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CYLINDER REPAIR
(MAST S/N B586, B588,
B590, B749, B751, AND
B753
S4.0FT, 4.5FT, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, H120FT) [U005]

PART NO. 4135739 2100 SRM 1947

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SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 Maintenance 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 ex-
ceed 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 flamma-
ble. 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 hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 HeavyManuals.com
Table of Contents

TABLE OF CONTENTS

General .....................................................................................................................................................................1
Description ...............................................................................................................................................................3
Safety Procedures When Working Near Mast ....................................................................................................... 5
Tilt Cylinder Repair ................................................................................................................................................ 7
Remove ................................................................................................................................................................ 7
Disassemble .........................................................................................................................................................8
Clean ....................................................................................................................................................................9
Inspect ............................................................................................................................................................... 10
Assemble ............................................................................................................................................................10
Install .................................................................................................................................................................11
Adjust Tilt Cylinders ........................................................................................................................................ 11
Adjusting Tilt Cylinders Without Tilt Limit Spacers .................................................................................13
Adjusting Tilt Cylinders With Tilt Limit Spacers ...................................................................................... 13
Tilt Cylinder Leak Check ................................................................................................................................. 14
Main Lift Cylinders ...............................................................................................................................................15
Remove .............................................................................................................................................................. 15
Two-Stage FFL ............................................................................................................................................. 15
Three-Stage FFL ...........................................................................................................................................18
Two-Stage LFL ............................................................................................................................................. 18
Disassemble .......................................................................................................................................................19
Two-Stage FFL ............................................................................................................................................. 19
Three-Stage FFL ...........................................................................................................................................22
Two-Stage LFL ............................................................................................................................................. 23
Clean ..................................................................................................................................................................24
Inspect ............................................................................................................................................................... 24
Assemble ............................................................................................................................................................24
Two-Stage FFL ............................................................................................................................................. 24
Three-Stage FFL ...........................................................................................................................................24
Two-Stage LFL ............................................................................................................................................. 25
Install .................................................................................................................................................................25
Two-Stage FFL ............................................................................................................................................. 25
System Air Bleed Procedures .................................................................................................................. 26
Three-Stage FFL ...........................................................................................................................................26
Two-Stage LFL ............................................................................................................................................. 27
Free-Lift Cylinder Repair ..................................................................................................................................... 28
Two and Three-Stage FFL Mast ...................................................................................................................... 28
Remove .......................................................................................................................................................... 28
Disassemble .................................................................................................................................................. 29
Clean ..............................................................................................................................................................30
Inspect ........................................................................................................................................................... 30
Assemble ....................................................................................................................................................... 30
Install ............................................................................................................................................................ 31
Integral Sideshift Cylinder Repair .......................................................................................................................31
Remove .............................................................................................................................................................. 31
Disassemble .......................................................................................................................................................33
Clean and Inspect ............................................................................................................................................. 33
Assemble and Install ........................................................................................................................................ 34
Lift Cylinder Leak Check ......................................................................................................................................34
Seal Kit Installation ..............................................................................................................................................35
External Installation (Seal and Back-Up Ring) .............................................................................................. 35

©2015 HYSTER COMPANY i

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Table of Contents

TABLE OF CONTENTS (Continued)

Internal Installation (Piston Rod Assembly) ...................................................................................................35

Torque Specifications ............................................................................................................................................ 36
Tilt Cylinders .................................................................................................................................................... 36
Piston Rod Locknut ...................................................................................................................................... 36
Gland ............................................................................................................................................................. 36
Tilt Cylinder Mounting Capscrew ............................................................................................................... 36
Tilt Cylinder Rod End Nut ...........................................................................................................................36
Main Lift and Free-Lift Cylinders ................................................................................................................... 36
Gland, Main Lift Cylinders .......................................................................................................................... 36
Gland, Free-Lift Cylinder .............................................................................................................................36
Piston, Main Lift Cylinders ..........................................................................................................................36
Main Lift Cylinder Mounting Nut To Outer Mast ......................................................................................36
Free-Lift Cylinder Mounting Capscrews .....................................................................................................36
Cylinder Shell Capscrew, Main Lift Cylinders ........................................................................................... 36
Integral Sideshift Cylinder ...............................................................................................................................36
Gland ............................................................................................................................................................. 36

This section is for the following models:

S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [J004];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, H120FT)
[U005]

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2100 SRM 1947 General

General
This section contains the repair and adjustment • B588
procedures for the following types of cylinders: • B590
• Tilt cylinders
• Main lift cylinders Lift truck models H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, H120FT)
• Free-lift cylinders (U005) are equipped with a mast with one of the
• Integral sideshift cylinder following serial numbers:
• B749
The number and design of the cylinder parts can be
different, but the repair, adjustment, and operation • B751
of the cylinders is the same. These cylinders are • B753
used on masts with one of the following serial
numbers listed below. See Figure 1 for the location of mast serial number
and for other information about the mast.
Lift truck models S4.0FT, 4.5FT, 5.5FT, S5.5FTS
(S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (J004) are equipped with a mast with
one of the following serial numbers:
• B586

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General 2100 SRM 1947

NOTE: MAST FOR LIFT TRUCK MODELS H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110,
H120FT) (U005) SHOWN. MAST SERIAL NUMBER AND OTHER INFORMATION FOR MAST USED ON LIFT
TRUCK MODELS S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(J004) IS IN SAME LOCATION.

1. MAST SERIAL NUMBER 4. MAST LIFT HEIGHT (IN MILLIMETERS)

2. MANUFACTURING PLANT 5. MAST ASSEMBLY PART NUMBER
3. PRODUCTION SEQUENCE

Figure 1. Mast Serial Number Location

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2100 SRM 1947 General

In the process of repairing the cylinders, other A751, A752, B513, B514, B586, B587, B588,
system and component parts will be discussed. See B589, B590, B591, B749, B750, B751, B752,
the following manuals listed below for more B753, B754) 4000SRM1250.
information related to these systems and parts.
Information related to the periodic maintenance of
Additional repair information on the mast can be the cylinders covered in this manual can be found
found at Mast Repairs (S/N A513, A514, A613, in Periodic Maintenance 8000SRM1902.
A614, A702, A703, A704, A705, A706, A707,

Description
This manual covers many different types of cylin- Each lift cylinder has an internal lowering control
ders. Each cylinder will be described in detail. See valve. A single external lowering control valve is
Figure 2. connected by tubing and hoses to all the lift cylin-
ders. See Figure 2.
Tilt cylinders are fastened between the frame of lift
truck and outer weldment of mast to change the The free-lift chains connect at one end of the mid-
angle of the mast and forks. crossmember of the inner mast. Two chain sheaves
are installed on a crosshead on the rod of the free-
Two single-stage main lift cylinders and a free-lift lift cylinder. The chains then go over sheaves on
cylinder are used to raise the carriage and extend the crosshead and connect to the carriage. See Fig-
mast weldments. See Figure 2. ure 2.

The two main lift cylinders are installed at the Some lift truck models may be equipped with an in-
back of the outer mast. The base of each lift cylin- tegral sideshift (ISS) carriage. On an ISS carriage,
der sits on a mount at the bottom crossmember of the cylinder is mounted in a hollowed out cylinder
the outer mast. The top of each main lift cylinder block that is welded to the ISS frame. The cylinder
rod fits into a guide on the top crossmember of the on an ISS carriage, moves the carriage left or right.
inner mast. The free-lift cylinder is installed in the See Figure 2.
inner mast.

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Description 2100 SRM 1947

NOTE: TWO-STAGE FFL MAST WITH OPTIONAL INTEGRAL SIDESHIFT CARRIAGE SHOWN.

A. FRONT VIEW B. REAR VIEW (DRIVER'S VIEW)

1. INTEGRAL SIDESHIFT CYLINDER 8. MAIN LIFT CYLINDER MOUNT (GUIDE, TOP
2. INTEGRAL SIDESHIFT CARRIAGE FRAME CROSSMEMBER OF INNER MAST)
3. LEFT MAIN LIFT CYLINDER 9. INTEGRAL SIDESHIFT CYLINDER BLOCK
4. RIGHT MAIN LIFT CYLINDER 10. EXTERNAL LOWERING CONTROL VALVE
5. FREE-LIFT CYLINDER 11. FREE-LIFT CROSSHEAD
6. TILT CYLINDERS 12. FREE-LIFT CHAIN SHEAVES
7. MAIN LIFT CYLINDER MOUNT (BOTTOM
CROSSMEMBER OF OUTER MAST)

Figure 2. Cylinder Locations

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2100 SRM 1947 Safety Procedures When Working Near Mast

Safety Procedures When Working Near Mast

The following procedures MUST be used when in- • If parts of the mast must be in a raised posi-
specting or working near the mast. Additional pre- tion, install a safety chain to restrain the
cautions and procedures can be required when re- moving parts of the mast. Connect moving
pairing or removing the mast. parts to a part that does not move. Follow
these procedures:

WARNING 1. Put mast in vertical position.

Mast parts are heavy and can move. Distances be-
2. Raise mast to align bottom crossmember of
tween parts are small. Serious injury or death can
weldment that moves in outer weldment with
result if part of the body is hit by parts of the mast
crossmember on outer weldment. On the two-
or the carriage.
stage and free-lift mast, the moving part is the
• Never put any part of the body into or under inner weldment. On the three-stage mast, it is
the mast or carriage unless all parts are the intermediate weldment. See Figure 3.
completely lowered or a safety chain is in-
stalled. Also make sure that the power is 3. Use a 3/8-inch (minimum) safety chain with a
OFF and the key is removed. Put a DO NOT hook to fasten the crossmembers together so
OPERATE tag in the operator's compart- the movable member cannot lower. Put hook on
ment. Disconnect the battery and put a tag back side of mast. Make sure hook is completely
or lock on the battery connector. engaged with a link in the chain. Make sure
safety chain does not touch lift chains or chain
• Be careful of the forks. When the mast is
sheaves, tubes, hoses, fittings, or other parts on
raised, the forks can be at a height to cause
the mast.
an injury.
• DO NOT climb on the mast or lift truck at 4. Lower mast until there is tension in safety
any time. Use a ladder or personnel lift to chain and free-lift cylinder (two-stage full free-
work on the mast. lift and three-stage full free-lift) is completely
• DO NOT use blocks to support the mast retracted. If running, turn the power OFF. Ap-
weldments nor to restrain their movement. ply the parking brake. Install a DO NOT RE-
MOVE tag on the safety chain(s).
• Mast repairs require disassembly and re-
moval of parts and can require removal of 5. Install another safety chain (3/8-in. minimum)
the mast or carriage. Follow the repair pro- between the top or bottom crossmember of the
cedures in this section. carriage bar and a crossmember on the outer
weldment.
WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely. 6. After lowering or restraining the mast, shut off
Push the lift/lower control lever forward and the power, and remove key.
make sure there is no movement in the
NOTE: Place a DO NOT OPERATE tag in the op-
mast. Make sure that all parts of the mast
erators compartment.
that move are fully lowered.
7. Disconnect battery and put a tag or lock on bat-
OR
tery connector.

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Safety Procedures When Working Near Mast 2100 SRM 1947

A. TWO-STAGE LFL MAST C. THREE-STAGE FFL MAST

B. TWO-STAGE FFL MAST
1. OUTER MAST 5. FREE-LIFT CYLINDER
2. INNER MAST 6. CARRIAGE BAR
3. INTERMEDIATE MAST 7. CROSSMEMBER
4. HOOK
Figure 3. Safety Chaining the Mast

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2100 SRM 1947 Safety Procedures When Working Near Mast

Tilt Cylinder Repair

REMOVE 3. Stroke cylinder to the full back tilt position. See
Figure 4.
WARNING 4. Disconnect the hydraulic lines at the tilt cylin-
Before removing the tilt cylinder(s), tilt the mast der. Install caps on the hydraulic lines and in
forward. Use a chain to hold the mast to the frame the cylinder ports.
and prevent the mast from moving forward.
WARNING
WARNING DO NOT permit the tilt cylinders to drop and
DO NOT push the anchor pins out of the rod end cause damage.
with your fingers. DO NOT permit the tilt cylinders
to drop and cause damage. 5. Use a lifting device to move large tilt cylinders.
Remove the capscrew and retainer from the an-
NOTE: Note positioning and orientation of tilt cyl- chor pin. Using a drift pin or similar tool, push
inder prior to removal to aid in installation. the anchor pin out of the frame.

1. Use a lifting device to hold tilt cylinder in posi- 6. Using a lifting device, remove the tilt cylinder
tion. from the lift truck.

2. At mast end, remove the capscrew and retainer 7. Remove bushing from frame end (12, Figure 5).
from the anchor pin. Using a drift pin or simi-
lar tool, push the anchor pin out of the rod end. 8. Repeat above steps for opposite tilt cylinder.
See Figure 4.

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Tilt Cylinder Repair 2100 SRM 1947

NOTE: TILT CYLINDER FOR LIFT TRUCK MODELS S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, 120FT; S80,
100FTBCS; S120FTS; S120FTPRS) (J004) SHOWN. TILT CYLINDER MOUNTING FOR LIFT TRUCK MODELS
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, H120FT) (U005) IS SIMILAR.

NOTE: HYDRAULIC HOSES SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 4. ANCHOR PIN

2. RETAINER 5. TILT SPACER
3. LUBRICATION FITTING

Figure 4. Tilt Cylinder Mounting

DISASSEMBLE NOTE: To prevent damage to sealing surfaces, use

brass tools when removing seals and O-rings.
NOTE: Note placement of components prior to dis-
assembly to aid in assembly. 3. Remove and discard the O-ring, backup ring,
seal, and wiper from the gland. See Figure 5.
NOTE: The following steps have detailed disassem-
bly instructions. Perform only those steps required NOTE: Perform Step 4 only if the piston or rod has
to repair the tilt cylinder. been damaged.

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

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2100 SRM 1947 Tilt Cylinder Repair

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

Figure 5. Tilt Cylinder Disassembly

6. Repeat above steps for opposite tilt cylinder. Compressed air can move particles so they can
cause injury to the user or to other personnel.
CLEAN Make sure the path of the compressed air is away
from all personnel. Wear protective goggles or a
WARNING face shield to prevent injury to the eyes.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning CAUTION
solvents, always follow the solvent manufactur- DO NOT allow cleaning solvent to come in contact
er's recommended safety procedures. with rubber components, as it will damage those
components.

1. Clean all metal components in solvent and dry

with compressed air.

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Tilt Cylinder Repair 2100 SRM 1947

INSPECT the inboard side of rod end. Install washer and

nut on capscrew. Washer and nut must be on
1. Inspect gland for damage to threads and seal the outboard side of rod end. Tighten nut to 90
surfaces. If damaged, replace gland. N•m (66 lbf ft). See Figure 6.
2. Inspect piston for any damage to seal surfaces.
If damaged, replace rod and piston assembly.

3. Inspect rod for damage to rod surface and en-

sure that rod is not bent. If damaged, replace
rod and piston assembly.

4. Inspect inner surface of shell for damage. If

damaged, replace tilt cylinder assembly.

ASSEMBLE
NOTE: To prevent damage to sealing surfaces, use
brass tool when installing seals and O-rings.

NOTE: Lubricate new seals and O-rings with clean

hydraulic oil prior to installation.

1. Install new O-ring and piston seal on piston.

See Figure 5.

NOTE: Perform Step 2 only if piston was removed NOTE: TILT CYLINDER FOR LIFT TRUCK MODELS
from rod. H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, H120FT) (U005) SHOWN. TILT CYLIN-
2. Place the rod in a soft-jaw vise and lube the DER MOUNTING FOR LIFT TRUCK MODELS
threads of the nut with hydraulic oil. Install the S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, 120FT;
piston on the rod and tighten locknut to 400 to S80, 100FTBCS; S120FTS; S120FTPRS) (J004) IS
440 N•m (295 to 325 lbf ft). SIMILAR.
3. Install a new wiper, seal, backup ring, and O- NOTE: LEFT TILT CYLINDER SHOWN.
ring on the gland. See Figure 5.
A. OUTBOARD SIDE OF ROD END
4. Install the rod and piston assembly in the cylin- B. INBOARD SIDE OF ROD END
der. Using a pin-type spanner, install the gland
in the cylinder. Tighten the gland to 400 to 1. NUT 3. ROD END
2. WASHER 4. CAPSCREW
500 N•m (295 to 370 lbf ft).
Figure 6. Rod End Installation
5. Place cylinder in a soft-jaw vise and install tilt
spacer, if equipped, and rod end on rod as noted
during removal. Lubricate threads on capscrew
6. Repeat for opposite tilt cylinder.
with lubricant, Hyster P/N 186061. Install cap-
screw in rod end so that capscrew head is on

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2100 SRM 1947 Tilt Cylinder Repair

INSTALL 3. Connect the hydraulic lines to the tilt cylinder.

Slowly stroke the cylinders until the rod holes
1. Install bushing in frame as noted during re- line up with the mast tilt anchor holes.
moval. See Figure 7.
4. Install anchor pin and retainer on tilt anchor.
2. Using a lifting device, place the cylinder in See Figure 4.
mounting position on the lift truck frame. In-
stall the anchor pin. Install the retainer and 5. Repeat above steps for opposite tilt cylinder.
capscrew. See Figure 4. Lubricate the threads
on the capscrew with lubricant, Hyster P/N
186061, and tighten capscrew to: WARNING
DO NOT put hands between the cylinder rod end
a. 66 to 73 N•m (49 to 54 lbf ft) for lift truck and the mast. Serious injury can occur.
models
6. Operate tilt cylinders. Check for correct opera-
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
tion and leakage. Adjust tilt cylinders.
H5.0-5.5FT (H80, 90, 100, 110,
H120FT) (U005) ADJUST TILT CYLINDERS
b. 68 N•m (50 lbf ft) for lift truck models
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, WARNING
100, 120FT; S80, 100FTBCS; If the tilt cylinders have tilt limit spacers, make
S120FTS; S120FTPRS) (J004) sure they are installed during installation proce-
dures. Without the tilt limit spacers, the mast can
tilt too much and cause an accident or serious in-
jury.

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 so there is no twist
in the mast weldments. See

Figure 8 for lift truck models

• S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (J004)

A. 24° ±5° = ROTATE BUSHING SPLIT TO ANGLE Figure 9 for lift truck models
SHOWN, BOTH SIDES • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
1. BUSHING H5.0-5.5FT (H80, 90, 100, 110, H120FT)
(U005)
Figure 7. Bushing Installation

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Tilt Cylinder Repair 2100 SRM 1947

A. DIMENSION A = 20 mm (0.80 in.)

1. MAST 4. WASHER
2. ROD END 5. CAPSCREW
3. TILT CYLINDER 6. NUT
A. DIMENSION A = 15 mm (0.60 in.) MINIMUM, Figure 9. Tilt Cylinder Adjustment, Lift Truck
25 mm (0.98 in.) MAXIMUM
Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
1. MAST 4. WASHER H5.0-5.5FT (H80, 90, 100, 110, H120FT) (U005)
2. ROD END 5. CAPSCREW
3. TILT CYLINDER 6. NUT
Figure 8. Tilt Cylinder Adjustment, Lift Truck
Models S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS; S120FTPRS)
(J004)

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2100 SRM 1947 Tilt Cylinder Repair

Adjusting Tilt Cylinders Without Tilt Limit c. Tilt the mast fully backward and measure
Spacers the tilt angle. See the Nameplate for tilt an-
gles. If necessary, adjust both rod ends
1. Adjust the stroke of the tilt cylinders WITH- equally for the correct angle.
OUT tilt limit spacers as follows:
Adjusting Tilt Cylinders With Tilt Limit
a. Adjust the rod ends to
Spacers
(1) 15 mm (0.60 in.) for lift truck models
1. Adjust the stroke of the tilt cylinders WITH tilt
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS limit spacers as follows:
(S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (J004). See a. Adjust the rod ends to 15 mm (0.60 in.) for
Figure 8. all tilt cylinders covered in this manual.

(2) 20 mm (0.80 in.) for lift truck models b. Slowly tilt the mast forward until one cylin-
der rod stops. On the opposite cylinder,
• H4.0FT5/FT6; H4.5FTS5,
loosen the capscrews on the rod end. Use a
H4.5FT6; H5.0-5.5FT (H80, 90,
wrench and turn the cylinder rod IN as nec-
100, 110, H120FT) (U005). See
essary. Repeat this procedure until both cyl-
Figure 9.
inder rods stop at the same position within
b. Slowly tilt the mast backward until one cyl- 1 mm (0.04 in.).
inder rod stops. On the opposite cylinder,
loosen the capscrews on the rod end. Meas- c. Slowly tilt the mast backward until one rod
end just contacts the spacer. Add shims to fill
ure the distance from the end of the cylinder
the gap at the opposite rod end until both rod
to the back end of the rod end. Use a wrench
ends contact the spacers within
and turn the cylinder rod IN until the dimen-
0.5 mm (0.02 in.).
sion starts to decrease, then stop. Repeat
this procedure until both cylinder rods stop d. After the adjustments are complete, tighten
at the same position within: the nuts on the rod ends to
90 N•m (66 lbf ft). See
(1) 1 mm (0.04 in.) for lift truck models
• H4.0FT5/FT6; H4.5FTS5, Figure 8 for lift truck models
H4.5FT6; H5.0-5.5FT (H80, 90, • S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80,
100, 110, H120FT) (U005) 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (J004)
(2) 0.5 mm (0.02 in.) for lift truck models
• S4.0FT, 4.5FT, 5.5FT, S5.5FTS Figure 9 for lift truck models
(S80, 100, 120FT; S80, 100FTBCS; • H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
S120FTS; S120FTPRS) (J004) H5.0-5.5FT (H80, 90, 100, 110,
H120FT) (U005)
(3) After the adjustments are complete,
tighten the nuts on the rod ends to e. Tilt the mast fully backward and measure
90 N•m (66 lbf ft). 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.

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 HeavyManuals.com
Tilt Cylinder Repair 2100 SRM 1947

TILT CYLINDER LEAK CHECK 3. If the tilt rate is greater than the specifications,
lower the mast and remove the load from the
forks. Install a gate valve between the port at
WARNING the front of the tilt cylinder and the hydraulic
Never allow anyone under a raised carriage. DO line. The gate valve must be able to completely
NOT put any part of your body in or through the shut off the flow of hydraulic oil. Put the load
lift mechanism unless all parts of the mast are on the forks again. Close the gate valve. Tilt the
completely lowered and the engine is STOPPED. mast forward just past the vertical position. If
the mast continues to tilt SLOWLY forward,
WARNING the seals on the piston are leaking.
DO NOT try to find hydraulic leaks by putting your 4. If the mast does not move, open the gate valve
hand on hydraulic components under pressure. and check the movement again. If the mast
Hydraulic oil can be injected into the body by the moves forward when the gate valve is open,
pressure. check for leaks in the hydraulic lines and fit-
tings. If leaks are not found, the main control
1. Put a capacity load on the forks. Use a safety
valve can be worn or damaged. Remove load
chain to hold the load to the carriage. See
from the forks when checks are complete.
Safety Procedures When Working Near Mast.
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 shown in Table 1 or Table 2 by the
time of the test and compare the numbers.

Table 1. Tilt Cylinder Movement Rates (Maximum), Lift Truck Models S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80,
100, 120FT; S80, 100FTBCS; S120FTS; S120FTPRS) (J004)

Hydraulic Oil Temperature/Mast Tilt Rate

20°C (68°F) 30°C (86°F) 40°C (104°F) 50°C (122°F) 60°C (140°F)
mm/min in./min mm/min in./min mm/min in./min mm/min in./min mm/min in./min
1.1 0.04 1.6 0.06 3.0 0.12 4.9 0.19 7.3 0.30

Table 2. Tilt Cylinder Movement Rates (Maximum), Lift Truck Models H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, H120FT) (U005)

Hydraulic Oil Temperature/Mast Tilt Rate

20°C (68°F) 30°C (86°F) 40°C (104°F) 50°C (122°F) 60°C (140°F)
mm/min in./min mm/min in./min mm/min in./min mm/min in./min mm/min in./min
1.1 0.04 2.0 0.08 3.2 0.13 5.0 0.20 7.3 0.30

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 HeavyManuals.com
2100 SRM 1947 Main Lift Cylinders

Main Lift Cylinders

REMOVE an injury. Always use the correct snap ring pliers,
and wear eye and face protection during removal
or installation.
WARNING
Before working on or near the mast, see Safety 2. Remove snap ring, shims, and washer at top of
Procedures When Working Near Mast. cylinder. Remove tube assembly from the top of
the left main lift cylinder. See Figure 10.
NOTE: The following procedures are for the re-
moval of lift cylinders with the mast installed on
lift truck. WARNING
Hydraulic oil is hot after system operation and
NOTE: Except as noted, the following procedures can cause burns. DO NOT disconnect any hy-
are for removal of both lift cylinders. draulic hoses until the oil in the system is cool.
1. Remove the carriage as described in the car- 3. Put a drain pan under the area of the hydraulic
riage removal procedures. See the Mast Re- fittings. Disconnect hydraulic lines at main lift
pair manual listed in the General section of cylinder and drain oil. Cap hydraulic lines and
this manual for procedures. cylinder ports. See Figure 10.

Two-Stage FFL 4. Remove two washers, two capscrews, and

bracket from mast. See Figure 10.
1. Raise and chain the mast as described in Safety
Procedures When Working Near Mast. The 5. Disconnect main lift chain at mount.
mast must be chained before proceeding to the
next step in this procedure. NOTE: After main lift cylinder has been completely
disconnected from the mast, the mast needs to be
raised high enough for the bottom of the cylinder to
WARNING clear the crossmember on the outer mast weldment.
Be careful when removing or installing snap The cylinder being removed needs to have the rod
rings. These snap rings can come loose during re- retracted into the cylinder.
moval or installation with enough force to cause
6. Using a lifting device, remove main lift cylinder
from mast.

15
 HeavyManuals.com
Main Lift Cylinders 2100 SRM 1947

Figure 10. Main Lift Cylinder, Remove and Install

16
 HeavyManuals.com
2100 SRM 1947 Main Lift Cylinders

Legend for Figure 10

NOTE: TWO-STAGE FFL MAIN LIFT CYLINDERS SHOWN. THREE-STAGE FFL AND TWO-STAGE LFL MAIN
LIFT CYLINDERS ARE SIMILAR. MAST REMOVED FOR CLARITY.

1. SNAP RING 7. BRACKET

2. SHIM 8. LEFT MAIN LIFT CYLINDER
3. WASHER 9. RIGHT MAIN LIFT CYLINDER
4. HYDRAULIC LINE 10. TUBE ASSEMBLY
5. CYLINDER PORT 11. LOWERING CONTROL HOUSING/VALVE
6. CAPSCREW

17
 HeavyManuals.com
Main Lift Cylinders 2100 SRM 1947

Three-Stage FFL 6. Using a lifting device, remove main lift cylinder

from mast.
1. Raise and chain the mast as described in Safety
Procedures When Working Near Mast. The Two-Stage LFL
mast must be chained before proceeding to the
next step in this procedure. 1. Raise and chain the mast as described in Safety
Procedures When Working Near Mast. The
mast must be chained before proceeding to the
WARNING next step in this procedure.
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval or installation with enough force to cause WARNING
an injury. Always use the correct snap ring pliers, Be careful when removing or installing snap
and wear eye and face protection during removal rings. These snap rings can come loose during re-
or installation. moval or installation with enough force to cause
an injury. Always use the correct snap ring pliers,
2. Remove snap ring, shims, and washer at top of and wear eye and face protection during removal
cylinder. Remove tube assembly from side of or installation.
main lift cylinder. See Figure 10.
2. Remove snap ring and shims at top of cylinder.
Remove tube assembly from side of main lift
WARNING cylinder. See Figure 10.
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. WARNING
Hydraulic oil is hot after system operation and
3. Put a drain pan under the area of the hydraulic can cause burns. DO NOT disconnect any hy-
fittings. Disconnect hydraulic lines at main lift draulic hoses until the oil in the system is cool.
cylinder and drain oil. Cap hydraulic lines and
cylinder ports. See Figure 10. 3. Put a drain pan under the area of the hydraulic
fittings. Disconnect hydraulic lines at main lift
4. Remove two washers, two capscrews, and cylinder and drain oil. Cap hydraulic lines and
bracket from mast. See Figure 10. cylinder ports. See Figure 10.
5. Disconnect main lift chain at mount.

NOTE: After the cylinder has been completely dis-

connected from the mast, the mast needs to be
raised high enough for the bottom of the cylinder to
clear the crossmember on the outer mast weldment.
The cylinder being removed needs to have the rod
retracted into the cylinder.

18
 HeavyManuals.com
2100 SRM 1947 Main Lift Cylinders

4. Remove two washers, two capscrews, and NOTE: To prevent damage to sealing surfaces, use
bracket from mast. See Figure 10. brass tools when removing seals and O-rings.

5. Disconnect main lift chain at mount. 4. Remove and discard rod wiper, rod seal, backup
ring, and O-ring from gland. See Figure 11.
NOTE: After the cylinder has been completely dis-
connected from the mast, the mast needs to be 5. Remove spacer, if installed, from rod.
raised high enough for the bottom of the cylinder to
clear the crossmember on the outer mast weldment. NOTE: Perform Step 6 for right main lift cylinder.
The cylinder being removed needs to have the rod Perform Step 7 for left main lift cylinder.
retracted into the cylinder.
6. Remove wear ring, and piston ring from piston
6. Using a lifting device, remove main lift cylinder end of rod. Discard wear ring. See Figure 11.
from mast.
7. Remove and discard wear ring from piston end
DISASSEMBLE of rod. See Figure 11.

8. Remove capscrew and washer seal. Discard

Two-Stage FFL
seal.
1. Loosen gland with spanner wrench.
NOTE: Perform Step 9 only if the piston is dam-
2. Remove gland from rod and shell. See Fig- aged.
ure 11.
9. Remove piston from rod using spanner wrench.
3. Remove rod and piston assembly from shell. See Figure 11.
Drain any remaining hydraulic oil into drain
pan.

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 HeavyManuals.com
Main Lift Cylinders 2100 SRM 1947

Figure 11. Right and Left Main Lift Cylinders, Two-Stage FFL Mast

20
 HeavyManuals.com
2100 SRM 1947 Main Lift Cylinders

Legend for Figure 11

A. LEFT MAIN LIFT CYLINDER B. RIGHT MAIN LIFT CYLINDER

1. SHELL 8. SPACER (OPTIONAL)
2. ROD 9. WEAR RING
3. GLAND 10. PISTON RING*
4. ROD WIPER 11. CAPSCREW
5. ROD SEAL 12. WASHER-SEAL
6. BACKUP RING 13. LEFT PISTON
7. O-RING 14. RIGHT PISTON

*PISTON RING ONLY USED ON RIGHT MAIN LIFT CYLINDER.

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 HeavyManuals.com
Main Lift Cylinders 2100 SRM 1947

Three-Stage FFL
1. Loosen gland with spanner wrench. See Fig-
ure 12.

2. Remove gland from rod and shell.

3. Remove rod and piston assembly from shell.

See Figure 12. Drain any remaining hydraulic
oil into drain pan.

NOTE: To prevent damage to sealing surfaces, use

brass tools when removing seals and O-rings.

4. Remove and discard rod wiper, backup ring,

seal, O-ring, and wear ring from gland.

5. Remove spacer, if installed, from rod. See Fig-

ure 12.

6. Remove backup ring, piston ring, and wear

ring, from piston. Discard backup ring piston
ring and wear ring.

WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval 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.

7. Remove snap ring from piston. See Figure 12.

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

Figure 12. Right and Left Main Lift Cylinders,

Three-Stage FFL Mast

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 HeavyManuals.com
2100 SRM 1947 Main Lift Cylinders

Two-Stage LFL
1. Loosen gland with spanner wrench. See Fig-
ure 13.

2. Remove gland from rod and shell.

3. Remove rod and piston assembly from shell.

See Figure 13. Drain any remaining hydraulic
oil into drain pan.

NOTE: To prevent damage to sealing surfaces, use

brass tools when removing seals and O-rings.

4. Remove and discard rod wiper, backup ring,

seal, O-ring, and wear ring from gland.

5. Remove spacer from rod. See Figure 13.

6. Remove backup ring, piston ring, and wear

ring, from piston. Discard backup ring piston
ring and wear ring.

WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval 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.

7. Remove snap ring from piston. See Figure 13.

1. SHELL 6. SEAL
2. ROD 7. O-RING
3. GLAND 8. BACKUP RING
4. SNAP RING 9. WEAR RING
5. ROD WIPER 10. PISTON

Figure 13. Limited Free-Lift Cylinder, Two-Stage

LFL Mast

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 HeavyManuals.com
Main Lift Cylinders 2100 SRM 1947

CLEAN 2. Install piston onto rod. Tighten piston to 170 to

200 N•m (125 to 148 lbf ft).
WARNING NOTE: Perform Step 3 for right main lift cylinders.
Cleaning solvents can be flammable and toxic and Perform Step 4 for left main lift cylinders.
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures. CAUTION
A difficult and important step in assembling lift
cylinders is the correct installation of the seals.
WARNING Most lift cylinder maintenance is caused by seal
Compressed air can move particles so they cause leaks. DO NOT damage any parts during assem-
injury to the user or to other personnel. Make sure bly.
the path of the compressed air is away from all
personnel. Wear protective goggles or a face NOTE: To prevent damage to sealing surfaces, use
shield to prevent injury to the eyes. brass tools when installing seals and O-rings.

3. Install spacer, new wear ring, and piston ring

CAUTION onto piston. See Figure 11.
DO NOT allow cleaning solvent to come in contact
4. Install spacer and new wear ring onto piston.
with rubber components, as it will damage those
See Figure 11.
components.
5. Install new backup ring, O-ring, rod seal, and
Clean all metal parts in solvent and dry with com- rod wiper on gland.
pressed air.
6. Install rod and piston assembly into shell.
INSPECT
NOTE: To prevent possible damage to rod and pis-
Inspect gland for damage to threads and seal surfa- ton assembly, use care while installing gland.
ces. If damaged, replace gland.
7. Install gland onto rod in shell. Tighten gland to
340 to 410 N•m (250 to 300 lbf ft).
Inspect piston for damage to seal surfaces. If dam-
aged, replace piston on two-stage FFL main lift cyl-
inders. Replace rod and piston assembly on three- CAUTION
stage FFL and two-stage LFL main lift cylinders. Additives may damage the hydraulic system. Be-
fore using additives, contact your local Hyster
Inspect rod for damage to rod surface and ensure dealer.
that rod is not bent. If damaged, replace rod.
8. Pour 150 cc (5 oz) of hydraulic oil into cylinder
Inspect inner surface of cylinder tube for damage. If through the capscrew hole. This oil provides a
damaged, replace lift cylinder assembly. hydraulic cushion when cylinder reaches the
top of its stroke. Install washer-seal and cap-
ASSEMBLE screw. Tighten capscrew to 6 to 8 N•m (53 to
71 lbf in).
Two-Stage FFL
Three-Stage FFL
1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil. Use new O-rings, 1. Lubricate all internal parts of the lift cylinder
seals, and wear rings. with clean hydraulic oil. Use new O-rings,
seals, and wear rings.
NOTE: Perform Step 2 if the piston was removed
from the rod.

24
 HeavyManuals.com
2100 SRM 1947 Main Lift Cylinders

WARNING WARNING
Be careful when removing or installing snap Be careful when removing or installing snap
rings. These snap rings can come loose during re- rings. These snap rings can come loose during re-
moval or installation with enough force to cause moval or installation with enough force to cause
an injury. Always use the correct snap ring pliers, an injury. Always use the correct snap ring pliers,
and wear eye and face protection during removal and wear eye and face protection during removal
or installation. or installation.

NOTE: To prevent damage to sealing surfaces, use 3. Install snap ring onto piston.
brass tools when installing seals and O-rings.

2. Install snap ring onto piston. See Figure 12. CAUTION

A difficult and important step in assembling lift
cylinder is the correct installation of the seals.
CAUTION Most lift cylinder maintenance is caused by seal
A difficult and important step in assembling lift leaks. DO NOT damage any parts during assem-
cylinder is the correct installation of the seals. bly.
Most lift cylinder maintenance is caused by seal
leaks. DO NOT damage any parts during assem- 4. Install wear ring, piston ring, and backup ring
bly. onto piston. See Figure 13.

3. Install new backup ring, piston ring, and wear 5. Install spacer onto rod.
ring on piston.
6. Install wear ring, O-ring, seal, backup ring, and
4. Install spacer, if removed, onto rod. See Fig- rod wiper onto gland. See Figure 13.
ure 12.
7. Install rod and piston assembly into shell.
5. Install new wear ring, O-ring, seal, backup
ring, and rod wiper onto gland. NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
6. Install rod and piston assembly into shell. See
Figure 12. 8. Install gland onto rod in shell. Tighten gland to
340 to 410 N•m (250 to 300 lbf ft). See Fig-
NOTE: To prevent possible damage to rod and pis- ure 13.
ton assembly, use care while installing gland.
INSTALL
7. Install gland onto rod in shell. Tighten gland to
400 to 475 N•m (295 to 350 lbf ft). NOTE: Except as noted, the following procedures
are for installation of both lift cylinders.
Two-Stage LFL
Two-Stage FFL
1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil. Use new O-rings, 1. Using lifting device, install main lift cylinder in
seals, backup rings, and wear rings. mount at bottom of outer mast.

NOTE: To prevent damage to sealing surfaces, use NOTE: After the cylinder has been completely dis-
brass tools when installing seals and O-rings. connected from the mast, raise the mast high
enough for the bottom of the cylinder to clear the
2. Install new O-ring on check valve. See Fig- crossmember on the outer mast weldment and push
ure 13. the rod back into the cylinder being removed.

25
 HeavyManuals.com
Main Lift Cylinders 2100 SRM 1947

2. Install bracket, two capscrews, and two wash- b. With forks unloaded, raise carriage using hy-
ers to mast. Tighten nut to 33 N•m (24 lbf ft). draulic control levers. Raise carriage
See Figure 10. 300 mm (12 in.) and then stop for 10 seconds
to reduce the pressure in the cylinder. Re-
3. Use lifting device to lower the inner mast onto peat this procedure until the oil flowing from
lift cylinder. Connect tube assembly to top of around the threads is free of air bubbles.
left lift cylinder. Install shims and snap ring at
top of lift cylinder. c. Stop carriage at the top of the cylinder
stroke. Tighten capscrew to 6 to 8 N•m (53
4. Reconnect main lift chain to chain anchor. to 71 lbf in).
5. Uncap hydraulic lines and cylinder ports. Con-
Three-Stage FFL
nect hydraulic lines to cylinder ports. See Fig-
ure 10. 1. Using lifting device, install main lift cylinder in
mount at bottom of outer mast.
CAUTION NOTE: After the cylinder has been completely dis-
Disposal of lubricants and fluids must meet local connected from the mast, raise the mast high
environmental regulations. enough for the bottom of the cylinder to clear the
crossmember on the outer mast weldment and push
6. Dispose of drain pan contents. the rod back into the cylinder being removed.
7. Connect main lift chains and adjust as speci- 2. Install bracket, two capscrews, and two wash-
fied. See the Mast Repair manual listed in the ers to mast. Tighten nut to 33 N•m (24 lbf ft).
General section of this manual for procedures. See Figure 10.
8. Check the main lift cylinders for leaks. See Lift 3. Use lifting device to lower intermediate mast
Cylinder Leak Check section for procedures. onto lift cylinder. Install shim and snap ring at
top of lift cylinder.
System Air Bleed Procedures
4. Install new cotter pin with cotter pin hole posi-
NOTE: The procedures for bleeding air out of the tioned toward the inside mast. Bend both legs
main lift cylinders apply only to lift trucks equip- of cotter pin against chain anchor pin to secure
ped with a two-stage FFL mast. Trucks equipped lift chain to chain anchor.
with a three-stage FFL mast or two-stage LFL
mast do not need to have air bled out of the main 5. Uncap hydraulic lines and cylinder ports. Con-
lift cylinders. nect hydraulic lines to cylinder ports. See Fig-
ure 10.
1. Remove the air from main lift cylinders as de-
scribed below. See Figure 11.

a. Loosen capscrew two turns to permit oil to

flow around threads of capscrew.

26
 HeavyManuals.com
2100 SRM 1947 Main Lift Cylinders

an injury. Always use the correct snap ring pliers,

CAUTION and wear eye and face protection during removal
Disposal of lubricants and fluids must meet local or installation.
environmental regulations.
3. Use lifting device to lower the inner mast onto
6. Dispose of drain pan contents. lift cylinder. Install shim and snap ring at top
of lift cylinder.
7. Connect main lift chains and adjust as speci-
fied. See the Mast Repair manual listed in the 4. Uncap hydraulic lines and cylinder ports. Con-
General section of this manual for procedures. nect the hydraulic lines to cylinder ports. See
Figure 10.
8. Check the main lift cylinders for leaks. See Lift
Cylinder Leak Check section for procedures.
CAUTION
Two-Stage LFL Disposal of lubricants and fluids must meet local
environmental regulations.
1. Using lifting device, install main lift cylinder in
mount at bottom of outer mast. 5. Dispose of drain pan contents.

NOTE: After the cylinder has been completely dis- 6. Connect main lift chains and adjust as speci-
connected from the mast, raise the mast high fied. See the Mast Repair manual listed in the
enough for the bottom of the cylinder to clear the General section of this manual for procedures.
crossmember on the outer mast weldment and push
the rod back into the cylinder being removed. 7. Check the main lift cylinders for leaks. See Lift
Cylinder Leak Check section for procedures.
2. Install bracket, two capscrews, and two wash-
ers to mast. Tighten nut to 33 N•m (24 lbf ft).
See Figure 10.

WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval or installation with enough force to cause

27
 HeavyManuals.com
Free-Lift Cylinder Repair 2100 SRM 1947

Free-Lift Cylinder Repair

TWO AND THREE-STAGE FFL MAST
Remove

WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast.

1. Remove the carriage and lower the mast com-

pletely. See the Mast Repair manual listed in
the General section of this manual for proce-
dures.

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 drain pan under the area of the hydraulic

fittings. Disconnect hydraulic lines at free-lift
cylinder and drain oil from cylinder. Cap hy-
draulic lines and cylinder ports.

3. Remove capscrew, two washers, two pins, and

chain guard from crosshead. Repeat for oppo-
site side. See Figure 14.
1. LIFT CHAIN
1. Remove lift chains from chain sheaves. 2. CHAIN SHEAVE
3. CHAIN GUARD
NOTE: Note placement of components during re- 4. SNAP RING
moval to aid in installation. 5. CROSSHEAD
6. PIN
7. FREE-LIFT CYLINDER
2. Remove capscrews, spacers, washers, and nuts 8. WASHER
holding free-lift cylinder to mast. See Figure 14. 9. CAPSCREW
10. NUT
3. Using a lifting device, as necessary, remove 11. SPACER
free-lift cylinder from mast.
Figure 14. Crosshead Assembly, Two and Three-
Stage FFL Mast

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 HeavyManuals.com
2100 SRM 1947 Free-Lift Cylinder Repair

WARNING
Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval or installation with enough force to cause
and injury. Always use the correct snap ring pli-
ers, and wear eye and face protection during re-
moval and installation.

4. Remove snap ring and chain sheaves from

crosshead.

5. Remove crosshead from cylinder rod and disas-

semble crosshead as necessary. See Figure 14.

Disassemble
NOTE: Perform only those steps below required to
repair the free-lift cylinder.

1. Loosen gland with spanner wrench.

2. Remove gland from rod and shell. See Fig-

ure 15.

3. Remove rod and piston assembly from shell.

Drain any remaining hydraulic oil into drain
pan.

NOTE: To prevent damage to sealing surfaces, use

brass tools when removing seals and O-rings.

4. Remove and discard rod wiper, rod seal, backup

ring, and O-ring from gland. See Figure 15.

5. Remove and discard wear ring, rod seal, and

backup ring from piston. See Figure 15.

WARNING
1. SHELL 8. ROD WIPER
Be careful when removing or installing snap 2. ROD 9. ROD SEAL
rings. These snap rings can come loose during re- 3. GLAND 10. BACKUP RING
moval or installation with enough force to cause 4. CAPSCREW 11. O-RING
an injury. Always use the correct snap ring pliers, 5. CHECK VALVE 12. WEAR RING
and wear eye and face protection during removal 6. SEAL 13. WASHER
7. SNAP RING 14. PISTON
and installation.
Figure 15. Free-Lift Cylinder, Two and Three-Stage
6. Remove snap ring, washer, and check valve FFL Mast
from piston base. Remove and discard O-ring
from check valve.

7. Remove capscrew and seal from shell. Discard

seal. See Figure 15.

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 HeavyManuals.com
Free-Lift Cylinder Repair 2100 SRM 1947

Clean NOTE: To prevent damage to sealing surfaces, use

brass tools when installing seals and O-rings.
WARNING 2. Install O-ring onto check valve. See Figure 15.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur- WARNING
er's recommended safety procedures. Be careful when removing or installing snap
rings. These snap rings can come loose during re-
moval or installation with enough force to cause
WARNING an injury. Always use the correct snap rings pliers
Compressed air can move particles so they can and war eye and face protections during removal
cause injury to the user or to other personnel. or installation.
Make sure the path of the compressed air is away
from all personnel. Wear protective goggles or a 3. Install check valve, washer, and snap ring into
face shield to prevent injury to the eyes. piston base. Make sure arrow on check valve is
toward piston base. See Figure 15.

CAUTION
DO NOT allow cleaning solvent to come in contact
CAUTION
with rubber components, as it will damage those A difficult and important step in assembling free-
components. lift cylinders is the correct installation of the
seals. Most free-lift cylinder maintenance is
Clean all metal parts in solvent and dry with com- caused by seal leaks. DO NOT damage any parts
pressed air. during assembly.

4. Install backup ring, rod seal, and wear ring

Inspect
onto piston.
NOTE: See Figure 15 for all components to inspect.
5. Install backup ring, O-ring, rod seal, and rod
wiper onto gland. See Figure 15.
Inspect gland for damage to threads and seal surfa-
ces. If damaged, replace gland. 6. Install rod and piston assembly into shell.

Inspect piston for any damage to seal surfaces. If NOTE: To prevent possible damage to rod and pis-
damaged, replace rod and piston assembly. ton assembly, use care while installing gland.

Inspect rod for damage to rod surface and ensure 7. Install gland onto rod in shell. Tighten gland to
that rod is not bent. If damaged, replace rod and 400 to 475 N•m (295 to 350 lbf ft).
piston assembly.
8. Pour 150 cc (5 oz) of hydraulic oil into the cylin-
der through the capscrew hole. This oil provides
Inspect inner surface of cylinder shell for damage.
a hydraulic cushion when cylinder reaches the
If damaged, replace free-lift cylinder assembly.
top of its stroke. Install seal and capscrew.
Tighten capscrew to 6 to 8 N•m (53 to
Assemble
70 lbf in).
1. Lubricate all internal parts of the free-lift cylin-
der with clean hydraulic oil. Use new O-rings,
seals, backup rings, and wear rings.

30
 HeavyManuals.com
2100 SRM 1947 Free-Lift Cylinder Repair

Install 6. Install chain guard, two pins, two washers, and

capscrew into crosshead. See Figure 14.
WARNING
Be careful when removing or installing snap CAUTION
rings. These snap rings can come loose during re- Disposal of lubricants and fluids must meet local
moval or installation with enough force to cause environmental regulations.
an injury. Always use the correct snap ring pliers,
and wear eye and face protection during removal 7. Uncap hydraulic line and cylinder port. Con-
or installation. nect hydraulic line to free-lift cylinder. Dispose
of drain pan contents.
1. Assemble crosshead, if disassembled. Install
crosshead onto cylinder rod. See Figure 14. 8. Install the carriage. See the Mast Repair man-
ual listed in the General section of this manual
2. Install chain sheaves and snap rings onto cross- for procedures.
head. See Figure 14.
9. Adjust the free-lift cylinders. See the Mast Re-
3. Using a lifting device install free-lift cylinder pair manual listed in the General section of
into mast. this manual for adjustment procedures.

4. Install spacers, washers, capscrews, and nuts 10. Check free-lift cylinder for leaks. See Lift Cylin-
onto crossmembers to hold free-lift cylinder on der Leak Check section for procedures.
mast as noted during removal. Tighten nuts to
175 N•m (129 lbf ft).

5. Install lift chains to chain sheaves. See Fig-

ure 14.

Integral Sideshift Cylinder Repair

REMOVE 2. Remove four capscrews from right lower re-
tainer and four capscrews from left lower re-
tainer. See Figure 16.
WARNING
Before working on or near the mast, see Safety 3. Lift outer frame up and away from cylinder
Procedures When Working Near Mast. block. See Figure 16.

1. Remove the Integral Sideshift Carriage from

the mast. See the Mast Repair manual listed
in the General section of this manual for proce-
dures.

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Integral Sideshift Cylinder Repair 2100 SRM 1947

1. CYLINDER ROD 7. CYLINDER BLOCK

2. SNAP RING 8. OUTER FRAME
3. WIPER 9. LOWER RETAINER
4. GLAND 10. CAPSCREW
5. O-RING 11. LOWER BEARING
6. UPPER BEARING

Figure 16. Integral Sideshift Carriage and Cylinder

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2100 SRM 1947 Integral Sideshift Cylinder Repair

DISASSEMBLE CLEAN AND INSPECT

NOTE: Disassemble the sideshift cylinder only as
necessary for repairs. Most repairs to sideshift cyl- WARNING
inder will be for replacement of O-rings, wipers, Cleaning solvents can be flammable and toxic and
snap ring, and retainers to stop leaks. If other parts can cause skin irritation. When using cleaning
of the sideshift cylinder need to be repaired, replace solvents, always follow solvent manufacturers
with new cylinder. See Parts Manual. recommended safety procedures.

NOTE: When removing gland from cylinder block,

DO NOT scratch cylinder rod on cylinder block WARNING
threads. Compressed air can move particles so they can
cause injury to user or to other personnel. Make
1. Place suitable container under cylinder block. sure the path of the compressed air is away from
Loosen gland from cylinder block thread and let all personnel. Wear protective goggles or face
oil drain into container. shield to prevent injury to the eyes.
2. Remover gland from cylinder block. See Fig-
ure 16. CAUTION
3. Push gland all the way down cylinder rod and DO NOT allow cleaning solvent to come in contact
remove gland from cylinder rod. with rubber components, as it will damage com-
ponents.
4. Remove O-ring, wiper, and snap ring from
gland. Discard parts after removal. See Fig- 1. Clean retainers, glands and cylinder rods with
ure 16. cleaning solvent and dry with compressed air.

5. Perform Step 1 through Step 4 for other side of 2. Inspect cylinder rod for damage to rod surface
integral sideshift cylinder. and ensure that rod is not bent or scored. If
damaged, replace sideshift cylinder assembly.
See Parts Manual.

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 HeavyManuals.com
Integral Sideshift Cylinder Repair 2100 SRM 1947

ASSEMBLE AND INSTALL 5. Install gland and cylinder rod into cylinder
block.
1. Lubricate new O-rings with clean hydraulic oil.
Install O-rings onto gland. See Figure 16. 6. Tighten gland to 340 to 410 N•m (250 to
300 lbf ft).
2. Apply a film of hydraulic oil to the inside of
gland. 7. Install snap ring into cylinder block. See Fig-
ure 16.
3. Slide wiper onto cylinder rod.
8. Install sideshift cylinder onto carriage.

CAUTION
To prevent damage to cylinder rod, DO NOT in- WARNING
stall assembled gland over tapered end of cylin- Before working on or near the mast, see Safety
der rod. Procedures When Working Near Mast.

4. Apply two drops of Loctite™ 277 on cylinder 9. Install the Integral Sideshift Carriage to the
block thread. See Figure 16. Slide assembled mast. See the Mast Repair manual listed in
gland over rounded end of cylinder rod. the General section of this manual for proce-
dures.

Lift Cylinder Leak Check

2. Put mast in vertical position and raise carriage
WARNING and load 2.5 m (8 ft). If carriage slowly lowers
During the test procedures for the hydraulic sys- when control valve is in NEUTRAL position,
tem, use chains to fasten the load to the carriage there are leaks in hydraulic system. The maxi-
to prevent it from falling. See Safety Procedures mum speed the carriage is allowed to lower is
When Working Near Mast. Keep all people away 100 mm (4 in.) per 10 minutes when hydraulic
from the lift truck during the tests. oil is at normal operating temperature.

DO NOT try to find hydraulic leaks by putting your 3. Check lift cylinders for internal leaks. Remove
hand on hydraulic components under pressure. load from forks. Install valve in supply line be-
Hydraulic oil can be injected into the body by the tween main control valve and mast. Put ca-
pressure. pacity load on forks again. Raise carriage
2.5 m (8 ft). Close valve. If carriage or mast
NOTE: The following checks are to be performed lower slowly, seals in lift cylinders have leaks.
with a capacity load on forks and with hydraulic oil
at normal operating temperature. 4. If carriage does not move, open valve and check
movement again. If carriage lowers when valve
1. Operate hydraulic system. Put capacity load on is open, check for leaks in hydraulic lines and
forks. Use safety chain to hold load to carriage. fittings. If no leaks are found, main control
Raise and lower load several times. Lower load valve can be worn or damaged. Remove load
and tilt mast forward and backward several from forks.
times. Check for leaks.

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2100 SRM 1947 Seal Kit Installation

Seal Kit Installation

EXTERNAL INSTALLATION (SEAL AND INTERNAL INSTALLATION (PISTON ROD
BACK-UP RING) ASSEMBLY)
NOTE: It is recommended that the seal is heated 1. Insert internal installation sleeve into end of
in hydraulic oil prior to installation to make it more cylinder tube. See Figure 18.
flexible and pliable.
2. Install piston rod assembly into cylinder tube.
1. Lubricate seal, back-up ring, external installa- See Figure 18.
tion sleeve and piston rod groove with hy-
draulic fluid. 3. Remove internal installation sleeve from cylin-
der tube and piston rod assembly. See Fig-
2. Install wear ring onto piston rod assembly. See ure 18.
Figure 17.

3. Slide external installation sleeve over piston

rod assembly and wear ring. See Figure 17.

4. Install back-up ring into piston rod groove. See

Figure 17.

5. Slide seal over external installation sleeve and

into piston rod groove. See Figure 17.

6. Remove external installation sleeve.

1. PISTON ROD ASSEMBLY
2. BACK-UP RING
3. SEAL
4. INTERNAL INSTALLATION SLEEVE
5. CYLINDER TUBE
6. WEAR RING

Figure 18. Cylinder Internal Installation

1. PISTON ROD ASSEMBLY

2. WEAR RING
3. EXTERNAL INSTALLATION SLEEVE
4. BACK-UP RING
5. SEAL
Figure 17. Cylinder External Seal Installation

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Torque Specifications 2100 SRM 1947

Torque Specifications
TILT CYLINDERS Gland, Free-Lift Cylinder

Piston Rod Locknut

400 to 475 N•m (295 to 350 lbf ft)
400 to 440 N•m (295 to 325 lbf ft)
Piston, Main Lift Cylinders
Gland
170 to 200 N•m (125 to 148 lbf ft)
400 to 500 N•m (295 to 370 lbf ft)
Main Lift Cylinder Mounting Nut To Outer
Tilt Cylinder Mounting Capscrew
Mast
S4.0FT, 4.5FT, 5.5FT, S5.5FTS (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (J004) 33 N•m (24 lbf ft)

Free-Lift Cylinder Mounting Capscrews

68 N•m (50 lbf ft)

H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT 175 N•m (129 lbf ft)

(H80, 90, 100, 110, H120FT) (U005)
Cylinder Shell Capscrew, Main Lift Cylinders

66 to 73 N•m (49 to 54 lbf ft)

6 to 8 N•m (53 to 71 lbf in)
Tilt Cylinder Rod End Nut
INTEGRAL SIDESHIFT CYLINDER
90 N•m (66 lbf ft) Gland

MAIN LIFT AND FREE-LIFT CYLINDERS

340 to 410 N•m (250 to 300 lbf ft)
Gland, Main Lift Cylinders

Two-Stage FFL and Two-Stage LFL Masts

340 to 410 N•m (250 to 300 lbf ft)

Three-Stage FFL Mast

400 to 475 N•m (295 to 350 lbf ft)

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 HeavyManuals.com

TECHNICAL PUBLICATIONS

2100 SRM 1947 3/15