE LEAVES
6. Visually inspect hoses/fittings for hydraulic leaks; 2. CRACKS 6. TURNED PIN
hose cover for cuts, cracks or exposed rein- 3. EDGE WEAR 7. CORROSION
4. HOLE WEAR
forcement; defective/broken clamping devices
or sheaves; proper tracking during operation. Ad- Figure 12. Lift Chain Check
just/repair/replace hose/components as necessary.
26
Operator Restraint System Adjust Seat - Full Suspension
NOTE: The seat belt can be either black or red. Seat Position Adjustment (Standard Seat)
• Fore and aft adjustment - It is recommended that the
The seat belt, hip restraint, seat, hood, and hood latch seat be adjusted so that the thigh is horizontal to the
are all part of the operator restraint system. Each item ground in order to achieve the best ergonomic posi-
must be checked to make sure it is fastened correctly, tion. See Figure 13.
functions correctly, and is in good condition. See Fig-
ure 13. Seat Position Adjustment (Swivel Seat)
• The seat swivels 12 degrees to the right to allow the
Emergency Locking Retractor (ELR) operator a more ergonomic position when driving in
reverse.
When the ELR style seat belt is properly buckled across
• The seat swivels 5 degrees to the left to allow an
the operator, the belt will permit slight operator repo-
easier exit of the truck.
sitioning without activating the locking mechanism. If
• The neutral position is shown in Figure 14.
truck tips, travels off a dock, or comes to a sudden stop,
the locking mechanism will be activated and hold the
operator’s lower torso in the seat.
A seat belt that is damaged, worn, or does not operate

properly will not provide protection when it is needed.
The end of the belt must fasten correctly in the latch.
The seat belt must be in good condition. Replace the
seat belt if damage or wear is seen. See Figure 13.
NOTE: The following seat belt operation checks must

be performed three times before replacing the seat belt
assembly.
• With the hood closed and in the locked position, pull

the seat belt slowly from the retractor assembly. Make
sure the seat belt pulls out and retracts smoothly. If
the seat belt cannot be pulled from the retractor as-
sembly or the belt will not retract, replace the seat belt
assembly.
• With the hood closed and in the locked position, pull 1. LATCH STRIKER
the seat belt with a sudden jerk. Make sure the seat 2. HOOD LATCH
belt will not pull from the retractor assembly. If the 3. FORWARD/BACKWARD ADJUSTMENT
4. HOOD
seat belt can be pulled from the retractor, when it is 5. OPERATOR WEIGHT ADJUSTMENT
pulled with a sudden jerk, replace the seat belt as- 6. SEAT RAIL
sembly. 7. ARM REST
• With the hood in the open position, make sure the 8. SEAT BELT
seat belt will not pull from the retractor assembly. If 9. SEAT
10. HIP RESTRAINT
the seat belt can be pulled from the retractor, with 11. HOOD HINGE
the hood in the open position, replace the seat belt
assembly. Figure 13. Hood and Seat Check
27
with the feet positioned on the pedals. This ensures

that the operator is set at the midpoint of the 80 mm
(3.15 in.) suspension.
• The handle can be turned as shown to increase or
decrease the weight resistance. Pull handle out be-
fore turning. As the handle is 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 15.
Seat Adjustment for Operator Weight
NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE CAUTION

1. BACKREST ANGLE ADJUSTMENT LEVER A major cause for high Whole Body Vibration is
2. SWIVEL ADJUSTMENT caused by the operator not adjusting the seat to
3. OPERATOR WEIGHT ADJUSTMENT his/her weight.
4. FORWARD/BACKWARD ADJUSTMENT HANDLE
5. SEAT BELT NOTE: It is important to adjust the weight setting for
each operator.
Figure 14. Swivel Seat Controls
NOTE: The seat is designed for maximum weight of
Seat Adjustment for Operator Weight
135 kg (298 lb).
CAUTION • The target is for the "ride indicator" to fall between

the arrows when the operator sits upright in the seat
A major cause for high Whole Body Vibration is
with the feet positioned on the pedals. This ensures
caused by the operator not adjusting the seat to
that the operator is set at the midpoint of the 40 mm
his/her weight.
(1.57 in.) suspension.
NOTE: It is important to adjust the weight setting for • The weight adjustment knob can be turned left or right
each operator. to increase or decrease the weight resistance. As
the weight adjustment knob is turned the "stiffness"
NOTE: The seat is designed for maximum weight of of the suspension can be felt to increase or decrease
135 kg (298 lb). on which way the weight adjustment knob is turned.
• The target is for the "ride indicator" to fall between

the arrows when the operator sits upright in the seat
28
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 15. Seat Adjustment
Hood and Seat Latches Paper Application

Make sure seat rails and latch striker are not loose. Vehicles used in paper applications require regular in-
Seat rails must lock tightly in position, but move freely spection and cleaning to minimize the risk of fire. This
when unlocked. See Figure 13. Seat rails must be cor- should be done at least once every eight hours or more
rectly fastened to the hood and the hood fastened to frequently depending upon operating environment. The
hinges on frame. Try to lift the hood to make sure it is paper application option will help limit the contact of pa-
fastened correctly and will not move. If adjustment is per or tissue scraps to hot surfaces under the hood, but
required, go to Hood Latch Check. frequent maintenance is required.
Engine Compartment WARNING

Check for the presence of any combustible material Engine and exhaust system components are hot to
such as paper, leaves, etc. Remove any combustible touch. Be sure lift truck components are cool be-
materials. fore starting inspection and cleaning or personal in-
jury may occur.
29
Ensure truck engine cools properly by allowing it to of material or oil. Protect electrical components from
idle for several minutes. Shutting truck down while hot moisture when steam cleaning. Do not spray exhaust
will not allow engine to cool quickly due to the loss of wraps directly with high pressure steam. Allow lift truck
coolant circulation. The heat trapped under the hood to air dry before returning to work in a contaminated
may actually increase engine temperature because of environment. Paper dust and scraps will adhere to wet
no heat transfer through the radiator. With engine off surfaces.
and lift truck components cooled, check and clean the
radiator and if equipped, radiator screen. Check engine Check the condition of exhaust wraps for wear, proper
manifold, exhaust pipes, muffler and catalytic converter fit, contamination with oil or antifreeze, gaps in cover-
for paper scraps. Clean as required. Check and clean age, failed fasteners and replace as necessary. Do not
engine compartment components, transmission, fan reuse wraps if they have been removed for some other
shroud, belly pan if equipped, and inside frame ledges service operation.
to avoid paper, dust and oil accumulation. Check axle
and cowl openings for paper buildup and bailing wire. Fuel, Oil, and Coolant Leaks, Check
Remove any debris.
WARNING
WARNING All fuels are very flammable and can burn or cause
Compressed air can move particles so that they an explosion. DO NOT use an open flame to check
cause injury to the user or to other personnel. the fuel level or to check for leaks in the fuel system.
Make sure that the path of the compressed air is If there is a leak in the fuel system, extra care must
away from all personnel. Wear protective goggles be used during the repair. DO NOT operate the lift
or a face shield to prevent injury to the eyes. truck until a leak is repaired.
Make a visual check for leaks on and under the lift truck.
CAUTION If possible, find and report leaks to maintenance for re-
Air pressure, nozzle or extension tube may cause pair. Leaks often indicate a need for repair of damaged
damage to exhaust wraps and radiator fins. Assure or worn components. Leaks in the LPG fuel system are
that air pressure, nozzle or extension tube does not usually not visible unless ice is present. There is how-
damage exhaust wraps or radiator fins. ever, usually a strong odor. Fuel leaks MUST be re-
paired IMMEDIATELY.
Paper removal can generally be accomplished using a
compressed air line and nozzle. An extension may be Check fuel system for leaks and the condition of parts.
helpful to access hard to reach places. Remove floor When fuel is added to lift truck, see section HOW TO
plates and side covers for better access to engine com- ADD FUEL TO THE LIFT TRUCK in the Operating
partment. Open or removed belly pan, if equipped. Manual.
Clean components with compressed air. Take care to
Also check the condition of radiator or heater hoses that
maintain the integrity of the exhaust wraps when clean-
are not leaking. Soft or cracked hoses need to be re-
ing with compressed air and use caution to not force
placed before a major leak occurs.
debris into openings. Check the condition of exhaust
wraps for wear, proper fit, contamination with oil or an-
Hydraulic Hoses
tifreeze, gaps in coverage, failed fasteners and replace
as necessary. Do not reuse wraps if they have been re- Check condition of hydraulic hoses for serviceability by
moved for some other service operation. inspecting for cracks or other obvious damage. Check
to ensure that the hydraulic hoses are not leaking. If
WARNING any hose is leaking, report it to maintenance for repair.
Be careful when cleaning with steam. Steam can
cause serious burns. Wear protective clothing,
Coolant Hoses
gloves, and eye protection. Never expose your skin Check condition of coolant hoses for serviceability by
to steam. inspecting for cracks or other obvious damage. Check
to ensure that the coolant hoses are not leaking. If any
If compressed air did not adequately remove debris,
hose is leaking, report it to maintenance for repair.
steam clean to remove any persistent accumulation
30
Steering Column Gas Cylinder Check hydraulic system for leaks and damaged or loose
components. Heavy-duty or high-temperature opera-
Make sure the gas cylinder for steering column oper- tions can require more frequent checks.
ates correctly. The cylinder must NOT allow column to
move unless tilt lever is released. See Figure 16. Engine Oil
WARNING
At operating temperature, the engine 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 engine when the oil
level is checked or the filter is changed.
Never operate the engine without oil. The operation

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

checking the oil level.
1. TILT LEVER 2. GAS CYLINDER See Figure 17 for Cummins 4.5L diesel engine.
Figure 16. Steering Column Gas Cylinder and Tilt See Figure 18 for Cummins QSB 3.3L diesel engine.
Lever
See Figure 19 for GM 4.3L engine with GFI installed.
Transmission
See Figure 20 for GM 4.3L LPG engine with PSI in-
Check transmission for leaks and damaged or loose stalled.
components. Heavy-duty or high temperature opera-
See Figure 21 for GM 4.3L gasoline engine with PSI
tions can require more frequent checks.
installed.
Hydraulic System Oil Keep oil at the correct level as indicated on the dipstick.
Use correct oil as shown in the Maintenance Schedule.
WARNING
At operating temperature, the hydraulic oil is HOT. Air Filter
DO NOT permit the hot oil to touch the skin and
The air filter canister should not be opened until an air
cause a burn.
filter element replacement is required. An air filter ele-
ment replacement is required when one of the following
CAUTION occurs:
DO NOT permit dirt to enter the hydraulic system • The optional air flow restriction indicator light on the
when the oil level is checked or the filter is changed. dash illuminates.
• If equipped, the manual air flow indicator is red.
Never operate the hydraulic pump without oil in the • The specified number of hours has passed since the
hydraulic system. The operation of the hydraulic last filter element replacement.
pump without oil will damage the pump.
DO NOT operate lift truck until the air filter element has
After engine has stopped, wait one minute before been replaced.
checking the oil level. Keep hydraulic oil at the correct
level as indicated on dipstick. Use correct oil as shown
in the Maintenance Schedule.
31
Legend for Figure 17

A. TOP VIEW
B. RIGHT SIDE SHOWN
1. BATTERY
2. AUXILIARY COOLANT RESERVOIR
3. RADIATOR CAP
4. WATER SEPARATOR
5. AIR FILTER
6. LIFT PUMP
7. FUEL INJECTION PUMP
8. ENGINE OIL FILL CAP
9. INLINE FUEL FILTER
10. DIPSTICK ENGINE OIL
11. FUEL INJECTOR
12. DRIVE BELT
Figure 17. Cummins 4.5L Diesel Engine

Maintenance Points for Lift Truck Models
(GP/GLP/GDP080, 090, 100, 110, 120VX) (F813)
32
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 18. Cummins QSB 3.3L Diesel Engine Maintenance Points for Lift Truck Models (GP/GLP/GDP080,
090, 100, 110, 120VX) (G813)
33
A. GAS ENGINE B. LPG ENGINE

1. DIPSTICK ENGINE OIL 7. AIR FILTER
2. BATTERY 8. FUEL FILTER
3. AUXILIARY COOLANT RESERVOIR 9. ENGINE OIL FILTER
4. RADIATOR CAP 10. SPARK PLUGS
5. ENGINE OIL FILL 11. FUEL INJECTOR
6. DRIVE BELT
Figure 19. GM 4.3L Engine Maintenance Points With GFI Installed
34
1. DIPSTICK ENGINE OIL 7. AIR FILTER

2. BATTERY 8. ENGINE OIL FILTER
3. AUXILIARY COOLANT RESERVOIR 9. SPARK PLUGS
4. RADIATOR CAP 10. ENGINE LABEL
5. ENGINE OIL FILL 11. LPG CONVERTER
6. DRIVE BELT
Figure 20. GM 4.3L LPG Engine Maintenance Points With PSI Installed
35
1. AIR FILTER 7. BATTERY

2. DIPSTICK ENGINE OIL 8. AUXILIARY COOLANT RESERVOIR
3. ENGINE LABEL 9. RADIATOR CAP
4. ENGINE OIL FILL 10. DRIVE BELT
5. ENGINE OIL FILTER 11. FUEL FILTER
6. SPARK PLUGS
Figure 21. GM 4.3L Gasoline Engine Maintenance Points With PSI Installed
36
Forks Install
NOTE: Forks must be removed or installed by trained

personnel only.
WARNING
DO NOT try to move a fork without a lifting device.
The identification of a fork describes how the fork is Each hook fork for these lift trucks can weigh 45 to
connected to the carriage. These lift trucks have hook 115 kg (99 to 253 lb).
forks.
Move fork and carriage so that the top hook on the fork
Remove can engage the upper carriage bar. Raise the carriage
to move the lower hook through the fork removal notch.
1. Lower fork onto blocks so bottom hook of fork Slide the fork on the carriage so that both upper and
moves through the fork removal notch. Lower car- lower hooks engage the carriage. Engage the lock pin
riage further so top hook of the fork is disengaged with a notch in the upper carriage bar.
from top carriage bar. Move carriage away from
fork or use a lifting device to move fork away from Adjust
carriage. See Figure 22.
NOTE: During the adjustment of the forks, the heel of
the forks should not be touching the ground.
WARNING
DO NOT try to move a fork without a lifting device. The forks are connected to the carriage by hooks and
Each hook fork for these lift trucks can weigh 45 to lock pins. See Figure 22 and Figure 24. Lock pins are
115 kg (99 to 253 lb). installed through the top fork hooks and fit into slots in
the top carriage bar. If pin does not remain engaged
NOTE: Forks are to be replaced only in sets and not in carriage slot, replace with new pin. Adjust forks as
individually. far apart as possible for maximum support of the load.
Hook forks will slide along carriage bars to adjust for
2. A fork can be removed from the carriage for re- the load to be lifted. Raise the lock pin in each fork to
placement of the fork or other maintenance. Lift slide the fork on the carriage bar. Make sure lock pin is
lock pin and slide a hook fork to the fork removal engaged in the carriage bar to lock fork in position after
notch on carriage. See Figure 22 and Figure 23. the width adjustment is made.
Lower fork onto blocks so that the bottom hook of
the fork moves through fork removal notch. See
Figure 23. Lower carriage further so that the top
hook of fork is disengaged from the top carriage
bar. Move carriage away from the fork, or use a
lifting device to move fork away from the carriage.
Inspect
1. Inspect forks for cracks and wear. Check that the

fork tips are aligned as shown in Figure 23.
2. Check that the bottom of fork is not worn. See Fig-

ure 23, item 4.
3. Replace any damaged or broken parts that are

used to keep the forks locked in position.
1. CARRIAGE BARS 3. BLOCKS

2. HOOK FORK
Figure 22. Hook Fork Removal
37
1. FORK 5. WEDGE
2. LOCK PIN 6. KNOB
3. SPRING 7. LOCK PIN
4. WASHER ASSEMBLY
Figure 24. Fork Lock Pin Assembly
Fork Tip Alignment

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

FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH
Figure 23. Forks Check
38
Integral Sideshift Carriage HOW TO MAKE CHECKS WITH ENGINE

RUNNING
Check for cracks, wear and damage. If damaged, see
Mast Repairs, 2- and 3-Stage Masts 4000 YRM 1250
for repair procedures. If necessary, lubricate sliding sur- WARNING
faces at grease fittings with multipurpose grease shown DO NOT operate a lift truck that needs repairs. Re-
in the Maintenance Schedule. See Figure 25. port the need for repair immediately. If repair is nec-
essary, put a DO NOT OPERATE tag in the opera-
tor’s area. If lift truck is equipped with a key switch,
remove the key.
WARNING
FASTEN YOUR SEAT BELT! The seat belt is installed
to help the operator stay on the truck if the lift truck
tips over. IT CAN ONLY HELP IF IT IS FASTENED.
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 the
lift truck is stationary during a check, apply the parking
brake and put the transmission in NEUTRAL. Make the
checks carefully.
1. CAPSCREWS Indicator Lights, Horn, Fuses, and Relays
2. LOWER HOOK
3. APRON
4. LOWER BEARING STRIPS If lift truck is equipped with a key switch, turn key to ON
5. UPPER BEARING STRIPS position. If lift truck is equipped with a Power ON/OFF
6. GREASE FITTINGS button, press button to turn system power ON. All warn-
7. CYLINDER ROD ing lights and indicator lights will light up for two seconds
8. SNAP RING (start check) when system power is turned ON. See Fig-
9. ROD SCRAPER
10. ROD BUSHINGS ure 26. Check all indicator lights for correct operation
11. SEAL as described in the Operating Manual. Check the op-
12. FIXED FRAME eration of the horn. Start the engine by turning the key
switch to the Start position, if truck is equipped with a
Figure 25. Integral Sideshift Carriage key switch, or press the engine start button, if lift truck is
equipped with this button. If any indicator lights do not
operate correctly, stop the engine and check the fuses.
The fuses are located in the Power Distribution Module
(PDM) which is under the hood and next to the battery
on the right side. See Figure 27.
39
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
14 Indicator Light, 1st Gear Locking (Techtronix 200X Transmissions)
15 Indicator Light, Water Separator (Diesel Only)
16 Indicator Light, Cold Start (Diesel Only)
Figure 26. Warning and Indicator Lights
40
NOTE: HOOD REMOVED FOR CLARITY.

1. BATTERY 11. SPARE FUEL PUMP RELAY
2. PDM 12. BATTERY (25-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 27. PDM Showing Fuses and Relays
Service Brakes truck. Replace the brake oil in the system if there is
dirt or water in the system.
Brake Oil Level
DO NOT use "DOT" fluid, only use Dexron III oil from
WARNING sealed container to prevent possible damage to the
brake system. Failure to observe the above Warn-
Small amounts of water in the brake system can
ing could result in death or serious injury.
cause reduced braking performance if the water
reaches the wheel cylinder areas. DO NOT allow There is an indicator light on the Display Switch Cluster
water entry. Ensure that the sealed reservoir lid is for the brake oil. The red light is ON when the key switch
properly replaced. is in the START position or the Power ON/OFF button is
pressed, and must go OFF when the engine is running.
The brake system has a boosted master cylinder,
If the light is on when the engine is running, the brake
braking will be more difficult if the engine is not run-
fluid oil in the reservoir is too low.
ning.
Loss of oil from the brake oil reservoir indicates a

leak. Repair the brake system before using the lift
41
Operation, Check QSB 3.3L diesel engine and powertrain protection sys-
tem, the engine will enter shutdown mode if engine oil
Check the operation of the service brakes. Push on the pressure is less than 49 kPa (7 psi).
inching/brake pedal. The service brakes must be ap-
plied before the inching/brake pedal reaches the floor There is an indicator light for the engine oil pressure
plate. The pedal must stop firmly and must not move on the Display Switch Cluster. During normal opera-
slowly down after the brakes are applied. The service tion, the red indicator light will illuminate when the key
brakes must apply equally to both drive wheels. The switch is turned to ON, if the truck is equipped with a key
service brakes must not pull the lift truck to either side switch, or when the power ON/OFF button is pressed, if
of the direction of travel when they are applied. The ser- the truck is equipped with this option, and will stay illu-
vice brakes are automatically adjusted when the trans- minated until correct oil pressure is obtained, at which
mission is in reverse and the lift truck is moving and the time the light will go off.
brakes are firmly applied. Full application of the inch-
ing/brake pedal applies the service brakes and puts the If the light continues to stay on when engine is running,
transmission in NEUTRAL. the engine oil pressure is low. Stop the engine and
check the oil level.
Lift trucks with a Foot Directional Control pedal.
When the inching/brake pedal is fully applied, a switch See Figure 17 for Cummins 4.5L diesel engine.
in the starting circuit is closed so that the engine can be
See Figure 18 for Cummins QSB 3.3L diesel engine.
started.
See Figure 19 for GM 4.3L engine with GFI installed.
Parking Brake
See Figure 20 for GM 4.3L LPG engine with PSI in-
There is an indicator icon on the display panel for the stalled.
parking brake. This icon is illuminated as describe in
the Operating Manual. There is a sensor in the seat See Figure 21 for GM 4.3L gasoline engine with PSI
that actuates an audible alarm. If the operator leaves installed.
the seat, with system power OFF, without applying the
parking brake, the alarm will sound for 10 seconds until Cooling System
the parking brake is applied or the operator sits back on
the seat. If system power is ON or the engine is running,
WARNING
and the operator leaves the seat, without applying the
parking brake, the alarm will sound continuously until DO NOT remove the radiator cap from the radiator
parking brake is applied or the operator sits back on the when the engine is hot. When the radiator cap is
seat. removed, the pressure is released from the system.
If the system is hot, the steam and boiling coolant
Make sure the service brakes operate correctly before can cause burns.
checking the operation of the parking brake. Check
the operation of the parking brake. The parking brake, NOTE: The engine will enter shutdown mode after a
when in good condition and correctly adjusted, will hold warning buzzer sounds and a 30-second countdown if
a lift truck with a full capacity load on a 15% grade [a coolant temperature reaches 118°C (245°F) or above
slope that increases 1.5 meters in 10 meters (1.5 feet for GM 4.3L lift trucks with powertrain protection sys-
increase in 10 feet)]. If parking brake requires adjust- tem. Lift trucks equipped with a Cummins 4.5L or QSB
ment, notify service personnel. 3.3L diesel engine will enter the shutdown mode when
the coolant temperature reaches 114°C (238°F) or
Engine Oil Pressure above on lift trucks with powertrain protection system.
See the Engine Shutdown procedures in the Operat-
NOTE: The engine will enter shutdown mode after a ing Manual.
warning buzzer sounds and a 30 second countdown,
if engine oil pressure is less than 207 kPa (30 psi) on There is an indicator light on the Display Switch Clus-
lift trucks with powertrain protection system and GM ter for the coolant temperature. The red light is on
4.3L engine. Lift trucks equipped with a Cummins 4.5L when key switch is in the START position or the Power
diesel engine and powertrain protection system will en- ON/OFF button is pressed, and must go off when the
ter shutdown mode if engine oil pressure is less than engine is running. If light is on when engine is running,
69 kPa (10 psi). If lift truck is equipped with a Cummins the coolant and engine are too hot. Stop engine and
check coolant level in the coolant recovery reservoir.
42
Make sure coolant level is between the ADD and FULL Steering System
marks on the auxiliary coolant reservoir. See Figure 28.
The coolant will expand as it is heated and the level in
WARNING
the auxiliary coolant reservoir will increase.
The lift truck has hydraulic power steering. The
steering can be difficult if the engine is not running.
CAUTION
Additives may damage the cooling system. Before Make sure steering system operates smoothly and pro-
using additives, contact your local Yale dealer. vides good steering control. Make sure steering column
can be adjusted and the gas cylinder function is correct.
If coolant is added, see Maintenance Schedule for cor-
rect solution. Control Levers and Pedals
Check that control levers for the transmission, mast,
WARNING and attachment operate as described in Operating
Compressed air can move particles so that they Manual. Check that pedals operate correctly as de-
cause injury to the user or to other personnel. scribed in Operating Manual.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles Lift System, Operate
or a face shield to prevent injury to the eyes.
Check the radiator fins. Turn engine OFF and clean WARNING
the radiator with compressed air or water as needed. When working on or near the mast, see Safety Pro-
Check for and remove any debris on the radiator core. cedures When Working Near Mast at the end of this
If the indicator light turns on again after restarting, shut section.
down the lift truck and do not operate the lift truck until
the problem is corrected. Lower the lift mechanism completely. Never allow
any person under a raised carriage. DO NOT put
any part of your body in or through the lift mech-
anism unless all parts of the mast are completely
lowered and the engine is STOPPED.
If the mast cannot be lowered, use chains on the

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

on pressurized hydraulic components. Hydraulic
oil can be injected into the body by the pressure.
Perform the following checks and inspections:
1. Turn engine OFF and check for leaks in the hy-

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

during raising and lowering.
1. FILL CAP 2. Slowly raise and lower mast several times without a
2. FULL HOT MARK load. Raise mast to its full height at least once. The
3. FULL COLD MARK mast components must raise and lower smoothly
4. ADD COLD MARK
in the correct sequence. Hose must track properly
Figure 28. Auxiliary Coolant Reservoir during operation.
43
First Service After First 100 Hours of Operation 8000 YRM 1248
3. The inner weldments and the carriage must lower 5. Lower the load to approximately 0.3 m (1 ft). Tilt
completely. mast forward and backward. The mast must tilt
smoothly and both tilt cylinders must stop evenly.
4. Raise the mast 1 m (3 ft) with a capacity load.
The inner weldments and the carriage must raise 6. Check that the controls for the attachment oper-
smoothly. Lower the mast. All moving components ate the functions of the attachment. See the sym-
must lower smoothly. bols by each of the controls. Make sure all of the
hydraulic lines are connected correctly and do not
leak.
First Service After First 100 Hours of Operation

GM 4.3L ENGINE OIL AND OIL FILTER
NOTE: The engine oil and oil filter must also be
changed after the first 100 hours of operation for a
newly installed engine.
Turn engine OFF and change engine oil and oil filter.
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. Fill engine with oil as specified in
Maintenance Schedule, until full mark reached on the
dipstick. Start engine. Check area around oil filter for
leaks, shut engine off and check oil dipstick, if low add
oil. See Figure 29.
NOTE: ALL OIL FILL COMPONENTS LISTED IN LEG-

END FOR GM 4.3L ENGINES EQUIPPED WITH GFI
OR PSI ARE LOCATED IN THE SAME AREA.
1. OIL FILTER
2. DRAIN PLUG
3. ENGINE OIL DIPSTICK
4. ENGINE OIL FILL
Figure 29. GM 4.3L Engine Filter Oil Change
44
8000 YRM 1248 Maintenance Procedures Every 250 Hours or 6 Months
CUMMINS 4.5L AND QSB 3.3L ENGINE

OIL AND OIL FILTER
Turn engine OFF and change engine oil and oil filter.
See Figure 30. Apply clean oil to gasket of new fil-
ter. Install new filter. Turn filter until gasket touches,
then tighten 1/2 to 3/4 turn with your hand. Fill engine
with oil as specified in Maintenance Schedule until full
mark reached on the dipstick. Start engine. Check area
around oil filter for leaks, shut engine off and check oil
dipstick, if low add oil.
NOTE: BOTTOM LEFT SIDE SHOWN. CUMMINS

4.5L DIESEL ENGINE SHOWN. CUMMINS QSB 3.3L
DIESEL ENGINE SIMILAR.
1. OIL FILTER 2. DRAIN PLUG
Figure 30. Engine Oil Filter Change, Cummins 4.5L

Diesel
Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform 8-hour checks prior to performing pro- DRIVE BELT
cedures in this section.
GM 4.3L Engine
GM 4.3L ENGINE OIL AND OIL FILTER
Fan and Alternator Drive Belt
NOTE: Change oil and oil filter for engine at first 100
hours of operation on new lift trucks. Check drive belt for wear and damage. See Figure 32.
A few small cracks that run across belt are acceptable.
Change engine oil and engine oil filter. Use correct oil A belt with cracks that run length of belt or a belt with
according to Maintenance Schedule. Apply clean oil to missing pieces is not acceptable. See Figure 33 for
gasket of new filter. Install new filter. Turn filter until drive belt arrangement.
gasket touches, then tighten 1/2 to 3/4 turn with your
hand. Start engine. Check area around oil filter for
leaks. See Figure 31.
45
Maintenance Procedures Every 250 Hours or 6 Months 8000 YRM 1248
NOTE: GM 4.3L ENGINES HAVE SELF-ADJUSTING

TENSIONERS.
NOTE: ALL OIL FILL COMPONENTS LISTED IN LEG- 1. FAN PULLEY

2. WATER PUMP PULLEY
END FOR GM 4.3L ENGINES EQUIPPED WITH GFI 3. CRANKSHAFT PULLEY
OR PSI ARE LOCATED IN SAME AREA. 4. SERPENTINE BELT
5. TENSIONER CENTERING PULLEY
1. OIL FILTER 6. ALTERNATOR PULLEY
2. DRAIN PLUG
3. ENGINE OIL DIPSTICK Figure 33. GM 4.3L Drive Belt Arrangement
4. ENGINE OIL FILL
Figure 31. GM 4.3L Engine Oil Change
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 32. Drive Belt Inspection
46
DRAIN TAR FROM LPG CONVERTER from LPG converter. If LPG converter cannot be
rotated a sufficient amount to drain tar, disconnect
NOTE: The following procedure is to be used on lift two cooling hoses.
trucks equipped with a GM 4.3L LPG Engine with PSI
installed. 8. Using mounting bolts, install LPG converter on
mounting bracket.
1. Move lift truck to a well ventilated area, and ensure
no external ignition sources are present. 9. Connect fuel line and outlet hose to LPG converter.
If disconnected, connect two cooling hoses.
2. Start engine.
10. Connect negative terminal on battery.
3. Close valve on LPG tank.
11. Open valve on LPG tank and check for leaks on the
4. When engine runs out of fuel, turn key switch OFF LPG converter using soapy water or a leak detector.
position or, if equipped, press Power ON/OFF but- If any leaks are found, tighten fittings or replace
ton OFF, and disconnect negative terminal on bat- hose clamps as applicable.
tery.
12. Start engine and recheck for leaks at converter.
CAUTION
A small amount of fuel may remain in the fuel line.
To prevent the possibility of burns wear gloves and
eye protection. If fuel continues to flow check to
make sure the LPG tank valve is completely closed.
5. Disconnect inlet line and outlet hose from LPG con-

verter. See Figure 34.
6. Remove mounting bolts and LPG converter from

mounting bracket.
CAUTION
Engine components may be hot. Use gloves when
handling the LPG converter to prevent the possibil-
ity of burns.
1. LPG CONVERTER
2. INLET LINE
CAUTION 3. OUTLET HOSE
4. MOUNTING BOLTS
Drain the tar into a container and dispose in accor- 5. COOLANT HOSE
dance with local environmental regulations.
Figure 34. LPG Converter Removal
7. Rotate LPG converter sightly so that outlet opening
is pointing toward container and allow tar to drain
47

NOTE: Perform the 8-hour and 250-hour checks prior
WARNING
to performing the procedures in this section.
HYDRAULIC SYSTEM OIL 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
WARNING or a face shield to prevent injury to the eyes.
At operating temperature, the hydraulic oil is HOT.
cause a burn. CAUTION
Direct air pressure on the filter element can cause
CAUTION damage. Direct air pressure away from filter ele-
ment.
DO NOT permit dirt to enter the hydraulic system
when the oil level is checked or the filter is changed. 2. Using compressed air, remove any dirt and debris
in the frame cavity around the breather. See Fig-
Never operate the hydraulic pump without oil in the
ure 35.
hydraulic system. The operation of the hydraulic
pump without oil will damage the pump. 3. If necessary, unscrew and replace the breather if oil
has accumulated in the cavity or on the breather, or
CAUTION if dirt has accumulated at the breather passages at
the bottom of the breather
Additives may damage the hydraulic system. Be-
fore using additives, contact your local Yale dealer. 4. Install right rear side panel and close hood. See
Figure 35.
Check the hydraulic oil level when the oil is at operat-
ing temperature with the mast in a vertical position, the
carriage lowered, and the engine stopped.
See Figure 42 for lift trucks equipped with iron transmis-

sion housing.
See Figure 43 for lift trucks equipped with aluminum

transmission housing.
Add hydraulic oil only as needed. If hydraulic oil is

above the FULL level, the hydraulic oil will leak from
the breather during operation. The oil level indicated by
the dipstick is most accurate when the oil temperature
is 53 to 93°C (130 to 200°F).
HYDRAULIC TANK BREATHER

Inspect
NOTE: When inspecting the breather, do not remove it.
The breather element is a non serviceable part. If it is
damaged, replace with a new breather element.
1. HOOD/SEAT ASSEMBLY
1. Raise the hood and remove the right rear side panel 2. RIGHT REAR SIDE PANEL
See Figure 35. 3. HYDRAULIC TANK BREATHER
Figure 35. Hydraulic Tank Breather
48
BATTERY
WARNING
The acid in the electrolyte can cause injury. If the
electrolyte is spilled, use water to flush the area.
Use a solution of sodium bicarbonate (soda) to
make the acid neutral. Acid in the eyes must be
flushed with water immediately. Wear eye protec-
tion.
WARNING
Batteries generate explosive fumes. Keep the vents
in the caps clean. Keep sparks or open flame away
from the battery area. DO NOT make sparks from
the battery connections. Disconnect the battery
ground cable when doing maintenance.
Disconnect the negative and positive terminals of the

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.
CUMMINS 4.5L AND QSB 3.3L ENGINE

OIL AND OIL FILTER
NOTE: Change the oil and oil filter for the engine at the NOTE: BOTTOM LEFT SIDE SHOWN. CUMMINS
first 100 hours of operation on new lift trucks. 4.5L DIESEL ENGINE SHOWN. CUMMINS QSB 3.3L
DIESEL ENGINE SIMILAR.
Change engine oil and engine oil filter. Use the correct
oil according to the Maintenance Schedule. Apply clean 1. OIL FILTER 2. DRAIN PLUG
oil to gasket of new filter. Install new filter. Turn filter
until gasket touches, then tighten 1/2 to 3/4 turn with Figure 36. Engine Oil Change Cummins 4.5L Diesel
your hand. Start engine. Check area around oil filter
for leaks. See Figure 36.
49
FUEL/WATER SEPARATOR FILTER Install

REPLACEMENT, CUMMINS 4.5L AND QSB
1. Clean fuel filter head mounting surface and apply
3.3L ENGINE a small amount of diesel fuel to the gasket on the
new fuel filter element.
CAUTION
See Figure 37 for lift trucks equipped with a Cum-
Disposal of lubricants and fluids must meet local
mins 4.5L diesel engine.
environmental regulations.
Replace the fuel filter at specified intervals to prevent
mins QSB 3.3L diesel engine.
contaminants from adversely affecting the diesel fuel
flow. 2. Before installing the filter element, fill the filter ele-
ment with diesel fuel. This method will aid in bleed-
Remove ing the fuel system.
1. Stop engine and allow it to cool.
CAUTION
2. Disconnect air inlet elbow to access the fuel filter
DO NOT overtighten the filter element. Overtighten-
element.
ing the filter element may distort the threads.
See Figure 37 for lift trucks equipped with Cummins
3. Install the new fuel filter element until it contacts
4.5L diesel engine.
the fuel filter head mounting surface. Tighten one
See Figure 38 for lift trucks equipped with Cummins additional turn.
QSB 3.3L diesel engine.
4. Connect the fuel sensor connector to fuel filter ele-
3. Disconnect fuel filter sensor connector from the fuel ment.
filter element.
5. Connect air inlet elbow hose.
CAUTION 6. Open the fuel supply valve.

Drain the water/fuel into a container and dispose in
7. Prime the fuel system. See Priming the Fuel Sys-
accordance with local environmental regulations.
tem (Cummins 4.5L and QSB 3.3L Engine).
4. Open the drain valve by turning the valve counter-
8. Check for fuel leaks.
clockwise approximately 3 1/2 turns until draining
occurs. Drain until fuel filter element is empty.
5. Remove and discard fuel filter element.

A. RIGHT SIDE VIEW B. FRONT VIEW
1. FUEL FILTER ELEMENT 6. FUEL SUPPLY VALVE
2. DRAIN VALVE 7. FUEL SENDING UNIT
3. LIFT PUMP 8. FUEL FILTER SENSOR CONNECTOR
4. FUEL PUMP 9. AIR INLET ELBOW
5. IN-LINE FUEL FILTER 10. FUEL LINE INJECTOR FITTINGS (4)
50
Figure 37. Cummins 4.5L Engine Fuel System
51

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
FINAL FUEL FILTER REPLACEMENT

(CUMMINS QSB 3.3L ENGINE)
CAUTION

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

fuel from draining.
2. Clean the area around the fuel filter head.
CAUTION
Drain the fuel into a container and dispose in accor-
3. Remove the fuel filter. See Figure 38.

Figure 38. Cummins QSB 3.3L Engine Fuel System
4. Clean the gasket surface.
52
If equipped with electronic fuel pump (Cummins QSB

CAUTION 3.3L), with the accelerator pedal or lever in the idle po-
DO NOT pour fuel directly into the center of the fil- sition, turn the key to the ON position. Wait for the "Wait
ter, since this will allow unfiltered fuel to enter the to Start" light to go out. Start the truck.
system and may cause damage to fuel system com-
ponents. If the engine does not start after 3 attempts, check fuel
supply system. The lack of blue or white smoke indi-
5. Pre-fill new filters, both pressure side and suction cates the lack of fuel being supplied to the engine.
side, with clean fuel prior to assembly. Use the
clean side block off plug packed with the filter. 1. Crack open the fuel line to the injector pump.
6. Lubricate the gasket with clean engine oil. See Figure 37 for lift trucks equipped with a Cum-
mins 4.5L diesel engine.
7. Install fuel filter. Tighten filter until gasket contacts
filter head surface. Tighten filter an additional 3/4 See Figure 38 for lift trucks equipped with a Cum-
turn after contact. mins QSB 3.3L diesel engine.
8. Start engine and check for leaks around the fuel 2. Operate the hand lever until fuel is expelled from
filter. the loosened fitting.
PRIMING THE FUEL SYSTEM (CUMMINS 3. Tighten the fuel line to the injector pump to 9 N•m
(80 lbf in).
4.5L AND QSB 3.3L ENGINE)
Controlled Venting mins 4.5L diesel engine.

CAUTION mins QSB 3.3L diesel engine.
When using the starting motor to vent the system,
DO NOT engage it for more than 30 seconds, or 4. Crack open one or more of the injector lines located
starter motor damage will occur. Wait two minutes on the cylinder head.
before engaging the starter again.
Controlled venting is provided at the injection pump WARNING

through the fuel drain manifold. Small amounts of air The pressure spray released by the fuel injectors
introduced by changing the filters or injection pump can penetrate the skin and cause serious personal
supply line will be vented automatically if the fuel filter injury. Wear clothes and protective clothing.
element is changed and filled prior to installation.
5. Crank the engine until fuel is expelled from the
Manual Bleeding loosen fittings. Tighten the injector line fittings
while cranking. The engine should fire.
Manual bleeding will be required if one of the following
conditions exist:
CAUTION
• The fuel filter is not filled prior to installation.
• The fuel injection pump is replaced. Disposal of lubricants and fluids must meet local
• The high pressure fuel line connections are loosened, environmental regulations.
or lines are replaced. 6. Wipe up any fuel that may have spilled and dispose
• It is an initial engine start up after an extended period of the fuel and rags in accordance with local envi-
of no engine operation. ronmental regulations.
53
DRIVE BELT
Cummins 4.5L and QSB 3.3L Diesel
Engine
Fan and Alternator Drive Belt
Check drive belt for wear and damage. See Figure 39.
A few small cracks that run across belt are acceptable.
A belt with cracks that run length of belt or a belt with
missing pieces is not acceptable. For drive belt ar-
rangement, see
Figure 40 for lift trucks equipped with a Cummins 4.5L

diesel engine.
Figure 41 for lift trucks equipped with a Cummins QSB

3.3L diesel engine.
Figure 40. Cummins 4.5L Diesel Engine Drive Belt

Arrangement
1. ACCEPTABLE CRACKS
2. NOT ACCEPTABLE CRACKS AND DAMAGE
Figure 39. Drive Belt Inspection
NOTE: CUMMINS 4.5L ENGINES HAVE SELF-AD-

JUSTING TENSIONERS.
1. ALTERNATOR PULLEY
2. CAMSHAFT PULLEY
3. WATER PUMP PULLEY
4. CRANKSHAFT PULLEY
5. TENSIONER CENTERING PULLEY
1. ALTERNATOR BELT ADJUSTMENT BRACKET
2. DRIVE BELT
3. CAMSHAFT PULLEY
4. CRANKSHAFT PULLEY
5. ALTERNATOR PULLEY
Figure 41. Cummins QSB 3.3L Diesel Engine Drive

Belt Arrangement
54
CLEAN DEBRIS FROM RADIATOR CORE

CAUTION
Check the radiator core for restrictions and remove ma- DO NOT permit dirt to enter the transmission when
terial causing radiator core to be plugged or restricted. the oil level is checked or the filter is changed.
NOTE: Transmission oil temperature should be at least

WARNING 50°C (120°F) when checking oil level.
cause injury to the user or to other personnel. If engine has been running, the engine must be shut
Make sure that the path of the compressed air is down for one minute or longer prior to checking the oil
away from all personnel. Wear protective goggles level.
or a face shield to prevent injury to the eyes.
See Figure 42 for lift trucks equipped with iron transmis-
Clean with compressed air, adjusted to a maximum out- sion housing.
put of 103 kPa (15 psi), and blow debris from core and
fan shroud. See Figure 43 for lift trucks equipped with aluminum
transmission housing.
TRANSMISSION OIL LEVEL
If the transmission oil is low, add oil to transmission at
the dipstick tube at the correct level as indicated on the
WARNING dipstick. Use the correct oil as shown in the Mainte-
At operating temperature, the transmission oil is nance Schedule.
HOT. DO NOT permit the hot oil to touch the skin
and cause a burn.
NOTE: IRON TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 42. Transmission and Hydraulic Oil Check
55
NOTE: ALUMINUM TRANSMISSION HOUSING SHOWN.

1. HYDRAULIC OIL DIPSTICK 2. TRANSMISSION OIL DIPSTICK
Figure 43. Transmission and Hydraulic Oil Check
WET BRAKE CENTER BODY OIL LEVEL See Figure 45 for lift truck models
CHECK • GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
G813)
WARNING 2. Visually check oil level. If necessary, add oil at
At operating temperature, the center section oil is the fill/level port until the oil/fill level port has over-
HOT. DO NOT permit the hot oil to touch the skin flowed. The Correct oil is shown in the Maintenance
and cause a burn. Schedule.
3. Install center body oil/level fill level plug and tighten

CAUTION
to 30 to 50 N•m (22 to 37 lbf ft).
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/level plug.
See Figure 44 for lift truck models

• GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VX-
PRS (E818)
56
A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER SECTION DRAIN PLUG
4. CENTER SECTION FILL/LEVEL PLUG
5. PLANETARY CARRIER HOUSING (RH)
6. PLANETARY CARRIER HOUSING (LH) A. REAR VIEW SHOWN
7. CENTER SECTION B. FRONT VIEW SHOWN
Figure 44. Wet Brake Drive Axle Drain and 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
Fill/Level Plug Location for Lift Truck Models 2. PLANETARY CARRIER HOUSING DRAIN
GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; PLUGS
GC/GLC120SVX; GC/GLC120VXPRS (E818) 3. CENTER SECTION FILL/LEVEL PLUG
4. CENTER SECTION DRAIN PLUG
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER SECTION
Figure 45. Wet Brake Drive Axle Drain and

Fill/Level Plug Location for Lift Truck Models
GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813)
57
FORKS NOTE: When lubricating the mast mounting/pivot pins,

the load must be removed from the normal contact sur-
WARNING face to allow grease to properly lubricate the normal
contact surfaces of the mast bushings.
Never repair damaged forks. DO NOT heat, weld,
or bend the forks. Forks are made of special steel 2. Raise carriage about 61 cm (2 ft), and tilt the mast
using special methods. Replace damaged forks as fully back. Place blocks under the outer mast chan-
a complete set. nels to within 13 mm (0.5 in.) of the channels. See
Figure 47.
Measure thickness of forks with a fork arm caliper (Yale
Part No. 150021700) at a vertical section where there is 3. Tilt the mast fully forward. See Figure 47.
no wear. This thickness is dimension X. Now measure
thickness at heel of fork (see Figure 23). If the thick-
ness of the heel is not greater than 90% of dimension
X, replace fork.
MAST LUBRICATION
WARNING
When working on or near the mast, see Safety Pro-
cedures When Working Near Mast in this section.
NOTE: The load rollers and sheaves have sealed bear-

ings and do not need additional lubrication.
1. Lubricate sliding surfaces and load roller surfaces

along full length of channels as shown in Figure 46.
A. UPPER LOAD ROLLERS

B. LOWER LOAD ROLLERS
1. LUBRICATE STRIP BEARING SURFACES A. MAST TILTED FULLY BACK
2. LUBRICATE LOAD ROLLER SURFACES B. MAST TILTED FORWARD
3. LOAD ROLLER
1. BLOCK 2. MAST
Figure 46. Mast Lubrication
Figure 47. Blocking the Mast
58
4. Lubricate the mast pivot bushings at grease fittings in the Maintenance Schedule. See Figure 48 and
on outer mast. Use multipurpose grease shown Figure 49.
1. MAST HANGER BUSHINGS 7. CAPSCREW

2. LUBE FITTINGS 8. NUT
3. MAST BUSHING PLUGS 9. WASHER
4. TILT PIN 10. ROD END BUSHING
5. ROD END 11. TILT CYLINDER ASSEMBLY
6. ANCHOR PIN 12. MAST MOUNTING CAP
Figure 48. Mast Mounting Hanger Lubrication
59
1. OUTER MAST 3. LUBRICATION FITTING

2. MAST PIVOT BUSHING
Figure 49. Pivot Pin Lubrication
5. Tilt mast fully back. Remove the blocks from under 12. FIXED FRAME
the channels.
6. If a integral sideshift carriage is installed, lubricate

sliding surfaces at grease fittings with multipurpose
grease shown in the Maintenance Schedule. See
Figure 50

1. CAPSCREWS
2. LOWER HOOK
3. APRON
4. LOWER BEARING STRIPS
5. UPPER BEARING STRIPS
6. GREASE FITTINGS
7. CYLINDER ROD
8. SNAP RING
9. ROD SCRAPER
10. ROD BUSHING Figure 50. Integral Sideshift Carriage
11. SEAL
60
HEADER HOSE CHECKS NOTE: The 500 Hour/6 Months Lift Chain Lubrication
should not be performed in combination with the 1000
Daily inspection plus; kinked, crushed, flattened or Hour/6 Months Lift Chain Lubrication.
twisted hose; hard, stiff or charred hose; hose fitting
slippage; proper hose tensioning. Adjust/repair/replace Lubricate lift chains with SAE 30W engine oil. The best
hose/components as necessary. Mast Repairs, 2- and procedure is to remove the chains from the lift truck and
3-Stage Masts 4000 YRM 1250 for quick disconnect soak them in engine oil. Be sure to clean any dirt or
procedures. grease from chains before lubricating. DO NOT USE
STEAM TO CLEAN THE LIFT CHAINS.
LIFT CHAIN LUBRICATION
TILT CYLINDER LUBRICATION
WARNING NOTE: The floor plate must be removed in order to lu-
When working on or near the mast, see Safety Pro- bricate the rear tilt cylinder lubrication fittings.
Lubricate the tilt cylinder ends. Use multipurpose
DO NOT repair worn or damaged lift chains. If a lift grease shown in the Maintenance Schedule. There are
chain is worn or damaged, both lift chains must be four lubrication fittings. See Figure 51.
replaced.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 4. LUBRICATION FITTING
2. RETAINER 5. TILT SPACER
3. ANCHOR PIN
Figure 51. Tilt Cylinder Lubrication
61
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 levers.
engine oil shown in the Maintenance Schedule. See Use spray lubricant as listed in the Maintenance Sched-
Figure 52. ule. See Figure 53.
1. ROD END PIN

2. COTTER PIN (LOCKING)
Figure 52. 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 53. Manual Hydraulic Levers Lubrication
62
BRAKE OIL
WARNING
Small amounts of water in the brake system can
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
sealed container to prevent possible damage to the
brake system.
Remove the dash board from the cowl. The brake oil
reservoir is located on the cowl, at the master cylinder.
Add brake oil, as necessary. Use the brake fluid shown
in the Maintenance Schedule. See Figure 54.
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 54. Brake Oil Reservoir
63
TIE ROD LUBRICATION FOR LIFT TRUCK TIE ROD LUBRICATION FOR LIFT TRUCK
MODELS GC/GLC080, 100, 120VX; MODELS GP/GLP/GDP080, 090, 100, 110,
GC/GLC080, 100VXBCS; GC/GLC120SVX; 120VX (F813, G813)
GC/GLC120VXPRS (E818)
Lubricate the tie rods. Use multipurpose grease shown
Lubricate the tie rods. Use multipurpose grease shown in the Maintenance Schedule. There is one lubrication
in the Maintenance Schedule. There is one lubrication fittings on each tie rod. See Figure 56.
fittings on each tie rod. See Figure 55.
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE) 1. LUBRICATION FITTING (TIE ROD)
2. LUBRICATION FITTING (SPINDLE)
Figure 55. Tie Rod Lubrication for Lift Truck 3. STEERING AXLE
Models GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS Figure 56. Tie Rod Lubrication for Lift Truck
(E818) Models GP/GLP/GDP080, 090, 100, 110, 120VX
(F813, G813)
64
DIFFERENTIAL AND DRIVE AXLE OIL,

LIFT TRUCK MODELS WITH DRY BRAKES
The differential and drive axle use the same oil supply.
The oil level must be between 0 to 10 mm (0 to 0.40 in.)
below the bottom edge of fill hole. The fill hole for check-
ing the oil level is on the front of the differential housing.
Remove fill plug and check fluid level by sticking a finger
into the fill hole to feel if the fluid level is at the bottom
edge of the fill hole.

• GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS (E818)

• GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
G813)
1. CHECK/FILL PLUG 3. DRIVE AXLE
If oil is low, add oil shown in the Maintenance Schedule 2. DRAIN PLUG
until the oil level is between 0 to 10 mm (0 to 0.40 in.)
below the bottom edge of fill hole. Install fill plug and Figure 58. Drive Axle (Dry Brake) Fluid Fill for
check for leaks. Lift Truck Models GP/GLP/GDP080, 090, 100, 110,
120VX (F813, G813)
1. DRIVE AXLE 3. DRAIN PLUG

2. CHECK/FILL PLUG
Figure 57. Drive Axle (Dry Brake) Fluid Fill for Lift
Truck Models GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VXPRS
(E818)
65
PARKING BRAKE ADJUSTMENT

Make sure the service brakes are adjusted and the op-
eration of the automatic adjuster mechanism is correct
before the parking brake is adjusted.
Lift trucks with a Foot Directional Control pedal.

The switch energizes the seat warning circuit when
hand lever is released. This switch puts the trans-
mission in NEUTRAL by de-energizing the direction
solenoid. There is also a switch on the left-hand side
of bracket. This switch prevents engine from starting
unless parking brake is applied.
NOTE: Make sure parking brake is released before

making adjustment.
1. Turn the adjustment knob to raise the equalized link

and tighten the parking brake cables shown in Fig-
ure 59. DO NOT tighten the adjustment so that the
brake is applied when the lever is released. The
lever for the parking brake has a lock. Use your
thumb or finger to release the lock on the lever when
the parking brake is released.
2. For burnished brakes, test the operation of the park- 1. LOCK BUTTON RELEASE
ing brake. The lift truck with a capacity load must 2. OFF POSITION
not move when parking brake is applied on a 15 3. ON POSITION
percent grade [a slope that increases 1.5 m in 10 m 4. ADJUSTMENT KNOB
(1.5 ft in 10 ft)].
Figure 59. Parking Brake

NOTE: Perform the 8-hour, 250-hour, and 500-hour IGNITION SYSTEM
checks prior to performing the procedures in this sec-
tion. GM 4.3L Engine
VALVE CLEARANCE, CHECK AND The GM 4.3L gasoline and LPG engines have an elec-
tronic control unit (ECU) that controls the ignition timing.
ADJUST
There are no adjustments. Change the spark plugs ev-
The GM 4.3L engine has hydraulic valve lifters and does ery 1000 hours. The correct spark plug gap is 1.5 mm
not require valve clearance adjustments during normal (0.059 in.).
service.
See the Maintenance Schedule for valve clearances.
Additional engine information is available in the follow-

ing sections:
• GM Engines, 4.3 Liter V-6 600 YRM 1251
66
LPG FUEL FILTER ELEMENT REPLACE, start option, press the Power ON/OFF button ON
GM 4.3L ENGINE and then OFF, to pressurize the fuel system. Check
for leaks.
Remove
8. Check for leaks at connections by using soapy so-
lution or electronic leak detector. If leaks are de-
WARNING tected, make proper repairs. See one of the follow-
LPG can cause an explosion. DO NOT permit any ing Service Manuals for procedures
sparks or open flames in the work area.
LPG Fuel System, GM 4.3L Engine With GFI 900
1. Close fuel valve on tank. Run engine until it stops. YRM 1242 for lift truck models equipped with GFI
fuel system.
2. Disconnect negative battery cable.
LPG Fuel System, GM 4.3L Engine With PSI 900
WARNING YRM 1556 for lift trucks equipped with PSI fuel sys-
tem.
A small amount of fuel may still be present in the
fuel line. Use gloves to prevent burns and wear eye
protection. If liquid fuel continues to flow from the
connections when loosened, check to make sure
the manual valve is fully closed.
3. Remove the bolt and seal washer retaining the

top section of the fuel filter housing. Discard seal
washer. See Figure 60.
4. Remove top section of fuel filter housing.
5. Remove and discard housing O-ring.
6. Remove fuel filter and fuel filter O-ring.
Install
1. Clean and inspect the fuel filter housing for contam-
ination or damage.
2. Install the new fuel filter and fuel filter O-ring. See
Figure 60.
3. Install new housing O-ring.
4. Install top section of fuel filter housing.
5. Install bolt and new seal washer. Tighten bolt to 1. BOLT

13 N•m (115 lbf in). 2. SEAL WASHER
3. FUEL FILTER HOUSING TOP SECTION
NOTE: Opening the fuel valve too quickly can cause 4. FUEL FILTER
the internal excessive flow valve to close, restricting the 5. FUEL FILTER O-RING
flow of fuel. If this happens, close the fuel valve, wait a 6. HOUSING O-RING
7. FUEL FILTER HOUSING BOTTOM SECTION
few seconds, and then slowly open the fuel valve again.
This will reset the excess fuel valve. Figure 60. Fuel Filter Removal and Installation
6. Slowly open the fuel valve on tank.
7. Turn the key to the ON position and back to the OFF

position, or of lift truck is equipped with a keyless
67
IN-LINE FILTER REPLACEMENT,

CUMMINS 4.5L ENGINE CAUTION
Drain the fuel into a container and dispose in accor-
CAUTION
Disposal of lubricants and fluids must meet local 3. Loosen clamps and disconnect two fuel lines from
environmental regulations. the inline fuel filter. Remove and discard the inline
fuel filter.
contaminants from adversely affecting the diesel fuel Install
flow.
1. Install inline fuel filter by connecting the two fuel
Remove lines and tighten clamps. See Figure 61.
1. Stop Engine and allow it to cool. 2. Open the fuel supply valve.
2. Close fuel supply valve located on the fuel sending 3. Check for fuel leaks.
unit. See Figure 61.

A. RIGHT SIDE VIEW B. FRONT VIEW
1. FUEL FILTER ELEMENT 6. FUEL SUPPLY VALVE
2. DRAIN VALVE 7. FUEL SENDING UNIT
3. LIFT PUMP 8. FUEL FILTER SENSOR CONNECTOR
4. FUEL PUMP 9. AIR INLET ELBOW
5. INLINE FUEL FILTER 10. FUEL LINE INJECTOR FITTINGS (4)
68
Figure 61. Cummins 4.5L Engine Fuel System
69
LIFT CHAINS WEAR CHECK Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
If a section of chain is 3% longer than a similar section that the path of the compressed air is away from all
of new chain, the chain is worn and must be replaced. personnel. Wear protective goggles or a face shield
Measure chain for wear where it moves over sheaves. to prevent injury to the eyes.
Using a chain scale, (Yale P/N 518096869) check lift
chains as shown in Figure 62. Remove the lift chains. Clean the lift chains by soaking
them in a solvent that has a petroleum base for at least
30 minutes. Use compressed air, adjusted to a maxi-
mum output of 103 kPa (15 psi), to completely dry the
chains when they are clean.
Lubricate the lift chains by soaking them in 30W engine

oil for at least 30 minutes. Remove the chains from the
oil. Hang the chains for one hour so excess oil will drain
from the chains.
INTEGRAL SIDESHIFT CARRIAGE, CHECK

SLIDING SURFACES
1. Check the sideshift carriage sliding surfaces, and
if necessary lubricate sliding surface at grease fit-
tings with multipurpose grease shown in the Main-
tenance Schedule. See Figure 63.
2. Clean the bearing strip areas. Inspect the sideshift

bearing strips for wear as follows:
a. Remove upper bearing strips from cylinder

Pitch Wear Limit body. If either upper bearing strip is worn to
Total Length of
(The Maximum less than 2.0 mm (0.08 in.) thickness, replace
20 Links (Pitch)
Length of 20 all upper bearing strips by driving the upper
of New Chain
Links) bearing strips from the cylinder body. See Fig-
12.7 mm 254.0 mm 261.6 mm ure 63. Install new upper bearing strips onto
(0.50 in.) (10.0 in.) (10.3 in.) cylinder body. See Parts Manual.
15.9 mm 317.5 mm 327.0 mm
b. Remove lower bearing strips from carriage
(0.63 in.) (12.5 in.) (12.9 in.)
apron. If either lower bearing strip is worn to
19.1 mm 381.0 mm 392.4 mm
less than 2.0 mm (0.08 in.) thickness, replace
(0.75 in.) (15.0 in.) (15.4 in.)
all lower bearing strips by prying the lower
25.4 mm 508.0 mm 523.3 mm
bearing strips from carriage apron. See Fig-
(1.00 in.) (20.0 in.) (20.6 in.)
ure 63. Install new lower bearing strips onto
carriage apron. See Parts Manual.
1. CHAIN WEAR SCALE
Figure 62. Lift Chains Check
LIFT CHAIN LUBRICATION
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.
70
STEERING AXLE (SPINDLE BEARINGS)

FOR LIFT TRUCK MODELS GC/GLC080,
100, 120VX; GC/GLC080, 100VXBCS;
GC/GLC120SVX; GC/GLC120VXPRS
(E818)
Lubricate the spindle bearings on the steering axle.
There are four lubrication fittings, two on each side of
the steering axle. Use multipurpose grease as shown
1. CAPSCREWS
2. LOWER HOOK
3. APRON
4. LOWER BEARING STRIPS
5. UPPER BEARING STRIPS
6. GREASE FITTINGS
7. CYLINDER ROD
8. SNAP RING
9. ROD SCRAPER
10. ROD BUSHING
11. SEAL
12. FIXED FRAME
Figure 63. Integral Sideshift Carriage
1. STEERING AXLE
2. LUBRICATION FITTING (TIE ROD)
3. LUBRICATION FITTING (SPINDLE BEARINGS)
Figure 64. Lubricate Spindle Bearings for Lift Truck

Models GC/GLC080, 100, 120VX; GC/GLC080,
(E818)
STEERING AXLE (SPINDLE BEARINGS)

FOR LIFT TRUCK MODELS
GP/GLP/GDP080, 090, 100, 110, 120VX
(F813, G813)
Lubricate the spindle bearings on the steering axle.
There are four lubrication fittings, two on each side of
the steering axle. Use multipurpose grease as shown
71
Maintenance Procedures Every 2000 Hours or Annually 8000 YRM 1248
CONTROL LEVERS AND PEDALS

Lubricate linkages, pedal shafts, control cables (throttle,
hood, parking brake), and seat rails. Use a silicone
spray lubricant, Yale Part No. 504236201.
INSPECT ENGINE ELECTRICAL SYSTEM,

CONNECTORS
When inspecting the electrical system, check the follow-
ing:
• Check and clean battery connection. Ensure that

connections are tight.
• Check battery for damage or cracks to the case. Re-
place if necessary.
• Check positive and negative cables for corrosion, rub-
bing, and chaffing. Tighten connections at both ends.
• Check engine wire harness for rubbing, chaffing,
pinching, and cracks or breaks in the wiring.
• Check engine harness connectors. Check to ensure
connectors are fitted and locked by pushing the con-
nectors together. Pull on the connector halves to
make sure they are locked.
1. LUBRICATION FITTING (TIE ROD) • Check ignition coil wire and spark plug wires for hard-
2. LUBRICATION FITTING (SPINDLE BEARINGS) ening, cracking, arching, chaffing, separation, split
3. STEERING AXLE boot covers, and proper fit. Replace spark plugs at
the recommended interval as shown in the Mainte-
Figure 65. Lubricate Spindle Bearings for Lift
nance Schedule.
Truck Models GP/GLP/GDP080, 090, 100, 110,
• Check that all electrical components are securely
120VX (F813, G813)
mounted and retained to the engine or chassis.
• Check the MIL, charging, and oil pressure lights for
operation by starting the engine and checking that the
light illuminates before turning out.
Maintenance Procedures Every 2000 Hours or Annually

NOTE: Perform the 8-hour, 250-hour, 500-hour, and Dirt can cause damage to the components of the
1000-hour checks prior to performing the procedures hydraulic system.
in this section.
HYDRAULIC SYSTEM hydraulic system. The operation of the hydraulic
pump without oil will damage the pump.
Hydraulic Filter, Replace
CAUTION
WARNING Disposal of lubricants and fluids must meet local
At operating temperature, the hydraulic oil is HOT. environmental regulations.
cause a burn. 1. Put lift truck on a level surface and lower the car-
riage. Unscrew and remove filter lid, gasket, and
spring from head. See Figure 66. Lift the hydraulic
CAUTION filter element enough to allow the hydraulic oil to
DO NOT permit dirt to enter the hydraulic system drain.
when the oil level is checked or the filter is changed.
72
8000 YRM 1248 Maintenance Procedures Every 2000 Hours or Annually
NOTE: Have container large enough to hold the filter

element and allow for final hydraulic oil draining.
2. Remove the hydraulic filter element and O-ring from

the bowl and place into the container. Cover the
head to prevent any foreign materials from getting
into the hydraulic tank.
3. Lubricate new O-ring with hydraulic oil and install it

on the bottom of the new filter element. Install the
new filter element into the bowl.
4. Inspect gasket for damage. If damaged, replace.
5. Lubricate gasket with hydraulic oil and seat it on

filter lid and install spring and lid onto head. Tighten
lid to 15 N•m (132.8 lbf in).
CAUTION
Additives may damage the hydraulic system. Be-
fore using additives, contact your local Yale dealer.
6. Start the truck, and allow it to run for 30 seconds.

Check for leaks. Stop engine and check hydraulic
oil level. Add oil, if necessary. Use hydraulic oil
shown in the Maintenance Schedule. To change
the hydraulic oil, see Hydraulic Oil, Replace.
1. LID 6. FITTING
2. SPRING 7. QUAD RING
3. O-RING 8. FILTER ELEMENT
4. CAPSCREW 9. BOWL
5. HEAD
Figure 66. Hydraulic Filter
73
Hydraulic Tank Breather, Replace which could be located on either the lower left or
right side of the radiator on the engine side of the
1. Raise the hood and remove the right rear side radiator.
panel. See Figure 67.
2. Unscrew and remove old hydraulic tank breather, WARNING

and replace with new hydraulic tank breather. DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
3. Install right rear side panel and close hood. See removed, the pressure is released from the system.
Figure 67. If the system is hot, the steam and boiling coolant
can cause burns. DO NOT remove the cover for the
radiator when the engine is running.
CAUTION
2. Open drain valve and remove radiator cap. Drain

coolant into the container. Flush cooling system.
Check hoses for damage. Replace with new hoses,
as needed.
3. Disconnect the hose leading from the auxiliary

reservoir to fitting at the top of the radiator un-
der the radiator cap, and drain the reservoir into
the same container used for the radiator coolant.
Check the reservoir for contaminants and flush, as
necessary. Connect the hose back on the fitting at
the top of the radiator.
1. HOOD/SEAT ASSEMBLY CAUTION

2. RIGHT REAR SIDE PANEL Additives may damage the cooling system. Before
3. HYDRAULIC TANK BREATHER using additives, contact your local Yale dealer.
Figure 67. Hydraulic Tank Breather 4. Close drain valve. Fill cooling system with a solu-
tion of ethylene glycol boron-free antifreeze. See
IGNITION SYSTEM; DISTRIBUTOR CAP, Maintenance Schedule for correct solution. Fill the
ROTOR, AND SPARK PLUG WIRES auxiliary reservoir to a level between the ADD and
FULL marks on the reservoir.
NOTE: Make sure the key is in the OFF position or, if
lift truck is equipped, press Power ON/OFF button OFF, 5. Install radiator cap. Start engine. Check for
and the negative battery cable has been removed from leaks. Add coolant to auxiliary coolant reservoir as
the battery before removing the ignition system. needed. Coolant level should be between the ADD
and FULL marks on the reservoir.
Remove and discard spark plug wire assembly, coil
wire, spark plugs, distributor cap, and rotor. For proce- AIR FILTER
dures see High Voltage Switch (HVS) Ignition, GM
4.3L EPA Compliant Engines and GM 5.7L LPG EPA The air filter canister should not be opened until an air
Compliant Engines 2200 YRM 1097. filter element replacement is required. An air filter ele-
ment replacement is required when one of the following
COOLING SYSTEM occurs:
• The optional air flow restriction indicator light on the
1. Put lift truck on a level surface. Stop engine. Refer dash illuminates.
to the Maintenance Schedule for coolant quantity • The optional manual air flow indicator button pops up.
and place a container under the radiator drain valve
74
• The specified number of hours has passed since the 6. Install liner assembly into canister by pushing in.
last filter element replacement. Make sure liner assembly is properly seated in the
canister. It will fit snugly into and be centered in the
canister.
CAUTION
DO NOT to allow dirt to enter the engine air in- If your air filter assembly is equipped with a sec-
take when replacing the air filter element. A small ondary element in place of the liner assembly, re-
amount of dirt could cause engine damage. place the secondary element with every 2 to 3 pri-
mary element replacements.
1. Shut off engine. Never open air filter canister or
remove filter element with engine running. 7. Inspect the new filter element for voids, cuts, tears
or indentations in the urethane-sealing surfaces.
2. Unlatch and remove cover. To remove filter ele- Do not use if damage is detected.
ment, press and rotate filter element counterclock-
wise about 1/8 turn until the filter element is free. To
assist removal, gently move the end back and forth CAUTION
to help break the seal. See Figure 68. The element must be properly installed to ensure
adequate engine protection. An improperly in-
3. Gently pull the filter element from the canister. stalled element may allow dirt and dust to enter
Avoid dislodging contaminants from the element or and damage the engine.
knocking it against the canister.
NOTE: Proper element installation is required to allow
4. With a clean, soft rag, clean the inside surface of the the cover to be installed correctly. Never reinstall a used
canister. Remove liner assembly to make clean- element. Never install a damaged element. Always use
ing easier. Clean well around the locking tabs that a Yale-approved filter element.
retain the element. Clean tabs make new filter el-
ement installation easier. Be careful not to knock 8. Install the new filter element into the canister. Press
any contaminants into the outlet tube to the engine. and rotate the filter element 1/8 turn clockwise until
fully engaged in the canister. See Figure 69.
5. Inspect liner and O-ring assembly for damage. If
damaged, replace liner and O-ring assembly.
1. CANISTER 4. FILTER ELEMENT

2. DUST EVACUATION VALVE 5. COVER
3. LINER ASSEMBLY
Figure 68. Air Filter
75
OXYGEN SENSOR GM 4.3L LPG ENGINES

WITH GFI INSTALLED
Check that the oxygen sensor electrical connector
is seated and locked. Check wires for cracks, splits,
chaffing, or burn through. If necessary, repair.

• GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
G813) and GC/GLC080, 100, 120VX; GC/GLC080,
(E818)
1. PUSH IN 2. TWIST TO LOCK See Figure 71 for lift truck models

• GC/GLC080, 100VXBCS (E818)
Figure 69. Air Filter Label
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 canister.
NOTE: If the filter element is properly installed, the

cover will fit easily into the canister with no gap between
the cover and the canister. If cover does not fit easily,
the filter element is not installed properly. Do not use a
cover that is bent, damaged, or missing latches.
9. Install cover into the canister and ensure the INLET

arrow is in line with the canister inlet.
1. OXYGEN SENSOR
2. ELECTRICAL CONNECTOR
NOTE: Do not use latches to pull cover down against 3. EXHAUST PIPES TO EXHAUST MANIFOLD
the canister. If cover does not fit completely against
the canister with no gaps, the element is not installed Figure 70. Oxygen Sensor Location for Lift
correctly. Truck Models GP/GLP/GDP080, 090, 100, 110,
120VX (F813, G813) and GC/GLC080, 100,
10. Fasten the latches to secure the cover to the can- 120VX; GC/GLC080, 100VXBCS, GC/GLC120SVX,
ister. Make sure the latches penetrate the slots in GC/GLC120VXPRS (E818)
both the canister and the cover.
11. Inspect the entire air intake system for leaks. In-
spect all clamps for tightness and tighten if neces-
sary. Inspect all hoses for damage. Replace dam-
aged hoses. Inspect the dust evacuation valve for
damage. If damaged, replace the dust evacuation
valve.
76
Install
1. Install a new screen in the LPG regulator.
2. Install a new O-ring on the outlet fitting. Using three

screws, install the outlet fitting on the LPG regula-
tor.
3. Install new rubber washer, paper filter, foam filter,

and plastic cap in the LPG regulator.
4. Install new O-ring on the inlet fitting. Install inlet

fitting into the LPG regulator and connect hose to
the inlet fitting.
5. Open shutoff valve on LPG tank and check for

leaks.
1. OXYGEN SENSOR (POST-CATALYTIC)

2. MUFFLER
3. OXYGEN SENSOR (PRE-CATALYTIC)
Figure 71. Oxygen Sensor (BCS Only) for Lift Truck

Models GC/GLC080, 100VXBCS (E818)
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. Dis-

card the O-ring. See Figure 72.
4. Remove and discard the plastic cap, foam filter, pa-

per filter, and rubber washer from the LPG regula-
tor. 1. LPG REGULATOR
2. INLET FITTING
5. Disconnect the hose from the outlet fitting. Remove 3. O-RING
three screws and the outlet fitting from the LPG reg- 4. PLASTIC CAP
ulator. Discard the O-ring. 5. FOAM FILTER
6. PAPER FILTER
6. Remove and discard the screen from the LPG reg- 7. RUBBER WASHER
ulator. 8. SCREWS
9. OUTLET FITTING
10. SCREEN
Figure 72. GM LPG Regulator
77
GASOLINE FUEL FILTER Remove and Replace for Lift Trucks

Equipped with PSI
Remove and Replace for Lift Trucks
Equipped with GFI 1. Raise the hood and disconnect the negative termi-
nal of the battery.
1. Raise the hood and disconnect the negative termi-
nal of the battery. 2. Remove the hose clamps on the return tube and
fuel filter. See Figure 74.
2. Remove and discard the fuel filter. See Figure 73.
3. Remove the return tube and set aside. See Fig-
3. Install the new fuel filter and tighten the clamp ure 74.
screws to 2.45 to 2.77 N•m (22 to 25 lbf in).
4. Remove the capscrew and nut in the clamp holding
4. Connect the negative terminal of the battery and the fuel filter. Remove clamp from fuel filter. See
close the hood. Figure 74.
5. Remove the supply hose from the fuel filter. See

Figure 74.
6. Remove the fuel filter from the supply tube and dis-
card the fuel filter. See Figure 74.
7. Install clamp on new fuel filter.
8. Connect the fuel filter to the supply tube. See Fig-

ure 74.
9. Connect the fuel supply hose to the fuel filter. Install

hose clamps on the fuel supply hose and the supply
tube as shown in Figure 74.
10. Install fuel filter and clamp on the manifold bracket

using the capscrew and nut. See Figure 74.
11. Install the return tube and return tube hose clamps.
See Figure 74.
12. Connect the negative terminal of the battery and

1. FUEL FILTER close the hood.
2. FUEL PUMP/SENDER UNIT
Figure 73. Fuel Filter Replacement (GM 4.3L with

GFI)
78
FUEL INJECTOR, CUMMINS 4.5L AND

QSB 3.3L ENGINE
For removal and cleaning instructions for lift truck mod-
els GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
G813) equipped with the Cummins 4.5L or QSB 3.3L
diesel engine, contact your local Yale dealer or see Yale
Axcess Online.
FORKS
WARNING
Never repair damaged forks. DO NOT heat, weld,
cut, drill, or bend the forks. Forks are made of spe-
cial steel using special methods. Replace damaged
forks as a set.
Check heel and attachment points of forks with a pen-

etrant or by magnetic particle inspection.
TRANSMISSION OIL AND FILTER (DRY

BRAKE), REPLACE
WARNING
1. HOSE CLAMP At operating temperature, the transmission oil is
2. NUT HOT. DO NOT permit the hot oil to touch the skin
3. CAPSCREW and cause a burn.
4. SUPPLY TUBE
5. RETURN TUBE
6. CLAMP CAUTION
7. FUEL FILTER
8. FUEL SUPPLY HOSE DO NOT permit dirt to enter the transmission when
9. MANIFOLD BRACKET the oil level is checked or the filter is changed. Dirt
can cause damage to the transmission compo-
Figure 74. Fuel Filter Replacement (GM 4.3L with nents.
PSI)
LPG FUEL INJECTOR, GM 4.3L ENGINES CAUTION

WITH GFI INSTALLED environmental regulations.
For removal and cleaning instructions, see the section
NOTE: Change the transmission oil filter at the first 500
LPG Fuel System, GM 4.3L Engine With GFI 900
hours of operation on new lift trucks. Before removing
YRM 1242.
the oil filter, make a hole at the top of the filter and allow
five minutes for the oil to drain down into the transmis-
GASOLINE FUEL INJECTOR, GM ENGINES
sion. This will reduce the oil that will run out of the filter
For removal and cleaning instructions, see the section and onto the transmission when the filter is removed.
Gasoline Fuel System, GM 4.3L Engine WITH GFI
NOTE: The drain plug for the transmission is on the
900 YRM 1244 and Gasoline Fuel System PSI GM
lower right side of the cover of the transmission, toward
4.3L 900 YRM 1570.
the rear of the lift truck.
1. Remove drain plug, spring, and screen. See Fig-

ure 75. Drain oil into a container.
79
the path of the compressed air is away from all per-

sonnel. Wear protective goggles or a face shield to
prevent injury to the eyes.
2. Clean screen with cleaning solvent, and dry with

compressed air, adjusted to a maximum output of
103 kPa (15 psi).
3. When oil has drained, first install screen, then

spring, and drain plug.
4. Remove and discard transmission breather. Install

new transmission breather and hand tighten.
5. Remove and discard old oil filter. Apply clean oil

to gasket of new filter. Install new filter and hand
tighten.
6. Add oil to transmission at the dipstick tube. The

correct oil is shown in the Maintenance Schedule.

NOTE: ALL MAJOR COMPONENTS AND FRAME 50°C (120°F) when checking oil level.
COMPONENTS REMOVED FOR THE SAKE OF
CLARITY. 7. Start and run the engine for approximately five min-
utes after fill to allow oil to lubricate parts within
1. TRANSMISSION
2. TRANSMISSION DRAIN PLUG the transmission and wet brake portion of the drive
3. SPRING axle center section. With truck in the ON position,
4. SCREEN see Maintenance Schedule to add additional oil at
5. TRANSMISSION OIL FILTER the transmission dipstick tube that will need to be
6. TRANSMISSION DIPSTICK added to properly fill the wet brake portion of the
7. TRANSMISSION BREATHER
drive axle center section and transmission.
Figure 75. Transmission Oil Change
50°C (120°F) when checking oil level.
WARNING
Cleaning solvents can be flammable and toxic and 8. Turn the key to the OFF position or push the Power
can cause skin irritation. When using cleaning ON/OFF button OFF if lift truck is equipped with this
solvents, always follow the solvent manufacturer’s option, and check for leaks and check oil level. If
recommended safety procedures. necessary, top off oil.
Compressed air can move particles so they cause

80
TRANSMISSION AND WET BRAKE

PLANETARY CARRIER HOUSING OIL
CHANGE
WARNING
The oil used for the wet brake drive axle or trans-
mission should not be contaminated. If either the
wet brake planetary carrier housings and/or trans-
mission oil becomes contaminated, the oil must be
drained and replaced with new oil.
WARNING
At operating temperature, the transmission and wet
brake planetary carrier housing 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 transmission or wet NOTE: ALL MAJOR COMPONENTS AND FRAME
brake planetary carrier housing when the oil level COMPONENTS REMOVED FOR CLARITY.
is checked or the filter is changed. Dirt will con-
taminate the oil and cause damage to the transmis- 1. TRANSMISSION
sion and wet brake planetary carrier housing com- 2. TRANSMISSION DRAIN PLUG
3. SPRING
ponents. 4. SCREEN
5. TRANSMISSION OIL FILTER
6. TRANSMISSION DIPSTICK
CAUTION 7. TRANSMISSION BREATHER
environmental regulations. Figure 76. Transmission Oil Change
NOTE: Change the transmission oil filter at the first 500 2. Remove planetary carrier housing drain plug and
hours of operation on new lift trucks. See Figure 76. fill/level plug. Drain oil into a suitable container.
Before removing the oil filter, make a hole at the top of When oil is completely drained, reinstall drain plug
the filter and allow five minutes for the oil to drain down and fill/level plug. Tighten to 30 to 50 N•m (22 to
into the transmission. This will reduce the oil that will 37 lbf ft).
run out of the filter and onto the transmission when the
filter is removed. See Figure 77 for lift truck models
• GC/GLC080, 100, 120VX; GC/GLC080,
1. The drain plug for the transmission is on the lower 100VXBCS; GC/GLC120SVX; GC/GLC120VX-
right side of the cover of the transmission, toward PRS (E818)
the rear of the lift truck. Remove drain plug, spring,
and screen. Drain oil into a container, once oil is See Figure 78 for lift truck models
completely drained, reinstall drain plug. See Fig- • GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
ure 76. G813)
81
A. REAR VIEW SHOWN

B. FRONT VIEW SHOWN
1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
2. PLANETARY CARRIER HOUSING DRAIN
PLUGS
3. CENTER BODY DRAIN PLUG
4. CENTER BODY FILL/LEVEL PLUG
6. PLANETARY CARRIER HOUSING (LH) A. REAR VIEW SHOWN
7. CENTER BODY B. FRONT VIEW SHOWN
Figure 77. Wet Brake Drive Axle Drain and 1. PLANETARY CARRIER HOUSING FILL/LEVEL
PLUGS
Fill/Level Plug Location for Lift Truck Models 2. PLANETARY CARRIER HOUSING DRAIN
GC/GLC080, 100, 120VX, GC/GLC080, 100VXBCS, PLUGS
GC/GLC120SVX, GC/GLC120VXPRS (E818) 3. CENTER BODY FILL/LEVEL PLUG
6. PLANETARY CARRIER HOUSING (LH)
7. CENTER BODY
Figure 78. Wet Brake Drive Axle Drain and

Fill/Level Plug Location for Lift Truck Models
GP/GLP/GDP080, 090, 100, 110, 120VX (F813, G813)
82
WET BRAKE CENTER SECTION OIL

WARNING
CHANGE
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning Remove
solvents, always follow the solvent manufacturer’s
recommended safety procedures. 1. Remove the center body fill/level plug. Removing
the fill/level plug will allow the oil to drain at a faster
Compressed air can move particles so they cause rate.
the path of the compressed air is away from all per- See Figure 77 for lift truck models
sonnel. Wear protective goggles or a face shield to • GC/GLC080, 100, 120VX; GC/GLC080,
prevent injury to the eyes. 100VXBCS; GC/GLC120SVX; GC/GLC120VX-
PRS (E818)
3. Clean screen with cleaning solvent, and dry with
compressed air, adjusted to a maximum output of See Figure 78 for lift truck models
103 kPa (15 psi). • GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
G813)
4. When oil has drained, first install screen, then
spring, and drain plug. 2. Place and empty container under the center body
drain plug.
5. Remove and discard transmission breather. Install
new transmission breather and hand tighten. 3. Remove the center body drain plug, and wait until
oil has drained completely.
6. Remove and discard old oil filter. Apply clean oil
to gasket of new filter. Install new filter and hand Install
tighten.
1. Install drain plug for the center body. Tighten to 30
7. Add oil to transmission at the dipstick tube. The to 50 N•m (22 to 37 lbf ft).
correct oil is shown in the Maintenance Schedule.
8. Start and run the engine for approximately five min- • GC/GLC080, 100, 120VX; GC/GLC080,
utes after fill to allow oil to lubricate parts within the 100VXBCS; GC/GLC120SVX; GC/GLC120VX-
transmission and wet brake planetary carrier hous- PRS (E818)
ings. With the truck in the ON position, see Mainte-
nance Schedule to add additional oil at the trans- See Figure 78 for lift truck models
mission dipstick tube that will need to be added • GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
to properly fill the planetary carrier housings and G813)
transmission.
See Figure 77 for lift truck models CAUTION

• GC/GLC080, 100, 120VX; GC/GLC080, Before adding oil, ensure the truck is parked and on
100VXBCS; GC/GLC120SVX; GC/GLC120VX- level ground.
PRS (E818)
2. Add oil at the fill/level port for the center body un-
See Figure 78 for lift truck models til the oil/fill level port has overflowed. The correct
• GP/GLP/GDP080, 090, 100, 110, 120VX (F813, oil is shown in the Maintenance Schedule or in Fig-
G813) ure 79.
NOTE: Transmission oil temperature should be at least See Figure 77 for lift truck models
50°C (120°F) when checking oil level. • GC/GLC080, 100, 120VX; GC/GLC080,
100VXBCS; GC/GLC120SVX; GC/GLC120VX-
9. Turn the key to the OFF position or push the Power PRS (E818)
ON/OFF button OFF if lift truck is equipped with this
option, and check for leaks and check oil level. See Figure 78 for lift truck models
• GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
G813)
83
A. RIGHT PLANETARY CARRIER HOUSING - USE C. CENTER BODY - USE SAE 80W/90
JDM J20C
B. LEFT PLANETARY CARRIER HOUSING - USE
JDM J20C
1. PLANETARY FILL/LEVEL PLUGS 5. RIGHT PLANETARY CARRIER HOUSING
2. PLANETARY DRAIN PLUGS 6. LEFT PLANETARY CARRIER HOUSING
3. CENTER BODY FILL/LEVEL PLUG 7. CENTER BODY
Figure 79. Oil Application Diagram
3. Install oil fill/level plug. Tighten to 30 to 50 N•m (22 water entry. Ensure that the sealed reservoir lid is
to 37 lbf ft). properly replaced.
BRAKE OIL (MASTER CYLINDER),

CAUTION
CHANGE
1. Remove dashboard from cowl. a sealed container to prevent possible damage to
the brake system.
CAUTION 3. Remove the brake oil reservoir cover and cylindri-
Disposal of lubricants and fluids must meet local cal block drain plug. Pour the oil into a suitable
environmental regulations. container with a 0.35 liter (0.74 pt) minimum capac-
ity. Install the cylindrical block drain plug. Refill the
2. Remove brake oil reservoir from bracket on cowl. reservoir with clean oil from a sealed container and
See Figure 80. install the cover on the reservoir. The correct oil is
shown in the Maintenance Schedule.
WARNING
4. Install the reservoir into the bracket located on the
Small amounts of water in the brake system can cowl. See Figure 80.
reaches the wheel cylinder areas. DO NOT allow
84
3. Loosen bleed screw at wheel cylinder one turn so

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

the color will be more clear than the used oil which will
be darker.
4. Repeat Step 1 through Step 3 until there is new

brake oil in the container.
5. Check the level of brake oil in the reservoir for the

master cylinder during the procedure. Make sure to
keep the brake oil at the correct level.
6. Repeat procedure for the other wheel cylinder.
SERVICE BRAKES (DRY BRAKE)

Check brake lining and parts of the brake assembly for
wear or damage. The minimum acceptable brake lin-
ing thickness is 1.0 mm (0.040 in.). If brake linings are
worn thinner than the specification, replace the brake
linings. See section Brake System 1800 YRM 1247
for the removal and installation procedures of the drive
1. RESERVOIR CAP
2. BRAKE OIL RESERVOIR wheels and brake drums. If the brake linings or brake
3. RESERVOIR MOUNTING BRACKET shoes are worn or damaged, they must be replaced.
4. COWL Brake shoes must be replaced in complete sets. In-
5. UPPER BRAKE OIL SUPPLY HOSE spect brake drums for cracks or damage. Replace any
6. CYLINDRICAL BLOCK OUTLET FITTING damaged parts.
7. LOWER BRAKE OIL SUPPLY HOSE
8. NIPPLE
9. MASTER CYLINDER WARNING
10. CYLINDRICAL BLOCK DRAIN PLUG
11. CYLINDRICAL BLOCK Brake linings can contain dangerous fibers.
12. CYLINDRICAL BLOCK MOUNTING BRACKET Breathing the dust from these brake linings is
CAPSCREW a cancer or lung disease hazard. DO NOT create
dust! DO NOT clean brake parts with compressed
Figure 80. Brake Oil Change air or by brushing. Follow the cleaning procedure
in this section. When the brake drums are removed,
BRAKE OIL (DRY BRAKE), REMOVE DO NOT create dust.
Perform the following procedure to remove used brake DO NOT sand, grind, chisel, hammer, or change lin-
oil from the remainder of the brake system. ings in any way that will create dust. Any changes
1. Ensure that the master cylinder reservoir is filled to brake linings must be done in a restricted area
with brake oil. with special ventilation. Protective clothing and a
respirator must be used.
NOTE: Two people are needed to perform procedure
described below.
2. Put one end of a rubber hose on the bleed screw

of the wheel cylinder. Put other end of hose into a
empty container.
85
Brake cleaning procedures are as follows: See Figure 82 for lift truck models
• GP/GLP/GDP080, 090, 100, 110, 120VX (F813,
G813)
CAUTION
DO NOT use an oil solvent to clean the wheel cylin-
der. Use a solvent approved for cleaning of brake
parts. DO NOT permit oil or grease in the brake fluid
or on the brake linings.
1. DO NOT release brake lining dust from brake lin-

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

to wet lining dust. Follow the instructions and cau-
tions of the manufacturer for the use of the solvent.
If a solvent spray is used, do not create brake lining
dust with the spray.
3. When the brake lining dust is wet, clean parts. Put

any cloth or towels in a plastic bag or an airtight
container while they are still wet. Put a DANGER-
OUS FIBERS warning label on the plastic bag or
airtight container.
4. Any cleaning cloths that will be washed must be

cleaned so that fibers are not released into the air.
1. DRIVE AXLE 3. DRAIN PLUG
2. CHECK/FILL PLUG
DIFFERENTIAL (DRY BRAKE)
NOTE: Additional information on the differential can be
Figure 81. Drive Axle (Dry Brake) Fluid
found in Drive Axle and Differential Assembly Re-
Fill for Lift Truck Models GC/GLC/GDC080,
pair, (Dry Brake) 1400 YRM 1245.
100, 120VX; GC/GLC/GDC080, 100VXBCS;
GC/GLC/GDC120SVX; GC/GLC/GDC120VXPRS
1. Place lift truck on blocks. See How to Raise Drive (E818)
Tires in this manual.
2. The differential and drive axle use the same oil sup-
ply. Place a container with a minimum capacity of
5 liter (5.3 qt) under the differential. Remove drain
plug located in the bottom of the differential and
drain the oil from the differential completely. Install
the drain plug.
3. The fill hole is on the front of the differential housing.

Add oil shown in the Maintenance Schedule until
the oil level is at the lower edge of the fill hole. Install
fill plug and rotate the drive wheels in order to get
oil pumped into the axle. Remove the fill plug and
check the oil level. Add oil, as necessary. Install fill
plug and check for leaks.

• GC/GLC/GDC080, 100, 120VX; GC/GLC/
GDC080, 100VXBCS; GC/GLC/GDC120SVX;
Figure 82. Drive Axle (Dry Brake) Fluid Fill for
GC/GLC/GDC120VXPRS (E818)
Lift Truck Models GP/GLP/GDP080, 090, 100, 110,
120VX (F813, G813)
86
Legend for Figure 82 3. Tighten the lock nut to 24 N•m (212 lbf in) and mea-
sure valve lash.
1. CHECK/FILL PLUG 3. DRIVE AXLE
2. DRAIN PLUG 4. Mark the vibration damper and rotate the crankshaft
360 degrees. See Figure 85.
TEST LPG/GAS REGULATOR PRESSURE
5. Perform Step 2 and Step 3 to adjust ONLY the
For more information regarding the Test LPG/GAS Reg- valves shown in Figure 86. See the Maintenance
ulator Pressure, see the section LPG Fuel System, GM Schedule for valve clearances.
4.3L Engine With GFI 900 YRM 1242 and Gasoline
Fuel System, GM 4.3L Engine WITH GFI 900 YRM
1244.
CHECK THROTTLE SHAFT FOR STICKING

Check Throttle body return action to ensure throttle
shaft is not sticking. Repair if necessary.
INSPECT EXHAUST MANIFOLD AND

PIPING FOR LEAKS
To check the exhaust manifold and piping for leaks, per-
form 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 necessary.
• Check all exhaust pipe extension connectors for leaks
and tighten, if necessary.
• Visually inspect converter for correct muffler mount- 1. CRANKSHAFT PULLEY
2. DRIVE BELT
ing and tail pipe mounting. 3. ENGRAVE TIMING MARK
• Check for any leaks at the inlet and outlet of the con-
verter. Figure 83. Cummins QSB 3.3L TDC Mark
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.
Check the valve clearance and make adjustments as

needed. To adjust the valve clearances do the following:
1. Align the TDC mark on the crankshaft pulley with

the engraved mark on the block. See Figure 83.
1. EXHAUST VALVE 4. CYLINDER 2
2. Adjust ONLY the valves shown in Figure 84, by 2. INTAKE VALVE 5. CYLINDER 3
loosening the locknut with a wrench and adjusting 3. CYLINDER 1 6. CYLINDER 4
the valve clearance using a screwdriver or Allen
wrench. Figure 84. Cummins Valve Adjustment
87
Maintenance Procedures Every 4000 Hours or 2 Years 8000 YRM 1248

2. INTAKE VALVE 5. CYLINDER 3
3. CYLINDER 1 6. CYLINDER 4
1. TIMING PIN
2. VIBRATION DAMPER Figure 86. Cummins Valve Adjustment
Figure 85. Cummins Vibration Damper WHEEL BEARINGS
Steer Wheels, Lubrication
Lubricate the wheel bearings in the hubs for the steer
wheels with multipurpose grease as shown in the Main-
tenance Schedule. See Steering Axle 1600 YRM 1133
for the procedures.
Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform the 8-hour, 250-hour, 500-hour, 1000- NOTE: Heavy-duty or contaminated applications will re-
hour, and 2000-hour checks prior to performing the pro- quire hydraulic oil change at 2000 hours.
cedures in this section.
NOTE: Replace the hydraulic oil filter at the same time
HYDRAULIC OIL, REPLACE the oil is changed.
1. Replace hydraulic oil as described below:

WARNING
At operating temperature the hydraulic oil is HOT. a. Place a container with a minimum capacity of
DO NOT permit the hot oil to touch the skin and 39.4 liter (42 qt) under the drain plug at the
cause a burn. bottom of the hydraulic tank. To drain the oil,
remove drain plug from the bottom of the hy-
draulic tank. See Figure 87.
CAUTION
DO NOT permit dirt to enter the hydraulic system b. When tank is empty, inspect the inside of the
when the oil level is checked or the filter is changed. tank for any foreign matter or possible fungus.
Dirt can cause damage to the components of the If necessary, clean the inside of the tank in ac-
hydraulic system. cordance with the instructions found in section
Frame 100 YRM 1243.
hydraulic system. The operation of the hydraulic c. When either the inspection or the cleaning of
pump without oil will damage the pump. the tank is completed, install drain plug in the
bottom of the hydraulic tank. Tighten drain plug
to 38 N•m (28 lbf ft).
CAUTION
88
8000 YRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years
1. Rotate the engine until it is at TDC for cylinder num-

CAUTION ber one (intake and exhaust valves closed). Insert
Additives may damage the hydraulic system. Be- timing pin. See Figure 88.
fore using additives, contact your local Yale dealer.
2. Adjust ONLY the valves shown in Figure 89, by
2. Fill hydraulic tank with oil specified in the Mainte- loosening the lock nut with a wrench and adjusting
nance Schedule. the clearance using a screwdriver or Allen wrench.
3. When oil level is correct, operate system and check 3. Tighten the lock nut to 24 N•m (18 lbf in) and mea-
for leaks. sure valve lash.
VALVE CLEARANCE, CHECK AND 4. Remove the timing pin. See Figure 88.
ADJUST FOR CUMMINS 4.5L DIESEL 5. Mark the vibration damper and rotate the crankshaft
ENGINE 360 degrees. See Figure 90.
The Cummins 4.5L engine does not require valve clear- 6. Perform Step 2 and Step 3 to adjust ONLY the
ance adjustments during normal service. See the Main- valves shown in Figure 91.
tenance Schedule for valve clearances.
Check the valve clearance and make adjustments as

needed. To adjust the valve clearance, do the following:
1. HYDRAULIC TANK 2. DRAIN PLUG
Figure 87. Hydraulic Oil Change
89
1. INSERT TIMING PIN HERE 3. TIMING BELT

2. FUEL/WATER SEPARATOR FILTER
Figure 88. Timing Pin Location, Cummins 4.5L Diesel Engine

3. CYLINDER 1 6. CYLINDER 4 1. TIMING PIN
2. VIBRATION DAMPER
Figure 89. Cummins Valve Adjustment
Figure 90. Cummins Vibration Damper
90
8000 YRM 1248 Maintenance Procedures Every 4000 Hours or 2 Years
NOTE: Visual inspection supported by dye penetrant

application is recommended with focus on areas de-
fined below.
NOTE: Dye penetrant checks are made in a three-step

process using a cleaner, penetrant, and developer. Fol-
low manufacturers instructions for cleaning the area to
be inspected, then applying penetrant and developer. If
a crack is present, it will show up as a well-defined ma-
roon/red line as the dye penetrant is drawn out into the
white developer coating.
Contact your local Yale dealer for instructions if a crack

1. EXHAUST VALVE 4. CYLINDER 2 is detected.
3. CYLINDER 1 6. CYLINDER 4
1. Carriage inspection: welded joints between cast in-
Figure 91. Cummins Valve Adjustment sert and top and vertical carriage bars. See Fig-
ure 92.
WELD INSPECTION
2. Mast inspection:
Initial inspection is suggested at 4000 hours, with sub-
a. Welded joints of lower crossmember of mast
sequent inspections at 2000 hour intervals. Removal of
outer channel and related gussets. See Fig-
carriage from mast is not required, but recommended,
ure 93.
to perform inspection. Removal of attachment is rec-
ommended for access to carriage. b. Welded joints around tilt anchor and intermedi-
ate cross member. See Figure 93.
A. FRONT VIEW B. REAR VIEW

1. WELDS
Figure 92. Carriage Bar Welds for Inspection
91
NOTE: The welded boss for tilt lock option is typically c. Right side rail of outer mast channel in area
located on right side of mast channel above tilt anchor of welded boss for optional tilt lock rod. See
bracket. Figure 93.
A. TYPICAL "XM" MAST C. WELDED BOSS FOR TILT LOCK OPTION

B. TYPICAL "FT" MAST
1. WELDS
Figure 93. Mast Welds for Inspection
92
8000 YRM 1248 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 sec- install a safety chain to restrain the moving parts of
tion for the specific mast being repaired. the mast. Connect moving parts to a part that does
not move. Follow these procedures:
WARNING a. Put mast in vertical position.

Mast parts are heavy and can move. Distances be-
tween parts are small. Serious injury or death can b. Raise mast to align bottom crossmember of
result if part of the body is hit by parts of the mast weldment that moves in outer weldment with
or the carriage. a crossmember on outer weldment. On the
two-stage and free-lift mast, the moving part is
• Never put any part of the body into or under the the inner weldment. On the three-stage mast,
mast or carriage unless all parts of the mast are it is the intermediate weldment. See Figure 94.
completely lowered or a safety chain is installed.
Also make sure that the power is off and the key c. Use a 3/8-in. minimum safety chain with a
is removed. Put a DO NOT OPERATE tag in the hook to fasten the crossmembers together so
operator’s compartment. the movable member cannot lower. Put the
• Be careful of the forks. When the mast is raised, hook on the back side of the mast. Make sure
the forks can be at a height to cause an injury. the hook is completely engaged with a link in
• DO NOT climb on the mast or lift truck at any time. the chain. Make sure the safety chain does
Use a ladder or personnel lift to work on the mast. not touch lift chains or chain sheaves, tubes,
• DO NOT use blocks to support the mast weld- hoses, fittings, or other parts on the mast.
ments nor to restrain their movement. d. Lower the mast until there is tension in the
• Mast repairs require disassembly and removal of safety chain and the free-lift cylinder (free-lift,
parts and can require removal of the mast or car- three-stage, and four-stage masts only) is com-
riage. Follow the repair procedures in the correct pletely retracted. If running, stop engine. Apply
Service Manual for the mast. parking brake. Install a DO NOT REMOVE tag
NOTE: If there is no power to lower the mast on lift on the safety chain(s).
trucks equipped with Electronic Hydraulic System, e. Install another safety chain (3/8-in. minimum)
there is an emergency load lowering valve located on between the top or bottom crossmember of the
the hoist/lower valve section of the main control valve. carriage and a crossmember on the outer weld-
See the Operating Manual for the procedures to lower ment.
a load using the emergency load lowering valve.
3. Apply parking brake. After lowering or restraining
1. Lower mast and carriage completely. Push lift/lower the mast, shut off power and remove key. Put a DO
control lever forward and make sure there is no NOT OPERATE tag in the operator’s compartment.
movement in the mast. Make sure all parts of the
mast that move are fully lowered.
93
Safety Procedures When Working Near Mast 8000 YRM 1248
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 94. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts
94
8000 YRM 1248 Fuel Filter Water Removal
Fuel Filter Water Removal

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

filter element.
2. To access fuel filter element and drain valve, re-

move the air inlet elbow. See Figure 95.
CAUTION
Drain water/fuel into a container and dispose in ac-
cordance 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
4. Close the drain valve by lifting and turning clockwise
until it is hand-tight. Figure 95. Engine Fuel Filter Drain Valve Location
(Cummins 4.5L Shown)
95
Hood Latch Check 8000 YRM 1248
Hood Latch Check

3. Carefully close hood to fully-closed position. The
WARNING hood latch has two positions. The hood latch is fully
The hood, hood latch, and latch striker must be cor- closed after two clicks of the latch.
rectly adjusted for the correct operation of the op-
erator restraint system. 4. Push down until hood just touches rubber bumper.
Make sure latch striker is still in center of hood latch.
1. Install hood latch on frame of hood. Tighten cap- Open hood and tighten capscrews for latch.
screws so that hood latch can still move when hood
is closed. See Figure 96. 5. Check operation of hood latch. Have an opera-
tor sit in the seat. Make sure hood is fully closed
2. Install latch striker in highest slot position. Check (two clicks). Also check that hood touches rubber
that latch striker is in center of jaws of hood latch bumper. If necessary, repeat Step 4.
when hood closes.
1. LATCH STRIKER 4. HOOD RELEASE HANDLE

2. BUMPER 5. HOOD LATCH
3. HOOD 6. FRAME
Figure 96. Hood Latch Check
96
8000 YRM 1248 Lift Chain Adjustments
Lift Chain Adjustments

WARNING
When working on or near the mast, see Safety Pro-
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 com-
pletely 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-
vent it from falling. Keep all personnel away from
1. MAST
the lift truck during the tests. 2. CARRIAGE
3. FORK
When lift chains are correctly adjusted: 4. HEEL OF FORK IS 6 ±3 mm (0.24 ±0.12 in.)
• Tension will be the same on each chain of chain set. ABOVE THE FLOOR LEVEL.
Check tension by pushing on both chains at the same
time. Figure 97. Lift Chain Adjustments With Forks
• Chain length will be correct. Installed
• Chains must travel freely through complete cycle.
NOTE: When chain adjustments are complete, make

sure threads on nuts of chain anchors are completely
engaged. Make sure all adjustment is not removed from
chain anchors. Chain anchors must be able to move on
their mounting.
1. When adjusting lift chains on forklift trucks

equipped with the forks installed, go to Step 2.
If forklift truck is equipped with an attachment with-
out 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 6 ±3 mm (0.24
±0.12 in.) above floor level. See Figure 97. 1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
3. Adjust chain anchors which support carriage until CARRIAGE BAR
the bottom of lower carriage bar is above the floor
level as shown in Table 2. See Figure 98. Figure 98. Lift Chain Adjustment Without Forks
Installed
97
Jump-Starting the Lift Truck 8000 YRM 1248
In Table 2, the masts are divided by class. Each Table 2. Carriage Chain Adjustment,
class is determined by the lifting capability of the Forks Not Installed
lift cylinders. The Class II mast would have the
lift capability of 2.5-3.5 tons, Class III has the lift 82.5 ±3 mm
Class II and Class III
capability of 3.5-4.0 tons, and Class IV has the lift (3.25 ±0.12 in.)
capability of 4.0-7.0 tons.
133.5 ±3 mm
Class IV
(5.26 ±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 towing To prevent possible arcing between the two lift
the lift truck. Damage to the hydraulic system can trucks, make sure that the lift trucks are not touch-
occur if engine is started by pushing or towing lift ing.
truck.
If the battery becomes discharged and requires a CAUTION

booster battery to start the engine, follow these proce- DO NOT try to start the engine by pushing or towing
dures carefully when connecting the jumper cables. the lift truck. Damage to the hydraulic system can
occur if engine is started by pushing or towing lift
1. Disconnect the negative battery terminal of the lift truck.
truck being started.
1. Always connect positive jumper cable to positive
2. Always connect positive jumper cable to positive terminal of discharged battery and negative jumper
terminal of discharged battery and negative jumper cable to negative terminal.
cable to negative terminal.
2. Always connect jumper cable, that is the ground
3. Always connect jumper cable, that is the ground cable, last.
cable, last.
3. Always connect jumper cables to discharged
4. Always connect jumper cables to discharged bat- lift truck battery before connecting them to the
tery before connecting them to booster battery. fully-charged lift truck battery.
98
8000 YRM 1248 Wheel and Tire Replacement
Welding Repairs
industrial hygiene practices including removal
WARNING of 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 fuel and/or supplied-air respiratory protection.
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 where the CAUTION
welding must be done. When an arc welder is used, always disconnect the
ground cable from the battery in the lift truck. This
DO NOT heat, weld, or bend forks. Forks are action will prevent damage to the alternator or the
made of special steel using special methods. 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 mast. close as possible to the weld area. This action will
prevent damage to a bearing from the large current
Forklift frames and components may be painted from the welder.
with a catalyzed paint such as polyurethane or a
two-part primer. Welding, burning, or other heat Some repairs require welding. If an acetylene or arc
sufficient to cause thermal decomposition of the welder is used, make sure procedures in previous
paint may release isocyanates. These chemicals WARNING and CAUTION are done.
are allergic sensitizers to the skin and respiratory
tract and overexposure may occur without odor See the American National Standard Safety in Welding
warning. Should work be performed, utilize good and Cutting, AWS Z 49.1 - 1999.
Overhead Guard Changes

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

GENERAL SOLID RUBBER TIRE, CHANGE
(GC/GLC SERIES)
The GC/GLC series lift trucks have solid rubber tires
(often called cushion tires) that are pressed onto the Solid rubber tires made from softer or harder material
rim. The GP/GLP/GDP series lift trucks have pneumatic can be installed as optional equipment. The tread on
tires or solid rubber tires that look like pneumatic tires. the solid rubber tires can be either smooth or it can have
These variations in tires also cause a variation in the lugs. DO NOT mix types of tires or tread on lift truck.
types of wheels and the disassembly and assembly pro- See Figure 99.
cedures.
99
Wheel and Tire Replacement 8000 YRM 1248
shown in Figure 99. Also, check the Nameplate of the

WARNING lift truck for the correct tire size and tread width.
The type of solid rubber tire is shown on the Name-
plate. Make sure the Nameplate is correct for the 1. The correct tools, equipment, and a press ring must
type of tires on the lift truck. The 12000 lb. capac- be used for each size of wheel. Use a press to push
ity solid rubber tired fork lift must be equipped with wheel from rim and tire. The capacity of the press
high load capacity steering tires. must be approximately 355 to 1779 kN (80,000 to
400,000 lbf). For the tire sizes, see the Nameplate.
Wheels must be changed and tires repaired by
trained personnel only. 2. When the drive wheels are installed on the lift
truck, tighten wheel nuts to a torque value of 610
Always wear safety glasses. to 680 N•m (450 to 502 lbf ft).
Lift truck tires and wheels are heavy. Use caution 3. The steering wheels are fastened to the spindle
when removing or installing lift truck tires and of the steering axle with a large castle nut. Make
wheels or personal injury can occur. sure inner and outer bearings are correctly lubri-
cated with grease. Install inner bearing assembly
1. Raise lift truck as described in How to Put Lift Truck and wheel on spindle. Install outer bearing cone
on Blocks in this manual. and castle nut. Tighten castle nut up to 203 N•m
2. Remove wheel nuts and remove wheel from lift (150 lbf ft) while rotating hub in both directions to
truck. Lift truck wheels are heavy. properly seat the bearings, loosen the castle nut un-
til wheel hub turns freely with no end play. Tighten
Remove and Install Tire on Wheel castle nut to 34 N•m (25 lbf ft). If the cotter pin can-
not be installed, loosen the castle nut to the first
NOTE: Make sure the tires are installed on the wheels position where the cotter pin can be installed. In-
so that the outside edges of the tire and wheel are as stall cap for bearings.
A. STEERING TIRE AND WHEEL B. DRIVE TIRES AND WHEELS C. WIDE TREAD
1. OUTSIDE OF SOLID RUBBER TIRE 3. OVERHANG
2. WHEEL
Figure 99. Tires and Wheels for GC/GL080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;
GC/GLC120VXPRS (E818, F818) Lift Trucks
100
PNEUMATIC TIRE WITH TUBE, REPAIR Always wear safety glasses.
Remove Wheels From Lift Truck Never loosen the nuts that hold the inner and outer
wheel halves together when there is air pressure in
the tire.
WARNING
A solid rubber tire that is the same shape as a pneu- Lift truck tires and wheels are heavy. Use caution
matic tire can be installed on a three-piece or four- when removing or installing lift truck tires and
piece wheel for a pneumatic tire. DO NOT make wheels or personal injury can occur.
changes in the parts of the rim if this type of solid
rubber tire is installed instead of a pneumatic tire. 1. Put lift truck on blocks as described in How to Put
Changes to the parts of the rim can cause a failure Lift Truck on Blocks at the beginning of this section.
of the wheel and cause an accident.
2. Remove air from tire. Remove valve core to make
sure all air is out of inner tube. Push a wire through
WARNING valve stem to make sure valve stem does not have
The type of tire and the tire pressure (pneumatic a restriction.
tires) are shown on the Nameplate. Make sure the
Nameplate is correct for the type of tires on the lift 3. Remove wheel nuts and remove wheel and tire from
truck. lift truck.
WARNING Remove Tire From Wheel

Wheels must be changed and tires repaired by NOTE: When you disassemble the wheels, see Fig-
trained personnel only. ure 100. There are several types of wheels used on
this series of lift trucks.
Deflate tire completely before removing the wheel
from the lift truck. If dual wheels are used, deflate
both tires. Air pressure in the tires can cause the
tire and rim parts to explode, causing serious injury
or death.
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 100. Types of Pneumatic Wheels
101
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.
102
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.
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.
STEP 4.
Remove wheel from tire.
103
Install Wheel in Tire 1. Clean and inspect all parts of wheel. Paint any
parts that have rust or corrosion.
WARNING 2. Install new inner tube in tire. Used tubes and flaps
Damage to the tire and wheel assembly and injury can cause tire failure.
or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of the wheel before
WARNING
installing the tire. DO NOT lubricate tire bead with antifreeze or petro-
• DO NOT use any damaged or repaired wheel leum-based liquid. Vapors from these liquids can
parts. cause an explosion during inflation or use.
• Make sure all parts of the wheel are the correct
3. Apply a rubber lubricant or a soap solution to the
parts for that wheel assembly.
tire bead and tube.
• DO NOT mix parts between different types or
manufacturers of wheels. 4. Install new tire flap.
• DO NOT mix types of tires, type of tire tread, or
wheel assemblies of different manufacturers on 5. Make sure rim is the correct size for tire. Lubricate
any one lift truck. part of wheel that contacts bead and flap.
DO NOT use a steel hammer on the wheel. Use a 6. Install the three-piece or four piece wheel in the
rubber, lead, plastic, or brass hammer to put parts tire as shown in Install Three-Piece or Four-Piece
together. Make sure the side ring is in the correct Wheel in Tire.
position. The ends of the side ring must not touch.
The clearance at the ends of the lock ring will be 7. Install the two-piece wheel in the tire as shown in
approximately 13 to 25 mm (0.5 to 1.0 in.) after it is Install Tire on Two-Piece Wheel.
installed. If the clearance is wrong, the wrong part
has been used.
104
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 proce-
dures:
• 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 together.
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.
105
STEP 4.
Put lock ring in the correct position on rim. Add air pres-
sure to tire as described in Install Wheel in Tire.
Install Tire on Two-Piece Wheel

CAUTION
DO NOT use pneumatic-shaped solid tires on two-
WARNING piece bolt together drive wheels. Spinning may oc-
Wheels can explode and cause injury or death if the cur.
following procedures are not followed:
• Clean and inspect all parts of the wheel before 1. Clean and inspect all parts of wheel. Paint any
installing the tire. parts that have rust or corrosion.
• DO NOT use any damaged or repaired wheel
parts. 2. Install new inner tube in tire. Used tubes and flaps
• Make sure all parts of the wheel are the correct can cause tire failure.
parts for that wheel assembly.
• DO NOT mix parts between different types or WARNING
manufacturers of wheels. DO NOT lubricate the tire bead with antifreeze or
• DO NOT mix types of tires, type of tire tread, or petroleum-based liquid. Vapors from these liquids
wheel assemblies of different manufacturers on can cause an explosion during inflation or use.
any one lift truck.
3. Apply a rubber lubricant or a soap solution to tire
DO NOT use a steel hammer on the wheel. Use a bead and tube.
rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct 4. Install new tire flap.
position. The ends of the side ring must not touch.
The clearance at the ends of the lock ring will be 5. Make sure rim is the correct size for tire. Lubricate
approximately 13 to 25 mm (0.5 to 1.0 in.) after it is part of wheel that contacts bead and flap.
installed. If the clearance is wrong, the wrong part
has been used.
106
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 pressure
from tire. Remove valve core to make sure all air
pressure has been removed and then make adjust-
WARNING
ments. The clearance at the ends of the lock ring
Add air pressure to the tires only in a safety cage. will be approximately 13 to 25 mm (0.5 to 1.0 in.)
Inspect the safety cage for damage before use. when the tire has the correct air pressure.
When air pressure is added, use a chuck that fas-
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 pressure
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 101.
3. Check that all wheel parts are correctly installed.

Hit lock ring lightly to make sure it is in the seat.
Figure 101. Add Air to Tires
4. If installation is correct, add air pressure to tire to
the specified pressure.
107
Install the Wheels make sure nuts that fasten rim halves together are
toward brake drum when they are installed.
WARNING 4. Install the valve extension bracket and tighten the
Lift truck tires and wheels are heavy. Use caution attaching nut to 8 N•m (70 lbf in). Install the valve
when removing and installing lift truck tires and extension hose into the bracket. See Figure 102.
wheels or personal injury can occur.
Install wheel on the hub. Tighten nuts in a cross pattern

to a torque value of 610 to 680 N•m (450 to 502 lbf ft) for
drive wheel nuts and 610 to 680 N•m (450 to 502 lbf ft)
for steer wheel nuts. If the wheels are the two-piece
rims, make sure nuts that fasten rim halves together are
toward brake drum when they are installed.
Dual Drive Wheels, Install
WARNING
Lift truck tires and wheels are heavy. Use caution
when removing and installing lift truck tires and
wheels or personal injury can occur.
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 in-
stalled.
2. Install wheel adapter spacers on the inner wheel

studs and tighten spacers to 100 to 125 N•m (74 to
92 lbf ft). Install the dual hub assembly and inner 1. TIRE
2. DUAL HUB ASSEMBLY
wheel nuts on the spacers and tighten the wheel 3. WHEEL NUT
nuts to 610 to 680 N•m (450 to 502 lbf ft). See 4. WHEEL
Figure 102. 5. WHEEL ADAPTER SPACER
6. VALVE EXTENSION
3. Install outer wheel on dual hub assembly. Tighten 7. BRACKET
nuts to a torque value of 610 to 680 N•m (450 to
502 lbf ft). If the wheels are the two-piece rims, Figure 102. Dual Drive Wheels Installation
108
PNEUMATIC TUBELESS TIRE, REPAIR Lift truck tires and wheels are heavy. Use caution
when removing and installing lift truck tires and
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 used
Wheels must be changed and tires repaired by with a tube.
trained personnel only.
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 ensure
from the lift truck. If dual wheels are used, deflate the air tightness of the existing wheel and the tubeless
both tires. Air pressure in tires can cause the tire tire assembly. See Figure 100.
and rim parts to explode causing serious injury or
death. 1. Put lift truck on blocks as described in How to Put
Lift Truck on Blocks at beginning of this section.
Always wear safety glasses.
2. Remove the valve cap and core to remove all air
Never loosen the nuts that hold the inner and outer from the tire.
wheels halves together when there is air 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.
injury.
NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 100.
STEP 1.
If wheel rim is a three- or four-piece rim, turn the valve
1/4 turn and remove valve from wheel.
109
STEP 2.
Put wheel and tire assembly on the press. Position the
feet of the press on the loose flange. Press down on
loose flange to expose the locking ring.
STEP 3.
Remove the loose flange locking ring and the advance
band (four-piece wheel only) using a tire tool.
STEP 4.
Remove the press and remove the loose flange locking
ring and the advance band (four-piece wheel only) from
the tire and wheel assembly.
STEP 5.
Push the TBS toward the inside of the tire to remove it.
110
Install Tire on Wheel
WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow procedures:
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
lift truck.
WARNING
WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can
cause an explosion during inflation or use.
STEP 1.
Clean interior and exterior bead of the tire. Lubricate
tire beads and the inside of the tire, up to the tire shoul-
ders. Apply lubricant to the entire underside of the TBS.
NOTE: If the wheel rim width is less than 152 mm (6 in.), the TBS will contain one valve hole to accommodate the
needle valve. If the wheel rim width is greater than 152 mm (6 in.), the TBS will have two holes for the needle valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve slot.
The valve hole that is not used should be sealed with a small plastic plug.
STEP 2.
Apply lubricant to the needle valve and the valve hole
that will be used (see NOTE) by inserting and removing
the lubricated valve several times. If a three- or four-
piece wheel is being used, remove the valve. If a two-
piece wheel is being used, leave valve in valve hole.
If the TBS has two-valve holes, lubricate the plastic plug

and insert into valve hole that will not be used.
111
STEP 3.
Place the TBS inside the tire, making sure that the wings
of the TBS are not folded over. Make a mark on the tire
to note the position of the valve hole in the TBS.
STEP 4.
Apply lubricant to the rim. If a four-piece wheel is being
used, lubricate the advance band. Slide the tire and the
TBS onto the wheel.
Line up the valve hole in the TBS with the valve slot in
the wheel. Lubricate and insert the valve into the valve
hole. Make sure it is fully inserted.
STEP 5.
Place the wheel and tire assembly on a flat surface.
Turn the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.
STEP 6.
Raise the tire and position the base and threaded stem
of the press through the hole in the center of the wheel.
Insert in wheel assembly, the following parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring
112
STEP 7.
Position the advance band. Ensure that it does not go
in too far and damage the valve. Position the arms of
the press onto the loose flange.
Push down on the press to depress the tire beads until

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

is shown on the Nameplate. Install valve cap to
ensure air stays in the tire. Figure 103. Add Air to Tires
113
Wheels, Install SOLID RUBBER TIRES ON PNEUMATIC

WHEELS, CHANGE
WARNING
Lift truck tires and wheels are heavy. Use caution WARNING
when removing and installing lift truck tires and Wheels must be changed and tires repaired by
wheels or personal injury can occur. trained personnel only.
Install wheel on hub. Tighten nuts in a cross pattern to Always wear safety glasses.
a torque value of 610 to 680 N•m (450 to 502 lbf ft) for
drive wheel nuts and 610 to 680 N•m (450 to 502 lbf ft) Lift truck tires and wheels are heavy. Use caution
for steer wheel nuts. If wheels are two-piece rims, make when removing and installing lift truck tires and
sure nuts that fasten rim halves together are toward wheels or personal injury can occur.
brake drum when they are installed.
1. Put lift truck on blocks as described in How to Put
Lift Truck on Blocks at the beginning of this section.
2. Remove wheel nuts and remove wheel and tire from

lift truck.
Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Figure 100. 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.
114
STEP 2.
Put tire tool into slot between lock ring and wheel rim.
Remove lock ring and side flange.
STEP 3.
Turn tire over. Put a support under wheel rim. Make
sure wheel rim is at least 150 to 200 mm (6 to 8 in.)
from bed of press.
STEP 4.
Put cage in position on tire. Use press to push tire from
wheel rim.
115
Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 100. 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 procedures.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
lift truck.
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.
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.
116
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, in-
stall lock ring. Use a tire tool to make sure lock ring is
in the correct position.
117
Adhesives and Sealants 8000 YRM 1248
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.
118
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
8000 YRM 1248 4/13 (8/12)(3/12)(2/12) (1/12)(10/11)(8/11)(1/11)(12/10)(8/10)(7/10) Printed in U.S.A.

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Maintenance

PART NO. 524262280 8000 YRM 1248

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

©2013 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

GC/GLC080, 100, 120VX; GC/GLC080, 100VXBCS; GC/GLC120SVX;

The recommendations for the time intervals provided is

How to Tow Lift Truck 2. Tow truck slowly.

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

A. COUNTERWEIGHT WITHOUT TOW PIN B. COUNTERWEIGHT WITH TOW PIN (STANDARD

Figure 1. Counterweight Types

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

1. DRIVE TIRES 2. STEERING TIRES

Figure 2. Put Lift Truck on Blocks

WARNING 1. Assure truck components are cool before starting

NOTE: The 250-hour, 500-hour, and 1000-hour/6-

Figure 3. GM 4.3L LPG Trucks With GFI Installed

Figure 4. GM 4.3L LPG Trucks With PSI Installed

Table 1. Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

15 Drive Belt X Check for Wear

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Tilt Cylinder Ends L 4 Fittings Multipurpose Grease

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Table 1. Maintenance Schedule (Continued)

Maintenance Procedures Every 8 Hours or Daily

Figure 11. Tire Check

7. Check that lift chains are correctly lubricated. Use

1. Inspect welds on mast and carriage for cracks.

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

3. Inspect channels for wear in areas where the rollers

4. Inspect load backrest extension for cracks and

5. If lift truck is equipped with an integral sideshift car-

Operator Restraint System Adjust Seat - Full Suspension

A seat belt that is damaged, worn, or does not operate

NOTE: The following seat belt operation checks must

• With the hood closed and in the locked position, pull

with the feet positioned on the pedals. This ensures

Adjust Seat - Internal Suspension

Seat Position Adjustment (Swivel Seat)

Seat Adjustment for Operator Weight

NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE CAUTION

CAUTION • The target is for the "ride indicator" to fall between

• The target is for the "ride indicator" to fall between

NOTE: OPTIONAL SWIVEL SEAT SHOWN.

Figure 15. Seat Adjustment

Hood and Seat Latches Paper Application