Yale ERP15-20VT Service Manual page 27

1800 YRM 1332
6. Loosen the nut and remove the clevis and nut from
the push rod if necessary.
7. Remove the retaining ring and extract the piston
assembly from the cylinder housing.
CLEAN AND INSPECT
Clean the inside of the master cylinder housing with a
clean cloth and solvent. Inspect the inside of the hous-
ing for grooves, wear, or scarring. If the housing shows
any visible damage, replace the master cylinder.
ASSEMBLE
CAUTION
The brake system uses Dexron III (same as used in
the transaxle). Use of other fluids can damage the
brake system.
NOTE: Lightly lubricate the piston assembly compo-
nents with Dexron III prior to installation.
1. Install the piston assembly into the cylinder hous-
ing:
a. Carefully install the piston assembly into the
cylinder housing (spring first) and hold in po-
sition.
b. Install the retaining ring into the cylinder hous-
ing against the cup. Ensure that the retain-
ing ring is securely seated in the groove of the
cylinder housing.
2. Install the transducer by screwing it into the cylinder
housing. Tighten to 23 to 28 N•m (17 to 21 lbf ft).
3. Install the elbow fitting into the cylinder housing.
Orient as removed.
4. Install the reservoir onto the cylinder housing.
Tighten the clamp to secure in position.
5. Install the boot to the housing.
6. Install nut onto rod and then install clevis onto rod
as removed. Wait to tighten nut until linkage has
been adjusted.
NOTE: Lightly lubricate the push rod with Dexron III to
ease in installation.
7. Install the push rod through the hole in the boot into
the cylinder housing.
8. Install master cylinder assembly to the truck. See
Install.
INSTALL
CAUTION
The brake system uses Dexron III (same as used in
the transaxle). Use of other fluids can damage the
brake system.
1. Position master cylinder to bracket and align mount-
ing holes.
2. Install capscrews and nuts securing master cylinder
to bracket. Tighten to 19 to 23 N•m (14 to 17 lbf ft).
3. Install the main pressure line to the elbow fitting on
top of the master cylinder.
4. Connect transducer and fluid sensor wiring as re-
moved.
5. Attach the clevis to the pedal using the clevis pin
and washer. Secure in place with a new cotter pin.
Adjust linkage as necessary. See Adjustments, Ad-
just Linkage.
6. Bleed air from the brake system. See Adjustments,
Bleed the Brake System.
ADJUSTMENTS
Bleed the Brake System
CAUTION
The brake system uses Dexron III (same as used in
the transaxle). Use of other fluids can damage the
brake system.
When the brake system is operating properly, the brake
pedal will have back pressure that will stop the pedal
before it can be pressed to the end of its mechanical
travel limit. A brake system that has air present may
have some back pressure but not enough to stop the
pedal before reaching its mechanical travel limit. The
pedal may feel soft and inconsistent (spongy) and must
be bled before operating the lift truck.
NOTE: Bleeding air from the brake system requires two
technicians. One technician must sit in the seat and op-
erate the brake pedal while the other opens and closes
the brake bleed valve located on the transaxle housing.
Master Cylinder Repair
7