Hyster F114 User manual

Hyster F114 (E25Z, E30Z, E35Z, E40ZS) Forklift

CYLINDER REPAIR
(MAST S/N A551, A555, A559, A661, A662,
A663, A66, B507, B508, B509, B551, B555,
B559, B562, B563, B564, B661, B662, B663,
C515, C551, C555, C559, D507, D508, D509,
D515, D562, D563, D564, E509, AND E564)
S30FT, S35FT, S40FTS [E010];
E1.50-2.00XM (E25-35Z, E40ZS) [E114, F114];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
J1.60-2.00XMT (J30-40ZT) [J160];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) [G004, H004];
J2.00-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT
(H80, 90, 100, 110, 120FT) [N005, P005, R005, S005];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098];
S50CT [A267];
H2.0-2.5CT (H50CT) [A274]
PART NO. 1580516 2100 SRM 1139

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.

©2014 HYSTER COMPANY
TABLE OF CONTENTS
General .....................................................................................................................................................................1
Description ...............................................................................................................................................................1
Safety Procedures When Working Near Mast .......................................................................................................2
Tilt Cylinder Repair ................................................................................................................................................ 5
Remove ................................................................................................................................................................ 5
Disassemble .........................................................................................................................................................6
Inspect ................................................................................................................................................................. 9
Clean ....................................................................................................................................................................9
Assemble ..............................................................................................................................................................9
Install .................................................................................................................................................................10
Tilt Cylinders, Adjust ....................................................................................................................................... 11
Tilt Cylinder Leak Check ................................................................................................................................. 13
Torque Specifications ........................................................................................................................................14
Piston Rod Nut ..............................................................................................................................................14
Gland ............................................................................................................................................................. 15
Tilt Cylinder Mounting Capscrew ............................................................................................................... 15
Tilt Cylinder Rod End Nut ...........................................................................................................................15
Lift Cylinder Repair .............................................................................................................................................. 15
Main Lift Cylinders ...........................................................................................................................................15
Remove .......................................................................................................................................................... 15
Disassemble .................................................................................................................................................. 18
Clean ..............................................................................................................................................................19
Inspect ........................................................................................................................................................... 19
Assemble ....................................................................................................................................................... 19
Install ............................................................................................................................................................ 20
System Air Bleed Procedures .................................................................................................................. 21
Two-Stage FFL Left Side Main Lift Cylinder ................................................................................................. 22
Disassemble .................................................................................................................................................. 22
Clean ..............................................................................................................................................................22
Inspect ........................................................................................................................................................... 22
Assemble ....................................................................................................................................................... 23
Install ............................................................................................................................................................ 25
Free-Lift Cylinder ............................................................................................................................................. 25
Remove .......................................................................................................................................................... 25
Disassemble .................................................................................................................................................. 28
Clean ..............................................................................................................................................................28
Inspect ........................................................................................................................................................... 29
Assemble ....................................................................................................................................................... 29
Install ............................................................................................................................................................ 30
Torque Specifications ........................................................................................................................................31
Lift Cylinder Leak Check ................................................................................................................................. 32
Fork Positioner Cylinder Repair .......................................................................................................................... 33
Remove .............................................................................................................................................................. 33
Disassemble .......................................................................................................................................................33
Clean ..................................................................................................................................................................36
Inspect ............................................................................................................................................................... 37
Assemble ............................................................................................................................................................37
Install .................................................................................................................................................................37
Fork Positioner Cylinder Adjustment ......................................................................................................... 37
Torque Specifications ........................................................................................................................................38
Cylinder Repair (Mast S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509, B551, B555, B559,
B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515, D562, D563, D564,
E509, and E564) Table of Contents
i

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TABLE OF CONTENTS (Continued)
Seal Kit Installation ..............................................................................................................................................39
External Installation (Seal and Back-Up Ring) .............................................................................................. 39
Internal Installation (Piston Rod Assembly) ...................................................................................................39
This section is for the following models:
(S30FT, S35FT, S40FTS) [E010];
E1.50-2.00XM (E25-35Z, E40ZS) [E114, F114];
H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT, H40FTS) [F001];
S2.0-3.5FT (S40-70FT, S55FTS) [F187];
J1.60-2.00XMT (J30-40ZT) [J160];
H2.0-3.5FT (H40-70FT) [L177];
S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100, 120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) [G004, H004];
J2.00-3.20XM (J40-65Z) [B416];
E2.00-3.20XM (E45-65Z) [G108];
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100, 110, 120FT)
[N005, P005, R005, S005];
E3.50-5.50XL, E4.50XLS (E70-120Z, E100ZS) [E098];
(S50CT) [A267];
H2.0-2.5CT (H50CT) [A274]
Table of Contents Cylinder Repair (Mast S/N A551, A555, A559, A661, A662, A663, A66, B507, B508, B509,
B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551, C555, C559, D507, D508, D509, D515,
D562, D563, D564, E509, and E564)
ii

General
This section contains repair procedures for tilt cylinders, main lift cylinders, and free-lift cylinders. The
number and the design of the parts can be different, but the operation of the cylinders is the same.
Description
This manual covers many different types of cylin-
ders. Each cylinder will be described in detail.
Tilt cylinders are fastened between the frame of the
lift truck and the outer weldment of the mast to
change the angle of the mast and forks.
Two single-stage main lift cylinders and a free-lift
cylinder are used to raise the carriage and extend
the mast weldments.
The two main lift cylinders are installed at the
back of the outer mast. The base of each lift 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 of the lift cylinders has an inter-
nal lowering control valve. A single external lower-
ing control valve is connected by tubing and hoses
to all the lift cylinders.
NOTE: On lift truck models listed below there are
two free-lift chains and chain sheaves.
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• H2.0-3.5FT (H40-70FT) (L177)
• E2.00-3.20XM (E45-65Z) (G108)
• J2.00-3.20XM (J40-65Z) (B416)
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS)
(G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
• S50CT (A267)
On lift truck models listed below there is one free-
lift chain and chain sheave.
• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)
(E114,F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
• H1.6FT, H1.8FT, H2.0FTS (H30FT, H35FT,
H40FTS) (F001)
2100 SRM 1139 General
1

On lift truck models listed below, equipped with a
three-stage full free-lift mast, there are two free lift
chains and chain sheaves. On lift truck models lis-
ted below, equipped with a two-stage limited free-
lift mast, there are no free lift chains or sheaves.
• H2.0-2.5CT (H50CT) (A274)
On all lift trucks, the free-lift chains connect at one
end of the mid-crossmember of the inner mast. Two
chain sheaves are installed on a crosshead on the
rod of the free-lift cylinder. The chains then go over
sheaves on the crosshead and connect to the car-
riage.
Safety Procedures When Working Near Mast
The following procedures MUST be used when in-
specting or working near the mast. Additional pre-
cautions and procedures can be required when re-
pairing or removing the mast.
WARNING
Mast parts are heavy and can move. Distances 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.
• DO NOT use blocks to support the mast
weldments nor to restrain their movement.
• Mast repairs require disassembly and re-
moval of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in this section.
Safety Procedures When Working Near Mast 2100 SRM 1139
2

WHEN WORKING NEAR THE MAST ALWAYS:
• Lower the mast and carriage completely.
Push the lift/lower control lever forward and
make sure there is no movement in the
mast. Make sure that all parts of the mast
that move are fully lowered.
OR
• If parts of the mast must be in a raised 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
weldment that moves in outer weldment with
crossmember on outer weldment. On the two-
stage and free-lift mast, the moving part is the
inner weldment. On the three-stage mast, it is
the intermediate weldment. On the four-stage
mast, it is the first intermediate weldment. See
Figure 1.
3. Use a 3/8-inch minimum safety chain with a
hook to fasten the crossmembers together so
the 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 (two-stage full free-
lift, three-stage, and four-stage) is completely
retracted. If running, turn the power OFF. Ap-
ply the parking brake. Install a DO NOT RE-
MOVE tag on the safety chain(s).
5. Install another safety chain (3/8-in. minimum)
between the top or bottom crossmember of the
carriage bar and a crossmember on the outer
weldment.
6. After lowering or restraining the mast, shut off
the power, and remove key.
NOTE: Place a DO NOT OPERATE tag in the op-
erator's compartment.
7. Disconnect battery and put a tag or lock on bat-
tery connector.
2100 SRM 1139 Safety Procedures When Working Near Mast
3

A. TWO-STAGE LFL MAST
B. TWO-STAGE FFL MAST
C. THREE-STAGE FFL MAST
D. FOUR-STAGE FFL MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. HOOK
5. FREE-LIFT CYLINDER
6. CARRIAGE BAR
7. CROSSMEMBER
8. FIRST INTERMEDIATE WELDMENT
Figure 1. Two-Stage LFL, Two-Stage FFL, Three-Stage FFL, and Four-Stage FFL Masts
Safety Procedures When Working Near Mast 2100 SRM 1139
4

Tilt Cylinder Repair
REMOVE
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.
1. At the mast, remove the capscrew and retainer
from the anchor pin. Using a drift pin or simi-
lar tool, push the anchor pin out of the rod end.
See Figure 2.
2. Stroke cylinder to the full back tilt position.
3. Disconnect the hydraulic lines at the tilt cylin-
der. Install caps on the hydraulic lines and in
the cylinder ports.
4. Use a lifting device to move large tilt cylinders.
Remove the capscrew and retainer from the an-
chor pin. Using a drift pin or similar tool, push
the anchor pin out of the frame.
5. Using a lifting device, remove the tilt cylinder
from the lift truck.
6. Repeat above steps for the remaining tilt cylin-
der.
NOTE: HYDRAULIC HOSES ARE SHOWN DISCONNECTED FOR CLARITY.
1. CAPSCREW
2. RETAINER
3. LUBRICATION FITTING
4. ANCHOR PIN
5. TILT SPACER
Figure 2. Tilt Cylinder Removal
2100 SRM 1139 Tilt Cylinder Repair
5

DISASSEMBLE
NOTE: The following steps have detailed disassem-
bly instructions. Perform only those steps required
to repair the tilt cylinder.
NOTE: Note the position of the rod end and num-
ber of turns used to remove the rod end.
1. Place the tilt cylinder in a soft jaw vise. Remove
the rod end and, if equipped, tilt spacer from
the rod.
See Figure 3 for lift truck models
• E2.00-3.20XM (E45-65Z) (G108)
• E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• H2.0-3.5FT (H40-70FT) (L177)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6,
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• H2.0-2.5CT (H50CT) (A274)
• J2.00-3.20XM (J40-65Z) (B416)
• S30FT, S35FT, S40FTS (E010)
• S2.0-3.5FT (S40-70FT, S55FTS) (F187)
• S4.0, 4.5, 5.5FT, S5.5FTS (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• S50CT (A267)
See Figure 4 for lift truck models
• E1.50-2.00XM (E25-35Z, E40ZS)
(E114,F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
2. Using a pin-type spanner wrench, remove the
gland from the tilt cylinder. Remove the rod
and piston assembly from the cylinder.
NOTE: To prevent damage to sealing surfaces, use
brass tools when removing seals and O-rings.
3. Remove and discard the O-ring, backup ring,
seal, and wiper from the gland.
NOTE: Perform Step 4 only if the piston or rod has
been damaged.
4. Place the rod in a soft-jaw vise and remove the
nut and piston from the rod.
5. Remove and discard the O-ring and piston seal
from the piston. See Figure 3.
Tilt Cylinder Repair 2100 SRM 1139
6

Figure 3. Tilt Cylinder
2100 SRM 1139 Tilt Cylinder Repair
7

Legend for Figure 3
A. S2.0-2.5FT (S40-S55FT, S55FTS) (F187),
S30FT, S35FT, S40FTS (E010), H1.6FT, H1.8FT,
H2.0FTS (H30FT, H35FT, H40FTS) (F001),
H2.0-2.5FT (H40-50FT) (L177), E2.00-3.20XM
(E45-65Z) (G108), J2.00-3.20XM (J40-65Z)
(B416), S50CT (A267), AND H2.0-2.5CT (H50CT)
(A274)
B. S3.0-3.5FT (S60-S70FT) (F187) AND H3.0-3.5FT
(H60-70FT) (L177)
C. S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100, 120FT;
S80, 100FTBCS; S120FTS; S120FTPRS) (G004,
H004), H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT) (N005,
P005, R005, S005) AND E3.50-5.50XL,
E4.50XLS (E70-120Z, E100ZS) (E098)
1. SHELL
2. GLAND
3. ROD
4. WIPER RING
5. SEAL
6. BACKUP RING
7. O-RING
8. PISTON
9. PISTON SEAL
10. NUT
11. WEAR RING
12. BUSHING
1. CYLINDER SHELL
2. RETAINER
3. ROD
4. WIPER RING
5. SEAL
6. BACKUP RING
7. O-RING
8. NUT
9. PISTON
10. PISTON SEAL
Figure 4. Tilt Cylinder for Lift Truck Models E1.50-2.00XM (E25-35Z, E40ZS) (E114,F114) and
J1.60-2.00XMT (J30-40ZT) (J160)
Tilt Cylinder Repair 2100 SRM 1139
8

INSPECT
Inspect the gland for damage to the threads and
the seal surfaces. Replace the gland if damaged.
Inspect the piston for any damage to the seal surfa-
ces and replace if damaged.
Inspect the rod for damage to the rod surface and
ensure that the rod is not bent. Replace the rod if
found to be damaged.
Inspect the inner surface of the cylinder tube for
damage. If the tube is found to be damaged, replace
the cylinder.
Inspect the bushings for damage. If damaged, re-
place bushings.
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.
ASSEMBLE
NOTE: To prevent damage to sealing surfaces, use
brass tools when installing seals and O-rings.
1. Install a new piston seal and O-ring on the pis-
ton. See Figure 3.
NOTE: Perform Step 2 only if the piston was re-
moved from the 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)
(F187)
• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)
(E114,F114)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• H2.0-2.5FT (H40-50FT) (L177)
• E2.00-3.20XM (E45-65Z) (G108)
• J2.00-3.20XM (J40-65Z) (B416)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
b. 320 to 400 N•m (240 to 295 lbf ft) on lift
truck models
• S3.0-3.5FT (S60-S70FT) (F187)
• H3.0-3.5FT (H60-70FT) (L177)
c. 163 to 190 N•m (120 to 140 lbf ft) on lift
truck model
• J1.60-2.00XMT (J30-40ZT) (J160)
d. 400-440 N•m (295 to 325 lbf ft) on lift truck
models
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
3. Install a new wiper, seal, backup ring, and O-
ring on the gland.
4. Install the rod and piston assembly in the cylin-
der. Using a pin-type spanner, install the gland
in the cylinder. Tighten the gland to:
2100 SRM 1139 Tilt Cylinder Repair
9

a. 170 to 237 N•m (125 to 175 lbf ft) for lift
truck models
• S2.0-2.5FT (S40-S55FT, S55FTS)
(F187)
• H2.0-2.5FT (H40-50FT) (L177
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
b. 163 to 190 N•m (120 to 140 lbf ft) for lift
truck models
• S30FT, S35FT, S40FTS (E010)
• E1.50-2.00XM (E25-35Z, E40ZS)
(E114,F114)
• J1.60-2.00XMT (J30-40ZT) (J160)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• E2.00-3.20XM (E45-65Z) (G108)
• J2.00-3.20XM (J40-65Z) (B416)
c. 400 to 500 N•m (295 to 370 lbf ft) for lift
truck models
• S3.0-3.5FT (S60-S70FT) (F187)
• H3.0-3.5FT (H60-70FT) (L177),
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
• E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
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 5.
Tighten nut to 90 N•m (66 lbf ft).
6. Repeat the above steps for the other tilt cylin-
der.
NOTE: LEFT TILT CYLINDER SHOWN. TILT CYLIN-
DER AND MAST FOR LIFT TRUCK MODELS
H4.0FT5/FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005, P005, R005, S005)
SHOWN, ALL OTHERS SIMILAR. PARTS OF MAST
OMITTED FOR CLARITY.
A. OUTBOARD SIDE B. INBOARD SIDE
1. NUT
2. WASHER
3. ROD END
4. CAPSCREW
Figure 5. Rod End Installation
INSTALL
1. Using a lifting device, place the cylinder in
mounting position on the lift truck frame. In-
stall the anchor pin. Install the retainer and
capscrew. See Figure 2. Lubricate the threads
on the capscrew with lubricant, Hyster P/N
186061, and tighten capscrew to:
Tilt Cylinder Repair 2100 SRM 1139
10

a. 38 N•m (28 lbf ft) for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-S70FT, S55FTS)
(F187)
• H2.0-3.5FT (H40-70FT) (L177)
• E1.50-2.00XM (E25-35Z, E40ZS)
(E114,F114)
• E2.00-3.20XM (E45-65Z) (G108)
• J2.00-3.20XM (J40-65Z) (B416)
• J1.60-2.00XMT (J30-40ZT) (J160)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
b. 66 N•m (49 lbf ft) for lift truck models
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004)
c. 66 to 73 N•m (49 to 54 lbf ft) for lift truck
models
• H4.0FT5/FT6; H4.5FTS5, H4.5FT6;
H5.0-5.5FT (H80, 90, 100, 110, 120FT)
(N005, P005, R005, S005)
d. 77 N•m (57 lbf ft) for lift truck model
• E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
2. Connect the hydraulic lines to the tilt cylinder.
Slowly stroke the cylinders until the rod holes
line up with the mast tilt anchor holes.
3. Install anchor pin and retainer on tilt anchor.
4. Repeat above steps for remaining tilt cylinder.
5. Remove chain holding the mast to the frame.
WARNING
DO NOT put hands between the cylinder rod end
and the mast. Serious injury can occur.
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.
Both tilt cylinders must stop their stroke at the
same time. Adjust the rod ends as shown in Fig-
ure 6. There must be no twist in the mast weld-
ments.
A. DIMENSION A = 15 mm (0.60 in.)
1. MAST
2. ROD END
3. SHIMS
4. TILT LIMIT SPACER
5. TILT CYLINDER
Figure 6. Tilt Cylinder Adjustments; for All Models
Except J1.60-2.00XMT (J30-40ZT) (J160), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004, H004), and H4.0FT5/
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005, S005)
2100 SRM 1139 Tilt Cylinder Repair
11

1. Adjust the stroke of the tilt cylinders WITH-
OUT tilt limit spacers as follows:
a. Adjust the rod ends to
(1) 15 mm (0.6 in.) for lift truck model
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004,
H004), See Figure 7.
(2) 20 mm (0.8 in.) for lift truck models
• H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005,
R005, S005) See Figure 7.
(3) 32 mm (1.25 in.) for lift truck model
• J1.60-2.00XMT (J30-40ZT) (J160)
See Figure 7.
b. Slowly tilt the mast backward until one cyl-
inder rod stops. On the opposite cylinder,
loosen the capscrews on the rod end. Meas-
ure the distance from the end of the cylinder
to the back end of the rod end. Use a wrench
and turn the cylinder rod IN until the dimen-
sion starts to decrease, then stop. Repeat
this procedure until both cylinder rods stop
at the same position within:
(1) 1 mm (0.04 in.) for lift truck models
• S30FT, S35FT, S40FTS (E010)
• H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001)
• S2.0-3.5FT (S40-S70FT, S55FTS)
(F187)
• H2.0-3.5FT (H40-70FT) (L177)
• E1.50-2.00XM (E25-35Z, E40ZS)
(E114,F114)
• E2.00-3.20XM (E45-65Z) (G108)
• J2.00-3.20XM (J40-65Z) (B416)
• J1.60-2.00XMT (J30-40ZT) (J160)
• H4.0FT5/FT6; H4.5FTS5,
H4.5FT6; H5.0-5.5FT (H80, 90,
100, 110, 120FT) (N005, P005,
R005, S005)
• E3.50-5.50XL, E4.50XLS
(E70-120Z, E100ZS) (E098)
• S50CT (A267)
• H2.0-2.5CT (H50CT) (A274)
(2) 0.5 mm (0.02 in.) for lift truck model
• S4.0, 4.5, 5.5FT, S5.5FTS, (S80,
100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004,
H004)
(3) After the adjustments are complete,
tighten the nuts on the rod ends to
90 N•m (66 lbf ft).
c. Tilt the mast fully backward and measure
the tilt angle. See the Nameplate for tilt an-
gles. If necessary, adjust both rod ends
equally for the correct angle.
Tilt Cylinder Repair 2100 SRM 1139
12

A. 32 mm (1.25 in.) FOR J1.60-2.00XMT
(J30-40ZT) (J160) SHOWN.
1. MAST
2. ROD END
3. TILT CYLINDER
Figure 7. Tilt Cylinder Adjustments for Lift Truck
Models J1.60-2.00XMT (J30-40ZT) (J160), S4.0, 4.5,
5.5FT, S5.5FTS, (S80, 100, 120FT; S80, 100FTBCS;
S120FTS; S120FTPRS) (G004, H004), and H4.0FT5/
FT6; H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80, 90, 100,
110, 120FT) (N005, P005, R005, S005) Only
2. Adjust the stroke of the tilt cylinders WITH tilt
limit spacers as follows:
a. Adjust the rod ends to 15 mm (0.6 in.) for all
tilt cylinders as shown in Figure 6.
b. Slowly tilt the mast forward until one cylin-
der rod stops. On the opposite cylinder,
loosen the capscrews on the rod end. Use a
wrench and turn the cylinder rod IN as nec-
essary. Repeat this procedure until both cyl-
inder rods stop at the same position within
1 mm (0.04 in.).
c. Slowly tilt the mast backward until one rod
end just contacts the spacer. Add shims to fill
the gap at the opposite rod end until both rod
ends contact the spacers within
0.5 mm (0.02 in.).
d. After the adjustments are complete, tighten
the nuts on the rod ends to
90 N•m (66 lbf ft).
e. Tilt the mast fully backward and measure
the tilt angle. See the nameplate for tilt an-
gles. If necessary, add an equal number of
shims to both rods for the correct angle.
TILT CYLINDER LEAK CHECK
WARNING
Never allow anyone under a raised carriage. DO
NOT put any part of your body in or through the
lift mechanism unless all parts of the mast are
completely lowered and the engine is STOPPED.
DO NOT try to find hydraulic leaks by putting your
hand on hydraulic components under pressure.
Hydraulic oil can be injected into the body by the
pressure.
1. Put a capacity load on the forks. Use a safety
chain to hold the load to the carriage. Raise the
load approximately 2.5 m (8 ft). Put the mast in
a vertical position.
2. Measure the distance that the rod for tilt cylin-
der extends from the shell. Check the distance
the rod moves in five or ten minutes. Multiply
the rate in Table 1 by the time of the test and
compare the numbers.
2100 SRM 1139 Tilt Cylinder Repair
13

Table 1. Movement Rates (Maximum) for Tilt Cylinders
Lift Truck Model Hydraulic Oil Temperature/Mast Tilt Rate
20°C (68°F) 60°C (140°F)
mm/min in./min mm/min in./min
S2.0-3.5FT (S40-S70FT, S55FTS) (F187),
E2.00-3.20XM (E45-65Z) (G108)
J2.00-3.20XM (J40-65Z) (B416), and
S50CT (A267)
1.0 0.04 6.8 0.30
S30FT, S35FT, S40FTS (E010) 1.0 0.04 5.4 0.21
H1.6FT, H1.8FT, H2.0FTS (H30FT,
H35FT, H40FTS) (F001)
1.0 0.04 5.7 0.23
H2.0-3.5FT (H40-70FT) (L177) and
H2.0-2.5CT (H50CT) (A274)
1.0 0.04 6.3 0.25
E1.50-2.00XM (E25-35Z, E40ZS) (E114)
and J1.60-2.00XMT (J30-40ZT) (J160)
0.8 0.03 5.0 0.20
S4.0, 4.5, 5.5FT, S5.5FTS, (S80, 100,
120FT; S80, 100FTBCS; S120FTS;
S120FTPRS) (G004, H004), H4.0FT5/FT6;
H4.5FTS5, H4.5FT6; H5.0-5.5FT (H80,
90, 100, 110, 120FT) (N005, P005, R005,
S005)
1.1 0.04 7.3 0.30
E1.50-2.00XM (E25-35Z, E40ZS) (F114) .63 0.25 4.3 0.16
E3.50-5.50XL, E4.50XLS (E70-120Z,
E100ZS) (E098)
.74 .029 4.94 1.94
3. If the tilt rate is greater than the specifications,
lower the mast and remove the load from the
forks. Install a valve between the port at the
front of the tilt cylinder and the hydraulic line.
The valve must be able to completely shut off
the flow of hydraulic oil. Put the load on the
forks again. Close the valve. Tilt the mast for-
ward just past the vertical position. If the mast
continues to tilt SLOWLY forward, the seals on
the piston are leaking.
4. If the mast does not move, open the valve and
check the movement again. If the mast moves
forward when the gate valve is open, check for
leaks in the hydraulic lines and fittings. If no
leaks are found, the main control valve can be
worn or damaged. Remove the load from the
forks when the checks are complete.
TORQUE SPECIFICATIONS
Piston Rod Nut
S2.0-2.5FT (S40-S50FT, S55FTS) (F187), S30FT,
S35FT, S40FTS (E010), E1.50-2.00XM (E25-35Z,
E40ZS) (E114,F114), H1.6FT, H1.8FT, H2.0FTS
(H30FT, H35FT, H40FTS) (F001), H2.0-2.5FT
(H40-50FT) (L177), J2.00-3.20XM (J40-65Z)
(B416), E2.00-3.20XM (E45-65Z) (G108), S50CT
(A267), and H2.0-2.5CT (H50CT) (A274)
170 to 220 N•m (125 to 162 lbf ft)
S3.0-3.5FT (S60-S70FT) (F187), H3.0-3.5FT
(H60-70FT) (L177)
320 to 400 N•m (240 to 295 lbf ft)
J1.60-2.00XMT (J30-40ZT) (J160)
163 to 190 N•m (120 to 140 lbf ft)
Tilt Cylinder Repair 2100 SRM 1139
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