Capacities and Specifications: Maintenance

Maintenance
CAPACITIES AND
SPECIFICATIONS
GP/GLP/GDP20-30RF/TF
(GP/GLP/GDP040-060RG/TG/ZG) [A875];
GC/GLC040-065RG/TG/ZG [E187]
PART NO. 524158901 8000 YRM 708

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Capacities and Specifications Table of Contents
TABLE OF CONTENTS
Lift Truck Weights ................................................................................................................................................ 1

Tire Pressure ....................................................................................................................................................... 1
Tire Sizes............................................................................................................................................................. 2
Capacities............................................................................................................................................................ 2
Electrical System ................................................................................................................................................. 3
Gasoline/LPG.................................................................................................................................................. 3
Diesel .............................................................................................................................................................. 3
Transmission Oil Pressures ................................................................................................................................. 4
Hydraulic System................................................................................................................................................. 4
Stall Speeds ........................................................................................................................................................ 5
Engine Specifications .......................................................................................................................................... 5
Gasoline/LPG.................................................................................................................................................. 5
Diesel .............................................................................................................................................................. 7
Mast Speeds........................................................................................................................................................ 8
Gasoline/LPG Engines (US Models)............................................................................................................... 8
Diesel Engines (US Models) ........................................................................................................................... 12
Gasoline/LPG Engines (US Models)............................................................................................................... 14
Gasoline/LPG Engines (European Models) .................................................................................................... 19
Diesel Engines (European Models)................................................................................................................. 23
Torque Specifications .......................................................................................................................................... 24
Frame .............................................................................................................................................................. 24
Brake System .................................................................................................................................................. 25
Mast ................................................................................................................................................................ 25
Steering System.............................................................................................................................................. 25
Drive Axle........................................................................................................................................................ 25
Transmission and Differential .......................................................................................................................... 25
Engine - Mazda FE and F2 ............................................................................................................................. 26
Engine - GM 3.0L ............................................................................................................................................ 27
Engine - Mazda XA and HA Diesel ................................................................................................................. 27
This section is for the following models:
GP/GLP/GDP20-30RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875];

GC/GLC040-065RG/TG/ZG [E187]
©2011 Yale Materials Handling Corp. i

8000 YRM 708 Tire Pressure
Lift Truck Weights

Unit kg lb
GC040RG 2,813 6,202
GC050RG/TG/ZG 3,173 6,995
GC060TG/ZG 3,574 7,880
GC065TG/ZG 3,721 8,203
GP20RF (GP040RG) 3,720 8,201
GP25TF (GP050ZG) 4,070 8,973
GP30TF (GP060TG) 4,555 10,041
NOTE: All pneumatic tire units are equipped with gasoline engine, standard carriage, forks, two-stage limited
free-lift mast, and 91 kg (200 lb) operator.
NOTE: All cushioned tire units are equipped with powershift transmission, standard tires, and overhead guard
(without the front end).
Tire Pressure
Bias Ply Tires
GP20-30RF/TF (GP040-060RG/TG/ZG)
Tire Size kPa psi
6.00 × 9, 10 ply 860 125
6.50 × 10, 10 ply 795 115
7.00 × 12, 12 ply 860 125
28 × 9 - 15, 12 ply 825 120
Radial Tires
Tire Size kPa psi Warning
6.00 R9 1000 145
6.50 R10 1000 145
7.00 R12 1000 145
225/75 R15 1000 145
1
Capacities 8000 YRM 708
Tire Sizes
GC040-065RG/TG/ZG
Drive Tires Steer Tires
21 × 7 × 15 16 × 5 × 10.5
21 × 8 × 15 16 × 6 × 10.5
Capacities
Item Quantity
Engine Oil (with filter)
Mazda FE Engine 4.5 liter (4.7 qt)
Mazda F2 Engine 4.6 liter (4.9 qt)
GM 3.0L Engine 4.3 liter (4.5 qt)
Mazda XA Diesel 7.4 liter (7.8 qt)
Mazda HA Diesel 7.4 liter (7.8 qt)
Cooling System
Mazda FE Engine 11.0 liter (11.6 qt)
Mazda F2 Engine 11.0 liter (11.6 qt)
GM 3.0L Engine 11.0 liter (11.6 qt)
Mazda XA Diesel 11.0 liter (11.6 qt)
Mazda HA Diesel 11.0 liter (11.6 qt)
Hydraulic System
GC040-065RG/TG/ZG Initial Fill 48.0 liter (51.0 qt)
GP20-30RF/TF (GP040-060TG/RG/ZG) Initial Fill 40.0 liter (42.3 qt)
Transmission
GC040-065RG/TG/ZG Powershift Transmission 8.5 liter (9.0 qt)
GP20-30RF/TF (GP040-060TG/RG/ZG) Powershift Transmis- 9.0 liter (9.5 qt)
sion
GP20-30RF/TF (GP040-060TG/RG/ZG) Hydrostatic Trans- 18.0 liter (19.0 qt)
mission
Differential
GC040-065RG/TG/ZG 8.0 liter (8.5 qt)
GP20-30RF/TF (GP040-060TG/RG/ZG) 7.6 liter (8.0 qt)
Transmission Axle Shaft Oil
Hydrostatic Transmission 0.36 liter (0.40 qt)
2
8000 YRM 708 Electrical System
Item Quantity
Fuel Tank
Mazda FE Engine 44.3 liter (11.7 gal)
Mazda F2 Engine 44.3 liter (11.7 gal)
GM 3.0L Engine 39.4 liter (10.4 gal)
Mazda XA Diesel 54.5 liter (14.4 gal)
Mazda HA Diesel 54.5 liter (14.4 gal)
Brake Fluid 0.2 liter (0.4 pt)
Electrical System
GASOLINE/LPG
Item Mazda FE and F2 Engines GM 3.0L Engine
All Models 12-volt, negative ground 12-volt, negative ground
Alternator Output (Hot) 37 amps @ 2700 rpm 56 amps @ 2600 rpm
Ignition Timing
Gasoline 0° BTDC Electronic Timing
LPG 9° BTDC Electronic Timing
Spark Plugs ND W9 EXR-U AC R44 LTSMA
Spark Plug Gap 0.8 mm (0.031 in.) 1.1 mm (0.043 in.)
DIESEL
Item Mazda XA Diesel Mazda HA Diesel
GDP20-30RF/TF
12 volt, negative ground 12 volt, negative ground
(GDP040-060RG/TG/ZG)
Alternator Output (Hot) 56 amps @ 2800 rpm 56 amps @ 2200 rpm
3
Hydraulic System 8000 YRM 708
Transmission Oil Pressures

Test Port 1 Test Port 2 Test Port 3 Test Port 4 Test Port 5 Test Port 6
965 to 1170 kPa 724 to 860 kPa 724 to 860 kPa 724 to 827 kPa 105 to 175 kPa Pressure
(140 to 170 psi) (105 to 125 psi) (105 to 125 psi) (105 to 120 psi) (15 to 25 psi) Variation
NOTES:
All pressures are measured at 2000 rpm, oil temperature at 50°C (122°F).
The difference in the forward and reverse clutch pressure must not be
more than 70 kPa (10 psi).
TEST PORT 1 - Pressure from the transmission pump
TEST PORT 2 - Pressure to the forward clutch
TEST PORT 3 - Pressure to the reverse clutch
TEST PORT 4 - Oil Pressure to the torque converter
TEST PORT 5 - Oil Pressure from the oil cooler
TEST PORT 6 - Modulator pressure
Hydraulic System
Item Specification
Hydraulic Pump
Type Gear
Priority Flow 10 liter/min (2.64 gal/min)
Relief Pressures
Steering (at Pump) 10.6 to 11.7 MPa (1540 to 1700 psi)
Primary (at Control Valve) 21.37 ±0.5 MPa (3100 ±75 psi)
Secondary (at Control Valve) 15.5 ±0.5 MPa (2250 ±75 psi)
All pressures with oil at 55 to 65°C (130 to 150°F) and engine at 2000 rpm.
4
8000 YRM 708 Engine Specifications
Stall Speeds
Engine New Engine Engine with 30+ Hours
Mazda FE
Gasoline 1930 to 2030 rpm 2050 to 2150 rpm
LPG 1880 to 1980 rpm 2000 to 2100 rpm
Mazda F2
Gasoline 2100 to 2200 rpm 2220 to 2320 rpm
LPG 2050 to 2150 rpm 2170 to 2270 rpm
GM 3.0L 1980 rpm 2080 rpm
Mazda HA (Diesel)
GDP040-060RG/TG 1835 to 1935 rpm 1870 to 1970 rpm
Mazda XA (Diesel)
GDP040-060RG/TG 2050 to 2150 rpm 2150 to 2250 rpm
Engine Specifications
GASOLINE/LPG
Item Mazda FE Mazda F2 GM 3.0L
No. of Cylinders In-Line, Four Cylinders In-Line, Four Cylinders 4
Firing Order 1-3-4-2 1-3-4-2 1-3-4-2
Bore and Stroke 86 mm × 86 mm 86 mm × 94 mm 120 mm × 91 mm
(3.39 in. × 3.39 in.) (3.39 in. × 3.70 in.) (4.72 in. × 3.60 in.)
Displacement 1998 cm 3 (122 in. 3 ) 2184 cm 3 (133.2 in. 3 ) 2966 cm 3 (181 in. 3 )
Compression Ratio 8.6:1 8.6:1 8.0:1
Compression Pressure 1131 kPa (164 psi) 1131 kPa (164 psi) 758 kPa (110 psi) @
@ 270 rpm @ 270 rpm 200 rpm
Oil Pressure 226 to 362 kPa (33 to 226 to 362 kPa (33 to 138 kPa (20 psi) min.
53 psi) @ 2400 rpm 53 psi) @ 2400 rpm @ 1200 rpm
Valve Clearance 0.3 mm (0.012 in.) Hot 0.3 mm (0.012 in.) Hot Not Adjustable
(Intake/Exhaust)
Idle Speed
Gasoline 800 ±25 rpm 800 ±25 rpm 800 ±25 rpm
Idle Speed
LPG (IMPCO) 700 to 750 rpm N/A 675 to 725 rpm
Idle Speed
LPG (Aisan Closed Loop) 800 ±25 rpm 800 ±25 rpm 800 ±25 rpm
5
Engine Specifications 8000 YRM 708
Item Mazda FE Mazda F2 GM 3.0L

Idle Speed
LPG (Aisan Open Loop) 800 ±25 rpm 800 ±25 rpm 800 ±25 rpm
Governed Speed
Gasoline GP20-30RF/TF 2700 to 2800 rpm 2700 to 2800 rpm 2900 ±50 rpm
(GP040-060RG/TG/ZG)
Governed Speed
Gasoline 2700 to 2800 rpm 2700 to 2800 rpm 2800 ±50 rpm
GC040-065RG/TG/ZG
Governed Speed
LPG (IMPCO) 2600 to 2700 rpm N/A 2850 to 2950 rpm
Governed Speed
LPG (Aisan Closed 2700 to 2800 rpm 2700 to 2800 rpm 2900 ±50 rpm
Loop) GLP20-30RF/TF
(GLP040-060RG/TG/ZG)
Governed Speed
LPG (Aisan Closed Loop) 2700 to 2800 rpm 2700 to 2800 rpm 2800 ±50 rpm
GLC040-065RG/TG/ZG
Governed Speed
LPG (Aisan Open 2700 to 2800 rpm 2700 to 2800 rpm 2900 ±50 rpm
Loop) GLP20-30RF/TF
(GLP040-060RG/TG/ZG)
Governed Speed
LPG (Aisan Open Loop) 2700 to 2800 rpm 2700 to 2800 rpm 2800 ±50 rpm
GLC040-065RG/TG/ZG
Thermostat Range
Starts to Open 80.5 to 83.5°C 80.5 to 83.5°C 80.5 to 83.5°C
(177 to 182°F) (177 to 182°F) (177 to 182°F)
Fully Open 93.5 to 96.5°C 93.5 to 96.5°C 93.5 to 96.5°C
(200 to 206°F) (200 to 206°F) (200 to 206°F)
Cooling System Pressure 103 kPa (15 psi) 103 kPa (15 psi) 88 kPa (13 psi)
6
8000 YRM 708 Engine Specifications
DIESEL
Item Mazda HA Mazda XA
No. of Cylinders In-Line, Four Cylinders In-Line, Four Cylinders
Firing Order 1-3-4-2 1-3-4-2
Bore and Stroke 95 mm × 105 mm 88.9 mm × 101.6 mm
(3.74 in. × 4.13 in.) (3.50 in. × 4.00 in.)
Displacement 2977 cm 3 (181.7 in. 3 ) 2522 cm 3 (153.9 in. 3 )
Compression Ratio 21:1 21:1
Compression Pressure 2944 kPa (427 psi) 2944 kPa (427 psi)
@ 200 rpm @ 200 rpm
Oil Pressure 245 kPa (36 psi) @ 2000 rpm 245 kPa (36 psi) @ 2000 rpm
Valve Clearance (Intake/Exhaust) 0.3 mm (0.012 in.) Hot 0.3 mm (0.012 in.) Hot
Governed Speed (No Load)
GDP040-060ZG N/A 2100 to 2200 rpm
GDP040-060RG N/A 2600 to 2700 rpm
GDP040-060TG 2100 to 2200 rpm N/A
Idle Speed 700 to 750 rpm 700 to 750 rpm
Thermostat Range
Starts to Open 80.5 to 83.5°C (177 to 182°F) 80.5 to 83.5°C (177 to 182°F)
Thermostat Range
Fully Open 93.5 to 96.5°C (200 to 206°F) 93.5 to 96.5°C (200 to 206°F)
Cooling System Pressure 103 kPa (15 psi) 103 kPa (15 psi)
7
Mast Speeds 8000 YRM 708
Mast Speeds
GASOLINE/LPG ENGINES (US MODELS)
Mazda FE Engine
Two-Stage Limited Free-Lift
Unit Lifting* Lowering*
No Load Rated Load No Load Rated Load
m/sec ft/min m/sec ft/min m/sec ft/min m/sec ft/min
GP040RG 0.60 118 0.55 107 0.42 83 0.50 99
GP050RG 0.60 118 0.53 104 0.42 83 0.50 99
GP060RG 0.53 104 0.46 91 0.42 83 0.50 99
* Hydraulic oil temperature 65°C (149°F). Plus or minus 10% acceptable for lifting and lowering.
Mazda FE Engine
Two-Stage Full Free-Lift
GP040RG 0.55 107 0.49 97 0.42 83 0.50 99
GP050RG 0.55 107 0.48 95 0.42 83 0.50 99
GP060RG 0.52 102 0.45 89 0.42 83 0.50 99
Mazda FE Engine
Three-Stage Full Free-Lift
GP040RG 0.58 113 0.52 102 0.42 83 0.50 99
GP050RG 0.58 113 0.50 99 0.42 83 0.50 99
GP060RG 0.51 100 0.45 88 0.42 83 0.50 99
8
8000 YRM 708 Mast Speeds
Mazda F2 Engine
GP040TG 0.66 130 0.60 117 0.42 83 0.50 99
GP050TG 0.66 130 0.58 114 0.42 83 0.50 99
GP060TG 0.58 114 0.50 99 0.42 83 0.50 99
Mazda F2 Engine
GP040TG 0.60 117 0.55 107 0.42 83 0.50 99
GP050TG 0.60 117 0.53 104 0.42 83 0.50 99
GP060TG 0.57 111 0.49 97 0.42 83 0.50 99
Mazda F2 Engine
GP040TG 0.63 123 0.57 112 0.42 83 0.50 99
GP050TG 0.63 123 0.56 109 0.42 83 0.50 99
GP060TG 0.56 110 0.49 96 0.42 83 0.50 99
9
GM 3.0L Engine (Gasoline Only)

GP040ZG 0.64 125 0.60 117 0.42 83 0.50 99
GP050ZG 0.64 125 0.59 115 0.42 83 0.50 99
GP060ZG 0.56 110 0.51 100 0.42 83 0.50 99

GP040ZG 0.58 113 0.54 106 0.42 83 0.50 99
GP050ZG 0.58 113 0.53 104 0.42 83 0.50 99
GP060ZG 0.55 108 0.50 98 0.42 83 0.50 99

GP040ZG 0.61 119 0.57 112 0.42 83 0.50 99
GP050ZG 0.61 119 0.56 110 0.42 83 0.50 99
GP060ZG 0.55 107 0.49 97 0.42 83 0.50 99
10
GM 3.0L Engine (LPG Fuel Only)

GLP040ZG 0.68 134 0.62 121 0.42 83 0.50 99
GLP050ZG 0.68 134 0.60 117 0.42 83 0.50 99
GLP060ZG 0.60 118 0.52 102 0.42 83 0.50 99

GLP040ZG 0.62 121 0.56 110 0.42 83 0.50 99
GLP050ZG 0.62 121 0.55 107 0.42 83 0.50 99
GLP060ZG 0.59 115 0.51 100 0.42 83 0.50 99

GLP040ZG 0.65 128 0.59 115 0.42 83 0.50 99
GLP050ZG 0.65 128 0.57 112 0.42 83 0.50 99
GLP060ZG 0.58 114 0.50 99 0.42 83 0.50 99
11
DIESEL ENGINES (US MODELS)

Mazda XA Engine
GDP040RG 0.61 119 0.55 108 0.42 83 0.50 99
GDP050RG 0.61 119 0.54 105 0.42 83 0.50 99
GDP060RG 0.53 104 0.46 91 0.42 83 0.50 99
Mazda XA Engine
GDP040RG 0.55 107 0.50 98 0.42 83 0.50 99
GDP050RG 0.55 107 0.49 96 0.42 83 0.50 99
GDP060RG 0.52 102 0.46 90 0.42 83 0.50 99
Mazda XA Engine
GDP040RG 0.58 113 0.53 103 0.42 83 0.50 99
GDP050RG 0.58 113 0.51 100 0.42 83 0.50 99
GDP060RG 0.52 101 0.45 89 0.42 83 0.50 99
12
Mazda HA Engine
GDP040TG 0.61 120 0.56 110 0.42 83 0.50 99
GDP050TG 0.61 120 0.55 108 0.42 83 0.50 99
GDP060TG 0.53 104 0.48 95 0.42 83 0.50 99
Mazda HA Engine
GDP040TG 0.56 110 0.52 102 0.42 83 0.50 99
GDP050TG 0.56 110 0.51 100 0.42 83 0.50 99
GDP060TG 0.56 110 0.47 93 0.42 83 0.50 99
Mazda HA Engine
GDP040TG 0.56 110 0.51 100 0.42 83 0.50 99
GDP050TG 0.56 110 0.50 99 0.42 83 0.50 99
GDP060TG 0.51 100 0.46 91 0.42 83 0.50 99
13
GASOLINE/LPG ENGINES (US MODELS)

Mazda FE Engine
GC040RG 0.62 123 0.56 111 0.42 83 0.50 99
GC050RG 0.62 123 0.55 108 0.42 83 0.50 99
Mazda FE Engine
GC040RG 0.56 111 0.51 101 0.42 83 0.50 99
GC050RG 0.56 111 0.50 99 0.42 83 0.50 99
Mazda FE Engine
GC040RG 0.56 117 0.52 106 0.42 83 0.50 99
GC050RG 0.56 117 0.51 103 0.42 83 0.50 99
Mazda FE Engine
Four-Stage Full Free-Lift
GC040RG 0.62 123 0.56 111 0.39 76 0.47 92
GC050RG 0.62 123 0.55 108 0.39 76 0.47 93
14
Mazda F2 Engine
GC050RG/TG 0.68 134 0.60 118 0.42 83 0.50 99
GC060RG/TG 0.60 118 0.52 103 0.42 83 0.50 99
GC065RG/TG 0.60 118 0.52 102 0.42 83 0.50 99
Mazda F2 Engine
GC050RG/TG 0.61 121 0.55 108 0.42 83 0.50 99
GC060RG/TG 0.58 115 0.51 101 0.42 83 0.50 99
GC065RG/TG 0.58 115 0.51 101 0.42 83 0.50 99
Mazda F2 Engine
GC050RG/TG 0.65 127 0.57 113 0.42 83 0.50 99
GC060RG/TG 0.58 114 0.51 101 0.42 83 0.50 99
GC065RG/TG 0.58 114 0.50 99 0.42 83 0.50 99
15
Mazda F2 Engine
GC050RG/TG 0.69 135 0.60 119 0.39 76 0.47 93
GC060RG/TG 0.69 135 0.56 111 0.39 76 0.48 95
GC065RG/TG 0.69 135 0.53 105 0.39 76 0.48 95

GC050ZG 0.69 136 0.64 125 0.42 83 0.50 99
GC060ZG 0.60 119 0.55 109 0.42 83 0.50 99
GC065ZG 0.60 119 0.55 109 0.42 83 0.50 99

GC050ZG 0.62 122 0.57 113 0.42 83 0.50 99
GC060ZG 0.59 117 0.54 107 0.42 83 0.50 99
GC065ZG 0.59 117 0.54 106 0.42 83 0.50 99
16

GC050ZG 0.66 129 0.60 119 0.42 83 0.50 99
GC060ZG 0.58 115 0.54 106 0.42 83 0.50 99
GP065ZG 0.58 115 0.53 105 0.42 83 0.50 99

GC050ZG 0.70 137 0.64 126 0.39 76 0.47 93
GC060ZG 0.70 137 0.62 123 0.39 76 0.48 95
GC065ZG 0.70 137 0.62 122 0.39 76 0.48 95

GLP050RG/TG 0.68 133 0.59 117 0.42 83 0.50 99
GLP060RG/TG 0.59 117 0.52 102 0.42 83 0.50 99
GLP065RG/TG 0.59 117 0.51 101 0.42 83 0.50 99
17

GLP050RG/TG 0.61 120 0.54 107 0.42 83 0.50 99
GLP060RG/TG 0.58 114 0.51 100 0.42 83 0.50 99
GLP065RG/TG 0.58 114 0.50 99 0.42 83 0.50 99

GLP050RG/TG 0.65 127 0.57 112 0.42 83 0.50 99
GLP060RG/TG 0.57 113 0.50 99 0.42 83 0.50 99
GLP065RG/TG 0.57 113 0.50 99 0.42 83 0.50 99

GLP050RG/TG 0.68 134 0.59 117 0.39 76 0.47 93
GLP060RG/TG 0.68 134 0.58 114 0.39 76 0.48 95
GLP065RG/TG 0.68 134 0.57 112 0.39 76 0.48 95
18
GASOLINE/LPG ENGINES (EUROPEAN MODELS)

Mazda FE Engine
GP020RF 0.60 118 0.55 107 0.42 83 0.50 99
GP025RF 0.60 118 0.53 104 0.42 83 0.50 99
GP030RF 0.53 104 0.46 90 0.42 83 0.50 99
Mazda FE Engine
GP020RF 0.55 107 0.49 97 0.42 83 0.50 99
GP025RF 0.55 107 0.48 95 0.42 83 0.50 99
GP030RF 0.52 102 0.45 89 0.42 83 0.50 99
Mazda FE Engine
GP020RF 0.58 113 0.52 102 0.42 83 0.50 99
GP025RF 0.58 113 0.50 99 0.42 83 0.50 99
GP030RF 0.51 100 0.45 88 0.42 83 0.50 99
19
Mazda F2 Engine
GP020TF 0.66 130 0.60 117 0.42 83 0.50 99
GP025TF 0.66 130 0.58 114 0.42 83 0.50 99
GP030TF 0.58 114 0.50 99 0.42 83 0.50 99
Mazda F2 Engine
GP020TF 0.60 117 0.55 107 0.42 83 0.50 99
GP025TF 0.60 117 0.53 104 0.42 83 0.50 99
GP030TF 0.51 111 0.49 97 0.42 83 0.50 99
Mazda F2 Engine
GP020TF 0.63 123 0.57 112 0.42 83 0.50 99
GP025TF 0.63 123 0.56 109 0.42 83 0.50 99
GP030TF 0.56 110 0.49 96 0.42 83 0.50 99
20
GM 3.0L Engine (Gasoline Only - Includes Hydrostatic Trucks)

GP020TF 0.64 125 0.60 117 0.42 83 0.50 99
GP025TF 0.64 125 0.59 115 0.42 83 0.50 99
GP030TF 0.56 110 0.51 100 0.42 83 0.50 99

GP020TF 0.58 113 0.54 106 0.42 83 0.50 99
GP025TF 0.58 113 0.53 104 0.42 83 0.50 99
GP030TF 0.55 108 0.50 98 0.42 83 0.50 99

GP020TF 0.61 119 0.57 112 0.42 83 0.50 99
GP025TF 0.61 119 0.56 110 0.42 83 0.50 99
GP030TF 0.55 107 0.49 97 0.42 83 0.50 99
21
GM 3.0L Engine (LPG Fuel Only - Includes Hydrostatic Trucks)

GLP20TF 0.68 134 0.62 121 0.42 83 0.50 99
GLP25TF 0.68 134 0.60 117 0.42 83 0.50 99
GLP30TF 0.60 118 0.52 102 0.42 83 0.50 99

GLP20TF 0.62 121 0.56 110 0.42 83 0.50 99
GLP25TF 0.62 121 0.55 107 0.42 83 0.50 99
GLP30TF 0.59 115 0.51 100 0.42 83 0.50 99

GLP20TF 0.65 128 0.59 115 0.42 83 0.50 99
GLP25TF 0.65 128 0.57 112 0.42 83 0.50 99
GLP30TF 0.58 114 0.50 99 0.42 83 0.50 99
22
DIESEL ENGINES (EUROPEAN MODELS)

Mazda XA Engine
GDP20RF 0.61 119 0.55 108 0.42 83 0.50 99
GDP25RF 0.61 119 0.54 105 0.42 83 0.50 99
GDP30RF 0.53 104 0.46 91 0.42 83 0.50 99
Mazda XA Engine
GDP20RF 0.55 107 0.50 98 0.42 83 0.50 99
GDP25RF 0.55 107 0.49 96 0.42 83 0.50 99
GDP30RF 0.52 102 0.46 90 0.42 83 0.50 99
Mazda XA Engine
GDP20RF 0.58 113 0.53 103 0.42 83 0.50 99
GDP25RF 0.58 113 0.51 100 0.42 83 0.50 99
GDP30RF 0.52 101 0.45 89 0.42 83 0.50 99
23
Torque Specifications 8000 YRM 708
Mazda HA Engine (Includes Hydrostatic Models)

GDP20TF 0.61 120 0.56 110 0.42 83 0.50 99
GDP25TF 0.61 120 0.55 108 0.42 83 0.50 99
GDP30TF 0.53 104 0.48 95 0.42 83 0.50 99

GDP20TF 0.56 110 0.52 102 0.42 83 0.50 99
GDP25TF 0.56 110 0.51 100 0.42 83 0.50 99
GDP30TF 0.56 110 0.47 93 0.42 83 0.50 99

GDP20TF 0.56 110 0.51 100 0.42 83 0.50 99
GDP25TF 0.56 110 0.50 99 0.42 83 0.50 99
GDP30TF 0.51 100 0.46 91 0.42 83 0.50 99
Torque Specifications
FRAME Cowl-to-Overhead Guard Legs
66 N•m (49 lbf ft)
Overhead Guard Mount
66 N•m (49 lbf ft) Counterweight
555 N•m (409 lbf ft)
Operator Compartment Mount
53 N•m (39 lbf ft)
24
8000 YRM 708 Torque Specifications
BRAKE SYSTEM Axle Mounts GC040-065RG/TG

Torque Wrench on Head of Bolt 780 N•m (575 lbf ft)
Wheel Cylinder Capscrews Torque Wrench on Nut of Bolt 715 N•m (527 lbf ft)
18 to 27 N•m (159 to 239 lbf in)
Axle Mounts GP20-30RF/TF
Back Plate-to-Axle Mount Capscrews (GP040-060RG/TG/ZG)
GC040-065RG/TG 255 N•m (188 lbf ft) Torque Wrench on Head of Bolt 540 N•m (400 lbf ft)
GP20-30RF/TF (GP040-060RG/TG/ZG) Torque Wrench on Nut of Bolt 473 N•m (350 lbf ft)
225 N•m (166 lbf ft)
Spindle-to-Differential Housing Capscrews
MAST GP20-30RF/TF (GP040-060RG/TG/ZG)
Only 66 N•m (50 lbf ft)
Lift Cylinder Mount Bolts
53 N•m (40 lbf ft) Axle Housings to Differential Housing
GC040-065RG/TG Only 90 N•m (66 lbf ft)
Mast Pivot Capscrews
90 N•m (66 lbf ft) Differential Housing to Diff. Adapter Housing
GC040-065RG/TG Only 38 N•m (28 lbf ft)
STEERING SYSTEM
Axle Shaft Capscrews
Axle Mount Capscrews GC040-065RG/TG 90 N•m (66 lbf ft)
88 N•m (65 lbf ft) GP20-30RF/TF (GP040-060RG/TG/ZG)
98 N•m (72 lbf ft)
Steering Cylinder Mount
GC040-065RG/TG 121 N•m (89 lbf ft) Wheel Nuts
GP20-30RF/TF (GP040-060RG/TG/ZG) GC040-065RG/TG 237 to 305 N•m (175 to 225 lbf ft)
490 to 510 N•m (361 to3760 lbf ft)
Tie Rods GC040-065RG/TG Only
163 N•m (120 lbf ft) Wheel Bearing Lock Nuts
Lower Spindle Cap GC040-065RG/TG Only 205 N•m (150 lbf ft) initial
Kingpin Nut GP20-30RF/TF 35 N•m (25 lbf ft) final
(GP040-060RG/TG/ZG) Only GC040-065RG/TG 205 N•m (150 lbf ft) initial
90 N•m (66 lbf ft) initial GC040-065RG/TG 35 N•m (25 lbf ft) final
34 N•m (25 lbf ft) final GC040-065RG/TG Newer Models 68 N•m
(50 lbf ft) initial
Wheel Bearings GC040-065RG/TG Newer Models 3 N•m
200 N•m (150 lbf ft) initial (27 lbf in) final
34 N•m (25 lbf ft) final
TRANSMISSION AND DIFFERENTIAL
Wheel Nuts GP20-30RF/TF
(GP040-060RG/TG/ZG) Only Control Valve Capscrews
Two-Piece Wheels 237 to 305 N•m (175 to 225 lbf ft) 19 N•m (168 lbf in)
Three-Piece Wheels 155 N•m (115 lbf ft)
Front Cover Capscrews
DRIVE AXLE 38 N•m (28 lbf ft)
Back Plate-to-Axle Mount Capscrews Torque Converter Drive Plate Capscrews

GC040-065RG/TG 255 N•m (188 lbf ft) GC040-065RG/TG 38 N•m (28 lbf ft)
GP20-30RF/TF (GP040-060RG/TG/ZG) GP20-30RF/TF (GP040-060RG/TG/ZG)
225 N•m (166 lbf ft) 45 N•m (33 lbf ft)
Torque Converter Housing

25
Torque Specifications 8000 YRM 708
Torque Converter Housing-to-Engine Capscrews Engine Mount Capscrew

GC040-065RG/TG Only 59 N•m (44 lbf ft) 66 N•m (49 lbf ft)
Transmission Housing-to-Engine Capscrews Exhaust Manifold

GP20-30RF/TF (GP040-060RG/TG/ZG) Only 22 to 29 N•m (195 to 257 lbf in)
M10 Capscrews 38 N•m (28 lbf ft)
M12 Capscrews 66 N•m (49 lbf ft) Flywheel
206 to 226 N•m (152 to 166 lbf ft)
Differential Bearing Lock Plate
GC040-065RG/TG Only 19 N•m (168 lbf ft) Flywheel Housing
M10 Capscrews 41 to 49 N•m (30 to 36 lbf ft)
Differential Bearing Caps M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft)
GP20-30RF/TF (GP040-060RG/TG/ZG) Only
175 N•m (129 lbf ft) Fuel Pump
16 to 22 N•m (141 to 195 lbf in)
Differential Adaptor to Transmission and
to Differential Housing Intake Manifold
GC040-065RG/TG Only 38 N•m (28 lbf ft) 19 to 31 N•m (168 to 274 lbf in)
Differential Case Main Bearing Cap

GP20-30RF/TF (GP040-060RG/TG/ZG) 84 to 90 N•m (62 to 66 lbf ft)
Oil Pan
Pinion Nut 7 to 12 N•m (62 to 106 lbf in)
750 N•m (553 lbf ft)
Oil Pump
Ring Gear Bolts M8 Capscrews 19 to 26 N•m (168 to 230 lbf in)
GC040-065RG/TG 111 N•m (82 lbf ft) M10 Capscrews 38 to 53 N•m (28 to 39 lbf ft)
Rocker Cover
142 N•m (105 lbf ft)
6 to 8 N•m (52 to 70 lbf in)
Thrust Bolt Lock Nut
Rocker Shaft Assembly
68 to 95 N•m (50 to 70 lbf ft)
18 to 27 N•m (159 to 239 lbf in)
ENGINE - MAZDA FE AND F2 Spark Plugs
15 to 23 N•m (133 to 204 lbf in)
Camshaft Pulley Lock Bolt
48 to 66 N•m (35 to 49 lbf ft) Starter
66 to 79 N•m (49 to 58 lbf ft)
Cooling Fan
8 to 11 N•m (71 to 97 lbf in) Thermostat Cover
Mazda FE 12 to 18 N•m (106 to 159 lbf in)
Connecting Rod Cap
Mazda F2 19 to 31 N•m (14 to 23 lbf ft)
Mazda FE 51 to 56 N•m (38 to 41 lbf ft)
Mazda F2 66 to 70 N•m (48 to 51 lbf ft) Timing Belt Cover
Mazda FE
Crankshaft Pulley
Upper Capscrews 8 to 12 N•m (71 to 106 lbf in)
12 to 17 N•m (80 to 115 lbf in)
Lower Capscrews 7 to 8 N•m (62 to 71 lbf in)
Cylinder Head Mazda F2
Cold Upper Capscrews 7 to 10 N•m (62 to 89 lbf in)
81 to 88 N•m (60 to 65 lbf ft) Lower Capscrews 7 to 10 N•m (62 to 89 lbf in)
Hot
Timing Tension Lock Bolt
95 to 100 N•m (70 to 74 lbf ft)
Mazda FE 20 to 35 N•m (15 to 26 lbf ft)
Engine Mount to Engine Mazda F2 38 to 53 N•m (28 to 39 lbf ft)
55 N•m (40 lbf ft)
26
8000 YRM 708 Torque Specifications
Water Pump Exhaust Manifold

19 to 26 N•m (168 to 230 lbf in) 18 to 22 N•m (159 to 195 lbf in)
ENGINE - GM 3.0L Flywheel

206 to 226 N•m (152 to 167 lbf ft)
Cylinder Head Capscrews
122 N•m (90 lbf ft) Flywheel Housing
M10 Capscrews 41 to 49 N•m (30 to 36 lbf ft)
Main Bearing Capscrews M14 Capscrews 114 to 136 N•m (84 to 100 lbf ft)
90 N•m (66 lbf ft)
Glow Plug
Connecting Rod Cap Nuts 10 to 15 N•m (89 to 133 lbf in)
50 N•m (37 lbf ft)
Injection Pump Drive Gear
Crankshaft Pulley Capscrews 40 to 70 N•m (30 to 52 lbf ft)
44 N•m (32 lbf ft)
Intake Manifold
Flywheel 16 to 24 N•m (142 to 212 lbf in)
107 N•m (79 lbf ft)
Main Bearing Cap
Torque Converter Drive Plate 110 to 117 N•m (81 to 86 lbf ft)
45 N•m (33 lbf ft)
Oil Pan
Starter Capscrews 16 to 24 N•m (142 to 212 lbf in)
44 N•m (32 lbf ft)
Rear Oil Seal
Torque Converter Housing 15 to 20 N•m (133 to 177 lbf in)
44 N•m (32 lbf ft)
Rocker Cover
Fan Capscrews 2.7 to 4.1 N•m (24 to 36 lbf in)
19 N•m (168 lbf in)
Rocker Shaft Assembly
ENGINE - MAZDA XA AND HA DIESEL 118 to 125 N•m (87 to 92 lbf ft)
Camshaft Gear Starter

64 to 95 N•m (47 to 69 lbf ft) 66 to 79 N•m (49 to 58 lbf ft)
Camshaft Thrust Plate Timing Gear Cover

16 to 24 N•m (12 to 18 lbf ft) 16 to 24 N•m (142 to 212 lbf in)
Cooling Fan Torque Converter Housing Adapter

16 to 24 N•m (12 to 18 lbf in) (GDP040RG Only)
43 to 51 N•m (32 to 38 lbf ft)
Connecting Rod Cap
82 to 90 N•m (60 to 66 lbf ft) Torque Converter Housing (GDP040RG Only)
41 N•m (30 lbf ft)
Crankshaft Pulley
343 to 392 N•m (253 to 289 lbf ft) Water Pump
16 to 24 N•m (142 to 212 lbf in)
Cylinder Head
118 to 125 N•m (87 to 92 lbf ft)
Engine Mount to Engine

55 N•m (40 lbf ft)
27
NOTES
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28
Yale Europe Materials Handling Limited
Flagship House, Reading Road North, Fleet, Hampshire GU138 HR United Kingdom
8000 YRM 708 1/11 (10/04)(1/04)(12/03)(1/03)(9/02)(8/02)(6/02)(2/02) Printed in the United Kingdom

Capacities and Specifications: Maintenance

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Maintenance

PART NO. 524158901 8000 YRM 708

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

• Wear safety glasses.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

Lift Truck Weights ................................................................................................................................................ 1

This section is for the following models:

GP/GLP/GDP20-30RF/TF (GP/GLP/GDP040-060RG/TG/ZG) [A875];

©2011 Yale Materials Handling Corp. i

Lift Truck Weights

Transmission Oil Pressures

Item Mazda FE Mazda F2 GM 3.0L

GM 3.0L Engine (Gasoline Only)

GM 3.0L Engine (Gasoline Only)

GM 3.0L Engine (Gasoline Only)

GM 3.0L Engine (LPG Fuel Only)

GM 3.0L Engine (LPG Fuel Only)

GM 3.0L Engine (LPG Fuel Only)

DIESEL ENGINES (US MODELS)

GASOLINE/LPG ENGINES (US MODELS)

GM 3.0L Engine (Gasoline Only)

GM 3.0L Engine (Gasoline Only)

GM 3.0L Engine (Gasoline Only)

GM 3.0L Engine (Gasoline Only)

GM 3.0L Engine (LPG Fuel Only)

GM 3.0L Engine (LPG Fuel Only)

GM 3.0L Engine (LPG Fuel Only)

GM 3.0L Engine (LPG Fuel Only)

GASOLINE/LPG ENGINES (EUROPEAN MODELS)

GM 3.0L Engine (Gasoline Only - Includes Hydrostatic Trucks)

GM 3.0L Engine (Gasoline Only - Includes Hydrostatic Trucks)

GM 3.0L Engine (Gasoline Only - Includes Hydrostatic Trucks)

GM 3.0L Engine (LPG Fuel Only - Includes Hydrostatic Trucks)

GM 3.0L Engine (LPG Fuel Only - Includes Hydrostatic Trucks)

GM 3.0L Engine (LPG Fuel Only - Includes Hydrostatic Trucks)

DIESEL ENGINES (EUROPEAN MODELS)

Mazda HA Engine (Includes Hydrostatic Models)

Mazda HA Engine (Includes Hydrostatic Models)

Mazda HA Engine (Includes Hydrostatic Models)

BRAKE SYSTEM Axle Mounts GC040-065RG/TG

Back Plate-to-Axle Mount Capscrews Torque Converter Drive Plate Capscrews

Torque Converter Housing

Torque Converter Housing-to-Engine Capscrews Engine Mount Capscrew

Transmission Housing-to-Engine Capscrews Exhaust Manifold

Differential Case Main Bearing Cap

Water Pump Exhaust Manifold

ENGINE - GM 3.0L Flywheel

Camshaft Gear Starter

Camshaft Thrust Plate Timing Gear Cover

Cooling Fan Torque Converter Housing Adapter

Engine Mount to Engine

8000 YRM 708 1/11 (10/04)(1/04)(12/03)(1/03)(9/02)(8/02)(6/02)(2/02) Printed in the United Kingdom

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