CYLINDER REPAIR
S30FT, S35FT, S40FTS [E010];
H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
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 ........................................................................................................................................................ 6
Install ............................................................................................................................................................. 6
Tilt Cylinders, Adjust .................................................................................................................................... 7
Tilt Cylinder Leak Check for Two-Stage LFL, Two-Stage FFL, and Three-Stage FFL............................. 8
Tilt Cylinder Leak Check for the Four-Stage Full Free-Lift....................................................................... 8
Torque Specifications..................................................................................................................................... 9
Piston Rod.................................................................................................................................................. 9
Gland.......................................................................................................................................................... 9
Tilt Cylinder Mounting Capscrew ............................................................................................................ 9
Tilt Cylinder Rod End Capscrew .............................................................................................................. 9
Lift Cylinder Repair........................................................................................................................................... 9
Main Lift Cylinders, Remove ........................................................................................................................ 9
Free-Lift Cylinder, Remove........................................................................................................................... 10
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];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
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 (E010) and
Two single-stage main lift cylinders and a free-lift
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
cylinder are used to raise the carriage and extend the
(F001) there is one free-lift chain and chain sheave.
mast weldments.
The description below applies to all trucks.
The two main lift cylinders are installed at the back
The free-lift chains connect at one end of the mid-
of the outer mast. The base of each lift cylinder sits
crossmember of the inner mast. Two chain sheaves
on a mount at the bottom crossmember of the outer
are installed on a crosshead on the rod of the free-
mast. The top of each main lift cylinder rod fits into a
lift cylinder. The chains then go over sheaves on the
guide on the top crossmember of the inner mast. The
crosshead and connect to the carriage.
free-lift cylinder is installed in the inner mast. Each
of the lift cylinders has an internal lowering control
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 inthis 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.
OR
Also make sure that the power is OFF and the
key is removed. Put a DO NOT OPERATE tag
" If parts of the mast must be in a raised po-
in the operator s compartment. Disconnect
sition, install a safety chain to restrain the
the battery and put a tag or lock on the bat-
moving parts of the mast. Connect moving
tery connector.
parts to a part that does not move. Follow
" Be careful of the forks. When the mast is
these procedures:
raised, the forks can be at a height to cause
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-
5. Install another safety chain (3/8-in. minimum)
termediate weldment. On the four-stage mast, it
between the top or bottom crossmember of the
is the first intermediate weldment. See Figure 1.
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-
NOTE: Apply the parking brake. After lowering or
able member cannot lower. Put hook on back side
restraining the mast, shut off the power, and remove
of mast. Make sure hook is completely engaged
key. Put a DO NOT OPERATE tag in the operator s
with a link in the chain. Make sure safety chain
compartment. Disconnect battery and put a tag or
does not touch lift chains or chain sheaves, tubes,
lock on battery connector.
hoses, fittings, or other parts on the mast.
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
the anchor pin out of the frame.
WARNING
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. ANCHORPIN
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.
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
INSPECT 2. Place the rod in a soft-jaw vise, and install the
piston on the rod and tighten the nut to
Inspect the gland for damage to the threads and the
" 170 to 220 N" m (125 to 163 lbf ft) on lift truck
seal surfaces. Replace the gland if damaged.
models S2.0-2.5FT (S40-S55FT, S55FTS)
(F187), S30FT, S35FT, S40FTS (E010),
Inspect the piston for any damage to the seal surfaces
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
and replace if damaged.
H40FTS) (F001), and H2.0-2.5FT (H40-50FT)
(L177)
Inspect the rod for damage to the rod surface and
" 320 to 400 N" m (240 to 295 lbf ft) on lift truck
ensure that the rod is not bent. Replace the rod if
models S3.0-3.5FT (S60-S70FT) (F187) and
found to be damaged.
H3.0-3.5FT (H60-70FT) (L177)
Inspect the inner surface of the cylinder tube for
3. Install a new wiper, seal, backup ring, and O-ring
damage. If the tube is found to be damaged, replace
on the gland.
the cylinder.
4. Install the rod and piston assembly in the cylin-
CLEAN
der. Using a pin-type spanner, install the gland
in the cylinder. Tighten the gland to
WARNING
" 170 to 237 N" m (125 to 175 lbf ft) for lift
Cleaning solvents can be flammable and toxic
truck models S2.0-2.5FT (S40-S55FT, S55FTS)
and can cause skin irritation. When using
(F187) and H2.0-2.5FT (H40-50FT) (L177)
cleaning solvents, always follow the solvent
" 163 to 190 N" m (120 to 140 lbf ft) for lift truck
manufacturer s recommended safety proce-
models S30FT, S35FT, S40FTS (E010) and
dures.
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001).
Compressed air can move particles so they
" 400 to 500 N" m (295 to 370 lbf ft) for lift
cause injury to the user or to other personnel.
truck models S3.0-3.5FT (S60-S70FT) (F187)
Make sure the path of the compressed air is
and H3.0-3.5FT (H60-70FT) (L177)
away from all personnel. Wear protective gog-
gles or a face shield to prevent injury to the
5. Place the cylinder in a soft-jaw vise and install
eyes.
the tilt spacer, if equipped, and rod end on the rod
as noted during removal. Tighten the capscrew
on the rod end to 90 N" m (66 lbf ft).
CAUTION
Do not allow cleaning solvent to come in con-
6. Repeat the above steps for the other tilt cylinder.
tact with rubber components, as it will damage
those components.
INSTALL
Clean all metal parts in solvent and dry with com-
1. Using a lifting device, place the cylinder on the
pressed air.
mounting point on the lift truck frame. Install
the anchor pin. Install the retainer and cap-
ASSEMBLE
screw. See Figure 2. Tighten the capscrew to
38 N" m (28 lbf ft).
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
2. Connect the hydraulic lines to the tilt cylinder.
Slowly stroke the cylinders until the rod holes
1. Install a new piston seal and O-ring on the pis-
line up with the mast tilt anchor holes.
ton. See Figure 3.
3. Install the anchor pin. Install the retainer and
NOTE: Perform Step 2 only if the piston was removed
capscrew. Tighten the capscrew to 38 N" m
from the rod.
(28 lbf ft).
4. Remove chain holding the mast to the frame.
6
2100 SRM 1139 Tilt Cylinder Repair
1. Adjust the stroke of the tilt cylinders WITHOUT
WARNING
tilt limit spacers as follows:
Do NOT put hands between the cylinder rod
a. Adjust the rod ends to 15 mm (0.6 in.) for all
end and the mast. Serious injury can occur.
tilt cylinders shown in Figure 4.
5. Operate the tilt cylinders. Check for correct op-
b. Slowly tilt the mast backward until one
eration and leakage. Adjust the tilt cylinders.
cylinder rod stops. On the opposite cylin-
TILT CYLINDERS, ADJUST der, loosen the capscrews on the rod end.
Measure the distance from the end of the
cylinder to the back end of the rod end. Use
WARNING
a wrench and turn the cylinder rod IN until
When the tilt cylinders have tilt limit spacers,
the dimension starts to decrease, then stop.
make sure they are installed during installa-
Repeat this procedure until both cylinder
tion procedures. Without the tilt limit spacers,
rods stop at the same position within 1 mm
the mast can tilt too much and cause an acci-
(0.04 in.). After the adjustments are com-
dent or serious injury.
plete, tighten the capscrews on the rod ends.
Check the tilt cylinder stroke by slowly tilting the
c. Tilt the mast fully backward and measure
mast fully forward and backward several times. Both
the tilt angle. See the nameplate for tilt
tilt cylinders must stop their stroke at the same time.
angles. If necessary, adjust both rod ends
Adjust the rod ends as shown in Figure 4. There
equally for the correct angle.
must be no twist in the mast weldments.
2. Adjust the stroke of the tilt cylinders WITH tilt
limit spacers as follows:
a. Adjust the rod ends to 15 mm (0.6 in.) for all
tilt cylinders as shown in Figure 4.
b. Slowly tilt the mast forward until one cylin-
der rod stops. On the opposite cylinder,
loosen the capscrews on the rod end. Use
a wrench and turn the cylinder rod IN as
necessary. Repeat this procedure until both
cylinder rods stop at the same position
within 1 mm (0.04 in.).
c. Slowly tilt the mast backward until one rod
end just contacts the spacer. Add shims to
fill the gap at the opposite rod end until both
rod ends contact the spacers within 0.5 mm
(0.02 in.).
d. After the adjustments are complete, tighten
the capscrews on the rod ends.
e. Tilt the mast fully backward and measure
the tilt angle. See the nameplate for tilt an-
A. DIMENSION A = 15 mm (0.60 in.)
gles. If necessary, add an equal number of
1. MAST 4. TILT LIMIT SPACER
shims to both rods for the correct angle.
2. ROD END 5. TILT CYLINDER
3. SHIMS
Figure 4. Tilt Cylinder Adjustments
7
Tilt Cylinder Repair 2100 SRM 1139
TILT CYLINDER LEAK CHECK FOR lower SLOWLY, the seals in the lift cylinders
have leaks.
TWO-STAGE LFL, TWO-STAGE FFL, AND
THREE-STAGE FFL
4. If the carriage does not move, open the gate valve
and check the movement again. If the carriage
WARNING
lowers when the gate valve is open, check for
leaks in the hydraulic lines and fittings. If no
During the test procedures for the hydraulic
leaks are found, the main control valve can be
system, use chains to fasten the load to the car-
worn or damaged. Remove the load from the
riage to prevent it from falling. Keep all people
forks.
away from the lift truck during the tests.
Do NOT try to find hydraulic leaks by putting
TILT CYLINDER LEAK CHECK FOR THE
your hand on hydraulic components under
FOUR-STAGE FULL FREE-LIFT
pressure. Hydraulic oil can be injected into
the body by the pressure.
WARNING
1. Operate the hydraulic system. Put a capacity Never allow anyone under a raised carriage.
load on the forks, and raise and lower the load Do not put any part of your body in or through
several times. Lower the load and tilt the mast the lift mechanism unless all parts of the mast
forward and backward several times. Check for are completely lowered and the engine is
leaks. STOPPED.
2. Raise the carriage andload1 m(3 ft). If the car- Do not try to find hydraulic leaks by putting
riage slowly lowers when the control valve is in your hand on hydraulic components under
the neutral position, there are leaks in the hy- pressure. Hydraulic oil can be injected into
draulic system. The maximum speed that the the body by the pressure.
carriage is allowed to lower is 50 mm (2 in.) per
1. Put a capacity load on the forks. Use a safety
10 minutes when the hydraulic oil is 30 C(86 F).
chainto hold the load to the carriage. Raise the
If the oil temperature is 70 C (158 F), the max-
load approximately 2.5 m (8 ft). Put the mast in
imum speed the carriage can lower is 150 mm
a vertical position.
(6 in.) per 10 minutes.
2. Measure the distance that the rod for tilt cylin-
3. Check the lift cylinders for internal leaks. Re-
der extends from the shell. Check the distance
move the load from the forks. Install a gate valve
the rod moves in five or ten minutes. Multiply
in the supply line between the main control valve
the rate in Table 1 by the time of the test and
and the mast. Put a capacity load on the forks
compare the numbers.
again. Raise the carriage 1 m (3 ft). Close the
gate valve. If the carriage or mast weldments
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
8
2100 SRM 1139 Lift Cylinder Repair
3. If the tilt rate is greater than the specifications, S3.0-3.5FT (S60-S70FT) (F187) and H3.0-3.5FT
lower the mast and remove the load from the (H60-70FT) (L177)
forks. Install a valve between the port at the 320 to 400 N" m (240 to 295 lbf ft)
front of the tilt cylinder and the hydraulic line.
Gland
The valve must be able to completely shut off the
flow of hydraulic oil. Put the load on the forks
S2.0-2.5FT (S40-S50FT, S55FTS) (F187) and
again. Close the valve. Tilt the mast forward just
H2.0-2.5FT (H40-50FT) (L177)
past the vertical position. If the mast continues
170 to 237 N" m (125 to 175 lbf ft)
to tilt SLOWLY forward, the seals on the piston
are leaking.
S3.0-3.5FT (S60-S70FT) (F187) and H3.0-3.5FT
(H60-70FT) (L177)
4. If the mast does not move, open the valve and
400 to 500 N" m (295 to 370 lbf ft)
check the movement again. If the mast moves
forward when the gate valve is open, check for
S30FT, S35FT, S40FTS (E010) and
leaks in the hydraulic lines and fittings. If no
H1.6FT, H1.8FT, H2.0FTS (H30FT,
leaks are found, the main control valve can be
H35FT, H40FTS) (F001)
worn or damaged. Remove the load from the
163 to 190 N" m (120 to 140 lbf ft)
forks when the checks are complete.
Tilt Cylinder Mounting Capscrew
TORQUE SPECIFICATIONS
38 N" m (28 lbf ft)
Piston Rod
Tilt Cylinder Rod End Capscrew
S2.0-2.5FT (S40-S50FT, S55FTS) (F187), S30FT,
S35FT, S40FTS (E010), H1.6FT, H1.8FT,
90 N" m (66 lbf ft)
H2.0FTS (H30FT, H35FT, H40FTS) (F001),
and H2.0-2.5FT (H40-50FT) (L177)
170 to 220 N" m (125 to 163 lbf ft)
Lift Cylinder Repair
MAIN LIFT CYLINDERS, REMOVE 2. Raise the mast until it is almost fully extended.
" On the two-stage mast, use safety chains to
connect the bottom crossmember of the inner
WARNING
mast section to the top crossmember of the
Before working on or near the mast, see Safety
outer mast section.
Procedures When Working Near Mast and Fig-
" On the three-stage mast, use safety chain to
ure 1.
connect the bottom crossmember of the inter-
mediate mast section to the top crossmember
NOTE: The following procedures are for the removal
of the outer mast section. Use another safety
of the lift cylinders with the mast installed on the lift
chain to connect the bottom crossmember to
truck.
a crossmember on the intermediate or outer
mast section.
1. Remove the carriage as described in the carriage
Lower the mast so the safety chains hold the
removal procedures located in the section Mast
weight of the mast sections.
Repairs, 2, 3, and 4-Stage Masts 4000 SRM
1148. See Figure 1.
3. Raise the mast until it is almost fully extended.
Use a safety chain to connect middle crossmem-
NOTE: Perform Step 2 if working on a lift truck
ber of first intermediate mast section to top cross-
equipped with a two- or three-stage mast. Perform
member on outer mast section. Lower mast so
Step 3 if working on a lift truck equipped with a
safety chain holds weight of the mast sections.
four-stage mast.
9
Lift Cylinder Repair 2100 SRM 1139
FREE-LIFT CYLINDER, REMOVE
WARNING
1. Remove the carriage as described in the car-
Be careful when removing or installing snap
riage removal procedures in the section Mast
rings. These snap rings can come loose dur-
Repairs, 2, 3, and 4-Stage Masts 4000 SRM
ing removal or installation with enough force
1148. Lower the mast completely.
to cause an injury. Always use the correct snap
ring pliers, and wear eye and face protection
during removal or installation.
WARNING
Hydraulic oil is hot after system operation and
4. If working on a two- or three-stage mast, remove
can cause burns. Do not disconnect any hy-
the snap ring or fitting at the top of the cylinder
draulic hoses until the oil in the system is cool.
to be removed.
2. Put a drain pan under the area of the hydraulic
5. If working on a four-stage mast, on left-hand lift
fittings. Disconnect the hydraulic line at the
cylinder, remove the snap ring from top of the
cylinder.
cylinder rod. On right-hand lift cylinder, remove
spacer and retainer fromcylinder rod.
NOTE: Perform Step 3 if working on a lift truck
equipped with a two- or three-stage mast. Perform
WARNING
Step 4 if working on a lift truck equipped with a
four-stage mast.
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
3. Remove the brackets for the free-lift cylinder. Re-
draulic hoses until the oil in the system is cool.
move the free-lift cylinder.
6. Put a drain pan under the area of the hydraulic
4. Remove chains from chain sheaves. Remove the
fittings. Disconnect the hydraulic line at the
clamp and brackets for the free-lift cylinder. Re-
cylinder. Retract the rod into the lift cylinder.
move the free-lift cylinder.
7. Remove the nut, bolt, and spacer at the mount.
5. Remove the crosshead from the cylinder rod. See
On a two- or three-stage mast, disconnect the
Figure 5, Figure 6, Figure 7, and Figure 8. Dis-
main lift chain at the mount. See Figure 13
assemble the crosshead as necessary.
8. Use a lifting device, as necessary, to remove lift
cylinder from mast. Remove the lift cylinder
from the front of the mast. On a lift cylinder be-
ing removed from a four-stage mast, keep shims
from top of left-hand cylinder with cylinder.
10
2100 SRM 1139 Lift Cylinder Repair
1. LIFT CHAIN 5. CROSSHEAD
1. CHAIN 7. LOCKWASHER
2. CHAIN SHEAVE 6. BEARING
2. CHAIN SHEAVE 8. WASHER
3. CHAIN GUARD 7. PIN
3. BEARING 9. LOCK NUT
4. SNAP RING 8. FREE-LIFT
4. CHAIN GUARD 10. CROSSHEAD PIN
CYLINDER
5. CROSSHEAD 11. PIN
6. CAPSCREW
Figure 5. Crosshead Assembly, Two-Stage and
Three-Stage FFL, Lift Truck Models S2.0-3.5FT
Figure 6. Crosshead Assembly, Two-Stage and
(S40-70FT, S55FTS) (F187) and H2.0-3.5FT
Three-Stage FFL, Lift Truck Models S30FT,
(H40-70FT) (L177)
S35FT, S40FTS (E010) and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001)
11
Lift Cylinder Repair 2100 SRM 1139
Figure 7. Crosshead and Four-Stage Free-Lift Cylinder Assembly, Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187)
12
2100 SRM 1139 Lift Cylinder Repair
Legend for Figure 7
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
SHOWNINFIGURE 7.
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
13
Lift Cylinder Repair 2100 SRM 1139
Figure 8. Crosshead and Three-Stage Free-Lift Cylinder Assembly, Lift Truck Models S30FT, S35FT,
S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) (F001)
14
2100 SRM 1139 Lift Cylinder Repair
Legend for Figure 8
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
during removal or installation.
DISASSEMBLE
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 Figure 9,
Figure 10, and Figure 11.
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
6. WASHER 12. WEAR RING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
Figure 9. Main Lift Cylinder, Two-Stage LFL
ing removal or installation with enough force
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 12.
1. Loosen the gland with a spanner wrench. See
Figure 12
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
Inspect the rod for damage to the rod surface and
4. SPACER 11. BACKUP RING
ensure that the rod is not bent. Replace the rod if
5. CHECK VALVE 12. WEAR RING
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 10. 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
gles or a face shield to prevent injury to the
2. ROD 8. WIPER
eyes.
3. GLAND 9. SEAL
4. SCREW 10. BACKUP RING
5. CHECK VALVE 11. O-RING
CAUTION
6. WASHER 12. WEAR RING
Do not allow cleaning solvent to come in con-
Figure 11. 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-
pressed air.
DISASSEMBLE
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 12. 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-
ders to act as a cushion during load lifting to prevent
CYLINDERS, ASSEMBLE
damage to the cylinders.
NOTE: The procedures in this section cover all masts
6. On free-lift cylinders, before installing gland,
except for two-stage FFL masts. See the section Two-
pour 150 cc (5 oz) of hydraulic oil into the cylin-
Stage FFL and Main Lift Cylinders, Assemble for the
der shell.
procedures.
7. Carefully install the gland on the piston rod.
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
8. Carefully engage threads and tighten gland
in shell until tight. Use the correct span-
1. Lubricate all internal parts of the lift cylinder
ner. Do NOT hit gland with a hammer and
with clean hydraulic oil or packing lubricant,
driver. Tighten gland to 340 to 410 N" m (250 to
Hyster Part No. 186061. Use new O-rings, seals,
300 lbf ft).
and wear rings. See Figure 11.
9. Install the lowering control valve in port at base
WARNING
of left-hand, main control cylinder. See Figure 10
Be careful when removing or installing snap and Figure 11.
rings. These snap rings can come loose dur-
TWO-STAGE FFL AND MAIN LIFT
ing removal or installation with enough force
to cause an injury. Always use the correct snap
CYLINDERS, ASSEMBLE
ring pliers and wear eye and face protection
NOTE: To prevent damage to sealing surfaces, use
during removal or installation.
brass tools when installing seals and O-rings.
2. Install check valve and O-ring in base of pis-
1. Install rodwiper androdseal inretainer. Install
ton of free-lift cylinder and left-hand lift cylinder.
O-ring on outside of retainer. Install retainer on
Make sure arrow on check valve is toward base
rod.
of piston. Install washer and snap ring for check
valve. See Figure 11.
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
3. Install O-ring and backup ring on piston for
lift cylinders is the correct installation of the
right-hand cylinder. If a spacer is used, install it
seals. Most lift cylinder maintenance is caused
on rod. Install piston in rod. Tighten piston to
by seal leaks. Do not damage any parts during
170 to 200 N" m (125 to 150. lbf ft).
assembly.
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-
ing removal or installation with enough force
4. Carefully push the piston and rod assembly into
to cause an injury. Always use the correct snap
the shell.
ring pliers and wear eye and face protection
during removal or installation.
5. Install the rod seal ring and wiper into the gland.
Install the O-ring and backup ring on the outside
4. Install check valve and O-ring in base of piston
of the retainer.
of free-lift cylinder. Make sure arrow on check
valve is toward base of piston.
CAUTION
5. For the right-hand main cylinder, install washer
Additives may damage the hydraulic system.
andsnapring for checkvalve. See Figure 11.
Before using additives, contact your local Hys-
ter dealer.
18
2100 SRM 1139 Lift Cylinder Repair
6. Carefully engage threads and tighten gland spacer (11, Figure 13) 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
3. Install shims at top of left-hand cylinder. Use
driver. Tighten gland to 475 to 540 N" m (350 to
a lifting device to lower the inner mast weld-
400 lbf ft).
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 10, Figure 11, and Figure 13 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 12. Install the screw and sealing just them as specified in the section Mast Re-
washer and tightento 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 fromthe cylinders on the two-
a special fitting that limits flow of the hydraulic stage FFL as described below. See Figure 12.
oil.
a. Loosen the screws two turns to permit oil to
flow around the threads of the screw.
MAIN LIFT CYLINDERS, INSTALL
b. With the forks unloaded and the engine
1. Use a lifting device with a capacity of at least
speed at idle, raise the carriage using the hy-
1600 kg (3527 lb) to raise the mast until it is al-
draulic control. Raise the carriage 300 mm
most fully extended. Use safety chains to connect
(12 in.) and then stop for ten seconds to
the bottom crossmember of the inner mast weld-
reduce the pressure in the cylinder. Repeat
ment (two-stage) or intermediate mast weldment
this procedure until the oil flowing from
(three-stage) to the top crossmember of the outer
around the threads is free of air bubbles.
mast weldment. Lower the mast so the safety
chains hold the weight of the weldments. See
c. Stop the carriage at the top of the cylinder
Figure 10, Figure 11, and Figure 13.
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 13. Main Lift Cylinders Installation
FREE-LIFT CYLINDER, INSTALL making sure the shaft is in correct position. See
Figure 5 and Figure 11.
1. Make sure alignment pin is in position, then in-
stall the crosshead mount and crosshead assem- 2. Install the cylinder in the mounts. Install the
bly on the cylinder rod. Tighten the capscrews for brackets, nuts, and tighten the bolts to 53 N" m
the chain guards to 66 N" m(49 lbf ft). Tighten (39 lbf ft). On the three-stage FFL cylinder,
the crosshead mount to 435 N" m (320 lbf ft). the nuts are installed on the bracket side of the
Install chain sheaves in mount. Install shaft free-lift cylinder. Tighten the nuts to 38 N" m
through sheaves. Install chain guard on mount, (28 lbf ft).
20
2100 SRM 1139 Lift Cylinder Repair
3. Connect the hydraulic line at the cylinder. LIFT CYLINDERS LEAK CHECK
4. Install the carriage and load backrest as de-
WARNING
scribed in the procedures for the section Mast
During the test procedures for the hydraulic
Repairs, 2, 3, and 4-Stage Masts 4000 SRM
system, use chains to fasten the load to the car-
1148.
riage to prevent it from falling. Keep all people
away from the lift truck during the tests.
TORQUE SPECIFICATIONS
Do NOT try to find hydraulic leaks by putting
Gland, Main Lift Cylinders
your hand on hydraulic components under
340 to 410 N" m (250 to 300 lbf ft)
pressure. Hydraulic oil can be injected into
Gland, Full Free-Lift Cylinders the body by the pressure.
475 to 540 N" m (350 to 400 lbf ft)
1. Operate hydraulic system. Put capacity load on
Piston, Main Lift Cylinders (Two-Stage forks. Use safety chain to hold load to carriage.
FFL Mast Only) Raise and lower load several times. Lower load
170 to 200 N" m (125 to 150 lbf ft) and tilt mast forward and backward several
times. Check for leaks.
Main Lift Cylinder Mounting Nut
To Outer Mast 2. Raise carriage and load 1 m (3 ft). If carriage
53 N" m (39 lbf ft) slowly lowers when control valve is in NEU-
TRAL position, there are leaks in hydraulic
Retainer Nuts
system. The maximum speed the carriage is
33 N" m (24 lbf ft)
allowed to lower is 50 mm (2 in.) per 10 minutes
when hydraulic oil is 30 C (86 F). If oil tem-
Chain Guard Capscrew (Free-Lift Cylinder)
perature is 70 C (158 F), the maximum speed
66 N" m (49 lbf ft)
the carriage can lower is 150 mm(6 in.) per 10
minutes.
Crosshead Mount Capscrew
435 N" m (320 lbf ft)
3. Check lift cylinders for internal leaks. Remove
load from forks. Install valve in supply line be-
Free-Lift Cylinder Mounting Bolts (All
tween main control valve and mast. Put capacity
Mast Except Three-Stage FFL)
load on forks again. Raise carriage 1 m (3 ft).
53 N" m (39 lbf ft)
Close valve. If carriage or mast lower slowly,
Free-Lift Cylinder Mounting Bolts seals in lift cylinders have leaks.
(Three-Stage FFL)
4. If carriage does not move, open valve and check
38 N" m (28 lbf ft)
movement again. If carriage lowers when valve
is open, check for leaks in hydraulic lines and
fittings. If no leaks are found, main control
valve can be worn or damaged. Remove load
from forks.
21
NOTES
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
22
TECHNICAL PUBLICATIONS
2100 SRM 1139 5/05 (12/04) Printed in U.S.A.