GLP/GDP3.5-5.5LJ/MJ (E813) SERVICE MANUAL CONTENTS SECTION FRAME............................................................................................................................ OPERATORS CAB......................................................................................................... GM ENGINES.................................................................................................................. PERKINS DIESEL ENGINE 1104 (RE)........................................................................... COOLING SYSTEM........................................................................................................ LPG FUEL SYSTEM....................................................................................................... ELEC. CONT. LPG/GAS FUEL SYS GM 3.0/4.3L EPA COMP. ENG........................... ELECTRONIC CONTROLLED LPG FUEL SYSTEM (GM 4.3L ENGINES).................. 2-SPEED POWERSHIFT TRANSMISSION DESCRIPTION AND OPERATION........... 2-SPEED POWERSHIFT TRANSMISSION REPAIR..................................................... HYDROSTATIC TRANSMISSION.................................................................................. HYDROSTATIC TRANSMISSION.................................................................................. DRIVE AXLE................................................................................................................... STEERING CONTROL UNIT.......................................................................................... STEERING AXLE............................................................................................................ BRAKE SYSTEM............................................................................................................ HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC GEAR PUMP............................................................................................. MAIN CONTROL VALVE................................................................................................ TILT CYLINDERS........................................................................................................... ALTERNATOR................................................................................................................ CARBURETED ENGINE MANAGEMENT SYSTEM...................................................... STARTER........................................................................................................................ INSTRUMENT PANEL GAUGES AND SENDERS........................................................ ECM DIAG. TROUBLESHOOTING GM 3.0L/4.3L EPA COMP. ENG........................... HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. ELECTRONIC CONTROL MODULE (ECM) DIAGNOSTIC TROUBLESHOOTING (GM 4.3L ENGINES).................................................................................................. MASTS............................................................................................................................ LIFT CYLINDER.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS........................................................................... DIAGRAMS.....................................................................................................................
PART NUMBER
YRM NUMBER
REV DATE
524173800 524173801 524153897 524201517 524173802 524173803 524208004 524282949 524173804 524173805 524153601 524153606 524173806 524153904 524173807 524173808 524153909 524173809 524153910 524173810 524150791 524173811 524153913 524153915 524208009 524208014
0100 YRM 0726 0100 YRM 0778 0600 YRM 0590 0600 YRM 1070 0700 YRM 0740 0900 YRM 0745 0900 YRM 1088 0900 YRM 1217 1300 YRM 0727 1300 YRM 0728 1300 YRM 0800 1300 YRM 0801 1400 YRM 0731 1600 YRM 0732 1600 YRM 0733 1800 YRM 0734 1900 YRM 0743 1900 YRM 0753 2000 YRM 0754 2100 YRM 0735 2200 YRM 0002 2200 YRM 0744 2200 YRM 0755 2200 YRM 0756 2200 YRM 1090 2200 YRM 1097
02/07 06/04 04/14 06/07 02/04 09/03 05/06 07/06 06/04 08/06 03/04 03/04 09/03 10/03 09/03 05/05 06/05 09/03 12/03 11/04 12/04 09/03 10/03 02/07 04/05 05/14
524283094 524153920 524153919 524150797 524173814 524173815 524173816
2200 YRM 1219 4000 YRM 0736 4000 YRM 0741 8000 YRM 0231 8000 YRM 0737 8000 YRM 0738 8000 YRM 0757
07/06 07/10 03/05 10/13 03/11 05/04 11/08
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 524208470 (05/14)
100 YRM 726
Counterweight Repair
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 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.
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
2660 to 2740 5864 to 6041 GLP/GDP4.50MJ (GP/GLP/GDP100MJ) 2906 to 2994 6407 to 6601 GLP/GDP5.00MJ (GP/GLP/GDP110MJ) 3152 to 3248 6949 to 7161 GLP/GDP5.50MJ (GP/GLP/GDP120MJ) 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.
1
Hood Repair
100 YRM 726
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. 3. Install tow pin. Install cover between hood and counterweight. 4. If removed, install the overhead exhaust pipe in the counterweight. Tighten the capscrews to 38 N•m (28 lbf ft).
1. COUNTERWEIGHT 2. LIFTING DEVICE 3. LIFTING EYE
4. WASHER 5. LOCKWASHER 6. MOUNTING BOLT
Figure 1. Counterweight
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
2
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.
100 YRM 726
Hood Repair b. Loosen the capscrews for the hood latch just enough to let the latch move. Position the latch. Tighten the capscrews for the latch.
WARNING The hood, hood latch, and hood striker must be correctly adjusted for the correct operation of the operator restraint system.
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 Step b.
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.
1. 2. 3. 4. 5. 6.
LATCH STRIKER HOOD LATCH LATCH LEVER SEAT SEAT BELT LATCH HIP RESTRAINT
7. 8. 9. 10. 11.
SEAT RAIL HOOD HINGE OPERATOR WEIGHT ADJUSTMENT FORWARD/BACKWARD ADJUSTMENT
Figure 2. Hood and Seat Latches Check
3
Overhead Guard Repair
100 YRM 726
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. 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 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. 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.
4
100 YRM 726
Operator Restraint System Repair Legend for Figure 3 A. LED ASSEMBLY WITH STANDARD EXHAUST B. LED ASSEMBLY WITH OVERHEAD EXHAUST 1. 2. 3. 4. 5. 6. 7. 8. 9.
LED LIGHT SCREW WASHER LOCK NUT MOUNTING BRACKET GROMMET PLUG SCREW OVERHEAD GUARD LEG
Figure 3. LED Backup and Brake Lights Assembly
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.
5
Operator Restraint System Repair
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 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
100 YRM 726 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) 5. SEAT BELT
Figure 4. Operator Restraint System (Swivel Seat Shown)
6
100 YRM 726
Radiator Repair
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.
9. Remove the upper and lower fan shroud halves from the radiator. 10. Remove the radiator from the lower radiator mounting plate.
INSTALL 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 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.
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.
8. Remove the coolant recovery reservoir from the overhead guard leg.
7
Radiator Repair
100 YRM 726
Figure 5. Radiator
8
100 YRM 726
Exhaust System Repair Legend for Figure 5
A. PERKINS DIESEL 1004.42
B. GM 4.3L V-6
1. 2. 3. 4. 5. 6.
7. 8. 9. 10. 11. 12.
COVER HOOD COUNTERWEIGHT RADIATOR HOSE HOSE
CLAMP RADIATOR SUPPORT PLATE COOLANT RECOVERY RESERVOIR HOSE COOLANT RECOVERY RESERVOIR OVERHEAD GUARD LEG 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.
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).
1. Remove the overhead exhaust pipe from the counterweight. See Figure 6 or Figure 7.
9
Exhaust System Repair
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
LEFT ENGINE EXHAUST PIPE RIGHT ENGINE EXHAUST PIPE UPPER EXHAUST PIPE MUFFLER SEAL FLANGE HEX HEAD BOLT SPRING CLAMP OVERHEAD EXHAUST LOWER EXHAUST PIPE COUNTERWEIGHT EXHAUST PIPE HEAT SHIELD CLAMP
100 YRM 726
15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
HEAT SHIELD SLEEVE HEAT SHIELD SLEEVE INTERMEDIATE UPPER EXHAUST PIPE MUFFLER MOUNTING BRACKET ISOLATOR WASHER HEX HEAD BOLT WASHER NUT HEX HEAD BOLT LOCKWASHER RIGHT-SIDE EXHAUST MANIFOLD LEFT-SIDE EXHAUST MANIFOLD
Figure 6. LPG/GAS Exhaust System (Without Low Emissions) Early Model Lift Trucks
10
100 YRM 726
Exhaust System Repair
Figure 7. LPG/GAS Exhaust System (Without Low Emissions) Later Model Lift Trucks
11
Exhaust System Repair
100 YRM 726 Legend for Figure 7
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
LEFT ENGINE EXHAUST PIPE RIGHT ENGINE EXHAUST PIPE UPPER EXHAUST PIPE MUFFLER COUNTERWEIGHT EXHAUST PIPE SEAL FLANGE HEX HEAD BOLT SPRING CLAMP OVERHEAD EXHAUST PIPE
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
LOWER EXHAUST PIPE HEAT SHIELD HEAT SHIELD SLEEVE LOCKWASHER INTERMEDIATE UPPER EXHAUST PIPE NUT MUFFLER MOUNTING BRACKET ISOLATOR WASHER PLUG
LPG/GAS ENGINE EXHAUST PIPE - LIFT TRUCKS WITHOUT LOW EMISSIONS
the lift truck has an overhead exhaust perform Step 1 through Step 4 and Step 6 through Step 8.
Remove
1. Install the left and right engine exhaust pipes on the engine exhaust manifolds. See Figure 6.
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.
2. Connect the left and right engine exhaust pipes to each other.
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.
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
Install
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.
NOTE: If the lift truck does not have an overhead exhaust perform Step 1 through Step 5, and Step 7. If
1. Remove the overhead exhaust pipe from the counterweight. See Figure 8.
8. Remove the left and right engine exhaust pipes from the engine exhaust manifolds.
12
100 YRM 726
Exhaust System Repair
Figure 8. EPA Compliant LPG/GAS Exhaust System
13
Exhaust System Repair
100 YRM 726 Legend for Figure 8
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
GASKET HEX HEAD BOLT SPRING SEAL UPPER EXHAUST PIPE LEFT ENGINE EXHAUST PIPE CLAMP RIGHT ENGINE EXHAUST PIPE HEAT SHIELD SLEEVE WIRE HARNESS (CLOSED LOOP) HEAT SHIELD
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
MUFFLER WASHER NUT MUFFLER MOUNTING BRACKET COUNTERWEIGHT EXHAUST PIPE ISOLATOR PLUG OXYGEN SENSOR LOWER EXHAUST PIPE OVERHEAD EXHAUST PIPE CAPSCREW
2. Remove the counterweight. See Counterweight Repair, Remove in this YRM.
4. Connect upper exhaust pipe to the left and rightside engine exhaust pipes.
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.
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.
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.
6. Connect the lower 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.
7. Install the counterweight. See Counterweight Repair, Install in this YRM.
6. Remove the metal heat shield from the left and right engine exhaust pipes.
8. Install the overhead exhaust pipe in the counterweight. Tighten the capscrews to 38 N•m (28 lbf ft).
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.
DIESEL ENGINE EXHAUST PIPE
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.
14
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.
100 YRM 726
Exhaust System Repair
6. Remove the intermediate exhaust pipe from the engine exhaust pipe.
7. Remove the engine exhaust pipe from the exhaust manifold.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
MUFFLER LOWER EXHAUST PIPE CLAMP UPPER EXHAUST PIPE INTERMEDIATE EXHAUST PIPE ENGINE EXHAUST PIPE ADAPTER OVERHEAD EXHAUST PIPE HEX HEAD BOLT SPRING SEAL
HEAT SHIELD SLEEVE COUNTERWEIGHT EXHAUST PIPE BRACKET HEX HEAD BOLT WASHER ISOLATOR NUT WASHER HEX HEAD BOLT WASHER ENGINE EXHAUST MANIFOLD
Figure 9. Diesel Exhaust System
15
Engine Repair
100 YRM 726
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.
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. 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.
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.
16
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 onetime 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.
100 YRM 726
1. 2. 3. 4.
Engine Repair
FOOT DIRECTIONAL CONTROL PEDAL ACCELERATOR PEDAL PEDAL BRACKET BRAKE BOOSTER/MASTER CYLINDER ASSEMBLY
5. 6. 7. 8.
INCHING LINKAGE RETURN SPRING INCHING CRANK RETURN SPRING INCH/BRAKE PEDAL
Figure 10. Pedal Assembly
17
Engine Repair 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. 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.
18
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).
100 YRM 726 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.). 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
100 YRM 726
Engine Repair 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.
master cylinder. Connect the wires to the brake switch.
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). 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. NOTE: A = 165 N•m (122 lbf ft). A. ENGINE MOUNTS (DIESEL SHOWN) B. ENGINE MOUNT (GAS/LPG SHOWN) 1. 2. 3. 4. 5. 6. 7.
CAPSCREW WASHER WASHER SNUBBING CUP ISOLATOR ENGINE MOUNT 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.
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.
Install the steering wheel or install the steering column and steering control unit to the bracket
19
Throttle Pedal Adjustment
100 YRM 726
4. Connect the fuel lines at the engine. Connect the throttle linkage at the engine. Connect the wires and wiring harnesses at the engine.
6. Install the alternator on units with a diesel engine. Install the battery and the battery tray. Connect the cables to the battery.
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.
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.
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 pump lever is touching the lever stop in Figure 13).
Lift Trucks With an Accelerator Pedal
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.).
1. Adjust the cable adjustment nuts to allow for a 3.0 mm (0.12 in.) maximum of free play on the
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
20
100 YRM 726
Throttle Pedal Adjustment
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 Âą2 mm (1.40 Âą0.08 in.). Secure in place with pedal stop jam nuts.
NOTE: DIESEL INJECTOR PUMP IS SHOWN IN THE IDLE POSITION. 1. INJECTION PUMP LEVER 2. LEVER STOP Figure 13. Diesel Injector Pump
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.
21
Throttle Pedal Adjustment
1. 2. 3. 4.
100 YRM 726
MONOTROL PEDAL DIESEL INJECTOR PUMP CABLE ADJUSTMENT NUTS CABLE LOCK NUTS
5. 6. 7. 8.
PEDAL STOP JAM NUTS PEDAL STOP UP POSITION PEDAL STOP CAPSCREW
Figure 14. Foot Directional Control Pedal Adjustment
22
100 YRM 726
Fuel and Hydraulic Tanks Repair
Fuel and Hydraulic Tanks Repair INSPECT Make a visual inspection of all sides of the tank. Inspect the welds for cracks and leakage. Check for wet areas, accumulation of dirt, and loose or missing paint caused by leakage. Areas of the tank that are not easily seen can be checked with an inspection mirror and a light that is approved for locations with flammable vapors.
SMALL LEAKS, REPAIR Use the following procedure to repair small leaks:
WARNING Do not use tools that can make sparks, heat, or static electricity. The vapors in the tank can cause an explosion. 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak. 2. Apply Loctite® 290 to the leak. Follow the instructions of the manufacturer.
LARGE LEAKS, REPAIR 1. Use one of the procedures described under Clean to clean and prepare the tank for repairs. 2. Use acceptable welding practices to repair the tank. See the American National Standard Safety In Welding and Cutting AWS Z 49.1 - 1999.
CLEAN WARNING Special procedures must be followed when large leaks or other repairs need welding or cutting. All work must be done by authorized personnel. If the tank is cleaned inside a building, make sure there is enough ventilation. See the following manuals for additional information: • Safe Practices For Welding And Cutting Containers That Have Held Combustibles by the American Welding Society, F4.1 - 1999. • Safety In Welding And Cutting American National Standard, AWS Z 49.1 - 1999. When cleaning the tank, do not use solutions that make dangerous gases at normal temperatures or when heated. Wear eye and face protection. Protect the body from burns.
When cleaning with steam, use a hose with a minimum diameter of 19 mm (0.75 in.). Control the pressure of the steam by a valve installed at the nozzle of the hose. If a metal nozzle is used, it must be made of a material that does not make sparks. Make an electrical connection between the nozzle and the tank. Connect a ground wire to the tank to prevent static electricity.
Steam Method Use the following procedure to clean the tank with steam: 1. Remove all the parts from the tank. Install the drain plug. 2. Fill the tank 1/4 full with a solution of water and sodium bicarbonate or sodium carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal) of water. 3. Mix the solution in the tank using air pressure. Make sure all the surfaces on the inside of the tank are flushed with the solution. Drain the tank. 4. Put steam into the tank until the tank does not have odors and the metal is hot. Steam vapors must come from all the openings. 5. Flush the inside of the tank with boiling water. Make sure all the loose material is removed from the inside of the tank. 6. Make an inspection of the inside of the tank. If it is not clean, repeat Step 4 and Step 5 and make another inspection. When making inspections, use a light that is approved for locations with flammable vapors. 7. Put plugs in all the openings in the tank. Wait 15 minutes; then remove the inlet and outlet plugs. Test a sample of the vapor with a special indicator for gas vapors. If the amount of flammable vapors is above the lower flammable limit, repeat the cleaning procedures.
Chemical Solution Method If the tank cannot be cleaned with steam, use the following procedure: 1. Mix a solution of water and trisodium phosphate or a cleaning compound with an alkali base. Follow the instructions given by the manufacturer.
23
Safety Labels
100 YRM 726
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. 2. Fill the tank with the cleaning solution. Use compressed air to mix the solution in the tank. 3. Drain the tank. Flush the inside of the tank with hot (boiling) water. Make sure all the cleaning compound is removed. 4. Make an inspection of the inside of the tank. If the tank is not clean, repeat Step 1 through Step 3. Make another inspection of the tank. When making inspections, use a light that is approved for locations with flammable vapors.
5. Check the tank for flammable vapors using a special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.
OTHER PREPARATION METHODS FOR REPAIR • If nitrogen gas or carbon dioxide gas is available, prepare the tank for welding using these gases. See the manual Safe Practices For Welding and Cutting Containers That Have Held Combustibles American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: • 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.
Safety Labels WARNING
WARNING
Safety labels are installed on the lift truck to give information about operation and possible hazards. It is important that all safety labels are installed on the lift truck and can be read.
Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the recommendations of the manufacturer.
DO NOT add to or modify the lift truck. Any change to the lift truck, its tires, or its equipment can change the lifting capacity. The lift truck must be rated as equipped, and the nameplate must show the new capacity rating. Contact your dealer for Yale lift trucks for a replacement nameplate.
1. Make sure the surface is dry and has no oil or grease. Do not use solvent on new paint. Clean the surface of old paint using a cleaning solvent.
If necessary, install new and correct labels as follows (see Figure 15):
3. Carefully hold the label in the correct position above the surface. The label cannot be moved after it touches the surface. Put the label on the surface. Make sure that all air is removed from under the label and the corners and edges are tight.
24
2. Remove the paper from the back of the label. Do not touch the adhesive surface.
100 YRM 726
Safety Labels
Figure 15. Label Positions
25
Safety Labels
100 YRM 726 Legend for Figure 15
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
26
MAST WARNING YALE LABEL NO RIDERS HOIST HANDLE LABEL TILT HANDLE LABEL PATENTS AND TRADEMARKS IMPACT WARNING LABEL NAMEPLATE COVER FAN WARNING FAN WARNING (PICTORIALLY) PARK BRAKE WITHOUT SEAT BRAKE ANTIFREEZE LABEL YALE LABEL DRIVETRAIN PROTECTION YALE LABEL
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
MAST WARNING PINCH POINT WARNING OPERATOR WARNING OPERATOR RESTRAINT LABEL NAMEPLATE FLAMMABLE LP GAS LABEL RADIAL TIRE WARNING (OPTIONAL) LABEL UL FUEL-TYPE WARNING LABEL LPG TANK LABEL FIRE SAFETY LABELS BATTERY DISCONNECT LABEL AUXILIARY FUNCTION LABEL DIESEL POWER LABEL (DIESEL TRUCKS ONLY)
100 YRM 778
General
General A fully-enclosed operator cab can be installed on the lift truck as an option. See Figure 1. When installed, the cab has doors, windows, window wipers, heater system, and an optional circulation fan. The overhead guard is an integral part of the operator cab. The operator cab is installed on a platform above the main frame
members. Step plates on both sides of the lift truck give access to the operator cab. The operator cab is a separate unit and can be removed as a complete unit from the module and frame of the lift truck.
Figure 1. Operator Cab
1
Cab Repair
100 YRM 778
Cab Repair REMOVE To remove the operator cab from the frame, do the following:
8. Remove the cab rear attaching hardware (1, 2, and 3, Figure 3).
1. Remove the retaining screws from the dash and the cowl panel. 2. Lift up the dash and remove the cowl panel. 3. Disconnect the main wiring harness, the front light harness, and the rear light harness between the lift truck and the operator cab. Stow front light harness in the cab leg before removing the cab from the lift truck. 4. Disconnect the water tube and the wiper motor harness connection to the windshield wipers. 5. Disconnect the air filter hose from the lower left corner of the cab frame. 6. Disconnect the water hoses to the heater and disconnect the heater wire harness. 7. Remove the cab front attaching hardware. See Figure 2.
1. 2. 3. 4. 5.
FLAT WASHER LOCKWASHER CAPSCREW CAPSCREW LOCKWASHER
6. 7. 8. 9. 10.
FLAT WASHER RING WASHER ISOLATOR ISOLATOR ISOLATOR CUP
Figure 3. Rear Attaching Hardware 9. Remove the rear isolator hardware and inspect for wear or damage. Replace if necessary. See Figure 3. 10. To prevent damage to the cab doors, remove them before attaching a lifting device.
WARNING Make sure that the lifting device has a minimum capacity to lift 500 kg (1100 lb).
1. CAPSCREW (2) 2. WASHER (4)
3. SHIM (AS REQUIRED) 4. LEFT FRONT LEG
Figure 2. Front Attaching Hardware
2
11. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator cab (under the overhead guard structure). Put material that will be a cushion at the top of the door openings to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lift strap on the operator cab.
100 YRM 778
Switch Panel 5. Install the rear attaching hardware to the frame and tighten finger-tight only.
CAUTION Lift the operator cab carefully. Check that all electrical wires and attachments are disconnected correctly and are not damaged. 12. Carefully lift the cab away from the lift truck. Set the cab assembly in a suitable storage area and put blocks under the unit to make it stable and prevent damage to parts still attached.
INSTALL If the operator cab was removed for repair or replacement, install it as follows: 1. Connect a lifting device to a spreader bar or lift strap, that is through the door openings at the top of the operator cab (under the overhead guard structure). Put material that will be a cushion at the top of the door openings to prevent damage. Operate the lifting device just enough to correctly position the spreader bar or lift strap on the operator cab. 2. Make sure that the bottom half of the isolators are in place. 3. Install the operator cab on the mounts making sure that the isolator is correctly positioned through the hole in the cab frame mount. See Figure 3.
6. Install the front attaching hardware. Install the shims as required and bend the tabs as necessary. Tighten finger-tight only. 7. Connect the wiring harnesses and wires to the components in the operator cab. 8. Connect the wiring harness to the heater. 9. Connect the air filter hose to the left rear leg of the cab frame. 10. Tighten the cab mounting bolts as follows: a. Front bolts - 90 N•m (66 lbf) b. Rear bolts - 90 N•m (66 lbf) 11. Connect the water tube and the wiper motor harness connection to the windshield wipers. 12. Connect the main wiring harness and the front and rear light harness between the lift truck and the operator cab. 13. Install the cowl cover. 14. Install the dash over the cowl cover and install the retaining screws. 15. Install the cab doors.
4. Install the rubber isolators, washers, nuts, and bolts for the mounts. Make sure that the isolators are correctly positioned.
Switch Panel The switch panel for the front and rear window wipers and the heater fan is located in the upper right rear of the cab. See Figure 4. Gauges and switches that are not an integral part of the cab are covered in Instrument Panel Indicators and Senders 2200 YRM 756.
1. FRONT WIPER/WASHER 2. REAR WIPER/WASHER 3. HEATER FAN Figure 4. Cab Switches
3
Window Wipers Replacement
100 YRM 778
Window Wipers Replacement Two window wiper motor assemblies are installed in the operator cab. The front window motor assembly has two wiper arms connected to a single wiper blade. The rear window has a wiper motor assembly that has one wiper arm attached to a single wiper blade.
3. Remove the water tube and disconnect the wiring harness.
FRONT WIPER ASSEMBLY
5. Install the water tube and connect the wiring harness.
1. To replace the front motor assembly, remove the retaining nuts and lockwashers from the wiper arms. Remove the wiper arm and blade from the outside. See Figure 5. 2. Remove the nuts, lockwashers, and flat washers from the two threaded shafts that pass through the metal frame (cowl) of the operator cab.
1. 2. 3. 4. 5.
WIPER ARM (2) RETAINING NUT (2) LOCKWASHER (2) NUT (2) LOCK NUT (2)
6. 7. 8. 9. 10.
4. Repair or replace defective parts and install the front wiper assembly as shown in Figure 5.
REAR WIPER ASSEMBLY 1. To replace the rear motor assembly, remove the retaining nut and lockwasher from the wiper arm. Remove the wiper arm and blade from the outside. See Figure 6.
FLAT WASHER (2) WIPER MOTOR ELECTRICAL CONNECTOR WATER TUBE HEATER
Figure 5. Front Window Wiper System
4
11. COVER 12. CHECK VALVE 13. GROMMET
100 YRM 778
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
MOUNTING STUD WASHER (2) GROMMET (2) GLASS WIPER MOTOR WASHER (2) NUT (2) COVER WATER TUBE CONNECTOR
Window Wipers Replacement
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
RESERVOIR SPRAY NOZZLE MOUNTING STUD GROMMET WASHER RETAINER NUT HARDWARE COVER NUT WASHER WIPER ARM
Figure 6. Rear Window Wiper System
5
Door Handle Assembly
100 YRM 778
2. Remove the hardware covers, nuts, retainers, and flat washers from the threaded shafts that pass through the glass of the operator cab.
5. From inside the cab, on the wiper motor, remove the nuts and washers from the mounting studs that pass through the glass from the back side.
3. Remove the wiper motor cover by pulling backward. The cover is held in place by plastic tabs on the inside of the cover.
6. Repair or replace any defective parts and install the rear wiper assembly as shown in Figure 6.
4. Remove the water tube and disconnect the wiring harness connector.
NOTE: One of the mounting studs is also the spray nozzle for the window washer. 7. Install the water tubes and connect the electrical wires harness.
Door Handle Assembly The door handle assemblies are made up of three components: an outside handle with lock, an inside levertype handle and latch mechanism, and the striker. See Figure 7. The outside door handle is fastened to the door by three screws installed through access holes from the inside of the door. The inside door handle is fastened to the door by a capscrew and washer at the bottom end of the handle and attaching hardware at the mechanism. The handle assembly has a latch mechanism that contacts the striker. The striker is threaded and is installed on the forward door post. Adjust the striker so that it mates with the latch mechanism.
1. DOOR FRAME 2. INSIDE HANDLE 3. COVER
4. STRIKER HARDWARE 5. SEAL 6. OUTSIDE HANDLE
Figure 7. Door Handle Assembly
6
100 YRM 778
Heater Assembly
Fuse Panel The fuse panel with the fuses for the window wipers, lights, fan, and heater system are inside the operator cab. This fuse panel is located in the upper right rear corner of the cab. The fuse arrangement is shown in Figure 8. The fuse panel can be pulled away or removed from the mount by loosening two capscrews, then disconnecting the fuse panel from the wire harness.
1. WIPER FRONT/REAR 2. DOMELIGHT
3. FAN/RADIO 4. HEATER/BLOWER
Figure 8. Fuse Panel
Heater Assembly REMOVE WARNING If the truck has been run for awhile, the heater hoses will be hot and the water can cause severe burns. Make sure that the hoses are cool before removal.
CAUTION When the engine heater hoses must be replaced in the cab, make sure to use heater hoses of the correct material and size. Order Yale part number 504323758 for the engine supply hose and 504323755 for the return hose. All hoses must conform to SAE Specification 20R3 Class C or 20R3 Class D-2. NOTE: If the heater fails, replace the heater assembly as a complete unit. 1. Disconnect the two preformed heater hoses from the heater. See Figure 9.
2. Disconnect the heater electrical connector. 3. Open the right-hand cab door and remove the two screws that fasten the heater duct to the bracket. 4. Remove the four screws that fasten the heater to the bracket and remove the heater assembly.
INSTALL 1. Attach the heater assembly to the mounting bracket with four screws and washers. See Figure 9. 2. Attach the heater duct to the mounting bracket with two screws and washers. Make sure that the duct mates with the heater input opening. 3. Make sure that the seal on the door side of the duct is installed correctly. 4. Connect the heater electrical connector. 5. Connect the two preformed heater hoses to the heater. See Figure 9.
7
Heater Assembly
1. 2. 3. 4. 5.
HEAT DUCT SEAL HEATER BRACKET SCREW (4)
100 YRM 778
6. 7. 8. 9.
WASHER (4) HEATER HOSE CONNECTIONS PREFORMED HEATER HOSE (RETURN) PREFORMED HEATER HOSE (SUPPLY)
Figure 9. Heater Assembly
8
100 YRM 778
Window Replacement
Window Replacement WARNING All windows installed in the cab are made of tempered glass. The overhead skylight is made of LexanÂŽ. All replacement windows must be made of the correct material and thickness as the windows furnished with the lift truck. See Table 1 for window specifications. The front window is a single unit held in place by screws through the glass. See Figure 10. The rear and lower
door windows are replaced as single units held in the window openings by a rubber seal. The slider windows and frames in the doors must be replaced as a unit. The top window is a single piece of curved Lexan and is fastened by an adhesive. In the event of breakage, cracking, or other damage to any of the cab windows, it is recommended that all windows be repaired or replaced by your Yale dealer or other qualified glazier.
Table 1. Material Specifications for Cab Windows Location of Window
Yale Part Number
Material Specification
Front
580014760
Rear
580014770
Thickness mm
inch
Tinted Tempered Safety Glass per ANSI Z26.1 AS1 Requirements
5.9 to 7.5
0.23 to 0.29
5.6 to 6.8
0.22 to 0.27
Tinted Tempered Safety Glass per ANSI Z26.1 AS2 Requirements
4.5 to 5.0
0.18 to 0.2
4.5 to 5.0
0.18 to 0.2
3.0
0.12
Doors Upper RH
580014007
Upper LH
580014006
Lower, R/L
524140139
Tinted Tempered Safety Glass per ANSI Z26.1 AS2 Requirements
580025892
Tinted LexanÂŽ MR 5004-310351
Top
9
Window Replacement
1. 2. 3. 4.
FRONT WINDOW SEAL ATTACHING HARDWARE CLAMP WITH HARDWARE
100 YRM 778
5. 6. 7. 8.
SKYLIGHT REAR WINDOW LOWER DOOR WINDOW UPPER DOOR WINDOW
Figure 10. Operator Cab Assembly Glass
10
100 YRM 778
Options
Options There are several options available for the cab. See your Yale dealer for the full range of available options.
REAR STROBE LIGHTS In addition to the standard overhead driving lights, the cab can be equipped with a rear-mounted strobe light with either a high or low mounting fixture. See Figure 11. The strobe light is normally configured to operate continuously. It can be optionally configured to activate when the lift truck is put into reverse gear. See Figure 12.
HEAVY-DUTY AIR CLEANER In environments with very dirty conditions, the lift truck can be equipped with a heavy-duty air cleaner which precleans the air before it enters the standard air filter. This precleaner is mounted on the rear of the cab in place of the air vent. See Figure 11. Clean or replace the heavy-duty precleaner as necessary. Inspect the canister, the hose, and the molded port for excessive wear, cracks, or damage.
1. LOW MOUNT OR HIGH MOUNT STROBE 2. HEAVY-DUTY AIR CLEANER 3. ADDITIONAL MIRROR Figure 11. Operator Cab Options
11
Electrical Schematics
100 YRM 778
Label Replacement 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 drive tires
can change the capacity rating. See a Yale lift trucks dealer for a replacement nameplate. The nameplate information is a safety item and must be correct for the equipment and configuration of the lift truck. Refer to Frame 100 YRM 726 for label placement.
Electrical Schematics The electrical schematic for the cab is included in this manual for the users convenience. See Figure 12 and Figure 13. Refer to Diagrams 8000 YRM 757 for the lift truck electrical schematics.
12
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