2. 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
GLP/GDP4.50MJ
(GP/GLP/GDP100MJ)
2660 to 2740 5864 to 6041
GLP/GDP5.00MJ
(GP/GLP/GDP110MJ)
2906 to 2994 6407 to 6601
GLP/GDP5.50MJ
(GP/GLP/GDP120MJ)
3152 to 3248 6949 to 7161
2. Remove cover between counterweight and hood.
Remove tow pin.
3. Install two eyebolts into the counterweight lifting
holes and attach a lifting device to the eyebolts.
CAUTION
When lifting the counterweight from the lift truck,
be careful not to bend the exhaust pipe.
4. Remove two capscrews, washers, and lockwash-
ers. Remove counterweight from lift truck.
1
3. Hood Repair 100 YRM 726
1. COUNTERWEIGHT
2. LIFTING DEVICE
3. LIFTING EYE
4. WASHER
5. LOCKWASHER
6. MOUNTING BOLT
Figure 1. Counterweight
INSTALL
1. Install counterweight in place on the lift truck.
See Figure 1. Install two lockwashers, washers,
and capscrews. Tighten capscrews to 555 N•m
(409 lbf ft).
2. Remove eyebolts from counterweight lifting holes.
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).
Hood Repair
REMOVE
WARNING
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the fol-
lowing assemblies will cause large changes in the
center of gravity: mast, drive axle, engine, trans-
mission, and counterweight. When the lift truck is
put on blocks, put additional blocks in the following
positions to maintain stability:
a. Before removing the mast and drive axle, put
blocks under the counterweight so the lift truck
cannot fall backward.
b. Before removing the counterweight, put blocks
under the mast assembly so the lift truck cannot
fall forward.
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks
used to support the lift truck are solid, one-piece
units.
1. Raise the hood and disconnect the two gas-assist
cylinders at the hood. Disconnect the park brake
alert wiring harness.
2. Remove the pins that hold the hood hinges to the
operator’s module crossmember. Remove the
hood.
INSTALL
1. Install the hood in position on the lift truck. Install
the pins that hold the hood hinges to the operator’s
module crossmember.
2. Connect the two gas-assist cylinders to the hood.
Connect the park brake alert wiring harness.
2
4. 100 YRM 726 Hood Repair
WARNING
The hood, hood latch, and hood striker must be cor-
rectly adjusted for the correct operation of the op-
erator restraint system.
3. Adjust the hood latch (see Figure 2) as follows:
a. Center the latch striker in the slot located in the
rear crossmember. Check that the latch striker
is in the center of the jaws of the hood latch and
tighten.
b. Loosen the capscrews for the hood latch just
enough to let the latch move. Position the latch.
Tighten the capscrews for the latch.
c. Check the operation of the hood latch. Have
an operator sit in the seat. Make sure that the
hood is fully closed (two clicks). Also, check
that the hood touches the rubber bumpers. If
necessary, repeat Step b.
1. LATCH STRIKER
2. HOOD LATCH
3. LATCH LEVER
4. SEAT
5. SEAT BELT LATCH
6. HIP RESTRAINT
7. SEAT RAIL
8. HOOD
9. HINGE
10. OPERATOR WEIGHT ADJUSTMENT
11. FORWARD/BACKWARD ADJUSTMENT
Figure 2. Hood and Seat Latches Check
3
5. 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, re-
move the key.
2. Disconnect the LED light from the chassis light har-
ness.
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
6. 100 YRM 726 Operator Restraint System Repair
Figure 3. LED Backup and Brake Lights Assembly
Legend for Figure 3
A. LED ASSEMBLY WITH STANDARD EXHAUST
B. LED ASSEMBLY WITH OVERHEAD EXHAUST
1. LED LIGHT
2. SCREW
3. WASHER
4. LOCK NUT
5. MOUNTING BRACKET
6. GROMMET
7. PLUG
8. SCREW
9. OVERHEAD GUARD LEG
Operator Restraint System Repair
WARNING
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the
following assemblies will cause large changes in
the center of gravity: mast, drive axle, engine and
transmission, and counterweight. When the lift
truck is put on blocks, put additional blocks in the
following positions to maintain stability:
a. Before removing the mast and drive axle, put
blocks under the counterweight so the lift truck
cannot fall backward.
b. Before removing the counterweight, put blocks
under the mast assembly so the lift truck cannot
fall forward.
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks
used to support the lift truck are solid, one-piece
units.
The seat belt, hip restraint brackets, seat and mounting,
hood, and latches are all part of the operator restraint
system. Each item must be checked to make sure it
is attached securely, functions correctly, and is in good
condition. See Figure 2.
AUTOMATIC LOCKING RETRACTOR (ALR)
NOTE: Lift trucks produced before November 2005 are
equipped with the ALR type seat belts.
The seat belt must fasten securely. Make sure the seat
belt extends and retracts smoothly and is not frayed or
torn. If the seat belt is damaged or does not operate
properly, it must be replaced. See Figure 4.
5
7. Operator Restraint System Repair 100 YRM 726
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 reposi-
tioning 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 per-
formed:
• 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 as-
sembly 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 as-
sembly.
• 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
8. 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 counter-
weight. See Figure 5.
WARNING
Disposal of coolant must be in accordance with lo-
cal regulations.
NOTE: To aid in the draining of coolant from the radiator,
remove the radiator cap.
2. Drain the coolant from the radiator.
3. Disconnect the upper and lower coolant hoses from
the radiator.
4. Disconnect the hydraulic hoses from the radiator
and install plugs in the hoses.
5. On the GM-powered lift truck, remove the clamp
and hose from the bottom of the radiator.
6. Remove the top radiator support plate.
7. Disconnect the coolant recovery reservoir hose
from the radiator.
8. Remove the coolant recovery reservoir from the
overhead guard leg.
9. Remove the upper and lower fan shroud halves
from the radiator.
10. Remove the radiator from the lower radiator mount-
ing plate.
INSTALL
1. Install the rubber isolators on the lower radiator lo-
cating 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 over-
head guard leg.
5. Connect the coolant recovery reservoir hose to the
radiator.
6. Install the rubber isolators on the upper radiator lo-
cating studs.
7. Install the top radiator support plate. Tighten the
outer screws to 66 N•m (49 lbf ft). Tighten the inner
screws to 38 N•m (28 lbf ft).
8. On the GM-powered lift truck, install the hose and
clamp on the bottom of the radiator.
9. Connect the upper and lower coolant hoses to the
radiator.
10. Connect the hydraulic hoses to the radiator.
CAUTION
To prevent possible damage to the engine, make
sure the engine is running at idle speed while per-
forming Step 11.
11. Add coolant to the system until the entire cooling
system is full.
12. Install the cover between the hood and counter-
weight.
7
10. 100 YRM 726 Exhaust System Repair
Legend for Figure 5
A. PERKINS DIESEL 1004.42 B. GM 4.3L V-6
1. COVER
2. HOOD
3. COUNTERWEIGHT
4. RADIATOR
5. HOSE
6. HOSE
7. CLAMP
8. RADIATOR SUPPORT PLATE
9. COOLANT RECOVERY RESERVOIR HOSE
10. COOLANT RECOVERY RESERVOIR
11. OVERHEAD GUARD LEG
12. LOWER RADIATOR MOUNTING PLATE
Exhaust System Repair
MUFFLER
Remove
WARNING
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the
following assemblies will cause large changes in
the center of gravity: mast, drive axle, engine and
transmission, and counterweight. When the lift
truck is put on blocks, put additional blocks in the
following positions to maintain stability:
a. Before removing the mast and drive axle, put
blocks under the counterweight so the lift truck
cannot fall backward.
b. Before removing the counterweight, put blocks
under the mast assembly so the lift truck cannot
fall forward.
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks
used to support the lift truck are solid, one-piece
units.
1. Remove the overhead exhaust pipe from the coun-
terweight. See Figure 6 or Figure 7.
2. Remove the counterweight. See Counterweight
Repair, Remove in this YRM.
3. Remove the lower exhaust pipe from the muffler
and disconnect the upper exhaust pipe from the
muffler.
4. Remove the muffler from the mounting bracket.
Install
1. Install the muffler on the mounting bracket. Tighten
bolts until all clearance has been removed; then
tighten one additional turn. See Figure 6 or Fig-
ure 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 Coun-
terweight Repair, Install in this YRM.
4. Install the overhead exhaust pipe in the counter-
weight. Tighten the capscrews to 38 N•m (28 lbf ft).
9
11. Exhaust System Repair 100 YRM 726
1. LEFT ENGINE EXHAUST PIPE
2. RIGHT ENGINE EXHAUST PIPE
3. UPPER EXHAUST PIPE
4. MUFFLER
5. SEAL
6. FLANGE
7. HEX HEAD BOLT
8. SPRING
9. CLAMP
10. OVERHEAD EXHAUST
11. LOWER EXHAUST PIPE
12. COUNTERWEIGHT EXHAUST PIPE
13. HEAT SHIELD
14. CLAMP
15. HEAT SHIELD SLEEVE
16. HEAT SHIELD SLEEVE
17. INTERMEDIATE UPPER EXHAUST PIPE
18. MUFFLER MOUNTING BRACKET
19. ISOLATOR
20. WASHER
21. HEX HEAD BOLT
22. WASHER
23. NUT
24. HEX HEAD BOLT
25. LOCKWASHER
26. RIGHT-SIDE EXHAUST MANIFOLD
27. LEFT-SIDE EXHAUST MANIFOLD
Figure 6. LPG/GAS Exhaust System (Without Low Emissions) Early Model Lift Trucks
10
12. 100 YRM 726 Exhaust System Repair
Figure 7. LPG/GAS Exhaust System (Without Low Emissions) Later Model Lift Trucks
11
13. Exhaust System Repair 100 YRM 726
Legend for Figure 7
1. LEFT ENGINE EXHAUST PIPE
2. RIGHT ENGINE EXHAUST PIPE
3. UPPER EXHAUST PIPE
4. MUFFLER
5. COUNTERWEIGHT EXHAUST PIPE
6. SEAL
7. FLANGE
8. HEX HEAD BOLT
9. SPRING
10. CLAMP
11. OVERHEAD EXHAUST PIPE
12. LOWER EXHAUST PIPE
13. HEAT SHIELD
14. HEAT SHIELD SLEEVE
15. LOCKWASHER
16. INTERMEDIATE UPPER EXHAUST PIPE
17. NUT
18. MUFFLER MOUNTING BRACKET
19. ISOLATOR
20. WASHER
21. PLUG
LPG/GAS ENGINE EXHAUST PIPE - LIFT
TRUCKS WITHOUT LOW EMISSIONS
Remove
NOTE: If the lift truck does not have an overhead ex-
haust, perform Step 2 and Step 4 through Step 8. If
the lift truck has an overhead exhaust, perform Step 1
through Step 3 and Step 5 through Step 8.
1. Remove the overhead exhaust pipe from the coun-
terweight. 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 intermedi-
ate upper exhaust pipe and disconnect the interme-
diate upper exhaust pipe from the left-side engine
exhaust pipe.
6. On early model lift trucks only, remove the metal
heat shield from the left and right engine exhaust
pipes.
7. Disconnect the left and right engine exhaust pipes
from each other.
8. Remove the left and right engine exhaust pipes
from the engine exhaust manifolds.
Install
NOTE: If the lift truck does not have an overhead ex-
haust perform Step 1 through Step 5, and Step 7. If
the lift truck has an overhead exhaust perform Step 1
through Step 4 and Step 6 through Step 8.
1. Install the left and right engine exhaust pipes on the
engine exhaust manifolds. See Figure 6.
2. Connect the left and right engine exhaust pipes to
each other.
3. On early model lift trucks only, install the metal heat
shield on the left and right engine exhaust pipes.
4. Connect the intermediate upper exhaust pipe to the
left-side engine exhaust pipe and connect the up-
per 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 Re-
pair, Install in this YRM.
8. Install the overhead exhaust pipe in the counter-
weight. Tighten the capscrews to 38 N•m (28 lbf ft).
EPA COMPLIANT LPG/GAS ENGINE
EXHAUST SYSTEM
Remove
NOTE: If the lift truck does not have an overhead ex-
haust, perform Step 2 and Step 4 through Step 8. If
the lift truck has an overhead exhaust, perform Step 1
through Step 3 and Step 5 through Step 8.
1. Remove the overhead exhaust pipe from the coun-
terweight. See Figure 8.
12
14. 100 YRM 726 Exhaust System Repair
Figure 8. EPA Compliant LPG/GAS Exhaust System
13
15. Exhaust System Repair 100 YRM 726
Legend for Figure 8
1. GASKET
2. HEX HEAD BOLT
3. SPRING
4. SEAL
5. UPPER EXHAUST PIPE
6. LEFT ENGINE EXHAUST PIPE
7. CLAMP
8. RIGHT ENGINE EXHAUST PIPE
9. HEAT SHIELD SLEEVE
10. WIRE HARNESS (CLOSED LOOP)
11. HEAT SHIELD
12. MUFFLER
13. WASHER
14. NUT
15. MUFFLER MOUNTING BRACKET
16. COUNTERWEIGHT EXHAUST PIPE
17. ISOLATOR
18. PLUG
19. OXYGEN SENSOR
20. LOWER EXHAUST PIPE
21. OVERHEAD EXHAUST PIPE
22. CAPSCREW
2. Remove the counterweight. See Counterweight
Repair, Remove in this YRM.
3. Remove the lower exhaust pipe from the right side
of the muffler and the upper exhaust pipe from the
left side of the muffler.
4. Remove the counterweight exhaust pipe from the
right side of the muffler and the upper exhaust pipe
from the left side of the muffler.
5. Disconnect upper exhaust pipe from the left and
right-side engine exhaust pipes.
6. Remove the metal heat shield from the left and right
engine exhaust pipes.
7. Disconnect the electrical connector from the oxy-
gen sensor. Remove oxygen sensor from the en-
gine exhaust pipes. Inspect oxygen sensor and if it
is damaged or broken, replace with new sensor.
8. Remove the left and right engine exhaust pipes
from the engine exhaust manifolds. See Figure 8.
Install
NOTE: If the lift truck does not have an overhead ex-
haust, 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 connec-
tor to the oxygen sensor.
3. Install the metal heat shield to the engine exhaust
pipes.
4. Connect upper exhaust pipe to the left and right-
side engine exhaust pipes.
5. Connect the upper exhaust pipe to the left side of
the muffler and install the counterweight exhaust
pipe on the right side of the muffler.
6. Connect the lower exhaust pipe from the right side
of the muffler and the upper exhaust pipe from the
left side of the muffler.
7. Install the counterweight. See Counterweight Re-
pair, Install in this YRM.
8. Install the overhead exhaust pipe in the counter-
weight. Tighten the capscrews to 38 N•m (28 lbf ft).
DIESEL ENGINE EXHAUST PIPE
Remove
NOTE: If the lift truck does not have an overhead ex-
haust, 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 coun-
terweight. 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 ex-
haust pipe.
14
16. 100 YRM 726 Exhaust System Repair
6. Remove the intermediate exhaust pipe from the en-
gine exhaust pipe.
7. Remove the engine exhaust pipe from the exhaust
manifold.
1. MUFFLER
2. LOWER EXHAUST PIPE
3. CLAMP
4. UPPER EXHAUST PIPE
5. INTERMEDIATE EXHAUST PIPE
6. ENGINE EXHAUST PIPE
7. ADAPTER
8. OVERHEAD EXHAUST PIPE
9. HEX HEAD BOLT
10. SPRING
11. SEAL
12. HEAT SHIELD SLEEVE
13. COUNTERWEIGHT EXHAUST PIPE
14. BRACKET
15. HEX HEAD BOLT
16. WASHER
17. ISOLATOR
18. NUT
19. WASHER
20. HEX HEAD BOLT
21. WASHER
22. ENGINE EXHAUST MANIFOLD
Figure 9. Diesel Exhaust System
15
17. Engine Repair 100 YRM 726
Install
NOTE: If the lift truck does not have an overhead ex-
haust, 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 man-
ifold. See Figure 9.
2. Connect the intermediate exhaust pipe to the en-
gine 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 Re-
pair, Install in this YRM.
7. If removed, install the overhead exhaust pipe on the
counterweight. Tighten the capscrews to 38 N•m
(28 lbf ft).
Engine Repair
REMOVE
1. Remove the overhead guard. Remove the floor
plates.
2. Disconnect the cables at the battery. Remove the
battery and the battery tray.
3. Disconnect the fuel lines at the engine. Disconnect
the throttle linkage at the engine. Disconnect the
wires and wiring harnesses at the engine.
4. Disconnect the hydraulic line between the main
control valve and the hydraulic oil tank.
5. Remove the engine only as described in the follow-
ing 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. Re-
move the pedal assembly from the lift truck.
b. Disconnect the wiring harness and throttle ca-
ble for the accelerator or Foot Directional Con-
trol pedal. Remove the pedal assembly from
the frame.
c. Remove the capscrews for the universal joints
from the hydraulic pump drive line at the crank-
shaft 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. 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 jack-
stand under the transmission housing.
h. Remove the engine mount capscrews and
washers at the fan end of the engine.
NOTE: The bolts being removed in Step i are a one-
time usage type of bolt and must be discarded when
removed.
i. Bar the engine over at the crankshaft and
remove and discard the torque converter flex
plate bolts. When all of the bolts have been
removed, move the engine forward just enough
to break the engine loose from the transmis-
sion.
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.
16
19. Engine Repair 100 YRM 726
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. Dis-
connect the exhaust pipe from the muffler. Re-
move 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 dis-
connected to aid in reconnecting the hoses.
c. Disconnect the hydraulic hoses from the steer-
ing control unit. Install caps on the steering
control unit and plugs on the hydraulic hoses.
d. Disconnect the horn wire at the steering col-
umn. Remove the capscrews that hold the
steering column and steering control unit to the
operator’s module. Remove the steering col-
umn assembly.
e. Disconnect the wiring harness and throttle ca-
ble for the accelerator or Foot Directional Con-
trol 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. Dis-
connect the transmission oil lines from the
transmission.
i. Remove the axle shafts from the drive axle.
j. Connect a lifting device to the engine. Make
sure the lifting device has a capacity of at least
700 kg (1500 lb).
k. Remove the capscrews that hold the transmis-
sion to the differential housing. Remove the en-
gine mount capscrews at the fan end of the en-
gine.
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 Re-
pairs 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. In-
stall 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 transmis-
sion to the drive axle. Tighten the capscrew to
66 N•m (49 lbf ft).
e. Connect the transmission oil lines to the trans-
mission. Connect the transmission wiring har-
ness 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
18
20. 100 YRM 726 Engine Repair
master cylinder. Connect the wires to the brake
switch.
NOTE: A = 165 N•m (122 lbf ft).
A. ENGINE MOUNTS (DIESEL SHOWN)
B. ENGINE MOUNT (GAS/LPG SHOWN)
1. CAPSCREW
2. WASHER
3. WASHER
4. SNUBBING CUP
5. ISOLATOR
6. ENGINE MOUNT
7. NUT
8. REBOUND
WASHER
9. BUMPER
10. SPACER
11. FRAME
12. SHIM*
*ROTATE ENGINE AROUND DRIVE AXLE CENTER-
LINE 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 accelera-
tor pedal to the frame. Connect the wiring har-
ness and throttle cable for the Foot Directional
Control pedal or accelerator.
i. Install the steering wheel or install the steering
column and steering control unit to the bracket
on the frame. Connect the four hydraulic hoses
to the steering control unit as noted during re-
moval. Connect the horn wire at the steering
column.
j. Connect the hydraulic hoses as noted during
removal to the steering control unit.
k. Remove the lift truck from the blocks.
2. Install the engine only as described in the following
steps:
a. Connect a lifting device to the engine. Make
sure the lifting device has a capacity of at least
450 kg (1000 lb).
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 wash-
ers at the fan end of the engine. Tighten the
capscrews to the correct torque values as
shown in Figure 11.
e. Connect the exhaust pipe to the muffler. Install
the air filter housing on the frame.
f. Connect the engine wiring harness to the main
wiring harness.
g. Install the capscrews for the universal joints
from the hydraulic pump drive line at the crank-
shaft.
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.
19
21. 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.
5. Install the air filter housing on the frame. Connect
the exhaust pipe to the muffler. Install the radiator,
fan, and fan shroud. See Radiator Repair, Install in
this section.
6. Install the alternator on units with a diesel engine.
Install the battery and the battery tray. Connect the
cables to the battery.
7. Install the overhead guard.
8. Check all of the fluid levels and fill as necessary.
Install the floor plates and covers. Connect the ca-
bles 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 en-
gine, see the section LPG Fuel System 900 YRM 745
for the procedures to adjust the throttle linkage.
Lift Trucks With an Accelerator Pedal
1. Adjust the cable adjustment nuts to allow for a
3.0 mm (0.12 in.) maximum of free play on the
throttle cable length. See Figure 12. Secure cable
length by tightening cable lock nuts.
2. Depress the accelerator pedal until the diesel injec-
tor pump is in the full power position (the injection
pump lever is touching the lever stop in Figure 13).
3. Turn capscrew stop (see Figure 12) clockwise until
it contacts the pedal. Continue for another 1/4 turn
until the capscrew height is 12.0 mm (0.50 in.).
4. Tighten capscrew stop with jam nut.
1. ACCELERATOR PEDAL
2. DIESEL INJECTOR PUMP
3. CABLE ADJUSTMENT NUTS
4. CABLE LOCK NUTS
5. CAPSCREW STOP
6. JAM NUT
Figure 12. Accelerator Pedal Adjustment
20
22. 100 YRM 726 Throttle Pedal Adjustment
NOTE: DIESEL INJECTOR PUMP IS SHOWN IN THE
IDLE POSITION.
1. INJECTION PUMP LEVER
2. LEVER STOP
Figure 13. Diesel Injector Pump
Lift Trucks With a Foot Directional Control
Pedal
1. Adjust the cable adjustment nuts to allow for a
3.0 mm (0.12 in.) maximum of free play on the
throttle cable length. See Figure 14. Secure cable
length by tightening cable lock nuts.
2. Set pedal stop to 35 ±2 mm (1.40 ±0.08 in.). Secure
in place with pedal stop jam nuts.
3. With the pedal against the stop, adjust the throttle
cable to ensure that the diesel injector pump is at
full power (the injection pump lever is touching the
lever stop in Figure 13).
4. Release the throttle pedal and adjust the up posi-
tion 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 posi-
tion pedal stop with capscrew. See Figure 14.
21
24. 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. Re-
move all paint and dirt around the leak.
2. Apply Loctite®
290 to the leak. Follow the instruc-
tions 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 Contain-
ers That Have Held Combustibles by the Ameri-
can 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 connec-
tion 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 in-
side 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 clean-
ing procedures.
Chemical Solution Method
If the tank cannot be cleaned with steam, use the fol-
lowing 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
25. 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 com-
pressed 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 com-
pound 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 mak-
ing inspections, use a light that is approved for lo-
cations 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, pre-
pare 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
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.
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.
If necessary, install new and correct labels as follows
(see Figure 15):
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the recommendations of the
manufacturer.
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.
2. Remove the paper from the back of the label. Do
not touch the adhesive surface.
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
27. Safety Labels 100 YRM 726
Legend for Figure 15
1. MAST WARNING
2. YALE LABEL
3. NO RIDERS
4. HOIST HANDLE LABEL
5. TILT HANDLE LABEL
6. PATENTS AND TRADEMARKS
7. IMPACT WARNING LABEL
8. NAMEPLATE COVER
9. FAN WARNING
10. FAN WARNING (PICTORIALLY)
11. PARK BRAKE WITHOUT SEAT BRAKE
12. ANTIFREEZE LABEL
13. YALE LABEL
14. DRIVETRAIN PROTECTION
15. YALE LABEL
16. MAST WARNING
17. PINCH POINT WARNING
18. OPERATOR WARNING
19. OPERATOR RESTRAINT LABEL
20. NAMEPLATE
21. FLAMMABLE LP GAS LABEL
22. RADIAL TIRE WARNING (OPTIONAL) LABEL
23. UL FUEL-TYPE WARNING LABEL
24. LPG TANK LABEL
25. FIRE SAFETY LABELS
26. BATTERY DISCONNECT LABEL
27. AUXILIARY FUNCTION LABEL
28. DIESEL POWER LABEL (DIESEL TRUCKS
ONLY)
26
28. 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 oper-
ator 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 sep-
arate unit and can be removed as a complete unit from
the module and frame of the lift truck.
Figure 1. Operator Cab
1
29. Cab Repair 100 YRM 778
Cab Repair
REMOVE
To remove the operator cab from the frame, do the fol-
lowing:
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 har-
ness connection to the windshield wipers.
5. Disconnect the air filter hose from the lower left cor-
ner of the cab frame.
6. Disconnect the water hoses to the heater and dis-
connect the heater wire harness.
7. Remove the cab front attaching hardware. See Fig-
ure 2.
1. CAPSCREW (2)
2. WASHER (4)
3. SHIM (AS
REQUIRED)
4. LEFT FRONT LEG
Figure 2. Front Attaching Hardware
8. Remove the cab rear attaching hardware (1, 2, and
3, Figure 3).
1. FLAT WASHER
2. LOCKWASHER
3. CAPSCREW
4. CAPSCREW
5. LOCKWASHER
6. FLAT WASHER
7. RING WASHER
8. ISOLATOR
9. ISOLATOR
10. ISOLATOR CUP
Figure 3. Rear Attaching Hardware
9. Remove the rear isolator hardware and inspect for
wear or damage. Replace if necessary. See Fig-
ure 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 ca-
pacity to lift 500 kg (1100 lb).
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 struc-
ture). 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
30. 100 YRM 778 Switch Panel
CAUTION
Lift the operator cab carefully. Check that all elec-
trical wires and attachments are disconnected cor-
rectly 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 replace-
ment, 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 struc-
ture). 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.
4. Install the rubber isolators, washers, nuts, and bolts
for the mounts. Make sure that the isolators are
correctly positioned.
5. Install the rear attaching hardware to the frame and
tighten finger-tight only.
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 com-
ponents 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 har-
ness connection to the windshield wipers.
12. Connect the main wiring harness and the front and
rear light harness between the lift truck and the op-
erator cab.
13. Install the cowl cover.
14. Install the dash over the cowl cover and install the
retaining screws.
15. Install the cab doors.
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
31. 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.
FRONT WIPER ASSEMBLY
1. To replace the front motor assembly, remove the re-
taining 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.
3. Remove the water tube and disconnect the wiring
harness.
4. Repair or replace defective parts and install the
front wiper assembly as shown in Figure 5.
5. Install the water tube and connect the wiring har-
ness.
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.
1. WIPER ARM (2)
2. RETAINING NUT (2)
3. LOCKWASHER (2)
4. NUT (2)
5. LOCK NUT (2)
6. FLAT WASHER (2)
7. WIPER MOTOR
8. ELECTRICAL CONNECTOR
9. WATER TUBE
10. HEATER
11. COVER
12. CHECK VALVE
13. GROMMET
Figure 5. Front Window Wiper System
4
33. 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.
3. Remove the wiper motor cover by pulling backward.
The cover is held in place by plastic tabs on the
inside of the cover.
4. Remove the water tube and disconnect the wiring
harness connector.
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.
6. Repair or replace any defective parts and install the
rear wiper assembly as shown in Figure 6.
NOTE: One of the mounting studs is also the spray noz-
zle 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 com-
ponents: an outside handle with lock, an inside lever-
type 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 mecha-
nism 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
34. 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 num-
ber 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
36. 100 YRM 778 Window Replacement
Window Replacement
WARNING
All windows installed in the cab are made of tem-
pered glass. The overhead skylight is made of
Lexan®
. 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
ThicknessLocation of
Window
Yale Part
Number
Material Specification
mm inch
Front 580014760 5.9 to 7.5 0.23 to 0.29
Rear 580014770
Tinted Tempered Safety Glass per ANSI
Z26.1 AS1 Requirements
5.6 to 6.8 0.22 to 0.27
Doors
Upper RH 580014007
Upper LH 580014006
Tinted Tempered Safety Glass per ANSI
Z26.1 AS2 Requirements
4.5 to 5.0 0.18 to 0.2
Lower, R/L 524140139 Tinted Tempered Safety Glass per ANSI
Z26.1 AS2 Requirements
4.5 to 5.0 0.18 to 0.2
Top 580025892 Tinted Lexan®
MR 5004-310351 3.0 0.12
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37. Window Replacement 100 YRM 778
1. FRONT WINDOW
2. SEAL
3. ATTACHING HARDWARE
4. CLAMP WITH HARDWARE
5. SKYLIGHT
6. REAR WINDOW
7. LOWER DOOR WINDOW
8. UPPER DOOR WINDOW
Figure 10. Operator Cab Assembly Glass
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38. 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 Fig-
ure 11. The strobe light is normally configured to op-
erate 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 neces-
sary. 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
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39. 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 differ-
ent 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 Fig-
ure 13. Refer to Diagrams 8000 YRM 757 for the lift truck electrical schematics.
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