Maintenance

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

PART NO. 524173800 100 YRM 726

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

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

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

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

CAUTION
Indicates a condition that can cause property damage!
Frame Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Counterweight Repair.......................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Install............................................................................................................................................................... 2
Hood Repair ........................................................................................................................................................ 2
Remove ........................................................................................................................................................... 2
Install............................................................................................................................................................... 2
Overhead Guard Repair ...................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Inspect............................................................................................................................................................. 4
Install............................................................................................................................................................... 4
LED Backup and Brake Lights, Replace ......................................................................................................... 4
Remove....................................................................................................................................................... 4
Install .......................................................................................................................................................... 4
Operator Restraint System Repair ...................................................................................................................... 5
Radiator Repair ................................................................................................................................................... 6
Remove ........................................................................................................................................................... 6
Install............................................................................................................................................................... 6
Exhaust System Repair ....................................................................................................................................... 8
Muffler ............................................................................................................................................................. 8
Remove....................................................................................................................................................... 8
Install .......................................................................................................................................................... 8
LPG/Gas Engine Exhaust Pipe - Lift Trucks Without Low Emissions.............................................................. 8
Remove....................................................................................................................................................... 8
Install .......................................................................................................................................................... 11
EPA Compliant LPG/Gas Engine Exhaust System ......................................................................................... 11
Remove....................................................................................................................................................... 11
Install .......................................................................................................................................................... 13
Diesel Engine Exhaust Pipe............................................................................................................................ 13
Remove....................................................................................................................................................... 13
Install .......................................................................................................................................................... 15
Engine Repair...................................................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Install............................................................................................................................................................... 17
Throttle Pedal Adjustment ................................................................................................................................... 19
Perkins 1104C-44(RE) Diesel Engine ............................................................................................................. 19
Lift Trucks With an Accelerator Pedal ......................................................................................................... 19
Lift Trucks With a Foot Directional Control Pedal........................................................................................ 20
Fuel and Hydraulic Tanks Repair......................................................................................................................... 22
Inspect............................................................................................................................................................. 22
Small Leaks, Repair ........................................................................................................................................ 22
Large Leaks, Repair ........................................................................................................................................ 22
Clean............................................................................................................................................................... 22
Steam Method ............................................................................................................................................ 22
Chemical Solution Method .......................................................................................................................... 23
Other Preparation Methods for Repair ............................................................................................................ 23
Safety Labels....................................................................................................................................................... 23

©2004 Yale Materials Handling Corp. i

Table of Contents Frame

TABLE OF CONTENTS (Continued)

This section is for the following models:

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

ii
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 Table 1. Weight of Counterweights

WARNING Lift Truck Weight (kg) Weight (lb)

The lift truck must be put on blocks for some types GLP/GDP3.50LJ 1782 to 1838 3929 to 4052
of maintenance and repair. The removal of the (GP/GLP/GDP70LJ)
following assemblies will cause large changes in
GLP/GDP4.00LJ 2068 to 2132 4559 to 4700
the center of gravity: mast, drive axle, engine and
(GP/GLP/GDP80LJ)
transmission, and counterweight. When the lift
truck is put on blocks, put additional blocks in the GLP/GDP4.00LJ 2355 to 2425 5192 to 5346
following positions to maintain stability: (GP/GLP/GDP90LJ)
a. Before removing the mast and drive axle, put
GLP/GDP4.50MJ 2660 to 2740 5864 to 6041
blocks under the counterweight so the lift truck
(GP/GLP/GDP100MJ)
cannot fall backward.
b. Before removing the counterweight, put blocks GLP/GDP5.00MJ 2906 to 2994 6407 to 6601
under the mast assembly so the lift truck cannot (GP/GLP/GDP110MJ)
fall forward.
GLP/GDP5.50MJ 3152 to 3248 6949 to 7161
The surface must be solid, even, and level when the (GP/GLP/GDP120MJ)
lift truck is put on blocks. Make sure that any blocks
used to support the lift truck are solid, one-piece 2. Remove cover between counterweight and hood.
units. Remove tow pin.

3. Install two eyebolts into the counterweight lifting

WARNING holes and attach a lifting device to the eyebolts.
Make sure that the lifting device used has the
correct lift capacity for the counterweight being
removed. See Table 1. CAUTION
When lifting the counterweight from the lift truck,
1. If installed, remove the overhead exhaust pipe from be careful not to bend the exhaust pipe.
the counterweight. See Figure 1.
4. Remove two capscrews, washers, and lockwash-
ers. Remove counterweight from lift truck.

1
Hood Repair 100 YRM 726

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

2. Remove eyebolts from counterweight lifting holes.

3. Install tow pin. Install cover between hood and

counterweight.

4. If removed, install the overhead exhaust pipe in the

counterweight. Tighten the capscrews to 38 N•m
(28 lbf ft).

1. COUNTERWEIGHT 4. WASHER
2. LIFTING DEVICE 5. LOCKWASHER
3. LIFTING EYE 6. MOUNTING BOLT

Figure 1. Counterweight

Hood Repair
REMOVE used to support the lift truck are solid, one-piece
units.
WARNING 1. Raise the hood and disconnect the two gas-assist
The lift truck must be put on blocks for some types cylinders at the hood. Disconnect the park brake
of maintenance and repair. The removal of the fol- alert wiring harness.
lowing assemblies will cause large changes in the
center of gravity: mast, drive axle, engine, trans- 2. Remove the pins that hold the hood hinges to the
mission, and counterweight. When the lift truck is operator’s module crossmember. Remove the
put on blocks, put additional blocks in the following hood.
positions to maintain stability:
a. Before removing the mast and drive axle, put INSTALL
blocks under the counterweight so the lift truck
cannot fall backward. 1. Install the hood in position on the lift truck. Install
b. Before removing the counterweight, put blocks the pins that hold the hood hinges to the operator’s
under the mast assembly so the lift truck cannot module crossmember.
fall forward.
2. Connect the two gas-assist cylinders to the hood.
The surface must be solid, even, and level when the Connect the park brake alert wiring harness.
lift truck is put on blocks. Make sure that any blocks

2
100 YRM 726 Hood Repair

b. Loosen the capscrews for the hood latch just

WARNING enough to let the latch move. Position the latch.
The hood, hood latch, and hood striker must be cor- Tighten the capscrews for the latch.
rectly adjusted for the correct operation of the op-
erator restraint system. c. Check the operation of the hood latch. Have
an operator sit in the seat. Make sure that the
3. Adjust the hood latch (see Figure 2) as follows: hood is fully closed (two clicks). Also, check
that the hood touches the rubber bumpers. If
a. Center the latch striker in the slot located in the necessary, repeat Step b.
rear crossmember. Check that the latch striker
is in the center of the jaws of the hood latch and
tighten.

1. LATCH STRIKER 7. SEAT RAIL

2. HOOD LATCH 8. HOOD
3. LATCH LEVER 9. HINGE
4. SEAT 10. OPERATOR WEIGHT ADJUSTMENT
5. SEAT BELT LATCH 11. FORWARD/BACKWARD ADJUSTMENT
6. HIP RESTRAINT

Figure 2. Hood and Seat Latches Check

3
Overhead Guard Repair 100 YRM 726

Overhead Guard Repair

REMOVE INSTALL
1. Connect a lifting device to the top of the overhead
WARNING guard. Put the overhead guard in position on the lift
The lift truck must be put on blocks for some types truck.
of maintenance and repair. The removal of the
following assemblies will cause large changes in 2. Install the capscrews at the rear of the overhead
the center of gravity: mast, drive axle, engine and guard. Tighten the capscrews to 90 N•m (67 lbf ft).
transmission, and counterweight. When the lift Install the capscrews that hold the overhead guard
truck is put on blocks, put additional blocks in the to the cowl. Tighten the capscrews to 90 N•m
following positions to maintain stability: (67 lbf ft).
a. Before removing the mast and drive axle, put
blocks under the counterweight so that the lift LED BACKUP AND BRAKE LIGHTS,
truck cannot fall backward. REPLACE
b. Before removing the counterweight, put blocks
under the mast assembly so that the lift truck NOTE: Newer models of lift trucks are equipped with
cannot fall forward. LED (Light Emitting Diode) backup and brake tail lights.
These light assemblies are non-repairable and must be
The surface must be solid, even, and level when the replaced as a complete unit. See the Parts Manual for
lift truck is put on blocks. Make sure that any blocks replacement LED lights.
used to support the lift truck are solid, one-piece
units. Remove

WARNING 1. Disconnect negative terminal of battery and, re-

move the key.
Do not operate the lift truck without the overhead
guard correctly fastened to the lift truck. 2. Disconnect the LED light from the chassis light har-
ness.
Do not make changes to the overhead guard by
welding. Changes that are made by welding, or by 3. Remove LED light assembly and harness from
drilling holes that are too big in the wrong location, mounting bracket. See Figure 3.
can reduce the strength of the overhead guard.
See the instructions for Changes to the Overhead 4. If the LED mounting bracket must be removed from
Guard in the Periodic Maintenance section included the overhead guard leg, remove the plug, screw
with this lift truck. and bracket from the overhead guard leg.

Connect a lifting device to the top of the overhead Install

guard. Remove the capscrews that hold the overhead
guard to the frame. Remove the capscrews that hold 1. If the mounting bracket was removed, install it onto
the overhead guard to the cowl and module. Lift the the overhead guard leg. Insert the plug and screw
overhead guard from the lift truck. to attach mounting bracket to overhead guard leg.
See Figure 3.
INSPECT
2. Install the LED light assembly and harness on the
Inspect the condition of the mount isolators located at mounting bracket.
the rear legs of the overhead guard for any damage.
Replace if damaged. 3. Connect the LED light to the chassis light harness.

4. Connect the negative terminal of battery and close

the hood.

4
100 YRM 726 Operator Restraint System Repair

Legend for Figure 3

A. LED ASSEMBLY WITH STANDARD EXHAUST
B. LED ASSEMBLY WITH OVERHEAD EXHAUST
1. LED LIGHT
2. SCREW
3. WASHER
4. LOCKNUT
5. MOUNTING BRACKET
6. GROMMET
7. PLUG
8. SCREW
9. OVERHEAD GUARD LEG

Figure 3. LED Backup and Brake Lights Assembly

Operator Restraint System Repair

system. Each item must be checked to make sure it
WARNING is attached securely, functions correctly, and is in good
The lift truck must be put on blocks for some types condition. See Figure 2.
of maintenance and repair. The removal of the
following assemblies will cause large changes in The seat belt must fasten securely. Make sure the seat
the center of gravity: mast, drive axle, engine and belt extends and retracts smoothly and is not frayed or
transmission, and counterweight. When the lift torn. If the seat belt is damaged or does not operate
truck is put on blocks, put additional blocks in the properly, it must be replaced.
following positions to maintain stability:
a. Before removing the mast and drive axle, put Make sure the seat rails and latch striker are not loose.
blocks under the counterweight so the lift truck The seat rails must lock securely in position, but move
cannot fall backward. freely when unlocked. The seat rails must be securely
b. Before removing the counterweight, put blocks attached to the mounting surface. The hood must be
under the mast assembly so the lift truck cannot fully closed. Lift on the hood to make sure it is closed
fall forward. and will not move.

The surface must be solid, even, and level when the Adjust the hood, hood latch, and latch striker when any
lift truck is put on blocks. Make sure that any blocks of the parts of the operator restraint system are installed
used to support the lift truck are solid, one-piece or replaced. See the Hood Repair procedures.
units.

The seat belt, hip restraint brackets, seat and mounting,

hood, and latches are all part of the operator restraint

5
Radiator Repair 100 YRM 726

Radiator Repair
REMOVE 9. Remove the upper and lower fan shroud halves
from the radiator.
WARNING 10. Remove the radiator from the lower radiator mount-
The lift truck must be put on blocks for some types ing plate.
of maintenance and repair. The removal of the
following assemblies will cause large changes in INSTALL
the center of gravity: mast, drive axle, engine and
transmission, and counterweight. When the lift 1. Install the rubber isolators on the lower radiator lo-
truck is put on blocks, put additional blocks in the cating studs. See Figure 4.
following positions to maintain stability:
a. Before removing the mast and drive axle, put 2. Install the radiator on the lower radiator mounting
blocks under the counterweight so the lift truck plate.
cannot fall backward.
3. Install the upper and lower fan shroud halves on the
b. Before removing the counterweight, put blocks
radiator.
under the mast assembly so the lift truck cannot
fall forward. 4. Install the coolant recovery reservoir on the over-
head guard leg.
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks 5. Connect the coolant recovery reservoir hose to the
used to support the lift truck are solid, one-piece radiator.
units.
6. Install the rubber isolators on the upper radiator lo-
1. Remove the cover between the hood and counter- cating studs.
weight. See Figure 4.
7. Install the top radiator support plate. Tighten the
outer screws to 66 N•m (49 lbf ft). Tighten the inner
WARNING
screws to 38 N•m (28 lbf ft).
Disposal of coolant must be in accordance with lo-
cal regulations. 8. On the GM-powered lift truck, install the hose and
clamp on the bottom of the radiator.
NOTE: To aid in the draining of coolant from the radiator,
remove the radiator cap. 9. Connect the upper and lower coolant hoses to the
radiator.
2. Drain the coolant from the radiator.
10. Connect the hydraulic hoses to the radiator.
3. Disconnect the upper and lower coolant hoses from
the radiator.
CAUTION
4. Disconnect the hydraulic hoses from the radiator To prevent possible damage to the engine, make
and install plugs in the hoses. sure the engine is running at idle speed while per-
forming Step 11.
5. On the GM-powered lift truck, remove the clamp
and hose from the bottom of the radiator. 11. Add coolant to the system until the entire cooling
system is full.
6. Remove the top radiator support plate.
12. Install the cover between the hood and counter-
7. Disconnect the coolant recovery reservoir hose
weight.
from the radiator.

8. Remove the coolant recovery reservoir from the

overhead guard leg.

6
100 YRM 726 Radiator Repair

Figure 4. Radiator

7
Exhaust System Repair 100 YRM 726

Legend for Figure 4

A. PERKINS DIESEL 1004.42 B. GM 4.3L V-6
1. COVER 7. CLAMP
2. HOOD 8. RADIATOR SUPPORT PLATE
3. COUNTERWEIGHT 9. COOLANT RECOVERY RESERVOIR HOSE
4. RADIATOR 10. COOLANT RECOVERY RESERVOIR
5. HOSE 11. OVERHEAD GUARD LEG
6. HOSE 12. LOWER RADIATOR MOUNTING PLATE

Exhaust System Repair

MUFFLER Install
Remove 1. Install the muffler on the mounting bracket. Tighten
bolts until all clearance has been removed; then
tighten one additional turn. See Figure 5 or Fig-
WARNING
ure 6.
The lift truck must be put on blocks for some types
of maintenance and repair. The removal of the 2. Connect the upper exhaust pipe to the muffler and
following assemblies will cause large changes in install the lower exhaust pipe on the muffler.
the center of gravity: mast, drive axle, engine and
transmission, and counterweight. When the lift 3. Install the counterweight on the lift truck. See Coun-
truck is put on blocks, put additional blocks in the terweight Repair, Install in this YRM.
following positions to maintain stability:
a. Before removing the mast and drive axle, put 4. Install the overhead exhaust pipe in the counter-
blocks under the counterweight so the lift truck weight. Tighten the capscrews to 38 N•m (28 lbf ft).
cannot fall backward.
b. Before removing the counterweight, put blocks
LPG/GAS ENGINE EXHAUST PIPE - LIFT
under the mast assembly so the lift truck cannot TRUCKS WITHOUT LOW EMISSIONS
fall forward.
Remove
The surface must be solid, even, and level when the
lift truck is put on blocks. Make sure that any blocks NOTE: If the lift truck does not have an overhead ex-
used to support the lift truck are solid, one-piece haust, perform Step 2 and Step 4 through Step 8. If
units. 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 5 or Figure 6. 1. Remove the overhead exhaust pipe from the coun-
terweight. See Figure 5 and Figure 6.
2. Remove the counterweight. See Counterweight
Repair, Remove in this YRM. 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 3. Remove the lower exhaust pipe from the right side
muffler. of the muffler and disconnect the upper exhaust
pipe from the left side of the muffler.
4. Remove the muffler from the mounting bracket.
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.

8
100 YRM 726 Exhaust System Repair

1. LEFT ENGINE EXHAUST PIPE 15. HEAT SHIELD SLEEVE

2. RIGHT ENGINE EXHAUST PIPE 16. HEAT SHIELD SLEEVE
3. UPPER EXHAUST PIPE 17. INTERMEDIATE UPPER EXHAUST PIPE
4. MUFFLER 18. MUFFLER MOUNTING BRACKET
5. SEAL 19. ISOLATOR
6. FLANGE 20. WASHER
7. HEX HEAD BOLT 21. HEX HEAD BOLT
8. SPRING 22. WASHER
9. CLAMP 23. NUT
10. OVERHEAD EXHAUST 24. HEX HEAD BOLT
11. LOWER EXHAUST PIPE 25. LOCKWASHER
12. COUNTERWEIGHT EXHAUST PIPE 26. RIGHT-SIDE EXHAUST MANIFOLD
13. HEAT SHIELD 27. LEFT-SIDE EXHAUST MANIFOLD
14. CLAMP

Figure 5. LPG/GAS Exhaust System (Without Low Emissions) Early Model Lift Trucks

9
Exhaust System Repair 100 YRM 726

Figure 6. LPG/GAS Exhaust System (Without Low Emissions) Later Model Lift Trucks

10
100 YRM 726 Exhaust System Repair

Legend for Figure 6

1. LEFT ENGINE EXHAUST PIPE 12. LOWER EXHAUST PIPE
2. RIGHT ENGINE EXHAUST PIPE 13. HEAT SHIELD
3. UPPER EXHAUST PIPE 14. HEAT SHIELD SLEEVE
4. MUFFLER 15. LOCKWASHER
5. COUNTERWEIGHT EXHAUST PIPE 16. INTERMEDIATE UPPER EXHAUST PIPE
6. SEAL 17. NUT
7. FLANGE 18. MUFFLER MOUNTING BRACKET
8. HEX HEAD BOLT 19. ISOLATOR
9. SPRING 20. WASHER
10. CLAMP 21. PLUG
11. OVERHEAD EXHAUST PIPE

5. Disconnect upper exhaust pipe from the intermedi- 7. Install the counterweight. See Counterweight Re-
ate upper exhaust pipe and disconnect the interme- pair, Install in this YRM.
diate upper exhaust pipe from the left-side engine
exhaust pipe. 8. Install the overhead exhaust pipe in the counter-
weight. Tighten the capscrews to 38 N•m (28 lbf ft).
6. On early model lift trucks only, remove the metal
heat shield from the left and right engine exhaust EPA COMPLIANT LPG/GAS ENGINE
pipes. EXHAUST SYSTEM
7. Disconnect the left and right engine exhaust pipes Remove
from each other.
NOTE: If the lift truck does not have an overhead ex-
8. Remove the left and right engine exhaust pipes haust, perform Step 2 and Step 4 through Step 8. If
from the engine exhaust manifolds. the lift truck has an overhead exhaust, perform Step 1
through Step 3 and Step 5 through Step 8.
Install
1. Remove the overhead exhaust pipe from the coun-
NOTE: If the lift truck does not have an overhead ex- terweight. See Figure 7.
haust perform Step 1 through Step 5, and Step 7. If
the lift truck has an overhead exhaust perform Step 1 2. Remove the counterweight. See Counterweight
through Step 4 and Step 6 through Step 8. Repair, Remove in this YRM.
1. Install the left and right engine exhaust pipes on the 3. Remove the lower exhaust pipe from the right side
engine exhaust manifolds. See Figure 5. of the muffler and the upper exhaust pipe from the
left side of the muffler.
2. Connect the left and right engine exhaust pipes to
each other. 4. Remove the counterweight exhaust pipe from the
right side of the muffler and the upper exhaust pipe
3. On early model lift trucks only, install the metal heat from the left side of the muffler.
shield on the left and right engine exhaust pipes.
5. Disconnect upper exhaust pipe from the left and
4. Connect the intermediate upper exhaust pipe to the right-side engine exhaust pipes.
left-side engine exhaust pipe and connect the up-
per exhaust pipe to the intermediate upper exhaust 6. Remove the metal heat shield from the left and right
pipe. engine exhaust pipes.
5. Connect the upper exhaust pipe to the left side of 7. Disconnect the electrical connector from the oxy-
the muffler and install the counterweight exhaust gen sensor. Remove oxygen sensor from the en-
pipe on the right side of the muffler. gine exhaust pipes. Inspect oxygen sensor and if it
is damaged or broken, replace with new sensor.
6. Connect the upper exhaust pipe to the left side of
the muffler and connect the lower exhaust pipe to 8. Remove the left and right engine exhaust pipes
the right side of the muffler. from the engine exhaust manifolds. See Figure 7.

11
Exhaust System Repair 100 YRM 726

Figure 7. EPA Compliant LPG/GAS Exhaust System

12
100 YRM 726 Exhaust System Repair

Legend for Figure 7

1. GASKET 12. MUFFLER
2. HEX HEAD BOLT 13. WASHER
3. SPRING 14. NUT
4. SEAL 15. MUFFLER MOUNTING BRACKET
5. UPPER EXHAUST PIPE 16. COUNTERWEIGHT EXHAUST PIPE
6. LEFT ENGINE EXHAUST PIPE 17. ISOLATOR
7. CLAMP 18. PLUG
8. RIGHT ENGINE EXHAUST PIPE 19. OXYGEN SENSOR
9. HEAT SHIELD SLEEVE 20. LOWER EXHAUST PIPE
10. WIRE HARNESS (CLOSED LOOP) 21. OVERHEAD EXHAUST PIPE
11. HEAT SHIELD 22. CAPSCREW

Install DIESEL ENGINE EXHAUST PIPE

NOTE: If the lift truck does not have an overhead ex- Remove
haust, perform Step 1 through Step 5 and Step 7. If
the lift truck has an overhead exhaust, perform Step 1 NOTE: If the lift truck does not have an overhead ex-
through Step 4 and Step 6 through Step 8. haust, perform Step 2 and Step 4 through Step 7. If
the lift truck has an overhead exhaust, perform Step 1
1. Install the left and right engine exhaust pipes to the through Step 3 and Step 5 through Step 7.
engine exhaust manifolds. See Figure 7.
1. Remove the overhead exhaust pipe from the coun-
2. Before installing the oxygen sensor, apply a small terweight. See Figure 8.
amount of antiseize compound. Install the oxygen
sensor to the engine exhaust pipes. Tighten sensor 2. Remove the counterweight. See Counterweight
to 39 N•m (29 lbf ft). Connect the electrical connec- Repair, Remove in this YRM.
tor to the oxygen sensor.
3. Remove the lower exhaust pipe from the right side
3. Install the metal heat shield to the engine exhaust of the muffler and disconnect the upper exhaust
pipes. pipe from the left side of the muffler.

4. Connect upper exhaust pipe to the left and right- 4. Remove the counterweight exhaust pipe from the
side engine exhaust pipes. right side of the muffler and disconnect the upper
exhaust pipe from the left side of the muffler.
5. Connect the upper exhaust pipe to the left side of
the muffler and install the counterweight exhaust 5. Remove the heat shield from the upper exhaust
pipe on the right side of the muffler. pipe and intermediate upper exhaust pipe. Remove
the upper exhaust pipe from the intermediate ex-
6. Connect the lower exhaust pipe from the right side haust pipe.
of the muffler and the upper exhaust pipe from the
left side of the muffler. 6. Remove the intermediate exhaust pipe from the en-
gine exhaust pipe.
7. Install the counterweight. See Counterweight Re-
pair, Install in this YRM. 7. Remove the engine exhaust pipe from the exhaust
manifold.
8. Install the overhead exhaust pipe in the counter-
weight. Tighten the capscrews to 38 N•m (28 lbf ft).

13
Exhaust System Repair 100 YRM 726

1. MUFFLER 12. HEAT SHIELD SLEEVE

2. LOWER EXHAUST PIPE 13. COUNTERWEIGHT EXHAUST PIPE
3. CLAMP 14. BRACKET
4. UPPER EXHAUST PIPE 15. HEX HEAD BOLT
5. INTERMEDIATE EXHAUST PIPE 16. WASHER
6. ENGINE EXHAUST PIPE 17. ISOLATOR
7. ADAPTER 18. NUT
8. OVERHEAD EXHAUST PIPE 19. WASHER
9. HEX HEAD BOLT 20. HEX HEAD BOLT
10. SPRING 21. WASHER
11. SEAL 22. ENGINE EXHAUST MANIFOLD

Figure 8. Diesel Exhaust System

14
100 YRM 726 Engine Repair

Install 4. Connect the upper exhaust pipe to the left side of

the muffler and install the counterweight exhaust
NOTE: If the lift truck does not have an overhead ex- pipe on the right side of the muffler.
haust, perform Step 1 through Step 4 and Step 6. If
the lift truck has an overhead exhaust, perform Step 1 5. Connect the upper exhaust pipe to the left side of
through Step 4 and Step 6 and Step 7. the muffler. Connect the lower exhaust pipe to the
right side of the muffler.
1. Install the engine exhaust pipe on the exhaust man-
ifold. See Figure 8. 6. Install the counterweight. See Counterweight Re-
pair, Install in this YRM.
2. Connect the intermediate exhaust pipe to the en-
gine exhaust pipe. 7. If removed, install the overhead exhaust pipe on the
counterweight. Tighten the capscrews to 38 N•m
3. Connect the upper exhaust pipe to the intermediate (28 lbf ft).
exhaust pipe. Install the heat shield on the upper
exhaust pipe and intermediate exhaust pipe.

Engine Repair
REMOVE c. Remove the capscrews for the universal joints
from the hydraulic pump drive line at the crank-
1. Remove the overhead guard. Remove the floor shaft and move the drive line out of the way.
plates.
d. Disconnect the engine wiring harness from the
2. Disconnect the cables at the battery. Remove the main wiring harness.
battery and the battery tray.
e. Disconnect the exhaust pipe from the muffler.
3. Disconnect the fuel lines at the engine. Disconnect Remove the air filter housing from the frame.
the throttle linkage at the engine. Disconnect the
wires and wiring harnesses at the engine. f. Connect a lifting device to the engine. Make
sure the lifting device has a capacity of at least
4. Disconnect the hydraulic line between the main 450 kg (992 lb).
control valve and the hydraulic oil tank.
g. Support the transmission by placing a jack-
5. Remove the engine only as described in the follow- stand under the transmission housing.
ing steps:
h. Remove the engine mount capscrews and
a. Remove the brake pedal assembly as follows washers at the fan end of the engine.
(see Figure 9): Disconnect the wires at the
brake switch. Disconnect the brake lines at the NOTE: The bolts being removed in Step i are a one-
brake booster/master cylinder and put plugs time usage type of bolt and must be discarded when
and caps on the openings. Disconnect the removed.
inching link at the transmission. Remove the
spring from the inching link. Remove the return i. Bar the engine over at the crankshaft and
spring from the inching pedal. Remove the four remove and discard the torque converter flex
capscrews at the top of the pedal bracket. Re- plate bolts. When all of the bolts have been
move the pedal assembly from the lift truck. removed, move the engine forward just enough
to break the engine loose from the transmis-
b. Disconnect the wiring harness and throttle ca- sion.
ble for the accelerator or Foot Directional Con-
trol pedal. Remove the pedal assembly from j. Carefully lift the engine from the frame. Make
the frame. sure all the connections have been removed
and that the torque converter does not come
out at the same time as the engine.

15
Engine Repair 100 YRM 726

1. FOOT DIRECTIONAL CONTROL PEDAL 5. INCHING LINKAGE

2. ACCELERATOR PEDAL 6. RETURN SPRING
3. PEDAL BRACKET 7. INCHING CRANK RETURN SPRING
4. BRAKE BOOSTER/MASTER CYLINDER 8. INCH/BRAKE PEDAL
ASSEMBLY

Figure 9. Pedal Assembly

16
100 YRM 726 Engine Repair

6. Remove the engine and powershift transmission as j. Connect a lifting device to the engine. Make
described in the following steps: sure the lifting device has a capacity of at least
700 kg (1500 lb).
a. Remove the radiator, fan, and fan shroud. See
Radiator Repair, Remove in this section. Dis- k. Remove the capscrews that hold the transmis-
connect the exhaust pipe from the muffler. Re- sion to the differential housing. Remove the en-
move the air filter housing from the frame. gine mount capscrews at the fan end of the en-
gine.
b. Put the lift truck on blocks. See the Operating
Manual for the correct procedures to put the lift l. Carefully lift the engine from the frame. As the
truck on blocks. engine is being lifted from the frame, make sure
all connections have been disconnected.
NOTE: Tag hydraulic hoses and fittings as they are dis-
connected to aid in reconnecting the hoses. m. Remove the powershift transmission from the
engine as described in the section Two-Speed
c. Disconnect the hydraulic hoses from the steer- Powershift Transmission, Troubleshooting
ing control unit. Install caps on the steering and Repairs 1300 YRM 728 or Single-Speed
control unit and plugs on the hydraulic hoses. Powershift Transmission, Troubleshooting
and Repair 1300 YRM 752.
d. Disconnect the horn wire at the steering col-
umn. Remove the capscrews that hold the
INSTALL
steering column and steering control unit to the
operator’s module. Remove the steering col- 1. Install the engine and powershift transmission as
umn assembly. follows:
e. Disconnect the wiring harness and throttle ca- a. See the section Two-Speed Powershift
ble for the accelerator or Foot Directional Con- Transmission, Troubleshooting and Re-
trol pedal. Remove the pedal assembly from pairs 1300 YRM 728 and install the powershift
the frame. transmission on the engine.
f. Remove the brake pedal assembly as follows b. Connect a lifting device to the engine. Make
(see Figure 9): Disconnect the wires at the sure the lifting device has a capacity of 700 kg
brake switch. Disconnect the brake lines at the (1500 in.).
master cylinder and put plugs and caps on the
openings. Disconnect the inching link at the c. Install the engine assembly in the lift truck. In-
transmission. Remove the spring from the inch- stall the capscrews and washers for the engine
ing link. Remove the return spring from the mounts. Tighten the capscrews to the correct
inching pedal. Remove the four capscrews at torque values as shown in Figure 10.
the top of the pedal bracket. Remove the pedal
assembly from the lift truck. d. Install the capscrews that mount the transmis-
sion to the drive axle. Tighten the capscrew to
g. Remove the transmission oil filter. Drain the oil 66 N•m (49 lbf ft).
from the transmission.
e. Connect the transmission oil lines to the trans-
h. Disconnect the linkages at the transmission. mission. Connect the transmission wiring har-
Disconnect the wires at the transmission. Dis- ness to the transmission. Connect the linkages
connect the transmission oil lines from the to the transmission.
transmission.
f. Install the transmission oil filter and fill the
i. Remove the axle shafts from the drive axle. transmission with oil specified in Capacities
and Specifications 8000 YRM 738.

17
Engine Repair 100 YRM 726

g. Install the brake pedal assembly as follows (see Legend for Figure 10
Figure 9): Install the pedal assembly on the
lift truck. Install the four capscrews at the top NOTE: A = 165 N•m (122 lbf ft).
of the pedal bracket. Install the return spring A. ENGINE MOUNTS (DIESEL SHOWN)
on the inching pedal. Install the spring on the B. ENGINE MOUNT (GAS/LPG SHOWN)
inching link. Connect the inching link to the
transmission. Connect the brake lines to the 1. CAPSCREW 8. REBOUND
master cylinder. Connect the wires to the brake 2. WASHER WASHER
3. WASHER 9. BUMPER
switch. 4. SNUBBING CUP 10. SPACER
5. ISOLATOR 11. FRAME
h. Install the Foot Directional Control or accelera- 6. ENGINE MOUNT 12. SHIM*
tor pedal to the frame. Connect the wiring har- 7. NUT
ness and throttle cable for the Foot Directional
Control pedal or accelerator. *ROTATE ENGINE AROUND DRIVE AXLE CENTER-
LINE UNTIL LH OR RH MOUNT CONTACTS. USE A
i. Install the steering wheel or install the steering MAXIMUM OF THREE SHIMS (12), ON THE OTHER
column and steering control unit to the bracket SIDE TO LESS THAN 1.0 mm (0.03937 in.).
on the frame. Connect the four hydraulic hoses
to the steering control unit as noted during re- k. Remove the lift truck from the blocks.
moval. Connect the horn wire at the steering
2. Install the engine only as described in the following
column.
steps:
j. Connect the hydraulic hoses as noted during
a. Connect a lifting device to the engine. Make
removal to the steering control unit.
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 10.

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 9): Install the pedal assembly in the lift
truck. Install the four capscrews at the top of the
Figure 10. Engine Mounts
pedal bracket. Install the return spring on the

18
100 YRM 726 Throttle Pedal Adjustment

inching pedal. Install the spring from the inch- fan, and fan shroud. See Radiator Repair, Install in
ing link. Connect the inching link at the trans- this section.
mission. Connect the brake lines at the brake
booster/master cylinder. Connect the wires at 6. Install the alternator on units with a diesel engine.
the brake switch. Install the battery and the battery tray. Connect the
cables to the battery.
3. Connect the hydraulic line between the main control
valve and the hydraulic oil tank. 7. Install the overhead guard.

4. Connect the fuel lines at the engine. Connect the 8. Check all of the fluid levels and fill as necessary.
throttle linkage at the engine. Connect the wires Install the floor plates and covers. Connect the ca-
and wiring harnesses at the engine. bles at the battery.

5. Install the air filter housing on the frame. Connect

the exhaust pipe to the muffler. Install the radiator,

Throttle Pedal Adjustment

PERKINS 1104C-44(RE) DIESEL ENGINE Lift Trucks With an Accelerator Pedal
NOTE: The procedures below are for lift trucks 1. Adjust the cable adjustment nuts to allow for a
equipped with the Perkins 1104C-44(RE) Diesel 3.0 mm (0.12 in.) maximum of free play on the
Engine. If your lift truck has either a gas or LPG en- throttle cable length. See Figure 11. Secure cable
gine, see the section LPG Fuel System 900 YRM 745 length by tightening cable lock nuts.
for the procedures to adjust the throttle linkage.

1. ACCELERATOR PEDAL 4. CABLE LOCKNUTS

2. DIESEL INJECTOR PUMP 5. CAPSCREW STOP
3. CABLE ADJUSTMENT NUTS 6. JAM NUT

Figure 11. Accelerator Pedal Adjustment

19
Throttle Pedal Adjustment 100 YRM 726

2. Depress the accelerator pedal until the diesel injec- cable when the injection pump lever is returned to
tor pump is in the full power position (the injection the idle position (see Figure 12). Tighten up posi-
pump lever is touching the lever stop in Figure 12). tion pedal stop with capscrew. See Figure 13.

3. Turn capscrew stop (see Figure 11) 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.

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 13. Secure cable
length by tightening cable locknuts.

2. Set pedal stop to 35 ±2 mm (1.40 ±0.08 in.). Secure NOTE: DIESEL INJECTOR PUMP IS SHOWN IN THE
in place with pedal stop jam nuts. IDLE POSITION.
3. With the pedal against the stop, adjust the throttle 1. INJECTION PUMP LEVER
cable to ensure that the diesel injector pump is at 2. LEVER STOP
full power (the injection pump lever is touching the
lever stop in Figure 12). Figure 12. Diesel Injector Pump

4. Release the throttle pedal and adjust the up posi-

tion pedal stop until the tension is removed from the

20
100 YRM 726 Throttle Pedal Adjustment

1. MONOTROL PEDAL 5. PEDAL STOP JAM NUTS

2. DIESEL INJECTOR PUMP 6. PEDAL STOP
3. CABLE ADJUSTMENT NUTS 7. UP POSITION PEDAL STOP
4. CABLE LOCKNUTS 8. CAPSCREW

Figure 13. Foot Directional Control Pedal Adjustment

21
Fuel and Hydraulic Tanks Repair 100 YRM 726

Fuel and Hydraulic Tanks Repair

INSPECT when heated. Wear eye and face protection. Protect
the body from burns.
Make a visual inspection of all sides of the tank. Inspect
the welds for cracks and leakage. Check for wet areas, When cleaning with steam, use a hose with a minimum
accumulation of dirt, and loose or missing paint caused diameter of 19 mm (0.75 in.). Control the pressure of
by leakage. Areas of the tank that are not easily seen the steam by a valve installed at the nozzle of the hose.
can be checked with an inspection mirror and a light that If a metal nozzle is used, it must be made of a material
is approved for locations with flammable vapors. that does not make sparks. Make an electrical connec-
tion between the nozzle and the tank. Connect a ground
SMALL LEAKS, REPAIR wire to the tank to prevent static electricity.

Use the following procedure to repair small leaks: Steam Method

Use the following procedure to clean the tank with
WARNING
steam:
Do not use tools that can make sparks, heat, or
static electricity. The vapors in the tank can cause 1. Remove all the parts from the tank. Install the drain
an explosion. plug.
1. Use steam to clean the area around the leak. Re- 2. Fill the tank 1/4 full with a solution of water and
move all paint and dirt around the leak. sodium bicarbonate or sodium carbonate. Mix
0.5 kg (1 lb) per 4 liter (1 gal) of water.
2. Apply Loctite® 290 to the leak. Follow the instruc-
tions of the manufacturer. 3. Mix the solution in the tank using air pressure.
Make sure all the surfaces on the inside of the tank
LARGE LEAKS, REPAIR are flushed with the solution. Drain the tank.
1. Use one of the procedures described under Clean 4. Put steam into the tank until the tank does not have
to clean and prepare the tank for repairs. odors and the metal is hot. Steam vapors must
come from all the openings.
2. Use acceptable welding practices to repair the
tank. See the American National Standard Safety 5. Flush the inside of the tank with boiling water. Make
In Welding and Cutting AWS Z 49.1 - 1999. sure all the loose material is removed from the in-
side of the tank.
CLEAN
6. Make an inspection of the inside of the tank. If it
WARNING is not clean, repeat Step 4 and Step 5 and make
another inspection. When making inspections, use
Special procedures must be followed when large
a light that is approved for locations with flammable
leaks or other repairs need welding or cutting. All
vapors.
work must be done by authorized personnel. If the
tank is cleaned inside a building, make sure there is 7. Put plugs in all the openings in the tank. Wait 15
enough ventilation. See the following manuals for minutes; then remove the inlet and outlet plugs.
additional information: Test a sample of the vapor with a special indicator
• Safe Practices For Welding And Cutting Contain- for gas vapors. If the amount of flammable vapors is
ers That Have Held Combustibles by the Ameri- above the lower flammable limit, repeat the clean-
can Welding Society, F4.1 - 1999. ing procedures.
• 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

22
100 YRM 726 Safety Labels

Chemical Solution Method Make another inspection of the tank. When mak-
ing inspections, use a light that is approved for lo-
If the tank cannot be cleaned with steam, use the fol- cations with flammable vapors.
lowing procedure:
5. Check the tank for flammable vapors using a
1. Mix a solution of water and trisodium phosphate or special indicator for gas vapors. If the amount of
a cleaning compound with an alkali base. Follow flammable vapors is not below the lower flammable
the instructions given by the manufacturer. limit, repeat the cleaning procedures.

WARNING OTHER PREPARATION METHODS FOR

Compressed air can move particles so that they REPAIR
cause injury to the user or to other personnel.
• If nitrogen gas or carbon dioxide gas is available, pre-
Make sure that the path of the compressed air is
pare the tank for welding using these gases. See
away from all personnel. Wear protective goggles
the manual Safe Practices For Welding and Cutting
or a face shield to prevent injury to the eyes.
Containers That Have Held Combustibles American
2. Fill the tank with the cleaning solution. Use com- Welding Society, F4.1 - 1999. If these gases are not
pressed air to mix the solution in the tank. available, another method using water can be used
as follows:
3. Drain the tank. Flush the inside of the tank with • Fill the tank with water to just below the point where
hot (boiling) water. Make sure all the cleaning com- the work will be done. Make sure the space above
pound is removed. the level of the water has a vent.

4. Make an inspection of the inside of the tank. If the

tank is not clean, repeat Step 1 through Step 3.

Safety Labels
WARNING WARNING
Safety labels are installed on the lift truck to give Cleaning solvents can be flammable and toxic and
information about operation and possible hazards. can cause skin irritation. When using cleaning sol-
It is important that all safety labels are installed on vents, always follow the recommendations of the
the lift truck and can be read. manufacturer.

DO NOT add to or modify the lift truck. Any change 1. Make sure the surface is dry and has no oil or
to the lift truck, its tires, or its equipment can grease. Do not use solvent on new paint. Clean
change the lifting capacity. The lift truck must be the surface of old paint using a cleaning solvent.
rated as equipped, and the nameplate must show
the new capacity rating. Contact your dealer for 2. Remove the paper from the back of the label. Do
Yale lift trucks for a replacement nameplate. not touch the adhesive surface.

If necessary, install new and correct labels as follows 3. Carefully hold the label in the correct position above
(see Figure 14): 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.

23
Safety Labels 100 YRM 726

Figure 14. Label Positions

24
100 YRM 726 Safety Labels

Legend for Figure 14

1. MAST WARNING 16. MAST WARNING
2. YALE LABEL 17. PINCH POINT WARNING
3. NO RIDERS 18. OPERATOR WARNING
4. HOIST HANDLE LABEL 19. OPERATOR RESTRAINT LABEL
5. TILT HANDLE LABEL 20. NAMEPLATE
6. PATENTS AND TRADEMARKS 21. FLAMMABLE LP GAS LABEL
7. IMPACT WARNING LABEL 22. RADIAL TIRE WARNING (OPTIONAL) LABEL
8. NAMEPLATE COVER 23. UL FUEL-TYPE WARNING LABEL
9. FAN WARNING 24. LPG TANK LABEL
10. FAN WARNING (PICTORIALLY) 25. FIRE SAFETY LABELS
11. PARK BRAKE WITHOUT SEAT BRAKE 26. BATTERY DISCONNECT LABEL
12. ANTIFREEZE LABEL 27. AUXILIARY FUNCTION LABEL
13. YALE LABEL 28. DIESEL POWER LABEL (DIESEL TRUCKS
14. DRIVETRAIN PROTECTION ONLY)
15. YALE LABEL

25
 NOTES

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26
 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

100 YRM 726 6/04 (5/04)(11/03)(1/03)(8/02) Printed in U.S.A.