YALE (C813) GP/GLP/GDP70-120LJ/MJ Lift Truck Service Repair Manual

Maintenance LIFT CYLINDERS ERC070-120HG [A839]; GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) [C813, E813]; GC070-120LJ/MJ [C818, D818]; ERC35-55HG (ERC70-120HH) [B839] PART NO. 524153919 4000 YRM 741

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR • When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas- tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. • Do not lift heavy parts by hand, use a lifting mechanism. • Wear safety glasses. • DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks. • Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. • Keep the unit clean and the working area clean and orderly. • Use the correct tools for the job. • Keep the tools clean and in good condition. • Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. • Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts. • Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs. • Be sure to follow the WARNING and CAUTION notes in the instructions. • Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems. • Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated. NOTE: The following symbols and words indicate safety information in this manual: WARNING Indicates a condition that can cause immediate death or injury! CAUTION Indicates a condition that can cause property damage!

Lift Cylinders Table of Contents TABLE OF CONTENTS Safety Procedures When Working Near Mast ..................................................................................................... 1 General ................................................................................................................................................................ 3 Description .......................................................................................................................................................... 3 Lowering Control Valve (Velocity Fuse) ........................................................................................................... 3 Lift Cylinder Repair .............................................................................................................................................. 6 Remove ........................................................................................................................................................... 6 Disassemble.................................................................................................................................................... 7 Assemble ........................................................................................................................................................ 7 Install ............................................................................................................................................................... 7 Lift System Leak Check ....................................................................................................................................... 8 Troubleshooting ................................................................................................................................................... 9 This section is for the following models: ERC070-120HG [A839]; GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP070-120LJ/MJ) [C813, E813]; GC070-120LJ/MJ [C818, D818]; ERC35-55HG (ERC70-120HH) [B839] ©2005 Yale Materials Handling Corp. i

4000 YRM 741 Safety Procedures When Working Near Mast Safety Procedures When Working Near Mast The following procedures MUST be used when inspect- ing or working near the mast. Additional precautions and procedures can be required when repairing or re- moving the mast. WARNING Mast parts are heavy and may shift. Distances be- tween parts are small. Serious injury can result if part of the body is hit by parts of the mast or the carriage. • Never put any part of the body into or under the mast or carriage unless all parts are completely lowered or a safety chain is installed. Make sure the power is OFF and the battery is disconnected. Put a DO NOT OPERATE tag in the operator’s compartment. • Be careful of the forks. When the mast is raised, the forks can be at a height to cause an injury. • DO NOT climb on the mast or lift truck at any time. Use a ladder or personnel lift to work on the mast. • DO NOT use blocks to support the mast weld- ments nor to restrain their movement. • Mast repairs require disassembly and removal of parts and can require removal of the mast or carriage. Follow the repair procedures in the correct Service Manual for the mast. WHEN WORKING NEAR THE MAST ALWAYS: • Lower the mast and carriage completely. Push the lift/lower control lever forward and make sure there is no movement in the mast. Make sure all parts of the mast that move are fully lowered. OR • If parts of the mast must be in a raised position, install a safety chain to restrain the moving parts of the mast. Connect moving parts to a part that does not move. Follow these procedures: 1. Put mast in a vertical position. 2. Raise mast to align bottom crossmember of weldment that moves in outer weldment with a crossmember on outer weldment. On two-stage and free-lift mast, the moving part is the inner weldment. On three-stage mast, it is the intermediate weldment. See Figure 1. 3. Use a 3/8-inch minimum safety chain with a hook to fasten cross members together so the movable member cannot lower. Put hook on back side of mast. Make sure hook is completely engaged with a link in the chain. Make sure safety chain does not touch lift chains or chain sheaves, tubes, hoses, fittings, or other parts on the mast. 4. Lower mast until there is tension in safety chain, and free-lift cylinder (two-stage full free-lift and three-stage masts only) is completely retracted. If running, stop engine. Apply parking brake. Install a DO NOT REMOVE tag on safety chain(s). 5. Install another safety chain (3/8 inch minimum) be- tween top or bottom crossmember of carriage and a crossmember on outer weldment. NOTE: After lowering or restraining the mast, shut off the power and remove the key. Put a DO NOT OPER- ATE tag in the operator’s compartment. 1

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YALE (C813) GP/GLP/GDP70-120LJ/MJ Lift Truck Service Repair Manual

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