CYLINDER REPAIR

(MAST S/N D515, E509,

E564)
S2.0-3.5FT (S40-70FT, S55FTS) [G187, H187];
H2.0-3.5FT (H40-70FT) [N177, P177]

PART NO. 4109213 2100 SRM 1692

 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.
 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 ....................................................................................................................................................................8
Inspect ................................................................................................................................................................. 8
Assemble ..............................................................................................................................................................8
Install .................................................................................................................................................................10
Tilt Cylinders, Adjust ....................................................................................................................................... 10
Tilt Cylinders With Tilt Limit Spacers ....................................................................................................... 10
Tilt Cylinders Without Tilt Limit Spacers .................................................................................................. 11
Tilt Cylinder Leak Check ................................................................................................................................. 12
Main Lift And Free-Lift Cylinders Repair ...........................................................................................................13
Main Lift Cylinders ...........................................................................................................................................13
Remove .......................................................................................................................................................... 13
Two-Stage FFL ......................................................................................................................................... 13
Four-Stage FFL ........................................................................................................................................ 13
Disassemble .................................................................................................................................................. 14
Two-Stage FFL ......................................................................................................................................... 14
Four-Stage FFL ........................................................................................................................................ 17
Clean ..............................................................................................................................................................17
Inspect ........................................................................................................................................................... 17
Assemble ....................................................................................................................................................... 17
Two-Stage FFL ......................................................................................................................................... 17
Four-Stage FFL ........................................................................................................................................ 18
Install ............................................................................................................................................................ 20
Two-Stage FFL ......................................................................................................................................... 20
System Air Bleed Procedures .................................................................................................................. 20
Four-Stage FFL ........................................................................................................................................ 20
Free-Lift Cylinder ............................................................................................................................................. 21
Remove .......................................................................................................................................................... 21
Two-Stage FFL ......................................................................................................................................... 21
Four-Stage FFL ........................................................................................................................................ 22
Disassemble .................................................................................................................................................. 24
Two-Stage FFL ......................................................................................................................................... 24
Four-Stage FFL ........................................................................................................................................ 25
Clean ..............................................................................................................................................................26
Inspect ........................................................................................................................................................... 26
Assemble ....................................................................................................................................................... 26
Two-Stage FFL ......................................................................................................................................... 26
Four-Stage FFL ........................................................................................................................................ 27
Install ............................................................................................................................................................ 27
Two-Stage FFL ......................................................................................................................................... 27
Four-Stage FFL ........................................................................................................................................ 27
Lift Cylinder Leak Check ................................................................................................................................. 28
Fork Positioner Cylinder Repair .......................................................................................................................... 29
Remove .............................................................................................................................................................. 29
Disassemble .......................................................................................................................................................29

©2014 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Clean ..................................................................................................................................................................29
Inspect ............................................................................................................................................................... 32
Assemble ............................................................................................................................................................32
Install .................................................................................................................................................................33
Fork Positioner Cylinder Adjustment ......................................................................................................... 33
Integral Sideshift Cylinder Repair .......................................................................................................................34
Remove .............................................................................................................................................................. 34
Disassemble .......................................................................................................................................................35
Clean and Inspect ............................................................................................................................................. 35
Assemble and Install ........................................................................................................................................ 36
Seal Kit Installation ..............................................................................................................................................36
External Installation (Seal and Back-Up Ring) .............................................................................................. 36
Internal Installation (Piston Rod Assembly) ...................................................................................................37
Torque Specifications ............................................................................................................................................ 37
Tilt Cylinders .................................................................................................................................................... 37
Piston Rod Nut ..............................................................................................................................................37
Gland ............................................................................................................................................................. 37
Tilt Cylinder Mounting Capscrew ............................................................................................................... 37
Tilt Cylinder Rod End Nut ...........................................................................................................................37
Main Lift and Free-Lift Cylinders ................................................................................................................... 37
Gland, Main Lift Cylinders .......................................................................................................................... 37
Gland, Free-Lift Cylinder .............................................................................................................................37
Piston, Main Lift Cylinders ..........................................................................................................................37
Main Lift Cylinder Mounting Nut To Outer Mast ......................................................................................37
Main Lift Cylinder Mounting Nut To Intermediate Mast (Four-Stage FFL, Right Cylinder Only) ........37
Retainer Nuts ................................................................................................................................................38
Chain Guard Capscrew (Free-Lift Cylinder) ...............................................................................................38
Crosshead Mounting Capscrew (Free-Lift Cylinder) ..................................................................................38
Free-Lift Cylinder Mounting Capscrews .....................................................................................................38
Cylinder Shell Capscrew, Main Lift Cylinders ........................................................................................... 38
Fork Positioner ..................................................................................................................................................38
Cylinder Rod Retainer ..................................................................................................................................38
Fork Positioner Cylinder Mounting Capscrews ..........................................................................................38
Cylinder Rod Anchor Plug ............................................................................................................................38
Fork Carrier Capscrews ............................................................................................................................... 38
Hose Guide Capscrews ................................................................................................................................. 38
Integral Sideshift Cylinder ...............................................................................................................................38
Cylinder Rod Retainer ..................................................................................................................................38
Gland ............................................................................................................................................................. 38

This section is for the following models:

S2.0-3.5FT (S40-70FT, S55FTS) [G187, H187];

H2.0-3.5FT (H40-70FT) [N177, P177]

ii
2100 SRM 1692 General

General
This section contains repair and adjustment The number and design of parts can be different,
procedures for the following types of cylinders: but the repair, adjustment, and operation of the
• Tilt cylinders cylinders is the same. These cylinders are used on
mast with one of the following serial numbers:
• Main lift cylinders D515, E509, and E564. See Figure 1 for the
• Free-lift cylinders location of mast serial number and for other
• Fork positioner cylinder information about the mast.
• Integral sideshift cylinder

1
General 2100 SRM 1692

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

2
2100 SRM 1692
Description
This manual covers many different types of cylin-
ders. Each cylinder will be described in detail. See
Figure 2.
Tilt cylinders are fastened between the frame of lift
truck and outer weldment of 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
mast weldments. See Figure 2.
The two main lift cylinders are installed at the
back of the outer mast. The base of each lift cylin-
der 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 lift cylinder has an internal low-
ering control valve. A single external lowering con-
trol valve is connected by tubing and hoses to all
the lift cylinders.
Description
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.
Some lift truck models may be equipped with an in-
tegral sideshift (ISS) carriage. On an ISS carriage,
the cylinder is mounted to two brackets on the ISS
frame with pins and cotter pins. The cylinder on an
ISS carriage, moves the carriage left or right. See
Figure 2.
The lift truck models covered in this manual may
be equipped with an optional fork positioner attach-
ment. The fork positioner is mounted to frame of
the integral sideshift carriage. The fork positioner
attachment has two cylinders and moves the forks
left or right without moving the ISS carriage. See
Figure 2.
3
Description 2100 SRM 1692

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

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

1. FORK POSITIONER CYLINDER 8. FREE-LIFT CYLINDER
2. INTEGRAL SIDESHIFT CYLINDER 9. TILT CYLINDER
3. INTEGRAL SIDESHIFT CARRIAGE FRAME 10. MAIN LIFT CYLINDER MOUNT (BOTTOM
4. UPPER CARRIAGE BAR CROSSMEMBER OF OUTER MAST)
5. ISS CYLINDER BRACKET 11. MAIN LIFT CYLINDER MOUNT (GUIDE, TOP
6. LEFT MAIN LIFT CYLINDER CROSSMEMBER OF INNER MAST)
7. RIGHT MAIN LIFT CYLINDER

Figure 2. Cylinder Locations

4
2100 SRM 1692
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 shift. Distances be-
tween 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
completely lowered or a safety chain is in-
stalled. Also make sure that the power is
OFF and the key is removed. Put a DO NOT
OPERATE tag in the operator's compart-
ment. Disconnect the battery and put a tag
or lock on the battery 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.
• 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:
Turn the key switch to the ON position and
push the lift/lower control lever forward un-
til there is no movement in the mast. Make
sure that all parts of the mast that move are
fully lowered.
OR
Safety Procedures When Working Near Mast
• If parts of the mast must be in a raised posi-
tion, install a safety chain to restrain the
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
mast upright that moves in outer mast with
crossmember on outer mast. On the two-stage
mast, the moving part is the inner mast. On the
four-stage mast, it is the first intermediate
mast. See Figure 3.
3. Use a 3/8-inch minimum safety chain with a
hook to fasten the crossmembers together so
the movable 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 (full free-lift models)
is completely retracted.
NOTE: Apply the parking brake. After lowering or
restraining the mast, shut off the power, and re-
move key. Put a DO NOT OPERATE tag in the
operator's compartment. Disconnect battery and
put a tag or lock on battery connector.
5. Install another safety chain (9.5 mm (3/8 in.)
minimum) between the top or bottom bar of the
carriage (5, Figure 3) and a crossmember on the
outer mast as a secondary safety device. Install
a DO NOT REMOVE tag on the safety
chain(s).
5
Safety Procedures When Working Near Mast 2100 SRM 1692

A. TWO-STAGE FFL MAST B. FOUR-STAGE FFL MAST

1. OUTER MAST 5. CARRIAGE BAR
2. INNER MAST 6. CROSSMEMBER
3. HOOK 7. FIRST INTERMEDIATE MAST
4. FREE-LIFT CYLINDER

Figure 3. Safety Chaining the Mast

6
2100 SRM 1692 Tilt Cylinder Repair

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 cylinders
to drop and cause damage.
der. Install caps on the hydraulic lines and in
the cylinder ports.
4. Use a lifting device to move large tilt cylinders.
Remove capscrew and retainer from anchor pin.
Using a drift pin or similar tool, push the an-
chor pin out of the frame. See Figure 4.
5. Using a lifting device, remove tilt cylinder from
lift truck.

1. At the mast, remove the capscrew and retainer 6. Repeat above steps for other tilt cylinder.
from the anchor pin. Using a drift pin or simi-
lar tool, push the anchor pin out of the rod end.
See Figure 4.

NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.

1. CAPSCREW 4. ANCHOR PIN

2. RETAINER 5. TILT SPACER
3. LUBRICATION FITTING

Figure 4. Tilt Cylinder Removal

7
Tilt Cylinder Repair
DISASSEMBLE
NOTE: The following steps have detailed disassem-
bly instructions. Perform only those steps required
to repair the tilt cylinder.
NOTE: Note position of rod end and number of
turns used to remove rod end.
1. Place tilt cylinder in a soft jaw vise. Remove rod
end and, if equipped, tilt spacer from the rod.
See Figure 4 and Figure 5.
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 gland. See Figure 5.
NOTE: Perform Step 4 only if piston or rod has
been damaged.
4. Place rod in a soft-jaw vise and remove nut and
piston from the rod.
5. Remove and discard the O-ring and piston seal
from piston. See Figure 5.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.
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 goggles or a face
shield to prevent injury to the eyes.
CAUTION
DO NOT allow cleaning solvent to come in contact
with rubber components, as it will damage those
components.
Clean all metal parts in solvent and dry with com-
pressed air.
8
2100 SRM 1692
INSPECT
NOTE: If any part needs to be replaced, see Parts
Manual for replacement parts.
Inspect gland for damage to threads and seal surfa-
ces. Replace gland if damaged.
Inspect piston for any damage to seal surfaces and
replace if damaged.
Inspect rod for damage to rod surface and ensure
that rod is not bent. Replace rod if found to be dam-
aged.
Inspect inner surface of cylinder tube for damage. If
tube is found to be damaged, replace cylinder.
Inspect bushings for damage. If damaged, replace
bushings.
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 piston.
See Figure 5.
NOTE: Perform Step 2 only if piston was removed
from rod.
2. Place the rod in a soft-jaw vise and lube the
threads of the nut with hydraulic oil. Install the
piston on the rod and tighten the nut to:
a. 170 to 220 N•m (125 to 162 lbf ft) on lift
truck models
• S2.0-2.5FT (S40-S55FT, S55FTS)
(G187, H187)
• H2.0-2.5FT (H40-50FT) (N177, P177)
b. 320 to 400 N•m (240 to 295 lbf ft) on lift
truck models
• S3.0-3.5FT (S60-S70FT) (G187, H187)
• H3.0-3.5FT (H60-70FT) (N177, P177)
3. Install a new wiper, seal, backup ring, and O-
ring on the gland. See Figure 5.
2100 SRM 1692 Tilt Cylinder Repair

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:
a. 170 to 237 N•m (125 to 175 lbf ft) for lift
truck models
• S2.0-2.5FT (S40-S55FT, S55FTS)
(G187, H187)
• H2.0-2.5FT (H40-50FT) (N177, P177)
b. 400 to 500 N•m (295 to 370 lbf ft) for lift
truck models
• S3.0-3.5FT (S60-S70FT) (G187, H187)
• H3.0-3.5FT (H60-70FT) (N177, P177),
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
with lubricant, Hyster P/N 186061. Install cap-
screw in rod end so that capscrew head is on
the inboard side of rod end. Install washer and
nut on capscrew. Washer and nut must be on
the outboard side of rod end. See Figure 6.
Tighten nut to 90 N•m (66 lbf ft).
6. Repeat the above steps for the other tilt cylin-
der.

A. S2.0-2.5FT (S40-S55FT, S55FTS) (G187, H187) B. S3.0-3.5FT (S60-S70FT) (G187, H187) AND
AND H2.0-2.5FT (H40-50FT) (N177, P177) H3.0-3.5FT (H60-70FT) (N177, P177)
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
Figure 5. Tilt Cylinder

9
Tilt Cylinder Repair 2100 SRM 1692

WARNING
DO NOT put hands between the cylinder rod end
and the mast. Serious injury can occur.

6. 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 installation
procedures. Without the tilt limit spacers, the
mast can tilt too much and cause an accident or
serious injury.

Check the tilt cylinder stroke by slowly tilting the

mast fully forward and backward several times.
A. OUTBOARD SIDE Both tilt cylinders must stop their stroke at the
B. INBOARD SIDE
same time. Adjust the rod ends as shown in Fig-
1. CAPSCREW ure 7 and Figure 8. There must be no twist in the
2. NUT mast weldments.
3. WASHER
4. TILT SPACER Tilt Cylinders With Tilt Limit Spacers
5. ROD END
6. MAST END MOUNT
1. Adjust the rod ends to 20 mm (0.80 in.). See
Figure 6. Rod End Installation Figure 7.

2. Slowly tilt mast forward until one cylinder rod

stops. On the opposite tilt cylinder, loosen cap-
INSTALL screws on rod end. Use a wrench and turn tilt
1. Using a lifting device, place tilt cylinder in cylinder rod IN as necessary. Repeat this proce-
mounting position on lift truck frame. Install dure until both tilt cylinder rods stop at the
anchor pin, retainer, and capscrew. See Fig- same position within 0.50 mm (0.02 in.).
ure 4. Lubricate threads on capscrew with lu-
3. Slowly tilt mast backward until one rod end
bricant, Hyster P/N 186061, and tighten cap-
just contacts the tilt limit spacer. Add shims to
screw to 38 N•m (28 lbf ft).
fill the gap at opposite rod end until both tilt
2. Connect hydraulic lines to tilt cylinder. Slowly cylinder rod ends contact tilt limit spacers
stroke tilt cylinders until rod holes line up with within 0.50 mm (0.02 in.). See Figure 7.
the mast tilt anchor holes.
4. After adjustments are completed, tighten nuts
3. Install anchor pin and retainer on tilt anchor. on tilt cylinder rod ends to 90 N•m (66 lbf ft).
See Figure 4. See Figure 6.

4. Repeat above steps for remaining tilt cylinder. 5. Tilt the mast fully backward and measure the
tilt angle. See Nameplate for tilt angles. If nec-
5. Remove chain holding mast to frame. essary, add an equal number of shims to both
rods for the correct angle.

10
2100 SRM 1692 Tilt Cylinder Repair

peat this procedure until both cylinder rods

stop at the same position within
0.50 mm (0.02 in.). See Figure 8.

3. After adjustments are complete, tighten nuts

on tilt cylinder rod ends to 90 N•m (66 lbf ft).
See Figure 6.

4. Tilt mast fully backward and measure tilt an-

gle. See Nameplate for tilt angles. If necessary,
adjust both rod ends equally for the correct an-
gle.

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

1. MAST
2. ROD END
3. SHIMS
4. TILT LIMIT SPACER
5. TILT CYLINDER
Figure 7. Tilt Cylinder Adjustments, Tilt Cylinder
With Tilt Limit Spacer

Tilt Cylinders Without Tilt Limit Spacers

1. Adjust tilt cylinder rod ends to20 mm (0.80 in.). A. 20 mm (0.80 in.)
See Figure 8.
1. MAST
2. Slowly tilt mast backward until one cylinder 2. ROD END
rod stops. On the opposite cylinder, loosen cap- 3. TILT CYLINDER
screws on tilt cylinder rod end. Measure dis- Figure 8. Tilt Cylinder Adjustments, Tilt Cylinder
tance from end of tilt cylinder to back end of rod Without Tilt Limit Spacer
end. Use a wrench and turn cylinder rod IN un-
til dimension starts to decrease, then stop. Re-

11
Tilt Cylinder Repair
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 forks. Use a safety chain
to hold load to carriage. Raise load approxi-
mately 2.5 m (8 ft). Put mast in a 90 degrees
vertical position.
2. Measure distance that rod for tilt cylinder ex-
tends from shell. Check distance rod moves in
five or ten minutes. Multiply rate in Table 1 by
the time of the test and compare the numbers.
Table 1. Movement Rates (Maximum) for Tilt Cylinders
Hydraulic Oil Temperature/Mast Tilt Rate
Lift Truck Model
mm/min
S2.0-3.5FT (S40-S70FT, S55FTS) (G187, 1.0
H187)
H2.0-3.5FT (H40-70FT) (N177, P177) 1.0
12
2100 SRM 1692
3. If tilt rate is greater than the specifications,
lower mast and remove load from forks. Install
a gate valve between port at the front of tilt cyl-
inder and hydraulic line. The gate valve must
be able to completely shut off the flow of hy-
draulic oil. Put a load on forks again. Close gate
valve. Tilt mast forward just past the vertical
position. If mast continues to tilt SLOWLY for-
ward, the seals on the piston are leaking.
4. If the mast does not move, open gate valve and
check movement again. If mast moves forward
when gate valve is open, check for leaks in hy-
draulic lines and fittings. If leaks are not found,
the main control valve can be worn or damaged.
Remove load from forks when checks are com-
pleted.
20°C (68°F) 60°C (140°F)
in./min mm/min in./min
0.04 6.8 0.30
0.04 6.3 0.25
2100 SRM 1692
Main Lift And Free-Lift Cylinders Repair
MAIN LIFT CYLINDERS
NOTE: Only lift truck models S40-70FT, S55FTS
(G187, H187) may be equipped with a four-stage
FFL mast.
Remove
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast.
NOTE: The following procedures are for the re-
moval of lift cylinders with the mast installed on
lift truck.
NOTE: Except as noted, the following procedures
are for removal of both lift cylinders.
1. Remove carriage as described in carriage re-
moval procedures located in Mast Repair (S/N
D515, E509, E564) 4000SRM1693.
Two-Stage FFL
1. Raise and chain the mast as instructed in
Safety Procedures When Working Near Mast
section. The mast must be chained before pro-
ceeding to the next step in this procedure.
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.
2. Remove snap ring and shims at top of cylinder.
Remove tube assembly from the top of left main
lift cylinder. See Figure 9.
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.
3. Put a drain pan under the area of the hydraulic
fittings. Disconnect hydraulic lines at lift cylin-
der and drain oil. See Figure 9. Cap hydraulic
lines and cylinder ports.
Main Lift And Free-Lift Cylinders Repair
4. Remove nut, washer, capscrew, and spacer at
mounting plate. See Figure 9.
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.
5. Using a lifting device, remove main lift cylinder
from mast.
Four-Stage FFL
1. Raise and chain the mast as instructed in
Safety Procedures When Working Near Mast
section. The mast must be chained before pro-
ceeding to the next step in this procedure.
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.
2. On left main lift cylinder, remove snap ring
from top of cylinder. See Figure 9.
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.
3. Put a drain pan under the area of the hydraulic
fittings. Disconnect hydraulic lines at lift cylin-
der and drain oil. See Figure 9. Cap hydraulic
lines and cylinder ports.
4. On right main lift cylinder, disconnect tube as-
sembly from straight fitting at top of cylinder.
Cap tube assembly. See Figure 9.
5. On right main lift cylinder, remove nut, re-
tainer, capscrew, and washer from cylinder
mount of intermediate mast section. See Fig-
ure 9.
6. Disconnect balance line from both cylinders.
13
Main Lift And Free-Lift Cylinders Repair
7. Remove nut, washer, capscrew, and spacer at
mounting plate. See Figure 9.
NOTE: Raise the mast high enough for the bottom
of the cylinder to clear the crossmember on the
outer mast weldment and push the rod back into
the cylinder being removed.
8. Using a lifting device, remove lift cylinder from
mast. Keep shims from top of left cylinder with
cylinder.
Disassemble
Two-Stage FFL
1. Loosen gland with spanner wrench.
2. Remove gland from rod and shell. See Fig-
ure 10.
3. Remove rod and piston assembly from shell.
Drain any remaining hydraulic oil into drain
pan. See Figure 10.
14
2100 SRM 1692
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 10.
5. Remove spacer, if installed, from rod.
NOTE: Perform Step 6 for right lift cylinder. Per-
form Step 7 for left lift cylinder.
6. Remove wear ring, and piston ring from piston
end of rod. Discard wear ring. See Figure 10.
7. Remove and discard wear ring from piston end
of rod.
8. Remove capscrew and seal. Discard seal. See
Figure 10.
NOTE: Perform Step 9 only if piston is damaged.
9. Remove piston from rod using spanner wrench.
See Figure 10.
2100 SRM 1692 Main Lift And Free-Lift Cylinders Repair

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

A. TWO-STAGE FFL MAIN LIFT CYLINDER. TYPICAL FOR BOTH LEFT AND RIGHT MAIN LIFT CYLINDERS
B. FOUR-STAGE FFL MAIN LIFT CYLINDERS
1. SNAP RING 9. MOUNTING PLATE
2. SHIM 10. LEFT MAIN LIFT CYLINDER
3. HYDRAULIC LINE 11. RIGHT MAIN LIFT CYLINDER
4. CYLINDER PORT 12. TUBE ASSEMBLY
5. NUT 13. STRAIGHT FITTING
6. WASHER 14. BALANCE LINE
7. CAPSCREW 15. RETAINER
8. SPACER

Figure 9. Main Lift Cylinders, Remove

15
Main Lift And Free-Lift Cylinders Repair 2100 SRM 1692

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

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

Figure 10. Main Lift Cylinders, Two-Stage FFL

16
2100 SRM 1692
Four-Stage FFL
1. Loosen gland with spanner wrench.
2. Remove gland from rod and shell. See Fig-
ure 11.
NOTE: To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings.
3. Remove and discard rod wiper, rod seal, and O-
ring, from gland.
4. Remove rod and piston assembly from shell.
5. Remove spacer, backup ring, rod seal, and wear
ring from piston. Discard backup ring, rod seal,
and wear ring. See Figure 11.
NOTE: Perform Step 6 for left main lift cylinder.
Perform Step 7 for right main lift cylinder.
6. Remove piston ring from piston.
7. Remove and discard O-ring and backup ring
from piston. See Figure 11.
NOTE: Perform Step 8 only if piston is damaged.
8. Remove piston from rod using spanner wrench.
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.
9. Remove snap ring, washer, and check valve
from piston base. Remove and discard O-ring
from check valve. See Figure 11.
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.
Main Lift And Free-Lift Cylinders Repair
WARNING
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 goggles or a face
shield to prevent injury to the eyes.
CAUTION
DO NOT allow cleaning solvent to come in contact
with rubber components. It will damage those
components.
Clean all metal parts in solvent and dry with com-
pressed air.
Inspect
NOTE: If any parts need to be replaced, see Parts
Manual for replacement parts.
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 surfa-
ces. 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
Two-Stage FFL
1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil. Use new O-rings,
seals, and wear rings.
NOTE: Perform Step 2 if piston was removed from
rod.
2. Install piston onto rod. Tighten piston to 170 to
200 mm (125 to 148 lbf ft). See Figure 10.
17
Main Lift And Free-Lift Cylinders Repair
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 assem-
bly.
NOTE: Perform Step 3 for right main lift cylinder.
Perform Step 4 for left main lift cylinder.
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
3. Install spacer, new wear ring, and piston ring
onto piston.
4. Install spacer and new wear ring onto piston.
See Figure 10.
5. Install new backup ring, O-ring, rod seal, and
rod wiper on gland.
6. Install rod and piston assembly into shell. See
Figure 10.
NOTE: To prevent possible damage to rod and pis-
ton assembly, use care while installing gland.
7. Install gland onto rod in shell. Tighten gland to
340 to 410 N•m (250 to 300 lbf ft).
CAUTION
Additives may damage the hydraulic system. Be-
fore using additives, contact your local Hyster
dealer.
8. Pour 150 cc (5 oz) hydraulic oil into cylinder
through the capscrew hole. This oil provides a
hydraulic cushion when cylinder reaches the
top of its stroke. Install seal and capscrew.
Tighten capscrew to 6 to 8 N•m (53 to
71 lbf in). See Figure 10.
Four-Stage FFL
1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil. Use new O-rings,
seals, and wear rings.
NOTE: Perform Step 2 for right main lift cylinder
only.
18
2100 SRM 1692
2. Install backup ring and O-ring onto piston. See
Figure 11.
NOTE: Perform Step 3 only if piston was removed
from rod.
3. Install piston onto rod. Tighten piston to 170 to
200 N•m (125 to 148 lbf ft). See Figure 11.
NOTE: Perform Step 4 for left main lift cylinder.
4. Install piston ring onto piston. See Figure 11.
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
5. Install new O-rings onto check valve.
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.
6. Install check valve, washer, and snap ring in
piston base. Make sure arrow on check valve is
toward piston base. See Figure 11.
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 assem-
bly.
7. Install wear ring, rod seal, backup ring, and
spacer onto piston. See Figure 11.
8. Install rod and piston assembly into shell.
9. Install new O-ring, rod seal, and rod wiper onto
gland. See Figure 11.
NOTE: To prevent possible damage to rod and pis-
ton assembly, use care while installing gland.
10. Install gland onto rod in shell. Tighten gland to
340 to 410 N•m (250 to 300 lbf ft).
2100 SRM 1692 Main Lift And Free-Lift Cylinders Repair

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

1. SHELL 9. WEAR RING
2. ROD 10. ROD SEAL
3. GLAND 11. BACKUP RING
4. PISTON RING 12. SPACER
5. SNAP RING 13. ROD WIPER
6. WASHER 14. LEFT PISTON
7. O-RING 15. RIGHT PISTON
8. CHECK VALVE

Figure 11. Main Lift Cylinders, Four-Stage FFL

19
Main Lift And Free-Lift Cylinders Repair
Install
NOTE: Except as noted, the following procedures
are for installation of both main lift cylinders.
Two-Stage FFL
1. Using lifting device, install lift cylinder in
mount at bottom of outer mast.
NOTE: After the cylinder has been completely dis-
connected from the mast, raise the mast high
enough for the bottom of the cylinder to clear the
crossmember on the outer mast weldment and push
the rod back into the cylinder being removed.
2. Install spacer, capscrew, washer, and nut at
mounting plate. Tighten nut to
40 N•m (30 lbf ft). See Figure 9.
3. Use lifting device to lower the inner mast onto
lift cylinder. Connect tube assembly to top of
left lift cylinder. Install shims and snap ring at
top of lift cylinder.
4. Uncap hydraulic lines and cylinder ports. Con-
nect hydraulic lines to cylinder ports. See Fig-
ure 9.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
5. Dispose of drain pan contents.
6. Connect main lift chains and adjust as descri-
bed in Mast Repair (S/N D515, E509, E564)
4000SRM1693.
System Air Bleed Procedures
NOTE: The procedures for bleeding air out of main
lift cylinders apply only to lift trucks equipped with
a two-stage FFL mast. Trucks equipped with a
four-stage FFL mast do not need to have air bled
out of main lift cylinders.
1. Loosen capscrew two turns to permit oil to flow
around threads of capscrew. See Figure 10.
2. With forks unloaded, raise carriage using hy-
draulic control. Raise carriage 300 mm (12 in.)
and then stop for 10 seconds to reduce pressure
20
2100 SRM 1692
in main lift cylinder. Repeat this procedure un-
til oil flowing from around the threads is free of
air bubbles.
3. Stop carriage at top of cylinder stroke. Tighten
capscrew to 6 to 8 N•m (53 to 71 lbf in).
Four-Stage FFL
1. Using lifting device, install lift cylinder in
mount at the bottom of the outer mast section.
NOTE: Raise mast high enough for the bottom of
main lift cylinder to clear crossmember on outer
mast weldment and push rod back into cylinder be-
ing removed.
2. Install spacer, capscrew, washer, and nut at
mounting plate. Tighten nut to
40 N•m (30 lbf ft). See Figure 9.
3. Use lifting device to lower mast onto lift cylin-
der.
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.
4. On left main lift cylinder, install shim(s) and
snap ring at top of cylinder. See Figure 9.
5. On right main lift cylinder, install retainer,
washer, capscrew, and nut to cylinder mount of
intermediate mast. Tighten nut to
33 N•m (24 lbf ft).
6. Connect main lift chains and adjust as descri-
bed in Mast Repair (S/N D515, E509, E564)
4000SRM1693.
7. On right main lift cylinder, uncap tube assem-
bly and connect to straight fitting at top of cyl-
inder. See Figure 9.
8. Uncap hydraulic lines and cylinder ports. Con-
nect the hydraulic lines at cylinder ports.
9. Install balance line between main lift cylinders.
See Figure 9.
2100 SRM 1692 Main Lift And Free-Lift Cylinders Repair

CAUTION WARNING
Disposal of lubricants and fluids must meet local Be careful when removing or installing snap
environmental regulations. rings. These snap rings can come loose during re-
moval or installation with enough force to cause
10. Dispose of drain pan contents. and injury. Always use the correct snap ring pli-
ers, and wear eye and face protection during re-
FREE-LIFT CYLINDER moval and installation.
NOTE: Only lift truck models S40-70FT, S55FTS 7. Remove snap ring and chain sheaves from
(G187) may be equipped with a four-stage FFL crosshead. See Figure 12.
mast.
8. Remove two pins from each side of crosshead.
Remove
9. Remove snap ring and crosshead from cylinder
Two-Stage FFL rod. Disassemble crosshead as necessary. See
Figure 12.

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

1. Remove carriage as described in the carriage

removal procedures, located in Mast Repair
(S/N D515, E509, E564) 4000SRM1693.

Lower mast completely.

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, pin, and chain

guard from crosshead. Repeat for opposite side. 1. LIFT CHAIN
See Figure 12. 2. CHAIN SHEAVE
3. CHAIN GUARD
4. Remove lift chains from chain sheaves. 4. SNAP RING
5. CROSSHEAD
6. PIN
NOTE: Note placement of components during re- 7. FREE-LIFT CYLINDER
moval to aid in installation. 8. WASHER
9. CAPSCREW
5. Remove brackets, capscrews, washers, and nuts
holding free-lift cylinder to mast. See Figure 13. Figure 12. Crosshead Assembly, Two-Stage FFL
Mast
6. Using a lifting device, as necessary, remove
free-lift cylinder from mast.

21
Main Lift And Free-Lift Cylinders Repair 2100 SRM 1692

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. See Figure 9.

3. Remove two capscrews, two washers, two pins,

and chain guard from crosshead. See Figure 14.

4. Remove chains from chain sheaves.

5. Remove two nuts, two washers, and strap from

mount. See Figure 14.

6. Remove four nuts, four washers, bracket, four

spacers, and four capscrews from mast.

1. CAPSCREW 7. Using lifting device, remove free-lift cylinder

2. CROSSHEAD ASSEMBLY from mast.
3. BRACKET
4. WASHER
5. NUT WARNING
Be careful when removing or installing snap
Figure 13. Free-Lift Cylinder Mounting, Two-Stage
rings. These snap rings can come loose during re-
FFL
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-
Four-Stage FFL moval and installation.

8. Remove four snap rings, four hose guides, and

WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast.
1. Remove the carriage. See Mast Repair (S/N
D515, E509, E564) 4000SRM1693 for proce-
dures.
Lower mast completely.
two chain sheaves from crosshead. See Fig-
ure 14.
9. Remove capscrew, two washers, and crosshead
from free-lift cylinder.
10. Remove alignment pin from free-lift cylinder.
See Figure 14.

22
2100 SRM 1692 Main Lift And Free-Lift Cylinders Repair

Figure 14. Crosshead and Four-Stage Free-Lift Cylinder Assembly

23
Main Lift And Free-Lift Cylinders Repair 2100 SRM 1692

Legend for Figure 14

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
9. SNAP RING 18. BEARING

Disassemble

Two-Stage FFL
NOTE: Perform only those steps below required to
repair 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.

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.
1. SHELL
6. Remove snap ring, washer, and check valve 2. ROD
3. GLAND
from piston base. Remove and discard O-ring 4. CAPSCREW
from check valve. See Figure 15. 5. CHECK VALVE
6. SEAL
7. Remove capscrew and seal from shell. Discard 7. SNAP RING
seal. 8. ROD WIPER
9. ROD SEAL
10. BACKUP RING
11. O-RING
12. WEAR RING
13. WASHER
Figure 15. Free-Lift Cylinder, Two-Stage FFL

24
2100 SRM 1692 Main Lift And Free-Lift Cylinders Repair

Four-Stage FFL
NOTE: Perform only those steps below required to
repair free-lift cylinder.

1. Loosen gland with spanner wrench.

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

ure 16.

3. Remove rod and piston assembly from shell.

Drain any remaining hydraulic oil into drain
pan.

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

ring, and O-ring from gland. See Figure 16.

5. Remove and discard backup ring, seal, and

wear ring from piston. See Figure 16.

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.

6. Remove snap ring, washer, and check valve

from piston base. Remove and discard O-ring
from check valve. See Figure 16.
1. SHELL
2. ROD
3. GLAND
4. ROD WIPER
5. ROD SEAL
6. BACKUP RING
7. O-RING
8. SEAL
9. WEAR RING
10. CHECK VALVE
11. WASHER
12. SNAP RING
13. CAPSCREW
14. SEAL

Figure 16. Free-Lift Cylinder, Four-Stage FFL

25
Main Lift And Free-Lift Cylinders Repair
Clean
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.
WARNING
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 goggles or a face
shield to prevent injury to the eyes.
CAUTION
DO NOT allow cleaning solvent to come in contact
with rubber components. It will damage those
components.
Clean all metal parts in solvent and dry with com-
pressed air.
Inspect
NOTE: If any parts need to be replaced, see Parts
Manual for replacement parts.
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 surfa-
ces. 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
Two-Stage FFL
1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil. Use new O-rings,
seals, backup rings, and wear rings.
26
2100 SRM 1692
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
2. Install O-ring onto check valve. See Figure 15.
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 rings pliers
and war eye and face protections during removal
or installation.
3. Install check valve, washer, and snap ring into
piston base. Make sure arrow on check valve is
toward piston base. See Figure 15.
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 assem-
bly.
4. Install backup ring, rod seal, and wear ring
onto piston.
5. Install backup ring, O-ring, rod seal, and rod
wiper onto gland. See Figure 15.
6. Install rod and piston assembly into shell.
NOTE: To prevent possible damage to rod and pis-
ton assembly, use care while installing gland.
7. Install gland onto rod in shell. Tighten gland to
475 to 540 N•m (350 to 400 lbf ft).
CAUTION
Additives may damage the hydraulic system. Be-
fore using additives, contact your local Hyster
dealer.
8. Pour 150 cc (5 oz) hydraulic oil into cylinder
through the capscrew hole (see Figure 15). This
oil provides a hydraulic cushion when cylinder
reaches the top of its stroke. Install seal and
capscrew. Tighten capscrew to 6 to 8 N•m (53
to 71 lbf in).
2100 SRM 1692
Four-Stage FFL
1. Lubricate all internal parts of the lift cylinder
with clean hydraulic oil. Use new O-rings,
seals, backup rings, and wear rings.
2. Install O-ring onto check valve. See Figure 16.
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 rings pliers
and war eye and face protections during removal
or installation.
3. Install snap ring, washer, and check valve into
piston base. Make sure arrow on check valve is
toward piston base. See Figure 16.
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 assem-
bly.
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
4. Install backup ring, seal, and wear ring onto
piston.
5. Install backup ring, O-ring, rod seal, and wiper
ring onto gland. See Figure 16.
6. Install rod and piston assembly into shell.
NOTE: To prevent possible damage to rod and pis-
ton assembly, use care while installing gland.
7. Install gland onto rod in shell. Tighten gland to
475 to 540 N•m (350 to 400 lbf ft). See Fig-
ure 16.
Install
Two-Stage FFL
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
Main Lift And Free-Lift Cylinders Repair
an injury. Always use the correct snap rings pliers
and war eye and face protections during removal
or installation.
1. Assemble crosshead, if disassembled. Install
crosshead and snap ring onto cylinder rod.
Tighten crosshead capsrews to
435 N•m (320 lbf ft). See Figure 12.
2. Install chain sheaves and snap rings onto cross-
head. See Figure 12.
3. Using a lifting device install free-lift cylinder
into mast.
4. Install brackets, washers, capscrews, and nuts
onto crossmembers to hold free-lift cylinder on
mast as noted during removal. Tighten nuts to
53 N•m (39 lbf ft). See Figure 13.
5. Install two pins into each side of crosshead.
6. Install lift chains to chain sheaves. See Fig-
ure 12.
7. Install chain guard, pin, two washers, and cap-
screw into crosshead. Pin to be installed on
right side of crosshead. Tighten capscrews to
38 N•m (28 lbf ft). See Figure 12.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
8. Uncap hydraulic line and cylinder port. Con-
nect hydraulic line to free-lift cylinder. Dispose
of drain pan contents.
9. Install carriage to mast. See Mast Repair (S/N
D515, E509, E564) 4000SRM1693 for proce-
dures.
10. Adjust free-lift cylinder as described in Mast
Repair (S/N D515, E509, E564)
4000SRM1693.
Four-Stage FFL
1. Install alignment pin into free-lift cylinder. See
Figure 14.
2. Install crosshead, two washers, and capscrew
onto free-lift cylinder. Tighten crosshead cap-
srews to 435 N•m (320 lbf ft). See Figure 14.
27
Main Lift And Free-Lift Cylinders 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
an injury. Always use the correct snap rings pliers
and war eye and face protections during removal
or installation.
3. Install two chain sheaves, four hose guides, and
four snap rings into crosshead.
4. Using a lifting device install free-lift cylinder
onto mast.
5. Install four spacers, bracket, four washers, four
capscrews, and four nuts around cylinder onto
mast. Tighten nuts to 53 N•m (39 lbf ft). See
Figure 14.
6. Install strap, two washers, and two nuts onto
mount.
7. Install chains into chain sheaves. See Fig-
ure 14.
8. Install chain guard, two pins, two washers, and
two capscrews onto crosshead. Tighten cap-
screws to 38 N•m (28 lbf ft). See Figure 14.
CAUTION
Disposal of lubricants and fluids must meet local
environmental regulations.
9. Uncap hydraulic line and cylinder port. Con-
nect hydraulic line to free-lift cylinder. Dispose
of drain pan contents.
10. Install carriage to mast. See Mast Repair (S/N
D515, E509, E564) 4000SRM1693 for proce-
dures.
11. Adjust free-lift cylinder as described in Mast
Repair (S/N D515, E509, E564)
4000SRM1693.
28
2100 SRM 1692
LIFT CYLINDER LEAK CHECK
WARNING
During the test procedures for the hydraulic sys-
tem, use chains to fasten the load to the carriage
to prevent it from falling. Keep all people away
from the lift truck during the tests.
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. Operate hydraulic system. Put capacity load on
forks. Use safety chain to hold load to carriage.
Raise and lower load several times. Lower load
and tilt mast forward and backward several
times. Check for leaks.
2. Raise carriage and load 1 m (3 ft). If carriage
slowly lowers when control valve is in NEU-
TRAL position, there are leaks in hydraulic
system. The maximum speed the carriage is al-
lowed to lower is 50 mm (2 in.) per 10 minutes
when hydraulic oil is 30°C (86°F). If oil temper-
ature is 70°C (158°F), the maximum speed the
carriage can lower is 150 mm (6 in.) per 10 mi-
nutes.
3. Check lift cylinders for internal leaks. Remove
load from forks. Install valve in supply line be-
tween main control valve and mast. Put ca-
pacity load on forks again. Raise carriage
1 m (3 ft). Close valve. If carriage or mast lower
slowly, seals in lift cylinders have leaks.
4. If carriage does not move, open valve and check
movement again. If carriage lowers when valve
is open, check for leaks in hydraulic lines and
fittings. If no leaks are found, main control
valve can be worn or damaged. Remove load
from forks.
2100 SRM 1692
Fork Positioner Cylinder Repair
Only lift truck models equipped with a two-stage
FFL mast (S/N E509 and E564) can be equipped
with an optional fork positioner attachment.
REMOVE
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast.
1. Remove the fork positioner and cylinders from
the integral sideshift carriage. See Mast Re-
pair (S/N D515, E509, E564) 4000SRM1693
for procedures.
DISASSEMBLE
CAUTION
Carefully disassemble the fork positioner so pis-
ton rods and sliding surfaces are not damaged.
NOTE: Disassemble fork positioner cylinders only
as necessary for repairs. On fork positioner covered
in this manual, there are only three items that can
be replaced: the bronze bearings in the outer fork
carriers, the relief tube assemblies, and hose
guides. If any other component parts need to be re-
placed, the whole fork positioner assembly will
need to be replaced. See Parts Manual for replace-
ment kits and part numbers.
NOTE: Depending on the size and configuration of
the forks installed on lift truck, there may be a
spacer bar between the inner and outer fork carri-
ers. See Figure 17.
1. Remove cylinder rod anchor plug. See Fig-
ure 17.
2. Move fork carriers towards manifold and fully
retract fork positioner cylinder rods.
3. Disconnect hydraulic hoses from fork positioner
manifold. See Figure 18.
Fork Positioner Cylinder Repair
4. Disconnect relief tube assembly. See Figure 18.
5. Remove cylinder rod retainer and fork posi-
tioner cylinder from manifold.
6. Remove fork carriers from cylinder shell.
7. Remove wiper shell and bronze bearings from
outer fork carrier. See Figure 17.
8. Remove integral sideshift cylinder from car-
riage. See Integral Sideshift Cylinder Repair
for procedures.
9. Remove setscrews from hose guides and remove
hose guides from outer frame. See Figure 19.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
solvents, always follow the solvent manufactur-
er's recommended safety procedures.
WARNING
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 goggles or a face
shield to prevent injury to the eyes.
CAUTION
DO NOT allow cleaning solvent to come in contact
with rubber components, as it will damage those
components.
1. Clean all metal parts in solvent and dry with
compressed air.
29
Fork Positioner Cylinder Repair 2100 SRM 1692

1. WIPER SHELL 5. CAPSCREW*

2. BRONZE BEARINGS 6. SPACER BAR*
3. OUTER FORK CARRIER 7. CYLINDER ROD ANCHOR PLUG
4. INNER FORK CARRIER

*PARTS USED ON 977 mm (38.5 in.) AND 1067 mm (42 in.) CLASS II CARRIAGES.

Figure 17. Fork Positioner, Disassemble

30
2100 SRM 1692 Fork Positioner Cylinder Repair

NOTE: BACK (DRIVER'S) VIEW SHOWN. TWO-STAGE FFL INTEGRAL SIDESHIFT CARRIAGE SHOWN.

1. FORK POSITIONER HYDRAULIC HOSE (OPEN) 5. OUTER FRAME

2. FORK POSITIONER HYDRAULIC HOSE 6. FORK CARRIER
(CLOSE) 7. RELIEF TUBE ASSEMBLY
3. INTEGRAL SIDESHIFT CARRIAGE HYDRAULIC 8. TUBE ASSEMBLY
HOSES 9. HOSE GUIDE
4. FORK POSITIONER MANIFOLD

Figure 18. Hydraulic Connections, Fork Positioner Cylinder

31
Fork Positioner Cylinder Repair
1. SETSCREW
2. HOSE GUIDE
3. HYDRAULIC HOSE
Figure 19. Fork Positioner Hose Guide
INSPECT
NOTE: The bronze bearings in the outer fork carri-
ers, the relief tube assemblies, and hose guides are
the only components that can be replaced. If other
components are worn or damaged, the whole fork
positioner assembly must be replaced. See the
Parts Manual for replacement parts.
Inspect rod, piston, and retainer for any damage to
seal surfaces. Replace fork positioner if damaged.
Inspect rod for damage to rod surface and ensure
rod is not bent. Replace fork positioner if damaged
or bent.
Inspect fork carrier bronze bearings for wear. Re-
place bronze bearings as necessary. See Figure 17.
32
2100 SRM 1692
4. INTEGRAL SIDESHIFT CYLINDER
5. OUTER FRAME
Inspect relief tube assembly for wear or damage.
Replace relief tube assembly if necessary. See Fig-
ure 18.
Inspect hose guides for wear or damage. Replace
hose guides if necessary. See Figure 19.
ASSEMBLE
1. Install hose guides onto outer frame. Tighten
setscrews to 17 N•m (150 lbf in). See Figure 19.
2. Install integral sideshift cylinder to carriage.
See Integral Sideshift Cylinder Repair for pro-
cedures.
NOTE: Lubricate all internal parts of the cylinder
with clean hydraulic oil during assembly.
2100 SRM 1692 Fork Positioner Cylinder Repair

3. Lubricate new fork carrier bronze bearings
with clean hydraulic oil. Install new bronze
bearings into outer fork carrier and install
wiper shell. See Figure 17.
4. Connect relief tube assemblies. See Mast Re-
pair (S/N D515, E509, E564) 4000SRM1693
for procedures.
2. Open forks all the way, then close the forks.
Watch for unequal fork movement.
3. To increase the speed of forks opening, turn
flow restrictor counterclockwise in ½ turn in-
crements. To decrease the speed of forks clos-
ing, turn flow restrictor clockwise in ½ turn in-
crements. See Figure 20.

5. Install fork carriers onto cylinder shell. 4. Open and close the forks again. If fork move-
ment is not equal, repeat Step 2 and Step 3.
6. Install fork positioner cylinder assembly to
manifold. See Figure 18. 5. If fork movement is equal, tighten jam nut on
flow restrictor. See Figure 20.
7. Install rod retainer. Tighten rod retainer to
165 N•m (120 lbf ft).

8. Connect hydraulic hoses to manifold. See Fig-

ure 18.

9. Install cylinder rod anchor plug. Tighten cylin-

der rod anchor plug to 65 N•m (50 lbf ft). See
Figure 17.

INSTALL

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

1. Install fork positioner assembly to the integral

sideshift carriage. See Mast Repair (S/N
D515, E509, E564) 4000SRM1693 for proce-
dures.
NOTE: BACK (DRIVER'S) VIEW SHOWN. LEFT
Fork Positioner Cylinder Adjustment FLOW RESTRICTOR SHOWN.

To adjust the flow restrictors for equal fork move- 1. JAM NUT
ment, perform the following: 2. FLOW RESTRICTOR

Figure 20. Fork Positioner Cylinder Adjustment

NOTE: Procedures below apply to flow restrictors
on both fork positioner cylinders.

1. Loosen jam nut on flow restrictor and screw

flow restrictor in until it bottoms. Turn flow re-
strictor counterclockwise approximately three
turns. See Figure 20.

33
Integral Sideshift Cylinder Repair 2100 SRM 1692

Integral Sideshift Cylinder Repair

REMOVE 2. Remove two cotter pins, two clevis pins, and
sideshift cylinder from sideshift carriage. See
Figure 21.
WARNING
Before working on or near the mast, see Safety 3. Remove pin from top of sideshift cylinder. See
Procedures When Working Near Mast. Figure 21.

1. Remove integral sideshift carriage from mast.

See Mast Repair (S/N D515, E509, E564)
4000SRM1693 for removal procedures.

NOTE: TWO-STAGE FFL IS SHOWN. INTEGRAL SIDESHIFT CARRIAGE ASSEMBLY FOR FOUR-STAGE FFL
IS SIMILAR.

1. INNER FRAME 11. LUBE FITTING

2. OUTER FRAME 12. CHAIN ANCHOR
3. SIDESHIFT CYLINDER 13. COTTER PIN
4. UPPER BEARING 14. SNAP RING
5. LOWER BEARING 15. LOAD ROLLER
6. LOWER HOOK 16. SHIMS
7. CAPSCREW 17. SPACER
8. WASHER 18. FORK REMOVAL NOTCH
9. CLEVIS PIN 19. CHAIN ANCHOR PIN
10. PIN
Figure 21. Integral Sideshift Carriage and Cylinder

34
2100 SRM 1692 Integral Sideshift Cylinder Repair

DISASSEMBLE
NOTE: Disassemble the sideshift cylinder only as
necessary for repairs. Most repairs to the sideshift
cylinder will be for replacement of O-rings, wipers,
seals, and retainers to stop leaks. If other parts of
the sideshift cylinder needs to be repaired, replace
with new cylinder. See Parts Manual.
NOTE: Drain oil from cylinder before making any
repairs.
1. Disassemble the sideshift cylinder as follows:
a. Clamp one end of cylinder shell in a vise be-
tween the hydraulic fitting and the retainer
on the same end.
CAUTION
DO NOT allow cleaning solvent to come in contact
with rubber components, as it will damage those
components.
1. Clean retainers, glands, and cylinder rods with
cleaning solvent and dry with compressed air.
See Figure 22.
2. Inspect cylinder rod for damage to rod surface
and ensure that rod is not bent or scored. If
damaged, replace sideshift cylinder assembly.
See Parts Manual.

b. Unscrew retainer from cylinder. Slide re-

tainer off cylinder rod. See Figure 22.

c. Clamp other end of cylinder shell in a vise

between the hydraulic fitting and retainer on
same end.

d. Unscrew retainer from cylinder. See Fig-

ure 22.

e. Remove and discard seals and O-ring from

each retainer with a brass O-ring tool. DO
NOT scratch the grooves.

CLEAN AND INSPECT

WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning 1. CYLINDER SHELL AND ROD
2. SEAL
solvents, always follow the solvent manufacturers 3. O-RING
recommended safety procedures. 4. RETAINER
5. WIPER
WARNING Figure 22. Integral Sideshift Cylinder
Compressed air can move particles so they can
cause injury to the user or to other personnel.
Make sure the path of the compressed air is away
from all personnel. Wear protective goggles or a
face shield to prevent injury to the eyes.

35
Integral Sideshift Cylinder Repair
ASSEMBLE AND INSTALL
1. Assemble the sideshift cylinder as follows (see
Figure 22):
NOTE: If new retainers that are already assembled
with seals and O-rings are being installed, proceed
to Step b.
a. Lubricate new O-rings and seals with clean
hydraulic oil. Install seals and O-rings into
retainer grooves. Form seals and O-rings
into a "kidney" shape to ease placement into
groove. Note direction of seals. Pressure
seals are installed with the lip toward
the pressure side of the cylinder.
b. Apply a film of hydraulic oil to inside of re-
tainers.
c. Clamp one end of cylinder shell in a vise be-
tween the hydraulic fitting and end.
d. Screw retainer into cylinder. Tighten re-
tainer to 295 to 355 N•m (218 to 262 lbf ft).
Seal Kit Installation
EXTERNAL INSTALLATION (SEAL AND
BACK-UP RING)
NOTE: It is recommended that seal is heated in hy-
draulic oil prior to installation to make it more flex-
ible and pliable.
1. Lubricate seal, back-up ring, external installa-
tion sleeve and piston rod groove with hy-
draulic fluid.
2. Install wear ring onto piston rod assembly. See
Figure 23.
3. Slide external installation sleeve over piston
rod assembly and wear ring.
4. Install back-up ring into piston rod groove. See
Figure 23.
5. Slide seal over external installation sleeve and
into piston rod groove.
36
2100 SRM 1692
e. Clamp other end of cylinder shell in a vise
between the hydraulic fitting and end.
f. Slide retainer onto cylinder rod. Screw re-
tainer into cylinder. Tighten retainer to 295
to 355 N•m (218 to 262 lbf ft).
NOTE: The pin, located on top left side of cylinder,
looking from the front of carriage, is for alignment
purposes and to prevent the cylinder from rolling to
the front or to the back. See Figure 21.
2. Install sideshift cylinder onto carriage with pin
in the up position. Install two clevis pins, two
cotter, and sideshift cylinder to carriage.
WARNING
Before working on or near the mast, see Safety
Procedures When Working Near Mast.
3. Install sideshift carriage to mast. See Mast Re-
pair (S/N D515, E509, E564) 4000SRM1693
for installation procedures.
6. Remove external installation sleeve. See Fig-
ure 23.
1. PISTON ROD ASSEMBLY
2. WEAR RING
3. EXTERNAL INSTALLATION SLEEVE
4. BACK-UP RING
5. SEAL
Figure 23. Cylinder External Seal Installation
2100 SRM 1692 Seal Kit Installation

INTERNAL INSTALLATION (PISTON ROD

ASSEMBLY)
1. Insert internal installation sleeve into end of
cylinder tube. See Figure 24.

2. Install piston rod assembly into cylinder tube.

3. Remove internal installation sleeve from cylin-

der tube and piston rod assembly. See Fig-
ure 24.
1. PISTON ROD ASSEMBLY
2. BACK-UP RING
3. SEAL
4. INTERNAL INSTALLATION SLEEVE
5. CYLINDER TUBE
6. WEAR RING

Figure 24. Cylinder Internal Installation

Torque Specifications
TILT CYLINDERS Tilt Cylinder Rod End Nut

Piston Rod Nut 90 N•m (66 lbf ft)

S2.0-2.5FT (S40-50FT, S55FTS) (G187, H187) and MAIN LIFT AND FREE-LIFT CYLINDERS
H2.0-2.5FT (H40-50FT) (N177, P177)
Gland, Main Lift Cylinders
170 to 220 N•m (125 to 162 lbf ft)
340 to 410 N•m (250 to 300 lbf ft)
S3.0-3.5FT (S60-70FT) (G187, H187) and
H3.0-3.5FT (H60-70FT) (N177, P177) Gland, Free-Lift Cylinder

320 to 400 N•m (240 to 295 lbf ft) 475 to 540 N•m (350 to 400 lbf ft)

Gland Piston, Main Lift Cylinders

S2.0-2.5FT (S40-50FT, S55FTS) (G187, H187) and 170 to 200 N•m (125 to 148 lbf ft)
H2.0-2.5FT (H40-50FT) (N177, P177)
Main Lift Cylinder Mounting Nut To Outer
170 to 237 N•m (125 to 175 lbf ft) Mast

S3.0-3.5FT (S60-70FT) (G187, H187) and 40 N•m (30 lbf ft)

H3.0-3.5FT (H60-70FT) (N177, P177)
Main Lift Cylinder Mounting Nut To
400 to 500 N•m (295 to 370 lbf ft) Intermediate Mast (Four-Stage FFL, Right
Cylinder Only)
Tilt Cylinder Mounting Capscrew
33 N•m (24 lbf ft)
38 N•m (28 lbf ft)

37
Torque Specifications 2100 SRM 1692

Retainer Nuts Fork Positioner Cylinder Mounting

Capscrews
35 N•m (24 lbf ft)
65 N•m (50 lbf ft)
Chain Guard Capscrew (Free-Lift Cylinder)
Cylinder Rod Anchor Plug
38 N•m (28 lbf ft)
65 N•m (50 lbf ft)
Crosshead Mounting Capscrew (Free-Lift
Cylinder) Fork Carrier Capscrews

435 N•m (320 lbf ft) 35 N•m (25 lbf ft)

Free-Lift Cylinder Mounting Capscrews Hose Guide Capscrews

53 N•m (39 lbf ft) 17 N•m (150 lbf in)

Cylinder Shell Capscrew, Main Lift Cylinders INTEGRAL SIDESHIFT CYLINDER

6 to 8 N•m (53 to 71 lbf in) Cylinder Rod Retainer

FORK POSITIONER 295 to 355 N•m (218 to 262 lbf ft)

Cylinder Rod Retainer Gland

165 N•m (120 lbf ft) 217 N•m (160 lbf ft)

38
 TECHNICAL PUBLICATIONS

2100 SRM 1692 12/14 (4/14)