CYLINDER REPAIR

S30FT, S35FT, S40FTS [E010]; E1.50-2.00XM (E25-35Z,

E40ZS) [E114/F114]; 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]; S4.0, 4.5, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) [G004];
J2.00-3.20XM (J40-65Z) [B416]; E2.00-3.20XM (E45-65Z) [G108];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) [N005]; E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098]

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.................................................................................................. 2
Tilt Cylinder Repair ........................................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Disassemble ................................................................................................................................................... 5
Inspect ............................................................................................................................................................ 5
Clean .............................................................................................................................................................. 5
Assemble ........................................................................................................................................................ 5
Install ............................................................................................................................................................. 8
Tilt Cylinders, Adjust .................................................................................................................................... 8
Tilt Cylinder Leak Check .............................................................................................................................. 10
Torque Specifications..................................................................................................................................... 11
Piston Rod Nut .......................................................................................................................................... 11
Gland.......................................................................................................................................................... 11
Tilt Cylinder Mounting Capscrew ............................................................................................................ 12
Tilt Cylinder Rod End Capscrew .............................................................................................................. 12
Lift Cylinder Repair........................................................................................................................................... 12
Main Lift Cylinders ....................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Disassemble ............................................................................................................................................... 13
Clean .......................................................................................................................................................... 14
Inspect........................................................................................................................................................ 14
Assemble .................................................................................................................................................... 14
Install ......................................................................................................................................................... 15
Two-Stage FFL Left Side Main Lift Cylinder .............................................................................................. 16
Disassemble ............................................................................................................................................... 16
Clean .......................................................................................................................................................... 18
Inspect........................................................................................................................................................ 18
Assemble .................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Free-Lift Cylinder.......................................................................................................................................... 18
Remove....................................................................................................................................................... 18
Disassemble ............................................................................................................................................... 21
Clean .......................................................................................................................................................... 22
Inspect........................................................................................................................................................ 22
Assemble .................................................................................................................................................... 22
Install ......................................................................................................................................................... 23
Torque Specifications..................................................................................................................................... 23
Lift Cylinders Leak Check ............................................................................................................................ 24

©2007 HYSTER COMPANY i

Table of Contents Cylinder Repair

TABLE OF CONTENTS (Continued)

This section is for the following models:

S30FT, S35FT, S40FTS [E010];

E1.50-2.00XM (E25-35Z, E40ZS) [E114/F114];
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];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004];
J2.00-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) [N005];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098]

ii
2100 SRM 1139
General
This section has a description and the repair proce-
dures for several different types of cylinders. The
Description
This manual covers many different types of cylin-
ders. Each cylinder will be described in detail.
Tilt cylinders are fastened between the frame of the
lift truck and the outer weldment of the mast to
change the angle of the mast and forks.
Two single-stage main lift cylinders and a free-lift
cylinder are used to raise the carriage and extend the
mast weldments.
The two main lift cylinders are installed at the back
of the outer mast. The base of each lift cylinder sits
on a mount at the bottom crossmember of the outer
mast. The top of each main lift cylinder rod fits into a
guide on the top crossmember of the inner mast. The
free-lift cylinder is installed in the inner mast. Each
of the lift cylinders has an internal lowering control
valve. A single external lowering control valve is con-
nected by tubing and hoses to all the lift cylinders.
NOTE: On lift truck models S2.0-3.5FT (S40-70FT,
S55FTS) (F187), H2.0-3.5FT (H40-70FT) (L177),
Description
number and the design of the parts can be different,
but the operation of the cylinders is the same.
E2.00-3.20XM (E45-65Z) (G108), J2.00-3.20XM
(J40-65Z) (B416), S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098)
there are two free-lift chains and chain sheaves.
On lift truck models S30FT, S35FT, S40FTS (E010),
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114), J1.60-
2.00XMT (J30-40ZT) (J160), and H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001) there is
one free-lift chain and chain sheave. The description
below applies to all trucks.
The free-lift chains connect at one end of the mid-
crossmember of the inner mast. Two chain sheaves
are installed on a crosshead on the rod of the free-
lift cylinder. The chains then go over sheaves on the
crosshead and connect to the carriage.
1
Safety Procedures When Working Near Mast
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast.
WARNING
Mast parts are heavy and can move. Distances
between parts are small. Serious injury or
death can result if part of the body is hit by
parts of the mast or the carriage.
• Never put any part of the body into or under
the mast or carriage unless all parts are com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a DO NOT OPERATE tag
in the operator’s compartment. Disconnect
the battery and put a tag or lock on the bat-
tery connector.
• Be careful of the forks. When the mast is
raised, the forks can be at a height to cause
an injury.
• DO NOT climb on the mast or lift truck at any
time. Use a ladder or personnel lift to work
on the mast.
• DO NOT use blocks to support the mast weld-
ments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in this section.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely.
Push the lift/lower control lever forward and
make sure there is no movement in the mast.
Make sure that all parts of the mast that
move are fully lowered.
OR
• If parts of the mast must be in a raised po-
sition, install a safety chain to restrain the
2
2100 SRM 1139
moving parts of the mast. Connect moving
parts to a part that does not move. Follow
these procedures:
1. Put mast in vertical position.
2. Raise mast to align bottom crossmember of weld-
ment that moves in outer weldment with cross-
member on outer weldment. On the two-stage
and free-lift mast, the moving part is the inner
weldment. On the three-stage mast, it is the in-
termediate weldment. On the four-stage mast, it
is the first intermediate weldment. See Figure 1.
3. Use a 3/8-inch minimum safety chain with a hook
to fasten the crossmembers together so the mov-
able member cannot lower. Put hook on back side
of mast. Make sure hook is completely engaged
with a link in the chain. Make sure safety chain
does not touch lift chains or chain sheaves, tubes,
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,
three-stage, and four-stage) is completely re-
tracted. If running, turn the power OFF. Apply
the parking brake. Install a DO NOT REMOVE
tag on the safety chain(s).
5. Install another safety chain (3/8-in. minimum)
between the top or bottom crossmember of the
carriage bar and a crossmember on the outer
weldment.
6. After lowering or restraining the mast, shut off
the power, and remove key.
NOTE: Place a DO NOT OPERATE tag in the oper-
ator’s compartment.
7. Disconnect battery and put a tag or lock on bat-
tery connector.
2100 SRM 1139 Safety Procedures When Working Near Mast

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

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 back tilt position.

3. Disconnect the hydraulic lines at the tilt cylin-

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

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
DISASSEMBLE
NOTE: The following steps have detailed disassembly
instructions. Perform only those steps required to
repair the tilt cylinder.
NOTE: Note the position of the rod end and number
of turns used to remove the rod end.
1. Place the tilt cylinder in a soft jaw vise. Remove
the rod end and, if equipped, tilt spacer from the
rod. See Figure 3 or Figure 4.
2. Using a pin-type spanner wrench, Remove the
gland from the tilt cylinder. Remove the rod and
piston assembly from the cylinder.
NOTE: To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings.
3. Remove and discard the O-ring, backup ring,
seal, and wiper from the gland.
NOTE: Perform Step 4 only if the piston or rod has
been damaged.
4. Place the rod in a soft-jaw vise and remove the
piston from the rod.
5. Remove and discard the O-ring and piston seal
from the piston.
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
and replace if damaged.
Inspect the rod for damage to the rod surface and
ensure that the rod is not bent. Replace the rod if
found to be damaged.
Inspect the inner surface of the cylinder tube for
damage. If the tube is found to be damaged, replace
the cylinder.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
Tilt Cylinder Repair
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-
gles or a face shield to prevent injury to the
eyes.
CAUTION
Do not allow cleaning solvent to come in con-
tact with rubber components, as it will damage
those components.
Clean all metal parts in solvent and dry with com-
pressed air.
ASSEMBLE
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
1. Install a new piston seal and O-ring on the pis-
ton. See Figure 3.
NOTE: Perform Step 2 only if the piston was removed
from the rod.
2. Place the rod in a soft-jaw vise, and install the
piston on the rod and tighten the nut to:
• 170 to 220 N•m (125 to 163 lbf ft) on lift truck
models S2.0-2.5FT (S40-S55FT, S55FTS)
(F187), S30FT, S35FT, S40FTS (E010),
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114),
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001), H2.0-2.5FT (H40-50FT)
(L177), E2.00-3.20XM (E45-65Z) (G108) and
J2.00-3.20XM (J40-65Z) (B416)
• 320 to 400 N•m (240 to 295 lbf ft) on lift truck
models S3.0-3.5FT (S60-S70FT) (F187) and
H3.0-3.5FT (H60-70FT) (L177)
• 163 to 190 N•m (120 to 140 lbf ft) on lift truck
models J1.60-2.00XMT (J30-40ZT) (J160)
• 400-440 N•m (295 to 325 lbf ft) on lift truck
models S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FT-
PRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
5
Tilt Cylinder Repair 2100 SRM 1139

Figure 3. Tilt Cylinder

6
2100 SRM 1139 Tilt Cylinder Repair

Legend for Figure 3

A. S2.0-2.5FT (S40-S55FT, S55FTS) (F187), S30FT, C. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S35FT, S40FTS (E010), H1.6FT, H1.8FT, H2.0FTS S80, 100FTBCS; S120FTS; S120FTPRS) (G004),
(H30FT, H35FT, H40FTS) (F001), H2.0-2.5FT H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H40-50FT) (L177), E2.00-3.20XM (E45-65Z) (H80, 90, 100, 110, 120FT) (N005) AND
(G108), AND J2.00-3.20XM (J40-65Z) (B416) E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
B. S3.0-3.5FT (S60-S70FT) (F187) AND H3.0-3.5FT (E098)
(H60-70FT) (L177)
1. SHELL 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

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 for Lift Truck Models E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114) and
J1.60-2.00XMT (J30-40ZT) (J160)

7
Tilt Cylinder Repair
3. Install a new wiper, seal, backup ring, and O-ring
on the gland.
4. Install the rod and piston assembly in the cylin-
der. Using a pin-type spanner, install the gland
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)
(F187) and H2.0-2.5FT (H40-50FT) (L177)
• 163 to 190 N•m (120 to 140 lbf ft) for lift
truck models S30FT, S35FT, S40FTS (E010),
E1.50-2.00XM (E25-35Z, E40ZS) (E114/F114),
J1.60-2.00XMT (J30-40ZT) (J160), H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001), E2.00-3.20XM (E45-65Z) (G108) and
J2.00-3.20XM (J40-65Z) (B416).
• 400 to 500 N•m (295 to 370 lbf ft) for lift
truck models S3.0-3.5FT (S60-S70FT) (F187)
and H3.0-3.5FT (H60-70FT) (L177), S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
5. Place the cylinder in a soft-jaw vise and install
the tilt spacer, if equipped, and rod end on the rod
as noted during removal. Lubricate the threads
on the capscrew with packing lubricant, Hyster
Part No. 186061. Tighten the capscrew on the
rod end to 90 N•m (66 lbf ft) for all lift truck mod-
els except H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005).
Lubricate the threads on the capscrew with
packing lubricant, Hyster Part No. 186061, and
tighten the capscrew on the rod end to 66 to
73 N•m (49 to 54 lbf ft) for lift truck models
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005).
6. Repeat the above steps for the other tilt cylinder.
INSTALL
1. Using a lifting device, place the cylinder on
the mounting point on the lift truck frame.
Install the anchor pin. Install the retainer
and capscrew. See Figure 2. Lubricate the
threads on the capscrew packing lubricant,
Hyster Part No. 186061. For all lift truck
models except S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5,
8
2100 SRM 1139
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098), tighten the capscrew to 38 N•m
(28 lbf ft).
For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005), tighten capscrew to
68 N•m (50 lbf ft).
For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098), tighten capscrews to
77 N•m (57 lbf ft).
2. Connect the hydraulic lines to the tilt cylinder.
Slowly stroke the cylinders until the rod holes
line up with the mast tilt anchor holes.
3. Remove chain holding the mast to the frame.
WARNING
DO NOT put hands between the cylinder rod
end and the mast. Serious injury can occur.
4. Operate the tilt cylinders. Check for correct op-
eration and leakage. Adjust the tilt cylinders.
TILT CYLINDERS, ADJUST
WARNING
When the tilt cylinders have tilt limit spacers,
make sure they are installed during installa-
tion procedures. Without the tilt limit spacers,
the mast can tilt too much and cause an acci-
dent or serious injury.
Check the tilt cylinder stroke by slowly tilting the
mast fully forward and backward several times. Both
tilt cylinders must stop their stroke at the same time.
Adjust the rod ends as shown in Figure 6. There
must be no twist in the mast weldments.
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
lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and 20 mm (0.8 in.) for
lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005). See Figure 5.
2100 SRM 1139
For lift truck models J1.60-2.00XMT (J30-
40ZT) (J160), adjust the rod ends to 32 mm
(1.25 in.). See Figure 5.
b. Slowly tilt the mast backward until one
cylinder rod stops. On the opposite cylinder,
loosen the capscrews on the rod end. Mea-
sure the distance from the end of the cylinder
to the back end of the rod end. Use a wrench
and turn the cylinder rod IN until the dimen-
sion starts to decrease, then stop. Repeat
this procedure until both cylinder rods stop
at the same position within 1 mm (0.04 in.)
for all lift trucks except for S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004) and within
0.5 mm (0.02 in.) for lift truck models S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004).
After the adjustments are complete, tighten
the capscrews on the rod ends.
Figure 5. Tilt Cylinder Adjustments for Lift
Truck Models J1.60-2.00XMT (J30-40ZT) (J160),
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004), and
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005) Only
Tilt Cylinder Repair
Legend for Figure 5
A. 32 mm (1.25 in.) FOR J1.60-2.00XMT (J30-40ZT)
(J160) SHOWN.
1. MAST
2. ROD END
3. TILT CYLINDER
c. Tilt the mast fully backward and measure
the tilt angle. See the Nameplate for tilt
angles. If necessary, adjust both rod ends
equally for the correct angle.
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 6.
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-
gles. If necessary, add an equal number of
shims to both rods for the correct angle.
9
Tilt Cylinder Repair
A. DIMENSION A = 15 mm (0.60 in.)
1. MAST 4. TILT LIMIT SPACER
2. ROD END 5. TILT CYLINDER
3. SHIMS
Figure 6. Tilt Cylinder Adjustments; for All
Models Except J1.60-2.00XMT (J30-40ZT)
(J160), S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), and H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005)
10
2100 SRM 1139
TILT CYLINDER LEAK CHECK
WARNING
Never allow anyone under a raised carriage.
Do not put any part of your body in or through
the lift mechanism unless all parts of the mast
are completely lowered and the engine is
STOPPED.
Do not try to find hydraulic leaks by putting
your hand on hydraulic components under
pressure. Hydraulic oil can be injected into
the body by the pressure.
1. Put a capacity load on the forks. Use a safety
chain to hold the load to the carriage. Raise the
load approximately 2.5 m (8 ft). Put the mast in
a vertical position.
2. Measure the distance that the rod for tilt cylin-
der extends from the shell. Check the distance
the rod moves in five or ten minutes. Multiply
the rate in Table 1 by the time of the test and
compare the numbers.
3. If the tilt rate is greater than the specifications,
lower the mast and remove the load from the
forks. Install a valve between the port at the
front of the tilt cylinder and the hydraulic line.
The valve must be able to completely shut off the
flow of hydraulic oil. Put the load on the forks
again. Close the valve. Tilt the mast forward just
past the vertical position. If the mast continues
to tilt SLOWLY forward, the seals on the piston
are leaking.
4. If the mast does not move, open the valve and
check the movement again. If the mast moves
forward when the gate valve is open, check for
leaks in the hydraulic lines and fittings. If no
leaks are found, the main control valve can be
worn or damaged. Remove the load from the
forks when the checks are complete.
2100 SRM 1139 Tilt Cylinder Repair

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),
E2.00-3.20XM (E45-65Z) (G108)
and J2.00-3.20XM (J40-65Z) (B416)
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
J1.60-2.00XMT (J30-40ZT) (J160)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 1.1 0.04 7.3 0.30
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005)
E1.50-2.00XM (E25-35Z, E40ZS) (F114) .63 0.25 4.3 0.16
E3.50-5.50XL, E4.50XLS (E70-120Z, .74 .029 4.94 1.94
E100ZS) (E098)

TORQUE SPECIFICATIONS Gland

Piston Rod Nut
S2.0-2.5FT (S40-S50FT, S55FTS) (F187), S30FT,
S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z,
E40ZS) (E114/F114), H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001), H2.0-2.5FT
(H40-50FT) (L177), J2.00-3.20XM (J40-65Z)
(B416) and E2.00-3.20XM (E45-65Z) (G108)
170 to 220 N•m (125 to 163 lbf ft)
S3.0-3.5FT (S60-S70FT) (F187) and H3.0-3.5FT
(H60-70FT) (L177)
320 to 400 N•m (240 to 295 lbf ft)
J1.60-2.00XMT (J30-40ZT) (J160)
163 to 190 N•m (120 to 140 lbf ft)
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
400 to 440 N•m (295 to 325 lbf ft)
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)
S3.0-3.5FT (S60-S70FT) (F187), H3.0-3.5FT
(H60-70FT) (L177), S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
120FT) (N005), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
400 to 500 N•m (295 to 370 lbf ft)
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)
163 to 190 N•m (120 to 140 lbf ft)

11
Lift Cylinder Repair
Tilt Cylinder Mounting Capscrew
For lift truck models S2.0-2.5FT (S40-S50FT,
S55FTS) (F187), S30FT, S35FT, S40FTS (E010),
E1.50-2.00XM (E25-35Z, E40ZS) (E114), H1.6FT,
H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS)
(F001), J1.60-2.00XMT (J30-40ZT) (J160) and
H2.0-2.5FT (H40-50FT) (L177)
38 N•m (28 lbf ft)
For lift truck models S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004) and H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005)
68 N•m (50 lbf ft)
Lift Cylinder Repair
MAIN LIFT CYLINDERS
Remove
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast and Fig-
ure 1.
NOTE: The following procedures are for the removal
of the lift cylinders with the mast installed on the lift
truck.
1. Remove the carriage as described in the car-
riage removal procedures located in the section
Mast Repairs, 2, 3, and 4-Stage Masts 4000
SRM 1148. for all lift truck models except
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098)
For lift truck models listed above, see Mast Re-
pairs, 2 and 3-Stage Masts 4000 SRM 1250.
See Figure 1.
NOTE: Perform Step 2 only if working on a lift truck
equipped with a two or three-stage mast. Perform
Step 3 if working on a lift truck equipped with a four-
stage mast.
12
2100 SRM 1139
Tilt Cylinder Rod End Capscrew
For all lift truck models except H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005)
90 N•m (66 lbf ft)
For lift truck models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005)
66 to 73 N•m (49 to 54 lbf ft)
For lift truck models E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
77 N•m (57 lbf ft)
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
mast section to the top crossmember of the
outer mast section.
• On the three-stage mast, use safety chain to
connect the bottom crossmember of the inter-
mediate mast section to the top crossmember
of the outer mast section. Use another safety
chain to connect the bottom crossmember to
a crossmember on the intermediate or outer
mast section.
Lower the mast so the safety chains hold the
weight of the mast sections.
3. Raise the mast until it is almost fully extended.
Use a safety chain to connect middle crossmem-
ber of first intermediate mast section to top cross-
member on outer mast section. Lower mast so
safety chain holds weight of the mast sections.
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
ring pliers, and wear eye and face protection
during removal or installation.
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.
2100 SRM 1139 Lift Cylinder Repair

5. If working on a four-stage mast, on left-hand lift

cylinder, remove the snap ring from top of the
cylinder rod. On right-hand lift cylinder, remove
spacer and retainer from cylinder rod.
WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic hoses until the oil in the system is cool.
6. Put a drain pan under the area of the hydraulic
fittings. Disconnect and cap the hydraulic lines
at the cylinder. Retract the rod into the lift cylin-
der.
7. Remove the nut, bolt, and spacer at the mount.
On a two or three-stage mast, disconnect the
main lift chain at the mount. See Figure 9.
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.
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection
during removal or installation.
NOTE: Step 5 does not apply for S4.0, 4.5, 5.5FT,
S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098) lift trucks, and lift trucks
equipped with a two-stage FFL mast.
5. Remove snap ring, washer, and check valve from
base of piston.
6. Repeat disassembly procedure for the opposite
cylinder.

Disassemble

CAUTION
Carefully disassemble the main lift cylinders
so the piston rods and sliding surfaces are not
damaged.

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 Left Side Main Lift
Cylinder.

NOTE: To prevent damage to sealing surfaces, use

brass tools when removing seals and O-rings.

1. Loosen gland with spanner wrench. 1. SHELL 7. O-RING

2. ROD 8. SNAP RING
3. GLAND 9. WIPER RING
2. Remove gland from shell. 4. ROD SEAL 10. SEAL
5. CHECK VALVE 11. BACKUP RING
3. Remove rod and piston assembly from shell. 6. WASHER 12. WEAR RING
Drain hydraulic oil into container. See Figure 7,
and Figure 8. Figure 7. Two-Stage LFL Main Lift Cylinder

4. Remove and discard O-rings, seals, backup rings,

wiper rings, and wear rings.

13
Lift Cylinder Repair 2100 SRM 1139

Inspect
Inspect the gland for damage to the threads and the
seal surfaces. If damaged, replace gland.

Inspect the piston for any damage to the seal sur-

faces. If damaged, replace piston.

Inspect the rod for damage to the rod surface and

ensure that the rod is not bent. If damaged replace
rod.

Inspect the inner surface of the cylinder tube for

damage. If damaged, replace cylinder assembly.

Assemble
NOTE: The procedures in this section cover all cylin-
ders except for the left side main lift cylinders on
1. SHELL 8. WIPER RING two-stage FFL masts. See the section Two-Stage FFL
2. ROD 9. SEAL
3. GLAND 10. O-RING Left Side Main Lift Cylinder for the procedures.
4. SPACER 11. BACKUP RING
5. CHECK VALVE 12. WEAR RING NOTE: To prevent damage to sealing surfaces, use
6. WASHER 13. ROD SEAL brass tools when installing seals and O-rings.
7. SNAP RING 14. PISTON RING
1. Lubricate all internal parts of the lift cylinder
Figure 8. Three-Stage FFL Main Lift Cylinder with clean hydraulic oil. Use new O-rings, seals,
and wear rings. See Figure 7 and Figure 8.
Clean
WARNING
WARNING
Be careful when removing or installing snap
Cleaning solvents can be flammable and toxic rings. These snap rings can come loose dur-
and can cause skin irritation. When using ing removal or installation with enough force
cleaning solvents, always follow the solvent to cause an injury. Always use the correct snap
manufacturer’s recommended safety proce- ring pliers and wear eye and face protection
dures. during removal or installation.
Compressed air can move particles so they NOTE: Step 2 does not apply for S4.0, 4.5, 5.5FT,
cause injury to the user or to other personnel. S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
Make sure the path of the compressed air is S120FTS; S120FTPRS) (G004), H4.0FT5/FT6;
away from all personnel. Wear protective gog- H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
gles or a face shield to prevent injury to the 110, 120FT) (N005), E3.50-5.50XL, and E4.50XLS
eyes. (E70-120Z, E100ZS) (E098) lift trucks, and lift trucks
equipped with two-stage FFL Mast.
CAUTION
2. Install check valve and O-ring in base of piston
Do not allow cleaning solvent to come in con- of main lift cylinder and left-hand lift cylinder.
tact with rubber components, as it will damage Make sure arrow on check valve is toward base
those components. of piston. Install washer and snap ring for check
Clean all metal parts in solvent and dry with com- valve. See Figure 7 and Figure 8.
pressed air.

14
2100 SRM 1139
CAUTION
A difficult and important step in assembling
lift cylinders is the correct installation of the
seals. Most lift cylinder maintenance is caused
by seal leaks. Do not damage any parts during
assembly.
3. Install the wear ring, piston seal, and backup
ring on to the piston assembly. On the main lift
cylinders, install seal ring. Install spacer, if used.
4. Push the piston and rod assembly into the shell.
5. Install the rod seal ring and wiper into the gland.
Install the O-ring and backup ring on the outside
of the gland.
CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
NOTE: To prevent possible damage to the piston rod,
use care while installing the gland.
6. Install the gland on the piston rod.
7. Install Gland into cylinder and tighten gland to
340 to 410 N•m (250 to 300 lbf ft).
8. Install the lowering control valve in port at base
of left-hand, main control cylinder. See Figure 8
and Figure 7.
Install
1. Using a lifting device, install the lift cylinders in
the mount at the bottom of the outer mast.
2. Install the nut, bolt, and spacer (11, Figure 9)
at the mount for the lift cylinders. For all lift
truck models except H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), E3.50-5.50XL, and E4.50XLS (E70-120Z,
E100ZS) (E098), tighten nut to 53 N•m (39 lbf ft).
For lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098), tighten nut to 38 N•m (28 lbf ft).
SeeFigure 9.
3. Use a lifting device to lower the inner mast weld-
ment (two-stage) or intermediate mast weldment
Lift Cylinder Repair
(three-stage) on to the lift cylinder. Figure 9 for
the correct adjustment of the lift cylinders.
a. If working on the two or three-stage mast,
install the snap ring or fitting at the top of
the cylinders.
b. If working on the four-stage mast, on the left
hand cylinder, install the washers and snap
ring from the top of the cylinder rod. On the
right-hand lift cylinder, install spacer and re-
tainer to the cylinder rod. Tighten nuts from
retainer to 33 N•m (24 lbf ft).
4. Connect the hydraulic line at the base of the lift
cylinders. Connect the hydraulic line at the top of
the left-hand main lift cylinder on the two-stage
and four-stage full free-lift masts. Connect hy-
draulic line at tube on right-hand lift cylinder.
5. For the four-stage full free-lift masts, install bal-
ance line between main lift cylinders. See Fig-
ure 9.
6. Connect the main lift chains as necessary and ad-
just as specified in the section Mast Repairs, 2,
3, and 4-Stage Masts 4000 SRM 1148. for all lift
truck models except H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), and E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098).
For lift truck models listed above, see Mast Re-
pairs, 2 and 3-Stage Masts 4000 SRM 1250.
7. Remove the air from the cylinders on the two-
stage FFL as described below. See Figure 10.
a. Loosen the screws two turns to permit oil to
flow around the threads of the screw.
b. With the forks unloaded and the engine
speed at idle, raise the carriage using the hy-
draulic control. Raise the carriage 300 mm
(12 in.) and then stop for 10 seconds to re-
duce the pressure in the cylinder. Repeat
this procedure until the oil flowing from
around the threads is free of air bubbles.
c. Stop the carriage at the top of the cylinder
stroke. Tighten the screws.
15
Lift Cylinder Repair 2100 SRM 1139

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

1. BALANCE LINE 8. HOSE
2. SNAP RING 9. LOWERING CONTROL VALVE
3. SHIM 10. RIGHT-HAND MAIN LIFT CYLINDER
4. FITTING AND O-RING 11. SPACER
5. LEFT-HAND MAIN LIFT CYLINDER 12. RETAINER
6. LOWERING CONTROL VALVE FITTING 13. NUT
7. HOUSING 14. BOLT

Figure 9. Main Lift Cylinders Installation

TWO-STAGE FFL LEFT SIDE MAIN LIFT 2. Remove gland, rod, and piston assembly from
CYLINDER shell. Drain hydraulic oil into a container.

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

NOTE: For disassembly procedures on the right side 4. Remove and discard rod wiper and rod seal from
main lift cylinder, see the section Main Lift Cylinders gland. Remove and discard O-ring, backup ring,
and Figure 10. and spacer from gland.

1. Loosen the gland with a spanner wrench. See 5. Remove and discard piston ring and wear ring
Figure 10. from piston.

16
2100 SRM 1139 Lift Cylinder Repair

A. RIGHT SIDE CYLINDER B. LEFT SIDE 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 10. Main Lift Cylinder, Right Side and Left Side Two-Stage FFL

17
Lift Cylinder Repair
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-
gles or a face shield to prevent injury to the
eyes.
CAUTION
Do not allow cleaning solvent to come in con-
tact with rubber components, as it will damage
those components.
Clean all metal parts in solvent and dry with com-
pressed air.
Inspect
Inspect the gland for damage to the threads and the
seal surfaces. If damaged, replace gland.
Inspect the piston for any damage to the seal sur-
faces. If damaged, replace piston.
Inspect the rod for damage to the rod surface and
ensure that the rod is not bent. If damaged replace
rod.
Inspect the inner surface of the cylinder tube for
damage. If damaged, replace cylinder assembly.
Assemble
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
1. Install piston ring and wear ring onto piston.
2. Install rod wiper and rod seal in gland. Install
O-ring, backup ring, and spacer outside of gland.
3. Install gland onto rod and install the piston.
Tighten piston to 170 to 200 N•m (125 to
150. lbf ft).
4. Install gland, rod, and piston assembly into shell.
18
2100 SRM 1139
5. Tighten gland in shell until tight. Use the correct
spanner. Do NOT hit gland with a hammer and
driver. Tighten gland to 340 to 410 N•m (250 to
300 lbf ft).
CAUTION
The correct screw and sealing washer must
be used in this location. The wrong parts will
cause leaks or damage the cylinder. See your
Hyster lift truck dealer for the correct parts.
CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
6. Remove screw and sealing washer. Pour 150 cc
(5 oz) of hydraulic oil into the cylinder through
the hole. This oil provides a hydraulic cushion
when the cylinder reaches the top of its stroke.
See Figure 9. Install the screw and sealing
washer and tighten to 6 N•m (53 lbf in).
7. Install fitting at base of free-lift cylinder. This is
a special fitting that limits flow of the hydraulic
oil.
Install
For installation procedures, see Main Lift Cylinders,
Install.
FREE-LIFT CYLINDER
Remove
1. Remove the carriage as described in the car-
riage removal procedures in the section Mast
Repairs, 2, 3, and 4-Stage Masts 4000
SRM 1148. for all lift truck models except
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004), and
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS)
(E098).
For lift truck models listed above, see Mast Re-
pairs, 2 and 3-Stage Masts 4000 SRM 1250.
Lower the mast completely.
2100 SRM 1139 Lift Cylinder Repair

WARNING
Hydraulic oil is hot after system operation and
can cause burns. Do not disconnect any hy-
draulic hoses until the oil in the system is cool.

2. Put a drain pan under the area of the hydraulic

fittings. Disconnect the hydraulic line at the
cylinder.

3. Remove chains from chain sheaves. Remove the

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

4. Remove the crosshead from the cylinder rod. See

Figure 11, Figure 12, Figure 13, and disassemble
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 12. Crosshead Assembly, Two-Stage and

Three-Stage FFL, for Lift Truck Models S30FT,
S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z,
E40ZS) (E114/F114), J1.60-2.00XMT (J30-40ZT)
(J160), and H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)

1. LIFT CHAIN 7. PIN

2. CHAIN SHEAVE 8. FREE-LIFT
3. CHAIN GUARD CYLINDER
4. SNAP RING 9. WASHER
5. CROSSHEAD 10. LOCKWASHER
6. BEARING 11. CAPSCREW

Figure 11. Crosshead Assembly, Two-Stage

and Three-Stage FFL, for Lift Truck Models
S2.0-3.5FT (S40-70FT, S55FTS) (F187),
H2.0-3.5FT (H40-70FT) (L177), S4.0, 5.0,
5.50FT ([S80, 100, 120FT;] S80, 100, 120FTBCS;
S120FTPRS) (G004), E2.00-3.20XM (E45-65Z)
(G108), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005),
E3.50-5.50XL, and E4.50XLS (E70-120Z,
E100ZS) (E098)

19
Lift Cylinder Repair 2100 SRM 1139

Figure 13. Crosshead and Four-Stage Free-Lift Cylinder Assembly, for Lift Truck Models S2.0-3.5FT
(S40-70FT, S55FTS) (F187)

20
2100 SRM 1139 Lift Cylinder Repair

Legend for Figure 13

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 13.
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

Disassemble 5. Remove snap ring, washer, and check valve from

base of piston. Remove and discard O-ring from
CAUTION check valve.
Carefully disassemble the free-lift cylinder so
the piston rods and sliding surfaces are not
damaged.

NOTE: To prevent damage to sealing surfaces, use

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

1. Loosen gland with a spanner wrench.

2. Remove gland from shell.

3. Remove rod and piston assembly from shell.

Drain hydraulic oil into container. See Fig-
ure 14. 1. SHELL 7. SNAP RING
2. ROD 8. WIPER
4. Remove and discard O-rings, seals, and wear 3. GLAND 9. SEAL
rings. 4. SCREW 10. BACKUP RING
5. CHECK VALVE 11. O-RING
6. WASHER 12. WEAR RING
WARNING
Figure 14. Free-Lift Cylinder, Two-Stage and
Be careful when removing or installing snap
Three-Stage FFL
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
ring pliers and wear eye and face protection
during removal or installation.

21
Lift Cylinder Repair
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-
gles or a face shield to prevent injury to the
eyes.
CAUTION
Do not allow cleaning solvent to come in con-
tact with rubber components, as it will damage
those components.
Clean all metal parts in solvent and dry with com-
pressed air.
Inspect
Inspect the gland for damage to the threads and the
seal surfaces. If damaged, replace gland.
Inspect the piston for any damage to the seal sur-
faces. If damaged, replace piston.
Inspect the rod for damage to the rod surface and
ensure that the rod is not bent. If damaged replace
rod.
Inspect the inner surface of the cylinder tube for
damage. If damaged, replace cylinder assembly.
Assemble
NOTE: The procedures in this section cover all masts.
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
1. Lubricate all internal parts of the free-lift cylin-
der with clean hydraulic oil. Use new O-rings,
seals, and wear rings. See Figure 14.
WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose dur-
ing removal or installation with enough force
to cause an injury. Always use the correct snap
22
2100 SRM 1139
ring pliers and wear eye and face protection
during removal or installation.
2. 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. Install washer and
snap ring for check valve. See Figure 14.
CAUTION
A difficult and important step in assembling
free-lift cylinder is the correct installation
of the seals. Most cylinders maintenance is
caused by seal leaks. Do not damage any parts
during assembly.
3. Install the wear ring, piston seal, and backup
ring on the piston assembly. On the free-lift
cylinder, install seal ring. Install spacer, if used.
4. Carefully push the piston and rod assembly into
the shell.
5. Install the rod seal ring and wiper into the gland.
Install the O-ring and backup ring on the outside
of the gland.
CAUTION
Additives may damage the hydraulic system.
Before using additives, contact your local Hys-
ter dealer.
NOTE: Hydraulic oil is poured into the free-lift cylin-
ders to act as a cushion during load lifting to prevent
damage to the cylinder.
6. Before installing gland, pour 150 cc (5 oz) of hy-
draulic oil into the cylinder shell.
7. Install the gland on the piston rod, and tighten
gland to 475 to 540 N•m (350 to 400 lbf ft) on
all free-lift cylinders except on lift truck models,
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FT-
BCS; S120FTS; S120FTPRS) (G004), and E3.50-
5.50XL, E4.50XLS (E70-120Z, E100ZS) (E098).
On lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005), S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), E3.50-5.50XL, and E4.50XLS (E70-120Z,
E100ZS) (E098), tighten to 400 to 475 N•m (295
to 350 lbf ft).
2100 SRM 1139
Install
1. Make sure alignment pin is in position, then in-
stall the crosshead mount and crosshead assem-
bly on the cylinder rod. Tighten the chain guards
to 66 N•m (49 lbf ft). Tighten the crosshead
mount to 435 N•m (320 lbf ft). Install chain
sheaves in mount. Install shaft through sheaves.
Install chain guard on mount, making sure the
shaft is in correct position. See Figure 11 and
Figure 14.
2. Install the cylinder in the mounts. Install the
brackets, nuts, and tighten the bolts to 53 N•m
(39 lbf ft). On the three-stage FFL cylinder,
the nuts are installed on the bracket side of the
free-lift cylinder. Tighten the nuts to 38 N•m
(28 lbf ft).
3. Connect the hydraulic line at the cylinder.
4. Install the carriage and load backrest as de-
scribed in the procedures for the section Mast
Repairs, 2, 3, and 4-Stage Masts 4000
SRM 1148. for all lift truck models except
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (G004),
E3.50-5.50XL, and E4.50XLS (E70-120Z,
E100ZS) (E098).
For lift truck models listed above, see Mast Re-
pairs, 2 and 3-Stage Masts 4000 SRM 1250.
TORQUE SPECIFICATIONS
Gland, Main Lift Cylinders Except,
340 to 410 N•m (250 to 300 lbf ft)
Gland, All Full Free-Lift Cylinders Except,
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) (N005), S4.0,
4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004), and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
475 to 540 N•m (350 to 400 lbf ft)
Lift Cylinder Repair
Gland, Full Free-Lift Cylinders, H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005), S4.0, 4.5, 5.5FT, S5.5FTS,
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004), and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)
400 to 475 N•m (295 to 350 lbf ft)
Piston, Main Lift Cylinders (Two-Stage
FFL Mast Only)
170 to 200 N•m (125 to 150 lbf ft)
Main Lift Cylinder Mounting Nut To
Outer Mast, All Lift Truck Models
Except H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005) and E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
53 N•m (39 lbf ft)
Main Lift Cylinder Mounting Nut To Outer
Mast, Lift Truck Models H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005) and E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)
38 N•m (28 lbf ft)
Retainer Nuts
33 N•m (24 lbf ft)
Chain Guard Capscrew (Free-Lift Cylinder)
66 N•m (49 lbf ft)
Crosshead Mount Capscrew
435 N•m (320 lbf ft)
Free-Lift Cylinder Mounting Bolts (All
Mast Except Three-Stage FFL)
53 N•m (39 lbf ft)
Free-Lift Cylinder Mounting Bolts
(Three-Stage FFL)
38 N•m (28 lbf ft)
23
Lift Cylinder Repair 2100 SRM 1139

LIFT CYLINDERS LEAK CHECK system. The maximum speed the carriage is
allowed to lower is 50 mm (2 in.) per 10 minutes
WARNING when hydraulic oil is 30 C (86 F). If oil tem-
perature is 70 C (158 F), the maximum speed
During the test procedures for the hydraulic
the carriage can lower is 150 mm (6 in.) per 10
system, use chains to fasten the load to the car-
minutes.
riage to prevent it from falling. Keep all people
away from the lift truck during the tests. 3. Check lift cylinders for internal leaks. Remove
load from forks. Install valve in supply line be-
Do NOT try to find hydraulic leaks by putting
tween main control valve and mast. Put capacity
your hand on hydraulic components under
load on forks again. Raise carriage 1 m (3 ft).
pressure. Hydraulic oil can be injected into
Close valve. If carriage or mast lower slowly,
the body by the pressure.
seals in lift cylinders have leaks.
1. Operate hydraulic system. Put capacity load on
4. If carriage does not move, open valve and check
forks. Use safety chain to hold load to carriage.
movement again. If carriage lowers when valve
Raise and lower load several times. Lower load
is open, check for leaks in hydraulic lines and
and tilt mast forward and backward several
fittings. If no leaks are found, main control
times. Check for leaks.
valve can be worn or damaged. Remove load
2. Raise carriage and load 1 m (3 ft). If carriage from forks.
slowly lowers when control valve is in NEU-
TRAL position, there are leaks in hydraulic

24
 TECHNICAL PUBLICATIONS

2100 SRM 1139 3/07 (11/06)(6/06)(3/06)(1/06)(9/05)(5/05)(12/04) Printed in U.S.A.