09 - Lift Cylinder 2013A

Service Manual A-Ergo — D003936, B, GBR, Translated
09 Lift cylinders
09 LIFT CYLINDERS
9.1 Design and function 131

9.1.1 General.......................................................................................................................... 131
9.2 Repair and maintenance instructions 131

9.2.1 General.......................................................................................................................... 131
9.2.2 Free lift cylinder TFV/DTFV ........................................................................................... 132
9.2.3 Lifting cylinder TV/TFV/DTFV........................................................................................ 133
9.2.4 Lift cylinder T ................................................................................................................. 135
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09 Lift cylinders
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09 Lift cylinders
09 LIFT CYLINDERS
9.1 Design and function
9.1.1 General
The lift cylinders consist of single-acting hydraulic cylinders, where hydraulic oil is pumped
into the cylinder, pressing out the piston rod.
When the driver activates the lowering function the cylinders are pressed together through a
control valve releasing oil out from the cylinders. They are then pushed together by the
weight of the forks, at the same time as the oil returns to the hydraulic tank.
As opposed to the lift cylinders, the side stabiliser cylinders are double-acting. This implies
that a hydraulic oil also acts in the opposite direction and pushes the cylinder together.
9.2 Repair and maintenance instructions

9.2.1 General
9.2.1.1 Bleeding of the hydraulic cylinders with the air bleed screw
WARNING!
When bleeding, the air screw must be opened no more than approx. a half turn. If
the air screw is opened completely the oil will spurt out and the forks crash
uncontrollably to their bottom position. The hose rupture valves do not function in
this phase.
Figure 95. Example, air screw.

1) Open the air bleed screw about half a turn.
2) Check that there is sufficient oil in the hydraulic tank and that the pump does not suck
air.
3) Carefully run the cylinder repeatedly between its end positions.
4) When oil without air bubbles comes out, the cylinders have been bled.
5) Adjust the oil level in the hydraulic tank.
6) Repeatedly lift from bottom to top position.
7) Check that the forks do not bounce. If they do, bleed the air one or more times.
9.2.1.2 Bleeding of the hydraulic cylinders without a bleed air screw

Cylinders without bleed air screws are bled by running the cylinder repeatedly between its
end positions.
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09 Lift cylinders
NOTE!
Check the oil level regularly.
9.2.2 Free lift cylinder TFV/DTFV

9.2.2.1 Dismantling and assembling
1) Remove the retaining screw that holds the lower end of the cylinder.
2) Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the chain pin that
goes through the chain bolt on the cylinder, and place the chain over the back of the fork
carriage.
3) Release the fork carriage from the mast by lifting up the inner mast with the hydraulic
pump. Reverse the truck away.
4) Lower so that all the cylinders are pushed together completely.
5) Loosen the bolts that hold the clamp at the top end of the cylinder, without removing it.
6) Disconnect the oil pipe.
7) Remove the clamp, and lift out the cylinder.
8) Plug the oil pipe.
9) Install in the reverse order.

1) Brace the lower end of the cylinder in a vice.
CAUTION!
Risk of deformation, use moderate force.
2) Remove the circlip (item 1) and remove the yoke, (item 2).
3) Place a container for oil spillage under the cylinder.
4) Remove the top nut (item 3) with a suitable tool and take it off the piston rod.
5) Pull out the piston rod.
6) Remove the seals (item 4) and guide rings (item 5) from the piston. Use a thin tool that
will not scratch.
7) Remove the seal (item 6) and scraper (item 7) from the top nut and O-ring (item 8).
8) Clean all parts and check for damage. Replace if necessary.
NOTE!
Always use original spare parts for maximum safety and service-life.
9) Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.
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09 Lift cylinders
Figure 96. Free lift cylinder TFV / DTFV
9.2.3 Lifting cylinder TV/TFV/DTFV

1) Lift the forks until the inner mast is raised approx. 20 mm. Place wooden blocks under
the inner mast, and lower it down onto the blocks.
2) Remove the upper securing screws (item 1).
3) Lower the cylinder to its compressed position.
4) Loosen, disconnect, and plug the oil pipe.
5) Remove the retaining screw (item 2).
6) Lift out the cylinder.
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09 Lift cylinders

1) Make a nore of how far the adjusting screw (1) is screwed into the piston rod end (this
will be needed when reassembling).
2) Unscrew the adjusting screw (item 1).
3) Support the lower end of the cylinder in a vice.
CAUTION!
Risk of deformation: use moderate force.
4) Place a container for oil spillage under the cylinder.

5) Unscrew and remove the top nut (item 2). Pull out the piston rod (item 3).
6) Remove the sealing rings and guides (item 4) from the top nut.
7) Remove the guide rings (item 5) from the piston rod.
NOTE!
Always use original spare parts for maximum safety and service life.
9) Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.
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09 Lift cylinders
9.2.4 Lift cylinder T

1) Lower the forks, e.g. on a pallet, so that the chains slacken. Remove the split pin bolt
(item 1) that sits in the top end of the cylinder.
2) Remove the chain and place it over the back of the fork carriage.
3) Release the fork carriage from the mast by lifting up the inner mast with the hydraulic
pump. Reverse the truck away.
4) Place a wooden block, 10-15 cm thick, under the inner mast, and carefully lower the
inner mast until it rests on the block.
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09 Lift cylinders
5) Secure the cylinder so that it cannot drop out of the mast! Remove the circlip (item 2)
and remove the lower securing screw (3).
6) Lower carefully so that the piston rod comes out of the yoke (item 4). When the piston
rod is fully pushed in, remove the oil pipe and return pipe. Tilt the cylinder forward and
lift it out.

1) Place the cylinder on a bench with the chain attachment facing down.
2) Slacken and remove the top nut (1) with a hook spanner.
3) Pull out the piston rod (item 2) and place it carefully on the bench to avoid damaging it.
4) Remove the parts (items 3, 5, 6, 7 and 8).
NOTE!
Always use original spare parts for maximum safety and service life.
6) Install in the reverse order. Lubricate all parts with hydraulic oil before fitting.
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09 Lift cylinders
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09 Lift cylinders
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Service Manual A-Ergo — D003936, B, GBR, Translated

9.1 Design and function 131

9.2 Repair and maintenance instructions 131

9.2 Repair and maintenance instructions

Figure 95. Example, air screw.

9.2.1.2 Bleeding of the hydraulic cylinders without a bleed air screw

9.2.2 Free lift cylinder TFV/DTFV

9.2.2.2 Dismantling and assembling

Figure 96. Free lift cylinder TFV / DTFV

9.2.3 Lifting cylinder TV/TFV/DTFV

9.2.3.2 Dismantling and assembling

4) Place a container for oil spillage under the cylinder.

9.2.4 Lift cylinder T

9.2.4.2 Dismantling and assembling

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