Maintenance

TILT CYLINDERS
ALL MODELS EXCEPT GLP/GDP3.5-5.5LJ/MJ
(GP/GLP/GDP70-120LJ/MJ) [C813, E813];
GC070-120LJ/MJ [C818, D818]

PART NO. 524150790 2100 YRM 103

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on

electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
Tilt Cylinders Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Tilt Cylinder Repair .............................................................................................................................................. 1
Remove ........................................................................................................................................................... 1
Disassemble.................................................................................................................................................... 1
Clean............................................................................................................................................................... 1
Assemble ........................................................................................................................................................ 2
Tilt Cylinders With O-Ring or Single-Lip Seals ........................................................................................... 2
Tilt Cylinders ............................................................................................................................................... 3
Install............................................................................................................................................................... 4
Tilt Cylinder Leak Check...................................................................................................................................... 4
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment ........................................................................................... 5
Torque Specifications .......................................................................................................................................... 6
Piston Rod Nut ................................................................................................................................................ 6
Retainer........................................................................................................................................................... 6
Troubleshooting ................................................................................................................................................... 7

This section is for the following models:

All Models except GLP/GDP3.5-5.5LJ/MJ (GP/GLP/GDP70-120LJ/MJ)

[C813, E813];GC070-120LJ/MJ [C818, D818]

©2004 Yale Materials Handling Corp. i

2100 YRM 103 Tilt Cylinder Repair

General
This section has a description and the repair proce- number and the design of the parts can be different,
dures for several different types of tilt cylinders. The but the operation of the tilt cylinders is the same.

Description
The tilt cylinders (Figure 1, Figure 2, and Figure 3) are returns to the hydraulic tank. To retract the cylinder rod
used to move the mast forward and backward. To ex- (tilt backward), the oil enters the port in front of the pis-
tend the cylinder rod (tilt forward), oil enters the tilt cylin- ton. The oil pressure pushes the cylinder rod into the
der port behind the piston. The oil pressure pushes the tilt cylinder. The oil behind the piston returns to the hy-
cylinder rod out of the cylinder. Oil in front of the piston draulic tank.

Tilt Cylinder Repair

REMOVE 2. Remove the retainer from the tilt cylinder. Remove
the rod and piston from the cylinder.
WARNING 3. Disassemble the tilt cylinder as necessary. See Fig-
Before removing the tilt cylinder(s), tilt the mast for- ure 2 and Figure 3.
ward. Use a chain to hold the mast to the frame, and
prevent the mast from moving forward. CLEAN
1. Disconnect the hydraulic lines at the tilt cylinder.
Install caps on the hydraulic lines and ports. WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
WARNING
solvents, always follow the solvent manufacturer’s
Do not push the anchor pins out of the rod end with recommended safety procedures.
your fingers. Do not permit the tilt cylinders to drop
and cause damage. Compressed air can move particles so that they
cause injury to the user or to other personnel.
2. Remove the retainers for the anchor pins. Push the Make sure that the path of the compressed air is
anchor pins out of the rod end with a tool. away from all personnel. Wear protective goggles
3. Use a lifting device to move large tilt cylinders. Re- or a face shield to prevent injury to the eyes.
move the anchor pins from the frame anchors. Re- Clean all parts in solvent and dry with compressed air.
move the tilt cylinder from the frame.

DISASSEMBLE
1. Put the tilt cylinder in a vise with soft jaws. Remove
the rod end from the rod.

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Tilt Cylinder Repair 2100 YRM 103

ASSEMBLE 2. Install the O-ring, seal ring, and guide ring on the
piston. The seal ring must be heated before in-
Tilt Cylinders With O-Ring or Single-Lip stallation. After heating, it must be pushed into its
Seals groove using a ring compressor. Let the seal ring
cool and return to its normal shape.
NOTE: Always use new seals and O-rings. Make sure
all parts are clean. Lubricate all parts with clean hy- 3. If used, install the O-ring and the backup ring in
draulic oil. the groove of the outer retainer. Install the rod seal
(O-ring toward the piston) and wiper seal in the in-
NOTE: During 1980 and 1981, a change was made in ner retainer.
the tilt cylinders used in most lift trucks. The O-ring seal
between the retainer and the cylinder shell was moved 4. Install the retainer on the piston rod. Install the
from above the threads to the area below the threads. piston and rod assembly and the retainer in the
A backup ring was added to increase the strength of the cylinder. If used, install the O-ring on the retainer.
O-ring. The assembly of the tilt cylinders is the same, Tighten the retainer to specifications given in
but caution must be used so that the O-ring seal is not Torque Specifications.
damaged by the threads.
NOTE: After assembly is complete, install the rod end
1. Install the O-ring inside the piston bore. See Fig- on the piston rod. Tighten the capscrew on the rod end
ure 1. Install the piston on the piston rod. Make as specified in Mast section for your specific lift truck.
sure the O-ring is not damaged. Tighten the nut on
the piston rod to the specifications given in Torque
Specifications.

1. PISTON ROD 6. GUIDE RING 11. RETAINER

2. PISTON RING 7. NUT 12. SEAL RING
3. O-RING 8. CYLINDER SHELL 13. WIPER RING
4. O-RING 9. O-RING 14. SPACER (SOME MODELS)
5. PISTON 10. BACKUP RING

Figure 1. Tilt Cylinders With O-Ring or Single-Lip Seals

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2100 YRM 103 Tilt Cylinder Repair

Tilt Cylinders the cylinder rod. Make sure the piston seal is not
damaged. Tighten the nut on the piston rod to the
NOTE: The following procedure are for these mod- value shown in Torque Specifications.
els: GC/GLC040-065RG/TG/ZG, GLP/GDP20-
30RF/TF (GP/GLP/GDP040-060RG/TG/ZG), ERC20- 2. Install a new wiper and rod seal. Install the O-ring
30AGF (ERC040-065RF/ZF, RG/ZG), ERP20-30ALF and backup ring onto the retainer.
(B216), ERP16-20ATF, GDP/GLP16-20AF (GP/GLP/
GDP030-040AF), GC/GLC030-040AF, ERC/P16- 3. Install the retainer assembly onto the rod.
20AAF (ERC030-040AF, AG/BG) and ERP20-30ALF
4. Install the piston and rod assembly into the cylinder.
(ERP040-060DH) (D216), ERC20-30AGF (ERC040-
Tighten the retainer to the value shown in Torque
065GH) (A908), and ERC/P16-20AAF (ERC030,
Specifications.
040AH) (B814).
NOTE: After assembly is complete, install the rod end
NOTE: Always use new seals and O-rings. Make sure
on the cylinder rod. Tighten the capscrew on the rod
all parts are clean. Lubricate all parts with clean hy-
end as specified in Mast section for your specific lift
draulic oil.
truck.
1. Install the piston seal and O-ring(s) onto the piston.
See Figure 2 and Figure 3. Install the piston onto

1. CYLINDER SHELL 5. SEAL RING 9. SEAL RING

2. NUT 6. PISTON ROD 10. RETAINER
3. PISTON 7. O-RING 11. WIPER RING
4. O-RING 8. BACKUP RING

Figure 2. Tilt Cylinders for GC/GLC040-065RG/TG/ZG, GLP/GDP20-30RF/TF (GP/GLP/GDP040-060RG/

TG/ZG), ERC20-30AGF (ERC040-065RF/ZF, RG/ZG) (E108), ERP20-30ALF (B216), ERP16-20ATF,
GDP/GLP16-20AF (GP/GLP/GDP030-040AF), GC/GLC030-040AF, ERP20-30ALF (ERP040-060DH) (D216),
and ERC20-30AGF (ERC040-065GH) (A908)

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Tilt Cylinder Leak Check 2100 YRM 103

1. CYLINDER SHELL 6. BACKUP RING

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

Figure 3. Tilt Cylinders for GDP/GLP16-20AF (GP/GLP/GDP030-040AF/BF), GC/GLC030-040AF,

ERC/P16-20AAF (ERC030-040AF, AG/BG) (A814), and ERC/P16-20AAF (ERC030-040AH) (B814), and
ERP16-20ATF

INSTALL 3. Connect the hydraulic lines to the tilt cylinder.

1. Use a lifting device to move large tilt cylinders. Put 4. Operate the tilt cylinders. Check for correct oper-
the cylinder in the lift truck. Install the anchor pin in ation and leakage. Adjust the tilt cylinders as de-
the frame. Install the retainer pin or cotter pin. scribed in Tilt Cylinder Leak Check and Tilt Cylin-
der Stroke and Mast Tilt Angle Adjustment.
2. Install the anchor pin at the mast mount. Install the
retainer pin or cotter pin for the anchor pin. Tighten
the capscrews for the retainer pins.

Tilt Cylinder Leak Check

Do not try to find hydraulic leaks by putting your
WARNING hand on hydraulic components under pressure.
Never allow anyone under a raised carriage. Do not Hydraulic oil can be injected into the body by the
put any part of your body in or through the lift mech- pressure.
anism unless all parts of the mast are completely
lowered and the engine is STOPPED.

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2100 YRM 103 Tilt Cylinder Stroke and Mast Tilt Angle Adjustment

1. Put a capacity load on the forks. Use a safety chain again. Close the valve. Tilt the mast forward just
to hold the load to the carriage. Raise the load past the vertical position. If the mast continues to
approximately 2.5 m (8 ft). Put the mast in a vertical tilt slowly forward, the seals on the piston are leak-
position. ing.

2. Measure the distance that the rod for tilt cylinder 4. If the mast does not move, open the gate valve and
extends from the shell. Check the distance the rod check the movement again. If the mast moves for-
moves in five or ten minutes. Multiply the rate in ward when the gate valve is open, check for leaks
Table 1 by the time of the test and compare the in the hydraulic lines and fittings. If no leaks are
numbers. found, the main control valve can be worn or dam-
aged. Remove the load from the forks when the
3. If the tilt rate is greater than the specifications, lower checks are complete.
the mast and remove the load from the forks. Install
a valve between the port at the front of the tilt cylin-
der and the hydraulic line. Put the load on the forks

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
ERP10-12-15RCF 1.3 0.05 9.1 0.50
ERC/P16-20AAF (ERC030-040AF, 0.8 0.03 5.0 0.20
AG/BG) (A814), ERC35-55HD/HG
(ERC070-120HD/HG),
ERC/P16-20AAF (ERC030-040AH) (B814)
ERP16-20ATF 0.8 0.03 5.0 0.20
ERC20-30AGF (ERC040-065GH) (A908), 0.8 0.03 5.0 0.20
ERC20-30AGF (ERC040-065RF/ZF
RG/ZG) (E108), ERP20-30ALF (B216), and
ERP20-30ALF (ERP040-060DH) (D216)
GC/GLC030-040AF, GDP/GLP16-20AF 0.8 0.03 5.0 0.20
(GP/GLP/GDP030-040AF)
GC/GLC040-065RG/TG/ZG, 1.0 0.04 6.8 0.30
GLP/GDP20-30RF/TF (GP/GLP/GDP040-
060RG/TG/ZG)
GP/GLP/GDP070-110LG/MG, 1.3 0.05 8.9 0.34
GDP60-70CA (GP/GLP/GDP135-155CA)
GLP/GDP165-250DA, GLP/GDP300- 1.8 0.07 11.7 0.05
360EA
GP170-280DB, GP300-360EB 1.8 0.07 11.7 0.05
GLC60-70CA (GC/GLC/GDC135-155CA) 1.2 0.05 8.2 0.32

Tilt Cylinder Stroke and Mast Tilt Angle Adjustment

Adjust the tilt cylinders as described in the Mast section.

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Torque Specifications 2100 YRM 103

Torque Specifications
PISTON ROD NUT RETAINER
ERP16-20ATF ERP16-20ATF
163 to 190 N•m (120 to 140 lbf ft) 163 to 176 N•m (120 to 130 lbf ft)

ERC20-30AGF (ERC040-065GH) (A908), ERC20-30AGF (ERC040-065GH) (A908),

ERC20-30AGF (ERC040-065RF/ZF RG/ZTG) ERC20-30AGF (ERC040-065RF/ZF RG/ZG)
(E108), ERP20-30ALF (B216), and ERP20-30ALF (E108), ERP20-30ALF (B216), ERP20-30ALF
(ERP040-060DH) (D216) (ERP040-060DH) (D216)
150 N•m (110 lbf ft) 170 to 237 N•m (125 to 175 lbf ft)

ERC35-55HD/HG (ERC070-120HD/HG) ERC35-55HD/HG (ERC070-120HD/HG)

400 to 440 N•m (295 to 325 lbf ft) 400 to 500 N•m (295 to 370 lbf ft)

GC/GLC030-040AF, GDP/GLP16-20AF GC/GLC030-040AF, GDP/GLP16-20AF

(GP/GLP/GDP030-040AF), ERC/P16-20AAF (GP/GLP/GDP030-040AF)
(ERC030-040AF, AG/BG) (A814), and 163 to 176 N•m (120 to 130 lbf ft)
ERC/P16-20AAF (ERC030-040AH) (B814)
163 to 190 N•m (120 to 140 lbf ft) GC/GLC040-065TF/RF, GLP/GDP20-30RF/TF
(GP/GLP/GDP040-060RG/TG/ZG)
GC/GLC040-065RG/TG/ZG, GLP/GDP20-30RF/TF 170 to 237 N•m (125 to 175 lbf ft)
(GP/GLP/GDP040-060RG/TG/ZG)
150 N•m (110 lbf ft) GP/GLP/GDP070-110LG/MG
400 to 500 N•m (295 to 369 lbf ft)
GP/GLP/GDP070-110LG/MG
400 to 440 N•m (295 to 325 lbf ft) GDP60-70CA (GP/GLP/GDP135-155CA)
542 to 610 N•m (400 to 450 lbf ft)
GDP60-70CA (GP/GLP/GDP135-155CA)
407 to 440 N•m (300 to 325 lbf ft) GLP/GDP165-280DA
542 to 610 N•m (400 to 450 lbf ft)
GLP/GDP165-280DA
950 to 985 N•m (700 to 725 lbf ft) GLP/GDP300-360EA
610 to 675 N•m (450 to 500 lbf ft)
GLP/GDP300-360EA
1105 to 1140 N•m (815 to 840 lbf ft) GP170-280DB
950 to 983 N•m (701 to 725 lbf ft)
GP170-280DB
950 to 983 N•m (701 to 725 lbf ft) GP300-360EB
1105 to 1140 N•m (815 to 841 lbf ft)
GP300-360EB
1105 to 1140 N•m (815 to 841 lbf ft) GC/GLC030-040AF
163 to 176 N•m (120 to 130 lbf ft)
GC/GLC030-040AF
163 to 190 N•m (120 to 140 lbf ft) GLC60-70CA (GC/GLC/GDC135-155CA)
542 to 610 N•m (400 to 450 lbf ft)
GC/GLC070-120LG/MG
400 to 440 N•m (295 to 325 lbf ft)

GLC60-70CA (GC/GLC/GDC135-155CA)
407 to 440 N•m (300 to 325 lbf ft)

6
2100 YRM 103 Troubleshooting

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

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

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

aged.

Restriction in the hydraulic lines. Repair hydraulic lines.

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

Tilt cylinders have internal damage. Repair or replace cylinder.

Load is greater than capacity. Reduce load.

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

correctly or is damaged.

Large leaks between spool and bore. Replace valve section.

Spool is not fully extended or retracted. Adjust linkage to spool.

Tilt control spool is damaged. Repair control valve.

The tilt cylinders permit the There are leaks in the hydraulic lines. Tighten fittings or repair leaks.
mast to move when the Tilt
control lever is in the Neutral
position.

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

Tilt cylinders have internal damage. Repair or replace cylinder.

Tilt control spool is damaged. Repair control valve.

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 NOTES

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

2100 YRM 103 11/04 (10/03)(3/03)(7/02)(8/01) Printed in U.S.A.