Maintenance
HYDRAULIC SYSTEM
ESC030AC, ESC035AC, ESC040AC
[B883]
PART NO. 550002993 1900 YRM 1413
SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Alwaysfasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Hydraulic System Table of Contents
TABLE OF CONTENTS
General ................................................................................................................................................................ 1
Hoses .............................................................................................................................................................. 1
Fittings............................................................................................................................................................. 1
Discharging the Capacitors ............................................................................................................................. 2
Multifunction Control Handle ............................................................................................................................... 3
Description ...................................................................................................................................................... 3
Standard (Right/Left) Configuration ............................................................................................................ 3
Optional (Push/Pull) Configuration.............................................................................................................. 4
Manual Lowering ................................................................................................................................................. 4
How to Lower Mast Manually .......................................................................................................................... 4
Main Hydraulic Control Valve .............................................................................................................................. 5
Description ...................................................................................................................................................... 5
Check and Adjust ............................................................................................................................................ 5
Check Manifold Pressures .......................................................................................................................... 5
Check Counterbalance Valve ...................................................................................................................... 5
Remove (Control Valve) .................................................................................................................................. 6
Repair (Control Valve) ..................................................................................................................................... 7
Disassemble ............................................................................................................................................... 7
Clean .......................................................................................................................................................... 7
Assemble .................................................................................................................................................... 8
Install (Control Valve) ...................................................................................................................................... 8
Lift Pump and Motor ............................................................................................................................................ 9
Remove ........................................................................................................................................................... 9
Install ............................................................................................................................................................... 10
Lift Pump ............................................................................................................................................................. 11
Disassemble.................................................................................................................................................... 11
Assemble ........................................................................................................................................................ 11
Hydraulic Tank ..................................................................................................................................................... 12
Inspect ............................................................................................................................................................. 12
Remove ........................................................................................................................................................... 13
Clean ............................................................................................................................................................... 15
Steam Method ............................................................................................................................................ 15
Trisodium Phosphate Method ..................................................................................................................... 15
Install ............................................................................................................................................................... 15
Troubleshooting ................................................................................................................................................... 16
This section is for the following models:
ESC030AC, ESC035AC, ESC040AC [B883]
©2012 Yale Materials Handling Corp. i
1900 YRM 1413 General
General
WARNING
Always wear the proper protective equipment in-
cluding eye protection and petroleum resistant
gloves when handling hydraulic oil. Thoroughly
wash oil from exposed areas of skin as soon as
possible.
Relieve pressure on all hydraulic components be-
fore disassembling any part of the lift pump or dis-
connecting any hydraulic hoses.
The hydraulic oil is hot at normal operating temper-
atures. Be careful when draining the oil.
Never check for leaks by putting hands on hydraulic
lines or components under pressure. Hydraulic oil
under pressure can be injected into the skin.
CAUTION
Protect the hydraulic system from dirt and contam-
inants when servicing the hydraulic system.
Never operate the pump without the proper amount
of oil in the hydraulic system. The operation of the
hydraulic pump with low oil levels will damage the
pump.
The hydraulic system for these lift trucks is comprised
of three subsystems. These subsystems are:
• Main Hydraulic - Lift and lower
• Auxiliary Hydraulic - Tilt and optional sideshift
• Power Steering
The hydraulic system includes two pumps. The lift
pump will only operate when the control handle is
moved to start the lift function, the tilt/sideshift disk
is pressed, or an auxiliary function button is pressed.
When the key is in the ON position and the brake pedal
is down, the steering pump operates at idle speed. As
the steer tiller is rotated, the steer pump is driven faster
to meet the increased demand of the steering circuit.
The lift pump and steering pump are located under the
front cover.
The main and auxiliary hydraulic functions are con-
trolled by an electro-hydraulic control valve. This valve
is custom designed to provide proportional control of
lift and lower functions. To provide maximum control,
each function is operated electronically using elec-
tro-hydraulic valves. Separate lift and auxiliary relief
valves are provided to allow operation at different
pressures and minimize energy consumption.
The electro-hydraulic control valve is actuated by the
control handle. The multifunction control handle is a
two axis control used for both hydraulic and traction op-
eration.
HOSES
The hydraulic hoses carry hydraulic fluid from the tank
to the hydraulic pumps, to the hydraulic functions,
and back to the tank. Hoses may be pressurized or
non-pressurized. Non-pressurized hoses slide onto
barbed fittings and are secured in place with hose
clamps. Pressurized hoses are reinforced with steel
mesh molded into the rubber to support the high
pressures created by the pump. These hoses have
hydraulic fittings crimped into each end.
FITTINGS
Various types of fittings are used to connect hoses and
hydraulic system components. Some of these include
flared fittings, O-ring fittings, and flat-faced O-ring
fittings. Certain fittings have properties that make
them better suited for particular applications. Check
the threads and mating surfaces of each fitting when
removed. Fittings with O-rings should be inspected
carefully and the O-ring replaced if it is brittle, cracked,
or otherwise damaged. Make sure mating surfaces
are clean and smooth and do not over tighten fittings.
Inspect fittings for leaks often following repairs.
1
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Description
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