Maintenance

TILT CYLINDERS
ESC030-040FA [A883];
MCW025/030/040-E [C819]

PART NO. 524153636 2100 YRM 999

 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!
Tilt Cylinders Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Tilt Cylinder Repair .............................................................................................................................................. 1
Remove ........................................................................................................................................................... 1
Disassemble.................................................................................................................................................... 1
Clean............................................................................................................................................................... 1
Assemble ........................................................................................................................................................ 1
Install............................................................................................................................................................... 3
Tilt Cylinder Leak Check...................................................................................................................................... 5
Mast Tilt Angle Adjustment.................................................................................................................................. 5
Troubleshooting ................................................................................................................................................... 6

This section is for the following models:

ESC030-040FA [A883];
MCW025/030/040-E [C819]

©2003 Yale Materials Handling Corp. i

2100 YRM 999 Tilt Cylinder Repair

General
This section has the description and repair procedures for the tilt cylinders.

Description
The tilt cylinders are used to move the mast forward then returns to the hydraulic tank. To retract the cylinder
and backward. To extend the cylinder rod (tilt forward), rod (tilt backward), the oil enters the port in front of the
oil enters the tilt cylinder port behind the piston. The oil piston. The oil pressure pushes against the piston and
pressure pushes against the piston and the cylinder rod the cylinder rod is pushed into the tilt cylinder. The oil
is pushed out of the cylinder. Oil in front of the piston behind the piston returns to the hydraulic tank.

Tilt Cylinder Repair

REMOVE 2. Remove retainer from tilt cylinder. Remove rod and
piston from cylinder. See Figure 4 and Figure 5.
WARNING 3. Disassemble tilt cylinder as necessary. See Fig-
Before removing the tilt cylinder(s), tilt the mast for- ure 2 and Figure 3.
ward. Use a chain to hold the mast to the frame, and
to prevent the mast from moving forward. CLEAN

WARNING WARNING
Hydraulic oil is hot after system operation and Cleaning solvents can be flammable and toxic and
can cause burns. Do not disconnect any hydraulic can cause skin irritation. When using cleaning
hoses until the oil in the system is cool. solvents, always follow the solvent manufacturer’s
recommended safety procedures.
1. See Figure 1 for the following procedures.
Compressed air can move particles so they cause
2. Disconnect hydraulic lines at tilt cylinder. Install injury to the user or to other personnel. Make sure
caps on hydraulic lines and ports. Clean up any the path of the compressed air is away from all per-
spilled oil. sonnel. Wear protective goggles or a face shield to
prevent injury to the eyes.
WARNING
Clean all parts in solvent and dry with compressed air.
Do not push the anchor pins out of the rod end with
your fingers. Do not permit the tilt cylinders to drop
ASSEMBLE
and cause damage.
NOTE: Always use new seals and O-rings. Make sure
NOTE: Always remove the anchor pins from the mast
all parts are clean. Lubricate all parts with clean hy-
first.
draulic oil.
3. Remove retainers for mast anchor pins. Push an-
1. Install piston seal onto piston. Install piston onto
chor pins out of rod end with a tool.
cylinder rod. Make sure piston seal is not damaged.
4. Remove anchor pins from frame anchors. Remove Tighten nut on piston rod to 176 N•m (130 lbf ft).
tilt cylinder from frame.
2. Install a new wiper and rod seal. Install O-ring and
backup ring onto retainer. See Figure 4 and Fig-
DISASSEMBLE
ure 5.
1. Put tilt cylinder in a vise with soft jaws. Remove rod
end from rod.

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Tilt Cylinder Repair 2100 YRM 999

1. CAPSCREW 8. ROD END

2. LOCKWASHER 9. TILT CYLINDER
3. NUT 10. PIN-CYLINDER END
4. CAPSCREW 11. COTTER PIN
5. LOCKWASHER 12. WASHER
6. WASHER 13. BUSHING
7. PIN-ROD END

Figure 1. Tilt Cylinders

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2100 YRM 999 Tilt Cylinder Repair

1. CYLINDER SHELL 6. BACKUP RING

2. ROD 7. O-RING
3. WIPER 8. PISTON
4. RETAINER 9. PISTON SEAL
5. ROD SEAL 10. NUT

Figure 2. Tilt Cylinders (ESC030-040FA)

3. Install retainer assembly onto rod. INSTALL

a. Install new wiper seal in retainer. See Figure 4. 1. Put cylinder in lift truck. Install anchor pin and wash-
Turn retainer into cylinder shell until threads ers into rod end and frame. Install retainer pin or
have started. Push piston in and out several cotter pin. See Figure 1.
times to make sure alignment is correct.
2. Install anchor pin at mast mount. Tighten capscrew
b. Tighten retainer to 176 N•m (130 lbf ft). See for the retainer pin to 38 N•m (28 lbf ft).
Figure 5.
3. Connect hydraulic lines to tilt cylinder.
4. Install piston and rod assembly into cylinder.
Tighten retainer to 176 N•m (130 lbf ft). 4. Operate tilt cylinders. Check for correct operation
and leakage. Adjust tilt cylinders as described in
5. Install rod assembly capscrew. Tighten retainer to Tilt Cylinder Leak Check and Mast Tilt Angle Ad-
176 N•m (130 lbf ft). justment.

NOTE: After assembly is complete, install the rod end

on the cylinder rod.

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Tilt Cylinder Repair 2100 YRM 999

1. NUT 7. O-RING
2. PISTON RING 8. BACKUP RING
3. PISTON SEAL 9. ROD SEAL
4. PISTON 10. RETAINER
5. CYLINDER SHELL 11. WIPER
6. ROD

Figure 3. Tilt Cylinder (MCW025/030/040-E)

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2100 YRM 999 Mast Tilt Angle Adjustment

1. WIPER SEAL 2. RETAINER

1. RETAINER
Figure 4. Wiper Seal Installation
Figure 5. Retainer Installation

Tilt Cylinder Leak Check

NOTE: Tilt drift must not exceed 2.5 degrees in five min-
WARNING utes with hydraulic oil at 49 C (120 F).
Never allow anyone under a raised carriage. Do not
put any part of your body in or through the lift mech- 3. If the tilt rate is greater than the specifications, lower
anism unless all parts of the mast are completely mast and remove load from forks. Install a valve be-
lowered, engine is STOPPED, and battery is discon- tween port at front of tilt cylinder and hydraulic line.
nected. Put load on forks again. Raise load approximately
2.5 m (8 ft). Close valve. Tilt mast forward just past
Do not try to find hydraulic leaks by putting your the vertical position. If mast continues to tilt slowly
bare hand on hydraulic components under pres- forward, the seals on the piston are leaking.
sure. Hydraulic oil can be injected into the body
by the pressure. 4. If mast does not move, open gate valve and check
movement again. If mast moves forward when gate
1. Put capacity load on forks. Use a safety chain to valve is open, check for leaks in hydraulic lines and
hold load to carriage. Raise load approximately fittings. If no leaks are found, the main control valve
2.5 m (8 ft). Put mast in vertical position. may be worn or damaged. Remove load from forks
when checks are complete.
2. Check distance (in degrees) the mast moves in one
minute.

Mast Tilt Angle Adjustment

From vertical, back tilt slowly until one rod end stops. (Relieve pressure in tilt cylinder if necessary). Repeat
Turn opposite rod end in by turning rod into the rod end. until both rod ends stop at the same time (within 1 mm).

5
Troubleshooting 2100 YRM 999

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Tilt cylinder movement is slow Air is in the hydraulic system. Remove air from hydraulic system.
or not smooth.

The hydraulic pump is worn or dam- Repair or replace hydraulic pump.

aged.

Restriction in the hydraulic lines. Repair hydraulic lines.

Seals in tilt cylinder are damaged. Replace seals and inspect cylinder
bore for damage.

Tilt cylinders have internal damage. Repair or replace cylinder.

Load is greater than capacity. Reduce load.

Pressure relief valve(s) is not adjusted Repair or adjust relief valve(s).

correctly or is damaged.

Control valve is leaking internally. Replace valve.

The tilt cylinders permit the There are leaks in the hydraulic lines. Tighten fittings or repair leaks.
mast to move when the tilt
valve is not operated.

Seals in tilt cylinder are damaged. Replace seals and inspect cylinder
bore for damage.

Tilt cylinders have internal damage. Repair or replace cylinder.

Tilt control valve is damaged. Replace control valve.

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 Yale Materials Handling Corp.
1400 Sullivan Dr., Greenville, NC 27834-2011

2100 YRM 999 4/03 (12/01) Printed in U.S.A.