YMM210001

Cylinder Repair
GLP/GDP15-20AK [C812];
GP/GLP/GDP20-35RK/TK [B871]

Safety Precautions Maintenance

and Repair
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, 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 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), 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!

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 Disclaimer
The Service Manuals are updated on a regular basis, but may not reflect recent design changes
to the product. Updated technical service information may be available from your local authorized
Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are
intended for use by trained and experienced technicians. Failure to properly maintain equipment
or to follow instructions contained in the Service Manual could result in damage to the products,
personal injury, property damage or death.
 GENERAL
This section has a description and the repair procedures for several different types of cylinders.
The number and the design of the parts can be different, but the operation of the cylinders is the
same.

DESCRIPTION
This manual covers many different types of cylinders. Each cylinder will be described in detail.
Tilt cylinders are fastened between the frame of the lift truck and the outer weldment of the mast
to change the angle of the mast and forks.
Two single-stage main lift cylinders and a free-lift cylinder are used to raise the carriage and
extend the mast weldments.
The two main lift cylinders are installed at the back of the outer mast. The base of each lift
cylinder sits on a mount at the bottom crossmember of the outer mast. The top of each main lift
cylinder rod fits into a guide on the top crossmember of the inner mast. The free-lift cylinder is
installed in the inner mast. Each of the lift cylinders has lowering control valve.

NOTE: On the lift truck models, there are two free-lift chains and chain sheaves. The description below
applies to all trucks.

The free-lift chains connect at one end of the mid-crossmember of the inner mast. Two chain
sheaves are installed on a crosshead on the rod of the free-lift cylinder. The chains then go over
sheaves on the crosshead and connect to the carriage

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 SAFETY PROCEDURES WHEN WORKING NEAR MAST
The following procedures MUST be used when inspecting or working near the mast. Additional
precautions and procedures can be required when repairing or removing the mast.

WARNING
Mast parts are heavy and can move. Distances between parts are small. Serious injury or
death 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. Also make sure that the power is OFF
and the key is removed. Put a DO NOT OPERATE tag in the operator’s compartment.
Disconnect the battery and put a tag or lock on the battery connector.
• 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 weldments 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 this section.

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 that 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 vertical position.

2. Raise mast to align bottom crossmember of weldment that moves in outer weldment with
crossmember on outer weldment. On the two-stage and free-lift mast, the moving part is the
inner weldment. On the 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 the crossmembers 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) is completely retracted. If running, turn the power OFF. Apply the parking
brake. Install a DO NOT REMOVE tag on the safety chain(s).
5. Install another safety chain (3/8-in. minimum) between the top or bottom crossmember of the
carriage bar and a crossmember on the outer weldment.

NOTE: Apply the parking brake. After lowering or restraining the mast, shut off the power, and remove key.
Put a DO NOT OPERATE tag in the operator’s compartment. Disconnect battery and put a tag or lock on
battery connector.

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 A. TWO-STAGE LFL MAST
B. TWO-STAGE FFL MAST
C. THREE-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CARRIAGE BAR
7. CROSSMEMBER
8. FIRST INTERMEDIATE WELDMENT

Figure 1. Two-Stage LFL, Two-Stage FFL and Three-Stage FFL Masts

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 TILT CYLINDER REPAIR

[1] Remove

WARNING
Before removing the tilt cylinder(s), tilt the mast forward. Use a chain to hold the mast to the
frame and prevent the mast from moving forward.

WARNING
Do not push the anchor pins out of the rod end with your fingers. Do not permit the tilt
cylinders to drop and cause damage.

1. At the mast, remove the capscrew and retainer from the anchor pin. Using a drift pin or
similar tool, push the anchor pin out of the rod end. See Figure 2.
2. Stroke cylinder to the full backtilt position.
3. Disconnect the hydraulic lines at the tilt cylinder. Install caps on the hydraulic lines and in the
cylinder ports.
4. Use a lifting device to move large tilt cylinders. Remove the capscrew and retainer from the
anchor pin. Using a drift pin or similar tool, push the anchor pin out of the frame.
5. Using a lifting device, remove the tilt cylinder from the lift truck.
6. Repeat above steps for the remaining tilt cylinder.

1. CAPSCREW
2. RETAINER
3. LUBRICATION FITTING
4. ANCHOR PIN
NOTE: Hydraulic hoses are shown disconnected for clarity.

Figure 2. Tilt Cylinder Removal

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[2] Disassemble
NOTE: The following steps have detailed disassembly instructions. Perform only those steps required to
repair the tilt cylinder.

NOTE: Note the position of the rod end and number of turns used to remove the rod end.

1. Put the tilt cylinder in a soft jaw vise. Remove the rod end. See Figure 3.
2. Using a pin-type spanner wrench, Remove the gland from the tilt cylinder. Remove the rod
and piston assembly from the cylinder.

NOTE: To prevent damage to sealing surfaces, use brass tools when removing seals and O-rings.

3. Remove and discard the O-ring, backup ring, seal, and wiper from the gland.

NOTE: Perform Step 4 only if the piston or rod has been damaged.

4. Place the rod in a soft-jaw vise and remove the piston from the rod.
5. Remove and discard the O-rings and piston seals from the piston.

1. TUBE 6. SEAL
2. PISTON ROD 7. SNAP RING
3. HEAD 8. WIPER RING
4. BUSHING 9. O-RING
5. U-RING 10. BACKUP RING

Figure 3. Tilt Cylinder

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[3] Inspect

Inspect the gland for damage to the threads and the seal surfaces. Replace the gland if
damaged.
Inspect the piston for any damage to the seal surfaces and replace if damaged.
Inspect the rod for damage to the rod surface and ensure that the rod is not bent. Replace the
rod if found to be damaged.
Inspect the inner surface of the cylinder tube for damage. If the tube is found to be damaged,
replace the cylinder.

[4] Clean

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When
using cleaning solvents, always follow the solvent manufacturer’s recommended safety
procedures.
Compressed air can move particles so they cause injury to the user or to other personnel.
Make sure the path of the compressed air is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the eyes.

CAUTION
Do not allow cleaning solvent to come in contact with rubber components, as it will damage
those components.

Clean all metal parts in solvent and dry with compressed air.

[5] Assemble
NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

1. Install a new piston seal and O-ring on the piston. See Figure 3.

NOTE: Perform Step 2 only if the piston was removed from the rod.

2. Install a new wiper, seal, backup ring, and O-ring on the gland.
3. Install the rod and piston assembly in the cylinder. Using a pin-type spanner, install the gland
in the cylinder. Tighten the gland to
• 265 to 422 N·m for lift truck models GP/GLP/GDP15-20AK [C812]
• 295 to 469 N·m for lift truck models GP/GLP/GDP20-30RK/TK [B871]
• 326 to 518 N·m for lift truck models GP/GLP/GDP35TK [B871]
4. Place the cylinder in a soft-jaw vise and install the rod end on the rod as noted during
removal. Tighten the capscrew on the rod end to 127 N·m.
5. Repeat the above steps for the other tilt cylinder.

[6] Install

1. Using a lifting device, place the cylinder on the mounting point on the lift truck frame. Install

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 the anchor pin. Install the retainer and capscrew. See Figure 2. Tighten the capscrew to 41 to
49 N·m.
2. Connect the hydraulic lines to the tilt cylinder. Slowly stroke the cylinders until the rod holes
line up with the mast tilt anchor holes.
3. Install the anchor pin. Install the retainer and capscrew. Tighten the capscrew to 41 to 49
N·m.
4. Remove chain holding the mast to the frame.

WARNING
Do NOT put hands between the cylinder rod end and the mast. Serious injury can occur.

5. Operate the tilt cylinders. Check for correct operation and leakage. Adjust the tilt cylinders.

[7] Tilt Cylinders, Adjust

WARNING
When the tilt cylinders have tilt limit spacers, make sure they are installed during installation
procedures. Without the tilt limit spacers, the mast can tilt too much and cause an accident
or serious injury.

Check the tilt cylinder stroke by slowly tilting the mast fully forward and backward several times.
Both tilt cylinders must stop their stroke at the same time. Adjust the rod ends as shown in Figure
4. There must be no twist in the mast weldments.

Lift Truck Model A

GP/GLP/GDP 15-20AK 10mm

GP/GLP/GDP 20-30RK/TK 14mm

GP/GLP/GDP 35TK 7mm

1. MAST
2. ROD END
3. TILT CYLINDER

Figure 4. Tilt Cylinder

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 1. Adjust the stroke of the tilt cylinders as follows:
a. Adjust the rod ends for all tilt cylinders shown in Figure 4.
b. Slowly tilt the mast backward until one cylinder rod stops. On the opposite cylinder, loosen
the capscrews on the rod end. Measure the distance from the end of the cylinder to the
back end of the rod end. Use a wrench and turn the cylinder rod in until the dimension
starts to decrease, then stop. Repeat this procedure until both cylinder rods stop at the
same position within 1 mm (0.04 in.). After the adjustments are complete, tighten the
capscrews on the rod ends.
c. Tilt the mast fully backward and measure the tilt angle. See the nameplate for tilt angles. If
necessary, adjust both rod ends equally for the correct angle.

[8] Tilt Cylinder Leak Check for Two-Stage LFL, Two-Stage FFL, and
Three-Stage FFL

WARNING
During the test procedures for the hydraulic system, use chains to fasten the load to the
carriage to prevent it from falling. Keep all people away from the lift truck during the tests.
Do NOT try to find hydraulic leaks by putting your hand on hydraulic components under
pressure. Hydraulic oil can be injected into the body by the pressure.

1. Operate the hydraulic system. Put a capacity load on the forks, and raise and lower the load
several times. Lower the load and tilt the mast forward and backward several times. Check for
leaks.
2. Raise the carriage and load 1 m (3 ft). If the carriage slowly lowers when the control valve is
in the neutral position, there are leaks in the hydraulic system. The maximum speed that the
carriage is allowed to lower is 50 mm (2 in.) per 10 minutes when the hydraulic oil is 30°C
(86°F). If the oil temperature is 70°C (158°F), the maximum speed the carriage can lower is
150 mm (6 in.) per 10 minutes.
3. Check the lift cylinders for internal leaks. Remove the load from the forks. Install a gate
valve in the supply line between the main control valve and the mast. Put a capacity load on
the forks again. Raise the carriage 1 m (3 ft). Close the gate valve. If the carriage or mast
weldments lower SLOWLY, the seals in the lift cylinders have leaks.
4. If the carriage does not move, open the gate valve and check the movement again. If the
carriage lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings.
If no leaks are found, the main control valve can be worn or damaged. Remove the load from
the forks.

Table 1. Movement Rates (Maximum) for Tilt Cylinders

Hydraulic Oil Temperature/Mast Tilt Rate

Lift Truck Model 20°C (68°F) 60°C (140°F)

mm/min in./min mm/min in./min

GP/GLP/GDP15-20AK [C812] 1.0 0.04 5.7 0.23

GP/GLP/GDP20-35RK-TK [B871] 1.0 0.04 6.3 0.25

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[9] Torque Specifications

(1) Gland
GP/GLP/GDP15-20AK [C812]
265 to 422 N·m
GP/GLP/GDP20-30RK/TK [B871]
400 to 500 N·m (295 to 370 lbf ft)
GP/GLP/GDP35TK [B871]
326 to 518 N·m

(2) Tilt Cylinder Mounting Capscrew

41 to 49 N·m

(3) Tilt Cylinder Rod End Capscrew

127 N·m

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 LIFT CYLINDER REPAIR

[1] Main Lift Cylinders, Remove

WARNING
Before working on or near the mast, see Safety Procedures When Working Near Mast and
Figure 1.

NOTE: The following procedures are for the removal of the lift cylinders with the mast installed on the lift
truck.

1. Remove the carriage as described in the carriage removal procedures located in the section
Mast Repairs, 2, 3-Stage Masts. See Figure 1.
2. Raise the mast until it is almost fully extended.
• On the two-stage mast, use safety chains to connect the bottom crossmember of the inner
mast section to the top crossmember of the outer mast section.
• On the three-stage mast, use safety chain to connect the bottom crossmember of the
intermediate mast section to the top crossmember of the outer mast section. Use another
safety chain to connect the bottom crossmember to a crossmember on the intermediate or
outer mast section.
Lower the mast so the safety chains hold the weight of the mast sections.

WARNING
Be careful when removing or installing snap rings. These snap rings can come loose during
removal or installation with enough force to cause an injury. Always use the correct snap
ring pliers, and wear eye and face protection during removal or installation.

3. If working on a two- or three-stage mast, remove the snap ring or fitting at the top of the
cylinder to be removed.

WARNING
Hydraulic oil is hot after system operation and can cause burns. Do not disconnect any
hydraulic hoses until the oil in the system is cool.

4. Put a drain pan under the area of the hydraulic fittings. Disconnect the hydraulic line at the
cylinder. Retract the rod into the lift cylinder.
5. Remove the nut, bolt, and spacer at the mount. On a two- or three-stage mast, disconnect the
main lift chain at the mount. See Figure 13.
6. Use a lifting device, as necessary, to remove lift cylinder from mast. Remove the lift cylinder
from the front of the mast.

[2] Free-Lift Cylinder, Remove

1. Remove the carriage as described in the carriage removal procedures in the section Mast
Repairs, 2 and 3 Stage Masts. Lower the mast completely.

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 WARNING
Hydraulic oil is hot after system operation and can cause burns. Do not disconnect any
hydraulic hoses until the oil in the system is cool.

2. Put a drain pan under the area of the hydraulic fittings. Disconnect the hydraulic line at the
cylinder.

NOTE: Perform Step 3 if working on a lift truck equipped with a two- or three-stage mast.

3. Remove the brackets for the free-lift cylinder. Remove the free-lift cylinder.
4. Remove the crosshead from the cylinder rod. See Figure 5 and Figure 6. Disassemble the
crosshead as necessary.

1. CHAIN SHEAVE
2. CHAIN GUARD
3. RETAINING RING
4. PIN
5. WA HEX HEAD BOLT

Figure 5. Crosshead Assembly, Two-Stage

and Three-Stage FFL,

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 4. FREE LIFT CYLINDER
5. MAIN CYLINDER ASS’Y
6. CHAIN ASSEMBLY
BL623
8. PIPE WLDMT
17. SET SCREW SOCKET
18. NUT
19. CROSS HEAD
33. GUARD BRACKET
34. GUARD BRACKET
WELD’T
35. WA HEX HEAD BOLT
36. NUT
37. NUT HEX
42. ADAPTOR
44. FTG-37
50. SNAP RING
54. PIN COTTER
56. HOSE ASSEMBLY
58. BOLT
59. HOSE ASSEMBLY
60. WASHER
61. BASE RING
62. NUT SPHERICAL
63. PIPE WELDMT
64. HOSE ASSEMBLY
65. BOLT
66. FTG-37
67. PLUG

Figure 6. Crosshead and Three-Stage Free-Lift Cylinder Assembly

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[3] Free-Lift and Main Lift Cylinders, Disassemble

CAUTION
Carefully disassemble the lift cylinders so the piston rods and sliding surfaces are not
damaged.

NOTE: To disassemble the left-hand main lift cylinder on trucks equipped with a two-stage FFL mast, see
the section Two-Stage FFL Cylinder, Disassemble.
NOTE: To prevent damage to sealing surfaces, use brass tools when removing or installing seals and
O-rings.

1. Remove gland from shell.

2. Remove rod and piston assembly from shell. Drain hydraulic oil into container. See Figure 7,
and Figure 8.
3. Remove and discard O-rings, seals, and wear rings.

WARNING
Be careful when removing or installing snap rings. These snap rings can come loose during
removal or installation with enough force to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection during removal or installation.

4. On left-hand lift cylinder, remove snap ring, washer, and check valve from base of piston.

1. SHELL 7. O-RING
2. ROD 8. SNAP RING
3. GLAND 9. WIPER RING
4. ROD SEAL 10. SEAL
5. CHECK VALVE 11. BACKUP RING
6. WASHER 12. WEAR RING

Figure 7. Main Lift Cylinder, Two-Stage LFL

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[4] Two-Stage FFL Cylinder, Disassemble
NOTE: The following procedure applies only to the left-hand main lift cylinder of the lift trucks covered in
this manual. For disassembly procedures on the right-hand main lift cylinder, see the section Free-Lift and
Main Lift Cylinders, Disassemble.

1. Loosen the gland with a spanner wrench.

2. Remove gland, rod, and piston assembly from shell. Drain hydraulic oil into a container.
3. Remove piston from rod (GP/GLP/GDP20-35RK/TK [B871] only). Remove gland from rod.

1. SHELL 11. SLIDE RING

2. ROD 12. SET SCREW
3. HEAD ASSY 13. CHECK VALVE
4. BUSH 14. CHUSION SPOOL
5. HOLDER 15. SPRING
6. U-RING 16. SNAP RING
7. BACK UP RING 17. SET SCREW
8. WIPER RING 18. STEEL BALL
9. O-RING 19. SPACER
10. PISTON

Figure 8. Main Lift Cylinder, Two-Stage FFL

[5] Inspect

Inspect the gland for damage to the threads and the seal surfaces. Replace the gland if
damaged.
Inspect the piston for any damage to the seal surfaces and replace if damaged.
Inspect the rod for damage to the rod surface and ensure that the rod is not bent. Replace the
rod if found to be damaged.
Inspect the inner surface of the cylinder tube for damage. If the tube is found to be damaged,
replace the cylinder.

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[6] Clean

WARNING
Cleaning solvents can be flammable and toxic and can cause skin irritation. When
using cleaning solvents, always follow the solvent manufacturer’s recommended safety
procedures.
Compressed air can move particles so they cause injury to the user or to other personnel.
Make sure the path of the compressed air is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the eyes.

CAUTION
Do not allow cleaning solvent to come in contact with rubber components, as it will damage
those components.

Clean all metal parts in solvent and dry with compressed air.

[7] Full Free-Lift and Main Lift Cylinders, Assemble

NOTE: The procedures in this section cover all masts except for two-stage FFL masts. See the section Two-
Stage FFL and Main Lift Cylinders, Assemble for the procedures.
NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

1. Lubricate all internal parts of the lift cylinder with clean hydraulic oil or packing lubricant, Yale
Part No. 504234269. Use new O-rings, seals, and wear rings. See Figure 9.

WARNING
Be careful when removing or installing snap rings. These snap rings can come loose during
removal or installation with enough force to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection during removal or installation.

2. Install check valve and O-ring in base of piston of free-lift cylinder and left-hand lift cylinder.
Make sure arrow on check valve is toward base of piston. Install washer and snap ring for
check valve. See Figure 9. On the free-liftt cylinder for GP/GLP/GDP20-35RK/TK [B871],
install the position to the rod with tightening torque of 59 to 78 N·m

CAUTION
A difficult and important step in assembling lift cylinders is the correct installation of the
seals. Most lift cylinder maintenance is caused by seal leaks. Do not damage any parts
during assembly.

3. Install the wear ring, piston seal, and backup ring on to the piston assembly. On the main lift
cylinders, install seal ring. Install spacer, if used.
4. Carefully push the piston and rod assembly into the shell.
5. Install the rod seal ring and wiper into the gland. Install the O-ring and backup ring on the
outside of the retainer.

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 1. SHELL 7. SNAP RING
2. ROD 8. WIPER
3. GLAND 9. SEAL
4. SCREW 10. BACKUP RING
5. CHECK VALVE 11. O-RING
6. WASHER 12. WEAR RING

Figure 9. Free-Lift Cylinder, Two-Stage and Three-Stage FFL

CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local Yale
dealer.

NOTE: Hydraulic oil is poured into the free-lift cylinders to act as a cushion during load lifting to prevent
damage to the cylinders.

6. On free-lift cylinders, before installing gland, pour 75~85 cc [C812], 100 cc [B871] of hydraulic
oil into the cylinder shell.
7. Carefully install the gland on the piston rod.
8. Carefully engage threads and tighten gland in shell until tight. Use the correct spanner. Do
NOT hit gland with a hammer and driver. Tighten gland to the torque specified in Table 2.
9. Install the lowering control valve in port at base of left-hand, main control cylinder.

[8] Two-Stage FFL and Main Lift Cylinders, Assemble

NOTE: To prevent damage to sealing surfaces, use brass tools when installing seals and O-rings.

1. Install rod wiper and rod seal in retainer. Install O-ring on outside of retainer. Install retainer
on rod.

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 2. For the free-lift cylinder, install the rod onto the piston. Tighten piston to 161 to 231 N·m.
3. Install O-ring and backup ring on piston for mian cylinder.

WARNING
Be careful when removing or installing snap rings. These snap rings can come loose during
removal or installation with enough force to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection during removal or installation.

4. Install check valve and O-ring in base of piston of free-lift cylinder. Make sure arrow on check
valve is toward base of piston.
5. Carefully engage threads and tighten gland in shell until tight. Use the correct spanner. Do
NOT hit gland with a hammer and driver. On the main lift cylinder, tighten gland to 167 to 245
N·m for GP/GLP/GDP 15-20AK [C812], 181 to 289 N·m for GP/GLP/GDP20-35RK/TK [B871].
For the free-lift cylinder, refer to Table 2 for tightening torque of the gland.

CAUTION
The correct screw and sealing washer must be used in this location. The wrong parts will
cause leaks or damage the cylinder. See your Yale lift truck dealer for the correct parts.

CAUTION
Additives may damage the hydraulic system. Before using additives, contact your local Yale
dealer.

7. Remove screw and sealing washer. Pour 150 cc of hydraulic oil into the cylinder through the
hole. This oil provides a hydraulic cushion when the cylinder reaches the top of its stroke. See
Figure 12.
8. Install fitting at base of free-lift cylinder. This is a special fitting that limits flow of the hydraulic
oil.

Table 2. Tightening Torque for the Gland

MAIN LIFT CYLINDER FREE LIFT CYLINDER
GP/GLP/GDP15-20AK [C812] 151 to 241 N·m 295 to 470 N·m

GP/GLP/GDP20-25RK/TK [B871] 181 to 289 N·m 392 to 490 N·m

GP/GLP/GDP30-35TK [B871] 213 to 337 N·m 343 to 441 N·m

[9] Installation, Main Lift Cylinders (See Figure 6., Figure 7., and Figure 8.)

1. Use a crane (the capacity of the crane must be at least 1 600 kg) to raise the mast until it is
almost fully extended. Use safety chains to connect the bottom crossmember of the inner
weldment (two-stage) or intermediate weldment (three-stage) to the top crossmember of the
outer weldment. Lower the mast so that the safety chains hold the weight of the weldments.
2. Install the lift cylinder in the mount at the bottom of the outer weldment. Install the nut, strap,
and spacer at the mount for the lift cylinder.
3. Use a lifting device to lower the inner weldment (two-stage) or intermediate weldment (three-

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 stage) on to the lift cylinder. Install the washers and capscrew at the top of the lift cylinder.
See the MAST Assembly procedures for the correct adjustment of the lift cylinders.
4. Connect the hydraulic line at the base of the lift cylinder. Connect the hydraulic line at the top
of the right-hand lift cylinder on the full free-lift mast.
5. Connect the main lift chains as necessary and adjust them as specified in CHECKS AND
ADJUSTMENTS.
6. Remove the air from the cylinders on the two-stage FFL. See FIGURE 8.
• Loosen the screws two turns to permit oil to flow around the threads of the screw.
• With the forks unloaded and the engine speed at idle, raise the carriage using the hydraulic
control. Raise the carriage 300 mm (12 in) and then stop for ten seconds to reduce the
pressure in the cylinder. Repeat this procedure until the oil flowing from around the threads
is free of air bubbles.
• Stop the carriage at the top of the cylinder stroke. Tighten the screws. Installation, Free-Lift
Cylinder (See Figure 6. and Figure 9.)

[10] Installation, Free-Lift Cylinder (See Figure 6. and Figure 9.)

1. Install the crosshead assembly on the cylinder rod.

2. Install the cylinder in the mounts. Tighten the bolts.
3. Connect the hydraulic line at the cylinder.
4. Install the carriage as described in the procedures for the CARRIAGE.

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 CHECKS AND ADJUSTMENTS

[1] Check For Leaks In The Lift And Tilt System

WARNING
During the test procedures for the hydraulic system, use chains to fasten the load to the
carriage to prevent it from falling. Keep all people away from the lift truck during the tests.
Do NOT try to find hydraulic leaks by putting your hand on hydraulic components under
pressure. Hydraulic oil can be injected into the body by the pressure.

(1) Check The Lift Cylinders For Leaks

1. Operate the hydraulic system. Put a capacity load on the forks and raise and lower the load
several times. Lower the load and tilt the mast forward and backward several times. Check for
leaks.
2. Raise the carriage and load one meter (3 ft). If the carriage slowly lowers when the control
valve is in the Neutral position, there are leaks in the hydraulic system.
3. Check the lift cylinders for internal leaks. Remove the load from the forks. Install a gate valve
in the supply line between the main control valve and the mast. Put a capacity load on the
forks again. Raise the carriage one meter (3 ft). Close the gate valve. If the carriage or mast
weldments lower slowly, the seals in the lift cylinders have leaks.
4. If the carriage does not move, open the gate valve and check the movement again. If the
carriage lowers when the gate valve is open, check for leaks in the hydraulic lines and fittings.
If no leaks are found, the main control valve can be worn or damaged. Remove the load from
the forks.

(2) Check The Tilt Cylinders For Leaks

1. Put a capacity load on the forks. Slowly tilt the mast forward. If the mast continues to slowly
tilt forward when the control valve is in the Neutral position, there are leaks inside the
hydraulic system.
2. If the leak rate is greater than the specifications, remove the load from the mast. Install a
valve between the port at the front of the tilt cylinder and the hydraulic line. Put the load on
the forks again. Close the valve. If the mast tilts slowly forward, the cylinder seals are leaking.
3. If the mast does not move, open the gate valve and check the movement again. If the mast
moves forward when the gate valve is open, check for leaks in the hydraulic lines and fittings.
If no leaks are found, the main control valve can be worn or damaged. Remove the load from
the forks when the checks are complete.

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