YALE E879 GDC60VX LIFT TRUCK Service Repair Manual

GLC/GDC60VX, GLC/GDC70VX (E879)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524288189 0100 YRM 1316 08/13
GM 4.3L V-6 ENGINES................................................................................................... 524265337 0600 YRM 1251 05/14
KUBOTA ENGINE REPAIR............................................................................................ 550048607 0600 YRM 1557 03/13
COOLING SYSTEM........................................................................................................ 524223757 0700 YRM 1123 03/13
LPG FUEL SYSTEM GM 4.3L ENGINE WITH PSI........................................................ 550043871 0900 YRM 1556 04/14
THREE-SPEED POWERSHIFT TRANSMISSION REPAIR........................................... 524288194 1300 YRM 1317 03/13
TRANSMISSION REPAIR (DANA SPICER) 2X2........................................................... 524294873 1300 YRM 1343 03/14
DRIVE AXLE AND DIFFERENTIAL ASSEMBLY REPAIR (WET BRAKE)................... 524288199 1400 YRM 1318 12/13
STEERING AXLE............................................................................................................ 524223764 1600 YRM 1133 07/13
BRAKE SYSTEM............................................................................................................ 524262279 1800 YRM 1247 03/13
HYDRAULIC GEAR PUMP............................................................................................. 524223766 1900 YRM 1136 04/14
HYDRAULIC CLEANLINESS PROCEDURES............................................................... 550073240 1900 YRM 1620 12/14
MAIN CONTROL VALVE................................................................................................ 524223767 2000 YRM 1137 04/14
CYLINDER REPAIR (MAST S/N A513, A514, A613, A614, B513, B514)..................... 524294878 2100 YRM 1328 02/14
HIGH VOLTAGE SWITCH (HVS) IGNITION.................................................................. 524208014 2200 YRM 1097 05/14
WIRE HARNESS REPAIR.............................................................................................. 524223769 2200 YRM 1128 12/14
USER INTERFACE......................................................................................................... 524223770 2200 YRM 1130 12/14
USER INTERFACE......................................................................................................... 524223771 2200 YRM 1131 12/14
ELECTRICAL SYSTEM.................................................................................................. 524223772 2200 YRM 1142 04/14
MAST REPAIRS (S/N A513, A514, A613, A614, A702, A703, A704, A705, A706,
A707, A751, A752, B513, B514, B586, B587, B588, B589, B590, B591, B749,
B750, B751, B752, B753, B754)................................................................................ 524265342 4000 YRM 1250 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
CALIBRATION PROCEDURES...................................................................................... 524223780 8000 YRM 1134 12/14
PERIODIC MAINTENANCE............................................................................................ 550048616 8000 YRM 1571 11/13
CAPACITIES AND SPECIFICATIONS........................................................................... 550048609 8000 YRM 1572 04/13
DIAGRAMS AND SCHEMATICS.................................................................................... 550055283 8000 YRM 1585 04/14
DIAGNOSTIC TROUBLESHOOTING MANUAL............................................................ 524221866 9000 YRM 1112 12/14
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center.
9000 YRM 1112 ON CD
PART NO. 550048594 (12/14)

General
This section contains repair procedures for tilt cylinders, main lift cylinder, and free-lift cylinders. The number and
the design of the parts can be different, but the operation of the cylinders is the same.
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional precau-
tions and procedures can be required when repairing
or removing the mast.
WARNING
Mast parts are heavy and can move. Distances be-
tween 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 in-
stalled. Also make sure that the power is
OFF and the key is removed. Put a DO NOT
OPERATE tag in the operator's compart-
ment. 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 re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures 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 posi-
tion, 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 weld-
ment that moves in outer weldment with cross-
member 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 inter-
mediate weldment. On the four-stage mast, it is
the first intermediate weldment. See Figure 1.
3. Use a 3/8-inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able 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, three-
stage, and four-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) be-
tween the top or bottom crossmember of the car-
riage bar and a crossmember on the outer weld-
ment.
6. After lowering or restraining the mast, shut off the
power, and remove key.
NOTE: Place a DO NOT OPERATE tag in the opera-
tor's compartment.
7. Disconnect battery and put a tag or lock on bat-
tery connector.
2100 YRM 1328 General
1

A. TWO-STAGE LFL MAST
B. TWO-STAGE FFL MAST
C. THREE-STAGE FFL MAST
D. FOUR-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, Three-Stage FFL, and Four-Stage FFL Masts
Safety Procedures When Working Near Mast 2100 YRM 1328
2

Tilt Cylinder Repair
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 or
backwards.
WARNING
DO NOT push the tilt pins out of the rod end with
your fingers. DO NOT permit the tilt cylinders to
drop and cause damage.
NOTE: Insure that the parking brake is applied be-
fore starting the procedure below.
NOTE: Perform Step 1 and Step 2 if mast is installed
on the lift truck.
1. At the mast end mount, remove the capscrew and
anchor pin from the tilt pin. Using a brass drift or
similar tool, push the tilt pin out of the rod end.
Remove lube fitting from tilt pin.
See Figure 2 for lift truck models
• GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878)
• GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879,
D879, E879, F879)
See Figure 3 for lift truck model
• GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909,
B909)
2. Stroke cylinder to the full back tilt position.
3. Remove floor mats, floor plates and side covers
to access the frame end mount of tilt cylinder. See
Side Covers Remove procedures in
Frame 0100YRM1321 for lift truck models
D878)
GDP175VX36, GLP/GDP190VX) (A909)
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879, E879, F879)
GDP135VX, GP/GLP/GDP155VX) (E878)
GDP175VX36, GLP/GDP190VX) (B909)
4. Disconnect the hydraulic lines at the cylinder hose
ports. Install caps on the hydraulic lines and in the
cylinder hose ports.
D878, E878)
D879, E879, F879)
B909)
5. Use a lifting device to support tilt cylinders. At
frame end mount, remove capscrew, washer, and
anchor pin from the tilt pin. Using a brass drift or
similar tool, push the tilt pin out to the bushing
and frame end mount. Remove lube fitting from tilt
pin.
D878, E878)
D879, E879, F879)
2100 YRM 1328 Tilt Cylinder Repair
3

Figure 2. Tilt Cylinder Installation for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)
Tilt Cylinder Repair 2100 YRM 1328
4

Legend for Figure 2
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.
A. GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879,
E879, F879)
B. GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878)
1. CAPSCREW
2. LOCK NUT
3. ANCHOR PIN
4. TILT PIN
5. FRAME END MOUNT
6. MAST END MOUNT
7. CYLINDER HOSE PORTS
8. ROD END
9. LUBE FITTINGS
10. WASHER
B909)
6. Using a lifting device, remove the tilt cylinder from
the lift truck.
7. Repeat Step 1 through Step 6 for the opposite tilt
cylinder.
DISASSEMBLE
NOTE: Perform only those steps below required to
repair the tilt cylinder.
NOTE: Perform Step 1 for lift truck models:
D878, E878)
D879, E879, F879)
NOTE: Note the position of the rod end and number
of turns used to remove the rod end.
1. Place the tilt cylinder in a soft jaw vise. Remove
capscrew, lock nut, and washer securing rod end
to rod. See Figure 2.
NOTE: Perform Step 2 for lift truck model GLP/
GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX)
(A909, B909).
NOTE: Note the position of the rod end and number
of turns used to remove the rod end.
2. Place the tilt cylinder in a soft jaw vise. Remove
hex nut, washer, capscrew and rod end from rod.
See Figure 3.
3. Using a pin-type spanner wrench, remove the
gland from the tilt cylinder shell. Remove the rod
and piston assembly from the cylinder shell.
D878, E878)
D879, E879, F879)
B909)
NOTE: To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings.
NOTE: Perform Step 4 for lift truck models
D878, E878)
D879, E879, F879)
4. Remove and discard the O-ring, backup ring,
seal, and wiper ring from the gland. See Figure 4.
5

Figure 3. Tilt Cylinder Installation for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)
6

Legend for Figure 3
A. OUTER VIEW B. INNER VIEW
1. TILT PIN
2. CAPSCREW
3. WASHER
4. ANCHOR PIN
5. CYLINDER HOSE PORT
6. FRAME END MOUNT
7. MAST END MOUNT
8. ROD END
9. LUBE FITTING
10. HEX NUT
(A909, B909).
5. Remove and discard the rod wiper, O-rings, rod
seal, and backup ring from the gland. See Fig-
ure 5.
NOTE: Perform Step 6 only if the piston or rod has
been damaged.
6. Place the rod in a soft-jaw vise and remove lock
nut and piston from the rod.
D878, E878)
D879, E879, F879)
B909)
7. Remove O-ring, and if equipped tilt spacer from
rod. Discard O-ring.
D878, E878)
D879, E879, F879)
B909)
8. Remove and discard the wear ring and piston
seal from the piston.
D878, E878)
D879, E879, F879)
B909)
CLEAN
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er'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 com-
pressed air.
7

NOTE: * USED ON TILT CYLINDER 6°
FORWARD/6° OR 10° BACK TILT FOR LIFT TRUCK
MODELS GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879,
E879, F879)
1. SHELL
2. GLAND
3. ROD
4. WIPER RING
5. SEAL
6. BACKUP RING
7. O-RING
8. PISTON
9. PISTON SEAL
10. LOCK NUT
11. WEAR RING
12. BUSHING
13. TILT SPACER*
14. CYLINDER HOSE PORTS
Figure 4. Tilt Cylinder Assembly for Lift Truck
Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878,
E878) and GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879,
D879, E879, F879)
1. SHELL
2. GLAND
3. ROD WIPER
4. O-RING
5. ROD SEAL
6. BACKUP RING
7. ROD
8. PISTON SEAL
9. WEAR RING
10. PISTON
11. LOCKNUT
12. BUSHING
13. CYLINDER HOSE PORT
Figure 5. Tilt Cylinder Assembly for Lift Truck
Model GLP/GDP80VX, GLP/GDP80VX9, GLP/
GDP90VX (GLP/GDP170VX, GLP/GDP175VX36,
GLP/GDP190VX) (A909, B909)
8

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 surfa-
ces and replace if damaged.
Inspect the rod for damage to the rod surface and en-
sure that the rod is not bent. Replace the rod if found
to be damaged.
Inspect the inner surface of the cylinder shell for dam-
age. If the shell is found to be damaged, replace the
cylinder assembly.
ASSEMBLE
brass tools when installing seals and O-rings.
1. Install a new piston seal and wear ring on the pis-
ton.
D878, E878)
D879, E879, F879)
B909)
2. Install new O-ring, and if equipped, install tilt
spacer onto rod.
D878, E878)
D879, E879, F879)
B909)
NOTE: Perform Step 3, if the piston was removed
from the rod, for lift truck models
D878, E878)
D879, E879, F879)
3. Place the rod in a soft-jaw vise, and install the pis-
ton on the rod and tighten the lock nut to
400-440 N•m (295 to 325 lbf ft). See Figure 4.
NOTE: Perform Step 4 and Step 5, if the piston was
removed from the rod, for lift truck model GLP/
(A909, B909).
4. Place the rod in a soft jaw vise and install the pis-
ton onto the rod. See Figure 5.
5. Install locknut onto rod. See Figure 5. Tighten
locknut to 400 to 440 N•m (295 to 325 lbf ft).
D878, E878)
D879, E879, F879)
6. Install a new wiper ring, seal, backup ring, and O-
ring onto gland. See Figure 4.
(A909, B909).
9

7. Install new O-rings, backup ring, rod seal, and rod
wiper onto gland. See Figure 5 for specific part or-
der.
8. Install the rod and piston assembly in the cylinder
shell.
D878, E878)
D879, E879, F879)
B909)
NOTE: Perform Step 9 and Step 10 for lift truck mod-
els
D878, E878)
D879, E879, F879)
9. Using a pin-type spanner wrench, install the gland
in the cylinder shell. Tighten the gland to 400 to
500 N•m (295 to 370 lbf ft). See Figure 4.
NOTE: Rod end to be turned and positioned as noted
during disassembly.
10. Install rod end on rod. Lubricate threads on cap-
screw with lubricant (Yale P/N 504234269). Install
capscrew in rod end so that capscrew head is on
the inboard side of rod end. Install washer and nut
on capscrew. Washer and nut must be on the out-
board side of rod end. Tighten nut to
90 N•m (66 lbf ft). See Figure 6.
NOTE: Perform Step 11 through Step 13 for lift truck
model GLP/GDP80VX, GLP/GDP80VX9, GLP/
GLP/GDP190VX) (A909, B909).
11. Apply two drops of Loctite®
545 or equivalent on
gland threads.
12. Using a pin-type spanner wrench, install the gland
onto the rod inside the shell. Tighten gland to 400
to 500 N•m (295 to 370 lbf ft). See Figure 5.
NOTE: Rod end to be turned and positioned as noted
during disassembly.
13. Install rod end, capscrew, washer, and hex nut
onto rod. Tighten hex nut to 120 to 130 N•m (89
to 96 lbf ft). See Figure 3.
14. Repeat Step 1 through Step 13 for the opposite
tilt cylinder.
NOTE: LEFT TILT CYLINDER SHOWN. TILT CYLIN-
DER AND MAST FOR LIFT TRUCK MODELS GLC/
GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879, D879, E879, F879)
SHOWN. PARTS OF MAST OMITTED FOR
CLARITY.
A. OUTBOARD SIDE
B. INBOARD SIDE
1. NUT
2. WASHER
3. ROD END
4. CAPSCREW
Figure 6. Rod End Installation
10

INSTALL
NOTE: Lock nut should be pointed toward outside of
truck, on lift truck models:
D878, E878)
D879, E879, F879)
1. Using a lifting device, place the tilt cylinder in
mounting point on the lift truck frame end mount.
D878, E878)
D879, E879, F879)
B909)
2. Install the lube fitting in the tilt pin and coat the tilt
pin with grease.
D878, E878)
D879, E879, F879)
B909)
3. Install tilt pin into rod end and frame end mount.
D878, E878)
D879, E879, F879)
B909)
NOTE: Perform Step 4 for lift truck models:
D878, E878)
D879, E879, F879)
NOTE: Lubricate the threads on the capscrew with
packing lubricant (Yale Part No. 504234269) prior to
installation.
4. Install the anchor pin and capscrew onto rod end
at frame end mount. Tighten capscrew to
(A909, B909).
NOTE: Lubricate threads on capscrew with multipur-
pose grease prior to installation.
5. Install anchor pin, washer, and capscrew onto rod
end at frame end mount. Tighten capscrew to
NOTE: Perform Step 6 and Step 7 if mast is installed
on lift truck.
6. At the mast end mount, place the rod end on the
mounting point.
D878, E878)
D879, E879, F879)
11

B909)
7. Install lube fitting in tilt pin and coat tilt pin with
grease. Install tilt pin into rod end and mast end
mount.
D878, E878)
D879, E879, F879)
B909)
D878, E878)
D879, E879, F879)
NOTE: Lubricate the threads on the capscrew with
packing lubricant (Yale P/N 504234269).
8. Install anchor pin and capscrew. Tighten cap-
screw to 90 N•m (66 lbf ft). See Figure 2.
(A909, B909).
9. Install washer, anchor pin, and capscrew onto rod
end at mast end mount. Tighten capscrew to 95
to 100 N•m (70 to 74 lbf ft). See Figure 3.
10. Uncap and connect the hydraulic lines to the tilt
cylinder hose ports. Slowly stroke the cylinder un-
til the rod holes line up with the mast tilt anchor
holes.
11. Repeat Step 1 through Step 10 for opposite tilt
cylinder.
12. Install side covers, floor mats, and floor plates.
See Side Covers Install procedures in
D878)
GDP175VX36, GLP/GDP190VX) (A909)
• GLC/GDC60VX, GLC/GDC70VX, (GC/GLC/
D879, E879, F879)
GDP175VX36, GLP/GDP190VX) (B909)
13. 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.
14. Operate the tilt cylinders. Check for correct opera-
tion and leakage. Adjust the tilt cylinders, see Tilt
Cylinders, Adjust.
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 cyl-
inders must stop their stroke at the same time. Adjust
the rod ends as shown in Figure 7. There must be no
twist in the mast weldments.
NOTE: Tilt cylinders with 6° forward/6° or 10° back tilt
for lift truck models GLC/GDC60VX, GLC/GDC70VX,
D879, E879) have internal tilt spacers. See Figure 4.
12

1. Adjust the stroke of the tilt cylinders with or with-
out tilt spacers as follows (see Figure 7).
a. Adjust the rod ends to:
15 mm (0.6 in.) for lift truck models
• GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (C879, D879, E879, F879)
• GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878)
B909)
b. Slowly tilt the mast backward until one cylinder
rod stops. On the opposite cylinder, loosen the
capscrews on the rod end. Measure the dis-
tance 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 de-
crease, then stop. Repeat this procedure until
both cylinder rods stop at the same position
within
GDP155VX) (C878, D878, E878)
B909)
0.5 mm (0.02 in.) for lift truck models
GDC155VX) (C879, D879, E879, F879)
c. After the adjustments are complete, tighten
lock nut on the rod end to
90 N•m (66 lbf ft) for lift truck models
GDP155VX) (C878, D878, E878)
GDC155VX) (C879, D879, E879, F879)
120 to 130 N•m (89 to 96 lbf ft) for lift truck
model
B909)
d. 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.
1. MAST
2. ROD END
3. TILT CYLINDER
4. CAPSCREW
5. LOCK NUT
Figure 7. Tilt Cylinder Adjustments
13

TILT CYLINDER LEAK CHECK
WARNING
Never allow anyone under a raised carriage. DO
NOT put any part of your body in or through the
lift mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
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. Put a capacity load on the forks. Use a safety
chain to hold the load to the carriage. Raise the
load approximately 2.5 m (8 ft). Put the mast in a
vertical position.
2. Measure the distance that the rod for tilt cylinder
extends from the shell. Check the distance the
rod moves after ten minutes. Multiply the rate in
Table 1 by the time of the test and compare the
numbers.
3. If the tilt rate is greater than the specifications,
lower the mast and remove the load from the
forks. Check for leaks in the hydraulic lines and
fittings and install a gate valve between the port at
the front of the tilt cylinder and the hydraulic line.
Place a load on the forks and tilt the mast forward
just past the vertical position and close the gate
valve. The gate valve must be able to completely
shut off the flow of hydraulic oil. If the mast contin-
ues to tilt SLOWLY forward, the seals on the pis-
ton are leaking.
4. 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, the
main control valve can be worn or damaged. Re-
move the load from the forks when the checks are
complete.
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Lift Truck Model Hydraulic Oil Temperature/Mast Tilt Rate
20°C (68°F) 60°C (140°F)
mm/min in./min mm/min in./min
GLC/GDC60VX, GLC/GDC70VX (GC/GLC/GDC135VX,
GC/GLC/GDC155VX) (C879, D879, E879, F879)
1.236 0.54 8.20 0.323
GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878)
1.303 0.51 8.65 0.323
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909)
1.3 0.51 8.9 0.35
14

Lift Cylinder Repair
REMOVE
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast and Fig-
ure 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 (S/N A513, A514, A613, A614,
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
B754) 4000YRM1250 for lift truck models
D878, E878)
D879, E879, F879)
Mast Repair (S/N A513, A514, A613, A614, A643,
A644, A683, A684) 4000YRM1406 for lift truck
model
B909)
2. On two-stage limited free-lift mast, raise the mast
a few inches and attach safety chain prior to re-
moving lift cylinder.
a. Use safety chains to connect the bottom cross-
member of the inner mast section to the top
crossmember of the outer mast section. See
Figure 1. Lower the mast so the safety chains
hold the weight of the mast sections.
3. On full free-lift mast, raise the mast a few inches
out of free-lift and attach safety chain prior to re-
moving lift cylinder.
a. Use safety chains to connect the bottom cross-
member 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 inter-
mediate or outer mast section. See Figure 1.
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 re-
moval 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. If working on a two-stage or three-stage mast, re-
move the snap rings at the top of the cylinder.
See Figure 8 and Figure 9 for lift truck models
D878, E878)
D879, E879, F879)
WARNING
Hydraulic oil is hot after system operation and
can cause burns. DO NOT disconnect any hy-
draulic hoses until the oil in the system is cool.
NOTE: Tag hydraulic lines during removal to aid in
installation.
5. Put a drain pan under the area of the hydraulic fit-
tings. Retract the rod into the lift cylinder. Discon-
nect and cap the hydraulic lines at the cylinder.
D878, E878)
D879, E879, F879)
See Figure 10 and Figure 11 for lift truck model
B909)
2100 YRM 1328 Lift Cylinder Repair
15

1. BOLT
2. WASHER
3. SHIM
4. SNAP RING
5. LOCK NUT
6. CAPSCREWS
7. HOSE CLAMPS
8. HYDRAULIC FITTINGS
9. LOWERING CONTROL VALVE HOUSING
10. HYDRAULIC LINES
11. HEADER HOSE (FIVE FUNCTION)
12. HEADER HOSE (THREE FUNCTION)
13. HEADER HOSE (FOUR FUNCTION)
14. BRACKET
15. CYLINDER MOUNT
16. CHAIN ANCHOR
17. OUTER MAST
Figure 8. Two-Stage Limited Free-Lift Mast, Cylinder Installation for Lift Truck Models GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/
GDC70VX (GC/GLC/GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)
Lift Cylinder Repair 2100 YRM 1328
16

Figure 9. Three-Stage Full Free-Lift Mast, Cylinder Installation for Lift Truck Models GLP/GDP60VX, GLP/
GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/
17

Legend for Figure 9
1. MAIN CYLINDER (RH)
3. MAIN CYLINDER (LH)
4. LOCK NUT
5. SPACER
6. WASHER
7. CAPSCREW
8. HEADER HOSE (THREE FUNCTION)
10. HEADER HOSE (FOUR FUNCTION)
11. HEADER HOSE (FIVE FUNCTION)
12. CHAIN ANCHOR
13. LOWERING CONTROL VALVE HOUSING
14. SNAP RING
15. CYLINDER MOUNT
16. HOSE CLAMPS
17. HYDRAULIC LINES
18. OUTER MAST
18

1. MAST
2. CARRIAGE
3. HYDRAULIC LINE
4. HYDRAULIC FITTING
5. LIFT CYLINDER
6. HOSE CLAMP
Figure 10. Two-Stage Mast, Hydraulic Lines and Fittings for Lift Truck Model GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)
19

1. MAST
2. CARRIAGE
3. HYDRAULIC LINE
5. LIFT CYLINDER
6. HOSE CLAMP
Figure 11. Three-Stage Mast, Hydraulic Lines and Fittings for Lift Truck Model GLP/GDP80VX, GLP/
20

6. Remove hose clamps securing hoses to lift cylin-
der.
D878, E878)
D879, E879, F879)
See Figure 10 and Figure 11 for lift truck model
B909)
els:
D878, E878)
D879, E879, F879)
7. For lift truck models equipped with a three-stage
full free-lift mast, see Figure 9.
a. Disconnect the main lift chain anchor and
header hoses at the cylinder mount.
b. Remove the lock nut, capscrew, and spacer
securing the cylinder mount to the outer mast.
8. For lift truck models equipped with a two-stage
limited free-lift mast, see Figure 8.
a. Remove the lock nuts and bracket and discon-
nect the main lift chain anchor at the cylinder
mount.
b. Remove the bolt, washer, and shims securing
the cylinder mount to the outer mast.
NOTE: Perform Step 9 and Step 10 for lift truck
GLP/GDP190VX) (A909, B909).
full free lift mast, see Figure 12.
a. Remove capscrews, washers, and bracket
from anchor bracket.
b. Remove snap ring and washer at top of lift cyl-
inder.
c. Remove retention screw from mast and bottom
of lift cylinder.
10. For lift truck model, GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX,
GLP/GDP175VX36, GLP/GDP190VX) (A909,
B909), equipped with a two-stage limited free-lift
mast, see Figure 13 and Figure 14.
a. Remove anchor screw, washer, and spacer
from top of lift cylinder and crossmember.
b. Remove retention screw from mast and bottom
of lift cylinder.
11. Using a lifting device, remove lift cylinder from
mast.
(A909, B909).
12. Remove convex washer from top of lift cylinder.
See Figure 15.
13. Repeat Step 4 through Step 12 for opposite lift
cylinder.
21

1. MAST
2. LIFT CYLINDER
3. SNAP RING
4. WASHER
5. CONVEX WASHER
6. CAPSCREW
7. WASHER
8. BRACKET
9. ANCHOR BRACKET
10. RETENTION SCREW
Figure 12. Three-Stage Full Free-Lift Mast, Cylinder Installation for Lift Truck Model GLP/GDP80VX, GLP/
22

1. LIFT CYLINDER
2. ANCHOR SCREW
3. WASHER
4. SPACER
5. CROSSMEMBER
Figure 13. Two-Stage Limited Free-Lift Mast,
Cylinder Installation - Top for Lift Truck Model
GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
(GLP/GDP170VX, GLP/GDP175VX36, GLP/
GDP190VX) (A909, B909)
1. MAST
2. LIFT CYLINDER
3. RETENTION SCREW
Figure 14. Two-Stage Limited Free-Lift Mast,
Cylinder Installation - Bottom for Lift Truck Model
GDP190VX) (A909, B909)
23

NOTE: TWO-STAGE LIMITED FREE-LIFT MAST
SHOWN.
1. MAST
2. LIFT CYLINDER
3. CONVEX WASHER
Figure 15. Lift Cylinder with Convex Washer
DISASSEMBLE
CAUTION
Carefully disassemble the main lift cylinders so
the piston rods and sliding surfaces are not dam-
aged.
brass tools when removing seals and O-rings.
1. Loosen gland with a spanner wrench.
D878, E878)
D879, E879, F879)
B909)
D878, E878)
D879, E879, F879)
NOTE: Note placement of components as removed
from gland during disassembly to aid in assembly.
2. Remove gland from shell. Remove and discard
rod wiper, backup ring, rod seal, O-ring, and wear
ring from gland.
D878, E878)
D879, E879, F879)
NOTE: Perform Step 3 and Step 4 for lift truck model
GDP190VX) (A909, B909).
3. Remove gland from shell. See Figure 18.
4. Remove and discard rod wiper from gland. See
Figure 18.
5. Remove rod and piston assembly from shell.
Drain hydraulic oil into container.
24

D878, E878)
D879, E879, F879)
B909)
els
D878, E878)
D879, E879, F879)
6. On lift trucks equipped with a two-stage limited
free-lift mast. Remove and discard backup ring,
seal, and wear ring from piston. See Figure 16.
7. On lift trucks equipped with a three-stage full free-
lift mast. Remove and discard backup ring, seal,
wear ring, and piston ring from piston. See Fig-
ure 17.
(A909, B909).
8. Remove backup ring, piston ring, piston seal, and
O-ring from piston. Discard backup ring, piston
seal, and O-ring. See Figure 18.
9. Repeat Step 1 through Step 8 for opposite lift cyl-
inder.
1. SHELL
2. WEAR RING
3. SEAL
4. BACKUP RING
5. ROD AND PISTON ASSEMBLY
6. O-RING
7. WEAR RING
8. ROD SEAL
9. ROD WIPER
10. GLAND
Figure 16. Two-Stage Mast, Lift Cylinder
Assembly for Lift Truck Models GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878) and GLC/
GC/GLC/GDC155VX) (C879, D879, E879, F879)
25

1. SHELL
2. PISTON RING
3. WEAR RING
4. SEAL
5. BACKUP RING
7. ROD SEAL
8. ROD WIPER
9. O-RING
10. GLAND
Figure 17. Three-Stage Mast, Lift Cylinder
Assembly for Lift Truck Models GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/
GDP155VX) (C878, D878, E878) and GLC/
GC/GLC/GDC155VX) (C879, D879, E879, F879)
1. ROD WIPER
2. GLAND
3. BLEED-BACK PORT
4. SHELL
5. ROD
6. PISTON
7. O-RING
8. PISTON SEAL
9. PISTON RING
10. BACKUP RING
11. RETENTION SCREW
Figure 18. Lift Cylinder Assembly for Lift Truck
Model GLP/GDP80VX, GLP/GDP80VX9, GLP/
GLP/GDP190VX) (A909, B909)
26

CLEAN
WARNING
CAUTION
components.
pressed air.
INSPECT
seal surfaces. If damaged, replace gland.
ces. If damaged, replace piston.
sure that the rod is not bent. If damaged replace rod.
age. If damaged, replace cylinder assembly.
ASSEMBLE, LIFT TRUCK MODELS GLP/
GDP60VX, GLP/GDP70VX (GP/GLP/
D878, E878) AND GLC/GDC60VX, GLC/
GDC70VX (GC/GLC/GDC135VX, GC/GLC/
GDC155VX) (C879, D879, E879, F879)
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 assem-
bly.
brass tools when installing seal and O-rings.
NOTE: Lubricate all internal parts of the lift cylinder
with clean hydraulic oil during to assembly.
1. On lift trucks equipped with a two-stage limited
free-lift mast. Install new backup ring, seal, and
wear ring into onto piston. See Figure 16.
2. On lift trucks equipped with a three-stage full free-
lift mast. Install new backup ring, seal, wear ring,
and piston ring onto piston. See Figure 17.
3. Install rod and piston assembly into shell.
4. Install new wear ring, O-ring, rod seal, backup
ring, and rod wiper onto gland as noted during
disassembly.
See Figure 16 and Figure 17.
5. Using a spanner wrench, install gland onto piston
rod inside shell. Tighten gland to 375 to
450 N•m (277 to 332 lbf ft).
6. Repeat Step 1 through Step 5 for the opposite lift
cylinder.
GDP80VX, GLP/GDP80VX9, GLP/
B909)
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 assem-
bly.
brass tools when installing seal and O-rings.
NOTE: Lubricate all internal parts of the lift cylinder
with clean hydraulic oil during to assembly.
1. Install new O-ring and piston seal onto piston.
See Figure 18.
2. Install piston ring onto piston and tighten. See
Figure 18.
3. Install new backup ring onto piston. See Fig-
ure 18.
27

4. Install rod and piston assembly into shell.
5. Install rod wiper onto gland. See Figure 18.
gland threads.
7. Using a spanner wrench, install gland onto piston
rod inside shell. Tighten gland to 350 to
8. Repeat Step 1 through Step 7 for the opposite lift
cylinder.
INSTALL, LIFT TRUCK MODELS GLP/
GDC155VX) (C879, D879, E879, F879)
1. Using a lifting device, install the lift cylinder in the
mount at the bottom of the outer mast. See Fig-
ure 8 and Figure 9.
a. Install spacer, capscrew, and lock nut to se-
cure the cylinder mount to the outer mast.
Tighten lock nut to 135 N•m (100 lbf ft).
b. Connect the main lift chain anchor and hy-
draulic header hoses at the cylinder mount.
Tighten chain anchor lock nut to
370 N•m (273 lbf ft).
3. For lift truck models equipped with a two-stage
limited free-lift mast, see Figure 8.
a. Install shims, washer, and bolt to secure cylin-
der mount to the outer mast. Tighten bolt to
555 N•m (410 lbf ft).
b. Install the bracket and lock nuts and connect
the main lift chain anchor at the cylinder mount.
Tighten chain anchor lock nut to
370 N•m (273 lbf ft).
WARNING
or installation.
4. If working on a two-stage or three-stage mast, in-
stall the snap rings at the top of the cylinder. See
Figure 8 and Figure 9.
5. Connect the hydraulic fittings and hydraulic lines
to lift cylinders as tagged during removal. See
Figure 8 and Figure 9.
inder.
7. Remove safety chains.
8. Use a lifting device to lower the inner mast (two-
stage limited free-lift) or intermediate mast (three-
stage full free-lift) onto the lift cylinders.
9. Install the carriage as described in the carriage In-
stall procedures. See Mast Repairs (S/N A513,
A514, A613, A614, A702, A703, A704, A705,
A706, A707, A751, A752, B513, B514, B586,
B587, B588, B589, B590, B591, B749, B750,
B751, B752, B753, B754) 4000YRM1250.
B909)
1. Install convex washer on top of lift cylinder.
2. Using a lifting device, install the lift cylinder in the
mount at the bottom of the outer mast. See Fig-
ure 12 and Figure 15.
3. For lift truck model equipped with a three-stage
a. Install retention screw into mast and bottom of
lift cylinder.
b. Install washer and snap ring onto top of lift cyl-
inder.
c. Install bracket, washers, and capscrews onto
anchor bracket.
4. For lift truck model equipped with a two-stage full
free-lift mast, see Figure 14.
a. Install retention screw into mast and bottom of
lift cylinder.
b. Install spacer, washer, and anchor screw onto
lift cylinder and crossmember.
28

5. Connect the hydraulic fittings and hydraulic lines
to lift cylinders as tagged during removal. See
Figure 11.
inder.
7. Remove safety chains.
8. Use a lifting device to lower the inner mast (two-
stage limited free-lift) or intermediate mast (three-
stage full free-lift) onto the lift cylinders.
9. Install the carriage as described in the carriage In-
stall procedures. See Mast Repair (S/N A513,
A514, A613, A614, A643, A644, A683, A684)
4000YRM1406.
Free-Lift Cylinder Repair
REMOVE
1. Remove the carriage and load backrest as descri-
bed in the carriage removal procedures in the
section
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D878, E878)
D879, E879, F879)
model
B909)
NOTE: Tag hydraulic lines during removal to aid in
installation.
2. Place a drain pan under the free-lift cylinder. Dis-
connect and cap the hydraulic hose and fittings at
the bottom of the cylinder.
D878, E878)
D879, E879, F879)
B909)
els:
D878, E878)
D879, E879, F879)
3. Remove capscrews, washers, and lockwashers
from hose sheave shaft and hose sheave bracket.
Remove hose sheave bracket from chain guard.
See Figure 20.
4. Remove hose sheaves and hose sheave shaft.
5. Disconnect and cap the hydraulic fittings at the
hose mounting brackets.
D878, E878)
D879, E879, F879)
B909)
2100 YRM 1328 Free-Lift Cylinder Repair
29

6. Remove hoses from hose sheaves.
D878, E878)
D879, E879, F879)
B909)
(A909, B909).
7. Remove four screws and hose sheave assembly
from chain guard. See Figure 22.
models:
D878, E878)
D879, E879, F879)
8. Remove chain guard from crosshead. See Fig-
ure 20.
9. Remove lock nuts from chain anchor and remove
chain. See Figure 19.
10. Using a brass drift, remove pin from crosshead.
See Figure 20.
11. Remove chain sheave assembly from crosshead.
GLP/GDP190VX) (A909, B909).
12. Remove lock nut from chain anchor; remove
chain anchor from crossmember; remove chain
from chain sheave. See Figure 23.
13. Remove chain sheave from top of free-lift cylinder
by unscrewing. See Figure 24.
models
D878, E878)
D879, E879, F879)
14. Remove two capscrews and washers securing
crosshead to cylinder rod. Remove crosshead.
See Figure 20.
15. Remove two capscrews, lock nuts, lockwashers,
washers, and spacer from inner mast mounting
bracket. With a lifting device, remove free-lift cyl-
inder assembly from inner mast.
D878, E878)
D879, E879, F879)
GLP/GDP190VX) (A909, B909).
16. Remove two screws, two washers, and bracket
from crossmember and free-lift cylinder. See Fig-
ure 25.
17. Remove retention screw from bottom of free-lift
cylinder and mast. See Figure 25.
18. Using a lifting device, remove free-lift cylinder
from inner mast.
(A909, B909).
19. Repeat above steps as required for opposite free-
lift cylinder.
Free-Lift Cylinder Repair 2100 YRM 1328
30

NOTE: BOTTOM CROSSMEMBER OF THE INNER MAST HAS BEEN REMOVED FOR CLARITY.
A. REAR VIEW B. FRONT VIEW
1. CAPSCREW
2. LOCK NUT
4. CHAIN
5. HOSE
6. CHAIN ANCHOR
7. INNER MAST
8. HOSE MOUNTING BRACKET
Figure 19. Free-Lift Cylinder Removal for Lift Truck Models GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879)
31

Figure 20. Hose Sheave, Chain Sheave, and Crosshead Installation for Lift Truck Models GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) and GLC/GDC60VX, GLC/
32

Legend for Figure 20
1. CAPSCREW
2. WASHER
3. LOCKWASHER
4. HOSE SHEAVE BRACKET
5. SNAP RING
6. HOSE SHEAVE SHAFT
7. HOSE SHEAVE
8. HOSE
10. CHAIN GUARD
11. CHAIN
12. COTTER PIN
13. PIN
14. BEARING
16. CHAIN SHEAVE ASSEMBLY
17. SPACER
18. PIN
19. CROSSHEAD
20. LOCK NUT
21. CHAIN ANCHOR
23. INNER MAST MOUNTING BRACKET
24. CYLINDER ROD
NOTE: MAST CROSSMEMBERS REMOVED FOR
CLARITY.
2. HYDRAULIC HOSE
3. FITTING
Figure 21. Free Lift Cylinder Hydraulic Lines and
Fittings for Lift Truck Model GLP/GDP80VX, GLP/
GDP80VX9, GLP/GDP90VX (GLP/GDP170VX, GLP/
GDP175VX36, GLP/GDP190VX) (A909, B909)
1. HOSE SHEAVE ASSEMBLY
2. CHAIN GUARD
3. SCREW
Figure 22. Hose Sheave for Lift Truck Model GLP/
(A909, B909)
33

1. LOCKNUT
2. CHAIN ANCHOR
3. CHAIN
Figure 23. Chain Anchor for Lift Truck Model GLP/
(A909, B909)
1. CHAIN SHEAVE
Figure 24. Chain Sheave for Lift Truck Model GLP/
(A909, B909)
34

A. FRONT VIEW B. REAR VIEW
1. CROSSMEMBER
2. BRACKET
3. SCREW
4. WASHER
5. RETENTION SCREW
6. MAST
Figure 25. Free-Lift Cylinder Mount for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
35

DISASSEMBLE
CAUTION
Carefully disassemble the free-lift cylinder so the
piston rods and sliding surfaces are not damaged.
brass tools when removing or installing seal and O-
rings.
1. Loosen gland with spanner wrench.
2. Remove gland from shell.
D878, E878)
D879, E879, F879)
B909)
(A909, B909).
3. Remove and discard rod wiper, rod seal, and O-
ring from gland. See Figure 27.
Drain hydraulic oil into container.
D878, E878)
D879, E879, F879)
B909)
models:
D878, E878)
D879, E879, F879)
5. Remove and discard O-ring from outside of gland
and remove, wear ring, backup ring, rod seal, and
rod wiper from inside of gland. See Figure 26.
WARNING
or installation.
6. Remove snap ring, washer, check valve from
base of piston. Remove and discard seal from
check valve. See Figure 26.
7. Remove wear ring and backup ring. Remove and
discard piston seal from piston. See Figure 26.
NOTE: Perform Step 8 and Step 9 for lift truck model
GDP190VX) (A909, B909).
8. Remove and discard wear ring from piston. See
Figure 27.
lift cylinder.
36

1. GLAND
2. O-RING
3. ROD WIPER
4. BACKUP RING
5. ROD SEAL
6. WEAR RING
8. PISTON SEAL
9. CHECK VALVE
10. SEAL
11. WASHER
12. SNAP RING
13. SHELL
Figure 26. Free-Lift Cylinder Assembly for Lift
Truck Models GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (C878,
D878, E878) and GLC/GDC60VX, GLC/GDC70VX
D879, E879, F879)
Figure 27. Free-Lift Cylinder Assembly for Lift
Truck Model GLP/GDP80VX, GDP80VX9, GLP/
GLP/GDP190VX) (A909, B909)
37

1. ROD WIPER
2. ROD SEAL
3. GLAND
4. O-RING
5. BLEED SCREW
6. SHELL
7. ROD
8. PISTON
9. WEAR RING
10. RETENTION SCREW
CLEAN
WARNING
CAUTION
Do not allow cleaning solvent to come in contact
components.
pressed air.
INSPECT
seal surfaces. If damaged, replace gland.
ces. If damaged, replace piston.
sure that the rod is not bent. If damaged replace rod.
age. If damaged, replace cylinder assembly.
GDC155VX) (C879, D879, E879, F879)
CAUTION
A difficult and important step in assembling free-
lift cylinders is the correct installation of the
seals. Most cylinders maintenance is caused by
seal leaks. DO NOT damage any parts during as-
sembly.
NOTE: Lubricate all internal parts of the free-lift cylin-
der with clean hydraulic oil.
NOTE:
1. Install check valve and new seal in base of piston
of free-lift cylinder. Make sure arrow on check
valve is toward base of piston. Install washer and
snap ring for check valve. See Figure 26.
2. Install new wear ring, piston seal, and backup ring
on rod an piston assembly. See Figure 26.
3. Carefully install rod and piston assembly into
shell. See Figure 26.
4. Install new wear ring, new rod seal, new backup
ring, and new rod wiper into gland. Install new O-
ring on outside of gland. See Figure 26.
NOTE: Hydraulic oil is pored into the free-lift cylinder
to act as a cushion during load lifting to prevent dam-
age to the cylinder.
5. Before installing gland, pour 150 cc (5 oz) of hy-
draulic oil into the cylinder shell.
6. Install gland on rod and piston assembly. See Fig-
ure 26. Tighten gland to 400 to 475 N•m (295 to
350 lbf ft).
lift cylinder.
38

B909)
CAUTION
A difficult and important step in assembling free-
lift cylinders is the correct installation of the
seals. Most cylinders maintenance is caused by
seal leaks. DO NOT damage any parts during as-
sembly.
NOTE: Lubricate all internal parts of the free-lift cylin-
der with clean hydraulic oil.
1. Install new wear ring onto piston. See Figure 27.
2. Carefully install rod and piston assembly into
3. Install new O-ring, new rod sea, and new rod
wiper onto gland. See Figure 27.
4. Install gland onto rod and piston assembly. See
Figure 27. Tighten gland to 350 to 400 N•m (258
to 295 lbf ft).
lift cylinder.
GDC155VX) (C879, D879, E879, F879)
1. Install crosshead onto cylinder rod, then install
two capscrews and lockwashers securing cross-
head to cylinder rod. See Figure 20.
2. Install chain sheave assembly and spacers into
crosshead. See Figure 20.
3. Using a brass drift, install pin through the chain
sheave assembly. See Figure 20.
4. Using a lifting device, install free-lift cylinder into
the inner mast and align cylinder mount holes with
inner mast mounting holes.
5. Install two capscrews through hose mounting
bracket, spacers and inner mast mounting
bracket. Secure capscrews with two washers,
lockwashers, and lock nuts. See Figure 20.
Tighten lock nut to 135 N•m (100 lbf ft).
6. Install chain and chain anchor over chain sheave
assembly and install chain anchor into cylinder
mount. Tighten lock nuts to 370 N•m (273 lbf ft).
7. Install chain guard over the chain sheave assem-
bly. See Figure 20.
8. Install hose sheave brackets to crosshead with
capscrews, washers, and lockwashers. Tighten
capscrews to 33 N•m (25 lbf ft). See Figure 20.
9. Place hose sheaves and hose sheave shaft inside
of hose sheave bracket and install two capscrews
and washers. Tighten capscrews to
10. Install the hoses over the hose sheaves and
through hose mounting bracket and uncap hoses.
Connect hoses to hydraulic fittings.
11. Install hydraulic fittings at the bottom of the cylin-
der. See Figure 19.
12. Perform above steps as required for opposite
free-lift cylinder.
13. Install the load backrest an carriage as described
in the carriage install procedures. See Mast Re-
pairs (S/N A513, A514, A613, A614, A702,
A703, A704, A705, A706, A707, A751, A752,
B513, B514, B586, B587, B588, B589, B590,
B591, B749, B750, B751, B752, B753, B754)
4000YRM1250.
39

B909)
1. Using a lifting device, install free-lift cylinder into
the inner mast and align cylinder mount holes with
inner mast mounting holes.
2. Install retention screw into bottom of mast and
free-lift cylinder. See Figure 25.
3. Install bracket, two washers, and two screws on
free-lift cylinder and crossmember. See Figure 25.
4. Install chain sheave into top of free-lift cylinder.
See Figure 24.
5. Install chain onto chain sheave; install chain an-
chor through crossmember; install locknut onto
chain anchor. See Figure 23.
6. Install the hoses over the hose sheaves and
through hose mounting bracket and uncap hoses.
Connect hoses to hydraulic fittings.
7. Install hose sheave assembly and four screws
onto chain guard. See Figure 22.
8. Install hydraulic hoses onto hose sheave.
9. Uncap and connect hydraulic lines at bottom of
free-lift cylinder. See Figure 25.
10. Perform above steps as required for opposite
free-lift cylinder.
11. Install the load backrest an carriage as described
in the carriage install procedures. See Mast Re-
pair (S/N A513, A514, A613, A614, A643, A644,
A683, A684) 4000YRM1406.
Sideshift Cylinder Repair
REMOVE
WARNING
ure 1.
1. Remove carriage as described in carriage re-
moval procedures.
See Mast Repairs (S/N A513, A514, A613, A614,
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D879, E879, F879)
D878, E878)
See Mast Repair (S/N A513, A514, A613, A614,
A643, A644, A683, A684) 4000YRM1406 for lift
truck model
• GLP/GDP80VX, GLP/GDP80VX9,
GLP/GDP90VX (GLP/GDP170VX, GLP/
B909)
D879, E879, F879)
D878, E878)
2. Remove sideshift cylinder from sideshift carriage
as described in disassemble procedures.
See Mast Repairs (S/N A513, A514, A613, A614,
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D879, E879, F879)
D878, E878)
Sideshift Cylinder Repair 2100 YRM 1328
40

WARNING
and wear eye and face protections during removal
or installation.
(A909, B909).
3. Remove four snap rings, two clevis pins, and
sideshift cylinder from carriage. See Figure 28.
1. SIDESHIFT CYLINDER
2. SNAP RING
3. CLEVIS PIN
4. ISS OUTER FRAME
Figure 28. Sideshift Cylinder Removal, Lift Truck Models GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX
2100 YRM 1328 Sideshift Cylinder Repair
41

DISASSEMBLE
NOTE: For lift trucks manufactured before August,
2012, perform Step 1 through Step 8 for lift truck mod-
els
D879, E879, F879)
D878, E878)
1. Position cylinder rod in fully extended position and
remove snap ring from retainer. See Figure 29.
2. Push cylinder retainer into cylinder shell approxi-
mately 50 mm (2 in.) until retainer ring is exposed.
3. Remove retainer ring. See Figure 29.
4. Remove rod assembly and retainer from cylinder
5. Remove retainer from rod. See Figure 29.
CAUTION
To prevent damage to sealing surfaces, use brass
tools when removing seals and O-rings.
6. Remove and discard, wiper, rod seal, backup
ring, and O-ring from retainer. See Figure 29.
7. Remove lock nut and piston from rod. See Fig-
ure 29.
8. Remove and discard backup ring and piston seal
from piston. See Figure 29.
NOTE: For lift trucks manufactured after August,
2012, perform Step 9 through Step 13 for lift truck
models
D879, E879, F879)
9. Remove the retainer. See Figure 30.
10. Remove rod wiper from retainer. See Figure 30.
11. Remove O-ring from retainer. See Figure 30.
12. Remove rod seal from retainer. See Figure 30.
13. Remove fittings and O-rings from cylinder assem-
bly. See Figure 30. Discard O-rings.
CAUTION
Carefully disassemble the sideshift cylinder so
the piston rods and sliding surfaces are not dam-
aged.
CAUTION
To prevent damage to sealing surfaces use brass
models
14. Loosen gland with spanner wrench. See Fig-
ure 31.
Figure 31.
17. Remove rod and piston assembly from shell. See
Figure 31. Drain hydraulic oil into container.
O-ring from piston. See Figure 31. Discard
backup ring, piston seal, and O-ring.
42

1. SNAP RING
2. RETAINER RING
3. ROD
4. RETAINER
5. CYLINDER SHELL
6. WIPER
7. ROD SEAL
8. BACKUP RING
9. O-RING
10. LOCK NUT
11. PISTON
12. PISTON SEAL
13. BACKUP RING
Figure 29. Hang On Sideshift Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) Manufactured Before August, 2012
43

1. ROD WIPER
2. RETAINER
3. O-RING
4. ROD SEAL
5. ROD
6. FITTINGS
7. CYLINDER ASSEMBLY
Figure 30. Hang On Sideshift Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (E879, F879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (E878) Manufactured After August, 2012
44

1. ROD
2. ROD WIPER
3. GLAND
4. PISTON
5. O-RING
6. PISTON SEAL
7. PISTON RING
8. BACKUP RING
9. SHELL
Figure 31. Sideshift Cylinder for Lift Truck Model GLP/GDP80VX, GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP170VX, GLP/GDP175VX36, GLP/GDP190VX) (A909, B909)
45

CLEAN
WARNING
CAUTION
components.
1. Clean all metal parts in solvent and dry with com-
pressed air.
INSPECT
1. Inspect gland and fittings for damage to threads
and seal surfaces. Replace if damaged.
2. Inspect piston for any damage to seal surfaces.
Replace if damaged.
3. Inspect rod for damage to rod surface and ensure
rod is not bent. Replace if damaged or bent.
4. Inspect inner surface of cylinder shell for damage.
Replace cylinder assembly if damaged.
ASSEMBLE
CAUTION
tools when installing seals and O-rings.
els
D879, E879, F879)
D878, E878)
NOTE: Lubricate all internal parts of the cylinder with
clean hydraulic oil prior to assembly.
1. Install new piston seal and backup ring onto pis-
ton. See Figure 29.
CAUTION
To prevent damage to the cylinder, DO NOT clamp
on cylinder rod sealing surface.
2. Place cylinder shell in soft-jawed vise and install
piston onto rod. See Figure 29.
3. Install lock nut onto rod. See Figure 29. Tighten
lock nut to 135 to 163 N•m (100 to 120 lbf ft).
4. Install rod and piston into cylinder shell.
5. Install new O-ring and backup ring into groove of
retainer. See Figure 29.
6. Push retainer into cylinder shell until retainer ring
groove is exposed.
7. Install retainer rig into groove of cylinder shell.
See Figure 29.
8. Pull rod and piston out of cylinder shell until re-
tainer stops on retainer ring and snap ring groove
is exposed. See Figure 29.
9. Install snap ring onto retainer. See Figure 29.
models
GDC135VX, GC/GLC/GDC155VX) (E879,
F879)
10. Install new O-ring on fittings and install fittings in
cylinder. See Figure 30.
11. Install rod seal in retainer. See Figure 30.
12. Install O-ring on retainer. See Figure 30.
13. Install rod wiper in retainer. See Figure 30.
14. Install retainer onto cylinder assembly. See Fig-
ure 30.
46

CAUTION
tools when installing seal and O-rings.
model
clean hydraulic oil prior to assembly.
See Figure 31.
Figure 31.
ure 31.
18. Install rod and piston assembly into shell. See
Figure 31.
gland threads.
21. Install gland onto shell. See Figure 31. Tighten
gland to 350 to 400 N•m (258 to 295 lbf ft).
INSTALL
D879, E879, F879)
D878, E878)
1. Install sideshift cylinder as described in install pro-
cedure in section
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D879, E879, F879)
D878, E878)
WARNING
and wear eye and face protections during removal
or installation.
(A909, B909).
2. Install sideshift cylinder, two clevis pins, and four
snap rings onto carriage. See Figure 28.
3. Install carriage as described in the carriage install
procedures located in the section
A702, A703, A704, A705, A706, A707, A751,
A752, B513, B514, B586, B587, B588, B589,
B590, B591, B749, B750, B751, B752, B753,
D879, E879, F879)
D878, E878)
model
B909)
2100 YRM 1328 Fork Positioner Cylinder Repair
47

Fork Positioner Cylinder Repair
REMOVE
WARNING
ure 1.
D879, E879, F879)
D878, E878)
1. Remove fork positioner cylinder as described in
Hang On Sideshift Carriage Repair removal pro-
cedures located in the section Mast Repairs (S/N
A513, A514, A613, A614, A702, A703, A704,
A705, A706, A707, A751, A752, B513, B514,
B586, B587, B588, B589, B590, B591, B749,
B750, B751, B752, B753, B754) 4000YRM1250.
model
2. Remove carriage as described in carriage re-
moval procedures located in the section Mast Re-
pair (S/N A513, A514, A613, A614, A643, A644,
A683, A684) 4000YRM1406.
NOTE: The following step to be performed for both
upper and lower fork positioner cylinders.
NOTE: Note placement of fork positioner cylinders
prior to removal to aid in installation.
3. Disconnect all hydraulic fittings and lines from fork
positioner cylinders on carriage. See Figure 32.
4. Remove screw, washer, and bushing from lower
fork positioner cylinder rod end and carriage. See
Figure 33.
5. Remove nut from lower fork positioner cylinder
shell end. See Figure 33.
6. Retract rod into shell and remove lower fork posi-
tioner cylinder from carriage.
7. Repeat Step 4 through Step 6 for upper fork posi-
tioner cylinder.
DISASSEMBLE
CAUTION
Carefully disassemble the fork positioner cylin-
ders so the piston rods and sliding surfaces are
not damaged.
els
D879, E879, F879)
D878, E878)
1. Unscrew cylinder rod retainer. See Figure 34.
CAUTION
2. Remove piston, rod, and cylinder rod retainer as
an assembly from cylinder shell. See Figure 34.
3. Remove cylinder rod retainer from cylinder rod.
See Figure 34.
4. Remove spacer from cylinder rod. See Figure 34.
5. Remove and discard rod wiper, rod seal, backup
rings, and O-rings from cylinder rod retainer. See
Figure 34.
CAUTION
To prevent damage to cylinder rod, DO NOT
clamp on the cylinder rod sealing surface.
6. Place cylinder rod in soft-jawed vise and remove
piston nut and piston. See Figure 34.
7. Remove and discard piston seal and O-ring from
piston. See Figure 34.
Fork Positioner Cylinder Repair 2100 YRM 1328
48

1. CARRIAGE
2. FORK POSITIONER CYLINDER
4. HYDRAULIC LINE
Figure 32. Hydraulic Connections Fork Positioner Cylinder
49

1. UPPER FORK POSITIONER CYLINDER ROD
END
2. UPPER FORK POSITIONER CYLINDER SHELL
END
3. LOWER FORK POSITIONER CYLINDER ROD
END
4. LOWER FORK POSITIONER CYLINDER SHELL
END
5. CARRIAGE
6. SCREW
7. WASHER
8. BUSHING
9. NUT
Figure 33. Fork Positioner Cylinder Mount
50

1. CYLINDER ROD
2. ROD SEAL
3. ROD WIPER
4. CYLINDER ROD RETAINER
5. BACKUP RING
6. O-RING
7. SPACER
8. CYLINDER SHELL
9. PISTON
10. PISTON SEAL
11. PISTON NUT
Figure 34. Fork Positioner Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
GDC135VX, GC/GLC/GDC155VX) (C879, D879, E879) and GLP/GDP60VX, GLP/GDP70VX (GP/GLP/
GDP135VX, GP/GLP/GDP155VX) (C878, D878, E878) Manufactured Before August, 2012
CAUTION
Carefully disassemble the fork positioner cylin-
ders so the piston rods and sliding surfaces are
not damaged.
CAUTION
To prevent damage to sealing surfaces use brass
models
GDC135VX, GC/GLC/GDC155VX) (D879,
E879, F879)
GDP135VX, GP/GLP/GDP155VX) (D878,
E878)
8. Place fork positioner on flat surface. Use clamps
to hold fork positioner in position and blocks for
clearance and to keep parts in alignment. See
Figure 35.
9. Remove cylinder rod anchor plug. Move fork car-
rier lug towards manifold and remove half-ring
keepers. Move cylinder rod to fully retracted posi-
tion shown in Figure 35.
10. Using retainer socket tool (see Special Tools), un-
screw cylinder retainer to remove cylinder assem-
bly from manifold.
CAUTION
DO NOT bend hydraulic tubes when removing
them. Damage to hydraulic tubes can result if they
are bent.
NOTE: Make note of which end hydraulic tubes are
removed from. If hydraulic tubes are removed from
cylinder head end, install hydraulic tubes first, before
installing cylinder and fork carrier lug assembly to
manifold.
11. Disconnect hydraulic tubes at manifold. Remove
clamps and remove cylinder and fork carrier lug
assembly. See Figure 35.
12. Slide fork carrier lug from cylinder shell. Remove
piston/rod assembly from cylinder shell.
51

1. ANCHOR PLUG
2. HALF-RING KEEPERS
3. FORK CARRIER LUG
4. RETAINER SOCKET TOOL
5. CYLINDER RETAINER
6. CYLINDER ROD
7. HEAD TIGHTENING TOOL
8. CYLINDER SHELL
Figure 35. Fork Positioner Assembly for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
NOTE: DO NOT scratch seal grooves. Use brass
seal removal tools to pry items from grooves.
13. Remove all seals, O-ring, wear rings and bearings
from components as shown in Figure 36.
14. If required, unscrew cylinder shell from head end
using head tightening tool. See Special Tools.
15. Repeat Step 9 through Step 14 for other cylinder.
model:
16. Loosen gland with spanner wrench. See Fig-
ure 37.
Figure 37.
Drain hydraulic oil into container. See Figure 37.
O-ring from piston. Discard backup ring, piston
seal, and O-ring. See Figure 37.
21. Repeat Step 16 through Step 20 for other fork po-
sitioner cylinder.
52

A. RETAINER B. PISTON C. FORK CARRIER LUG
1. RETAINER
2. MANIFOLD
3. CYLINDER SHELL
4. CYLINDER ROD
5. FORK CARRIER LUG
6. INTERNAL SPACER (IF RE-
QUIRED)
7. HEAD END/MOUNTING
FOOT
8. O-RING
9. U-CUP PRESSURE SEAL
10. WIPER SEAL
11. WEAR RING
12. TWO-PIECE PRESSURE SEAL
13. WIPERS
14. BEARINGS
Figure 36. Fork Positioner Cylinder for Lift Truck Models GLC/GDC60VX, GLC/GDC70VX (GC/GLC/
53

Figure 37. Fork Positioner Cylinder
1. ROD WIPER
2. GLAND
3. SHELL
4. ROD
5. PISTON
6. O-RING
7. PISTON SEAL
8. PISTON RING
9. BACKUP RING
CLEAN
WARNING
CAUTION
components.
1. Clean all metal parts in solvent and dry with com-
pressed air.
INSPECT
1. Inspect gland for damage to threads and seal sur-
faces. Replace if damaged.
2. Inspect piston for any damage to seal surfaces.
Replace if damaged.
3. Inspect rod for damage to rod surface and ensure
rod is not bent. Replace if damaged or bent.
4. Inspect inner surface of cylinder shell for damage.
Replace cylinder assembly if damaged.
54

ASSEMBLE
CAUTION
tools when installing seal and O-ring.
clean hydraulic oil during assembly.
els
D879, E879, F879)
D878, E878)
1. Install new O-rings, backup rings, rod seal, and
rod wiper onto cylinder rod retainer. See Fig-
ure 34.
CAUTION
To prevent damage to cylinder rod, DO NOT
clamp on cylinder rod sealing surface.
2. Place cylinder rod in soft-jawed vise and install
piston onto rod. See Figure 34.
3. Apply Loctite®
242 (Blue) to threads of piston nut.
Install piston nut onto cylinder rod. Tighten piston
nut to 75 N•m (55 lbf ft). See Figure 34.
4. Install new piston seal onto piston. See Figure 34.
5. Install cylinder rod retainer onto cylinder rod. See
Figure 34.
models
D879, E879, F879)
GDP135VX, GP/GLP/GDP155VX) (D878,
E878)
NOTE: If necessary, use 400-grit emery cloth to
break any sharp edge on the piston, retainer and cyl-
inder shell chamfer angles and threads to prevent
seal damage.
6. If the cylinder head end was removed during dis-
assembly, replace cylinder head end O-ring and
apply Loctite®
242 (Blue) to threads. Clamp head
end in vice and tighten cylinder shell to
270 N•m (200 lbf ft).
7. Lubricate new seals, O-rings and wear rings with
O-ring lube or hydraulic fluid.
NOTE: Fork carrier lug bearings snap into their re-
spective grooves. Bronze bearings consist of three
separate segments.
8. Install new seals, O-rings, wear rings and fork
carrier lug bearings as shown in Figure 36.
9. Twist seal into "figure 8" or half circle shape see
Figure 38.
1. SEAL
2. ROD
3. RETAINER
4. PIN PUNCH
5. FLAT BRASS O-RING TOOL
Figure 38. Installing Retainer Internal Seals for Lift
Truck Models GLC/GDC60VX, GLC/GDC70VX
(GC/GLC/GDC135VX, GC/GLC/GDC155VX) (E879,
F879) and GLP/GDP60VX, GLP/GDP70VX
(GP/GLP/GDP135VX, GP/GLP/GDP155VX) (E878)
Manufactured After August, 2012
55

NOTE: DO NOT use a pin punch with sharp edges.
10. Lubricate seal and force partially into grove using
15 mm (0.6 in.) pin punch. See Figure 38.
NOTE: Make sure piston seal is not damaged by cyl-
inder shell threads during installation.
11. Use flat brass O-ring tool to seat seals fully into
groove. See Figure 38.
12. Slide fork carrier lug onto cylinder shell with the
plug heads facing outwards. See Figure 35.
13. Align cylinder assembly to manifold and engage
opposite cylinder rod into fork carrier. Install exter-
nal spacer on cylinder rod, if required. Install cyl-
inder retainer through opposite side of manifold
and screw partially into cylinder shell. See Fig-
ure 35.
14. Make sure cylinder is properly oriented with re-
strictor fittings on backside. Engage tube and
screw retainer fully into shell. Reclamp assembly
to bench.
15. Tighten retainer to 165 N•m (120 lbf ft). Tighten
hydraulic tubes at manifold and cylinder head
end.
16. Repeat Step 6 through Step 15 for other cylinder.
CAUTION
tools when installing seal and O-ring.
models
clean hydraulic oil during assembly.
See Figure 37.
Figure 37.
ure 37.
20. Install rod and piston assembly into shell. See
Figure 37.
gland threads.
23. Install gland onto shell. Tighten gland to 350 to
24. Repeat Step 17 through Step 23 for other fork po-
sitioner cylinder.
INSTALL
D879, E879, F879)
D878, E878)
1. Install fork positioner cylinder and carriage as de-
scribed in Hang On Sideshift Carriage Repair in-
stallation procedures located in the section Mast
Repairs (S/N A513, A514, A613, A614, A702,
A703, A704, A705, A706, A707, A751, A752,
B513, B514, B586, B587, B588, B589, B590,
B591, B749, B750, B751, B752, B753, B754)
4000YRM1250.
model
2. Install upper fork positioner cylinder onto carriage
as noted during removal. See Figure 33.
3. Install nut onto upper fork positioner cylinder shell
end. See Figure 33.
4. Install bushing, washer, and screw onto upper
fork positioner rod end and carriage. See Fig-
ure 33.
5. Connect hydraulic fittings and lines onto upper
fork positioner cylinder. See Figure 32.
6. Install lower fork positioner cylinder onto carriage
as noted during removal. Install bushing, washer,
and screw onto lower fork positioner rod end and
carriage. See Figure 33.
7. Install nut onto lower fork positioner cylinder shell
end. See Figure 33.
56

8. Install bushing, washer, and screw onto lower fork
positioner rod end and carriage. See Figure 33.
9. Connect hydraulic fittings and lines onto lower
fork positioner cylinder. See Figure 32.
10. Install carriage as described in carriage install
procedures in the section Mast Repair (S/N
A513, A514, A613, A614, A643, A644, A683,
A684) 4000YRM1406.
Lift Cylinder Leak Check
WARNING
During the test procedures for the hydraulic sys-
tem, 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.
NOTE: The following checks are to be performed
with a capacity load on forks and with hydraulic oil at
normal operating temperature.
1. Operate hydraulic system. Put capacity load on
forks. Use safety chain to hold load to carriage.
Raise and lower load several times. Lower load
and tilt mast forward and backward several times.
Check for leaks.
2. Put mast in vertical position and raise carriage
and load 2.5 m (8 ft).
If carriage slowly lowers when control valve is in
NEUTRAL position, there are leaks in hydraulic
system. The maximum speed the carriage is al-
lowed to lower is 100 mm (4 in.) per 10 minutes
when hydraulic oil is at normal operating tempera-
ture.
3. Check lift cylinders for internal leaks. Remove
load from forks. Install valve in supply line be-
tween main control valve and mast. Put capacity
load on forks again. Raise carriage 2.5 m (8 ft).
Close valve. If carriage or mast lower slowly,
seals in lift cylinders have leaks.
4. If carriage does not move, open valve and check
movement again. If carriage lowers when valve is
open, check for leaks in hydraulic lines and fit-
tings. If no leaks are found, main control valve
can be worn or damaged. Remove load from
forks.
Seal Kit Installation
EXTERNAL INSTALLATION (SEAL AND
BACK-UP RING)
NOTE: It is recommended that seal is heated in hy-
draulic oil prior to installation to make it more flexible
and pliable.
1. Lubricate seal, back-up ring, external installation
sleeve and piston rod groove with hydraulic fluid.
2. Install wear ring onto piston rod assembly. See
Figure 39.
3. Slide external installation sleeve over piston rod
assembly and wear ring. See Figure 39.
4. Install back-up ring into piston rod groove. See
Figure 39.
5. Slide seal over external installation sleeve and
into piston rod groove. See Figure 39.
6. Remove external installation sleeve.
INTERNAL INSTALLATION (PISTON ROD
ASSEMBLY)
1. Insert internal installation sleeve into end of cylin-
der tube. See Figure 40.
2. Install piston rod assembly into cylinder tube. See
Figure 40.
3. Remove internal installation sleeve from cylinder
tube and piston rod assembly. See Figure 40.
2100 YRM 1328 Lift Cylinder Leak Check
57

1. PISTON ROD ASSEMBLY
2. WEAR RING
3. EXTERNAL INSTALLATION SLEEVE
4. BACK-UP RING
5. SEAL
Figure 39. Cylinder External Seal Installation
1. PISTON ROD ASSEMBLY
2. BACK-UP RING
3. SEAL
4. INTERNAL INSTALLATION SLEEVE
5. CYLINDER TUBE
6. WEAR RING
Figure 40. Cylinder Internal Installation
SPECIAL TOOLS
Special Tool Cascade Part Number
6075028
6075087
Cylinder Repair (Mast S/N A513, A514, A613, A614, B513, B514) 2100 YRM 1328
58

Torque Specifications
FOR LIFT TRUCK MODELS GLC/
GDC60VX, GLC/GDC70VX (GC/GLC/
D879, E879, F879) AND GLP/GDP60VX,
GLP/GDP70VX (GP/GLP/GDP135VX,
GP/GLP/GDP155VX) (C878, D878, E878)
Tilt Cylinder Piston Rod Nut
400 to 440 N•m (295 to 325 lbf ft)
Tilt Cylinder Gland
400 to 440 N•m (295 to 325 lbf ft)
Tilt Cylinder Rod End to Rod Locknut- Mast End
90 N•m (66 lbf ft)
Tilt Cylinder Rod End to Rod Capscrew - Frame
End
90 N•m (66 lbf ft)
Tilt Cylinder Anchor Pin Capscrew
90 N•m (66 lbf ft)
Lift Cylinder Gland
375 to 450 N•m (277 to 332 lbf ft)
Lift Cylinder Mount to Outer Mast Lock Nut
135 N•m (100 lbf ft)
Lift Cylinder Chain Anchor Lock Nuts
370 N•m (273 lbf ft)
Lift Cylinder Mounting Bolts to Outer Mast
555 N•m (410 lbf ft)
Free- Lift Cylinder Gland
400 to 475 N•m (295 to 350 lbf ft)
Free- Lift Cylinder Mount Lock Nut to Inner Mast
370 N•m (273 lbf ft)
Free- Lift Cylinder Chain Anchor to Cylinder
Mount Lock Nuts
135 N•m (100 lbf ft)
Free- Lift Cylinder Hose Sheave Bracket to Chain
Sheave Bracket Capscrews
33 N•m (25 lbf ft)
Free- Lift Cylinder Hose Sheave Bracket to Hose
Sheave Shaft Capscrews
33 N•m (25 lbf ft)
FOR LIFT TRUCK MODEL GLP/GDP80VX,
GLP/GDP80VX9, GLP/GDP90VX (GLP/
GDP190VX) (A909, B909)
Tilt Cylinder Piston Rod Nut
400 to 440 N•m (295 to 325 lbf ft)
Tilt Cylinder Gland
400 to 500 N•m (295 to 325 lbf ft)
Rod End Hex Nut
120 to 130 N•m (89 to 96 lbf ft)
Tilt Cylinder Rod End to Rod Capscrew- Mast End
95 to 100 N•m (70 to 74 lbf ft)
Tilt Cylinder Rod End to Rod Capscrew - Frame
End
66 N•m (49 lbf ft)
Tilt Cylinder Anchor Pin Capscrew
90 N•m (66 lbf ft)
Lift Cylinder Gland
350 to 400 N•m (258 to 295 lbf ft)
Fork Positioner Cylinder Gland
350 to 400 N•m (258 to 295 lbf ft)
Sideshift Cylinder Gland
350 to 400 N•m (258 to 295 lbf ft)
2100 YRM 1328 Torque Specifications
59

General
This section covers the repair of the wire harness
connectors, pins, sockets, and splicing of wires.
Deutsch Crimping Tool
HOW TO STRIP A WIRE FOR USE WITH
DEUTSCH CRIMPING TOOL
1. Choose the correct AWG for the contact being
used. See Table 1.
2. See Table 1 for recommended strip length for
contact size. Measure strip length from end of
wire as shown in Figure 1.
Figure 1. Strip Length Measurement
3. Strip the wire to the recommended strip length. A
small piece of insulation should come off the wire
after stripping. See Figure 2.
Figure 2. Stripped Wire
4. Check for any broken strands or for a nick in the
wire. If either exists, the wires are damaged and
should be cut and stripped again.
5. Measure the exposed strands to verify strip length
is correct. See Figure 3.
Figure 3. Strip Length Measurement Verification
2200 YRM 1128 General
1

YALE E879 GDC60VX LIFT TRUCK Service Repair Manual

YALE E879 GDC60VX LIFT TRUCK Service Repair Manual

Recommended

Recommended

More Related Content

Similar to YALE E879 GDC60VX LIFT TRUCK Service Repair Manual

Similar to YALE E879 GDC60VX LIFT TRUCK Service Repair Manual (13)

More from yjekmmd jksmefjmm

More from yjekmmd jksmefjmm (9)

Recently uploaded

Recently uploaded (20)

YALE E879 GDC60VX LIFT TRUCK Service Repair Manual