CYLINDERS

Cylinders

Cylinders
Great care and cleanliness should be exercised in the
disassembly and assembly of any hydraulic cylinders.
1. Wipe all surfaces clean of dirt and oil before disas-
sembly.
2. Care should be taken when removing the ram from
the cylinder to prevent damage to the packing on
the piston end.
3. After cylinder components are disassembled and
seals, o-rings and wipers are removed, thoroughly
wash all metallic parts in solvent and blow dry with
compressed air.
4. Carefully inspect the ram assembly and cylinder
bore. Replace if scored, grooved, pitted or worn.
Minor damage to the cylinder bore can be removed
with the use of a cylindrical honing tool.
5. Place washed components in a clean container un-
til reassembly. Whenever new packings are re-
quired, new wiper rings should also be installed.

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CYLINDERS
Cylinders

Mast Cylinder

RH Only

RH Only

Figure 15293

The mast cylinder is secured to the outer mast. The

mast cylinder is a single acting ram type cylinder. Ex-
treme care should be taken when performing any type
of repair. In the event of excessive oil leakage around
the rod end of the cylinder or its inability to lift the load,
the cylinder will have to be removed from the truck and
repaired.

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 CYLINDERS
Cylinders

Mast Cylinder Inspection Mast Cylinder Repair

1. Before disconnecting battery and initial cylinder re-
pair, a careful inspection should be made of the WARNING
cylinder assembly throughout a complete lift and
lower sequence. Avoid high pressure fluids - escaping fluids under pres-
sure can penetrate the skin, causing serious injury. Re-
2. Check ram (12) for any signs of nicks, scratches, lieve pressure before disconnecting hydraulic lines.
surface imperfections, etc. that allow abnormal Tighten all connections before applying pressure.
leakage, improper cylinder operation, or create Keep hands and body away from pin holes which eject
seal damage. fluids under high pressure. Use a piece of cardboard or
3. Check wiper ring (14) and complete cap area for paper to search for leaks. Do not use your hand.
component wear and/or leakage that is abnormal. Any fluid injected into the skin under high pressure
should be considered a serious medical emergency
As the cylinder assembly is repaired be aware of com- despite an initial normal appearance of the skin. There
ponent part condition and not only replace a worn or is a delayed onset of pain, and serious tissue damage
damaged part, but correct or replace a part that may be may occur. Medical attention should be sought imme-
causing other premature wear. diately from a specialist who has experience with this
type of injury.
Mast Cylinder Disassembly
When an excessive amount of hydraulic oil is evident
1. Turn the cap counterclockwise and unscrew it from on the top of the cylinder where the ram exits from the
the cylinder tube. Refer to Figure 15962. cap, the rod packing is probably bad and should be re-
placed. The replacement of the packing can be accom-
plished without removing the ram assembly from the
cylinder tube or truck.
1 Cylinder Tube
1. Make sure all hydraulic pressure has been re-
2 Cap
moved from the mast cylinders.
3 O-Ring
2. Carefully remove hydraulic fittings from lift cylinder
4 Bleed Screw
rams. Attempt to absorb any hydraulic oil draining
from lines during this procedure.
3. Remove cylinder cap by turning it in a counter-
clockwise direction.

NOTE
Seals used in the cylinders are made of an extremely
durable, hard polyurethane material which can be de-
formed temporarily to allow for installation without per-
manent damage.

Figure 15962

2. Remove the cap and carefully extract the ram as-

sembly from the cylinder bore, never allowing the
ram to come in contact with any sharp edges.

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CYLINDERS
Cylinders

4. The packing is located below the cap and remains

in the cylinder bore after the cap is removed. A pair
of special tools can be used to facilitate packing
removal (refer to Figure 15963).

1 Seal Pulling Tool

1 Screwdriver 152 mm (6 in) Shaft Length (Min.) 4 mm
2 Ram
(0.156 in) Shaft Diameter (Max.)
3 Cylinder Tube
2 No. 8 Metal Screw Headless (4 mm Self-Tapping)
4 Seal
3 Weld (Grind Off Excess) to a Max. Dia. of 4 mm
(0.156 in)
4 Tape Figure 15964

6. After the threads are sufficiently secured into the

Figure 15963
packing, evenly pull on the screwdriver handles
until the packing is removed.
To make these tools, weld or braze a headless 4.0 mm
self-tapping (No. 8 metal) screw to the end of a screw-
driver. The screwdriver must have at least 150 mm CAUTION
(6.0 in) of shank length with no larger than 4.0 mm
Close inspection of seal seating critical areas should
(0.156 in) shank diameter. After attaching the screw to
be made before the new seal is installed.
the screwdriver, grind off excess weld to a diameter of
4.0 mm (0.156 in). Wrap the shank with electrical tape
from the tip of the screw to the screwdriver handle. This
will prevent scratching of the cylinder bore or the ram.

NOTE
Extreme care should be taken to prevent damage to
cylinder wall and ram assembly.
5. Insert the tools between the ram and the cylinder
walls, 180° apart, and screw into the face of the
packing (refer to Figure 15964).

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 CYLINDERS
Cylinders

Refer to Figure 15970. Seal failure may not have been Mast Cylinder Reassembly
caused by a worn seal, but rather by burrs, nicks and
dirt located on the seal seating area, causing the seal
to deform and lose its sealing ability. CAUTION
Care should be taken when inserting the cylinder cap,
to prevent threads and sharp edges from damaging
new seals and packings. Packings can also be dam-
aged by forcing air past seals.
When repacking the mast cylinder, carefully bring oil
back into the system while the bleed screw is fully open
to allow air to burp.
After packings and seals are in place and the ram as-
sembly has been installed, reattach the cap.

Mast Cylinder Bleeding and Flushing Pro-

cedures

WARNING
Avoid high pressure fluids - escaping fluid under pres-
1 Critical Seal Seating Area
sure can penetrate the skin causing serious injury. Re-
2 Seal lieve pressure before disconnecting hydraulic lines.
3 Forging Tool Tighten all connections before applying pressure.
4 Sleeve Keep hands and body away from pin holes which eject
5 Cylinder Tube fluids under high pressure. Use a piece of cardboard or
paper to search for leaks. Do not use your hand.
6 Collar
Any fluid injected into the skin under high pressure
should be considered as a serious medical emergency
Figure 15970 despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue damage
7. At this time, the wiper ring should also be removed
may occur. Medical attention should be sought imme-
since packings and wiper rings should always be
diately by a specialist who has had experience with this
replaced in pairs. Thoroughly clean the area where
type of injury.
the seals seat. Any burrs, dirt or seal debris must
be removed before installing new seals. Mast hydraulic circuits need to be flushed after repair
of mast cylinders and bled of all air. Before flushing and
8. Tools used to install hydraulic seals should be of
bleeding of system inspect all hydraulic connections
soft metal or suitable plastic, free of burrs and
and verify that all filters are installed and hydraulic fluid
sharp edges. Screwdrivers and other similar tools
levels are adequate for test. Hydraulic system must be
should not be used as they may damage the seal-
pressurized during the flushing and bleeding proce-
ing edges.
dures.
9. The area in contact with the seal should be free of
burrs, sharp edges and nicks.
CAUTION
10. If necessary to force seal over sharp edges, slots
or undercuts, protective devices should be used. Do not attempt to bleed a line by cracking an o-ring
face seal fitting. This will result in damaging the o-ring
11. Light lubrication should be applied to the seal and which then must be replaced to prevent hydraulic fluid
installation groove prior to installation. The same leakage.
oil that will be used later in the cylinder should be
applied.

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CYLINDERS
Cylinders

Mast Cylinder Bleeding

1. Elevate carriage to approximately 1220 mm
(48.0 in).
2. Slowly open each cylinder's bleed screws and
bleed air from cylinders until a solid stream of hy-
draulic fluid flows out of the cylinders.
3. Tighten bleed screw.

Mast Cylinder Flushing

1. After bleeding cylinders, actuate control valve to
raise carriage through free and stage lift and stop
to hold in position.
2. With carriage raised, examine cylinders for any
leaks.
3. Actuate control valve to lower carriage through
stage and free lift to examine operation and stag-
ing.
4. Raise and lower carriage rapidly for a minimum of
10 cycles to flush system.

CAUTION
Never stand or work under a suspended load.
Fully extend the mast with maximum rated load. The
load may not drift down more than 50 mm (2.0 in)
within five minutes.
Occasionally, a slight creep of the fork assembly may
occur due to internal cylinder seal leakage, but it can
also be caused by leakage in the check valves, control
valve, etc. To seat these valves properly when this oc-
curs, raise and lower the forks to flush out any foreign
material from the valve seat.

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 CYLINDERS
Cylinders

Carriage Cylinder

Figure 15296

The carriage cylinder is located at the base of the inner 4. Check wiper ring (9) and complete cap area for
mast, and is a single acting ram type cylinder. Extreme component wear and/or leakage that is abnormal.
care should be taken when performing any type of re-
As the cylinder assembly is repaired be aware of com-
pair. In the event of excessive oil leakage around the
ponent part condition and not only replace a worn or
cap end of the cylinder or its inability to lift the load, the
damaged part, but correct or replace a part that may be
cylinder will have to be removed from the truck and re-
causing other premature wear.
paired.

Inspection
1. Before disconnecting battery and initial cylinder re-
pair, a careful inspection should be made of the
cylinder assembly throughout a complete lift and
lower sequence.
2. Check roller bar or yoke area for signs of abnormal
wear, damage, etc.
3. Check ram (1) for any signs of nicks, scratches,
surface imperfections, etc. that allow abnormal
leakage, improper cylinder operation, or create
seal damage.

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CYLINDERS
Cylinders

Carriage Cylinder Disassembly When an excessive amount of hydraulic oil is evident

on the top of the cylinder where the ram exits from the
1. Turn the cap counterclockwise and unscrew it from cap, the rod packing is probably bad and should be re-
the cylinder tube. Refer to Figure 15962. placed. The replacement of the packing can be accom-
plished without removing the ram assembly from the
cylinder tube or truck.
1 Cylinder Tube
1. Make sure all hydraulic pressure has been re-
2 Cap
moved from the carriage cylinders.
3 O-Ring
2. Carefully remove hydraulic fittings from carriage
4 Bleed Screw
cylinder ram. Attempt to absorb any hydraulic oil
draining from lines during this procedure.
3. Remove cylinder cap by turning it in a counter-
clockwise direction.

NOTE
Seals used in the cylinders are made of an extremely
durable, hard polyurethane material which can be de-
formed temporarily to allow for installation without per-
manent damage.
4. The packing is located below the cap and remains
in the cylinder bore after the cap is removed. A pair
of special tools can be used to facilitate packing
removal (refer to Figure 15963).

Figure 15962

2. Remove the cap and carefully extract the ram as-

sembly from the cylinder bore, never allowing the
ram to come in contact with any sharp edges.

Carriage Cylinder Repair

WARNING
Avoid high pressure fluids - escaping fluids under pres-
sure can penetrate the skin, causing serious injury. Re-
lieve pressure before disconnecting hydraulic lines.
Tighten all connections before applying pressure. 1 Screwdriver 152 mm (6 in) Shaft Length (Min.) 4 mm
Keep hands and body away from pin holes which eject (0.156 in) Shaft Diameter (Max.)
fluids under high pressure. Use a piece of cardboard or 2 No. 8 Metal Screw Headless (4 mm Self-Tapping)
paper to search for leaks. Do not use your hand. 3 Weld (Grind Off Excess) to a Max. Dia. of 4 mm
Any fluid injected into the skin under high pressure (0.156 in)
should be considered a serious medical emergency 4 Tape
despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue damage
may occur. Medical attention should be sought imme- Figure 15963
diately from a specialist who has experience with this
type of injury.

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 CYLINDERS
Cylinders

To make these tools, weld or braze a headless 4.0 mm and dirt located on the seal seating area, causing the
self-tapping (No. 8 metal) screw to the end of a screw- seal to deform and lose its sealing ability.
driver. The screwdriver must have at least 150 mm
(6.0 in) of shank length with no larger than 4.0 mm
(0.156 in) shank diameter. After attaching the screw to
the screwdriver, grind off excess weld to a diameter of
4.0 mm (0.156 in). Wrap the shank with electrical tape
from the tip of the screw to the screwdriver handle. This
will prevent scratching of the cylinder bore or the ram.

NOTE
Extreme care should be taken to prevent damage to
cylinder wall and ram assembly.
5. Insert the tools between the ram and the cylinder
walls, 180° apart, and screw into the face of the
packing (refer to Figure 15964).

1 Critical Seal Seating Area

2 Seal
3 Forging Tool
4 Sleeve
5 Cylinder Tube
6 Collar

Figure 15970

7. At this time, the wiper ring should also be removed

since packings and wiper rings should always be
replaced in pairs. Thoroughly clean the area where
the seals seat. Any burrs, dirt or seal debris must
be removed before installing new seals.
1 Seal Pulling Tool
8. Tools used to install hydraulic seals should be of
2 Ram
soft metal or suitable plastic, free of burrs and
3 Cylinder Tube sharp edges. Screwdrivers and other similar tools
4 Seal should not be used as they may damage the seal-
ing edges.
Figure 15964 9. The area in contact with the seal should be free of
burrs, sharp edges and nicks.
6. After the threads are sufficiently secured into the
packing, evenly pull on the screwdriver handles 10. If necessary to force seal over sharp edges, slots
until the packing is removed. or undercuts, protective devices should be used.
11. Light lubrication should be applied to the seal and
CAUTION installation groove prior to installation. The same
oil that will be used later in the cylinder should be
Close inspection of seal seating critical areas should applied.
be made before the new seal is installed.
Refer to Figure 15970. Your seal failure may not have
been caused by a worn seal, but rather by burrs, nicks

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CYLINDERS
Cylinders

Carriage Cylinder Reassembly 2. Slowly open each cylinder's bleed screws and
bleed air from cylinders until a solid stream of hy-
draulic fluid flows out of the cylinders.
CAUTION
3. Tighten bleed screw.
Care should be taken when inserting the cylinder cap,
to prevent threads and sharp edges from damaging Carriage Cylinder Flushing
new seals and packings. Packings can also be dam-
aged by forcing air past seals. 1. Slowly elevate the empty carriage to approximately
1 220 mm (48.0 in).
When repacking the carriage cylinder, carefully bring After bleeding cylinders, actuate control valve to
oil back into the system while the bleed screw is fully raise carriage through free and stage lift and stop
open to allow air to burp. to hold in position.
After packings and seals are in place and the ram as- 2. With carriage raised, examine cylinders for any
sembly has been installed, reattach the cap. leaks.
3. Actuate control valve to lower carriage through
Carriage Cylinder Bleeding and Flushing
stage and free lift to examine operationand stag-
Procedures ing.
4. Raise and lower carriage rapidly for a minimum of
WARNING 10 cycles to flush system.
Avoid high pressure fluids - escaping fluid under pres-
sure can penetrate the skin causing serious injury. Re- CAUTION
lieve pressure before disconnecting hydraulic lines.
Tighten all connections before applying pressure. Never stand or work under a suspended load.
Keep hands and body away from pin holes which eject Fully extend the mast with maximum rated load. The
fluids under high pressure. Use a piece of cardboard or load may not drift down more than 50 mm (2.0 in)
paper to search for leaks. Do not use your hand. within five minutes.
Any fluid injected into the skin under high pressure
should be considered as a serious medical emergency Occasionally, a slight creep of the fork assembly may
despite an initial normal appearance of the skin. There occur due to internal cylinder seal leakage, but it can
is a delayed onset of pain, and serious tissue damage also be caused by leakage in the check valves, control
may occur. Medical attention should be sought imme- valve, etc. To seat these valves properly when this oc-
diately by a specialist who has had experience with this curs, raise and lower the forks to flush out any foreign
type of injury. material from the valve seat.

Carriage hydraulic circuits need to be flushed after re-

pair of carriage cylinders and bled of all air. Before
flushing and bleeding of system inspect all hydraulic
connections and verify that all filters are installed and
hydraulic fluid levels are adequate for test. Hydraulic
system must be pressurized during the flushing and
bleeding procedures.

CAUTION
Do not attempt to bleed a line by cracking a seal fitting.
This will result in damaging the seal which then must
be replaced to prevent hydraulic fluid leakage.

Carriage Cylinder Bleeding

1. Slowly elevate the empty carriage to approximately
1220 mm (48.0 in).

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 CYLINDERS
Cylinders

Tilt Cylinder

Figure 15301

The tilt cylinder is mounted at the base of the front As the cylinder assembly is repaired be aware of com-
frame. This tilt cylinder is a double acting piston type ponent part condition and not only replace a worn or
cylinder. Extreme care should be taken when perform- damaged part, but correct or replace a part that may be
ing any type of repair. In the event of excessive oil leak- causing other premature wear.
age around the rod end of the cylinder or its inability to
tilt the load, the cylinder will have to be removed from
the truck and repaired.

Tilt Cylinder Inspection

1. Before disconnecting battery and initial cylinder re-
pair, a careful inspection should be made of the
cylinder assembly throughout a complete tilting se-
quence.
2. Check piston rod (3) for any signs of nicks,
scratches, surface imperfections, etc. that allow
abnormal leakage, improper cylinder operation, or
create seal damage.
3. Check wiper ring (9) and complete cap area for
component wear and/or leakage that is abnormal.

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CYLINDERS
Cylinders

Tilt Cylinder Disassembly 3. Inspect the rod for scoring or damaged material. If
damages or scoring is evident, the rod must be re-
Before proceeding with disassembly, thoroughly clean placed.
the outside of the cylinder to remove all grease and dirt
build-up.
Tilt Cylinder Repair
1. Place the cylinder in a vise. Care should be taken
to avoid over-tightening, as the tube assembly (1)
may be easily damaged. The use of an adjustable CAUTION
spanner wrench, similar to the one shown in Figure
Never use a screwdriver to remove seals, as irrepara-
15966, is required for disassembly. A face spanner
ble damage and leakage may occur.
wrench with 4.75 mm (0.187 in) pins and a spread
of at least 66.7 mm (2.625 in) is sufficient. 1. With the use of a small hooked tool, carefully pull
the seals from their mounting grooves.
2. After all the seals have been removed, inspect the
contact surface of the piston for scoring. If slight
scoring is evident, sand with a fine emery paper
until all high surfaces have been removed. Heavily
scored components must be replaced.

NOTE
When cleaning the piston, be sure to clean seal seating
areas. Protect eyes and face when using compressed
air.
3. When all parts have been disassembled and in-
spected, wash all cylinder components in a good
grade solvent and dry with air pressure.
4. After all parts have been thoroughly cleaned, place
Figure 15966
in a dirt free area until ready for reassembly.
2. Using a scraper or similar tool, remove any mate-
rial, burrs, etc. from the edge of the cylinder. If Tilt Cylinder and Rod Reassembly
burrs, etc. are not removed, piston removal may be
difficult. 1. Apply a coating of hydraulic oil (Crown No.
063001-001) to all seals before they are assem-
3. Using spanner wrench, remove the rod guide (2), bled.
o-ring (6), back-up ring (7), packing rod (8) and
wiper ring (9). 2. Install all seals by hand.

4. Next, carefully remove the roll pin (19), nut (10), 3. After the seals have been installed, install piston
piston seal (11), piston (4), back-up rings (18), o- and fasten hex jam nut; be sure piston
ring (17) and spacer (20) out of the end of the tube is seated properly against the rod shoulder.
assembly.
5. Inspect the tube assembly for any signs of scoring.
If scoring is evident, the tube assembly must be
CAUTION
replaced. The tube assembly should be honed to Care should be taken when inserting the rod guide to
remove any remaining burrs. prevent sharp edges from damaging the new seals and
packings.
Rod Disassembly 4. After installing the rod assembly into the tube as-
1. Remove cotter pin and then use wrench flats on sembly, carefully assemble the rod guide into the
rod to remove castle nut. tube.

2. Slide all components off the end of the rod.

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 CYLINDERS
Cylinders

Tilt Cylinder Adjustment so that both cylinders bottom out at the same time
when the mast is tilted forward.
1. Turn rod end on piston rod until the end of the rod
end is 24.5 mm (0.96 in) from the shoulder on the 6. Use an inclinometer to check the tilt of the mast on
piston rod. Hex jam nut is to be against the end of the first stage. If the measured degree is not within
the rod end (refer to Figure 15967). Repeat proce- the ± 0.5° tolerance, rotate the piston rods until the
dure for the other tilt cylinder. desired degree of tilt is within tolerance. (The mast
may need tilted back to allow clearance for the
wrench to turn the cylinder shaft.)
7. Once all adjustments are complete, tighten the hex
jam nut up against the end of the rod end and
torque hex jam nut to 339 ± 27 Nm (3000 ±
239 in lb).
8. Tilt mast to back until one of the tilt cylinder spac-
ers is snug and cannot be rotated freely. Do not tilt
back any further than this.
9. Use an inclinometer to check the tilt of the mast. If
1 Rod End the measured degree is not within the +0/-30° tol-
2 Hex Jam Nut erance add retaining rings (Crown Part No.
3 Spacer
060009-168) between the spacer and the cylinder
until desired degree of tilt is achieved. There may
now be a gap between the other spacer and cylin-
Figure 15967 der. Measure the gap, and then tilt the mast for-
ward. Add retaining rings between the spacer and
2. Connect both tilt cylinders to the mast with appro-
cylinder so the gap is less than 1.59 mm
priate hardware. The date code on the rod end is
(0.0625 in).
to face the mast channel and the large flat washer
is to be on the outboard side.
Tilt Cylinder Bleeding and Flushing Proce-
3. The truck must be empty and located on a surface
dures
plate to make the following adjustments to the tilt
cylinder rod end.
4. Extend cylinders to full forward position. Determine WARNING
degree of forward tilt based on which tilt cylinder Avoid high pressure fluids - escaping fluid under pres-
assembly is being used by referring to Chart 1 - sure can penetrate the skin causing serious injury. Re-
Degree of Tilt below. lieve pressure before disconnecting hydraulic lines.
Tighten all connections before applying pressure.
Keep hands and body away from pin holes which eject
Chart 1 - Degree of Tilt fluids under high pressure. Use a piece of cardboard or
paper to search for leaks. Do not use your hand.
Tilt Cylinder Any fluid injected into the skin under high pressure
Forward Tilt Backward Tilt should be considered as a serious medical emergency
Assembly
despite an initial normal appearance of the skin. There
136589-053 5° 3° is a delayed onset of pain, and serious tissue damage
136589-055 5° 5° may occur. Medical attention should be sought imme-
diately by a specialist who has had experience with this
136589-103 10° 3° type of injury.
136589-105 10° 5°

5. Loosen the hex jam nut to allow the piston rod to

be rotated using a 27 mm (1.06 in) open end
wrench on the flats provided. Adjust the piston rods

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CYLINDERS
Cylinders

Tilt hydraulic circuits need to be flushed after repair of

tilt cylinders and bled of all air. Before flushing and
bleeding of system inspect all hydraulic connections
and verify that all filters are installed and hydraulic fluid
levels are adequate for test. Hydraulic system must be
pressurized during the flushing and bleeding proce-
dures.

CAUTION
Do not attempt to bleed a line by cracking an o-ring
face seal fitting. This will result in damaging the o-ring
which then must be replaced to prevent hydraulic fluid
leakage.

Tilt Cylinder Bleeding and Flushing

1. Turn truck on and raise the carriage approximately
305 mm (12.0 in).
2. Tilt the mast completely forward, then back.
3. Repeat this complete cycle, totally forward and
then completely back, a minimum of 10 times.
4. If it is suspected that any air is still in the system,
repeat the process.

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