Yale Forklift B809 (GC_GLC030-040AF) Service Manual – PDF DOWNLOAD

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Yale Forklift B809 (GC_GLC030-040AF) Service Manual – PDF DOWNLOAD

FILE DETAILS:

Yale Forklift B809 (GC_GLC030-040AF) Service Manual – PDF DOWNLOAD

Language : English
Pages : 756
Downloadable : Yes
File Type : PDF

PART NO. 524150790

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TABLE OF CONTENTS:

Yale Forklift B809 (GC_GLC030-040AF) Service Manual – PDF DOWNLOAD

toc 1
Tilt Cylinders 1
Safety Precautions Maintenance and Repair 2
General 5
Description 5
Tilt Cylinder Repair 5
Remove 5
Disassemble 5
Clean 5
Assemble 6
Tilt Cylinders With O-Ring or Single-Lip Seals 6
Tilt Cylinders 7
Install 8
Tilt Cylinder Leak Check 10
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment 11
Torque Specifications 11
Piston Rod Nut 11
Retainer 11
Troubleshooting 12
tables 1
Table 1 Movement Rates (Maximum) for Tilt Cylinders 10
General 23
Threaded Fasteners 23
Nomenclature, Threads 23
Strength Identification 24
Cotter (Split) Pins 25
Fastener Torque Tables 30
Conversion Table 32
General 43
Threaded Fasteners 43
Nomenclature, Threads 43
Strength Identification 44
Cotter (Split) Pins 45
Fastener Torque Tables 50
Conversion Table 52
toc 59
Mazda Engine 59
Safety Precautions Maintenance and Repair 60
General 63
Description 63
Engine Removal and Installation 63
Cylinder Head, Camshaft, and Valve Mechanism Repair 64
Remove 64
Clean 65
Inspect and Repair 66
Cylinder Head 66
Rocker Shaft Assembly 66
Camshaft 66
Valve Guides 67
Valve Seats 68
Valves 68
Valve Springs 69
Install 69
Crankshaft and Main Bearings Repair 72
Remove 72
Inspect and Repair 72
Crankshaft 72
Main Bearings 72
Install 73
Pistons and Connecting Rods Repair 74
Remove and Disassemble 74
Clean 74
Inspect and Repair 74
Pistons 74
Piston Rings 75
Connecting Rods and Bearings 75
Assemble and Install 76
Cylinder Block Repair 77
Oil Pump Repair 77
Remove 77
Disassemble 78
Clean 78
Inspect 78
Assemble 79
Install 80
Cooling System Repair 80
Thermostat 80
Replace 80
Fan Assembly 80
Remove and Disassemble 80
Assemble and Install 81
Water Pump 81
Remove and Disassemble 81
Assemble and Install 82
Distributor Repair 83
Remove 83
Install 83
Flywheel and Ring Gear Repair 84
Remove 84
Ring Gear, Replace 84
Install 84
Flywheel Repair 85
Remove 85
Install 85
Valve Adjustment 86
Compression Pressure Check 86
Engine Timing Adjustment 87
Throttle Linkage Adjustment 87
Gasoline Engines 87
LPG Engines (IMPCO) 87
LPG Engines (AISAN) 88
Engine Specifications 88
Engine Data 88
Thermostat 88
Cylinder Head 88
Valve Mechanism 88
Camshaft 89
Crankshaft 89
Connecting Rods 90
Cylinder Block 90
Pistons 90
Oil Pump 90
Torque Specifications 91
Troubleshooting 92
toc 97
LPG Fuel System 97
Safety Precautions Maintenance and Repair 98
General 101
Description and Operation 101
Fuel Tank 102
Regulator 102
Start Mode 104
Idle Mode 104
Run Mode 104
Resonator 104
Carburetor 105
Start Mode 105
Idle Mode 105
Run Mode 105
Governor 106
Hoses Replacement 107
LPG Tank Repair 107
Remove 107
Install 107
Relief Valve Repair 108
Remove and Install 108
Carburetor Repair 108
Remove 108
Disassemble 108
Clean 109
Assemble 109
Install 110
Governor Repair 110
Remove 110
Inspect 110
Install 110
Regulator Repair 111
Remove 111
Disassemble 111
Clean 111
Inspect 111
Assemble 113
Install 114
Regulator Adjustment 114
Regulator Height Adjustment 114
Regulator Assembly Air Tightness Test 115
Carburetor Adjustment 116
Idle Speed and Fuel Mixture 116
Idle Control Adjustment 116
Governor Adjustment 117
Checks 117
Adjustments 117
Throttle Linkage Adjustment 118
Foot Directional Control Pedal Check 119
Throttle Linkage Adjustment 120
Troubleshooting 121
tables 97
Table 1 Power Adjusting Screw 110
Table 2 Air Adjusting Screw 110
Table 3 Idle Mixture Adjusting Screw 113
Table 4 Idle Mixture Adjusting Screw 116
toc 129
LPG Fuel System 129
Safety Precautions Maintenance and Repair 130
General 133
Description and Operation 133
Fuel Tank 133
Oxygen Sensor 133
Regulator 133
Start Mode 136
Idle Mode 139
Run Mode 139
Resonator 139
Carburetor 139
Start Mode 139
Idle Mode 140
Run Mode 140
Governor 141
Hoses Replacement 141
LPG Tank Repair 142
Remove 142
Install 142
Relief Valve Repair 143
Remove and Install 143
Carburetor Repair 143
Remove 143
Disassemble 143
Clean 144
Assemble 144
Install 145
Fuel Injector Repair 145
Remove 145
Clean and Inspect 145
Install 145
Governor Repair 146
Remove 146
Inspect 146
Install 146
Regulator Repair 146
Remove 146
Install 146
Oxygen Sensor Repair 146
Remove and Install 146
Vacuum Switches Repair 147
Remove and Install 147
Inspect 147
Resistor Repair 147
Remove and Install 147
Inspect 147
Carburetor and New Regulator Adjustment 147
Idle Speed and Fuel Mixture 147
Idle Control Adjustment 148
Governor Checks and Adjustments 149
Checks 149
Adjustments 149
Throttle Linkage Adjustment 149
Foot Directional Control Pedal Check 151
Check Engine Light 151
Inspect Warning Lamp 151
Check Feedback Operation 151
Check VAC1 and VAC2 Signals 151
Check Resistor 151
Check Fuel Injector 151
Check Oxygen Sensor 152
Check Vacuum Switch 1 152
Check Vacuum Switch 2 152
After Completing Checks 152
Troubleshooting 152
tables 129
Table 1 Adjusting Screw 145
toc 161
Steering Housing and Control Unit 161
Safety Precautions Maintenance and Repair 162
General 165
Description 165
Operation 166
Steering Wheel and Column Assembly Repair 167
Assembly Components, Remove 167
Steering Control Unit, Disassemble 172
Steering Control Unit, Clean 172
Steering Control Unit, Assemble 172
Assembly Components, Install 174
System Air Removal 176
Troubleshooting 176
toc 181
Instrument Cluster 181
Safety Precautions Maintenance and Repair 182
General 185
Description 185
Instrument Cluster Display Panel, Internal Combustion Lift Truck 185
Instrument Cluster Display Panel, Electric Lift Truck Models 192
Optional Basic Display Panel 192
Features of the Optional Basic Display Panel 192
Description of Features on the Optional Basic Display Panel 192
Standard Display Panel 193
Features of the Standard Display Panel 193
Description of Features on the Standard Display Panel 193
Premium Display Panel 194
Features on the Premium Display Panel 194
Description of Features on the Premium Display Panel 195
Curtis 1215 Display Panel 197
Description and Features 197
Operation 198
Cluster-Type Display Panel (Internal Combustion) Replacement 199
Remove 199
Install 199
Cluster Display Panel (Electric Lift Truck) Replacement 202
Curtis 1215 Display Panel Replacement 207
Remove 207
Install 207
tables 181
Table 1 Instrument Cluster, Internal Combustion 186
toc 211
Electrical System 211
Safety Precautions Maintenance and Repair 212
General 215
Description 215
Starting System 215
Ignition System 215
Charging System 216
Starter Repair 217
Remove and Disassemble 217
Assemble and Install 217
Coil Replacement 219
Distributor Repair 220
Remove and Disassemble 220
Assemble and Install 220
Distributor Repair 222
Remove and Disassemble 222
Assemble and Install 224
Alternator Repair 224
Remove and Disassemble 224
Assemble and Install 225
General Checks and Adjustments 226
Starter Checks 226
Operation, Check 226
Brush Holder, Check 227
Armature, Check 227
Field Windings, Check 227
Clutch and Bearing, Check 227
Ignition System Check and Adjustment 228
Engine Timing, Adjust 228
Spark Plugs, Check 228
Charging Circuit Checks 229
Low Output, Check 229
High Output, Check 230
Diodes, Check 230
Rotor Field Winding, Check 231
Stator Windings, Check 231
Brushes and Bearings, Check 231
Voltage Regulator, Check 231
Troubleshooting 232
toc 237
Mast 237
Safety Precautions Maintenance and Repair 238
General 241
Description and Operation 241
Carriages 241
Mast Mounts 243
Two-Stage Mast, Limited Free-Lift (LFL) 244
Description and Operation 244
Two-Stage Mast, Full Free-Lift (FFL) 246
Description and Operation 246
Three-Stage Mast, Full Free-Lift (FFL) 248
Description and Operation 248
Four-Stage Mast 250
Description and Operation 250
Cylinder Cushion During Lifting Sequence 254
Cylinder Cushion During Lowering Sequence 255
toc 259
Mast 259
Safety Precautions Maintenance and Repair 260
General 263
Safety Procedures When Working Near Mast 264
Fork Repair 266
Remove 266
Install 266
Carriages Repair 268
Standard Carriage, Remove 268
Hang-On Sideshift Carriage, Remove 269
Standard Carriage and Hang-On Sideshift Carriage, Repair 270
Standard Carriage, Install 271
Hang-On Sideshift Carriage, Install 272
Integral Sideshift Carriage 272
Remove 272
Clean and Inspect 276
Repair 277
Install 278
Mast Repair 279
Remove 279
Two-Stage LFL and Two-Stage FFL Masts, Disassemble 281
Three-Stage FFL Mast 289
Disassemble 289
Mast and Chains, Clean and Inspect 292
Two-Stage LFL and Two-Stage FFL Mast, Assemble 293
Three-Stage FFL Mast, Assemble 294
Install 295
Lift Cylinders Repair 297
Main Lift Cylinders, Remove 297
Free-Lift Cylinder, Remove 297
Cylinders, Disassemble 298
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 298
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 300
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 300
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 301
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 302
Clean and Inspect 303
Cylinders, Assemble 303
Two-Stage Full Free-Lift Mast, Right-Hand Main Lift Cylinder 303
Two-Stage Full Free-Lift Mast, Left-Hand Main Lift Cylinder 304
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 305
Two-Stage Limited Free-Lift Mast and Three-Stage Full Free-Lift 305
Two-Stage Full Free-Lift Mast and Three-Stage Full Free-Lift Mas 306
Main Lift Cylinders, Install 307
Free-Lift Cylinder, Install 307
Header Hose Arrangements 308
Two-Stage LFL Mast, New Hose Install 308
Two-Stage LFL Mast, Adjust Hoses After Installation 313
Two-Stage FFL Mast, New Hose Install 313
Two-Stage FFL Mast, Adjust Hoses After Installation 321
Three-Stage FFL Mast, New Hose Install 321
Three-Stage FFL Mast, Adjust Hoses After Installation 332
Header Hose Arrangement 333
Two-Stage LFL Mast, New Hose Install 333
Two-Stage LFL Mast, Adjust Hoses After Installation 338
Two-Stage FFL Mast, New Hose Install 338
Two-Stage FFL Mast, Adjust Hoses After Installation 344
Three-Stage FFL Mast, New Hose Install 344
Three-Stage FFL Mast, Adjust Hoses After Install 353
Lift and Tilt System Leak Check 354
Lift Cylinders Leak Check 354
Tilt Cylinders Leak Check 354
Tilt Cylinders Adjustment 355
Lift Chains Adjustment 357
Mast Adjustment 359
Carriage Adjustment 361
Troubleshooting 362
tables 259
Table 1 Hook-Type Carriage Chain Adjustment 357
Table 2 Pin-Type Carriage Chain Adjustment 358
toc 365
Mazda XA and HA Diesel Engines 365
Safety Precautions Maintenance and Repair 366
General 371
Description 371
Engine Removal and Installation 371
Cylinder Head and Valve Mechanism Repair 373
Remove 373
Clean 373
Inspect and Repair 374
Cylinder Head 374
Rocker Shaft Assembly 374
Valve Guides 375
Valve Seats 375
Valves 376
Valve Springs 376
Push Rods 377
Cylinder Head, Assemble 377
Cylinder Head, Install 378
Timing Gears Repair 379
Remove 379
Clean and Inspect 379
Install 380
Camshaft Repair 381
Remove 381
Inspect and Repair 381
Install 382
Crankshaft and Main Bearings Repair 382
Remove 382
Inspect and Repair 382
Crankshaft 382
Main Bearings 383
Install 383
Piston and Connecting Rods Repair 384
Remove and Disassemble 384
Clean 384
Inspect and Repair 384
Pistons 384
Piston Rings 385
Connecting Rods and Bearings 385
Assemble and Install 386
Cylinder Block and Liners Repair 387
Inspect and Repair 387
Lubrication System Repair 389
Oil Pump 389
Remove 389
Disassemble 389
Clean 389
Inspect 389
Assemble 390
Install 391
Oil Filter Mount 391
Remove 391
Install 391
Oil Cooler 392
Remove 392
Clean and Inspect 392
Install 392
Cooling System Repair 392
Thermostat 392
Remove and Install 392
Water Pump 393
Remove 393
Disassemble 393
Inspect 394
Assemble 394
Install 395
Fuel System Repair 396
Description and Operation 396
Fuel Injection Pump 396
Remove 396
Install 397
Fuel Filter 398
Filter, Replace 398
Water Sensor Check 399
Fuel System Air Removal 399
Fuel Injectors 400
Remove and Disassemble 400
Clean and Inspect 400
Assemble 400
Inspect and Adjust 400
Install 401
Flywheel and Ring Gear Repair 401
Flywheel, Remove 401
Ring Gear, Replace 401
Flywheel, Install 402
Flywheel, Remove 402
Flywheel, Install 402
Alternator Repair 403
Starting System Repair 404
Cold Start Aid 404
Description and Operation 404
Glow Plugs, Replace 404
Glow Plugs, Check 405
Fuse 405
Relay and Controller 405
Checks and Adjustments 406
Valves, Adjust 406
Compression Pressure Check 406
Throttle Linkage, Adjust 407
Fuel Injection Pump Timing Check 408
Engine Specifications 409
Engine Data 409
Cylinder Head 409
Camshaft 410
Crankshaft 411
Connecting Rods 412
Cylinder Block 413
Pistons 413
Oil Pump 413
Torque Specifications 414
Special Tools 415
Troubleshooting 417
tables 365
Table 1 Camshaft Journal Diameters 381
Table 2 Crankshaft Journal Diameters 383
Table 3 Piston Diameters 385
Table 4 Cylinder Liner Diameters 387
toc 425
Frame 425
Safety Precautions Maintenance and Repair 426
General 429
Description 429
Operator Module Repair 429
Remove 429
Install 431
Hood and Side Covers Repair 432
Remove 432
Install 433
Overhead Guard Repair 434
Remove and Install 434
LED Backup and Brake Lights, Replace 434
Remove 434
Install 434
Counterweight Repair 435
Remove 436
Install 437
Exhaust System Repair 437
Muffler, Replace 437
Radiator and Cooling System Repair 441
Remove 441
Install 441
Operator Restraint System Repair 442
Engine Repair 443
Remove (Engine Only) 443
Remove (Engine and Transmission) 444
Install (Engine Only) 444
Install (Engine and Transmission) 445
Fuel and Hydraulic Tanks Repair 445
Clean 445
Steam Method of Cleaning 445
Chemical Solution Method of Cleaning 446
Inspect 446
Repair 446
Small Leaks 446
Large Leaks 446
Safety Labels 447
tables 425
Table 1 Weight of Counterweights 435
toc 455
Gasoline Fuel System 455
Safety Precautions Maintenance and Repair 456
Description 459
Governor 459
Carburetor Repair 460
Remove 460
Disassemble 462
Clean 464
Inspect 464
Assemble 465
Install 468
Carburetor Checks and Adjustments 468
Idle Speed and Mixture, Adjust 468
Throttle Linkage, Adjust 469
Governor Checks and Adjustments 470
Troubleshooting 472
toc 477
Single-Speed Powershift Transmission 477
Safety Precautions Maintenance and Repair 478
General 481
Torque Converter Description and Operation 482
Description 482
Operation 482
Clutch Assemblies Description and Operation 484
Description 484
Operation 485
Hydraulic System Operation 486
Control Valve Operation 488
Regulator for Clutch Pressure 488
Inching Spool Assembly 488
Direction Spool 488
Modulator Circuit 488
Regulator for the Torque Converter 488
Foot Directional Control Pedal Operation 489
Start Circuit For The Foot Directional Control Pedal 489
Direction Control Lever Operation 490
Differential Operation 490
Torque Converter and Transmission Pump Repair 490
Remove and Disassemble 490
Inspect 490
Assemble and Install 491
Clutch Assemblies Repair 492
Remove and Disassemble 492
Inspect 495
Assemble and Install 495
Differential Repair 496
Remove and Disassemble 496
Inspect 496
Assemble and Install 496
New Ring and Pinion Assembly, Install 497
Pinion Assembly, Install 500
Differential and Ring Gear Assembly, Assemble 501
Control Valve Repair 502
Remove 502
Disassemble, Earlier Models 502
Disassemble, Later Models 503
Inspect 503
Assemble, Earlier Models 504
Assemble, Later Models 504
Install 504
Foot Directional Control Pedal Repair 505
Remove and Disassemble 505
Assemble and Install 505
Direction Control Lever Repair 508
Remove and Disassemble 508
Assemble and Install 509
Torque Converter Stall Test 510
Transmission Pressure Tests 510
Transmission Pump Pressure Check, Test Port No 1 511
Torque Converter Inlet Pressure Check, Test Port No 2 511
Clutch Pressure Check, Test Port No 3 511
Inching/Brake Pedal Adjustment 511
Troubleshooting 512
tables 477
Table 1 Pinion Assembly Shims Adjustment 498
Table 2 Ring and Pinion Tooth Contact Adjustment 499
Table 3 Stall Speeds 510
Table 4 Pressure Test Ports 511
toc 521
Drive Axle 521
Safety Precautions Maintenance and Repair 522
General 525
Description 526
Drive Axle Repair 526
Remove and Disassemble 526
Clean and Inspect 527
Assemble and Install 527
Torque Specifications 529
Troubleshooting 529
toc 533
Steering Axle 533
Safety Precautions Maintenance and Repair 534
General 537
Description 537
Steering Axle Assembly Repair 538
Remove 538
Install 538
Wheels and Hubs Repair 538
Pneumatic Tires, Remove and Disassemble 538
Cushion Tires, Remove and Disassemble 540
Pneumatic Tires, Assemble and Install 540
Cushion Tires, Assemble and Install 540
Spindles, Bearings, and Tie Rods Repair 541
Pneumatic Tires, Remove 541
Cushion Tires, Remove 541
Pneumatic Tires, Install 541
Cushion Tires, Install 542
Steering Cylinder Repair 542
Remove and Disassemble 542
Clean and Inspect 542
Assemble and Install 542
Torque Specifications 543
Troubleshooting 544
toc 547
Brake System 547
Safety Precautions Maintenance and Repair 548
General 551
Description and Operation 551
Service Brake 551
Parking Brake 552
Service Brakes Repair 552
Remove and Disassemble 552
Clean 555
Inspect 555
Assemble and Install 555
Adjust 558
Parking Brake Repair 559
Remove and Disassemble 559
Assemble and Install 560
Adjust 560
Master Cylinder Repair 560
Remove 560
Disassemble 560
Clean and Inspect 562
Assemble 562
Install 562
Service Brakes Adjustment 562
Brake System Air Removal 563
Parking Brake Not Applied Switch Test 563
Parking Brake Switch Test (Foot Directional Control Pedal Only) 563
Inching/Brake Pedal Adjustment 564
Torque Specifications 564
Troubleshooting 566
toc 571
Hydraulic System and Gear Pump Assembly 571
Safety Precautions Maintenance and Repair 572
General 575
Description and Operation 575
Hydraulic System 575
Gear Pump Assembly 577
Pump Drive Shaft 579
Steering Flow Divider 580
Relief Valve (Steering) 580
Relief Valve (Main Hydraulic) 581
Gear Pump Assembly Repair 582
Remove and Disassemble 582
Assemble and Install 582
Pump Drive Shaft Repair 582
Disassemble 582
Assemble and Install 583
Steering Relief Pressure Check and Adjust 583
Gear Pump Flow Check 583
Troubleshooting 584
toc 589
Main Control Valve 589
Safety Precautions Maintenance and Repair 590
General 593
Description 593
Operation 594
Lift Section 595
Tilt Section 595
Tilt Backward 595
Tilt Forward 595
Steering Flow Divider 598
Relief Valve (Steering) 598
Relief Valve (Main Hydraulic) 598
Main Control Valve Repair 599
Remove 599
Disassemble 599
Clean and Inspect 599
Assemble 599
Install 599
Pressure Relief Valve Check and Adjustment 603
Steering Relief Valve 603
Main Hydraulic Relief Valve 604
Troubleshooting 604
toc 609
Electrical System 609
Safety Precautions Maintenance and Repair 610
General 613
Description 613
Starting Circuit 613
Charging System 614
Starter Repair 615
Remove and Disassemble 615
Assemble and Install 615
Alternator Repair 617
Remove and Disassemble 617
Assemble and Install 618
General Checks and Adjustments 619
Starter Checks 619
Operation Check 619
Solenoid Coil Checks 620
Brush Holder Check 620
Armature Check 620
Field Windings Check 620
Clutch and Bearing Check 620
Cold Start Aid Checks 621
Glow Plugs 621
Fuse 621
Relay and Controller 621
Charging Circuit Checks 622
Low-Output Check 622
High-Output Check 622
Diodes Check 623
Rotor Field Winding Check 624
Stator Windings Check 624
Brushes and Bearings 625
Voltage Regulator Check 625
Troubleshooting 625
toc 631
Periodic Maintenance 631
Safety Precautions Maintenance and Repair 632
General 637
Serial Number 637
How to Move Disabled Lift Truck 637
How to Tow Lift Truck 637
How to Put Lift Truck on Blocks 638
How to Raise Drive Tires 638
How to Raise Steering Tires 638
Maintenance Schedule 639
Maintenance Procedures Every 8 Hours or Daily 647
How to Make Checks With Engine Stopped 647
Tires and Wheels 647
Forks 648
Adjust 648
Remove 649
Install 649
Inspection of Forks, Mast, and Lift Chains 649
Safety Labels 650
Operator Restraint System 650
Steering Column Latch 651
Fuel, Oil, or Coolant Leaks Check 651
Drive Belts 651
Engine Oil Level 652
Brake Fluid 652
Hydraulic Oil Level 653
Transmission Oil 653
Gasoline and LPG Fuel Filters 653
Diesel Fuel Filter 653
How to Drain Water From Fuel Filter 653
Battery Electrolyte 654
How to Make Checks With Engine Running 654
Gauges, Indicator Lights, Horn, Fuses, and Relays 654
Control Levers and Pedals 654
Steering System 654
Service Brakes 654
Parking Brake 656
Cooling System 656
Lift System Operation 657
Maintenance Procedures Every 250 Hours or 6 Weeks 657
Engine Oil and Filter 657
Changing Engine Oil and Filter 657
Air Filter 657
Transmission Oil Level 658
Battery 658
Wheel Nuts 659
Engine Speed 659
LPG Engine 659
Gasoline Engine 659
Diesel Engine 659
Lift Chains 659
Lubrication 659
Wear Check 659
Mast 660
Spark Plugs, Mazda FE Engine 660
Differential 660
Drive Belts 661
Mazda FE Gasoline and LPG Engines 661
Mazda XA Diesel Engine 661
Inching/Brake Pedal 662
Forks 662
Maintenance Procedures Every 500 Hours or 3 Months 662
PCV Valve 662
Diesel Fuel System 662
Replace Diesel Fuel Filter 662
Remove Air From Fuel System 663
Drain Tar From LPG Regulator 663
Steering Axle 663
Maintenance Procedures Every 1000 Hours or 6 Months 664
Pedals, Levers, Cables, and Other Linkages 664
Air Filter 664
LPG Fuel Filter 664
IMPCO Fuel Filter 664
Regulator Pressure/Diaphragm and O-Ring Checks 664
Spark Plugs 664
Ignition System, Mazda FE Engines 664
Injection Pump Timing, Mazda XA Diesel Engine 665
Valve Clearance Adjustment 666
Integral Sideshift Carriage, Check Bearings 666
Hydraulic Pump Drive Shaft 666
Idle Circuit/Injector Filter Replace, Aisan Fuel System 667
Maintenance Procedures Every 2000 Hours or Yearly 667
Throttle Cable 667
Differential 667
Main Solenoid Valve (LPG Engine) 667
Hydraulic System 668
Replace Hydraulic Oil and Filter 668
Clean Hydraulic Tank Breather 668
Cooling System 668
Transmission 669
Replace Transmission Oil and Filter 669
Fuel Injectors 669
LPG Engine (Closed-Loop) 669
Integral Sideshift Carriage, Replace Bearings 669
Gasoline Fuel Filter 669
LPG Fuel Filter 669
Aisan Fuel Filter 669
Hood Latch Check 670
Safety Procedures When Working Near Mast 671
Lift and Tilt System Leak Check 672
Lift Cylinders, Leak Check 672
Tilt Cylinders, Leak Check 674
Tilt Cylinder Adjustment 674
Lift Chain Adjustments 675
Service Brake Check 677
Diesel Engine Fuel Injector Check 677
Welding Repairs 678
Overhead Guard Changes 678
Wheel and Tire Replacement 678
General 678
How to Change Solid Rubber Tire (GC Series) 678
Remove and Install Tire on Wheel 678
Pneumatic Tire, Repair 680
Remove Wheels From Lift Truck 680
Remove Tire From Wheel 680
Remove Tire From Two-Piece Wheel 681
Remove Tire From Three- and Four-Piece Wheels 682
Install Wheel in Tire 683
Install Two-Piece Wheel in Tire 684
Install Three- or Four-Piece Wheel in Tire 685
Add Air to Pneumatic Tires 686
Wheels, Install 686
Solid Rubber Tires on Pneumatic Wheels, Change 686
Remove Tire From Wheel 687
Install Tire on Wheel 688
Operating Procedures for New or Rebuilt Engine 690
tables 631
Table 1 Maintenance Schedule 639
Table 2 Hook-Type Carriage Chain Adjustment 676
Table 3 Pin-Type Carriage Chain Adjustment 676
toc 693
Capacities and Specifications 693
Safety Precautions Maintenance and Repair 694
Engine Specifications 697
Electrical System 697
Hydraulic System 698
Lift Truck Weights 698
Torque Converter Stall Speeds 699
Tire Pressure 699
Capacities 700
Mast Speeds 701
Mazda D5 Engine Mast Speeds 701
Mazda FE Engine Mast Speeds 701
Mazda XA Engine Mast Speeds 702
Transmission Oil Pressures 702
Torque Specifications 703
Brake System 703
Drive Axle 703
Engine – Mazda D5 703
Engine – Mazda FE 703
Engine – Mazda XA 704
Frame 704
Mast 705
Steering System 705
Transmission and Differential 705
toc 709
Diagrams 709
Safety Precautions Maintenance and Repair 710
toc 745
Cooling System 745
Safety Precautions Maintenance and Repair 746
General 749
Description 750
Radiator 750
Radiator Cap 750
Thermostat 750
Water Pump 751
Fan and Fan Shroud 751
Cooling System Checks 751
Radiator 751
Thermostat 751
Water Pump 752
Exhaust Leaks 752
Fan and Fan Shroud 752
Radiator Cleaning 752
Drain 752
Clean 752
Fill 753
Troubleshooting 754

S.V 06/24