Yale A875 (GDP GLP20-30RF TF Europe) Service Manual - PDF DOWNLOAD

Yale Axcess Online

Notepad About User Settings Feedback Help Log Out

Marina, your selected truck is A875 (GDP/GLP20-30RF/TF Europe)

Select a Truck Truck Details Mast Details

Search Publications

View Cart: Pick List 2 Announcements Parts Info Service Manuals Software Support Items

Service Manuals Manuals Available For A875 (GDP/GLP20-30RF/TF Europe) Note: Service manuals do not contain serial number specific data.

Manual

Manual Title

Release Date

0100YRM0505

FRAME

06-2004

0600YRM0496

MAZDA FE AND F2 ENGINE

01-2011

0600YRM1019

MAZDA HA/XA DIESEL ENGINES

01-2011

0600YRM1020

GM 3.0L GAS/LPG ENGINE

10-2006

0700YRM0626

COOLING SYSTEM

03-2003

0900YRM0498

LPG FUEL SYSTEM (GM 3.0L)

12-2003

0900YRM0523

LPG FUEL SYSTEM (MAZDA)

12-2003

0900YRM0925

LPG FUEL SYSTEM (AISAN OPEN-LOOP)

12-2003

0900YRM0948

LPG FUEL SYSTEM AISAN CLOSED-LOOP

10-2006

http://www.yaleaxcessonline.com/eng/myt/truck_details.cfm?action=4 (1 of 3)26.10.2011 16:35:12

Yale Axcess Online

0900YRM1088

ELECTRONIC CONTROLLED LPG/GASOLINE FUEL SYSTEM GM 3.0L AND 4.3L EPA COMPLIANT ENGINES

05-2006

1300YRM0500

SINGLE-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION

08-2003

1300YRM0501

SINGLE-SPEED POWERSHIFT TRANSMISSION-REPAIR

03-2004

1300YRM0717

HYDROSTATIC TRANSMISSION

07-2003

1400YRM0499

DRIVE AXLE

10-2004

1600YRM0316

STEERING AXLE

08-2006

1600YRM0720

STEERING HOUSING AND CONTROL UNIT (LATER MODELS)

11-2006

1800YRM0506

BRAKE SYSTEM

05-2005

1900YRM0513

HYDRAULIC SYSTEM, GEAR PUMP ASSEMBLY

06-2004

2000YRM0516

MAIN CONTROL VALVE

12-2003

2100YRM0103

TILT CYLINDERS

03-2007

2200YRM0002

ALTERNATOR WITH REGULATOR

10-2003

2200YRM0106

STARTER - DELCO

03-2003

2200YRM0107

HIGH ENERGY IGNITION SYSTEM

03-2008

2200YRM0514

INSTRUMENT CLUSTER

01-2004

2200YRM0524

ELECTRICAL SYSTEM (MAZDA FE AND F2 ENGINES)

12-2003

2200YRM0603

MSTS-GM 3.0L (EARLY MODELS)

12-2003

2200YRM0611

ELECTRONIC ENGINE CONTROL-TROUBLESHOOTING AND REPAIR

2200YRM0612

ELECTRONIC ENGINE CONTROL - DESC AND OPER

2200YRM0765

MSTS-GM 3.0L AND 4.3L LPG FUEL ENGINES (LATER MODULES)

03-2003

2200YRM1090

ELECTRONIC CONTROL MODULE (ECM) DIAGNOSTIC TROUBLESHOOTING GM 3.0L AND 4.3L EPA COMPLIANT ENGINES

04-2005

http://www.yaleaxcessonline.com/eng/myt/truck_details.cfm?action=4 (2 of 3)26.10.2011 16:35:12

Yale Axcess Online

2200YRM1097

HIGH VOLTAGE SWITCH IGNITION (HVS) GM 3.0L AND 4.3L

06-2010

4000YRM0521

MAST-DESCRIPTION

03-2006

4000YRM0522

MAST-REPAIR

07-2010

8000YRM0231

METRIC AND INCH (SAE) FASTENERS

12-2004

8000YRM0707

PERIODIC MAINTENANCE

07-2006

8000YRM0708

CAPACITIES AND SPECIFICATIONS

01-2011

8000YRM0709

DIAGRAMS

10-2004

©2011 Yale Axcess Online

http://www.yaleaxcessonline.com/eng/myt/truck_details.cfm?action=4 (3 of 3)26.10.2011 16:35:12

524158636-0100YRM0505-(06-2004)-UK-EN

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Indicates a condition that can cause immediate death or injury!

CAUTION Indicates a condition that can cause property damage!

TABLE OF CONTENTS General Description Operator Module Repair Remove Install Hood and Side Covers Repair http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (3 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Remove Install and Adjust Overhead Guard Repair Remove and Install LED Backup and Brake Lights, Replace Remove Install Counterweight Repair Remove Install Exhaust System Repair Muffler, Replace Radiator and Cooling System Repair Remove Install Operator Restraint System Repair Engine Repair Remove Engine Only Remove Engine and Transmission Install Engine Only Install Engine and Transmission Fuel and Hydraulic Tanks Repair Inspect Small Leaks, Repair Large Leaks, Repair Clean Steam Method of Cleaning Chemical Solution Method of Cleaning Additional Preparations for Repair Safety Labels This section is for the following models: GP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875]; GC/GLC040-065RG/TG/ZG [E187]

General WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (4 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

• Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the Periodic Maintenance manual for your lift truck.

This section has the description of the frame and some connected parts. See Figure 1. Procedures for the removal and installation of the counterweight, hood, overhead guard, and engine (including the transmission) are found in this section. Checks for the operator restraint system and procedures for the repair of fuel and hydraulic tanks and installation of safety labels are also included.

Description The frame is one weldment and includes the hydraulic tank and the fuel tank for gasoline or diesel fuel.

There is a counterweight for each capacity of lift truck. The counterweights are similar, but are different weights. The muffler is fastened to the frame inside of the counterweight.

An operator module is installed on the frame with rubber mounts. See Figure 1. The overhead guard, steering controls, instrument panel, hood, and seat are installed on the operator module. The hood is connected to the operator module with hinges. The floor plates and side access doors can be removed for access to the engine, transmission, and other components.

Operator Module Repair Remove 1. Remove the hood and side covers. See Figure 2.

2. Remove the steering housing and instrument cluster from the cowl. Remove the capscrews that hold the parking brake lever to the cowl.

3. Remove the nuts and bolts at the mounts for the operator module.

4. Connect a lifting device to the overhead guard. The overhead guard and module weigh approximately 385 kg (850 lb). Lift the operator module from the frame.

Install NOTE: If the overhead guard was removed from the operator module, tighten the rear leg mount capscrews to 53 N•m (39 lbf ft). On GP2.00-3.00TF/RF (GP040-060RG/TG/ZG) units, tighten the capscrews that fasten the module cowl side plate to the front legs to 66 N•m (49 lbf ft). See Figure 1.

1. Connect a lifting device to the overhead guard. The overhead guard and module weigh approximately 385 kg (850 lb). Lift the operator module onto the frame.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (5 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

2. Make sure the rubber mounts are installed in the frame. Install the large washer and nut on the bottom of the mount. Tighten the nuts to 53 N•m (39 lbf ft).

3. Install the hood and side covers.

4. Install the steering controls and the parking brake lever.

5. Install the floor plates.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (6 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Figure 1. Frame and Operator Module Legend for Figure 1 1. Operator Module 2. Frame 3. Hydraulic Tank 4. Steering Axle Mount 5. Drive Axle Mount 6. Capscrew 7. Washer 8. Rubber Mount 9. Nut 10. Cover 11. Storage Compartment 12. Overhead Guard (Raised) 13. Screw 14. Handle 15. Plug 16. Lockwasher 17. Bar 18. Fender 19. Crossmember

Hood and Side Covers Repair WARNING The hood and hood latch must be correctly adjusted for the correct operation of the operator restraint system.

The operator’s seat is fastened to the upper hood panel. This upper hood panel opens forward for access to the engine compartment. Two hinges fasten the upper hood panel to the front plate weldment of the engine compartment. A latch mechanism with a push knob holds the upper hood panel in position during operation of the lift truck. See Figure 2.

A torsion spring is fastened between the front plate weldment and the upper hood panel to help personnel when opening and closing the hood. Sound-absorbing materials are fastened inside the hood panels to reduce noise during operation. See Figure 2 and Figure 3.

Remove Remove the floor plate and the hood and side covers.

Install and Adjust Install and adjust the hood and side covers as follows: 1. Install the crossmember onto the frame. Install the front plate weldment, but do not tighten the four capscrews.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (7 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

2. Install the hinges on the upper hood panel. Do not tighten the capscrews.

3. Install the latch hook.

4. Install the upper hood panel in position on the front plate weldment. Connect the torsion spring. Install the hinge pins. Install the rod.

5. Close the upper hood panel until the rubber cushions are against the rear crossmember of the engine compartment. Align the edge of the upper hood panel with the rear crossmember of the engine compartment. Tighten the capscrews for the hinges.

6. When the upper hood panel is fully closed, check that the latch fully engages the latch hook. If the latch does not engage correctly, add or remove washers (shims) as necessary to adjust the latch assembly.

When the adjustment is correct, tighten the capscrews that hold the latch assembly.

7. Install the hinges onto the engine compartment, but do not tighten the bolts.

8. Install the access doors on the hinges. Close the access doors. Adjust the stop bolts and front plate so that the front plate is even from side to side and the access doors will engage the tabs. Tighten the capscrews on the front plate. Tighten the jam nuts on the stop bolts.

9. Adjust the hinges so that the front edges of the access doors are even with the front plate. Tighten the bolts for the hinges. Install washers (shims) as necessary so that the access doors are against the hood seal when they are closed.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (8 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. Access Door (LH) 2. Access Door (RH) 3. Crossmember 4. Upper Hood Panel 5. Plate 6. Hinge 7. Rod 8. Torsion Spring 9. Latch Hook 10. Spacer 11. Bushing 12. Rubber Cushion 13. Trim 14. Capscrew 15. Nut 16. Washer

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (9 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

17. Pin 18. Cotter Pin 19. Seal 20. Latch Assembly Figure 2. Hood and Side Covers Arrangement

1. Latch Assembly 2. Push Knob 3. Latch Hook 4. Latch (Engaged) 5. Latch (Disengaged) 6. Shims (As Necessary) 7. Upper Hood Panel 8. Front Plate 9. Rear Crossmember of Engine Compartment 10. Torsion Spring 11. Stop Bolt 12. Front Crossmember of Engine Compartment Figure 3. Hood Assembly

Overhead Guard Repair Remove and Install

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (10 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.

Changes that are made by welding, or by drilling holes that are too big or in the wrong location, can reduce the strength of the overhead guard. See the section Changes to the Overhead Guard in the Periodic Maintenance 8000 YRM 707 for instructions on making changes to the overhead guard.

1. Connect a crane or lifting device to remove or install the overhead guard. Disconnect the air intake at the overhead guard leg.

2. Disconnect any wires between the frame and the overhead guard. When the overhead guard is lifted from the frame, make sure that any electrical wires are moved through the holes in the frame so that they are not damaged.

3. There are two capscrews at each corner of the left-hand leg of the overhead guard. Remove and install the capscrews for the overhead guard as follows: a. Access to the bolts at the front of the overhead guard is under the dash panel. Remove the plastic box from the right-hand side of the dash panel. b. Access to the bolts at the rear of the overhead guard is under the rear fender wells. c. Tighten the rear leg mount capscrews to 53 N•m (39 lbf ft). On GP2.00-3.00TF/RF (GP040060RG/TG/ZG) units, tighten the capscrews that fasten the module cowl side plate to the front legs to 66 N•m (49 lbf ft).

NOTE: The air inlet for the air filter is installed in the left-hand leg of the overhead guard. Make sure the grill is installed with the louvers pointed downward.

LED Backup and Brake Lights, Replace NOTE: Newer models of lift trucks are equipped with LED (Light Emitting Diode) backup and brake tail lights. These light assemblies are non-repairable and must be replaced as a complete unit. See the Parts Manual for replacement LED lights.

Remove 1. Disconnect negative terminal of battery and remove the key.

2. Disconnect the LED light from the chassis light harness.

3. Remove LED light assembly and harness from mounting bracket. See Figure 4.

4. If the LED mounting bracket must be removed from the overhead guard leg, remove the plug, screw and bracket from the overhead guard leg.

Install

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (11 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. If the mounting bracket was removed, install it onto the overhead guard leg. Insert the plug and screw to attach mounting bracket to overhead guard leg. See Figure 4.

2. Install the LED light assembly and harness on the mounting bracket.

3. Connect the LED light to the chassis light harness.

4. Connect the negative terminal of battery and close the hood.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (12 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

A. LED assembly with standard exhaust B. led assembly with overhead exhaust 1. LED light 2. screw 3. washer 4. locknut 5. mounting bracket 6. grommet 7. plug 8. screw 9. overhead guard leg Figure 4. LED Backup and Brake Lights Assembly

Counterweight Repair WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

• Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or Periodic Maintenance 8000 YRM 707 for your lift truck.

The counterweight is held in position on the frame by two hooks that are part of the frame. One M24 × 3 capscrew holds the counterweight to the lower part of the frame.

Remove

WARNING Do not operate the lift truck if the capscrew for the counterweight is not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system. LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (26 ft) from any open flame, motor vehicles, electrical equipment, or ignition source.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (13 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Close the shutoff valve on the LPG tank before any part of the engine fuel system is disconnected.

Run the engine until the fuel in the system is used and the engine stops.

If the engine will not run, close the shutoff valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit. Permit the pressure in the fuel system to decrease slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

1. If the lift truck has an LPG fuel system, use the following procedure to remove the LPG tank and bracket so that the counterweight can be removed. See Figure 5.

Additional information on the LPG fuel system can be found in the following sections:LPG Fuel System, GM 2.2L and 3.0L Engines 900 YRM 498, LPG Fuel System, Mazda FE Engine 900 YRM 523, or Electronic Controlled LPG/Gasoline Fuel System, GM 3.0L and 4.3L EPA Compliant Engines 900 YRM 1088. a. LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (26 ft) from any flame or ignition source. b. Move the lift truck to the area where tanks are changed. c. Turn the shutoff valve clockwise until the valve is completely closed. d. Run the engine until it stops, then turn the key switch to the OFF position. e. Disconnect the quick-disconnect fitting. f. Release the LPG tank latch and remove the tank from the bracket.

2. If an overhead exhaust is installed, remove it as shown in Figure 12.

WARNING The counterweight is heavy. Make sure that the eyebolt and lifting devices have enough capacity to lift the weight. The approximate weights of the counterweight castings are shown in Table 1.

3. Install a lifting eye in the lifting hole of the counterweight. See Figure 5. Connect a crane to the lifting eye and raise the crane until it holds part of the weight of the counterweight. Remove the capscrew that holds the counterweight to the frame. Use the crane to lift the counterweight from the lift truck. Put the counterweight on the floor so that it has stability and will not fall over. Remove the spacers from the mounts.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (14 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. Counterweight 2. Capscrew (M24 × 3 × 180) 3. Lockwasher 4. Washer 5. Tow Pin

6. Roll Pin 7. Seal 8. Shim 9. Nut 10. Cap 11. Lifting Hole

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (15 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Figure 5. Counterweight Table 1. Weight of Counterweights Model

kg

lbs

GP 040

1,080 ±16

2380 ±35

GP 050

1406 ±21

3100 ±46

GP 060

1800 ±27

3970 ±60

GC 040

1070 ±15

2360 ±33

GC 050

1433 ±21

3160 ±46

GC 060

1855 ±28

4090 ±62

Install 1. Install the spacers on the mounts. See Figure 6. Use a crane to install the counterweight on the lift truck. When the counterweight is installed, make sure the hooks on the frame fully engage the counterweight so it is aligned with the parts of the frame. Use the spacers to obtain a gap of 8.5 to 11.5 mm (0.33 to 0.45 in.) between the counterweight and the overhead guard leg. Install and tighten the M24 × 3 capscrew to 555 N•m (409 lbf ft).

2. If the lift truck has an LPG fuel system, use the following procedure to install the bracket and LPG tank after the counterweight has been installed: a. Before the LPG tank is installed on the lift truck, make sure the tank has fuel in it. Check the operation of the fuel gauge. Look at the fuel gauge and move the tank. If the gauge needle does not move, a new tank must be installed. b. Put the tank in the tank bracket. Make sure the tank is aligned with the alignment pin. c. Close the latch. d. Connect the quick-disconnect fitting to the shutoff valve on the tank. Use your hand to tighten the fitting. Do not open the shutoff valve until the quick-disconnect fitting is completely tightened. Turn the shutoff valve counterclockwise to open the valve. e. Inspect the fuel system for leaks when the shutoff valve is open. Frost on the surface of the tank, valves, or fittings or a strong odor indicates leakage.

3. If the lift truck has an overhead exhaust, install it as shown in Figure 12.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (16 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (17 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Figure 6. Counterweight Installation Legend for Figure 6 1. Spacer 2. Rubber Seal

3. Capscrew

Exhaust System Repair The muffler is installed inside the cavity of the counterweight. A short exhaust pipe sends the exhaust gases from the lift truck through the grille in the counterweight. See Figure 7, Figure 8, Figure 9 or Figure 10.

An optional catalytic converter can be installed in the exhaust system between the engine and the muffler.

See Figure 11. The type of catalytic converter installed depends on the fuel the engine uses. See the Parts Manual for your lift truck model.

The GP2.00-3.00RF/TF (GP040-060RG/TG/ZG) series of lift trucks can have an overhead exhaust system.

The exhaust pipe is fastened to the top of the counterweight. See Figure 12.

Muffler, Replace The counterweight must be removed to repair or install a new muffler or other parts of the exhaust system.

See Figure 7. When connecting the exhaust pipe to the engine, do the following: 1. Install the adapter on the exhaust manifold. Tighten the nuts for the adapter to 40 N•m (30 lbf ft). Install the exhaust seal, spacer, and exhaust pipe. Install the springs and special capscrews. Tighten the special capscrews to 38 N•m (28 lbf ft).

2. On units with an overhead exhaust, tighten the capscrews that hold the overhead exhaust to the counterweight to 38 N•m (28 lbf ft). Install the cover.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (18 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. Muffler 2. Clamp 3. Capscrew 4. Nut 5. Washer 6. Spacer 7. Pipe 8. Tube 9. Seal 10. Spring 11. Lockwasher 12. Gasket 13. Adapter Figure 7. Exhaust System (Gasoline and LPG)

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (19 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. muffler 2. counterweight exhaust pipe 3. gasket 4. exhaust pipe 5. seal 6. spring 7. special screw 8. oxygen sensor port 9. raw gas check port Figure 8. Exhaust System, GM3.0L EPA Compliant

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (20 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. Muffler 2. Spacer 3. Bracket 4. Catalytic Converter 5. Diffuser 6. Clamp 7. Gasket 8. Adapter 9. Seal 10. Spring 11. Special Capscrew 12. Plug Figure 9. Exhaust System (Low Emissions)

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (21 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Figure 10. EPA Compliant Exhaust System Mazda 2.0L and 2.2L Legend for Figure 10 1. Muffler 2. Spacer 3. Bracket http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (22 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

4. Catalytic Converter 5. Diffuser 6. Clamp 7. Gasket 8. Adapter 9. Seal 10. Spacer 11. Spring 12. Special Capscrew 13. Plug (Raw Gas Check Port) 14. Oxygen Sensor 15. overhead exhaust pipe

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (23 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Figure 11. Exhaust System (Diesel) Legend for Figure 11 1. Muffler 2. Clamp 3. Capscrew 4. Nut 5. Washer 6. Spacer 7. Pipe 8. Tube 9. Gasket 10. Spring 11. Lockwasher 12. Adapter 13. Seal 14. Catalytic Converter 15. Heat Shield 16. Fitting

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (24 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Figure 12. Overhead Exhaust Legend for Figure 12 1. Tube 2. tailpipe 3. Capscrew 4. Lockwasher

5. Washer 6. Cover 7. Clamp

Radiator and Cooling System Repair Remove

WARNING DO NOT remove the radiator cap while it is hot. Hot coolant and steam can cause burns. Make sure the label is on the radiator cap. See Figure 17.

1. Use the drain valve and drain the coolant from the radiator. Remove the bottom radiator hose and drain the coolant from the engine. See Figure 13 and Figure 14.

2. Remove the capscrews that fasten the fan to the hub. Remove the capscrews that hold the fan shroud to the radiator. Remove both the fan and the fan shroud.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (25 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

3. Disconnect the top coolant hose at the radiator. Disconnect the lines to the oil cooler in the side of the radiator. Put caps on the open lines and ports. Remove the capscrews that hold the radiator to the frame.

Remove the radiator.

Install 1. Install the radiator. See Figure 13 and Figure 14. Install the fan and fan shroud in position on the radiator. Install the capscrews that hold the fan shroud. Install the capscrews that fasten the fan to the hub. Tighten the capscrews to 26 N•m (19 lbf ft).

2. Connect the upper coolant hoses at the radiator. Connect the lines for transmission oil to the oil cooler in the radiator.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (26 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. Radiator 2. Radiator Cap 3. Auxiliary Coolant Reservoir 4. Shroud 5. Drain Valve Figure 13. Cooling System (Older)

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (27 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

A. Mazda FE and F2 Engines 1. Radiator 2. Radiator Cap 3. Auxiliary Coolant Reservoir 4. Shroud 5. Drain Valve Figure 14. Cooling System (Newer)

Operator Restraint System Repair The seat belt, hip restraint, seat and mount, hood, and latch are all part of the operator restraint system.

Each item must be checked to make sure it is fastened correctly, functions correctly, and is in good condition. See Figure 15.

The end of the seat belt must fasten correctly in the latch. Make sure the seat belt pulls from the retractor assembly and retracts smoothly. The seat belt must be in good condition. A seat belt that is damaged or worn will not give protection when it is needed.

Adjust the hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See Hood and Side Covers Repair for the adjustment procedures.

1. Hood Latch 2. Latch Hook 3. Push Knob 4. Seat

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (28 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

5. Hip Restraint 6. Seat Belt 7. Upper Hood Panel 8. Hinge 9. Torsion Spring Figure 15. Hood and Seat Check

Engine Repair Remove Engine Only

WARNING The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast, drive axle, engine and transmission, and counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: • Before removing the mast and drive axle, put blocks under the counterweight so the lift truck cannot fall backward.

• Before removing the counterweight, put blocks under the mast assembly so the lift truck cannot fall forward.

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units. See the Operating Manual or the Periodic Maintenance section for your lift truck.

The engine can be removed with or without the transmission. Follow this procedure to remove the engine without the transmission.

WARNING Always disconnect the cables at the battery before you make repairs to the engine. Disconnect the cable at the negative terminal first.

1. Remove the floor plates. Remove the hood and side covers. Remove the crossmember that is the hood mount. Remove the air filter and battery. Remove the radiator.

2. Disconnect the throttle linkage. Disconnect the exhaust system.

3. Disconnect the wires and wiring harnesses at the engine. Disconnect the fuel lines at the engine.

4. Connect a lifting device to the engine. Put a block under the transmission housing as a support.

5. Remove the capscrews that hold the torque converter housing to the flywheel housing. Remove the capscrews that hold the drive plate to the torque converter.

WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (29 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

engine can weigh approximately 340 kg (750 lb).

6. Remove the nuts and bolts from the engine mounts. Use the lifting device to carefully move the engine away from the torque converter. Make sure all hoses, wires, and cables are disconnected from the engine, then lift the engine from the frame.

Remove Engine and Transmission The engine can be removed with or without the transmission. Follow this procedure to remove the engine with the transmission.

1. Remove the mast. See the section Mast, Repairs 4000 YRM 522. Put the lift truck on blocks so you have access under the lift truck. See the section Periodic Maintenance 8000 YRM 707.

2. Perform Step 1 through Step 3 from Remove Engine Only.

3. Remove the crossmember for the brake and throttle pedals.

4. Remove the hydraulic hose between the pump and the tank. Put a cap on the tank fitting. Remove the hydraulic filter and hoses. Remove the supply line to the main control valve.

5. Drain the oil from the axle housing. Remove the capscrews that hold the axle shafts to the hubs.

Remove the axle shafts. Disconnect the brake lines and parking brake cables. Remove the capscrews that hold the transmission housing to the axle housing.

WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb).

6. Connect a lifting device to the engine and transmission. Make sure the engine and transmission assembly can be raised at an angle so they will clear the frame. Remove the nuts and bolts from the engine mounts. Use the lifting device to carefully lift the engine and transmission from the frame.

Install Engine Only The engine can be installed with or without the transmission. Follow this procedure to install the engine without the transmission.

WARNING The engine is heavy. Make sure that any lifting device has enough capacity to lift the engine. The engine can weigh approximately 340 kg (750 lb).

1. Make sure the torque converter is installed in the transmission and the drive plate is on the flywheel.

Connect a lifting device to the engine. Lift the engine into the frame. Carefully align the drive plate with the transmission. See the section Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 YRM 501. Make sure the pilot on the torque converter is in the hole in the flywheel. Install the

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (30 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

capscrews that hold the torque converter housing to the flywheel housing. Install the capscrews that hold the drive plate to the torque converter.

2. Install the nuts and bolts for the engine mounts. Install the parts of the mounts as shown in Figure 16.

Use a maximum of three spacers to bring the engine mounts within 1.0 mm (0.04 in.) of a vertical position. Tighten the nuts to 66 N•m (49 lbf ft).

3. Install the radiator and connect the coolant hoses and the lines to the transmission.

4. Install the crossmember that is the hood mount. Connect the wires and wiring harnesses at the engine.

Connect the fuel lines at the engine.

5. Connect the throttle linkage. Connect the exhaust system. Install the air filter assembly.

6. Install the battery. Install the side covers and the hood.

7. Check all fluid levels as described in Periodic Maintenance 8000 YRM 707.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (31 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. Bolt 2. Engine Mount 3. Flat Washer 4. Spacer 5. Cup

6. Rubber Mount 7. Tube Spacer 8. Bumper 9. Lockwasher 10. Nut Figure 16. Engine Mounts

Install Engine and Transmission The engine can be installed with or without the transmission. Follow this procedure to install the engine with the transmission.

1. Put the lift truck on blocks so you have access under the lift truck. See the section Periodic http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (32 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Maintenance 8000 YRM 707.

WARNING The engine and transmission are heavy. Make sure that any lifting device has enough capacity to lift the weight. The engine and transmission can weigh approximately 680 kg (1500 lb).

2. Apply a gasket sealant to the flange of the axle housing. Connect a lifting device to the engine and transmission. Lift the engine and transmission into the frame. Connect the transmission housing to the axle housing. Install a capscrew in the "tight fit" hole first. This hole is on the side of the transmission with the dipstick, near the top. Install the remaining capscrews. Tighten the capscrews to 38 N•m (28 lbf ft).

3. Install the nuts and bolts for the engine mounts. Install the parts of the mounts as shown in Figure 16.

Use a maximum of three spacers (4) to bring the engine mounts within 1.0 mm (0.04 in.) of a vertical position. Tighten the nuts to 66 N•m (49 lbf ft).

4. Install the hydraulic hose between the pump and the tank. Install the hydraulic filter and hoses.

Connect the supply line to the main control valve.

5. Install the crossmember for the brake and throttle pedals.

6. Perform Step 3 through Step 7 from Install Engine Only.

Fuel and Hydraulic Tanks Repair Inspect

WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside a building, make sure there is enough ventilation. See the following manuals for additional information: • Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999.

• Safety in Welding and Cutting, American National Standard, AWS Z 49.1 - 1999.

WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion.

Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

Small Leaks, Repair Use the following procedure to repair small leaks: http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (33 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.

Large Leaks, Repair 1. Use one of the procedures described under Clean to clean and prepare the tank for repairs.

2. Contact your dealer for Yale lift trucks for welding instructions.

3. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

Clean

WARNING When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank.

Connect a ground wire to the tank to prevent static electricity.

Steam Method of Cleaning Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug.

2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water.

3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank.

4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings.

5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank.

6. Make an inspection of the inside of the tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors.

7. Put plugs in all the openings in the tank. Wait 15 minutes, then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (34 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

the lower flammable limit, repeat the cleaning procedures.

Chemical Solution Method of Cleaning

WARNING When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.

If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkaline base. Follow the instructions given by the manufacturer.

2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank.

3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed.

4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 through Step 3.

Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors.

5. Check the tank for flammable vapors using special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

Additional Preparations for Repair If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices for Welding and Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. Fill the tank with water to just below the point where the work will be done. Make sure the space above the level of the water has a vent.

2. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

Safety Labels WARNING Safety labels are installed on the lift truck to give information about operation and possible hazards.

It is important that all safety labels are installed on the lift truck and can be read.

DO NOT add to or modify the lift truck. Any change to the lift truck, the tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped, and the nameplate must show the new capacity rating. Contact your dealer for a new nameplate.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (35 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.

If a new label must be installed, use the following procedure to install a new label (Figure 17): 1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint with a cleaning solvent.

2. Remove the paper from the back of the label. Do not touch the adhesive surface.

3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure that all air is removed from under the label and the corners and edges are tight.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (36 of 37)26.10.2011 16:36:12

524158636-0100YRM0505-(06-2004)-UK-EN

Figure 17. Safety Label Positions Legend for Figure 17 NOTE: Labels for GC040-065RF/TF model lift trucks shown. Label positions for GP2.00-3.00TF/RF (GP040060RG/TG/ZG) are similar.

NOTE: See Parts Manual for part numbers of labels.

1. Mast Warning 2. Nameplate 3. Tipover Warning 4. Warning, Operation 5. Fan Warning 6. Radiator Cap Warning 7. Flammable LP-Gas* 8. Optional Fire Safety Rating* 9. No Riders 10. Drive Train Protection* 11. No One on or Under Forks 12. Pinch Point Warning 13. Warning For Parking Brake 14. Auxiliary Function Label 15. UL LPG Tank Label* 16. Overhead Guard 17. Boron-Free Antifreeze* *Not Used on All Units

Yale Europe Materials Handling Limited Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0505.html (37 of 37)26.10.2011 16:36:12

524158742-0600YRM0496-(01-2011)-UK-EN

Mazda Engine FE and F2 GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030-040AF/BF) [A810]; GC/GLC030-040AF [B809]; GLP/GDP16-20AF (GP/GLP/GDP030-040AF) [B810]; GP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875]; GC/GLC040-065RG/TG/ZG [E187]

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (1 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Safety Precautions Maintenance and Repair • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load.

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

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (2 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.

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

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.

Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

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

CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background. The CAUTION symbol and word are on yellow background.

TABLE OF CONTENTS General

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (3 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Description Engine Removal and Installation Cylinder Head, Camshaft, and Valve Mechanism Repair Remove Clean Inspect and Repair Cylinder Head Rocker Shaft Assembly Camshaft Valve Guides Valve Seats Valves Valve Springs Install Crankshaft and Main Bearings Repair Remove Inspect and Repair Crankshaft Main Bearings Install Pistons and Connecting Rods Repair Remove and Disassemble Clean Inspect and Repair Pistons Piston Rings Connecting Rods and Bearings Assemble and Install Cylinder Block Repair Oil Pump Repair Remove Disassemble Clean Inspect Assemble Install Cooling System Repair Thermostat Replace Fan Assembly Remove and Disassemble Assemble and Install Water Pump

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (4 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Remove and Disassemble Assemble and Install Distributor Repair Remove Install Flywheel and Ring Gear Repair Remove Ring Gear, Replace Install Flywheel Repair Remove Install Valve Adjustment Compression Pressure Check Engine Timing Adjustment Throttle Linkage Adjustment Gasoline Engines LPG Engines (IMPCO) LPG Engines (AISAN) Engine Specifications Engine Data Thermostat Cylinder Head Valve Mechanism Camshaft Crankshaft Connecting Rods Cylinder Block Pistons Oil Pump Torque Specifications Troubleshooting This section is for the following models: GP/GLP/GDP16-20AF/BF (GP/GLP/GDP030-040AF/BF) [A810]; GC/GLC030-040AF [B809]; GLP/GDP16-20AF (GP/GLP/GDP030-040AF) [B810]; GP/GLP/GDP2.00-3.00RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875]; GC/GLC040-065RG/TG/ZG [E187]

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (5 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

General This section has the instructions for removal, disassembly, repair, assembly, installation, checks, adjustments, and troubleshooting for the Mazda FE and F2 engines. The engine specifications are given at the end of the section.

Additional information on engine components can be found in the sections for Gasoline Fuel System, LPG Fuel System, and Electrical System.

Description WARNING Some gaskets used in this engine can contain dangerous fibers. Breathing dust from these fibers is a cancer or lung disease hazard. Do not create dust! Use vacuum equipment for asbestos or follow the cleaning procedure described below.

• Make sure the gasket material is wet with water or oil to prevent particles in the air.

• Use a hand scraper to remove old gasket material. Do not use a power tool or compressed air.

• Discard all asbestos material in a closed container while it is still wet.

• Put a DANGEROUS FIBERS warning label on the container. Discard dangerous fiber material safely.

CAUTION Disconnect the battery cables before doing any disassembly and repair to the engine or parts of the electrical system.

The diodes and resistors in the electrical system can be damaged if the following cautions are not followed: • Do not disconnect the battery when the engine is running. The voltage surge can damage the diodes and resistors.

• Do not disconnect an electric wire before the engine is stopped and the key switch is OFF. • Do not cause a short circuit by connection of the electric wires to the wrong terminals. Make sure a correct identification of the wire is made wire before it is connected.

• Make sure a battery is the correct voltage and polarity before it is connected.

• Do not check for current flow by making a spark because the transistors can be damaged.

The Mazda FE and F2 engines have four cylinders. The displacement of the FE is 1998 cm3 (121.9 in.3).

The displacement of the F2 is 2184 cm3 (133.2 in.3). The firing order is 1 – 3 – 4 – 2. They are both available with either a gasoline or LPG fuel system. The No. 1 cylinder is toward the end of the engine with the cooling fan.

The overhead camshaft is driven by a cog belt. The camshaft operates the rocker arms that actuate the valves.

The crankshaft has five main bearings. The main bearing in the center of the crankshaft is also the thrust bearing.

The pistons are aluminum alloy and have three piston rings. Each of the two compression rings have a

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (6 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

special shape designed for its position on the piston. The third piston ring is the oil control ring.

Engine Removal and Installation The removal and installation procedures for the engine are not included in this section. See the following manuals for the procedures: Frame 100 YRM 545. For model units: • GP/GLP/GDP16-20AF/BF (GP/GLP/BDP030-040AF/BF), GC/GLC030-040AF, and GLP/GDP16-20AF (GP/GLP/GDP030-040AF) Frame 100 YRM 505 for lift truck models: • GP/GLP/GDP2.0-3.0RF/TF (GP/GLP/GDP040-060RG/TG/ZG) and GC/GLC040-065TF/RF

Cylinder Head, Camshaft, and Valve Mechanism Repair Remove 1. Disconnect connections at battery.

2. Drain cooling system.

3. Remove air cleaner, carburetor linkage, and inlet and exhaust manifolds.

4. Remove coolant hoses.

5. Remove bracket for cooling fan.

6. Remove upper and lower timing belt covers. See Figure 1.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (7 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

1. Lower Timing Belt Cover 2. Upper Timing Belt Cover 3. timing belt tensioner http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (8 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Figure 1. Timing Belt Covers 7. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner.

8. Use chalk to mark direction of timing belt rotation. See Figure 2. Remove timing belt.

Figure 2. Timing Belt 9. Put labels on wires to aid in correct installation. Disconnect wires at distributor. Remove capscrew for distributor mount and pull distributor from front housing.

10. Remove camshaft pulley. Keep pulley from rotating and loosen capscrew. Remove capscrew and pulley. See Figure 3.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (9 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Figure 3. Camshaft Gear Removal 11. Remove nuts and capscrews for front housing. Then remove housing. See Figure 4.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (10 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

1. Front 3. Oil Housing Seal 2. Gasket Figure 4. Front Housing 12. Remove valve cover.

13. Loosen capscrews for rocker shaft supports in proper sequence. See Figure 5. Remove rocker shaft assembly and camshaft.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (11 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Figure 5. Rocker Assembly Removal Sequence 14. Remove capscrews for cylinder head in proper sequence. See Figure 6.

15. Lift cylinder head from the block.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (12 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Figure 6. Cylinder Head Removal Sequence 16. Use valve spring compressor to remove valve retainers, springs, and valves from head. See Figure 7.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (13 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Figure 7. Valve Removal

Clean

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.

Clean all parts in solvent. Make sure all oil passages are clean and all machined surfaces are smooth.

Inspect and Repair Cylinder Head Use straight edge and thickness gauge to check bottom surface of cylinder head for distortion. Do the measurements at the positions shown in Figure 8.

Maximum amount of distortion is 0.15 mm (0.0059 in.). If grinding of cylinder head is necessary, maximum amount of correction is 0.2 mm (0.008 in.).

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (14 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Figure 8. Cylinder Head Inspection

Rocker Shaft Assembly 1. Disassemble rocker shaft assembly. Put marks on rocker arms so they can be installed on correct shafts.

2. Clean oil passages in rocker shafts and rocker arms.

3. Check clearance between rocker arms and rocker shafts. Maximum clearance is 0.10 mm (0.004 in.).

Correct dimension for inside diameter of rocker arm is 16.000 to 16.027 mm (0.6299 to 0.6311 in.).

Correct dimension for outside diameter of rocker shaft is 15.966 to 15.984 mm (0.6286 to 0.6293 in.). If components do not meet specifications, replace rocker arm(s) or rocker shaft(s) as http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (15 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

necessary.

Camshaft 1. Check camshaft for cracks or damage.

2. Use dial indicator on end of camshaft to check movement of camshaft in cylinder head. See Figure 9.

Maximum movement is 0.20 mm (0.008 in.).

Figure 9. Camshaft Check 3. Measure height of camshaft lobes. See Figure 10. Minimum height of intake and exhaust lobes is 36.902 mm (1.4528 in.).

4. Measure camshaft journals at four points (A-D) as shown in Figure 10. Minimum dimensions for the journals are as follows: Front and Rear Journals (Nos. 1 and 5) - 31.940 to 31.965 mm (1.2575 to 1.2585 in.)

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (16 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Center Journals (Nos. 2, 3 and 4) - 31.910 to 31.935 mm (1.2563 to 1.2573 in.)

Front Oil Seal Surface - 33.961 to 34.000 mm (1.3371 to 1.3386 in.)

Fuel Pump Lobe - 37.1 mm (1.46 in.)

5. Check camshaft for straightness. Put front and rear journals in V blocks and rotate camshaft one complete turn. See Figure 11. Maximum amount that the dial indicator should indicate is 0.03 mm (0.0012 in.).

6. Measure clearance between camshaft and bore in cylinder head as follows: a. Install camshaft in cylinder head. b. Put plastic gauge material between each camshaft journal and cap. Do not allow camshaft to rotate. c. Tighten capscrews for caps to 18 to 27 N•m (159 to 239 lbf in). See Figure 12.

Correct clearance for journals No. 1 and 5 is 0.035 to 0.085 mm (0.0014 to 0.0033 in.).

Correct clearance for journals No. 2, 3, and 4 is 0.065 to 0.115 mm (0.0026 to 0.0045 in.). If any clearances are greater than 0.15 mm (0.0059 in.), replace cylinder head assembly.

7. Replace camshaft if there is any damage or if it does not meet specifications.

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (17 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

1. Front Oil Seal Surface 2. Front Journal (No. 1) 3. Center Journals (Nos. 2, 3, and 4) 4. Rear Journal (No. 5) 5. Fuel Pump Lobe Figure 10. Camshaft Inspection

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (18 of 85)26.10.2011 16:38:10

524158742-0600YRM0496-(01-2011)-UK-EN

Figure 11. Camshaft Check

http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0600YRM0496.html (19 of 85)26.10.2011 16:38:10