BOOM
BOOM
BOOM
• 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.
• 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.
• 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!
Boom Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description and Operation ................................................................................................................................ 1
Boom............................................................................................................................................................... 1
Hydraulic System .......................................................................................................................................... 1
Boom Repair ....................................................................................................................................................... 3
Remove ........................................................................................................................................................... 3
Disassemble ................................................................................................................................................... 7
Clean and Inspect .......................................................................................................................................... 7
Assemble ........................................................................................................................................................ 7
Install ............................................................................................................................................................. 8
Dampening Cylinder Repair.............................................................................................................................. 10
Remove ........................................................................................................................................................... 10
Disassemble ................................................................................................................................................... 10
Clean .............................................................................................................................................................. 12
Inspect ............................................................................................................................................................ 12
Assemble ........................................................................................................................................................ 12
Install ............................................................................................................................................................. 12
Boom Extension Cylinder Repair...................................................................................................................... 13
Remove ........................................................................................................................................................... 13
Disassemble ................................................................................................................................................... 13
Clean .............................................................................................................................................................. 14
Inspect ............................................................................................................................................................ 14
Assemble ........................................................................................................................................................ 14
Install ............................................................................................................................................................. 16
Derricking Cylinder Repair ............................................................................................................................... 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 18
Clean .............................................................................................................................................................. 19
Inspect ............................................................................................................................................................ 20
Assemble ........................................................................................................................................................ 20
Install ............................................................................................................................................................. 20
Troubleshooting ................................................................................................................................................. 21
HYSTER
APPROVED
PARTS
4500 SRM 1260 Description and Operation
General
This section has the description and repair procedures for the boom assembly. This section also has removal,
disassembly, cleaning, inspection, assembly, and installation procedures for the dampening cylinder, boom ex-
tension cylinder, and derricking cylinders.
1
Description and Operation 4500 SRM 1260
2
4500 SRM 1260 Boom Repair
Boom Repair
REMOVE c. Disconnect the dampening cylinder at the ro-
tator frame by removing nut from the pin.
Repairs to parts of the boom can be made with the See Figure 2.
boom installed. Remove the complete boom only if
necessary. d. Push the pin through the cylinder head and
frame mounting brackets with a drift.
1. Fully retract the boom.
e. Remove the pin on the other dampening
2. Place the attachment on a loaded container, or cylinder using the same procedure.
use a 15 ton fork lift truck to support the boom.
f. Remove the two spacers.
3. Place the boom in a slightly upwards position.
WARNING
Do not disconnect any hydraulic lines when the
engine is running or personal injury may oc-
cur.
3
Boom Repair 4500 SRM 1260
1. BUSHING 5. PIN
2. WASHER 6. FIXED BUSHING
3. LOCK NUT 7. CAPSCREW
4. SLIDING BUSHING
4
4500 SRM 1260 Boom Repair
d. Use a press to push the pivot pin towards the d. Remove the three capscrews and replace
outside of the boom. with longer capscrews for removing the cap,
located at the outside. Tighten capscrews
e. Remove the pivot pin. alternating each screw to remove cap from
the pivot pin
f. Follow Step a through Step e to remove the
pivot pin of the other derricking cylinder. e. Remove the cap.
g. Start the engine.
WARNING
h. Fully retract the derricking cylinders. Verify that the lifting device has the rated ca-
pacity to lift the pin or personal injury may oc-
i. Shut down the engine.
cur.
12. Disconnect the boom from the frame as follows:
f. Remove pivot pin.
a. Disconnect the two hydraulic lines and three
g. Remove the pivot pin from the other side of
electrical connectors between the boom and
the boom using the same procedure.
frame. Put caps on open lines.
5
Boom Repair 4500 SRM 1260
6
4500 SRM 1260 Boom Repair
13. Lift the boom assembly from the lift truck and CLEAN AND INSPECT
set the boom on supports.
a. Disconnect the hose support chain from the NOTE: When the wearplates have been worn to
support weldment on the right side of the a minimum thickness of 18 mm (0.709 in.), the
inner boom section. wearplates must be replaced.
b. Put identification tags on the hoses. Clean all the parts of the boom section with solvent.
Inspect all the welds for cracks. Inspect the wear
c. Disconnect the hoses. Put caps or plugs in all plates and retainers for damaged threads, deep
open fittings. grooves, or cracks. Check the wear surfaces of the
boom sections. Replace wear plates that are worn.
d. Remove the two capscrews and beveled
See Figure 6.
washers and the keeper from the boom ex-
tension cylinder at the rear side of the boom.
7
Boom Repair 4500 SRM 1260
6. Apply Loctite® 270 to the six capscrews and in- 22. Adjust each adjuster screw so the inner boom sec-
stall the six capscrews. tion is in the center of the outer boom section.
7. Connect a lifting device to the inner boom sec- 23. Tighten the jam nuts.
tion.
24. Fasten the hose support chain to the support
8. Install the two wear plates under the wear plate weldment on the left side of the inner boom
retainers and put the assemblies on the lower section.
inside surface at the front end of the outer boom.
25. Attach the hoses to the extension cylinder.
9. Install the four capscrews and washers in each
retainer at the end of the boom and then install 26. Install the hoses.
the capscrew and washer from under the outer
27. Install the bushing into the boom pivot supports.
boom into each wear pad retainer.
28. Install the spherical bearing in each derricking
10. Slide the inner boom section into the outer boom
cylinder.
section so the pin tube on the cylinder shell aligns
with the holes at the rear of the outer boom sec- 29. Install a snap ring into one of the grooves at the
tion. rod end of the dampening cylinder.
11. Install the pin so the slot for the keeper is at the 30. Install the joint ball in the dampening cylinder.
top side.
INSTALL
12. Install the keeper, two capscrews, and washers.
Tighten capscrews to 265 N•m (195 lbf ft).
CAUTION
13. Push the inner boom section fully into the outer Verify the used chain for the rear side is ap-
boom section and install the wear plate retainer proximately 0.75 mm (29.5 in.) then the chain
at the rear of the inner boom section. used at the boom tip side.
14. Apply Loctite® 270 to the retainer capscrews and NOTE: Orientation of the boom must be slightly up-
install the wear plate retainer at the rear of the wards to allow a correct line up.
inner boom section.
1. Connect a lifting device to lift the boom assembly
15. Install the two wear plates on the upper side of at the boom tip and rear side.
the inside of the outer boom section.
2. Lift and place the boom assembly into position for
16. Install the capscrews from the outer end of the installing the pins and carefully align the center
outer boom section. of the spherical bushing with the center of the
spacer tubes.
17. Install the capscrews and washers from the top
of the boom. 3. Connect the boom to the frame as follows:
18. Install one of the adjustable wear cup assemblies,
in one of the holes in the sides of the outer boom WARNING
section near the front. Verify that the lifting device has the rated ca-
pacity to lift the pin or personal injury may oc-
19. Loosen the jam nut and turn the adjuster screw cur.
counterclockwise so the retainer is fully against
the boom. a. Install the pivot pin from the outside, to-
wards the center of the frame.
20. Apply Loctite® 270 to the retainer capscrews. In-
stall and tighten capscrews. b. Install the two caps, capscrews, two washers,
and nut to the pivot pin.
21. Install the other retainer assemblies above and
on the other side of the boom.
8
4500 SRM 1260 Boom Repair
c. Tighten nut to 550 to 688 N•m (406 to i. Extend the derricking cylinders and care-
507 lbf ft). fully align the center of the spherical bear-
ings with the center of the hole in the boom.
d. Install the pivot pin from the other side of the
boom using the same procedures. j. Shut down the engine.
e. Connect the two hydraulic lines and three k. Install the pivot pin from the outside so the
electrical connectors between the boom and pivot pin can be fixed with the plate, using a
frame. press.
4. Connect the derricking cylinders to the boom as l. Install the ring and capscrew from the out-
follows. side of the pivot pin.
9
Dampening Cylinder Repair 4500 SRM 1260
10. Connect the dampening cylinder as follows: f. Connect the hydraulic lines at the dampen-
ing cylinder.
NOTE: Lubricate the pin with molybdenum disulfide
grease before installing. 11. Start the engine and operate the boom functions.
Check that functions of the boom assembly work
a. Align the rod end of the dampening cylinder correctly as described in the Operating Man-
with the pin yoke. ual.
b. Push the pin partway in the dampening 12. Operate the hydraulic system until air is out of
cylinder head from the outside towards the the system. Bleed air from system if necessary.
center of the rotator frame.
3. Apply the parking brake. 9. Connect a lifting device to the dampening cylin-
der.
WARNING 10. Remove the nut and washer from the pin. See
Do not disconnect any hydraulic lines when the Figure 7.
engine is running or personal injury may oc-
cur. 11. Push the pin through the cylinder holes and
boom mounting bracket with a drift.
4. Shut down the engine.
12. Remove the spacer and ball joint from the boom
NOTE: Move all control levers back and forth a min- mounting bracket hole.
imum of 20 times to remove all hydraulic pressure
from the pilot system. 13. Remove the dampening cylinder from the rotator
frame and boom tip.
5. Put identification tags on the lines during re-
moval. 14. Remove the pin on the other dampening cylinder
using the same procedure.
6. Disconnect the hydraulic lines at the dampening
cylinder. Put caps on the open lines. DISASSEMBLE
7. Disconnect the dampening cylinder at the rota- 1. Put the dampening cylinder in a vise with soft
tor frame by removing nut from the pin. See Fig- jaws, placed in a horizontal position.
ure 4.
2. Disassemble the gland using a pin wrench to un-
8. Push the pin through the cylinder head and screw the gland. See Figure 8.
frame mounting brackets with a drift.
10
4500 SRM 1260 Dampening Cylinder Repair
CAUTION
Use caution not to damage the finished surface
of the piston rod when removing the piston rod
from the cylinder shell in a horizontal position
(parallel with the cylinder shell).
11
Dampening Cylinder Repair 4500 SRM 1260
WARNING
WARNING Verify that the lifting device has the rated ca-
Compressed air can move particles so that they pacity to lift the dampening cylinder or per-
cause injury to the user or to other personnel. sonal injury may occur.
Make sure the path of the compressed air is
away from all personnel. Wear protective gog- 1. Install the ball joint in the boom mounting
gles or a face shield to prevent injury to the bracket holes.
eyes.
2. Use a lifting device to put the dampening cylin-
Clean all parts with solvent and remove residual sol- der in position.
vent or allow the solvent to evaporate.
3. Install the pin from the outside toward the center
INSPECT of the rotator frame.
Inspect the parts of the dampening cylinder for dam- 4. Install the washer and nut. Tighten nut to
age, rust, or wear. Carefully inspect the rod sur- 500 N•m (369 lbf ft).
faces for dents and scratches. Verify that the internal
5. Align the rod end of the dampening cylinder with
stroke surfaces of the cylinder shell and the grooves
the pin yoke.
for the seals do not show any nicks, scratches, or
other damage. Repair or replace parts as needed. 6. Push the pin partway in the dampening cylinder
head from the outside toward the center of the
ASSEMBLE rotator frame.
NOTE: Verify that all parts are clean before assembly. 7. Install the spacer and push the pin completely
NOTE: Always use new seals. Lubricate all parts through the dampening cylinder head.
with clean hydraulic oil. 8. Install the nut and tighten.
1. Assemble new seals on the piston and gland. 9. Install the pin on the other dampening cylinder
2. Assemble the gland on the piston rod. using the same procedure.
12
4500 SRM 1260 Boom Extension Cylinder Repair
WARNING
Verify that the lifting device has the rated ca-
pacity to lift the dampening cylinder or per-
sonal injury may occur.
1. EXTENSION CYLINDER
2. PIN
8. Connect a lifting device to the boom extension 3. CAPSCREW
cylinder. 4. COVER
9. Put identification tags on the hoses. Figure 9. Extension Cylinder to Inner Boom
Mounting
13
Boom Extension Cylinder Repair 4500 SRM 1260
12. Remove the cylinder and piston rod from the pis- NOTE: Always use new seals. Lubricate all parts
ton hose. with clean hydraulic oil.
CLEAN CAUTION
Be careful not to damage the finished surface
of the piston hose when installing the piston
WARNING
hose into the cylinder shell in a horizontal po-
Cleaning solvents may be flammable and toxic sition (parallel to the cylinder shell).
and can cause severe skin irritation. When
using cleaning solvents, always follow the 3. Lubricate the cylinder shell bore with clean hy-
solvent manufacturer’s recommended safety draulic oil. Put the piston hose assembly into the
precautions. cylinder shell.
14
4500 SRM 1260 Boom Extension Cylinder Repair
15
Boom Extension Cylinder Repair 4500 SRM 1260
9. Route the three hoses as shown in Figure 11. 5. Apply Loctite® 270 to the six capscrews and in-
stall capscrews.
WARNING
Do not try to locate hydraulic leaks by placing
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
16
4500 SRM 1260 Derricking Cylinder Repair
6. Remove the two capscrews, washers, and plate 13. Shut down the engine.
for the pivot pin at the top of the derricking cylin-
der. 14. Put identification tags on hydraulic lines.
17
Derricking Cylinder Repair 4500 SRM 1260
Do not use the lifting eyes on the derricking 23. If necessary, remove the other derricking cylin-
cylinder for removal and install activities. The der using the same procedure.
derricking cylinder can suddenly swing to hor-
izontal position and can cause serious personal DISASSEMBLE
injury.
1. Place the entire cylinder on a support that is long
16. Connect a lifting device to the derricking cylin- enough to support the cylinder in a horizontal
der. position.
17. Remove the two capscrews, washers, and plate 2. Drain the remaining hydraulic oil out of the der-
from the pivot pin at the frame. See Figure 13. ricking cylinder.
18. Remove the nut, washer, ring, and capscrew. 3. Disassemble the bearing using a pin wrench to
unscrew the bearing counterclockwise. See Fig-
19. Use a press to push the pivot pin towards the ure 14.
outside of the boom.
18
4500 SRM 1260 Derricking Cylinder Repair
19
Derricking Cylinder Repair 4500 SRM 1260
NOTE: Always use new seals. Lubricate all parts Do not use the lifting eyes on the derricking
with clean hydraulic oil. cylinder for removal and install activities. The
derricking cylinder can suddenly swing to hor-
1. Assemble the piston on the piston rod by turning izontal position and can cause serious personal
the piston clockwise. Apply Loctite® 243 on the injury.
threaded area of the piston rod. Torque the pis-
ton to 4000 N•m (2952 lbf ft). 3. Connect a lifting device to the derricking cylin-
der.
2. Assemble the new seals, O-rings, backup ring,
wearband, and wiper on the piston rod, piston, 4. Carefully align the center of the spherical bear-
and bearing. ing with the center of the hole in the frame.
CAUTION 5. Install the pivot pin from the outside so the pivot
Be careful not to damage the finished surface pin can be fixed with the plate, using a press.
of the piston rod when installing the piston rod
into the cylinder shell in a horizontal position 6. Install the ring and capscrew from the outside of
(parallel to the cylinder shell). the pivot pin.
5. Lubricate the cylinder shell bore with clean hy- 7. Install the washer and nut onto the capscrew and
draulic oil. Put the piston rod assembly into the torque the nut to 1100 N•m (812 lbf ft).
cylinder shell. 8. Install the plate, two capscrews and washers.
NOTE: No special torque is required when tightening 9. Connect the hydraulic lines to the derricking
the bearing. Securely tighten the bearing into the cylinder.
cylinder shell.
10. Start the engine.
6. Lubricate the thread of the bearing with clean
hydraulic oil and screw the bearing into the cylin- 11. Extend the derricking cylinders and carefully
der shell. align the center of the spherical bearings with
the center of the hole in the boom.
INSTALL
12. Shut down the engine.
1. Install a locking ring in one of the grooves at
the rod side of the derricking cylinder and one 13. Install the pivot pin from the outside so the pivot
pin can be fixed with the plate.
20
4500 SRM 1260 Troubleshooting
Troubleshooting
Boom extends or retracts Relief valve adjusted wrong. Adjust relief valve.
slowly or not at all.
Boom wear pads worn or adjusted too Replace or adjust boom wear pads.
tight.
Boom lifts slowly or not at Relief valve adjusted wrong. Adjust relief valve.
all.
21
Troubleshooting 4500 SRM 1260
All attachment cylinders op- Attachment relief valve adjusted Adjust attachment relief valve.
erate slowly or not at all. wrong.
22
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