GDP/GLP80-120DB (D876), GDP/GLP130-160EB (D877)

SERVICE MANUAL CONTENTS

PART YRM REV
SECTION NUMBER NUMBER DATE
OPERATOR'S CAB........................................................................................................ 524206063 0100 YRM 1100 09/08
FRAME............................................................................................................................ 524300812 0100 YRM 1349 01/11
OPERATOR'S CAB........................................................................................................ 550033400 0100 YRM 1390 11/13
CAB HEATER (PRIOR TO OCT. 2008).......................................................................... 550033397 0100 YRM 1458 04/11
CUMMINS ENGINE FAULT CODE GUIDE.................................................................... 524211827 0600 YRM 1101 07/14
MULTIPLE ALIGNED COOLING SYSTEM.................................................................... 524300813 0700 YRM 1350 05/12
TRANSMISSION REPAIR.............................................................................................. 524302733 1300 YRM 1356 03/11
TRANSMISSION OPERATION AND DIAGNOSTICS.................................................... 524304019 1300 YRM 1358 11/11
APC200 FAULT CODE GUIDE...................................................................................... 550022606 1300 YRM 1435 02/12
DIFFERENTIAL............................................................................................................... 524150779 1400 YRM 0046 08/12
PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. 524150780 1400 YRM 0944 08/12
PLANETARY DRIVE AXLE (DRY SYSTEM)................................................................. 524150781 1400 YRM 0945 08/11
STEERING AXLE............................................................................................................ 524150783 1600 YRM 0326 03/07
STEERING SYSTEM...................................................................................................... 524150782 1600 YRM 0936 03/07
BRAKE SYSTEM (DRY)................................................................................................. 524150784 1800 YRM 0937 04/10
BRAKE SYSTEM (WET)................................................................................................. 524150785 1800 YRM 0951 03/11
HYDRAULIC SYSTEM.................................................................................................... 524150787 1900 YRM 0938 03/07
MAIN CONTROL VALVE................................................................................................ 524150788 2000 YRM 0943 03/07
TILT CYLINDERS........................................................................................................... 524150790 2100 YRM 0103 03/07
INSTRUMENT PANEL INDICATORS AND SENDERS................................................. 524206632 2200 YRM 1105 03/07
ELECTRICAL SYSTEM.................................................................................................. 524300814 2200 YRM 1351 04/07
MAST AND CARRIAGES............................................................................................... 524203754 4000 YRM 1062 08/12
2-STAGE MAST.............................................................................................................. 550088524 4000 YRM 1647 05/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
ASSEMBLY GUIDE........................................................................................................ 524230692 8000 YRM 1181 12/14
DIAGRAMS..................................................................................................................... 524298462 8000 YRM 1346 05/07
PERIODIC MAINTENANCE............................................................................................ 524298463 8000 YRM 1347 09/13
CAPACITIES AND SPECIFICATIONS........................................................................... 524298464 8000 YRM 1348 07/13
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 524295484 (12/14)
100 YRM 1100
General
A fully-enclosed operators cab is positioned on four
large rubber anti-vibration mounts to isolate operator
from shock, noise, and vibration. See Figure 1. Op-
erator’s compartment includes electronic controls for
hydraulic systems, steering wheel, instrument panel,
transmission, brake system controls, and operators
seat. An overhead guard forms an integral part of the
1. INCHING, BRAKE, AND THROTTLE PEDALS
2. SEAT
3. STEERING COLUMN
4. FRONT, REAR, AND TOP WIPER ASSEMBLIES
Figure 1. Operators Cab
General
operators cab. The cab is installed on a platform above
main frame members. Step plates on both sides of
lift truck give access to cab. The operators cab can
be tilted, providing access to major components. For
major repairs to cab, cab can be completely removed
from frame of lift truck.
5. FRONT, REAR, AND TOP WINDOWS
6. OPERATOR’S CONSOLE, CONTROLS, AND
ARMREST
7. HEATER SECTION
1
Cab Repair 100 YRM 1100

Cab Repair
REAR CAB ASSEMBLY NOTE: Interior covers are affixed with self-tapping
screws.
See Figure 2 for rear cab assembly.

1. COVER PLATE 6. HEADLINER

2. FUSE SECTION 7. REAR DUCT ASSEMBLY
3. RELAY SECTION 8. CONSOLE COVER
4. HYDRAULIC VALVE CONTROLLER 9. CONSOLE TOP
5. FOAM COVER 10. INSTRUMENT PANEL

Figure 2. Rear Cab Assembly

2
100 YRM 1100 Cab Repair

BOTTOM CAB ASSEMBLY 1. Tilt mast fully forward.

See Figure 3 for bottom cab assembly. 2. Remove all unsecured items from cab.

3. Close and securely latch both cab doors.

4. Clear all obstacles from right-hand side (as seen

from driver’s position) of truck. Provide minimum of
2 m (7 ft) of clearance space.

5. Use pump lever to turn direction valve clockwise to

"Raise" position. See Figure 4.

1. WIPER MOTOR 4. COVER PLATE

ASSEMBLY 5. STEERING PUMP
2. WIPER COUPLING 6. HORN 1. PUMP LEVER CONNECTION
3. AIR FILTER 2. DIRECTION VALVE SELECTION: CLOCKWISE -
RAISE, COUNTERCLOCKWISE - LOWER
Figure 3. Bottom Cab Assembly
Figure 4. Pump and Direction Valve

RAISING AND LOWERING CAB 6. Operate pump with pump lever until cab locks in
partially open position.
Raise Cab
NOTE: Just before fully open position is reached, move-
ment may be gravity controlled.
WARNING
Make sure no one is under cab when raising or low- 7. Pull tilt latch release and continue to raise cab to
ering cab. fully open position. See Figure 5.

WARNING
Before you place any part of your body under cab,
always make sure that cab is fully tilted, or when
partially open, is locked by tilt latch.
CAUTION
Cab damage may occur if mast is not completely
tilted forward.
NOTE: If cab will not fully raise, lower cab until cab locks
in partially open position, and fill tilt system with oil. See
Oil Filling for Tilt System.
NOTE: Raising cab gives access to components such
as engine, transmission/hydraulic compartment, throt-
tle/brake and steering control, heater, air conditioner,
and electrical connectors.

3
Cab Repair 100 YRM 1100

pump direction control. Procedure to raise or lower is

the same.

CAB REPAIR
Remove

WARNING
Before removing heater hoses, allow time for heater
hoses to cool down. Hot water may cause severe
burns.

WARNING
Make sure the lifting device has a minimum capac-
1. CAB ity to lift 1000 kg (2205 lb). A lifting device that does
2. FRAME not have the minimum capacity can break causing
3. TILT LATCH RELEASE the cab to drop and may result in serious personal
4. PUMP LEVER
injury.
Figure 5. Pump Lever and Tilt Latch Release Knob
CAUTION
Lower Cab Lift the operator’s cab carefully. Make sure all wires
and attachments are disconnected and loose com-
WARNING ponents are not obstructing the movement.
Make sure no one is under cab when raising or low-
ering cab. 1. Switch off engine.

2. Disconnect battery ground lead.

WARNING
Before you place any part of your body under cab, 3. Raise operator’s cab. See Raise Cab.
always make sure that cab is fully tilted, or when 4. Remove four hex bolts holding steering pump. See
partially open, is locked by tilt latch. Figure 6.

CAUTION 5. Remove two bolts holding brake valve.

Cab damage may occur if mast is not completely
tilted forward.
1. Use pump lever to turn direction valve counterclock-
wise to "Lower" position. See Figure 4.
2. Check that all foreign items/tools are cleared away.
3. Operate pump with pump lever until cab locks in
partially open position.
4. Pull tilt latch release and continue to lower cab until
it is in fully lowered position and latched. See Fig-
ure 5.
NOTE: An electric-powered cab tilt system is available
to replace standard manual tilt system. The electric tilt
system contains a push button located on left side of
6. Disconnect electrical cable to throttle pedal sensor.
See Figure 11.
7. Disconnect electrical cable.
8. Disconnect electrical plugs that are located to right
of heater unit.
9. Disconnect window washer hoses and mark their
positions.
10. Remove three bolts and swing heater unit down.
11. Disconnect electrical connections, control cables,
and air duct from heater unit.
12. Disconnect ground lead.

4
100 YRM 1100 Cab Repair

19. Remove four rubber isolation mounts from frame

and inspect for damage. Reinstall or replace if nec-
essary.

Install
1. Connect lift strap under overhead guard structure.
Provide cushion at top of door area to prevent dam-
age.

2. Make sure that insulators are in place. See Fig-

ure 7.

1. STEERING PUMP HEX BOLTS

2. BRAKE VALVE BOLTS
3. STEERING PUMP
4. BRAKE VALVE 1. TOP PART OF INSULATOR
5. ELECTRICAL CONNECTIONS 2. BOTTOM PART OF INSULATOR
3. BOLT
Figure 6. Steering Pump, Throttle and Inching 4. WASHER
5. LOCKWASHER
Connections
Figure 7. Insulators
CAUTION
3. Lift operator’s cab.
When lowering cab, make sure loose components
are not obstructing the movement. 4. Carefully lower cab on insulators and make sure
that it is properly centered.
13. Lower operator’s cab. See Lower Cab.
5. Mount cab with washers and bolts.
14. Remove left and right side panels giving access to
cab mounting bolts. 6. Tighten cab mounting bolts to 66 N•m (49 lbf ft).
15. Remove four mounting bolts, two on left side and 7. Raise cab. See Raise Cab.
two on right side of truck.
8. Connect electrical cables, ground wire, hoses,
16. Remove cab doors before attaching a lifting device. steering pump, and brake valve. Make sure that all
connections have been restored.
17. Connect a lift strap under overhead guard structure.
Provide a cushion at top of door area to prevent 9. Mount heater unit to hinge. Connect control cables
damage. and electrical connections. Pivot unit up and install
with three bolts.
18. Carefully lift cab away from lift truck. Set cab as-
sembly in a suitable storage area and put blocks 10. Connect inching and throttle cables. See Inching
under cab to stabilize and prevent damage. and Brake Pedals.

5
Oil Filling for Tilt System 100 YRM 1100

11. Lower cab. See Lower Cab. 13. Connect battery ground lead.

12. Install doors. 14. Install side panels.

Oil Filling for Tilt System

CAUTION
When oil has been added, put oil-absorbing mate-
rial around filler plug before lowering cab. Excess
oil may bleed out of relief valve, which is fitted in
filler plug.

NOTE: When cab does not reach the maximum opening

the oil level is low.

1. Lower cab until it locks in partially open position.

See Lower Cab.

2. Put pump lever connection in fully down position to

gain access to the fill cap. See Figure 8.

3. Remove fill cap. See Figure 8. 1. FILL CAP

4. Add hydraulic oil into filler opening until level is Figure 8. Hand Pump
within 30 to 35 mm (1.18 to 1.38 in.) of top of
reservoir. See Figure 9.

5. Install fill cap. See Figure 8.

6. Raise cab and make sure that maximum tilt can be

reached. See Raise Cab.

7. Repeat procedure if necessary.

8. Lower cab until it is in fully lowered position and

completely latched.

Figure 9. Cab Tilt Label

6
100 YRM 1100 Inching and Brake Pedals

Inching and Brake Pedals

BRAKE PEDAL, ADJUST 3. Proceed with inching pedal sensor adjustment.

1. Adjust bolt (3), behind the brake pedal, on the brake
pedal assembly so that the roller has contact with
the bolt on the valve until there is no free travel. See
Figure 10.
INCHING PEDAL SENSOR, ADJUST
NOTE: When the brake pedals are not activated, the
analog output of the inch sensor should be between 600
and 700 mV. This means the sensor is slightly turned as
the lowest possible reading is 400 mV.

1. Loosen the two, one shown, sensor mounting bolts.

See Figure 11.

NOTE: To read the voltage, use the "Inching Pedal Cal-

ibration" mode of the Userlink® program as explained in
the section Transmission 1300 YRM 1082.

2. Rotate sensor in the slotted holes underneath the

inching pedal so that the output voltage of the sen-
sor of the released inching pedal is between 600
and 700 mV.

3. Tighten the mounting screws and recheck the volt-

age output at the sensor.
1. BRAKE PEDAL
2. INCHING PEDAL 4. Calibrate the inching pedal. See the section Trans-
3. ADJUSTMENT BOLT FOR BRAKE PEDAL mission 1300 YRM 1082.
4. ADJUSTMENT BOLT FOR INCHING/BRAKE
PEDAL COUPLING
5. ADJUSTMENT BOLT FOR INCHING PEDAL

Figure 10. Brake Pedal System

2. Proceed with inching pedal adjustment.

INCHING PEDAL, ADJUST

NOTE: Adjust the inching pedal so that the brake pedal
moves at the same time, which means there is no free
play with the brake pedal.

NOTE: When brake pedal and inching pedal are in re-

leased position their position must be equally high or in
line.

1. When activating inching pedal, brake pedal should

be activated as soon as top of inching pedal and
top of brake pedal are on same plane. Use adjust- 1. MOUNTING BOLT
ment bolt (4) for inching/brake pedal coupling ad-
justment. See Figure 10. Figure 11. Sensor Adjustment
2. Adjust bolt (5) for inching pedal to eliminate free
travel of inching pedal before braking action occurs.

7
Throttle Pedal Sensor 100 YRM 1100

Throttle Pedal Sensor

CHECK 7. Lower cab. See Lower Cab.

NOTE: When a new throttle pedal sensor is installed,

rotate the throttle pedal sensor counterclockwise, when
looking inside the throttle box, until the end of the slotted
holes. See Figure 12.

1. Switch engine ON.

2. Operate throttle pedal. See Figure 12.

3. Check position, dimension A, of the throttle pedal at

which the engine rpm goes from idle to higher rpm
value.

4. If dimension A is not within 6 to 10 mm (0.236 to

0.394 in.), adjust the mechanical position of the
electronic throttle potentiometer. See Adjust.

ADJUST
1. Raise cab. See Raise Cab.

2. Make sure the throttle pedal stop is adjusted so that

it is against the cabin floor plate. 1. DIMENSION A
2. THROTTLE PEDAL
3. THROTTLE PEDAL ADJUSTMENT
3. Position a 5 mm (0.197 in.) spacer between the 4. THROTTLE PEDAL SENSOR
throttle pedal and throttle pedal stop. 5. MOUNTING SCREW
6. COUPLING
4. Loosen mounting screws and turn the throttle pedal 7. CABIN FLOOR PLATE
sensor to position at which engine rpm increases 8. THROTTLE PEDAL STOP
from idle or decreases rpm to idle. 9. COUNTERCLOCKWISE
10. SLOTTED HOLE
5. Tighten mounting screws.
Figure 12. Throttle Arrangement
6. Remove the 5 mm (0.197 in.) spacer between the
throttle pedal and throttle pedal stop.

8
100 YRM 1100 Power Assist Armrest

Seat Assembly Removal

NOTE: Use a lifting device for removal of seat.

NOTE: For mechanical seat, there will be one connec-

tor. For air suspension seat, there will be two connec-
tors.

1. Disconnect battery ground lead.

2. Disconnect connector(s). See Figure 13.

3. Disconnect plug to side console.

4. Loosen four bolts connecting seat to cab.

5. Remove seat.

Legend for Figure 13

1. ELECTRICAL CONNECTORS AND PLUG TO
SIDE CONSOLE (REAR OF SEAT)
2. BOLTS

Figure 13. Operators Seat

Power Assist Armrest

ADJUST
1. Disconnect cable from lever. See Figure 14.

2. Remove the mounting bolts that hold the gas spring

assembly.

3. Loosen nut.

4. Adjust top section, clockwise or counterclockwise,

to obtain a free lever movement of 1.5 to 2.0 mm
(0.06 to 0.079 in.).

NOTE: Apply small bead of non permanent Loctite® to

bolt treads.

5. Install gas spring assembly using the two bolts.

6. Install and adjust cable on lever to obtain correct

operation.

Legend for Figure 14

1. LEVER 4. BOLT
2. TOP SECTION 5. LEVER
3. NUT 6. CABLE

Figure 14. Power Assist Armrest

9
Steering Column Repair 100 YRM 1100

Steering Column Repair

REMOVE
1. Raise cab. See Raise Cab.

2. Disconnect battery ground lead.

3. Disconnect steering column connector. See Fig-

ure 15 and Figure 16.

4. Remove four hex bolts fastening steering pump to

cab and carefully remove steering pump.

5. Remove two cab mounting bolts holding steering

column to the floor.

6. Lower cab. See Lower Cab.

1. STEERING COLUMN TO BRACKET BOLTS
7. Remove two hex bolts holding steering column to 2. STEERING COLUMN TO FLOOR PLATE BOLTS
bracket.
Figure 15. Steering Column
8. Remove steering column. Push grommet out of
hole and slide connector through hole.

INSTALL
1. Slide connector through hole in floor and push
grommet into hole.

2. Connect steering column to bracket with two cab

mounting bolts.

3. Raise cab. See Raise Cab.

4. Mount steering column to cab base with two steer-

ing column hex bolts.

5. Carefully mount steering pump with four steering

pump hex bolts to allow non-forced coupling be-
tween steering pump and steering column.

6. Connect electrical connector. 1. STEERING COLUMN CONNECTOR

2. STEERING COLUMN BOLTS
7. Connect battery ground lead. 3. STEERING PUMP BOLTS

8. Lower cab. See Lower Cab. Figure 16. Steering Pump

10
100 YRM 1100 Window Wipers Replacement

Window Wipers Replacement

NOTE: Three window wiper motor assemblies are in- FRONT WINDOW WIPER MOTOR
stalled in the cab. The front window has a single-arm, ASSEMBLY, REPLACE
parallelogram-type, wiper motor system to give a large
wiped surface area. The wiper motor is mounted under 1. Disconnect battery ground lead.
the cab so as not to obstruct visibility. The top window
is provided with a wiper motor assembly that has one 2. Disconnect connector. See Figure 18.
wiper arm with wiper blade. The rear window is pro-
3. Remove clamp tightening bolt and arm.
vided with a wiper motor assembly that has one wiper
arm with wiper blade. A washer system is connected to 4. Remove three bolts.
all wipers.
5. Remove motor assembly.
WINDOW WIPER ASSEMBLY, REPLACE
6. Install new motor assembly. Proceed in reverse or-
1. Lift cover. See Figure 17. der.

2. Loosen and remove nut and washer.

3. Mark position of blade on window.

4. Disconnect wiper.

5. Disconnect washer hose if applicable.

6. Install new wiper assembly. Make sure that wiper

assembly is properly positioned to give optimal cov-
erage of window. Proceed in reverse order.

1. CLAMP TIGHTENING BOLT AND ARM

2. BOLTS
3. MOTOR ASSEMBLY
4. CONNECTOR

Figure 18. Front Window Wiper Motor Assembly

1. COVER 3. NUT WITH

2. COVER OPEN WASHER

Figure 17. Wiper Assembly

11
Window Wipers Replacement 100 YRM 1100

REAR WINDOW WIPER MOTOR TOP WINDOW WIPER MOTOR ASSEMBLY,

ASSEMBLY, REPLACE REPLACE
1. Disconnect battery ground lead. 1. Disconnect battery ground lead.

2. Remove wiper assembly. See Window Wiper As- 2. Remove 10 screws fastening headliner to cab. See
sembly, Replace. Figure 20.

3. Remove cover of motor assembly unit. 3. Remove headliner.

4. Disconnect connector. See Figure 19. 4. Follow procedure as listed under Rear Window
Wiper Motor Assembly, Replace.
5. Remove nuts and washers.
5. Replace cab headliner.
6. Remove motor assembly.
6. Connect battery ground lead.
7. Install new motor assembly. Proceed in reverse or-
der.

1. SCREWS

1. CONNECTOR Figure 20. Cab Headliner

2. NUTS AND WASHERS

Figure 19. Rear Wiper Motor Assembly

12
100 YRM 1100 Window Washer Motors and Pumps

Window Washer Motors and Pumps

NOTE: Three window washer motors with pump as-
semblies are attached to a water reservoir. See Fig-
ure 21.
NOTE: When replacing washer motor(s), make sure
that water hose(s) is connected to proper pump(s).
WINDOW WIPER AND WASHER
OPERATING SWITCHES
NOTE: The switch panel for the front, top, and rear win-
dow wipers and washers is located on the side of the
operators arm rest/console. See Figure 22.

NOTE: The fuses, protecting wiper, and washer sys-

tems are located inside the operators compartment.
See Fuse Panel.

1. FRONT WINDOW WASHER MOTOR AND PUMP

2. TOP WINDOW WASHER MOTOR AND PUMP
3. REAR WINDOW WASHER MOTOR AND PUMP

Figure 21. Washer Motors and Pumps

1. FRONT WINDOW WIPER
2. TOP WINDOW WIPER AND WASHER
3. REAR WINDOW WIPER AND WASHER
4. FRONT WINDOW WASHER

Figure 22. Wiper and Washer Switches

13
Window Replacement 100 YRM 1100

Window Replacement
WARNING
All windows installed in the cab are made of spe-
cial glass. All replacement windows must be made
of the correct material and must be made of the cor-
rect thickness. Failure to have the correct material
or thickness may cause the glass to break easily
when struck and may cause personal injury.
NOTE: Before replacing any window, remove all broken
glass bits. Make sure replacement glass is dry, clean,
and free of grease.
Front, rear, and top windows are single units. Front and
rear windows are held in place by a rubber seal only.
The top window is fastened by clamps. Door windows
are mounted to door frames with bolts. Door window
and sliding window assembly are glued in. See Fig-
ure 23.

1. SEAL 6. SEAL
2. WINDOW 7. FRAME
3. WINDOW EDGE PROTECTION SEAL 8. GLUED SEAL
4. UPPER WINDOW 9. LOWER WINDOW
5. GLUED SEAL 10. WINDOW EDGE PROTECTION SEAL

Figure 23. Doors/Glass Assemblies

14
100 YRM 1100 Window Replacement

FRONT WINDOW, REPLACE REAR WINDOW, REPLACE

1. Remove string from rubber seal. See Figure 24. 1. Proceed as per instructions for the front window.
See Front Window, Replace.
2. Install rubber seal around window.
2. Install wiper assembly.
3. Insert a plastic thread (insulated electrical wire) ap-
proximately 3 mm (0.118 in.) in slot of rubber seal TOP WINDOW, REPLACE
(cab side slot).
1. Remove caps and loosen screws of three right an-
4. Position and press windows against frame. gle brackets. See Figure 25.
5. Pull out (inside cab) plastic thread. This will ensure 2. Remove caps and loosen five screws.
that the slot of rubber seal slides properly over win-
dow frame. 3. Remove rear bracket.

6. Press front window firmly into place. 4. Remove window.

7. Insert string. 5. Check seal. Replace if necessary.

6. Mount right angle brackets but leave loose at this

time.

7. Slide window into right angle brackets.

8. Mount rear bracket.

9. Carefully tighten all screws and replace caps.

1. FRONT WINDOW
2. SEAL
3. CROSS SECTION SEAL
4. STRING
5. PLASTIC THREAD (INSTALLATION TOOL)
6. CAB FRAME

Figure 24. Front Window and Seal

1. RIGHT ANGLE BRACKETS
2. SCREWS
3. REAR BRACKET

Figure 25. Top Window Brackets

15
Window Replacement 100 YRM 1100

DOOR WINDOW, REPLACE 4. Install new windows.

1. Remove screws. See Figure 26. 5. Install track.

2. Remove window track. 6. Install screws.

3. Remove windows.

1. WINDOW 3. SCREWS
2. WINDOW TRACK 4. WINDOW

Figure 26. Door Window, LH Shown

16
100 YRM 1100 Heater and Air Conditioning Assembly

Heater and Air Conditioning Assembly

A high-capacity heater system, with 10 outlet air vents,
provides all-around heating and cooling. See Figure 27
and Figure 28. A replaceable filter element ensures that
the operator receives clean air from outside. Recircu-
lated fresh air can be manually selected. The three-
speed fan and heat controls are located on the right-
hand side console.

NOTE: The air conditioning condenser is mounted on

top of the central hood spine. The compressor is lo-
cated in the engine compartment.

1. HEATER 2. HEATER UNIT

CONTROLS 3. AIR FILTER

Figure 27. Heater Unit 1. HEATER HOUSING

2. BLOWER BRACKET
3. HEATER CONTROL VALVE
4. HEATER COIL
5. EVAPORATOR COIL
6. BLOCK VALVE
7. THERMOSTAT
8. COVER PLATE
9. BLOWER
10. VENT DOOR

Figure 28. Heater/Air Conditioning Assembly

17
Heater and Air Conditioning Assembly 100 YRM 1100

HEATER PARTS, REPLACE HEAT CONTROL KNOB/SWITCHES

WARNING
Before removing heater hoses, make sure heater
hoses are cool. Hot water may cause severe burns.
WARNING
When replacing engine heater hoses, make sure re-
placement hoses meet correct specifications. Fail-
ure to meet correct specifications may cause per-
sonal injury.
CAUTION
Repairs to air conditioning that require discharging
and/or refilling of the refrigeration fluid must be per-
formed only by a trained and certified air condition-
ing specialist.
The fuses protecting the heater and air conditioning
systems are located inside the operators compartment.
See Rear Cab Assembly and Fuses.
HEAT CONTROL KNOB/CABLE
Adjust
NOTE: Without air conditioning, the heat control knob
(see Figure 30) is mechanically coupled via a cable to
the heater control valve. After replacing the cable or
associated item, adjustment of the cable is required.
NOTE: With air conditioning, the heater control valve is
controlled by an electrical signal and no adjustment is
required.

1. Disconnect battery ground lead.

2. Raise cab. See Raise Cab.

3. Disconnect heater hoses if required. See Fig-

ure 29.

1. HEATER/AC FAN 3. AIR CONTROL

SWITCH KNOB
2. HEAT CONTROL 4. A/C SWITCH
KNOB (OPTIONAL)

1. SCREWS 4. CONNECTIONS Figure 30. Heater Control Switches

2. HINGES 5. AIR FILTER PLATE
3. HEATER HOSES
CAUTION
Figure 29. Heater Unit The heater control valve cable should always be ad-
justed with the heater turned off.
4. Remove three screws.
1. Turn heat control knob clockwise to full hot position.
5. Tilt unit out. See Figure 30 and Figure 31.
6. Remove cover plate. See Figure 28. 2. Position the water valve open against the stop. See
7. Remove defective part. Figure 32.

8. Replace faulty component. 3. Fasten the cable clips. See Figure 32.

18
100 YRM 1100 Heater and Air Conditioning Assembly

AIR CONTROL KNOB/CABLE

Adjust
NOTE: The air control knob (see Figure 30) is mechan-
ically coupled via a cable to the vent door. This vent
door controls the ratio of outdoor air and cabin air. Af-
ter replacing the cable or associated item, adjustment
of the cable is required.

1. Turn air control knob clockwise to the recirculation

position. See Figure 30.

2. Position the recirculation valve open against the

stop. See Figure 33.

3. Fasten the cable clips.

1. EXTENDED CABLE (FULL HOT POSITION)

2. ROTARY CONTROL

Figure 31. Rotary Control

1. RECIRCULATION POSITION

Figure 33. Recirculation Valve

AIR FILTER, REPLACE

1. Raise cab. See Raise Cab.

2. Remove air filter plate. See Figure 29.

3. Slide out filter.

4. Insert new filter.

1. AGAINST PLASTIC 2. CABLE CLIPS 5. Mount cover plate.

STOP POSITION
6. Lower cab. See Lower Cab.
Figure 32. Water Valve

19
Instruments, Switches, and Controls 100 YRM 1100

AIR CONDITIONING CONDENSER FAN(S) 2. Disconnect battery ground lead.

Remove 3. Open hood.

NOTE: The condenser is mounted on top of the central 4. Loosen the twelve screws holding the cover of the
hood spine. condenser.

5. Loosen the four screws holding the fan(s).

CAUTION
Repairs to air conditioning that require discharging 6. Replace fan(s) if found to be faulty.
and/or refilling of the refrigeration fluid must be per-
formed only by a trained and certified air condition-
Install
ing specialist. 1. Install and tighten the four screws holding the
fan(s).
1. Shut down the engine.
2. Install and tighten the twelve screws holding the
CAUTION cover of the condenser.
For trucks with ECM (Engine Control Module), bat- 3. Close hood.
tery disconnect should only be performed 30 sec-
onds after switching OFF ignition. 4. Connect battery ground lead.

Instruments, Switches, and Controls

NOTE: The instruments and switches are fastened to
the instrument console. Disconnect the wiring harness
and remove the screws that hold the panels to the in-
strument panel. See the section Diagrams 8000 YRM
1103. These diagrams will help identify the wiring har-
nesses and components.

For the replacement of gauges, see the section Instru-

ment Panel Indicators and Senders 2200 YRM 1105.

NOTE: The rocker switches are replaced by pressing in

on flexible tabs at back side to release switch assem-
bly from instrument panel. The replacement switch is
1. MAST WORK LIGHT
installed from top side of instrument panel and pressed 2. FRONT FENDER SIDE LIGHTS
in until tabs on the switch lock in the opening for the 3. FLOOD LIGHTS
switch. 4. REAR DRIVING LIGHTS
5. BEACON
SWITCHES 6. HAZARD LIGHT

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

20
100 YRM 1100 Instruments, Switches, and Controls

Legend for Figure 36

1. LIFT/LOWER CONTROL LEVER
2. TILT CONTROL LEVER
3. SIDESHIFT/AUXILIARY CONTROL LEVER
4. AUXILIARY CONTROL LEVER
5. RIGHT FORK POSITION SWITCH
6. LEFT FORK POSITION SWITCH

1. HORN
2. FRONT WINDOW WIPER
3. FRONT WINDOW WASHER
4. REAR WINDOW WIPER/WASHER
5. TOP WINDOW WIPER/WASHER

Figure 35. Switches

CONTROLS 1. LEFT FORK POSITION SWITCH

2. RIGHT FORK POSITION SWITCH
See Figure 36 and Figure 37 for locations of controls. 3. HORN BUTTON
4. AUXILIARY CONTROL LEVER
5. MAST CONTROL LEVER
6. LIFT/LOWER CONTROL
7. TILT DIRECTION CONTROL

Figure 37. Joystick Hydraulic Controls

Figure 36. Hydraulic Control Levers

21
Fuses and Relays 100 YRM 1100

Fuses and Relays

NOTE: Fuses protecting the various systems are lo- FUSES
cated inside the operators compartment. See Fuse
Panel. See Figure 39 for fuse locations.

FUSE PANEL
1. Disconnect battery ground lead.

2. Loosen retaining screws. See Figure 38.

3. Remove cover.

4. Remove suspected fuse.

5. Check fuse.

6. Insert new fuse.

7. Reconnect battery lead.

8. Check operation.

Figure 39. Fuse Panel

Legend for Figure 39

FUSE DETAILS

1. FUSE PANEL #1 LOCATOR

• HYDRAULIC CONTROLS, 15A
• TRANSMISSION, 10A
• ATTACHMENT CONTROLS, 15A
• OPEN
• TRANSMISSION B+, 7.5A
• PARK BRAKE, 10A
• TRANSMISSION B+, 7.5A
• FRONT WINDOW WASHER/WIPER, 10A
• ROOF WINDOW WASHER/WIPER, 10A
• REAR WINDOW WASHER/WIPER, 10A
2. FUSE PANEL #2 LOCATOR
• FRONT INNER FLOOD LIGHTS, 10A
• FRONT OUTER FLOOD LIGHTS, 10A
1. RETAINING 2. COVER • REAR DRIVE LIGHTS, 10A
SCREWS • BEACON/STROBE, 10A
• STOP LIGHTS, 10A
Figure 38. Fuse Panel and Cover Location • MAST LIGHTS, 10A
• HAZARD LIGHTS, 10A
• DIRECTION INDICATORS, 10A
• SIDE/TAIL LIGHTS, 10A
• FRONT DRIVE LIGHTS, 10A

22
100 YRM 1100 Fuses and Relays

Legend for Figure 39 (Continued)

3. FUSE PANEL #3 LOCATOR

• ENGINE START, 5A
• AIR CONDITIONING, 15A
• INSTRUMENTATION, 10A
• CAB TILT POWER ASSIST, 20A
• HORN, 10A
• INTERIOR LIGHTING, 5A
• SEAT SUSPENSION COMPRESSOR, 15A
• HEATER/AC/VENTILATION FAN, 20A
• OIL COOLER/AIR DRYER, 10A
• REVERSE LIGHTS/ALARM, 5A
4. FUSE PANEL #4 LOCATOR UP TO S/N 01646
(C876) AND 01587 (C877)
• CONSOLE ACCESSORY SOCKET, 10A
• RADIO/CB/INTERCOM, 3A
• CONVERTER, 10A
• OPEN
• OPEN
• OPEN
• ECM/ACC PEDAL (CUMMINS), 5A
• OPEN
• OPEN
• OPEN
5. FUSE PANEL #4 LOCATOR STARTING WITH S/N
01647 (C876) AND 01588 (C877)
• CONSOLE ACCESSORY SOCKET, 10A Figure 40. Perkins Diesel Engine Relays (Located
• RADIO/CB/INTERCOM, 3A
• CONVERTER, 10A Left of Fuse Panel)
• 12V RELAY, 5A
• OPEN
• OPEN
• ECM/ACC PEDAL (CUMMINS)/LPG RELAY, 5A
• OPEN
• OPEN
• OPEN

RELAYS
See Figure 40, Figure 41, Figure 42 for locations of re-
lays.

Figure 41. Cummins Diesel Engine Relays Up to

S/N 01646 (C876) and 01587 (C877) (Located Left
of Fuse Panel)

23
Electrical Schematics 100 YRM 1100

Figure 42. Cummins Diesel/LPG Engine Relays Starting With S/N 01647 (C876) and 01588 (C877) and Up
(Located Left of Fuse Panel)

NOTE: Start aid (Perkins only), Pressure signal (ECH

only), and Flasher (Optional).

Label Replacement
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 the kind
of drive tires can change the capacity rating. See
a dealer for Yale lift trucks for a replacement name-
plate. The nameplate information is a safety item
and must be correct for the equipment and config-
uration of the lift truck.
2. Remove paper from back of label. Do not touch
adhesive surface.
3. Carefully hold label in correct position above sur-
face. Label cannot be moved after it touches sur-
face. Put label on surface. Make sure all air is re-
moved from under label and corners and edges are
tight.
See Parts Manual for correct location and part number.

1. Make sure surface is dry and free of oil or grease.

Do not use solvent on new paint. Clean the surface
of old paint using cleaning solvent.

Electrical Schematics
See the section Diagrams 8000 YRM 1103.

24
100 YRM 1349 Description

General
This section has the removal and installation instruc-
tions for major assemblies attached to the frame. The
removal and installation procedures for some assem-
blies are described in the following service manuals:
• Operator’s Cab 100 YRM 1100
• Multiple Aligned Cooling System 700 YRM 1350
• Planetary Drive Axle, (Wet System) 1400 YRM 944
• Planetary Drive Axle, (Dry System) 1400 YRM 945
• Steering System 1600 YRM 1365
• Hydraulic System 1900 YRM 938
• Masts and Carriages, Starting 2003 4000 YRM
1062

Description
The frame is a weldment with mounts for the major as-
CAUTION semblies. See Figure 1. The mounts are designed to
Do not initiate repairs to the frame without consult- keep the attaching parts in position and transfer the nor-
ing a Yale service representative or damage to the mal forces acting on them.
lift truck may occur.

1. TILT CYLINDER MOUNT 7. TRANSMISSION MOUNT

2. MAIN FRAME 8. MAIN COUNTERWEIGHT MOUNT
3. MAST MOUNT 9. STEER AXLE MOUNT
4. DRIVE AXLE MOUNT 10. ENGINE MOUNT
5. SIDE TILTING CAB MOUNT 11. MAIN CONTROL VALVE MOUNT
6. FUEL/HYDRAULIC TANK MOUNT

Figure 1. Frame

1
Air Cleaner 100 YRM 1349

Air Cleaner
REMOVE 7. Close the hoods.

1. Open the left- and right-hand hood.

2. Loosen the air duct clamp. See Figure 2.

3. Close the left- or right-hand hood to access the pre-

cleaner.

4. Remove the pre-cleaner, with the air duct attached,

from the air cleaner.

5. Disconnect the connector from the restriction indi-

cator by pressing the metal clip.

6. Remove the hose clamp from the air filter hose and
remove the hose from the air cleaner.

7. Remove the bolts of the two mounting clamps.

8. Rotate the air cleaner until the air duct connection

is clear from the center of the hood opening and
remove the air cleaner to the right-hand side of the
truck.

9. Remove the retaining hardware from the mount-

ing clamps and remove the clamps and plate po-
sitioned under the hood.

INSTALL
1. Install the retaining hardware to the mounting
clamps and install the clamps and plate positioned
under the hood.

2. Position the air cleaner assembly at the mounting

clamps and tighten the two clamp bolts. 1. PRE-CLEANER
2. CAPSCREW
3. Connect the air filter hose to the air cleaner assem- 3. HOSE CLAMP
bly and tighten the hose clamp. 4. CLAMP BOLT
5. MOUNTING CLAMP
4. Connect the restriction indicator connector to the air 6. AIR FILTER HOSE
cleaner assembly. 7. AIR CLEANER ASSEMBLY
8. RESTRICTION INDICATOR
9. AIR DUCT CLAMP
5. Close the left- or right-hand hood. 10. AIR DUCT
6. Install the pre-cleaner, with the air duct attached, Figure 2. Air Cleaner
on the air cleaner and tighten the air duct clamp.

2
100 YRM 1349 Exhaust System

Exhaust System
REMOVE

WARNING
Exhaust system must be at room temperature be-
fore starting disassembly or personal injury may
occur.

1. Remove the two clamps from the flex tube. See

Figure 3.

2. Remove the clamp that connects the turbo charge

pipe to the exhaust pipe.

3. Remove the clamp that holds the exhaust pipe to

the engine and remove the exhaust pipe and flex
tube.

4. Affix a tool that will retain the nut when loosening

a capscrew of the muffler. Remove the four cap-
screws and nuts.

5. Remove the muffler from the hood.

INSTALL
1. Position the muffler at the hood.

2. Install the four capscrews and nuts of the muffler.

3. Install the flex tube and two clamps to the muffler.

4. Install the exhaust pipe and exhaust pipe clamp to

the engine.
1. MUFFLER 4. FLEX TUBE
5. Install the clamp that connects the turbo charge 2. CAPSCREWS 5. EXHAUST PIPE
3. CLAMP 6. CLAMP
pipe to the exhaust pipe.
Figure 3. Exhaust System
6. Tighten all clamps.

3
Hood Assembly 100 YRM 1349

Hood Assembly
REMOVE
1. Tilt the mast completely forward.

2. Completely tilt (raise) the cab.

3. Open the rear cover. See Figure 4.

4. Remove the bolts from the two isolators on top of

the radiator. See Figure 5.

5. Remove the four capscrews that hold the bracket of

the hood assembly to the counterweight.

6. Disconnect the two gas springs from the rear cover

at the counterweight.

7. Open the left- and right-hand hood.

8. Remove the exhaust pipe, flex tube, and U-bolt.

1. RADIATOR
2. BOLT
3. WASHER
4. ISOLATOR
5. BRACKET
6. LEFT-HAND HOOD
7. HOOD FRAME

Figure 5. Top Isolators

9. Remove the inlet suction tube.

10. Remove the two capscrews, washers, and nuts and

remove the expansion tank located underneath the
hood.

11. Place the expansion tank inside the engine com-

partment.

12. Remove all tie-wraps holding electrical cables to the

hood covers or hood assembly.

NOTE: Step 13 is for LPG (Liquefied Petroleum Gas)

engines only.
1. REAR COVER
2. HOOD FRAME 13. Remove the two hose clamps and crankcase
3. MUFFLER breather hoses from the front hood cover and
4. LEFT-HAND HOOD remove the crankcase breather.
5. HINGE
6. FRONT HOOD COVER 14. Remove the two nuts that hold the front hood cover
7. RIGHT-HAND HOOD
to the frame.
Figure 4. Hood Assembly
15. Attach a lifting device to the hood assembly.

4
100 YRM 1349
CAUTION
Use caution when lifting the hood assembly to
avoid damage to the rear of the operators cab.
16. Lift the hood assembly from the frame and place it
on the ground in a horizontal position by putting a
support under the rear of the hood frame.
INSTALL
1. Attach a lifting device to the hood assembly.
CAUTION
Use caution when installing the hood assembly to
avoid damage to the rear of the operators cab.
2. Position the hood assembly onto the frame.
3. Install the two nuts that hold the front hood cover to
the frame.
NOTE: Step 4 is for LPG engines only.
4. Install the crankcase breather and breather hoses
to the front hood cover with the two hose clamps.
Hydraulic Tank
The hydraulic tank is installed on the right side of the
frame between the front fender and counterweight.
REMOVE
NOTE: The hydraulic tank removal and installation must
be done with aid of an assistant.
1. Place the truck on a solid, level surface.
2. Lower the mast completely.
3. Shut down the engine.
4. Apply the parking brake.
5. Remove the four capscrews (3) and washers (4)
holding the right-hand panel on top of the hydraulic
tank and remove the right-hand panel. See Fig-
ure 6.
6. Remove the three capscrews (7) and washers (8)
holding the right-hand extension plate and remove
the extension plate. See Figure 6.
Hydraulic Tank
5. Attach the electrical cables at the original locations
to the hood assembly with tie-wraps.
6. Install the expansion tank under the hood with the
two capscrews, washers, and nuts.
7. Install the inlet suction tube. See the section Air
Cleaner, Install.
8. Install the exhaust pipe, flex tube, and U-bolt. See
the section Exhaust System, Install.
9. Install the four capscrews that hold the hood as-
sembly to the counterweight.
10. Install the two gas springs to the rear cover at the
counterweight.
11. Attach the radiator to the bracket of the hood as-
sembly. See Figure 5.
12. Close the left- and right- hand hood.
13. Completely lower the cab.
14. Start the engine and check for leaks.
7. Remove the drain plug at the bottom of the hydraulic
tank and drain the hydraulic oil into clean contain-
ers.
8. Put tags on the four return hoses and pipes at the
top of the hydraulic tank for identification.
NOTE: Use a drain pan to collect the oil from the hy-
draulic hoses.
9. Disconnect the four return hoses from the two pipes
at the top of the hydraulic tank. See Figure 7.
10. Put caps on the hoses and pipes.
11. Put tags on the two hoses and connections at the
frame side of the hydraulic tank for identification.
12. Disconnect the two hoses from the two connections
at the frame side of the hydraulic tank. See Fig-
ure 7.
13. Put caps on the hoses and connections on the hy-
draulic tank.
5
Hydraulic Tank 100 YRM 1349

1. HYDRAULIC TANK 6. SEAL

2. BATTERY BOX 7. CAPSCREWS
3. CAPSCREWS 8. WASHERS
4. WASHERS 9. RIGHT-HAND EXTENSION PLATE
5. RIGHT-HAND PANEL 10. BATTERY CABLE ACCESS

Figure 6. Hydraulic Tank

CAUTION
Disconnect the negative (ground) cable first or lift
truck damage may occur.
14. Disconnect the negative (ground) and positive
(power) cables from the batteries.
15. Remove the batteries from the battery box.
NOTE: When moving the front cab tilt shaft, maintain
the position of the shims between the cab and frame tilt
brackets.
19. Use a short rounded 19 mm (0.75 in.) shaft and
hammer it into the front tilt bracket of the cab.
20. Push the cab tilt shaft further rearwards until the
shaft slightly protrudes out of the rear bracket.

16. Remove the battery cables from the access hole of

the hydraulic tank. See Figure 6.
17. Remove the capscrews that hold the right running
board to the counterweight, front fender, and hy-
draulic tank and remove the running board.
18. Remove the anchor that secures the cab tilt shaft.
WARNING
Make sure the hydraulic tank is supported with a
hydraulic jack, hand pallet lift, or a lift truck.
21. Support the hydraulic tank with blocks of at least
50 mm (2.0 in.) thick to cover the height of the
bracket at the bottom of the hydraulic tank.

6
100 YRM 1349
1. RETURN PIPE
2. HOSE CONNECTION
3. DRAIN PLUG
Figure 7. Hydraulic Tank Connection and Fittings
22. Remove the three nuts and washers that hold the
hydraulic tank to the frame.
CAUTION
DO NOT to damage the studs during removal of the
hydraulic tank from the frame.
23. Lift the hydraulic tank from the studs and move the
hydraulic tank away from the frame.
INSPECT
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can cause
an explosion.
Make a visual inspection of all sides of the tank. Inspect
the welds for cracks and leakage. Check for wet areas,
accumulation of dirt, and loose or missing paint caused
by leakage. Areas of the tank that are not easily seen
can be checked with an inspection mirror and a light that
is approved for locations with flammable vapors.
Hydraulic Tank
CLEAN
Tank can be cleaned with or without steam. If steam is
available use a hose with a minimum diameter of 19 mm
(0.75 in.). Control the pressure of the steam by a valve
installed at the nozzle of the hose. If a metal nozzle
is used, it must be made of a material that does not
make sparks. Make an electrical connection between
the nozzle and the tank. Connect a ground wire to the
tank to prevent static electricity.
1. Remove all the parts from the tank. Install the drain
plug.
WARNING
When cleaning the tank, do not use solutions that
make dangerous gases at normal temperatures or
when heated. Wear eye and face protection. Protect
the body from burns. If the tank is cleaned inside a
building, make sure there is enough ventilation.
CAUTION
Disposal of lubricants, fluids, and chemicals must
meet local environmental regulations.
2. Fill the tank with a cleaning solution. Proceed as
follows:
• If steam is available, fill the tank 1/4 full with a so-
lution of water and sodium bicarbonate or sodium
carbonate. Mix 0.5 kg (1 lb) per 4 liter (1 gal).
• If the tank cannot be cleaned with steam, mix
a solution of water and trisodium phosphate or
cleaning compound with an alkaline base. Follow
the instructions given by the manufacturer.
WARNING
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
3. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the tank
are flushed with the solution.
4. Drain the tank.
5. If steam is available, put steam into the tank until
the tank does not have odors and the metal is hot.
Steam vapors must come from all the openings.
7
Hydraulic Tank
6. Flush the inside of the tank with boiling water. Make
sure all the loose material and cleaning compound
is removed from the inside of the tank.
7. Make an inspection of the inside of the tank. If it
is not clean, repeat Step 5 and Step 6 and make
another inspection. When making inspections, use
a light that is approved for locations with flammable
vapors.
8. Check the tank for flammable vapors. Put plugs in
all the openings in the tank. Wait 15 minutes, then
remove the inlet and outlet plugs. Test a sample of
the vapor with a special indicator for gas vapors. If
the amount of flammable vapors is above the lower
flammable limit, repeat the cleaning procedures.
ADDITIONAL PREPARATIONS FOR
REPAIR
If nitrogen gas or carbon dioxide gas is available, pre-
pare the cleaned tank for welding using these gases.
See the manual Safe Practices for Welding and Cutting
Containers That Have Held Combustibles by the Amer-
ican Welding Society, F4.1-1999.
If these gases are not available, fill the tank with water to
just below the point where the work will be done. Make
sure the space above the level of the water has a vent.
REPAIR
Small Leaks
Use the following procedure to repair small leaks:
1. Use steam to clean the area around the leak. 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
WARNING
Special procedures must be followed when large
leaks or other repairs need welding or cutting. All
work must be done by authorized personnel.
8
100 YRM 1349
CAUTION
Welding on the truck may cause damage to the en-
gine, transmission, and/or hydraulic electronic con-
trol units if proper precautions are not taken. Dis-
connect the negative battery terminal from the bat-
tery. Disconnect all ECM’s. If welding must be done
in a close proximity of an ECM, that ECM must be
removed. When welding to the chassis, attach the
ground cable as close the weld as possible.
1. Use the procedure described under Clean to pre-
pare the tank for repairs.
2. Contact your dealer for Yale lift trucks for welding
instructions.
3. Use acceptable welding practices to repair the
tank. See the American National Standard Safety
in Welding and Cutting, AWS Z 49.1 - 1999.
Preparations for use After Repair
1. Add more water to the tank so that the water goes
above the point of where the work was done. Check
to see if there are any leaks coming from tank.
2. If there are no leaks coming from the tank, remove
all the water from the tank.
INSTALL
NOTE: When installing the hydraulic system oil filter, it
is important to grease the O-ring before installation.
1. Place the hydraulic tank on lifting equipment and
support with blocks of at least 50 mm (2.00 in.) thick
to cover the height of the bracket at the bottom of
the hydraulic tank.
2. Raise and place the hydraulic tank in front of the
right side of the frame in the correct height position.
CAUTION
DO NOT to damage the studs during installation of
the hydraulic tank to the frame.
3. Careful place the hydraulic tank over the studs with-
out damaging the studs.
100 YRM 1349
4. Install the three washers and nuts that hold the top
of the hydraulic tank to the frame.
5. Remove the lifting device.
NOTE: While pushing the cab tilt shaft to the front of the
truck, keep the shims in their position between the cab
and cab tilt system.
6. Push the cab tilt shaft towards the front of the truck
and guide the shaft into the front bracket.
7. Install the anchor that secures the cab tilt shaft.
8. Inspect the right running board grommets. Replace
if damaged.
9. Put the right running board in place and install the
capscrews that hold the running board to the coun-
terweight, front fender, and hydraulic tank.
10. Install the right-hand extension plate using the three
capscrews and washer. See Figure 6.
11. Feed the battery cables through the access hole of
the hydraulic tank. See Figure 6.
12. Install the batteries into the battery box.
CAUTION
Connect the positive (power) cable first or lift truck
damage may occur.
13. Connect the positive (power) and negative (ground)
cables to the batteries.
Fuel Tank
The fuel tank is installed on the left side of the frame
between the front fender and counterweight.
The LPG version has a cover instead of a fuel tank. This
cover can be replaced in a similar way.
REMOVE
1. Place the truck on a solid, level surface.
2. Lower the mast completely.
3. Shut down the engine.
4. Apply the parking brake.
5. Completely tilt (Raise) the cab.
Fuel Tank
14. Connect the two hoses to the two connections at
the frame side of the hydraulic tank.
15. Connect the four return hoses to the two pipes at
the top of the hydraulic tank. Torque the large fit-
tings to 88 to 98 N•m (65 to 72 lbf ft).
16. Make sure the drain plug is installed at the bottom
of the hydraulic tank.
17. Use a filtration system when refilling the hydraulic
tank to the correct level with the oil specified in the
maintenance table. See the section Periodic Main-
tenance 8000 YRM 1347.
18. Start the engine and operate the hydraulic system.
19. Make sure all functions work correctly.
WARNING
Do not try to locate hydraulic leaks by putting hands
on pressurized hydraulic components. Hydraulic
oil can be injected into the body and cause personal
injury.
20. Check for leaks.
21. Bleed the system.
22. If necessary, fill the hydraulic tank to the correct
level after bleeding the system.
23. Position the right-hand panel on top of the hydraulic
tank and install the four washers and capscrews.
6. Remove the connector from the pushbutton switch
at the left-hand panel.
7. Remove the four capscrews and washers holding
the left-hand panel and remove the panel.
8. Remove the left-hand extension plate between the
fuel tank and counterweight.
WARNING
When removing the fuel tank, do not use tools that
can make sparks, heat, or static electricity. The va-
pors in the tank can cause an explosion and per-
sonal injury may occur.
9. Put a drain pan under the fuel tank.
9
Fuel Tank 100 YRM 1349

10. Remove the drain plug to drain the fuel from the 11. Disconnect the fuel sender connector at the top of
tank. See Figure 8. the fuel tank. See Figure 8.

12. Put tags on the check valve and shutoff valve fuel
WARNING hoses and fittings for identification.
If fuel is drained, put the fuel in a can or barrel that
has a protected seal cap.

1. FUEL HOSE 4. DRAIN PLUG

2. FUEL SHUTOFF VALVE 5. CHECK VALVE
3. FUEL TANK 6. FUEL SENDER CONNECTOR

Figure 8. Fuel Tank

10
100 YRM 1349
NOTE: Use a drain pan to catch the fuel in the fuel
hoses.
13. Disconnect the two fuel hoses from the check valve
and shutoff valve at the top of the fuel tank. See
Figure 8.
14. Put caps on the fuel hoses and fittings.
15. Remove the check valve and shut off valve at the
top of the fuel tank. See Figure 8.
16. Put caps on the fittings at the top of the fuel tank.
17. Loosen the fuel hose clamp located on top of the
frame.
18. Turn the ends of the hoses parallel with the frame.
19. Remove the hose clamp for the cab tilt hoses.
20. Remove the retaining hardware of the left- and
right-hand latch located on the frame.
21. Remove the two capscrews, and washers at the
back of the hand pump. See Figure 9.
1. ELECTRICAL TILT PUMP 2. HAND PUMP
Figure 9. Fuel Tank, Hand Pump, and Electric Lift Pump
Fuel Tank
22. Remove the capscrews holding the left running
board to the counterweight, front fender, and fuel
tank and remove the running board.
WARNING
Make sure that the lifting device has the rated ca-
pacity of 100 kg (2205 lb)to lift the fuel tank.
NOTE: Removal of the fuel tank can be done with a lift-
ing device, hydraulic jack, hand pallet jack, or lift truck.
NOTE: Follow step Step 23 and Step 24 when a lifting
device is used.
NOTE: Follow Step 25 when a hydraulic jack, hand pal-
let jack, or lift truck is used.
NOTE: When lifting, keep the fuel tank in the horizontal
position.
23. Attach a lifting device to the fuel tank. Attach lifting
eyes at the locations shown in Figure 10.
24. Create slight tension on the chains.
3. FUEL TANK
11
Fuel Tank 100 YRM 1349

Figure 10. Lifting Points

25. Support the fuel tank with blocks of at least 50 mm
(2.0 in.) thick to cover the height of the bracket on
the bottom of the fuel tank.
CAUTION
DO NOT to damage the studs during removal of the
fuel tank from the frame.
26. Remove the two nuts and washers that hold the top
of the fuel tank and the electrical tilt pump bracket
to the frame.
27. Remove the electrical tilt pump and bracket from
the frame.
28. Place the electrical tilt pump, hand pump, left and
right latch inside the frame to avoid damage to the
hoses during the removal of the fuel tank.
29. Remove the remaining nut that holds the fuel tank
to the frame.
30. Lift the fuel tank from the studs and move the fuel
tank away from the frame.

12
100 YRM 1349
REPAIR
WARNING
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can cause
an explosion.
Repair the fuel tank as described in the section Hy-
draulic Tank.
INSTALL
NOTE: Follow Step 1 when a lifting device is used.
NOTE: Follow Step 2 when a hydraulic jack, hand pallet
jack, or lift truck will be used.
NOTE: When lifting, keep the fuel tank in a horizontal
position.
1. Attach a lifting device with lifting straps and lifting
eyes to the fuel tank.
2. Place the fuel tank on lifting equipment and support
with blocks of at least 50 mm (2.00 in.) thick to cover
the height of the bracket at the bottom of the fuel
tank.
3. Raise and place the fuel tank in front of the left side
of the frame.
CAUTION
DO NOT to damage the studs during installation of
the fuel tank.
4. Place the fuel tank over the studs of the frame.
5. Install the washer and nut, located behind the hand
pump, that hold the top of the fuel tank to the frame.
6. Position the hand pump, electrical tilt pump, left and
right latch at the frame and route the hoses cor-
rectly.
7. Install the two washers and nuts that hold the top of
the fuel tank and the electrical tilt pump bracket to
the frame.
8. Install the hand pump with the two washers and
capscrews located behind the hand pump.
Fuel Tank
9. Install the left and right latch, located at the frame,
with the capscrews, spring washers, washers, and
nuts.
10. Install the hose clamps located on top of the frame.
11. Inspect the left running board grommets. Replace
if damaged.
12. Put the left running board in place and install the
capscrews that hold the running board to the coun-
terweight, front fender, and fuel tank.
13. Install the left hand extension plate between the
fuel tank and counterweight using the three wash-
ers and capscrews.
14. Install the drain plug at the bottom of the fuel tank.
15. Install the check valve and shutoff valve at the top
of the fuel tank.
16. Connect the two fuel hoses to the check valve and
shut off valve at the top of the fuel tank.
17. Connect the connector to the electrical tilt pump.
18. Connect the connector of the fuel sender to the top
of the fuel tank.
19. Position the left-hand panel on top of the fuel tank
and install the four capscrews and washers.
20. Connect the connector, located at the left-hand
panel, to the push button switch.
21. Fill the fuel tank to the correct level with fuel spec-
ified in the section Periodic Maintenance 8000
YRM 1347.
CAUTION
Connect the positive (power) cable first or lift truck
damage may occur.
22. Connect the positive (power) and negative (ground)
cable to the batteries.
23. Completely lower the cab.
24. Start the engine.
25. Check for leaks.
13
Cab Repair 100 YRM 1349

Cab Repair
REAR CAB ASSEMBLY NOTE: Interior covers are affixed with self-tapping
screws.
See Figure 11 for rear cab assembly.

1. COVER PLATE 6. HEADLINER

2. FUSE SECTION 7. REAR DUCT ASSEMBLY
3. RELAY SECTION 8. CONSOLE COVER
4. HYDRAULIC VALVE CONTROLLER 9. CONSOLE TOP
5. FOAM COVER 10. INSTRUMENT PANEL

Figure 11. Rear Cab Assembly

14
100 YRM 1349 Cab Repair

BOTTOM CAB ASSEMBLY 1. Tilt mast fully forward.

See Figure 12 for bottom cab assembly. 2. Remove all unsecured items from cab.

3. Close and securely latch both cab doors.

4. Clear all obstacles from right-hand side (as seen

from driver’s position) of truck. Provide minimum of
2 m (7 ft) of clearance space.

5. Use pump lever to turn direction valve clockwise to

"Raise" position. See Figure 13.

1. WIPER MOTOR ASSEMBLY

2. WIPER COUPLING
3. AIR FILTER 1. PUMP LEVER CONNECTION
4. COVER PLATE 2. DIRECTION VALVE SELECTION: CLOCKWISE -
5. STEERING PUMP RAISE, COUNTERCLOCKWISE - LOWER
6. HORN
Figure 13. Pump and Direction Valve
Figure 12. Bottom Cab Assembly
6. Operate pump with pump lever until cab locks in
partially open position.
RAISING AND LOWERING CAB
NOTE: Just before fully open position is reached, move-
Raise Cab ment may be gravity controlled.

WARNING 7. Pull tilt latch release and continue to raise cab to

Make sure no one is under cab when raising or low-
ering cab.
WARNING
Before you place any part of your body under cab,
always make sure that cab is fully tilted, or when
partially open, is locked by tilt latch.
CAUTION
Cab damage may occur if mast is not completely
tilted forward.
fully open position. See Figure 14.
NOTE: If cab will not fully raise, lower cab until cab locks
in partially open position, and fill tilt system with oil. See
Oil Filling for Tilt System.
NOTE: Raising cab gives access to components such
as engine, transmission/hydraulic compartment, throt-
tle/brake and steering control, heater, air conditioner,
and electrical connectors.

15
Cab Repair 100 YRM 1349

pump direction control. Procedure to raise or lower is

the same.

CAB REPAIR
Remove

WARNING
Before removing heater hoses, allow time for heater
hoses to cool down. Hot water may cause severe
burns.

WARNING
Make sure the lifting device has a minimum capac-
1. CAB ity to lift 1000 kg (2205 lb). A lifting device that does
2. FRAME not have the minimum capacity can break causing
3. TILT LATCH RELEASE the cab to drop and may result in serious personal
4. PUMP LEVER
injury.
Figure 14. Pump Lever and Tilt Latch Release Knob
CAUTION
Lower Cab Lift the operator’s cab carefully. Make sure all wires
and attachments are disconnected and loose com-
WARNING ponents are not obstructing the movement.
Make sure no one is under cab when raising or low-
ering cab. 1. Switch off engine.

2. Disconnect battery ground lead.

WARNING
Before you place any part of your body under cab, 3. Raise operator’s cab. See Raise Cab.
always make sure that cab is fully tilted, or when 4. Remove four hex bolts holding steering pump. See
partially open, is locked by tilt latch. Figure 15.

CAUTION 5. Remove two bolts holding brake valve.

Cab damage may occur if mast is not completely
tilted forward.
1. Use pump lever to turn direction valve counterclock-
wise to "Lower" position. See Figure 13.
2. Check that all foreign items/tools are cleared away.
3. Operate pump with pump lever until cab locks in
partially open position.
4. Pull tilt latch release and continue to lower cab until
it is in fully lowered position and latched. See Fig-
ure 14.
NOTE: An electric-powered cab tilt system is available
to replace standard manual tilt system. The electric tilt
system contains a push button located on left side of
6. Disconnect electrical cable to throttle pedal sensor.
See Sensor Adjustment.
7. Disconnect electrical cable.
8. Disconnect electrical that are located to right of
heater unit.
9. Disconnect window washer hoses and mark their
positions.
10. Remove three bolts and swing heater unit down.
11. Disconnect electrical connections, control cables,
and air duct from heater unit.
12. Disconnect ground lead.

16
100 YRM 1349 Cab Repair

19. Remove four rubber isolation mounts from frame

and inspect for damage. Reinstall or replace if nec-
essary.

Install
1. Connect lift strap under overhead guard structure.
Provide cushion at top of door area to prevent dam-
age.

2. Make sure that insulators are in place. See Fig-

ure 16.

3. Lift operator’s cab.

4. Carefully lower cab on insulators and make sure

that it is properly centered.

5. Mount cab with washers and bolts.

6. Tighten cab mounting bolts to 66 N•m (49 lbf ft).

7. Raise cab. See Raise Cab.

8. Connect electrical cables, ground wire, hoses,

steering pump, and brake valve. Make sure that all
connections have been restored.
1. STEERING PUMP HEX BOLTS
2. BRAKE VALVE BOLTS 9. Mount heater unit to hinge. Connect control cables
3. STEERING PUMP and electrical connections. Pivot unit up and install
4. BRAKE VALVE with three bolts.
5. ELECTRICAL CONNECTIONS
10. Connect inching and throttle cables. See Inching
Figure 15. Steering Pump, Throttle and Inching
and Brake Pedals.
Connections

CAUTION
When lowering cab, make sure loose components
are not obstructing the movement.

13. Lower operator’s cab. See Lower Cab.

14. Remove left and right side panels giving access to

cab mounting bolts.

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

two on right side of truck.

16. Remove cab doors before attaching a lifting device.

17. Connect a lift strap under overhead guard structure.

Provide a cushion at top of door area to prevent 1. TOP PART OF INSULATOR
damage. 2. BOTTOM PART OF INSULATOR
3. BOLT
18. Carefully lift cab away from lift truck. Set cab as- 4. WASHER
5. LOCKWASHER
sembly in a suitable storage area and put blocks
under cab to stabilize and prevent damage. Figure 16. Insulators

17
Engine
11. Lower cab. See Lower Cab.
12. Install doors.
Engine
REMOVE
WARNING
Engine must be at room temperature before starting
disassembly or personal injury may occur.
CAUTION
Repairs to air conditioning that require discharging
and/or refilling of the refrigeration fluid must be per-
formed only by a trained and certified air condition-
ing specialist.
1. Place the truck on a solid, level surface.
2. Lower the mast completely.
3. Shut down the engine.
4. Apply the parking brake.
5. Completely tilt (Raise) the cab.
CAUTION
Disconnect the negative (ground) cable first or
damage to the lift truck may occur.
6. Disconnect the negative (ground) and positive
(power) cables from the batteries.
7. Remove the hood. See the section Hood Assem-
bly, Remove.
8. Disconnect the electrical cable from the air condi-
tioner compressor.
NOTE: Removing the compressor for the air conditioner
with the hoses attached prevents the need to have a
certified specialist suction and refill the air conditioning
system.
NOTE: DO NOT remove the refrigerant hoses.
9. Remove the air conditioner compressor from the
mounting bracket located on the engine.
18
100 YRM 1349
13. Connect battery ground lead.
14. Install side panels.
10. Attach the air conditioner compressor with the
hoses to the cab. Make sure the hoses are free
from the engine/transmission during removal.
11. Put tags on the two heater hoses for identification.
12. Disconnect the two heater hoses located under the
operators compartment at the engine side.
13. Put caps on the two heater hoses.
WARNING
DO NOT remove the pressure cap from the expan-
sion bottle when the engine is hot. When the pres-
sure cap is removed, the pressure is released from
the system. If the system is hot, the steam and boil-
ing coolant can cause burns.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
14. Let coolant cool to room temperature.
15. Use a drain pan to catch the coolant.
16. Remove the pressure cap from the expansion tank.
17. Remove the radiator return hose from the engine to
drain the coolant.
NOTE: Use a drain pan to drain the transmission oil
from the transmission.
18. Remove the drain plug at the bottom of the trans-
mission and put the transmission oil in a clean bar-
rel.
19. Install the drain plug at the bottom of the transmis-
sion.
NOTE: Step 20 through Step 25 is for diesel engines
only.
20. Close the fuel shutoff valve at the top of the fuel
tank.
100 YRM 1349
21. Put tags on the fuel hoses and fittings for identifica-
tion.
NOTE: Use a drain pan to catch the fuel in the fuel
hoses.
22. Disconnect the fuel hose at the diesel fuel filter.
23. Disconnect the fuel hose at the check valve.
24. Put caps on the fuel hoses and fittings.
25. Attach the fuel hoses to the engine.
NOTE: Step 26 until Step 30 are for LPG engines only.
26. Turn both fuel valves on the LPG tanks clockwise
until the fuel valves are completely closed.
WARNING
Odor of LPG fuel may be detected when the hose
of the LPG liquid fuel filter is disconnected. Avoid
breathing the odor or personal injury may occur.
27. Disconnect the LPG fuel hose at the LPG liquid fuel
filter.
28. Put tags on the two crankcase breather hoses and
fittings for identification.
29. Disconnect the two crankcase breather hoses at
the engine.
30. Put caps on the two hoses and fittings.
31. Remove the two charge air cooler pipes from the
charge air cooler core and engine assembly.
32. Remove the two engine coolant hoses from the en-
gine coolant core and engine assembly.
33. Put tags on the two transmission oil hoses for iden-
tification.
34. Disconnect the two transmission oil hoses from the
thermostat manifold at the inlet and outlet port.
35. Put caps on the two transmission hoses and on the
inlet and outlet port of the thermostat manifold.
36. Clean the suction hose and hydraulic pump to avoid
dirt entering the suction hose.
NOTE: Make sure the suction hose end remains above
the hydraulic tank oil level.
37. Disconnect the suction hose from the hydraulic
pump.
Engine
38. Place a cap on the suction hose from the hydraulic
pump.
39. Put tags on the two pressure hoses of the hydraulic
pump for identification.
NOTE: Use a drain pan to catch the hydraulic oil in the
pressure hoses.
40. Disconnect the two pressure hoses from the hy-
draulic pump.
41. Put caps on the two pressure hoses.
42. Disconnect the return hoses to the hydraulic tank.
43. Disconnect the three electrical wires located at the
left side of the engine from the alternator. See Fig-
ure 17.
44. Disconnect the four electrical wires located at the
left side of the engine from the starter. See Fig-
ure 17.
45. Disconnect the electrical wire located at the left side
of the transmission from the transmission control
valve. See Figure 17.
46. Disconnect the electrical wire for the output speed
sensor and speed/temperature sensor located at
the left side of the transmission. See Figure 17.
47. Disconnect the ECM connector and Engine supply
connector located at the right side of the engine
from the engine. See Figure 18.
48. Disconnect the two electrical wires for the engine
oil pressure located at the right side of the engine
from the engine. See Figure 18.
49. Disconnect the electrical wire for the fuel filter
sender, located at the right side of the engine, from
the engine. See Figure 18.
50. Disconnect the electrical wire for the convertor out
temp sensor located at the right side of the trans-
mission from the transmission. See Figure 18.
51. Disconnect the electrical wire for the turbine speed
sensor located at the right side of the transmission
from the transmission. See Figure 18.
52. Remove the clamps that hold the two electrical
wires at the top of the engine that run from the right
to the left side. Reposition the two electrical wires
to the right side of the frame.
19
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