Maintenance

PERIODIC
MAINTENANCE
GP040-060MX [A390]

PART NO. 550141720 8000 YRM 2000

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions
contained in the Service Manual could result in damage to the products, personal injury, property damage
or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks.
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 man-
ual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General....................................................................................................................................................................1
Serial Number Data............................................................................................................................................1
How to Move Disabled Lift Truck....................................................................................................................... 1
How to Tow Lift Truck...................................................................................................................................... 1
How to Put Lift Truck on Blocks......................................................................................................................... 2
How to Raise Drive Tires.................................................................................................................................2
How to Raise Steering Tires............................................................................................................................2
How to Clean a Lift Truck...................................................................................................................................3
Maintenance Schedule............................................................................................................................................4
Maintenance Procedures Every 8 Hours or Daily................................................................................................. 15
How to Make Checks With Engine Stopped.................................................................................................... 15
Tires and Wheels...........................................................................................................................................15
Safety Labels.................................................................................................................................................15
Mast, Carriage, Lift Chains, Header Hoses, Attachment...............................................................................15
Operator Restraint System............................................................................................................................16
Emergency Locking Retractor (ELR).......................................................................................................... 16
Adjust Seat - Standard Full Suspension..................................................................................................... 18
Adjust Seat - Premium Full Suspension..................................................................................................... 18
Hood and Seat Latches.................................................................................................................................19
Engine Compartment.....................................................................................................................................19
Fuel, Oil, and Coolant Leaks, Check.............................................................................................................19
Hydraulic Hoses............................................................................................................................................ 20
Coolant Hoses...............................................................................................................................................20
Steering Column............................................................................................................................................20
Transmission................................................................................................................................................. 20
Hydraulic System Oil..................................................................................................................................... 20
Engine Oil......................................................................................................................................................20
Air Filter......................................................................................................................................................... 22
Forks..............................................................................................................................................................23
Remove.......................................................................................................................................................23
Inspect........................................................................................................................................................ 26
Install...........................................................................................................................................................26
Adjust..........................................................................................................................................................27
Brake Fluid.................................................................................................................................................... 27
How to Make Checks With Engine Running.................................................................................................... 28
Indicator Lights, Horn, Fuses, and Relays.....................................................................................................28
Service Brakes.............................................................................................................................................. 30
Operation, Check........................................................................................................................................30
Parking Brake................................................................................................................................................30
Engine Oil Pressure.......................................................................................................................................31
Cooling System............................................................................................................................................. 31
Steering System............................................................................................................................................ 32
Control Levers and Pedals............................................................................................................................ 32
Lift System, Operate......................................................................................................................................32
First Service After First 100 Hours of Operation................................................................................................... 33
PSI Engine Oil and Oil Filter............................................................................................................................ 33
Yanmar Engine Oil and Oil Filter......................................................................................................................33
Maintenance Procedures Every 250 Hours or 6 Months...................................................................................... 34
PSI 2.4L Engine Oil and Oil Filter Change.......................................................................................................34
Drain Oil from LPG Vaporizer Regulator (LPG Converter) - PSI Engine......................................................... 34
Differential and Drive Axle Oil (Dry Brake).......................................................................................................36
Maintenance Procedures Every 300 Hours.......................................................................................................... 37

©2019 Yale Materials Handling Corp. i

Table of Contents

TABLE OF CONTENTS (Continued)

Tie Rod Lubrication.......................................................................................................................................... 37
King Pin Lubrication......................................................................................................................................... 38
Maintenance Procedures Every 500 Hours or 6 Months...................................................................................... 38
Hydraulic System Oil........................................................................................................................................38
Battery..............................................................................................................................................................39
Yanmar Engine Oil and Oil Filter Change........................................................................................................ 39
Drive Belt..........................................................................................................................................................39
Yanmar Diesel Engine................................................................................................................................... 39
Fan and Alternator Drive Belt......................................................................................................................39
Clean Debris From Radiator Core....................................................................................................................40
Transmission Oil Level.....................................................................................................................................41
Forks................................................................................................................................................................ 41
Inspect...........................................................................................................................................................41
Mast Lubrication...............................................................................................................................................42
Header Hose Checks.......................................................................................................................................44
Lift Chain Lubrication....................................................................................................................................... 44
Tilt Cylinder Lubrication....................................................................................................................................44
Master Brake Cylinder Rod End Pin Lubrication..............................................................................................46
Manual Hydraulic Levers Lubrication...............................................................................................................46
Brake Fluid (Master Cylinder) Change.............................................................................................................46
Maintenance Procedures Every 1000 Hours or 6 Months.................................................................................... 47
Drive Belt Check.............................................................................................................................................. 47
LPG Fuel Filter Replace, PSI Engines.............................................................................................................47
Remove......................................................................................................................................................... 47
Clean/Inspect.................................................................................................................................................48
Install............................................................................................................................................................. 48
Gasoline Fuel System, PSI 2.4L Bi-Fuel Engine..............................................................................................49
Remove and Disassemble.............................................................................................................................49
Assemble and Install..................................................................................................................................... 53
Fuel Filter Replacement, Yanmar Engine........................................................................................................ 54
Priming the Fuel System (Yanmar).................................................................................................................. 55
Ignition System.................................................................................................................................................56
PSI 2.4L Engines...........................................................................................................................................56
Lift Chains Wear Check................................................................................................................................... 56
Lift Chain Lubrication....................................................................................................................................... 56
Integral Sideshift Carriage, Check Bearings.................................................................................................... 57
Integral Sideshift Carriage, Check Lower Mounting Hooks............................................................................. 57
Control Levers, Pedals, and Parking Brake..................................................................................................... 58
Maintenance Procedures Every 2000 Hours or 1 Year......................................................................................... 58
Hydraulic System............................................................................................................................................. 58
Return Filter, Replace....................................................................................................................................58
Air Filter Element, Replace.............................................................................................................................. 60
Air Filter Without Silencer..............................................................................................................................60
Air Filter With Silencer ..................................................................................................................................62
PCV Valve........................................................................................................................................................ 63
PSI LPG and Bi-Fuel Engines....................................................................................................................... 63
Oxygen Sensor................................................................................................................................................ 63
Fuel Injector, Yanmar Engines......................................................................................................................... 63
Forks, Inspect...................................................................................................................................................64
Integral Sideshift Carriage................................................................................................................................64
Bearings, Replace......................................................................................................................................... 64
Service Brakes.................................................................................................................................................64

ii
 Table of Contents

TABLE OF CONTENTS (Continued)

Differential........................................................................................................................................................ 65
Transmission Oil and Filter, Replace............................................................................................................... 66
Brake Fluid (Master Cylinder) Change.............................................................................................................67
Brake Fluid, Remove........................................................................................................................................67
Maintenance Procedures Every 4000 Hours or 2 Years....................................................................................... 68
Hydraulic Oil, Replace......................................................................................................................................68
Cooling System................................................................................................................................................69
Replace Throttle (Accelerator) Cable, Yanmar Diesel Engine......................................................................... 70
Maintenance Procedures Every 5000 Hours........................................................................................................ 70
Fuel Injector Check, PSI Engine...................................................................................................................... 70
Maintenance Procedures Every 6000 Hours........................................................................................................ 71
Timing Belt Change, PSI Engine......................................................................................................................71
Safety Procedures When Working Near Mast.......................................................................................................71
Hood Lock Assembly Check................................................................................................................................. 72
Lift Chain Adjustments.......................................................................................................................................... 74
Lift Trucks Equipped With Forks....................................................................................................................74
Lift Trucks Equipped with Hook-Type Carriage and Attachment Without Forks............................................74
Jump-Starting the Lift Truck.................................................................................................................................. 75
Jump-Starting Using a Battery Charger........................................................................................................... 75
Jump-Starting a Lift Truck Using Another Lift Truck.........................................................................................75
Welding Repairs.................................................................................................................................................... 76
Wheel and Tire Replacement................................................................................................................................76
General............................................................................................................................................................ 76
Pneumatic Tire With Tube, Repair................................................................................................................... 76
Remove Wheels From Lift Truck................................................................................................................... 76
Remove Tire From Wheel............................................................................................................................. 77
Remove Tire From Two-Piece Wheel......................................................................................................... 78
Remove Tire From Three- and Four-Piece Wheels....................................................................................79
Install Wheel in Tire....................................................................................................................................... 80
Install Three-Piece or Four-Piece Wheel in Tire......................................................................................... 81
Install Tire on Two-Piece Wheel................................................................................................................. 82
Install Two-Piece Wheel in Tire...................................................................................................................82
Add Air to Pneumatic Tires With Tube............................................................................................................. 83
Install the Wheels.......................................................................................................................................... 83
Pneumatic Tubeless Tire, Repair..................................................................................................................... 84
Remove Wheels From Lift Truck................................................................................................................... 84
Remove Tire From Wheel............................................................................................................................. 84
Install Tire on Wheel......................................................................................................................................86
Add Air to Pneumatic Tubeless Tire.............................................................................................................. 89
Wheels, Install............................................................................................................................................... 89
Solid Rubber Tires on Pneumatic Wheels, Change.........................................................................................89
Remove Tire From Wheel............................................................................................................................. 89
Install Tire on Wheel......................................................................................................................................91
Overhead Guard Changes.................................................................................................................................... 93
Adhesives and Sealants........................................................................................................................................93

iii
8000 YRM 2000 General

General
from your dealer for Yale lift trucks to help users who
WARNING do their own maintenance.
DO NOT make repairs or adjustments unless you
have both authorization and training. Repairs and
SERIAL NUMBER DATA
adjustments that are not correct can make a Serial number for lift truck is on Nameplate. It is also
dangerous operating condition. on right side of frame, under floor plate.

HOW TO MOVE DISABLED LIFT TRUCK

WARNING How to Tow Lift Truck
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair is
necessary, put a DO NOT OPERATE tag in the WARNING
operator's area. Remove the key from the key Use extra caution when towing a lift truck if any of
switch. the following conditions exist:
• Brakes do not operate correctly.
• Steering does not operate correctly.
CAUTION
Disposal of lubricants and fluids must meet local • Tires are damaged.
environmental regulations. • Traction conditions are bad.
• The lift truck must be towed on a slope.
This section contains a Maintenance Schedule and
instructions for maintenance and inspection. If the engine cannot run, there is no power
available for the hydraulic steering system and the
The Maintenance Schedule has time intervals for service brakes. This condition can make the lift
inspection, lubrication, and maintenance of your lift truck difficult to steer and stop. If the lift truck
truck. Service intervals are provided in both operating uses power from the engine to help apply the
hours recorded on lift truck hourmeter and in calendar brakes, the application of the brakes will be more
time. Recommendation is to use the interval that difficult. Poor traction can cause the disabled lift
comes first. truck or towing vehicle to slide. A slope will also
Recommendations for time intervals provided is for make the lift truck more difficult to stop.
eight hours of operation per day. Time intervals must Never lift and move a disabled lift truck unless the
be decreased from recommendations in Maintenance disabled lift truck MUST be moved and cannot be
Schedule for the following conditions: towed. A lift truck used to move a disabled lift
• Lift truck is used more than eight hours per day. truck MUST have a capacity rating equal to or
• Lift truck must work in dirty operating conditions. greater than the weight of the disabled lift truck.
The capacity of the lift truck used to move a
• Poor ground conditions.
disabled lift truck must have a load center equal to
• Intensive usage at high performance levels or half the width of the disabled lift truck. See the
other abnormal conditions will require more Nameplate of the disabled lift truck for the
frequent servicing. approximate total weight. The forks must extend
Your dealer for Yale lift trucks has equipment and the full width of the disabled lift truck. Put the
trained service personnel to do a complete program of weight center of the disabled lift truck on load
inspection, lubrication, and maintenance. A regular center of the forks. Be careful to not damage the
program of inspection, lubrication, and maintenance underside of the lift truck.
will help your lift truck provide more efficient
performance and operate for a longer period of time. 1. The towed lift truck must have an operator.
Some users have service personnel and equipment to 2. Tow truck slowly.
do inspection, lubrication, and maintenance shown in
Maintenance Schedule. Service manuals are available

1
General 8000 YRM 2000

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

attached to the mast (I.E. come-a-long), raise
carriage and forks approximately 30 cm (12 in.) CAUTION
from surface. Install chain around a mast These lift trucks are equipped with cowl lifting
crossmember and carriage to prevent carriage eyes. The cowl lifting eyes are to be used to lift the
and mast channels from moving. front of the lift truck only. Lifting more than the
front of the lift truck with the cowl lifting eyes will
4. If another lift truck is used to tow disabled lift damage the cowl section.
truck, that lift truck must have an equal or larger
capacity than disabled lift truck. Install 1. Put blocks on each side (front and back) of
approximately ½ of a capacity load on forks of lift steering tires to prevent movement of lift truck.
truck that is being used to tow disabled lift truck. See Figure 1.
This ½ capacity load will increase traction of lift
truck. Keep load as low as possible. 2. Put mast in vertical position. Put a block under
each outer mast channel.
5. Use a towing link made of steel that fastens to
tow pins in counterweights of both lift trucks. 3. Tilt mast fully forward until drive tires are raised
from surface.
HOW TO PUT LIFT TRUCK ON BLOCKS
4. Put additional blocks under frame behind drive
How to Raise Drive Tires tires.

5. If hydraulic system will not operate, use a

WARNING hydraulic jack under the side of the frame near
The lift truck must be put on blocks for some types the front. Make sure jack has a capacity equal to
of maintenance and repair. The removal of the at least half the weight of the lift truck. See
following assemblies will cause large changes in Nameplate.
the center of gravity: mast, drive axle, engine,
transmission, and counterweight. When the lift How to Raise Steering Tires
truck is put on blocks, put additional blocks in the
following positions to maintain stability: 1. Apply parking brake. Put blocks on both sides
(front and back) of drive tires to prevent
• Before removing the mast and drive axle, put movement of lift truck. See Figure 1.
blocks under the counterweight so the lift
truck cannot fall backward. 2. Use hydraulic jack to raise steering tires. Make
• Before removing the counterweight, put sure jack has a capacity of at least 2/3 of total
blocks under the mast assembly so the lift weight of lift truck as shown on the Nameplate.
truck cannot fall forward.
The surface must be solid, even, and level when 3. Put jack under steering axle or frame to raise lift
the lift truck is put on blocks. Make sure any truck. Put blocks under frame to support lift truck.
blocks used to support the lift truck are solid, one-
piece units.

2
8000 YRM 2000 General

1. DRIVE TIRES 2. STEERING TIRES

Figure 1. Put Lift Truck on Blocks

HOW TO CLEAN A LIFT TRUCK NOTE: Lift trucks used in paper applications may
need cleaning beyond what is described here. Please
refer to Paper Application section in the applicable
WARNING Operating Manual and to available Service Gram/
Engine, exhaust system components and other Bulletin for more detail.
components are hot to the touch. Be sure lift truck
components are cool before starting inspection If it becomes necessary to clean the fork lift, follow the
and cleaning, or personal injury may occur. guidelines listed below.

1. Assure truck components are cool before starting

the cleaning procedure.
WARNING
Compressed air can move particles so that they 2. Disconnect the battery. If an electric truck,
cause injury to the user or to other personnel. remove the traction battery.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles 3. Remove accumulated debris using a compressed
or a face shield to prevent injury to the eyes. air line and nozzle.

4. Lightly spray a non-corrosive cleaning agent onto

CAUTION the areas to be cleaned. This will help loosen
Units may be washed with a non-heated pressure grime, so close contact direct spraying will not be
washer. Steam cleaning is not recommended in necessary.
most instances, as condensation may form in
electrical components causing damage or erratic
behavior.

3
Maintenance Schedule 8000 YRM 2000

5. Be sure to avoid directing the spray into electrical moisture at a minimum as some units have a
panel compartment. Ensure overspray does not traction or hydraulic motor directly below the
come in contact with electrical components; do battery compartment.
not spray water directly at electrical components,
wiring connectors or electrical enclosures. Even 8. DO NOT pressure wash the battery. Do not use
sealed connectors may allow water egress under hot water. For cleaning traction batteries, refer to
pressure or if connector is damaged. the Battery section of the Service Manual.

6. Avoid spraying in areas containing electrical 9. DO NOT pressure wash lift chains, sheaves or
components such as: load rollers in the mast assembly. Refer to the
Chains, Sheaves and Load Rollers maintenance
• Floor Plates
section in the Service Manual for proper cleaning
• Battery Compartment procedures.
• Dash/cowl assembly
10. After cleaning, immediately start and run the lift
• Armrests with electrical components
truck to dry out components.
7. Clean battery compartment by using a clean cloth
to wash the battery with water. Dry with
compressed air. Care should be taken to keep

Maintenance Schedule
NOTE: The 250-hour, 500-hour, and 1000-hour/6 the specified hours or at 6 months whichever occurs
months maintenance services are performed either at first.

4
8000 YRM 2000 Maintenance Schedule

Figure 2. Maintenance and Lubrication Points, PSI 2.4L LPG Trucks

5
Maintenance Schedule 8000 YRM 2000

Figure 3. Maintenance and Lubrication Points, Yanmar Diesel Trucks

6
8000 YRM 2000 Maintenance Schedule

Figure 4. Maintenance and Lubrication Points, PSI 2.4L Bi-Fuel Trucks

7
Maintenance Schedule 8000 YRM 2000

Table 1. Maintenance Schedule

Ite Item 8 250 500 1000 2000 4000 hr/ Procedure or Specification
m hr/ hr/ hr/ hr/ hr/ 2 yr Quantity
No. 1 6 6 6 1 yr
day mo mo mo
30 Tires and Wheels X Check Condition See Nameplate
Safety Labels X Replace as See Parts Manual
Necessary
31, Mast, Carriage, X Check Condition See Parts Manual
33, Header Hoses, Lift and Lubrication
34, Chains, Attachment
35
Seat Belt, Hip X Check Condition
Restraints, and Seat and Operation
Rails
Hood and Seat X Check Condition
Latches and Operation
Engine X Remove
Compartment Combustible
Materials
See NOTE 5.
Check for Leaks - X Check for Leaks
Fuel, Oil, Water See NOTE 1.
Hydraulic Hoses X Check Condition See Parts Manual
9 Coolant Hoses X Check Condition See Parts Manual
16 Fuel Tank CIL 29.9 liter (7.9 gal) LPG - HD 5
PSI 2.4L LPG 15.2 kg (33.5 lb)
Engine
17 Fuel Tank CIL 69 liter (18.2 gal) Diesel No. 2
Yanmar Diesel
Engines
17 Fuel Tank (Gasoline) CIL 69 liter (18.2 gal) 86 Octane Gasoline
PSI 2.4L Bi-Fuel Minimum
Engine
Horn, Lights, Alarms, X Check Operation
Fuses, and Relays
37 Service Brakes X Check Operation
37 Service Brakes X Check Lining 1.0 mm (0.04 in.)
Thickness. Minimum
26 Parking Brake X Check Operation
Accelerator Cable C 1 Cable See Parts Manual
36 Drive Axle X Check for Leaks.
Check Operation.
36 Differential and Drive X C 6.5 liter (6.9 qt) 80W-90
Axle Oil See NOTE 14. API GC5
Steering Controls X Check Condition
and Operation
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

8
8000 YRM 2000 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 250 500 1000 2000 4000 hr/ Procedure or Specification
m hr/ hr/ hr/ hr/ hr/ 2 yr Quantity
No. 1 6 6 6 1 yr
day mo mo mo
24 Transmission X Check for Leaks
Check Operation
24 Transmission Oil X Check Oil Level John Deere
Dipstick JDM J20C
25 Transmission Oil C 8.3 liter (8.8 qt) John Deere
JDM J20C
28 Transmission Oil C 1 Filter See Parts Manual
Filter See NOTE 4.
27 Transmission Oil C 1 Breather See Parts Manual
Breather See NOTE 4.
4 Hydraulic Oil X X C 30 liter (32 qt) See ISO VG 46 Hydraulic
NOTE 2, NOTE 3, Oil
NOTE 12, and -20°C (-4°F) and
NOTE 17. Above
8 Hydraulic Oil Return C 1 Filter See Parts Manual
Filter See NOTE 12.
7 Hydraulic Tank X C Inspect and See Parts Manual
Breather Replace as
Required
See NOTE 12.
5 Battery and Cable X Clean
Terminals
14, Engine Oil X C 4.9 liter (5.2 qt) -20 to 30°C (20°F)
22 PSI Engine CIL See NOTE 4 and and Below
NOTE 5. SAE 5W-20
16°C (60°F)
and Below
SAE 5W-30
-18°C (0°F)
and Above
SAE 10W-30
API SL
ILSAC GF3
SAE J2362
15 Engine Oil Filter C 1 Filter See Parts Manual
PSI Engine See NOTE 4 and
NOTE 5.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

9
Maintenance Schedule 8000 YRM 2000

Table 1. Maintenance Schedule (Continued)

Ite Item 8 250 500 1000 2000 4000 hr/ Procedure or Specification
m hr/ hr/ hr/ hr/ hr/ 2 yr Quantity
No. 1 6 6 6 1 yr
day mo mo mo
14, Engine Oil X C 10.2 liter (10.8 qt) 20°C (68°F)
22 Yanmar Diesel CIL See NOTE 4 and and Over
Engines NOTE 5. SAE 40
10 to 30°C (50 to
86°F)
SAE 30
0 to 20°C (32 to
68°F)
SAE 20
-16 to 40°C (3 to
103°F)
SAE 15W-40
-20 to 30°C (-4 to
86°F)
SAE 10W-30
-10 to 10°C (14 to
50°F)
SAE 20W
-20 to 10°C (-4 to
50°F)
SAE 10W
API CG-4 or Better
15 Engine Oil Filter C 1 Filter See Parts Manual
Yanmar Diesel See NOTE 4 and
Engine NOTE 5.
19 Air Filter X C 1 Filter See Parts Manual
CIL See NOTE 5,
NOTE 6, and
NOTE 10.
13 Drive Belt X Check for Wear
PSI Engine and Damage
Adjust As Needed
13 Drive Belt X Check for Wear
Yanmar Diesel and Damage
Engine Adjust as Needed
6 LPG Regulator X Drain Tar
PSI Engine See NOTE 5.
20 LPG Vaporizer X
PSI Engine
Engine Idle Speed X 850 ±25 RPM
PSI Engine
Engine Governed X 2700 ±25 RPM
Speed (No Load)
PSI Engine
Engine Idle Speed X 850 ±25 RPM
Yanmar Engine
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

10
8000 YRM 2000 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 250 500 1000 2000 4000 hr/ Procedure or Specification
m hr/ hr/ hr/ hr/ hr/ 2 yr Quantity
No. 1 6 6 6 1 yr
day mo mo mo
Engine Governed X 2625 ±25 RPM
Speed
Yanmar Engine
20 PCV Valve C Replace as See Parts Manual
PSI 2.4L Engine Necessary.
23 Valve Adjustment Not Adjustable
PSI 2.4L Engine
23 Valve Adjustment X Adjust as Required Intake
Yanmar Engine 0.20 mm (0.008 in.)
Cold
Exhaust
0.20 mm (0.008 in.)
Cold
Timing X Adjust as Required Preset at 4° ATDC
Yanmar 2.6L Engine
Timing X Adjust as Required Preset at 6° ATDC
Yanmar 3.3L Engine
21 LPG Fuel Filter C 1 Filter See Parts Manual
PSI Engines
18 Gasoline Fuel Filter C 1 Filter See Parts Manual
PSI Bi-Fuel Engine
21 Fuel Water CIL C 1 Filter See Parts Manual
Separator Filter Drain Water from
Yanmar Diesel Filter as Required
Engine
21 In-Line Fuel Strainer C 1 Filter See Parts Manual
Yanmar Diesel
Engine
3 Fuel Injectors X Check and See Parts Manual
PSI Engine Replace if
Required
4 Injectors
See NOTE 13.
3 Fuel Injectors X Check and See Parts Manual
Yanmar Diesel Replace if
Engine Required
4 Injectors
3 Spark Plugs C Change Spark Torch P/N DK7RTC
PSI Bi-Fuel Engine Plugs 0.9 mm (0.035 in.)
4 Spark plugs
12 Cooling System X C 11.0 liter (11.6 qt) See NOTE 11.
PSI Engine CIL
12 Cooling System X C 11.5 liter (12.2 qt) See NOTE 11.
Yanmar Engine CIL
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

11
Maintenance Schedule 8000 YRM 2000

Table 1. Maintenance Schedule (Continued)

Ite Item 8 250 500 1000 2000 4000 hr/ Procedure or Specification
m hr/ hr/ hr/ hr/ hr/ 2 yr Quantity
No. 1 6 6 6 1 yr
day mo mo mo
Clean Debris From X See NOTE 5.
Radiator Core
32 Forks X X X Check Condition.
Replace as
Necessary
32 Fork Latches L Lubricate as Multipurpose Grease
Necessary See NOTE 7.
Lift System, Operate X Check Operation
31 Mast L Lubricate As Multipurpose Grease
Sliding Surfaces and Required See NOTE 7.
Load Roller Surfaces See NOTE 8.
35 Header Hoses X Check Condition
34 Lift Chains X L X, L Check for Wear. Engine Oil
Lube as Required. SAE 30W
See NOTE 9.
Mast L 2 Fittings Multipurpose Grease
Pivots See NOTE 7.
Mast X L X C Lube as Required Multipurpose Grease
Sideshift 2 Fittings for Upper See NOTE 7 and
Carriage (Upper and Bearings and NOTE 9.
Lower 2 Lower Bearing 0 mm (0 in.)
Bearing Strips) Strips
Check Lower
Bearing Strips for
Wear
Mast X L X Lube as Required Multipurpose Grease
Fork Positioner 2 Fittings See NOTE 7.
Mast X L X Lube as Required Multipurpose Grease
Fork Positioner 2 Anchors See NOTE 7.
Cylinder
Rod Anchors
Mast X Check Torque See NOTE 7.
Fork Positioner and 8 Capscrews
Lower Hook
Capscrews
Tilt Cylinder Ends L 4 Fittings Multipurpose Grease
See NOTE 7.
Brake Master L Use Silicone Spray
Cylinder Rod End Yale Part No.
Pin 504236201
Manual Hydraulic L API SM
Hand Levers ILSAC GF4
SAE J2362
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

12
8000 YRM 2000 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Ite Item 8 250 500 1000 2000 4000 hr/ Procedure or Specification
m hr/ hr/ hr/ hr/ hr/ 2 yr Quantity
No. 1 6 6 6 1 yr
day mo mo mo
29 Brake Fluid X X C 0.2 liter (0.21 pt) SAE J-1703
Master Cylinder DOT-3
1 Drive Axle L Check Grease Multipurpose Grease
Wheel Bearings See NOTE 7.
11 Steering Axle L 4 Fittings Multipurpose Grease
Tie Rod Ends See NOTE 7
and NOTE 16.
10 Steering Axle L 2 Fittings Multipurpose Grease
King Pins See NOTE 7
and NOTE 16..
Steering Axle L Check Grease Multipurpose Grease
Wheel Bearings See NOTE 7.
2 Pedals, Levers, Seat X L Lubricate as Use Silicone Spray
Rails, Cables, Necessary Yale Part No.
Hinges, Linkages 504236201
26 Parking Brake X Adjust as Must Hold a Full
Adjustment Necessary Capacity Load on a
15% Grade
26 Parking Brake L Lubricate as Use Silicone Spray
Necessary Yale Part No.
504236201
Wheel Nuts X Check Torque 450 to 500 N•m
Drive Wheels (332 to 369 lbf ft)
Wheel Nuts X Check Torque 155 to 175 N•m
Steer Wheels (114 to 129 lbf ft)
Timing Belt C Replace. See Parts Manual
PSI Engine See NOTE 5. See NOTE 15.
Inspect Engine X
Electrical
System Connectors
Inspect Engine X
Vacuum and
Fuel Lines and
Fittings
Inspect Lock-off for X
Leaks
and Ensure Lock-off
Closing
Test LPG/Gas X
Regulator Pressure
Check Air Induction X
System
for Leaks
Check Manifold for X
Vacuum Leaks
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

13
Maintenance Schedule 8000 YRM 2000

Table 1. Maintenance Schedule (Continued)

Ite Item 8 250 500 1000 2000 4000 hr/ Procedure or Specification
m hr/ hr/ hr/ hr/ hr/ 2 yr Quantity
No. 1 6 6 6 1 yr
day mo mo mo
Check Throttle Shaft X
for Sticking
Check Injectors and X
Rails for Leaks
Inspect Exhaust X
Manifold and
Piping for Leaks
Inspect Catalyst X
Inlet and Outlet
Inspect Muffler Inlet X Replace as
and Outlet Required
NOTE 1: Check fuel system for leaks prior to any service or maintenance activity.
NOTE 2: Heavy-duty or high-temperature operations require more frequent checks.
NOTE 3: Heavy-duty or contaminated applications will require hydraulic oil change at 2000 hours.
NOTE 4: Change engine oil and filter after first 100 hours of operation. Change transmission oil filter after first 500 hours of
operation.
NOTE 5: Recommended service intervals are based on a normal application in a clean environment. Applications involving
contaminated environments such as high levels of air borne debris (dust and waste paper); chemical or abrasive compounds;
poor ground conditions; intensive usage at high performance levels; or other abnormal conditions will require more frequent
servicing. At your request your Yale dealer will advise you of the appropriate service intervals based on an application
survey.
NOTE 6: In dirty or dusty environments, replace at 1000 hours or as needed.
NOTE 7: Multipurpose grease with 2 to 4% Molybdenum Disulfide.
NOTE 8: Lubricate mast every three months if unit has less than 1000 hours.
NOTE 9: Lubricate if dry or at first sign of visible surface rust.
NOTE 10: Do not open the air filter canister except to change the air filter element. See Maintenance Procedures Every
2000 Hours or 1 Year for procedure to change air filter element.
NOTE 11: Use Ethylene Glycol Boron-free Antifreeze. Purchase a pre-diluted 50/50 solution; or mix 50% concentrate with
50% distilled water or deionized water.
NOTE 12: Hydraulic oil sampling and analysis is a recommended practice. See Hydraulic Cleanliness Procedures
1900YRM1620 for oil cleanliness and water content guidelines. For lift trucks operating in heavy duty applications or highly
contaminated environments, take oil samples every 500 hours. Normal Operating conditions may allow for less frequent oil
sampling. Oil sampling should be done just prior to all oil and filter changes.
NOTE 13: Check fuel injectors at 5000 hours or 7 years. See PSI 2.4L Engine 0600YRM1755 for procedures.
NOTE 14: Change differential/drive axle oil at 2400 hours. Use hour interval only.
NOTE 15: Change timing belt at 6000 hours. Use hour interval only. Use Kit-Service 6000 hours specified in the Parts
Manual for your lift truck.
NOTE 16: Lubricate tie rod ends and king pins at 300 hours. Use hour interval only.
NOTE 17: Check and clean hydraulic oil strainer screen, every time hydraulic oil is changed.
X=Check C=Change L=Lubricate CIL=Check Indicator Light during operation

14
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

Maintenance Procedures Every 8 Hours or Daily

HOW TO MAKE CHECKS WITH ENGINE hood and check for leaks and conditions that are not
STOPPED normal. Clean any oil or fuel spills. Ensure all surfaces
are free of oils, lubricants, fuel, and organic dust or
fibers (paper, wood, cotton, agricultural grass/grain,
WARNING etc.).
DO NOT operate a lift truck that needs repairs.
Report the need for repairs immediately. If repair is Tires and Wheels
necessary, put a DO NOT OPERATE tag in the Check tires for damage. Check tread and remove any
operator's area. If the lift truck is equipped with a objects that will cause damage. Check for bent or
key switch, remove the key from the key switch. damaged rims. Check for loose or missing hardware.
Remove any wire, strapping, or other material that is
Put lift truck on a level surface. Lower carriage and wrapped around axle. See Figure 5.
forks, stop engine, and apply parking brake. Open

1. CHECK FOR DAMAGE (REMOVE NAILS, GLASS AND OTHER OBJECTS FROM THE TREAD)
2. MAKE SMOOTH EDGES
3. CHECK TIRE PRESSURE (PNEUMATIC TIRES)

Figure 5. Tire Check

Safety Labels Mast, Carriage, Lift Chains, Header Hoses,

Attachment
WARNING
Safety labels are installed on the lift truck to WARNING
provide information about operation and possible Lower the lift mechanism completely. Never allow
hazards. It is important that all safety labels are any person under a raised carriage. DO NOT put
installed on the lift truck and can be read. any part of your body in or through the lift
mechanism unless all parts of the mast are
Check that all safety labels are installed in correct completely lowered and the engine is STOPPED.
location on lift truck. See the Parts Manual, Model DO NOT try to correct the alignment of the fork
Description section in your Operating Manual or tips by bending the forks or adding shims. Never
Frame 0100YRM1984 for correct location of safety repair damaged forks by heating or welding. Forks
labels. See Parts Manual for part numbers of safety
labels.

15
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

are made of special steel using special

procedures. If either fork is damaged, replace the
forks as a set.

1. Inspect welds on mast and carriage for cracks.

Make sure that capscrews and nuts are tight.

2. Inspect channels for wear in areas where rollers

travel. Inspect rollers for wear or damage.

3. Inspect load backrest extension for cracks and

damage.

4. If lift truck is equipped with an integral sideshift

carriage or attachment, inspect for cracks and
wear. Make sure parts that fasten integral
sideshift carriage or attachment to carriage are in
good condition.

5. Visually inspect hoses/fittings for hydraulic leaks; 1. WORN PIN

hose cover for cuts, cracks or exposed 2. CRACKS
reinforcement; defective/broken clamping devices 3. EDGE WEAR
or sheaves; proper tracking during operation. 4. HOLE WEAR
Adjust/repair/replace hose/components as 5. LOOSE LEAVES
6. TURNED PIN
necessary. For quick disconnect procedures, see 7. CORROSION
Mast Repair (S/N A387, A389, A397, A399)
4000YRM1999. Figure 6. Lift Chain Check

6. Check that lift chains are correctly lubricated. Use Operator Restraint System
SAE 30W engine oil as necessary to lubricate lift
chains. NOTE: The seat belt can be either black or red.
Seat belt, hip restraint, seat, hood, and hood lock
7. Inspect lift chains for cracks or broken links, and assembly are all part of operator restraint system.
worn or turned pins. See Figure 6. Each item must be checked to make sure it is fastened
correctly, functions correctly, and is in good condition.
8. Inspect chain anchors and pins for cracks and
See Figure 7.
damage.
Lift truck is equipped with one of three seat belt
9. Make sure lift chains are adjusted so that they configurations.
have equal tension. Adjustments or • Seat belt with no operation interlock.
replacement of the lift chains must be done by
authorized personnel. • Seat belt with operation interlock. Seat belt must
be fastened for lift truck to start or to travel.

Emergency Locking Retractor (ELR)

When ELR style seat belt is properly buckled across
operator, belt will permit slight operator repositioning
without activating locking mechanism. If truck tips,
travels off a dock, or comes to a sudden stop, locking
mechanism will be activated and hold 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.

16
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

The seat belt must be in good condition. Replace seat • With hood closed and in locked position, pull
belt if damage or wear is seen. See Figure 7. seat belt with a sudden jerk. Make sure seat belt
will not pull from retractor assembly. If seat belt
NOTE: The following seat belt operation checks must can be pulled from retractor, when it is pulled
be performed three times before replacing seat belt with a sudden jerk, replace seat belt assembly.
assembly.
• With hood in open position, make sure seat belt
will not pull from retractor assembly. If seat belt
• With hood closed and in locked position, pull
can be pulled from retractor, with hood in open
seat belt slowly from retractor assembly. Make
position, replace seat belt assembly.
sure seat belt pulls out and retracts smoothly. If
seat belt cannot be pulled from retractor
assembly or belt will not retract, replace seat
belt assembly.

1. BACKWARD ANGLE ADJUSTMENT LEVER 6. FORWARD/BACKWARD ADJUSTMENT LEVER

2. HOOD 7. SEAT RAIL
3. SEAT BELT 8. OPERATOR WEIGHT ADJUSTMENT
4. HIP RESTRAINTS 9. HOOD LATCH
5. SEAT

Figure 7. Hood and Seat Check

17
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

Adjust Seat - Standard Full Suspension Seat Adjustment for Operator Weight
Seat Position Adjustment
• Fore and aft adjustment - It is recommended CAUTION
that the seat be adjusted so that the thigh is A major cause for high Whole Body Vibration is
horizontal to the ground so that the best caused by the operator not adjusting the seat to
ergonomic position is achieved. See Figure 7. his/her weight.
Seat Adjustment for Operator Weight
NOTE: It is important to adjust weight setting for each
NOTE: It is important to adjust the weight setting for operator.
each operator.
NOTE: The seat is designed for maximum weight of
NOTE: The seat is designed for maximum weight of 145 kg (320 lb) for premium full suspension seat.
125 kg (275 lb) for standard full suspension seat.
• The target is for the "ride indicator" to fall
• The weight adjustment knob handle can be between the arrows when operator sits upright
turned counterclockwise to increase or in seat with feet positioned on pedals. This
clockwise to decreasethe weight resistance, pull ensures that the operator is set at the midpoint
handle out before turning. As the handle is of the 80 mm (3.15 in.) suspension.
turned, the "stiffness" of the suspension can be The handle can be turned as shown to increase
•
felt to increase or decrease depending on which or decrease weight resistance. Pull handle out
way the handle is turned. Seat should be before turning. As the handle is turned the
adjusted as low as possible without deflating "stiffness" of the suspension can be felt to
completely. See Figure 8. increase or decrease on which way handle is
turned. See Figure 8.
Adjust Seat - Premium Full Suspension
Seat Position Adjustment
• Fore and aft adjustment - It is recommended
that seat be adjusted so that thigh is horizontal
to the ground in order to achieve the best
ergonomic position. See Figure 7.

18
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

A. STANDARD FULL SUSPENSION SEAT C. PREMIUM FULL SUSPENSION SEAT

B. NON-SUSPENSION SEAT

1. HIP RESTRAINT 4. WEIGHT ADJUSTMENT KNOB

2. SEAT BELT 5. BACKREST ANGLE ADJUSTMENT LEVER
3. FORWARD/BACKWARD ADJUSTMENT LEVER 6. RIDE POSITION INDICATOR

Figure 8. Seat Adjustment Controls

Hood and Seat Latches Fuel, Oil, and Coolant Leaks, Check
Make sure seat rails and hood lock assembly are not
loose. Seat rails must lock tightly in position, but move WARNING
freely when unlocked. See Figure 7. Seat rails must be
All fuels are very flammable and can burn or cause
correctly fastened to hood and hood fastened to
an explosion. DO NOT use an open flame to check
hinges on frame. Try to lift hood to make sure it is
the fuel level or to check for leaks in the fuel
fastened correctly and will not move. If adjustment is
system. If there is a leak in the fuel system, extra
required, go to Hood Lock Assembly Check.
care must be used during the repair. DO NOT
operate the lift truck until a leak is repaired.
Engine Compartment
Check for presence of any combustible material such Make a visual check for leaks on and under lift truck. If
as paper, leaves, etc. Remove any combustible possible, find and report leaks to maintenance for
materials. repair. Leaks often indicate a need for repair of
damaged or worn components. Leaks in LPG fuel
system are usually not visible unless ice is present.
There is however, usually a strong odor. Fuel leaks
MUST be repaired IMMEDIATELY.
Check fuel system for leaks and condition of parts.
When fuel is added to lift truck, see section HOW TO

19
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

ADD FUEL TO THE LIFT TRUCK in the Operating Hydraulic System Oil
Manual.
Also check condition of radiator or heater hoses that
are not leaking. Soft or cracked hoses need to be WARNING
replaced before a major leak occurs. At operating temperature, the hydraulic oil is HOT.
DO NOT permit the hot oil to touch the skin and
Hydraulic Hoses cause a burn.

Check condition of hydraulic hoses for serviceability by

inspecting for cracks or other obvious damage. Check
CAUTION
to ensure that hydraulic hoses are not leaking. If any
DO NOT permit dirt to enter the hydraulic system
hose is leaking, report it to maintenance for repair.
when the oil level is checked or the filter is
changed.
Coolant Hoses
Never operate the hydraulic pump without oil in
Check condition of coolant hoses for serviceability by the hydraulic system. The operation of the
inspecting for cracks or other obvious damage. Check hydraulic pump without oil will damage the pump.
to ensure that coolant hoses are not leaking. If any
hose is leaking, report it to maintenance for repair. After engine has stopped, wait one minute before
checking oil level. Keep hydraulic oil at correct level as
Steering Column indicated on dipstick. Use correct oil as shown in the
Make sure tilt mechanism for steering column operates Maintenance Schedule.
correctly. Tilt mechanism must NOT allow steering Check hydraulic system for leaks and damaged or
column to move unless lever is released. See loose components. Heavy-duty or high-temperature
Figure 9. operations can require more frequent checks.

Engine Oil
After engine has stopped, wait one minute before
checking oil level. Keep oil at correct level as indicated
on dipstick. Use correct oil as shown in Maintenance
Schedule.
See Figure 10 for lift trucks equipped with a PSI 2.4L
LPG engine.
See Figure 11 for lift trucks equipped with a Yanmar
2.6L diesel engine.
See Figure 12 for lift trucks equipped with a Yanmar
3.3L diesel engine.
See Figure 13 for lift trucks equipped with a PSI 2.4L
Bi-Fuel engine.
There is an indicator light for engine oil pressure on
Dash Display. During normal operation, red indicator
A. LOCK light will illuminate when key switch is turned to ON, if
B. RELEASE LOCK truck is equipped with a key switch, or when Power
ON/OFF button is pressed, if truck is equipped with a
Figure 9. Steering Column Tilt Lever Power ON/OFF option, and will stay illuminated until
correct oil pressure is obtained, at which time the light
Transmission will go OFF.
Check transmission for leaks and damaged or loose If light continues to stay on when engine is running,
components. Heavy-duty or high temperature engine oil pressure is low. Stop engine and check oil
operations can require more frequent checks.

20
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

level. Do not restart engine until low pressure condition

has been corrected.

1. BATTERY
2. AUXILIARY COOLANT RESERVOIR
3. DRIVE BELT
4. RADIATOR CAP
5. AIR FILTER
1. BATTERY 6. FUEL FILTER
2. PCV VALVE 7. DIPSTICK ENGINE OIL
3. SPARK PLUGS 8. ENGINE OIL FILTER
4. DRIVE BELT 9. ENGINE OIL FILL
5. ENGINE OIL FILL 10. SPARK PLUGS
6. RADIATOR CAP
7. AUXILIARY COOLANT RESERVOIR Figure 11. Yanmar 2.6L Diesel Engine Maintenance
8. FUEL FILTER Points
9. ENGINE OIL FILTER
10. AIR FILTER
11. ENGINE OIL DRAIN PLUG
12. DIPSTICK ENGINE OIL

Figure 10. PSI 2.4L LPG Engine Maintenance

Points

21
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

1. BATTERY 1. BATTERY
2. DRIVE BELT 2. PCV VALVE
3. RADIATOR CAP 3. SPARK PLUGS
4. AUXILIARY COOLANT RESERVOIR 4. ENGINE OIL FILL
5. AIR FILTER 5. DRIVE BELT
6. ENGINE OIL FILTER 6. RADIATOR CAP
7. FUEL FILTER 7. LPG FUEL FILTER
8. DIPSTICK ENGINE OIL 8. AUXILIARY COOLANT RESERVOIR
9. SPARK PLUGS 9. ENGINE OIL FILTER
10. ENGINE OIL FILL 10. AIR FILTER
11. GASOLINE FUEL FILTER
Figure 12. Yanmar 3.3L Diesel Engine Maintenance 12. ENGINE OIL DRAIN PLUG
Points 13. DIPSTICK ENGINE OIL
14. INJECTOR

Figure 13. PSI 2.4L Bi-Fuel Engine Maintenance

Points

Air Filter
The air filter canister should not be opened until an air
filter element replacement is required. Check air filter
canister to ensure hoses are attached, all seals are
tight, and no cracks are apparent. An air filter element
replacement is required when one of the following
occurs:
• If equipped, the manual air flow indicator is red.
• The specified number of hours has passed
since the last filter element replacement.
• DO NOT operate lift truck until the air filter
element has been replaced.

22
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

Forks NOTE: Forks are to be replaced only in sets and not

NOTE: Forks must be removed or installed by trained individually.
personnel only. NOTE: If lift truck is equipped with a fork positioner
The identification of a fork describes how fork is attachment, perform Step 1 through Step 3. If lift truck
connected to carriage. These lift trucks have hook is not equipped with a fork positioner attachment, go to
forks. Step 4.
1. Lower carriage and remove four capscrews from
Remove inner fork carriers. Remove inner fork carriers
from integral sideshift carriage. See Figure 14 or
Figure 15.
WARNING
DO NOT try to move a fork without a lifting device. 2. Slide fork to fork removal notch in bottom bar of
Each hook fork for these lift trucks can weigh carriage. See Figure 14 or Figure 15.
45 to 115 kg (99 to 253 lb).
3. Lower fork onto blocks so bottom hook of fork
moves through fork removal notch. Lower
CAUTION carriage further so top hook of fork is disengaged
Remove fork latch pins if adding a fork positioner from top carriage bar. Move carriage away from
attachment. Damage to forks and other carriage fork or use a lifting device to move fork away from
components can occur if fork latch pins are not carriage. See Figure 16.
removed prior to using attachment.

1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME

Figure 14. Fork Removal, Lift Trucks Equipped With Fork Positioner Prior to December, 2016

23
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

1. OUTER FORK CARRIER 5. FORK POSITIONER

2. FORKS 6. CAPSCREWS
3. INNER FORK CARRIER 7. FORK REMOVAL NOTCH
4. OUTER FRAME

Figure 15. Fork Removal, Lift Trucks Equipped With Fork Positioner After December, 2016

24
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

1. CARRIAGE BARS
2. HOOK FORK
3. BLOCKS

Figure 16. Hook Fork Removal

Fork Tip Alignment
4. A fork can be removed from carriage for
replacement of fork or other maintenance. Lift Length of Forks 3% Dimension
lock pin and slide a hook fork to fork removal 914 mm (36 in.) 27 mm (1.08 in.)
notch on carriage. See Figure 17. Lower fork onto 1016 mm (40 in.) 30 mm (1.2 in.)
blocks so that bottom hook of fork moves through 1067 mm (42 in.) 32 mm (1.26 in.)
fork removal notch. See Figure 17. Lower 1207 mm (47.5 in.) 36 mm (1.42 in.)
carriage further so that top hook of fork is 1219 mm (48 in.) 37 mm (1.46 in.)
disengaged from top carriage bar. Move carriage 1372 mm (54 in.) 41 mm (1.61 in.)
away from fork, or use a lifting device to move 1524 mm (60 in.) 46 mm (1.81 in.)
fork away from carriage. 1829 mm (72 in.) 55 mm (2.17 in.)

1. TIP ALIGNMENT (MUST BE WITHIN 3%

OF FORK LENGTH)
2. CRACKS
3. LATCH DAMAGE
4. HEEL OF FORK (MUST BE 90% OF
DIMENSION X)
5. CARRIAGE
6. LOAD BACKREST EXTENSION
7. MAXIMUM ANGLE 93°
8. FORK REMOVAL NOTCH

Figure 17. Forks Check

25
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

Inspect

WARNING
DO NOT try to correct fork tip alignment by
bending the forks or adding shims. Replace bent
forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special
procedures. Replace damaged forks. Forks are to
be replaced only in sets and not individually.

1. Inspect forks for cracks and wear. Check that fork

tips are aligned as shown in Figure 17. Check
that bottom of fork is not worn (item 4, Figure 17).

CAUTION
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment.

2. Replace any damaged or broken parts that are Figure 18. Fork Wear Check
used to keep forks locked in position.
Install
3. Inspect fork wear. Ensure heel wear is not more
than 10% of original thickness. If fork wear is
more than 10%, fork must be replaced or rerated. WARNING
Perform fork wear inspection using a BOL256N1 DO NOT try to move a fork without a lifting device.
caliper ruler Yale P/N 550088603 as follows. See Each hook fork for these lift trucks can weigh
Figure 18 . 45 to 115 kg (99 to 253 lb).

a. Determine normal thickness of "N" of fork

using scale or ruler portion of caliper ruler.
Measurement has to be done on fork shank
CAUTION
using caliper ruler. Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
b. Position caliper at end of heel internal radius components can occur if fork latch pins are not
(item 4, Figure 17) with opening corresponding removed prior to using attachment.
to measured thickness of fork shank in Step a
NOTE: Forks are to be replaced only in sets and not
above. (e.g. for N 1.75 use N 1.75 opening).
individually.
This is typically the section of fork where wear
is greatest. Note that opening distance has NOTE: If lift truck is not equipped with fork positioner,
been reduced by 10% from nominal thickness. go to Step 1. If lift truck is equipped with fork
positioner, go to Step 2.
c. If fork enters opening, it is mandatory to
1. Move fork and carriage so top hook on fork can
replace it. DANGER OF BREAKING.
engage upper carriage bar. Raise carriage to
Furthermore, a 10% reduction in fork blade
move lower hook through fork removal notch.
thickness results in 20% reduction in operating
Slide fork on carriage so that both upper and
capacity.
lower hooks engage carriage. Engage lock pin
with a notch in upper carriage bar. See Figure 19.

26
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

2. If lift truck is equipped with a fork positioner The forks are connected to carriage by hooks and lock
attachment, install inner fork carriers using four pins. See Figure 16 and Figure 19. Lock pins are
capscrews. Tighten capscrews to installed through top fork hooks and fit into slots in top
35 N•m (25 lbf ft). See Figure 14 or Figure 15. carriage bar. If pin does not remain engaged in
carriage slot, replace new pin. Adjust forks as far apart
as possible for maximum support of load. Hook forks
will slide along carriage bars to adjust for load to be
lifted. Raise lock pin in each fork to slide fork on
carriage bar. Make sure lock pin is engaged in carriage
bar to lock fork in position after width adjustment is
made.

Brake Fluid

WARNING
Small amounts of water in the brake system can
1. FORK cause reduced braking performance if the water
2. LOCK PIN reaches the wheel cylinder areas. DO NOT allow
3. SPRING water entry. Ensure that the sealed reservior lid is
4. WASHER properly replaced.
5. WEDGE
6. KNOB Replace the brake fluid if there is dirt or water in
7. LOCK PIN ASSEMBLY the system.

Figure 19. Fork Lock Pin Assembly On lift trucks with dry brake axles, only use SAE
J-1703 (DOT 3) brake fluid int he master cylinder.
Adjust Open cover to brake fluid reservior. Open reservior
NOTE: During adjustment of forks, heel of forks and check fluid level. If fluid is low, fill to within
should not be touching the ground. 2.5 mm (0.1 in.) of max line on reservior. See
Figure 20.
NOTE: The information below applies to lift trucks
NOT equipped with fork positioner attachment.

27
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

A. COVER CLOSED B. COVER OPEN

1. COVER 4. BRAKE FLUID RESERVIOR

2. CAPSCREW 5. MOUNTING BRACKET
3. NUT

Figure 20. Brake Fluid Reservior Cover

HOW TO MAKE CHECKS WITH ENGINE Be careful when making checks. If lift truck is
RUNNING stationary during a check, apply parking brake and put
transmission in NEUTRAL. Make checks carefully.

WARNING Indicator Lights, Horn, Fuses, and Relays

DO NOT operate a lift truck that needs repairs. If lift truck is equipped with a key switch, turn key to
Report the need for repair immediately. If repair is ON position. If lift truck is equipped with a Power
necessary, put a DO NOT OPERATE tag in the ON/OFF button, press button to turn system power
operator's area. If lift truck is equipped with a key ON. All warning lights and indicator lights will light up
switch, remove the key. for two seconds (start check) when system power is
turned ON. See Figure 21. Check all indicator lights for
correct operation as described in Operating Manual.
WARNING Check operation of horn. Start engine by turning key
FASTEN YOUR SEAT BELT! The seat belt is switch to Start position, if truck is equipped with a key
installed to help the operator stay on the truck if switch, or press engine start button, if lift truck is
the lift truck tips over. IT CAN ONLY HELP IF IT IS equipped with this button. If any indicator lights do not
FASTENED. operate correctly, stop engine and check fuses. The
fuses are located in Power Distribution Module (PDM)
Make sure that the area around lift truck is clear before which is under hood and next to battery on right side.
starting engine or making any checks of the operation. See Figure 22.

28
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

Item Warning and Indicator Light

1 Warning Light, Sedimenter Malfunction Indicator
2 Indicator Light, Cold Start (Diesel Only)
3 Warning Light, Alternator Malfunction Indicator
4 Warning Light, Engine Oil Pressure Malfunction Indicator
5 Warning Light, Torque Converter Oil Temperature Indicator
6 Indicator Light, Warning Symbol
7 Indicator Light, Maintenance Required
8 Warning Light, Engine Coolant Temperature Malfunction Indicator
9 Indicator Light, Alarm Set
10 Indicator Light, Hour Meter and Calendar
11 Indicator Light, Clock or Speedometer or Message
12 Indicator Light, Fasten Seat Belt Malfunction Indicator
13 Indicator Light, Fuel Amount

Figure 21. Warning and Indicator Lights

29
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

NOTE: HOOD REMOVED FOR CLARITY.

1. BATTERY 12. REAR WORK LIGHT (20 AMP)

2. POWER DISTRIBUTION MODULE (PDM) 13. FRONT WORK LIGHT RELAY
3. START RELAY 14. BACKUP RELAY
4. STARTER (30 AMP) 15. BATTERY+ (25 AMP)
5. RESISTOR (68 OHM) 16. FRONT WORK LIGHT (20 AMP)
6. FUEL/RUN RELAY 17. BATTERY+ (20 AMP)
7. TRANZORB 18. BACKUP (20 AMP)
8. IGNITION 1+ RELAY 19. IGNITION 3+ (30 AMP)
9. REAR WORK LIGHT RELAY 20. FUEL/RUN (20 AMP)
10. BATTERY (25 AMP) 21. FUEL/RUN RELAY
11. IGNITION 1 (20 AMP)

Figure 22. PDM Showing Fuses and Relays

Service Brakes Parking Brake

Operation, Check Check operation of parking brake. Lift truck with a
capacity load must not move when parking brake is
Check operation of service brakes. Push on inching/ applied on a 15 percent grade [a slope that increases
brake pedal. Service brakes must be applied before 1.5 m in 10 m (1.5 ft in 10 ft)].
inching/brake pedal reaches floor plate. Pedal must
stop firmly and must not move slowly down after Adjust parking brake by turning adjustment knob
brakes are applied. Service brakes must apply equally clockwise. See Figure 23.
to both drive wheels. Service brakes must not pull lift Parking brake lever has a lock, pull lever rearward,
truck to either side of the direction of travel when they then press lock release button when parking brake is
are applied. Service brakes are automatically adjusted released. See Figure 23.
when transmission is in reverse and lift truck is moving
and brakes are firmly applied. Full application of Lift trucks with aFoot Directional Control pedal.
inching/brake pedal applies service brakes and puts When parking brake is applied, a switch in starting
transmission in NEUTRAL. circuit is closed so engine can be started. Switch also
places transmission in NEUTRAL when parking brake
is applied.

30
8000 YRM 2000 Maintenance Procedures Every 8 Hours or Daily

Cooling System

WARNING
DO NOT remove the radiator cap from the radiator
when the engine is hot. When the radiator cap is
removed, the pressure is released from the
system. If the system is hot, the steam and boiling
coolant can cause burns.

There is a bar gauge on dash display for coolant

temperature. All bars are on about 0.5 seconds when
key switch is in ON position, and must indicate actual
temp level when engine is running. As engine coolant
temperature rises, bar level indicators appear in
sequience from underneath. At intermediate position,
coolant is at suitable temperature. If gauge indicates 5
1. LOCK RELEASE BUTTON bars when engine is running, coolant and engine are
2. ADJUSTMENT KNOB too hot. Display will show "Hi" as a warning. Display
3. SWITCH
bar level indicator blinks and sounds a WARNING
Figure 23. Parking Brake buzzer, if coolant temperature reaches 115°C (239°F)
or above. See Table 2. Stop engine and check coolant
level in auxiliary coolant reservoir. Make sure coolant
Engine Oil Pressure
level is between ADD and FULL marks on auxiliary
There is an indicator light for engine oil pressure on coolant reservoir. See Figure 24. Coolant expands as
dash display. During normal operation, the red it heats and the level in auxiliary coolant reservoir will
indicator light will illuminate when key switch is turned increase.
to ON, if truck is equipped with a key switch, or when
power ON/OFF button is pressed, if truck is equipped
with this option, and will stay illuminated until correct CAUTION
oil pressure is obtained, at which time the light will go Additives may damage the cooling system. Before
off. using additives, contact your local Yale dealer.
If the light continues to stay on when engine is If coolant is added, see Maintenance Schedule for
running, engine oil pressure is low. Stop engine and correct solution.
check oil level. Do not restart engine until low pressure
condition has been corrected.
See Figure 10 for lift trucks equipped with a PSI 2.4L WARNING
LPG engine. Compressed air can move particles so that they
cause injury to the user or to other personnel.
See Figure 11 for lift trucks equipped with a Yanmar
Make sure that the path of the compressed air is
2.6L diesel engine.
away from all personnel. Wear protective goggles
See Figure 12 for lift trucks equipped with a Yanmar or a face shield to prevent injury to the eyes.
3.3L diesel engine.
Check radiator fins. Turn engine OFF and clean
See Figure 13 for lift trucks equipped with a PSI 2.4L
radiator with compressed air or water as needed.
Bi-Fuel engine.
Check for and remove any debris on radiator core. If
WARNING buzzer sounds again after restarting, shut
down lift truck and do not operate lift truck until
problem is corrected.

31
Maintenance Procedures Every 8 Hours or Daily 8000 YRM 2000

Table 2. Coolant Temperature Gauge

Display and warning tone of coolant temperature gauge
Bar level indicator Warning condition Warning display Warning tone
5 blinking Major warning [ ! ] + [ Hi ] Beep
5 lighted Minor warning [ ! ] + [ Hi ] --
4 lighted OK -- --
3 lighted OK -- --
2 lighted OK -- --
1 lighted OK -- --

Control Levers and Pedals

Check that control levers for transmission, mast, and
attachment operate as described in Operating
Manual. Check that pedals operate correctly as
described in Operating Manual.

Lift System, Operate

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast at the end of
this section.
Lower the lift mechanism completely. Never allow
any person under a raised carriage. DO NOT put
any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
1. RADIATOR CAP If the mast cannot be lowered, use chains on the
2. FILL CAP mast weldments and carriage so that they cannot
3. FULL MARK
4. AUXILIARY COOLANT RESERVOIR move. Make sure the moving parts are attached to
5. ADD MARK a part that does not move.
DO NOT try to find hydraulic leaks by putting
Figure 24. Auxiliary Coolant Reservoir
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by the
Steering System pressure.

Perform following checks and inspections:

WARNING
The lift truck has hydraulic power steering. The 1. Turn engine OFF and check for leaks in hydraulic
steering can be difficult if the engine is not system. Check condition of hydraulic hoses and
running. tubes.
Make sure steering system operates smoothly and NOTE: Some parts of mast move at different speeds
provides good steering control. Make sure steering during raising and lowering.
column can be adjusted.

32
8000 YRM 2000 First Service After First 100 Hours of Operation

2. Slowly raise and lower mast several times without 5. Lower load to approximately 0.3 m (1 ft). Tilt mast
a load. Raise mast to its full height at least once. forward and backward. Mast must tilt smoothly
Mast components must raise and lower smoothly and both tilt cylinders must stop evenly.
in correct sequence. Hoses must track properly
during operation. 6. Check that controls for attachment operate
functions of attachment. See symbols by each of
3. Inner weldments and carriage must lower the controls. Make sure all hydraulic lines are
completely. connected correctly and do not leak.

4. Raise mast 1 m (3 ft) with a capacity load. Inner

weldments and carriage must raise smoothly.
Lower mast. All moving components must lower
smoothly.

First Service After First 100 Hours of Operation

PSI ENGINE OIL AND OIL FILTER
NOTE: The engine oil and oil filter must also be
changed after the first 100 hours of operation for a
newly installed engine.
Start the engine and run until it reaches normal
operating temperature. Shut engine off. Remove drain
plug and allow the oil to drain into the container.
Remove and discard oil filter and filter gasket. Coat
new sealing ring on the new filter with clean engine oil;
wipe the sealing surface on the filter mounting surface
to remove any dust, dirt, or debris. Install and tighten
filter securely. DO NOT over tighten. Check drain plug
gasket for damage, replace if necessary. Wipe plug
with clean rag; wipe oil pan surface with clean rag and
re-install plug into oil pan. Tighten plug to
39 N•m (29 lbf ft). See Figure 25. Fill engine oil, see
Maintenance Schedule for correct quantity and oil
type. Start engine. Check area around oil filter for
leaks.

1. DRAIN PLUG
2. OIL FILTER

Figure 25. Engine Oil Change - PSI 2.4L Engine

YANMAR ENGINE OIL AND OIL FILTER

NOTE: The engine oil and oil filter must also be
changed after the first 100 hours of operation for a
newly installed engine.
Turn engine OFF and change engine oil and oil filter.
Apply clean oil to gasket of new filter. Install new filter.
Turn filter until gasket touches, then tighten 1/2 to 3/4
turn with your hand. Fill engine with oil as specified in
Maintenance Schedule, until full mark reached on the

33
Maintenance Procedures Every 250 Hours or 6 Months 8000 YRM 2000

dipstick. Start engine. Check area around oil filter for

leaks, shut engine off and check oil dipstick, if low add
oil. See Figure 26.

NOTE: BOTTOM VIEW OF ENGINE SHOWN.

1. OIL FILTER
2. DRAIN PLUG

Figure 26. Engine Oil Change - Yanmar Engines

Maintenance Procedures Every 250 Hours or 6 Months

NOTE: Perform Maintenance Procedures Every 8 DRAIN OIL FROM LPG VAPORIZER
Hours or Daily checks prior to performing procedures REGULATOR (LPG CONVERTER) - PSI
in this section.
ENGINE
PSI 2.4L ENGINE OIL AND OIL FILTER
CHANGE WARNING
NOTE: The engine oil and oil filter must also be LPG can cause an explosion. DO NOT cause
changed after the first 100 hours of operation for a sparks or permit flammable material near the LPG
newly installed engine. system. LPG fuel system can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
Start engine and run until it reaches normal operating from any open flame, motor vehicles, electrical
temperatures. Shut engine off. Remove drain plug and equipment, or ignition source.
allow oil to drain into container. Remove and discard
oil filter and filter gasket. Coat new sealing ring on new Close the shutoff valve on the LPG tank before any
filter with clean engine oil; wipe sealing surface on part of the engine fuel system is disconnected.
filter mounting surface to remove any dust, dirt, or Run the engine until the fuel is the system is used
debris. Install and tighten filter securely. DO NOT over and the engine stops.
tighten. Check drain plug gasket for damage, replace if If the engine will not run, close the shutoff valve
necessary. Wipe plug with clean rag; wipe oil pan on the LPG tank. Loosen the fitting on the supply
surface with clean rag and re-install plug into oil pan. hose from the LPG tank where it enters the filter
Tighten plug to 39 N•m (29 lbf ft). See Figure 25. Fill unit. Permit the pressure in the fuel system to
engine oil, see Maintenance Schedule for correct decrease slowly. Fuel leaving the fitting removes
quantity and oil type. Start engine. Check area around heat. Use a cloth to protect your hands from the
oil filter for leaks. cold fitting.

1. Close shutoff valve on LPG tank and run lift truck

until engine stops. Turn key or keyless switch to
OFF position.

2. Raise hood and disconnect negative battery

cable.

34
8000 YRM 2000 Maintenance Procedures Every 250 Hours or 6 Months

8. Install LPG regulator and two capscrews on LPG

WARNING mounting bracket. Tighten capscrews to
A small amount of fuel may still be present in the 10 to 11 N•m (88 to 97 lbf in).
fuel line. Use gloves to prevent burns and wear
eye protection. If liquid fuel continues to flow from 9. Install LPG lockoff fitting on LPG regulator.
the connections when loosened, check to make
10. Connect coolant hoses and fuel vapor hose as
sure the manual valve is fully closed.
tagged during removal.
NOTE: Tag hoses during removal to aid in installation.
11. Connect negative battery cable and close hood.
3. Disconnect fuel vapor hose and two coolant
hoses from LPG regulator. See Figure 27. 12. Slowly open shutoff valve on LPG tank.

4. Remove LPG lockoff fitting from LPG regulator. 13. Start engine and check for leaks at LPG regulator.
See Figure 27. If leaks are detected, make repairs immediately.
See Fuel System PSI 2.4L 0900YRM1987 for
5. Remove two capscrews from bottom of LPG repair or replacement procedures.
mounting bracket.

6. Rotate LPG regulator 90° so fuel inlet is pointing CAUTION

down and drain oil from regulator into suitable
Disposal of lubricants and fluids must meet local
container. See Figure 28.
environmental regulations.
7. Inspect regulator and remove any oil or debris 14. Dispose of all drain material in a safe and proper
from secondary chamber. manner.

35
Maintenance Procedures Every 250 Hours or 6 Months 8000 YRM 2000

1. LPG FUEL SUPPLY HOSE 4. MOUNTING BRACKET

2. COOLANT HOSE 5. LPG VAPORIZER REGULATOR
3. LPG FUEL VAPOR HOSE 6. LPG LOCKOFF FITTING

Figure 27. LPG Regulator Connections

DIFFERENTIAL AND DRIVE AXLE OIL

(DRY BRAKE)
The differential and drive axle use the same oil supply.
The oil level must be between
0 to 10 mm (0 to 0.40 in.) below bottom edge of fill
hole. The fill hole for checking oil level is on front of
differential housing. Remove fill plug and check fluid
level by sticking a finger into fill hole to feel if fluid level
is at bottom edge of fill hole. See Figure 29. If oil is
low, add oil shown in Maintenance Scheduleuntil oil
level is between 0 to 10 mm (0 to 0.40 in.) below
bottom edge of fill hole. Install fill plug and check for
leaks.

1. FUEL INLET

Figure 28. Regulator Oil Drain

36
8000 YRM 2000 Maintenance Procedures Every 300 Hours

1. DRIVE AXLE 3. DRAIN PLUG

2. CHECK/FILL PLUG 4. FILL LINE (OIL LEVEL)

Figure 29. Drive Axle Fluid Fill

Maintenance Procedures Every 300 Hours

TIE ROD LUBRICATION
NOTE: Heavy-duty, dirty, or wet conditions will require
lubrication of tie rods on a weekly basis.
Lubricate tie rods. Use multipurpose grease shown in
Maintenance Schedule. There are two lubrication
fittings on each tie rod. See Figure 30.

1. After initial lubrication, turn each steer wheel and

lubricate again.

2. Repeat Step 1 two more times for each wheel.

1. AXLE
2. LUBRICATION FITTING

Figure 30. Tie Rod Lubrication

37
Maintenance Procedures Every 500 Hours or 6 Months 8000 YRM 2000

KING PIN LUBRICATION

Lubricate steering axle king pins. Use multipurpose
grease shown in Maintenance Schedule. See
Figure 31.

1. KING PIN
2. LUBRICATION FITTING

Figure 31. King Pin Lubrication

Maintenance Procedures Every 500 Hours or 6 Months

NOTE: Perform the Maintenance Procedures Every 8 Check hydraulic oil level when oil is at operating
Hours or Daily and Maintenance Procedures Every temperature with mast in a vertical position, carriage
250 Hours or 6 Months checks prior to performing lowered, and engine stopped. See Figure 32.
procedures in this section.
Add hydraulic oil only as needed. If hydraulic oil is
above FULL level, hydraulic oil will leak from breather
HYDRAULIC SYSTEM OIL during operation. Oil level indicated by dipstick is most
accurate when oil temperature is
53 to 93°C (130 to 200°F).
WARNING
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.
Never operate the hydraulic pump without oil in
the hydraulic system. The operation of the
hydraulic pump without oil will damage the pump.

CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Yale
dealer.

38
8000 YRM 2000 Maintenance Procedures Every 500 Hours or 6 Months

Disconnect negative and positive terminals of battery.

Using a damp cloth, clean case of battery. If terminals
are corroded, clean terminals with a wire brush.
Connect negative and positive cables to their
respective terminals.

YANMAR ENGINE OIL AND OIL FILTER

CHANGE
NOTE: Change the oil and oil filter for the engine at
the first 100 hours of operation on new lift trucks.
Change engine oil and engine oil filter. See
Maintenance Schedule for correct oil type and amount.
Apply clean oil to gasket of new filter. Install new filter.
Turn filter until gasket touches, then tighten ½ to 3/4
turn with your hand. Start engine. Check area around
oil filter for leaks. See Figure 26.

DRIVE BELT
Yanmar Diesel Engine
Fan and Alternator Drive Belt
1. DIPSTICK
2. RETURN FILTER NOTE: The drive belt tension may be checked at any
3. SUCTION FILTER of the three positions A, B, or C shown in Figure 33
4. BREATHER/FILLER NECK which ever is most easily accessible.
5. RIGHT FRAME CHANNEL
Check drive belt for fan and alternator for wear and
Figure 32. Hydraulic Oil Check damage. Check tension by pushing on drive belt with a
force of 98 N (22 lbf) to check deflection at any one of
BATTERY three possible positions. See Figure 33. Check Table 3
for correct deflection of V-belt. Loosen alternator
support bracket bolt to adjust tension of belt. See
WARNING Figure 34. When tension of V-belt is correct, tighten
The acid in the electrolyte can cause injury. If the alternator support bracket bolt, and check belt tension
electrolyte is spilled, use water to flush the area. again.
Use a solution of sodium bicarbonate (soda) to
make the acid neutral. Acid in the eyes must be
flushed with water immediately. Wear eye
protection.

WARNING
Batteries generate explosive fumes. Keep the
vents in the caps clean. Keep sparks or open flame
away from the battery area. DO NOT make sparks
from the battery connections. Disconnect the
battery ground cable when doing maintenance.

39
Maintenance Procedures Every 500 Hours or 6 Months 8000 YRM 2000

Table 3. V-Belt Deflection Table

Used V-Belt Tension New V-Belt Tension
A B C A B C
10-13 mm 7-10 mm 8-13 mm 8-11 mm 5-8 mm 7-11 mm
(0.375-0.5 in.) (0.250-0.375 in.) (0.3125-0.5 in.) (0.3125-0.4375 in.) (0.1875-0.3125 in.) (0.250-0.4375 in.)

1. SUPPORT BRACKET BOLT

2. ALTERNATOR
3. PRY BAR

Figure 34. Yanmar Diesel Engine Drive Belt

Adjustment

CLEAN DEBRIS FROM RADIATOR CORE

NOTE: SEE TABLE 3 FOR DEFLECTION MEAS-
UREMENTS A, B, AND C. Check radiator core for restrictions and remove
material causing radiator core to be plugged or
Figure 33. Yanmar Diesel Engine Drive Belt restricted.

WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.

Clean with compressed air, adjusted to a maximum

output of 103 kPa (15 psi), and blow debris from core
and fan shroud.

40
8000 YRM 2000 Maintenance Procedures Every 500 Hours or 6 Months

TRANSMISSION OIL LEVEL NOTE: Transmission oil temperature should be at

least 50°C (120°F) when checking oil level.
WARNING If engine has been running, engine must be shut down
At operating temperature, the transmission oil is for one minute or longer prior to checking oil level. See
HOT. DO NOT permit the hot oil to touch the skin Figure 35.
and cause a burn. If transmission oil is low, add oil to transmission at
dipstick tube to correct level as indicated on dipstick.
Use correct oil as shown in Maintenance Schedule.
CAUTION
DO NOT permit dirt to enter the transmission when
the oil level is checked or the filter is changed.

1. TRANSMISSION OIL DIPSTICK

Figure 35. Transmission Oil Check

FORKS Inspect
NOTE: Forks must be removed and installed by
trained personnel. WARNING
The identification of a fork describes how the fork is DO NOT try to correct fork tip alignment by
connected to the carriage. These lift trucks have hook bending the forks or adding shims. Replace bent
forks. forks.
Never repair damaged forks by heating or welding.
Forks are made of special steel using special
procedures. Replace damaged forks. Forks are to
be replaced only in sets and not individually.

41
Maintenance Procedures Every 500 Hours or 6 Months 8000 YRM 2000

1. Inspect forks for cracks and wear. Check that fork

tips are aligned as shown in Figure 17. Check
that bottom of fork is not worn (item 4, Figure 17).

CAUTION
Remove fork latch pins if adding a fork positioner
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment.

2. Replace any damaged or broken parts that are

used to keep forks locked in position.

3. Inspect fork wear. Ensure heel wear is not more A. UPPER LOAD ROLLERS
than 10% of original thickness. If fork wear is B. LOWER LOAD ROLLERS
more than 10%, fork must be replaced or rerated.
Perform fork wear inspection using a BOL256N1 1. LUBRICATE STRIP BEARING SURFACES
caliper ruler Yale P/N 550088603 as follows. See 2. LUBRICATE LOAD ROLLER SURFACES
3. LOAD ROLLER
Figure 18.
Figure 36. Mast Lubrication
a. Determine normal thickness of "N" of fork
using scale or ruler portion of caliper ruler. NOTE: When lubricating mast mounting/pivot pins,
Measurement has to be done on fork shank load must be removed from normal contact surface to
using caliper ruler. allow grease to properly lubricate normal contact
surfaces of mast bushings.
b. Position caliper at end of heel internal radius
(item 4, Figure 17) with opening corresponding 2. Raise carriage about 61 cm (2 ft), and tilt mast
to measured thickness of fork shank in Step a fully back. Place blocks under outer mast
above. (e.g. for N 1.75 use N 1.75 opening). channels to within 13 mm (0.5 in.) of channels.
This is typically the section of fork where wear See Figure 37.
is greatest. Note that opening distance has
been reduced by 10% from nominal thickness. 3. Tilt mast fully forward. See Figure 37.

c. If fork enters opening, it is mandatory to

replace it. DANGER OF BREAKING.
Furthermore, a 10% reduction in fork blade
thickness results in 20% reduction in operating
capacity.

MAST LUBRICATION

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.

NOTE: The load rollers and sheaves have sealed

bearings and do not need additional lubrication.
1. Lubricate sliding surfaces and load roller surfaces
along full length of channels as shown in
Figure 36.

42
8000 YRM 2000 Maintenance Procedures Every 500 Hours or 6 Months

1. MAST PIVOT PIN

2. CAPSCREW
3. BUSHING (BRONZE)
4. LUBRICATION FITTING
5. OUTER MAST

Figure 38. Pivot Pin Lubrication

5. Tilt mast fully back. Remove blocks from under

channels.

6. If a integral sideshift carriage is installed, lubricate

sliding surfaces at grease fittings with
multipurpose grease shown in Maintenance
Schedule. See Figure 39.

A. MAST TILTED FULLY BACK

B. MAST TILTED FORWARD

1. BLOCK
2. MAST

Figure 37. Blocking the Mast

4. Lubricate mast pivot bushings at grease fittings

on outer mast. Use multipurpose grease shown in
Maintenance Schedule. See Figure 38.

43
Maintenance Procedures Every 500 Hours or 6 Months 8000 YRM 2000

slippage; proper hose tensioning. Adjust/repair/replace

hose/components as necessary. For quick disconnect
procedures, see Mast Repair (S/N A387, A389, A397,
A399) 4000YRM1999.

LIFT CHAIN LUBRICATION

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
DO NOT repair worn or damaged lift chains. If a lift
chain is worn or damaged, both lift chains must be
replaced.

NOTE: The 500 Hour/6 Months lift chain lubrication

should not be performed in combination with the 1000
Hour/6 Months lift chain lubrication.
1. UPPER BEARINGS
2. LOWER HOOKS Lubricate lift chains with SAE 30W engine oil. The best
3. LOAD ROLLER procedure is to remove chains from lift truck and soak
4. SNAP RING them in engine oil. Be sure to clean any dirt or grease
5. SIDESHIFT CYLINDER
6. LOWER BEARINGS from chains before lubricating. DO NOT USE STEAM
7. SHIMS TO CLEAN THE LIFT CHAINS.
8. INNER CARRIAGE
9. LUBE FITTINGS TILT CYLINDER LUBRICATION
10. OUTER FRAME
NOTE: The floor plate must be removed in order to
Figure 39. Integral Sideshift Carriage lubricate the rear tilt cylinder lubrication fittings.
Lubricate tilt cylinder ends. Use multipurpose grease
HEADER HOSE CHECKS shown in Maintenance Schedule. There are two
Daily inspection plus; kinked, crushed, flattened or lubrication fittings. See Figure 40.
twisted hose; hard, stiff or charred hose; hose fitting

44
8000 YRM 2000 Maintenance Procedures Every 500 Hours or 6 Months

NOTE: HYDRAULIC HOSES ARE NOT SHOWN FOR CLARITY.

1. LUBRICATION FITTING 6. RETAINING PLATE

2. ROD END WITH BUSHING AND SNAP RING 7. NUT
3. TILT ANCHOR 8. WASHER
4. TILT CYLINDER PIN 9. ROD END WITH BUSHING
5. CAPSCREW

Figure 40. Tilt Cylinder Lubrication

45
Maintenance Procedures Every 500 Hours or 6 Months 8000 YRM 2000

MASTER BRAKE CYLINDER ROD END

PIN LUBRICATION
Lubricate master brake cylinder rod end pin. Use
engine oil as shown in Maintenance Schedule. See
Figure 41.

1. ROD END PIN NOTE: FOUR FUNCTION LEVERS WITH RTST

2. COTTER PIN (LOCKING) SHOWN.
Figure 41. Master Brake Cylinder Rod End Pin 1. HYDRAULIC LEVERS
Lubrication 2. BUSHINGS
3. LOCKING RING (COTTER PIN)
MANUAL HYDRAULIC LEVERS 4. ROD END PIN
LUBRICATION Figure 42. Manual Hydraulic Levers Lubrication
Lubricate bushings for manual hydraulic levers. Use
spray lubricant listed in Maintenance Schedule. See BRAKE FLUID (MASTER CYLINDER)
Figure 42. CHANGE

WARNING
Small amounts of water in the brake system can
cause reduced braking performance if the water
reaches the wheel cylinder areas. DO NOT allow
water entry. Ensure that the sealed reservoir lid is
properly replaced.
Replace the brake fluid in the system if there is dirt
or water in the system.
On lift trucks with dry brake drive axles, only use
SAE J-1703 (DOT 3) brake fluid in the master
cylinder.

46
8000 YRM 2000 Maintenance Procedures Every 1000 Hours or 6 Months

Open cover to brake fluid reservoir. Brake fluid brake fluid, as necessary. Use brake fluid shown in
reservoir is located on cowl, at master cylinder. Add Maintenance Schedule. See Figure 20.

Maintenance Procedures Every 1000 Hours or 6 Months

NOTE: Perform the Maintenance Procedures Every 8
1. Close fuel valve on tank and run engine until it
Hours or Daily, Maintenance Procedures Every 250
runs out of fuel and stops. Try to restart engine
Hours or 6 Months, and Maintenance Procedures
2-3 times until it no longer starts.
Every 500 Hours or 6 Months checks prior to
performing the procedures in this section. 2. Open hood and disconnect negative battery
cable.
DRIVE BELT CHECK
See PSI 2.4L Engine 0600YRM1755 for belt check
instructions and replacement procedures. WARNING
A small amount of fuel may still be present in the
LPG FUEL FILTER REPLACE, PSI fuel line. Use gloves to prevent burns and wear
ENGINES eye protection. If liquid fuel continues to flow from
the connections when loosened, check to make
Remove sure the manual valve is fully closed.

3. Remove bolt and seal washer from fuel filter

WARNING housing top section. Discard seal washer. See
LPG can cause an explosion. DO NOT permit any Figure 43.
sparks or open flames in the work area.

47
Maintenance Procedures Every 1000 Hours or 6 Months 8000 YRM 2000

1. BOLT* 5. FUEL FILTER O-RING

2. SEAL WASHER 6. HOUSING O-RING
3. FUEL FILTER HOUSING TOP SECTION* 7. FUEL FILTER HOUSING BOTTOM SECTION*
4. FUEL FILTER 8. LOW PRESSURE SWITCH
*not service separately

Figure 43. PSI LPG Fuel Filter Remove/Install

4. Remove fuel filter housing top section from fuel 3. Install fuel filter housing top section onto fuel filter
filter housing bottom section. housing bottom section.

5. Remove and discard housing o-ring. 4. Install new seal washer and bolt. Tighten bolt to
13 N•m (115 lbf in).
6. Remove and discard fuel filter and fuel filter o-
ring. NOTE: Opening fuel valve too quickly can cause
internal excess flow valve to close, restricting flow of
Clean/Inspect fuel. If this happens, close fuel valve, wait a few
seconds, and then slowly open fuel valve again. This
1. Clean and inspect fuel filter housing top section
will reset excess flow valve.
for contamination or damage. If damaged, replace
housing. 5. Slowly open fuel valve on tank.

2. Clean and inspect fuel filter housing bottom 6. Connect negative battery cable and close hood.
section for contamination or damage. If damaged,
replace housing. 7. Turn key or keyless switch to ON position and
back to OFF position to pressurize fuel system.
Install
8. Check for leaks at connections by using soapy
1. Install new fuel filter and fuel filter O-ring. See solution or electron leak detector. If leaks are
Figure 43. detected, make proper repairs.

2. Install new housing O-ring.

48
8000 YRM 2000 Maintenance Procedures Every 1000 Hours or 6 Months

GASOLINE FUEL SYSTEM, PSI 2.4L BI- 14. Loosen clamps (9) and remove fuel supply tube
FUEL ENGINE assembly (16) from mounting plate (19).

Remove and Disassemble 15. Loosen clamps (9) and separate fitting (12),
hoses, (10), fuel filter with filter clamp (13 and
1. Disconnect fuel pump connector on wiring
14), and fuel supply tube (15).
harness from fuel pump.
16. Remove two capscrews (2) and manifold
2. Run the engine unti it runs out of fuel and stops.
assembly (5) from bracket (17).
3. Try to restart engine 2-3 times until it no longer
17. Remove four capscrews (2) and bracket (17) from
starts.
frame.
4. Stop engine and allow it to cool.
18. Remove six nuts (18) from mounting plate (19).
5. Disconnect electrical connectors from manifold
19. Remove clamp (14) from fuel filter (13).
assembly connector.
NOTE: See Figure 45 for Step 20 through Step 27.
NOTE: See Figure 44 for Step 6 through Step 19.
20. Disconnect electrical connector from fuel pump
6. Disconnect fitting (1) from fuel rail of bi-fuel
harness jumper (1).
engine.
21. Disconnect fuel pump harness jumper (1) from
7. Remove capscrew (2) and insulated clamp (3)
fuel pump wire harness (6). Remove swivel clamp
from transmission adapter.
(2) from jumper. Remove pump jumper connector
(3) and O-ring (4) from mounting plate (15).
8. Disconnect fitting (4) from manifold assembly (5).
Remove hoses, tubes, clamps, and fittings
22. Remove mounting plate, with pump assembly
attached to fittings (1 and 4) from engine.
attached, from frame.
9. Disconnect supply fitting (6) from manifold
23. Remove five bolts (17), five washers (16), and
assembly (5).
pump assembly (14) from mounting plate (15).
10. Loosen clamp (9) and remove tube assembly (11)
24. Remove strap clamps (7). Disconnect fuel pump
from mounting plate (19).
wire harness (6) from fuel pump (13).
11. Disconnect supply fitting (6) from fitting (7).
25. Remove clamp (8) and isolator (10) from fuel
Remove fitting (7) from fuel return tube (8).
pump (13).
Loosen clamps (9) and remove fuel return tube
(8) from hose (10). 26. Remove clamps (9) and hose (11) from fuel pump
tube and fuel pump.
12. Disconnect fitting (12) from manifold assembly
(5). 27. Remove fuel pump (13) from strainer (12).
13. Remove capscrew (2) from bracket (17) and filter
clamp (14).

49
Maintenance Procedures Every 1000 Hours or 6 Months 8000 YRM 2000

Figure 44. Gasoline Fuel System - PSI 2.4L Bi-Fuel

50
8000 YRM 2000 Maintenance Procedures Every 1000 Hours or 6 Months

Legend for Figure 44.

1. FITTING 11. TUBE ASSEMBLY

2. CAPSCREW 12. FITTING
3. INSULATE CLAMP 13. FUEL FILTER
4. FITTING 14. FILTER CLAMP
5. MANIFOLD ASSEMBLY 15. FUEL SUPPLY TUBE
6. FITTING 16. FUEL SUPPLY TUBE ASSEMBLY
7. FITTING 17. BRACKET
8. TUBE ASSEMBLY 18. NUT
9. CLAMP 19. FUEL TANK PLATE
10. HOSE

51
Maintenance Procedures Every 1000 Hours or 6 Months 8000 YRM 2000

Figure 45. Fuel Pump and Attaching Parts - PSI 2.4L Bi-Fuel

52
8000 YRM 2000 Maintenance Procedures Every 1000 Hours or 6 Months

Legend for Figure 45.

1. FUEL PUMP HARNESS JUMPER 10. ISOLATOR

2. SWIVEL CLAMP 11. HOSE
3. CONNECTOR 12. STRAINER
4. O-RING 13. FUEL PUMP
5. CLIP NUT 14. PUMP
6. FUEL PUMP WIRE HARNESS 15. MOUNTING PLATE
7. STRAP CLAMP 16. WASHER
8. CLAMP 17. BOLT
9. CLAMP

Assemble and Install 14. Re-assemble fuel supply tube assembly using
fuel supply tube (15), fuel filter with filter clamp
NOTE: See Figure 45 for Step 1 through Step 9. (13 and 14), hoses (10), with fitting (12) and
tighten clamps (9).
1. Install fuel pump (13) on new strainer (12).
15. Install fuel supply tube assembly (16) on
2. Install hose (11) and clamps (9) on fuel pump
mounting plate and tighten clamps (9).
tube and fuel pump
16. Install filter clamp and capscrew (2) on bracket
3. Install isolator (10) and clamp (8) on fuel pump
(17).
(13).
17. Install fitting (12) in manifold assembly (5).
4. Connect fuel pump wire harness (6) to fuel pump
(13). Install strap clamps (7). 18. Insert fuel return tube (8) in hose (10) and tighten
clamps (9). Install fitting (7) in fuel return tube (8).
5. Install pump assembly (14) five washers (16), and
Connect fitting (7) to supply fitting (6).
five bolts (17) on mounting plate (15).
19. Install tube assembly (11) to mounting plate (19)
6. Clean frame opening and apply a 3 mm (0.12 in.)
and tighten clamps (9).
bead of Loctite 5699 sealer to frame opening in
pattern shown in Figure 46. 20. Connect supply fitting (6) to manifold assembly
(5).
7. Install mounting plate, with pump assembly
attached, on frame. 21. Connect fitting (4) to manifold assembly (5).
Install hoses, tubes, clamps, and fittings attached
8. Install O-ring (4) and pump jumper connector (3)
to fittings (1 and 4) on engine. Connect fitting (1)
on mounting plate (15). Connect fuel pump
to fuel rail.
harness jumper (1) to fuel pump wire harness (6).
Install swivel clamp on jumper. 22. Install insulated clamp (3) and capscrew (2) to
transmission adapter.
9. Connect electrical connector to fuel pump
harness jumper (1). 23. Connect manifold assembly connector to
electrical connector.
NOTE: See Figure 44 for Step 10 through Step 22.
24. Connect fuel pump connector on wiring harness
10. Install clamp (14) on new fuel filter (13).
to fuel pump.
11. Install six nuts (18) on mounting plate (19).
Tighten nuts to 12 to 15 N•m (106 to 133 lbf in).

12. Install bracket (17) and four capscrews (2) on

frame.

13. Install manifold assembly (5) and two capscrews

(2) on bracket (17).

53
Maintenance Procedures Every 1000 Hours or 6 Months 8000 YRM 2000

1. SEALANT PATTERN
2. FRAME OPENING

Figure 46. Sealant Pattern for Fuel Tank Cover

FUEL FILTER REPLACEMENT, YANMAR

ENGINE

CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.

Replace fuel filter at specified intervals to prevent

contaminants from adversely affecting the diesel fuel
flow.
NOTE: See Figure 47 for all steps in the following
procedure.

1. FUEL FILTER ASSEMBLY

2. FUEL FILTER ELEMENT
3. FUEL FILTER SENSOR CONNECTOR
4. FUEL FILTER HEAD
5. O-RING
6. DRAIN PLUG
7. FUEL FILTER SENSOR
8. INLINE FUEL FILTER
9. INLET NIPPLE

Figure 47. Yanmar Fuel Filter Replacement

1. Stop engine and allow it to cool.

2. Close all fuel cocks in line.

54
8000 YRM 2000 Maintenance Procedures Every 1000 Hours or 6 Months

NOTE: Tag connectors prior to disconnecting to aid in 14. Clean fuel filter head mounting surface and apply
reconnecting. a small amount of diesel fuel to gasket on new
fuel filter element.
3. Disconnect fuel filter sensor connector.
15. Install new fuel filter element until it contacts fuel
4. Place an approved container under fuel filter.
filter head mounting surface. Tighten one
5. Open drain plug to drain fuel from fuel filter. additional turn.

6. Remove fuel filter from fuel filter head. Wipe up 16. Open all fuel cocks in fuel line.
any spilled fuel immediately.
17. Reconnect fuel filter sensor connector.
7. Remove drain plug from fuel filter. Discard O-ring.
18. Prime fuel system. See Priming the Fuel System
8. Remove fuel filter sensor from fuel filter element (Yanmar).
and discard O-ring.
19. Check for fuel leaks.
9. Remove inline fuel filter from inlet nipple that goes
to fuel injection pump. See Figure 48. PRIMING THE FUEL SYSTEM (YANMAR)
1. Place an approved container under air bleed port.
See Figure 49.

2. Loosen air bleed port 2 or 3 turns.

CAUTION
NEVER use the starter motor to crank the engine
in order to prime the fuel system. This may cause
the starter to overheat and damage the coils
and/or the ring gear.

3. Operate fuel priming pump until fuel coming out of

air bleed port is free of bubbles. See Figure 49.

1. INLINE FUEL FILTER

2. FUEL LINE
3. WATER SEPARATOR/FUEL FILTER

Figure 48. In-Line Fuel Filter Replacement

10. Dispose of fuel, fuel filters, and O-ring in

accordance with local directives.

11. Install new inline fuel filter into inlet nipple.

12. Install fuel filter sensor assembly in new fuel filter

using new O-ring supplied with fuel filter.

13. Install new O-ring on drain plug, and install drain

plug on new fuel filter element. Hand tighten only.

55
Maintenance Procedures Every 1000 Hours or 6 Months 8000 YRM 2000

Pitch Total Length of Wear Limit

20 Links (The Maximum
(Pitch) of New Length of 20
Chain Links)
12.7 mm 254.0 mm 261.6 mm
(0.50 in.) (10.0 in.) (10.3 in.)
1. AIR BLEED PORT
2. FUEL PRIMING PUMP 15.9 mm 317.5 mm 327.0 mm
(0.63 in.) (12.5 in.) (12.9 in.)
Figure 49. Priming the Fuel System 19.1 mm 381.0 mm 392.4 mm
(0.75 in.) (15.0 in.) (15.4 in.)
4. Tighten air bleed port. 25.4 mm 508.0 mm 523.3 mm
(1.00 in.) (20.0 in.) (20.6 in.)
5. Wipe up any fuel that may have spilled, and
dispose of fuel and rags in accordance with local 1. CHAIN WEAR SCALE
directives.
Figure 50. Lift Chains Check
IGNITION SYSTEM
LIFT CHAIN LUBRICATION
PSI 2.4L Engines
The PSI engine used on lift trucks covered in this
service manual has an electronic ignition system. WARNING
Change spark plugs and check timing every 1000 Cleaning solvents can be flammable and toxic and
hours. The correct spark plug gap is shown in can cause skin irritation. When using cleaning
Maintenance Schedule. solvents, always follow the recommendations of
the manufacturer.
LIFT CHAINS WEAR CHECK Compressed air can move particles so they cause
If a section of chain is 3% longer than a similar section injury to the user or to other personnel. Make sure
of new chain, chain is worn and must be replaced. that the path of the compressed air is away from
Measure chain for wear where it moves over sheaves. all personnel. Wear protective goggles or a face
Using a chain scale, (Yale P/N 518096869 ) check lift shield to prevent injury to the eyes.
chains as shown in Figure 50.

56
8000 YRM 2000 Maintenance Procedures Every 1000 Hours or 6 Months

Remove lift chains. Clean lift chains by soaking them

in a solvent that has a petroleum base for at least 30
minutes. Use compressed air, adjusted to a maximum
output of 103 kPa (15 psi), to completely dry chains
when they are clean.
Lubricate lift chains by soaking them in 30W engine oil
for at least 30 minutes. Remove chains from oil. Hang
chains for one hour so excess oil will drain from
chains.

INTEGRAL SIDESHIFT CARRIAGE,

CHECK BEARINGS
1. Lower carriage completely and remove forks.

2. Remove backrest and lower mounting hooks from

sideshift carriage. See Figure 51.

3. Use a lifting device with a capacity of at least

450 kg (1000 lb) to lift outer frame away from 1. UPPER BEARING
inner carriage. 2. LOWER HOOK
3. LOAD ROLLER
4. SNAP RING
4. Clean bearing areas. Inspect sideshift bearings 5. SIDESHIFT CYLINDER
for wear as follows: 6. LOWER BEARING
7. SHIMS
a. If either upper bearing is worn to less than 8. INNER CARRIAGE
2.5 mm (3/32 in.) thickness, replace both upper 9. LUBE FITTING
bearings by driving upper bearings out of 10. OUTER FRAME
carriage bar. Figure 51. Integral Sideshift Carriage
b. If either lower bearing is worn to less than
2.5 mm (3/32 in.) thickness, replace both lower
INTEGRAL SIDESHIFT CARRIAGE,
bearings by prying lower bearings from lower CHECK LOWER MOUNTING HOOKS
carriage bar. Inspect lower mounting hooks for wear. Replace hooks
if they are worn beyond wear limit. The wear limit
clearance range is 0.76 mm (0.03 in.) minimum and
1.52 mm (0.06 in.) maximum. See A in Figure 52.

57
Maintenance Procedures Every 2000 Hours or 1 Year 8000 YRM 2000

Legend for Figure 52.

A. WEAR LIMIT - 0.76 mm (0.03 in.) MINIMUM AND

1.52 mm (0.06 in.) MAXIMUM.
B. CLEARANCE ADJUSTMENT - 0.76 mm (0.03 in.)
MINIMUM AND 1.52 mm (0.06 in.) MAXIMUM.

CONTROL LEVERS, PEDALS, AND

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

Figure 52. Lower Mounting Hooks Wear Limit and

Clearance Adjustment

Maintenance Procedures Every 2000 Hours or 1 Year

NOTE: Perform Maintenance Procedures Every 8
Hours or Daily, Maintenance Procedures Every 250 CAUTION
Hours or 6 Months, Maintenance Procedures Every
Disposal of lubricants and fluids must meet local
500 Hours or 6 Months, and Maintenance Procedures
environmental regulations.
Every 1000 Hours or 6 Months checks prior to
performing procedures in this section. NOTE: Turn lift truck engine OFF before replacing
hydraulic oil filter.
HYDRAULIC SYSTEM
NOTE: See Figure 54 for steps below:
Return Filter, Replace 1. Put lift truck on a level surface and lower carriage.

WARNING 2. Place a drain pan with a capacity of

At operating temperature, the hydraulic oil is HOT. approximately 30 liter (31.7 qt) under hydraulic
DO NOT permit the hot oil to touch the skin and tank.
cause a burn.
3. Remove hydraulic oil drain plug from bottom of
right frame channel. When oil has completely
drained, install drain plug.
CAUTION
DO NOT permit dirt to enter the hydraulic system 4. Open hood.
when the oil level is checked or the filter is
changed. Dirt can cause damage to the 5. Remove hydraulic dipstick.
components of the hydraulic system.
6. Loosen hose clamp and remove return hose from
Never operate the hydraulic pump without oil in
return pipe.
the hydraulic system. The operation of the
hydraulic pump without oil will damage the pump. 7. Remove six nuts and hydraulic tank cover from
top of right frame channel.

58
8000 YRM 2000 Maintenance Procedures Every 2000 Hours or 1 Year

8. Remove return pipe and return filter from right 11. Install suction filter onto suction pipe. Tighten
frame channel; remove return pipe from return suction filter to 30 to 40 N•m (22 to 29.5 lbf ft).
filter. Discard return filter.
12. Install suction pipe in right frame channel, attach
9. Loosen hose clamp and remove suction hose suction hose and tighten hose clamp.
from suction pipe.
13. Install new return filter onto return pipe. Tighten
10. Remove suction filter and suction pipe from right filter to 30 to 40 N•m (22 to 29.5 lbf ft).
frame channel; remove suction pipe from suction
filter. Clean suction filter and inspect for damage. 14. Clean frame opening for hydraulic tank cover and
Replace if damaged. See Parts Manual for new apply 3 mm (0.12 in.) bead of Loctite 5699 in
part. pattern shown in Figure 53.

1. SEALANT PATTERN - HYDRAULIC TANK 3. SEALANT PATTERN - HYDRAULIC TANK FILLER

COVER PLATE
2. FRAME OPENING 4. FRAME OPENING

Figure 53. Sealant Pattern for Hydraulic Tank Cover and Filler Plate

15. Install return pipe, hydraulic tank cover, and six

16. Remove cap from breather/fill neck and add
nuts on right frame channel. Tighten nuts to
hydraulic oil. See Maintenance Schedule for
12 to 15 N•m (106 to 133 lbf in). Install return
correct oil and quantity.
hose onto return pipe and tighten hose clamp.
17. Start lift truck and allow it to run for 30 seconds.
Check for leaks. Stop engine and check hydraulic
CAUTION oil level. Add oil, if necessary.
Additives may damage the hydraulic system.
Before using additives, contact your local Yale
dealer.

59
Maintenance Procedures Every 2000 Hours or 1 Year 8000 YRM 2000

1. DIPSTICK 8. SUCTION PIPE

2. HOSE CLAMP 9. SUCTION FILTER
3. RETURN HOSE 10. SUCTION HOSE
4. NUT 11. BREATHER/FILL NECK
5. HYDRAULIC TANK COVER 12. RIGHT FRAME CHANNEL
6. RETURN PIPE 13. DRAIN PLUG
7. RETURN FILTER

Figure 54. Return Filter, Replace

AIR FILTER ELEMENT, REPLACE 3. Gently pull both air filter elements from canister.
Avoid dislodging contaminates from elements or
The air filter canister should not be opened until an air knocking either against canister.
filter element replacement is required. An air filter
element replacement is required when specified 4. Remove inner filter element from outer filter
number of hours has passed since last filter element element. See Figure 55.
replacement.
5. With a clean, soft rag, wipe the inside surface of
Air Filter Without Silencer canister. Clean well around locking tabs to retain
element. Clean tabs make new filter element
installation easier. Be careful not to knock any
CAUTION contaminates into outlet tube to engine.
DO NOT allow dirt to enter the engine air intake
when replacing the air filter element. A small 6. Inspect new filter element for voids, cuts, tears, or
amount of dirt could cause engine damage. indentations in the urethane-sealing surfaces. DO
NOT use if damaged.
1. Shut off engine. Never open air filter canister or
remove filter element with engine running.

2. Unlatch and remove cover.

60
8000 YRM 2000 Maintenance Procedures Every 2000 Hours or 1 Year

between the cover and the canister. If cover does not

CAUTION fit easily, the filter element is not installed properly. Do
The element must be properly installed to ensure not use a cover that is bent, damaged, or missing
adequate engine protection. An improperly latches.
installed element may allow dirt and dust to enter 8. Install cover into the canister and ensure the
and damage the engine. INLET arrow is in line with the canister inlet.

NOTE: Proper element installation is required to allow NOTE: Do not use latches to pull cover down against
cover to be installed correctly. Never reinstall a used the canister. If cover does not fit completely against
element. Never install a damaged element. Always the canister with no gaps, the element is not installed
use a Yale approved filter element. correctly.
7. Install new filter element into canister. 9. Fasten the latches to secure the cover to the
canister. Make sure the latches penetrate the
slots in both the canister and the cover.
CAUTION
During cover installation, DO NOT force the cover 10. Inspect the entire air intake system for leaks.
on the canister. To do so will result in damage to Inspect all clamps for tightness and tighten if
the filter element, cover, and possibly the canister. necessary. Inspect all hoses for damage. Replace
damaged hoses. Inspect the dust evacuation
NOTE: If the filter element is properly installed, the valve for damage. If damaged, replace the dust
cover will fit easily into the canister with no gap evacuation valve.

1. CANISTER 4. COVER
2. INNER FILTER ELEMENT 5. DUCT EVACUATION VALVE
3. OUTER FILTER ELEMENT

Figure 55. Air Filter Assembly Without Silencer

61
Maintenance Procedures Every 2000 Hours or 1 Year 8000 YRM 2000

CAUTION
The element must be properly installed to ensure
adequate engine protection. An improperly
installed element may allow dirt and dust to enter
and damage the engine.

NOTE: Proper element installation is required to allow

cover to be installed correctly. Never reinstall a used
element. Never install a damaged element. Always
use a Yale approved filter element.
6. Install new filter element into canister. Press and
rotate filter element ⅛ turn clockwise until fully
1. PUSH IN engaged in canister. See Figure 56.
2. TWIST TO LOCK

Figure 56. Air Filter Label

CAUTION
Air Filter With Silencer During cover installation, DO NOT force the cover
on the canister. To do so will result in damage to
the filter element, cover, and possibly the canister.
CAUTION
DO NOT allow dirt to enter the engine air intake NOTE: If the filter element is properly installed, the
when replacing the air filter element. A small cover will fit easily into the canister with no gap
amount of dirt could cause engine damage. between the cover and the canister. If cover does not
fit easily, the filter element is not installed properly. Do
1. Shut off engine. Never open air filter canister or not use a cover that is bent, damaged, or missing
remove filter element with engine running. latches.
7. Install cover into the canister and ensure the
2. Unlock and remove cover. To remove filter
INLET arrow is in line with the canister inlet.
element, press and rotate filter element
counterclockwise about ⅛ turn until filter element
NOTE: Do not use latches to pull cover down against
is free. To assist removal, gently move end back
the canister. If cover does not fit completely against
and forth to help break seal. See Figure 57.
the canister with no gaps, the element is not installed
correctly.
3. Gently pull filter element from canister. Avoid
dislodging contaminants from element or 8. Fasten the latches to secure the cover to the
knocking it against canister. canister. Make sure the latches penetrate the
slots in both the canister and the cover.
4. With a clean, soft rag, wipe the inside surface of
canister. Clean well around locking tabs to retain 9. Inspect the entire air intake system for leaks.
element. Clean tabs make new filter element Inspect all clamps for tightness and tighten if
installation easier. Be careful not to knock any necessary. Inspect all hoses for damage. Replace
contaminants into outlet tube to engine. damaged hoses. Inspect the dust evacuation
valve for damage. If damaged, replace the dust
5. Inspect new filter element for voids, cuts, tears, or evacuation valve.
indentations in the urethane-sealing surfaces. DO
NOT use if damaged.

62
8000 YRM 2000 Maintenance Procedures Every 2000 Hours or 1 Year

1. PLUG 4. COVER
2. DUST EVACUATION VALVE 5. OUTER FILTER ELEMENT
3. INNER FILTER ELEMENT 6. CANISTER

Figure 57. Air Filter With Silencer

PCV VALVE
PSI LPG and Bi-Fuel Engines
NOTE: Turn engine OFF before installing new PCV
valve.
Install a new PCV valve.
See Figure 10 for PSI LPG engine.
See Figure 13 for PSI Bi-Fuel engine.

OXYGEN SENSOR
Check that oxygen sensor electrical connector is
seated and locked. Check wires for cracks, splits,
chaffing, or burn through. If necessary, repair.
See Figure 58 for lift trucks equipped with a PSI
engine.
1. EXHAUST MANIFOLD
2. OXYGEN SENSOR
3. EXHAUST PIPE

Figure 58. Oxygen Sensor - PSI 2.4L Engine

FUEL INJECTOR, YANMAR ENGINES

For removal and cleaning instructions, see Yanmar
Diesel Engines 0600YRM1205.

63
Maintenance Procedures Every 2000 Hours or 1 Year 8000 YRM 2000

FORKS, INSPECT INTEGRAL SIDESHIFT CARRIAGE

Bearings, Replace
WARNING Replace all four bearings regardless of wear. See
DO NOT try to correct fork tip alignment by Maintenance Procedures Every 1000 Hours or 6
bending the forks or adding shims. Replace bent Months, Integral Sideshift Carriage, Check Bearings
forks. for procedure.
Never repair damaged forks. DO NOT heat, weld,
cut, drill, or bend the forks. Forks are made of SERVICE BRAKES
special steel using special methods. Replace
Check brake lining and parts of brake assembly for
damaged forks as a set.
wear or damage. Minimum acceptable brake lining
1. Inspect forks for cracks and wear. Check that fork thickness is 1.0 mm (0.040 in.). If brake linings are
tips are aligned as shown in Figure 17. Check worn thinner than the specification, replace brake
that bottom of fork is not worn (item 4, Figure 17). linings. See Brake System 1800YRM1991 for removal
and installation procedures of drive wheels and brake
drums. If brake linings or brake shoes are worn or
damaged, they must be replaced. Brake shoes must
CAUTION
be replaced in complete sets. Inspect brake drums for
Remove fork latch pins if adding a fork positioner cracks or damage. Replace any damaged parts.
attachment. Damage to forks and other carriage
components can occur if fork latch pins are not
removed prior to using attachment. WARNING
Brake linings can contain dangerous fibers.
2. Replace any damaged or broken parts that are
Breathing the dust from these brake linings is a
used to keep forks locked in position.
cancer or lung disease hazard. DO NOT create
3. Inspect fork wear. Ensure heel wear is not more dust! DO NOT clean brake parts with compressed
than 10% of original thickness. If fork wear is air or by brushing. Follow the cleaning procedure
more than 10%, fork must be replaced or rerated. in this section. When the brake drums are
Perform fork wear inspection using a BOL256N1 removed, DO NOT create dust.
caliper ruler Yale P/N 550088603 as follows. See DO NOT sand, grind, chisel, hammer, or change
Figure 18. linings in any way that will create dust. Any
changes to brake linings must be done in a
a. Determine normal thickness of "N" of fork restricted area with special ventilation. Protective
using scale or ruler portion of caliper ruler. clothing and a respirator must be used.
Measurement has to be done on fork shank
using caliper ruler. Brake cleaning procedures are as follows:

b. Position caliper at end of heel internal radius

(item 4, Figure 17) with opening corresponding CAUTION
to measured thickness of fork shank in Step a DO NOT use an oil solvent to clean the wheel
above. (e.g. for N 1.75 use N 1.75 opening). cylinder. Use a solvent approved for cleaning of
This is typically the section of fork where wear brake parts. DO NOT permit oil or grease in the
is greatest. Note that opening distance has brake fluid or on the brake linings.
been reduced by 10% from nominal thickness.
1. DO NOT release brake lining dust from brake
c. If fork enters opening, it is mandatory to linings into the air when brake drum is removed.
replace it. DANGER OF BREAKING.
Furthermore, a 10% reduction in fork blade 2. Use a solvent approved for cleaning of brake
thickness results in 20% reduction in operating parts to wet lining dust. Follow instructions and
capacity. cautions of manufacturer for use of solvent. If a
solvent spray is used, do not create brake lining
dust with spray.

64
8000 YRM 2000 Maintenance Procedures Every 2000 Hours or 1 Year

3. When brake lining dust is wet, clean parts. Put

any cloth or towels in a plastic bag or an airtight
container while they are still wet. Put a
DANGEROUS FIBERS warning label on plastic
bag or airtight container.

4. Any cleaning cloths that will be washed must be

cleaned so that fibers are not released into the
air.

DIFFERENTIAL
NOTE: Additional information on differential can be
found in Drive Axle Repair 1400YRM1989.

1. Place lift truck on blocks. See How to Raise Drive

Tires in this manual.

2. Differential and drive axle use the same oil

supply. Place a container with a minimum
capacity of 7 liter (7.4 qt) under differential.
Remove drain plug located in bottom of
differential and drain oil from differential
completely. Install drain plug. See Figure 59. A. FRONT VIEW
B. BOTTOM VIEW
3. Fill hole is on front of differential housing. Add oil
shown in Maintenance Schedule until oil level is 1. DIFFERENTIAL
at lower edge of fill hole. Install fill plug and rotate 2. FILL PLUG
3. DRAIN PLUG
drive wheels in order to get oil pumped into axle.
See Figure 60. Figure 59. Differential Oil Drain/Fill
4. Remove fill plug and check oil level. Add oil, as
necessary. Install fill plug and check for leaks.
See Figure 60.

1. FILL LINE

Figure 60. Differential Oil Level

65
Maintenance Procedures Every 2000 Hours or 1 Year 8000 YRM 2000

TRANSMISSION OIL AND FILTER, 4. Remove and discard transmission breather.

REPLACE Install new transmission breather and hand
tighten.

WARNING 5. Remove and discard old transmission oil filter.

At operating temperature, the transmission oil is Apply clean oil to gasket of new transmission oil
HOT. DO NOT permit the hot oil to touch the skin filter. Install new filter and hand tighten. See
and cause a burn. Figure 61.

6. Add oil to transmission at dipstick tube. Correct oil

is shown in Maintenance Schedule.
CAUTION
DO NOT permit dirt to enter the transmission when 7. Start and run engine for approximately five
the oil lever is check or the filter is changed. Dirt minutes after fill to allow oil to lubricate parts
can cause damage to the transmission within transmission.
components.
NOTE: Transmission oil temperature should be at
least 50°C (120°F) when checking oil level.
CAUTION 8. Turn key to OFF position, check for leaks, and
Disposal of lubricants and fluids must meet local check oil level. Top off oil, if necessary.
environmental regulations.

NOTE: Change transmission oil filter at first 500 hours

of operation on new lift trucks. Before removing oil
filter, make a hole in the filter and allow five minutes for
oil to drain down into transmission. This will reduce oil
that will run out of filter and onto transmission when
filter is removed.
NOTE: The transmission drain plug is on lower left
side of torque converter housing.
1. Remove drain plug, spring, and screen. Drain oil
into container. See Figure 61.

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufacturer's
recommended safety procedures.
Compressed air can move particles so they cause
injury to the user or to other personnel. Make sure
the path of the compressed air is away from all 1. TRANSMISSION OIL FILTER
personnel. Wear protective goggles or a face 2. TRANSMISSION BREATHER
3. TRANSMISSION DIPSTICK
shield to prevent injury to the eyes. 4. TRANSMISSION
5. TORQUE CONVERTER HOUSING
2. Clean screen with cleaning solvent, and dry with 6. SCREEN
compressed air, adjusted to maximum output of 7. SPRING
103 kPa (15 psi). 8. TRANSMISSION DRAIN PLUG

3. When oil has drained, first install screen, then Figure 61. Transmission Oil Change
spring, and transmission drain plug.

66
8000 YRM 2000 Maintenance Procedures Every 2000 Hours or 1 Year

BRAKE FLUID (MASTER CYLINDER) 3. Remove brake fluid reservoir cap. Pour fluid into
CHANGE a suitable container with a 0.2 liter (0.42 pt)
minimum capacity. Refill reservoir with clean oil
1. Open brake fluid reservoir cover. See Figure 62. from a sealed container and install cover on
reservoir. Correct oil is shown in Maintenance
Schedule.
CAUTION
Disposal of lubricants and fluids must meet local 4. Install brake reservoir, two capscrews, and two
environmental regulations. nuts onto mounting bracket on cowl.

2. Remove two capscrew, two nuts, and brake fluid 5. Close brake fluid reservoir cover. See Figure 62.
reservoir from mounting bracket on cowl. See
Figure 62.

A. COVER CLOSED B. COVER OPEN

1. COVER 4. BRAKE FLUID RESERVOIR

2. CAPSCREW 5. MOUNTING BRACKET
3. NUT

Figure 62. Brake Fluid Change

BRAKE FLUID, REMOVE 2. Put one end of a rubber hose on special fitting of
wheel cylinder. Put other end of hose into an
Perform following procedure to remove used brake empty container.
fluid from remainder of brake system.
3. Loosen special fitting at wheel cylinder one turn
1. Ensure brake fluid reservoir is filled with brake so that used brake fluid can be removed from
fluid. brake system. Slowly push brake pedal and hold
it at the end of its stroke. Close special fitting.
Release brake pedal.

67
Maintenance Procedures Every 4000 Hours or 2 Years 8000 YRM 2000

NOTE: New brake fluid will be easily recognized, as 5. Check level of brake fluid in brake fluid reservoir
the color will be more clear than used fluid, with will be during procedure. Make sure to keep brake fluid
darker. at correct level.
4. Repeat Step 1 through Step 3 until there is new
6. Repeat procedure for opposite wheel cylinder.
brake fluid in container.

Maintenance Procedures Every 4000 Hours or 2 Years

NOTE: Perform Maintenance Procedures Every 8 NOTE: Check and clean hydraulic oil strainer screen,
Hours or Daily, Maintenance Procedures Every 250 every time hydraulic oil is changed.
Hours or 6 Months, Maintenance Procedures Every
1. Replace hydraulic oil as described below:
500 Hours or 6 Months, Maintenance Procedures
Every 1000 Hours or 6 Months, and Maintenance a. Place a container with a minimum capacity of
Procedures Every 2000 Hours or 1 Year checks prior 30 liter (31.7 qt) under drain plug at bottom of
to performing procedures in this section. the hydraulic tank. To drain oil, remove drain
plug from bottom of right frame channel. See
HYDRAULIC OIL, REPLACE Figure 63.

b. When tank is empty, inspect inside of tank for

WARNING
any foreign matter or possible fungus. If
At operating temperature the hydraulic oil is HOT. necessary, clean inside of tank in accordance
DO NOT permit the hot oil to touch the skin and with instructions found in Frame
cause a burn. 0100YRM1984.

c. When either inspection or cleaning of tank is

CAUTION completed, install drain plug in bottom of right
DO NOT permit dirt to enter the hydraulic system frame channel. Tighten drain plug to
when the oil level is checked or the filter is 38 N•m (28 lbf ft).
changed. Dirt can cause damage to the
components of the hydraulic system.
Never operate the hydraulic pump without oil in CAUTION
the hydraulic system. The operation of the Additives may damage the hydraulic system.
hydraulic pump without oil will damage the pump. Before using additives, contact your local Yale
dealer.

2. Fill hydraulic tank with oil specified in

CAUTION Maintenance Schedule.
Disposal of lubricants and fluids must meet local
environmental regulations. 3. When oil level is correct, operate system and
check for leaks.
NOTE: Heavy-duty or contaminated applications will
require hydraulic oil change at 2000 hours.
NOTE: Replace hydraulic oil filter at the same time oil
is changed.

68
8000 YRM 2000 Maintenance Procedures Every 4000 Hours or 2 Years

1. HYDRAULIC TANK 2. DRAIN PLUG

Figure 63. Hydraulic Oil Change

COOLING SYSTEM 3. Disconnect hose leading from auxiliary reservoir

to fitting at top of radiator under radiator cap, and
1. Put lift truck on a level surface. Stop engine. drain reservoir into same container used for
Place a container with a minimum capacity of radiator coolant. Check reservoir for contaminants
30.1 liter (32 qt) under radiator drain valve which and flush, as necessary. Connect hose back on
could be located on either lower left or right side fitting at top of radiator.
of radiator on engine side of radiator.

CAUTION
WARNING
Additives may damage the cooling system. Before
DO NOT remove the radiator cap from the radiator using additives, contact your local Yale dealer.
when the engine is hot. When the radiator cap is
removed, the pressure is released from the 4. Close drain valve. Fill cooling system, use
system. If the system is hot, the steam and boiling Ethylene Glycol Boron-free Antifreeze. Purchase
coolant can cause burns. DO NOT remove the a pre-diluted 50/50 solution; or mix 50%
cover for the radiator when the engine is running. concentrate with 50% distilled or deionized water.
Fill auxiliary reservoir to a level between ADD and
FULL marks on reservoir.
CAUTION
Disposal of lubricants and fluids must meet local Install radiator cap. Start engine. Check for leaks. Add
environmental regulations. coolant to auxiliary coolant reservoir as needed.
Coolant level should be between ADD and FULL
2. Open drain valve and remove radiator cap. Drain marks on reservoir.
coolant into container. Flush cooling system.
Check hoses for damage. Replace with new
hoses, as needed.

69
Maintenance Procedures Every 5000 Hours 8000 YRM 2000

REPLACE THROTTLE (ACCELERATOR) 4. Install throttle cable, pin, washer, and cotter pin
CABLE, YANMAR DIESEL ENGINE on bellcrank. See Figure 64.

1. Remove floor plate. 5. Install throttle cable, pin, washer, and cotter pin
on accelerator lever. See Figure 64.
2. Remove cotter pin, washer, pin, and throttle cable
from accelerator lever. See Figure 64. 6. For throttle pedal and cable adjustments see
Frame 0100YRM1984.
3. Remove cotter pin, washer, pin, and throttle cable
from bellcrank. See Figure 64. 7. Install floor plate.

1. ACCELERATOR LEVER 4. WASHER

2. COTTER PIN 5. THROTTLE CABLE
3. PIN 6. BELLCRANK

Figure 64. Throttle (Accelerator) Cable, Replace

Maintenance Procedures Every 5000 Hours

FUEL INJECTOR CHECK, PSI ENGINE
See PSI 2.4L Engine 0600YRM1755 for injector
check instructions and replacement procedures.

70
8000 YRM 2000 Maintenance Procedures Every 6000 Hours

Maintenance Procedures Every 6000 Hours

TIMING BELT CHANGE, PSI ENGINE To change timing belt, use Kit-Service 6000 hours
specified in the Parts Manual for your lift truck. See
NOTE: When changing timing belt make sure ALL PSI 2.0 LPG Engine 0600YRM1736 for belt check
components from service kit are used and not just the instructions and replacement procedures.
timing belt.

Safety Procedures When Working Near Mast

The following procedures must be used when 1. Lower mast and carriage completely. Push lift/
inspecting or working near the mast. Additional lower control lever forward and make sure there
precautions and procedures can be required when is no movement in the mast. Make sure all parts
repairing or removing the mast. See the correct of the mast that move are fully lowered.
Service Manual section for the specific mast being
OR
repaired.
2. If parts of the mast must be in a raised position,
install a safety chain to restrain the moving parts
WARNING of the mast. Connect moving parts to a part that
Mast parts are heavy and can move. Distances does not move. Follow these procedures:
between parts are small. Serious injury or death
can result if part of the body is hit by parts of the a. Put mast in vertical position.
mast or the carriage.
b. Raise mast to align bottom crossmember of
• Never put any part of the body into or under weldment that moves in outer weldment with a
the mast or carriage unless all parts of the crossmember on outer weldment. On the two-
mast are completely lowered or a safety stage and free-lift mast, the moving part is the
chain is installed. Also make sure that the inner weldment. On the three-stage mast, it is
power is off and the key is removed. Put a
the intermediate weldment. See Figure 65 .
DO NOT OPERATE tag in the operator's
compartment.
c. Use a 3/8-in. minimum safety chain with a
• Be careful of the forks. When the mast is hook to fasten the crossmembers together so
raised, the forks can be at a height to cause the movable member cannot lower. Put the
an injury.
hook on the back side of the mast. Make sure
• DO NOT climb on the mast or lift truck at any the hook is completely engaged with a link in
time. Use a ladder or personnel lift to work the chain. Make sure the safety chain does not
on the mast.
touch lift chains or chain sheaves, tubes,
• DO NOT use blocks to support the mast hoses, fittings, or other parts on the mast.
weldments nor to restrain their movement.
• Mast repairs require disassembly and d. Lower the mast until there is tension in the
removal of parts and can require removal of safety chain and the free-lift cylinder (free-lift
the mast or carriage. Follow the repair masts only) is completely retracted. If running,
procedures in the correct Service Manual for stop engine. Apply parking brake. Install a DO
the mast. NOT REMOVE tag on the safety chain(s).
NOTE: If there is no power to lower the mast on lift e. Install another safety chain (3/8-in. minimum)
trucks equipped with Electronic Hydraulic System, between the top or bottom crossmember of the
there is an emergency load lowering valve located on carriage and a crossmember on the outer
the hoist/lower valve section of the main control valve. weldment.
See the Operating Manual for the procedures to
lower a load using the emergency load lowering valve.

71
Hood Lock Assembly Check 8000 YRM 2000

3. Apply parking brake. After lowering or restraining

the mast, shut off power and remove key. Put a
DO NOT OPERATE tag in the operator's
compartment.

A. TWO-STAGE LFL MAST B. THREE-STAGE FFL MAST

1. OUTER MAST 5. FREE-LIFT CYLINDER

2. INNER MAST 6. CROSSMEMBER
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK

Figure 65. Two-Stage Limited Free-Lift and Three-Stage Full Free-Lift Masts

Hood Lock Assembly Check

2. Carefully close hood to fully-closed position. The
WARNING hood latch is fully closed after two clicks.
The hood, hood latch, and latch striker must be
correctly adjusted for the correct operation of the 3. Push down until hood just touches rubber
operator restraint system. bumper. Make sure lock assembly is still in center
of hood latch. Open hood and tighten capscrews.
1. Install hood lock assembly on frame of hood.
Tighten capscrews so that hood latch can still 4. Check operation of hood lock assembly. Have an
move when hood is closed. See Figure 66. operator sit in the seat. Make sure hood is fully
closed. Also check that hood touches rubber
bumper. If necessary, repeat Step 3.

72
8000 YRM 2000 Hood Lock Assembly Check

1. HOOD 5. BRACKET
2. CAPSCREW 6. LEVER
3. HOOD LOCK ASSEMBLY 7. SPRING
4. HOOD LOCK COVER

Figure 66. Hood Lock Assembly Check

73
Lift Chain Adjustments 8000 YRM 2000

Lift Chain Adjustments

WARNING
When working on or near the mast, see Safety
Procedures When Working Near Mast in this
section.
During test procedures for the hydraulic system,
fasten the load to the carriage with chains to
prevent it from falling. Keep all personnel away
from the lift truck during the tests.
Never allow anyone under a raised carriage. DO
NOT put any part of your body in or through the lift
mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
Never check for leaks by putting hands on
hydraulic lines or components under pressure.
Hydraulic oil under pressure can be injected into 1. MAST
the skin. 2. CARRIAGE
3. FORK
When lift chains are correctly adjusted: 4. HEEL OF FORK IS
12 +3.0/-6.0 mm (0.47 +0.12/-0.24 in.) ABOVE
• Tension will be the same on each chain of chain FLOOR LEVEL
set. Check tension by pushing on both chains at
the same time. Figure 67. Lift Chain Adjustment, With Forks
• Chain length will be correct.
• Chains must travel freely through complete Lift Trucks Equipped with Hook-Type
cycle. Carriage and Attachment Without Forks
NOTE: Prior to performing adjustment procedures, 1. Adjust chain anchors that support carriage until
make sure lift truck is parked on a level surface and bottom of lower carriage bar is above floor level
mast is in vertical position. as shown in Table 4 and Figure 68.

Lift Trucks Equipped With Forks Table 4. Hook-Type Carriage Chain Adjustment
1. Adjust chain anchors that support carriage until Class II and III 82.5 ±3.0 mm (3.25
bottom of fork heel is ±0.12 in.)
12 +3.0/-6.0 mm (0.47 +0.12/-0.24 in.) above floor
Class IV 133.5 ±3.0 mm (5.26
level. See Figure 67.
±0.12 in.)

74
8000 YRM 2000 Jump-Starting the Lift Truck

Legend for Figure 68.

1. MAST
2. CARRIAGE
3. DISTANCE FROM FLOOR TO LOWER
CARRIAGE BAR

Figure 68. Lift Chain Adjustment, Hook-Type

Carriage

Jump-Starting the Lift Truck

JUMP-STARTING USING A BATTERY JUMP-STARTING A LIFT TRUCK USING
CHARGER ANOTHER LIFT TRUCK

CAUTION WARNING
DO NOT try to start the engine by pushing or To prevent possible arcing between the two lift
towing the lift truck. Damage to the hydraulic trucks, make sure that the lift trucks are not
system can occur if engine is started by pushing touching.
or towing lift truck.

If battery becomes discharged and requires a booster CAUTION

battery to start engine, follow these procedures DO NOT try to start the engine by pushing or
carefully when connecting jumper cables. towing the lift truck. Damage to the hydraulic
system can occur if engine is started by pushing
1. Disconnect negative battery terminal of lift truck or towing lift truck.
being started.
1. Always connect positive jumper cable to positive
2. Always connect positive jumper cable to positive terminal of discharged battery and negative
terminal of discharged battery and negative jumper cable to negative terminal.
jumper cable to negative terminal.
2. Always connect jumper cable, that is the ground
3. Always connect jumper cable, that is the ground cable, last.
cable, last.
3. Always connect jumper cables to discharged lift
4. Always connect jumper cables to discharged truck battery before connecting them to the fully-
battery before connecting them to booster battery. charged lift truck battery.

75
Welding Repairs 8000 YRM 2000

Welding Repairs
industrial hygiene practices including removal of
WARNING all paint (prime and finish coats) to the metal
around the area to be welded, local ventilation,
Welding can cause a fire or an explosion. Always
and/or supplied-air respiratory protection.
follow the instructions in the Frame section if a
fuel or hydraulic tank must be welded. Make sure
there is no fuel, oil, or grease near the weld area.
Make sure there is good ventilation in the area CAUTION
where the welding must be done. When an arc welder is used, always disconnect the
ground cable from the battery in the lift truck. This
DO NOT heat, weld, or bend forks. Forks are made action will prevent damage to the alternator or the
of special steel using special methods. The battery.
strength of the overhead guard can be reduced by
welding or heating. Get information from your Connect the ground clamp for the arc welder as
dealer for Yale lift trucks before welding on a close as possible to the weld area. This action will
mast. prevent damage to a bearing from the large current
from the welder.
Forklift frames and components may be painted
with a catalyzed paint such as polyurethane or a Some repairs require welding. If an acetylene or arc
two-part primer. Welding, burning, or other heat welder is used, make sure procedures in previous
sufficient to cause thermal decomposition of the WARNING and CAUTION are done.
paint may release isocyanates. These chemicals
are allergic sensitizers to the skin and respiratory See the American National Standard Safety in Welding
tract and overexposure may occur without odor and Cutting, AWS Z 49.1 - 1999.
warning. Should work be performed, utilize good

Wheel and Tire Replacement

GENERAL
This series of lift trucks have pneumatic tires or solid WARNING
rubber tires that look like pneumatic tires. These Type of tire and the tire pressure (pneumatic tires)
variations in tires also cause a variation in the types of are shown on the Nameplate. Make sure the
wheels and disassembly and assembly procedures. Nameplate is correct for the type of tires on the lift
truck. If the truck is equipped with bias-ply tires,
PNEUMATIC TIRE WITH TUBE, REPAIR the ply rating listed on the Nameplate is the
minimum ply rating that must be installed. Tires
Remove Wheels From Lift Truck with ply ratings greater than or equal to the
Nameplate listed ply rating may be acceptable.
WARNING Check with your Yale dealer whether a specific
bias-ply tire is approved for use on Yale trucks.
A solid rubber tire that is the same shape as a
pneumatic tire can be installed on a three-piece or
four-piece wheel for a pneumatic tire. DO NOT
make changes in the parts of the rim if this type of
solid rubber tire is installed instead of a pneumatic
tire. Changes to the parts of the rim can cause a
failure of the wheel and cause an accident.

76
8000 YRM 2000 Wheel and Tire Replacement

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

WARNING Lift Truck on Blocks at the beginning of this
Wheels must be changed and tires repaired by section.
trained personnel only.
2. Remove air from tire. Remove valve core to make
Deflate tire completely before removing the wheel sure all air is out of inner tube. Push a wire
from the lift truck. If dual wheels are used, deflate through valve stem to make sure valve stem does
both tires. Air pressure in the tires can cause the not have a restriction.
tire and rim parts to explode, causing serious
injury or death. 3. Remove wheel nuts and remove wheel and tire
Always wear safety glasses. from lift truck. Lift truck tires and wheels are
heavy.
Never loosen the nuts that hold the inner and outer
wheel halves together when there is air pressure in
Remove Tire From Wheel
the tire.
NOTE: When you disassemble the wheels, see
Lift truck tires and wheels are heavy. Use caution
Figure 69. There are several types of wheels used on
when removing or installing lift truck tires and
this series of lift trucks.
wheels or personal injury can occur.

CAUTION
Not all makes of radial tires have sufficient
sidewall strength for successful use on forklift
trucks. This can affect stability and ride quality.
Check with your Yale dealer whether a specific
radial tire is approved for use on Yale trucks.

A. TWO-PIECE WHEEL C. THREE-PIECE WHEEL

B. OPTIONAL RIM ASSEMBLY D. FOUR-PIECE WHEEL

1. WHEEL RIM 3. LOCK RING

2. SIDE FLANGE 4. FLANGE SEAT

Figure 69. Types of Pneumatic Wheels

77
Wheel and Tire Replacement 8000 YRM 2000

Remove Tire From Two-Piece Wheel

WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the
tires can cause the tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause an injury.

STEP 1.
Remove nuts that fasten wheel rims together.

STEP 2.
Loosen tire bead from wheel rim.

STEP 3.
Remove wheel rims from tire. Remove inner tube
and flap.

78
8000 YRM 2000 Wheel and Tire Replacement

Remove Tire From Three- and Four-Piece Wheels

WARNING
Make sure all the air pressure is removed from the tire before a wheel is disassembled. Air pressure in the
tires can cause the tire and rim parts to explode, causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause an injury.

STEP 1.
Loosen tire bead from side flange.

STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange. If there is
a flange seat, remove it.

STEP 3.
Loosen bead from other side of wheel rim.
Remove valve stem from wheel.

79
Wheel and Tire Replacement 8000 YRM 2000

STEP 4.
Remove wheel from tire.

Install Wheel in Tire 1. Clean and inspect all parts of wheel. Paint any
parts that have rust or corrosion.
WARNING
2. Install new inner tube in tire. Used tubes and flaps
Damage to the tire and wheel assembly and injury can cause tire failure.
or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of the wheel WARNING
before installing the tire.
DO NOT lubricate tire bead with antifreeze or
• DO NOT use any damaged or repaired wheel petroleum-based liquid. Vapors from these liquids
parts. can cause an explosion during inflation or use.
• Make sure all parts of the wheel are the
correct parts for that wheel assembly. 3. Apply a rubber lubricant or a soap solution to the
• DO NOT mix parts between different types or tire bead and tube.
manufacturers of wheels.
4. Install new tire flap.
• DO NOT mix types of tires, type of tire tread,
or wheel assemblies of different
manufacturers on any one lift truck. 5. Make sure rim is the correct size for tire.
Lubricate part of wheel that contacts bead and
DO NOT use a steel hammer on the wheel. Use a flap.
rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct 6. Install three-piece or four piece wheel in tire as
position. The ends of the side ring must not touch. shown in Install Three-Piece or Four-Piece Wheel
The clearance at the ends of the lock ring will be in Tire.
approximately 13 to 25 mm (0.5 to 1.0 in.) after it is
installed. If the clearance is wrong, the wrong part 7. Install two-piece wheel in tire as shown in Install
has been used. Tire on Two-Piece Wheel.

80
8000 YRM 2000 Wheel and Tire Replacement

Install Three-Piece or Four-Piece Wheel in Tire

WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the following
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any
one lift truck.
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct position. The ends of the side ring must not touch. The
clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed.
If the clearance is wrong, the wrong part has been used.

STEP 1.
Install inner tube and rubber flap in tire.

STEP 2.
Install wheel rim in tire. Make sure stem of inner
tube is aligned with slot in rim.

STEP 3.
Turn over rim and tire. Put blocks under rim so rim
is 8 to 10 cm (3 to 4 in.) above floor. Install flange
seat (if used) and lock ring.

81
Wheel and Tire Replacement 8000 YRM 2000

STEP 4.
Put lock ring in the correct position on rim. Add air
pressure to tire as described in Install Wheel in
Tire.

Install Tire on Two-Piece Wheel

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

Install Two-Piece Wheel in Tire

STEP 1.
Install inner tube and rubber flap in tire. Install
both halves of wheel rim in tire. Make sure stem
of inner tube is aligned with slot in rim.

82
8000 YRM 2000 Wheel and Tire Replacement

STEP 2.
Tighten nuts that hold rim halves together to
175 N•m (130 lbf ft). Add air pressure to tire (see
Nameplate) as described in Add Air to Pneumatic
Tires With Tube.

ADD AIR TO PNEUMATIC TIRES WITH

TUBE

WARNING
Add air pressure to the tires only in a safety cage.
Inspect the safety cage for damage before use.
When air pressure is added, use a chuck that
fastens onto the valve stem of the inner tube. Make
sure there is enough hose to permit the operator
to stand away from the safety cage when air
pressure is added to the tire.
DO NOT sit or stand by the safety cage. DO NOT
use a hammer to try and correct the position of the
side flange or lock ring when the tire has air
pressure greater than 20 kPa (3 psi).
Figure 70. Add Air to Tires
1. Put tire in a safety cage.
Install the Wheels
2. Add 20 kPa (3 psi) of air pressure to tire. See
Figure 70.
WARNING
3. Check that all wheel parts are correctly installed. Lift truck tires and wheels are heavy. Use caution
Hit lock ring lightly to make sure it is in the seat. when removing and installing lift truck tires and
wheels or personal injury can occur.
4. If installation is correct, add air pressure to tire to
the specified pressure. Install wheel on the hub. Tighten nuts in a cross
pattern to a torque value of
5. Check that all wheel parts are correctly installed. 450 to 500 N•m (332 to 369 lbf ft) for drive wheel nuts.
If installation is not correct, remove all air If the wheels are two-piece rims, make sure nuts that
pressure from tire. Remove valve core to make fasten rim halves together are toward brake drum
sure all air pressure has been removed and then when they are installed.
make adjustments. The clearance at the ends of
The steering wheels are fastened to the spindle of
the lock ring will be approximately
steering axle with a large castle nut. Make sure inner
13 to 25 mm (0.5 to 1.0 in.) when the tire has the
and outer bearings are correctly lubricated with
correct air pressure.
grease. Install inner bearing assembly and wheel on
spindle. Install outer bearing cone and castle nut.
Tighten castle nut to 60 N•m (44 lbf ft)while wheel is
rotated. Loosen castle nut until hub turns freely with no
end play. Tighten castle nut to
3.0 to 6.0 N•m (425 to 850 lbf in). Install cotter pin in
castle nut. If cotter pin cannot be installed, loosen

83
Wheel and Tire Replacement 8000 YRM 2000

castle nut to first position where cotter pin can be

The Tubeless Bead Seal (TBS) enables tubeless tires
installed. Install cap for bearings.
to be used on wheel rims that were designed to be
used with a tube. See Figure 69.
PNEUMATIC TUBELESS TIRE, REPAIR
The main component of TBS is a special rubber ring
Remove Wheels From Lift Truck that fits inside the tire between tire beads to ensure the
airtightness of existing wheel and tubeless tire
assembly.
WARNING
Wheels must be changed and tires repaired by 1. Put lift truck on blocks as described in How to Put
trained personnel only. Lift Truck on Blocks at beginning of this section.
Deflate tire completely before removing the wheel
2. Remove the valve cap and core to remove all air
from the lift truck. If dual wheels are used, deflate
from the tire.
both tires. Air pressure in tires can cause the tire
and rim parts to explode causing serious injury or
3. Remove the wheel nuts and remove the wheel
death.
and tire from the lift truck. Lift truck tires and
Always wear safety glasses. wheels are heavy.
Never loosen the nuts that hold the inner and outer
wheels halves together when there is air pressure
in the tire.

Remove Tire From Wheel

WARNING
Make sure all of the air pressure is removed from the tire before a wheel is disassembled. Air pressure in
the tires can cause the tire and rim parts to explode causing serious injury or death.
Keep tire tools in firm contact with the wheel parts. If the tool slips, it can move with enough force to
cause injury.

NOTE: There are several types of wheels used on these lift trucks. When disassembling wheels, see Figure 69.

STEP 1.
If the tire is equipped with a Tubeless Bead Seal
(TBS) style rubber sealing ring with a separate
valve stem, turn the valve stem ¼ turn and
remove valve stem from wheel, as shown in
illustration. If the tire is equipped with a Tubeless
Sealing Ring (TSR) style rubber sealing ring, the
valve stem is an integral part of the rubber sealing
ring and is not removable.

84
8000 YRM 2000 Wheel and Tire Replacement

STEP 2.
Put wheel and tire assembly on the press.
Position the feet of the press on the loose flange.
Press down on loose flange to expose the locking
ring.

STEP 3.
Remove the loose flange locking ring and the
advance band (four-piece wheel only) using a tire
tool.

STEP 4.
Remove the press and remove the loose flange
locking ring and the advance band (four-piece
wheel only) from the tire and wheel assembly.

STEP 5.
Push the TBS or TSR toward the inside of the tire
to remove it.

85
Wheel and Tire Replacement 8000 YRM 2000

Install Tire on Wheel

WARNING
Damage to the tire and wheel assembly and injury or death can occur if you do not do the follow
procedures:
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure that all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any
one lift truck.

WARNING
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together.

WARNING
DO NOT lubricate the tire bead with antifreeze or petroleum-based liquid. Vapors from these liquids can
cause an explosion during inflation or use.

WARNING
DO NOT mix brands of rubber sealing rings and tires. Serious injury to personnel or damage to the lift
truck can occur if the rubber sealing rings are not compatible with the tire brand.

STEP 1.
Clean interior and exterior bead of the tire.
Lubricate tire beads and the inside of the tire, up
to the tire shoulders. Apply lubricant to the entire
underside of the TBS or TSR. Use lubricant
approved by the tire manufacturer.

NOTE: If the wheel rim width is less than 152 mm (6 in.), the TBS will contain one valve hole to accommodate
the needle valve. If the wheel rim width is greater than 152 mm (6 in.), the TBS will have two holes for the needle
valve.
One hole is centrally located and the other is offset, to ensure the correct positioning of the valve in the valve slot.
The valve hole that is not used should be sealed with a small plastic plug.

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8000 YRM 2000 Wheel and Tire Replacement

STEP 2.
For TBS, apply lubricant to the needle valve and
the valve hole that will be used (see NOTE) by
inserting and removing the lubricated valve
several times. If a three- or four-piece wheel is
being used, remove the valve. If a two-piece
wheel is being used, leave valve in valve hole.
If the TBS has two-valve holes, lubricate the
plastic plug and insert into valve hole that will not
be used.

STEP 3.
Place the TBS or TSR rubber sealing ring inside
the tire, making sure the wings are not folded
over. For the TBS rubber sealing ring, with
separate valve stem, make a mark on the tire to
note the position of the valve hole. For TSR
rubber sealing ring with integral valve stem, align
valve slot in the rim with the TSR valve stem.

STEP 4.
Apply lubricant to the rim. If a four-piece wheel is
being used, lubricate the advance band. Slide the
tire and the rubber sealing ring onto the wheel.
For TSR, use a lever to push the valve stem
through the valve slot in the wheel. For TBS tires,
line up the valve hole in the TBS with the valve
slot in the wheel. Lubricate and insert the valve
into the valve hole. Make sure it is fully inserted.

STEP 5.
For TBS, with separate valve stems, place the
wheel and tire assembly on a flat surface. Turn
the valve a 1/4 turn to lock the collar under the
edges of the rim valve slot.

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Wheel and Tire Replacement 8000 YRM 2000

STEP 6.
Raise the tire and position the base and threaded
stem of the press through the hole in the center of
the wheel. Insert in wheel assembly, the following
parts:
• Advance band (four-piece wheel only)
• Loose flange
• Locking ring

STEP 7.
Position the advance band. Ensure that it does
not go in too far and damage the valve. Position
the arms of the press onto the loose flange.

CAUTION
DO NOT compress the bead too far and cause the
rubber sealing ring to become dislocated and
damage the valve stem.

Push down on the press to depress the tire beads

until locking ring groove is fully exposed.

STEP 8.
Insert tire tool into the locking ring groove, and a
vise grip on other end. Remove vise grip. Release
the press and check that all component parts are
correctly positioned. Replace the valve core.

STEP 9.
Inflate tire to 103 kPa (15 psi). Tap wheel with a
mallet to ensure all components are correctly
sealed. Remove the press from wheel and tire
assembly.

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8000 YRM 2000 Wheel and Tire Replacement

Add Air to Pneumatic Tubeless Tire Install wheel on hub. Tighten nuts in a cross pattern to
a torque value of 450 to 500 N•m (332 to 369 lbf ft) for
WARNING drive wheel nuts. If wheels are two-piece rims, make
sure nuts that fasten rim halves together are toward
Add air pressure to tires only in safety cage.
brake drum when they are installed.
Inspect safety cage for damage before use. When
air pressure is added, use a chuck that fastens The steering wheels are fastened to the spindle of
onto valve stem. Make sure there is enough hose steering axle with a large castle nut. Make sure inner
to permit operator to stand away from safety cage and outer bearings are correctly lubricated with
when air pressure is added to tire. grease. Install inner bearing assembly and wheel on
spindle. Install outer bearing cone and castle nut.
DO NOT sit or stand by safety cage.
Tighten castle nut to 60 N•m (44 lbf ft)while wheel is
1. Put tire in safety cage. See Figure 71. rotated. Loosen castle nut until hub turns freely with no
end play. Tighten castle nut to
2. Add air to tire to the recommended air pressure 3.0 to 6.0 N•m (425 to 850 lbf in). Install cotter pin in
that is shown on the Nameplate. Install valve cap castle nut. If cotter pin cannot be installed, loosen
to ensure air stays in the tire. castle nut to first position where cotter pin can be
installed. Install cap for bearings.

SOLID RUBBER TIRES ON PNEUMATIC

WHEELS, CHANGE

WARNING
Wheels must be changed and tires repaired by
trained personnel only.
Always wear safety glasses.
Lift truck tires and wheels are heavy. Use caution
when removing and installing lift truck tires and
wheels or personal injury can occur.

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

Lift Truck on Blocks at the beginning of this
Figure 71. Add Air to Tires section.

2. Remove wheel nuts and remove wheel and tire

Wheels, Install from lift truck.

WARNING
Lift truck tires and wheels are heavy. Use caution
when removing and installing lift truck tires and
wheels or personal injury can occur.

Remove Tire From Wheel

NOTE: When you disassemble the wheels, see Figure 69. There are several types of wheels used on these
series of lift trucks.

WARNING
Keep tire tools in firm contact with the wheel. If the tool slips, it can move with enough force to cause
serious injury. Always wear safety glasses.

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Wheel and Tire Replacement 8000 YRM 2000

STEP 1.
Put wheel rim on bed of press. Put cage in
position on tire. Use press to push tire away from
side flange.

STEP 2.
Put tire tool into slot between lock ring and wheel
rim. Remove lock ring and side flange.

STEP 3.
Turn tire over. Put a support under wheel rim.
Make sure wheel rim is at least
150 to 200 mm (6 to 8 in.) from bed of press.

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8000 YRM 2000 Wheel and Tire Replacement

STEP 4.
Put cage in position on tire. Use press to push tire
from wheel rim.

Install Tire on Wheel

NOTE: When you assemble the wheels, see Figure 69. There are several types of wheels used on these series
of lift trucks. DO NOT use a two-piece pneumatic wheel for solid rubber tires.

WARNING
Damage to tire and wheel assembly and injury or death can occur if you do not do the following
procedures.
• Clean and inspect all parts of the wheel before installing the tire.
• DO NOT use any damaged or repaired wheel parts.
• Make sure all parts of the wheel are the correct parts for that wheel assembly.
• DO NOT mix parts between different types or manufacturers of wheels.
• DO NOT mix types of tires, type of tire tread, or wheel assemblies of different manufacturers on any
one lift truck.
DO NOT use a steel hammer on the wheel. Use a rubber, lead, plastic, or brass hammer to put parts
together. Make sure the side ring is in the correct position. The ends of the side ring must not touch. The
clearance at the ends of the lock ring will be approximately 13 to 25 mm (0.5 to 1.0 in.) after it is installed.
If the clearance is wrong, the wrong part has been used.

CAUTION
Too much lubricant can cause the tire to slide and move around the wheel rim.

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Wheel and Tire Replacement 8000 YRM 2000

STEP 1.
Lubricate wheel rim and inner surface of tire with
tire lubricant or soap.

STEP 2.
Put wheel rim on bed of press. Put tire over wheel
rim. Put cage in position on tire. Use press to
install tire on wheel rim.

STEP 3.
Remove cage and put flange seat (if used), side
ring, and lock ring in position on wheel rim. Install
cage on tire. Use press to push tire onto wheel
rim so side flange and lock ring can be installed.

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8000 YRM 2000 Overhead Guard Changes

STEP 4.
While the cage is holding the tire on the wheel
rim, install lock ring. Use a tire tool to make sure
lock ring is in the correct position.

Overhead Guard Changes

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

Adhesives and Sealants

Loctite® Part
Yale Part No. Description Size
No.
501702901 222 Small Screw Threadlock (Purple) 50 ml
505965518 242 Removable Threadlock (Blue) 10 ml
580012519 271 High Strength Threadlock (Red) 10 ml
501702904 290 Low Viscosity Threadlock (Green) 50 ml
518806679 422 SuperBonder® Adhesive 3 ml
500009917 515 Gasket Eliminator (Purple) 50 ml
518795676 567 Pipe Sealant with Teflon® 50 ml
502058904 595 Super Flex® Silicone 100 ml
504226218 767 Antiseize Compound 1 lb
150015825 Chisel Gasket Remover (10 Aerosol cans per case) 18 oz
® ® ®
Loctite , Super Flex , and Super Bonder are registered trademarks of the Loctite Corporation.
Teflon® is a registered trademark of Du Pont de Nemours Co., Inc.

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8000 YRM 2000 10/19 (11/18)(1/18)(12/17)(9/17)(5/17)