CYLINDER REPAIR

S30FT, S35FT, S40FTS [E010];

E1.50-2.00XM (E25-35Z, E40ZS) [E114];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
J1.60-2.00XMT (J30-40ZT) [J160];
H2.0-3.5FT (H40-70FT) [L177]

PART NO. 1580516 2100 SRM 1139

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, 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 Mainte-
nance 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 HYSTER 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!
Cylinder Repair Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Safety Procedures When Working Near Mast.................................................................................................. 1
Tilt Cylinder Repair ........................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 6
Clean .............................................................................................................................................................. 6
Assemble ........................................................................................................................................................ 7
Install ............................................................................................................................................................. 7
Tilt Cylinders, Adjust .................................................................................................................................... 7
Tilt Cylinder Leak Check for Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL............................. 9
Tilt Cylinder Leak Check for the Four-Stage Full Free-Lift....................................................................... 9
Torque Specifications..................................................................................................................................... 10
Piston Rod.................................................................................................................................................. 10
Gland.......................................................................................................................................................... 10
Tilt Cylinder Mounting Capscrew ............................................................................................................ 10
Tilt Cylinder Rod End Capscrew .............................................................................................................. 10
Lift Cylinder Repair........................................................................................................................................... 11
Main Lift Cylinders, Remove ........................................................................................................................ 11
Free-Lift Cylinder, Remove ........................................................................................................................... 11
Free-Lift and Main Lift Cylinders, Disassemble ......................................................................................... 15
Two-Stage FFL Cylinder, Disassemble......................................................................................................... 16
Inspect ............................................................................................................................................................ 16
Clean .............................................................................................................................................................. 16
Full Free-Lift and Main Lift Cylinders, Assemble ...................................................................................... 18
Two-Stage FFL and Main Lift Cylinders, Assemble.................................................................................... 18
Main Lift Cylinders, Install .......................................................................................................................... 19
Free-Lift Cylinder, Install ............................................................................................................................. 20
Torque Specifications..................................................................................................................................... 21
Lift Cylinders Leak Check ............................................................................................................................ 21

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

E1.50-2.00XM (E25-35Z, E40ZS) [E114];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
J1.60-2.00XMT (J30-40ZT) [J160];
H2.0-3.5FT (H40-70FT) [L177]

©2005 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2100 SRM 1139 Safety Procedures When Working Near Mast

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 cylinders. The but the operation of the cylinders is the same.

Description
This manual covers many different types of cylin- valve. A single external lowering control valve is con-
ders. Each cylinder will be described in detail. nected by tubing and hoses to all the lift cylinders.

Tilt cylinders are fastened between the frame of the NOTE: On lift truck models S2.0-3.5FT (S40-70FT,
lift truck and the outer weldment of the mast to S55FTS) (F187) and H2.0-3.5FT (H40-70FT) (L177)
change the angle of the mast and forks. there are two free-lift chains and chain sheaves.
On lift truck models S30FT, S35FT, S40FTS
Two single-stage main lift cylinders and a free-lift (E010), E1.50-2.00XM (E25-35Z, E40ZS) (E114),
cylinder are used to raise the carriage and extend the J1.60-2.00XMT (J30-40ZT) (J160), and H1.6FT,
mast weldments. H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
there is one free-lift chain and chain sheave. The
The two main lift cylinders are installed at the back
description below applies to all trucks.
of the outer mast. The base of each lift cylinder sits
on a mount at the bottom crossmember of the outer The free-lift chains connect at one end of the mid-
mast. The top of each main lift cylinder rod fits into a crossmember of the inner mast. Two chain sheaves
guide on the top crossmember of the inner mast. The are installed on a crosshead on the rod of the free-
free-lift cylinder is installed in the inner mast. Each lift cylinder. The chains then go over sheaves on the
of the lift cylinders has an internal lowering control crosshead and connect to the carriage.

Safety Procedures When Working Near Mast

The following procedures MUST be used when in- • DO NOT use blocks to support the mast weld-
specting or working near the mast. Additional pre- ments nor to restrain their movement.
cautions and procedures can be required when re- • Mast repairs require disassembly and re-
pairing or removing the mast. moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in this section.
WARNING
Mast parts are heavy and can move. Distances WHEN WORKING NEAR THE MAST ALWAYS:
between parts are small. Serious injury or • Lower the mast and carriage completely.
death can result if part of the body is hit by Push the lift/lower control lever forward and
parts of the mast or the carriage. make sure there is no movement in the mast.
• Never put any part of the body into or under Make sure that all parts of the mast that
the mast or carriage unless all parts are com- move are fully lowered.
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the OR
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect • If parts of the mast must be in a raised po-
the battery and put a tag or lock on the bat- sition, install a safety chain to restrain the
tery connector. moving parts of the mast. Connect moving
• Be careful of the forks. When the mast is parts to a part that does not move. Follow
raised, the forks can be at a height to cause these procedures:
an injury. 1. Put mast in vertical position.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.

1
Safety Procedures When Working Near Mast 2100 SRM 1139

2. Raise mast to align bottom crossmember of weld- three-stage, and four-stage) is completely re-
ment that moves in outer weldment with cross- tracted. If running, turn the power OFF. Apply
member on outer weldment. On the two-stage the parking brake. Install a DO NOT REMOVE
and free-lift mast, the moving part is the inner tag on the safety chain(s).
weldment. On the three-stage mast, it is the in-
termediate weldment. On the four-stage mast, it 5. Install another safety chain (3/8-in. minimum)
is the first intermediate weldment. See Figure 1. between the top or bottom crossmember of the
carriage bar and a crossmember on the outer
3. Use a 3/8-inch minimum safety chain with a hook weldment.
to fasten the crossmembers together so the mov-
able member cannot lower. Put hook on back side NOTE: Apply the parking brake. After lowering or
of mast. Make sure hook is completely engaged restraining the mast, shut off the power, and remove
with a link in the chain. Make sure safety chain key. Put a DO NOT OPERATE tag in the operator’s
does not touch lift chains or chain sheaves, tubes, compartment. Disconnect battery and put a tag or
hoses, fittings, or other parts on the mast. lock on battery connector.

4. Lower mast until there is tension in safety chain

and free-lift cylinder (two-stage full free-lift,

Legend for Figure 1

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST
B. TWO-STAGE FFL MAST D. FOUR-STAGE FFL MAST
1. OUTER WELDMENT 5. FREE-LIFT CYLINDER
2. INNER WELDMENT 6. CARRIAGE BAR
3. INTERMEDIATE WELDMENT 7. CROSSMEMBER
4. HOOK 8. FIRST INTERMEDIATE WELDMENT

2
2100 SRM 1139 Safety Procedures When Working Near Mast

Figure 1. Two-Stage LFL, Two-Stage FFL, Three-Stage FFL, and Four-Stage FFL Masts

3
Tilt Cylinder Repair 2100 SRM 1139

Tilt Cylinder Repair

REMOVE 2. Stroke cylinder to the full backtilt position.

3. Disconnect the hydraulic lines at the tilt cylin-

WARNING der. Install caps on the hydraulic lines and in
Before removing the tilt cylinder(s), tilt the the cylinder ports.
mast forward. Use a chain to hold the mast to
the frame and prevent the mast from moving 4. Use a lifting device to move large tilt cylinders.
forward. Remove the capscrew and retainer from the an-
chor pin. Using a drift pin or similar tool, push
WARNING the anchor pin out of the frame.
Do not push the anchor pins out of the rod end 5. Using a lifting device, remove the tilt cylinder
with your fingers. Do not permit the tilt cylin- from the lift truck.
ders to drop and cause damage.
6. Repeat above steps for the remaining tilt cylin-
1. At the mast, remove the capscrew and retainer der.
from the anchor pin. Using a drift pin or similar
tool, push the anchor pin out of the rod end. See
Figure 2.

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 4. ANCHOR PIN
2. RETAINER 5. TILT SPACER
3. LUBRICATION FITTING

Figure 2. Tilt Cylinder Removal

4
2100 SRM 1139 Tilt Cylinder Repair

DISASSEMBLE NOTE: To prevent damage to sealing surfaces, use

brass tools when removing seals and O-rings.
NOTE: The following steps have detailed disassembly
instructions. Perform only those steps required to 3. Remove and discard the O-ring, backup ring,
repair the tilt cylinder. seal, and wiper from the gland.

NOTE: Note the position of the rod end and number NOTE: Perform Step 4 only if the piston or rod has
of turns used to remove the rod end. been damaged.

1. Put the tilt cylinder in a soft jaw vise. Remove 4. Place the rod in a soft-jaw vise and remove the
the rod end and, if equipped, tilt spacer from the piston from the rod.
rod. See Figure 3 or Figure 4.
5. Remove and discard the O-ring and piston seal
2. Using a pin-type spanner wrench, Remove the from the piston.
gland from the tilt cylinder. Remove the rod and
piston assembly from the cylinder.

A. S2.0-2.5FT (S40-S55FT, S55FTS) (F187), B. S3.0-3.5FT (S60-S70FT) (F187) AND H3.0-3.5FT

S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT, (H60-70FT) (L177)
H2.0FTS (H30FT, H35FT, H40FTS) (F001), AND
H2.0-2.5FT (H40-50FT) (L177)
1. TUBE 7. O-RING
2. GLAND 8. PISTON
3. ROD 9. PISTON SEAL
4. WIPER RING 10. NUT
5. SEAL 11. WEAR RING
6. BACKUP RING 12. BUSHING

Figure 3. Tilt Cylinder

5
Tilt Cylinder Repair 2100 SRM 1139

1. CYLINDER SHELL 6. BACKUP RING

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

Figure 4. Tilt Cylinder - E1.50-2.00XM (E25-35Z, E40ZS) (E114) and J1.60-2.00XMT (J30-40ZT) (J160)

INSPECT cleaning solvents, always follow the solvent

manufacturer’s recommended safety proce-
Inspect the gland for damage to the threads and the dures.
seal surfaces. Replace the gland if damaged.
Compressed air can move particles so they
Inspect the piston for any damage to the seal surfaces cause injury to the user or to other personnel.
and replace if damaged. Make sure the path of the compressed air is
away from all personnel. Wear protective gog-
Inspect the rod for damage to the rod surface and
gles or a face shield to prevent injury to the
ensure that the rod is not bent. Replace the rod if
eyes.
found to be damaged.

Inspect the inner surface of the cylinder tube for CAUTION

damage. If the tube is found to be damaged, replace
Do not allow cleaning solvent to come in con-
the cylinder.
tact with rubber components, as it will damage
those components.
CLEAN
Clean all metal parts in solvent and dry with com-
WARNING pressed air.
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using

6
2100 SRM 1139 Tilt Cylinder Repair

ASSEMBLE as noted during removal. Tighten the capscrew

on the rod end to 90 N•m (66 lbf ft).
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings. 6. Repeat the above steps for the other tilt cylinder.

1. Install a new piston seal and O-ring on the pis- INSTALL

ton. See Figure 3.
1. Using a lifting device, place the cylinder on the
NOTE: Perform Step 2 only if the piston was removed mounting point on the lift truck frame. Install
from the rod. the anchor pin. Install the retainer and cap-
screw. See Figure 2. Tighten the capscrew to
2. Place the rod in a soft-jaw vise, and install the
38 N•m (28 lbf ft).
piston on the rod and tighten the nut to
• 170 to 220 N•m (125 to 163 lbf ft) on lift truck 2. Connect the hydraulic lines to the tilt cylinder.
models S2.0-2.5FT (S40-S55FT, S55FTS) Slowly stroke the cylinders until the rod holes
(F187), S30FT, S35FT, S40FTS (E010), line up with the mast tilt anchor holes.
E1.50-2.00XM (E25-35Z, E40ZS) (E114),
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, 3. Install the anchor pin. Install the retainer and
H40FTS) (F001), and H2.0-2.5FT (H40-50FT) capscrew. Tighten the capscrew to 38 N•m
(L177) (28 lbf ft).
• 320 to 400 N•m (240 to 295 lbf ft) on lift truck
models S3.0-3.5FT (S60-S70FT) (F187) and 4. Remove chain holding the mast to the frame.
H3.0-3.5FT (H60-70FT) (L177)
• 163 to 190 N•m (120 to 140 lbf ft) on lift truck WARNING
models J1.60-2.00XMT (J30-40ZT) (J160) Do NOT put hands between the cylinder rod
end and the mast. Serious injury can occur.
3. Install a new wiper, seal, backup ring, and O-ring
on the gland. 5. Operate the tilt cylinders. Check for correct op-
eration and leakage. Adjust the tilt cylinders.
4. Install the rod and piston assembly in the cylin-
der. Using a pin-type spanner, install the gland
TILT CYLINDERS, ADJUST
in the cylinder. Tighten the gland to
• 170 to 237 N•m (125 to 175 lbf ft) for lift
truck models S2.0-2.5FT (S40-S55FT, S55FTS) WARNING
(F187) and H2.0-2.5FT (H40-50FT) (L177) When the tilt cylinders have tilt limit spacers,
• 163 to 190 N•m (120 to 140 lbf ft) for make sure they are installed during installa-
lift truck models S30FT, S35FT, S40FTS tion procedures. Without the tilt limit spacers,
(E010), E1.50-2.00XM (E25-35Z, E40ZS) the mast can tilt too much and cause an acci-
(E114), J1.60-2.00XMT (J30-40ZT) (J160), and dent or serious injury.
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001). Check the tilt cylinder stroke by slowly tilting the
• 400 to 500 N•m (295 to 370 lbf ft) for lift mast fully forward and backward several times. Both
truck models S3.0-3.5FT (S60-S70FT) (F187) tilt cylinders must stop their stroke at the same time.
and H3.0-3.5FT (H60-70FT) (L177) Adjust the rod ends as shown in Figure 5. There
must be no twist in the mast weldments.
5. Place the cylinder in a soft-jaw vise and install
the tilt spacer, if equipped, and rod end on the rod

7
Tilt Cylinder Repair 2100 SRM 1139

A. DIMENSION A = 15 mm (0.60 in.) 1. MAST

2. ROD END
1. MAST 4. TILT LIMIT SPACER 3. TILT CYLINDER
2. ROD END 5. TILT CYLINDER
3. SHIMS Figure 6. Tilt Cylinder Adjustments (Models
J1.60-2.00XMT (J30-40ZT) (J160) Only)
Figure 5. Tilt Cylinder Adjustments (All Models
Except J1.60-2.00XMT (J30-40ZT) (J160)) 2. Adjust the stroke of the tilt cylinders WITH tilt
limit spacers as follows:
1. Adjust the stroke of the tilt cylinders WITHOUT
tilt limit spacers as follows: a. Adjust the rod ends to 15 mm (0.6 in.) for all
tilt cylinders as shown in Figure 5.
a. Adjust the rod ends to 15 mm (0.6 in.) for all
tilt cylinders shown in Figure 5 and 23 mm b. Slowly tilt the mast forward until one cylin-
(1.25 in.) for all tilt cylinders shown in Fig- der rod stops. On the opposite cylinder,
ure 6. loosen the capscrews on the rod end. Use
a wrench and turn the cylinder rod IN as
b. Slowly tilt the mast backward until one necessary. Repeat this procedure until both
cylinder rod stops. On the opposite cylin- cylinder rods stop at the same position
der, loosen the capscrews on the rod end. within 1 mm (0.04 in.).
Measure the distance from the end of the
cylinder to the back end of the rod end. Use c. Slowly tilt the mast backward until one rod
a wrench and turn the cylinder rod IN until end just contacts the spacer. Add shims to
the dimension starts to decrease, then stop. fill the gap at the opposite rod end until both
Repeat this procedure until both cylinder rod ends contact the spacers within 0.5 mm
rods stop at the same position within 1 mm (0.02 in.).
(0.04 in.). After the adjustments are com-
plete, tighten the capscrews on the rod ends. d. After the adjustments are complete, tighten
the capscrews on the rod ends.
c. Tilt the mast fully backward and measure
the tilt angle. See the nameplate for tilt e. Tilt the mast fully backward and measure
angles. If necessary, adjust both rod ends the tilt angle. See the nameplate for tilt an-
equally for the correct angle. gles. If necessary, add an equal number of
shims to both rods for the correct angle.

8
2100 SRM 1139 Tilt Cylinder Repair

TILT CYLINDER LEAK CHECK FOR TILT CYLINDER LEAK CHECK FOR THE
TWO-STAGE LFL, TWO-STAGE FFL, AND FOUR-STAGE FULL FREE-LIFT
THREE-STAGE FFL
WARNING
WARNING Never allow anyone under a raised carriage.
During the test procedures for the hydraulic Do not put any part of your body in or through
system, use chains to fasten the load to the car- the lift mechanism unless all parts of the mast
riage to prevent it from falling. Keep all people are completely lowered and the engine is
away from the lift truck during the tests. STOPPED.

Do NOT try to find hydraulic leaks by putting Do not try to find hydraulic leaks by putting
your hand on hydraulic components under your hand on hydraulic components under
pressure. Hydraulic oil can be injected into pressure. Hydraulic oil can be injected into
the body by the pressure. the body by the pressure.

1. Operate the hydraulic system. Put a capacity 1. Put a capacity load on the forks. Use a safety
load on the forks, and raise and lower the load chain to hold the load to the carriage. Raise the
several times. Lower the load and tilt the mast load approximately 2.5 m (8 ft). Put the mast in
forward and backward several times. Check for a vertical position.
leaks.
2. Measure the distance that the rod for tilt cylin-
2. Raise the carriage and load 1 m (3 ft). If the car- der extends from the shell. Check the distance
riage slowly lowers when the control valve is in the rod moves in five or ten minutes. Multiply
the neutral position, there are leaks in the hy- the rate in Table 1 by the time of the test and
draulic system. The maximum speed that the compare the numbers.
carriage is allowed to lower is 50 mm (2 in.) per
3. If the tilt rate is greater than the specifications,
10 minutes when the hydraulic oil is 30 C (86 F).
lower the mast and remove the load from the
If the oil temperature is 70 C (158 F), the max-
forks. Install a valve between the port at the
imum speed the carriage can lower is 150 mm
front of the tilt cylinder and the hydraulic line.
(6 in.) per 10 minutes.
The valve must be able to completely shut off the
3. Check the lift cylinders for internal leaks. Re- flow of hydraulic oil. Put the load on the forks
move the load from the forks. Install a gate valve again. Close the valve. Tilt the mast forward just
in the supply line between the main control valve past the vertical position. If the mast continues
and the mast. Put a capacity load on the forks to tilt SLOWLY forward, the seals on the piston
again. Raise the carriage 1 m (3 ft). Close the are leaking.
gate valve. If the carriage or mast weldments
4. If the mast does not move, open the valve and
lower SLOWLY, the seals in the lift cylinders
check the movement again. If the mast moves
have leaks.
forward when the gate valve is open, check for
4. If the carriage does not move, open the gate valve leaks in the hydraulic lines and fittings. If no
and check the movement again. If the carriage leaks are found, the main control valve can be
lowers when the gate valve is open, check for worn or damaged. Remove the load from the
leaks in the hydraulic lines and fittings. If no forks when the checks are complete.
leaks are found, the main control valve can be
worn or damaged. Remove the load from the
forks.

9
Tilt Cylinder Repair 2100 SRM 1139

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
S2.0-3.5FT 1.0 0.04 6.8 0.30
(S40-S70FT, S55FTS) (F187)
S30FT, S35FT, S40FTS (E010) 1.0 0.04 5.4 0.21
H1.6FT, H1.8FT, H2.0FTS (H30FT, 1.0 0.04 5.7 0.23
H35FT, H40FTS) (F001)
H2.0-3.5FT (H40-70FT) (L177) 1.0 0.04 6.3 0.25
E1.50-2.00XM (E25-35Z, E40ZS) (E114) 0.8 0.03 5.0 0.20
and J1.60-2.00XMT (J30-40ZT) (J160)

TORQUE SPECIFICATIONS S3.0-3.5FT (S60-S70FT) (F187) and H3.0-3.5FT

(H60-70FT) (L177)
Piston Rod 400 to 500 N•m (295 to 370 lbf ft)

S2.0-2.5FT (S40-S50FT, S55FTS) (F187), S30FT, S35FT, S40FTS (E010), E1.50-2.00XM

S30FT, S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z, E40ZS) (E114), J1.60-2.00XMT
(E25-35Z, E40ZS) (E114), H1.6FT, H1.8FT, (J30-40ZT) (J160), and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001), H2.0FTS (H30FT, H35FT, H40FTS) (F001)
and H2.0-2.5FT (H40-50FT) (L177) 163 to 190 N•m (120 to 140 lbf ft)
170 to 220 N•m (125 to 163 lbf ft)
Tilt Cylinder Mounting Capscrew
S3.0-3.5FT (S60-S70FT) (F187) and H3.0-3.5FT
(H60-70FT) (L177) 38 N•m (28 lbf ft)
320 to 400 N•m (240 to 295 lbf ft)
Tilt Cylinder Rod End Capscrew
J1.60-2.00XMT (J30-40ZT) (J160)
163 to 190 N•m (120 to 140 lbf ft) 90 N•m (66 lbf ft)

Gland
S2.0-2.5FT (S40-S50FT, S55FTS) (F187) and
H2.0-2.5FT (H40-50FT) (L177)
170 to 237 N•m (125 to 175 lbf ft)

10
2100 SRM 1139 Lift Cylinder Repair

Lift Cylinder Repair

MAIN LIFT CYLINDERS, REMOVE 4. If working on a two- or three-stage mast, remove
the snap ring or fitting at the top of the cylinder
to be removed.
WARNING
Before working on or near the mast, see Safety 5. If working on a four-stage mast, on left-hand lift
Procedures When Working Near Mast and Fig- cylinder, remove the snap ring from top of the
ure 1. cylinder rod. On right-hand lift cylinder, remove
spacer and retainer from cylinder rod.
NOTE: The following procedures are for the removal
of the lift cylinders with the mast installed on the lift
truck. WARNING
Hydraulic oil is hot after system operation and
1. Remove the carriage as described in the carriage can cause burns. Do not disconnect any hy-
removal procedures located in the section Mast draulic hoses until the oil in the system is cool.
Repairs, 2, 3, and 4-Stage Masts 4000 SRM
1148. See Figure 1. 6. Put a drain pan under the area of the hydraulic
fittings. Disconnect the hydraulic line at the
NOTE: Perform Step 2 if working on a lift truck cylinder. Retract the rod into the lift cylinder.
equipped with a two- or three-stage mast. Perform
Step 3 if working on a lift truck equipped with a 7. Remove the nut, bolt, and spacer at the mount.
four-stage mast. On a two- or three-stage mast, disconnect the
main lift chain at the mount. See Figure 15.
2. Raise the mast until it is almost fully extended.
• On the two-stage mast, use safety chains to 8. Use a lifting device, as necessary, to remove lift
connect the bottom crossmember of the inner cylinder from mast. Remove the lift cylinder
mast section to the top crossmember of the from the front of the mast. On a lift cylinder be-
outer mast section. ing removed from a four-stage mast, keep shims
• On the three-stage mast, use safety chain to from top of left-hand cylinder with cylinder.
connect the bottom crossmember of the inter-
mediate mast section to the top crossmember FREE-LIFT CYLINDER, REMOVE
of the outer mast section. Use another safety
chain to connect the bottom crossmember to 1. Remove the carriage as described in the car-
a crossmember on the intermediate or outer riage removal procedures in the section Mast
mast section. Repairs, 2, 3, and 4-Stage Masts 4000 SRM
Lower the mast so the safety chains hold the 1148. Lower the mast completely.
weight of the mast sections.
WARNING
3. Raise the mast until it is almost fully extended.
Hydraulic oil is hot after system operation and
Use a safety chain to connect middle crossmem-
can cause burns. Do not disconnect any hy-
ber of first intermediate mast section to top cross-
draulic hoses until the oil in the system is cool.
member on outer mast section. Lower mast so
safety chain holds weight of the mast sections. 2. Put a drain pan under the area of the hydraulic
fittings. Disconnect the hydraulic line at the
WARNING cylinder.
Be careful when removing or installing snap
NOTE: Perform Step 3 if working on a lift truck
rings. These snap rings can come loose dur-
equipped with a two- or three-stage mast. Perform
ing removal or installation with enough force
Step 4 if working on a lift truck equipped with a
to cause an injury. Always use the correct snap
four-stage mast.
ring pliers, and wear eye and face protection
during removal or installation. 3. Remove the brackets for the free-lift cylinder. Re-
move the free-lift cylinder.

11
Lift Cylinder Repair 2100 SRM 1139

4. Remove chains from chain sheaves. Remove the

clamp and brackets for the free-lift cylinder. Re-
move the free-lift cylinder.

5. Remove the crosshead from the cylinder rod. See

Figure 7, Figure 8, Figure 9, and Figure 10. Dis-
assemble the crosshead as necessary.

1. CHAIN 7. LOCKWASHER
2. CHAIN SHEAVE 8. WASHER
3. BEARING 9. LOCK NUT
4. CHAIN GUARD 10. CROSSHEAD PIN
5. CROSSHEAD 11. PIN
6. CAPSCREW

Figure 8. Crosshead Assembly, Two-Stage and

1. LIFT CHAIN 5. CROSSHEAD Three-Stage FFL, Lift Truck Models S30FT,
2. CHAIN SHEAVE 6. BEARING S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z,
3. CHAIN GUARD 7. PIN E40ZS) (E114), J1.60-2.00XMT (J30-40ZT)
4. SNAP RING 8. FREE-LIFT (J160), and H1.6FT, H1.8FT, H2.0FTS (H30FT,
CYLINDER H35FT, H40FTS) (F001)
Figure 7. Crosshead Assembly, Two-Stage and
Three-Stage FFL, Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187) and H2.0-3.5FT
(H40-70FT) (L177)
Legend for Figure 9

NOTE: LIFT TRUCK MODELS H2.0-3.5FT (H40-70FT) (L177) DO NOT HAVE A FOUR-STAGE MAST, BUT THE
CROSSHEAD AND TWO AND THREE-STAGE FREE-LIFT CYLINDER ASSEMBLY IS SIMILAR TO WHAT IS
SHOWN IN FIGURE 9.
1. HOSE 10. PIN
2. HOSE SHEAVE 11. CROSSHEAD
3. STUB SHAFT WELDMENT 12. ALIGNMENT PIN
4. WASHER 13. FREE-LIFT CYLINDER
5. CAPSCREW 14. STRAP
6. CHAIN GUARD 15. TUBE SPACER
7. SPACER 16. BRACKET
8. CHAIN SHEAVE 17. LOWERING CONTROL VALVE FITTING
9. SNAP RING 18. BEARING

12
2100 SRM 1139 Lift Cylinder Repair

Figure 9. Crosshead and Four-Stage Free-Lift Cylinder Assembly, Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187)

13
Lift Cylinder Repair 2100 SRM 1139

Figure 10. Crosshead and Three-Stage Free-Lift Cylinder Assembly, Lift Truck Models S30FT,
S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z, E40ZS) (E114), J1.60-2.00XMT (J30-40ZT) (J160),
and H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)

14
2100 SRM 1139 Lift Cylinder Repair

Legend for Figure 10

1. HOSE ASSEMBLY 13. LOCK NUT
2. CHAIN 14. WASHER
3. HOSE SHEAVE 15. PIN
4. BUSHING 16. FREE-LIFT CYLINDER
5. STUBSHAFT WELDMENT 17. BRACKET
6. LOCKWASHER 18. COTTER PIN
7. CAPSCREW 19. CHAIN ANCHOR
8. CHAIN SHEAVE 20. HARDENED WASHER
9. CHAIN SHEAVE BEARING 21. NUT
10. CROSSHEAD PIN 22. FLOW VALVE
11. CROSSHEAD 23. O-RING
12. CHAIN GUARD

FREE-LIFT AND MAIN LIFT CYLINDERS, ring pliers and wear eye and face protection
DISASSEMBLE during removal or installation.

4. On left-hand lift cylinder, remove snap ring,

CAUTION washer, and check valve from base of piston.
Carefully disassemble the lift cylinders so the
piston rods and sliding surfaces are not dam-
aged.

NOTE: To disassemble the left-hand main lift cylin-

der on trucks equipped with a two-stage FFL mast,
see the section Two-Stage FFL Cylinder, Disassem-
ble.

NOTE: To prevent damage to sealing surfaces, use

brass tools when removing or installing seals and
O-rings.

1. Remove gland from shell.

2. Remove rod and piston assembly from shell.

Drain hydraulic oil into container. See Fig-
ure 11, Figure 12, and Figure 13.

3. Remove and discard O-rings, seals, and wear 1. SHELL 7. O-RING

rings. 2. ROD 8. SNAP RING
3. GLAND 9. WIPER RING
4. ROD SEAL 10. SEAL
WARNING 5. CHECK VALVE 11. BACKUP RING
Be careful when removing or installing snap 6. WASHER 12. WEAR RING
rings. These snap rings can come loose dur-
ing removal or installation with enough force Figure 11. Main Lift Cylinder, Two-Stage LFL
to cause an injury. Always use the correct snap

15
Lift Cylinder Repair 2100 SRM 1139

in this manual. For disassembly procedures on the

right-hand main lift cylinder, see the section Free-
Lift and Main Lift Cylinders, Disassemble and Fig-
ure 14.

1. Loosen the gland with a spanner wrench. See

Figure 14.

2. Remove gland, rod, and piston assembly from

shell. Drain hydraulic oil into a container.

3. Remove piston from rod. Remove gland from rod.

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 surfaces

1. SHELL 8. WIPER RING and replace if damaged.
2. ROD 9. SEAL
3. GLAND 10. O-RING
4. SPACER 11. BACKUP RING Inspect the rod for damage to the rod surface and
5. CHECK VALVE 12. WEAR RING ensure that the rod is not bent. Replace the rod if
6. WASHER 13. ROD SEAL found to be damaged.
7. SNAP RING 14. PISTON RING
Inspect the inner surface of the cylinder tube for
Figure 12. Main Lift Cylinders, Three-Stage damage. If the tube is found to be damaged, replace
Full Free-Lift the cylinder.

CLEAN

WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.

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 gog-
1. SHELL 7. SNAP RING
2. ROD 8. WIPER gles or a face shield to prevent injury to the
3. GLAND 9. SEAL eyes.
4. SCREW 10. BACKUP RING
5. CHECK VALVE 11. O-RING
6. WASHER 12. WEAR RING CAUTION
Do not allow cleaning solvent to come in con-
Figure 13. Free-Lift Cylinder, Two-Stage and tact with rubber components, as it will damage
Three-Stage FFL those components.

TWO-STAGE FFL CYLINDER, Clean all metal parts in solvent and dry with com-
DISASSEMBLE pressed air.

NOTE: The following procedure applies only to the

left-hand main lift cylinder of the lift trucks covered

16
2100 SRM 1139 Lift Cylinder Repair

A. RIGHT-HAND CYLINDER B. LEFT-HAND CYLINDER

1. SHELL 8. WEAR RING
2. ROD 9. ROD RING
3. GLAND 10. SCREW
4. SPACER 11. SEAL
5. WIPER RING 12. PISTON RING
6. BACKUP RING 13. PISTON
7. O-RING

Figure 14. Main Lift Cylinder, Right-Hand and Left-Hand Two-Stage FFL

17
Lift Cylinder Repair 2100 SRM 1139

FULL FREE-LIFT AND MAIN LIFT NOTE: Hydraulic oil is poured into the free-lift cylin-
CYLINDERS, ASSEMBLE ders to act as a cushion during load lifting to prevent
damage to the cylinders.
NOTE: The procedures in this section cover all masts
except for two-stage FFL masts. See the section Two- 6. On free-lift cylinders, before installing gland,
Stage FFL and Main Lift Cylinders, Assemble for the pour 150 cc (5 oz) of hydraulic oil into the cylin-
procedures. der shell.

NOTE: To prevent damage to sealing surfaces, use 7. Carefully install the gland on the piston rod.
brass tools when installing seals and O-rings.
8. Carefully engage threads and tighten gland
1. Lubricate all internal parts of the lift cylinder in shell until tight. Use the correct span-
with clean hydraulic oil or packing lubricant, ner. Do NOT hit gland with a hammer and
Hyster Part No. 186061. Use new O-rings, seals, driver. Tighten gland to 340 to 410 N•m (250 to
and wear rings. See Figure 13. 300 lbf ft).

9. Install the lowering control valve in port at base

WARNING of left-hand, main control cylinder. See Figure 12
Be careful when removing or installing snap and Figure 13.
rings. These snap rings can come loose dur-
ing removal or installation with enough force TWO-STAGE FFL AND MAIN LIFT
to cause an injury. Always use the correct snap CYLINDERS, ASSEMBLE
ring pliers and wear eye and face protection
during removal or installation. NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
2. Install check valve and O-ring in base of pis-
ton of free-lift cylinder and left-hand lift cylinder. 1. Install rod wiper and rod seal in retainer. Install
Make sure arrow on check valve is toward base O-ring on outside of retainer. Install retainer on
of piston. Install washer and snap ring for check rod.
valve. See Figure 13.
2. For the left-hand main cylinder, install gland
onto rod and install the piston. Tighten piston
CAUTION to 170 to 200 N•m (125 to 150. lbf ft).
A difficult and important step in assembling
lift cylinders is the correct installation of the 3. Install O-ring and backup ring on piston for
seals. Most lift cylinder maintenance is caused right-hand cylinder. If a spacer is used, install it
by seal leaks. Do not damage any parts during on rod. Install piston in rod. Tighten piston to
assembly. 170 to 200 N•m (125 to 150. lbf ft).

3. Install the wear ring, piston seal, and backup WARNING

ring on to the piston assembly. On the main lift
Be careful when removing or installing snap
cylinders, install seal ring. Install spacer, if used.
rings. These snap rings can come loose dur-
4. Carefully push the piston and rod assembly into ing removal or installation with enough force
the shell. to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection
5. Install the rod seal ring and wiper into the gland. during removal or installation.
Install the O-ring and backup ring on the outside
of the retainer. 4. Install check valve and O-ring in base of piston
of free-lift cylinder. Make sure arrow on check
valve is toward base of piston.
CAUTION
Additives may damage the hydraulic system. 5. For the right-hand main cylinder, install washer
Before using additives, contact your local Hys- and snap ring for check valve. See Figure 13.
ter dealer.

18
2100 SRM 1139 Lift Cylinder Repair

6. Carefully engage threads and tighten gland spacer (11, Figure 15) at the mount for the lift
in shell until tight. Use the correct span- cylinder. Tighten nut to 53 N•m (39 lbf ft).
ner. Do NOT hit gland with a hammer and
driver. Tighten gland to 475 to 540 N•m (350 to 3. Install shims at top of left-hand cylinder. Use
400 lbf ft). a lifting device to lower the inner mast weld-
ment (two-stage) or intermediate mast weldment
(three-stage) on to the lift cylinder. Install the
CAUTION washers and snap ring at the top of the left-hand
The correct screw and sealing washer must lift cylinder. Install retainer, fittings, and tube
be used in this location. The wrong parts will at the top of the right-hand lift cylinder. Tighten
cause leaks or damage the cylinder. See your nuts from retainer to 33 N•m (24 lbf ft). See Fig-
Hyster lift truck dealer for the correct parts. ure 12, Figure 13, and Figure 15 for the correct
adjustment of the lift cylinders.
CAUTION 4. Connect the hydraulic line at the base of the lift
Additives may damage the hydraulic system. cylinder. Connect the hydraulic line at the top of
Before using additives, contact your local Hys- the left-hand main lift cylinder on the two-stage
ter dealer. and four-stage full free-lift masts. Connect hy-
draulic line at tube on right-hand lift cylinder.
7. Remove screw and sealing washer. Pour 150 cc
(5 oz) of hydraulic oil into the cylinder through 5. Install balance line between main lift cylinder.
the hole. This oil provides a hydraulic cushion
when the cylinder reaches the top of its stroke. 6. Connect the main lift chains as necessary and ad-
See Figure 14. Install the screw and sealing just them as specified in the section Mast Re-
washer and tighten to 6 N•m (53 lbf in). pairs, 2, 3, and 4-Stage Masts 4000 SRM 1148.

8. Install fitting at base of free-lift cylinder. This is 7. Remove the air from the cylinders on the two-
a special fitting that limits flow of the hydraulic stage FFL as described below. See Figure 14.
oil.
a. Loosen the screws two turns to permit oil to
MAIN LIFT CYLINDERS, INSTALL flow around the threads of the screw.

1. Use a lifting device with a capacity of at least b. With the forks unloaded and the engine
1600 kg (3527 lb) to raise the mast until it is al- speed at idle, raise the carriage using the hy-
most fully extended. Use safety chains to connect draulic control. Raise the carriage 300 mm
the bottom crossmember of the inner mast weld- (12 in.) and then stop for ten seconds to
ment (two-stage) or intermediate mast weldment reduce the pressure in the cylinder. Repeat
(three-stage) to the top crossmember of the outer this procedure until the oil flowing from
mast weldment. Lower the mast so the safety around the threads is free of air bubbles.
chains hold the weight of the weldments. See
c. Stop the carriage at the top of the cylinder
Figure 12, Figure 13, and Figure 15.
stroke. Tighten the screws.
2. Install the lift cylinder in the mount at the bot-
tom of the outer mast. Install the nut, bolt, and

19
Lift Cylinder Repair 2100 SRM 1139

NOTE: BALANCE LINE IS USED ON FOUR-STAGE FFL MAST ONLY.

1. BALANCE LINE 7. HOUSING
2. SNAP RING 8. HOSE
3. SHIM 9. LOWERING CONTROL VALVE
4. FITTING AND O-RING 10. RIGHT-HAND MAIN LIFT CYLINDER
5. LEFT-HAND MAIN LIFT CYLINDER 11. SPACER
6. LOWERING CONTROL VALVE FITTING 12. RETAINER

Figure 15. Main Lift Cylinders Installation

FREE-LIFT CYLINDER, INSTALL 2. Install the cylinder in the mounts. Install the
brackets, nuts, and tighten the bolts to 53 N•m
1. Make sure alignment pin is in position, then in- (39 lbf ft). On the three-stage FFL cylinder,
stall the crosshead mount and crosshead assem- the nuts are installed on the bracket side of the
bly on the cylinder rod. Tighten the capscrews for free-lift cylinder. Tighten the nuts to 38 N•m
the chain guards to 66 N•m (49 lbf ft). Tighten (28 lbf ft).
the crosshead mount to 435 N•m (320 lbf ft).
Install chain sheaves in mount. Install shaft 3. Connect the hydraulic line at the cylinder.
through sheaves. Install chain guard on mount,
making sure the shaft is in correct position. See 4. Install the carriage and load backrest as de-
Figure 7 and Figure 13. scribed in the procedures for the section Mast
Repairs, 2, 3, and 4-Stage Masts 4000 SRM
1148.

20
2100 SRM 1139 Lift Cylinder Repair

TORQUE SPECIFICATIONS Do NOT try to find hydraulic leaks by putting

your hand on hydraulic components under
Gland, Main Lift Cylinders pressure. Hydraulic oil can be injected into
340 to 410 N•m (250 to 300 lbf ft) the body by the pressure.
Gland, Full Free-Lift Cylinders 1. Operate hydraulic system. Put capacity load on
475 to 540 N•m (350 to 400 lbf ft) forks. Use safety chain to hold load to carriage.
Raise and lower load several times. Lower load
Piston, Main Lift Cylinders (Two-Stage
and tilt mast forward and backward several
FFL Mast Only)
times. Check for leaks.
170 to 200 N•m (125 to 150 lbf ft)
2. Raise carriage and load 1 m (3 ft). If carriage
Main Lift Cylinder Mounting Nut
slowly lowers when control valve is in NEU-
To Outer Mast
TRAL position, there are leaks in hydraulic
53 N•m (39 lbf ft)
system. The maximum speed the carriage is
Retainer Nuts allowed to lower is 50 mm (2 in.) per 10 minutes
33 N•m (24 lbf ft) when hydraulic oil is 30 C (86 F). If oil tem-
perature is 70 C (158 F), the maximum speed
Chain Guard Capscrew (Free-Lift Cylinder) the carriage can lower is 150 mm (6 in.) per 10
66 N•m (49 lbf ft) minutes.

Crosshead Mount Capscrew 3. Check lift cylinders for internal leaks. Remove
435 N•m (320 lbf ft) load from forks. Install valve in supply line be-
tween main control valve and mast. Put capacity
Free-Lift Cylinder Mounting Bolts (All load on forks again. Raise carriage 1 m (3 ft).
Mast Except Three-Stage FFL) Close valve. If carriage or mast lower slowly,
53 N•m (39 lbf ft) seals in lift cylinders have leaks.
Free-Lift Cylinder Mounting Bolts 4. If carriage does not move, open valve and check
(Three-Stage FFL) movement again. If carriage lowers when valve
38 N•m (28 lbf ft) is open, check for leaks in hydraulic lines and
fittings. If no leaks are found, main control
LIFT CYLINDERS LEAK CHECK valve can be worn or damaged. Remove load
from forks.
WARNING
During the test procedures for the hydraulic
system, use chains to fasten the load to the car-
riage to prevent it from falling. Keep all people
away from the lift truck during the tests.

21
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 TECHNICAL PUBLICATIONS

2100 SRM 1139 9/05 (5/05)(12/04) Printed in U.S.A.