CYLINDERS

Lift Cylinders

Lift Cylinders 1. Move the truck to a level area set aside for service
under a lifting device.
RM 6000 Series trucks are equipped with two lift cylin-
2. Chock the drive wheels.
ders. The primary cylinder, mounted to the right-hand
side of the mast and the secondary cylinder, mounted 3. Lower the mast completely. Remove the forks.
inside the mast. Refer to the Hydraulic Circuits chapter
4. Key the truck OFF. Disconnect and remove the
of this manual for further information on the hydraulic
battery.
operation of the lift cylinders.
5. Lockout/Tagout the truck as described in Control of
Hazardous Energy.
WARNING
6. Open the manual lowering valve (MVL).
AVOID HIGH PRESSURE FLUIDS - Escaping fluids
under pressure can penetrate the skin causing serious 7. Disconnect the large diameter tube that supplies
injury. Relieve pressure before disconnecting hydraulic the primary lift hose at the T-fitting on the chassis
lines. Tighten all connections before applying pres- near the accessory manifold. Cap the T-fitting and
sure. plug the tube. The remaining tube on the T-fitting
Keep hands and body away from pin holes which eject supplies hydraulic pressure to the secondary cylin-
fluids under high pressure. Use a piece of cardboard or der, allowing the mast to be raised as long as the
paper to search for leaks. Do not use your hand. T-fitting to the primary cylinder lift hose is capped.
Any fluid injected into the skin under high pressure Refer to Figure 24605.
should be considered as a serious medical emergency
despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue damage
may occur. Medical attention should be sought imme-
diately from a specialist who has had experience treat-
ing this type of injury.

Primary Cylinder

Primary Cylinder Removal

These instructions are for removing the primary cylin-
der with the mast in an upright position. Refer to the
Mast service section for instructions to remove the cyl-
inder with the mast removed from the truck. It is not
necessary to remove the primary cylinder for repack-
ing.
NOTE
In this section there are circumstances which require
the collection of hydraulic oil that may leak from com-
ponents. Be prepared to catch hydraulic oil with a catch
pan or absorbent material. Do not reuse hydraulic oil.
Follow applicable laws and environmental standards
when disposing of used hydraulic oil. Many hazardous
waste facilities have oil recycling capabilities.
Figure 24605
8. Through the access hole in the front of the battery
compartment, loosen, but do not remove, the pri-
mary lift hose from the primary cylinder.
9. Replace and connect the battery. Key the truck
ON.
10. Close MVL.
11. Raise the mast and block the second stage, third
stage, and reach mechanism to a height that the
bottom of the primary cylinder is above the top of
the chassis. Refer to the Control of Hazardous En-
ergy section for proper blocking procedures.
12. Key the truck OFF and open MVL.

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CYLINDERS
Lift Cylinders
13. Disconnect the electrical connectors (1) that clip to
the base of the primary cylinder. Remove the con-
nectors from the clips. Refer to Figure 24706.
Figure 24706
14. Use masking tape to mark and identify the hydrau-
lic hoses with the associated fittings so that re-in-
stallation will be easier. Disconnect the hydraulic
lines from the straight fittings secured to the pri-
mary cylinder. Refer to Figure 24596.
Figure 24596
M8.0-1460-002
600
15. Remove the two screws that secure the oval-
shaped cable clamp (2) to the base of the primary
cylinder. Refer back to Figure 24706.
16. Remove the metal clamp that secures the control
cables to the hose guide.
17. Remove the accessory hoses (2) and control ca-
bles from the hose guide. Refer to Figure 24598.
18. Remove the screws that secure the lower hose
guide (1) at the base of the primary cylinder. Refer
to Figure 24598.
19. Remove the cover plate in the side of the primary
yoke and the top pin.
20. Disconnect the primary lift chains, hoses and con-
trol cables from the primary cylinder. Pull them
through the primary yoke and drape them over the
reach carriage.
21. Remove the primary yoke from the ram.
22. Disconnect the primary lift hose from the flow lim-
iter valve at the bottom of the primary cylinder (3).
Cap the hose and valve to prevent contamination.
Refer to Figure 24598.
23. Use lifting device to completely remove cylinder
from the truck.
Figure 24598
24. Remove the two screws and nuts that secure the
top of the primary cylinder to the mast.
Crown 2010 PF25202-2
 CYLINDERS
Lift Cylinders

CAUTION
Make sure lifting device and sling/cylinder clamp are
sufficiently rated to withstand the weight being lifted.
25. Use a lifting device and sling or cylinder clamp to
lift the primary cylinder off the dowel pin on which
it rests far enough to remove some tension from
the primary hose.

Primary Cylinder Installation

These instructions are for installing the primary cylinder
with the mast in an upright position. Refer to the Mast
service section for instructions to install the cylinder
with the mast removed from the truck.
1. Check the condition of the o-ring on the flow limiter
valve in the base of the primary cylinder. Replace
if damaged, worn or missing. Apply a small amount
of hydraulic oil to lubricate the o-ring and install the
flow limiter valve in the base of the primary cylin-
der. If the mast is assembled to the power unit, this
valve can be accessed from the cutout inside the Figure 24598
battery compartment or with the mast fully ex-
2. Check the condition of the dowel pin installed on
tended and blocked. Refer to Figures 24685 and
the third stage column that is used to mount the
24598.
primary cylinder on the mast. Replace if damaged,
worn or missing.
3. Apply a small amount of hydraulic oil on the dowel
pin.
4. Use the lifting device to position the cylinder just
above the dowel pin and connect the primary lift
hose to the flow limiter valve (3) at the base of the
primary cylinder. Refer to Figure 24598.
5. Use a lifting device and sling or cylinder clamp to
slide the primary cylinder onto the dowel pin. En-
sure that the cylinder is firmly seated onto the lower
mounting block and secure the primary cylinder to
the mast with two screws and nuts near the top of
the cylinder.
6. Taking care not to cross the two control cables
Figure 24685 route them through the hole in lower hose guide (1)
in the same position they were removed. Route the
cables on the center path of the hose guide. Posi-
tion the curved metal hose clamp to secure the ca-
bles in the hose guide and secure it with a screw.
Refer to Figure 24598.

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CYLINDERS
Lift Cylinders

7. Clip the control cable connectors to the appropriate

connector clips on the base of the primary cylinder.
Refer to Figure 24706.

Figure 24596

8. Install the remaining screws into the lower hose
guide to secure it to the base of the primary cylin-
der.
9. Route both accessory hoses underneath the lower
hose guide, being careful not to cross the hoses
and to route them in the same position as previ-
ously removed.
10. Continue routing the accessory hoses to the
straight fittings on the side of the primary cylinder.
Connect the hoses to the straight fittings. Refer to
Figure 24596.
11. Secure the cables with an oval-shaped cable
clamp (2) and screw near the base of the primary
cylinder. Refer to Figure 24706.
Figure 24706
12. Pull any slack out of the hoses and cables from the
mast end and secure the hoses and control cables
to the lower hose guide with a cable tie.
13. If previously removed, assemble the primary yoke
to the primary cylinder. Secure the ram to the yoke
with a screw in the front of the yoke.
14. Pull the primary lift chains, hoses and control ca-
bles from the reach carriage through the primary
yoke.
15. Replace the top pin in the primary yoke.
16. Install the cover plate on the side of the primary
yoke with two screws.
17. Complete all electrical and hydraulic connections.
Attach the primary lift chains if previously removed.
Secure and adjust the chain anchors as described
in Lifting Mechanism - Mast.
18. Close MVL and ky the truck ON.
19. Raise mast and remove blocks from second stage,
the third stage and the reach carriage. Lower the
mast to the floor.
20. Key the truck OFF. Disconnect and remove the
battery. Open MVL.

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 CYLINDERS
Lift Cylinders

21. Through the access hole in front of the battery 3. Raise and block the reach carriage high enough to
compartment, tighten the primary lift hose to the access the lower chain anchors. Refer to Control of
primary cylinder. Hazardous Energy for more information on lifting
and blocking the truck. Remove the forks.
22. Connect the large diameter tube that supplies the
primary lift hose at the T-fitting on the chassis near 4. Key the truck OFF. Disconnect and remove the
the accessory manifold. battery.
23. Close MVL and install the battery. 5. Lockout/Tagout the truck as described in Control of
Hazardous Energy.
24. Connect the battery, key the truck ON and bleed
any air out of the cylinder as described in Primary 6. Open the manual lowering valve (MVL).
Cylinder Bleeding in this section.
7. Remove the cotter pins and nuts from the lower
secondary chain anchors on the front of the mast.
Primary Cylinder Bleeding Refer to Figure 24690 and 24705.
Bleed hydraulic circuits of all air after repair. Before
bleeding the system, inspect all hydraulic connections.
Verify proper installation of all filters. Ensure fluid levels
are adequate for testing. Pressurize the hydraulic sys-
tem before completing the following steps.
1. Key the truck ON. Slowly elevate the carriage in
free lift to approximately 1220 mm (4 ft).
2. Open the bleed screw on the primary cylinder ap-
proximately ½ of a turn until a steady stream of oil,
with no bubbles in it, flows out.
3. Tighten the bleed screw and wipe up any oil.
Figure 24690

Secondary Cylinder

Secondary Cylinder Removal

These instructions are for removing the secondary cyl-
inder with the mast in an upright position. In many situ-
ations, overhead clearance does not permit removal of
the secondary cylinder in the upright position. Refer to
Lifting Mechanism - Mast for instructions to remove the
cylinder with the mast removed from the truck. It is not
necessary to remove the secondary cylinder for re-
packing.

NOTE
In this section there are circumstances which require
the collection of hydraulic oil that may leak from com- Figure 24705
ponents. Be prepared to catch hydraulic oil with a catch
pan or absorbent material. Do not reuse hydraulic oil. 8. Through the battery compartment, disconnect the
Follow applicable laws and environmental standards large diameter tube from the flow limiter valve at
when disposing of used hydraulic oil. Many hazardous the base of the secondary cylinder. Remove the
waste facilities have oil recycling capabilities. flow limiter valve from the cylinder. Cap the tube
and cylinder to prevent contamination.
1. Move the truck to a level area set aside for service
under a lifting device.
2. Chock the drive wheels.

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CYLINDERS
Lift Cylinders

9. Remove the screws that secure the rear mast 11. Remove the screw and spacer that secure the sec-
cover (1) and remove the cover. Refer to Figure ondary cylinder to the mast through the hole in the
24603. bottom-front of the mast. Refer to Figure 24696.

Figure 24603
10. Remove the mast’s top cover (1). Pull the ends of
the chains out of the mast from the top. The chains
will remain attached to the back of the secondary
cylinder. Drape the chains over the back of the
mast. Refer to Figure 24691.
Figure 24696
12. Remove the three screws that secure the second-
ary yoke at the front of the mast (near the top).
Note the position of the longest screw that holds
the ram of the secondary cylinder in the yoke as-
sembly. Refer to Figure 24692.

Figure 24691
Figure 24692

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CAUTION
Take care not to drop any tools or fasteners into the
mast.
13. Taking care not to drop fasteners or tools inside the
mast, remove the four screws that secure the sec-
ondary yoke at the top of the mast. Refer to Figure
24693.
Figure 24693
14. Remove the secondary yoke from inside the top of
the mast. A pry bar and lifting strap and lifting de-
vice may be necessary to accomplish this step.
Refer to Figure 24694 and 24695.
Figure 24694
Crown 2010 PF25202-7
CYLINDERS
Lift Cylinders
Figure 24695
15. Use the threaded hole (M12) provided in the sec-
ondary cylinder, with a lifting device, to lift the sec-
ondary cylinder out of the mast. Carefully lay the
cylinder in a clean work place.
16. Remove the chain anchors and chains from the
back of the secondary cylinder.
Secondary Cylinder Installation
These instructions are for installing the secondary cyl-
inder with the mast in an upright position. Refer to Lift-
ing Mechanism - Mast service section for instructions
to install the cylinder with the mast removed from the
truck.
1. Assemble two chain anchors to the back side of the
secondary cylinder. Adjust the chain anchors as
described in Lifting Mechanism - Mast.
2. Secure the chain anchors with two nuts each.
Thread the first nut onto the chain anchor until the
specified gap is achieved. Then install the second
nut until it is finger tight against the first nut. Tighten
the nuts against one another.
3. Install a cotter pin through the base of each chain
anchor. Bend the cotter pin in place.
4. With the lift chains securely in place on the back of
the secondary cylinder, use the threaded hole
(M12) provided in the secondary cylinder, with a
lifting device, to lift and lower the cylinder into the
mast taking care that the chains do not damage the
cylinder.
M8.0-1460-007
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CYLINDERS
Lift Cylinders

5. Using blue thread locking adhesive, secure the

secondary cylinder to the mast with a screw and
spacer installed through the hole in the bottom-
front of the mast. Torque the screw to 75 Nm
(55 ft lb). Refer to Figure 24696.

Figure 24694

7. Secure the secondary yoke to the mast using three

Figure 24696
6. Thread the remaining lift chain anchors through the
yoke and then draw the yoke along the chains until
it is can be moved into position on the cylinder. Re-
fer to Figures 24695 and 24694.
screws in the front. Install the longest of the three
screws in the lower left corner of the triangle-
shaped pattern of holes on the mast so that it holds
the secondary cylinder ram in the secondary yoke
assembly. Torque the screws to 101 Nm (75 ft lb).
Refer to Figure 24692.

Figure 24692

Figure 24695

M8.0-1460-008 Crown 2010 PF25202-8

606

8. Use four more screws to secure the yoke on the
top. Torque the screws to 101 Nm (75 ft lb). Refer
to Figure 24693.
Figure 24693
NOTE
If the reach assembly is on the truck, it may be neces-
sary to raise and block the reach assembly to access
the chain anchor mounting holes at the base of the
third stage column.
9. Lift the chain anchors over the top of the yoke and
pulley and route them down the front of the mast
underneath the cut-out panel on the third stage col-
umn. Install the chain anchors in the bottom of the
third stage column. Secure and adjust the chain
anchors as described in Lifting Mechanism - Mast.
10. Secure the chain anchors with two nuts each.
Tighten the nuts against one another and install a
cotter pin through the base of each chain anchor.
Bend the cotter pin in place.
11. Check the condition of the o-ring on the flow limiter
valve. Replace if damaged, worn or missing. Re-
move the caps on the large diameter tube and the
cylinder. Apply a small amount of hydraulic oil to
lubricate the o-ring and install the flow limiter valve
in the base of the secondary cylinder. Access the
valve from the cutout inside the battery compart-
ment.
12. Install the top cover on the truck. Refer back to Fig-
ure 24691.
13. Install the rear mast cover on the truck. Refer back
to Figure 24603.
14. Install and connect the battery.
Crown 2010 PF25202-9
CYLINDERS
Lift Cylinders
15. Bleed any air out of the cylinder as described in
Secondary Cylinder Bleeding in this section.
16. Close MVL.
Secondary Cylinder Bleeding
Bleed hydraulic circuits of all air after repair. Before
bleeding the system, inspect all hydraulic connections.
Verify proper installation of all filters. Ensure fluid levels
are adequate for testing. Pressurize the hydraulic sys-
tem before completing the following steps.
1. Key the truck ON.
2. Position the mast so that the secondary cylinder is
fully retracted and the primary cylinder is slightly
raised, but does not interfere with access to the
secondary cylinder bleed screw, which is located
just below the three screws used to secure the sec-
ondary yoke from the front side of the mast. Refer
to Figure 24708.
Figure 24708
CAUTION
Take care not to drop any tools or fasteners into the
mast.
3. Place a small wooden block between the second-
ary lift chains to maintain clear access to the bleed
screw. Use a flat blade screw driver with a long
shaft to open and close the bleed screw. Refer to
Figure 24708.
4. Place an absorbent cloth to catch the hydraulic oil
that will be spilled during bleeding. Open the bleed
screw ½ turn until a steady stream of hydraulic oil
flows out of the screw.
5. Tighten the bleed screw and wipe up any spilled
oil.
M8.0-1460-009
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CYLINDERS
Lift Cylinders

Lift Cylinder Repair

The lift cylinders on this truck contain seals that prevent
oil from leaking out of the cylinder as the ram (1) ex-
tends and retracts. The top of the lift cylinder contains
a cap (2) that holds a wiper ring (3). The wiper ring
wipes hydraulic oil off the ram as it extends from the
cylinder tube. Below the wiper ring is a seal called the
rod packing (4). The rod packing keeps oil in the cylin-
der while allowing the ram to extend. The cap keeps
the rod packing in place. The ram has a smooth, pol-
ished chrome plated surface that allows it to "slide"
through the wiper ring and rod packing without tearing
them. A bushing (6) at the bottom and a cap (2) at the
top of the cylinder keep the ram straight as it raises and
lowers. Refer to Figure 24881 (primary cylinder
shown).
Over time, wear may cause the wiper ring and rod
packing to leak. Other causes of such leaks may be
damage or nicks on the ram surface caused by slack
lift chains or chain-to-ram impact. The seals can also
be damaged by splinters from wooden pallets or a
build-up of an abrasive material around the top of the
cylinder.
Failing to properly bleed the hydraulic system can also
lead to rod packing and wiper ring failure. Air trapped
in a cylinder will seek its way to the top of the cylinder
where air pressure builds as hydraulic pressure in-
creases. The pressurized air cuts the rod packing as
the pressure forces it out of the cylinder.
Oil running across the top of the cylinder cap and down
the side of the cylinder or a large build up of oil soaked
dirt on top of the cylinder cap usually means that the
rod packing and wiper ring need to be replaced. A worn
wiper ring allows contaminants into the cylinder. These
contaminants may be abrasive, accelerating the wear
on the rod packing or scoring the ram.
Occasionally, a slight creep of the fork assembly may
occur. An internal leakage in the piston pack may be
the cause, but a leakage in the solenoid or check valve
may also be the cause. To seat these valves properly
when this occurs, raise and lower the forks to flush out
any foreign material from the valve seat. Conduct a
thorough check of the system for leaks if abnormal oil
losses occur.

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 CYLINDERS
Lift Cylinders

Figure 24881

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CYLINDERS
Lift Cylinders

Primary Cylinder Repacking 10. Use the cap socket from the tool kit to loosen and
remove the cap (2) from the cylinder in a counter-
It is not necessary to remove the cylinder from the truck clockwise direction. Refer to Figure 24883.
to repack it. Use a cylinder seal tool kit, Crown part
number 149558, to replace the rod packing. Failure to
use appropriate tools may result in damage to the rod
packing, the cylinder tube or the ram.
1. Move the truck to a level area set aside for service,
under a lifting device if possible. Remove the forks.
2. Extend the primary cylinder to allow a visual in-
spection of the cylinder and ram. Replace the ram
if there are deep scratches or grooves on it. Re-
placing the wiper ring and rod packing on a cylinder
with a damaged ram will cause the new wiper ring
and rod packing to quickly deteriorate and leak.
3. Raise and block the reach carriage to create slack
in the primary lift chains. Refer to the Control of
Hazardous Energy chapter for lifting and blocking
instructions.
4. Chock the drive wheels and key the truck OFF.
Disconnect the battery.
5. Lockout/Tagout the truck as described in Control of
Hazardous Energy. Figure 24883

11. Remove the bleed screw and seal (5).

NOTE 12. The rod packing (3) is recessed in the cylinder bore
The yoke assembly must be separated from the pri- (6). Refer to Figure 24883.
mary cylinder ram in order to repack the cylinder. This
can be done without removing the cylinder from the
truck and without disconnecting any hoses, cables or
lift chains.

CAUTION
Use a sling or rope that is sufficiently rated to support
the weight of the material being lifted.
6. Place a sling or rope through the yoke and secure
it to the overhead guard or the mast to support the
yoke, chains, cables and hoses out of the way with-
out disassembling the yoke.
7. Remove the screw from the bottom of the primary
yoke that secures the ram of the primary cylinder.
8. Open MVL, allowing the sling or rope to support the
yoke while the ram lowers into the cylinder hous-
ing.
9. Remove any dirt or debris from the top of the cylin-
der.

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 CYLINDERS
Lift Cylinders

NOTE
Take extreme care to prevent scratching of the cylinder
(7) walls or the ram.
13. Remove the rod packing using a pair of specially
made tools. Refer to Figure 15963-01.
– To make the tools, weld or braze a headless
4 mm self-tapping (No. 8 metal) screw to the
end of a screwdriver. The screwdriver must
have at least 152 mm (6 in) of shank length
with no larger than 4 mm (0.156 in) shank di-
ameter.
– After attaching the screw to the screwdriver,
grind off the excess weld to a diameter of 4 mm
(0.156 in).
– To prevent scratching of the cylinder bore or
the ram, wrap the shank with electrical tape
from the tip of the screw to the screwdriver han-
dle.

Figure 24882

15. Since the wiper ring and rod packing should al-
ways be replaced at the same time, remove the
wiper ring (1) from the cap. Refer to Figure 24883.
16. Thoroughly clean the areas where the wiper ring
Figure 15963-01
and rod packing seat. All burrs, sharp edges, dirt
1 Screwdriver and debris must be removed before reinstalling
152 mm (6 in) shaft length (min.) new seals.
4 mm (0.156 in) shaft diameter (max.)
17. Inspect the existing collar. Ensure it is properly
2 No. 8 Metal Screw
seated in the cylinder bore. Replace if necessary.
Headless (4 mm Self-Tapping)
3 Weld (grind off excess) to a max. dia. of 4 mm (0.156 in)
4 Tape

14. Insert the tools between the ram and the cylinder
walls, 180° apart. Push on the handles while turn-
ing them in a clockwise direction to bore the screws
into the rod packing. When the screws are firmly
seated in the rod packing, gently pull on the tools
to work the rod packing out of the cylinder bore.
Refer to Figure 24882 (different cylinder shown).

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CYLINDERS
Lift Cylinders

18. With the same type of hydraulic oil used in the cyl-
inder, lightly lubricate the groove (1) in the cap and
gently install the new wiper ring. Refer to Figure
24884.

Figure 24884

19. To protect the rod packing from damage caused by

contact with the threads, use the sleeve (2) from
the tool kit. Refer to Figure 24885.

Figure 24885

20. Apply a light coating of clean hydraulic oil to the

new rod packing and the inside diameter of the
sleeve. Insert the sleeve into the cylinder housing
bore.
21. Carefully insert the new rod packing into the sleeve
and seat it into the cylinder bore. Use the driver (3)
from the tool kit to gently seat the rod packing into
the cylinder bore.
22. Remove the sleeve and driver from the cylinder.

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 CYLINDERS
Lift Cylinders

Secondary Cylinder Repacking

CAUTION
It is not necessary to remove the cylinder from the truck
When inserting the cap take care to prevent the to repack it. Use a cylinder seal tool kit, Crown part
threads and sharp edges from damaging the new seals number 149558, to replace the rod packing. Failure to
and rod packing. use appropriate tools may result in damage to the rod
23. Install the cap on the cylinder. Use the cap socket packing, the cylinder tube or the ram.
to tighten the cap. 1. Move the truck to a level area set aside for service.
24. Install the replacement bleed screw and seal. 2. Chock the drive wheels.
25. Close MVL. Connect the battery and key the truck 3. Raise and block the reach carriage high enough to
ON. access the lower chain anchors. Remove the forks.
Refer to Control of Hazardous Energy for more in-
formation on lifting and blocking the truck.
CAUTION
4. Key the truck OFF.
Do not place your hand or fingers between the top of
the ram and yoke assembly. 5. Lockout/Tagout the truck as described in Control of
Hazardous Energy.
26. Very slowly, lift the multi-task control handle until
the primary cylinder begins to extend. Guide the 6. Remove the cotter pins and nuts from the lower
primary yoke into place on the primary ram. secondary chain anchors on the front of the mast.
Refer to Figure 24690 and 24705.
27. When the ram begins to seat into the yoke, release
the multi-task control handle and loosen the sling
or rope on the yoke. Ensure the yoke seats
squarely on the cylinder ram.
28. Remove the sling or rope from the yoke. Raise the
carriage until it is no longer sitting on the blocks,
removing chain slack.
29. Bleed air from the primary cylinder as described in
Primary Cylinder Bleeding in this section.
30. Remove the blocks. Key the truck ON. Lower the
mast completely.
31. Key the truck OFF and check the hydraulic oil level. Figure 24690
Add oil as necessary.
32. Reinstall the forks and covers as necessary.
33. Remove the wheel chocks and verify proper truck
operation.

Figure 24705

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CYLINDERS
Lift Cylinders

7. Open MVL.
8. Remove the screws that secure the rear mast
cover (1) and remove the cover. Refer to Figure
24603.
10. Remove the three screws that secure the second-
ary yoke at the front of the mast (near the top).
Note the position of the longest screw that holds
the ram of the secondary cylinder in the yoke as-
sembly. Refer to Figure 24692.

Figure 24692

Figure 24603
9. Remove the mast’s top cover (1). Pull the ends of
the chains out of the mast from the top. The chains
will remain attached to the back of the secondary
cylinder. Refer to Figure 24691.
CAUTION
Take care not to drop any tools or fasteners into the
mast.
11. Taking care not to drop fasteners or tools inside the
mast, remove the four screws that secure the sec-
ondary yoke at the top of the mast. Refer to Figure
24693.

Figure 24691

Figure 24693

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 CYLINDERS
Lift Cylinders

12. Remove the secondary yoke from inside the top of 14. Use the cap socket from the tool kit to loosen and
the mast. A pry bar and lifting strap and lifting de- remove the cap (2) from the cylinder in a counter-
vice may be necessary to accomplish this step. clockwise direction. Refer to Figure 24883.
Drape the lift chains and yoke over the overhead
guard or mast. Ensure that they are secured to the
overhead guard or mast so that they will not fall.
Refer to Figure 24694 and 24695.

Figure 24883
Figure 24694
15. From the front of the mast and taking extreme care
not to drop the screw into the mast, remove the
bleed screw and seal (5).
16. The rod packing (3) is recessed in the cylinder bore
(6).

Figure 24695

13. Remove any dirt or debris from the top of the cylin-
der.

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CYLINDERS
Lift Cylinders

NOTE
Take extreme care to prevent scratching of the cylinder
(7) walls or the ram.
17. Remove the rod packing using a pair of specially
made tools. Refer to Figure 15963-01.
– To make the tools, weld or braze a headless
4 mm self-tapping (No. 8 metal) screw to the
end of a screwdriver. The screwdriver must
have at least 152 mm (6 in) of shank length
with no larger than 4 mm (0.156 in) shank di-
ameter.
– After attaching the screw to the screwdriver,
grind off the excess weld to a diameter of 4 mm
(0.156 in).
– To prevent scratching of the cylinder bore or
the ram, wrap the shank with electrical tape
from the tip of the screw to the screwdriver han-
dle.

Figure 24882

19. Since the wiper ring and rod packing should al-
ways be replaced at the same time, remove the
wiper ring (1) from the cap. Refer to Figure 24883.
20. Thoroughly clean the areas where the wiper ring
Figure 15963-01
and rod packing seat. All burrs, sharp edges, dirt
1 Screwdriver and debris must be removed before reinstalling
152 mm (6 in) shaft length (min.) new seals.
4 mm (0.156 in) shaft diameter (max.)
21. Inspect the existing collar (4). Ensure it is properly
2 No. 8 Metal Screw
seated in the cylinder bore. Replace if necessary.
Headless (4 mm Self-Tapping)
Refer to Figure 24883.
3 Weld (grind off excess) to a max. dia. of 4 mm (0.156 in)
4 Tape

18. Insert the tools between the ram and the cylinder
walls, 180° apart. Push on the handles while turn-
ing them in a clockwise direction to bore the screws
into the rod packing. When the screws are firmly
seated in the rod packing, gently pull on the tools
to work the rod packing out of the cylinder bore.
Refer to Figure 24882 (different cylinder shown).

M8.0-1460-018 Crown 2010 PF25202-18

616
 CYLINDERS
Lift Cylinders

22. With the same type of hydraulic oil used in the cyl-
inder, lightly lubricate the groove (1) in the cap and
gently install the new wiper ring. Refer to Figure
24884.

Figure 24884

23. To protect the rod packing from damage caused by

contact with the threads, use the sleeve (2) from
the tool kit. Refer to Figure 24885.

Figure 24885

24. Apply a light coating of clean hydraulic oil to the

new rod packing and the inside diameter of the
sleeve.
25. Carefully insert the new rod packing into the sleeve
and seat it into the cylinder bore. Use the driver (3)
from the tool kit to gently seat the rod packing into
the cylinder bore.
26. Remove the sleeve and driver from the cylinder.

Crown 2010 PF25202-19 M8.0-1460-019

617
CYLINDERS
Lift Cylinders
CAUTION
When inserting the cap take care to prevent the
threads and sharp edges from damaging the new seals
and rod packing.
27. Install the cap on the cylinder. Use the cap socket
to tighten the cap.
28. Install the replacement bleed screw and seal.
29. Close MVL.
CAUTION
Do not place hands or fingers between the secondary
yoke and the mast when installing the yoke in the truck.
30. Install the secondary yoke in the top of the mast.
Refer back to Figures 24694 and 24695.
CAUTION
Take care not to drop any tools or fasteners into the
mast.
31. Taking care not to drop fasteners or tools inside the
mast, install the four screws that secure the sec-
ondary yoke at the top of the mast. Torque the
screws to 101 Nm (75 ft lb). Refer back to Figure
24693.
32. Install the three screws that secure the secondary
yoke at the front of the mast (near the top). Install
the longest screw in the lower left corner of the tri-
angle-shaped pattern of holes on the mast so that
it holds the secondary cylinder ram in the second-
ary yoke assembly. Refer back to Figure 24692.
NOTE
If the reach assembly is on the truck, it may be neces-
sary to raise and block the mast to access the chain
anchor mounting holes at the base of the third stage
column.
33. Lift the chain anchors over the top of the yoke and
pulley and route them down the front of the mast
underneath the cut-out panel on the third stage col-
umn. Adjust the chain anchors so that there is
22.23 mm (7/8 in) between the base of the third
stage column and top of the main frame base plate.
M8.0-1460-020
618
34. Secure the chain anchors with two nuts each.
Thread the first nut onto the fully seated chain an-
chor until it is finger tight. Then install the second
nut until it is finger tight against the first nut. Tighten
the nuts against one another and install a cotter pin
through the base of each chain anchor. Refer back
to Figures 24705 and 24690.
35. Install the top cover on the truck. Refer back to Fig-
ure 24691.
36. Install the rear mast cover on the truck. Refer back
to Figure 24603.
37. Connect the battery and key the truck ON.
38. Bleed air out of the cylinder. Refer to Secondary
Cylinder Bleeding in this section.
39. Lower the mast completely.
40. Key the truck OFF and check the hydraulic oil level.
Add oil as necessary.
41. Reinstall the forks and covers as necessary.
42. Remove the wheel chocks and verify proper truck
operation.
Flow Limiter Valves
Flow limiter valves at the base of both the primary and
secondary cylinders act as safety devices to stop the
mast from lowering rapidly in the event of a mast hose
rupture. Refer to the Hydraulic Circuits section for fur-
ther information.
Primary Cylinder Flow Limiter Valve
Replacement
NOTE
In this section there are circumstances which require
the collection of hydraulic oil that will leak from compo-
nents. Be prepared to catch hydraulic oil with a catch
pan or absorbent material. Do not reuse hydraulic oil.
Follow applicable laws and environmental standards
when disposing of used hydraulic oil. Many hazardous
waste facilities have oil recycling capabilities.
Crown 2010 PF25202-20

WARNING
Do not attempt to remove the flow limiter valve if the
mast and carriage are not properly blocked. Risk of se-
rious injury or even death may occur.
1. Move the truck to a level area set aside for service.
2. Chock the drive wheels.
3. Raise and block the third stage mast 102-127 mm
(4-5 in) from the floor to relieve some primary hose
tension. Lower the forks completely. Do not raise
the mast more than this, as it will be difficult to ac-
cess the flow limiter valve.
4. Key the truck OFF. Disconnect and remove the
battery.
5. Lockout/Tagout the truck as described in Control of
Hazardous Energy.
6. Open MVL to relieve hydraulic pressure.
7. From the inside of the battery compartment, re-
move the primary lift hose from the flow limiter
valve at the base of the primary cylinder. Remove
the flow limiter valve and existing o-rings. Refer to
Figure 24685.
Figure 24685
8. Lightly lubricate the new o-rings with hydraulic oil.
Install the o-rings on the replacement flow limiter
valve. Install the flow limiter valve on the base of
the primary cylinder.
9. Install the primary lift hose on the flow limiter valve.
Tighten the hydraulic fittings.
10. Close MVL.
11. Connect the battery and key the truck ON.
Crown 2010 PF25202-21
CYLINDERS
Lift Cylinders
12. Raise the mast and remove the blocks.
13. Bleed the primary cylinder as described in Primary
Cylinder Bleeding in this section.
14. Remove the wheel chocks.
Secondary Cylinder Flow Limiter Valve
Replacement
NOTE
In this section there are circumstances which require
the collection of hydraulic oil that will leak from compo-
nents. Be prepared to catch hydraulic oil with a catch
pan or absorbent material. Do not reuse hydraulic oil.
Follow applicable laws and environmental standards
when disposing of used hydraulic oil. Many hazardous
waste facilities have oil recycling capabilities.
WARNING
Do not attempt to remove the flow limiter valve if the
mast and carriage are not completely lowered. Risk of
serious injury or even death may occur.
1. Move the truck to a level area set aside for service.
2. Chock the drive wheels.
3. Completely lower the mast and carriage.
4. Key the truck OFF. Disconnect and remove the
battery.
5. Lockout/Tagout the truck as described in Control of
Hazardous Energy.
6. Open MVL to relieve hydraulic pressure.
7. From inside the battery compartment, disconnect
the large diameter tube from the flow limiter valve.
Remove the flow limiter valve and existing o-rings
from the base of the secondary cylinder.
8. Lightly lubricate the new o-rings with hydraulic oil.
Install the o-rings on the replacement flow limiter
valve. Install the flow limiter valve into the base of
the secondary cylinder.
9. Connect the tube assembly to the flow limiter
valve. Tighten the hydraulic fittings.
10. Close MVL.
11. Install and connect the battery. Key the truck ON.
12. Bleed the secondary cylinder as described in Sec-
ondary Cylinder Bleeding in this section.
M8.0-1460-021
619
Notes:

620