Hyster E010 (S40FTS) Forklift Service Repair Manual

General

Thissectionhasadescriptionandtherepairproceduresforseveraldifferenttypesofcylinders.The

numberandthedesignofthepartscanbedifferent, buttheoperationofthecylindersisthesame.

Description

Thismanualcoversmanydifferenttypesofcylinders.Eachcylinderwillbedescribedindetail.

Tiltcylindersarefastenedbetweentheframeofthe lifttruckandtheouterweldmentofthemastto changetheangleofthemastandforks.

Twosingle-stagemainliftcylindersandafree-lift cylinderareusedtoraisethecarriageandextendthe mastweldments.

Thetwomainliftcylindersareinstalledattheback oftheoutermast.Thebaseofeachliftcylindersits onamountatthebottomcrossmemberoftheouter mast.Thetopofeachmainliftcylinderrodfitsintoa guideonthetopcrossmemberoftheinnermast.The free-liftcylinderisinstalledintheinnermast.Each oftheliftcylindershasaninternalloweringcontrol valve.Asingleexternalloweringcontrolvalveisconnectedbytubingandhosestoalltheliftcylinders.

NOTE: OnlifttruckmodelsS2.0-3.5FT(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),H4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005,P005), andE3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS) (E098)therearetwofree-liftchainsandchain sheaves.

OnlifttruckmodelsS30FT,S35FT,S40FTS(E010), E1.50-2.00XM(E25-35Z,E40ZS)(E114/F114),J1.602.00XMT(J30-40ZT)(J160),andH1.6FT,H1.8FT, H2.0FTS(H30FT,H35FT,H40FTS)(F001)thereis onefree-liftchainandchainsheave.Thedescription belowappliestoalltrucks.

Thefree-liftchainsconnectatoneendofthemidcrossmemberoftheinnermast.Twochainsheaves areinstalledonacrossheadontherodofthefreeliftcylinder.Thechainsthengooversheavesonthe crossheadandconnecttothecarriage.

SafetyProceduresWhenWorkingNearMast

ThefollowingproceduresMUSTbeusedwheninspectingorworkingnearthemast.Additionalprecautionsandprocedurescanberequiredwhenrepairingorremovingthemast.

WARNING

Mastpartsareheavyandcanmove.Distances betweenpartsaresmall.Seriousinjuryor deathcanresultifpartofthebodyishitby partsofthemastorthecarriage.

•Neverputanypartofthebodyintoorunder themastorcarriageunlessallpartsarecompletelyloweredorasafetychainisinstalled. AlsomakesurethatthepowerisOFFandthe keyisremoved.PutaDONOTOPERATEtag intheoperator’scompartment.Disconnect thebatteryandputatagorlockonthebatteryconnector.

•Becarefuloftheforks.Whenthemastis raised,theforkscanbeataheighttocause aninjury.

•DONOTclimbonthemastorlifttruckatany time.Usealadderorpersonnellifttowork onthemast.

•DONOTuseblockstosupportthemastweldmentsnortorestraintheirmovement.

•Mastrepairsrequiredisassemblyandremovalofpartsandcanrequireremovalof themastorcarriage.Followtherepairproceduresinthissection.

WHENWORKINGNEARTHEMASTALWAYS:

•Lowerthemastandcarriagecompletely. Pushthelift/lowercontrolleverforwardand makesurethereisnomovementinthemast. Makesurethatallpartsofthemastthat movearefullylowered.

•Ifpartsofthemastmustbeinaraisedposition,installasafetychaintorestrainthe

movingpartsofthemast.Connectmoving partstoapartthatdoesnotmove.Follow theseprocedures:

1. Putmastinverticalposition.

2. Raisemasttoalignbottomcrossmemberofweldmentthatmovesinouterweldmentwithcrossmemberonouterweldment.Onthetwo-stage andfree-liftmast,themovingpartistheinner weldment.Onthethree-stagemast,itistheintermediateweldment.Onthefour-stagemast,it isthefirstintermediateweldment.SeeFigure1.

3. Usea3/8-inchminimumsafetychainwithahook tofastenthecrossmemberstogethersothemovablemembercannotlower.Puthookonbackside ofmast.Makesurehookiscompletelyengaged withalinkinthechain.Makesuresafetychain doesnottouchliftchainsorchainsheaves,tubes, hoses,fittings,orotherpartsonthemast.

4. Lowermastuntilthereistensioninsafetychain andfree-liftcylinder(two-stagefullfree-lift, three-stage,andfour-stage)iscompletelyretracted.Ifrunning,turnthepower OFF.Apply theparkingbrake.Installa DONOTREMOVE tagonthesafetychain(s).

5. Installanothersafetychain(3/8-in.minimum) betweenthetoporbottomcrossmemberofthe carriagebarandacrossmemberontheouter weldment.

6. Afterloweringorrestrainingthemast,shutoff thepower,andremovekey.

NOTE: Placea DONOTOPERATE tagintheoperator’scompartment.

7. Disconnectbatteryandputatagorlockonbatteryconnector.

Figure1.Two-StageLFL,Two-StageFFL,Three-StageFFL,andFour-StageFFLMasts

TiltCylinderRepair

REMOVE

WARNING

Beforeremovingthetiltcylinder(s),tiltthe mastforward.Useachaintoholdthemastto theframeandpreventthemastfrommoving forward.

WARNING

Donotpushtheanchorpinsoutoftherodend withyourfingers.Donotpermitthetiltcylinderstodropandcausedamage.

1. Atthemast,removethecapscrewandretainer fromtheanchorpin.Usingadriftpinorsimilar tool,pushtheanchorpinoutoftherodend.See Figure2.

2. Strokecylindertothefullbacktiltposition.

3. Disconnectthehydrauliclinesatthetiltcylinder.Installcapsonthehydrauliclinesandin thecylinderports.

4. Usealiftingdevicetomovelargetiltcylinders. Removethecapscrewandretainerfromtheanchorpin.Usingadriftpinorsimilartool,push theanchorpinoutoftheframe.

5. Usingaliftingdevice,removethetiltcylinder fromthelifttruck.

6. Repeatabovestepsfortheremainingtiltcylinder.

NOTE: HYDRAULICHOSESARESHOWNDISCONNECTEDFORCLARITY.

DISASSEMBLE

NOTE: Thefollowingstepshavedetaileddisassembly instructions.Performonlythosestepsrequiredto repairthetiltcylinder.

NOTE: Notethepositionoftherodendandnumber ofturnsusedtoremovetherodend.

Figure2.TiltCylinderRemoval

1. Placethetiltcylinderinasoftjawvise.Remove therodendand,ifequipped,tiltspacerfromthe rod.SeeFigure3orFigure4.

2. Usingapin-typespannerwrench,Removethe glandfromthetiltcylinder.Removetherodand pistonassemblyfromthecylinder.

NOTE: Topreventdamagetosealingsurfaces,use brasstoolswhenremovingsealsandO-rings.

3. RemoveanddiscardtheO-ring,backupring, seal,andwiperfromthegland.

NOTE: PerformStep4onlyifthepistonorrodhas beendamaged.

4. Placetherodinasoft-jawviseandremovethe pistonfromtherod.

5. RemoveanddiscardtheO-ringandpistonseal fromthepiston.

INSPECT

Inspecttheglandfordamagetothethreadsandthe sealsurfaces.Replacetheglandifdamaged.

Inspectthepistonforanydamagetothesealsurfaces andreplaceifdamaged.

Inspecttherodfordamagetotherodsurfaceand ensurethattherodisnotbent.Replacetherodif foundtobedamaged.

Inspecttheinnersurfaceofthecylindertubefor damage.Ifthetubeisfoundtobedamaged,replace thecylinder.

CLEAN WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprocedures.

Compressedaircanmoveparticlessothey causeinjurytotheuserortootherpersonnel.

Makesurethepathofthecompressedairis awayfromallpersonnel.Wearprotectivegogglesorafaceshieldtopreventinjurytothe eyes.

CAUTION

Donotallowcleaningsolventtocomeincontactwithrubbercomponents,asitwilldamage thosecomponents.

Cleanallmetalpartsinsolventanddrywithcompressedair.

ASSEMBLE

NOTE: Topreventdamagetosealingsurfaces,use brasstoolswheninstallingsealsandO-rings.

1. InstallanewpistonsealandO-ringonthepiston.SeeFigure3.

NOTE: PerformStep2onlyifthepistonwasremoved fromtherod.

2. Placetherodinasoft-jawvise,andinstallthe pistonontherodandtightenthenutto:

• 170to220N•m(125to163lbfft)onlifttruck modelsS2.0-2.5FT(S40-S55FT,S55FTS) (F187),S30FT,S35FT,S40FTS(E010), E1.50-2.00XM(E25-35Z,E40ZS)(E114/F114), H1.6FT,H1.8FT,H2.0FTS(H30FT,H35FT, H40FTS)(F001),H2.0-2.5FT(H40-50FT) (L177),E2.00-3.20XM(E45-65Z)(G108)and J2.00-3.20XM(J40-65Z)(B416)

• 320to400N•m(240to295lbfft)onlifttruck modelsS3.0-3.5FT(S60-S70FT)(F187)and H3.0-3.5FT(H60-70FT)(L177)

• 163to190N•m(120to140lbfft)onlifttruck modelsJ1.60-2.00XMT(J30-40ZT)(J160)

• 400-440N•m(295to325lbfft)onlifttruck modelsS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS)(G004),H4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110, 120FT)(N005,P005),andE3.50-5.50XL, E4.50XLS(E70-120Z,E100ZS)(E098)

Figure3.TiltCylinder

LegendforFigure3

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),ANDJ2.00-3.20XM(J40-65Z)(B416)

B.S3.0-3.5FT(S60-S70FT)(F187)ANDH3.0-3.5FT (H60-70FT)(L177)

C.S4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT; S80,100FTBCS;S120FTS;S120FTPRS)(G004), H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100, 110,120FT)(N005,P005)AND E3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS) (E098)

Figure4.TiltCylinderforLiftTruckModelsE1.50-2.00XM(E25-35Z,E40ZS)(E114/F114)and J1.60-2.00XMT(J30-40ZT)(J160)

3. Installanewwiper,seal,backupring,andO-ring onthegland.

4. Installtherodandpistonassemblyinthecylinder.Usingapin-typespanner,installthegland inthecylinder.Tightentheglandto:

• 170to237N•m(125to175lbfft)forlift truckmodelsS2.0-2.5FT(S40-S55FT,S55FTS) (F187)andH2.0-2.5FT(H40-50FT)(L177)

• 163to190N•m(120to140lbfft)forlift truckmodelsS30FT,S35FT,S40FTS(E010), E1.50-2.00XM(E25-35Z,E40ZS)(E114/F114), J1.60-2.00XMT(J30-40ZT)(J160),H1.6FT, H1.8FT,H2.0FTS(H30FT,H35FT,H40FTS) (F001),E2.00-3.20XM(E45-65Z)(G108)and J2.00-3.20XM(J40-65Z)(B416).

• 400to500N•m(295to370lbfft)forlift truckmodelsS3.0-3.5FT(S60-S70FT)(F187) andH3.0-3.5FT(H60-70FT)(L177),S4.0, 4.5,5.5FT,S5.5FTS,(S80,100,120FT; S80,100FTBCS;S120FTS;S120FTPRS) (G004),H4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005),andE3.50-5.50XL,E4.50XLS (E70-120Z,E100ZS)(E098)

5. Placethecylinderinasoft-jawviseandinstall thetiltspacer,ifequipped,androdendontherod asnotedduringremoval.Lubricatethethreads onthecapscrewwithpackinglubricant,Hyster PartNo.186061.Tightenthecapscrewonthe rodendto90N•m(66lbfft)foralllifttruckmodelsexceptH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005).

Lubricatethethreadsonthecapscrewwith packinglubricant,HysterPartNo.186061,and tightenthecapscrewontherodendto66to 73N•m(49to54lbfft)forlifttruckmodels H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005).

6. Repeattheabovestepsfortheothertiltcylinder.

INSTALL

1. Usingaliftingdevice,placethecylinderon themountingpointonthelifttruckframe. Installtheanchorpin.Installtheretainer andcapscrew.SeeFigure2.Lubricatethe threadsonthecapscrewpackinglubricant,HysterPartNo.186061.Foralllifttruckmodels exceptS4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS)

(G004),H4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005)andE3.50-5.50XL,E4.50XLS(E70-120Z, E100ZS)(E098),tightenthecapscrewto38N•m (28lbfft).

ForlifttruckmodelsS4.0,4.5,5.5FT,S5.5FTS, (S80,100,120FT;S80,100FTBCS;S120FTS; S120FTPRS)(G004)andH4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90, 100,110,120FT)(N005,P005),tightencapscrew to68N•m(50lbfft).

ForlifttruckmodelsE3.50-5.50XL,E4.50XLS (E70-120Z,E100ZS)(E098),tightencapscrewsto 77N•m(57lbfft).

2. Connectthehydrauliclinestothetiltcylinder. Slowlystrokethecylindersuntiltherodholes lineupwiththemasttiltanchorholes.

3. Removechainholdingthemasttotheframe.

WARNING

DONOTputhandsbetweenthecylinderrod endandthemast.Seriousinjurycanoccur.

4. Operatethetiltcylinders.Checkforcorrectoperationandleakage.Adjustthetiltcylinders.

TILTCYLINDERS,ADJUST

WARNING

Whenthetiltcylindershavetiltlimitspacers, makesuretheyareinstalledduringinstallationprocedures.Withoutthetiltlimitspacers, themastcantilttoomuchandcauseanaccidentorseriousinjury.

Checkthetiltcylinderstrokebyslowlytiltingthe mastfullyforwardandbackwardseveraltimes.Both tiltcylindersmuststoptheirstrokeatthesametime. AdjusttherodendsasshowninFigure6.There mustbenotwistinthemastweldments.

1. AdjustthestrokeofthetiltcylindersWITHOUT tiltlimitspacersasfollows:

a. Adjusttherodendsto15mm(0.6in.)for lifttruckmodelsS4.0,4.5,5.5FT,S5.5FTS, (S80,100,120FT;S80,100FTBCS;S120FTS; S120FTPRS)(G004)and20mm(0.8in.)for lifttruckmodelsH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110, 120FT)(N005,P005).SeeFigure5.

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ForlifttruckmodelsJ1.60-2.00XMT(J3040ZT)(J160),adjusttherodendsto32mm (1.25in.).SeeFigure5.

b. Slowlytiltthemastbackwarduntilone cylinderrodstops.Ontheoppositecylinder, loosenthecapscrewsontherodend.Measurethedistancefromtheendofthecylinder tothebackendoftherodend.Useawrench andturnthecylinderrodINuntilthedimensionstartstodecrease,thenstop.Repeat thisprocedureuntilbothcylinderrodsstop atthesamepositionwithin1mm(0.04in.) foralllifttrucksexceptforS4.0,4.5,5.5FT, S5.5FTS,(S80,100,120FT;S80,100FTBCS; S120FTS;S120FTPRS)(G004)andwithin 0.5mm(0.02in.)forlifttruckmodelsS4.0, 4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80, 100FTBCS;S120FTS;S120FTPRS)(G004). Aftertheadjustmentsarecomplete,tighten thecapscrewsontherodends.

LegendforFigure5

A. 32mm(1.25in.) FORJ1.60-2.00XMT(J30-40ZT) (J160)SHOWN.

1.MAST

2.RODEND

3.TILTCYLINDER

c. Tiltthemastfullybackwardandmeasure thetiltangle.SeetheNameplatefortilt angles.Ifnecessary,adjustbothrodends equallyforthecorrectangle.

2. AdjustthestrokeofthetiltcylindersWITHtilt limitspacersasfollows:

a. Adjusttherodendsto15mm(0.6in.)forall tiltcylindersasshowninFigure6.

b. Slowlytiltthemastforwarduntilonecylinderrodstops.Ontheoppositecylinder, loosenthecapscrewsontherodend.Use awrenchandturnthecylinderrodINas necessary.Repeatthisprocedureuntilboth cylinderrodsstopatthesameposition within1mm(0.04in.).

c. Slowlytiltthemastbackwarduntilonerod endjustcontactsthespacer.Addshimsto fillthegapattheoppositerodenduntilboth rodendscontactthespacerswithin0.5mm (0.02in.).

d. Aftertheadjustmentsarecomplete,tighten thecapscrewsontherodends.

e. Tiltthemastfullybackwardandmeasure thetiltangle.Seethenameplatefortiltangles.Ifnecessary,addanequalnumberof shimstobothrodsforthecorrectangle.

Figure5.TiltCylinderAdjustmentsforLift TruckModelsJ1.60-2.00XMT(J30-40ZT)(J160), S4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80, 100FTBCS;S120FTS;S120FTPRS)(G004),and H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005)Only

A. DIMENSIONA=15mm(0.60in.)

1.MAST

2.RODEND

3.SHIMS

4.TILTLIMITSPACER

5.TILTCYLINDER

Figure6.TiltCylinderAdjustments;forAll ModelsExceptJ1.60-2.00XMT(J30-40ZT) (J160),S4.0,4.5,5.5FT,S5.5FTS,(S80,100, 120FT;S80,100FTBCS;S120FTS;S120FTPRS) (G004),andH4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT)(N005, P005)

TILTCYLINDERLEAKCHECK

WARNING

Neverallowanyoneunderaraisedcarriage. Donotputanypartofyourbodyinorthrough theliftmechanismunlessallpartsofthemast arecompletelyloweredandtheengineis STOPPED.

Donottrytofindhydraulicleaksbyputting yourhandonhydrauliccomponentsunder pressure.Hydraulicoilcanbeinjectedinto thebodybythepressure.

1. Putacapacityloadontheforks.Useasafety chaintoholdtheloadtothecarriage.Raisethe loadapproximately2.5m(8ft).Putthemastin averticalposition.

2. Measurethedistancethattherodfortiltcylinderextendsfromtheshell.Checkthedistance therodmovesinfiveortenminutes.Multiply therateinTable1bythetimeofthetestand comparethenumbers.

3. Ifthetiltrateisgreaterthanthespecifications, lowerthemastandremovetheloadfromthe forks.Installavalvebetweentheportatthe frontofthetiltcylinderandthehydraulicline. Thevalvemustbeabletocompletelyshutoffthe flowofhydraulicoil.Puttheloadontheforks again.Closethevalve.Tiltthemastforwardjust pasttheverticalposition.Ifthemastcontinues totiltSLOWLYforward,thesealsonthepiston areleaking.

4. Ifthemastdoesnotmove,openthevalveand checkthemovementagain.Ifthemastmoves forwardwhenthegatevalveisopen,checkfor leaksinthehydrauliclinesandfittings.Ifno leaksarefound,themaincontrolvalvecanbe wornordamaged.Removetheloadfromthe forkswhenthechecksarecomplete.

Table1.MovementRates(Maximum)forTiltCylinders

120FT;S80,100FTBCS;S120FTS;

TORQUESPECIFICATIONS

PistonRodNut

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)andE2.00-3.20XM(E45-65Z)(G108)

170to220N•m(125to163lbfft)

S3.0-3.5FT(S60-S70FT)(F187)andH3.0-3.5FT (H60-70FT)(L177)

320to400N•m(240to295lbfft)

J1.60-2.00XMT(J30-40ZT)(J160)

163to190N•m(120to140lbfft)

S4.0,4.5,5.5FT,S5.5FTS,(S80,100,120FT; S80,100FTBCS;S120FTS;S120FTPRS) (G004),H4.0FT5/FT6;H4.5FTS5,H4.5FT6; H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005),andE3.50-5.50XL,E4.50XLS (E70-120Z,E100ZS)(E098)

400to440N•m(295to325lbfft)

Gland

S2.0-2.5FT(S40-S50FT,S55FTS)(F187)and H2.0-2.5FT(H40-50FT)(L177)

170to237N•m(125to175lbfft)

S3.0-3.5FT(S60-S70FT)(F187),H3.0-3.5FT (H60-70FT)(L177),S4.0,4.5,5.5FT,S5.5FTS, (S80,100,120FT;S80,100FTBCS;S120FTS; S120FTPRS)(G004),H4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110,120FT) (N005,P005),andE3.50-5.50XL,E4.50XLS (E70-120Z,E100ZS)(E098)

400to500N•m(295to370lbfft)

S30FT,S35FT,S40FTS(E010),E1.50-2.00XM (E25-35Z,E40ZS)(E114),J1.60-2.00XMT (J30-40ZT)(J160),andH1.6FT,H1.8FT, H2.0FTS(H30FT,H35FT,H40FTS)(F001) 163to190N•m(120to140lbfft)

TiltCylinderMountingCapscrew

ForlifttruckmodelsS2.0-2.5FT(S40-S50FT, S55FTS)(F187),S30FT,S35FT,S40FTS(E010), E1.50-2.00XM(E25-35Z,E40ZS)(E114),H1.6FT, H1.8FT,H2.0FTS(H30FT,H35FT,H40FTS) (F001),J1.60-2.00XMT(J30-40ZT)(J160)and H2.0-2.5FT(H40-50FT)(L177)

38N•m(28lbfft)

ForlifttruckmodelsS4.0,4.5,5.5FT,S5.5FTS, (S80,100,120FT;S80,100FTBCS;S120FTS; S120FTPRS)(G004)andH4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90, 100,110,120FT)(N005,P005)

68N•m(50lbfft)

MAINLIFTCYLINDERS

Remove WARNING

TiltCylinderRodEndCapscrew

ForalllifttruckmodelsexceptH4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90, 100,110,120FT)(N005,P005)

90N•m(66lbfft)

ForlifttruckmodelsH4.0FT5/FT6;H4.5FTS5, H4.5FT6;H5.0-5.5FT(H80,90,100,110, 120FT)(N005,P005)

66to73N•m(49to54lbfft)

ForlifttruckmodelsE3.50-5.50XL,E4.50XLS (E70-120Z,E100ZS)(E098)

77N•m(57lbfft)

LiftCylinderRepair

2. Raisethemastuntilitisalmostfullyextended.

• Onthetwo-stagemast,usesafetychainsto connectthebottomcrossmemberoftheinner mastsectiontothetopcrossmemberofthe outermastsection.

Beforeworkingonornearthemast,seeSafety ProceduresWhenWorkingNearMastandFigure1.

NOTE: Thefollowingproceduresarefortheremoval oftheliftcylinderswiththemastinstalledonthelift truck.

1. Removethecarriageasdescribedinthecarriageremovalprocedureslocatedinthesection MastRepairs, 2,3,and4-StageMasts 4000 SRM1148.foralllifttruckmodelsexcept H4.0FT5/FT6;H4.5FTS5,H4.5FT6;H5.0-5.5FT (H80,90,100,110,120FT)(N005,P005),S4.0, 4.5,5.5FT,S5.5FTS,(S80,100,120FT;S80, 100FTBCS;S120FTS;S120FTPRS)(G004),and E3.50-5.50XL,E4.50XLS(E70-120Z,E100ZS) (E098)

Forlifttruckmodelslistedabove,see MastRepairs, 2and3-StageMasts 4000SRM1250. SeeFigure1.

NOTE: PerformStep2onlyifworkingonalifttruck equippedwithatwoorthree-stagemast.Perform Step3ifworkingonalifttruckequippedwithafourstagemast.

• Onthethree-stagemast,usesafetychainto connectthebottomcrossmemberoftheintermediatemastsectiontothetopcrossmember oftheoutermastsection.Useanothersafety chaintoconnectthebottomcrossmemberto acrossmemberontheintermediateorouter mastsection.

Lowerthemastsothesafetychainsholdthe weightofthemastsections.

3. Raisethemastuntilitisalmostfullyextended. Useasafetychaintoconnectmiddlecrossmemberoffirstintermediatemastsectiontotopcrossmemberonoutermastsection.Lowermastso safetychainholdsweightofthemastsections.

WARNING

Becarefulwhenremovingorinstallingsnap rings.Thesesnapringscancomelooseduringremovalorinstallationwithenoughforce tocauseaninjury.Alwaysusethecorrectsnap ringpliers,andweareyeandfaceprotection duringremovalorinstallation.

4. Ifworkingonatwoorthree-stagemast,remove thesnapringorfittingatthetopofthecylinder toberemoved.

5. Ifworkingonafour-stagemast,onleft-handlift cylinder,removethesnapringfromtopofthe cylinderrod.Onright-handliftcylinder,remove spacerandretainerfromcylinderrod.

WARNING

Hydraulicoilishotaftersystemoperationand cancauseburns.Donotdisconnectanyhydraulichosesuntiltheoilinthesystemiscool.

6. Putadrainpanundertheareaofthehydraulic fittings.Disconnectandcapthehydrauliclines atthecylinder.Retracttherodintotheliftcylinder.

7. Removethenut,bolt,andspaceratthemount. Onatwoorthree-stagemast,disconnectthe mainliftchainatthemount.SeeFigure9.

8. Usealiftingdevice,asnecessary,toremovelift cylinderfrommast.Removetheliftcylinder fromthefrontofthemast.Onaliftcylinderbeingremovedfromafour-stagemast,keepshims fromtopofleft-handcylinderwithcylinder.

Disassemble CAUTION

Carefullydisassemblethemainliftcylinders sothepistonrodsandslidingsurfacesarenot damaged.

NOTE: Todisassembletheleft-handmainliftcylinderontrucksequippedwithatwo-stageFFLmast, seethesectionTwo-StageFFLLeftSideMainLift Cylinder.

NOTE: Topreventdamagetosealingsurfaces,use brasstoolswhenremovingsealsandO-rings.

1. Loosenglandwithspannerwrench.

2. Removeglandfromshell.

3. Removerodandpistonassemblyfromshell. Drainhydraulicoilintocontainer.SeeFigure7, andFigure8.

4. RemoveanddiscardO-rings,seals,backuprings, wiperrings,andwearrings.

WARNING

Becarefulwhen removingorinstallingsnap rings.Thesesnapringscancomelooseduringremovalor installationwithenoughforce tocauseaninjury.Alwaysusethecorrectsnap ringpliersandweareyeandfaceprotection duringremovalorinstallation.

NOTE: Step5doesnotapplyforS4.0,4.5,5.5FT, S5.5FTS,(S80,100,120FT;S80,100FTBCS; S120FTS;S120FTPRS)(G004),H4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90,100,110, 120FT)(N005,P005),andE3.50-5.50XL,E4.50XLS (E70-120Z, E100ZS)(E098)lifttrucks,andlifttrucks equippedwithatwo-stageFFLmast.

5. Removesnap ring,washer,andcheckvalvefrom baseofpiston.

6. Repeatdisassemblyprocedurefortheopposite cylinder.

Figure7.Two-StageLFLMainLiftCylinder

Figure8.Three-StageFFLMainLiftCylinder Clean

WARNING

Cleaningsolventscanbeflammableandtoxic andcancauseskinirritation.Whenusing cleaningsolvents,alwaysfollowthesolvent manufacturer’srecommendedsafetyprocedures.

Compressedaircanmoveparticlessothey causeinjurytotheuserortootherpersonnel. Makesurethepathofthecompressedairis awayfromallpersonnel.Wearprotectivegogglesorafaceshieldtopreventinjurytothe eyes.

CAUTION

Donotallowcleaningsolventtocomeincontactwithrubbercomponents,asitwilldamage thosecomponents.

Cleanallmetalpartsinsolventanddrywithcompressed air.

Inspect

Inspecttheglandfordamagetothethreadsandthe sealsurfaces.Ifdamaged,replacegland.

Inspectthepistonforanydamagetothesealsurfaces.Ifdamaged,replacepiston.

Inspecttherodfordamagetotherodsurfaceand ensurethattherodisnotbent.Ifdamagedreplace rod.

Inspecttheinnersurfaceofthecylindertubefor damage.Ifdamaged,replacecylinderassembly.

Assemble

NOTE: Theproceduresinthissectioncoverallcylindersexceptfortheleftsidemainliftcylinderson two-stageFFLmasts.SeethesectionTwo-StageFFL LeftSideMainLiftCylinderfortheprocedures.

NOTE: Topreventdamagetosealingsurfaces,use brasstoolswheninstallingsealsandO-rings.

1. Lubricateallinternalpartsoftheliftcylinder withcleanhydraulicoil.UsenewO-rings,seals, andwearrings.SeeFigure7andFigure8.

WARNING

Becarefulwhenremovingorinstallingsnap rings.Thesesnapringscancomelooseduringremovalorinstallationwithenoughforce tocauseaninjury.Alwaysusethecorrectsnap ringpliersandweareyeandfaceprotection duringremovalorinstallation.

NOTE: Step2doesnotapplyforS4.0,4.5,5.5FT, S5.5FTS,(S80,100,120FT;S80,100FTBCS; S120FTS;S120FTPRS)(G004),H4.0FT5/FT6; H4.5FTS5,H4.5FT6;H5.0-5.5FT(H80,90,100,110, 120FT)(N005,P005),E3.50-5.50XL,andE4.50XLS (E70-120Z,E100ZS)(E098)lifttrucks,andlifttrucks equippedwithtwo-stageFFLMast.

2. InstallcheckvalveandO-ringinbaseofpiston ofmainliftcylinderandleft-handliftcylinder. Makesurearrowoncheckvalveistowardbase ofpiston.Installwasherandsnapringforcheck valve.SeeFigure7andFigure8.