Page 1

GDP80DC, GDP90DC, GDP100DC, GDP100DCS, GDP120DC (GDP190DC, GDP210DC, GDP230DC, GDP230DCS, GDP250DC, GDP280DC) (F876); GDP130EC, GDP140EC, GDP160EC (GDP300EC, GDP330EC, GDP360EC) (F877) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

OPERATOR'S CAB........................................................................................................ CAB HEATER................................................................................................................. FRAME............................................................................................................................ CUMMINS ENGINE FAULT CODE GUIDE.................................................................... COOLING SYSTEM........................................................................................................ ZF TRANSMISSION OPERATION AND DIAGNOSTICS............................................... TRANSMISSION REPAIR (ZF-WG161)......................................................................... DIFFERENTIAL............................................................................................................... PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. STEERING SYSTEM...................................................................................................... BRAKE AND HYDRAULIC COOLING SYSTEM........................................................... HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC CONTROL SYSTEM................................................................................. ELECTRICAL SYSTEM.................................................................................................. 2-STAGE MAST.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... ASSEMBLY GUIDE........................................................................................................ DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS...........................................................................

550033400 550033398 550061801 524211827 550061806 550035502 550035503 524150779 524150780 550035504 550035505 550035506 550035498 550061811 550088524 524150797 524230692 550061816 550061821 550061826

0100 YRM 1390 0100 YRM 1459 0100 YRM 1594 0600 YRM 1101 0700 YRM 1595 1300 YRM 1455 1300 YRM 1456 1400 YRM 0046 1400 YRM 0944 1600 YRM 1479 1800 YRM 1498 1900 YRM 1478 2200 YRM 1481 2200 YRM 1592 4000 YRM 1647 8000 YRM 0231 8000 YRM 1181 8000 YRM 1591 8000 YRM 1593 8000 YRM 1596

11/13 08/12 08/12 07/14 09/13 09/13 08/12 08/12 08/12 08/12 03/13 11/14 08/12 09/13 05/14 10/13 12/14 10/13 07/12 07/13

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 550061831 (12/14)


0100 YRM 1459

MCC Heater and Air Conditioner

MCC Heater and Air Conditioner HEATER SYSTEM General Lift trucks with a closed cab are equipped with a heater assembly which is installed on the underside of the cab. The main components of the heater assembly are the fan, heater core, vent door, and an evaporator for the optional air conditioning system. See Figure 1.

Cabs that are equipped with an air conditioner have an electrically controlled vent door that can be used to vary the percentage of recirculated air between 0 and 100 percent. The operator can select the position of the vent door by turning a knob on the dashboard. Cooling performance increases by reducing the percentage of incoming fresh air. Recirculated air enters the heater assembly through the openings in the side console at the fuse cover. Fresh air enters the heater assembly through the cab air filter, which is located at the left rear corner of the cab. As the filter becomes restricted or clogged, the percentage of recirculated air will increase and the percentage of fresh air will decrease. When fresh air content and fan speed is increased, positive air pressure is created in the cab, preventing dust from entering the cab. The air pressure escapes through the cab door posts and through openings in the pedal area and sliding window brush profiles.

A. RECIRCULATED AIR B. FRESH AIR ENTRY C. CAB AIR FLOW 1. 2. 3. 4. 5. 6. 7. 8.

VENT DOOR VENT DOOR ACTUATOR EVAPORATOR CORE HEATER CORE BLOWER THERMOSTAT WATER VALVE EXPANSION VALVE Figure 1. Heater/Airco Assembly Components

The vent door determines the percentage of fresh air and recirculated air that the fan pulls through the heater assembly. In heater assemblies without an air conditioner, the vent door is in a fixed position and allows for an air mixture of 85% fresh air and 15% recirculated air.

When the fan is switched ON, air is pushed through channels in the cab floor to the air ducts at the front window. Cabs that are equipped with an air conditioner have three additional vents at the foot area that can be opened or closed. Cooling capacity is increased by opening the three vents. When the three vents are open, air flow is less restricted, increased air volume passes through the evaporator, and the majority of the air no longer becomes warm in the air channels that lead to the front window. See Figure 2. The heater consists of a heater core and a water valve. See Figure 1. The water valve controls the flow of heated coolant to the heater core. By varying the opening of the water valve, the desired amount of heat is transferred by the heater core to the air that enters the cab. The water valve opens proportionally to the selected position of the heat control knob. On standard units the knob and valve are connected mechanically, on units with an Air Conditioning system there is an electronic connection.

1


MCC Heater and Air Conditioner

0100 YRM 1459 that are connected in series. The operator must switch ON the button for the air conditioning system and select one of the fan switch speeds. Refer to the electrical schematic SRM pertaining to each lift truck, for the schematic locations and interconnections of the sensors and switches. The compressor compresses the refrigerant and continuously pumps the refrigerant through the air conditioning system. As the refrigerant is being compressed, the refrigerant temperature will rise. The absorbed heat is dissipated in the condenser, which is installed outside the cab. Fans at the condenser accelerate heat dissipation.

A. B. C. D.

OPTIONAL AIR VENT AIR TO FRONT WINDOW CAB AIR FLOW FRESH AIR ENTRY

1. CAB AIR FILTER Figure 2. Ventilation

AIR CONDITIONING General

CAUTION Replacement, installation, and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid may only be performed by a certified technician. The air conditioning system consists of a compressor with an electromagnetic clutch, condenser, dryer, evaporator, and interconnected sensors and switches. See Figure 3. The engine drives the compressor when the clutch at the compressor has been activated. Activation of the clutch is determined by several sensors and switches

2

After the refrigerant passes through the condenser, the liquefied refrigerant passes through the dryer that also serves as a reservoir for the refrigerant. At the expansion valve, the refrigerant will expand in the evaporator, causing the temperature of the refrigerant to drop substantially. The expansion valve regulates the flow of the refrigerant, depending on the pressure difference between the dryer and the compressor inlet. A minimum pressure difference is necessary to open the valve. After leaving the evaporator, the refrigerant will reenter the compressor.

Dryer The refrigerant functions as a coolant, and contains lubricant for the compressor. Because humidity affects the properties of the refrigerant and the lubricant, a dryer is installed to absorb the trapped humidity. The dryer also filters impurities in the refrigerant. Normal refrigerant leakage is approximately 10% per year. To help prevent additional leakage through the compressor seals, the air conditioning system should be operated at least every two weeks for 15 minutes. The air conditioning system cannot be operated at temperatures below 0°C (32°F) because the anti-ice switch will prevent the compressor clutch from being activated. The dryer, refrigerant, and lubricant must be replaced every three years. Contact a certified technician every three years to perform these repairs.


0100 YRM 1459

1. 2. 3. 4. 5.

MCC Heater and Air Conditioner

CONDENSER SERVICE CONNECTION, HIGH PRESSURE COMPRESSOR SERVICE CONNECTION, LOW PRESSURE ANTI-ICE SENSOR

6. 7. 8. 9. 10.

EVAPORATOR EXPANSION VALVE RESERVOIR DRYER PRESSURE SWITCH

Figure 3. Refrigerant Cycle

Compressor Lubrication The oil specification for the compressor is indicated on the nameplate of the compressor. Most of the compressors used on Big Truck air conditioning systems use SP-15 oil. The compressor on QSM-11 engines requires ZXL 100PG oil.

Control Systems, Sensors, and Switches The air conditioning system (A/C) is activated by pushing the A/C switch on the dashboard and selecting one of the fan speeds. A control light in the A/C switch will illuminate, and the fans on the condenser will turn. The anti-ice switch and the pressure switches must be closed before the clutch engages the compressor. If the anti-ice switch or one

of the pressure switches is open, the clutch will disengage and the air conditioning system will not activate. Water in the air condensates on the evaporator. Normally, the condensated water drips on the bottom plate of the heater assembly and escapes through two hoses that open into the engine compartment. If the condensated water becomes ice, the air flow through the evaporator will be blocked, which will block the entire cab ventilation system. The anti-ice switch protects the evaporator against ice buildup by opening at -1째C (30.2째F), causing the clutch to disengage and allowing air to warm the evaporator. The anti-ice switch, which is inserted between the fins of the evaporator, will close when the temperature reaches 2.3째C (36.14째F). The anti-ice sensor is indicated by "T" on the electrical schematic.

3


MCC Heater and Air Conditioner The pressure switches are located at the dryer, and protect the system against pressures that are too low or too high. See Figure 4. If the system pressure drops below 2 bar (29 psi), the refrigerant level is too low for proper functioning of the system and proper lubrication of the compressor.

0100 YRM 1459

CAUTION NEVER bypass the electric clutch of the air conditioning compressor. If the clutch does not receive a signal, there is either an insufficient amount of refrigerant, or the condenser or the evaporator is iced, and the pressure switch will not be enabled to protect the system against excessive pressure. If the clutch does not receive a signal, contact a certified and qualified air conditioning specialist. Bypassing the compressor will ALWAYS lead to system damage. The pressure switch, as installed on the dryer, physically combines the high and low pressure switches and their electrical interconnection. The pressure switch is indicated by "P1" on the electrical schematic. The pressure switch has an integrated third function called the medium pressure switch. The medium pressure switch changes the connection to the fans on the condenser, causing them to turn at a higher speed when pressure in the system has exceeded 16 bar (232 psi). At lower pressures, the fans are connected in series, causing them to turn at a lower speed. The medium pressure switch is indicated by "P2" on the electrical schematic.

1. 2. 3. 4. 5. 6.

CONDENSER COVER CONDENSER COIL SIGHT GLASS DRYER PRESSURE SWITCH FAN Figure 4. Condenser

High system pressure is a recurrent situation. The evaporator valve has a limited flow capacity. The refrigerant flow generated by the compressor fluctuates with engine speed, and regularly exceeds the flow capacity of the evaporator valve. When the flow capacity of the evaporator valve is exceeded, the compressor will have raised system pressure to the maximum allowable level. The pressure switch will send a signal to disengage the compressor clutch, and the evaporator valve will continue to regulate refrigerant flow. Pressure will drop until the pressure switch is enabled, causing the clutch to reengage. System pressure will rise again until the maximum allowable level has been reached.

4

CLIMATE CONTROL Description Functionality of the individual components of the normal air conditioning systems and the Climate Control system is the same. The difference is that for the Climate Control a controller sends the signals to the components instead of the manually operated knobs on the dashboard for the normal system. This Controller is part of the control unit on the dashboard that also has a display and a select button. The display provides information on mode, temperature, blower speed and fault conditions. An explanation of the normally available information and settings is in the Operating Manual. The explanation for how to read information and apply settings for service purposes is described under Service Menu.


0100 YRM 1459

MCC Heater and Air Conditioner

Service Menu 1. Push the Power Button to turn the HVAC unit ON. See Figure 5. 2. Pressing the Set Button scrolls the screen between: •

Climate Control Mode Settings

Air Circulation Settings

Display Settings

The date format is Month/Day/Year. To set the date, go to Set Up screen and push the Set Button until it flashes digital for "Month". Turn the Set Button until the correct month number appears and push the button to confirm. The digits for "Day" will now flash. Repeat the procedure to set "Day" and "Year". When finished, turn the knob to scroll to the Exit screen and push the button to leave the service menu.

View 1 and View 2 There are two View pages that show readings and actual setting of the HVAC unit. After leaving the previous service screen "Set Up", screen View 1 will appear. Push the button to scroll between screen View 1 and screen View 2 (see Figure 6). Screen "View 1" displays below information:

1. POWER BUTTON

2. SET BUTTON

Figure 5. Climate Control 3. Press the set button to scroll to the Air Circulation Settings. 4. Push and hold the Power Button, and turn the Set Button three clicks clockwise to enter one of the service menu selections: •

Set Up (Not an option for Hyster Lift trucks)

View

Error List

Statistics

Exit

To scroll to a next service screen, turn the Set Button one click clockwise. Push the Set Button to enter the selected service screen. Turning the Set Button after the Exit screen further clockwise will bring you back to the Set Up screen. To leave the Service Menu scroll to Exit and push the Set Button.

Set Up The Set Up screen allows setting the date and the blower speed for an additional interior heater. An additional interior heater is not a standard option.

Scale - Selected temperature scale: Cel for Celsius or Fah for Fahrenheit.

Setpoint - Selected (desired) interior temperature.

Inside - Cab interior temperature as measured by the Inside Sensor.

Outside - Cab exterior temperature as measured by the Outside Sensor.

Deice - Temperature of the refrigerant leaving the evaporator coil.

Coil - Temperature of the air at the blower.

Heat - Flapper door position: Fresh or Recirc.

Screen "View 2" displays below information: •

AC - Indicates whether Air conditioning Mode is switched ON or OFF.

Heater - Indicates whether Heating Mode is switched ON or OFF.

Blower - Indicates the selected percentage of maximum blower speed.

D Heat Fan - Indicates the selected blower speed percentage for an additional interior heater.

Valve - Indicates the percentage of maximum heater valve opening that the controller sends out as a signal.

Contrast - Indicates the contrast percentage of the display.

Brightness - Indicates the brightness percentage of the display.

5


MCC Heater and Air Conditioner

0100 YRM 1459

In case a temperature sensor is disconnected, the display will show "open". Comparison of the different values may provide an indication for a possible defect.

Figure 8. Climate Control Error Display

Figure 6. Climate Control View Display

Error List The Main Display shows a warning sign in the left hand bottom corner of the Main Display if a fault occurs. See Figure 7.

To further establish the cause of failure, see Temperature Sensors or Water Valve. To reset the number of occurrences and the reset date, turn the Set Button one click in a counter clockwise direction and push the Set Button for a dialog box. When the dialog box is shown, press the Set Button once to reset all values.

Statistics The Statistics page shows operating hours and cycle times since the last reset date. To reset the Statistics Page, go to the Error Page, turn the Set Button one click counter clockwise. A dialog box will appear. When the dialog box is shown, press the Set Button once to reset all values. See Figure 9.

1. WARNING SIGN Figure 7. Climate Control Warning The Error List page shows for each of the temperature sensors and for the water valve the number of occurrences that the connection was shortened or open since the last reset date. For the Water Valve there is an additional indication for the number of times that the Water Valve was stuck. See Figure 8.

6

Figure 9. Climate Control Statistics Display


0100 YRM 1459

MCC Heater and Air Conditioner

Exit

Table 1. Sensor Resistance Values (Continued)

To leave the Service menu scroll to Exit and push the Set Button.

Temperature Sensors In addition to the normally present de-ice temperature sensor in the evaporator, there are three further temperature sensors that influence the reaction of the controller: •

Outside Temperature Sensor, which is located outside the cab under the condenser.

Coil sensor, which is located behind the evaporator and heater coil, in the suctioned air flow of the blower fan.

Inside Sensor, which is located in the side console, measures the cab interior temperature. Interior air flow past the sensor is through a tube that connects between suction side of the blower fan and inside sensor.

Troubleshooting Disconnect the sensor for which an error has been indicated. Use an Ohm meter to measure its resistance. See Table 1 that provides an overview of the resistance value for different temperatures. The electrical properties of the four sensors are the same. When the sensor itself shows no defects, check continuity of the wiring harness. See Figure 10. The sensors are connected to the controller connector at the following pin numbers:

°C

°F

k?

15

59

15,713

20

68

12,493

25

77

10,000

30

86

8,056

Water Valve Fault indication "Valve Stuck" indicates a physical obstruction that prevents the valve from moving. The physical obstruction may have its cause at the outside or inside of the water valve. The components of the water valve are not serviced separately. Replace the water valve if there is no obvious problem that can be rectified.

Troubleshooting When a fault for open or short circuit has been indicated, use a volt meter to measure the voltage over the different connections. Measures can be taken at either the connector of the water valve or at the controller connector. See Table 2. There are also two 15 amp fuses located in the wiring system check these if a fault for open or short circuit has been indicated. For location of theses fuses see Figure 11. Table 2. Water Valve Pin Outs Water Valve

Controller

Value

Inside Sensor: Pin 14 and 32.

Pin 8

Pin 31

ground

Outside Sensor: Pin 4 and 33

Pin 10

Pin 30

3.3 Volt

De-Ice Sensor: Pin 13 and 24

Pin 9

Pin 5

Coil Sensor: Pin 12 and 34

0.6 Volt when valve is closed. 2.2 Volt when valve is open.

Pin 6

Pin 18

12 Volt when the valve is closing. 0 Volt when opening or not moving.

Pin 5

Pin 19

12 Volt when the valve is opening. 0 Volt when closing or not moving.

Table 1. Sensor Resistance Values °C

°F

k?

0

32

32,649

5

41

25,394

10

50

19,903

7


MCC Heater and Air Conditioner

Figure 10. Climate Control Wiring Diagram

8

0100 YRM 1459


0100 YRM 1459

MCC Heater and Air Conditioner

1. 15A FUSES

9


MCC Heater and Air Conditioner

0100 YRM 1459 Figure 11. Standard A/C Wiring Diagram

STANDARD HEATER ASSEMBLY Access

WARNING Make sure no one is under cab when raising or lowering cab.

WARNING Before placing any part of your body under cab, always make sure the cab is fully tilted, or when partially open, is locked using the tilt latch. To access the heater assembly, raise the cab to the fully open position. Support the heater assembly, then remove the three screws holding the heater assembly in place. Lower the heater assembly down, remove screws and the cover plate. Individual components are now accessible.

Remove

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns. 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Fuse Panel and Cover Location. 2. Remove the heat control knob at the instrument panel top console. See Switch Locations. 3. Remove the nut that retains the rotary control to the instrument panel top console. See Figure 12. 4. Remove the rotary control assembly for the water valve from the underside of the instrument panel top console and place it with the cable on the heater assembly. 5. Disconnect the wire harness from the fan speed knob at the underside of the instrument panel top console.

10

1. 2. 3. 4. 5.

CABLE CLIP EXTENDED CABLE (FULL HOT POSITION) NUT KNOB LOCATION ROTARY CONTROL Figure 12. Rotary Control

WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 6. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 7. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. 8. Tag and disconnect the two heater hoses from the heater inlet and outlet ports, and plug the heater hoses and ports. See Figure 13.


0100 YRM 1459

MCC Heater and Air Conditioner 3. Support the heater assembly and install the capscrews to retain the heater assembly to the hinge brackets. Do not tighten capscrews at this time. 4. Swing the heater assembly up toward the cab and install the three capscrews to retain the heater assembly to the cab. See Figure 13 for the location of the capscrews. 5. Tighten the two capscrews at the hinge bracket. 6. Remove the plugs and connect the heater hoses to the inlet and outlet ports.

1. 2. 3. 4.

HEATER HINGE BRACKET HEATER ASSEMBLY CAPSCREW LOCATION HEATER OUTLET HEATER INLET Figure 13. Heater Assembly

7. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 8. Connect the outer cable to the rotary control as described in the section Push/Pull Cable Replacement, Water Valve Cable, Install.

NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab.

9. Connect the inner cable to the rotary control as described in the section Push/Pull Cable Replacement, Heater/Air Conditioner Assembly, Install.

9. Loosen the two nuts and capscrews at the hinge bracket. Remove the three capscrews that retain the heater assembly to the cab. Pull the heater assembly downwards and push simultaneously towards the hinge bracket to provide sufficient clearance between heater assembly and cab frame. See Figure 13 for the location of the capscrews.

10. Connect the wire harness for the fan speed knob to the connector at the underside of the instrument panel top console.

10. Make sure the wire harness and the cable control are free and can be removed together with the heater assembly.

11. Install the rotary control assembly for the water valve to the underside of the instrument panel top console. 12. Install the nut to retain the rotary control to the instrument panel top console. See Figure 12. 13. Install the heat control knob at the instrument panel top console. See Switch Locations.

11. Support the heater assembly and remove the capscrews that retain the heater assembly to the hinge brackets.

14. Position the fuse panel cover to the right side of the instrument panel and install the four screws. See Fuse Panel and Cover Location.

12. Remove the heater assembly from the underside of the cab.

15. If required, fill the coolant to the correct level. Refer to the manual .

Install

16. Start the engine and warm the engine to normal operating temperature.

1. Position the heater assembly to the underside of the cab.

17. Make sure the heater functions correctly.

2. Route the cable harness and cable control correctly to the inside of the instrument panel box.

11


MCC Heater and Air Conditioner

STANDARD HEATER PARTS REPLACEMENT Heater Core Remove

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.

0100 YRM 1459 6. Remove the top cover from the heater assembly. 7. Loosen the hose clamp and disconnect the top heater hose from the heater core, located between the heater core and the water valve. See Figure 14. 8. Remove the two capscrews that retain the heater core bracket to the inside of the heater assembly. See Figure 15.

WARNING When replacing the heater hoses, make sure the replacement hoses meet correct specifications. Failure to meet specifications may cause personal injury.

WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 1. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 2. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab.

1. 2. 3. 4. 5.

BOTTOM HEATER HOSE WATER VALVE TOP HEATER HOSE HEATER CORE HOSE CLAMP Figure 14. Heater Water Valve

3. Loosen the hose clamp and disconnect the heater inlet hose from the heater core pipe located at the underside of the heater assembly and plug the heater hose. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 4. Loosen the two nuts and capscrews at the hinge bracket. Remove the three capscrews that retain the heater assembly to the cab. Pull the heater assembly downwards and push simultaneously towards the hinge bracket to provide sufficient clearance between heater assembly and cab frame. See Figure 13 for the location of the capscrews. 5. Remove the 10 screws that retain the top cover to the heater assembly. Figure 15. Heater Assembly Components 12


0100 YRM 1459 Legend for Figure 15 1. 2. 3. 4. 5.

HEATER CORE BLOWER WATER VALVE HEATER CORE BRACKET HEATER CORE BRACKET CAPSCREWS

9. Remove the heater core bracket from the heater assembly. 10. Slide the heater core out of the heater assembly.

MCC Heater and Air Conditioner NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 2. Remove the three capscrews that retain the heater assembly to the cab and swing the heater assembly down. See Figure 13 for the location of the capscrews. 3. Remove the 10 screws that retain the top cover to the heater assembly.

Install

4. Remove the top cover from the heater assembly.

1. Slide the heater core into the heater assembly.

5. Tag and disconnect the electrical connector connected to the blower assembly. See Figure 16.

2. Position the heater core bracket to the inside of the heater assembly and install the two retaining capscrews.

6. Remove the four screws that retain the blower to the heater assembly housing. See Figure 17.

3. Connect the top heater hose to the heater core and tighten the hose clamp. 4. Position the top cover on the heater assembly. 5. Install the 10 screws to retain the top cover to the heater assembly. 6. Swing the heater assembly up toward the cab and install the three capscrews to retain the heater assembly to the cab. See Figure 13 for the location of the capscrews. 7. Connect the heater inlet hose to the heater core pipe located at the underside of the heater assembly and tighten the hose clamp. 8. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 9. Add coolant as needed. Refer to the manual . 10. Start the engine and check for leaks. Add coolant as needed. 11. Make sure the heater functions correctly.

Blower

1. ELECTRICAL CONNECTOR Figure 16. Blower Electrical Connector

Remove 1. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab.

13


MCC Heater and Air Conditioner

0100 YRM 1459 3. Install the four screws to retain the blower to the heater assembly housing. See Figure 17. 4. Connect the electrical connector to the blower assembly. See Figure 16. 5. Position the top cover on the heater assembly. 6. Install the 10 screws to retain the top cover to the heater assembly. 7. Swing the heater assembly up toward the cab and install the three capscrews to retain the heater assembly to the cab. See Figure 13 for the location of the capscrews.

1. BLOWER RETAINING CAPSCREWS Figure 17. Blower Retaining Screws

8. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 9. Make sure the blower functions correctly.

7. Partially remove the blower assembly from the heater assembly housing and tag and disconnect the four electrical wires from the blower assembly. See Figure 18. 8. Remove the blower assembly from the heater assembly housing.

Water Valve Remove

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.

WARNING When replacing the heater hoses, make sure the replacement hoses meet correct specifications. Failure to meet specifications may cause personal injury.

WARNING

1. ELECTRICAL WIRE CONNECTION Figure 18. Blower Electrical Wire Connection

Install 1. Connect the electrical wires to the blower assembly. See Figure 18. 2. Position the blower assembly into the heater assembly housing. 14

DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 1. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 2. Turn the heat control knob on the instrument panel counterclockwise to the fully open position or (full hot position). See Switch Locations . 3. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab.


0100 YRM 1459

MCC Heater and Air Conditioner

NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab.

9. Swing the heater assembly up toward the cab and install the three capscrews to retain the heater assembly to the cab. See Figure 13 for the location of the capscrews.

4. Remove the three capscrews that retain the heater assembly to the cab and swing the heater assembly down. See Figure 13 for the location of the capscrews.

10. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab.

5. Remove the 10 screws that retain the top cover to the heater assembly. 6. Remove the top cover from the heater assembly. 7. Remove the cable clip that retains the outer cable to the water valve. 8. Remove the snap ring that retains the inner cable to the water valve and disconnect the inner cable from the water valve. 9. Loosen the two hose clamps that retain the water valve between the heater hoses. See Figure 14. 10. Disconnect the two heater hoses from the water valve.

11. Add coolant as needed. Refer to the manual . 12. Start the engine and check for leaks. Add coolant as needed. 13. Make sure the heat control knob functions correctly.

PUSH/PULL CABLE REPLACEMENT Water Valve Cable Remove 1. Turn the heat control knob on the instrument panel counterclockwise to the fully open position or the (full hot position). See Switch Locations .

Install

2. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Fuse Panel and Cover Location.

1. Make sure the heat control knob in the cab is in the full hot position

3. Remove the heat control knob at the instrument panel top console. See Switch Locations.

2. Position the water valve between the two heater hoses inside the heater assembly. See Figure 14.

4. Remove the nut that retains the rotary control assembly to the instrument panel top console. See Figure 12.

11. Remove the water valve from the heater assembly.

3. Connect the two heater hoses to the water valve and tighten the hose clamps. 4. Connect the inner cable to the water valve and install the snap ring to retain the inner cable to the water valve. 5. Push the lever of the water valve towards the heater core until it reaches its final position. Hold the lever and push the outer cable towards the water valve. 6. Install and tighten the cable clip to retain the outer cable to the water valve. 7. Position the top cover on the heater assembly.

5. Remove the cable clip that retains the outer cable to the rotary control assembly. 6. Remove the snap ring that retains the inner cable to the rotary control and remove the inner cable from the rotary control. 7. Raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab.

8. Install the 10 screws to retain the top cover to the heater assembly. 15


MCC Heater and Air Conditioner 8. Remove the three capscrews that retain the heater assembly to the cab and swing the heater assembly down. See Figure 13. 9. Remove the 10 screws that retain the top cover to the heater assembly.

0100 YRM 1459 11. Hold the inner cable extended and pull the outer cable away from the rotary control. 12. Install the cable clip to retain the outer cable to the rotary control assembly.

10. Remove the top cover from the heater assembly.

13. Make sure the heat control knob functions correctly.

11. Remove the cable clip that retains the outer cable to the water valve.

14. Install the rotary control assembly to the underside of the instrument panel top console.

12. Remove the snap ring that retains the inner cable to the water valve and disconnect the inner cable from the water valve.

15. Install the nut to retain the rotary control assembly to the instrument panel top console. See Figure 12.

13. Remove the water valve cable from the instrument panel box and heater assembly.

16. Install the heat control knob at the instrument panel top console. See Switch Locations.

Install

17. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Fuse Panel and Cover Location.

1. Position the water valve cable inside the instrument panel box and heater assembly. 2. Connect the inner cable to the water valve and install the snap ring to retain the inner cable to the water valve. 3. Push the lever of the water valve towards the heater core until it reaches its final position. Position the outer cable until it extends a few mm out of the cable clip.

Heater/Air Conditioner Assembly Remove

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.

4. Install and tighten the cable clip to retain the outer cable to the water valve.

1. Turn the key switch to the ON position.

5. Position the top cover on the heater assembly.

2. Place the recirculation knob on the instrument panel in position 1 or position 2.

6. Install the 10 screws to retain the top cover to the heater assembly.

3. Turn the key switch to the OFF position.

7. Swing the heater assembly up toward the cab and install the three capscrews to retain the heater assembly to the cab. See Figure 13.

4. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Fuse Panel and Cover Location.

8. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 9. Turn the rotary control into the (full hot position). See Figure 12. 10. Connect the inner cable to the rotary control and install the snap ring to retain the inner cable to the rotary control. See Figure 12.

16

5. Disconnect the wire harness for the fan speed knob, heater knob, and recirculation knob from the connectors at the underside of the instrument panel top console. 6. Tag and disconnect the electrical wires for the air conditioner switch at the underside of the instrument panel top console.


0100 YRM 1459

WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 7. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 8. Tilt/raise the cab to the fully open position. Refer to the section Fuse Panel and Cover Location. 9. Tag and disconnect the two heater hoses from the heater inlet and outlet ports and plug the heater hoses and ports. See Figure 19.

CAUTION Repairs to the air conditioning system that require discharging and/or refilling of the refrigeration fluid must be performed only by a certified air conditioning specialist. 10. Contact a certified air conditioning specialist to have the refrigerant extracted from the air conditioning system.

MCC Heater and Air Conditioner 11. Disconnect and plug the hose fittings leading to the evaporator. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 12. Loosen the two nuts and capscrews at the hinge bracket. Remove the three capscrews that retain the heater assembly to the cab. Pull the heater assembly downwards and push simultaneously towards the hinge bracket to provide sufficient clearance between heater assembly and cab frame. See Figure 19 for the location of the capscrews. 13. Make sure the wire harness is free and can be removed together with the heater/air conditioner assembly. 14. Disconnect the electrical connector on top of the top cover from the actuator that controls the vent door position. 15. Support the heater/air conditioner assembly and remove the capscrews that retain the heater/air conditioner assembly to the hinge brackets. 16. Remove the heater/air conditioner assembly from the underside of the cab.

Install 1. Position the heater/air conditioner assembly to the underside of the cab. 2. Support the heater/air conditioner assembly and install the capscrews to retain the heater/air conditioner assembly to the hinge brackets. Do not tighten the capscrews at this time. 3. Connect the electrical connector on top of the top cover to the actuator that controls the vent door position. 1. 2. 3. 4. 5. 6. 7.

HEATER INLET HEATER OUTLET HEATER ASSEMBLY CAPSCREW LOCATION CONDENSATION DRAINS AIR CONDITIONING OUTLET AIR CONDITIONING INLET HEATER HINGE BRACKET Figure 19. Heater/Air Conditioner Assembly

4. Route the wire harness correctly to the side instrument panel box. 5. Swing the heater/air conditioner assembly up toward the cab and install the three screws to retain the heater/air conditioner assembly to the cab. See Figure 19 for the location of the capscrews. 6. Tighten the two nuts and capscrews at the hinge bracket. 17


MCC Heater and Air Conditioner

0100 YRM 1459

7. Remove the plugs and connect the heater hose to the inlet and outlet ports.

4. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab.

8. Connect the hose fittings leading to the evaporator.

NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab.

CAUTION Repairs to the air conditioning system that require discharging and/or refilling of the refrigeration fluid must be performed only by a certified air conditioning specialist.

5. Remove the three capscrews that retain the heater/air conditioner assembly to the cab and swing the heater/air conditioner assembly down. See Figure 19 for the location of the capscrews.

9. Contact a qualified and certified technician to have the air conditioning system filled with refrigerant. See Air Conditioning Technical Detail, Table 3 for the type and the amount of refrigerant required to charge an evacuated A/C system.

6. Disconnect the electrical connector on top of the top cover from the actuator that controls the vent door position. See Figure 20.

10. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 11. Connect the electrical wires for the air conditioning switch at the underside of the instrument panel top console. 12. Connect the wire harness for the fan speed knob, heater knob, and recirculation knob to the connectors at the underside of the instrument panel top console.

7. Remove the 12 screws that retain the top cover to the heater/air conditioner assembly. 8. Remove the top cover from the heater/air conditioner assembly. 9. Remove the washer located on top of the nylon bushing. 10. Remove the capscrew, two nuts, two washers, and lock washer that retain the vent door to the actuator that is located on the top cover. 11. Remove the vent door.

13. Add coolant as needed. Refer to the manual . 14. Position the fuse panel cover to the right side of the instrument panel and install the four retaining screws. See Fuse Panel and Cover Location. 15. Make sure the heater/air conditioner functions correctly. Turn the recirculation knob a few times to the fully open and fully closed positions to be sure that the recirculation functions correctly.

HEATER/AIR CONDITIONER PARTS REPLACEMENT Vent Door Remove 1. Turn the key switch to the ON position. 2. Turn the recirculation knob located on the instrument panel to position 1 or position 2. See Switch Locations. 3. Turn the key switch to the OFF position.

18

1. ELECTRICAL CONNECTOR 2. VENT DOOR ACTUATOR 3. TOP COVER Figure 20. Electrical Connector Location of Vent Door Actuator


0100 YRM 1459

Install 1. Position the vent door and install the capscrew, two nuts, two washers, and lock washer to retain the vent door to the actuator on the top cover. NOTE: Make sure the nylon bushing and washer are correctly positioned inside the heater/air conditioner assembly. 2. Position the top cover on the heater/air conditioner assembly and make sure the pin at the underside of the vent door is positioned in the washer and nylon bushing. 3. Install the 12 screws to retain the top cover to the heater/air conditioner assembly. 4. Connect the electrical connector on top of the top cover to the actuator that controls the vent door position. See Figure 20. 5. Swing the heater/air conditioner assembly up toward the cab and install the three capscrews to retain the heater/air conditioner assembly to the cab. See Figure 19 for the location of the capscrews. 6. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. NOTE: The key switch much be turned to the ON position before performing the following step. 7. Turn the recirculation knob a few times from the fully open position to the fully closed position to be sure that the recirculation system functions correctly. See Switch Locations.

Heater Core Remove

MCC Heater and Air Conditioner

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.

WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 4. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 5. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. 6. Loosen the hose clamp and disconnect the inlet heater hose from the heater core pipe located at the underside of the heater/air conditioner assembly. Plug the inlet heater hose. See Figure 19. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 7. Remove the three capscrews that retain the heater/air conditioner assembly to the cab and swing the heater/air conditioner assembly down. See Figure 19 for the location of the capscrews. 8. Disconnect the electrical connector on top of the top cover from the actuator that controls the vent door position. See Figure 20. 9. Remove the 12 screws that retain the top cover to the heater/air conditioner assembly.

1. Turn the key switch to the ON position.

10. Remove the top cover from the heater/air conditioner assembly.

2. Turn the recirculation knob located on the instrument panel to position 1 or position 2. See Switch Locations.

11. Remove the washer that is positioned on top of the nylon bushing.

3. Turn the key switch to the OFF position.

12. Tag and disconnect the two electrical connectors from the thermostat. See Figure 21.

19


MCC Heater and Air Conditioner 13. Loosen the hose clamp that retains the top heater hose to the heater core inside the heater/air conditioner assembly and disconnect the heater hose from the heater core.

0100 YRM 1459 NOTE: The key switch much be turned to the ON position before performing the following step.

14. Slide the heater core out of the heater/air conditioner assembly.

11. Turn the recirculation knob a few times from the fully open position to the fully closed position to be sure that the recirculation system functions correctly. See Switch Locations.

Install

Evaporator Core

1. Slide the heater core into the heater/air conditioner assembly.

Remove

2. Connect the top heater hose between the water valve and heater core to the heater core and tighten the hose clamp. See Figure 21. 3. Connect the two electrical connectors to the thermostat.

1. Turn the key switch to the ON position. 2. Turn the recirculation knob located on the instrument panel to position 1 or position 2. See Switch Locations. 3. Turn the key switch to the OFF position.

NOTE: Make sure the nylon bushing and washer are correctly positioned inside the heater/air conditioner assembly. 4. Position the top cover on the heater/air conditioner assembly and make sure the pin at the underside of the vent door is positioned in the washer and nylon bushing. 5. Install the 12 screws to retain the top cover to the heater/air conditioner assembly. 6. Connect the electrical connector on top of the top cover to the actuator that controls the vent door position. See Figure 20. 7. Swing the heater/air conditioner assembly up toward the cab and install the three capscrews to retain the heater/air conditioner assembly to the cab. See Figure 19 for the correct location of the capscrews. 8. Connect the inlet heater hose to the heater core pipe located at the underside of the heater/air conditioner assembly and tighten the hose clamp. 9. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 10. Start the engine and check for leaks. Add coolant as needed. Refer to the manual for the correct coolant specifications.

20

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

THERMOSTAT ELECTRICAL CONNECTION POINTS TOP HEATER HOSE HOSE CLAMP HEATER CORE WATER VALVE BOTTOM HEATER HOSE BRACKET CAPSCREW (INNER) BRACKET CAPSCREW (OUTER) WATER VALVE BRACKET

Figure 21. Thermostat, Water Valve, and Heater Hoses


0100 YRM 1459

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.

WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 4. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 5. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab.

MCC Heater and Air Conditioner 11. Remove the 12 screws that retain the top cover to the heater/air conditioner assembly. 12. Remove the top cover from the heater/air conditioner assembly. 13. Remove the washer that is positioned on top of the nylon bushing. 14. Remove the blower. Refer to the section Blower, Remove. 15. Remove the water valve. Refer to the section Water Valve, Remove. 16. Remove the two clips that retain the evaporator core inside the heater/air conditioner assembly. See Figure 22.

CAUTION Repairs to the evaporator core that require discharging and/or refilling of the refrigeration fluid must be performed only by a trained and certified air conditioning specialist. 6. Contact a certified technician to have the refrigerant extracted from the air-conditioning system. See Air Conditioning Technical Detail, Table 3 for the type and amount of refrigerant required to charge an evacuated A/C system. 7. Tag and disconnect the two evaporator hoses that are connected to the expansion block at the underside of the heater/air conditioner assembly. See Figure 19. 8. Remove the two capscrews that retain the expansion block bracket to the bottom plate of the heater/air conditioner assembly. See Figure 23. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 9. Remove the three capscrews that retain the heater/air conditioner assembly to the cab and swing the heater/air conditioner assembly down. See Figure 19 for the correct location of the capscrews. 10. Disconnect the electrical connector on top of the top cover from the actuator that controls the vent door position. See Figure 20.

1. EVAPORATOR CORE CLIP Figure 22. Evaporator Core Clips 17. Slide the evaporator core out of the heater/air conditioner assembly. 18. Remove the expansion block from the evaporator core pipes.

Install 1. Install the expansion block to the evaporator core pipes. 2. Slide the evaporator core into the heater/air conditioner assembly. Make sure the expansion block is positioned correctly at the underside of the heater/air conditioner assembly.

21


MCC Heater and Air Conditioner 3. Install the two clips to retain the evaporator core inside the heater/air conditioner assembly. See Figure 22.

0100 YRM 1459

CAUTION Repairs to the evaporator core that require discharging and/or refilling of the refrigeration fluid must be performed only by a trained and certified air conditioning specialist. 11. Connect the two evaporator hoses to the expansion block at the underside of the heater/air conditioner assembly. 12. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 13. Start the engine and check for leaks. Add coolant as needed, see .

1. EXPANSION BRACKET CAPSCREWS Figure 23. Expansion Bracket Capscrews 4. Install the two capscrews to retain the expansion block bracket to the bottom plate of the heater/air conditioner assembly. See Figure 23.

14. Turn the recirculation knob a few times from the fully open position to the fully closed position to be sure that the recirculation system functions properly. See Switch Locations.

Blower Remove 1. Turn the key switch to the ON position.

5. Install the water valve. Refer to the section Water Valve, Install.

2. Turn the recirculation knob located on the instrument panel to position 1 or position 2. See Switch Locations.

6. Install the blower. Refer to the section Blower, Install.

3. Turn the key switch to the OFF position.

NOTE: Make sure the nylon bushing and washer are correctly positioned inside the heater/air conditioner assembly. 7. Position the top cover on the heater/air conditioner assembly and make sure the pin at the underside of the vent door is positioned in the washer and nylon bushing. 8. Install the 12 screws to retain the top cover to the heater/air conditioner assembly. 9. Connect the electrical connector on top of the top cover to the actuator that controls the vent door position. See Figure 20. 10. Swing the heater/air conditioner assembly up toward the cab and install the three capscrews to retain the heater/air conditioner assembly to the cab. See Figure 19 for the correct location of the capscrews.

22

4. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 5. Remove the three capscrews that retain the heater/air conditioner assembly to the cab and swing the heater/air conditioner assembly down. See Figure 19 for the correct location of the capscrews. 6. Disconnect the electrical connector on top of the top cover from the actuator that controls the vent door position. See Figure 20. 7. Remove the 12 screws that retain the top cover to the heater/air conditioner assembly.


0100 YRM 1459 8. Remove the top cover from the heater/air conditioner assembly. 9. Remove the washer that is positioned on top of the nylon bushing.

MCC Heater and Air Conditioner 9. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 10. Make sure the blower functions correctly.

10. Tag and disconnect the electrical connector connected to the blower assembly. See Figure 16.

Thermostat

11. Remove the four screws and nuts that retain the blower inside the heater/air conditioner assembly. See Figure 17.

1. Turn the key switch to the ON position.

12. Partially remove the blower assembly from the heater/air conditioner assembly housing and tag and disconnect the four electrical wires from the blower assembly. See Figure 18. 13. Remove the blower assembly from the heater/air conditioner assembly housing.

Install 1. Connect the four electrical wires to the blower assembly. See Figure 18. 2. Position the blower assembly into the heater/air conditioner assembly. 3. Install the four screws and nuts to retain the blower inside the heater/air conditioner assembly. See Figure 17. 4. Connect the electrical connector to the blower assembly. See Figure 16. NOTE: Make sure the nylon bushing and washer are correctly positioned inside the heater/air conditioner assembly. 5. Position the top cover on the heater/air conditioner assembly and make sure the pin at the underside of the vent door is positioned in the washer and nylon bushing. 6. Install the 12 screws to retain the top cover to the heater/air conditioner assembly. 7. Connect the electrical connector on top of the top cover to the actuator that controls the vent door position. See Figure 20. 8. Swing the heater/air conditioner assembly up toward the cab and install the three capscrews to retain the heater/air conditioner assembly to the cab. See Figure 19.

Remove

2. Turn the recirculation knob located on the instrument panel to position 1 or position 2. See Switch Locations. 3. Turn the key switch to the OFF position.

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.

WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 4. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 5. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 6. Remove the three capscrews that retain the heater/air conditioner assembly to the cab and swing the heater/air conditioner assembly down. See Figure 19. 7. Disconnect the electrical connector on top of the top cover from the actuator that controls the vent door position. See Figure 20. 8. Remove the 12 screws that retain the top cover to the heater/air conditioner assembly. 9. Remove the top cover from the heater/air conditioner assembly.

23


MCC Heater and Air Conditioner 10. Remove the washer that is positioned on top of the plastic bushing. 11. Tag and disconnect the two electrical connectors from the thermostat. See Figure 21. 12. Loosen the hose clamp that retains the top heater hose to the water valve inside the heater/air conditioner assembly and disconnect the heater hose. 13. Remove the temperature switch from the evaporator core. See Figure 24.

0100 YRM 1459 2. Install the nut and washer located outside the heater/air conditioner assembly to retain the thermostat inside the heater/air conditioner assembly. 3. Install the temperature switch to the evaporator core. See Figure 24. 4. Connect the top heater hose between the water valve and heater core to the water valve and tighten the hose clamp. 5. Connect the two electrical connectors to the thermostat. See Figure 21. NOTE: Make sure the nylon bushing and washer are correctly positioned inside the heater/air conditioner assembly. 6. Position the top cover on the heater/air conditioner assembly and make sure the pin at the underside of the vent door is positioned in the washer and nylon bushing. 7. Install the 12 screws to retain the top cover to the heater/air conditioner assembly. 8. Connect the electrical connector on top of the top cover to the actuator that controls the vent door position. See Figure 20. 9. Swing the heater/air conditioner assembly up toward the cab and install the three capscrews to retain the heater/air conditioner assembly to the cab. See Figure 19. 10. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab.

1. TEMPERATURE SWITCH Figure 24. Temperature Switch

11. Start the engine and check for leaks. Add coolant as needed. Refer to Periodic Maintenance manual for your lift truck.

14. Remove the nut and washer located outside the heater/air conditioner assembly that retains the thermostat inside the heater/air conditioner assembly.

12. Turn the recirculation knob a few times from the fully open position to the fully closed position to be sure that the recirculation system functions correctly. See Switch Locations.

15. Remove the thermostat and temperature switch from the heater/air conditioner assembly.

Water Valve

Install 1. Position the thermostat and temperature switch inside the heater/air conditioner assembly and correctly route the temperature switch. 24

Remove 1. Turn the key switch to the ON position.


0100 YRM 1459

MCC Heater and Air Conditioner

2. Turn the recirculation knob located on the instrument panel to position 1 or position 2. See Switch Locations.

12. Loosen the two hose clamps that retain the top heater hose between the water valve and heater core.

3. Turn the key switch to the OFF position.

13. Remove the top heater hose and the two hose clamps between the water valve and heater core.

WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.

WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 4. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 5. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 6. Remove the three capscrews that retain the heater/air conditioner assembly to the cab and swing the heater/air conditioner assembly down. See Figure 19. 7. Disconnect the electrical connector on top of the top cover from the actuator that controls the vent door position. See Figure 20. 8. Remove the 12 screws that retain the top cover to the heater/air conditioner assembly. 9. Remove the top cover from the heater/air conditioner assembly. 10. Remove the washer that is positioned on top of the plastic bushing. 11. Tag and disconnect the two electrical connectors from the thermostat. See Figure 21.

14. Loosen the hose clamp that retains the bottom heater hose to the water valve. 15. Remove the two capscrews located at the outside of the heater/air conditioner assembly that retain the water valve bracket to the heater/air conditioner assembly. 16. Disconnect the electrical connector from the water valve actuator. 17. Loosen the hose clamp and disconnect the bottom heater hose from the water valve. 18. Remove the water valve bracket from the heater/air conditioner assembly. 19. Remove the two screws that retain the water valve to the water valve bracket.

Install 1. Position the water valve to the water valve bracket and install the two retaining screws. 2. Position the water valve bracket inside the heater/air conditioner assembly. 3. Connect the bottom heater hose to the water valve and tighten the hose clamp. 4. Connect the electrical connector to the water valve actuator. 5. Install the two capscrews located at the outside of the heater/air conditioner assembly to retain the water valve bracket inside the heater/air conditioner assembly. See Figure 21. 6. Install the top heater hose and the two hose clamps between the water valve and heater core. Tighten the hose clamps. 7. Connect the two electrical connectors to the thermostat.

25


MCC Heater and Air Conditioner

0100 YRM 1459

NOTE: Make sure the nylon bushing and washer are correctly positioned inside the heater/air conditioner assembly.

12. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab.

8. Position the top cover on the heater/air conditioner assembly and make sure that the pin at the underside of the vent door is positioned in the washer and nylon bushing.

13. Start the engine and check for leaks. Add coolant as needed. Refer to Periodic Maintenance manual for your lift truck.

9. Install the 12 screws to retain the top cover to the heater/air conditioner assembly. 10. Connect the electrical connector on top of the top cover to the actuator that controls the vent door position. See Figure 20. 11. Swing the heater/air conditioner assembly up toward the cab and install the three capscrews that retain the heater/air conditioner assembly to the cab. See Figure 19.

14. Turn the heat control knob a few times from the fully open position to the fully closed position to be sure that the heating system functions properly. See Switch Locations.

AIR CONDITIONING TECHNICAL DETAIL NOTE: Table 3 provides technical details. It is intended for use by a certified air conditioning specialist.

Table 3. Air Conditioning Specifications Compressor

Values

Lubricant Type

PAG See Compressor Nameplate

Lubricant Quantity

200 grams

Suction Port

7/8-14 UNF

Discharge Port

3/4-16 UNF Refrigerant

Refrigerant

R134a

Fill Capacity

1300 ± 25 grams Pressure Switch

High pressure OFF

2.70 ±0.2 MPa (392 ±29 psi)

High pressure ON

2.10 ±0.2 MPa (305 ±29 psi)

Med pressure OFF

1.30 ±0.15 MPa (188 ±22 psi)

Med pressure ON

1.60 ±0.13 MPa (232 ±19 psi)

Low pressure OFF

0.20 ±0.02 MPa (29 ±2.9 psi)

Low pressure ON

0.21 ±0.03 MPa (30.5 ±4.4 psi) Anti-Icing Switch

Opens

-1°C (30.2°F)

Closes

2°C (35.6°F)

This chart is intended for use by a certified air conditioning specialist.

26


100 YRM 1594

Description

General This manual contains the removal and installation instructions for major assemblies attached to the frame. The removal and installation procedures for some assemblies are described in the following service manuals: • Operator’s Cab 100 YRM 1390

• Planetary Drive Axle, (Wet System) 1400 YRM 944 • Masts and Carriages, Starting 2003 4000 YRM 1062 • Hydraulic System 1900 YRM 1478 • Steering System 1600 YRM 1479

Description CAUTION Do not initiate repairs to the frame without consulting a Yale service representative or damage to the lift truck may occur.

The frame is a weldment with mounts for the major assemblies. See Figure 1. The mounts are designed to keep the attached parts in position and transfer the forces acting on them.

1


Description

1. 2. 3. 4. 5. 6. 7.

MAIN COUNTERWEIGHT MOUNT COOLING ASSEMBLY MOUNT TILT CYLINDER MOUNT MAST MOUNT DRIVE AXLE MOUNT MAIN FRAME SIDE TILTING CAB MOUNT

100 YRM 1594

8. 9. 10. 11. 12. 13.

HYDRAULIC TANK MOUNT STEER AXLE MOUNT ENGINE MOUNT TRANSMISSION MOUNT MAIN CONTROL VALVE MOUNT CAB TILT CYLINDER MOUNT

Figure 1. Frame

2


100 YRM 1594

Air Cleaner

Air Cleaner AIR CLEANER ASSEMBLY, TIER 3/STAGE III A, F876/F877 Remove 1. Open the left- and right-hand hood doors. 2. Loosen the air duct clamp. See Figure 2. 3. Close the left- or right-hand hood to access the precleaner. 4. Remove the precleaner, with the air duct attached, from the air cleaner. 5. Disconnect the connector from the vacuum switch by pressing the metal clip. 6. Loosen the hose clamps on the air filter hose and remove the hose. 7. Remove the bolts of the two air cleaner mounting clamps. 8. Rotate the air cleaner until the air duct connection clears the center of the hood opening and move the air cleaner to the right-hand side of the truck. 9. Remove the retaining hardware from the mounting clamps and remove the clamps from the hood.

Install 1. Install the retaining hardware to the mounting clamps and install the clamps under the hood. 2. Position the air cleaner assembly in the mounting clamps and tighten the two clamp bolts. 3. Install the air filter hose and tighten the hose clamps. 4. Connect the vacuum switch connector to the air cleaner assembly. 5. Close the left- or right-hand hood door.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

AIR FILTER HOSE AIR CLEANER ASSEMBLY VACUUM SWITCH AIR DUCT CLAMP PRECLEANER CLAMP PRECLEANER AIR DUCT UPPER AIR HOSE CLAMP MOUNTING CLAMP BOLT AIR CLEANER MOUNTING CLAMP

Figure 2. Air Cleaner Assembly, Tier 3/Stage III A, F876/F877

6. Install the precleaner, with the air duct attached, on the air cleaner and install and tighten the air duct clamp. 7. Close the hood doors.

3


Air Cleaner

100 YRM 1594

AIR CLEANER ASSEMBLY, TIER 4I/STAGE III B, F876/F877 Remove 1. Open the left- and right-hand hood doors. 2. Loosen the hose clamps on the air filter hose and remove the hose. See Figure 3. 3. On F877 trucks, tag and disconnect the connectors to the vacuum switch and to the Temperature and Barometric Air Pressure (TBAP) sensor. 4. On F876 tag and disconnect the connectors to the vacuum switch and to the Mass Air Flow (MAF) Sensor. See Figure 4. 5. Remove the 4 capscrews that retain the brackets of the air cleaner unit to the hood. 6. Lower the air cleaner unit until it clears the air duct. 7. Move the air cleaner to the right-hand side of the truck.

Install 1. If removed, install the brackets on the cleaner unit. 2. Verify presence and correct seating of the seal on the air cleaner intake tube 3. Move the air cleaner into its position under the hood and then upwards, until it engages with the air duct. 4. Align the holes in the brackets with the spacers under the hood. 5. Install the capscrews on the cleaner brackets. 6. On F877 trucks, connect the connectors to the vacuum switch and to the Temperature and Barometric Air Pressure (TBAP) sensor according to tags. 7. On F876 trucks, connect the connectors to the vacuum switch and to the Mass Air Flow (MAF) Sensor according to tags. 8. Install the air filter hose and tighten clamps. 9. Close the hood doors.

4

1. 2. 3. 4. 5. 6. 7. 8. 9.

AIR HOSE AIR CLEANER UNIT VACUUM SWITCH TBAP SENSOR AIR CLEANER BRACKET CAPSCREWS PRECLEANER CLAMP AIR PRECLEANER AIR DUCT

Figure 3. Air Cleaner Assembly, Tier 4i/Stage III B, F877


100 YRM 1594

Exhaust System

Legend for Figure 4 1. 2. 3. 4. 5. 6. 7. 8.

AIR HOSE VACUUM SWITCH AIR CLEANER UNIT MAF SENSOR AIR CLEANER BRACKET AIR DUCT PRECLEANER CLAMP AIR PRECLEANER

Figure 4. Air Cleaner Assembly, Tier 4i/Stage III B, F876

Exhaust System EXHAUST ASSEMBLY, TIER 3/STAGE III A, F876/F877 Remove WARNING Exhaust system must be at room temperature before starting disassembly or personal injury may occur. 1. Remove the two clamps from the flex tube. See Figure 5. 2. Remove the U-bolt that retains the charge air cooler tube to the exhaust tube. 3. Remove the clamp that holds the exhaust tube to the engine and remove the exhaust tube and flex tube.

5. Remove the muffler from the hood.

Install 1. Position the muffler on the hood. 2. Install the four capscrews and nuts that retain the muffler to the hood. 3. Install the flex tube on the muffler. Do not yet tighten the clamp. 4. Install the exhaust tube and clamp on the engine. 5. Connect the exhaust tube and flex tube. 6. Install the U-bolt that retains the charge air cooler tube to the exhaust tube. 7. Tighten the clamps on the flex tube.

4. Use a tool to retain the nut when loosening the capscrews that retain the muffler to the hood. Remove the four capscrews and nuts.

5


Exhaust System

100 YRM 1594 3. Loosen the clamps at the bottom of the muffler. 4. Remove the T-bolt strap that retains the muffler to the muffler bracket. 5. Remove the muffler from the muffler bracket. 6. Remove the 4 capscrews that retain the muffler bracket to the hood. 7. Remove the muffler bracket from the hood. 8. On F877 trucks, remove the U-bolt that retains the left-hand charge air cooler tube to the exhaust tube. 9. Remove the left-hand charge air cooler tube. 10. Remove the bolts that retain the hose clamps of the coolant de-aeration hoses to the heat shield. 11. Loosen the lower clamp from the exhaust tube. 12. Maneuver the exhaust tube out of the engine compartment.

Install 1. Maneuver the exhaust tube into the engine compartment.

1. 2. 3. 4. 5. 6. 7.

FLEX TUBE CLAMP FLEX TUBE CAPSCREWS MUFFLER U-BOLT EXHAUST TUBE EXHAUST TUBE CLAMP

Figure 5. Exhaust Assembly, Tier 3/Stage III A, F876/F877

EXHAUST ASSEMBLY, TIER 4I/STAGE III B, F876/F877 Remove WARNING Exhaust system must be at room temperature before starting disassembly or personal injury may occur. 1. Remove the 6 capscrews from the perforated cover on the exhaust muffler. 2. Remove the perforated cover from the exhaust muffler.

6

2. Maneuver the upper end through the opening in the hood. See Figure 6 and Figure 7. 3. Slide the lower end onto the turbocharger and tighten the clamp. 4. Position the hose clamps for the coolant de-aeration hoses on the heat shield and install and tighten the bolts. 5. On F877 trucks, install the left-hand charge air cooler tube and install the U-bolt on the charge air cooler tube. Tighten the nuts on the U-bolt. 6. Install the muffler bracket onto the hood. 7. Install the 4 capscrews that retain the muffler bracket to the hood. 8. Install the muffler into the bracket and on the exhaust tube. 9. Install the T-bolt strap that retains the muffler to the muffler bracket. 10. Tighten the clamps at the bottom of the muffler.


100 YRM 1594

Exhaust System

11. Install the perforated cover on the exhaust muffler bracket.

12. Install the 6 capscrews that retain the perforated cover to the exhaust muffler bracket.

1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

U-BOLT CAPSCREWS MUFFLER BRACKET CAPSCREWS ON MUFFLER COVER PERFORATED COVER

CHARGE AIR COOLER TUBE HEAT SHIELD EXHAUST TUBE BRACKET EXHAUST TUBE EXHAUST TUBE CLAMP

Figure 6. Exhaust Assembly, Tier 4i/Stage III B, F877 Shown

7


Hood Assembly

100 YRM 1594

Legend for Figure 7 NOTE: PERFORATED COVER REMOVED 1. 2. 3. 4.

MUFFLER CLAMP BOLTS EXHAUST TUBE DOUBLE T-BOLT STRAP

Figure 7. Exhaust Muffler, Tier 4i/Stage III B

Hood Assembly REMOVE 1. Tilt the mast completely forward. 2. Completely tilt (raise) the cab. 3. Disconnect the battery cables from the battery. 4. Open the rear cover and disconnect its two gas springs from the counterweight. 5. Remove the rear cover by sliding it sideways off its flexible hinge. See Figure 8. 6. Open the left and right hood doors. 7. On trucks with Tier 3/Stage III A engines, disconnect the air filter vacuum switch connector. 8. On trucks with Tier 4i/Stage III B engines, tag and disconnect: – The air filter vacuum switch connector.

8

– On F877 trucks, the connector to the TBAP (Temperature Barometric Air Pressure) sensor on the air filter assembly. – On F876 trucks, the connector to the MAF (Mass Air Flow) sensor. 9. Remove all tie-wraps holding electric cables to the hood. 10. On Tier 3/Stage III A engines: – Release the clamps on the flex tube – Remove the air filter hose. 11. On Tier 4i/Stage III B engines: – Remove the 6 capscrews from the perforated cover on the exhaust muffler. – Remove the perforated cover from the exhaust muffler. – Loosen the clamp at the bottom of the muffler. – Remove the curved air filter hose.


100 YRM 1594

Hood Assembly

NOTE: Note: Filled to the “MAX” mark, the expansion tank with connecting hoses weighs 7 kg (15.4 lb).

4. Install the capscrews that retain the rear hood bracket to the counterweight.

12. Remove the capscrews, washers and nuts that retain the expansion tank bracket to the hood.

5. Install the capscrews in the insulators at the top of the cooling core assembly.

13. Place the expansion tank inside the engine compartment and secure it to keep it from moving.

6. Install the expansion tank bracket to the hood.

14. Remove the capscrews from the two insulators at the top of the cooling core assembly. See Figure 9. 15. Remove the nut and washer on each side of the hood that hold the front plate of the hood assembly to the frame. 16. Remove the capscrews that retain the rear hood bracket to the counterweight. 17. Attach a lifting device to the hood assembly.

CAUTION Be very careful when lifting the hood assembly to avoid damage to the rear of the operator’s cab. 18. Slowly lift the hood assembly and make sure all electric cables are removed from the hood. 19. Place the hood assembly on the ground and put a support under the rear of the assembly.

INSTALL 1. Attach a lifting device to the hood assembly.

CAUTION Be very careful when installing the hood assembly to avoid damage to the rear of the operator’s cab. 2. Make sure the muffler slides into the exhaust tube and carefully position the hood assembly onto the frame. 3. Install the nut and washer on each side of the hood that hold the front plate of the hood assembly to the frame.

7. On Tier 3/Stage III A engines: – Tighten the clamps on the flex tube. – Install the air filter hose.

8. On Tier 4i/Stage III B engines: – Tighten the clamp at the bottom of the muffler. – Install the perforated cover on the exhaust muffler. – Install the 6 capscrews to retain the perforated cover to the exhaust muffler. – Install the curved air filter hose. 9. On Tier 3/Stage III A engines: – Connect the air filter vacuum switch connector. 10. On trucks with Tier 4i/Stage III B engines, connect according to tags: – The air filter vacuum switch connector. – On F877 trucks, the connector to the TBAP (Temperature Barometric Air Pressure) sensor on the air filter assembly. – On F876 trucks, the connector to the MAF (Mass Air Flow) sensor. 11. Install the electric cables to the hood with tie-wraps. 12. Close the left and right hood doors. 13. Slide the rear cover sideways onto its flexible hinge. 14. Install the two gas springs between rear cover and counterweight. 15. Connect the battery cables. 16. Completely lower the cab. 17. Start the engine and check for leaks.

9


Hydraulic Tank

100 YRM 1594

1. 2. 3. 4. 5. 6.

HOOD LEFT HOOD DOOR HOOD FRONT PLATE NUT ON THREADED FRAME STUD RIGHT HOOD DOOR CAPSCREWS ON COUNTERWEIGHT (NOT VISIBLE) 7. REAR COVER

1. 2. 3. 4. 5. 6. 7.

COOLING CORE ASSEMBLY BOLT WASHER INSULATOR BRACKET LEFT DOOR HOOD

Figure 9. Top Insulators

Figure 8. Hood Assembly, Tier 3/Stage III A Shown

Hydraulic Tank The hydraulic tank is installed on the right side of the frame between the front fender and counterweight.

6. Remove the three capscrews and washers holding the right-hand extension plate and remove the extension plate. See Figure 10.

REMOVE NOTE: The hydraulic tank removal and installation must be done with aid of an assistant.

CAUTION Disconnect the negative (ground) cable first or lift truck damage may occur.

1. Place the truck on a solid, level surface. 2. Lower the mast completely.

7. Disconnect the negative (ground) and positive (power) cables from the batteries.

3. Shut down the engine.

8. Remove the batteries from the battery box.

4. Apply the parking brake.

NOTE: Use a drain pan to collect the oil from the hydraulic tank and hoses. The hydraulic system contains 125 liter (33 gal) of hydraulic oil.

5. Remove the four capscrews and washers holding the right-hand panel on top of the hydraulic tank and remove the right-hand panel. See Figure 10.

10


100 YRM 1594

Hydraulic Tank

9. Remove the drain plug at the bottom of the hydraulic tank and drain the hydraulic oil into clean suitable container. 10. Tag all hoses and tubes connected to the hydraulic tank to facilitate re-installing. 11. Loosen and remove the hose clamps from the main pump suction hose and from the wet brake pump suction hose at the bottom of the hydraulic tank. See Figure 11. 12. Put caps on the suction hoses. See Figure 11. 13. Disconnect the wet brake return, the main valve return, and the main valve drain hoses from the hydraulic tank. See Figure 11.

1. 2. 3. 4. 5.

HYDRAULIC TANK BATTERY BOX CAPSCREWS WASHERS RIGHT-HAND PANEL

14. On trucks with a 3-stage mast, disconnect the lift cylinder drain hose at the top of the hydraulic tank. 15. Put caps on the hoses and on the connections on the hydraulic tank. 16. Disconnect wiring harness from hydraulic sensor and remove hydraulic sensor, if necessary. 17. Remove the battery cables from the access hole of the hydraulic tank. See Figure 10. 18. Remove the capscrews that hold the right running board to the counterweight, front fender, and hydraulic tank and remove the running board.

6. 7. 8. 9. 10.

SEAL CAPSCREWS WASHERS RIGHT-HAND EXTENSION PLATE BATTERY CABLE ACCESS

Figure 10. Hydraulic Tank

11


Hydraulic Tank

100 YRM 1594

WARNING

CAUTION

Make sure the hydraulic tank is supported with a hydraulic jack, hand pallet lift, or a lift truck.

DO NOT to damage the studs during removal of the hydraulic tank from the frame.

19. Support the hydraulic tank with blocks of at least 50 mm (2.0 in.) high to compensate the height of the bracket at the bottom of the hydraulic tank.

21. Lift the hydraulic tank from the studs and move the hydraulic tank away from the frame.

20. Remove the three nuts and washers that hold the hydraulic tank to the frame.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

TO PORT P2 ON STEERING PUMP LOAD SENSE HOSES TO MAIN VALVE PUMP 1 BRAKE PUMP TO HYDRAULIC COOLING CORE WET BRAKE PUMP SUCTION HOSE WET BRAKE PUMP SUPPLY HOSE MAIN PUMP SUPPLY HOSE PUMP DRAIN HOSE

11. 12. 13. 14. 15. 16. 17. 18. 19.

MAIN VALVE DRAIN HOSE HYDRAULIC TEMPERATURE SENSOR MAIN RETURN HOSE DRAIN PLUG LIFT CYLINDER DRAIN HOSE (ONLY ON TRUCKS WITH THREE-STAGE MASTS) EXCESS WET BRAKE FLOW HOSE WET BRAKE RETURN HOSE TO WET BRAKE COOLING CORE PUMP 2

Figure 11. Hydraulic Tank Connection, F876/F877, Tier 3/Stage III A, F876, Tier 4i/Stage III B

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100 YRM 1594

INSPECT

Hydraulic Tank cleaning compound with an alkaline base. Follow the instructions given by the manufacturer.

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

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. 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. 4. Drain the tank.

CLEAN Tank can be cleaned with or without steam. If steam is available 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 produce sparks. Make an electrical connection between the nozzle and the tank. Connect a ground wire to the tank to prevent static electricity. 1. Remove all the parts from the tank. Install the drain plug.

WARNING When cleaning the tank, do not use solutions that produce dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns. If the tank is cleaned inside a building, make sure there is enough ventilation.

CAUTION Disposal of lubricants, fluids, and chemicals must meet local environmental regulations. 2. Fill the tank with a cleaning solution. Proceed as follows: • If steam is available, fill the tank 1/4 full (approximately 30 liter (8 gal) with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal). • If the tank cannot be cleaned with steam, mix a solution of water and trisodium phosphate or

5. If steam is available, 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. 6. Flush the inside of the tank with boiling water. Make sure all the loose material and cleaning compound is removed from the inside of the tank. 7. Perform an inspection of the inside of the tank. If it is not clean, repeat Step 5 and Step 6 and perform another inspection. In these inspections, use a light that is approved for locations with flammable vapors. 8. Check the tank for flammable vapors. 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 the lower flammable limit, repeat the cleaning procedures.

ADDITIONAL PREPARATIONS FOR REPAIR If nitrogen gas or carbon dioxide gas is available, prepare the cleaned 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, 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.

13


Hydraulic Tank

REPAIR WARNING Special procedures must be followed when leaks or other repairs need welding or cutting. All work must be done by authorized personnel.

CAUTION Welding on the truck may cause damage to the engine, transmission, and/or hydraulic electronic control units if proper precautions are not taken. Disconnect the negative battery terminal from the battery. Disconnect all controllers. If welding must be done in close proximity to a controller, that controller must be removed. When welding to the chassis, attach the ground cable as close to the weld as possible.

100 YRM 1594 3. Careful place the hydraulic tank over the studs without damaging the studs. 4. Install the three washers and nuts that hold the top of the hydraulic tank to the frame. 5. Remove the lifting device. NOTE: While pushing the cab tilt shaft to the front of the truck, keep the shims in their position between the cab and cab tilt system. 6. Push the cab tilt shaft towards the front of the truck and guide the shaft into the front bracket. 7. Install the anchor that secures the cab tilt shaft. 8. Inspect the right running board grommets. Replace if damaged.

1. Use the procedure described under Clean to prepare the tank for repairs.

9. Put the right running board in place and install the capscrews that hold the running board to the counterweight, front fender, and hydraulic tank.

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

10. Install the right-hand extension plate using the three capscrews and washer. See Figure 10.

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

11. Feed the battery cables through the access hole of the hydraulic tank. See Figure 10.

Preparations for use After Repair 1. Add more water to the tank so that the water goes above the point of where the work was done. Check to see if any water leaks from the tank. 2. If the tank shows no signs of leaks, remove all the water from the tank.

INSTALL NOTE: When installing the hydraulic system oil filter, it is important to grease the O-ring before installation. 1. Place the hydraulic tank on lifting equipment and support it with blocks of at least 50 mm (2.00 in.) high to compensate the height of the bracket at the bottom of the hydraulic tank. 2. Raise and place the hydraulic tank in front of the right side of the frame in the correct height position.

CAUTION DO NOT to damage the studs during installation of the hydraulic tank to the frame.

14

12. Install the clamp on the large suction hose at the bottom of the hydraulic tank. Connect large suction hose to the hydraulic tank. Torque the clamp to 4 6 N•m (3 - 4 lbf ft). 13. Install the clamp on the smaller suction hose at the bottom of the hydraulic tank. Connect smaller suction hose to the hydraulic tank and tighten clamp. 14. Install the wet brake return, the main valve return, and the main valve drain hoses on the hydraulic tank. 15. On trucks with a 3-stage mast, install the lift cylinder drain hose at the top of the hydraulic tank. 16. Install the hydraulic temperature sensor and connect the wiring harness. 17. Make sure the drain plug is installed at the bottom of the hydraulic tank.


100 YRM 1594

CAUTION The pump is designed for a certain flow range, if there is not enough or too much flow going through the pumps, the resulting turbulence and vortices can reduce performance and may damage the pumps or equipment. 18. Fill the pump through the drain port with clean hydraulic oil. Install the drain hose.

CAUTION Never start the engine with closed shutoff valves. Open the shutoff valves before starting the engine to prevent damage to hydraulic components. 19. Connect the suction hose and pressure hose to the hydraulic pump.

Hydraulic Tank 24. Start the engine while operating the lift function. Keep engine speed at idle. 25. Lift the mast until it has almost reached its end of stroke. 26. Lower the mast and keep the engine at idle for about one minute. 27. Repeat Step 25 if the pump has produced a sound that relates to cavitation. 28. Raise engine speed to high idle (1000 – 1200 rpm) and lift the mast until it has almost reached its end of stroke. 29. Lower the mast and keep the engine at idle for about one minute. 30. Return to Step 28 if the pump has produced a sound that relates to cavitation.

CAUTION Use a filtration system when filling the hydraulic tank to prevent dirt and contamination from entering the hydraulic system. If dirt or contamination enters the hydraulic system, damage may occur to the components of the hydraulic system. 20. Fill the hydraulic tank with clean hydraulic oil as specified in the maintenance table. Refer to the manual Periodic Maintenance 8000 YRM 1593. 21. Release the clamp of the suction hose at the pump. Slide the hose partly from its fitting allowing trapped air to escape and tank oil to reach the pump. Reinstall the hose and tighten the clamp. 22. Install the batteries into the battery box.

CAUTION Connect the positive (power) cable first or lift truck damage may occur. 23. Connect the positive (power) and negative (ground) cables to the batteries.

31. Operate each hydraulic function in both directions twice, at high engine speed (1600 – 1900 rpm). Release the function when it has reached its end of stroke. 32. Turn the engine OFF.

WARNING Do not try to locate hydraulic leaks by putting hands on pressurized hydraulic components. Hydraulic oil can be injected into the body and cause personal injury. 33. Check for leaks. 34. Check hydraulic tank oil level. Fill the hydraulic tank with clean hydraulic oil as specified in the maintenance table. Refer to the manual Periodic Maintenance 8000 YRM 1593. 35. Position the right-hand panel on top of the hydraulic tank and install the four washers and capscrews.

15


Fuel Tank

100 YRM 1594

Fuel Tank The fuel tank is installed on the left side of the frame between the front fender and counterweight.

REMOVE

13. Disconnect the two fuel hoses from the check valve and shutoff valve at the top of the fuel tank. See Figure 12. 14. Put caps on the fuel hoses and fittings.

1. Place the truck on a solid, level surface. 2. Lower the mast completely.

15. Remove the check valve and shut off valve at the top of the fuel tank. See Figure 12.

3. Shut down the engine.

16. Put caps on the fittings at the top of the fuel tank.

4. Apply the parking brake.

17. Loosen the fuel hose clamp located on top of the frame.

5. Completely tilt (raise) the cab. 6. Remove the connector from the push-button switch at the left-hand panel.

18. Turn the ends of the hoses parallel to the frame. 19. Remove the hose clamp for the cab tilt hoses.

7. Remove the four capscrews and washers holding the left-hand panel and remove the panel.

20. Remove the retaining hardware of the left- and right-hand latch located on the frame.

8. Remove the left-hand extension plate between the fuel tank and counterweight.

21. Remove the two capscrews, and washers at the back of the hand pump. See Figure 13.

WARNING When removing the fuel tank, do not use tools that can produce sparks, heat, or static electricity. The vapors in the tank can cause an explosion and personal injury may occur. NOTE: Use a drain pan to collect the fuel from the fuel tank. The fuel tank contains a maximum of 128 liter (34 gal) of fuel.

22. Remove the capscrews holding the left running board to the counterweight, front fender, and fuel tank and remove the running board.

WARNING Make sure that the lifting device has the rated capacity of 100 kg (220 lb) to lift the fuel tank. NOTE: Removal of the fuel tank can be done with a lifting device, hydraulic jack, hand pallet jack, or lift truck.

9. Put a drain pan under the fuel tank. 10. Remove the drain plug to drain the fuel from the tank. See Figure 12.

WARNING

NOTE: Follow Step 23 and Step 24 when a lifting device is used. NOTE: Follow Step 25 when a hydraulic jack, hand pallet jack, or lift truck is used.

If fuel is drained, put the fuel in a can or barrel that has a protected seal cap.

NOTE: When lifting, keep the fuel tank in the horizontal position.

11. Disconnect the fuel sender connector at the top of the fuel tank. See Figure 12.

23. Attach a lifting device to the fuel tank. Attach lifting eyes at the locations shown in Figure 14.

12. Put tags on the check valve and shutoff valve fuel hoses and fittings for identification.

24. Create slight tension on the chains.

NOTE: Use a drain pan to catch the fuel in the fuel hoses.

16

25. Support the fuel tank with blocks of at least 50 mm (2.0 in.) high to compensate the height of the bracket on the bottom of the fuel tank.


100 YRM 1594

1. FUEL HOSE 2. FUEL SHUTOFF VALVE 3. FUEL TANK

Fuel Tank

4. DRAIN PLUG 5. CHECK VALVE 6. FUEL SENDER CONNECTOR

Figure 12. Fuel Tank

17


Fuel Tank

100 YRM 1594 Repair the fuel tank as described in the section Hydraulic Tank.

CAUTION DO NOT to damage the studs during removal of the fuel tank from the frame. 26. Remove the two nuts and washers that hold the top of the fuel tank and the electrical tilt pump bracket to the frame. 27. Remove the electrical tilt pump and bracket from the frame. 28. Place the electrical tilt pump, hand pump, left and right latch inside the frame to avoid damage to the hoses during the removal of the fuel tank. 29. Remove the remaining nut that holds the fuel tank to the frame. 30. Lift the fuel tank from the studs and move the fuel tank away from the frame.

INSTALL NOTE: Follow Step 1 when a lifting device is used. NOTE: Follow Step 2 when a hydraulic jack, hand pallet jack, or lift truck will be used. NOTE: When lifting, keep the fuel tank in a horizontal position. 1. Attach a lifting device with lifting straps and lifting eyes to the fuel tank. 2. Place the fuel tank on lifting equipment and support with blocks of at least 50 mm (2.00 in.) high to compensate the height of the bracket at the bottom of the fuel tank. 3. Raise and place the fuel tank in front of the left side of the frame.

REPAIR

CAUTION

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

DO NOT to damage the studs during installation of the fuel tank.

1. ELECTRICAL TILT PUMP 2. HAND PUMP

3. FUEL TANK

4. Place the fuel tank over the studs of the frame.

Figure 13. Fuel Tank, Hand Pump, and Electric Tilt Pump

18


100 YRM 1594

Fuel Tank

5. Install the washer and nut, located behind the hand pump, that hold the top of the fuel tank to the frame. 6. Position the hand pump, electrical tilt pump, left and right latch at the frame and route the hoses correctly. 7. Install the two washers and nuts that hold the top of the fuel tank and the electrical tilt pump bracket to the frame. 8. Install the hand pump with the two washers and capscrews located behind the hand pump.

9. Install the left and right latch, located at the frame, with the capscrews, spring washers, washers, and nuts. 10. Install the hose clamps located on top of the frame. 11. Inspect the left running board grommets. Replace if damaged. 12. Put the left running board in place and install the capscrews that hold the running board to the counterweight, front fender, and fuel tank. 13. Install the left hand extension plate between the fuel tank and counterweight using the three washers and capscrews.

Figure 14. Lifting Eyes

19


Cab

100 YRM 1594

14. Install the drain plug at the bottom of the fuel tank. 15. Install the check valve and shutoff valve at the top of the fuel tank. 16. Connect the two fuel hoses to the check valve and shut off valve at the top of the fuel tank. 17. Connect the connector to the electrical tilt pump. 18. Connect the connector of the fuel sender to the top of the fuel tank. 19. Position the left-hand panel on top of the fuel tank and install the four capscrews and washers. 20. Connect the connector, located at the left-hand panel, to the push button switch.

21. Fill the fuel tank to the correct level with fuel specified in the section Periodic Maintenance 8000 YRM 1593.

CAUTION Connect the positive (power) cable first or lift truck damage may occur. 22. Connect the positive (power) and negative (ground) cable to the batteries. 23. Completely lower the cab. 24. Start the engine. 25. Check for leaks.

Cab RAISING AND LOWERING CAB Raise Cab WARNING Make sure no one is under cab when raising or lowering cab.

WARNING Before you place any part of your body under cab, always make sure that cab is fully tilted, or when partially open, is locked by tilt latch.

NOTE: Just before fully open position is reached, movement may be gravity controlled. 7. Pull tilt latch release and continue to raise cab to fully open position. See Figure 16. NOTE: If cab will not fully raise, lower cab until cab locks in partially open position, and fill tilt system with oil. See Oil Filling for Cab Tilt System. NOTE: Raising cab gives access to components such as engine, transmission/hydraulic compartment, throttle/brake and steering control, heater, air conditioner, and electrical connectors.

CAUTION Cab damage may occur if mast is not completely tilted forward. 1. Tilt mast fully forward. 2. Remove all unsecured items from cab. 3. Close and securely latch both cab doors. 4. Clear all obstacles from right-hand side (as seen from driver’s position) of truck. Provide minimum of 2 m (7 ft) of clearance space. 5. Use pump lever to turn direction valve clockwise to "Raise" position. See Figure 15. 6. Operate pump with pump lever until cab locks in partially open position.

1. PUMP LEVER CONNECTION 2. VALVE DIRECTION SELECTION: CLOCKWISE RAISE, COUNTERCLOCKWISE - LOWER

Figure 15. Cab Tilt Pump and Direction Valve

20


100 YRM 1594

Cab pump direction control. Procedure to raise or lower is the same.

CAB REPAIR Remove WARNING Before removing heater hoses, allow time for heater hoses to cool down. Hot water may cause severe burns.

WARNING 1. 2. 3. 4.

CAB FRAME TILT LATCH RELEASE PUMP LEVER

Make sure the lifting device has a minimum capacity to lift 1000 kg (2205 lb). A lifting device that does not have the minimum capacity can break causing the cab to drop and may result in serious personal injury.

Figure 16. Pump Lever and Tilt Latch Release Knob

Lower Cab WARNING Make sure no one is under cab when raising or lowering cab.

CAUTION Lift the operator’s cab carefully. Make sure all wires and attachments are disconnected and loose components are not obstructing the movement. 1. Switch off engine. 2. Disconnect battery ground lead.

WARNING Before you place any part of your body under cab, always make sure that cab is fully tilted, or when partially open, is locked by tilt latch.

CAUTION Cab damage may occur if mast is not completely tilted forward.

3. Raise operator’s cab. See Raise Cab. 4. Remove the two side covers. 5. Disconnect connector CPR04 to throttle pedal sensor. 6. Disconnect connector CPS07 to cab signals. 7. Disconnect connector CPS06 to cab power.

1. Use pump lever to turn direction valve counterclockwise to "Lower" position. See Figure 15. 2. Check that all foreign items/tools are cleared away. 3. Operate pump with pump lever until cab locks in partially open position. 4. Pull tilt latch release and continue to lower cab until it is in fully lowered position and latched. See Figure 16. NOTE: An electric-powered cab tilt system is available to replace standard manual tilt system. The electric tilt system contains a push button located on left side of

8. Disconnect connector CPS35 to aux-signals. NOTE: Cab is equipped with a heater and air conditioner assembly which is installed on the underside of the cab. 9. Place a drain pan under the two heater hoses before disconnecting the heater hoses to catch the coolant in the hoses and heater core. 10. Tag and disconnect the two heater hoses from the heater inlet and outlet ports, and plug the heater hoses and ports. See Figure 17.

21


Cab

100 YRM 1594

CAUTION Replacement, installation, and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid may only be performed by a certified technician.

20. Remove four rubber isolation mounts from frame and inspect for damage. Reinstall or replace if necessary.

11. If the cab is provided with air conditioning, disassemble the air conditioning compressor from the engine while keeping the hoses attached to the compressor. Attach the compressor to the cab and make sure the hoses are clear of all obstacles and components. If the hoses must be detached from the compressor, first have the system emptied by a certified technician. After the system has been emptied, disconnect the hoses and plug the fittings. NOTE: Use a drain pan to collect the oil from the hydraulic hoses.

1. 2. 3. 4.

HEATER HINGE BRACKET HEATER ASSEMBLY CAPSCREW LOCATION HEATER OUTLET HEATER INLET

Figure 17. Heater Assembly

12. Tag and disconnect the steering hoses that are connected to the steering pump at ports LS, L, T, R, and P. See Figure 18. 13. Place a cap on hydraulic hoses and open ports of steering pump. 14. Tag and disconnect the three hydraulic hoses from brake treadle valve. Place a cap on hydraulic hoses and open ports of brake treadle valve.

CAUTION When lowering cab, make sure loose components are not obstructing the movement. 15. Lower operator’s cab. See Lower Cab. 16. Remove four mounting bolts, two on left side and two on right side of truck. 17. Open cab doors before attaching a lifting device. 18. Put a lifting strap underneath the roof of the cab. Put a cushion at top of door area to prevent damage. Close the cab doors. 19. Carefully lift cab away from lift truck. Set cab assembly in a suitable storage area and put blocks under cab to stabilize and prevent damage.

22

1. 2. 3. 4. 5.

STEERING STEERING STEERING STEERING STEERING

HOSE HOSE HOSE HOSE HOSE

PORT PORT PORT PORT PORT

LS L T R P

Figure 18. Steering Pump Connections


100 YRM 1594

Oil Filling for Cab Tilt System

Install 1. Open cab doors before attaching a lifting device. 2. Put a lifting strap underneath the roof of the cab. Put a cushion at top of door area to prevent damage. Close the cab doors.

17. Remove tags and connect the two heater hoses from the heater to the inlet and outlet ports, 18. Lower cab. See Lower Cab. 19. Install doors. 20. Connect battery ground lead.

3. Make sure that insulators are in place. See Figure 19.

21. Install side panels.

4. Lift operator’s cab.

22. Start lift truck and check for leaks on all hoses that were removed. Tighten if necessary.

5. Carefully lower cab on insulators and make sure that it is properly centered. 6. Install four mounting bolts, two on left side and two on right side of truck mount cab. 7. Tighten cab mounting bolts to 66 N•m (49 lbf ft). 8. Raise cab. See Raise Cab. 9. Connect ground lead. 10. Connect CPS35 to aux-signals. 11. Connect CPS06 to cab power. 12. Connect CPS07 to cab signals. 13. Connect CPR04 to throttle pedal sensor. 14. Remove caps on hydraulic hoses and open ports of brake treadle valve. Remove tags and connect three hydraulic hoses to brake treadle valve.

1. TOP PART OF INSULATOR 2. BOTTOM PART OF INSULATOR

3. BOLT 4. WASHER 5. LOCKWASHER

Figure 19. Insulators

15. Connect steering hoses to ports P, R, T, L, and LS on steering pump. See Figure 18. 16. Replace compressor on the engine. Make sure the hoses are clear of all obstacles and components.

Oil Filling for Cab Tilt System CAUTION When oil is added to the cab tilt system, place an oil absorbing material around the fill cap before lowering the cab. Excess oil may bleed out of the relief valve, which is located in the fill cap. NOTE: If the oil level is low, the cab will not tilt/raise completely. NOTE: If the cab is lowered, perform Step 1. If the cab is raised, go to Step 2.

1. Tilt/Raise raise the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab. 2. Lower the cab until it locks in the partially open position. Refer to the section Raising and Lowering Cab. 3. Place the pump lever connection in the fully down position to create easy access to the fill cap. See Figure 20.

23


Engine

100 YRM 1594

4. Remove the fill cap. See Figure 20. 5. Add hydraulic oil through the filler opening until the level is within 30 to 35 mm (1.18 to 1.38 in.) of the top of the reservoir. See Figure 21. For your lift truck, refer to the appropriate Periodic Maintenance YRMfor the correct hydraulic oil specification. 6. Install the fill cap. See Figure 20. 7. Tilt/raise the cab and make sure the maximum tilted/raised (fully opened) position can be reached. Refer to the section Raising and Lowering Cab. 8. If necessary, repeat Step 1 through Step 7. 9. Lower the cab until it is in the fully lowered position and completely latched. Refer to the section Raising and Lowering Cab.

1. FILL CAP 2. PUMP LEVER CONNECTION

Figure 20. Hand Pump

Figure 21. Cab Tilt Label

Engine REMOVE WARNING Engine must be at room temperature before starting disassembly or personal injury may occur.

CAUTION

4. Apply the parking brake. 5. Completely tilt (Raise) the cab.

CAUTION Disconnect the negative (ground) cable first or damage to the lift truck may occur.

Repairs to air conditioning that require discharging and/or refilling of the refrigeration fluid must be performed only by a trained and certified air conditioning specialist.

6. Let coolant cool to room temperature.

1. Place the truck on a solid, level surface.

8. Remove the hood. See Hood Assembly, Remove.

2. Lower the mast completely.

9. Disconnect the electrical cable from the air conditioner compressor.

3. Shut down the engine.

24

7. Disconnect the negative (ground) and positive (power) cables from the batteries.


100 YRM 1594 NOTE: Removing the compressor for the air conditioner with the hoses attached prevents the need to have a certified specialist suction and refill the air conditioning system.

Engine 20. Remove the drain plug at the bottom of the transmission and put the transmission oil in a clean barrel.

NOTE: DO NOT remove the refrigerant hoses.

21. Install the drain plug at the bottom of the transmission.

10. Remove the air conditioner compressor from the mounting bracket located on the engine.

22. Close the fuel shutoff valve at the top of the fuel tank.

11. Attach the air conditioner compressor with the hoses to the cab. Make sure the hoses are free from the engine/transmission during removal.

23. Put tags on the fuel hoses and fittings for identification.

12. Put tags on the two heater hoses for identification. 13. Disconnect the two heater hoses located under the operators compartment at the engine side. 14. Put caps on the two heater hoses.

WARNING DO NOT remove the radiator cap from the expansion bottle 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.

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 15. Make sure engine and coolant have cooled to room temperature. NOTE: Use drain pans large enough to catch all coolant. For coolant volume see, Cooling System 700 YRM 1595.

NOTE: Use a drain pan to catch the fuel in the fuel hoses. 24. Disconnect the fuel hose at the diesel fuel filter. 25. Disconnect the fuel hose at the check valve. 26. Put caps on the fuel hoses and fittings. 27. Strap the fuel hoses to the engine. 28. Remove the two charge air cooler tubes from the charge air cooler core and engine assembly. 29. Remove the two engine coolant hoses from the engine cooling core and engine assembly. 30. Put tags on the two transmission oil hoses for identification. 31. Disconnect the two transmission oil hoses from the thermostat manifold at the inlet and outlet port. 32. Put caps on the two transmission hoses and on the inlet and outlet port of the thermostat manifold. 33. Drain the hydraulic tank.

16. Remove the radiator cap from the expansion tank.

34. Disconnect the suction hoses from the hydraulic pumps.

17. Open the coolant drain valve at the lower end of the engine cooling core.

35. Place a cap on the suction hose from the hydraulic pump.

18. Alternatively, to speed up the draining process, loosen the clamp on the coolant return hose at the water pump. Remove the hose from the water pump. Attention: the coolant will now flow out of the cooling core very rapidly.

36. Put tags on the two pressure hoses of the hydraulic pump for identification.

19. Use a drain pan to catch the coolant. For coolant volume see, Cooling System 700 YRM 1595.

37. Disconnect the two pressure hoses from the hydraulic pump.

NOTE: Use a drain pan to drain the transmission oil from the transmission. Total volume of transmission oil: 27 liter (7.1 gal).

38. Put caps on the two pressure hoses.

NOTE: Use a drain pan to catch the hydraulic oil in the pressure hoses.

25


Engine

100 YRM 1594

39. Disconnect the return hoses from the hydraulic tank. See Figure 11.

NOTE: The hexagon nut that connects the fan clutch to the fan spacer has LEFT HAND THREAD.

40. Disconnect the three electrical wires located at the left side of the engine from the alternator.

52. On trucks with Tier 4i/Stage III B engines: – Hold the fan spacer with a spanner, and unscrew the hexagon nut by turning it CLOCKWISE. – Put the fan clutch assembly inside the shroud.

41. Disconnect the four electrical wires located at the left side of the engine from the starter. 42. Disconnect the electrical wire located at the left side of the transmission from the transmission control valve. 43. Disconnect the electrical wire for the output speed sensor and speed/temperature sensor located at the left side of the transmission. 44. Disconnect the controller connector and Engine supply connector located at the right side of the engine from the engine.

53. Disconnect the drive shaft from the transmission.

WARNING Make sure that the lifting device has the rated capacity of 2500 kg (5512 lb). 54. Install lifting eyes at the locations indicated in Figure 25. The size of the thread in the transmission housing is 3/4-10 UNC.

45. Disconnect the two electrical wires for the engine oil pressure located at the right side of the engine from the engine. 46. Disconnect the electrical wire for the fuel filter sender, located at the right side of the engine, from the engine. 47. Disconnect the electrical wire for the convertor out temperature sensor located at the right side of the transmission from the transmission. 48. Disconnect the electrical wire for the turbine speed sensor located at the right side of the transmission from the transmission. 49. Remove the clamps that hold the two electrical wires at the top of the engine that run from the right to the left side. Reposition the two electrical wires to the right side of the frame. 50. On trucks with Tier 3/Stage III A engines, reach between the fan blades with a tool and remove the four capscrews which hold the fan and fan spacer. Put the fan inside the shroud. 51. On trucks with Tier 4i/Stage III B engines: – Disconnect the electric connector of the fan clutch. See Figure 22 – Remove the bolt that connects the anti-rotation bracket to the support bracket. – Remove tie-wrap(s) from the electric cable of the fan clutch, except those around the anti-rotation bracket.

26

1. 2. 3. 4. 5. 6. 7.

ENGINE CORE SUPPLY HOSE SUPPORT BRACKET BOLT ANTI-ROTATION BRACKET FAN PULLEY FAN SPACER HEXAGON NUT

Figure 22. Fan Clutch Assembly, Tier 4i/Stage III B only


100 YRM 1594

1. 2. 3. 4.

Engine

ALTERNATOR CONNECTORS STARTER CONNECTORS SPEED/TEMPERATURE SENSOR TRANSMISSION CONTROL VALVE CONNECTOR

5. TRANSMISSION SPEED SENSOR 6. CONVERTER OUT TEMPERATURE SENSOR

Figure 23. Electric Engine Connections, Left-Hand Side

27


Engine

100 YRM 1594

1. CONTROLLER CONNECTOR 2. ENGINE SUPPLY CONNECTOR 3. ENGINE OIL PRESSURE CONNECTORS

4. FUEL FILTER SENDER WIRE 5. INTERMEDIATE SPEED SENSOR 6. TURBINE SPEED SENSOR

Figure 24. Electric Engine Connections, Right-Hand Side

28


100 YRM 1594

Engine

55. Connect a lifting device to the two engine lifting eyes and to the lifting eyes at the transmission. 56. Remove the two engine mount capscrews, small washers, large washers, and nuts that hold the rear of the engine to the frame. See Figure 26. 57. Remove the two transmission mount capscrews, small washers, large washers, and nuts that hold the transmission to the transmission frame bracket. See Figure 27. 58. Lift the engine and transmission assembly from the frame. Make sure all the connections to the engine and transmission have been removed. 59. Remove the four bolts and washers to remove the transmission frame bracket. 60. Remove the four transmission housing capscrews and washers from the transmission mount bracket. 61. Remove transmission housing bracket.

1. 2. 3. 4. 5. 6.

ENGINE MOUNT CAPSCREW ENGINE MOUNT BRACKET WASHER (SMALL) INSULATOR WASHER (LARGE) NUT

Figure 26. Engine Mounts

1. ENGINE LIFTING EYES 2. TRANSMISSION LIFTING EYES

Figure 25. Engine Assembly

29


Engine

100 YRM 1594

INSTALL

– Reconnect the electric connector of the fan clutch assembly. – Install tie-wraps as necessary to keep the electric cable from touching any moving part. See Figure 22.

1. Install the transmission mounting bracket onto the transmission housing with the capscrews. Tighten the capscrews to 390 N•m (288 lbf ft). See Figure 27. 2. If the transmission frame bracket was removed, install the bracket with the washers and the four capscrews to the frame. Tighten the capscrews to 390 N•m (288 lbf ft). See Figure 27. 3. Install the insulators onto the transmission frame bracket and onto the engine mounts on the frame.

WARNING Make sure that the lifting device has the rated capacity of 2500 kg (5512 lb) or personal injury may occur.

11. Connect the return hoses to the hydraulic tank. 12. Connect the two pressure hoses to the hydraulic pump. 13. Connect the suction hoses to the hydraulic pumps. 14. Connect the two transmission oil hoses to the thermostat manifold at the inlet and outlet port. 15. Connect the two engine coolant hoses to the engine coolant core and engine assembly.

4. Connect a lifting device to the two engine lifting eyes and to the lifting eyes at the transmission. See Figure 25. 5. Lift and position the engine and transmission assembly in the frame. 6. Install the capscrews, small washers, large washers and nuts to the engine and transmission mounts. Tighten to 165 N•m (122 lbf ft). 7. Connect the drive shaft to the transmission and tighten the bolts to 50 N•m (37 lbf ft). 8. On trucks with Tier 3/Stage III A engines: – Lift the fan out of the shroud. – Install the fan spacer and the fan to the fan pulley. – Install the four capscrews which hold the fan and fan spacer to the fan pulley, and torque to 43 N•m (31.7 lbf ft). 9. On trucks with Tier 4i/Stage III B engines: – Lift the fan clutch assembly out of the shroud and install it onto the fan spacer. NOTE: The hexagon nut that connects the fan clutch to the fan spacer has LEFT HAND THREAD. 10. On trucks with Tier 4i/Stage III B engines: – Hold the fan spacer with a spanner, and hand tighten the hexagon nut by turning it COUNTERCLOCKWISE. Final torqueing will occur by normal operation of the engine. – Connect the anti-rotation bracket to the support with the bolt, washer and nut.

30

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

TRANSMISSION MOUNT BRACKET TRANSMISSION MOUNT CAPSCREW SMALL WASHER INSULATOR TRANSMISSION FRAME BRACKET LARGE WASHER NUT WASHER TRANSMISSION HOUSING CAPSCREW WASHER FRAME BRACKET CAPSCREW

Figure 27. Transmission Mounts


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YALE F876 GDP210DC LIFT TRUCK Service Repair Manual  
YALE F876 GDP210DC LIFT TRUCK Service Repair Manual  
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