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SERVICE MANUAL CONTENTS
PART YRM REV
SECTION NUMBER NUMBER DATE
OPERATOR'S CAB........................................................................................................ 550033400 0100 YRM 1390 11/13
CAB HEATER................................................................................................................. 550033398 0100 YRM 1459 08/12
FRAME............................................................................................................................ 550061801 0100 YRM 1594 08/12
CUMMINS ENGINE FAULT CODE GUIDE.................................................................... 524211827 0600 YRM 1101 07/14
COOLING SYSTEM........................................................................................................ 550061806 0700 YRM 1595 09/13
ZF TRANSMISSION OPERATION AND DIAGNOSTICS............................................... 550035502 1300 YRM 1455 09/13
TRANSMISSION REPAIR (ZF-WG161)......................................................................... 550035503 1300 YRM 1456 08/12
DIFFERENTIAL............................................................................................................... 524150779 1400 YRM 0046 08/12
PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. 524150780 1400 YRM 0944 08/12
STEERING SYSTEM...................................................................................................... 550035504 1600 YRM 1479 08/12
BRAKE AND HYDRAULIC COOLING SYSTEM........................................................... 550035505 1800 YRM 1498 03/13
HYDRAULIC SYSTEM.................................................................................................... 550035506 1900 YRM 1478 11/14
HYDRAULIC CONTROL SYSTEM................................................................................. 550035498 2200 YRM 1481 08/12
ELECTRICAL SYSTEM.................................................................................................. 550061811 2200 YRM 1592 09/13
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..................................................................................................................... 550061816 8000 YRM 1591 10/13
PERIODIC MAINTENANCE............................................................................................ 550061821 8000 YRM 1593 07/12
CAPACITIES AND SPECIFICATIONS........................................................................... 550061826 8000 YRM 1596 07/13
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
PART NO. 550061831 (12/14)
0100 YRM 1459 MCC Heater and Air Conditioner

MCC Heater and Air Conditioner


HEATER SYSTEM Cabs that are equipped with an air conditioner have
an electrically controlled vent door that can be used to
General vary the percentage of recirculated air between 0 and
100 percent. The operator can select the position of
Lift trucks with a closed cab are equipped with a the vent door by turning a knob on the dashboard.
heater assembly which is installed on the underside of Cooling performance increases by reducing the
the cab. The main components of the heater percentage of incoming fresh air.
assembly are the fan, heater core, vent door, and an
evaporator for the optional air conditioning system. Recirculated air enters the heater assembly through
See Figure 1. the openings in the side console at the fuse cover.
Fresh air enters the heater assembly through the cab
air filter, which is located at the left rear corner of the
cab. As the filter becomes restricted or clogged, the
percentage of recirculated air will increase and the
percentage of fresh air will decrease.

When fresh air content and fan speed is increased,


positive air pressure is created in the cab, preventing
dust from entering the cab. The air pressure escapes
through the cab door posts and through openings in
the pedal area and sliding window brush profiles.

When the fan is switched ON, air is pushed through


channels in the cab floor to the air ducts at the front
window. Cabs that are equipped with an air
conditioner have three additional vents at the foot
area that can be opened or closed. Cooling capacity
is increased by opening the three vents. When the
three vents are open, air flow is less restricted,
A. RECIRCULATED AIR increased air volume passes through the evaporator,
B. FRESH AIR ENTRY and the majority of the air no longer becomes warm in
C. CAB AIR FLOW the air channels that lead to the front window. See
1. VENT DOOR Figure 2.
2. VENT DOOR ACTUATOR
3. EVAPORATOR CORE The heater consists of a heater core and a water
4. HEATER CORE valve. See Figure 1. The water valve controls the flow
5. BLOWER of heated coolant to the heater core. By varying the
6. THERMOSTAT
7. WATER VALVE opening of the water valve, the desired amount of
8. EXPANSION VALVE heat is transferred by the heater core to the air that
enters the cab. The water valve opens proportionally
Figure 1. Heater/Airco Assembly Components to the selected position of the heat control knob. On
standard units the knob and valve are connected
mechanically, on units with an Air Conditioning
The vent door determines the percentage of fresh air system there is an electronic connection.
and recirculated air that the fan pulls through the
heater assembly. In heater assemblies without an air
conditioner, the vent door is in a fixed position and
allows for an air mixture of 85% fresh air and 15%
recirculated air.

1
MCC Heater and Air Conditioner 0100 YRM 1459

that are connected in series. The operator must


switch ON the button for the air conditioning system
and select one of the fan switch speeds. Refer to the
electrical schematic SRM pertaining to each lift truck,
for the schematic locations and interconnections of
the sensors and switches.

The compressor compresses the refrigerant and


continuously pumps the refrigerant through the air
conditioning system. As the refrigerant is being
compressed, the refrigerant temperature will rise. The
absorbed heat is dissipated in the condenser, which is
installed outside the cab. Fans at the condenser
accelerate heat dissipation.

After the refrigerant passes through the condenser,


the liquefied refrigerant passes through the dryer that
also serves as a reservoir for the refrigerant. At the
expansion valve, the refrigerant will expand in the
evaporator, causing the temperature of the refrigerant
to drop substantially. The expansion valve regulates
the flow of the refrigerant, depending on the pressure
difference between the dryer and the compressor
inlet. A minimum pressure difference is necessary to
open the valve. After leaving the evaporator, the
A. OPTIONAL AIR VENT refrigerant will reenter the compressor.
B. AIR TO FRONT WINDOW
C. CAB AIR FLOW Dryer
D. FRESH AIR ENTRY
1. CAB AIR FILTER The refrigerant functions as a coolant, and contains
Figure 2. Ventilation lubricant for the compressor. Because humidity
affects the properties of the refrigerant and the
lubricant, a dryer is installed to absorb the trapped
AIR CONDITIONING humidity. The dryer also filters impurities in the
refrigerant.
General
Normal refrigerant leakage is approximately 10% per
CAUTION year. To help prevent additional leakage through the
Replacement, installation, and repairs to air compressor seals, the air conditioning system should
conditioning units that require discharging and/or be operated at least every two weeks for 15 minutes.
refilling of the refrigeration fluid may only be The air conditioning system cannot be operated at
performed by a certified technician. temperatures below 0°C (32°F) because the anti-ice
switch will prevent the compressor clutch from being
The air conditioning system consists of a compressor activated.
with an electromagnetic clutch, condenser, dryer,
evaporator, and interconnected sensors and switches. The dryer, refrigerant, and lubricant must be replaced
See Figure 3. every three years. Contact a certified technician every
three years to perform these repairs.
The engine drives the compressor when the clutch at
the compressor has been activated. Activation of the
clutch is determined by several sensors and switches

2
0100 YRM 1459 MCC Heater and Air Conditioner

1. CONDENSER 6. EVAPORATOR
2. SERVICE CONNECTION, HIGH PRESSURE 7. EXPANSION VALVE
3. COMPRESSOR 8. RESERVOIR
4. SERVICE CONNECTION, LOW PRESSURE 9. DRYER
5. ANTI-ICE SENSOR 10. PRESSURE SWITCH

Figure 3. Refrigerant Cycle

Compressor Lubrication of the pressure switches is open, the clutch will


disengage and the air conditioning system will not
The oil specification for the compressor is indicated activate.
on the nameplate of the compressor.
Water in the air condensates on the evaporator.
Most of the compressors used on Big Truck air Normally, the condensated water drips on the bottom
conditioning systems use SP-15 oil. plate of the heater assembly and escapes through
two hoses that open into the engine compartment. If
the condensated water becomes ice, the air flow
The compressor on QSM-11 engines requires ZXL through the evaporator will be blocked, which will
100PG oil. block the entire cab ventilation system. The anti-ice
switch protects the evaporator against ice buildup by
Control Systems, Sensors, and Switches opening at -1°C (30.2°F), causing the clutch to
disengage and allowing air to warm the evaporator.
The air conditioning system (A/C) is activated by The anti-ice switch, which is inserted between the fins
pushing the A/C switch on the dashboard and of the evaporator, will close when the temperature
selecting one of the fan speeds. A control light in the reaches 2.3°C (36.14°F). The anti-ice sensor is
A/C switch will illuminate, and the fans on the indicated by "T" on the electrical schematic.
condenser will turn. The anti-ice switch and the
pressure switches must be closed before the clutch
engages the compressor. If the anti-ice switch or one

3
MCC Heater and Air Conditioner 0100 YRM 1459

The pressure switches are located at the dryer, and


protect the system against pressures that are too low CAUTION
or too high. See Figure 4. If the system pressure NEVER bypass the electric clutch of the air
drops below 2 bar (29 psi), the refrigerant level is too conditioning compressor. If the clutch does not
low for proper functioning of the system and proper receive a signal, there is either an insufficient
lubrication of the compressor. amount of refrigerant, or the condenser or the
evaporator is iced, and the pressure switch will
not be enabled to protect the system against
excessive pressure. If the clutch does not receive
a signal, contact a certified and qualified air
conditioning specialist. Bypassing the
compressor will ALWAYS lead to system damage.

The pressure switch, as installed on the dryer,


physically combines the high and low pressure
switches and their electrical interconnection. The
pressure switch is indicated by "P1" on the electrical
schematic.

The pressure switch has an integrated third function


called the medium pressure switch. The medium
pressure switch changes the connection to the fans
on the condenser, causing them to turn at a higher
speed when pressure in the system has exceeded
16 bar (232 psi). At lower pressures, the fans are
connected in series, causing them to turn at a lower
speed. The medium pressure switch is indicated by
"P2" on the electrical schematic.

1. CONDENSER COVER
CLIMATE CONTROL
2. CONDENSER COIL
3. SIGHT GLASS Description
4. DRYER
5. PRESSURE SWITCH Functionality of the individual components of the
6. FAN normal air conditioning systems and the Climate
Figure 4. Condenser Control system is the same. The difference is that for
the Climate Control a controller sends the signals to
High system pressure is a recurrent situation. The the components instead of the manually operated
evaporator valve has a limited flow capacity. The knobs on the dashboard for the normal system. This
refrigerant flow generated by the compressor Controller is part of the control unit on the dashboard
fluctuates with engine speed, and regularly exceeds that also has a display and a select button. The
the flow capacity of the evaporator valve. When the display provides information on mode, temperature,
flow capacity of the evaporator valve is exceeded, the blower speed and fault conditions. An explanation of
compressor will have raised system pressure to the the normally available information and settings is in
maximum allowable level. The pressure switch will the Operating Manual.
send a signal to disengage the compressor clutch,
and the evaporator valve will continue to regulate The explanation for how to read information and apply
refrigerant flow. Pressure will drop until the pressure settings for service purposes is described under
switch is enabled, causing the clutch to reengage. Service Menu.
System pressure will rise again until the maximum
allowable level has been reached.

4
0100 YRM 1459 MCC Heater and Air Conditioner

Service Menu The date format is Month/Day/Year. To set the date,


go to Set Up screen and push the Set Button until it
1. Push the Power Button to turn the HVAC unit ON. flashes digital for "Month". Turn the Set Button until
See Figure 5. the correct month number appears and push the
button to confirm. The digits for "Day" will now flash.
2. Pressing the Set Button scrolls the screen
Repeat the procedure to set "Day" and "Year". When
between:
finished, turn the knob to scroll to the Exit screen and
• Climate Control Mode Settings push the button to leave the service menu.
• Air Circulation Settings
View 1 and View 2
• Display Settings
There are two View pages that show readings and
actual setting of the HVAC unit. After leaving the
previous service screen "Set Up", screen View 1 will
appear. Push the button to scroll between screen
View 1 and screen View 2 (see Figure 6).

Screen "View 1" displays below information:


• Scale - Selected temperature scale: Cel for
Celsius or Fah for Fahrenheit.
• Setpoint - Selected (desired) interior
temperature.
1. POWER BUTTON 2. SET BUTTON • Inside - Cab interior temperature as measured
by the Inside Sensor.
Figure 5. Climate Control
• Outside - Cab exterior temperature as
measured by the Outside Sensor.
3. Press the set button to scroll to the Air Circulation • Deice - Temperature of the refrigerant leaving
Settings. the evaporator coil.
• Coil - Temperature of the air at the blower.
4. Push and hold the Power Button, and turn the Set
Button three clicks clockwise to enter one of the • Heat - Flapper door position: Fresh or Recirc.
service menu selections:
Screen "View 2" displays below information:
• Set Up (Not an option for Hyster Lift trucks)
• AC - Indicates whether Air conditioning Mode
• View
is switched ON or OFF.
• Error List
• Heater - Indicates whether Heating Mode is
• Statistics switched ON or OFF.
• Exit • Blower - Indicates the selected percentage of
maximum blower speed.
To scroll to a next service screen, turn the Set
Button one click clockwise. Push the Set Button to • D Heat Fan - Indicates the selected blower
enter the selected service screen. Turning the Set speed percentage for an additional interior
Button after the Exit screen further clockwise will heater.
bring you back to the Set Up screen. To leave the • Valve - Indicates the percentage of maximum
Service Menu scroll to Exit and push the Set heater valve opening that the controller sends
Button. out as a signal.
• Contrast - Indicates the contrast percentage of
Set Up
the display.
The Set Up screen allows setting the date and the • Brightness - Indicates the brightness
blower speed for an additional interior heater. An percentage of the display.
additional interior heater is not a standard option.

5
MCC Heater and Air Conditioner 0100 YRM 1459

In case a temperature sensor is disconnected, the


display will show "open". Comparison of the different
values may provide an indication for a possible
defect.

Figure 8. Climate Control Error Display

To further establish the cause of failure, see


Temperature Sensors or Water Valve.
Figure 6. Climate Control View Display
To reset the number of occurrences and the reset
Error List date, turn the Set Button one click in a counter
clockwise direction and push the Set Button for a
The Main Display shows a warning sign in the left dialog box. When the dialog box is shown, press the
hand bottom corner of the Main Display if a fault Set Button once to reset all values.
occurs. See Figure 7.
Statistics

The Statistics page shows operating hours and cycle


times since the last reset date. To reset the Statistics
Page, go to the Error Page, turn the Set Button one
click counter clockwise. A dialog box will appear.
When the dialog box is shown, press the Set Button
once to reset all values. See Figure 9.

1. WARNING SIGN
Figure 7. Climate Control Warning

The Error List page shows for each of the


temperature sensors and for the water valve the
number of occurrences that the connection was Figure 9. Climate Control Statistics Display
shortened or open since the last reset date. For the
Water Valve there is an additional indication for the
number of times that the Water Valve was stuck. See
Figure 8.

6
0100 YRM 1459 MCC Heater and Air Conditioner

Exit Table 1. Sensor Resistance Values (Continued)

To leave the Service menu scroll to Exit and push the °C °F k?


Set Button. 15 59 15,713
20 68 12,493
Temperature Sensors
25 77 10,000
In addition to the normally present de-ice temperature 30 86 8,056
sensor in the evaporator, there are three further
temperature sensors that influence the reaction of the
Water Valve
controller:
• Outside Temperature Sensor, which is located Fault indication "Valve Stuck" indicates a physical
outside the cab under the condenser. obstruction that prevents the valve from moving. The
• Coil sensor, which is located behind the physical obstruction may have its cause at the outside
evaporator and heater coil, in the suctioned air or inside of the water valve. The components of the
flow of the blower fan. water valve are not serviced separately. Replace the
water valve if there is no obvious problem that can be
• Inside Sensor, which is located in the side
rectified.
console, measures the cab interior
temperature. Interior air flow past the sensor is
Troubleshooting
through a tube that connects between suction
side of the blower fan and inside sensor.
When a fault for open or short circuit has been
indicated, use a volt meter to measure the voltage
Troubleshooting over the different connections. Measures can be
taken at either the connector of the water valve or at
Disconnect the sensor for which an error has been
the controller connector. See Table 2. There are also
indicated. Use an Ohm meter to measure its
two 15 amp fuses located in the wiring system check
resistance. See Table 1 that provides an overview of
these if a fault for open or short circuit has been
the resistance value for different temperatures. The
indicated. For location of theses fuses see Figure 11.
electrical properties of the four sensors are the same.
When the sensor itself shows no defects, check
Table 2. Water Valve Pin Outs
continuity of the wiring harness. See Figure 10. The
sensors are connected to the controller connector at Water Controller Value
the following pin numbers: Valve
• Inside Sensor: Pin 14 and 32. Pin 8 Pin 31 ground
• Outside Sensor: Pin 4 and 33 Pin 10 Pin 30 3.3 Volt
• De-Ice Sensor: Pin 13 and 24 Pin 9 Pin 5 0.6 Volt when valve
• Coil Sensor: Pin 12 and 34 is closed. 2.2 Volt
when valve is open.
Table 1. Sensor Resistance Values Pin 6 Pin 18 12 Volt when the
°C °F k? valve is closing. 0
Volt when opening or
0 32 32,649 not moving.
5 41 25,394 Pin 5 Pin 19 12 Volt when the
10 50 19,903 valve is opening. 0
Volt when closing or
not moving.

7
MCC Heater and Air Conditioner 0100 YRM 1459

Figure 10. Climate Control Wiring Diagram

8
0100 YRM 1459 MCC Heater and Air Conditioner

1. 15A FUSES

9
MCC Heater and Air Conditioner 0100 YRM 1459

Figure 11. Standard A/C Wiring Diagram

STANDARD HEATER ASSEMBLY


Access

WARNING
Make sure no one is under cab when raising or
lowering cab.

WARNING
Before placing any part of your body under cab,
always make sure the cab is fully tilted, or when
partially open, is locked using the tilt latch.

To access the heater assembly, raise the cab to the


fully open position. Support the heater assembly, then
remove the three screws holding the heater assembly
in place. Lower the heater assembly down, remove
screws and the cover plate. Individual components
are now accessible.

Remove

WARNING
Before removing the heater hoses, make sure the 1. CABLE CLIP
heater hoses are cool. Hot coolant may cause 2. EXTENDED CABLE (FULL HOT POSITION)
severe burns. 3. NUT
4. KNOB LOCATION
1. Remove the four screws that retain the fuse panel 5. ROTARY CONTROL
cover to the right side of the instrument panel and Figure 12. Rotary Control
remove the cover to gain access to the underside
of the instrument panel. See Fuse Panel and
Cover Location.
WARNING
2. Remove the heat control knob at the instrument
panel top console. See Switch Locations. DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
3. Remove the nut that retains the rotary control to pressure cap is removed, pressure is released
the instrument panel top console. See Figure 12. from the system. If the system is hot, the steam
and boiling coolant can cause burns.
4. Remove the rotary control assembly for the water
valve from the underside of the instrument panel 6. Remove the pressure cap to release the pressure
top console and place it with the cable on the and place it back on the radiator expansion tank.
heater assembly.
7. Tilt/raise the cab to the fully open position. Refer
5. Disconnect the wire harness from the fan speed to the section Raising and Lowering Cab.
knob at the underside of the instrument panel top
console. 8. Tag and disconnect the two heater hoses from
the heater inlet and outlet ports, and plug the
heater hoses and ports. See Figure 13.

10
0100 YRM 1459 MCC Heater and Air Conditioner

3. Support the heater assembly and install the


capscrews to retain the heater assembly to the
hinge brackets. Do not tighten capscrews at this
time.

4. Swing the heater assembly up toward the cab and


install the three capscrews to retain the heater
assembly to the cab. See Figure 13 for the
location of the capscrews.

5. Tighten the two capscrews at the hinge bracket.

6. Remove the plugs and connect the heater hoses


to the inlet and outlet ports.

7. Lower the cab to the fully lowered and latched


1. HEATER HINGE BRACKET
2. HEATER ASSEMBLY CAPSCREW LOCATION position. Refer to the section Raising and
3. HEATER OUTLET Lowering Cab.
4. HEATER INLET
8. Connect the outer cable to the rotary control as
Figure 13. Heater Assembly described in the section Push/Pull Cable
Replacement, Water Valve Cable, Install.

NOTE: The heater assembly fits tightly underneath 9. Connect the inner cable to the rotary control as
the cab and will require a limited amount of force to described in the section Push/Pull Cable
swing the heater assembly down and away from the Replacement, Heater/Air Conditioner Assembly,
cab. Install.

9. Loosen the two nuts and capscrews at the hinge 10. Connect the wire harness for the fan speed knob
bracket. Remove the three capscrews that retain to the connector at the underside of the
the heater assembly to the cab. Pull the heater instrument panel top console.
assembly downwards and push simultaneously
11. Install the rotary control assembly for the water
towards the hinge bracket to provide sufficient
valve to the underside of the instrument panel top
clearance between heater assembly and cab
console.
frame. See Figure 13 for the location of the
capscrews. 12. Install the nut to retain the rotary control to the
instrument panel top console. See Figure 12.
10. Make sure the wire harness and the cable control
are free and can be removed together with the 13. Install the heat control knob at the instrument
heater assembly. panel top console. See Switch Locations.
11. Support the heater assembly and remove the 14. Position the fuse panel cover to the right side of
capscrews that retain the heater assembly to the the instrument panel and install the four screws.
hinge brackets. See Fuse Panel and Cover Location.
12. Remove the heater assembly from the underside 15. If required, fill the coolant to the correct level.
of the cab. Refer to the manual .

Install 16. Start the engine and warm the engine to normal
operating temperature.
1. Position the heater assembly to the underside of
the cab. 17. Make sure the heater functions correctly.

2. Route the cable harness and cable control


correctly to the inside of the instrument panel box.

11
MCC Heater and Air Conditioner 0100 YRM 1459

STANDARD HEATER PARTS 6. Remove the top cover from the heater assembly.
REPLACEMENT
7. Loosen the hose clamp and disconnect the top
Heater Core heater hose from the heater core, located
between the heater core and the water valve. See
Remove Figure 14.

8. Remove the two capscrews that retain the heater


WARNING core bracket to the inside of the heater assembly.
Before removing the heater hoses, make sure the See Figure 15.
heater hoses are cool. Hot coolant may cause
severe burns.

WARNING
When replacing the heater hoses, make sure the
replacement hoses meet correct specifications.
Failure to meet specifications may cause personal
injury.

WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
1. BOTTOM HEATER HOSE
1. Remove the pressure cap to release the pressure 2. WATER VALVE
and place it back on the radiator expansion tank. 3. TOP HEATER HOSE
4. HEATER CORE
2. Tilt/raise the cab to the fully open position. Refer 5. HOSE CLAMP
to the section Raising and Lowering Cab.
Figure 14. Heater Water Valve
3. Loosen the hose clamp and disconnect the heater
inlet hose from the heater core pipe located at the
underside of the heater assembly and plug the
heater hose.

NOTE: The heater assembly fits tightly underneath


the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.

4. Loosen the two nuts and capscrews at the hinge


bracket. Remove the three capscrews that retain
the heater assembly to the cab. Pull the heater
assembly downwards and push simultaneously
towards the hinge bracket to provide sufficient
clearance between heater assembly and cab
frame. See Figure 13 for the location of the
capscrews.

5. Remove the 10 screws that retain the top cover to


the heater assembly.
Figure 15. Heater Assembly Components

12
0100 YRM 1459 MCC Heater and Air Conditioner

Legend for Figure 15 NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
1. HEATER CORE swing the heater assembly down and away from the
2. BLOWER
3. WATER VALVE cab.
4. HEATER CORE BRACKET
5. HEATER CORE BRACKET CAPSCREWS 2. Remove the three capscrews that retain the
heater assembly to the cab and swing the heater
assembly down. See Figure 13 for the location of
9. Remove the heater core bracket from the heater the capscrews.
assembly.
3. Remove the 10 screws that retain the top cover to
10. Slide the heater core out of the heater assembly. the heater assembly.

4. Remove the top cover from the heater assembly.


Install
5. Tag and disconnect the electrical connector
1. Slide the heater core into the heater assembly.
connected to the blower assembly. See
2. Position the heater core bracket to the inside of Figure 16.
the heater assembly and install the two retaining
6. Remove the four screws that retain the blower to
capscrews.
the heater assembly housing. See Figure 17.
3. Connect the top heater hose to the heater core
and tighten the hose clamp.

4. Position the top cover on the heater assembly.

5. Install the 10 screws to retain the top cover to the


heater assembly.

6. Swing the heater assembly up toward the cab and


install the three capscrews to retain the heater
assembly to the cab. See Figure 13 for the
location of the capscrews.

7. Connect the heater inlet hose to the heater core


pipe located at the underside of the heater
assembly and tighten the hose clamp.

8. Lower the cab to the fully lowered and latched


position. Refer to the section Raising and
Lowering Cab.

9. Add coolant as needed. Refer to the manual .

10. Start the engine and check for leaks. Add coolant
as needed.

11. Make sure the heater functions correctly.


1. ELECTRICAL CONNECTOR
Blower
Figure 16. Blower Electrical Connector
Remove
1. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.

13
MCC Heater and Air Conditioner 0100 YRM 1459

3. Install the four screws to retain the blower to the


heater assembly housing. See Figure 17.

4. Connect the electrical connector to the blower


assembly. See Figure 16.

5. Position the top cover on the heater assembly.

6. Install the 10 screws to retain the top cover to the


heater assembly.

7. Swing the heater assembly up toward the cab and


install the three capscrews to retain the heater
assembly to the cab. See Figure 13 for the
location of the capscrews.

8. Lower the cab to the fully lowered and latched


1. BLOWER RETAINING CAPSCREWS position. Refer to the section Raising and
Figure 17. Blower Retaining Screws Lowering Cab.

9. Make sure the blower functions correctly.


7. Partially remove the blower assembly from the
heater assembly housing and tag and disconnect Water Valve
the four electrical wires from the blower assembly.
See Figure 18. Remove

8. Remove the blower assembly from the heater


assembly housing. WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.

WARNING
When replacing the heater hoses, make sure the
replacement hoses meet correct specifications.
Failure to meet specifications may cause personal
injury.

WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
1. ELECTRICAL WIRE CONNECTION
Figure 18. Blower Electrical Wire Connection 1. Remove the pressure cap to release the pressure
and place it back on the radiator expansion tank.

Install 2. Turn the heat control knob on the instrument


panel counterclockwise to the fully open position
1. Connect the electrical wires to the blower or (full hot position). See Switch Locations .
assembly. See Figure 18.
3. Tilt/raise the cab to the fully open position. Refer
2. Position the blower assembly into the heater to the section Raising and Lowering Cab.
assembly housing.

14
0100 YRM 1459 MCC Heater and Air Conditioner

NOTE: The heater assembly fits tightly underneath 9. Swing the heater assembly up toward the cab and
the cab and will require a limited amount of force to install the three capscrews to retain the heater
swing the heater assembly down and away from the assembly to the cab. See Figure 13 for the
cab. location of the capscrews.

4. Remove the three capscrews that retain the 10. Lower the cab to the fully lowered and latched
heater assembly to the cab and swing the heater position. Refer to the section Raising and
assembly down. See Figure 13 for the location of Lowering Cab.
the capscrews.
11. Add coolant as needed. Refer to the manual .
5. Remove the 10 screws that retain the top cover to
the heater assembly. 12. Start the engine and check for leaks. Add coolant
as needed.
6. Remove the top cover from the heater assembly.
13. Make sure the heat control knob functions
7. Remove the cable clip that retains the outer cable correctly.
to the water valve.
PUSH/PULL CABLE REPLACEMENT
8. Remove the snap ring that retains the inner cable
to the water valve and disconnect the inner cable Water Valve Cable
from the water valve.
Remove
9. Loosen the two hose clamps that retain the water
valve between the heater hoses. See Figure 14. 1. Turn the heat control knob on the instrument
panel counterclockwise to the fully open position
10. Disconnect the two heater hoses from the water or the (full hot position). See Switch Locations .
valve.
2. Remove the four screws that retain the fuse panel
11. Remove the water valve from the heater cover to the right side of the instrument panel and
assembly. remove the cover to gain access to the underside
of the instrument panel. See Fuse Panel and
Install Cover Location.
1. Make sure the heat control knob in the cab is in 3. Remove the heat control knob at the instrument
the full hot position panel top console. See Switch Locations.
2. Position the water valve between the two heater 4. Remove the nut that retains the rotary control
hoses inside the heater assembly. See Figure 14. assembly to the instrument panel top console.
See Figure 12.
3. Connect the two heater hoses to the water valve
and tighten the hose clamps. 5. Remove the cable clip that retains the outer cable
to the rotary control assembly.
4. Connect the inner cable to the water valve and
install the snap ring to retain the inner cable to the 6. Remove the snap ring that retains the inner cable
water valve. to the rotary control and remove the inner cable
from the rotary control.
5. Push the lever of the water valve towards the
heater core until it reaches its final position. Hold 7. Raise the cab to the fully open position. Refer to
the lever and push the outer cable towards the the section Raising and Lowering Cab.
water valve.
NOTE: The heater assembly fits tightly underneath
6. Install and tighten the cable clip to retain the outer the cab and will require a limited amount of force to
cable to the water valve. swing the heater assembly down and away from the
cab.
7. Position the top cover on the heater assembly.

8. Install the 10 screws to retain the top cover to the


heater assembly.

15
MCC Heater and Air Conditioner 0100 YRM 1459

8. Remove the three capscrews that retain the 11. Hold the inner cable extended and pull the outer
heater assembly to the cab and swing the heater cable away from the rotary control.
assembly down. See Figure 13.
12. Install the cable clip to retain the outer cable to
9. Remove the 10 screws that retain the top cover to the rotary control assembly.
the heater assembly.
13. Make sure the heat control knob functions
10. Remove the top cover from the heater assembly. correctly.

11. Remove the cable clip that retains the outer cable 14. Install the rotary control assembly to the
to the water valve. underside of the instrument panel top console.

12. Remove the snap ring that retains the inner cable 15. Install the nut to retain the rotary control assembly
to the water valve and disconnect the inner cable to the instrument panel top console. See
from the water valve. Figure 12.

13. Remove the water valve cable from the 16. Install the heat control knob at the instrument
instrument panel box and heater assembly. panel top console. See Switch Locations.

Install 17. Position the fuse panel cover to the right side of
the instrument panel and install the four retaining
1. Position the water valve cable inside the screws. See Fuse Panel and Cover Location.
instrument panel box and heater assembly.
Heater/Air Conditioner Assembly
2. Connect the inner cable to the water valve and
install the snap ring to retain the inner cable to the Remove
water valve.

3. Push the lever of the water valve towards the WARNING


heater core until it reaches its final position. Before removing the heater hoses, make sure the
Position the outer cable until it extends a few mm heater hoses are cool. Hot coolant may cause
out of the cable clip. severe burns.
4. Install and tighten the cable clip to retain the outer 1. Turn the key switch to the ON position.
cable to the water valve.
2. Place the recirculation knob on the instrument
5. Position the top cover on the heater assembly. panel in position 1 or position 2.
6. Install the 10 screws to retain the top cover to the 3. Turn the key switch to the OFF position.
heater assembly.
4. Remove the four screws that retain the fuse panel
7. Swing the heater assembly up toward the cab and cover to the right side of the instrument panel and
install the three capscrews to retain the heater remove the cover to gain access to the underside
assembly to the cab. See Figure 13. of the instrument panel. See Fuse Panel and
Cover Location.
8. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and 5. Disconnect the wire harness for the fan speed
Lowering Cab. knob, heater knob, and recirculation knob from
the connectors at the underside of the instrument
9. Turn the rotary control into the (full hot position).
panel top console.
See Figure 12.
6. Tag and disconnect the electrical wires for the air
10. Connect the inner cable to the rotary control and
conditioner switch at the underside of the
install the snap ring to retain the inner cable to the
instrument panel top console.
rotary control. See Figure 12.

16
0100 YRM 1459 MCC Heater and Air Conditioner

11. Disconnect and plug the hose fittings leading to


WARNING the evaporator.
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the NOTE: The heater assembly fits tightly underneath
pressure cap is removed, pressure is released the cab and will require a limited amount of force to
from the system. If the system is hot, the steam swing the heater assembly down and away from the
and boiling coolant can cause burns. cab.

7. Remove the pressure cap to release the pressure 12. Loosen the two nuts and capscrews at the hinge
and place it back on the radiator expansion tank. bracket. Remove the three capscrews that retain
the heater assembly to the cab. Pull the heater
8. Tilt/raise the cab to the fully open position. Refer assembly downwards and push simultaneously
to the section Fuse Panel and Cover Location. towards the hinge bracket to provide sufficient
clearance between heater assembly and cab
9. Tag and disconnect the two heater hoses from frame. See Figure 19 for the location of the
the heater inlet and outlet ports and plug the capscrews.
heater hoses and ports. See Figure 19.
13. Make sure the wire harness is free and can be
removed together with the heater/air conditioner
CAUTION assembly.
Repairs to the air conditioning system that require
discharging and/or refilling of the refrigeration 14. Disconnect the electrical connector on top of the
fluid must be performed only by a certified air top cover from the actuator that controls the vent
conditioning specialist. door position.

10. Contact a certified air conditioning specialist to 15. Support the heater/air conditioner assembly and
have the refrigerant extracted from the air remove the capscrews that retain the heater/air
conditioning system. conditioner assembly to the hinge brackets.

16. Remove the heater/air conditioner assembly from


the underside of the cab.

Install
1. Position the heater/air conditioner assembly to the
underside of the cab.

2. Support the heater/air conditioner assembly and


install the capscrews to retain the heater/air
conditioner assembly to the hinge brackets. Do
not tighten the capscrews at this time.

3. Connect the electrical connector on top of the top


cover to the actuator that controls the vent door
position.

4. Route the wire harness correctly to the side


1. HEATER INLET instrument panel box.
2. HEATER OUTLET
3. HEATER ASSEMBLY CAPSCREW LOCATION 5. Swing the heater/air conditioner assembly up
4. CONDENSATION DRAINS toward the cab and install the three screws to
5. AIR CONDITIONING OUTLET retain the heater/air conditioner assembly to the
6. AIR CONDITIONING INLET cab. See Figure 19 for the location of the
7. HEATER HINGE BRACKET
capscrews.
Figure 19. Heater/Air Conditioner Assembly
6. Tighten the two nuts and capscrews at the hinge
bracket.

17
MCC Heater and Air Conditioner 0100 YRM 1459

7. Remove the plugs and connect the heater hose to 4. Tilt/raise the cab to the fully open position. Refer
the inlet and outlet ports. to the section Raising and Lowering Cab.

8. Connect the hose fittings leading to the NOTE: The heater assembly fits tightly underneath
evaporator. the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
CAUTION
Repairs to the air conditioning system that require 5. Remove the three capscrews that retain the
discharging and/or refilling of the refrigeration heater/air conditioner assembly to the cab and
fluid must be performed only by a certified air swing the heater/air conditioner assembly down.
conditioning specialist. See Figure 19 for the location of the capscrews.

9. Contact a qualified and certified technician to 6. Disconnect the electrical connector on top of the
have the air conditioning system filled with top cover from the actuator that controls the vent
refrigerant. See Air Conditioning Technical Detail, door position. See Figure 20.
Table 3 for the type and the amount of refrigerant
required to charge an evacuated A/C system. 7. Remove the 12 screws that retain the top cover to
the heater/air conditioner assembly.
10. Lower the cab to the fully lowered and latched
position. Refer to the section Raising and 8. Remove the top cover from the heater/air
Lowering Cab. conditioner assembly.

11. Connect the electrical wires for the air 9. Remove the washer located on top of the nylon
conditioning switch at the underside of the bushing.
instrument panel top console. 10. Remove the capscrew, two nuts, two washers,
12. Connect the wire harness for the fan speed knob, and lock washer that retain the vent door to the
heater knob, and recirculation knob to the actuator that is located on the top cover.
connectors at the underside of the instrument 11. Remove the vent door.
panel top console.

13. Add coolant as needed. Refer to the manual .

14. Position the fuse panel cover to the right side of


the instrument panel and install the four retaining
screws. See Fuse Panel and Cover Location.

15. Make sure the heater/air conditioner functions


correctly. Turn the recirculation knob a few times
to the fully open and fully closed positions to be
sure that the recirculation functions correctly.

HEATER/AIR CONDITIONER PARTS


REPLACEMENT
Vent Door

Remove 1. ELECTRICAL CONNECTOR


2. VENT DOOR ACTUATOR
1. Turn the key switch to the ON position. 3. TOP COVER
2. Turn the recirculation knob located on the Figure 20. Electrical Connector Location of Vent
instrument panel to position 1 or position 2. See Door Actuator
Switch Locations.

3. Turn the key switch to the OFF position.

18
0100 YRM 1459 MCC Heater and Air Conditioner

Install
WARNING
1. Position the vent door and install the capscrew, Before removing the heater hoses, make sure the
two nuts, two washers, and lock washer to retain heater hoses are cool. Hot coolant may cause
the vent door to the actuator on the top cover. severe burns.
NOTE: Make sure the nylon bushing and washer are
correctly positioned inside the heater/air conditioner WARNING
assembly. DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
2. Position the top cover on the heater/air
pressure cap is removed, the pressure is released
conditioner assembly and make sure the pin at
from the system. If the system is hot, the steam
the underside of the vent door is positioned in the
and boiling coolant can cause burns.
washer and nylon bushing.
4. Remove the pressure cap to release the pressure
3. Install the 12 screws to retain the top cover to the
and place it back on the radiator expansion tank.
heater/air conditioner assembly.
5. Tilt/raise the cab to the fully open position. Refer
4. Connect the electrical connector on top of the top
to the section Raising and Lowering Cab.
cover to the actuator that controls the vent door
position. See Figure 20. 6. Loosen the hose clamp and disconnect the inlet
heater hose from the heater core pipe located at
5. Swing the heater/air conditioner assembly up
the underside of the heater/air conditioner
toward the cab and install the three capscrews to
assembly. Plug the inlet heater hose. See
retain the heater/air conditioner assembly to the
Figure 19.
cab. See Figure 19 for the location of the
capscrews. NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
6. Lower the cab to the fully lowered and latched
swing the heater assembly down and away from the
position. Refer to the section Raising and
cab.
Lowering Cab.
7. Remove the three capscrews that retain the
NOTE: The key switch much be turned to the ON
heater/air conditioner assembly to the cab and
position before performing the following step.
swing the heater/air conditioner assembly down.
7. Turn the recirculation knob a few times from the See Figure 19 for the location of the capscrews.
fully open position to the fully closed position to
8. Disconnect the electrical connector on top of the
be sure that the recirculation system functions
top cover from the actuator that controls the vent
correctly. See Switch Locations.
door position. See Figure 20.
Heater Core 9. Remove the 12 screws that retain the top cover to
the heater/air conditioner assembly.
Remove
10. Remove the top cover from the heater/air
1. Turn the key switch to the ON position. conditioner assembly.
2. Turn the recirculation knob located on the 11. Remove the washer that is positioned on top of
instrument panel to position 1 or position 2. See the nylon bushing.
Switch Locations.
12. Tag and disconnect the two electrical connectors
3. Turn the key switch to the OFF position. from the thermostat. See Figure 21.

19
MCC Heater and Air Conditioner 0100 YRM 1459

13. Loosen the hose clamp that retains the top heater NOTE: The key switch much be turned to the ON
hose to the heater core inside the heater/air position before performing the following step.
conditioner assembly and disconnect the heater
hose from the heater core. 11. Turn the recirculation knob a few times from the
fully open position to the fully closed position to
14. Slide the heater core out of the heater/air be sure that the recirculation system functions
conditioner assembly. correctly. See Switch Locations.

Install Evaporator Core


1. Slide the heater core into the heater/air Remove
conditioner assembly.
1. Turn the key switch to the ON position.
2. Connect the top heater hose between the water
valve and heater core to the heater core and 2. Turn the recirculation knob located on the
tighten the hose clamp. See Figure 21. instrument panel to position 1 or position 2. See
Switch Locations.
3. Connect the two electrical connectors to the
thermostat. 3. Turn the key switch to the OFF position.

NOTE: Make sure the nylon bushing and washer are


correctly positioned inside the heater/air conditioner
assembly.

4. Position the top cover on the heater/air


conditioner assembly and make sure the pin at
the underside of the vent door is positioned in the
washer and nylon bushing.

5. Install the 12 screws to retain the top cover to the


heater/air conditioner assembly.

6. Connect the electrical connector on top of the top


cover to the actuator that controls the vent door
position. See Figure 20.

7. Swing the heater/air conditioner assembly up


toward the cab and install the three capscrews to
retain the heater/air conditioner assembly to the
cab. See Figure 19 for the correct location of the
capscrews. 1. THERMOSTAT
2. ELECTRICAL CONNECTION POINTS
8. Connect the inlet heater hose to the heater core 3. TOP HEATER HOSE
pipe located at the underside of the heater/air 4. HOSE CLAMP
conditioner assembly and tighten the hose clamp. 5. HEATER CORE
6. WATER VALVE
9. Lower the cab to the fully lowered and latched 7. BOTTOM HEATER HOSE
position. Refer to the section Raising and 8. BRACKET CAPSCREW (INNER)
9. BRACKET CAPSCREW (OUTER)
Lowering Cab. 10. WATER VALVE BRACKET
10. Start the engine and check for leaks. Add coolant Figure 21. Thermostat, Water Valve, and Heater
as needed. Refer to the manual for the correct Hoses
coolant specifications.

20
0100 YRM 1459 MCC Heater and Air Conditioner

11. Remove the 12 screws that retain the top cover to


WARNING the heater/air conditioner assembly.
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause 12. Remove the top cover from the heater/air
severe burns. conditioner assembly.

13. Remove the washer that is positioned on top of


WARNING the nylon bushing.
DO NOT remove the pressure cap from the
14. Remove the blower. Refer to the section Blower,
expansion tank when the engine is hot. When the
Remove.
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam 15. Remove the water valve. Refer to the section
and boiling coolant can cause burns. Water Valve, Remove.
4. Remove the pressure cap to release the pressure 16. Remove the two clips that retain the evaporator
and place it back on the radiator expansion tank. core inside the heater/air conditioner assembly.
See Figure 22.
5. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.

CAUTION
Repairs to the evaporator core that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a trained and
certified air conditioning specialist.

6. Contact a certified technician to have the


refrigerant extracted from the air-conditioning
system. See Air Conditioning Technical Detail,
Table 3 for the type and amount of refrigerant
required to charge an evacuated A/C system.

7. Tag and disconnect the two evaporator hoses that


are connected to the expansion block at the
1. EVAPORATOR CORE CLIP
underside of the heater/air conditioner assembly.
See Figure 19. Figure 22. Evaporator Core Clips
8. Remove the two capscrews that retain the
expansion block bracket to the bottom plate of the
17. Slide the evaporator core out of the heater/air
heater/air conditioner assembly. See Figure 23.
conditioner assembly.
NOTE: The heater assembly fits tightly underneath
18. Remove the expansion block from the evaporator
the cab and will require a limited amount of force to
core pipes.
swing the heater assembly down and away from the
cab.
Install
9. Remove the three capscrews that retain the
1. Install the expansion block to the evaporator core
heater/air conditioner assembly to the cab and
pipes.
swing the heater/air conditioner assembly down.
See Figure 19 for the correct location of the 2. Slide the evaporator core into the heater/air
capscrews. conditioner assembly. Make sure the expansion
block is positioned correctly at the underside of
10. Disconnect the electrical connector on top of the
the heater/air conditioner assembly.
top cover from the actuator that controls the vent
door position. See Figure 20.

21
MCC Heater and Air Conditioner 0100 YRM 1459

3. Install the two clips to retain the evaporator core


inside the heater/air conditioner assembly. See CAUTION
Figure 22. Repairs to the evaporator core that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a trained and
certified air conditioning specialist.

11. Connect the two evaporator hoses to the


expansion block at the underside of the heater/air
conditioner assembly.

12. Lower the cab to the fully lowered and latched


position. Refer to the section Raising and
Lowering Cab.

13. Start the engine and check for leaks. Add coolant
as needed, see .

14. Turn the recirculation knob a few times from the


fully open position to the fully closed position to
be sure that the recirculation system functions
1. EXPANSION BRACKET CAPSCREWS properly. See Switch Locations.
Figure 23. Expansion Bracket Capscrews
Blower

Remove
4. Install the two capscrews to retain the expansion
block bracket to the bottom plate of the heater/air 1. Turn the key switch to the ON position.
conditioner assembly. See Figure 23.
2. Turn the recirculation knob located on the
5. Install the water valve. Refer to the section Water instrument panel to position 1 or position 2. See
Valve, Install. Switch Locations.
6. Install the blower. Refer to the section Blower, 3. Turn the key switch to the OFF position.
Install.
4. Tilt/raise the cab to the fully open position. Refer
NOTE: Make sure the nylon bushing and washer are to the section Raising and Lowering Cab.
correctly positioned inside the heater/air conditioner
assembly. NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
7. Position the top cover on the heater/air swing the heater assembly down and away from the
conditioner assembly and make sure the pin at cab.
the underside of the vent door is positioned in the
washer and nylon bushing. 5. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
8. Install the 12 screws to retain the top cover to the swing the heater/air conditioner assembly down.
heater/air conditioner assembly. See Figure 19 for the correct location of the
capscrews.
9. Connect the electrical connector on top of the top
cover to the actuator that controls the vent door 6. Disconnect the electrical connector on top of the
position. See Figure 20. top cover from the actuator that controls the vent
door position. See Figure 20.
10. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews to 7. Remove the 12 screws that retain the top cover to
retain the heater/air conditioner assembly to the the heater/air conditioner assembly.
cab. See Figure 19 for the correct location of the
capscrews.

22
0100 YRM 1459 MCC Heater and Air Conditioner

8. Remove the top cover from the heater/air 9. Lower the cab to the fully lowered and latched
conditioner assembly. position. Refer to the section Raising and
Lowering Cab.
9. Remove the washer that is positioned on top of
the nylon bushing. 10. Make sure the blower functions correctly.

10. Tag and disconnect the electrical connector Thermostat


connected to the blower assembly. See
Figure 16. Remove
11. Remove the four screws and nuts that retain the 1. Turn the key switch to the ON position.
blower inside the heater/air conditioner assembly.
See Figure 17. 2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2. See
12. Partially remove the blower assembly from the Switch Locations.
heater/air conditioner assembly housing and tag
and disconnect the four electrical wires from the 3. Turn the key switch to the OFF position.
blower assembly. See Figure 18.

13. Remove the blower assembly from the heater/air WARNING


conditioner assembly housing. Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
Install severe burns.

1. Connect the four electrical wires to the blower


assembly. See Figure 18. WARNING
DO NOT remove the pressure cap from the
2. Position the blower assembly into the heater/air expansion tank when the engine is hot. When the
conditioner assembly. pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
3. Install the four screws and nuts to retain the
and boiling coolant can cause burns.
blower inside the heater/air conditioner assembly.
See Figure 17. 4. Remove the pressure cap to release the pressure
and place it back on the radiator expansion tank.
4. Connect the electrical connector to the blower
assembly. See Figure 16. 5. Tilt/raise the cab to the fully open position. Refer
to the section Raising and Lowering Cab.
NOTE: Make sure the nylon bushing and washer are
correctly positioned inside the heater/air conditioner NOTE: The heater assembly fits tightly underneath
assembly. the cab and will require a limited amount of force to
swing the heater assembly down and away from the
5. Position the top cover on the heater/air
cab.
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in the 6. Remove the three capscrews that retain the
washer and nylon bushing. heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly down.
6. Install the 12 screws to retain the top cover to the
See Figure 19.
heater/air conditioner assembly.
7. Disconnect the electrical connector on top of the
7. Connect the electrical connector on top of the top
top cover from the actuator that controls the vent
cover to the actuator that controls the vent door
door position. See Figure 20.
position. See Figure 20.
8. Remove the 12 screws that retain the top cover to
8. Swing the heater/air conditioner assembly up
the heater/air conditioner assembly.
toward the cab and install the three capscrews to
retain the heater/air conditioner assembly to the 9. Remove the top cover from the heater/air
cab. See Figure 19. conditioner assembly.

23
MCC Heater and Air Conditioner 0100 YRM 1459

10. Remove the washer that is positioned on top of 2. Install the nut and washer located outside the
the plastic bushing. heater/air conditioner assembly to retain the
thermostat inside the heater/air conditioner
11. Tag and disconnect the two electrical connectors assembly.
from the thermostat. See Figure 21.
3. Install the temperature switch to the evaporator
12. Loosen the hose clamp that retains the top heater core. See Figure 24.
hose to the water valve inside the heater/air
conditioner assembly and disconnect the heater 4. Connect the top heater hose between the water
hose. valve and heater core to the water valve and
tighten the hose clamp.
13. Remove the temperature switch from the
evaporator core. See Figure 24. 5. Connect the two electrical connectors to the
thermostat. See Figure 21.

NOTE: Make sure the nylon bushing and washer are


correctly positioned inside the heater/air conditioner
assembly.

6. Position the top cover on the heater/air


conditioner assembly and make sure the pin at
the underside of the vent door is positioned in the
washer and nylon bushing.

7. Install the 12 screws to retain the top cover to the


heater/air conditioner assembly.

8. Connect the electrical connector on top of the top


cover to the actuator that controls the vent door
position. See Figure 20.

9. Swing the heater/air conditioner assembly up


toward the cab and install the three capscrews to
retain the heater/air conditioner assembly to the
cab. See Figure 19.

10. Lower the cab to the fully lowered and latched


position. Refer to the section Raising and
Lowering Cab.

1. TEMPERATURE SWITCH 11. Start the engine and check for leaks. Add coolant
as needed. Refer to Periodic Maintenance
Figure 24. Temperature Switch
manual for your lift truck.

14. Remove the nut and washer located outside the 12. Turn the recirculation knob a few times from the
heater/air conditioner assembly that retains the fully open position to the fully closed position to
thermostat inside the heater/air conditioner be sure that the recirculation system functions
assembly. correctly. See Switch Locations.

15. Remove the thermostat and temperature switch Water Valve


from the heater/air conditioner assembly.
Remove
Install
1. Turn the key switch to the ON position.
1. Position the thermostat and temperature switch
inside the heater/air conditioner assembly and
correctly route the temperature switch.

24
0100 YRM 1459 MCC Heater and Air Conditioner

2. Turn the recirculation knob located on the 12. Loosen the two hose clamps that retain the top
instrument panel to position 1 or position 2. See heater hose between the water valve and heater
Switch Locations. core.

3. Turn the key switch to the OFF position. 13. Remove the top heater hose and the two hose
clamps between the water valve and heater core.
WARNING 14. Loosen the hose clamp that retains the bottom
Before removing the heater hoses, make sure the heater hose to the water valve.
heater hoses are cool. Hot coolant may cause
severe burns. 15. Remove the two capscrews located at the outside
of the heater/air conditioner assembly that retain
the water valve bracket to the heater/air
WARNING conditioner assembly.
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the 16. Disconnect the electrical connector from the water
pressure cap is removed, the pressure is released valve actuator.
from the system. If the system is hot, the steam
17. Loosen the hose clamp and disconnect the
and boiling coolant can cause burns.
bottom heater hose from the water valve.
4. Remove the pressure cap to release the pressure
18. Remove the water valve bracket from the
and place it back on the radiator expansion tank.
heater/air conditioner assembly.
5. Tilt/raise the cab to the fully open position. Refer
19. Remove the two screws that retain the water
to the section Raising and Lowering Cab.
valve to the water valve bracket.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to Install
swing the heater assembly down and away from the
1. Position the water valve to the water valve
cab.
bracket and install the two retaining screws.
6. Remove the three capscrews that retain the
2. Position the water valve bracket inside the
heater/air conditioner assembly to the cab and
heater/air conditioner assembly.
swing the heater/air conditioner assembly down.
See Figure 19. 3. Connect the bottom heater hose to the water
valve and tighten the hose clamp.
7. Disconnect the electrical connector on top of the
top cover from the actuator that controls the vent 4. Connect the electrical connector to the water
door position. See Figure 20. valve actuator.
8. Remove the 12 screws that retain the top cover to 5. Install the two capscrews located at the outside of
the heater/air conditioner assembly. the heater/air conditioner assembly to retain the
water valve bracket inside the heater/air
9. Remove the top cover from the heater/air
conditioner assembly. See Figure 21.
conditioner assembly.
6. Install the top heater hose and the two hose
10. Remove the washer that is positioned on top of
clamps between the water valve and heater core.
the plastic bushing.
Tighten the hose clamps.
11. Tag and disconnect the two electrical connectors
7. Connect the two electrical connectors to the
from the thermostat. See Figure 21.
thermostat.

25
MCC Heater and Air Conditioner 0100 YRM 1459

NOTE: Make sure the nylon bushing and washer are 12. Lower the cab to the fully lowered and latched
correctly positioned inside the heater/air conditioner position. Refer to the section Raising and
assembly. Lowering Cab.

8. Position the top cover on the heater/air 13. Start the engine and check for leaks. Add coolant
conditioner assembly and make sure that the pin as needed. Refer to Periodic Maintenance
at the underside of the vent door is positioned in manual for your lift truck.
the washer and nylon bushing.
14. Turn the heat control knob a few times from the
9. Install the 12 screws to retain the top cover to the fully open position to the fully closed position to
heater/air conditioner assembly. be sure that the heating system functions
properly. See Switch Locations.
10. Connect the electrical connector on top of the top
cover to the actuator that controls the vent door AIR CONDITIONING TECHNICAL DETAIL
position. See Figure 20.
NOTE: Table 3 provides technical details. It is
11. Swing the heater/air conditioner assembly up intended for use by a certified air conditioning
toward the cab and install the three capscrews specialist.
that retain the heater/air conditioner assembly to
the cab. See Figure 19.

Table 3. Air Conditioning Specifications

Compressor Values
Lubricant Type PAG See Compressor Nameplate
Lubricant Quantity 200 grams
Suction Port 7/8-14 UNF
Discharge Port 3/4-16 UNF
Refrigerant
Refrigerant R134a
Fill Capacity 1300 ± 25 grams
Pressure Switch
High pressure OFF 2.70 ±0.2 MPa (392 ±29 psi)
High pressure ON 2.10 ±0.2 MPa (305 ±29 psi)
Med pressure OFF 1.30 ±0.15 MPa (188 ±22 psi)
Med pressure ON 1.60 ±0.13 MPa (232 ±19 psi)
Low pressure OFF 0.20 ±0.02 MPa (29 ±2.9 psi)
Low pressure ON 0.21 ±0.03 MPa (30.5 ±4.4 psi)
Anti-Icing Switch
Opens -1°C (30.2°F)
Closes 2°C (35.6°F)
This chart is intended for use by a certified air conditioning specialist.

26
100 YRM 1594 Description

General
This manual contains the removal and installation in- • Planetary Drive Axle, (Wet System) 1400 YRM 944
structions for major assemblies attached to the frame. • Masts and Carriages, Starting 2003 4000 YRM
The removal and installation procedures for some as- 1062
semblies are described in the following service manu- • Hydraulic System 1900 YRM 1478
als: • Steering System 1600 YRM 1479
• Operator’s Cab 100 YRM 1390

Description
The frame is a weldment with mounts for the major as-
CAUTION semblies. See Figure 1. The mounts are designed
Do not initiate repairs to the frame without consult- to keep the attached parts in position and transfer the
ing a Yale service representative or damage to the forces acting on them.
lift truck may occur.

1
Description 100 YRM 1594

1. MAIN COUNTERWEIGHT MOUNT 8. HYDRAULIC TANK MOUNT


2. COOLING ASSEMBLY MOUNT 9. STEER AXLE MOUNT
3. TILT CYLINDER MOUNT 10. ENGINE MOUNT
4. MAST MOUNT 11. TRANSMISSION MOUNT
5. DRIVE AXLE MOUNT 12. MAIN CONTROL VALVE MOUNT
6. MAIN FRAME 13. CAB TILT CYLINDER MOUNT
7. SIDE TILTING CAB MOUNT

Figure 1. Frame

2
100 YRM 1594 Air Cleaner

Air Cleaner
AIR CLEANER ASSEMBLY, TIER 3/STAGE
III A, F876/F877
Remove
1. Open the left- and right-hand hood doors.

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 precleaner, with the air duct attached,


from the air cleaner.

5. Disconnect the connector from the vacuum switch


by pressing the metal clip.

6. Loosen the hose clamps on the air filter hose and


remove the hose.

7. Remove the bolts of the two air cleaner mounting


clamps.

8. Rotate the air cleaner until the air duct connection


clears the center of the hood opening and move the
air cleaner to the right-hand side of the truck.

9. Remove the retaining hardware from the mounting


clamps and remove the clamps from the hood.

Install
1. Install the retaining hardware to the mounting
1. AIR FILTER HOSE
clamps and install the clamps under the hood. 2. AIR CLEANER ASSEMBLY
3. VACUUM SWITCH
2. Position the air cleaner assembly in the mounting 4. AIR DUCT CLAMP
clamps and tighten the two clamp bolts. 5. PRECLEANER CLAMP
6. PRECLEANER
3. Install the air filter hose and tighten the hose 7. AIR DUCT
clamps. 8. UPPER AIR HOSE CLAMP
9. MOUNTING CLAMP BOLT
4. Connect the vacuum switch connector to the air 10. AIR CLEANER MOUNTING CLAMP
cleaner assembly.
Figure 2. Air Cleaner Assembly, Tier 3/Stage III A,
5. Close the left- or right-hand hood door. F876/F877

6. Install the precleaner, with the air duct attached, on


the air cleaner and install and tighten the air duct
clamp.

7. Close the hood doors.

3
Air Cleaner 100 YRM 1594

AIR CLEANER ASSEMBLY, TIER 4I/STAGE


III B, F876/F877
Remove
1. Open the left- and right-hand hood doors.

2. Loosen the hose clamps on the air filter hose and


remove the hose. See Figure 3.

3. On F877 trucks, tag and disconnect the connectors


to the vacuum switch and to the Temperature and
Barometric Air Pressure (TBAP) sensor.

4. On F876 tag and disconnect the connectors to the


vacuum switch and to the Mass Air Flow (MAF)
Sensor. See Figure 4.

5. Remove the 4 capscrews that retain the brackets of


the air cleaner unit to the hood.

6. Lower the air cleaner unit until it clears the air duct.

7. Move the air cleaner to the right-hand side of the


truck.
1. AIR HOSE
Install 2. AIR CLEANER UNIT
3. VACUUM SWITCH
1. If removed, install the brackets on the cleaner unit. 4. TBAP SENSOR
5. AIR CLEANER BRACKET
2. Verify presence and correct seating of the seal on 6. CAPSCREWS
the air cleaner intake tube 7. PRECLEANER CLAMP
8. AIR PRECLEANER
3. Move the air cleaner into its position under the hood 9. AIR DUCT
and then upwards, until it engages with the air duct.
Figure 3. Air Cleaner Assembly, Tier 4i/Stage III
4. Align the holes in the brackets with the spacers un- B, F877
der the hood.

5. Install the capscrews on the cleaner brackets.

6. On F877 trucks, connect the connectors to the vac-


uum switch and to the Temperature and Barometric
Air Pressure (TBAP) sensor according to tags.

7. On F876 trucks, connect the connectors to the vac-


uum switch and to the Mass Air Flow (MAF) Sensor
according to tags.

8. Install the air filter hose and tighten clamps.

9. Close the hood doors.

4
100 YRM 1594 Exhaust System

Legend for Figure 4


1. AIR HOSE
2. VACUUM SWITCH
3. AIR CLEANER UNIT
4. MAF SENSOR
5. AIR CLEANER BRACKET
6. AIR DUCT
7. PRECLEANER CLAMP
8. AIR PRECLEANER

Figure 4. Air Cleaner Assembly, Tier 4i/Stage III


B, F876

Exhaust System
EXHAUST ASSEMBLY, TIER 3/STAGE III 5. Remove the muffler from the hood.
A, F876/F877
Install
Remove
1. Position the muffler on the hood.

WARNING 2. Install the four capscrews and nuts that retain the
Exhaust system must be at room temperature be- muffler to the hood.
fore starting disassembly or personal injury may
occur. 3. Install the flex tube on the muffler. Do not yet tighten
the clamp.
1. Remove the two clamps from the flex tube. See
Figure 5. 4. Install the exhaust tube and clamp on the engine.

2. Remove the U-bolt that retains the charge air cooler 5. Connect the exhaust tube and flex tube.
tube to the exhaust tube. 6. Install the U-bolt that retains the charge air cooler
3. Remove the clamp that holds the exhaust tube to tube to the exhaust tube.
the engine and remove the exhaust tube and flex 7. Tighten the clamps on the flex tube.
tube.

4. Use a tool to retain the nut when loosening the cap-


screws that retain the muffler to the hood. Remove
the four capscrews and nuts.

5
Exhaust System 100 YRM 1594

3. Loosen the clamps at the bottom of the muffler.

4. Remove the T-bolt strap that retains the muffler to


the muffler bracket.

5. Remove the muffler from the muffler bracket.

6. Remove the 4 capscrews that retain the muffler


bracket to the hood.

7. Remove the muffler bracket from the hood.

8. On F877 trucks, remove the U-bolt that retains the


left-hand charge air cooler tube to the exhaust tube.

9. Remove the left-hand charge air cooler tube.

10. Remove the bolts that retain the hose clamps of the
coolant de-aeration hoses to the heat shield.

11. Loosen the lower clamp from the exhaust tube.

12. Maneuver the exhaust tube out of the engine com-


partment.

Install
1. Maneuver the exhaust tube into the engine com-
partment.

2. Maneuver the upper end through the opening in the


hood. See Figure 6 and Figure 7.
1. FLEX TUBE CLAMP
2. FLEX TUBE 3. Slide the lower end onto the turbocharger and
3. CAPSCREWS tighten the clamp.
4. MUFFLER
5. U-BOLT
6. EXHAUST TUBE 4. Position the hose clamps for the coolant de-aera-
7. EXHAUST TUBE CLAMP tion hoses on the heat shield and install and tighten
the bolts.
Figure 5. Exhaust Assembly, Tier 3/Stage III A,
F876/F877 5. On F877 trucks, install the left-hand charge air
cooler tube and install the U-bolt on the charge air
EXHAUST ASSEMBLY, TIER 4I/STAGE III cooler tube. Tighten the nuts on the U-bolt.
B, F876/F877 6. Install the muffler bracket onto the hood.
Remove 7. Install the 4 capscrews that retain the muffler
bracket to the hood.
WARNING
8. Install the muffler into the bracket and on the ex-
Exhaust system must be at room temperature be-
haust tube.
fore starting disassembly or personal injury may
occur. 9. Install the T-bolt strap that retains the muffler to the
muffler bracket.
1. Remove the 6 capscrews from the perforated cover
on the exhaust muffler. 10. Tighten the clamps at the bottom of the muffler.
2. Remove the perforated cover from the exhaust muf-
fler.

6
100 YRM 1594 Exhaust System

11. Install the perforated cover on the exhaust muffler 12. Install the 6 capscrews that retain the perforated
bracket. cover to the exhaust muffler bracket.

1. U-BOLT 6. CHARGE AIR COOLER TUBE


2. CAPSCREWS 7. HEAT SHIELD
3. MUFFLER BRACKET 8. EXHAUST TUBE BRACKET
4. CAPSCREWS ON MUFFLER COVER 9. EXHAUST TUBE
5. PERFORATED COVER 10. EXHAUST TUBE CLAMP

Figure 6. Exhaust Assembly, Tier 4i/Stage III B, F877 Shown

7
Hood Assembly 100 YRM 1594

Legend for Figure 7

NOTE: PERFORATED COVER REMOVED


1. MUFFLER
2. CLAMP BOLTS
3. EXHAUST TUBE
4. DOUBLE T-BOLT STRAP

Figure 7. Exhaust Muffler, Tier 4i/Stage III B

Hood Assembly
REMOVE – On F877 trucks, the connector to the TBAP (Tem-
perature Barometric Air Pressure) sensor on the
1. Tilt the mast completely forward. air filter assembly.
– On F876 trucks, the connector to the MAF (Mass
2. Completely tilt (raise) the cab.
Air Flow) sensor.
3. Disconnect the battery cables from the battery.
9. Remove all tie-wraps holding electric cables to the
4. Open the rear cover and disconnect its two gas hood.
springs from the counterweight.
10. On Tier 3/Stage III A engines:
5. Remove the rear cover by sliding it sideways off its – Release the clamps on the flex tube
flexible hinge. See Figure 8. – Remove the air filter hose.

6. Open the left and right hood doors. 11. On Tier 4i/Stage III B engines:
– Remove the 6 capscrews from the perforated
7. On trucks with Tier 3/Stage III A engines, discon- cover on the exhaust muffler.
nect the air filter vacuum switch connector. – Remove the perforated cover from the exhaust
muffler.
8. On trucks with Tier 4i/Stage III B engines, tag and – Loosen the clamp at the bottom of the muffler.
disconnect: – Remove the curved air filter hose.
– The air filter vacuum switch connector.

8
100 YRM 1594 Hood Assembly

NOTE: Note: Filled to the “MAX” mark, the expansion 4. Install the capscrews that retain the rear hood
tank with connecting hoses weighs 7 kg (15.4 lb). bracket to the counterweight.

12. Remove the capscrews, washers and nuts that re- 5. Install the capscrews in the insulators at the top of
tain the expansion tank bracket to the hood. the cooling core assembly.

13. Place the expansion tank inside the engine com- 6. Install the expansion tank bracket to the hood.
partment and secure it to keep it from moving.
7. On Tier 3/Stage III A engines:
14. Remove the capscrews from the two insulators at – Tighten the clamps on the flex tube.
the top of the cooling core assembly. See Figure 9. – Install the air filter hose.

15. Remove the nut and washer on each side of the


hood that hold the front plate of the hood assembly
to the frame. 8. On Tier 4i/Stage III B engines:
– Tighten the clamp at the bottom of the muffler.
16. Remove the capscrews that retain the rear hood – Install the perforated cover on the exhaust muf-
bracket to the counterweight. fler.
– Install the 6 capscrews to retain the perforated
17. Attach a lifting device to the hood assembly. cover to the exhaust muffler.
– Install the curved air filter hose.
CAUTION 9. On Tier 3/Stage III A engines:
Be very careful when lifting the hood assembly to – Connect the air filter vacuum switch connector.
avoid damage to the rear of the operator’s cab.
10. On trucks with Tier 4i/Stage III B engines, connect
18. Slowly lift the hood assembly and make sure all according to tags:
electric cables are removed from the hood. – The air filter vacuum switch connector.
– On F877 trucks, the connector to the TBAP (Tem-
19. Place the hood assembly on the ground and put a
perature Barometric Air Pressure) sensor on the
support under the rear of the assembly.
air filter assembly.
INSTALL – On F876 trucks, the connector to the MAF (Mass
Air Flow) sensor.
1. Attach a lifting device to the hood assembly.
11. Install the electric cables to the hood with tie-wraps.

CAUTION 12. Close the left and right hood doors.


Be very careful when installing the hood assembly
13. Slide the rear cover sideways onto its flexible hinge.
to avoid damage to the rear of the operator’s cab.
14. Install the two gas springs between rear cover and
2. Make sure the muffler slides into the exhaust tube
counterweight.
and carefully position the hood assembly onto the
frame. 15. Connect the battery cables.
3. Install the nut and washer on each side of the hood 16. Completely lower the cab.
that hold the front plate of the hood assembly to the
frame. 17. Start the engine and check for leaks.

9
Hydraulic Tank 100 YRM 1594

1. COOLING CORE ASSEMBLY


2. BOLT
1. HOOD 3. WASHER
2. LEFT HOOD DOOR 4. INSULATOR
3. HOOD FRONT PLATE 5. BRACKET
4. NUT ON THREADED FRAME STUD 6. LEFT DOOR
5. RIGHT HOOD DOOR 7. HOOD
6. CAPSCREWS ON COUNTERWEIGHT (NOT
VISIBLE) Figure 9. Top Insulators
7. REAR COVER

Figure 8. Hood Assembly, Tier 3/Stage III A Shown

Hydraulic Tank
The hydraulic tank is installed on the right side of the 6. Remove the three capscrews and washers holding
frame between the front fender and counterweight. the right-hand extension plate and remove the ex-
tension plate. See Figure 10.
REMOVE
NOTE: The hydraulic tank removal and installation must CAUTION
be done with aid of an assistant. Disconnect the negative (ground) cable first or lift
truck damage may occur.
1. Place the truck on a solid, level surface.
7. Disconnect the negative (ground) and positive
2. Lower the mast completely. (power) cables from the batteries.
3. Shut down the engine. 8. Remove the batteries from the battery box.
4. Apply the parking brake. NOTE: Use a drain pan to collect the oil from the hy-
draulic tank and hoses. The hydraulic system contains
5. Remove the four capscrews and washers holding
125 liter (33 gal) of hydraulic oil.
the right-hand panel on top of the hydraulic tank and
remove the right-hand panel. See Figure 10.

10
100 YRM 1594 Hydraulic Tank

9. Remove the drain plug at the bottom of the hydraulic 14. On trucks with a 3-stage mast, disconnect the lift
tank and drain the hydraulic oil into clean suitable cylinder drain hose at the top of the hydraulic tank.
container.
15. Put caps on the hoses and on the connections on
10. Tag all hoses and tubes connected to the hydraulic the hydraulic tank.
tank to facilitate re-installing.
16. Disconnect wiring harness from hydraulic sensor
11. Loosen and remove the hose clamps from the main and remove hydraulic sensor, if necessary.
pump suction hose and from the wet brake pump
suction hose at the bottom of the hydraulic tank. 17. Remove the battery cables from the access hole of
See Figure 11. the hydraulic tank. See Figure 10.

12. Put caps on the suction hoses. See Figure 11. 18. Remove the capscrews that hold the right running
board to the counterweight, front fender, and hy-
13. Disconnect the wet brake return, the main valve draulic tank and remove the running board.
return, and the main valve drain hoses from the
hydraulic tank. See Figure 11.

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 10. Hydraulic Tank

11
Hydraulic Tank 100 YRM 1594

WARNING CAUTION
Make sure the hydraulic tank is supported with a DO NOT to damage the studs during removal of the
hydraulic jack, hand pallet lift, or a lift truck. hydraulic tank from the frame.

19. Support the hydraulic tank with blocks of at least 21. Lift the hydraulic tank from the studs and move the
50 mm (2.0 in.) high to compensate the height of hydraulic tank away from the frame.
the bracket at the bottom of the hydraulic tank.

20. Remove the three nuts and washers that hold the
hydraulic tank to the frame.

1. TO PORT P2 ON STEERING PUMP 11. MAIN VALVE DRAIN HOSE


2. LOAD SENSE HOSES 12. HYDRAULIC TEMPERATURE SENSOR
3. TO MAIN VALVE 13. MAIN RETURN HOSE
4. PUMP 1 14. DRAIN PLUG
5. BRAKE PUMP 15. LIFT CYLINDER DRAIN HOSE (ONLY ON
6. TO HYDRAULIC COOLING CORE TRUCKS WITH THREE-STAGE MASTS)
7. WET BRAKE PUMP SUCTION HOSE 16. EXCESS WET BRAKE FLOW HOSE
8. WET BRAKE PUMP SUPPLY HOSE 17. WET BRAKE RETURN HOSE
9. MAIN PUMP SUPPLY HOSE 18. TO WET BRAKE COOLING CORE
10. PUMP DRAIN HOSE 19. PUMP 2

Figure 11. Hydraulic Tank Connection, F876/F877, Tier 3/Stage III A, F876, Tier 4i/Stage III B

12
100 YRM 1594 Hydraulic Tank

INSPECT cleaning compound with an alkaline base. Follow


the instructions given by the manufacturer.
WARNING
Do not use tools that can produce sparks, heat, or WARNING
static electricity. The vapors in the tank can cause Compressed air can move particles so that they
an explosion. cause injury to the user or to other personnel.
Make sure that the path of the compressed air is
Perform a visual inspection of all sides of the tank. In- away from all personnel. Wear protective goggles
spect the welds for cracks and leakage. Check for wet or a face shield to prevent injury to the eyes.
areas, accumulation of dirt, and loose or missing paint
caused by leakage. Areas of the tank that are not eas- 3. Mix the solution in the tank using air pressure.
ily seen can be checked with an inspection mirror and Make sure all the surfaces on the inside of the tank
a light that is approved for locations with flammable va- are flushed with the solution.
pors.
4. Drain the tank.
CLEAN
5. If steam is available, put steam into the tank until
Tank can be cleaned with or without steam. If steam is the tank does not have odors and the metal is hot.
available use a hose with a minimum diameter of 19 mm Steam vapors must come from all the openings.
(0.75 in.). Control the pressure of the steam by a valve
installed at the nozzle of the hose. If a metal nozzle is 6. Flush the inside of the tank with boiling water. Make
used, it must be made of a material that does not pro- sure all the loose material and cleaning compound
duce sparks. Make an electrical connection between is removed from the inside of the tank.
the nozzle and the tank. Connect a ground wire to the
7. Perform an inspection of the inside of the tank. If
tank to prevent static electricity.
it is not clean, repeat Step 5 and Step 6 and per-
1. Remove all the parts from the tank. Install the drain form another inspection. In these inspections, use
plug. a light that is approved for locations with flammable
vapors.

WARNING 8. Check the tank for flammable vapors. Put plugs in


When cleaning the tank, do not use solutions that all the openings in the tank. Wait 15 minutes, then
produce dangerous gases at normal temperatures remove the inlet and outlet plugs. Test a sample of
or when heated. Wear eye and face protection. Pro- the vapor with a special indicator for gas vapors. If
tect the body from burns. If the tank is cleaned in- the amount of flammable vapors is above the lower
side a building, make sure there is enough ventila- flammable limit, repeat the cleaning procedures.
tion.
ADDITIONAL PREPARATIONS FOR
CAUTION REPAIR
Disposal of lubricants, fluids, and chemicals must If nitrogen gas or carbon dioxide gas is available, pre-
meet local environmental regulations. pare the cleaned tank for welding using these gases.
See the manual Safe Practices for Welding and Cutting
2. Fill the tank with a cleaning solution. Proceed as
Containers That Have Held Combustibles by the Amer-
follows:
ican Welding Society, F4.1-1999.
• If steam is available, fill the tank 1/4 full (approxi-
mately 30 liter (8 gal) with a solution of water and If these gases are not available, fill the tank with water to
sodium bicarbonate or sodium carbonate. Mix just below the point where the work will be done. Make
0.5 kg (1 lb) per 4 liter (1 gal). sure the space above the level of the water has a vent.
• If the tank cannot be cleaned with steam, mix
a solution of water and trisodium phosphate or

13
Hydraulic Tank 100 YRM 1594

REPAIR 3. Careful place the hydraulic tank over the studs with-
out damaging the studs.
WARNING
4. Install the three washers and nuts that hold the top
Special procedures must be followed when leaks or of the hydraulic tank to the frame.
other repairs need welding or cutting. All work must
be done by authorized personnel. 5. Remove the lifting device.

NOTE: While pushing the cab tilt shaft to the front of the
CAUTION truck, keep the shims in their position between the cab
Welding on the truck may cause damage to the en- and cab tilt system.
gine, transmission, and/or hydraulic electronic con-
trol units if proper precautions are not taken. Dis- 6. Push the cab tilt shaft towards the front of the truck
connect the negative battery terminal from the bat- and guide the shaft into the front bracket.
tery. Disconnect all controllers. If welding must
be done in close proximity to a controller, that con- 7. Install the anchor that secures the cab tilt shaft.
troller must be removed. When welding to the chas- 8. Inspect the right running board grommets. Replace
sis, attach the ground cable as close to the weld as if damaged.
possible.
9. Put the right running board in place and install the
1. Use the procedure described under Clean to pre- capscrews that hold the running board to the coun-
pare the tank for repairs. terweight, front fender, and hydraulic tank.
2. Contact your dealer for Yale lift trucks for welding 10. Install the right-hand extension plate using the three
instructions. capscrews and washer. See Figure 10.
3. Use acceptable welding practices to repair the 11. Feed the battery cables through the access hole of
tank. See the American National Standard Safety the hydraulic tank. See Figure 10.
in Welding and Cutting, AWS Z 49.1 - 1999.
12. Install the clamp on the large suction hose at the
Preparations for use After Repair bottom of the hydraulic tank. Connect large suction
hose to the hydraulic tank. Torque the clamp to 4 -
1. Add more water to the tank so that the water goes
6 N•m (3 - 4 lbf ft).
above the point of where the work was done. Check
to see if any water leaks from the tank. 13. Install the clamp on the smaller suction hose at the
bottom of the hydraulic tank. Connect smaller suc-
2. If the tank shows no signs of leaks, remove all the
tion hose to the hydraulic tank and tighten clamp.
water from the tank.
14. Install the wet brake return, the main valve return,
INSTALL and the main valve drain hoses on the hydraulic
tank.
NOTE: When installing the hydraulic system oil filter, it
is important to grease the O-ring before installation. 15. On trucks with a 3-stage mast, install the lift cylinder
drain hose at the top of the hydraulic tank.
1. Place the hydraulic tank on lifting equipment and
support it with blocks of at least 50 mm (2.00 in.) 16. Install the hydraulic temperature sensor and con-
high to compensate the height of the bracket at the nect the wiring harness.
bottom of the hydraulic tank.
17. Make sure the drain plug is installed at the bottom
2. Raise and place the hydraulic tank in front of the of the hydraulic tank.
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.

14
100 YRM 1594 Hydraulic Tank

24. Start the engine while operating the lift function.


CAUTION Keep engine speed at idle.
The pump is designed for a certain flow range,
if there is not enough or too much flow going 25. Lift the mast until it has almost reached its end of
through the pumps, the resulting turbulence and stroke.
vortices can reduce performance and may damage
26. Lower the mast and keep the engine at idle for
the pumps or equipment.
about one minute.
18. Fill the pump through the drain port with clean hy-
27. Repeat Step 25 if the pump has produced a sound
draulic oil. Install the drain hose.
that relates to cavitation.

CAUTION 28. Raise engine speed to high idle (1000 – 1200 rpm)
Never start the engine with closed shutoff valves. and lift the mast until it has almost reached its end
Open the shutoff valves before starting the engine of stroke.
to prevent damage to hydraulic components.
29. Lower the mast and keep the engine at idle for
19. Connect the suction hose and pressure hose to the about one minute.
hydraulic pump.
30. Return to Step 28 if the pump has produced a
sound that relates to cavitation.
CAUTION
Use a filtration system when filling the hydraulic 31. Operate each hydraulic function in both directions
tank to prevent dirt and contamination from enter- twice, at high engine speed (1600 – 1900 rpm).
ing the hydraulic system. If dirt or contamination Release the function when it has reached its end
enters the hydraulic system, damage may occur to of stroke.
the components of the hydraulic system. 32. Turn the engine OFF.
20. Fill the hydraulic tank with clean hydraulic oil as
specified in the maintenance table. Refer to the WARNING
manual Periodic Maintenance 8000 YRM 1593. Do not try to locate hydraulic leaks by putting hands
on pressurized hydraulic components. Hydraulic
21. Release the clamp of the suction hose at the pump.
oil can be injected into the body and cause personal
Slide the hose partly from its fitting allowing trapped
injury.
air to escape and tank oil to reach the pump. Rein-
stall the hose and tighten the clamp. 33. Check for leaks.
22. Install the batteries into the battery box. 34. Check hydraulic tank oil level. Fill the hydraulic tank
with clean hydraulic oil as specified in the mainte-
CAUTION nance table. Refer to the manual Periodic Mainte-
nance 8000 YRM 1593.
Connect the positive (power) cable first or lift truck
damage may occur. 35. Position the right-hand panel on top of the hydraulic
tank and install the four washers and capscrews.
23. Connect the positive (power) and negative (ground)
cables to the batteries.

15
Fuel Tank 100 YRM 1594

Fuel Tank
The fuel tank is installed on the left side of the frame 13. Disconnect the two fuel hoses from the check valve
between the front fender and counterweight. and shutoff valve at the top of the fuel tank. See
Figure 12.
REMOVE
14. Put caps on the fuel hoses and fittings.
1. Place the truck on a solid, level surface.
15. Remove the check valve and shut off valve at the
2. Lower the mast completely. top of the fuel tank. See Figure 12.

3. Shut down the engine. 16. Put caps on the fittings at the top of the fuel tank.

4. Apply the parking brake. 17. Loosen the fuel hose clamp located on top of the
frame.
5. Completely tilt (raise) the cab.
18. Turn the ends of the hoses parallel to the frame.
6. Remove the connector from the push-button switch
at the left-hand panel. 19. Remove the hose clamp for the cab tilt hoses.

7. Remove the four capscrews and washers holding 20. Remove the retaining hardware of the left- and
the left-hand panel and remove the panel. right-hand latch located on the frame.

8. Remove the left-hand extension plate between the 21. Remove the two capscrews, and washers at the
fuel tank and counterweight. back of the hand pump. See Figure 13.

22. Remove the capscrews holding the left running


WARNING board to the counterweight, front fender, and fuel
When removing the fuel tank, do not use tools that tank and remove the running board.
can produce sparks, heat, or static electricity. The
vapors in the tank can cause an explosion and per-
sonal injury may occur. WARNING
Make sure that the lifting device has the rated ca-
NOTE: Use a drain pan to collect the fuel from the fuel pacity of 100 kg (220 lb) to lift the fuel tank.
tank. The fuel tank contains a maximum of 128 liter
(34 gal) of fuel. NOTE: Removal of the fuel tank can be done with a lift-
ing device, hydraulic jack, hand pallet jack, or lift truck.
9. Put a drain pan under the fuel tank.
NOTE: Follow Step 23 and Step 24 when a lifting device
10. Remove the drain plug to drain the fuel from the is used.
tank. See Figure 12.
NOTE: Follow Step 25 when a hydraulic jack, hand pal-
let jack, or lift truck is used.
WARNING
If fuel is drained, put the fuel in a can or barrel that NOTE: When lifting, keep the fuel tank in the horizontal
has a protected seal cap. position.

11. Disconnect the fuel sender connector at the top of 23. Attach a lifting device to the fuel tank. Attach lifting
the fuel tank. See Figure 12. eyes at the locations shown in Figure 14.

12. Put tags on the check valve and shutoff valve fuel 24. Create slight tension on the chains.
hoses and fittings for identification.
25. Support the fuel tank with blocks of at least 50 mm
NOTE: Use a drain pan to catch the fuel in the fuel (2.0 in.) high to compensate the height of the
hoses. bracket on the bottom of the fuel tank.

16
100 YRM 1594 Fuel Tank

1. FUEL HOSE 4. DRAIN PLUG


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

Figure 12. Fuel Tank

17
Fuel Tank 100 YRM 1594

Repair the fuel tank as described in the section Hy-


CAUTION draulic Tank.
DO NOT to damage the studs during removal of the
fuel tank from the frame. INSTALL
26. Remove the two nuts and washers that hold the top NOTE: Follow Step 1 when a lifting device is used.
of the fuel tank and the electrical tilt pump bracket
to the frame. NOTE: Follow Step 2 when a hydraulic jack, hand pallet
jack, or lift truck will be used.
27. Remove the electrical tilt pump and bracket from
the frame. NOTE: When lifting, keep the fuel tank in a horizontal
position.
28. Place the electrical tilt pump, hand pump, left and
right latch inside the frame to avoid damage to the 1. Attach a lifting device with lifting straps and lifting
hoses during the removal of the fuel tank. eyes to the fuel tank.

29. Remove the remaining nut that holds the fuel tank 2. Place the fuel tank on lifting equipment and support
to the frame. with blocks of at least 50 mm (2.00 in.) high to
compensate the height of the bracket at the bottom
30. Lift the fuel tank from the studs and move the fuel of the fuel tank.
tank away from the frame.
3. Raise and place the fuel tank in front of the left side
REPAIR of the frame.

WARNING CAUTION
Do not use tools that can produce sparks, heat, or DO NOT to damage the studs during installation of
static electricity. The vapors in the tank can cause the fuel tank.
an explosion.
4. Place the fuel tank over the studs of the frame.

1. ELECTRICAL TILT PUMP 3. FUEL TANK


2. HAND PUMP

Figure 13. Fuel Tank, Hand Pump, and Electric Tilt Pump

18
100 YRM 1594 Fuel Tank

5. Install the washer and nut, located behind the hand 9. Install the left and right latch, located at the frame,
pump, that hold the top of the fuel tank to the frame. with the capscrews, spring washers, washers, and
nuts.
6. Position the hand pump, electrical tilt pump, left and
right latch at the frame and route the hoses cor- 10. Install the hose clamps located on top of the frame.
rectly.
11. Inspect the left running board grommets. Replace
7. Install the two washers and nuts that hold the top of if damaged.
the fuel tank and the electrical tilt pump bracket to
the frame. 12. Put the left running board in place and install the
capscrews that hold the running board to the coun-
8. Install the hand pump with the two washers and terweight, front fender, and fuel tank.
capscrews located behind the hand pump.
13. Install the left hand extension plate between the
fuel tank and counterweight using the three wash-
ers and capscrews.

Figure 14. Lifting Eyes

19
Cab 100 YRM 1594

14. Install the drain plug at the bottom of the fuel tank. 21. Fill the fuel tank to the correct level with fuel spec-
ified in the section Periodic Maintenance 8000
15. Install the check valve and shutoff valve at the top YRM 1593.
of the fuel tank.

16. Connect the two fuel hoses to the check valve and CAUTION
shut off valve at the top of the fuel tank. Connect the positive (power) cable first or lift truck
damage may occur.
17. Connect the connector to the electrical tilt pump.
22. Connect the positive (power) and negative (ground)
18. Connect the connector of the fuel sender to the top cable to the batteries.
of the fuel tank.
23. Completely lower the cab.
19. Position the left-hand panel on top of the fuel tank
and install the four capscrews and washers. 24. Start the engine.

20. Connect the connector, located at the left-hand 25. Check for leaks.
panel, to the push button switch.

Cab
RAISING AND LOWERING CAB NOTE: Just before fully open position is reached, move-
ment may be gravity controlled.
Raise Cab
7. Pull tilt latch release and continue to raise cab to
fully open position. See Figure 16.
WARNING
Make sure no one is under cab when raising or low- NOTE: If cab will not fully raise, lower cab until cab locks
ering cab. in partially open position, and fill tilt system with oil. See
Oil Filling for Cab Tilt System.
WARNING NOTE: Raising cab gives access to components such
Before you place any part of your body under cab, as engine, transmission/hydraulic compartment, throt-
always make sure that cab is fully tilted, or when tle/brake and steering control, heater, air conditioner,
partially open, is locked by tilt latch. and electrical connectors.

CAUTION
Cab damage may occur if mast is not completely
tilted forward.

1. Tilt mast fully forward.

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 15. 1. PUMP LEVER CONNECTION
2. VALVE DIRECTION SELECTION: CLOCKWISE -
6. Operate pump with pump lever until cab locks in RAISE, COUNTERCLOCKWISE - LOWER
partially open position.
Figure 15. Cab Tilt Pump and Direction Valve

20
100 YRM 1594 Cab

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 16. 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 the two side covers.
partially open, is locked by tilt latch.
5. Disconnect connector CPR04 to throttle pedal sen-
CAUTION sor.
Cab damage may occur if mast is not completely 6. Disconnect connector CPS07 to cab signals.
tilted forward.
7. Disconnect connector CPS06 to cab power.
1. Use pump lever to turn direction valve counterclock-
wise to "Lower" position. See Figure 15. 8. Disconnect connector CPS35 to aux-signals.

2. Check that all foreign items/tools are cleared away. NOTE: Cab is equipped with a heater and air condi-
tioner assembly which is installed on the underside of
3. Operate pump with pump lever until cab locks in the cab.
partially open position.
9. Place a drain pan under the two heater hoses be-
4. Pull tilt latch release and continue to lower cab until fore disconnecting the heater hoses to catch the
it is in fully lowered position and latched. See Fig- coolant in the hoses and heater core.
ure 16.
10. Tag and disconnect the two heater hoses from the
NOTE: An electric-powered cab tilt system is available heater inlet and outlet ports, and plug the heater
to replace standard manual tilt system. The electric tilt hoses and ports. See Figure 17.
system contains a push button located on left side of

21
Cab 100 YRM 1594

20. Remove four rubber isolation mounts from frame


CAUTION and inspect for damage. Reinstall or replace if nec-
Replacement, installation, and repairs to air condi- essary.
tioning units that require discharging and/or refill-
ing of the refrigeration fluid may only be performed
by a certified technician.

11. If the cab is provided with air conditioning, disas-


semble the air conditioning compressor from the
engine while keeping the hoses attached to the
compressor. Attach the compressor to the cab and
make sure the hoses are clear of all obstacles and
components.

If the hoses must be detached from the compres-


sor, first have the system emptied by a certified
technician.

After the system has been emptied, disconnect the


hoses and plug the fittings. 1. HEATER HINGE BRACKET
2. HEATER ASSEMBLY CAPSCREW LOCATION
NOTE: Use a drain pan to collect the oil from the hy- 3. HEATER OUTLET
draulic hoses. 4. HEATER INLET

12. Tag and disconnect the steering hoses that are con- Figure 17. Heater Assembly
nected to the steering pump at ports LS, L, T, R, and
P. See Figure 18.

13. Place a cap on hydraulic hoses and open ports of


steering pump.

14. Tag and disconnect the three hydraulic hoses from


brake treadle valve. Place a cap on hydraulic hoses
and open ports of brake treadle valve.

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

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

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


two on right side of truck.

17. Open cab doors before attaching a lifting device.


1. STEERING HOSE PORT LS
18. Put a lifting strap underneath the roof of the cab. 2. STEERING HOSE PORT L
Put a cushion at top of door area to prevent dam- 3. STEERING HOSE PORT T
4. STEERING HOSE PORT R
age. Close the cab doors. 5. STEERING HOSE PORT P
19. Carefully lift cab away from lift truck. Set cab as- Figure 18. Steering Pump Connections
sembly in a suitable storage area and put blocks
under cab to stabilize and prevent damage.

22
100 YRM 1594 Oil Filling for Cab Tilt System

Install 17. Remove tags and connect the two heater hoses
from the heater to the inlet and outlet ports,
1. Open cab doors before attaching a lifting device.
18. Lower cab. See Lower Cab.
2. Put a lifting strap underneath the roof of the cab.
Put a cushion at top of door area to prevent dam- 19. Install doors.
age. Close the cab doors.
20. Connect battery ground lead.
3. Make sure that insulators are in place. See Fig-
ure 19. 21. Install side panels.

4. Lift operator’s cab. 22. Start lift truck and check for leaks on all hoses that
were removed. Tighten if necessary.
5. Carefully lower cab on insulators and make sure
that it is properly centered.

6. Install four mounting bolts, two on left side and two


on right side of truck mount cab.

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

8. Raise cab. See Raise Cab.

9. Connect ground lead.

10. Connect CPS35 to aux-signals.

11. Connect CPS06 to cab power.

12. Connect CPS07 to cab signals.

13. Connect CPR04 to throttle pedal sensor. 1. TOP PART OF 3. BOLT


INSULATOR 4. WASHER
14. Remove caps on hydraulic hoses and open ports 2. BOTTOM PART OF 5. LOCKWASHER
of brake treadle valve. Remove tags and connect INSULATOR
three hydraulic hoses to brake treadle valve. Figure 19. Insulators
15. Connect steering hoses to ports P, R, T, L, and LS
on steering pump. See Figure 18.

16. Replace compressor on the engine. Make sure the


hoses are clear of all obstacles and components.

Oil Filling for Cab Tilt System


1. Tilt/Raise raise the cab until it locks in the partially
CAUTION open position. Refer to the section Raising and
When oil is added to the cab tilt system, place an oil Lowering Cab.
absorbing material around the fill cap before lower-
ing the cab. Excess oil may bleed out of the relief 2. Lower the cab until it locks in the partially open po-
valve, which is located in the fill cap. sition. Refer to the section Raising and Lowering
Cab.
NOTE: If the oil level is low, the cab will not tilt/raise
completely. 3. Place the pump lever connection in the fully down
position to create easy access to the fill cap. See
NOTE: If the cab is lowered, perform Step 1. If the cab Figure 20.
is raised, go to Step 2.

23
Engine 100 YRM 1594

4. Remove the fill cap. See Figure 20.

5. Add hydraulic oil through the filler opening until the


level is within 30 to 35 mm (1.18 to 1.38 in.) of the
top of the reservoir. See Figure 21. For your lift
truck, refer to the appropriate Periodic Maintenance
YRMfor the correct hydraulic oil specification.

6. Install the fill cap. See Figure 20.

7. Tilt/raise the cab and make sure the maximum


tilted/raised (fully opened) position can be reached.
Refer to the section Raising and Lowering Cab.

8. If necessary, repeat Step 1 through Step 7.

9. Lower the cab until it is in the fully lowered position 1. FILL CAP
and completely latched. Refer to the section Rais- 2. PUMP LEVER CONNECTION
ing and Lowering Cab.
Figure 20. Hand Pump

Figure 21. Cab Tilt Label

Engine
REMOVE 4. Apply the parking brake.

5. Completely tilt (Raise) the cab.


WARNING
Engine must be at room temperature before starting
disassembly or personal injury may occur. CAUTION
Disconnect the negative (ground) cable first or
damage to the lift truck may occur.
CAUTION
Repairs to air conditioning that require discharging 6. Let coolant cool to room temperature.
and/or refilling of the refrigeration fluid must be per-
formed only by a trained and certified air condition- 7. Disconnect the negative (ground) and positive
ing specialist. (power) cables from the batteries.

1. Place the truck on a solid, level surface. 8. Remove the hood. See Hood Assembly, Remove.

2. Lower the mast completely. 9. Disconnect the electrical cable from the air condi-
tioner compressor.
3. Shut down the engine.

24
100 YRM 1594 Engine

NOTE: Removing the compressor for the air conditioner 20. Remove the drain plug at the bottom of the trans-
with the hoses attached prevents the need to have a mission and put the transmission oil in a clean bar-
certified specialist suction and refill the air conditioning rel.
system.
21. Install the drain plug at the bottom of the transmis-
NOTE: DO NOT remove the refrigerant hoses. sion.

10. Remove the air conditioner compressor from the 22. Close the fuel shutoff valve at the top of the fuel
mounting bracket located on the engine. tank.

11. Attach the air conditioner compressor with the 23. Put tags on the fuel hoses and fittings for identifica-
hoses to the cab. Make sure the hoses are free tion.
from the engine/transmission during removal.
NOTE: Use a drain pan to catch the fuel in the fuel
12. Put tags on the two heater hoses for identification. hoses.

13. Disconnect the two heater hoses located under the 24. Disconnect the fuel hose at the diesel fuel filter.
operators compartment at the engine side.
25. Disconnect the fuel hose at the check valve.
14. Put caps on the two heater hoses.
26. Put caps on the fuel hoses and fittings.

WARNING 27. Strap the fuel hoses to the engine.


DO NOT remove the radiator cap from the expan-
sion bottle when the engine is hot. When the radi- 28. Remove the two charge air cooler tubes from the
ator cap is removed, the pressure is released from charge air cooler core and engine assembly.
the system. If the system is hot, the steam and boil- 29. Remove the two engine coolant hoses from the en-
ing coolant can cause burns. gine cooling core and engine assembly.

CAUTION 30. Put tags on the two transmission oil hoses for iden-
tification.
Disposal of lubricants and fluids must meet local
environmental regulations. 31. Disconnect the two transmission oil hoses from the
thermostat manifold at the inlet and outlet port.
15. Make sure engine and coolant have cooled to room
temperature. 32. Put caps on the two transmission hoses and on the
inlet and outlet port of the thermostat manifold.
NOTE: Use drain pans large enough to catch all
coolant. For coolant volume see, Cooling System 700 33. Drain the hydraulic tank.
YRM 1595.
34. Disconnect the suction hoses from the hydraulic
16. Remove the radiator cap from the expansion tank. pumps.
17. Open the coolant drain valve at the lower end of the 35. Place a cap on the suction hose from the hydraulic
engine cooling core. pump.
18. Alternatively, to speed up the draining process, 36. Put tags on the two pressure hoses of the hydraulic
loosen the clamp on the coolant return hose at pump for identification.
the water pump. Remove the hose from the water
pump. Attention: the coolant will now flow out of NOTE: Use a drain pan to catch the hydraulic oil in the
the cooling core very rapidly. pressure hoses.

19. Use a drain pan to catch the coolant. For coolant 37. Disconnect the two pressure hoses from the hy-
volume see, Cooling System 700 YRM 1595. draulic pump.

NOTE: Use a drain pan to drain the transmission oil 38. Put caps on the two pressure hoses.
from the transmission. Total volume of transmission oil:
27 liter (7.1 gal).

25
Engine 100 YRM 1594

39. Disconnect the return hoses from the hydraulic NOTE: The hexagon nut that connects the fan clutch to
tank. See Figure 11. the fan spacer has LEFT HAND THREAD.

40. Disconnect the three electrical wires located at the 52. On trucks with Tier 4i/Stage III B engines:
left side of the engine from the alternator. – Hold the fan spacer with a spanner, and unscrew
the hexagon nut by turning it CLOCKWISE.
41. Disconnect the four electrical wires located at the – Put the fan clutch assembly inside the shroud.
left side of the engine from the starter.
53. Disconnect the drive shaft from the transmission.
42. Disconnect the electrical wire located at the left side
of the transmission from the transmission control
valve.
WARNING
Make sure that the lifting device has the rated ca-
43. Disconnect the electrical wire for the output speed pacity of 2500 kg (5512 lb).
sensor and speed/temperature sensor located at
the left side of the transmission. 54. Install lifting eyes at the locations indicated in Fig-
ure 25. The size of the thread in the transmission
44. Disconnect the controller connector and Engine housing is 3/4-10 UNC.
supply connector located at the right side of the
engine from the engine.

45. Disconnect the two electrical wires for the engine


oil pressure located at the right side of the engine
from the engine.

46. Disconnect the electrical wire for the fuel filter


sender, located at the right side of the engine, from
the engine.

47. Disconnect the electrical wire for the convertor out


temperature sensor located at the right side of the
transmission from the transmission.

48. Disconnect the electrical wire for the turbine speed


sensor located at the right side of the transmission
from the transmission.

49. 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.

50. On trucks with Tier 3/Stage III A engines, reach


between the fan blades with a tool and remove the
four capscrews which hold the fan and fan spacer.
Put the fan inside the shroud.
1. ENGINE CORE SUPPLY HOSE
51. On trucks with Tier 4i/Stage III B engines: 2. SUPPORT BRACKET
– Disconnect the electric connector of the fan 3. BOLT
4. ANTI-ROTATION BRACKET
clutch. See Figure 22 5. FAN PULLEY
– Remove the bolt that connects the anti-rotation 6. FAN SPACER
bracket to the support bracket. 7. HEXAGON NUT
– Remove tie-wrap(s) from the electric cable of the
fan clutch, except those around the anti-rotation Figure 22. Fan Clutch Assembly, Tier 4i/Stage III
bracket. B only

26
100 YRM 1594 Engine

1. ALTERNATOR CONNECTORS 5. TRANSMISSION SPEED SENSOR


2. STARTER CONNECTORS 6. CONVERTER OUT TEMPERATURE SENSOR
3. SPEED/TEMPERATURE SENSOR
4. TRANSMISSION CONTROL VALVE
CONNECTOR

Figure 23. Electric Engine Connections, Left-Hand Side

27
Engine 100 YRM 1594

1. CONTROLLER CONNECTOR 4. FUEL FILTER SENDER WIRE


2. ENGINE SUPPLY CONNECTOR 5. INTERMEDIATE SPEED SENSOR
3. ENGINE OIL PRESSURE CONNECTORS 6. TURBINE SPEED SENSOR

Figure 24. Electric Engine Connections, Right-Hand Side

28
100 YRM 1594 Engine

55. Connect a lifting device to the two engine lifting


eyes and to the lifting eyes at the transmission.

56. Remove the two engine mount capscrews, small


washers, large washers, and nuts that hold the rear
of the engine to the frame. See Figure 26.

57. Remove the two transmission mount capscrews,


small washers, large washers, and nuts that hold
the transmission to the transmission frame bracket.
See Figure 27.

58. Lift the engine and transmission assembly from the


frame. Make sure all the connections to the engine
and transmission have been removed.

59. Remove the four bolts and washers to remove the


transmission frame bracket.

60. Remove the four transmission housing capscrews


and washers from the transmission mount bracket.

61. Remove transmission housing bracket.

1. ENGINE MOUNT CAPSCREW


2. ENGINE MOUNT BRACKET
3. WASHER (SMALL)
4. INSULATOR
5. WASHER (LARGE)
6. NUT

Figure 26. Engine Mounts

1. ENGINE LIFTING EYES


2. TRANSMISSION LIFTING EYES

Figure 25. Engine Assembly

29
Engine 100 YRM 1594

INSTALL – Reconnect the electric connector of the fan clutch


assembly.
1. Install the transmission mounting bracket onto the – Install tie-wraps as necessary to keep the electric
transmission housing with the capscrews. Tighten cable from touching any moving part. See Fig-
the capscrews to 390 N•m (288 lbf ft). See Fig- ure 22.
ure 27.
11. Connect the return hoses to the hydraulic tank.
2. If the transmission frame bracket was removed, in-
stall the bracket with the washers and the four cap- 12. Connect the two pressure hoses to the hydraulic
screws to the frame. Tighten the capscrews to pump.
390 N•m (288 lbf ft). See Figure 27.
13. Connect the suction hoses to the hydraulic pumps.
3. Install the insulators onto the transmission frame
bracket and onto the engine mounts on the frame. 14. Connect the two transmission oil hoses to the ther-
mostat manifold at the inlet and outlet port.

WARNING 15. Connect the two engine coolant hoses to the engine
Make sure that the lifting device has the rated ca- coolant core and engine assembly.
pacity of 2500 kg (5512 lb) or personal injury may
occur.

4. Connect a lifting device to the two engine lifting


eyes and to the lifting eyes at the transmission. See
Figure 25.

5. Lift and position the engine and transmission as-


sembly in the frame.

6. Install the capscrews, small washers, large wash-


ers and nuts to the engine and transmission
mounts. Tighten to 165 N•m (122 lbf ft).

7. Connect the drive shaft to the transmission and


tighten the bolts to 50 N•m (37 lbf ft).

8. On trucks with Tier 3/Stage III A engines:


– Lift the fan out of the shroud.
– Install the fan spacer and the fan to the fan pulley.
– Install the four capscrews which hold the fan and
fan spacer to the fan pulley, and torque to 43 N•m
(31.7 lbf ft).

9. On trucks with Tier 4i/Stage III B engines:


– Lift the fan clutch assembly out of the shroud and
install it onto the fan spacer. 1. TRANSMISSION MOUNT BRACKET
2. TRANSMISSION MOUNT CAPSCREW
NOTE: The hexagon nut that connects the fan clutch to 3. SMALL WASHER
the fan spacer has LEFT HAND THREAD. 4. INSULATOR
5. TRANSMISSION FRAME BRACKET
10. On trucks with Tier 4i/Stage III B engines: 6. LARGE WASHER
– Hold the fan spacer with a spanner, and hand 7. NUT
8. WASHER
tighten the hexagon nut by turning it COUNTER- 9. TRANSMISSION HOUSING CAPSCREW
CLOCKWISE. Final torqueing will occur by nor- 10. WASHER
mal operation of the engine. 11. FRAME BRACKET CAPSCREW
– Connect the anti-rotation bracket to the support
with the bolt, washer and nut. Figure 27. Transmission Mounts

30
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