Yale 524150797, Maintenance Manual

Page: 119 / 382

Hydraulic Pump Reservoir
REMOVE
The reservoir of the hydraulic pump unit can be re-
moved without removing the complete hydraulic unit.
The motor will also come loose, with one set of
screws holding the reservoir to the subunit to the mo-
tor.
WARNING
The capacitor in the transistor controller can hold
an electrical charge after the battery is disconnec-
ted. To prevent electrical shock and personal in-
jury, discharge the capacitor before inspecting or
repairing any component in the drive unit com-
partment. Wear safety glasses. Make certain the
battery has been disconnected. Refer to the Spe-
cial Precautions section in this manual.
CAUTION
Make certain the hydraulic cylinder is fully col-
lapsed.
NOTE: The reservoir must be lowered below the suc-
tion tube before attempting to move the reservoir
away from the lift truck. Remember the reservoir may
contain hydraulic oil. Dispose of all used oil in accord-
ance with local regulations.
1. Turn the key switch to the OFF position and dis-
connect the battery.
2. Remove the drive unit compartment cover. Refer
to
AC Motor Repair 0620YRM1513, Accessing
the Drive Unit Compartment.
3. Discharge the capacitor. See Special Precau-
tions.
4. Disassemble and plug the hydraulic lines to the
hydraulic unit.
5. Remove the four capscrews retaining the reser-
voir to the hydraulic unit. Carefully remove the
reservoir.
6. Clean the reservoir and the suction screen. In-
spect the screen for damage and replace if nec-
essary.
NOTE: The capscrews that hold the reservoir to the
subunit also hold the motor to the subunit. When the
capscrews are removed, the motor will be resting on
the subunit. When reinserting the capscrews, ensure
that the motor is located correctly and the coupler is
seated properly.
INSTALL
1. Lubricate a new O-ring using clean hydraulic oil
and install into the pump body.
2. Align the reservoir in the proper position and in-
stall the four capscrews to retain the reservoir to
the hydraulic unit.
3. Install the hydraulic lines to the hydraulic unit.
4. Remove the blocks and lower the lift truck to the
floor.
5. Remove the breather and add the recommended
hydraulic oil until it reaches the full mark. Replace
the breather. If too much hydraulic oil is added,
the oil will leak from the breather during operation.
If too much oil has been added, drain or use a
suction device to remove excess oil.
6. Connect the battery. Run the pump for 5 seconds
and energize the lowering valve at the same time
so that oil gets through the pump body and valve
at 0.0 psi. Operate the forks up and down three or
four times to remove air from the system. Operate
the lift truck until the hydraulic oil reaches operat-
ing temperature. Remove the breather and check
the hydraulic oil level. Add additional oil if neces-
sary. Check for hydraulic oil leaks.
7. Install the drive unit compartment cover. Test the
operation of the lift truck prior to returning the
truck to service.
1900 YRM 1506 Hydraulic Pump
9