Yale d876 glp120db lift truck (europe)service repair manual by 163048

GDP/GLP80-120DB (D876), GDP/GLP130-160EB (D877) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

OPERATOR'S CAB........................................................................................................ FRAME............................................................................................................................ OPERATOR'S CAB........................................................................................................ CAB HEATER (PRIOR TO OCT. 2008).......................................................................... CUMMINS ENGINE FAULT CODE GUIDE.................................................................... MULTIPLE ALIGNED COOLING SYSTEM.................................................................... TRANSMISSION REPAIR.............................................................................................. TRANSMISSION OPERATION AND DIAGNOSTICS.................................................... APC200 FAULT CODE GUIDE...................................................................................... DIFFERENTIAL............................................................................................................... PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. PLANETARY DRIVE AXLE (DRY SYSTEM)................................................................. STEERING AXLE............................................................................................................ STEERING SYSTEM...................................................................................................... BRAKE SYSTEM (DRY)................................................................................................. BRAKE SYSTEM (WET)................................................................................................. HYDRAULIC SYSTEM.................................................................................................... MAIN CONTROL VALVE................................................................................................ TILT CYLINDERS........................................................................................................... INSTRUMENT PANEL INDICATORS AND SENDERS................................................. ELECTRICAL SYSTEM.................................................................................................. MAST AND CARRIAGES............................................................................................... 2-STAGE MAST.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... ASSEMBLY GUIDE........................................................................................................ DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS...........................................................................

524206063 524300812 550033400 550033397 524211827 524300813 524302733 524304019 550022606 524150779 524150780 524150781 524150783 524150782 524150784 524150785 524150787 524150788 524150790 524206632 524300814 524203754 550088524 524150797 524230692 524298462 524298463 524298464

0100 YRM 1100 0100 YRM 1349 0100 YRM 1390 0100 YRM 1458 0600 YRM 1101 0700 YRM 1350 1300 YRM 1356 1300 YRM 1358 1300 YRM 1435 1400 YRM 0046 1400 YRM 0944 1400 YRM 0945 1600 YRM 0326 1600 YRM 0936 1800 YRM 0937 1800 YRM 0951 1900 YRM 0938 2000 YRM 0943 2100 YRM 0103 2200 YRM 1105 2200 YRM 1351 4000 YRM 1062 4000 YRM 1647 8000 YRM 0231 8000 YRM 1181 8000 YRM 1346 8000 YRM 1347 8000 YRM 1348

09/08 01/11 11/13 04/11 07/14 05/12 03/11 11/11 02/12 08/12 08/12 08/11 03/07 03/07 04/10 03/11 03/07 03/07 03/07 03/07 04/07 08/12 05/14 10/13 12/14 05/07 09/13 07/13

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524295484 (12/14)

100 YRM 1100

General

General A fully-enclosed operators cab is positioned on four large rubber anti-vibration mounts to isolate operator from shock, noise, and vibration. See Figure 1. Operator’s compartment includes electronic controls for hydraulic systems, steering wheel, instrument panel, transmission, brake system controls, and operators seat. An overhead guard forms an integral part of the

operators cab. The cab is installed on a platform above main frame members. Step plates on both sides of lift truck give access to cab. The operators cab can be tilted, providing access to major components. For major repairs to cab, cab can be completely removed from frame of lift truck.

1. 2. 3. 4.

5. FRONT, REAR, AND TOP WINDOWS 6. OPERATOR’S CONSOLE, CONTROLS, AND ARMREST 7. HEATER SECTION

INCHING, BRAKE, AND THROTTLE PEDALS SEAT STEERING COLUMN FRONT, REAR, AND TOP WIPER ASSEMBLIES

Figure 1. Operators Cab

Cab Repair

100 YRM 1100

Cab Repair REAR CAB ASSEMBLY See Figure 2 for rear cab assembly.

1. 2. 3. 4. 5.

COVER PLATE FUSE SECTION RELAY SECTION HYDRAULIC VALVE CONTROLLER FOAM COVER

NOTE: Interior covers are affixed with self-tapping screws.

6. 7. 8. 9. 10.

HEADLINER REAR DUCT ASSEMBLY CONSOLE COVER CONSOLE TOP INSTRUMENT PANEL

Figure 2. Rear Cab Assembly

100 YRM 1100

Cab Repair

BOTTOM CAB ASSEMBLY

1. Tilt mast fully forward.

See Figure 3 for bottom cab assembly.

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 driverâ&#x20AC;&#x2122;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 4.

1. WIPER MOTOR ASSEMBLY 2. WIPER COUPLING 3. AIR FILTER

4. COVER PLATE 5. STEERING PUMP 6. HORN

Figure 3. Bottom Cab Assembly

1. PUMP LEVER CONNECTION 2. DIRECTION VALVE SELECTION: CLOCKWISE RAISE, COUNTERCLOCKWISE - LOWER Figure 4. Pump and Direction Valve

RAISING AND LOWERING CAB

6. Operate pump with pump lever until cab locks in partially open position.

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.

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

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 5. 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 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.

Cab Repair

100 YRM 1100 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 5. 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 operatorâ&#x20AC;&#x2122;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

3. Raise operatorâ&#x20AC;&#x2122;s cab. See Raise Cab. 4. Remove four hex bolts holding steering pump. See Figure 6. 5. Remove two bolts holding brake valve.

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

6. Disconnect electrical cable to throttle pedal sensor. See Figure 11.

1. Use pump lever to turn direction valve counterclockwise to "Lower" position. See Figure 4.

7. Disconnect electrical cable.

2. Check that all foreign items/tools are cleared away.

8. Disconnect electrical plugs that are located to right of heater unit.

3. Operate pump with pump lever until cab locks in partially open position.

9. Disconnect window washer hoses and mark their positions.

4. Pull tilt latch release and continue to lower cab until it is in fully lowered position and latched. See Figure 5.

10. Remove three bolts and swing heater unit down.

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

11. Disconnect electrical connections, control cables, and air duct from heater unit. 12. Disconnect ground lead.

100 YRM 1100

Cab Repair 19. Remove four rubber isolation mounts from frame and inspect for damage. Reinstall or replace if necessary.

Install 1. Connect lift strap under overhead guard structure. Provide cushion at top of door area to prevent damage. 2. Make sure that insulators are in place. See Figure 7.

1. 2. 3. 4. 5.

STEERING PUMP HEX BOLTS BRAKE VALVE BOLTS STEERING PUMP BRAKE VALVE ELECTRICAL CONNECTIONS Figure 6. Steering Pump, Throttle and Inching Connections

1. 2. 3. 4. 5.

TOP PART OF INSULATOR BOTTOM PART OF INSULATOR BOLT WASHER LOCKWASHER Figure 7. Insulators

3. Lift operator’s cab. 4. Carefully lower cab on insulators and make sure that it is properly centered. 5. Mount cab with washers and bolts. 6. Tighten cab mounting bolts to 66 N•m (49 lbf ft).

15. Remove four mounting bolts, two on left side and two on right side of truck.

7. Raise cab. See Raise Cab.

16. Remove cab doors before attaching a lifting device.

8. Connect electrical cables, ground wire, hoses, steering pump, and brake valve. Make sure that all connections have been restored.

17. Connect a lift strap under overhead guard structure. Provide a cushion at top of door area to prevent damage. 18. 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.

9. Mount heater unit to hinge. Connect control cables and electrical connections. Pivot unit up and install with three bolts. 10. Connect inching and throttle cables. See Inching and Brake Pedals.

Oil Filling for Tilt System

100 YRM 1100

11. Lower cab. See Lower Cab.

13. Connect battery ground lead.

12. Install doors.

14. Install side panels.

Oil Filling for Tilt System CAUTION When oil has been added, put oil-absorbing material around filler plug before lowering cab. Excess oil may bleed out of relief valve, which is fitted in filler plug. NOTE: When cab does not reach the maximum opening the oil level is low. 1. Lower cab until it locks in partially open position. See Lower Cab. 2. Put pump lever connection in fully down position to gain access to the fill cap. See Figure 8. 3. Remove fill cap. See Figure 8. 4. Add hydraulic oil into filler opening until level is within 30 to 35 mm (1.18 to 1.38 in.) of top of reservoir. See Figure 9.

1. FILL CAP Figure 8. Hand Pump

5. Install fill cap. See Figure 8. 6. Raise cab and make sure that maximum tilt can be reached. See Raise Cab. 7. Repeat procedure if necessary. 8. Lower cab until it is in fully lowered position and completely latched.

Figure 9. Cab Tilt Label

100 YRM 1100

Inching and Brake Pedals

Inching and Brake Pedals BRAKE PEDAL, ADJUST

3. Proceed with inching pedal sensor adjustment.

1. Adjust bolt (3), behind the brake pedal, on the brake pedal assembly so that the roller has contact with the bolt on the valve until there is no free travel. See Figure 10.

INCHING PEDAL SENSOR, ADJUST NOTE: When the brake pedals are not activated, the analog output of the inch sensor should be between 600 and 700 mV. This means the sensor is slightly turned as the lowest possible reading is 400 mV. 1. Loosen the two, one shown, sensor mounting bolts. See Figure 11. NOTE: To read the voltage, use the "Inching Pedal Calibration" mode of the UserlinkÂŽ program as explained in the section Transmission 1300 YRM 1082. 2. Rotate sensor in the slotted holes underneath the inching pedal so that the output voltage of the sensor of the released inching pedal is between 600 and 700 mV.

1. 2. 3. 4.

BRAKE PEDAL INCHING PEDAL ADJUSTMENT BOLT FOR BRAKE PEDAL ADJUSTMENT BOLT FOR INCHING/BRAKE PEDAL COUPLING 5. ADJUSTMENT BOLT FOR INCHING PEDAL

3. Tighten the mounting screws and recheck the voltage output at the sensor. 4. Calibrate the inching pedal. See the section Transmission 1300 YRM 1082.

Figure 10. Brake Pedal System 2. Proceed with inching pedal adjustment.

INCHING PEDAL, ADJUST NOTE: Adjust the inching pedal so that the brake pedal moves at the same time, which means there is no free play with the brake pedal. NOTE: When brake pedal and inching pedal are in released position their position must be equally high or in line. 1. When activating inching pedal, brake pedal should be activated as soon as top of inching pedal and top of brake pedal are on same plane. Use adjustment bolt (4) for inching/brake pedal coupling adjustment. See Figure 10.

1. MOUNTING BOLT Figure 11. Sensor Adjustment

2. Adjust bolt (5) for inching pedal to eliminate free travel of inching pedal before braking action occurs.

Throttle Pedal Sensor

100 YRM 1100

Throttle Pedal Sensor CHECK

7. Lower cab. See Lower Cab.

NOTE: When a new throttle pedal sensor is installed, rotate the throttle pedal sensor counterclockwise, when looking inside the throttle box, until the end of the slotted holes. See Figure 12. 1. Switch engine ON. 2. Operate throttle pedal. See Figure 12. 3. Check position, dimension A, of the throttle pedal at which the engine rpm goes from idle to higher rpm value. 4. If dimension A is not within 6 to 10 mm (0.236 to 0.394 in.), adjust the mechanical position of the electronic throttle potentiometer. See Adjust.

ADJUST 1. Raise cab. See Raise Cab. 2. Make sure the throttle pedal stop is adjusted so that it is against the cabin floor plate. 3. Position a 5 mm (0.197 in.) spacer between the throttle pedal and throttle pedal stop. 4. Loosen mounting screws and turn the throttle pedal sensor to position at which engine rpm increases from idle or decreases rpm to idle. 5. Tighten mounting screws. 6. Remove the 5 mm (0.197 in.) spacer between the throttle pedal and throttle pedal stop.

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

DIMENSION A THROTTLE PEDAL THROTTLE PEDAL ADJUSTMENT THROTTLE PEDAL SENSOR MOUNTING SCREW COUPLING CABIN FLOOR PLATE THROTTLE PEDAL STOP COUNTERCLOCKWISE SLOTTED HOLE Figure 12. Throttle Arrangement

100 YRM 1100

Power Assist Armrest

Seat Assembly Removal NOTE: Use a lifting device for removal of seat. NOTE: For mechanical seat, there will be one connector. For air suspension seat, there will be two connectors. 1. Disconnect battery ground lead. 2. Disconnect connector(s). See Figure 13. 3. Disconnect plug to side console. 4. Loosen four bolts connecting seat to cab. 5. Remove seat. Legend for Figure 13 1. ELECTRICAL CONNECTORS AND PLUG TO SIDE CONSOLE (REAR OF SEAT) 2. BOLTS Figure 13. Operators Seat

Power Assist Armrest ADJUST 1. Disconnect cable from lever. See Figure 14. 2. Remove the mounting bolts that hold the gas spring assembly. 3. Loosen nut. 4. Adjust top section, clockwise or counterclockwise, to obtain a free lever movement of 1.5 to 2.0 mm (0.06 to 0.079 in.). NOTE: Apply small bead of non permanent LoctiteÂŽ to bolt treads. 5. Install gas spring assembly using the two bolts. 6. Install and adjust cable on lever to obtain correct operation. Legend for Figure 14 1. LEVER 2. TOP SECTION 3. NUT

4. BOLT 5. LEVER 6. CABLE Figure 14. Power Assist Armrest

Steering Column Repair

100 YRM 1100

Steering Column Repair REMOVE 1. Raise cab. See Raise Cab. 2. Disconnect battery ground lead. 3. Disconnect steering column connector. See Figure 15 and Figure 16. 4. Remove four hex bolts fastening steering pump to cab and carefully remove steering pump. 5. Remove two cab mounting bolts holding steering column to the floor. 6. Lower cab. See Lower Cab. 7. Remove two hex bolts holding steering column to bracket.

1. STEERING COLUMN TO BRACKET BOLTS 2. STEERING COLUMN TO FLOOR PLATE BOLTS Figure 15. Steering Column

8. Remove steering column. Push grommet out of hole and slide connector through hole.

INSTALL 1. Slide connector through hole in floor and push grommet into hole. 2. Connect steering column to bracket with two cab mounting bolts. 3. Raise cab. See Raise Cab. 4. Mount steering column to cab base with two steering column hex bolts. 5. Carefully mount steering pump with four steering pump hex bolts to allow non-forced coupling between steering pump and steering column. 6. Connect electrical connector. 7. Connect battery ground lead. 8. Lower cab. See Lower Cab.

1. STEERING COLUMN CONNECTOR 2. STEERING COLUMN BOLTS 3. STEERING PUMP BOLTS Figure 16. Steering Pump

100 YRM 1100

Window Wipers Replacement

Window Wipers Replacement NOTE: Three window wiper motor assemblies are installed in the cab. The front window has a single-arm, parallelogram-type, wiper motor system to give a large wiped surface area. The wiper motor is mounted under the cab so as not to obstruct visibility. The top window is provided with a wiper motor assembly that has one wiper arm with wiper blade. The rear window is provided with a wiper motor assembly that has one wiper arm with wiper blade. A washer system is connected to all wipers.

FRONT WINDOW WIPER MOTOR ASSEMBLY, REPLACE 1. Disconnect battery ground lead. 2. Disconnect connector. See Figure 18. 3. Remove clamp tightening bolt and arm. 4. Remove three bolts. 5. Remove motor assembly.

WINDOW WIPER ASSEMBLY, REPLACE 1. Lift cover. See Figure 17.

6. Install new motor assembly. Proceed in reverse order.

2. Loosen and remove nut and washer. 3. Mark position of blade on window. 4. Disconnect wiper. 5. Disconnect washer hose if applicable. 6. Install new wiper assembly. Make sure that wiper assembly is properly positioned to give optimal coverage of window. Proceed in reverse order.

1. 2. 3. 4.

CLAMP TIGHTENING BOLT AND ARM BOLTS MOTOR ASSEMBLY CONNECTOR

Figure 18. Front Window Wiper Motor Assembly

1. COVER 2. COVER OPEN

3. NUT WITH WASHER

Figure 17. Wiper Assembly

Window Wipers Replacement

100 YRM 1100

REAR WINDOW WIPER MOTOR ASSEMBLY, REPLACE

TOP WINDOW WIPER MOTOR ASSEMBLY, REPLACE

1. Disconnect battery ground lead.

2. Remove wiper assembly. See Window Wiper Assembly, Replace.

2. Remove 10 screws fastening headliner to cab. See Figure 20.

3. Remove cover of motor assembly unit.

3. Remove headliner.

4. Disconnect connector. See Figure 19.

4. Follow procedure as listed under Rear Window Wiper Motor Assembly, Replace.

5. Remove nuts and washers. 6. Remove motor assembly. 7. Install new motor assembly. Proceed in reverse order.

5. Replace cab headliner. 6. Connect battery ground lead.

1. SCREWS 1. CONNECTOR 2. NUTS AND WASHERS Figure 19. Rear Wiper Motor Assembly

Figure 20. Cab Headliner

100 YRM 1100

Window Washer Motors and Pumps

Window Washer Motors and Pumps NOTE: Three window washer motors with pump assemblies are attached to a water reservoir. See Figure 21. NOTE: When replacing washer motor(s), make sure that water hose(s) is connected to proper pump(s).

WINDOW WIPER AND WASHER OPERATING SWITCHES NOTE: The switch panel for the front, top, and rear window wipers and washers is located on the side of the operators arm rest/console. See Figure 22. NOTE: The fuses, protecting wiper, and washer systems are located inside the operators compartment. See Fuse Panel.

1. FRONT WINDOW WASHER MOTOR AND PUMP 2. TOP WINDOW WASHER MOTOR AND PUMP 3. REAR WINDOW WASHER MOTOR AND PUMP Figure 21. Washer Motors and Pumps 1. 2. 3. 4.

FRONT WINDOW WIPER TOP WINDOW WIPER AND WASHER REAR WINDOW WIPER AND WASHER FRONT WINDOW WASHER Figure 22. Wiper and Washer Switches

Window Replacement

100 YRM 1100

Window Replacement WARNING All windows installed in the cab are made of special glass. All replacement windows must be made of the correct material and must be made of the correct thickness. Failure to have the correct material or thickness may cause the glass to break easily when struck and may cause personal injury.

1. 2. 3. 4. 5.

SEAL WINDOW WINDOW EDGE PROTECTION SEAL UPPER WINDOW GLUED SEAL

NOTE: Before replacing any window, remove all broken glass bits. Make sure replacement glass is dry, clean, and free of grease. Front, rear, and top windows are single units. Front and rear windows are held in place by a rubber seal only. The top window is fastened by clamps. Door windows are mounted to door frames with bolts. Door window and sliding window assembly are glued in. See Figure 23.

6. 7. 8. 9. 10.

SEAL FRAME GLUED SEAL LOWER WINDOW WINDOW EDGE PROTECTION SEAL

Figure 23. Doors/Glass Assemblies

100 YRM 1100

Window Replacement

FRONT WINDOW, REPLACE

REAR WINDOW, REPLACE

1. Remove string from rubber seal. See Figure 24.

1. Proceed as per instructions for the front window. See Front Window, Replace.

2. Install rubber seal around window. 3. Insert a plastic thread (insulated electrical wire) approximately 3 mm (0.118 in.) in slot of rubber seal (cab side slot). 4. Position and press windows against frame.

2. Install wiper assembly.

TOP WINDOW, REPLACE 1. Remove caps and loosen screws of three right angle brackets. See Figure 25.

5. Pull out (inside cab) plastic thread. This will ensure that the slot of rubber seal slides properly over window frame.

2. Remove caps and loosen five screws.

6. Press front window firmly into place.

4. Remove window.

7. Insert string.

5. Check seal. Replace if necessary.

3. Remove rear bracket.

6. Mount right angle brackets but leave loose at this time. 7. Slide window into right angle brackets. 8. Mount rear bracket. 9. Carefully tighten all screws and replace caps.

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

FRONT WINDOW SEAL CROSS SECTION SEAL STRING PLASTIC THREAD (INSTALLATION TOOL) CAB FRAME Figure 24. Front Window and Seal 1. RIGHT ANGLE BRACKETS 2. SCREWS 3. REAR BRACKET Figure 25. Top Window Brackets

Window Replacement

100 YRM 1100

DOOR WINDOW, REPLACE

4. Install new windows.

1. Remove screws. See Figure 26.

5. Install track.

2. Remove window track.

6. Install screws.

3. Remove windows.

1. WINDOW 2. WINDOW TRACK

3. SCREWS 4. WINDOW Figure 26. Door Window, LH Shown

100 YRM 1100

Heater and Air Conditioning Assembly

Heater and Air Conditioning Assembly A high-capacity heater system, with 10 outlet air vents, provides all-around heating and cooling. See Figure 27 and Figure 28. A replaceable filter element ensures that the operator receives clean air from outside. Recirculated fresh air can be manually selected. The threespeed fan and heat controls are located on the righthand side console. NOTE: The air conditioning condenser is mounted on top of the central hood spine. The compressor is located in the engine compartment.

1. HEATER CONTROLS

2. HEATER UNIT 3. AIR FILTER

Figure 27. Heater Unit

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

HEATER HOUSING BLOWER BRACKET HEATER CONTROL VALVE HEATER COIL EVAPORATOR COIL BLOCK VALVE THERMOSTAT COVER PLATE BLOWER VENT DOOR

Figure 28. Heater/Air Conditioning Assembly

Heater and Air Conditioning Assembly

100 YRM 1100

HEATER PARTS, REPLACE

HEAT CONTROL KNOB/SWITCHES

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

The fuses protecting the heater and air conditioning systems are located inside the operators compartment. See Rear Cab Assembly and Fuses.

HEAT CONTROL KNOB/CABLE WARNING When replacing engine heater hoses, make sure replacement hoses meet correct specifications. Failure to meet correct specifications may cause personal injury.

CAUTION 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.

Adjust NOTE: Without air conditioning, the heat control knob (see Figure 30) is mechanically coupled via a cable to the heater control valve. After replacing the cable or associated item, adjustment of the cable is required. NOTE: With air conditioning, the heater control valve is controlled by an electrical signal and no adjustment is required.

1. Disconnect battery ground lead. 2. Raise cab. See Raise Cab. 3. Disconnect heater hoses if required. ure 29.

See Fig-

1. HEATER/AC FAN SWITCH 2. HEAT CONTROL KNOB 1. SCREWS 2. HINGES 3. HEATER HOSES

4. CONNECTIONS 5. AIR FILTER PLATE

Figure 29. Heater Unit 4. Remove three screws. 5. Tilt unit out. 6. Remove cover plate. See Figure 28.

3. AIR CONTROL KNOB 4. A/C SWITCH (OPTIONAL)

Figure 30. Heater Control Switches

CAUTION The heater control valve cable should always be adjusted with the heater turned off. 1. Turn heat control knob clockwise to full hot position. See Figure 30 and Figure 31.

7. Remove defective part.

2. Position the water valve open against the stop. See Figure 32.

8. Replace faulty component.

3. Fasten the cable clips. See Figure 32.

100 YRM 1100

Heater and Air Conditioning Assembly

AIR CONTROL KNOB/CABLE Adjust NOTE: The air control knob (see Figure 30) is mechanically coupled via a cable to the vent door. This vent door controls the ratio of outdoor air and cabin air. After replacing the cable or associated item, adjustment of the cable is required. 1. Turn air control knob clockwise to the recirculation position. See Figure 30. 2. Position the recirculation valve open against the stop. See Figure 33. 3. Fasten the cable clips.

1. EXTENDED CABLE (FULL HOT POSITION) 2. ROTARY CONTROL Figure 31. Rotary Control

1. RECIRCULATION POSITION Figure 33. Recirculation Valve

AIR FILTER, REPLACE 1. Raise cab. See Raise Cab. 2. Remove air filter plate. See Figure 29. 3. Slide out filter. 4. Insert new filter. 1. AGAINST PLASTIC STOP POSITION

2. CABLE CLIPS

5. Mount cover plate. 6. Lower cab. See Lower Cab.

Figure 32. Water Valve

Instruments, Switches, and Controls

100 YRM 1100

AIR CONDITIONING CONDENSER FAN(S)

2. Disconnect battery ground lead.

Remove

3. Open hood.

NOTE: The condenser is mounted on top of the central hood spine.

4. Loosen the twelve screws holding the cover of the condenser. 5. Loosen the four screws holding the fan(s).

6. Replace fan(s) if found to be faulty.

Install 1. Install and tighten the four screws holding the fan(s). 2. Install and tighten the twelve screws holding the cover of the condenser.

CAUTION For trucks with ECM (Engine Control Module), battery disconnect should only be performed 30 seconds after switching OFF ignition.

3. Close hood. 4. Connect battery ground lead.

Instruments, Switches, and Controls NOTE: The instruments and switches are fastened to the instrument console. Disconnect the wiring harness and remove the screws that hold the panels to the instrument panel. See the section Diagrams 8000 YRM 1103. These diagrams will help identify the wiring harnesses and components. For the replacement of gauges, see the section Instrument Panel Indicators and Senders 2200 YRM 1105. NOTE: The rocker switches are replaced by pressing in on flexible tabs at back side to release switch assembly from instrument panel. The replacement switch is installed from top side of instrument panel and pressed in until tabs on the switch lock in the opening for the switch.

SWITCHES See Figure 34 and Figure 35 for locations of switches.

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

MAST WORK LIGHT FRONT FENDER SIDE LIGHTS FLOOD LIGHTS REAR DRIVING LIGHTS BEACON HAZARD LIGHT Figure 34. Switches

100 YRM 1100

Instruments, Switches, and Controls Legend for Figure 36

1. 2. 3. 4. 5.

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

LIFT/LOWER CONTROL LEVER TILT CONTROL LEVER SIDESHIFT/AUXILIARY CONTROL LEVER AUXILIARY CONTROL LEVER RIGHT FORK POSITION SWITCH LEFT FORK POSITION SWITCH

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

LEFT FORK POSITION SWITCH RIGHT FORK POSITION SWITCH HORN BUTTON AUXILIARY CONTROL LEVER MAST CONTROL LEVER LIFT/LOWER CONTROL TILT DIRECTION CONTROL

HORN FRONT WINDOW WIPER FRONT WINDOW WASHER REAR WINDOW WIPER/WASHER TOP WINDOW WIPER/WASHER Figure 35. Switches

CONTROLS See Figure 36 and Figure 37 for locations of controls.

Figure 37. Joystick Hydraulic Controls

Figure 36. Hydraulic Control Levers

Fuses and Relays

100 YRM 1100

Fuses and Relays NOTE: Fuses protecting the various systems are located inside the operators compartment. See Fuse Panel.

FUSES See Figure 39 for fuse locations.

FUSE PANEL 1. Disconnect battery ground lead. 2. Loosen retaining screws. See Figure 38. 3. Remove cover. 4. Remove suspected fuse. 5. Check fuse. 6. Insert new fuse. 7. Reconnect battery lead. 8. Check operation.

Figure 39. Fuse Panel Legend for Figure 39 FUSE DETAILS

1. RETAINING SCREWS

2. COVER

Figure 38. Fuse Panel and Cover Location

1. FUSE PANEL #1 LOCATOR • HYDRAULIC CONTROLS, 15A • TRANSMISSION, 10A • ATTACHMENT CONTROLS, 15A • OPEN • TRANSMISSION B+, 7.5A • PARK BRAKE, 10A • TRANSMISSION B+, 7.5A • FRONT WINDOW WASHER/WIPER, 10A • ROOF WINDOW WASHER/WIPER, 10A • REAR WINDOW WASHER/WIPER, 10A 2. FUSE PANEL #2 LOCATOR • FRONT INNER FLOOD LIGHTS, 10A • FRONT OUTER FLOOD LIGHTS, 10A • REAR DRIVE LIGHTS, 10A • BEACON/STROBE, 10A • STOP LIGHTS, 10A • MAST LIGHTS, 10A • HAZARD LIGHTS, 10A • DIRECTION INDICATORS, 10A • SIDE/TAIL LIGHTS, 10A • FRONT DRIVE LIGHTS, 10A

100 YRM 1100

Fuses and Relays

Legend for Figure 39 (Continued) 3. FUSE PANEL #3 LOCATOR • ENGINE START, 5A • AIR CONDITIONING, 15A • INSTRUMENTATION, 10A • CAB TILT POWER ASSIST, 20A • HORN, 10A • INTERIOR LIGHTING, 5A • SEAT SUSPENSION COMPRESSOR, 15A • HEATER/AC/VENTILATION FAN, 20A • OIL COOLER/AIR DRYER, 10A • REVERSE LIGHTS/ALARM, 5A 4. FUSE PANEL #4 LOCATOR UP TO S/N 01646 (C876) AND 01587 (C877) • CONSOLE ACCESSORY SOCKET, 10A • RADIO/CB/INTERCOM, 3A • CONVERTER, 10A • OPEN • OPEN • OPEN • ECM/ACC PEDAL (CUMMINS), 5A • OPEN • OPEN • OPEN 5. FUSE PANEL #4 LOCATOR STARTING WITH S/N 01647 (C876) AND 01588 (C877) • CONSOLE ACCESSORY SOCKET, 10A • RADIO/CB/INTERCOM, 3A • CONVERTER, 10A • 12V RELAY, 5A • OPEN • OPEN • ECM/ACC PEDAL (CUMMINS)/LPG RELAY, 5A • OPEN • OPEN • OPEN

Figure 40. Perkins Diesel Engine Relays (Located Left of Fuse Panel)

RELAYS See Figure 40, Figure 41, Figure 42 for locations of relays.

Figure 41. Cummins Diesel Engine Relays Up to S/N 01646 (C876) and 01587 (C877) (Located Left of Fuse Panel)

Electrical Schematics

100 YRM 1100

Figure 42. Cummins Diesel/LPG Engine Relays Starting With S/N 01647 (C876) and 01588 (C877) and Up (Located Left of Fuse Panel) NOTE: Start aid (Perkins only), Pressure signal (ECH only), and Flasher (Optional).

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

WARNING Labels that have WARNINGS or CAUTIONS must be replaced if they are damaged. If a mast of a different size or an accessory carriage is installed, the capacity rating can change. Changes in the kind of drive tires can change the capacity rating. See a dealer for Yale lift trucks for a replacement nameplate. The nameplate information is a safety item and must be correct for the equipment and configuration of the lift truck.

3. Carefully hold label in correct position above surface. Label cannot be moved after it touches surface. Put label on surface. Make sure all air is removed from under label and corners and edges are tight. See Parts Manual for correct location and part number.

1. Make sure surface is dry and free of oil or grease. Do not use solvent on new paint. Clean the surface of old paint using cleaning solvent.

Electrical Schematics See the section Diagrams 8000 YRM 1103.

100 YRM 1349

Description

General This section has 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 1100 • Multiple Aligned Cooling System 700 YRM 1350

• • • • •

Planetary Drive Axle, (Wet System) 1400 YRM 944 Planetary Drive Axle, (Dry System) 1400 YRM 945 Steering System 1600 YRM 1365 Hydraulic System 1900 YRM 938 Masts and Carriages, Starting 2003 4000 YRM 1062

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

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

TILT CYLINDER MOUNT MAIN FRAME MAST MOUNT DRIVE AXLE MOUNT SIDE TILTING CAB MOUNT FUEL/HYDRAULIC TANK MOUNT

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

7. 8. 9. 10. 11.

TRANSMISSION MOUNT MAIN COUNTERWEIGHT MOUNT STEER AXLE MOUNT ENGINE MOUNT MAIN CONTROL VALVE MOUNT

Figure 1. Frame

Air Cleaner

100 YRM 1349

Air Cleaner REMOVE

7. Close the hoods.

1. Open the left- and right-hand hood. 2. Loosen the air duct clamp. See Figure 2. 3. Close the left- or right-hand hood to access the precleaner. 4. Remove the pre-cleaner, with the air duct attached, from the air cleaner. 5. Disconnect the connector from the restriction indicator by pressing the metal clip. 6. Remove the hose clamp from the air filter hose and remove the hose from the air cleaner. 7. Remove the bolts of the two mounting clamps. 8. Rotate the air cleaner until the air duct connection is clear from the center of the hood opening and remove the air cleaner to the right-hand side of the truck. 9. Remove the retaining hardware from the mounting clamps and remove the clamps and plate positioned under the hood.

INSTALL 1. Install the retaining hardware to the mounting clamps and install the clamps and plate positioned under the hood. 2. Position the air cleaner assembly at the mounting clamps and tighten the two clamp bolts. 3. Connect the air filter hose to the air cleaner assembly and tighten the hose clamp. 4. Connect the restriction indicator connector to the air cleaner assembly. 5. Close the left- or right-hand hood. 6. Install the pre-cleaner, with the air duct attached, on the air cleaner and tighten the air duct clamp.

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

PRE-CLEANER CAPSCREW HOSE CLAMP CLAMP BOLT MOUNTING CLAMP AIR FILTER HOSE AIR CLEANER ASSEMBLY RESTRICTION INDICATOR AIR DUCT CLAMP AIR DUCT

Figure 2. Air Cleaner

100 YRM 1349

Exhaust System

Exhaust System 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 3. 2. Remove the clamp that connects the turbo charge pipe to the exhaust pipe. 3. Remove the clamp that holds the exhaust pipe to the engine and remove the exhaust pipe and flex tube. 4. Affix a tool that will retain the nut when loosening a capscrew of the muffler. Remove the four capscrews and nuts. 5. Remove the muffler from the hood.

INSTALL 1. Position the muffler at the hood. 2. Install the four capscrews and nuts of the muffler. 3. Install the flex tube and two clamps to the muffler. 4. Install the exhaust pipe and exhaust pipe clamp to the engine. 5. Install the clamp that connects the turbo charge pipe to the exhaust pipe. 6. Tighten all clamps.

1. MUFFLER 2. CAPSCREWS 3. CLAMP

4. FLEX TUBE 5. EXHAUST PIPE 6. CLAMP

Figure 3. Exhaust System

Hood Assembly

100 YRM 1349

Hood Assembly REMOVE 1. Tilt the mast completely forward. 2. Completely tilt (raise) the cab. 3. Open the rear cover. See Figure 4. 4. Remove the bolts from the two isolators on top of the radiator. See Figure 5. 5. Remove the four capscrews that hold the bracket of the hood assembly to the counterweight. 6. Disconnect the two gas springs from the rear cover at the counterweight. 7. Open the left- and right-hand hood. 8. Remove the exhaust pipe, flex tube, and U-bolt.

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

RADIATOR BOLT WASHER ISOLATOR BRACKET LEFT-HAND HOOD HOOD FRAME

Figure 5. Top Isolators 9. Remove the inlet suction tube. 10. Remove the two capscrews, washers, and nuts and remove the expansion tank located underneath the hood. 11. Place the expansion tank inside the engine compartment. 12. Remove all tie-wraps holding electrical cables to the hood covers or hood assembly. NOTE: Step 13 is for LPG (Liquefied Petroleum Gas) engines only. 1. 2. 3. 4. 5. 6. 7.

REAR COVER HOOD FRAME MUFFLER LEFT-HAND HOOD HINGE FRONT HOOD COVER RIGHT-HAND HOOD

Figure 4. Hood Assembly

13. Remove the two hose clamps and crankcase breather hoses from the front hood cover and remove the crankcase breather. 14. Remove the two nuts that hold the front hood cover to the frame. 15. Attach a lifting device to the hood assembly.

100 YRM 1349

Hydraulic Tank 5. Attach the electrical cables at the original locations to the hood assembly with tie-wraps.

CAUTION Use caution when lifting the hood assembly to avoid damage to the rear of the operators cab.

6. Install the expansion tank under the hood with the two capscrews, washers, and nuts.

16. Lift the hood assembly from the frame and place it on the ground in a horizontal position by putting a support under the rear of the hood frame.

7. Install the inlet suction tube. See the section Air Cleaner, Install.

INSTALL

8. Install the exhaust pipe, flex tube, and U-bolt. See the section Exhaust System, Install.

1. Attach a lifting device to the hood assembly.

9. Install the four capscrews that hold the hood assembly to the counterweight.

CAUTION Use caution when installing the hood assembly to avoid damage to the rear of the operators cab.

10. Install the two gas springs to the rear cover at the counterweight.

2. Position the hood assembly onto the frame.

11. Attach the radiator to the bracket of the hood assembly. See Figure 5.

3. Install the two nuts that hold the front hood cover to the frame.

12. Close the left- and right- hand hood.

NOTE: Step 4 is for LPG engines only.

13. Completely lower the cab.

4. Install the crankcase breather and breather hoses to the front hood cover with the two hose clamps.

14. Start the engine and check for leaks.

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

REMOVE NOTE: The hydraulic tank removal and installation must be done with aid of an assistant. 1. Place the truck on a solid, level surface. 2. Lower the mast completely. 3. Shut down the engine. 4. Apply the parking brake. 5. Remove the four capscrews (3) and washers (4) holding the right-hand panel on top of the hydraulic tank and remove the right-hand panel. See Figure 6. 6. Remove the three capscrews (7) and washers (8) holding the right-hand extension plate and remove the extension plate. See Figure 6.

7. Remove the drain plug at the bottom of the hydraulic tank and drain the hydraulic oil into clean containers. 8. Put tags on the four return hoses and pipes at the top of the hydraulic tank for identification. NOTE: Use a drain pan to collect the oil from the hydraulic hoses. 9. Disconnect the four return hoses from the two pipes at the top of the hydraulic tank. See Figure 7. 10. Put caps on the hoses and pipes. 11. Put tags on the two hoses and connections at the frame side of the hydraulic tank for identification. 12. Disconnect the two hoses from the two connections at the frame side of the hydraulic tank. See Figure 7. 13. Put caps on the hoses and connections on the hydraulic tank.

Hydraulic Tank

1. 2. 3. 4. 5.

100 YRM 1349

HYDRAULIC TANK BATTERY BOX CAPSCREWS WASHERS RIGHT-HAND PANEL

6. 7. 8. 9. 10.

SEAL CAPSCREWS WASHERS RIGHT-HAND EXTENSION PLATE BATTERY CABLE ACCESS

Figure 6. Hydraulic Tank

CAUTION Disconnect the negative (ground) cable first or lift truck damage may occur. 14. Disconnect the negative (ground) and positive (power) cables from the batteries. 15. Remove the batteries from the battery box. 16. Remove the battery cables from the access hole of the hydraulic tank. See Figure 6. 17. Remove the capscrews that hold the right running board to the counterweight, front fender, and hydraulic tank and remove the running board. 18. Remove the anchor that secures the cab tilt shaft.

NOTE: When moving the front cab tilt shaft, maintain the position of the shims between the cab and frame tilt brackets. 19. Use a short rounded 19 mm (0.75 in.) shaft and hammer it into the front tilt bracket of the cab. 20. Push the cab tilt shaft further rearwards until the shaft slightly protrudes out of the rear bracket.

WARNING Make sure the hydraulic tank is supported with a hydraulic jack, hand pallet lift, or a lift truck. 21. Support the hydraulic tank with blocks of at least 50 mm (2.0 in.) thick to cover the height of the bracket at the bottom of the hydraulic tank.

100 YRM 1349

Hydraulic 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 make 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 make 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 1. RETURN PIPE 2. HOSE CONNECTION 3. DRAIN PLUG

Figure 7. Hydraulic Tank Connection and Fittings 22. Remove the three nuts and washers that hold the hydraulic tank to the frame.

CAUTION DO NOT to damage the studs during removal of the hydraulic tank from the frame. 23. Lift the hydraulic tank from the studs and move the hydraulic tank away from the frame.

INSPECT WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.

Disposal of lubricants, fluids, and chemicals must meet local environmental regulations. 2. Fill the tank with a cleaning solution. Proceed as follows: â&#x20AC;˘ If steam is available, fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal). â&#x20AC;˘ If the tank cannot be cleaned with steam, mix a solution of water and trisodium phosphate or cleaning compound with an alkaline base. Follow the instructions given by the manufacturer.

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. 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.

Hydraulic Tank 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. Make an inspection of the inside of the tank. If it is not clean, repeat Step 5 and Step 6 and make another inspection. When making 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.

REPAIR Small Leaks Use the following procedure to repair small leaks: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak. 2. Apply LoctiteÂŽ 290 to the leak. Follow the instructions of the manufacturer.

100 YRM 1349

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 ECMâ&#x20AC;&#x2122;s. If welding must be done in a close proximity of an ECM, that ECM must be removed. When welding to the chassis, attach the ground cable as close the weld as possible. 1. Use the procedure described under Clean to prepare the tank for repairs. 2. Contact your dealer for Yale lift trucks for welding instructions. 3. Use acceptable welding practices to repair the tank. See the American National Standard Safety in Welding and Cutting, AWS Z 49.1 - 1999.

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 there are any leaks coming from tank. 2. If there are no leaks coming from the tank, 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 with blocks of at least 50 mm (2.00 in.) thick to cover 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.

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

DO NOT to damage the studs during installation of the hydraulic tank to the frame. 3. Careful place the hydraulic tank over the studs without damaging the studs.

100 YRM 1349

Fuel Tank

4. Install the three washers and nuts that hold the top of the hydraulic tank to the frame.

14. Connect the two hoses to the two connections at the frame side of the hydraulic tank.

5. Remove the lifting device.

15. Connect the four return hoses to the two pipes at the top of the hydraulic tank. Torque the large fittings to 88 to 98 Nâ&#x20AC;˘m (65 to 72 lbf ft).

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.

16. Make sure the drain plug is installed at the bottom of the hydraulic tank. 17. Use a filtration system when refilling the hydraulic tank to the correct level with the oil specified in the maintenance table. See the section Periodic Maintenance 8000 YRM 1347. 18. Start the engine and operate the hydraulic system.

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.

19. Make sure all functions work correctly.

10. Install the right-hand extension plate using the three capscrews and washer. See Figure 6.

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.

11. Feed the battery cables through the access hole of the hydraulic tank. See Figure 6.

WARNING

20. Check for leaks.

12. Install the batteries into the battery box.

21. Bleed the system.

CAUTION Connect the positive (power) cable first or lift truck damage may occur. 13. Connect the positive (power) and negative (ground) cables to the batteries.

22. If necessary, fill the hydraulic tank to the correct level after bleeding the system. 23. Position the right-hand panel on top of the hydraulic tank and install the four washers and capscrews.

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

6. Remove the connector from the pushbutton switch at the left-hand panel.

The LPG version has a cover instead of a fuel tank. This cover can be replaced in a similar way.

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

REMOVE

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

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

WARNING

4. Apply the parking brake.

When removing the fuel tank, do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion and personal injury may occur.

5. Completely tilt (Raise) the cab.

9. Put a drain pan under the fuel tank.

3. Shut down the engine.

Fuel Tank

100 YRM 1349

10. Remove the drain plug to drain the fuel from the tank. See Figure 8.

11. Disconnect the fuel sender connector at the top of the fuel tank. See Figure 8. 12. Put tags on the check valve and shutoff valve fuel hoses and fittings for identification.

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

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

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

Figure 8. Fuel Tank

100 YRM 1349

Fuel Tank

NOTE: Use a drain pan to catch the fuel in the fuel hoses. 13. Disconnect the two fuel hoses from the check valve and shutoff valve at the top of the fuel tank. See Figure 8.

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

WARNING

14. Put caps on the fuel hoses and fittings.

Make sure that the lifting device has the rated capacity of 100 kg (2205 lb)to lift the fuel tank.

15. Remove the check valve and shut off valve at the top of the fuel tank. See Figure 8.

NOTE: Removal of the fuel tank can be done with a lifting device, hydraulic jack, hand pallet jack, or lift truck.

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

NOTE: Follow step Step 23 and Step 24 when a lifting device is used.

17. Loosen the fuel hose clamp located on top of the frame. 18. Turn the ends of the hoses parallel with the frame.

NOTE: Follow Step 25 when a hydraulic jack, hand pallet jack, or lift truck is used.

19. Remove the hose clamp for the cab tilt hoses.

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

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

23. Attach a lifting device to the fuel tank. Attach lifting eyes at the locations shown in Figure 10.

21. Remove the two capscrews, and washers at the back of the hand pump. See Figure 9.

24. Create slight tension on the chains.

1. ELECTRICAL TILT PUMP

2. HAND PUMP

3. FUEL TANK

Figure 9. Fuel Tank, Hand Pump, and Electric Lift Pump

Fuel Tank

100 YRM 1349

Figure 10. Lifting Points 25. Support the fuel tank with blocks of at least 50 mm (2.0 in.) thick to cover the height of the bracket on the bottom of the fuel 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.

100 YRM 1349

REPAIR WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. Repair the fuel tank as described in the section Hydraulic Tank.

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.) thick to cover 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.

CAUTION DO NOT to damage the studs during installation of the fuel tank. 4. Place the fuel tank over the studs of the frame. 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.

Fuel Tank 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. 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 1347.

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 Repair

100 YRM 1349

Cab Repair REAR CAB ASSEMBLY

NOTE: Interior covers are affixed with self-tapping screws.

See Figure 11 for rear cab assembly.

1. 2. 3. 4. 5.

COVER PLATE FUSE SECTION RELAY SECTION HYDRAULIC VALVE CONTROLLER FOAM COVER

6. 7. 8. 9. 10.

HEADLINER REAR DUCT ASSEMBLY CONSOLE COVER CONSOLE TOP INSTRUMENT PANEL

Figure 11. Rear Cab Assembly

100 YRM 1349

Cab Repair

BOTTOM CAB ASSEMBLY

1. Tilt mast fully forward.

See Figure 12 for bottom cab assembly.

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

WIPER MOTOR ASSEMBLY WIPER COUPLING AIR FILTER COVER PLATE STEERING PUMP HORN

Figure 12. Bottom Cab Assembly

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.

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

Figure 13. Pump and Direction Valve 6. Operate pump with pump lever until cab locks in partially open position. 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 14. 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 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.

Cab Repair

100 YRM 1349 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

Figure 14. Pump Lever and Tilt Latch Release Knob

Lower 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.

CAUTION

3. Raise operatorâ&#x20AC;&#x2122;s cab. See Raise Cab. 4. Remove four hex bolts holding steering pump. See Figure 15. 5. Remove two bolts holding brake valve.

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

6. Disconnect electrical cable to throttle pedal sensor. See Sensor Adjustment.

1. Use pump lever to turn direction valve counterclockwise to "Lower" position. See Figure 13.

7. Disconnect electrical cable.

2. Check that all foreign items/tools are cleared away.

8. Disconnect electrical that are located to right of heater unit.

3. Operate pump with pump lever until cab locks in partially open position.

9. Disconnect window washer hoses and mark their positions.

4. Pull tilt latch release and continue to lower cab until it is in fully lowered position and latched. See Figure 14.

10. Remove three bolts and swing heater unit down.

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

11. Disconnect electrical connections, control cables, and air duct from heater unit. 12. Disconnect ground lead.

100 YRM 1349

Cab Repair 19. Remove four rubber isolation mounts from frame and inspect for damage. Reinstall or replace if necessary.

Install 1. Connect lift strap under overhead guard structure. Provide cushion at top of door area to prevent damage. 2. Make sure that insulators are in place. See Figure 16. 3. Lift operator’s cab. 4. Carefully lower cab on insulators and make sure that it is properly centered. 5. Mount cab with washers and bolts. 6. Tighten cab mounting bolts to 66 N•m (49 lbf ft). 7. Raise cab. See Raise Cab. 8. Connect electrical cables, ground wire, hoses, steering pump, and brake valve. Make sure that all connections have been restored. 1. 2. 3. 4. 5.

STEERING PUMP HEX BOLTS BRAKE VALVE BOLTS STEERING PUMP BRAKE VALVE ELECTRICAL CONNECTIONS

Figure 15. Steering Pump, Throttle and Inching Connections

9. Mount heater unit to hinge. Connect control cables and electrical connections. Pivot unit up and install with three bolts. 10. Connect inching and throttle cables. See Inching and Brake Pedals.

CAUTION When lowering cab, make sure loose components are not obstructing the movement. 13. Lower operator’s cab. See Lower Cab. 14. Remove left and right side panels giving access to cab mounting bolts. 15. Remove four mounting bolts, two on left side and two on right side of truck. 16. Remove cab doors before attaching a lifting device. 17. Connect a lift strap under overhead guard structure. Provide a cushion at top of door area to prevent damage. 18. 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.

1. 2. 3. 4. 5.

TOP PART OF INSULATOR BOTTOM PART OF INSULATOR BOLT WASHER LOCKWASHER

Figure 16. Insulators

Engine

100 YRM 1349

11. Lower cab. See Lower Cab.

13. Connect battery ground lead.

12. Install doors.

14. Install side panels.

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

CAUTION 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. 1. Place the truck on a solid, level surface. 2. Lower the mast completely. 3. Shut down the engine. 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. 6. Disconnect the negative (ground) and positive (power) cables from the batteries. 7. Remove the hood. See the section Hood Assembly, Remove. 8. Disconnect the electrical cable from the air conditioner compressor. 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. NOTE: DO NOT remove the refrigerant hoses. 9. Remove the air conditioner compressor from the mounting bracket located on the engine.

10. Attach the air conditioner compressor with the hoses to the cab. Make sure the hoses are free from the engine/transmission during removal. 11. Put tags on the two heater hoses for identification. 12. Disconnect the two heater hoses located under the operators compartment at the engine side. 13. Put caps on the two heater hoses.

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

CAUTION Disposal of lubricants and fluids must meet local environmental regulations. 14. Let coolant cool to room temperature. 15. Use a drain pan to catch the coolant. 16. Remove the pressure cap from the expansion tank. 17. Remove the radiator return hose from the engine to drain the coolant. NOTE: Use a drain pan to drain the transmission oil from the transmission. 18. Remove the drain plug at the bottom of the transmission and put the transmission oil in a clean barrel. 19. Install the drain plug at the bottom of the transmission. NOTE: Step 20 through Step 25 is for diesel engines only. 20. Close the fuel shutoff valve at the top of the fuel tank.

100 YRM 1349

Engine

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

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

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

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

22. Disconnect the fuel hose at the diesel fuel filter.

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

23. Disconnect the fuel hose at the check valve. 24. Put caps on the fuel hoses and fittings.

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

25. Attach the fuel hoses to the engine.

41. Put caps on the two pressure hoses.

NOTE: Step 26 until Step 30 are for LPG engines only.

42. Disconnect the return hoses to the hydraulic tank.

26. Turn both fuel valves on the LPG tanks clockwise until the fuel valves are completely closed.

43. Disconnect the three electrical wires located at the left side of the engine from the alternator. See Figure 17.

WARNING Odor of LPG fuel may be detected when the hose of the LPG liquid fuel filter is disconnected. Avoid breathing the odor or personal injury may occur. 27. Disconnect the LPG fuel hose at the LPG liquid fuel filter. 28. Put tags on the two crankcase breather hoses and fittings for identification. 29. Disconnect the two crankcase breather hoses at the engine. 30. Put caps on the two hoses and fittings. 31. Remove the two charge air cooler pipes from the charge air cooler core and engine assembly. 32. Remove the two engine coolant hoses from the engine coolant core and engine assembly. 33. Put tags on the two transmission oil hoses for identification. 34. Disconnect the two transmission oil hoses from the thermostat manifold at the inlet and outlet port. 35. Put caps on the two transmission hoses and on the inlet and outlet port of the thermostat manifold. 36. Clean the suction hose and hydraulic pump to avoid dirt entering the suction hose. NOTE: Make sure the suction hose end remains above the hydraulic tank oil level. 37. Disconnect the suction hose from the hydraulic pump.

44. Disconnect the four electrical wires located at the left side of the engine from the starter. See Figure 17. 45. Disconnect the electrical wire located at the left side of the transmission from the transmission control valve. See Figure 17. 46. Disconnect the electrical wire for the output speed sensor and speed/temperature sensor located at the left side of the transmission. See Figure 17. 47. Disconnect the ECM connector and Engine supply connector located at the right side of the engine from the engine. See Figure 18. 48. Disconnect the two electrical wires for the engine oil pressure located at the right side of the engine from the engine. See Figure 18. 49. Disconnect the electrical wire for the fuel filter sender, located at the right side of the engine, from the engine. See Figure 18. 50. Disconnect the electrical wire for the convertor out temp sensor located at the right side of the transmission from the transmission. See Figure 18. 51. Disconnect the electrical wire for the turbine speed sensor located at the right side of the transmission from the transmission. See Figure 18. 52. 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.

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