
Description 4000 SRM 135
CYLINDERS (GENERAL)
Standard masts use a single-stage lift cylinder.
Most three-stage and four-stage masts use two sin-
gle-stage lift cylinders. A single-stage lift cylinder
has one piston rod. See Figure 6.
Most full free-lift masts and some three-stage masts
use a two-stage lift cylinder. A two-stage lift cylin-
derhastwotelescopicpistonrods.SeeFigure7.The
two-stage lift cylinder operates similar to a one-stage
lift cylinder. Hydraulic pressure pushes the primary
(larger) piston rod from the cylinder first because
it has a larger diameter. The secondary piston rod
moveswiththeprimarypistonrod. Whenthepri-
mary piston rod reaches the limit of its stroke, the
secondary piston rod extends from the primary pis-
ton rod.
Spacers are used in some cylinders to give a limit to
the stroke of the piston rod. Worn spacers must be
replaced with the same size spacer.
Most of the lift cylinders use a single-lip seal assem-
bly to prevent hydraulic oil leaks past the piston
and past the retainer. See Figure 4. There are
many lift cylinders in use that have an older design
chevron-style packing. The chevron-style packing
can be replaced with a seal kit that has the newer
single lip seal and an adaptor. There are no replace-
ments of single lip seals for chevron-style packing
for lift trucks over 7,000 kg (15,000 lb) capacity.
Lift cylinders and other hydraulic parts can have in-
ternal leaks. Internal leakage will increase as the
temperature of the hydraulic oil increases. The in-
ternal leak rate of the hydraulic system is normally
checked after every 1000 hours of operation. See Lift
System Leak Check for test procedures and leakage
rates within the specifications.
During operation, some leakage of hydraulic oil can
movepastthepistonsealtotherodsideofthepis-
ton. A small leakage is permitted if the internal leak
rate of the hydraulic system is not greater than the
specification. An internal check valve is installed in
the piston of many of the lift cylinders. When the rod
extends, the pressure increases more quickly on any
oil in the rod end of the cylinder. The hydraulic oil
transfers through the check valve to the piston end of
the cylinder. This action prevents hydraulic damage
to the wiper seal. See Figure 8. Lift cylinders that
do not have an internal check valve have a drain line
on the outside of the cylinder shell.
CYLINDERS (H520-620B, H700-800A)
The rod side of the lift cylinder is used for the storage
of hydraulic oil on the H520-620B and H700-800A lift
trucks. This storage decreases the required size of
the hydraulic tank. When the piston raises in the
cylinder, the oil on the rod side of the piston trans-
fers to the hydraulic tank. When the piston lowers
inthecylinder,someoftheoiltransferstotherod
side of the cylinder. Approximately one half of the oil
in the bottom of the cylinder goes through the main
control valve to the rod side of the cylinder. See the
Main Control Valve of Service Manual for more
information. See Figure 9.
Retainer, Install
1. Install the retainer over the piston and into the
cylinder. Make sure the single-lip seal assembly,
the O-ring, and the backup ring are not damaged.
SeeFigure9.
2. Turn the retainer ring into the threads in the
cylinder. Turn the retainer ring until it is even
with the top of the cylinder.
3. Install the capscrews loosely.
4. The stroke of the cylinder rod can be adjusted by
turning the retainer ring one-half turn in either
direction.
5. Install and tighten the setscrew.
6. Tighten the capscrews to 36 to 46 N•m (27 to
34 lbf ft).
8