Frame Us

Maintenance
FRAME
GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]
PART NO. 550013974 100 YRM 1423

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a 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.
Frame Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Hood, Seat, and Side Covers Replacement........................................................................................................ 2
Remove ........................................................................................................................................................... 2
Install............................................................................................................................................................... 8
Belly Pan (Optional) ........................................................................................................................................ 9
Remove....................................................................................................................................................... 9
Clean and Inspect ....................................................................................................................................... 9
Install .......................................................................................................................................................... 9
Steering Column.................................................................................................................................................. 10
Description ...................................................................................................................................................... 10
Steering Column Repair.................................................................................................................................. 10
Remove....................................................................................................................................................... 10
Disassemble ............................................................................................................................................... 11
Clean .......................................................................................................................................................... 14
Inspect ........................................................................................................................................................ 14
Assemble .................................................................................................................................................... 14
Install .......................................................................................................................................................... 14
Counterweight Replacement ............................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Install............................................................................................................................................................... 17
Overhead Guard Replacement............................................................................................................................ 17
Remove ........................................................................................................................................................... 17
Install............................................................................................................................................................... 18
Rain Top (Optional) ..................................................................................................................................... 18
Remove .................................................................................................................................................. 18
Clean and Inspect................................................................................................................................... 18
Install ...................................................................................................................................................... 18
Operator Restraint System Replacement............................................................................................................ 19
Description ...................................................................................................................................................... 19
Emergency Locking Retractor (ELR) .......................................................................................................... 19
Engine Replacement ........................................................................................................................................... 21
Remove ........................................................................................................................................................... 21
LPG Engine ................................................................................................................................................ 21
Diesel Engine.............................................................................................................................................. 29
Install............................................................................................................................................................... 34
LPG Engine ................................................................................................................................................ 34
Diesel Engine.............................................................................................................................................. 35
Transmission Replacement ................................................................................................................................. 36
Remove ........................................................................................................................................................... 36
Install............................................................................................................................................................... 38
Throttle Pedal and Cable Adjustment .................................................................................................................. 39
Mazda LPG Engine ......................................................................................................................................... 39
Throttle Pedal Stop Adjustment .................................................................................................................. 39
Yanmar Diesel Engine ..................................................................................................................................... 39
Yanmar Diesel Engine With Electronic Throttle............................................................................................... 41
Cooling System ................................................................................................................................................... 41
Description ...................................................................................................................................................... 41
Hydraulic Filter Repair ......................................................................................................................................... 41
Remove ........................................................................................................................................................... 41
Clean and Inspect ........................................................................................................................................... 42
Install............................................................................................................................................................... 42
©2012 Yale Materials Handling Corp. i

Table of Contents Frame
TABLE OF CONTENTS (Continued)

Tank Repair ......................................................................................................................................................... 42
LPG Tank Repair............................................................................................................................................. 42
Hydraulic and Diesel Tanks ............................................................................................................................. 42
Inspect ........................................................................................................................................................ 42
Clean .......................................................................................................................................................... 43
Steam Method of Cleaning ..................................................................................................................... 43
Chemical Solution Method of Cleaning .................................................................................................. 44
Additional Preparations for Repair .................................................................................................................. 44
Small Leaks, Repair ........................................................................................................................................ 44
Large Leaks, Repair ........................................................................................................................................ 44
Preparations for Use After Repair ................................................................................................................... 45
Label Replacement.............................................................................................................................................. 45
This section is for the following models:
GLC050LX [A967];
GLP/GDP20-25LX (GLP/GDP050LX) [A974]
ii
100 YRM 1423 General
General
The surface must be solid, even, and level when the
WARNING lift truck is put on blocks. Make sure that any blocks
The lift truck must be put on blocks for some types used to support the lift truck are solid, one-piece
of maintenance and repairs. The removal of the units. See the Operating Manual or the section Pe-
following assemblies will cause large changes in riodic Maintenance 8000 YRM 1424.
the center of gravity: mast, drive axle, engine and
transmission, and counterweight. When the lift This section contains the description of the frame (see
truck is put on blocks, put additional blocks in the Figure 1) and connected parts. Procedures for remov-
following positions to maintain stability: ing and installing the counterweight, hood, overhead
• Before removing the mast and drive axle, put guard, engine, and cooling system are found in this sec-
blocks under the counterweight so the lift truck tion. Checks for the operator restraint system, adjust-
cannot fall backward. ments for the throttle pedal stop, and procedures for the
• Before removing the counterweight, put blocks repair of tanks and installation of safety labels are also
under the mast assembly so the lift truck cannot included.
fall forward.
1. COWL PLATE 5. COUNTERWEIGHT SUPPORT

2. FENDER 6. LEFT-HAND FRAME WELDMENT
3. FRAME 7. HYDRAULIC TANK
4. HOOD MOUNT
Figure 1. Frame
1
Hood, Seat, and Side Covers Replacement 100 YRM 1423
Hood, Seat, and Side Covers Replacement

REMOVE 8. Fully lower the steering column.
1. Slide the seat to the closest position to the steering

column.
2. Fully tilt the steering column forward.
NOTE: Perform Step 3 for lift trucks equipped with LPG.
3. Swing LPG tank off to side. See LPG Fuel System,

Mazda FE and F2 Emission Compliant Engines
900 YRM 1326 for procedures.
4. Raise the hood latch on the left, front corner of the

hood to unlatch and lift up the hood. See Figure 2.
5. Remove the floor mat and floor plate. See Figure 3.
6. Remove the two capscrews holding the left and

right rear side covers to the frame. Remove the rear
side covers from the frame. See Figure 3.
7. Remove the four capscrews and clip nuts holding 1. HOOD LATCH 3. HOOD
the left and right front side covers and left and right 2. SEAT
cowl plates to the frame. Remove front side covers Figure 2. Hood Latch
and cowl plates.
Legend for Figure 3

1. DASH ASSEMBLY 13. LEFT REAR SIDE COVER
2. UPPER STEERING COLUMN COVER 14. RIGHT REAR SIDE COVER
3. LOWER STEERING COLUMN COVER 15. FLOOR MAT
4. KICK PANEL 16. FLOOR PLATE
5. PLATE ASSEMBLY 17. RADIATOR COVER
6. GROMMET 18. SEALS
7. LEFT FRONT SIDE COVER 19. CAPSCREW
8. RIGHT FRONT SIDE COVER 20. CLIP NUT
9. LEFT STEP PANEL 21. INSERT
10. RIGHT STEP PANEL 22. PLATE ASSEMBLY SEAL
11. LEFT STEP PLATE 23. LEFT COWL PLATE
12. RIGHT STEP PLATE 24. RIGHT COWL PLATE
2
100 YRM 1423 Hood, Seat, and Side Covers Replacement
Figure 3. Side Cover, Floor Plate, and Cowl Components
3
9. Remove upper steering column cover by pulling up 11. Pull kick panel up from bottom and out to remove
on the base of the upper steering column cover to kick panel from seal plate and clips on dash panel.
release the latches (one on either side), and pulling
cover away from steering column. See Figure 4. 12. Remove dash panel from cowl. See Figure 5.
10. Remove the five Allen Head screws (see Figure 4) 13. Remove three capscrews holding the seal plate.
securing the dash to top of cowl. Remove seal plate. See Figure 5.
NOTE: TOP VIEW OF DASH PANEL SHOWN

A. INDICATES TO PULL UP TO UNLATCH
1. ALLEN HEAD SCREWS 3. UPPER STEERING COLUMN COVER
2. COWL 4. LOWER STEERING COLUMN COVER
Figure 4. Dash Panel and Upper Steering Column Cover Removal
4
1. ALLEN HEAD SCREWS 5. KICK PANEL NOTCHES

2. COWL 6. SEAL PLATE
3. DASH PANEL 7. CAPSCREWS
4. KICK PANEL 8. CLIPS
Figure 5. Dash Panel, Kick Panel, and Seal Plate Removal
5
14. Remove two capscrews and washers from cover and nuts holding the seat to the hood. Lift the seat
plate and remove electrical cover. Disconnect seat off the hood. See Figure 7. Close hood.
harness from chassis harness. See Figure 6.
16. Remove the nuts from ball studs on gas springs.
Remove gas springs from the hood. See Figure 8.
CAUTION
When removing the seat from the hood, do not use 17. Remove the hinge capscrews and nuts, located in
an impact wrench to remove the capscrews. Dam- the rear of the hood. See Figure 8.
age can be caused to the threads on the capscrews
18. Lift the hood from the truck.
and in the holes.
15. Open hood and pull chassis harness through hole

in hood. See Figure 7. Remove the four capscrews
A. NON-SUSPENSION SEAT B. FULL SUSPENSION SEAT

1. CAPSCREWS 4. ELECTRICAL CONNECTOR (SEAT HARNESS)
2. WASHER 5. ELECTRICAL COVER
3. COVER PLATE
Figure 6. Disconnect Seat Wire Harness
6
Legend for Figure 7
NOTE: MOUNTING HOLES FOR FULL SUSPENSION

SEAT SHOWN. MOUNTING HOLES FOR NON-SUS-
PENSION SEAT ARE THE SAME.
1. CAPSCREW
2. NUT
3. HOLE FOR CHASSIS HARNESS
4. HOOD LINER
Figure 7. Remove Seat From Hood
A. HOOD HINGE ARRANGEMENT B. GAS SPRING ARRANGEMENT (LEFT SIDE

SHOWN)
1. NUT 6. BALL STUD
2. CAPSCREW 7. GAS SPRING MOUNTING BRACKET
3. HOOD HINGE MOUNT 8. HOOD MOUNT
4. HOOD HINGE ARM 9. GAS SPRING
5. HOOD
Figure 8. Gas Spring and Hood Removal
7
INSTALL (two clicks). Also check that hood touches rubber

bumper. If necessary, repeat Step 4 and Step 5.
1. Place the hood onto the lift truck frame.
2. Install the hood hinge mount screws and nuts, lo- CAUTION
cated in the rear of the hood, and tighten to 38 N•m When installing the seat to the hood, do not use an
(28 lbf ft). See Figure 8. impact wrench to install the capscrews. Damage
can be caused to the threads on the screws and in
3. Align the ball studs in the gas springs with holes in
the holes.
the gas spring mounting bracket and hood mount.
See Figure 9 for holes to use depending on type 7. Place the seat on the hood and thread the chassis
of seat being installed. Install nuts on ball studs harness through the holes in the hood. See Fig-
to attach gas springs to the hood. Tighten nuts to ure 7.
19.2 N•m (170 lbf in).
8. Align the holes in the seat with the holes in the
4. Install latch striker in highest slot position. Check hood. See Figure 7. Insert capscrews and nuts.
that latch striker is in center of jaws of hood latch Tighten capscrews to 18 N•m (159 lbf in).
when hood closes. Open and close the hood to en-
sure that the center pin strikes the hood latch prop- 9. Connect seat harness to chassis harness. Install
erly and that the stop screw contacts the frame. A cover plate to electrical cover using two capscrews
properly closed hood MUST click twice on the hood and washers. See Figure 6.
latch. If the hood latch does not close properly,
loosen the capscrews on the back of the center pin 10. Using three capscrews, install seal plate. See Fig-
and adjust the center pin up or down as required for ure 5. Tighten capscrews to 10.8 N•m (95.6 lbf in).
correct alignment. See Figure 10.
11. Place dash panel on cowl and secure dash panel
5. Push down until hood just touches rubber bumper. to cowl using five Allen Head screws. Tighten Allen
Make sure latch striker is still in center of hood latch. Head screws to 3.5 N•m (31 lbf in). See Figure 4.
Open hood and tighten capscrews for latch.
12. Align notches on kick panel to clips on dash panel
6. Check operation of hood latch. Have an opera- and push kick panel into place on seal plate. See
tor sit in the seat. Make sure hood is fully closed Figure 5.
A. LEFT SIDE B. RIGHT SIDE

1. FULL SUSPENSION SEAT 3. GAS SPRING MOUNTING BRACKET
2. NON-SUSPENSION SEAT 4. HOOD MOUNT
Figure 9. Gas Spring and Seat Hole Alignment
8
NOTE: Perform Step 17 for lift trucks equipped with

LPG.
17. Swing the LPG tank into position on back of coun-

terweight. See LPG Fuel System, Mazda FE and
F2 Emission Compliant Engines 900 YRM 1326
for procedures.
18. Adjust the steering column and seat positions.
BELLY PAN (OPTIONAL)

Remove
1. Remove four capscrews and four nuts from belly
pan and frame. See Figure 11.
2. Remove belly pan from frame. See Figure 11.
Clean and Inspect

Remove debris from belly pan and inspect for damage.
Replace if necessary.
Install
1. Slide belly pan into position on frame. See Fig-
ure 11.
2. Install four capscrews and four nuts onto belly pan

and frame. See Figure 11.
1. HOOD 3. CENTER PIN

2. HOOD LATCH 4. CAPSCREW
Figure 10. Hood Latch Adjustment
13. Raise steering column to highest position and in-

stall upper steering column cover by aligning the
two latches and pushing down until latched. See
Figure 4.
14. Using four capscrews and clip nuts, install the left
and right front side covers and left and right cowl
plates to the frame. See Figure 3.
15. Using two capscrews, install the left and right rear
side covers to the frame. See Figure 3.
1. BELLY PAN 3. NUT
16. Install the floor mat and floor plate. 2. CAPSCREW 4. FRAME
Figure 11. Belly Pan
9
Steering Column 100 YRM 1423
Steering Column
DESCRIPTION 2. Attach a tag on the battery connector or nega-
tive battery cable stating, DO NOT CONNECT
This section describes the repair procedures for the BATTERY. Move the steering column to the most
steering column. The Steering Column Assembly FORWARD position.
mounts to the cowl inside the operator compartment
and is the mechanical connection between the steering
wheel and the steering control unit. The steering col- CAUTION
umn includes the steering wheel, housing, bracket and If a puller tool is used to remove steering wheel
lower shaft. For lift trucks with gas and LPG engines, from steering column, be careful not to damage
bolts and bushings attach the steering column to the horn wires.
cowl standoffs. For lift trucks with diesel engines, bolts,
bushings and isolators attach the steering column to NOTE: This procedure is for the removal of all compo-
the cowl standoffs See Figure 12. nents of the steering column assembly. All components
are not often removed for a repair procedure. Do only
STEERING COLUMN REPAIR those steps of the procedure necessary to remove the
required component.
Remove
NOTE: Tag wires prior to disconnect
1. Put blocks on each side (front and back) of tires to
3. Remove the horn button assembly and disconnect
prevent lift truck from moving.
electrical wires. Remove large hex nut and steering
wheel from steering column. See Figure 13.
CAUTION
Disconnect the negative battery cable on internal 4. Remove steering column covers. Remove floor
combustion trucks. Disconnect the battery before mats and floor plate. See section Hood, Seat, and
removing any covers. Side Covers Replacement.
NOTE: Perform Step 5 for lift trucks equipped with gas

or LPG engines.
5. Remove four capscrews, four bushings and steer-

ing column from cowl standoffs. See Figure 14.
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

1. STEERING WHEEL 1. HORN BUTTON 4. STEERING
2. STEERING COLUMN 2. HEX NUT COLUMN
3. COWL 3. STEERING WHEEL
Figure 12. Steering Column and Cowl Figure 13. Steering Wheel Remove/Install
10
100 YRM 1423 Steering Column
NOTE: Perform Step 6 for lift trucks equipped with See Figure 16
diesel engines. • For lift trucks manufactured after January, 2012
6. Remove four capscrews, four bushings, four isola- 3. Remove split pin and lower shaft from upper shaft.
tors, steering column and four isolators from cowl
standoffs. See Figure 14. See Figure 15
• For lift trucks manufactured before January, 2012
Disassemble
See Figure 16
NOTE: Remove and discard snap rings if installed. • For lift trucks manufactured after January, 2012
1. Remove two pins and gas spring from housing. 4. Remove connector from connector bracket. Re-
move connector bracket, fastener, four screws and
See Figure 15 two horn contacts from housing.
See Figure 15
See Figure 16 • For lift trucks manufactured before January, 2012
• For lift trucks manufactured after January, 2012
See Figure 16
2. Remove two pivot bolts, two bushings, two nuts and • For lift trucks manufactured after January, 2012
bracket from housing.
See Figure 15
NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

1. CAPSCREW 4. STEERING COLUMN
2. BUSHING 5. COWL STANDOFF
3. ISOLATOR
Figure 14. Steering Column Remove/Install
11
Figure 15. Steering Column Assembly, Lift Trucks Manufactured Before January, 2012
12
100 YRM 1423 Steering Column
Legend for Figure 15

1. PIN 9. CONNECTOR BRACKET
2. LOWER SHAFT 10. PIVOT BOLT
3. SPLIT PIN 11. BUSHING
4. UPPER SHAFT 12. NUT
5. HOUSING 13. GAS SPRING
6. HORN CONTACT 14. BRACKET
7. SCREW 15. CONNECTOR
8. FASTENER
1. BRACKET 9. PIN
2. SPACER 10. LOWER SHAFT
3. JOINT 11. GAS SPRING
4. NUT 12. BOLT
5. WASHER 13. BUSHING
6. SCREW 14. CONNECTOR
7. UPPER SHAFT 15. FASTENER
8. HOUSING 16. HORN CONTACT
Figure 16. Steering Column Assembly, Lift Trucks Manufactured After January, 2012
13
Clean 3. Assemble lower shaft and upper shaft, secure with

spit pin.
WARNING See Figure 15
Cleaning solvents can be flammable and toxic and • For lift trucks manufactured before January, 2012
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer’s See Figure 16
recommended safety precautions. • For lift trucks manufactured after January, 2012
4. Install two pivot bolts, two bushings, two nuts and

WARNING bracket onto housing.
Compressed air is used for cleaning and drying pur-
poses, or for cleaning restrictions. wear protective See Figure 15
clothing (goggles/shields, gloves, etc.). Make sure • For lift trucks manufactured before January, 2012
the path of the compressed air is away from all per-
sonnel to avoid injury. See Figure 16
1. Clean metal parts in solvent. Remove all traces of
old lubricant and dirt. Clean nonmetal parts with 5. Install gas spring and two pins on housing.
warm soapy water and a lint free cloth.
See Figure 15
2. After cleaning dry parts with compressed air. DO • For lift trucks manufactured before January, 2012
NOT dry parts with a cloth.
See Figure 16
Inspect
1. Inspect for loose, burned, missing, cracked or dam- Install
aged hardware.
NOTE: Lubricate spline end of lower shaft with multi
2. Inspect all parts for dents, holes, bends, burrs, rust, purpose grease, see Periodic Maintenance Manual
corrosion or marred finishes. for your lift truck.
3. Replace all defective or damaged parts. NOTE: Perform Step 1 for lift trucks equipped with gas
or LPG engines.
Assemble
1. Install steering column, four bushings and four
NOTE: This procedure is for the installation of all com- bolts on cowl standoffs. Tighten bolts to 38 N•m
ponents of the steering column assembly. All compo- (28 lbf ft). See Figure 14.
nents are not often removed for a repair procedure. Do
NOTE: Perform Step 2 for lift trucks equipped with
only those steps of the procedure necessary to install
diesel engines.
the required component.
2. Install four isolators, steering column four isolators,
NOTE: Perform Step 1 only for lift trucks manufactured
four bushings and four bolts standoffs on cowl.
before January, 2012.
Tighten bolts to 38 N•m (28 lbf ft). See Figure 14.
1. Lubricate the horn contact slip rings with a small
3. Install floor plate, floor mats and steering column
amount of conductive grease Yale P/N 582014302.
covers. See section Hood, Seat, and Side Covers
See Figure 15.
Replacement.
2. Install fastener, connector bracket and connector,
4. Install steering wheel and hex nut on steering
two horn contacts and four screws.
column. Tighten hex nut to 40 to 54 N•m (30 to
See Figure 15 40 lbf ft). Connect electrical wiring and install horn
• For lift trucks manufactured before January, 2012 button. See Figure 13.
See Figure 16 5. Remove tag from negative battery connector and

• For lift trucks manufactured after January, 2012 connect to battery. Adjust steering column to neu-
tral position.
14
100 YRM 1423 Counterweight Replacement
6. Remove blocks from each side of tires.
Counterweight Replacement
REMOVE from the LPG tank where it enters the filter unit.
Permit the pressure in the fuel system to decrease
WARNING slowly. Fuel leaving the fitting removes heat. Use a
cloth to protect your hands from the cold fitting.
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the NOTE: The counterweight is held in position on the
following assemblies will cause large changes in frame by two hooks that are part of the frame. One M24
the center of gravity: mast, drive axle, engine and × 3 × 110 capscrew holds the counterweight to the lower
transmission, and counterweight. When the lift part of the frame on lift truck models See Figure 17.
truck is put on blocks, put additional blocks in the
following positions to maintain stability: NOTE: Perform Step 1 for lift trucks equipped with LPG.
• Before removing the mast and drive axle, put
blocks under the counterweight so the lift truck 1. Use the procedures in LPG Fuel System, Mazda
cannot fall backward. FE and F2 Emission Compliant Engines 900
• Before removing the counterweight, put blocks YRM 1326 to remove the LPG tank and bracket so
under the mast assembly so the lift truck cannot that the counterweight can be removed.
fall forward.
Additional information on the LPG fuel system can
be found in LPG Fuel System, Mazda FE and F2
lift truck is put on blocks. Make sure that any blocks
Emission Compliant Engines 900 YRM 1326.
used to support the lift truck are solid, one-piece
units. See the Operating Manual or the section Pe-
riodic Maintenance 8000 SRM 1424. WARNING
The counterweight is heavy. Make sure that the eye-
WARNING bolts and lifting devices have enough capacity to lift
DO NOT operate the lift truck if the capscrew for the the weight. The approximate weights of the coun-
counterweight is not installed. When the capscrew terweight castings are shown in Table 1.
is removed, the counterweight can fall from the lift
2. Install washers, lifting eyebolts, and nuts into lift
truck.
holes of the counterweight. See Figure 18. Con-
nect a crane to the lifting eyebolts and raise the
WARNING crane until it holds part of the weight of the coun-
LPG can cause an explosion. DO NOT cause sparks terweight.
or permit flammable material near the LPG system.
LPG fuel systems can be disconnected indoors 3. Remove the tow pin from counterweight.
only if the lift truck is at least 8 m (26 ft) from any
4. Remove the capscrew from counterweight and
open flame, motor vehicles, electrical equipment,
frame. See Figure 17 and Figure 18. Use the
or ignition source.
crane to lift the counterweight from the lift truck.
Close the shutoff valve on the LPG tank before any Put counterweight on the floor so that it has stabil-
part of the engine fuel system is disconnected. Run ity and will not fall over. Take care not to damage
the engine until the fuel in the system is used and exhaust or cooling system components.
the engine stops.
If the engine will not run, close the shutoff valve on

the LPG tank. Loosen the fitting on the supply hose
15
Counterweight Replacement 100 YRM 1423
1. TOW PIN 4. WASHER

2. CAPSCREW 5. FRAME
3. LOCKWASHER 6. SEAL
Figure 17. Counterweight Installation
Table 1. Weight of Counterweights 1. SEAL 6. LOCKWASHER

2. COUNTERWEIGHT 7. WASHER
Model kg lb 3. LIFT HOLE 8. LPG ACCESS
4. TOW PIN HOLE
GLC050LX (A967) 1401 3088 5. CAPSCREW 9. LIFTING EYEBOLT
10. NUT
GLP/GDP20LX (A974) 950 2094
Figure 18. Counterweight With Lifting Eyebolts
GLP/GDP25LX 1230 2712
(GLP/GDP050LX) (A974)
GLP/GDP25LX 1335 2943
16
100 YRM 1423 Overhead Guard Replacement
INSTALL 3. Install capscrew onto counterweight and frame.

See Figure 17 and Figure 18. Tighten capscrew to
1. Make sure the seals are on the counterweight. If lift- 555 N•m (409 lbf ft).
ing eyebolts were removed from counterweight, in-
stall washers, lifting eyebolts, and nuts into lift holes 4. Install tow pin onto counterweight.
on counterweight. See Figure 18.
NOTE: Perform Step 5 for lift trucks equipped with LPG.
2. Connect a crane to the lifting eyebolts and place
counterweight in position on lift truck frame. Make 5. Use the procedures in LPG Fuel System, Mazda
sure hooks on frame fully engage counterweight so FE and F2 Emission Compliant Engines 900
it is aligned with the frame. YRM 1326 to install the LPG tank and bracket after
the counterweight has been installed.
Overhead Guard Replacement

REMOVE 3. Remove capscrews from overhead guard rear legs
and frame. See Figure 19.
WARNING
DO NOT operate the lift truck without the overhead
guard correctly fastened to the lift truck.
WARNING
DO NOT weld mounts for lights or accessories to
legs of the overhead guard. Changes that are made
by welding, or by drilling holes that are too big or in
the wrong location, can reduce the strength of the
overhead guard.
See your dealer for Yale lift trucks BEFORE perform-

ing any changes to the overhead guard.
NOTE: The lifting device can be connected to any num-

ber of positions on the overhead guard depending upon
the lifting device available. The ideal choices are a four
point sling connected to all four corners on the top of
the overhead guard, or a two point sling connected to
two opposite corners of the overhead guard. If a sin-
gle point hoist is used, make sure that the lift point is as
close to the center of the overhead guard as possible.
If during the initial start of the lift, the overhead guard is
off balance, lower immediately and move the hoist to a
more centered point.
No welding or drilling on legs of overhead guard is per-

mitted as per previous WARNING.
1. OVERHEAD GUARD REAR LEG
2. CAPSCREW
1. Connect a lifting device to overhead guard. 3. FRAME
4. OVERHEAD GUARD FRONT LEG
NOTE: Note routing of electrical wires prior to discon- 5. HANDLE
necting. Tag electrical connectors during removal to aid
in installation. Figure 19. Overhead Guard
2. Disconnect wires between frame and overhead

guard.
17
Overhead Guard Replacement 100 YRM 1423
4. Remove dash and kick panel from cowl. See Hood, 3. Remove two capscrews, two wheel nuts and two
Seat, and Side Covers Replacement for removal brackets from front center of overhead guard. See
procedures. Figure 20.
5. Remove capscrews from overhead guard front legs 4. Remove two capscrews, two wheel nuts, right
and frame. See Figure 19. bracket and left bracket from front corner of over-
head guard. See Figure 20.
NOTE: When overhead guard is lifted from the frame,
make sure that any electrical wires are moved through NOTE: Note position of rain top on overhead guard be-
the holes in the frame so that they are not damaged. fore removal.
6. Using lifting device, remove overhead guard from 5. Remove rain top from overhead guard. See Fig-
frame. See Figure 19. ure 20.
7. Remove capscrews and handle from overhead Clean and Inspect

guard. See Figure 19.
1. Clean all remaining sealer residue from rain top and
INSTALL overhead guard surfaces.
NOTE: Make sure electrical wires are routed as noted 2. Inspect rain top and brackets for cracks. Replace if
during removal to ensure that wires do not get pinched. necessary.
1. Using lifting device, install overhead guard onto Install

frame.
1. Apply a continuous bead of sealer to back corners
2. Install capscrews onto overhead guard front legs of overhead guard. See (item 10) Figure 20.
and frame. See Figure 19. Tighten capscrews to
NOTE: Apply even pressure to rain top to squeeze down
66 N•m (49 lbf ft).
sealer to a thickness of 3 to 5 mm (0.118 to 0.197 in.).
3. Install kick panel and dash onto cowl. See for install
2. Install rain top onto overhead guard as noted during
procedures.
removal.
4. Install capscrews onto overhead guard rear legs
3. Install right bracket, left bracket two capscrews, two
and frame. See Figure 19. Tighten capscrews to
wheel nuts, onto front corner of overhead guard.
66 N•m (49 lbf ft).
See Figure 20.
5. Connect electrical wires as tagged during removal.
4. Install two brackets, two capscrews, and two wheel
6. Install handle and capscrews onto overhead guard. nuts to front center of overhead guard. See Fig-
See Figure 19. ure 20.
Rain Top (Optional) 5. Install two capscrews, two bushings, two washers
and two locknuts onto bracket and rain top at front
Remove corners of overhead guard. See Figure 20.
1. Remove two capscrews, two locknuts, two bush- 6. Install two capscrews, two bushings, two washers
ings and two washers from bracket and rain top at and two locknuts onto bracket and rain top at front
front center of overhead guard. See Figure 20. center of overhead guard. See Figure 20.
2. Remove two capscrews, two locknuts, two bush-

ings and two washers from bracket and rain top at
front corners of overhead guard. See Figure 20.
18
100 YRM 1423 Operator Restraint System Replacement
1. RAIN TOP 7. RIGHT BRACKET

2. CAPSCREW 8. CENTER BRACKET
3. WHEEL NUT 9. BUSHING
4. LOCKNUT 10. SEALER
5. WASHER 11. OVERHEAD GUARD
6. LEFT BRACKET
Figure 20. Overhead Guard Rain Top
Operator Restraint System Replacement

DESCRIPTION Emergency Locking Retractor (ELR)
The seat belt, hip restraint brackets, seat and mounting, When the ELR style seat belt is properly buckled across
hood, and latches are all part of the operator restraint the operator, the belt will permit slight operator reposi-
system. Each item must be checked to make sure it tioning without activating the locking mechanism. If the
is attached securely, functions correctly, and is in good truck tips over, travels off a dock, or comes to a sudden
condition. See Figure 21. 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.
19
Operator Restraint System Replacement 100 YRM 1423
The seat belt must be in good condition. Replace the seat belt can be pulled from the retractor, when it is
seat belt if it is damaged or worn. See Figure 21. pulled with a sudden jerk, replace the seat belt as-
sembly.
NOTE: The following seat belt operation checks must • With the hood in the open position, make sure the
be performed three times before replacing the seat belt seat belt will not pull from the retractor assembly. If
assembly: the seat belt can be pulled from the retractor, with
• With the hood closed and in the locked position, pull the hood in the open position, replace the seat belt
the seat belt slowly from the retractor assembly. Make assembly.
sure the seat belt pulls out and retracts smoothly. If
the seat belt does not pull out of the retractor assem- Make sure the seat rails and hood latch are not loose.
bly, the internal latch may be locked. Pull firmly on The seat rails must lock securely in position but move
the seat belt and hold for a moment to remove slack freely when unlocked. The seat rails must be securely
from the belt in the retractor. Release the seat belt. attached to the mounting surface. The hood must be
Seat belt will retract and the internal latch will unlock. fully closed. Lift the hood to make sure it is closed and
If the seat belt cannot be pulled from the retractor as- will not move.
sembly or the belt will not retract, replace the seat belt
assembly. Adjust hood and hood latch when any of the parts of
• With the hood closed and in the locked position, pull the operator restraint system are installed or replaced.
the seat belt with a sudden jerk. Make sure the seat See the section Hood, Seat, and Side Covers Replace-
belt will not pull from the retractor assembly. If the ment in this manual for the adjustment procedures for
the hood.
A. NON-SUSPENSION SEAT B. FULL-SUSPENSION SEAT

1. HOOD 7. WEIGHT ADJUSTMENT KNOW
2. SEAT 8. RIDE POSITION INDICATOR
3. HIP RESTRAINT 9. FORWARD/BACKWARD ADJUSTMENT LEVER
4. SEAT BELT 10. BACKREST ADJUSTMENT LEVER
5. LATCH 11. SEAT RAIL
6. HOOD HINGE
Figure 21. Operator Restraint System
20
100 YRM 1423 Engine Replacement
Engine Replacement
REMOVE 3. Remove overhead guard. See section Overhead
Guard Replacement for procedures.
LPG Engine
4. Remove the floor mat and floor plate.
WARNING
WARNING
of maintenance and repairs. The removal of the DO NOT remove the radiator cap from the radiator
following assemblies will cause large changes in when the engine is hot. When the radiator cap is
the center of gravity: mast, drive axle, engine and removed, the pressure is released from the system.
transmission, and counterweight. When the lift If the system is hot, the steam and boiling coolant
truck is put on blocks, put additional blocks in the can cause burns.
following positions to maintain stability:
5. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capacity
blocks under the counterweight so the lift truck
of the cooling system under radiator. Remove radi-
cannot fall backward.
ator cap.
• Before removing the counterweight, put blocks
under the mast assembly so the lift truck cannot
fall forward. CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
used to support the lift truck are solid, one-piece 6. Open the drain plug or disconnect the bottom radi-
units. See the Operating Manual or the section Pe- ator hose to drain coolant from radiator and engine.
riodic Maintenance 8000 YRM 1424. See Figure 23.
WARNING 7. Remove the hood and seat combination and rear

side covers. See the section Hood, Seat, and Side
Always disconnect the cables at the battery before
Covers Replacement for procedures.
you make repairs to the engine. Disconnect the ca-
ble at the negative terminal first. 8. Disconnect the ground strap from the frame and
remove the power distribution module (PDM) from
WARNING the battery tray. See Figure 24.
LPG can cause an explosion. DO NOT cause sparks 9. Remove battery and battery tray from lift truck as
or permit flammable material near the LPG system. described in the steps below:
LPG fuel systems can be disconnected indoors
only if the lift truck is at least 8 m (26 ft) from any a. Remove cap, flange nut, and lockwasher from
open flame, motor vehicles, electrical equipments, battery lockdown bar. See Figure 24.
or ignition source.
b. Disengage battery lockdown bars and remove
1. Close the shutoff valve on the LPG tank and run bar from top of battery. See Figure 24.
engine until all fuel is gone and engine stops.
c. Remove battery from battery tray. See Fig-
2. For removal of the LPG Tank, see service manual ure 24.
LPG Fuel System, Mazda FE and F2 Emission
Compliant Engines 900 YRM 1326 for the proce- d. Remove three capscrews and battery tray from
dures. frame. See Figure 24.
21
Engine Replacement 100 YRM 1423
Figure 22. Mazda LPG Engine and Transmission Mounting Arrangement
22
NOTE: PART OF THE FRAME NOT SHOWN FOR CLARITY.
NOTE: MAZDA 2.0 SHOWN, MAZDA 2.2 SIMILAR.

A. LIFT TRUCK MODEL GLC050LX (A967) B. LIFT TRUCK MODEL GLP/GDP20-25LX
1. TRANSMISSION ISOLATOR ASSEMBLY 5. ENGINE ISOLATOR ASSEMBLY
2. TRANSMISSION MOUNTING BRACKET 6. FRAME
3. ENGINE MOUNTING BRACKET 7. ENGINE WIRING HARNESS
4. CROSSMEMBER 8. CHASSIS WIRING HARNESS
23
Figure 23. Mazda 2.0L LPG Engine and Transmission Removal
24
NOTE: MAZDA 2.0L SHOWN, MAZDA 2.2L SIMILAR.

A. TOP VIEW B. LEFT SIDE VIEW
1. BOTTOM RADIATOR HOSE 13. FAN
2. AIR FILTER HOSE 14. SHROUD
3. AIR FILTER AND BRACKET ASSEMBLY 15. EXHAUST PIPE TO EXHAUST MANIFOLD
4. LEFT HAND CHASSIS HARNESS CONNECTOR 16. FUEL LINES
5. ENGINE HARNESS CONNECTOR 17. RADIATOR CAP
6. LPG REGULATOR CONNECTOR 18. TRANSMISSION MOUNT
7. RIGHT HAND CHASSIS HARNESS 19. BATTERY CABLE (POSITIVE)
8. ELECTRONIC CONTROL MODULE (ECM) 20. BATTERY CABLE (NEGATIVE)
9. POWER DISTRIBUTION MODULE (PDM) 21. HYDRAULIC RETURN HOSE
10. BATTERY AND BATTERY TRAY 22. TRANSMISSION OIL COOLER LINES
11. COOLANT HOSES 23. HYDRAULIC SUPPLY HOSE
12. FAN PULLEY AND FAN SPACER 24. UPPER RADIATOR HOSE
10. Disconnect the remaining coolant hoses from the

radiator and cap them to prevent leakage. See Fig-
ure 23.
11. Remove the radiator fan pulley, shroud, and fan as-
sembly. See the section Cooling System 700 YRM
1123 for the removal procedures.
WARNING
All fuels are very flammable and can burn or cause
an explosion. DO NOT use an open flame to check
the fuel level or to check for leaks in the fuel system.
No smoking.
Breathing fuel vapor may cause nausea, uncon-

sciousness, or death. Long-term exposure to
gasoline vapors may cause liver or kidney damage
and cancer. Avoid breathing vapor.
1. BATTERY LOCKDOWN BAR
12. Disconnect the fuel lines at the engine. Put caps on 2. CAP
3. FLANGE NUT
fuel lines to prevent fuel leakage. See Figure 23. 4. LOCKWASHER
5. BATTERY
13. Disconnect the engine harness connectors from the 6. BATTERY TRAY
chassis harness connectors. See Figure 22. 7. CAPSCREW
8. PDM
14. Disconnect engine wiring harness connectors from 9. GROUND STRAP
proportional valve connectors, transducer connec- 10. FRAME
tors, solenoid valve connector, temperature sensor
Figure 24. Power Distribution Module and Battery
connector, and transmission. See Figure 25.
Tray
25
15. Remove exhaust pipe to exhaust manifold. See

LPG Fuel System, Mazda FE and F2 Emission
Compliant Engines 900 YRM 1326.
16. Use the access port on the side of engine and re-
move the four bolts that attached the flywheel to the
torque converter. See Figure 26.
17. Connect a lifting device to the engine. Put a block

under the transmission housing to support the
transmission.
18. Remove four flange bolts from torque converter

housing and flywheel housing on transmission
side. See Figure 27.
19. Remove six hex head capscrews and six lockwash-

ers from flywheel housing and torque converter
housing on flywheel housing side. See Figure 27.
1. ACCESS PORT
2. ENGINE MOUNTING BRACKET AND
HARDWARE
Figure 26. Mazda Engine Removal Access Port
1. ENGINE WIRING HARNESS

2. TRANSMISSION HOUSING
3. PROPORTIONAL VALVE CONNECTOR
4. TRANSDUCER CONNECTOR
5. TRANSMISSION SENSOR PLUG
6. SOLENOID VALVE CONNECTOR
7. TEMPERATURE SENSOR CONNECTOR
Figure 25. Transmission Electrical Connectors
26
1. FLANGE BOLT 5. HEX HEAD CAPSCREW

2. EYEBOLT BRACKET 6. LOCKWASHER
3. TORQUE CONVERTER HOUSING 7. FLYWHEEL HOUSING
4. TRANSMISSION ASSEMBLY 8. ENGINE ASSEMBLY
Figure 27. Mazda Flywheel and Torque Converter Housings
27
WARNING
The engine is heavy. Make sure that any lifting de-
vice has enough capacity to lift the engine. The en-
gine can weigh approximately 194 kg (428 lb).
20. Remove the flange nuts, washers, capscrews, and

isolators from the engine mounts. Remove engine
adapter to transmission bolts, if equipped. See Fig-
ure 22, Figure 28, and Figure 29.
CAUTION
When separating the engine away from the trans-
mission, place a piece of plywood in front of radi-
ator. This will keep the engine from damaging the
radiator.
CAUTION
Keep the engine level when the engine is separated
from the transmission so the drive plate is not dam-
aged.
21. Use the lifting device to carefully move the engine

away from the torque converter. Make sure all
hoses, wires, and cables are disconnected from 1. LEFT ENGINE MOUNT
the engine, then lift the engine from the frame and 2. RIGHT ENGINE MOUNT
place engine on blocks. 3. WASHER
4. CAPSCREW
22. Remove torque converter from torque converter 5. CROSSMEMBER (OPTIONAL)
housing. 6. ISOLATOR
7. FLANGE NUT
Figure 29. Mazda Engine Mounts
1. FRAME 3. FLANGE NUT

2. ENGINE MOUNT
Figure 28. Mazda LPG Engine and Frame
28
Diesel Engine The surface must be solid, even, and level when the
used to support the lift truck are solid, one-piece
WARNING
The lift truck must be put on blocks for some types riodic Maintenance 8000 YRM 1424.
of maintenance and repairs. The removal of the
following assemblies will cause large changes in
the center of gravity: mast, drive axle, engine and WARNING
transmission, and counterweight. When the lift Always disconnect the cables at the battery before
truck is put on blocks, put additional blocks in the you make repairs to the engine. Disconnect the ca-
following positions to maintain stability: ble at the negative terminal first.
1. Remove overhead guard. See section Overhead
blocks under the counterweight so the lift truck
Guard Replacement for procedures.
• Before removing the counterweight, put blocks 2. Remove floor mast and floor plate.
fall forward.
NOTE: PART OF THE FRAME NOT SHOWN FOR CLARITY. LIFT TRUCK MODELS GDP25LX (GDP050LX) (A974)
SHOWN.
1. TRANSMISSION ISOLATOR 5. FRAME
2. TRANSMISSION MOUNTING BRACKET 6. ENGINE WIRING HARNESS
3. ENGINE ISOLATOR 7. CHASSIS WIRING HARNESS
4. ENGINE MOUNTING BRACKET
Figure 30. Yanmar Diesel Engine and Transmission Mounting Arrangement
29
c. Remove battery from battery tray. See Fig-

WARNING ure 32.
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is d. Remove three capscrews and battery tray from
removed, the pressure is released from the system. frame. See Figure 32.
If the system is hot, the steam and boiling coolant
can cause burns. 8. Disconnect remaining coolant hoses from radiator
and cap them to prevent leakage. See Figure 31.
3. Let coolant cool to ambient temperature. Place a
drain pan with a capacity greater than the capacity 9. Remove radiator fan pulley, shroud, and fan assem-
of cooling system under radiator. Remove radiator bly. See section Cooling System 700 YRM 1123
cap. for the removal procedures.
CAUTION WARNING
Disposal of lubricants and fluids must meed local
4. Open drain plug or disconnect bottom radiator hose
No smoking.
to drain coolant from radiator and engine. See Fig-
ure 31. Breathing fuel vapor may cause nausea, uncon-
sciousness, or death. Long term exposure to
5. Remove hood and seat combination and rear side
covers. See section Hood, Seat, and Side Covers
Replacement for procedures.
10. Disconnect fuel lines at engine. Put caps on fuel
6. Disconnect ground strap from frame. Remove three
lines to prevent fuel leakage. See Figure 31.
flange bolts and power distribution module (PDM)
from battery tray. See Figure 32. 11. Disconnect engine harness connectors from chas-
sis harness connectors. See Figure 30.
7. Remove battery and battery tray from lift truck as
described in the steps below: 12. Disconnect engine wiring harness connectors from
proportional valve connectors, transducer connec-
a. Remove cap, flange nut, and lockwasher from
tors, solenoid valve connector, temperature sensor
battery lockdown bar. See Figure 32.
connector, and transmission. See Figure 33.
b. Disengage battery lockdown bars and remove
bar from top of battery. See Figure 32.

A. TOP VIEW B. LEFT VIEW
1. AIR FILTER AND BRACKET ASSEMBLY 12. HYDRAULIC RETURN HOSE
2. AIR FILTER HOSE 13. CHASSIS HARNESS
3. SHROUD 14. TRANSMISSION MOUNT
4. RADIATOR CAP 15. TRANSMISSION OIL COOLER LINES
5. COOLANT HOSES 16. ELECTRONIC CONTROL MODULE (ECM) AND
6. BATTERY AND BATTERY TRAY BRACKET
7. BATTERY CABLE (NEGATIVE) 17. FAN
8. BATTERY CABLE (POSITIVE) 18. FAN PULLEY AND FAN SPACER
9. POWER DISTRIBUTION MODULE (PDM) 19. BOTTOM RADIATOR HOSE
10. EXHAUST PIPE TO EXHAUST MANIFOLD 20. FUEL LINE
11. ENGINE HARNESS CONNECTOR 21. HYDRAULIC SUPPLY HOSE
30
Figure 31. Yanmar 2.6L Diesel Engine and Transmission Removal
31

1. ENGINE WIRING HARNESS
3. PROPORTIONAL VALVE CONNECTOR
4. TRANSDUCER CONNECTOR
5. TRANSMISSION SENSOR PLUG
6. SOLENOID VALVE CONNECTOR
7. TEMPERATURE SENSOR CONNECTOR
1. BATTERY LOCKDOWN BAR

2. CAP
3. FLANGE NUT
4. LOCKWASHER
5. BATTERY
6. BATTERY TRAY
7. CAPSCREW
8. PDM
9. GROUND STRAP
10. FRAME
Figure 32. Power Distribution Module and Battery

Tray 1. ACCESS PORT
2. FLYWHEEL HOUSING
Figure 34. Yanmar Torque Converter Bolt Access
13. Use the access port on the side of engine and re-
move four bolts attaching flywheel to torque con-
verter. See Figure 34.
14. Connect lifting device to engine. Put a block under

transmission housing to support transmission.
15. Remove four flange bolts from torque converter

housing and flywheel housing on transmission
side. See Figure 35.
16. Remove six hex head capscrews and six lockwash-

ers from flywheel housing and torque converter
housing on flywheel housing side. See Figure 35.
Figure 33. Transmission Electrical Connectors
32
1. TORQUE CONVERTER HOUSING 5. LOCKWASHER

2. EYEBOLT BRACKET 6. FLANGE BOLT
3. HEX HEAD CAPSCREW 7. TRANSMISSION ASSEMBLY
4. FLYWHEEL HOUSING 8. ENGINE ASSEMBLY
Figure 35. Yanmar Flywheel and Torque Converter Housings

17. Remove flange locknuts, washers, snubbing wash-
WARNING ers, capscrews, and isolators from the engine
The engine is heavy. Make sure that any lifting de- mounts. Remove engine adapter to transmission
vice has enough capacity to lift the engine. bolts, if equipped. See Figure 36.
The engine can weigh approximately 194 kg (428 lb).
33
6. Install six lockwashers and six hex head capscrews

CAUTION in torque converter housing and flywheel housing
When separating the engine away from the trans- from flywheel housing side. Tighten bolts to 38 N•m
mission, place a piece of plywood in front of radi- (28 lbf ft). See Figure 27.
ator. This will keep the engine from damaging the
radiator. 7. Install exhaust pipe to exhaust manifold. See LPG
Fuel System, Mazda FE and F2 Emission Com-
pliant Engines 900 YRM 1326.
CAUTION
Keep the engine level when the engine is separated 8. Connect engine wiring harness connectors to pro-
from the transmission so the drive plate is not dam- portional valve connectors, transducer connectors,
aged. solenoid valve connector, temperature sensor con-
nector, and transmission. See Figure 25.
18. Use a lifting device to carefully move engine away
from torque converter. Make sure all hoses, wires, 9. Connect chassis wiring harness connectors to en-
and cables are disconnected from the engine, then gine harness connectors. See Figure 22.
lift the engine from the frame and place engine on
blocks.
19. Remove torque converter from torque converter

housing.
INSTALL
LPG Engine
WARNING
vice has enough capacity to lift the engine. The en-
gine can weigh approximately 194 kg (428 lb).
CAUTION
Keep the engine level when installing the engine to
the transmission so the drive plate is not damaged.
1. Install torque converter in torque converter housing.
2. Connect lifting device to engine and lift engine into

frame. Install engine adapter to transmission bolts.
3. Install isolators, bolts, washers, and flange nuts on

engine mounts. See Figure 22, Figure 28, and
1. CAPSCREW
Figure 29. Tighten the flange nuts to 150 N•m 2. WASHER
(110 lbf ft). 3. ENGINE BRACKET
4. SNUBBING WASHER
4. Use access port on side of engine and install bolts 5. ISOLATOR
to hold torque converter to flywheel. Tighten bolt to 6. FLANGE LOCKNUT
56 N•m (41 lbf ft). See Figure 26.
Figure 36. Yanmar Engine Mounts
5. Align torque converter housing holes with flywheel
housing holes and install four flange bolts from
torque converter housing side. Tighten bolts to
38 N•m (28 lbf ft). See Figure 27.
34
20. Swing LPG tank into position on back of counter-

WARNING weight and open shutoff valve on tank.
an explosion. DO NOT use an open flame to check Diesel Engine
No smoking. WARNING
Breathing fuel vapor may cause nausea, uncon- vice has enough capacity to lift the engine. The en-
sciousness, or death. Long-term exposure to gine can weight approximately 194 kg (428 lb).
CAUTION
10. Remove caps from fuel lines and connect the fuel Keep the engine level when installing the engine to
lines at the engine. the transmission so the drive plate is not damaged.
11. Install the radiator shroud, fan pulley, and fan as- 1. Install torque converter in torque converter housing.
sembly. See Figure 23. See the section Cooling
System 700 YRM 1123 for the installation proce- 2. Connect lifting device to engine and lift engine into
dures. frame. Install engine adapter to transmission bolts,
if equipped.
12. Connect the coolant hoses and lines to the trans-
mission. Fill cooling system with a mixture speci- 3. Install isolators, capscrews, washers, snubbing
fied in Periodic Maintenance 8000 YRM 1424. washers, and flange locknuts on engine mounts.
See Figure 36. Tighten flange locknuts to 150 N•m
13. Connect the PDM and connect the ground strap to (110 lbf ft).
lift truck frame and attach it to battery.
4. Use access port on side of engine and install four
14. Install battery and battery tray. See Figure 24. bolts attached flywheel to torque converter. See
Figure 34. Tighten bolts to 55 N•m (41 lbf ft).
15. Install LPG tank and bracket on lift truck. See ser-
vice manual LPG Fuel System, Mazda FE and F2 5. Install six hex head capscrews and six lockwashers
Emission Compliant Engines 900 YRM 1326 for on flywheel housing and torque converter housing
the procedures. on torque converter housing side. See Figure 35.
Tighten capscrews to 38 N•m (28 lbf ft).
16. Install the rear side covers, floor plates, and hood
and seat combination. See the section Hood, Seat, 6. Install four flange bolts on flywheel housing and
and Side Covers Replacement for the procedures. torque converter housing on transmission side.
See Figure 35. Tighten capscrews to 38 N•m
17. If removed, install overhead guard. See section
(28 lbf ft).
Overhead Guard Replacement for procedures.
7. Connect engine wiring harness connectors to
18. Check all fluid levels and fill as needed. See the
transmission, temperature sensor connector, sole-
section Periodic Maintenance 8000 YRM 1424 for
noid valve connector, transducer connectors, and
quantities and procedures.
proportional valve connectors. See Figure 33.
CAUTION 8. Connect engine wiring harness connectors to chas-

sis harness connectors. See Figure 30.
19. Empty drain pan contents.
35
Transmission Replacement 100 YRM 1423
c. Install battery lockdown bar on top of battery

WARNING and engage with bar on side of battery tray. See
All fuels are very flammable and can burn or cause Figure 32.
the fuel lever or to check for leaks in the fuel system. d. Install lockwasher and flange nut on battery
lockdown bar. Tighten flange nut to 2.0 to
No smoking. 2.5 N•m (18 to 22 lbf in). Install cap on bat-
tery lockdown bar. See Figure 32.
Breathing fuel vapor may cause nausea, uncon-
sciousness, or death. Long term exposure to 13. Install power distribution module (PDM) and three
gasoline vapors may cause liver or kidney damage flange bolts on battery tray. Tighten flange bolts to
and cancer. Avoid breathing vapor. 3.2 to 3.5 N•m (28 to 31 lbf in). Connect the PDM
to chassis wire harness. Install ground strap on
9. Remove caps from fuel lines and connect lines at frame. See Figure 32.
engine. See Figure 31.
14. Install rear side covers and hood and seat combi-
10. Install radiator shroud, fan pulley, and fan assembly. nation. See section Hood, Seat, and Side Covers
See Figure 31. See section Cooling System 700 Replacement for procedures.
YRM 1123 for the installation procedures.
15. Install overhead guard. See section Overhead
11. Connect coolant hoses and lines to transmission. Guard Replacement for procedures.
Fill cooling system with a mixture specified in sec-
tion Periodic Maintenance 8000 YRM 1424. 16. Check all fluid levels and fill as needed. See section
Periodic Maintenance 8000 YRM 1424 for quanti-
12. Install battery tray and battery as described in the ties and procedures.
steps below:
a. Install battery tray and three capscrews on CAUTION

frame. See Figure 32. Disposal of lubricants and fluids must meet local
b. Install battery in battery tray. See Figure 32. environmental regulations.
17. Empty drain pan contents.
Transmission Replacement
REMOVE used to support the lift truck are solid, one piece
WARNING riodic Maintenance 8000 YRM 1424.
of maintenance and repairs. The removal of the fol- WARNING
lowing assemblies will cause large changes in the The transmission is heavy. Make sure that any lift-
center of gravity: mast, drive axle, engine, trans- ing device has enough capacity to lift the weight.
mission, and counterweight. When the lift truck is The transmission can weigh approximately 83.8 kg
put on blocks put additional blocks in the following (184.7 lb).
positions to maintain stability:
• Before removing the mast and drive axle, put NOTE: Make sure the transmission is supported by
blocks under the counterweight so the lift truck blocks or a lifting device before removing the engine.
1. Remove engine from lift truck. See section Re-
• Before removing the counterweight, put blocks
move, Engine Replacement for procedures.
fall forward. 2. Remove seal plate for brake and throttle pedals.
See Figure 5.
36
100 YRM 1423 Transmission Replacement

CAUTION
Disposal of lubricants and fluids must meet local NOTE: MAZDA LPG ENGINE SHOWN FOR REFER-
environmental regulations. ENCE ONLY.
3. Place a suitable container under transmission. Dis- 1. TRANSMISSION HOUSING

2. DRAIN FITTING
connect transmission cooling lines. 3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
4. Remove drain fitting from transmission housing 5. HYDRAULIC GEAR PUMP INLET PORT
and drain transmission oil. See Figure 37 and 6. HYDRAULIC GEAR PUMP OUTLET PORT
Figure 38. 7. HYDRAULIC HOSE
5. Disconnect and cap suction hose from hydraulic

gear pump inlet port. Cap hydraulic gear pump in-
let port. See Figure 37 and Figure 38.
6. Disconnect and cap hydraulic hose from hydraulic

gear pump outlet port. Cap hydraulic gear pump
outlet port. See Figure 37 and Figure 38.
NOTE: Perform Step 7 for lift trucks built prior to Jan-

uary, 2011.
7. Install an eyebolt in top of transmission housing.

Connect a lifting device to the eyebolt.
NOTE: Perform Step 8 for lift trucks built after January,

2011.
8. Connect a lifting device to the eyebolt bracket. See

Figure 27.
NOTE: MAZDA LPG ENGINE SHOWN FOR REFER-

ENCE ONLY.
2. DRAIN FITTING
3. HYDRAULIC GEAR PUMP
4. SUCTION HOSE
5. HYDRAULIC GEAR PUMP INLET PORT
6. HYDRAULIC GEAR PUMP OUTLET PORT
7. HYDRAULIC HOSE
Figure 38. Hydraulic Hose, Aluminum

Transmission Housing After January, 2011
Figure 37. Hydraulic Hose, Aluminum

Transmission Housing Prior to January, 2011
37
Transmission Replacement 100 YRM 1423
9. Remove capscrew, washer, snubbing washers, and NOTE: Note position of oil seal prior to removal to aid
isolators from the mount bracket at the rear of the in installation.
transmission. See Figure 39.
12. Remove oil seal from transmission housing. See
10. Use the lifting device to carefully lift the transmis- Figure 40.
sion from the frame.
INSTALL
11. Remove flange head capscrew, yoke, and spacer
from transmission housing. Make sure to not dam-
WARNING
age the oil seal. Remove and discard stat-o-seal
from yoke. See Figure 40. The transmission is heavy. Make sure that any lift-
ing device has enough capacity to lift the weight.
The transmission can weigh approximately 83.8 kg
(184.7 lb).
1. Using a lifting device, install transmission in lift truck

frame. Place a block under the transmission hous-
ing to support the transmission.
2. Install oil seal on back of transmission housing. See

Figure 40.
3. Install new stat-o-seal on yoke. See Figure 40.
4. Install spacer, yoke, and flange head capscrew

on back of transmission housing. See Figure 40.
Tighten capscrew to 77 N•m (57 lbf ft).
5. Install isolators, snubbing washers, washer, and

capscrew on mounting bracket at the rear of the
transmission. See Figure 39. Tighten capscrew to
225 to 250 N•m (166 to 184 lbf ft).
6. Connect hydraulic hose to hydraulic gear pump out-

let port. See Figure 37 and Figure 38.
NOTE: DRIVE AXLE NOT SHOWN FOR CLARITY.

1. FLANGE HEAD CAPSCREW
1. MOUNT BRACKET 2. STAT-O-SEAL
2. CAPSCREW 3. YOKE
3. WASHER 4. OIL SEAL
4. SNUBBING WASHER 5. SPACER
5. ISOLATOR 6. TRANSMISSION HOUSING
Figure 39. Rear Mount- Transmission Figure 40. Drive Shaft Yoke
38
100 YRM 1423 Throttle Pedal and Cable Adjustment
7. Connect suction hose to hydraulic gear pump inlet 11. Install engine in lift truck. See section Install, En-
port. See Figure 37 and Figure 38. gine Replacement for procedures.
8. Install drain fitting on transmission housing. See 12. Remove lifting device from eyebolt or eyebolt
Figure 37 and Figure 38. bracket on transmission.
9. Connect transmission cooling line to transmission. 13. Fill transmission oil. For fill instruction, oil type,
See Figure 37 and Figure 38. and amount see the section Periodic Maintenance
8000 YRM 1424.
10. Install seal plate for brake and throttle pedals. See
Figure 5.
Throttle Pedal and Cable Adjustment

MAZDA LPG ENGINE 6. Install floor plate. Fully depress throttle pedal and
adjust pedal stop so that it touches floor plate.
Throttle Pedal Stop Adjustment Tighten jam nuts (6, Figure 42) to 8 to 15 N•m (71
to 133 lbf in).
The Mazda FE LPG engines used on lift trucks covered
in this manual have an electronic throttle that is self-
adjusting and self-calibrating. There is only a throttle
pedal stop adjustment. To replace the throttle pedal
position sensor, see service manual Electrical System
2200 YRM 1427.
1. Fully depress throttle pedal and adjust pedal stop

so that it touches floor plate. Tighten jam nut to
10 N•m (88.5 lbf in). See Figure 41.
YANMAR DIESEL ENGINE

1. Remove floor plate and disconnect throttle cable
from bellcrank and engine.
2. Fully depress throttle pedal and verify that the di-

mension between the bellcrank and cowl plate is 5
±1 mm (0.20 ±0.04 in.). See Figure 42.
3. If dimension is not correct, adjust ball ends on

push rod so that a minimum of 6 mm (0.24 in.)
of threaded rod screws into each ball end. After
adjusting push rod, tighten jam nuts to 8 to 15 N•m
(71 to 133 lbf in).
4. Connect throttle cable to bellcrank and engine. See

Figure 42. 1. THROTTLE PEDAL POSITION SENSOR
2. SPRING
5. With throttle pedal in full up position, adjust throttle 3. THROTTLE PEDAL
cable, using jam nuts (10, Figure 42) to remove all 4. ADJUSTING NUT
slack from cable. Cable should be adjusted to the 5. PEDAL STOP
point where additional adjustment will pull control 6. FLOOR PLATE
lever off idle stop. Tighten jam nuts 8 to 15 N•m (71 Figure 41. Throttle Pedal Stop Adjustment, Mazda
to 133 lbf in). FE LPG Engines
39
Throttle Pedal and Cable Adjustment 100 YRM 1423
NOTE: THROTTLE PEDAL NOT SHOWN IN FULLY DEPRESSED POSITION (WIDE OPEN POSITION).
NOTE: MOUNTING BRACKET FOR THREE FUNCTION CONTROL VALVE SHOWN, FOUR FUNCTION CON-
TROL VALVE SIMILAR.
1. COWL 7. PEDAL STOP
2. BELLCRANK 8. THROTTLE CABLE
3. PUSH ROD 9. CABLE BRACKET
4. BALL END 10. JAM NUTS
5. THROTTLE PEDAL 11. THROTTLE CRANK
6. JAM NUT
Figure 42. Throttle Pedal and Cable Adjustment, Yanmar Diesel Engine
40
100 YRM 1423 Hydraulic Filter Repair
YANMAR DIESEL ENGINE WITH

ELECTRONIC THROTTLE
If lift truck is equipped with an electronic throttle, see
section Yanmar Diesel Engines, 2.6L and 3.3L 600
YRM 1205 for adjustment procedures.
Cooling System
DESCRIPTION • Fan shroud
• Coolant hoses and lines
The cooling system is used to cool the engine and keep • Coolant reservoir
it at the correct operating temperature. The cooling sys-
tem is comprised of the following main components: For the procedures to repair, clean, inspect, and install
• Radiator the radiator and cooling system components, refer to
• Fan and belt Cooling System 700 YRM 1123.
Hydraulic Filter Repair

REMOVE 3. Remove filter element and O-ring from filter housing
and place in container. Cover head to prevent any
WARNING foreign material from getting into the hydraulic tank.
See Figure 43.
At operating temperature, the hydraulic oil is HOT.
DO NOT permit the hot oil to touch the skin and
cause a burn.
CAUTION
DO NOT permit dirt to enter the hydraulic system
when the oil level is checked or the filter is changed.
Dirt can cause damage to the components of the
hydraulic system.
Never operate the hydraulic pump without oil in the

hydraulic system. The operation of the hydraulic
pump without oil will damage the pump.
CAUTION
1. Put lift truck on level surface and lower carriage.
2. Unscrew and remove lid and spring from head. Re- 1. LID
move and discard O-ring from lid. See Figure 43. 2. SPRING
3. O-RING
NOTE: Have container large enough to hold filter ele- 4. FILTER ELEMENT
ment and allow for final hydraulic oil draining. 5. HEAD
6. FILTER HOUSING
NOTE: Note placement of filter element and handle 7. QUAD RING
prior to removal to aid in installation.
Figure 43. Hydraulic Filter
41
Tank Repair 100 YRM 1423
4. After filter element has drained, discard filter ele- 3. Lubricate new O-ring with clean hydraulic oil and in-
ment and O-ring. stall on bottom of new filter element. See Figure 43.
5. Remove and discard quad ring from filter housing. 4. Install new filter element into filter housing as noted
See Figure 43. during removal. See Figure 43.
CLEAN AND INSPECT 5. Lubricate new O-ring with clean hydraulic oil and
install on lid. See Figure 43.
1. Clean housing and cover plate as necessary.
6. Install spring and lid onto filter housing. See Fig-
2. Inspect filter housing, especially sealing surfaces, ure 43. Tighten lid to 14 N•m (124 lbf in).
for damage. Replace, if damaged.
3. Inspect dipstick plug. Replace O-ring and plug as CAUTION

necessary. Additives may damage the hydraulic system. Be-
fore using additives, contact your local Yale dealer.
INSTALL
7. Start lift truck, and allow it to run for 30 seconds.
1. Lubricate sealing surfaces on filter housing with Check for leaks. Stop engine and check hydraulic
clean hydraulic oil. oil level. Add oil, if necessary. Use hydraulic oil in-
dicated in Periodic Maintenance 8000 YRM 1424.
2. Lubricate new quad ring with clean hydraulic oil and
install onto filter housing. See Figure 43.
Tank Repair
LPG TANK REPAIR • Safety in Welding and Cutting, American National
Standard, AWS Z 49.1 - 1999.
For repair of LPG tank, see section LPG Fuel System,
Mazda FE and F2 Emission Compliant Engines 900
YRM 1326. WARNING
DO NOT use tools that can make sparks, heat, or
HYDRAULIC AND DIESEL TANKS static electricity. The vapors in the tank can cause
an explosion.
Inspect
CAUTION
WARNING Additives may damage the hydraulic system. Be-
Special procedures must be followed when large fore using additives, contact your local Yale dealer.
leaks or other repairs need welding or cutting. All
work must be done by authorized personnel. If the Make a visual inspection of all sides of the tank. Inspect
tank is cleaned inside a building, make sure there is the welds for cracks and leakage. Check for wet areas,
enough ventilation. See the following manuals for accumulation of dirt, and loose or missing paint caused
additional information: by leakage. Areas of the tank that are not easily seen
• Safe Practices for Welding and Cutting Contain- can be checked with an inspection mirror and a light that
ers That Have Held Combustibles by the Ameri- is approved for locations with flammable vapors.
can Welding Society, F4.1 - 1999.
42
100 YRM 1423 Tank Repair
A. FRAME FOR LPG LIFT TRUCK B. FRAME FOR DIESEL LIFT TRUCK
1. HYDRAULIC TANK 2. DIESEL FUEL TANK
Figure 44. Hydraulic and Diesel Tanks
Clean Steam Method of Cleaning
WARNING WARNING
When cleaning the tank, do not use solutions that Compressed air can move particles so that they
make dangerous gases at normal temperatures or cause injury to the user or to other personnel.
when heated. Wear eye and face protection. Protect Make sure that the path of the compressed air is
the body from burns. away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
WARNING
Compressed air can move particles so that they WARNING
cause injury to the user or to other personnel. Be careful when cleaning with steam. Steam can
Make sure that the path of the compressed air is cause serious burns. Wear protective clothing,
away from all personnel. Wear protective goggles gloves, and eye protection. Never expose your skin
or a face shield to prevent injury to the eyes. to steam.
Use the following procedure to clean the tank with

WARNING steam:
Be careful when cleaning with steam. Steam can
cause serious burns. Wear protective clothing, 1. Remove all the parts from the tank. Install the drain
gloves, and eye protection. Never expose your skin plug.
to steam.
2. Fill the tank 1/4 full with a solution of water and
When cleaning with steam, use a hose with a minimum sodium bicarbonate or sodium carbonate. Mix
diameter of 19 mm (0.75 in.). Control the pressure of 0.5 kg (1 lb) per 4 liter (1 gal) of water.
the steam by a valve installed at the nozzle of the hose.
If a metal nozzle is used, it must be made of a material 3. Mix the solution in the tank using air pressure.
that does not make sparks. Make an electrical connec- Make sure all the surfaces on the inside of the tank
tion between the nozzle and the tank. Connect a ground are flushed with the solution. Drain the tank.
wire to the tank to prevent static electricity.
43
Tank Repair 100 YRM 1423
4. Put steam into the tank until the tank does not have 4. Make an inspection of the inside of the tank. If the
odors and the metal is hot. Steam vapors must tank is not clean, repeat Step 1 through Step 3.
come from all the openings. Make another inspection of the tank. When mak-
ing inspections, use a light that is approved for lo-
5. Flush the inside of the tank with boiling water. Make cations with flammable vapors.
sure all the loose material is removed from the in-
side of the tank. 5. Check the tank for flammable vapors using special
indicator for gas vapors. If the amount of flammable
6. Make an inspection of the inside of the tank. If it vapors is not below the lower flammable limit, re-
is not clean, repeat Step 4 and Step 5 and make peat the cleaning procedures.
another inspection. When making inspections, use
a light that is approved for locations with flammable ADDITIONAL PREPARATIONS FOR
vapors. REPAIR
7. Put plugs in all the openings in the tank. Wait If nitrogen gas or carbon dioxide gas is available, pre-
15 minutes, then remove the inlet and outlet plugs. pare the tank for welding using these gases. See the
Test a sample of the vapor with a special indicator manual Safe Practices for Welding and Cutting Con-
for gas vapors. If the amount of flammable vapors is tainers That Have Held Combustibles by the American
above the lower flammable limit, repeat the clean- Welding Society, F4.1 - 1999. If these gases are not
ing procedures. available, another method using water can be used as
Chemical Solution Method of Cleaning follows:
1. Fill the tank with water to just below the point where
WARNING the work will be done. Make sure the space above
When cleaning the tank, do not use solutions that the level of the water has a vent.
make dangerous gases at normal temperatures or
2. Use acceptable welding practices to repair the
when heated. Wear eye and face protection. Protect
tank. See the American National Standard Safety
the body from burns.
in Welding and Cutting, AWS Z 49.1 - 1999.
WARNING SMALL LEAKS, REPAIR

Compressed air can move particles so that they
cause injury to the user or to other personnel. Use the following procedure to repair small leaks:
Make sure that the path of the compressed air is 1. Use steam to clean the area around the leak. Re-
away from all personnel. Wear protective goggles move all paint and dirt around the leak.
or a face shield to prevent injury to the eyes.
2. Apply Loctite® 290 to the leak. Follow the instruc-
CAUTION tions of the manufacturer.
Disposal of lubricants, fluids, and chemicals must
LARGE LEAKS, REPAIR
meet local environmental regulations.
1. Use one of the procedures described under Clean
If the tank cannot be cleaned with steam, use the fol-
to clean and prepare the tank for repairs.
lowing procedure:
2. Contact your dealer for Yale lift trucks for welding
1. Mix a solution of water and trisodium phosphate or
instructions.
a cleaning compound with an alkaline base. Follow
the instructions given by the manufacturer. 3. Use acceptable welding practices to repair the
tank. See the American National Standard Safety
2. Fill the tank with the cleaning solution. Use com-
in Welding and Cutting, AWS Z 49.1 - 1999.
pressed air to mix the solution in the tank.
3. Drain the tank. Flush the inside of the tank with

hot (boiling) water. Make sure all the cleaning com-
pound is removed.
44
100 YRM 1423 Label Replacement
PREPARATIONS FOR USE AFTER REPAIR 2. If there are no leaks coming from the tank, remove
all the water from the tank.
1. Add more water to the tank so that the water goes
above the point of where the work was done. Check
to see if there are any leaks coming from tank.
Label Replacement
See Figure 45 for lift truck models below with Mazda
WARNING LPG engine:
Safety labels are installed on the lift truck to provide • GLC050LX (A967)
information about operation and possible hazards. • GLP20-25LX (GLP050LX) (A974)
It is important that all safety labels are installed on
the lift truck and can be read. See Figure 46 for lift truck models below with Yanmar
Diesel engine:
DO NOT add to or modify the lift truck. Any change • GDP20-25LX (GDP050LX) (A974)
to the lift truck, the tires, or its equipment can
change the lifting capacity. The lift truck must be If a new label must be installed, use the following pro-
rated as equipped, and the Nameplate must show cedure to install a new label.
the new capacity rating. Contact your dealer for a
new Nameplate. 1. Make sure the surface is dry and has no oil or
grease. Do not use solvent on new paint. Clean
the surface of old paint with a cleaning solvent.
WARNING
Cleaning solvents can be flammable and toxic and 2. Remove the paper from the back of the label. Do
can cause skin irritation. When using cleaning sol- not touch the adhesive surface.
vents, always follow the recommendations of the
3. Carefully hold the label in the correct position above
manufacturer.
the surface. The label cannot be moved after it
Not all labels that are used on the lift trucks covered in touches the surface. Put the label on the surface.
this manual are shown in Figure 45 and Figure 46. See Make sure that all air is removed from under the
the Parts Manual for a complete listing of all labels used label, and the corners and edges are tight.
on these lift trucks and their part numbers.
45
Label Replacement 100 YRM 1423
Figure 45. Warning and Safety Labels for Lift Trucks with Mazda LPG Engine
46
NOTE: ITEM 21 IS OPTIONAL FOR LIFT TRUCK MODEL GLP/GDP20-25LX (GLP/GDP050LX) (A974); NOT USED
ON LIFT TRUCK MODEL GLC050LX (A967).
1. TIP OVER WARNING 13. LIFT AND TILT LABEL
2. OVERHEAD GUARD LABEL 14. FLAMMABLE LP GAS
3. OPERATION WARNING 15. LPG TANK WARNING
4. NO RIDERS 16. AIR FILTER INSTALL CAUTION
5. PARKING BRAKE WARNING LABEL 17. FAN WARNING
6. MAST WARNING 18. BORON-FREE LABEL
7. MAST WARNING 19. ANTIFREEZE LABEL
8. NOTICE TO USER LABEL 20. SINGLE SPEED POWERSHIFT TRANSMISSION
9. UL LABEL 21. SPLIT WHEEL WARNING (OPTIONAL)
10. NAMEPLATE 22. STABILITY SYSTEM LABEL*
11. NO ONE ON OR UNDER FORKS 23. WARNING FOR PARKING BRAKE**
12. LOCKING GAS SPRING
* THIS LABEL USED ONLY ON U.S. LIFT TRUCK MODELS MANUFACTURED AFTER JANUARY, 2012.
** THIS LABEL USED ONLY ON LIFT TRUCKS MANUFACTURED AFTER JANUARY, 2012.
47
Label Replacement 100 YRM 1423
Figure 46. Warning and Safety Labels for Lift Trucks with Yanmar Diesel Engine
48

1. FUEL LABEL (DIESEL)* 13. PINCH POINT WARNING
2. AIR FILTER INSTALL CAUTION 14. NO ONE ON OR UNDER FORKS
3. PARKING BRAKE WARNING LABEL 15. NO RIDERS
4. ETHER WARNING LABEL 16. LOCKING GAS SPRING
5. OVERHEAD GUARD LABEL 17. SINGLE SPEED POWERSHIFT TRANSMISSION
6. OPERATION WARNING 18. FAN WARNING
7. UL LABEL* 19. BORON-FREE LABEL
8. MAST WARNING 20. ANTIFREEZE LABEL
9. TIP OVER WARNING 21. SPLIT WHEEL WARNING* (OPTIONAL)
10. LIFT AND TILT LABEL 22. STABILITY SYSTEM LABEL**
11. NOTICE TO USER LABEL 23. WARNING FOR PARKING BRAKE***
12. NAMEPLATE
*U.S. TRUCKS ONLY

** THIS LABEL USED ONLY ON U.S. LIFT TRUCK MODELS MANUFACTURED AFTER JANUARY, 2012.
*** THIS LABEL USED ONLY ON LIFT TRUCKS MANUFACTURED AFTER JANUARY, 2012.
49
NOTES
____________________________________________________________
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____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
50
Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011
100 YRM 1423 3/12 (12/11)(7/11)(11/10)(5/10) Printed in U.S.A.

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Maintenance

PART NO. 550013974 100 YRM 1423

• 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.

©2012 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

This section is for the following models:

1. COWL PLATE 5. COUNTERWEIGHT SUPPORT

Hood, Seat, and Side Covers Replacement

1. Slide the seat to the closest position to the steering

2. Fully tilt the steering column forward.

NOTE: Perform Step 3 for lift trucks equipped with LPG.

3. Swing LPG tank off to side. See LPG Fuel System,

4. Raise the hood latch on the left, front corner of the

5. Remove the floor mat and floor plate. See Figure 3.

6. Remove the two capscrews holding the left and

Legend for Figure 3

Figure 3. Side Cover, Floor Plate, and Cowl Components

NOTE: TOP VIEW OF DASH PANEL SHOWN

Figure 4. Dash Panel and Upper Steering Column Cover Removal

1. ALLEN HEAD SCREWS 5. KICK PANEL NOTCHES

Figure 5. Dash Panel, Kick Panel, and Seal Plate Removal

15. Open hood and pull chassis harness through hole

A. NON-SUSPENSION SEAT B. FULL SUSPENSION SEAT

Figure 6. Disconnect Seat Wire Harness

Legend for Figure 7

NOTE: MOUNTING HOLES FOR FULL SUSPENSION

Figure 7. Remove Seat From Hood

A. HOOD HINGE ARRANGEMENT B. GAS SPRING ARRANGEMENT (LEFT SIDE

Figure 8. Gas Spring and Hood Removal

INSTALL (two clicks). Also check that hood touches rubber

A. LEFT SIDE B. RIGHT SIDE

Figure 9. Gas Spring and Seat Hole Alignment

NOTE: Perform Step 17 for lift trucks equipped with

17. Swing the LPG tank into position on back of coun-

18. Adjust the steering column and seat positions.

BELLY PAN (OPTIONAL)

2. Remove belly pan from frame. See Figure 11.

Clean and Inspect

2. Install four capscrews and four nuts onto belly pan

1. HOOD 3. CENTER PIN

Figure 10. Hood Latch Adjustment

13. Raise steering column to highest position and in-

Figure 11. Belly Pan

NOTE: Perform Step 5 for lift trucks equipped with gas

5. Remove four capscrews, four bushings and steer-

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

NOTE: DIESEL SHOWN, LPG AND GAS SIMILAR.

Figure 14. Steering Column Remove/Install

Legend for Figure 15

Clean 3. Assemble lower shaft and upper shaft, secure with

4. Install two pivot bolts, two bushings, two nuts and

See Figure 16 5. Remove tag from negative battery connector and

6. Remove blocks from each side of tires.

If the engine will not run, close the shutoff valve on

1. TOW PIN 4. WASHER

Figure 17. Counterweight Installation

Table 1. Weight of Counterweights 1. SEAL 6. LOCKWASHER

INSTALL 3. Install capscrew onto counterweight and frame.

Overhead Guard Replacement