Yale Forklift Truck A839 Series: ERC070HD, ERC080HD, ERC100HD, ERC120HD Workshop Manual

Yale IndustrialTrucks SERVICE MAINTENANCE MANUAL For Models ERC 070-120 HD (A839) S) © For Service & Parts-Contact Yale Materials Handling Corp. 1400 Sullivan Drive Caller No. 12011 Greenville, NC 27834-2011 Authorized Dea er Part Number 5203716-39 Publication ITD 1639 ©Yale Materials Handling Corporation April 1999 (7/98) (2/96)

Yale IndustrialTrucks MODEL NOMENCLATURE POWER E - Electric TYPE R - Sit Down Rider — TIRES P - Pneumatic C - Solid NOTE The lift truck model and serial number are indicated on the Capacity Plate. The serial number is also stamped into the front crossmember of the frame to¬ ward the right-hand side. RATED CAPACITY 070- 7 0001b 080- 8 0001b 100 -10 000 lb 120 -12 000 lb H SPECIAL DESIGNATION (As Assigned) - DESIGN SERIES A - B - C Etc. D N 1 1 MAST OVERALL HEIGHT (In Inches) MAST TYPE V - Simplex E - Triplex F - Duplex CONTROL S - SCR VOLTAGE 36 - 48 MFG. SOURCE

Yale Industrial Trucks SECTIONS GENERAL INFORMATION GENERAL LIFT TRUCK INFORMATION AND LUBRICATION SCHEDULE ELECTRICAL SYSTEM DRIVE AXLE This Maintenance Manu¬ 5 BRAKES al is divided into 10 major sections which are shown at the right side of this page. Quick refer¬ ence to these sections 6 STEERING AXLE can be made by placing the right thumb on the tab of the desired sec¬ tion, bending the book back and thumbing the 7 POWER STEERING pages to the correspond¬ ing tab. 8 HYDRAULIC SYSTEM MAST 10 BATTERY INDEX

Yale Industrial Trucks SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure that ail slings, chains or cables are correctly fastened and that the load being lifted is balanced. Make sure that the crane, cables and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand. Use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See "How To Put The Lift Truck On Blocks" in the OPERATOR'S MANUAL or SECTION 2, GENERAL LIFT TRUCK INFORMATION AND LUBRICATION SCHEDULE. • Keep the unit and working area clean and in order. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure that all nuts, bolts, snap rings and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE sign to the controls of the unit when making repairs or if the unit needs repairs. • Make sure you follow the DANGER, WARNING and CAUTION notes in the instructions. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area has ventilation. NOTE: The following symbols and words indicate safety information in this manual: A WARNING Indicates a condition that can cause death or injury! A CAUTION Indicates a condition that can cause property dam¬ age!

Yale Industrial Trucks CONTENTS Section 1 SUPPORT INFORMATION 1-1 SERVICE PARTS ORDERING INSTRUCTIONS 1-1 How To Order Service Parts 1-1 When Ordering Parts 1-1 SPECIAL TOOLS 1-1 TECHNICAL SERVICE PUBLICATIONS ..... 1-1 OPERATOR TRAINING 1-1 DAILY OPERATOR CHECK-OFF LISTS .... 1-1 SERVICE TRAINING COURSES 1-1 SERVICE TRAINING MATERIALS 1-1 Section 2 GENERAL LIFT TRUCK MAINTENANCE AND LUBRICATION SCHEDULE 2-1 GENERAL 2-1 HOW TO MOVE A DISABLED LIFT TRUCK . 2-1 How to Tow a Lift Truck 2-1 HOW TO PUT A LIFT TRUCK ON BLOCKS . 2-1 How To Raise the Drive Tires 2-2 How To Raise the Steering Tires 2-2 MAINTENANCE SCHEDULE 2-4 MAINTENANCE PROCEDURES EVERY 8 HOURS OR DAILY 2-9 CHECKS WITH THE KEY "OFF" 2-9 Hydraulic System 2-9 Battery 2-9 Battery Restraint System 2-10 Operator Restraint System 2-11 Inspection Of The Mast, Forks And Lift Chains 2-11 Tires And Wheels 2-12 Forks, Adjustment 2-13 Forks, Removal And Installation 2-13 SAFETY LABELS 2-13 CHECKS WITH THE KEY "ON" 2-14 Gauges and Horn 2-14 Lift System Operation 2-14 Service Brakes 2-14 Parking Brake 2-14 Steering System 2-15 EVERY 350 HOURS OR TWO MONTHS .... 2-15 HYDRAULIC TANK BREATHER 2-15 DIFFERENTIAL AND SPEED REDUCER .... 2-15 WHEEL NUT TORQUES 2-15 STEERING AXLE SPINDLES 2-15 MAST 2-15 LIFT CHAINS 2-16 Check for Wear 2-16 Lubrication 2-16 FORKS 2-17 BRAKE FLUID 2-17 OTHER LUBRICATION 2-17 SEAT BRAKE 2-17 ELECTRICAL INSPECTION 2-18 Contactors 2-19 Motor Brushes 2-19 EVERY 2000 HOURS OR YEARLY 2-20 HYDRAULIC SYSTEM 2-20 Change the Filter for the Hydraulic Oil ____ 2-20 Change the Hydraulic Oil 2-20 DIFFERENTIAL AND SPEED REDUCER .... 2-20 SERVICE BRAKES 2-21 CONTACTORS 2-21 WHEEL BEARINGS 2-21 Steer Wheels, Lubrication 2-21 Drive Wheels, Lubrication 2-21 LIFT CHAINS 2-21 GENERAL PROCEDURES 2-22 HOW TO CHARGE THE BATTERY 2-22 HOW TO CHANGE THE BATTERY 2-22 SAFETY PROCEDURES WHEN WORKING NEAR THE MAST 2-26 CHECK FOR LEAKS IN THE LIFT AND TILT SYSTEM 2-27 Check the Lift Cylinders for Leaks 2-27 Check the Tilt Cylinders for Leaks 2-28 LIFT CHAIN ADJUSTMENTS 2-28 WELDING REPAIRS 2-29 CHANGES TO THE OVERHEAD GUARD ... 2-29 SOLID RUBBER TIRES (PRESS-ON) ...... 2-29 How To Change A Solid Rubber Tire ..... 2-29 Install The Wheels 2-29 FRAME REPAIR 2-30 Overhead Guard, Removal 2-31 Overhead Guard, Installation 2-31 Battery Restraint And Seat Assembly ..... 2-31 Counterweight 2-34 Removal 2-34

Yale Industrial Trucks Installation 2-34 TRACTION MOTOR 2-35 Removal 2-35 Installation 2-36 HYDRAULIC TANK 2-36 Inspection 2-36 Repairs, Small Leaks 2-36 Repairs, Large Leaks 2-36 Cleaning 2-37 Steam Method Of Cleaning 2-37 Chemical Solution Method of Cleaning ____ 2-37 Additional Preparations For Repair 2-37 PAINT INSTRUCTIONS 2-37 LABEL REPLACEMENT 2-38 Section 3 ELECTRICAL SYSTEM 3-1 DC MOTOR MAINTENANCE, GENERAI _____ 3-1 BRUSH AND COMMUTATOR INSPECTION . 3-1 Hydraulic Pump Motor And Traction Motor 3-1 Steering Pump Motor 3-2 Commutator Problems 3-3 BRUSH REPLACEMENT 3-6 DISASSEMBLY OF MOTORS 3-8 Traction Motor And Hydraulic Pump Motor 3-8 Steering Pump Motor 3-9 ASSEMBLY OF MOTORS 3-12 Traction Motor And Hydraulic Pump Motor 3-12 Steering Pump Motor 3-12 BRUSH ALIGNMENT, TRACTION AND HYDRAULIC MOTORS 3-12 TESTS FOR A DAMAGED FIELD AND ARMATURE 3-12 Test For An Open Circuit In The Armature . 3-13 Test For A Short-Circuit In One Armature Winding 3-13 Test For A Short-Circuit To Armature Shaft 3-13 Test For An Open Circuit In A Field Coil ... 3-14 Test For A Short-Circuit In A Field Coil ... 3-14 Test For A Short-Circuit Between The Field And The Motor Case 3-14 Brush Holder Test 3-14 EV-1 00/200 LX MOTOR CONTROLLER EV-100LX AND EV-200LX MOTOR CONTROLLERS, GENERAL 3-15 ELECTRONIC SPEED CONTROLS 3-16 The Silicon Controlled Rectifier (SCR) .... 3-16 A Motor Circuit That Operates With Pulses 3-17 Traction Circuit 3-18 Hydraulic Pump Motor 3-18 The SCR 1 "OFF" Circuit 3-18 INDUCTION CURRENT FROM THE MOTOR 3-21 THE CONTROL CARD 3-21 Pulse Monitor Trip (PMT) (Traction Circuit Only) 3-22 SRO Circuit (Traction Circuit Only) 3-23 Control Card Adjustments (Traction Circuit) 3-23 Accelerator Control 3-26 SCR CONTROL, DUAL HYDRAULIC PUMP MOTORS 3-26 VOLTAGE ADJUSTMENTS, SCR CONTROL FOR HYDRAULIC PUMP 3-27 CONTACTORS 3-27 CIRCUIT PROTECTION 3-28 Traction Circuit Fuse 3-28 Current Limit 3-28 Thermal Protection 3-28 Suppressors 3-28 SEQUENCE OF OPERATION 3-28 CONTROL CARD, CHECKS AND ADJUSTMENTS 3-29 Status Codes 3-29 HAND SET 3-30 INSTRUMENT PANEL DISPLAY 3-31 Battery Gauge With Lift Interrupt (Curtis 933/1 or Curtis 933/4 Lift Interrupt Controller) ..... 3-31 Battery Gauge With Lift Interrupt And Brush Wear Indicator (General Electric) .. 3-32 Instrument Panel Display (I.T.W. Controller) 3-33 Motor Temperature Indicators 3-34 Brush Wear Indicators 3-34 CONTROL CARD CONNECTIONS 3-35 CHECKS AND ADJUSTMENTS, CONTROL CARD 3-39 Function Codes 3-39 Checks And Adjustments On The Bench . . 3-40 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck ..... 3-40 FUNCTION SETTINGS, CHECKS AND ADJUSTMENTS 3-41 General 3-41 How To Connect, Disconnect, And Check The Hand Set 3-41

Yale Industrial Trucks How To Check And Adjust Functions ..... 3-41 FUNCTION DESCRIPTIONS 3-42 Traction Control Cards (label letters - LX, LXT and LXM) 3-42 Pump Control Card (label letter PX) ...... 3-45 Tables for the Function Value Settings 3-46 TROUBLESHOOTING 3-50 REPAIRS 3-81 FUSES 3-82 CHECK AN SCR 3-83 The SCR 1 Assembly 3-84 Thermal Protector 3-84 Replace The SCR 1 Assembly 3-84 THE "OFF" CIRCUIT FOR SCR 1 3-84 Check The Reactor Assembly 3-84 Check Suppressors For SCR 2 And SCR 5 3-85 Check SCR 2 And SCR 5 3-85 REPLACE THE SCR 2 AND SCR 5 ...... 3-86 Check Capacitor C1 3-86 DIODES D3 AND D4 3-86 Check The Diodes D3 And D4 3-86 Replacement, Diodes D3 and D4 3-86 MOTOR CURRENT SENSOR 3-86 CONTACTORS 3-86 Contactor Repair 3-87 CONTROL CARD 3-88 CONTROL CARD PLUGS 3-89 CONTROL SWITCHES 3-89 Seat Switch 3-89 Key Switch 3-89 Direction Control Switch (Steering Column) 3-89 Parking Brake Switch And Buzzer Alarm . . 3-90 Start Switch 3-90 Accelerator Circuit 3-90 DIAGRAMS FOR THE EV-1 00/200 LX MOTOR CONTROLLER 3-95 Figure 3-60. Schematic Diagram, EV-100LX Or EV-200LX SCR Traction Motor Control, 36-48 Volts 3-96 Figure 3-61. Hydraulic Pump Moto r Controls 3-97 Figure 3-62. Hydraulic Pump Motor Controls 3-98 Figure 3-63. Hydraulic Pump Motor Controls 3-99 Figure 3-64. Hydraulic Pump Motor Controls 3-100 Figure 3-65. Wiring Diagram, EV-100LX SCR Traction Motor Control With Single Or Dual Hydraulic Pump Motor Contactor Control . 3-102 Figure 3-66. Wiring Diagram, EV-200LX SCR Traction Motor Control With EV-100LX SCR Hydraulic Pump Motor Control 3-104 Figure 3-67. Control Switches 3-106 Figure 3-68. Wiring Diagram, Control Switches Without On-Demand Power Steering ____ 3-108 Figure 3-69. Wiring Diagram, Control Switches, On-Demand Power Steering .. 3-110 Figure 3-70. Hydraulic Pump Motor Controls 3-112 Figure 3-71. Hydraulic Pump Motor Controls 3-114 Figure 3-72. EV-1 00 "LX" Series GE Or ITW Display With Lift Interrupt - Without Pump Motor SCR Control Schematic .... 3-115 Figure 3-73. Battery Indicators 3-116 Figure 3-74. Battery Indicators 3-117 Figure 3-75. "LX" SCR Hydraulics Wiring Diagram 3-118 Figure 3-76. Contactor Hydraulics Wiring Diagram 3-119 EV-1 00/200 ZX MOTOR CONTROLLER EV-100ZX AND EV-200ZX MOTOR CONTROLLERS, GENERAL 3-121 ELECTRONIC SPEED CONTROLLERS ..... 3-122 The Silicon Controlled Rectifier (SCR) .... 3-123 A Motor Circuit That Operates With Pulses 3-123 Traction Circuit 3-124 Hydraulic Pump Motor 3-124 The SCR 1 "OFF" Circuit 3-125 Induction Current From The Motor ....... 3-127 The Control Card 3-127 Pulse Monitor Trip (PMT) (Traction Circuit Only) 3-128 SRO Circuit (Traction Circuit Only) ....... 3-129 Control Card Adjustments (Traction Circuit) 3-129 Accelerator Control 3-132 SCR Control, Dual Hydraulic Pump Motors 3-132 VOLTAGE ADJUSTMENTS, SCR CONTROL FOR HYDRAULIC PUMP 3-133 CONTACTORS 3-133 CIRCUIT PROTECTION 3-134 Traction Circuit Fuse 3-134 Current Limit 3-134

Yale Industrial Trucks Thermal Protection 3-134 Suppressors 3-134 SEQUENCE OF OPERATION 3-134 CONTROL CARD, CHECKS AND ADJUSTMENTS 3-135 Status Codes 3-135 Table 16. STATUS CODES LIST 3-136 INSTRUMENT PANEL DISPLAY 3-136 Motor Temperature Indicators 3-141 Brush Wear Indicators 3-141 Table 17. Terminal And Plug Wire Connections For Control Card ZY, SCR Control Of Traction Circuit, Contactor Control Of Hydraulic Pump, Standard or GE Panel Display, Without Regenerative Braking, Without Brush Wear or Motor Temperature Indicators ... 3-143 Table 18. Terminal And Plug Wire Connections For Control Card ZH, SCR Control Of Traction Circuit, Contactor Control Of Hydraulic Pump, Performance Panel Display, With Regenerative Braking, With Brush Wear And Motor Temperature Indicators 3-144 Table 19. Terminal And Plug Wire Connections For Control Card ZH, SCR Control Of Traction Circuit, SCR Control Of Hydraulic Pump, Performance Panel Display, With Regenerative Braking, With Brush Wear And Motor Temperature Indicators 3-145 Table 20. Terminal And Plug Wire Connections For Controller With SCR Control Of Traction Circuit And SCR Control Of The Hydraulic Pump Motor — Control Card - Type ZP .. 3-146 CONTROL CARD CONNECTIONS 3-147 REGISTER PARAMETERS 3-147 General 3-147 Function Numbers 3-147 CONTROL CARD, CHECKS AND ADJUSTMENTS 3-147 HANDSET 3-148 How To Check And Adjust The Registers . 3-148 How To Scroll Through The Fault Codes And Clear Them 3-149 Checks And Adjustments On The Work Bench 3-149 When The Hand Set Is Connected To A Control Card Installed In A Lift Truck . . . 3-149 COMPUTER SYSTEM 3-151 When A PC Is Connected To A Control Card 3-152 Help 3-161 Communications Program (MODEM) ..... 3-162 Monitor Program 3-163 GE SENTRY SOFTWARE) 3-165 Getting Started 3-165 Table 21. Cable Connections - Modem To Controller 3-165 Installation of the GE SENTRY SOFTWARE 3-166 Configuration of the GE SENTRY SOFTWARE 3-166 Where To Get Help 3-166 Hardware and Software Requirements ____ 3-166 How To Start The GE SENTRY Program . . 3-167 How To Reset The MIN and MAX Display . 3-168 How To Exit The GE SENTRY Program ... 3-168 FUNCTION NUMBER DESCRIPTIONS ..... 3-168 TRACTION CONTROL CARDS (LABEL LETTERS - ZH AND ZY) 3-168 PUMP CONTROL CARD (LABEL LETTER ZP) 3-174 REGISTER PARAMETERS 3-177 REGISTER MAPS 3-177 Table 22. REGISTER MAP FOR CONTROL CARDS ZH AND ZY (TRACTION) ....... 3-178 Table 23. REGISTER MAP FOR CONTROL CARD ZP (HYDRAULIC PUMP) 3-181 Table 24. EV-100ZX Parameters - 13 Inch 36 to 48V Motor(Traction Card Type ZH With Regenerative Braking and Field Weakening) 3-185 Table 25. EV-100ZX Parameters - 11.6 Inch 36 to 48V Motor(Traction Card Type ZH With Regenerative Braking and Field Weakening) 3-188 Table 26. EV-100ZX Parameters - 36 to 48 volts (Hydraulic Pump Card Type ZP) . 3-191 TROUBLESHOOTING 3-193 Status Codes 3-194 REPAIRS 3-228 FUSES 3-229 CHECK AN SCR 3-229 Table 27. Fuses 3-229 The SCR 1 Assembly 3-231 Thermal Protector 3-231 Replace The SCR 1 Assembly 3-231 THE "OFF" CIRCUIT FOR SCR 1 3-232 Check The Reactor Assembly 3-232 Check Suppressors For SCR 2 And SCR 5 3-232

Yale Industrial Trucks Check SCR 2 And SCR 5 3-233 Replace The SCR 2 And SCR 5 3-233 Check Capacitor C1 3-233 DIODES D3 AND D4 3-233 Check The Diodes D3 And D4 3-233 Replacement, Diodes D3 and D4 3-233 MOTOR CURRENT SENSOR 3-234 CONTACTORS 3-234 Contactor Repair 3-235 CONTROL CARD 3-236 CONTROL CARD PLUGS 3-236 CONTROL SWITCHES 3-236 Seat Switch 3-237 Key Switch 3-237 Direction Control Switch (Steering Column) (Earlier) 3-237 Direction Control Switch (Steering Column) (Later) 3-237 Parking Brake Switch And Buzzer Alarm . . 3-238 Start Switch 3-238 Brush Wear Indicators 3-238 Over Temperature Indicators 3-239 Direction Switches Of Direction Control Pedal 3-239 Accelerator Or Direction Control Circuit . . . 3-240 Figure 3-138. Hydraulic Schematic 3-242 Figure 3-139. Schematic Diagram, EV-100ZX or EV-200ZX SCR Motor Controllers, 36-48 Volts 3-244 Figure 3-140. Wiring Diagram, EV-100ZX or EV-200ZX SCR Motor Controllers, 36-48 Volts (1 of 6) 3-252 Figure 3-141. Cable Diagram, EV-100ZX or EV-200ZX SCR Motor Controllers, 36-48 Volts 3-262 Figure 3-142. Detail Diagram, EV-100ZX or EV-200ZX SCR Motor Controllers, 36-48 Volts 3-263 Figure 3-143. Control Panels, EV-100ZXor EV-200ZX SCR Motor Controllers, 36-48 Volts 3-264 Figure 3-144. Schematic And Wiring Diagram - 12V Lights 3-266 Section 4 DRIVE AXLE ASSEMBLY 4-1 DESCRIPTION 4-1 DRIVE AXLE, REMOVAL 4-2 Traction Motor, Speed Reducer, and Differential 4-2 DISASSEMBLY 4-5 Speed Reducer 4-5 Differential 4-5 CLEANING 4-5 INSPECTION 4-5 ASSEMBLY 4-6 Speed Reducer 4-6 TABLE 1. ADJUSTMENT OF SHIMS FOR THE PINION ASSEMBLY 4-7 Differential 4-8 DRIVE AXLE HOUSING 4-11 Removal 4-11 Cleaning 4-11 Inspection 4-11 Assembly 4-11 TROUBLESHOOTING 4-14 Section 5 THE BRAKE SYSTEM 5-1 MASTER CYLINDER 5-1 SERVICE BRAKE ASSEMBLY 5-1 PARKING BRAKE 5-1 Brake Shoes, Removal and Disassembly . 5-2 Cleaning and Inspection 5-3 Assembly and Installation 5-5 MASTER CYLINDER 5-7 Cleaning and Inspection 5-8 Assembly and Installation 5-8 CHECKS AND ADJUSTMENTS 5-8 Remove The Air From The Brake System . 5-8 Adjust The Brake Pedal 5-8 Adjust The Brake Shoes 5-9 TROUBLESHOOTING 5-10 Section 6 STEERING AXLE ASSEMBLY 6-1 DESCRIPTION 6-1 STEERING AXLE ASSEMBLY 6-1 Removal 6-1 Installation 6-1 WHEELS AND HUBS 6-2 Removal and Disassembly 6-2 Cleaning 6-2 Assembly And Installation 6-2 SPINDLES, BEARINGS AND TIE RODS .... 6-3

Yale Industrial Trucks Removal And Disassembly 6-3 Cleaning 6-4 Assembly And Installation 6-4 STEERING CYLINDER 6-5 Removal And Disassembly 6-5 Cleaning and Inspection 6-5 Assembly and Installation 6-5 TORQUE SPECIFICATIONS 6-6 TROUBLESHOOTING 6-6 Section 7 POWER STEERING SYSTEM 7-1 GENERAL 7-1 STEERING WHEEL AND COLUMN ASSEMBLY 7-2 Removal Of The Assembly Components . . 7-2 Installation Of The Assembly Components 7-3 POWER STEERING MOTOR AND PUMP ... 7-5 Removal And Disassembly 7-5 Assembly And Installation 7-6 Repairs, Power Steering Pump 7-7 Seal Replacement 7-8 TROUBLESHOOTING, STEERING MOTOR AND PUMP 7-9 STEERING CONTROL UNIT (ROSS HGF) .. 7-11 Control Valve Section 7-11 Metering Section 7-11 Disassembly And Inspection 7-13 Assembly 7-20 Installation 7-27 TROUBLESHOOTING (ROSS HGF) 7-28 STEERING CONTROL UNIT (DANFOSS) ... 7-28 Description 7-28 Removal 7-29 Disassembly 7-29 Cleaning 7-32 Assembly 7-32 Installation 7-32 TROUBLESHOOTING (DANFOSS) 7-36 CHECKS AND ADJUSTMENTS 7-37 Remove Air From The System 7-37 Steering Relief Valve 7-37 Check Optical Encoder And Activator Circuits For "ON-DEMAND" Steering .... 7-37 Section 8 HYDRAULIC SYSTEM 8-1 DESCRIPTION, HYDRAULIC SYSTEM ..... 8-1 OPERATION, HYDRAULIC SYSTEM 8-2 Hydraulic Pump 8-3 Steering Pump 8-3 HYDRAULIC PUMP, REPAIRS 8-4 Removal 8-4 Seal Replacement 8-5 Installation 8-5 CHECKS AND ADJUSTMENTS 8-5 Main Control Valve 8-5 Linkage and Switches 8-7 Relief Valve 8-7 Steering Relief Valve 8-7 SPECIFICATIONS, HYDRAULIC SYSTEM ... 8-8 TABLE 1. TROUBLESHOOTING, HYDRAULIC SYSTEM 8-9 LIFT CYLINDERS 8-10 Lowering Control Valve 8-11 Lift Cylinders, Removal 8-11 Standard and Full Free-Lift Masts with the Lift Cylinder Fastened to a Crosshead ... 8-11 Lift Cylinders, Disassembly 8-12 Main Lift Cylinders, Assembly 8-14 Main Lift Cylinders, Installation 8-15 Free-Lift Cylinder, Installation 8-15 CHECKS AND ADJUSTMENTS 8-15 Check For Leaks In The Lift System ...... 8-15 TABLE 3. TROUBLESHOOTING, LIFT CYLINDERS 8-16 TILT CYLINDERS 8-17 Description 8-17 Tilt Cylinders, Removal 8-17 Tilt Cylinders, Disassembly 8-17 Cleaning 8-17 Tilt Cylinders, Assembly 8-17 Tilt Cylinders With O-Ring or Single Lip Seals 8-17 Tilt Cylinders, Installation 8-17 Check The Tilt Cylinders For Leaks ...... 8-18 TABLE 4.TORQUE SPECIFICATIONS FOR THE TILT CYLINDERS 8-19 TABLE 5. INTERNAL LEAK RATES (MAXIMUM) FOR TILT CYLINDERS 8-19 TABLE 6.TROUBLESHOOTING, TILT CYLINDERS 8-19

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Yale Forklift Truck A839 Series: ERC070HD, ERC080HD, ERC100HD, ERC120HD Workshop Manual

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