Yale C813 (GDP GLP35-55LJ MJ Europe) Service Manual - PDF DOWNLOAD

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Service Manuals Manuals Available For C813 (GDP/GLP35-55LJ/MJ Europe) Note: Service manuals do not contain serial number specific data.

Manual

Manual Title

Release Date

0100YRM0726

FRAME

02-2007

0100YRM0778

OPERATORS CAB

06-2004

0600YRM0590

GM ENGINES 4.3 LITER V-6

08-2005

0600YRM0705

PERKINS DIESEL ENGINES 1004-42 (AR), 1006-60 (YG), 100660T (YH)

03-2006

0700YRM0740

COOLING SYSTEM

02-2004

0900YRM0745

LPG FUEL SYSTEM

09-2003

1300YRM0727

TWO-SPEED POWERSHIFT TRANSMISSION-DESCRIPTION AND OPERATION

06-2004

1300YRM0728

TWO-SPEED POWERSHIFT TRANSMISSION-REPAIR

08-2006

1300YRM0800

HYDROSTATIC TRANSMISSION DESCRIPTION AND REPAIR

03-2004

1300YRM0801

HYDROSTATIC TRANSMISSION-TROUBLESHOOTING AND REPAIR

03-2004

1400YRM0731

DRIVE AXLE

09-2003

1600YRM0732

STEERING CONTROL UNIT

10-2003

1600YRM0733

STEERING AXLE

09-2003

1800YRM0734

BRAKE SYSTEM

05-2005

1900YRM0743

HYDRAULIC SYSTEM

06-2005

1900YRM0753

HYDRAULIC GEAR PUMPS

09-2003

2000YRM0754

MAIN CONTROL VALVE

12-2003

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Yale Axcess Online

2100YRM0735

TILT CYLINDERS

11-2004

2200YRM0002

ALTERNATOR WITH REGULATOR

10-2003

2200YRM0107

HIGH ENERGY IGNITION (HEI) SYSTEM

03-2008

2200YRM0744

CARBURETED ENGINE MANAGEMENT SYSTEM

09-2003

2200YRM0755

STARTER

10-2003

2200YRM0756

INSTRUMENT PANEL INDICATORS AND SENDERS

02-2007

4000YRM0736

MAST-DESCRIPTION AND REPAIR

07-2010

4000YRM0741

LIFT CYLINDERS (NEW MAST)

03-2005

8000YRM0231

METRIC AND INCH (SAE) FASTENERS

12-2004

8000YRM0737

PERIODIC MAINTENANCE

03-2011

8000YRM0738

CAPACITIES AND SPECIFICATIONS

05-2004

8000YRM0757

DIAGRAMS

11-2008

©2011 Yale Axcess Online

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Frame GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) [C813, E813]

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

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

• Wear safety glasses.

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

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

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

CAUTION Indicates a condition that can cause property damage!

TABLE OF CONTENTS General Description Counterweight Repair Remove Install Hood Repair Remove Install Overhead Guard Repair Remove Inspect Install LED Backup and Brake Lights, Replace Remove Install Operator Restraint System Repair Automatic Locking Retractor (ALR) Emergency Locking Retractor (ELR) Radiator Repair Remove Install Exhaust System Repair Muffler Remove Install LPG/Gas Engine Exhaust Pipe - Lift Trucks Without Low Emissions Remove Install EPA Compliant LPG/Gas Engine Exhaust System Remove Install Diesel Engine Exhaust Pipe Remove

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Install Engine Repair Remove Install Throttle Pedal Adjustment Perkins 1104C-44(RE) Diesel Engine Lift Trucks With an Accelerator Pedal Lift Trucks With a Foot Directional Control Pedal Fuel and Hydraulic Tanks Repair Inspect Small Leaks, Repair Large Leaks, Repair Clean Steam Method Chemical Solution Method Other Preparation Methods for Repair Safety Labels This section is for the following models: GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP70-120LJ/MJ) [C813, E813]

General This section has the description and repair procedures for the frame and connected parts. Included in this section are the frame, counterweight, hood, hydraulic and fuel tanks, radiator, exhaust system, and cab assembly. Also included are the instructions for removal and installation of the engine.

Description The frame is a one-piece weldment and has mounts for the counterweight, overhead guard, operator’s module, engine and transmission, axles, and other parts. The hydraulic tank and fuel tank are part of the frame.

Counterweight Repair Remove

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

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units.

WARNING Make sure that the lifting device used has the correct lift capacity for the counterweight being removed. See Table 1.

1. If installed, remove the overhead exhaust pipe from the counterweight. See Figure 1.

Table 1. Weight of Counterweights Lift Truck

Weight (kg)

Weight (lb)

GLP/GDP3.50LJ (GP/GLP/GDP70LJ)

1782 to 1838

3929 to 4052

GLP/GDP4.00LJ (GP/GLP/GDP80LJ)

2068 to 2132

4559 to 4700

GLP/GDP4.00LJ (GP/GLP/GDP90LJ)

2355 to 2425

5192 to 5346

GLP/GDP4.50MJ (GP/GLP/GDP100MJ)

2660 to 2740

5864 to 6041

GLP/GDP5.00MJ (GP/GLP/GDP110MJ)

2906 to 2994

6407 to 6601

GLP/GDP5.50MJ (GP/GLP/GDP120MJ)

3152 to 3248

6949 to 7161

2. Remove cover between counterweight and hood. Remove tow pin.

3. Install two eyebolts into the counterweight lifting holes and attach a lifting device to the eyebolts.

CAUTION When lifting the counterweight from the lift truck, be careful not to bend the exhaust pipe.

4. Remove two capscrews, washers, and lockwashers. Remove counterweight from lift truck.

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1. Counterweight 2. Lifting Device 3. Lifting Eye

4. Washer 5. Lockwasher 6. Mounting Bolt Figure 1. Counterweight

Install 1. Install counterweight in place on the lift truck. See Figure 1. Install two lockwashers, washers, and capscrews. Tighten capscrews to 555 N•m (409 lbf ft).

2. Remove eyebolts from counterweight lifting holes.

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4. If removed, install the overhead exhaust pipe in the counterweight. Tighten the capscrews to 38 N•m (28 lbf ft).

Hood Repair Remove

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

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units.

1. Raise the hood and disconnect the two gas-assist cylinders at the hood. Disconnect the park brake alert wiring harness.

2. Remove the pins that hold the hood hinges to the operator’s module crossmember. Remove the hood.

Install 1. Install the hood in position on the lift truck. Install the pins that hold the hood hinges to the operator’s module crossmember.

2. Connect the two gas-assist cylinders to the hood. Connect the park brake alert wiring harness.

WARNING The hood, hood latch, and hood striker must be correctly adjusted for the correct operation of the operator restraint system.

3. Adjust the hood latch (see Figure 2) as follows: a. Center the latch striker in the slot located in the rear crossmember. Check that the latch striker is in the center of the jaws of the hood latch and tighten. b. Loosen the capscrews for the hood latch just enough to let the latch move. Position the latch.

Tighten the capscrews for the latch. c. Check the operation of the hood latch. Have an operator sit in the seat. Make sure that the hood is fully closed (two clicks). Also, check that the hood touches the rubber bumpers. If necessary, repeat http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0726.html (7 of 39)31.10.2011 16:23:59

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Step b.

1. Latch Striker 2. Hood Latch 3. Latch Lever 4. Seat 5. Seat Belt Latch 6. Hip Restraint 7. Seat Rail 8. Hood 9. Hinge 10. Operator Weight Adjustment 11. Forward/Backward Adjustment Figure 2. Hood and Seat Latches Check

Overhead Guard Repair Remove

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

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

Do not make changes to the overhead guard by welding. Changes that are made by welding, or by drilling holes that are too big in the wrong location, can reduce the strength of the overhead guard.

See the instructions for Changes to the Overhead Guard in the Periodic Maintenance section included with this lift truck.

Connect a lifting device to the top of the overhead guard. Remove the capscrews that hold the overhead guard to the frame. Remove the capscrews that hold the overhead guard to the cowl and module. Lift the overhead guard from the lift truck.

Inspect Inspect the condition of the mount isolators located at the rear legs of the overhead guard for any damage.

Replace if damaged.

Install 1. Connect a lifting device to the top of the overhead guard. Put the overhead guard in position on the lift truck.

2. Install the capscrews at the rear of the overhead guard. Tighten the capscrews to 90 N•m (67 lbf ft).

Install the capscrews that hold the overhead guard to the cowl. Tighten the capscrews to 90 N•m (67 lbf ft).

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

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

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

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

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

Install 1. If the mounting bracket was removed, install it onto the overhead guard leg. Insert the plug and screw to attach mounting bracket to overhead guard leg. See Figure 3.

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

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

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

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

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

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units.

The seat belt, hip restraint brackets, seat and mounting, hood, and latches are all part of the operator restraint system. Each item must be checked to make sure it is attached securely, functions correctly, and is in good condition. See Figure 2.

Automatic Locking Retractor (ALR) NOTE: Lift trucks produced before November 2005 are equipped with the ALR type seat belts.

The seat belt must fasten securely. Make sure the seat belt extends and retracts smoothly and is not frayed or torn. If the seat belt is damaged or does not operate properly, it must be replaced. See Figure 4.

Emergency Locking Retractor (ELR) NOTE: Lift trucks produced after November 2005 are equipped with the Emergency Locking Retractor (ELR) style seat belt.

When the ELR style seat belt is properly buckled across the operator, the belt will permit slight operator repositioning without activating the locking mechanism. If the truck tips, travels off a dock, or comes to a http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0726.html (11 of 39)31.10.2011 16:23:59

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sudden stop, the locking mechanism will be activated and hold the operator’s lower torso in the seat.

A seat belt that is damaged worn or does not operate properly will not give protection when it is needed.

The end of the belt must fasten correctly in the latch. The seat belt must be in good condition. Replace the seat belt if damage or wear is seen. See Figure 4.

The following seat belt operation checks must be performed: • With the hood closed and in the locked position, pull the seat belt slowly from the retractor assembly.

Make sure the seat belt pulls out and retracts smoothly. if the seat belt cannot be pulled from the retractor assembly or the belt will not retract, replace the seat belt assembly.

• With the hood closed and in the locked position, pull the seat belt with a sudden jerk. Make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, when it is pulled with a sudden jerk, replace the seat belt assembly.

• With the hood in the open position, make sure the seat belt will not pull from the retractor assembly. If the seat belt can be pulled from the retractor, with the hood in the open position, replace the seat belt assembly.

Make sure the seat rails and latch striker are not loose. The seat rails must lock securely in position but move freely when unlocked. The seat rails must be securely attached to the mounting surface. The hood must be fully closed. Lift the hood to make sure it is closed and will not move.

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

NOTE: SWIVEL SEAT IS AN OPTIONAL FEATURE A. AUTOMATIC LOCKING RETRACTOR B. EMERGENCY LOCKING RETRACTOR 1. FORWARD/BACKWARD ADJUSTMENT 2. SWIVEL ADJUSTMENT 3. OPERATOR WEIGHT ADJUSTMENT 4. SEAT POSITION ADJUSTMENT (seat rail) http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0726.html (12 of 39)31.10.2011 16:23:59

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5. SEAT BELT Figure 4. Operator Restraint System (Swivel Seat Shown)

Radiator Repair Remove

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

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units.

1. Remove the cover between the hood and counterweight. See Figure 5.

WARNING Disposal of coolant must be in accordance with local regulations.

NOTE: To aid in the draining of coolant from the radiator, remove the radiator cap.

2. Drain the coolant from the radiator.

3. Disconnect the upper and lower coolant hoses from the radiator.

4. Disconnect the hydraulic hoses from the radiator and install plugs in the hoses.

5. On the GM-powered lift truck, remove the clamp and hose from the bottom of the radiator.

6. Remove the top radiator support plate.

7. Disconnect the coolant recovery reservoir hose from the radiator.

8. Remove the coolant recovery reservoir from the overhead guard leg.

9. Remove the upper and lower fan shroud halves from the radiator.

10. Remove the radiator from the lower radiator mounting plate.

Install

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1. Install the rubber isolators on the lower radiator locating studs. See Figure 5.

2. Install the radiator on the lower radiator mounting plate.

3. Install the upper and lower fan shroud halves on the radiator.

4. Install the coolant recovery reservoir on the overhead guard leg.

5. Connect the coolant recovery reservoir hose to the radiator.

6. Install the rubber isolators on the upper radiator locating studs.

7. Install the top radiator support plate. Tighten the outer screws to 66 N•m (49 lbf ft). Tighten the inner screws to 38 N•m (28 lbf ft).

8. On the GM-powered lift truck, install the hose and clamp on the bottom of the radiator.

9. Connect the upper and lower coolant hoses to the radiator.

10. Connect the hydraulic hoses to the radiator.

CAUTION To prevent possible damage to the engine, make sure the engine is running at idle speed while performing Step 11.

11. Add coolant to the system until the entire cooling system is full.

12. Install the cover between the hood and counterweight.

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Figure 5. Radiator Legend for Figure 5 A. Perkins Diesel 1004.42 B. GM 4.3L V-6 1. Cover 2. Hood http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0726.html (15 of 39)31.10.2011 16:23:59

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3. Counterweight 4. Radiator 5. Hose 6. Hose 7. Clamp 8. Radiator Support Plate 9. Coolant Recovery Reservoir Hose 10. Coolant Recovery Reservoir 11. Overhead Guard Leg 12. Lower Radiator Mounting Plate

Exhaust System Repair Muffler Remove

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

The surface must be solid, even, and level when the lift truck is put on blocks. Make sure that any blocks used to support the lift truck are solid, one-piece units.

1. Remove the overhead exhaust pipe from the counterweight. See Figure 6 or Figure 7.

2. Remove the counterweight. See Counterweight Repair, Remove in this YRM. 3. Remove the lower exhaust pipe from the muffler and disconnect the upper exhaust pipe from the muffler.

4. Remove the muffler from the mounting bracket.

Install 1. Install the muffler on the mounting bracket. Tighten bolts until all clearance has been removed; then tighten one additional turn. See Figure 6 or Figure 7.

2. Connect the upper exhaust pipe to the muffler and install the lower exhaust pipe on the muffler.

3. Install the counterweight on the lift truck. See Counterweight Repair, Install in this YRM. 4. Install the overhead exhaust pipe in the counterweight. Tighten the capscrews to 38 N•m (28 lbf ft).

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1. Left Engine Exhaust Pipe 2. Right Engine Exhaust Pipe 3. Upper Exhaust Pipe 4. Muffler 5. Seal 6. Flange 7. Hex Head Bolt 8. Spring 9. Clamp 10. Overhead Exhaust 11. Lower Exhaust Pipe 12. Counterweight Exhaust Pipe 13. Heat Shield 14. Clamp 15. Heat Shield Sleeve 16. Heat Shield Sleeve 17. Intermediate Upper Exhaust Pipe 18. Muffler Mounting Bracket 19. Isolator 20. Washer 21. Hex Head Bolt http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0726.html (17 of 39)31.10.2011 16:23:59

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22. Washer 23. Nut 24. Hex Head Bolt 25. Lockwasher 26. Right-Side Exhaust Manifold 27. Left-Side Exhaust Manifold Figure 6. LPG/GAS Exhaust System (Without Low Emissions) Early Model Lift Trucks

Figure 7. LPG/GAS Exhaust System (Without Low Emissions) Later Model Lift Trucks

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Legend for Figure 7 1. Left Engine Exhaust Pipe 2. Right Engine Exhaust Pipe 3. Upper Exhaust Pipe 4. Muffler 5. Counterweight Exhaust Pipe 6. Seal 7. Flange 8. Hex Head Bolt 9. Spring 10. Clamp 11. Overhead Exhaust Pipe 12. Lower Exhaust Pipe 13. Heat Shield 14. Heat Shield Sleeve 15. Lockwasher 16. Intermediate Upper Exhaust Pipe 17. Nut 18. Muffler Mounting Bracket 19. Isolator 20. Washer 21. Plug

LPG/Gas Engine Exhaust Pipe - Lift Trucks Without Low Emissions Remove NOTE: If the lift truck does not have an overhead exhaust, perform Step 2 and Step 4 through Step 8. If the lift truck has an overhead exhaust, perform Step 1 through Step 3 and Step 5 through Step 8.

1. Remove the overhead exhaust pipe from the counterweight. See Figure 6 and Figure 7.

2. Remove the counterweight. See Counterweight Repair, Remove in this YRM. 3. Remove the lower exhaust pipe from the right side of the muffler and disconnect the upper exhaust pipe from the left side of the muffler.

4. Remove the counterweight exhaust pipe from the right side of the muffler and disconnect the upper exhaust pipe from the left side of the muffler.

5. Disconnect upper exhaust pipe from the intermediate upper exhaust pipe and disconnect the intermediate upper exhaust pipe from the left-side engine exhaust pipe.

6. On early model lift trucks only, remove the metal heat shield from the left and right engine exhaust pipes.

7. Disconnect the left and right engine exhaust pipes from each other.

8. Remove the left and right engine exhaust pipes from the engine exhaust manifolds.

Install

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NOTE: If the lift truck does not have an overhead exhaust perform Step 1 through Step 5, and Step 7. If the lift truck has an overhead exhaust perform Step 1 through Step 4 and Step 6 through Step 8.

1. Install the left and right engine exhaust pipes on the engine exhaust manifolds. See Figure 6.

2. Connect the left and right engine exhaust pipes to each other.

3. On early model lift trucks only, install the metal heat shield on the left and right engine exhaust pipes.

4. Connect the intermediate upper exhaust pipe to the left-side engine exhaust pipe and connect the upper exhaust pipe to the intermediate upper exhaust pipe.

5. Connect the upper exhaust pipe to the left side of the muffler and install the counterweight exhaust pipe on the right side of the muffler.

6. Connect the upper exhaust pipe to the left side of the muffler and connect the lower exhaust pipe to the right side of the muffler.

7. Install the counterweight. See Counterweight Repair, Install in this YRM. 8. Install the overhead exhaust pipe in the counterweight. Tighten the capscrews to 38 N•m (28 lbf ft).

EPA Compliant LPG/Gas Engine Exhaust System Remove NOTE: If the lift truck does not have an overhead exhaust, perform Step 2 and Step 4 through Step 8. If the lift truck has an overhead exhaust, perform Step 1 through Step 3 and Step 5 through Step 8.

1. Remove the overhead exhaust pipe from the counterweight. See Figure 8.

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Figure 8. EPA Compliant LPG/GAS Exhaust System Legend for Figure 8 1. Gasket 2. Hex Head Bolt 3. Spring 4. Seal 5. Upper Exhaust Pipe

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6. Left Engine Exhaust Pipe 7. Clamp 8. Right Engine Exhaust Pipe 9. Heat Shield Sleeve 10. Wire Harness (Closed Loop) 11. Heat Shield 12. Muffler 13. Washer 14. Nut 15. Muffler Mounting Bracket 16. Counterweight Exhaust Pipe 17. Isolator 18. Plug 19. Oxygen Sensor 20. Lower Exhaust Pipe 21. Overhead Exhaust Pipe 22. Capscrew 2. Remove the counterweight. See Counterweight Repair, Remove in this YRM. 3. Remove the lower exhaust pipe from the right side of the muffler and the upper exhaust pipe from the left side of the muffler.

4. Remove the counterweight exhaust pipe from the right side of the muffler and the upper exhaust pipe from the left side of the muffler.

5. Disconnect upper exhaust pipe from the left and right-side engine exhaust pipes.

6. Remove the metal heat shield from the left and right engine exhaust pipes.

7. Disconnect the electrical connector from the oxygen sensor. Remove oxygen sensor from the engine exhaust pipes. Inspect oxygen sensor and if it is damaged or broken, replace with new sensor.

8. Remove the left and right engine exhaust pipes from the engine exhaust manifolds. See Figure 8.

Install NOTE: If the lift truck does not have an overhead exhaust, perform Step 1 through Step 5 and Step 7. If the lift truck has an overhead exhaust, perform Step 1 through Step 4 and Step 6 through Step 8.

1. Install the left and right engine exhaust pipes to the engine exhaust manifolds. See Figure 8.

2. Before installing the oxygen sensor, apply a small amount of antiseize compound. Install the oxygen sensor to the engine exhaust pipes. Tighten sensor to 39 N•m (29 lbf ft). Connect the electrical connector to the oxygen sensor.

3. Install the metal heat shield to the engine exhaust pipes.

4. Connect upper exhaust pipe to the left and right-side engine exhaust pipes.

5. Connect the upper exhaust pipe to the left side of the muffler and install the counterweight exhaust pipe on the right side of the muffler.

6. Connect the lower exhaust pipe from the right side of the muffler and the upper exhaust pipe from the

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left side of the muffler.

7. Install the counterweight. See Counterweight Repair, Install in this YRM. 8. Install the overhead exhaust pipe in the counterweight. Tighten the capscrews to 38 N•m (28 lbf ft).

Diesel Engine Exhaust Pipe Remove NOTE: If the lift truck does not have an overhead exhaust, perform Step 2 and Step 4 through Step 7. If the lift truck has an overhead exhaust, perform Step 1 through Step 3 and Step 5 through Step 7.

1. Remove the overhead exhaust pipe from the counterweight. See Figure 9.

2. Remove the counterweight. See Counterweight Repair, Remove in this YRM. 3. Remove the lower exhaust pipe from the right side of the muffler and disconnect the upper exhaust pipe from the left side of the muffler.

4. Remove the counterweight exhaust pipe from the right side of the muffler and disconnect the upper exhaust pipe from the left side of the muffler.

5. Remove the heat shield from the upper exhaust pipe and intermediate upper exhaust pipe. Remove the upper exhaust pipe from the intermediate exhaust pipe.

6. Remove the intermediate exhaust pipe from the engine exhaust pipe.

7. Remove the engine exhaust pipe from the exhaust manifold.

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1. Muffler 2. Lower Exhaust Pipe 3. Clamp 4. Upper Exhaust Pipe 5. Intermediate Exhaust Pipe 6. Engine Exhaust Pipe 7. Adapter 8. Overhead Exhaust Pipe 9. Hex Head Bolt 10. Spring 11. Seal 12. Heat Shield Sleeve 13. Counterweight Exhaust Pipe 14. Bracket 15. Hex Head Bolt 16. Washer 17. Isolator 18. Nut 19. Washer 20. Hex Head Bolt 21. Washer 22. Engine Exhaust Manifold Figure 9. Diesel Exhaust System

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Install NOTE: If the lift truck does not have an overhead exhaust, perform Step 1 through Step 4 and Step 6. If the lift truck has an overhead exhaust, perform Step 1 through Step 4 and Step 6 and Step 7.

1. Install the engine exhaust pipe on the exhaust manifold. See Figure 9.

2. Connect the intermediate exhaust pipe to the engine exhaust pipe.

3. Connect the upper exhaust pipe to the intermediate exhaust pipe. Install the heat shield on the upper exhaust pipe and intermediate exhaust pipe.

4. Connect the upper exhaust pipe to the left side of the muffler and install the counterweight exhaust pipe on the right side of the muffler.

5. Connect the upper exhaust pipe to the left side of the muffler. Connect the lower exhaust pipe to the right side of the muffler.

6. Install the counterweight. See Counterweight Repair, Install in this YRM. 7. If removed, install the overhead exhaust pipe on the counterweight. Tighten the capscrews to 38 N•m (28 lbf ft).

Engine Repair Remove 1. Remove the overhead guard. Remove the floor plates.

2. Disconnect the cables at the battery. Remove the battery and the battery tray.

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

4. Disconnect the hydraulic line between the main control valve and the hydraulic oil tank.

5. Remove the engine only as described in the following steps: a. Remove the brake pedal assembly as follows (see Figure 10): Disconnect the wires at the brake switch. Disconnect the brake lines at the brake booster/master cylinder and put plugs and caps on the openings. Disconnect the inching link at the transmission. Remove the spring from the inching link.

Remove the return spring from the inching pedal. Remove the four capscrews at the top of the pedal bracket. Remove the pedal assembly from the lift truck. b. Disconnect the wiring harness and throttle cable for the accelerator or Foot Directional Control pedal. Remove the pedal assembly from the frame. c. Remove the capscrews for the universal joints from the hydraulic pump drive line at the crankshaft and move the drive line out of the way.

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d. Disconnect the engine wiring harness from the main wiring harness. e. Disconnect the exhaust pipe from the muffler. Remove the air filter housing from the frame. f. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (992 lb). g. Support the transmission by placing a jackstand under the transmission housing. h. Remove the engine mount capscrews and washers at the fan end of the engine.

NOTE: The bolts being removed in Step i are a one-time usage type of bolt and must be discarded when removed. i. Bar the engine over at the crankshaft and remove and discard the torque converter flex plate bolts. When all of the bolts have been removed, move the engine forward just enough to break the engine loose from the transmission. j. Carefully lift the engine from the frame. Make sure all the connections have been removed and that the torque converter does not come out at the same time as the engine.

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1. Foot Directional control Pedal 2. Accelerator Pedal 3. Pedal Bracket 4. Brake Booster/Master Cylinder Assembly 5. Inching Linkage 6. Return Spring 7. Inching Crank Return Spring 8. Inch/Brake Pedal Figure 10. Pedal Assembly 6. Remove the engine and powershift transmission as described in the following steps: a. Remove the radiator, fan, and fan shroud. See Radiator Repair, Remove in this section.

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Disconnect the exhaust pipe from the muffler. Remove the air filter housing from the frame. b. Put the lift truck on blocks. See the Operating Manual for the correct procedures to put the lift truck on blocks.

NOTE: Tag hydraulic hoses and fittings as they are disconnected to aid in reconnecting the hoses. c. Disconnect the hydraulic hoses from the steering control unit. Install caps on the steering control unit and plugs on the hydraulic hoses. d. Disconnect the horn wire at the steering column. Remove the capscrews that hold the steering column and steering control unit to the operator’s module. Remove the steering column assembly. e. Disconnect the wiring harness and throttle cable for the accelerator or Foot Directional Control pedal. Remove the pedal assembly from the frame. f. Remove the brake pedal assembly as follows (see Figure 10): Disconnect the wires at the brake switch. Disconnect the brake lines at the master cylinder and put plugs and caps on the openings.

Disconnect the inching link at the transmission. Remove the spring from the inching link. Remove the return spring from the inching pedal. Remove the four capscrews at the top of the pedal bracket.

Remove the pedal assembly from the lift truck. g. Remove the transmission oil filter. Drain the oil from the transmission. h. Disconnect the linkages at the transmission. Disconnect the wires at the transmission.

Disconnect the transmission oil lines from the transmission. i. Remove the axle shafts from the drive axle. j. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 700 kg (1500 lb). k. Remove the capscrews that hold the transmission to the differential housing. Remove the engine mount capscrews at the fan end of the engine. l. Carefully lift the engine from the frame. As the engine is being lifted from the frame, make sure all connections have been disconnected. m. Remove the powershift transmission from the engine as described in the section Two-Speed Powershift Transmission, Troubleshooting and Repairs 1300 YRM 728 or Single-Speed Powershift Transmission, Troubleshooting and Repair 1300 YRM 752.

Install 1. Install the engine and powershift transmission as follows: a. See the section Two-Speed Powershift Transmission, Troubleshooting and Repairs 1300 YRM 728 and install the powershift transmission on the engine. b. Connect a lifting device to the engine. Make sure the lifting device has a capacity of 700 kg (1500 in.). http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0726.html (28 of 39)31.10.2011 16:23:59

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c. Install the engine assembly in the lift truck. Install the capscrews and washers for the engine mounts. Tighten the capscrews to the correct torque values as shown in Figure 11. d. Install the capscrews that mount the transmission to the drive axle. Tighten the capscrew to 66 N•m (49 lbf ft). e. Connect the transmission oil lines to the transmission. Connect the transmission wiring harness to the transmission. Connect the linkages to the transmission. f. Install the transmission oil filter and fill the transmission with oil specified in Capacities and Specifications 8000 YRM 738. g. Install the brake pedal assembly as follows (see Figure 10): Install the pedal assembly on the lift truck. Install the four capscrews at the top of the pedal bracket. Install the return spring on the inching pedal. Install the spring on the inching link. Connect the inching link to the transmission. Connect the brake lines to the master cylinder. Connect the wires to the brake switch.

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NOTE: A = 165 N•m (122 lbf ft).

A. Engine Mounts (Diesel Shown) B. Engine Mount (Gas/LPG Shown) 1. Capscrew 2. Washer 3. Washer 4. Snubbing Cup 5. Isolator 6. Engine Mount 7. Nut

8. Rebound Washer 9. Bumper 10. Spacer 11. frame 12. Shim*

*Rotate engine around drive axle centerline until LH or RH mount contacts. Use a maximum of three shims (12), on the other side to less than 1.0 mm (0.03937 in.).

Figure 11. Engine Mounts h. Install the Foot Directional Control or accelerator pedal to the frame. Connect the wiring harness and throttle cable for the Foot Directional Control pedal or accelerator. i. Install the steering wheel or install the steering column and steering control unit to the bracket on the frame. Connect the four hydraulic hoses to the steering control unit as noted during removal.

Connect the horn wire at the steering column. j. Connect the hydraulic hoses as noted during removal to the steering control unit. k. Remove the lift truck from the blocks.

2. Install the engine only as described in the following steps: a. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (1000 lb).

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b. Carefully install the engine in the frame. c. Bar the engine over at the crankshaft and install new torque converter flex plate bolts. Tighten bolts to 38 N•m (28 lbf ft). d. Install the engine mount capscrews and washers at the fan end of the engine. Tighten the capscrews to the correct torque values as shown in Figure 11. e. Connect the exhaust pipe to the muffler. Install the air filter housing on the frame. f. Connect the engine wiring harness to the main wiring harness. g. Install the capscrews for the universal joints from the hydraulic pump drive line at the crankshaft. h. Install the pedal assembly for the accelerator or Foot Directional Control pedal in the frame.

Connect the wiring harness and throttle cable. i. Install the brake pedal assembly as follows (see Figure 10): Install the pedal assembly in the lift truck. Install the four capscrews at the top of the pedal bracket. Install the return spring on the inching pedal. Install the spring from the inching link. Connect the inching link at the transmission. Connect the brake lines at the brake booster/master cylinder. Connect the wires at the brake switch.

3. Connect the hydraulic line between the main control valve and the hydraulic oil tank.

4. Connect the fuel lines at the engine. Connect the throttle linkage at the engine. Connect the wires and wiring harnesses at the engine.

5. Install the air filter housing on the frame. Connect the exhaust pipe to the muffler. Install the radiator, fan, and fan shroud. See Radiator Repair, Install in this section.

6. Install the alternator on units with a diesel engine. Install the battery and the battery tray. Connect the cables to the battery.

7. Install the overhead guard.

8. Check all of the fluid levels and fill as necessary. Install the floor plates and covers. Connect the cables at the battery.

Throttle Pedal Adjustment Perkins 1104C-44(RE) Diesel Engine NOTE: The procedures below are for lift trucks equipped with the Perkins 1104C-44(RE) Diesel Engine. If your lift truck has either a gas or LPG engine, see the section LPG Fuel System 900 YRM 745 for the procedures to adjust the throttle linkage.

Lift Trucks With an Accelerator Pedal 1. Adjust the cable adjustment nuts to allow for a 3.0 mm (0.12 in.) maximum of free play on the throttle cable length. See Figure 12. Secure cable length by tightening cable lock nuts.

2. Depress the accelerator pedal until the diesel injector pump is in the full power position (the injection http://www.yaleaxcessonline.com/lib/service/UK/EN/html/0100YRM0726.html (31 of 39)31.10.2011 16:23:59

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pump lever is touching the lever stop in Figure 13).

3. Turn capscrew stop (see Figure 12) clockwise until it contacts the pedal. Continue for another 1/4 turn until the capscrew height is 12.0 mm (0.50 in.).

4. Tighten capscrew stop with jam nut.

1. Accelerator pedal 2. Diesel injector pump 3. cable adjustment nuts 4. cable lock nuts 5. capscrew stop 6. jam nut Figure 12. Accelerator Pedal Adjustment

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NOTE: Diesel injector pump is shown in the idle position.

1. injection pump lever 2. lever stop Figure 13. Diesel Injector Pump

Lift Trucks With a Foot Directional Control Pedal 1. Adjust the cable adjustment nuts to allow for a 3.0 mm (0.12 in.) maximum of free play on the throttle cable length. See Figure 14. Secure cable length by tightening cable lock nuts.

2. Set pedal stop to 35 ±2 mm (1.40 ±0.08 in.). Secure in place with pedal stop jam nuts.

3. With the pedal against the stop, adjust the throttle cable to ensure that the diesel injector pump is at full power (the injection pump lever is touching the lever stop in Figure 13).

4. Release the throttle pedal and adjust the up position pedal stop until the tension is removed from the cable when the injection pump lever is returned to the idle position (see Figure 13). Tighten up position pedal stop with capscrew. See Figure 14.

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