/,)7 &</,1'(56

ALL, EXCEPT H7.00-12.50H (H150-275H),

H13.50-16.00B (H300-350B), H16.00-30.00C
(H360-650C), H32.00-42.00B (H700-920B)

PART NO. 910119 4000 SRM 135

 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!
4000 SRM 135
Safety Procedures When Working Near Mast
The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast. See the correct Service Manual sec-
tion for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between 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 com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a "DO NOT OPERATE"
tag in the operator’s compartment.
• 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 weld-
ments 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 the correct Service Manual for
the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. 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.
Safety Procedures When Working Near Mast
OR
2. If parts of the mast must be in raised position,
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:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom cross-
member of the inner weldment with a cross-
member on the outer weldment. See Fig-
ure 1.
c. Use a 12 mm (0.5 in.) minimum safety chain
with a hook to fasten the crossmembers to-
gether so that the movable member cannot
lower. Put the hook on the back side of the
mast. Make sure the hook is completely en-
gaged with a link in the chain. Make sure
the safety chain does not touch lift chains or
chain sheaves, tubes, hoses, fittings or other
parts on the mast.
d. Lower the mast until there is tension in the
safety chain. If running, stop the engine. Ap-
ply the parking brake. Install a "DO NOT
REMOVE" tag on the safety chain(s).
e. Install another safety chain 12 mm (0.5 in.)
minimum between the top or bottom cross-
member of the carriage and a crossmember
on the outer weldment.
3. Apply the parking brake. After lowering or re-
straining the mast, shut off the power and re-
move the key. Put a "DO NOT OPERATE" tag
in the operator’s compartment.
1
Safety Procedures When Working Near Mast
1. INNER WELDMENT 2. OUTER WELDMENT
Figure 1. Mast
The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast. See the correct Service Manual sec-
tion for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between 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 com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a "DO NOT OPERATE"
tag in the operator’s compartment.
2
4000 SRM 135
3. HOOK 4. CARRIAGE
• 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 weld-
ments 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
procedures in the correct Service Manual
section for the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push
the lift/lower control lever forward and make
sure there is no movement in the mast. Make
4000 SRM 135
sure that all parts of the mast that move are
fully lowered.
OR
2. If parts of the mast must be in raised position,
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:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom of the in-
ner weldment to below the anchor for the tilt
cylinders. See Figure 2.
1. INNER WELDMENT 2. TILT CYLINDERS
Figure 2. Mast
Safety Procedures When Working Near Mast
c. Use a 12 mm (0.5 in.) minimum safety chain
with a hook to fasten the weldments together
so that the inner weldment cannot lower. In-
stall the chain on both sides of the mast.
Make sure the hooks are completely engaged
with a link in the chain.
d. Lower the mast until there is tension in the
safety chain. If the engine is running, stop
the engine. Apply the parking brake. Install
a "DO NOT REMOVE" tag on the safety
chain. Put a "DO NOT OPERATE" tag in
the operator’s compartment.
3. HOOK
3
Safety Procedures When Working Near Mast
The following procedures must be used when inspect-
ing or working near the mast. Additional precautions
and procedures can be required when repairing or re-
moving the mast. See the correct Service Manual sec-
tion for the specific mast being repaired.
WARNING
Mast parts are heavy and can move. Distances
between 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 com-
pletely lowered or a safety chain is installed.
Also make sure that the power is OFF and the
key is removed. Put a "DO NOT OPERATE"
tag in the operator’s compartment.
• 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 weld-
ments 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
procedures in the correct Service Manual
section for the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. 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
2. If parts of the mast must be in raised position,
install a safety chain to restrain the moving parts
4
4000 SRM 135
of the mast. Connect moving parts to a part that
does not move. Follow these procedures:
a. Put the mast in a vertical position.
b. Raise the mast to align the bottom cross-
member of the weldment that moves in the
outer weldment with a crossmember on the
outer weldment. On the two-stage and free-
lift mast, the moving part is the inner weld-
ment. On the three-stage mast, it is the
intermediate weldment. On the four-stage
mast, it is the first intermediate weldment.
See Figure 3.
c. Use a 10 mm (0.375 in.) minimum safety
chain with a hook to fasten the crossmembers
together so that the movable member cannot
lower. Put the hook on the back side of the
mast. Make sure the hook is completely en-
gaged with a link in the chain. Make sure
the safety chain does not touch lift chains or
chain sheaves, tubes, hoses, fittings or other
parts on the mast.
d. Lower the mast until there is tension in the
safety chain and the free-lift cylinder (free-
lift and three-stage masts only) is completely
retracted. If the engine is running, stop the
engine. Apply the parking brake. Install
a "DO NOT REMOVE" tag on the safety
chain(s).
e. Install another safety chain 10 mm
(0.375 in.) minimum between the top or
bottom crossmember of the carriage and a
crossmember on the outer weldment.
3. Apply the parking brake. After lowering or re-
straining the mast, shut off the power and re-
move the key. Put a "DO NOT OPERATE" tag
in the operator’s compartment.
4000 SRM 135 Safety Procedures When Working Near Mast

Figure 3. Two-Stage, Free-Lift, Three-Stage, and Four-Stage Masts

5
Description
Legend for Figure 3
A. TWO-STAGE MAST
B. FREE-LIFT MAST
1. OUTER WELDMENT
2. INNER WELDMENT
3. INTERMEDIATE WELDMENT
4. FIRST INTERMEDIATE WELDMENT
General
This section has the description for lift cylinders used
in masts and the instructions for their repair. There
are many different sizes of lift cylinders used in Hys-
ter Company lift trucks. The operation and repair
procedures for the different lift cylinders are simi-
lar. The illustrations in this section are for typical
Description
All lift cylinders are single-acting cylinders. See Fig-
ure 4. The hydraulic force is applied only in one di-
rection. When hydraulic oil enters one end of the lift
cylinder, the hydraulic force extends the piston rod.
When the force is removed, the weight of the carriage
and inner mast retracts the piston rod.
A common maintenance problem is the repair of oil
leaks from the seals and wiper around the piston rod.
If the bore of the shell of the lift cylinder is damaged
and cannot be repaired, the lift cylinder must be re-
placed.
Lowering Control Valve
A lowering control valve is installed in the inlet port.
See Figure 5. It permits easy entry of hydraulic oil
into the cylinder, but gives a restriction when the rod
is retracted. This restriction gives limits to the speed
that a load on the forks can be lowered.
There are two types of lowering control valves. Both
types have the same function and similar operation.
The most common type of valve has a design that
has good operation using large flows and lower pres-
sures. Some lift trucks have a lift system design us-
ing higher pressures and a lower flow. These systems
need a different type of lowering control valve.
6
4000 SRM 135
C. THREE-STAGE MAST
D. FOUR-STAGE MAST
5. HOOK
6. FREE-LIFT CYLINDER
7. CROSSMEMBER
8. CROSSMEMBER
lift cylinders. All of the variations in lift cylinders
used in lift trucks are not shown. A section for Lift
Cylinders For VISTA® Masts is included later in this
section.
The most common type of lowering control valve uses
these parts: (1) a special fitting for the valve body, (2)
a spring, and (3) a special washer. There is a varia-
tion in the shapes of the special washer. Different
lift cylinders use different shapes of special washers.
The volume of the hydraulic oil flowing through the
inlet port controls the shape of the special washer.
(A typical shape of a special washer is shown in Fig-
ure 5.) When the piston rod is lowered, the oil flow
pushes against the special washer and spring. When
the oil flow reaches the limit, the special washer is
moved against the special fitting. The oil then flows
only through the hole in the center of the special
washer. This restriction permits the piston rod to
lower only at a maximum controlled speed.
The other type of lowering control valve uses these
basic parts: (1) valve body, (2) spring, (3) washer, (4)
cylinder, (5) orifice sleeve, (6) plunger, and (7) main
sleeve. The orifice sleeve position is controlled com-
pletely by oil flow. The plunger position is controlled
by oil pressure and spring tension. During lifting,
oil entering the lift cylinder goes through the center
of the main sleeve to the large holes. The oil flow
through the plunger and bore moves the orifice sleeve
to the end of the plunger. The flange of the orifice
sleeve is then aligned with the large part of the bore
in the body. This alignment lets the oil flow past the
orifice sleeve to the cylinder.
4000 SRM 135 Description

A. INSTALLED B. NOT INSTALLED

1. LOWERING CONTROL VALVE 5. SHELL 9. BACK-UP RING
2. PISTON 6. NYLON RING 10. O-RING
3. BEARING 7. RETAINER 11. ROD
4. CHECK VALVE 8. WIPER SEAL 12. SINGLE-LIP SEAL

Figure 4. Two-Speed Lift Cylinder

7
Description 4000 SRM 135

A. LOW PRESSURE DESIGN C. RESTRICTED FLOW E. LIFTING

B. LOWERING D. HIGH PRESSURE DESIGN F. FREE FLOW
1. SPECIAL FITTING OR VALVE 3. SPECIAL WASHER 6. PLUNGER
BODY 4. CYLINDER 7. MAIN SLEEVE
2. SPRING 5. ORIFICE SLEEVE

Figure 5. Lowering Control Valves

During lowering, oil from the lift cylinder moves the
orifice sleeve. The orifice sleeve moves away from the
larger inner diameter area of the bore in the valve
body. This movement makes a restriction to the oil
flow. As the pressure increases, the plunger begins
to move against the spring. The movement begins
to close the openings of the large holes in the main
sleeve. Additional pressure will push the plunger
against the main sleeve to close the large holes com-
pletely. All the oil must then go through the small
holes to the center of the main sleeve. This restric-
tion permits the piston rod to lower only at a maxi-
mum controlled speed.

8
4000 SRM 135
Cylinders (General)
Standard masts use a single-stage lift cylinder.
Most three-stage and four-stage masts use two sin-
gle-stage lift cylinders. A single-stage lift cylinder
has one piston rod. See Figure 6.
Most full free-lift masts and some three-stage masts
use a two-stage lift cylinder. A two-stage lift cylin-
der has two telescopic piston rods. See Figure 7. The
two-stage lift cylinder operates similar to a one-stage
lift cylinder. Hydraulic pressure pushes the primary
(larger) piston rod from the cylinder first because
it has a larger diameter. The secondary piston rod
moves with the primary piston rod. When the pri-
mary piston rod reaches the limit of its stroke, the
secondary piston rod extends from the primary pis-
ton rod.
Spacers are used in some cylinders to give a limit to
the stroke of the piston rod. Worn spacers must be
replaced with the same size spacer.
Most of the lift cylinders use a single-lip seal assem-
bly to prevent hydraulic oil leaks past the piston
and past the retainer. See Figure 4. There are
many lift cylinders in use that have an older design
chevron-style packing. The chevron-style packing
can be replaced with a seal kit that has the newer
single lip seal and an adaptor. There are no replace-
ments of single lip seals for chevron-style packing
for lift trucks over 7,000 kg (15,000 lb) capacity.
Lift cylinders and other hydraulic parts can have in-
ternal leaks. Internal leakage will increase as the
temperature of the hydraulic oil increases. The in-
ternal leak rate of the hydraulic system is normally
checked after every 1000 hours of operation. See Lift
System Leak Check for test procedures and leakage
rates within the specifications.
During operation, some leakage of hydraulic oil can
move past the piston seal to the rod side of the pis-
ton. A small leakage is permitted if the internal leak
rate of the hydraulic system is not greater than the
specification. An internal check valve is installed in
Description
the piston of many of the lift cylinders. When the rod
extends, the pressure increases more quickly on any
oil in the rod end of the cylinder. The hydraulic oil
transfers through the check valve to the piston end of
the cylinder. This action prevents hydraulic damage
to the wiper seal. See Figure 8. Lift cylinders that
do not have an internal check valve have a drain line
on the outside of the cylinder shell.
Cylinders (H520-620B, H700-800A)
The rod side of the lift cylinder is used for the storage
of hydraulic oil on the H520-620B and H700-800A lift
trucks. This storage decreases the required size of
the hydraulic tank. When the piston raises in the
cylinder, the oil on the rod side of the piston trans-
fers to the hydraulic tank. When the piston lowers
in the cylinder, some of the oil transfers to the rod
side of the cylinder. Approximately one half of the oil
in the bottom of the cylinder goes through the main
control valve to the rod side of the cylinder. See the
Main Control Valve of Service Manual for more
information. See Figure 9.
Retainer, Install
1. Install the retainer over the piston and into the
cylinder. Make sure the single-lip seal assembly,
the O-ring, and the back-up ring are not dam-
aged. See Figure 9.
2. Turn the retainer ring into the threads in the
cylinder. Turn the retainer ring until it is even
with the top of the cylinder.
3. Install the capscrews loosely.
4. The stroke of the cylinder rod can be adjusted by
turning the retainer ring one-half turn in either
direction.
5. Install and tighten the setscrew.
6. Tighten the capscrews to 36 to 46 N•m (27 to
34 lbf ft).
9
Description 4000 SRM 135

A. MAIN LIFT CYLINDER B. FREE-LIFT CYLINDER

1. WIPER RING 7. HYDRAULIC LINE MOUNT 12. LOWERING CONTROL VALVE
2. SINGLE-LIP SEAL 8. INTERNAL CHECK VALVE (ALL CYLINDERS)
3. BEARING 9. ROD ASSEMBLY 13. PISTON RING
4. O-RING 10. SPACER 14. CUSHION RING
5. RETAINER 11. TO SENSING PORT FOR
6. CHAIN ANCHOR MOUNT PHASING VALVE PRESSURE

Figure 6. Single-Stage Lift Cylinders

10
4000 SRM 135 Description

A. INSTALLED B. NOT INSTALLED

1. POPPET 5. SINGLE-LIP SEAL
2. SPRING 6. O-RING
3. SEAL 7. NYLON BACK-UP
4. INLET AND RING
OUTLET PORT

Figure 8. Internal Check Valve and Single-Lip

Seal
1. WIPER RING 8. PISTON HALF (1
2. RETAINER OF 2) Cylinders (H360-460B)
3. SEAL 9. INTERNAL CHECK
4. SCREW (DO NOT VALVE The lift cylinders used in the H360-460B lift trucks
CHANGE LENGTH) 10. SINGLE-LIP SEAL are displacement cylinders. The design and repairs
5. PRIMARY ROD 11. SECONDARY ROD
ASSEMBLY ASSEMBLY for these cylinders are similar to the other lift cylin-
6. SPACERS 12. O-RING der in this section. A displacement cylinder does not
7. BEARING 13. PLUG have a piston or piston seal. The rod diameter is al-
most the same as the inside diameter of the cylin-
Figure 7. Two-Stage Lift Cylinder der. There are wear rings on the rod that are the
bearings between the rod and the walls of the cylin-
der. The wiper seal at the top of the cylinder is also
the high-pressure seal for these cylinders. The wiper
seal has chevron-style packing. See Figure 10.

11
Description 4000 SRM 135

A. LOWERING CONTROL VALVE

1. SETSCREW (1) 5. RETAINER 10. SPACER 15. FLANGE
2. CAPSCREW (2) 6. BACK-UP RING 11. PISTON 16. SPACER PLATE
3. RETAINER RING 7. O-RING 12. PISTON RING NUT 17. SPACER
4. SINGLE-LIP SEAL 8. CYLINDER SHELL 13. NYLON SETSCREW 18. VALVE BODY
ASSEMBLY 9. ROD 14. SPRING 19. SPECIAL WASHER

Figure 9. Lift Cylinder for H700-800A

12
4000 SRM 135 Description

Legend for Figure 10

NOTE: OIL LEAKAGE IS NOT CONTROLLED BY

THE TORQUE ON THE PACKING GLAND. TIGHTEN
THE PACKING RETAINER TO STOP OIL LEAKS.
REPLACE CHEVRON-STYLE PACKING WHEN
PACKING RETAINER CANNOT COMPRESS PACK-
ING FURTHER TO CONTROL OIL LEAKS. DO NOT
TIGHTEN MORE THAN NECESSARY TO STOP OIL
LEAKS.
1. WIPER 7. PACKING
2. NYLON RING RETAINER
3. CHEVRON-STYLE 8. PACKING GLAND
PACKING 9. CYLINDER SHELL
4. BACK-UP RING 10. INLET AND
5. O-RING OUTLET PORT
6. ROD HEAD 11. WEAR RING

Figure 10. Displacement Cylinders

13
Description 4000 SRM 135

Cylinders (Two-Speed) piston transfers to the bottom of the piston. When

Two-speed lift cylinders are single-stage lift cylinders
with a special valve and path for the hydraulic oil.
The lift cylinder is filled with oil on both sides of the
piston. For loads less than 45% of the rated capacity,
the cylinder rod can be extended at high speed. When
the cylinder rod extends, the oil on the rod side of the
the oil transfers, the increase almost doubles the flow
of oil to the base of the cylinder. The pump pressure
is applied to both sides of the piston. The area on the
bottom of the piston is greater than the rod side of
the piston. The difference in force pushes the piston
up the cylinder. See Figure 11.

A. HIGH-SPEED OPERATION FOR NO LOAD OR LIGHT LOADS

B. NORMAL OPERATION FOR RATED CAPACITY LOAD OR HEAVY LOADS
1. FORCE 3. GREATER LIFTING FORCE
2. FROM HYDRAULIC PUMP 4. TO HYDRAULIC TANK

Figure 11. Two-Speed Lift Cylinders

For loads greater than 45% of capacity, the cylinder S60-80B H150-250E
rod extends at normal speed. A special valve senses
S125-150A H150-275H
the increased oil pressure caused by the load. The
oil is returned from the rod side of the lift cylinder H60-80C H250-300A
to the hydraulic tank. All of the pump pressure is
H300-350B P125-180A
applied to the bottom side of the piston. The cylinder
rod extends at a slower speed, but can lift a greater H110-150F P150-200B
load. The two-speed lifting system is used only with
standard masts. A two-speed lift system is used on NOTE: The maximum loads that the above models
the following lift trucks: will lift at high speed are shown on Table 1.

14
4000 SRM 135 Lift Cylinder Repair

Table 1. Lift Trucks with Two-Speed Lift Cylinders

Model Load
S60-100B 1589 to 2043 kg (3500-4500 lb)
H60-80C 1589 to 2043 kg (3500 to 4500 lb)
H110-150F 1589 to 2043 kg (3500 to 4500 lb)
S125-150A 2270 to 2724 kg (5000 to 6000 lb)
H150-200ES, Standard Masts 2270 to 3087 kg (5000 to 6800 lb)
P125-180A, Standard Masts 2270 to 3087 kg (5000 to 6800 lb)
H150-250E, Heavy Duty Masts 3133 to 4041 kg (6900 to 8900 lb)
P125-180A, Heavy Duty Masts 3133 to 4041 kg (6900 to 8900 lb)
H250-300A 4540 to 4994 kg (10,000 to 11,000 lb)
This table shows the approximate maximum load that the mast will lift at high speed. Loads greater than
those shown will cause the mast to lift at normal speed. These loads will have a variation because of the
different attachments that can be installed on the lift truck.

Lift Cylinder Repair

LIFT CYLINDER REMOVAL WITHOUT
REMOVING MAST
Remove the carriage before the lift cylinder. See the
procedure described in the Masts section. If the mast
must be removed for repairs, then remove the lift
cylinder when the mast is disassembled. Remove the
lift cylinder from the mast as described in the follow-
ing paragraphs.
Standard Masts with Main Lift Cylinder
Fastened to Crossmember of Inner Mast
1. Fully lower the mast. Loosen, but do not discon-
nect the capscrew that fastens the cylinder rod to
the crossmember of the inner mast.
2. Clean the area next to the fittings that connect
the hydraulic lines to the lift cylinder. Put a
drain pan under the area where the hydraulic
lines will be disconnected. Disconnect the hy-
draulic lines and put a cap on each open fitting.
WARNING
Make sure the lifting mechanism has enough
capacity to lift the loads. See the Weight Guide
for lift cylinders in Table 1.
3. Connect a lifting mechanism to the inner mast.
Lift the inner mast approximately 300 mm
(12 in.). Fasten the inner and outer masts to-
gether at the crossmembers with a heavy chain.
Make sure that the inner mast cannot move.
Remove the lifting mechanism.
4. Connect a heavy-duty sling to the upper part of
the cylinder. Raise the lifting mechanism until
the sling is tight. Make sure the sling will not
slide.
5. Remove the capscrew and washer connecting the
piston rod to the inner mast. Remove the spacer.
CAUTION
Oil can come out of the cylinder fittings with
pressure when retracting the rod.
6. Loosen the cap on the lower fitting of the cylinder.
Manually retract the piston rod.
7. Remove the capscrew and the plate from the
lower side of the cylinder.
8. Raise the cylinder and move it away from the
mast. Move the lift cylinder to a position where
it can be disassembled.

15
Lift Cylinder Repair 4000 SRM 135

Standard and Full Free-Lift Masts with Lift

Cylinder Fastened to Crosshead
1. Remove the lift chains and chain anchors from
the mast and the lift cylinder. Connect a sling
to the upper area of the lift cylinder. Raise the
lifting mechanism until the sling is tight. See
Figure 12 and Figure 13.

1. SHEAVE 5. CHAIN ANCHOR

2. SNAP RING 6. WASHER AND NUT
3. CROSSHEAD 7. SHIM
4. CYLINDER GUIDE 8. GUIDE SHOE
ASSEMBLY 9. BEARING

Figure 13. Free-Lift Cylinder and Crosshead

2. Remove the capscrews that connect the piston

rod to the crosshead.

3. Disconnect and remove the crosshead assembly

from the mast. Make a note of the shim arrange-
ment on the crosshead guide.

1. CHAIN GUARD 6. CHAIN ANCHOR 4. Clean the area next to the fittings that connect
2. CROSSHEAD 7. SPECIAL WASHER the hydraulic lines to the lift cylinder. Put a
ASSEMBLY 8. LOCK NUT drain pan under the area where the hydraulic
3. SNAP RING 9. SPACER lines will be disconnected. Disconnect the hy-
4. SHEAVE 10. WEAR PLATE draulic lines and put a cap on each open fitting.
5. BEARING 11. PAD
5. Remove the snap ring that connects the bottom
Figure 12. Standard Mast Cylinder and
of the lift cylinder to the outer mast.
Crosshead
6. Raise the lift cylinder and move it away from the
mast. Move the lift cylinder to a position where
it can be disassembled.

16
4000 SRM 135
Masts that have Two Cylinders, Main Lift
Cylinder and Free-Lift Cylinder
1. Remove the free-lift cylinder as described in
the section above for removing a lift cylinder
fastened to a crosshead.
2. Remove the main lift cylinder as described in
the section above for removing a lift cylinder fas-
tened to an inner mast.
DISASSEMBLE
WARNING
Use slings and a crane to handle and disassem-
ble the lift cylinders of most lift trucks. Make
sure that the crane and slings can lift the load.
See Table 1.
CAUTION
Carefully disassemble and assemble the lift
cylinders so that the rods and sliding surfaces
are not damaged.
NOTE: Disassembly of single-stage and two-stage lift
cylinders is the same except the two-stage lift cylin-
der has a second piston rod assembly. The disassem-
bly of the secondary piston rod assembly is similar to
the disassembly of the primary piston rod assembly.
1. Loosen the retainer with a spanner. Disconnect
the retainer from the shell. See Figure 14 and
Figure 15.
2. Remove the cap from the inlet and slide the pis-
ton rod assembly from the shell. Use drain pans
for the hydraulic oil.
3. Remove the retainer from the piston rod. Re-
move and discard the O-rings, seals, and bear-
ings.
4. Remove the internal check valve.
5. Remove the lowering control valve.
6. Clean all the parts. Check the sliding surfaces
for damage. Repair or replace any damaged
parts.
Lift Cylinder Repair
ASSEMBLE
NOTE: Lubricate all internal parts of the lift cylinder
with hydraulic oil during assembly.
Use new O-rings, seals and bearings. Apply lubri-
cant during assembly. Packing lubricant (Part Num-
ber 186061) is available.
Make sure the single-lip seal assemblies are installed
with the O-ring towards the base of the lift cylinder.
See Figure 8.
The spacers control the maximum stroke of the pis-
ton rod assembly. If a new spacer is necessary, make
sure the same size spacer is installed.
1. Install the internal check valve. Make sure the
arrow on the internal check valve is toward the
base of the piston.
CAUTION
A difficult and important step in assembling
cylinders is the correct installation of the seals
without damage. Most cylinder maintenance is
caused by seal leakage.
2. Install the seal and bearing (and spacer if
equipped) on the rod piston. Use shim material
and a band clamp as a guide to move the sin-
gle-lip seal past the threads of the shell.
3. Carefully push piston and piston rod into the
shell. Release the band clamp on the seal when
the seal travels past the threads of the shell.
4. Install the seals, O-rings, and bearings (when
used) in the retainer. If the wiper seal has a
spring backup ring, the spring must be towards
the base of the lift cylinder.
5. Carefully install the retainer on the piston rod.
6. Engage the threads and tighten the retainer in
the shell to the correct torque. Use a correct
spanner. Do not hit the retainer with a hammer
and driver.
17
Lift Cylinder Repair 4000 SRM 135

1. PLUG 6. BEARING 11. INTERNAL CHECK 15. BACKUP RING

2. O-RING 7. O-RING VALVE 16. SINGLE-LIP SEAL
3. RETAINER 8. CYLINDER SHELL 12. O-RING 17. BEARING
4. WIPER RING 9. CYLINDER ROD 13. WASHER
5. SINGLE-LIP SEAL 10. SPACER 14. SNAP RING

Figure 14. Single-Stage Lift Cylinder

1. PLUG 9. SPACER 17. SNAP RING

2. RETAINER 10. BEARING 18. WASHER
3. BEARING 11. SINGLE-LIP SEAL 19. INTERNAL CHECK VALVE
4. O-RING 12. BACKUP RING 20. CYLINDER
5. SINGLE-LIP SEAL 13. PRIMARY CYLINDER ROD 21. SCREW
6. WIPER RING 14. SPACER 22. SEAL
7. RETAINER 15. O-RING
8. SECONDARY CYLINDER ROD 16. PISTON RING HALF (2)

Figure 15. Two-Stage Lift Cylinder

18
4000 SRM 135
CAUTION
When the screw is installed on two-stage cylin-
ders, never use a screw longer than 9.5 mm
(0.375 in.). A longer screw will touch and
damage the primary piston rod. Always install
a seal under the head of the screw. If you do
not install the screw and seal, the cylinder will
have leaks.
7. Install the lowering control valve. Make sure the
special washer and the spring are installed cor-
rectly. A wrong installation can cause the load to
lower too fast.
LIFT CYLINDER INSTALLATION IN MAST
Standard Masts with Main Lift Cylinder
Fastened to Crossmember of Inner Mast
1. Put the lift cylinder into position in the mast.
Make sure the base of the lift cylinder is aligned
correctly on its mount.
2. Connect a chain to the upper section of the lift
cylinder and the overhead guard. Make sure the
chain will hold the lift cylinder in position until
it can be fastened to the mast.
3. Connect a lifting mechanism to the inner mast.
CAUTION
Do not connect a wrench to the sliding surface
of the piston rod. Any damage to the sliding
surface will cause leaks.
4. Disconnect the inner mast from the outer mast.
Lower the inner mast until it touches the piston
rod. Align the holes of the inner mast and the
piston rod.
5. Install capscrews, washer, and spacer to fasten
the lift cylinder to the crossmember of the inner
mast.
6. Fasten the base of the lift cylinder to the cross-
member of the outer mast with a capscrew and
plate.
7. Connect the hydraulic lines.
Lift Cylinder Repair
8. Install the carriage.
Standard and Full Free-Lift Masts with Lift
Cylinder Fastened to Crosshead
1. Put the lift cylinder into position in the mast.
Align the guide pin with the hole in the bottom
crossmember.
2. Install the crosshead assembly in the mast.
Align the holes in the piston rod and the
crosshead.
3. Fasten the crosshead to the piston rod with cap-
screws.
4. Fasten the base of the lift cylinder to its mount
with a snap ring.
5. Connect the hydraulic lines.
6. Install the chain anchors.
7. Install the lifting chains.
8. Install the carriage. See masts section for checks
and adjustments.
CHEVRON-STYLE PACKING
The replacement seal kits for chevron-style packing
have a single-lip seal and an aluminum spacer. The
seal kits also have one or two backup rings. If one
backup ring is in the seal kit, install it as shown in
B of Figure 16. Two backup rings are installed as
shown in C of Figure 16. Make sure the single-lip
seal is always installed correctly against the direc-
tion of pressure.
The installation of chevron-style packing on a pis-
ton is shown in Chevron-Style Packing Installation
on Piston. The installation of chevron-style packing
in a packing gland nut used at the top of the cylin-
der is shown in Chevron-Style Packing Installation
in Packing Gland. There will be some variation in
the design of the different lift cylinders. The prin-
ciples of installation of the chevron-style packing is
similar.
Lubricate the parts with hydraulic oil or packing lu-
bricant (Part No. 186061) before assembly.
19
Lift Cylinder Repair 4000 SRM 135

A. MANY EARLIER PRODUCTION LIFT TRUCKS WITH LESS THAN 7000 kg (15,000 lb) CAPACITY THAT
HAVE CHEVRON-STYLE PACKING CAN BE CHANGED TO SINGLE-LIP SEALS.
B. THE PARTS ARE INSTALLED IN THE ARRANGEMENT SHOWN.
C. IF TWO BACKUP RINGS ARE IN THE SEAL KIT, THE PARTS ARE INSTALLED IN THE ARRANGEMENT
SHOWN.
1. CHEVRON-STYLE PACKING 3. BACKUP RING 5. DIRECTION OF OIL
2. ALUMINUM SPACER 4. SINGLE-LIP SEAL ASSEMBLY PRESSURE

Figure 16. Chevron-Style Packing Replacement Seal Kits

Chevron-Style Packing Installation on Piston

STEP 1.
Lubricate the new O-ring with hydraulic oil and then
install it on the piston end of the cylinder rod.

STEP 2.
Install a new packing assembly on the piston half.
The packing must extend approximately 3 mm
(1/8 in.) beyond the end of the piston half.

1. THIS RING MUST EXTEND 3 mm (1/8 in.)

BEYOND END OF PISTON HALF.

20
4000 SRM 135 Lift Cylinder Repair

STEP 3.
Install the piston half and snap ring.

STEP 4.
Install the nylon spacer.

STEP 5.
Install the piston in the lift cylinder. Carefully push the piston and piston rod into the lift cylinder. Release
the clamp on the packing when the packing moves past the threads of the cylinder.

1. PISTON
2. SPECIAL TOOL OR BAND CLAMP TO INSTALL PACKING

21
Lift Cylinder Repair 4000 SRM 135

Chevron-Style Packing Installation in Packing Gland

STEP 1.
Assemble the packing gland nut using new packing, O-ring, and backup ring.

1. PACKING ASSEMBLY 4. PACKING RING MUST EXTEND 3 mm (1/8 in.)

2. BACKUP RING BEYOND EDGE OF BUSHING.
3. O-RING

STEP 2.
Assemble the gland nut using a new O-ring, backup
ring, and inner seal.

NOTE: Install inner seal (if equipped).

STEP 3.
Install the bushing assembly and gland nut assembly
in the rod.

22
4000 SRM 135
STEP 4.
Install a new wiper ring and spring on the retainer. Install the retainer against the packing gland nut. Lightly
hit the retainer to move against the internal threads in the cylinder shell. Use a spanner to tighten the retainer.
1. O-RING
Lift Cylinders for Vista® Masts
DESCRIPTION
All lift cylinders for Vista® masts are single-action
hydraulic cylinders. The hydraulic force is applied
only in one direction. When hydraulic oil enters one
end of the lift cylinder, the hydraulic force extends
the piston rod. When the force is removed, the weight
of the carriage and inner mast causes the piston rod
to retract.
The most common maintenance problem is the repair
of oil leaks. If the bore of the shell of the lift cylinder
is damaged and cannot be repaired, the lift cylinder
must be replaced.
VISTA® two-stage, three-stage, and four-stage masts
have two main lift cylinders. The free-lift mast has
two main lift cylinders and a shorter free-lift cylin-
der. See Figure 17 and Figure 18.
Spacers are used in some cylinders to limit the stroke
of the piston rod. Worn spacers must be replaced
with the same size spacer.
The free-lift cylinder has a single-lip seal on the pis-
ton to prevent hydraulic oil leaks past the piston and
Lift Cylinders for Vista® Masts
retainer. The piston rod is a smaller diameter than
the piston.
During operation, some hydraulic oil will leak past
the piston area to the rod end of the lift cylinder.
Small leaks are permitted if the internal leak rate
of the hydraulic system is not greater than the spec-
ification. An internal check valve is installed in the
piston of the free-lift cylinders. When the piston rod
extends, the pressure increases more quickly on any
oil in the rod end of the lift cylinder. The hydraulic oil
transfers through the check valve to the piston end of
the free-lift cylinder. This action prevents hydraulic
damage to the single lip seal and the wiper ring. See
Figure 19.
Lowering Control Valve
A lowering control valve is installed in the hydraulic
line to the bases of the lift cylinders. See Figure 20.
The lowering control valve permits easy entry of hy-
draulic oil into the cylinders, but gives a restriction
when the rods retract. This restriction controls the
maximum speed at which a load on the forks can be
lowered. The lowering control valve prevents a load
23
Lift Cylinders for Vista® Masts 4000 SRM 135

on the forks from freely falling if a hydraulic hose

breaks.

Figure 17. Vista® Masts Typical Lift Cylinders

24
4000 SRM 135 Lift Cylinders for Vista® Masts

Legend for Figure 17

1. SHELL 6. WASHER 11. BACK-UP RING
2. BEARING 7. INNER PISTON 12. WIPER SEAL
3. PISTON 8. CHECK VALVE 13. RETAINER
4. PISTON ROD 9. O-RING
5. SNAP RING 10. SINGLE-LIP SEAL

1. SNAP RING 7. ROD 12. RETAINER [TIGHTEN 340 to

2. INNER PISTON 8. SHELL 410 N•m (250 to 300 lbf ft)]
3. BEARING 9. O-RING 13. WIPER SEAL
4. SINGLE-LIP SEAL 10. BACK-UP RING 14. PISTON
5. BACK-UP RING 11. SEAL RING 15. 7.9 mm (0.31 in.) DIAMETER
6. SPACER HOLE
16. WRENCH FLATS

Figure 18. Free-Lift Mast Main Lift Cylinder

The lowering control valve includes the following
parts: (1) valve body, (2) spring, (3) washer, (4)
cylinder, (5) orifice sleeve, (6) plunger, and (7) main
sleeve. The orifice sleeve position is controlled by
oil flow. The plunger position is controlled by oil
pressure and spring tension. During lifting, oil
entering the lift cylinder goes through the center of
the main sleeve to the large holes. The oil continues
between the plunger and bore to move the orifice
sleeve to the end of the plunger. The flange of the
orifice sleeve is then aligned with the large part of
the bore in the body. This alignment lets the oil flow
around the orifice sleeve to the inlet port of the lift
cylinder.
small holes to the center of the main sleeve. This
restriction permits the piston rod to lower only at a
maximum controlled speed.
REMOVE
NOTE: Remove the carriage before removing the lift
cylinder. See the procedure described in the Masts
section. If the mast assembly must be removed for re-
pairs, then remove the lift cylinders when the mast
assembly is disassembled. When only the lift cylin-
ders must be removed for repairs, then remove the
lift cylinders from the mast as described in the fol-
lowing paragraphs.

During the lowering operation, oil from the lift
cylinder moves the orifice sleeve. The sleeve moves
away from the larger area of the bore in the valve
body. This movement makes a restriction to the
oil flow. When the pressure increases, the plunger
begins to move against the spring. The movement
begins to close the openings of the large holes in
the main sleeve. Additional pressure will push the
plunger against the main sleeve to close the large
holes completely. All the oil must go through the
1. Clean the area around the hydraulic fittings for
the lift cylinders. Disconnect the fittings at the
lift cylinders and put caps on the open lines.
2. On the free-lift mast, remove the capscrews,
washers, and cylinder clamp from the mount
for the free-lift cylinder. Remove the free-lift
cylinder.
3. Remove the snap rings and washers from the top
of each main lift cylinder. Remove the cylinder

25
Lift Cylinders for Vista® Masts 4000 SRM 135

clamps near the top of each lift cylinder. Each DISASSEMBLE

cylinder clamp is fastened to the top crossmem-
ber of the inner mast by two capscrews and wash-
ers.
4. Support the cylinder. Connect a crane to the top
of the inner mast using chains. Raise the inner
mast from the outer mast approximately 30 cm
(12 in.). Disengage the piston rod ends of lift
cylinders from the top crossmember of the inner
mast. Remove the lift cylinders from the mount
plates at the bottom of the outer mast.
WARNING
Use slings and a crane to handle and disassem-
ble the lift cylinders of most lift trucks. Make
sure that the crane and slings can lift the load
correctly. See Table 1 for weight guide.
CAUTION
Carefully disassemble and assemble the lift
cylinders so that the piston rods and sliding
surfaces are not damaged.

NOTE: Disassembly of the main lift cylinders and the

free-lift cylinder is similar. All of the lift cylinders are
disassembled from the rod end of the cylinder shell.

1. Loosen the retainer with a spanner. Disconnect

the retainer from the shell.

2. Remove the protective cap from the inlet and

slide the rod and piston assembly from the shell.
Drain the hydraulic oil into a container.

NOTE: To remove the retainer, the piston rod and pis-

ton assembly must be disassembled if the lift cylin-
der is the type shown in Figure 18. Use the following
procedure:

a. Put a round bar through the 7.9 mm (0.31 in.)

hole in the piston. Hold the rod in a vise or
clamp so that it does not turn. Use the round
bar and turn the threaded piston from the
piston rod.

b. If an adhesive was used on the threaded rod

and piston, heat the rod to a maximum of 170
to 225 C (300 to 400 F) to loosen the adhe-
sive.
A. INSTALLED B. NOT INSTALLED
3. Remove the retainer from the piston rod. Re-
1. PISTON AND ROD 4. INLET AND move and discard the O-rings, seals, and bear-
ASSEMBLY OUTLET PORT ings.
2. CHECK VALVE 5. SINGLE-LIP SEAL
3. O-RING 6. O-RING 4. Remove the internal check valve from the base of
7. BACK-UP RING
the lift cylinder.
Figure 19. Internal Check Valve and Single Lip
5. Clean all the parts. Check the sliding surfaces
Seal
for damage. Repair or replace any damaged
parts.

26
4000 SRM 135
ASSEMBLE
NOTE:
• Lubricate all internal parts of the lift cylinder with
hydraulic oil during assembly.
• Use new O-rings, seals, and bearings. Apply lubri-
cant (hydraulic oil) during assembly. Packing lu-
bricant (Part No. 186061) is also available.
• Make sure the single-lip seal assemblies are in-
stalled with the O-ring toward the base of the lift
cylinder. (See Figure 19.)
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.
1. Install the internal check valve, if installed.
Make sure the arrow on the internal check valve
is toward the base of the piston.
2. Install the wear ring, single lip seal, and back-up
ring onto the piston assembly. If a spacer sleeve
is used, install it. Use shim material and a clamp
as a guide to move the single-lip seal over the
threads of the shell.
A. FREE FLOW C. RESTRICTED FLOW
B. LIFTING D. LOWERING
1. VALVE BODY 3. WASHER
2. SPRING 4. CYLINDER
Figure 20. Lowering Control Valve
Lift Cylinders for Vista® Masts
3. Carefully push the piston and rod assembly into
the shell. Release the clamp on the seal when the
seal travels past the threads of the shell.
NOTE: When a main lift cylinder of the type shown in
Figure 18 is assembled, use the following procedure:
a. Install the seal ring and wiper ring into the
retainer. Assemble the retainer onto the pis-
ton rod.
b. Install the piston to the threaded part of the
piston rod. Use a round bar through the hole
in the piston and tighten the piston to the
piston rod. Hold the piston rod in a vise or
clamp by the two flats on the top end of the
piston rod.
NOTE: Do not use an adhesive on the threads of the
piston rod and piston.
4. Install the seal, O-ring, wear ring, and wiper ring
in the retainer. If the wiper seal has a spring for a
back-up ring, the spring must be toward the base
of the lift cylinder.
5. Carefully install the retainer on the piston rod.
5. ORIFICE SLEEVE
6. MAIN SLEEVE
27
Lift System Leak Check
6. Engage the threads and tighten the retainer in
the shell until it is tight. Use a correct span-
ner. Do not hit the retainer with a hammer and
driver.
7. Install the lowering control valve. Make sure the
special washer and the spring are installed cor-
rectly. A wrong installation can cause the load to
lower too fast.
INSTALL
Main Lift Cylinders
WARNING
Connect slings and a crane to the top of the in-
ner mast [and intermediate mast(s), if it is a
3-stage (4-stage) mast] using chains. If it is a
3-stage mast, make sure that all masts are fas-
tened together. Make sure that the chains will
not damage the sheaves, tubing or other parts
of the mast. Make sure the crane and slings can
lift the load correctly. See Table 1 for weight
guide.
1. Install the main lift cylinders to the mounts at
the base of the outer mast. Use a crane and lower
the inner mast to engage the piston rods of the
lift cylinders to the holes in the top crossmember
of the inner mast. Install the washers and snap
rings, or other locking device, at the top of the lift
cylinders. Install the cylinder clamps near the
top of each cylinder. Fasten the clamps, if used,
Lift System Leak Check
WARNING
Never allow anyone under a raised carriage.
Do not put any part of your body through the
lift mechanism unless all parts of the mast are
completely lowered and the engine is stopped.
Before making any repairs, use blocks and
chains on the mast and carriage so that they
can not move. Make sure the moving parts are
attached to the parts that can not move.
Do not try to find hydraulic leaks by putting
hydraulic components under pressure. Hy-
draulic oil can be injected into the body by
pressure.
28
4000 SRM 135
to the top crossmember of the outer mast with
the capscrews and washers.
2. Install the lowering control valve on the outer
mast. Connect the hydraulic lines and fittings
between the lowering control valve and the lift
cylinders.
3. Install the chain sheaves and brackets. Connect
the lift chains to the chain anchors on the inner
mast. Fasten wires between the ends of the lift
chains so that they can be controlled during in-
stallation of the carriage.
4. Install the carriage. Connect the lift chains.
Free-Lift Cylinder
1. When the inner mast is lowered, install the free-
lift cylinder in the inner mast. A pin in the base
of the lift cylinder will fit into the cylinder mount
at the base of the inner mast. Fasten the up-
per end of the cylinder to the center crossmember
with the bracket, washers, and capscrews. In-
stall the chain sheave and brackets to the top of
the free-lift piston rod.
2. Install the tubes and fittings at the bottom of the
main lift cylinders. Install the lowering control
valve. Install the hydraulic fitting in the end of
the rod at the top of the left main cylinder. Install
the tube between the top of the main lift cylinder
and the base of the free-lift cylinder.
3. Install the carriage. Install the lift chain.
During the test procedures for the hydraulic
system, fasten the load to the carriage with
chains to prevent it from falling. Keep all
personnel away from the lift truck during the
tests.
1. Operate the hydraulic system. Put a capacity
load on the forks and raise and lower the load
several times. Lower the load and tilt the mast
forward and backward several times. Check for
leaks.
2. Raise the carriage and the load 1 m (3 ft). If the
carriage lowers slowly with the control valve in a
neutral position, there are leaks inside the hy-
draulic system. The maximum speed that the
carriage is allowed to lower is 50 mm (2 in.) per
4000 SRM 135 Specifications

10 minutes when the hydraulic oil is 30 C (90 F).
If the oil temperature is 70 C (160 F), the maxi-
mum speed that the carriage can lower is 150 mm
(6 in.) per 10 minutes.
3. Check the lift cylinder for internal leaks. Remove
the load from the forks. Install a gate valve in the
supply line between the main control valve and
the mast. Put a capacity load on the forks again.
Raise the carriage 1 m (3 ft). Close the gate valve.
If the carriage or mast lower slowly, the seals in
the lift cylinders have leaks.
4. If the carriage does not move, open the gate valve
and check the movement again. If the carriage
lowers 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 have
a defect. Remove the load from the forks.
NOTE: See the procedures in the mast repair sec-
tions for lift chain adjustments, mast adjustments,
carriage adjustment, and header hose roller adjust-
ment.

Specifications
Table 2. Cylinder Retainer Torque Specifications and Weight Guide

Rod Diameter Typical Outer Retainer Lifting

Torque Values Mechanism
mm in. N•m lbf ft
One-Stage Cylinders for Lift Trucks with Less than 7000 kg (15,000 lb) Capacity
57.2 2.25 373-441 275-325 Use crane and slings with at least 500 kg
(1000 lb) capacity to lift the cylinder.
63.5 2.50 203-271 150-200
69.9 2.75 373-441 275-325
76.2 3.00 407-475 300-350
81.3 3.20 407-475 300-350
88.9 3.50 475-452 350-400
101.6 4.00 407-475 300-350
114.3 4.50 610-678 450-500
One-Stage Cylinders for Lift Trucks with More than 7000 kg (15,000 lb) Capacity
108.0 4.25 Tighten Use crane and slings with at least 1000 kg
retainer or (2000 lb) capacity to lift the cylinder.
113.4 5.25
packing gland
nut.
Oil leakage is
not controlled
by the torque on
the retainer.
241.3 9.50 Use crane and slings with at least 2000 kg
(4000 lb) capacity to lift the cylinder.
254.0 10.00

29
Troubleshooting 4000 SRM 135

Table 2. Cylinder Retainer Torque Specifications and Weight Guide (Continued)

Rod Diameter Typical Outer Retainer Lifting

Torque Values Mechanism
mm in. N•m lbf ft
Two-Stage Cylinders for Lift Trucks with Less than 5000 kg (10,000 lb) Capacity
82.6 3.25 373-509 325-375 Use crane and slings with at least 500 kg
(1000 lb) capacity to lift the cylinder.
95.3 3.75 271-305 200-225
101.6 4.00 271-339 200-250
114.3 4.50 339-407 250-300
122.0 5.00 407-475 300-350
Inner retainer torque value is 122 N•m (90 lbf ft).

Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

No movement of lift cylin- Pilot line(s) to control valve are dis- Tighten or connect fittings.
ders or tilt cylinders. connected or leaking.

No oil or not enough oil in the hy- Fill tank. Check for leaks.
draulic tank.

Relief valve(s) not set correctly. Adjust or install new relief valve.

Hydraulic pump does not operate or Repair or install new pump.

has damage.

Remote control valve does not oper- Check and repair valve.
ate.

Slow movement of lift or tilt No oil or not enough oil to lift or tilt Fill tank. Check for leaks.
cylinders. cylinders.

Cylinders have internal or external Repair leaks. Install new parts.

leaks.

Relief valve is not set correctly. Adjust or install new relief valve.

There is a restriction in a hydraulic Remove restriction. Install new

line. parts.

Load is more than capacity. Reduce load.

30
4000 SRM 135 Troubleshooting

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

Rough movement of the mast There is air in the hydraulic system. Remove air. Check for loose connec-
assembly. tions or breaks in lines.

Lift cylinder(s) is damaged. Repair or install new lift cylinder.

Mast weldments are damaged or not Align weldments. Install new parts.
aligned.

Mast weldments are not lubricated. Lubricate correctly.

Load rollers or bearing blocks are Repair or adjust the parts.

damaged or not adjusted correctly.

Lift chains are damaged. Replace lift chains.

31
 TECHNICAL PUBLICATIONS

4000 SRM 135 2/01 (5/95)(9/87)(10/84)(3/83)(4/82)(7/81)(11/80) Printed in U.S.A.