YALE A879 GDC135-155CA LIFT TRUCK Service Repair Manual

GC/GLC/GDC135-155CA (A879) SERVICE MANUAL CONTENTS SECTION

PART NUMBER

YRM NUMBER

REV DATE

FRAME............................................................................................................................

GM ENGINES..................................................................................................................

PERKINS DIESEL ENGINE............................................................................................

COOLING SYSTEM........................................................................................................

LPG FUEL SYSTEM.......................................................................................................

2-SPEED POWERSHIFT TRANSMISSION DESCRIPTION AND OPERATION...........

2-SPEED POWERSHIFT TRANSMISSION REPAIR.....................................................

DIFFERENTIAL...............................................................................................................

DRIVE AXLE...................................................................................................................

STEERING CONTROL UNIT..........................................................................................

STEERING AXLE............................................................................................................

BRAKE SYSTEM............................................................................................................

HYDRAULIC GEAR PUMP.............................................................................................

HYDRAULIC ASSEMBLY PUMP...................................................................................

HYDRAULIC SYSTEM....................................................................................................

MAIN CONTROL VALVE................................................................................................

TILT CYLINDERS...........................................................................................................

ALTERNATOR................................................................................................................

STARTER........................................................................................................................

HIGH ENERGY IGNITION (HEI) SYSTEM.....................................................................

INSTRUMENT PANEL INDICATORS AND SENDERS.................................................

MICROPROCESSOR SPARK TIMING SYSTEM (GM 3.0L/4.3L) (LATER MODELS).

EEC-DESCRIPTION AND OPERATION (GM 3.0L/4.3L)...............................................

EEC-TROUBLESHOOTING AND REPAIR....................................................................

LIFT CYLINDERS...........................................................................................................

MAST DESCRIPTION AND REPAIR..............................................................................

METRIC AND INCH (SAE) FASTENERS.......................................................................

PERIODIC MAINTENANCE............................................................................................

CAPACITIES AND SPECIFICATIONS...........................................................................

DIAGRAMS.....................................................................................................................

524192611 524153897 524150774 524150775 524153900 524185156 524185157 524150779 524192612 524185160 524192613 524192614 524153907 524153908 524192615 524185164 524150790 524150791 524150792 524153914 524185165 524153916 524153917 524153918 524150794 524185167 524150797 524192617 524192616 524185171

0100 YRM 0449 0600 YRM 0590 0600 YRM 0705 0700 YRM 0626 0900 YRM 0348 1300 YRM 0324 1300 YRM 0325 1400 YRM 0046 1400 YRM 0450 1600 YRM 0054 1600 YRM 0451 1800 YRM 0452 1900 YRM 0097 1900 YRM 0339 1900 YRM 0453 2000 YRM 0090 2100 YRM 0103 2200 YRM 0002 2200 YRM 0106 2200 YRM 0107 2200 YRM 0143 2200 YRM 0765 2200 YRM 0781 2200 YRM 0782 4000 YRM 0135 4000 YRM 0329 8000 YRM 0231 8000 YRM 0393 8000 YRM 0454 8000 YRM 0519

02/07 04/14 03/06 03/03 03/03 10/03 10/03 08/12 09/03 10/03 09/03 02/04 05/12 10/03 09/03 10/03 03/07 12/04 12/04 03/08 02/07 03/03 03/03 03/03 03/11 09/10 10/13 06/09 10/03 06/07

Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.

PART NO. 524192610 (04/14)

100 YRM 449

Description

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, and exhaust system. 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, upright, overhead guard, engine and transmission, axles, and other parts. See Figure 1.

1. HOOD 2. FLOOR PLATE 3. OVERHEAD GUARD

4. COUNTERWEIGHT 5. FRAME Figure 1. Frame and Connected Parts

1

Counterweight Repair

100 YRM 449

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 causes large changes in the center of gravity: upright, drive axle, engine and transmission, and the counterweight. When the lift truck is put on blocks, put additional blocks in the following positions to maintain stability: a. Before removing the upright 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 upright assembly so that the lift truck cannot fall forward.

slowly. Fuel leaving the fitting removes heat. Use a cloth to protect your hands from the cold fitting.

2. Use the following procedure to remove the LPG tank: a. Removable LPG tanks can be removed and replaced indoors only if the lift truck is at least 8 m (25 ft) from any open flame or ignition source. b. Move the lift truck to the area where tanks are changed. c. Turn the tank fuel valve clockwise until the valve is completely closed. d. Run the engine until it stops, then turn the key switch to the OFF position.

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.

Do not operate the lift truck if the capscrews for the counterweight are not installed. When the capscrew is removed, the counterweight can fall from the lift truck.

WARNING Make sure any lifting devices have the correct capacity for the parts being moved. See Figure 2.

1. If the lift truck has an LPG fuel system, remove the LPG tank and bracket so that the counterweight can be removed. See Figure 2.

WARNING LPG can cause an explosion. Do not cause sparks or permit flammable material near the LPG system.

LPG fuel systems can be disconnected indoors only if the lift truck is at least 8 m (25 ft) from any open flame, motor vehicles, electrical equipment, or ignition source.

Close the fuel valve on the LPG tank before any part of the engine fuel system is disconnected. Run the engine until the fuel in the system is used and the engine stops.

If the engine will not run, close the fuel valve on the LPG tank. Loosen the fitting on the supply hose from the LPG tank where it enters the filter unit.

Permit the pressure in the fuel system to decrease

2

Weight of Counterweights GLC135CA (GC/GDC/ GLC135CA) 2873 to 2953 kg (6335 to 6511 lb) 1. LIFT TRUCK FRAME 2. COUNTERWEIGHT 3. GRILL 4. CAPSCREW

GLC155CA (GC/GDC/ GLC155CA) 3330 to 3420 kg (7343 to 7541 lb) 5. ACCESS DOOR 6. TRANSITION PLATE 7. HOOD

Figure 2. Counterweight

100 YRM 449

Hood Repair

e. Disconnect the quick disconnect fitting. f.

Release the LPG tank latch and remove the tank from the bracket.

3. Open the access door between the counterweight and the hood. Remove the LPG tank and tank bracket if the unit has the LPG fuel system.

4. Install a lifting eye in the hole in the top of the counterweight. Connect a lifting device to the lifting eye.

Remove the two vertical capscrews and the capscrew behind the tow pin that hold the counterweight to the frame.

5. Lift the counterweight from the frame. Put the counterweight in a position so that it has stability and will not fall.

INSTALL 1. Connect a lifting device to the lifting eye on the counterweight. Lift the counterweight into position on the frame. See Figure 2.

2. Install the capscrews for the counterweight.

Tighten the capscrews to 655 N•m (485 lbf ft).

3. Close the access door. Install the LPG tank on LPG units.

Hood Repair REMOVE 1. Remove the capscrews that fasten the transition plate. Do NOT remove the plate. See Figure 2.

2. Open the access door, reach under the transition plate, and remove the radiator overflow hose from the two J clamps.

3. Raise the hood and disconnect the gas assist cylinder at the hood. Remove the hood, transition plate, and access door.

3. Use the following procedure to adjust the hood latch (see Figure 3): a. Install the floor plates and tighten the capscrews. b. Install the latch striker in the highest slot position on the rear floor plate. Check that the latch striker is in the center of the jaws of the hood latch.

INSTALL

c. Close the hood to the fully-closed position. The hood latch has two positions. The hood is fully closed after two clicks of the latch.

1. Install the hood, transition plate, and access door in position on the lift truck. Install the capscrews for the transition plate. Connect the gas assist cylinder to the hood. Align the hood for the latch on the front cover. Tighten the capscrews for the transition plate.

d. Loosen the capscrews for the latch striker just enough to let the striker move. Push the hood down until the hood just touches the rubber bumpers on the frame. Make sure the latch striker is still in the center of the hood latch.

Tighten the capscrews for the latch striker.

2. Install the overflow hose in the J clamps. Close the access door.

e. Check the operation of the hood latch. Have an operator sit in the seat. Make sure the hood is fully closed (two clicks). Also check that the hood touches the rubber bumpers. If necessary, repeat Step d.

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

3

Overhead Guard Repair

100 YRM 449

A. GAS/DIESEL ARRANGEMENT 1.

2.

3.

4.

LATCH STRIKER HOOD LATCH LATCH LEVER SEAT

B. LPG ARRANGEMENT 5.

6.

7.

8.

SEAT BELT LATCH HIP RESTRAINT SEAT RAIL FLOOR PLATE

9. HOOD 10. GAS CYLINDER 11. HINGE

Figure 3. Hood and Seat Latches Check

Overhead Guard Repair REMOVE WARNING Do not operate the lift truck without the overhead guard correctly fastened to the lift truck.

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. If installed, remove the overhead exhaust and LPG fuel line clamps. If installed, disconnect the light wiring harness. Remove the capscrews that hold the overhead guard to the frame. Remove the capscrews

4

that hold the overhead guard to the cowl. overhead guard from the lift truck.

Lift the

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. Install the capscrews that hold the overhead guard to the cowl. Tighten the rear and top front capscrews to 90 N•m (67 lbf ft). Tighten the front capscrews under the cowl to 165 N•m (122 lbf ft).

3. If removed, install the overhead exhaust and LPG fuel line. Connect the light wiring harness.

100 YRM 449

Operator Restraint System Repair

Operator Restraint System Repair The seat belt, hip restraint brackets, seat and mounting, hood, latches, and floor plates 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.

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.

1. FORWARD/BACKWARD ADJUSTMENT 2. SWIVEL ADJUSTMENT 3. OPERATOR WEIGHT ADJUSTMENT

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.

4. SEAT POSITION ADJUSTMENT (SEAT RAIL) 5. SET BELT

Figure 4. Operator Restraint System (Swivel Seat Shown)

5

Fuel and Hydraulic Tanks Repair 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

100 YRM 449 the hood in the open position, replace the seat belt assembly.

Make sure the seat rails and latch striker are not loose.

See Figure 3. The seat rails must lock tightly in position, but move freely when unlocked. The seat rails must be correctly fastened to the mount surface. If the mount surface is the hood, the hood must be fastened to the floor plate with the latch. The floor plate must be fastened to the lift truck frame. Try to lift the hood to make sure it is fastened correctly and will not move.

Adjust the hood, hood latch, and latch striker when any of the parts of the operator restraint system are installed or replaced. See the Hood Repair section for more details.

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: 1. Use steam to clean the area around the leak. Remove all paint and dirt around the leak.

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

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 in this section 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.

6

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, 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.

100 YRM 449

Radiator Repair

Steam Method of Cleaning 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 of Cleaning 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.

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 special indicator for gas vapors. If the amount of flammable vapors is not below the lower flammable limit, repeat the cleaning procedures.

ADDITIONAL PREPARATIONS 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 by the American Welding Society, F4.1 - 1999. If these gases are not available, another method using water can be used as follows: 1. 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.

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

Radiator Repair REMOVE NOTE: To make radiator removal easier, remove the counterweight as described in Counterweight Repair, Remove.

1. Open the access door between the hood and the counterweight. Remove the cover plate over the radiator. If installed, remove the LPG tank and bracket.

2. Drain the coolant from the radiator. Remove the radiator hoses. Disconnect the oil lines at the radiator.

Put caps on the open lines.

3. Remove the remote fill assembly and radiator hoses to the engine. Disconnect the hose to the auxiliary coolant reservoir.

4. Remove the hood and transition plate as described in Hood Repair, Remove. Remove the fan shroud and fan. Loosen the exhaust band clamp on the

7

Exhaust System Repair

100 YRM 449

gasoline and LPG units. Remove the engine water outlet on diesel units.

5. Remove the muffler and inlet exhaust pipe to the muffler. Remove the capscrews that fasten the radiator. Move the exhaust pipe for clearance of the radiator flange.

6. Tip the radiator forward over the engine as you lift and remove the radiator.

INSTALL NOTE: The installation of the radiator is easier if the counterweight is removed. See Counterweight Repair, Remove in this section.

1. Tip the radiator forward over the engine as you install the radiator in the lift truck. Move the exhaust pipe for clearance to the radiator flange.

3. Install the engine water outlet on diesel units.

Tighten the exhaust band clamp on gasoline or LPG units. Install the fan and fan shroud. Install the hood and transition plate as described in the Hood Repair, Install section.

4. Connect the hose to the auxiliary coolant reservoir.

Install the remote fill assembly and radiator hoses to the engine. Make sure the hose clamp screws have an access at the wheel wells.

5. Connect the oil lines at the radiator. Install the cover plate over the radiator and fill the radiator with the coolant specified in the table in the Periodic Maintenance 8000 YRM 393.

6. If removed, install the counterweight as described in the Counterweight Repair, Install section. If the LPG tank and bracket were removed, install them.

2. Install the capscrews that fasten the radiator. Install the muffler and inlet exhaust pipe at the muffler.

Exhaust System Repair MUFFLER

Install

Remove

1. On overhead exhaust units, install the counterweight exhaust pipe on the muffler, but do NOT tighten. See Figure 5, Figure 6, and Figure 7..

1. Remove the grill by removing the retaining plate at the top of the grill. See Figure 5, Figure 6, and Figure 7.

2. Disconnect the exhaust pipes and remove the clamps.

3. Remove the clamp from the muffler outlet and remove the muffler.

2. Install the muffler and, on units with the overhead exhaust, rotate the muffler so the outlet is at the top. Install the other exhaust pipes and tighten the clamps. Rotate the counterweight exhaust pipe so that it points straight back and down at a 45 angle.

3. Install the grill and align the end of the counterweight exhaust pipe so that it is between the grill bars.

Legend for Figure 5 1.

2.

3.

4.

5.

8

COUNTERWEIGHT GM-V6 ENGINE PERKINS ENGINE MUFFLER CLAMP

6.

7.

8.

9.

EXHAUST PIPE CROSSOVER PIPE TAIL PIPE BAND CLAMP

100 YRM 449

Exhaust System Repair

Figure 5. Exhaust System

9

Exhaust System Repair

100 YRM 449

A. GAS/LPG COUNTERWEIGHT EXHAUST EPA COMPLIANT 1.

2.

3.

4.

5.

6.

UPPER EXHAUST PIPE TAIL PIPE COUNTERWEIGHT MUFFLER GASKET LOWER EXHAUST PIPE

B. GAS/LPG COUNTERWEIGHT EXHAUST NON-EPA COMPLIANT 7.

8.

9.

10.

11.

RAW GAS CHECK PORT OXYGEN SENSOR PORT CROSSOVER PIPE FLEX PIPE CLAMP

Figure 6. Exhaust System EPA Compliant Engine

10

100 YRM 449

Exhaust System Repair

A. DIESEL COUNTERWEIGHT EXHAUST EPA COMPLIANT

B. GAS/LPG/DIESEL OVERHEAD EXHAUST

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

UPPER EXHAUST PIPE TAIL PIPE COUNTERWEIGHT MUFFLER CLAMP

FLEX PIPE LOWER EXHAUST PIPE OVERHEAD TAIL PIPE OUTER SHIELD INNER SHIELD

Figure 7. Exhaust System, Diesel EPA Compliant

11

Engine Repair

100 YRM 449

Engine Repair REMOVE NOTE: The lift truck can have a powershift or a manual transmission. The powershift transmission and the torque converter are attached to the engine. The engine and powershift transmission are normally removed as a unit. The manual transmission is attached to the drive axle housing. This engine is removed without removing the manual transmission.

1. Put the lift truck on blocks. See the Operating Manual or the Periodic Maintenance 8000 YRM 393 for the correct procedures to put the lift truck on blocks. Remove the overhead guard, hood, transition plate, and access door. See the Hood Repair, Remove section for more details. Remove the floor plates.

2. Disconnect the cables at the battery. Remove the battery, air cleaner inlet duct, and battery tray.

Disconnect the brake fluid reservoir and engine crankcase breather lines.

3. Remove the fan and fan shroud. Disconnect the exhaust pipe at the exhaust headers.

4. Disconnect the fuel lines at the engine. Disconnect the throttle linkage at the engine. Disconnect the wires and wiring harnesses at the engine and powershift transmission.

f.

Disconnect the drive line at the universal joint.

7. Manual transmission. Do the following procedure: a. Disconnect the drive line at the universal joint near the clutch. b. Disconnect the hydraulic and brake lines. Disconnect the push rod to the brake booster. Disconnect the electrical wiring.

WARNING Do NOT leave the clutch pedal free in the up position with the over-center spring installed. The spring is under tension and can cause an injury. Fasten the clutch pedal so that it cannot move down, remove the spring or carefully move the pedal to the down position to remove the tension. c. Remove the brake booster. Disconnect the clutch push rod from the clutch cover.

8. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (1000 lb). Remove the four motor mount bolts.

Raise the engine from the frame. Be careful of the hydraulic pump. Make sure that all wires and hoses are disconnected. Put the engine in a position so that it has stability and will not fall.

5. Disconnect the oil lines at the hydraulic pumps.

Drain the hydraulic tank and put plugs in the open ports. Disconnect the oil cooler lines from the powershift transmission.

9. Remove the powershift transmission from the engine as described in the Two-Speed Powershift Transmission, Repairs 1300 YRM 325. On units with the manual transmission, remove the oil clutch housing and clutch cover from the engine.

6. Powershift transmission. Do the following procedure:

INSTALL

a. Disconnect the linkage between the transmission and the pedals at the transmission.

1. Install the engine mounts on the engine as follows (see Figure 8):

b. Disconnect the hydraulic lines to the brake booster.

a. GM V-6: Tighten the capscrews that hold the engine mount to the fan end of the engine to 30 N•m (22 lbf ft). Tighten the bolts that hold the engine mounts to the mount plate to 65 N•m (48 lbf ft).

c. Disconnect the brake line at the booster. Disconnect the electrical wiring. d. Remove the pedal bracket. e. On units without the Foot Directional Control pedal, disconnect the direction control linkage at the transmission.

12

b. PERKINS: Apply a sealant to the threads of the capscrews and tighten the capscrews that hold the engine mounts to the fan end of the engine to 65 N•m (48 lbf ft).

100 YRM 449

A. B. C. D.

Engine Repair

FRONT MOUNTS PERKINS, POWERSHIFT GM-V6, POWERSHIFT ONLY PERKINS, GM-V6 MANUAL ONLY

E. REAR MOUNTS F. PERKINS G. GM-V6

1. ENGINE OR TRANSMISSION MOUNT 2. ENGINE, TRANSMISSION, OR CLUTCH HOUSING 3. MOUNT PLATE

4.

5.

6.

7.

BOLT WASHER RUBBER MOUNT FRAME MOUNT WELDMENT

Figure 8. Engine Mounts

CAUTION Apply a sealant (Yale Part Number 520042831) to the flange of the flywheel housing. Make sure the torque converter or clutch is installed correctly and engaged with the oil pump. If the parts are not engaged, the oil pump or torque converter will be damaged.

2. If removed, install the torque converter and powershift transmission on the engine as described in the

Two-Speed Powershift Transmission, Repairs 1300 YRM 325. If removed, install the oil clutch housing and cover on the engine.

3. Connect a lifting device to the engine. Make sure the lifting device has a capacity of at least 450 kg (1000 lb). Install the engine in the unit. Be careful of the hydraulic pump. Make sure that all wires and hoses are not damaged. Install the four motor mount bolts. Connect all hoses and wiring. Make

13

Throttle Pedal Adjustment

100 YRM 449

sure the clamp screws for the radiator hoses are aligned for access from the wheel wells.

b. Connect the hydraulic and brake lines. Connect the push rod to the brake booster.

4. Install the bolts for the engine mounts. See Figure 5. Tighten the bolts to 120 N•m (89 lbf ft).

c. Connect the drive line at the universal joint near the clutch.

5. Powershift transmission: do the following procedure:

7. Connect the oil lines at the hydraulic pumps. Fill the hydraulic tank with the oil specified in the Periodic Maintenance 8000 YRM 393.

a. Connect the drive line at the universal joint. b. On units without the Foot Directional Control pedal, connect the direction control linkage at the transmission. c. Install the pedal bracket. Connect the brake line at the booster. d. Connect the hydraulic lines to the brake booster. e. Connect the linkage between the transmission and the pedals at the transmission. f.

Connect the oil cooler lines for the transmission.

6. Manual transmission: do the following procedure: a. Install the brake booster. Connect the clutch push rod to the clutch cover.

8. Connect the fuel lines at the engine. Connect the throttle linkage at the engine.

9. Connect the exhaust pipe at the exhaust header.

Install the fan and fan shroud.

10. Connect the engine crankcase breather and the brake fluid reservoir lines. Install the battery tray, air cleaner inlet duct, and battery. Connect the cables at the battery.

11. Install the floor plates. Install the overhead guard and the hood, transition plate, and access door.

See Hood Repair, Install in this section. Remove the blocks that support the lift truck using the reverse of the installation procedure in the section Periodic Maintenance 8000 YRM 393 or in the Operating Manual.

12. Check all of the fluid levels and fill as necessary.

Remove the air from the brake system.

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 348 for the procedures to adjust the throttle linkage.

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 9. 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.

14

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 10).

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. Tighten up position pedal stop with capscrew. See Figure 9.

100 YRM 449

Throttle Pedal Adjustment

NOTE: THE FOOT DIRECTIONAL CONTROL PEDAL IS SHOWN. THE ADJUSTMENT PROCEDURES FOR THE ACCELERATOR PEDAL ARE THE SAME. 1.

2.

3.

4.

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 9. Foot Directional Control and Accelerator Pedal Adjustment

15

Safety Labels

100 YRM 449 Legend for Figure 10 NOTE: DIESEL INJECTOR PUMP IS SHOWN IN THE IDLE POSITION. 1. INJECTION PUMP LEVER 2. LEVER STOP

Figure 10. Diesel Injector Pump

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, the 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 Hyster 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 with a cleaning solvent.

If a label must be replaced, use the following procedure to install a new label (see Figure 11):

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.

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

100 YRM 449

Safety Labels

A. GASOLINE/LPG

B. DIESEL

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11. CASE, OPERATING MANUAL 12. REPLACE OPERATING MANUAL LABEL (NOT REQUIRED FOR ENGLISH SPEAKING COUNTRIES) 13. FLAMMABLE LP GAS 14. LABEL, LP TANK IDENTIFIER (U.S. AND CANADA ONLY) 15. PARKING BRAKE WARNING 16. NO RIDERS 17. OPERATOR WARNING 18. ANTIFREEZE 19. MAST WARNING

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FAN WARNING (ON SHROUD) INSPECTION PLATE, UL HOIST/TILT AUXILIARY FUNCTIONS IMPACT RATING PLATE NAMEPLATE (INFORMATION MUST BE COMPLETE) OPERATOR RESTRAINT (FOR EQUIPPED UNITS) OR TIPOVER WARNING (FOR OTHER UNITS) PATENT LABEL (INSIDE COWL, RIGHT) SAFETY TREAD (LEFT AND RIGHT) MODEL LABEL (2)

Figure 11. Label Positions

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1400 YRM 46

Differential Repair

General This section contains description and repair procedures for the differential. There is a Specifications section and a Troubleshooting section at the end of this section.

Description This differential is fastened to the drive axle housing of the lift truck. The differential provides a single-speed reduction for an increase in torque to the drive wheels.

There is a housing, a ring and pinion gear set, and the differential assembly. The ring gear transfers power

from the pinion through the differential assembly to the axles. The differential assembly permits the drive wheels to rotate at different speeds during a turn. See Figure 1.

Differential Repair REMOVE NOTE: The repair procedures cover all units unless otherwise indicated.

Differential Carrier From Axle Housing, Remove NOTE: The differential assembly can normally be removed without removing the drive axle. If removal of

the drive axle is necessary, see the Drive Axle service manual for your lift truck model.

1. Remove the mast. See the Mast service manual for your lift truck model for the removal procedures.

2. Raise the end of the vehicle where the axle is mounted. Use a jack or other lifting tool, and place safety stands under each side of the axle. See Figure 2.

1

Differential Repair

1400 YRM 46

Figure 1. Typical Differential Assembly

2

1400 YRM 46

Differential Repair

Legend for Figure 1 NOTE: *SOME AXLES DO NOT HAVE THE PARTS DESCRIBED. 1.

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PINION NUT WASHER* INPUT YOKE* DEFLECTOR TRIPLE-LIP OIL SEAL DIFFERENTIAL CARRIER FILL PLUG ADJUSTMENT RING LOCK PLATE CAPSCREW SIDE GEAR THRUST WASHER CASE HALF BEARING CONE BEARING CUP PINION SPIDER

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CAPSCREW OR RIVET* RING GEAR CASE HALF, FLANGE NUT* NUT WASHER THRUST BLOCK* BEARING CAP COTTER PIN (ADJUSTING RING)* JAM NUT* THRUST SCREW* RETAINING RING WASHER SPIGOT BEARING PINION SPACER

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SHIM PINION CARRIER COVER BOLT SHIFT FORK SPRING SHIFT SHAFT PIN AIR CYLINDER TUBE SCREW IN DIFFERENTIAL LOCK CYLINDER CYLINDER COVER GASKET PLUG SHIFT COLLAR PISTON O-RING

NOT work under a lift truck supported only by jacks.

Jacks can slip and fall over. Serious personal injury can result.

3. Place jack stands under each spring seat of the axle, to hold the lift truck in the raised position.

4. Remove plug from the bottom of the axle housing and drain the oil from the axle assembly.

5. Disconnect the drive shaft at the differential. If a speed reducer or gear box is installed, remove the speed reducer or gear box.

6. Some units have a drum or disc brake attached to the output yoke. Disconnect any brake linkage or brake lines. See the Brake manual for your unit.

1. SAFETY STANDS

Figure 2. Lift Truck Support

WARNING Block the wheels to prevent the lift truck from moving. Support the lift truck with safety stands. DO

7. Disconnect the driveline universal joint from the pinion input yoke or flange on the differential carrier.

See Figure 3.

8. Remove the axle shafts from the axle housing. See the Drive Axle manual for your model of lift truck for the procedures.

9. Place a transmission jack under the differential carrier for support. See Figure 4.

3

Differential Repair

1. BEARING CUPS 2. END YOKE 3. YOKE SADDLE

1400 YRM 46

4. WELD YOKE 5. BEARING STRAP 6. CAPSCREWS

7. U-JOINT CROSS 8. SLIP YOKE 9. TUBING

Figure 3. Typical Driveline Universal Joint Legend for Figure 4 1. WOOD BLOCK 2. TRANSMISSION JACK 3. CAPSCREWS 10. Remove all but the top two differential carrier housing capscrews. See Figure 4.

11. Loosen the top two differential carrier housing capscrews and leave them attached to the assembly.

The capscrews will hold the differential carrier in the housing.

12. Loosen the differential carrier in the axle housing.

Use a leather mallet to hit the mounting flange of the differential carrier at several points.

Figure 4. Differential Carrier Support

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13. After the differential carrier is loosened, remove the top two capscrews.

Thank you very much for your reading.

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