Hyster H3.50-5.50XM User manual

TILT CYLINDERS
ALL MODELS EXCEPT
H3.50-5.50XM (H70-120XM) [K005, L005]
S3.50-5.50XM (S70-120XM) [E004, F004]
PART NO. 910102 2100 SRM 103

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly
fastened, and that the load being lifted is balanced. Make sure the crane, cables, and
chains have the capacity to support the weight of the load.
•Do not lift heavy parts by hand, use a lifting mechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair
on electric lift trucks.
•Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT
THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Mainte-
nance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts
must meet or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before
using force to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs,
or if the unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel
are flammable. Be sure to follow the necessary safety precautions when handling these
fuels and when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks
away from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

Tilt Cylinders Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Tilt Cylinder Repair........................................................................................................................................... 1
Remove ........................................................................................................................................................... 1
Disassemble ................................................................................................................................................... 1
Clean .............................................................................................................................................................. 1
Assemble ........................................................................................................................................................ 2
Tilt Cylinders With O-Ring or Single-Lip Seals ...................................................................................... 2
Tilt Cylinders for XM and XMS Models................................................................................................... 3
Tilt Cylinders for H700-800A and Early Model H700-920B................................................................... 4
Install ............................................................................................................................................................. 5
Tilt Cylinders Using Chevron Packing .................................................................................................... 6
Install..................................................................................................................................................... 7
Tilt Cylinder Leak Check .................................................................................................................................. 9
Tilt Cylinder Stroke and Mast Tilt Angle Adjustment ....................................................................................10
Torque Specifications ......................................................................................................................................... 11
Piston Rod Nut............................................................................................................................................... 11
Retainer.......................................................................................................................................................... 12
Troubleshooting.................................................................................................................................................. 14
This section is for the following models:
All Models except
H3.50-5.50XM (H70-120XM) [K005, L005]
S3.50-5.50XM (S70-120XM) [E004, F004]
©2003 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

2100 SRM 103 Tilt Cylinder Repair
General
This section has a description and the repair proce-
dures for several different types of tilt cylinders. The number and the design of the parts can be different, but the operation of the tilt cylinders is the same.
Description
The tilt cylinders (Figure 2, Figure 3, Figure 4, and
Figure5)areusedtomovethemastforwardand
backward. To extend the cylinder rod (tilt forward),
oil enters the tilt cylinder port behind the piston. The
oil pressure pushes the cylinder rod out of the cylin-
der. Oil in front of the piston returns to the hydraulic
tank. To retract the cylinder rod (tilt backward), the
oil enters the port in front of the piston. The oil pres-
sure pushes the cylinder rod into the tilt cylinder.
The oil behind the piston returns to the hydraulic
tank.
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.
1. Disconnect the hydraulic lines at the tilt cylinder.
Install caps on the hydraulic lines and ports.
WARNING
Do not push the anchor pins out of the rod end
with your fingers. Do not permit the tilt cylin-
ders to drop and cause damage.
2. Remove the retainers for the anchor pins. Push
the anchor pins out of the rod end with a tool.
3. Use a lifting device to move large tilt cylinders.
Remove the anchor pins from the frame anchors.
Removethetiltcylinderfromtheframe.
DISASSEMBLE
1. Put the tilt cylinder in a vise with soft jaws. Re-
move the rod end from the rod.
2. Remove the retainer from the tilt cylinder. Re-
move the rod and piston from the cylinder.
3. Disassemble the tilt cylinder as necessary. See
Figure 2, Figure 3, Figure 4, and Figure 5.
CLEAN
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety proce-
dures.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Make sure that the path of the compressed air
is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
eyes.
Clean all parts in solvent and dry with compressed
air.
1

Tilt Cylinder Repair 2100 SRM 103
ASSEMBLE
Tilt Cylinders With O-Ring or Single-Lip
Seals
NOTE: Always use new seals and O-rings. Make sure
all parts are clean. Lubricate all parts with clean
hydraulic oil.
NOTE: During 1980 and 1981, a change was made in
the tilt cylinders used in most lift trucks. The O-ring
seal between the retainer and the cylinder shell was
moved from above the threads to the area below the
threads. A backup ring was added to increase the
strength of the O-ring. The assembly of the tilt cylin-
ders is the same, but caution must be used so that the
O-ring seal is not damaged by the threads.
1. Install the O-ring inside the piston bore. See Fig-
ure1.Installthepistononthepistonrod.Make
sure the O-ring is not damaged. Tighten the nut
on the piston rod to the specifications given in
Torque Specifications.
2. Install the O-ring, seal ring, and guide ring on
thepiston. Thesealringmustbeheatedbefore
installation. After heating, it must be pushed
into its groove using a ring compressor. Let the
seal ring cool and return to its normal shape.
3. If used, install the O-ring and the backup ring in
the groove of the outer retainer. Install the rod
seal (O-ring toward the piston) and wiper seal in
the inner retainer.
4. Install the retainer on the piston rod. Install
the piston and rod assembly and the retainer in
the cylinder. If used, install the O-ring on the
retainer. Tighten the retainer to specifications
given in Torque Specifications.
NOTE: After assembly is complete, install the rod
end on the piston rod. Tighten the capscrew on the
rod end as specified in Mast section for your specific
lift truck.
1. PISTON ROD
2. PISTONRING
3. O-RING
4. O-RING
5. PISTON
6. GUIDE RING
7. NUT
8. CYLINDER SHELL
9. O-RING
10. BACKUP RING
11. RETAINER
12. SEAL RING
13. WIPER RING
14. SPACER (SOME MODELS)
Figure 1. Tilt Cylinders With O-Ring or Single-Lip Seals
2

2100 SRM 103 Tilt Cylinder Repair
Tilt Cylinders for XM and XMS Models
NOTE: The following procedure is for these models:
S/H/E/2.00-3.00XM (S/H/E/40-65XM), J2.00-3.00XM
(J40-60XM, J40-60XM2) (A216), J2.00-3.00XM
(J40-60Z) (A416), J1.60-2.00XMT (J30-40XM)
H/S/E1.25-1.75XM, H/S/E2.00XMS (S/H/E25-35XM,
S/H/E40XMS).
NOTE: Always use new seals and O-rings. Make sure
all parts are clean. Lubricate all parts with clean
hydraulic oil.
1. Install the piston seal and O-ring(s) onto the pis-
ton. See Figure 2 and Figure 3. Install the piston
ontothecylinderrod. Makesurethepistonseal
is not damaged. Tighten the nut on the piston
rod to the value shown in Torque Specifications.
2. Install a new wiper and rod seal. Install the
O-ring and backup ring onto the retainer.
3. Install the retainer assembly onto the rod.
4. Install the piston and rod assembly into the cylin-
der. Tighten the retainer to the value shown in
Torque Specifications.
NOTE: After assembly is complete, install the rod
end on the cylinder rod. Tighten the capscrew on the
rod end as specified in Mast section for your specific
lift truck.
1. CYLINDER SHELL
2. NUT
3. PISTON
4. O-RING
5. SEAL RING
6. PISTON ROD
7. O-RING
8. BACKUP RING
9. SEAL RING
10. RETAINER
11. WIPER RING
Figure 2. Tilt Cylinders for S/H/E/2.00-3.20XM (S/H/E/40-65XM), J2.00-3.00XM (J40-60XM,
J40-60XM2) (A216), J2.00-3.20XM (J40-60Z) (A416)
3

Tilt Cylinder Repair 2100 SRM 103
1. CYLINDER SHELL
2. RETAINER
3. ROD
4. WIPER RING
5. ROD SEAL
6. BACKUP RING
7. O-RING
8. NUT
9. PISTON
10. PISTON SEAL
Figure 3. Tilt Cylinders for H/S/E/J1.25-1.75XM, XMS, XMT (H/S/E/J25-40XM, XMS, XMT)
Tilt Cylinders for H700-800A and Early
Model H700-920B
NOTE: Always use new seals and O-rings. Make sure
all parts are clean. Lubricate all parts with clean
hydraulic oil.
1. Install the thrust plate on the rod. Install the
backup ring and O-ring on the rod. Install the
piston on the rod. Install the piston rings and
seals on the piston. See Figure 4.
2. Install the lock nut on the rod. Tighten the lock
nut until the thrust plate is tight against the rod.
Install the pin in the lock nut and rod if neces-
sary, drill a hole in the rod for the pin. Install
thesnapringtoholdthepininposition.
3. Install the piston and rod assembly in the shell.
Install the seals on the retainer. Install the re-
tainer in the shell.
4. Install the lock ring in the shell, but do not
tighten it. Install the capscrews in the lock ring.
Turn the lock ring until it is even with the end
of the shell. Install the pipe plug in the lock
ring and tighten the plug to 34 to 48 N•m (25 to
35 lbf ft). Tighten the capscrews in the lock ring
to 14 to 20 N•m (10 to 15 lbf ft).
5. Install the rod end on the rod. Tighten the cap-
screws on the rod end to 610 N•m (450 lbf ft).
4

2100 SRM 103 Tilt Cylinder Repair
1. CYLINDER SHELL
2. SNAP RING
3. LOCK NUT
4. DOWEL
5. PISTON RING
6. O-RING
7. SEAL RING
8. PISTON RING
9. PISTON
10. THRUST PLATE
11. O-RING
12. BACKUP RING
13. PISTON ROD
14. O-RING
15. BACKUP RING
16. RETAINER
17. SEAL RING
18. WIPER RING
19. RETAINER RING
20. PLUG
21. CAPSCREW
Figure 4. Tilt Cylinders for H700-800A, Early Model H700-920B
INSTALL
1. Use a lifting device to move large tilt cylinders.
Put the cylinder in the lift truck. Install the an-
chorpinintheframe.Installtheretainerpinor
cotter pin.
2. Install the anchor pin at the mast mount. Install
the retainer pin or cotter pin for the anchor pin.
Tighten the capscrews for the retainer pins.
3. Connect the hydraulic lines to the tilt cylinder.
4. Operate the tilt cylinders. Check for correct op-
eration and leakage. Adjust the tilt cylinders
as described in Tilt Cylinder Leak Check and
Tilt Cylinder Stroke and Mast Tilt Angle Adjust-
ment.
5

Tilt Cylinder Repair 2100 SRM 103
Tilt Cylinders Using Chevron Packing
NOTE: Always use new seals and O-rings. Make
sure all parts are clean. Lubricate all parts with
clean hydraulic oil.
NOTE: The following procedure is for the H360-650C
(early model). See Figure 5.
NOTE: After assembly is complete, install the rod
end on the cylinder rod. Tighten the capscrew on the
rod end as specified in Mast section for your specific
lift truck.
1. CYLINDER SHELL
2. NUT
3. PISTON HEAD
4. O-RING
5. NYLON RING
6. PACKING
7. NYLON RING
8. PISTON HALF (FLAT)
9. PISTON ROD
10. O-RING
11. BACKUP RING
12. RETAINER
13. O-RING
14. BACKUP RING
15. BUSHING
16. PACKING
17. RETAINER RING
18. SETSCREW
19. WIPER RING
Figure 5. Tilt Cylinders With Chevron Packing (Early Model H360-650C)
6