BOOM YARDMASTER®

HR45-25, HR45-27, HR45-31, HR45-40S,

HR45-36L, HR45-40LS, HR45-45LSX,
HR45H [A227, B227]

PART NO. 1470236 4500 SRM 787

 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!
Boom YardMaster® Table of Contents

TABLE OF CONTENTS

Boom ................................................................................................................................................................... 1
Description and Operation ............................................................................................................................ 1
Hydraulic System............................................................................................................................................... 2
Derricking ...................................................................................................................................................... 2
Description................................................................................................................................................. 2
Derricking Up ............................................................................................................................................ 2
Derricking Down ....................................................................................................................................... 2
Holding Valve ............................................................................................................................................ 2
Adjustments............................................................................................................................................... 2
Derricking-up Speed ............................................................................................................................. 2
Derricking-down Speed......................................................................................................................... 4
Cylinder Pressure ................................................................................................................................. 5
Derricking Down Pressure Difference ................................................................................................. 5
Telescoping ..................................................................................................................................................... 6
Description................................................................................................................................................. 6
Telescoping Out (Extend) .......................................................................................................................... 7
Telescoping In (Retract) ............................................................................................................................ 7
Adjustments............................................................................................................................................... 7
Dampening ..................................................................................................................................................... 7
Description................................................................................................................................................. 7
Adjustment of the 4 bar (58 psi) Pressure Reducer................................................................................. 8
Boom Repair ....................................................................................................................................................... 9
Spreader ......................................................................................................................................................... 9
Remove....................................................................................................................................................... 9
Install ......................................................................................................................................................... 9
Yoke ................................................................................................................................................................ 10
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Dampening Cylinder ..................................................................................................................................... 10
Remove....................................................................................................................................................... 10
Install ......................................................................................................................................................... 10
Pivot Bearing ................................................................................................................................................. 11
Removal ..................................................................................................................................................... 11
Install ......................................................................................................................................................... 11
Derricking Cylinder....................................................................................................................................... 12
Remove....................................................................................................................................................... 12
Install ......................................................................................................................................................... 13
Boom............................................................................................................................................................... 14
Remove....................................................................................................................................................... 14
Disassemble ............................................................................................................................................... 15
Clean, Inspect, and Repair........................................................................................................................ 16
Outer Boom ........................................................................................................................................... 16
Inner Boom ............................................................................................................................................ 17
Assemble .................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Telescoping Cylinder...................................................................................................................................... 19
Remove....................................................................................................................................................... 19
Install ......................................................................................................................................................... 19
Shimming Key Clearance ......................................................................................................................... 21
How to Determine the Slope Shims at the Left Side Key................................................................... 22
How to Determine the Slope Shims at the Right Side Key ................................................................ 23

©2003 HYSTER COMPANY i

Table of Contents Boom YardMaster®

TABLE OF CONTENTS (Continued)

Alignment Shimming............................................................................................................................ 23
Wear Pads........................................................................................................................................................... 24
General ........................................................................................................................................................... 24
Side Wear Pads .............................................................................................................................................. 24
Remove....................................................................................................................................................... 24
Clean and Inspect...................................................................................................................................... 24
Install ......................................................................................................................................................... 24
Adjust ......................................................................................................................................................... 26
Inner Boom Side Wear Pads................................................................................................................. 26
Outer Boom Side Wear Pads ................................................................................................................ 26
Horizontal Front Wear Pads ......................................................................................................................... 26
Remove....................................................................................................................................................... 26
Clean and Inspect...................................................................................................................................... 27
Install ......................................................................................................................................................... 27
Horizontal Rear Wear Pads........................................................................................................................... 28
Remove....................................................................................................................................................... 28
Clean and Inspect...................................................................................................................................... 28
Install ......................................................................................................................................................... 28
Hydraulic Cylinder Repair ................................................................................................................................ 28
General Inspection and Assembly Instructions ........................................................................................... 28
Derricking Cylinder....................................................................................................................................... 29
Disassembly ............................................................................................................................................... 29
Clean and Inspect...................................................................................................................................... 29
Assemble .................................................................................................................................................... 29
Test ............................................................................................................................................................. 29
Telescoping Cylinder...................................................................................................................................... 30
Disassemble ............................................................................................................................................... 30
Clean and Inspect...................................................................................................................................... 32
Assemble .................................................................................................................................................... 32
Test ............................................................................................................................................................. 32
Dampening Cylinder ..................................................................................................................................... 32
Disassemble ............................................................................................................................................... 32
Clean and Inspect...................................................................................................................................... 32
Assemble .................................................................................................................................................... 33
Test ............................................................................................................................................................. 33

This section is for the following models:

HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS,

HR45-45LSX, HR45H [A227, B227]

ii
4500 SRM 787 Boom

Boom
DESCRIPTION AND OPERATION
The boom is the support for the rotator and the
spreader. The boom pivots on two pivot assemblies
located on the support towers on the back of the
frame. Two derricking cylinders mount to the outer
section of the boom and at the front of the frame.
These cylinders allow the operator to raise or lower
the boom. See Figure 1.
The boom has an inner section that can be extended
to allow the spreader to reach over one container to
the container behind it. The inner section slides on
wear plates and is moved by the telescoping cylinder.
booms is the length and the different mounting of the
telescoping cylinder.
The articulating yoke connects the boom with the ro-
tator and the spreader. The articulation of the yoke
is controlled by the dampening system, which con-
tains, amongst others, two dampening cylinders and
a dampening valve.
The electric cable and the hydraulic hoses for the
spreader and the dampening system are held in a
support chain that keeps the cable and the hoses
from bending sharply when the boom is extended or
retracted.

Yardmasters are delivered with either a 5H9’6" boom

or a 5H8’6" boom. The difference between these two

1. DAMPENING CYLINDER 4. TELESCOPING CYLINDER 7. SUPPORT FOR HOSES

2. INNER BOOM 5. PIVOT ASSEMBLY 8. YOKE FOR SPREADER
3. OUTER BOOM 6. DERRICKING CYLINDER 9. DAMPENING VALVE

Figure 1. Boom Assembly

1
Hydraulic System
Hydraulic System
DERRICKING
Description
The derricking cylinders are activated by the hoist
sections of the main control valve. The hoist sections
are operated by direction control spools, which re-
ceive hydraulic pressure from the joystick in the op-
erator cabin. The joystick receives pressure from the
manipulator valve. See Figure 2.
Derricking Up
By moving the joystick backward, port 1 of the joy-
stick provides a pilot flow to ports ZB4 and ZB5 of
the main control valve. Both direction control spools
will direct pump pressure via the flow control spools
to the piston sides of the derricking cylinders and
simultaneously allow the extruded oil from the rod
side of the cylinders to drain to the tank. Derricking
speed is restricted by the speed limiter spool in the
holding valve.
For the optional sliding cab, the pilot pressure will
be drained if E7 is not activated. This prohibits a
container from being lifted above the cabin.
Derricking Down
By moving the joystick forward, port 3 of the joystick
provides a pilot flow to ports ZA3 and ZA4 of the main
control valve, and to the holding valves on the der-
ricking cylinders.
Pilot pressure from the holding valve opens a check
valve and allows a restricted oil flow through the
speed limiter spool.
Both direction control spools will direct pump pres-
sure via the flow control spools to the rod sides of the
derricking cylinders and simultaneously allow the
extruded oil from the piston side to drain to the tank.
In case of an overload situation, anti-tipping solenoid
E8 is deactivated, which drains the pilot pressure to
the tank. This prohibits further derricking down.
Holding Valve
Hydraulic oil flow to and from the rod side of the der-
ricking cylinders is directly connected with port A4
on the main control valve. See Figure 3.
2
4500 SRM 787
Hydraulic oil flow to and from the piston side of the
derricking cylinders runs via the holding valve to the
derricking control valve.
The main function of the holding valve is to prevent
the cylinder from unintentional derricking down.
Only sufficient pilot pressure at port Pst will re-
lieve the pressure at the piston side of the cylinder.
Other functions of the holding valve are to restrict
maximum occurring cylinder pressure and to control
maximum oil flow.
When derricking up, oil pressure enters main port A,
and opens check valve B. After having opened check
valve C, oil leaves through port V, which connects
with the piston side of the derricking cylinder. See
Figure 4.
When derricking down, pilot pressure at port Pst
triggers movement of spools S and R.
1. Spool S initially opens check valve C, and with
increased pilot pressure, lifts valve C1 from its
seat in the housing. This allows oil to flow to
spool R. No adjustments can be made to spool S.
2. Spool R releases openings R1 and, with increas-
ing pressure, opens R2. The position of spool R
directly relates to the lowering speed of the der-
ricking cylinders as long as check valve C1 is kept
open. The maximum stroke of spool R can be in-
creased by turning adjustment plug G counter-
clockwise. The flow restriction can be increased
by adding shims (H) on the speed limiter spring.
Adjustments
NOTE: Adjustments must be made with the engine
temperature between 60 to 80 C (140 to 176 F), en-
gine running at full speed, spreader fitted, hydraulic
oil temperature between 45 to 65 C (113 to 149 F) and
no load.
Derricking-up Speed
Derricking up speed is set by the flow control valves
in the main control valve at B3 and B4. The time to
derrick up completely is between 22 and 23 seconds.
4500 SRM 787 Hydraulic System

Figure 2. Derricking System Hydraulic Schematic

3
Hydraulic System 4500 SRM 787

Legend for Figure 2

1. DERRICKING CYLINDER 9. FROM MAIN PUMP
2. SPEED LIMITER SPOOL 10. SPREADER AND BOOM CONTROL SOLENOIDS
3. HOLDING VALVE 11. SLIDING CAB SOLENOID
4. MAIN RELIEF VALVE 12. ANTI-TIPPING SOLENOID
5. DIRECTIONAL SPOOL 13. SPREADER SOLENOID
6. FLOW CONTROL SPOOL 14. DERRICKING UP
7. MAIN CONTROL VALVE, DERRICKING 15. DERRICKING DOWN
SECTIONS 16. FROM MANIPULATOR VALVE
8. STEERING PRIORITY 2 VALVE 17. JOYSTICK CONTROL VALVE

A PORT RELIEF VALVES B1 PORT P1 PORT

A2 PORT B2 PORT R1 PORT
A4 PORT B3 PORT ZA PILOT PORTS
B PORT RELIEF VALVES B4 PORT ZB PILOT PORTS

1. STEERING/MAIN VALVE SECTION 5. DERRICKING VALVE SECTION

2. SPREADER VALVE SECTION 6. MAIN RELIEF VALVE SECTION
3. TELESCOPING VALVE SECTION 7. FLOW CONTROL VALVES
4. DERRICKING VALVE SECTION

Figure 3. Ports on the Main Control Valve

Derricking-down Speed the flow control valve A4 supplies 120 liter (126.8 qt)/
min. Turn the adjustment plugs G at both holding
The time required to fully lower the boom at full valves counterclockwise to increase the speed.
throttle, is between 30 and 32 seconds. Verify that

4
4500 SRM 787 Hydraulic System

Cylinder Pressure Derricking Down Pressure Difference

To adjust the maximum occurring cylinder pressure,
connect a pressure gauge at port M. Temporarily ad-
just relief valve B4 on the main valve to 420 bar
(6092 psi). Derrick up the boom completely and keep
pressurizing the derricking up function. Maximum
pressure of 420 bar (6092 psi) at port V is set by re-
lief valve D.
To adjust the pressure, remove cap E, and turn plug
F clockwise to increase relief pressure. When com-
pleted for both cylinders, adjust the pressure at B4 to
its normal setting of 350 bar (5076 psi). During der-
ricking up, 350 bar (5076 psi) is the maximum pres-
sure in the cylinder.
While lowering, the pressure distance at the piston
side of the derricking cylinders should not exceed
5 bar (72.5 psi) during full speed lowering (= at max-
imum throttle), or 3 bar (43.5 psi) during lowering at
idle speed. To correct the pressure values, add a shim
to the speed limiter which causes the lower pressure
reading. After the adjustment has been made, check
the pressure differences between the two cylinders
while derricking down again.

A. MAIN PORT H. SHIM

B. CHECK VALVE M. GAUGE PORT
C. CHECK VALVE PST. PILOT PORT
C1. CHECK VALVE R. SPEED LIMITER SPOOL
D. RELIEF VALVE R1. SMALL SPOOL OPENING
E. CAP R2. LARGE SPOOL OPENING
F. ADJUSTMENT PLUG S. ACTUATING SPOOL
G. STROKE ADJUSTER T. TANK PORT

Figure 4. Holding Valve

5
Hydraulic System 4500 SRM 787

TELESCOPING system is operated by a pilot valve, which receives

Description
The telescoping system is activated by the telescop-
ing section of the main control valve. The telescoping
the hydraulic pressure from the joystick in the oper-
ators cabin. The joystick receives pressure from the
manipulator valve. See Figure 5.

Figure 5. Telescoping System Hydraulic Schematic

6
4500 SRM 787
Legend for Figure 5
1. TELESCOPING CYLINDER
2. FROM PILOT PUMP
3. TELESCOPING RETRACT VALVE
4. MAIN CONTROL VALVE, TELESCOPING
SECTION
5. LOAD SENSE LINE
6. FROM STEERING PRIORITY 2 VALVE
7. SPREADER AND BOOM CONTROL SOLENOIDS
Telescoping Out (Extend)
By moving the joystick to the right, port 4 of the joy-
stick provides a pilot pressure to port ZA2 of the main
control valve and to solenoid E8 of the anti-tipping
system.
The direction control spool at ZA2 will direct pump
pressure via the flow control spool to the piston side
of the telescoping cylinder, and simultaneously allow
the extruded oil from the rod side of the cylinder to
drain to the tank.
In case of an overload situation, anti-tipping solenoid
E8 is deactivated, which drains the pilot pressure to
the tank. This prohibits further telescoping out.
Telescoping In (Retract)
By moving the joystick to the left, port 2 of the joy-
stick provides a pilot flow to port ZB3 of the main
control valve and to the telescoping retract valve that
is fitted on port F of the steering section of the main
control valve. This retract valve provides pilot pump
pressure to the holding valve at the telescoping cylin-
der, when the pressure from joystick port 2 has ex-
ceeded 7 bar (101.5 psi). Pilot pump pressure will
open the holding valve, which is fitted at the bottom
of the cylinder.
Joystick pressure at port ZB3 opens the directional
control spool to provide pump pressure via the flow
control spool to the rod side of the telescoping cylin-
der. This retracts the cylinder shell, and extrudes the
oil at the piston side of the cylinder to the tank, via
the direction control spool at the control valve.
Adjustments
Both telescoping retraction and telescoping exten-
sion speed is restricted by the flow control valve
at the A side of the telescoping section of the main
control valve. This implies that a compromise must
be found for both speeds.
Hydraulic System
8. SLIDING CAB SOLENOID
9. ANTI-TIPPING SOLENOID
10. SPREADER SOLENOID
11. JOYSTICK CONTROL VALVE
12. TELESCOPING OUT
13. TELESCOPING IN
14. FROM MANIPULATOR VALVE
The time required to fully extend the telescoping
cylinder is between 28 and 30 seconds. The time
required to fully retract the telescoping cylinder is
between 25 and 28 seconds.
DAMPENING
Description
The dampening system restricts oil flow to and from
the dampening system. The oil flow restriction de-
pends on whether or not the truck is loaded and/or is
derricking. See Figure 6.
The loaded situation is recognized by the locked po-
sition of the twistlocks, which de-energizes solenoid
E54. Oil flow from the dampening cylinders is forced
to pass the 1.10 mm (0.04 in.) and 1.80 mm (0.07 in.)
restrictions. See Figure 7.
Derricking up and down is recognized by two 3.5 bar
(50.76 psi) pressure sensors at the main control
valve. The sensor for derricking up is connected
with ports ZB4 and ZB5. The sensor for derricking
down is connected with ports ZA3 and ZA4. The sen-
sors activate solenoid E49, which allows an almost
unrestricted oil flow. When E49 is activated, the
pressure in the dampening system is limited by the
4 bar (58 psi) regulator.
For special operations, the dampening system can be
locked (deactivated) with a switch on the dashboard.
This activates locking solenoids E50 and E51. Oil
pressure is limited by the 200 bar (2901 psi) relief
valve.
The gas accumulator supplies both the piston and the
rod side of the dampening cylinder across the two
check valves. The 5 bar (72.5 psi) relief valve allows
the accumulator to pressurize the return line to avoid
cavitation, when the dampening system operates.
7
Hydraulic System 4500 SRM 787

1. LOCKING 7. RELIEF VALVE

SOLENOID 8. ACCUMULATOR
2. DERRICKING 9. BIG SHUTOFF
RELEASE VALVE
3. RESTRICTION, 10. SMALL SHUTOFF
1.8 mm (0.07 in.) VALVE
4. RELIEF VALVE, 11. CONTROL VALVE
5 bar (72.5 psi) 12. RESTRICTION,
5. CHECK VALVES 1.1 mm (0.043 in.)
6. REGULATOR, 4 bar
(58 psi)

Figure 7. Dampening Lock

Adjustment of the 4 bar (58 psi) Pressure

Reducer
To correctly adjust the pressure reducer, first rotate
1. CONTROL VALVE 4. DAMPENING the adjustment knob fully counterclockwise. Remove
2. ACCUMULATOR CYLINDER the plug located at the side of the dampening valve
3. SMALL SHUTOFF 5. SOLENOID FOR and install a pressure fitting for a pressure gauge
VALVE SELF LEVELING of about 60 bar (870 psi). Do not exceed 4.5 bar
6. BIG SHUTOFF (65.3 psi).
VALVE

Figure 6. Dampening System Hydraulic

Schematic

8
4500 SRM 787 Boom Repair

Boom Repair
Repairs to parts of the boom can be made with the
boom installed. The spreader and the inner boom
have to be removed for the removal of the telescop-
ing cylinder. Remove the complete boom only if nec-
essary.

SPREADER
Remove
1. Retract the boom fully.

2. Put the switch in the cabin in the unlocked posi-

tion to allow unrestricted movement of the yoke.

3. Place the spreader on a container or a support.

Lower the boom just enough to release the weight
of the container. Keep the boom high enough to
carry the weight of the boom head and the yoke
only.
1. PIN 5. PLATE
4. Shut down the engine. 2. SPACER 6. GREASE FITTING
3. INNER BOOM 7. YOKE
NOTE: The shutoff valves are open when the cold 4. PIVOT PIN
struck line on the shutoff valve is parallel with the
boom (pointing to the operator’s cab). The valves are Figure 8. Boom Yoke Arrangement
closed when the cold struck line on the valve is at
right angles with the boom. The handles cannot be Install
used as an indication unless they are in line with the
1. Move the boom head as close as possible to the
struck line. The function of the shutoff valves is only
spreader rotator frame.
to assist in fitting or detaching the attachment.
2. Align the four holes of the yoke with the rotator
5. Close both shutoff valves of the dampening sys-
frame by rotating the yoke. The yoke can be ro-
tem.
tated by extending or retracting the dampening
6. Disconnect the wiring harness between the boom cylinders. The dampening cylinders will extend
and the spreader. Fit the electrical shunt plug by opening the big valve and closing the small
at the boom plug to allow the operation of the valve. The dampening cylinders will retract by
derricking and telescoping functions. opening the small valve and closing the big valve.

7. Tag and disconnect the four hydraulic lines. Put 3. When required, move the boom to precisely align
caps on the open lines. the four pin holes. Stop the engine.

8. Remove the four bolts and nuts which secure the 4. Fit the four pins and the securing bolts and nuts.
four pins connecting the yoke of the spreader
5. Connect the four hydraulic hoses.
with the rotator. See Figure 8.
6. Remove the electric shunt plug from the boom
9. Remove the four pins with a drift.
plug and store the shunt plug in the cab. Connect
10. Start the engine and move the boom head away the wiring harness.
from the spreader rotator.

9
Boom Repair 4500 SRM 787

7. Place the shutoff valves in their normal posi-

tions. Put the small shutoff valve in the closed
position (with cold struck line perpendicular to
the boom). Put the large shut off valve in the
opened position (with cold struck line parallel to
the boom).

8. Place the switch in the cabin for the dampening

system in the locked position.

YOKE
Remove
1. Remove the spreader. See Spreader, Remove.

2. Remove the pins which connect the lower part of

the dampening cylinders with the yoke for the
spreader. See Figure 9.

3. Align the rod ends of the dampening cylinders

with the brackets on the boom head by extend-
ing or retracting the dampening cylinders. The
dampening cylinders will extend by opening the
big valve and closing the small valve. The damp-
ening cylinders will retract by opening the small
valve and closing the big valve.

4. Use the pins to refit the lower part of the damp-

ening cylinders on the brackets on the boom
head.

5. Support the yoke.

1. BOOM HEAD BRACKET
6. Remove the securing plates of the pivot pin and 2. MOUNTING PIN
push out the pivot pin. 3. PIVOT PIN

7. Move the boom head away by derricking up. Figure 9. Dampening Cylinder Arrangement

Install DAMPENING CYLINDER

1. Move the boom head to align it with the hole in Remove
the yoke for the pivot pin.
1. Put tags for identification on the hydraulic lines.
2. Install the pivot pin and fit the securing plates. Remove the hydraulic lines at the cylinder. See
Figure 9.
3. Remove the pins securing the lower part of the
dampening cylinders. 2. Remove the locknut, washer, spacer, and pin
from the cylinder.
4. Extend the dampening cylinders by opening the
big valve and closing the small valve. 3. Remove the cylinder.
5. Fit the pins and securing pins which connect the Install
lower part of the dampening cylinders with the
yoke for the spreader. 1. Place the cylinder in position on the brackets.

10
4500 SRM 787 Boom Repair

2. Install the pin, washer, spacer, and locknut. The

shell side of the hoses are fitted at the side of the
spreader attachment or at the carriage.

3. Connect the hydraulic lines to the cylinder.

NOTE: After installation, carry out the first move-

ments at slow speed without a load.

PIVOT BEARING
Removal
NOTE: It is not necessary to remove the boom to re-
place the pivot bearings, provided one pivot bearing
remains fitted during the exchange of the other and
that the spreader is supported by a container.

1. Put the spreader on a container. Lower the boom

until the weight of the inner and outer boom are
both supported by the container.

2. Remove the capscrews for the mounting pin that

attach the pivot bracket to the frame. See Fig-
ure 10.

3. Remove the mounting pin with a drift. An un-

changed position of the pivot bearing is an indi-
cation of proper support of the boom.
1. OUTER BOOM 7. COVER
4. Remove the rear mounting pin. 2. SPACER 8. CAPSCREW
3. SEAL 9. PLATE
5. Remove the cover from the bracket by loosening 4. BEARING 10. MOUNTING PIN
the 10 mounting bolts. 5. SPACER 11. BRACKETS
6. WASHER 12. SHIMS
6. Remove the bolts for the washer, rotate the
bracket 180 and slide the bracket from the Figure 10. Boom Pivot Bearing Arrangement
boom pivot.

7. Remove the bearing, seal, and spacer.

Install
1. Place the spacer and the seal on the boom pivot.
See Figure 10.

2. Place the bracket, bearing, and spacer on the

boom pivot.

3. Position the splits on the external face of the

bearing as shown in Figure 11.

1. SPLITS ON THE EXTERNAL JOINT RACE

Figure 11. External Joint Race Positioning

11
Boom Repair 4500 SRM 787

4. Fit the washer with the 10 mounting bolts to the
boom pivot.
5. Center the bracket and bearing with the washer
and install the plug by tightening the 10 mount-
ing bolts.
6. Use shims to fill the space between the pivot
bracket and the frame.
7. Fit the mounting pin in the mounting holes at the
rear of the bracket and the frame.
8. If necessary, derrick the boom slightly to align
the front mounting holes.
9. Fit the mounting pin at the front and secure both
mounting pins with the capscrews.
10. Grease the mounting pins to prevent fretting.
DERRICKING CYLINDER
Remove
NOTE: It is not necessary to remove the boom to re-
place the derricking cylinders, provided the spreader
is supported by a container.
1. Retract and lower the boom until the weight of
the spreader and the boom is supported by a con-
tainer. Do not push down on the boom.
2. Attach a pulling device between the pivot point of
the boom and the upper bracket of the derricking
cylinder. See Figure 12.

1. LIFTING POINT 5. BOOM PILLOW BLOCK

2. NYLON SLING, 4 EACH 6. REAR PIN
3. NYLON SLING 7. FRONT PIN
4. PULLING DEVICE 8. SOFTENER

Figure 12. Boom Lifting Points

12
4500 SRM 787
3. Apply tension to the pulling device to compensate
for the weight of the derricking cylinder. The
derricking cylinder weighs approximately 520 kg
(1146 lb).
4. Remove the bolts holding the lock plate and the
pin from the cylinder top mount. Prevent the
spacers from falling while pushing the pin out
from the mount with a drift.
5. Secure a metal plate of 200 × 50 × 15 mm (8 × 2
× 0.6 in.) between the frame and the underside
of the derricking cylinder. Release the pulling
device to slant the cylinder until it is supported
by the plate. See Figure 13.
6. Start the engine and slowly retract the derrick-
ing cylinder completely. Stop the engine and
eliminate residual oil pressure by operating all
of the control levers.
1. DERRICKING CYLINDER
2. SUPPORT PLATE
Figure 13. Support Plate Placement for
Derricking Cylinders
Boom Repair
7. Detach the hoses from the holding valve and col-
lect the escaping oil. Plug all openings.
8. Attach a sling through the top bracket with a
crane and apply tension to compensate for the
weight.
9. Remove the bolts holding the lockplate and re-
move the pin from the lower cylinder.
10. Remove the cylinder and place it on a support.
Install
1. Verify that the mounting brackets of the cylin-
ders are in a parallel position.
WARNING
Verify the lifting device has the rated capacity
of 1150 kg (2535 lb)
2. Use a sling to lift the derricking cylinder.
3. Position the split on the external face of the bear-
ings in a position as shown in Figure 14.
4. Attach the lower part of the cylinder by pushing
the lower pivot through the holes of the mount,
the spacers, and the cylinder.
5. Secure a metal plate of 200 × 50 × 15 mm (8 × 2
× 0.6 in.) between the frame and the underside
of the derricking cylinder. Release the pulling
device to slant the cylinder until it is supported
by the plate. See Figure 13.
6. Remove the sling holding the cylinder.
7. Connect the hydraulic hoses with the holding
valve.
8. Attach a pulling device as shown in Figure 12,
move and extend the cylinder to allow insertion
of the upper pivot pin, and secure it with the lock
plate and bolts.
13
Boom Repair
1. SPLIT ON EXTERNAL JOINT RACE
Figure 14. Derricking Cylinder Bearing Positioning
BOOM
Remove
NOTE: Remove the yoke and the dampening cylinder
only if necessary. See Yoke, Remove and Dampening
Cylinder, Remove.
1. Remove the spreader. See Spreader, Remove.
2. Loosen the tubes leading to the telescoping cylin-
der at the frame end and collect the escaping hy-
draulic oil.
3. Remove the hydraulic tubes completely.
14
4500 SRM 787
4. Detach the hoses and the wire harness between
the boom and vehicle.
5. Attach slings to the lifting holes on the boom
and let a lifting device carry the weight of the
boom. Use a total of 4 slings of 5 m (16.4 ft)
long, each with a minimum carrying capacity of
5000 kg (11,000 lb). The boom weighs approxi-
mately 14,500 kg (32,000 lb). See Figure 12.
6. Attach a pulling device between the pivot point
at the boom end and the upper brackets of the
derricking cylinders. See Figure 12.
7. Apply tension to compensate for the weight of the
derricking cylinders.
4500 SRM 787 Boom Repair

8. Secure metal plates of 200 × 50 ×15 mm (8 × 2 ×
0.6 in.) between the frame and the underside of
the derricking cylinders. See Figure 13.
9. Verify that the boom is being carried as indicated
in Figure 12.
10. Remove the bolts holding the lock plate and the
pin from the cylinder top mount. Prevent the
spacers from falling while pushing the pin out of
the mount with a drift.
6. Remove the two lower wear pads at the front of
the inner boom.
7. Place wooden blocks on the lower part of the ex-
tension chain to carry the weight of the upper
chain support. Attach a rope around the upper
and lower part of the extension chain to clamp
these at the location of the wooden blocks. See
Figure 15.

11. Relax the pulling device until the metal plate

fully supports the derricking cylinder.

NOTE: For the removal of the boom, the derricking

cylinders can stay on the machine provided that the
cylinders are secured in their backward position by
means of a sling.

12. Remove the capscrews for the mounting pins that

attach the pivot bracket to the frame. See Fig-
ure 10.

13. Remove the front mounting pin with a drift on

each side of the boom. An unchanged position of
the pivot bearing is an indication for the proper
support of the boom. 1. UPPER SUPPORT EXTENSION CHAIN
2. EXTENSION CHAIN
3. ROPE
14. Remove the two rear mounting pins. 4. LOWER SUPPORT EXTENSION CHAIN
5. BLOCKS
15. Lift the boom together with the pivot bearing
brackets. Be careful not to touch the still-fitted Figure 15. How to Place Wooden Blocks
derricking cylinders.
8. Remove the four mounting bolts of the extension
16. Put the boom on support. chain support as fitted on the inner boom.

Disassemble 9. Replace the middle fitted washers to the inner

1. To remove the pivot bearing bracket from the
boom, first remove the cover from the bracket by
loosening the 10 mounting bolts.
2. Remove the bolts for the washer and slide the
bracket from the boom pivot.
3. Remove the bearing, seal, and spacer.
4. Remove the side wear pad holders at the rear of
the inner boom and at the front of the outer boom.
5. Remove the upper wear pads fitted at the rear
of the inner boom and at the front of the outer
boom.
boom for protecting these against damage or loss.
10. Remove the four M20 bolts which attach the
cylinder rod with the support on the outer boom.
See Figure 16.
11. Remove the hydraulic tubing and hoses from the
telescoping cylinder.
12. Using a lifting device to move the inner boom out
of the outer boom.
13. Place the inner boom on supports.
14. Place a sling around the telescoping cylinder rod
to support the weight of the cylinder.

15
Boom Repair 4500 SRM 787

solvent manufacturer’s recommended safety

precautions.

Clean the boom to allow inspection of the welds for

cracks. Inspect wear plates and retainers for dam-
aged threads, deep grooves, or cracks. Check wear
surfaces of boom sections. Replace wear plates that
are worn to a thickness of 20 mm (0.8 in.).

Outer Boom

NOTE: The following inspection is for trucks before

serial number A227J01530.

Check if there is a hole present in the outer boom

behind the derricking cylinder. If this is the case,
fill a hole with a round plate and weld it flush with
the inside surface of the outer boom. This plate is
to provide full support to the side wear pads in this
area. See Figure 17.

1. M20 BOLT
2. CYLINDER ROD
3. OUTER BOOM

Figure 16. Telescoping Cylinder Rod Support

Mount

15. Remove the six M20 bolts holding the two clamp
brackets on each side of the cylinder.

16. Slide the cylinder out of the inner boom until the
guide at the front of the cylinders touches the
boom bracket.

17. Remove the protection tube from the guide when

fitted.

18. Place a second strap around the cylinder at the

guide end and complete the removal of the cylin-
der.

NOTE: To retract the rod of the removed cylinder,

open the bleed screw of the small chamber and of the
large chamber. Immobilize the body of the cylinder
using a lifting device, and gently push the rod in-
ward. Be careful not to damage the cylinder rod.
Clean, Inspect, and Repair
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
Figure 17. Outer Boom Repair
Check the vertical weld on the inside of the outer
boom in the area of the central pivoting point. If nec-
essary, grind the weld flush with the surface. Start
50 mm (2 in.) from the top surface over a distance of
250 mm (10 in.) along the weld. This is to smoothen
the track of the side wear pads.
NOTE: Contact your nearest Hyster service depart-
ment if you need further information about these
modifications.

16
4500 SRM 787
Inner Boom
NOTE: The following inspection is for trucks before
serial number A227J01530.
1. Verify that the mounting plate for the wear pad
at the top of the inner boom extends 15 mm
(0.59 in.) above the upper surface of the inner
boom. See Figure 18.
2. Verify that grease fittings are present to lubri-
cate the wear pads at the top of the inner boom.
1. 15 mm (0.59 in.) PLATE
2. GREASE FITTING
Figure 18. Inner Boom Inspection Points
Boom Repair
3. Verify the plate at the bottom rear of the inner
boom extends 25 mm (0.98 in.) below the lower
surface.
4. Measure the distance between the two vertical
planes between the inner boom support brack-
ets. With the support plates fitted, the distance
should be 366 to 368 mm (14.4 to 14.5 in.). If nec-
essary, grind the sides of the inner boom support
brackets and the support plates to obtain correct
distance. See Figure 19.
3. 25 mm (0.98 in.) PLATE
17
Boom Repair
Figure 19. Inner Boom Support Bracket
Measurement
NOTE: Contact your nearest Hyster service depart-
ment if you need further information about these
modifications.
Assemble
1. Install the telescoping cylinder. See Telescoping
Cylinder, Install.
2. Install the pivot bearings. See Pivot Bearing, In-
stall.
3. Use a lifting device to enter the first 2 m (6.6 ft)
of the inner boom together with the telescoping
cylinder into the outer boom.
4. Fit new lower wear pads in the outer boom. Po-
sition the "V" of the grooves to point towards the
inside of the section. See Wear Pads.
5. Proceed with inserting the inner boom into the
outer boom.
6. With an assistant, insert the cylinder rod into the
support of the outer boom.
7. Apply strong Loctite® and tighten the 4 M20 bolts
to 550 N•m (406 lbf ft).
8. Fit the upper wear pads at the front of the outer
boom. Position the "V" of the grooves to point
towards the inside of the section. Use shims to
adjust the clearance between 2 to 4 mm (0.08 to
0.16 in.) between the pad and the inner boom.
Apply medium Loctite® to the bolts and torque to
130 N•m (96 lbf ft). See Wear Pads.
18
4500 SRM 787
9. Fit the upper wear pads at the rear of the inner
boom. Position the "V" of the grooves to point
towards the inside of the section. Use shims to
adjust the clearance between 0 to 2 mm (0 to
0.08 in.) between the pad and the outer boom.
Apply medium Loctite® to the bolts and torque to
130 N•m (96 lbf ft). See Wear Pads.
10. Fit the clamp plates to the upper wear pads at the
rear of the inner boom. Apply strong Loctite® to
the bolts and torque to 280 N•m (207 lbf ft).
NOTE: Use the latest design of shouldered side wear
pads together with the steel support washer. The
central hole allows greasing with a gun, instead of
applying grease to the tracks with a brush.
11. Put the washer and the wear pad in the sup-
port. Apply medium Loctite® to the mounting
bolts and torque to 200 N•m (148 lbf ft).
12. Tighten the adjustment bolts in the pad holders
in order to:
• Center the telescoping cylinder between the
two clamp plates.
• Center the front of the inner boom in the outer
boom.
• Adjust the clearance of all the side pads.
See Wear Pads, Adjust.
13. When applicable, remove the ropes and the
blocks holding the upper and lower part of the
extension chain.
14. Fit the extension chain supports to the inner and
outer boom.
15. Reconnect the hoses, tubes, and harnesses.
Install
1. Place slings on the boom.
2. Lift the boom until the rear bracket pin of the
pivot bearings can be fitted in the frame.
3. Place an equal number of shims at both sides
of the truck to fill up the space between pivot
bracket and frame.
4. Slide the mountings into their final positions.
5. Fit the securing capscrews for the mounting pins.
6. Repeat Step 2 through Step 5 for the mounting
pin at the front of the pivot bracket.
4500 SRM 787 Boom Repair

7. Align and reconnect the derricking cylinders.

See Derricking Cylinder, Install.

8. Remove the slings holding the boom.

9. Reconnect the hoses and the wire harness be-

tween the boom and the vehicle.

10. Install the yoke, dampening cylinders, and the

spreader on the boom. See Yoke, Install, Damp-
ening Cylinder, Install, and Spreader, Install.

11. Start the engine and operate the different hy-

draulic functions several times, slowly and with-
out load. Stop the engine and check for leaks.

TELESCOPING CYLINDER
Remove
1. Remove the inner boom. See Boom, Disassemble.

2. Place a sling around the rod to support the

1. WELDED NUTS
weight of the cylinder. The cylinder weighs ap-
proximately 1050 kg (2300 lb). Figure 20. Front Cylinder Support Modification
3. Remove the six M20 bolts holding the two clamp
brackets on each side of the cylinder.

4. Use a lifting device and slide the cylinder out of

the inner boom until the guide at the front of the
cylinder touches the boom bracket.

5. Remove the protection tube from the guide.

6. Put a second sling around the cylinder at the

guide end and complete the removal of the cylin-
der.

7. To retract the rod of the removed cylinder, open

the bleed plug of the small chamber M2 and of
the large chamber M1. Immobilize the body of
the cylinder by using a lifting device, and gently
push the rod inwards.
Install
NOTE: Provide the parts required to fit the support
block under the telescoping cylinder. Check that the
front cylinder support has been enlarged to a width
of approximately 350 mm (13.78 in.). See Figure 20.
1. KEY
Figure 21. Key Placement on Cylinder Support
2. Fit the front support with the modified guide on
the cylinder with the six M14×40 bolts. Estab-
lish the perpendicular position of the 350 mm
(13.78 in.) long support plate of the guide in re-
lation to the key. Tighten the bolts and secure
with strong Loctite® 270 or equivalent. Torque
to 180 N•m (133 lbf ft).

1. Fit two new keys. The longer side of the key must 3. Assemble the support block and position it at a
be fitted at the upper section. Torque to 390 N•m distance of 870 mm (34.25 in.) from the keys.
(288 lbf ft). Do NOT use Loctite®. See Figure 21. Verify that the support areas of the support block
and the front guide are parallel.

19
Boom Repair
4. Verify that the distance between the cylinder up-
per side and the block support area is 320 mm
(12.6 in.) ±1 mm (0.04 in.).
5. Open the bleed plugs on the cylinder head.
6. Use a lifting device to pull the telescoping cylin-
der rod out approximately 1300 mm (51.2 in.).
Protect the rod against damage.
7. Tighten the two bleed plugs on the cylinder head
and the two bolts on the cylinder shell.
8. Grease the bottom part of the front cylinder sup-
port.
9. Use a lifting device to enter the cylinder into the
inner boom until the front cylinder support has
passed over the support brackets.
10. Fit the cylinder protection tube on the front cylin-
der support. Use medium Loctite® and torque
130 N•m (96 lbf ft).
1. INNER BOOM CYLINDER SUPPORT
2. SUPPORT SHIM
3. SUPPORT PLATE
4. KEY
Figure 22. Telescoping Support Assembly
20
4500 SRM 787
NOTE: To measure clearances, the support bracket,
support plate, and the key have to be free from im-
purities and grease.
NOTE: To facilitate checks, it is advisable to fit
two studs M20×160 in the threads of the centering
bracket to service as centering pins. Fit one support
plate on each side.
11. Insert the cylinder further and press the keys
against the 10 mm (0.39 in.) support plates while
centering the cylinder in the inner boom. See
Figure 22.
NOTE: The following step is only a provisional assem-
bly for measuring clearances.
12. Fit two new clamp brackets with a central
M20×140 bolt and steel washer between the
clamp bracket and the support plate. Tighten
the two new clamp brackets.
5. CLEARANCE SHIM
6. CLAMP BRACKET
7. 1 to 2 mm (0.04 to 0.08 in.) PLAY BY SHIMMING
4500 SRM 787 Boom Repair

13. Perform clearance measurements and determine
which shims to use. See Shimming Key Clear-
ance.
NOTE: Both the tapered shims, as well as the align-
ment shims are to be fitted between the support
bracket of the inner boom and the 10 mm (0.39 in.)
support plate.
seated between the pressure plate and measure
the clearance between the key and the clamp
bracket. The clearance must be between 1 and
2 mm (0.04 and 0.08 in.). Add or remove shims
as required.
23. Torque the bolts for the clamp bracket to
390 N•m (288 lbf ft).

14. Remove the clamp brackets and insert the shims Shimming Key Clearance
as determined.
The following two sections are examples of how to
15. Replace the clamp bracket with the washer and determine the required shims and obtain the correct
measure the clearances again. Correct the situ- clearances. For these procedures refer to Figure 23
ation if the clearance between high end and low and Figure 24.
end exceeds 0.2 mm (0.008 in.) and the clearance
between the right side and the left side exceeds
0.4 mm (0.016 in.).

16. Remove the two clamp brackets and the steel

washers.

17. Move the cylinder out approximately 1 m (3 ft)

with a lifting device.

18. Grease the bearing surfaces of the keys and the

support plates with Molycote BR2+ type grease.

19. Replace the cylinder in the inner boom.

20. Fit one additional clearance shim of 1 mm

(0.04 in.) on each side.

21. Grease the inside of the clamp brackets and

attach to the boom with the six M20 bolts and 1. LEFT SIDE
washers. Keep the clamps parallel with the 2. RIGHT SIDE
cylinder bracket and at a distance between 3 and
6.5 mm (0.12 and 0.26 in.). Figure 23. Key Clearance Measurements

22. Check the clearance of the key between the pres-

sure plate and the clamp bracket. Have the key

21
Boom Repair 4500 SRM 787

A. TAPERED SHIMS B. ALIGNMENT SHIMS

1. 1 mm (0.04 in.) SLOPED SHIM 3. SLOT (SHOWS THICKEST SIDE OF SHIM)
2. 0.25 mm (0.001 in.) SLOPED SHIM

Figure 24. Available Support Shims

How to Determine the Slope Shims at the Left Side Cover the 1.2 mm (0.047 in.) slope difference by
Key inserting sloped shims. Take one shim of 1 mm
(0.04 in.), and one shim of 0.25 mm (0.01 in.) slope.
The following calculation example for the left side Fit both shims with the slots at the sides with the
key is based on the clearance measurements as biggest clearance. In this example, the side with the
shown on Figure 23: biggest clearance is at point B.
At point A: 0 mm (0 in.) (seated) The total covered slope difference is :
At point B: 1.2 mm (0.047 in.) (clearance) 0.25 mm (0.01 in.) + 1 mm (0.04 in.) = 1.25 mm
(0.05 in.)
Slope 1.2 mm (0.047 in.)
difference:

With the sloped shims fitted, the distance between the key and the support bracket will be:

Point A Point B
Measurement ( ) 0 mm ( 0 in.) 1.2 mm ( 0.047 in.)
1 mm (0.04 in.) sloped shim 2 mm (0.079 in.) 3 mm (0.118 in.)
0.25 mm (0.01 in.) sloped shim 2.25 mm (0.089 in.) 2.50 mm (0.098 in.)
Total distance: 4.25 mm (0.168 in.) 4.3 mm (0.17 in.)

NOTE: The maximum allowable difference between

the top end and the bottom end is 0.2 mm (0.008 in.).

22
4500 SRM 787 Boom Repair

How to Determine the Slope Shims at the Right Cover the 0.7 mm (0.028 in.) slope difference by
Side Key inserting sloped shims. Take one shim of 1 mm
(0.04 in.) slope with the slot at the biggest clearance
The following calculation example for the right side side (point D) and one shim of 0.25 mm (0.01 in.)
key is based on the clearance measurements as slope with the slot at the smaller clearance side
shown on Figure 23: (point C).
At point C: 0.9 mm (0.035 in.) (clearance) The total covered distance is:
At point D: 1.6 mm (0.063 in.) (clearance) 1 mm (0.04 in.) 0.25 mm (0.01 in.) = 0.75 mm
(0.03 in.)
Slope 0.7 mm (0.028 in.)
difference:

With the sloped shims fitted, the distance between the key and the support bracket will be (see Figure 23):

Point C Point D
Measurement ( ) 0.9 mm ( 0.035 in.) 1.6 mm ( 0.063 in.)
1 mm (0.04 in.) sloped shim 2 mm (0.079 in.) 3 mm (0.118 in.)
0.25 mm (0.01 in.) sloped shim 2.5 mm (0.098 in.) 2.25 mm (0.089 in.)
Total distance: 3.6 mm (0.142 in.) 3.65 mm (0.144 in.)

NOTE: The maximum allowable difference between
the top end and the bottom end is 0.2 mm (0.008 in.).
Alignment Shimming
The total distance between the key and support plate
is not equal for the left and right side. Alignment
shims are used to cover the average distance between
the left side and the right side key distance.
Based on the above example, the calculation is as fol-
lows:
Insert one alignment shim of 0.50 mm (0.02 in.) at
the right side. The remaining difference at the left
and right side key distance will be:
0.65 mm (0.026 in.) 0.50 mm (0.02 in.) = 0.15 mm
(0.006 in.)
NOTE: Maximum allowable alignment difference
between the right side and the left side is 0.40 mm
(0.016 in.).

Average left side key distance: 4.27 mm

(0.168 in.)
Average right side key distance: 3.62 mm
(0.143 in.)
Difference: 0.65 mm
(0.026 in.)

23
Wear Pads
Wear Pads
GENERAL
Maximum clearance between wear pads and boom is
3 mm (0.12 in.). Reshim when play has reached 3 mm
(0.12 in.). When reshimming, maintain a minimum
clearance of 1 mm (0.04 in.).
Replace a wear pad when its wear pattern is worn off.
For side wear pads this is at a remaining thickness
of 55 mm (2.17 in.). For horizontal wear pads this is
at a remaining thickness of 21 mm (0.83 in.). Always
replace horizontal wear pads in pairs to retain the
parallel position of the inner boom in the outer boom.
NOTE: When loosening bolts for wear pads, be aware
that these are secured with Loctite®.
NOTE: Use medium Loctite® when fitting bolts for
wear pads.
SIDE WEAR PADS
Remove
NOTE: There are four side wear pads at the front of
the outer boom and two side wear pads at the rear of
the inner boom which can be replaced and adjusted.
Latest side wear pads have a wear mark, which al-
lows verification if the pad requires replacement or
if adjustment is still possible.
NOTE: Replacement of the pads at the rear end of the
inner boom takes place from the inside. Replacement
of the pads at the front end of the outer boom takes
place from the outside.
24
4500 SRM 787
1. Retract the boom.
2. Remove the six bolts holding the bracket and re-
move the assembly. See Figure 25.
Clean and Inspect
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
Clean and degrease all parts. Check for damage
and wear. Replace any damaged parts and wear
pads with a remaining thickness of less than 55 mm
(2.17 in.).
Install
NOTE: When replacing, use the latest design of
shouldered side wear pads, support washer, and
adjustment bolt, which now have a central hole for
greasing purposes.
1. Place the assembly in position on the boom.
2. Apply medium Loctite® to the bolts and install.
3. Torque the bolts to 200 N•m (148 lbf ft).
4500 SRM 787 Wear Pads

1. BOLT 6. WEAR PAD

2. WASHER 7. LOCKING NUT
3. SUPPORT BRACKET 8. ADJUSTMENT BOLT
4. SHIM 9. GREASE NIPPLE
5. WASHER, SUPPORT 10. GREASE NIPPLE COVER

Figure 25. Side Wear Pads Arrangement

25
Wear Pads
Adjust
Inner Boom Side Wear Pads
1. Loosen the securing nut and turn the adjustment
bolts in the pad holders to center the telescoping
cylinder bracket between the two clamp brack-
ets.
2. Measure the equal distances between the clamp
brackets and the cylinder bracket. See Figure 26.
J. REPRESENTS EQUAL DISTANCES
1. CLAMP PLATE
2. CYLINDER BRACKET
Figure 26. Centering the Rear of the Inner
Boom
3. Loosen the adjustment bolt and install a 1 mm
(0.04 in.) shim between the wear pad and the
flank of the outer boom.
4. Retighten the bolt to establish contact with the
shim. Do not move the inner boom in the outer
boom.
5. Remove the shim and secure the position of the
bolt by tightening the securing nut.
Outer Boom Side Wear Pads
1. Loosen the securing nut and tighten the adjust-
ment bolt to center the lower portion of the inner
boom in the outer boom. See Figure 27.
26
4500 SRM 787
1. INNER BOOM 3. DISTANCE
2. OUTER BOOM 4. LOWER WEAR
PADS
Figure 27. Centering the Front of the Inner
Boom
2. Loosen the adjustment bolt to allow inserting a
1 mm (0.04 in.) shim between the wear pad and
the outer flank of the outer boom.
3. Retighten the bolt to establish contact with the
adjustment shim. Do not move the inner boom
in the outer boom.
4. Remove the shim and secure the position of the
bolt by tightening the securing nut. Proceed with
adjusting clearances of the upper side wear pads
without moving the inner boom.
HORIZONTAL FRONT WEAR PADS
Remove
1. Remove the boom stop.
2. Remove the bolts securing the upper front wear
pads and shims. Remove the wear pads and
shims. See Figure 28.
3. Lift the inner boom until it touches the top of the
outer boom.
4. Remove the bolts securing the lower front wear
pads. Remove the wear pads and shims.
4500 SRM 787 Wear Pads

1. BOLT 5. SHIMS
2. WASHER 6. GREASE NIPPLE
3. BOOM STOP 7. GREASE NIPPLE COVER
4. WEAR PADS

Figure 28. Horizontal Wear Pads

Clean and Inspect Install

WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
Clean and degrease all parts. Check for damage
and wear. Replace any damaged parts and wear
pads with a remaining thickness of less than 21 mm
(0.83 in.).
1. Reassemble the front wear pad while maintain-
ing a thickness of 25 mm (0.98 in.) for the pad
and shim combined.
2. Position the pad with the "V" towards the inside
of the boom.
3. Apply Loctite® to the bolts toque to 130 N•m
(96 lbf ft).
4. Place the boom stop in position, apply medium
Loctite® to the bolts and torque to 200 N•m
(148 lbf ft).

5. Lower the inner boom until it rests in the outer

boom.

27
Hydraulic Cylinder Repair
6. Shim the upper wear pad to a clearance of 2 mm
(0.08 in.). Apply medium Loctite® to the bolts and
torque to 130 N•m (96 lbf ft).
HORIZONTAL REAR WEAR PADS
Remove
1. Retract the boom completely to gain access to the
rear pads at the top of the inner boom.
2. Place the spreader on a container to verify that
the rear end of the inner boom is seated in the
outer boom.
3. Remove the bolts securing the pad retainer and
the wear pads. Remove the pad retainer and
wear pads.
Hydraulic Cylinder Repair
GENERAL INSPECTION AND ASSEMBLY
INSTRUCTIONS
1. Use a thermometer to make sure not to exceed
250 C (482 F), when heat is required to weaken
Loctite® for disassembly of parts.
2. Clean and degrease all parts.
3. Place the cylinder in a proper support.
4. Use a suited lifting device which can lift out the
rod along the center line of the cylinder. Use a
proper support for the removed rod.
5. Carefully inspect the rod surface for absence
of dents and scratches. Verify that the inter-
nal stroke surface does not show any nicks or
scratches.
6. Remove all seals while carefully noting the
mounting orientation. Thoroughly clean and
degrease the seal seatings and cavities. Always
28
4500 SRM 787
Clean and Inspect
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
Clean and degrease all parts. Check for damage
and wear. Replace any damaged parts and wear
pads with a remaining thickness of less than 21 mm
(0.83 in.).
Install
1. Position the pads with the "V" towards the inside
of the boom.
2. Shim the pads to a clearance of 2 mm (0.08 in.).
3. Apply strong Loctite® to the bolts for the pad re-
tainers and refit the pad retainers by torquing
the bolts to 280 N•m (207 lbf ft).
install new seals and packings when reassem-
bling. Lightly oil the seals for installation. Heat
PTFE seals before making an attempt to fit.
7. Verify the presence of proper chamfers to prevent
damage of the seals during installation. Cham-
fers must be rounded and polished.
8. Use belts to pull the seals over edges. Use guides
to properly seat the seals in their seatings.
9. Use a guide to install the piston and the end cap
into the cylinder.
10. Apply two dots of glue under guide bearings to fix
their position during installation. Position the
ends of the guide bearings at an angular offset
when positioned next to another.
11. Work only in a clean working environment with
suited tools. Verify that no impurities enter the
cylinder during assembly.
12. Use clean hydraulic oil lubricate the components
for assembly.
4500 SRM 787
13. When torque values are not specified, apply
strong manual effort on the lever arm of stan-
dard wrenches.
14. After reassembly, carry out the first movements
at a slow speed without a load.
DERRICKING CYLINDER
Disassembly
1. Place cylinder in a proper support.
2. Remove attached hose and holding valve to
prevent damage. The empty weight is 495 kg
(1091 lb). See Figure 29.
3. Place the hydraulic connection at the gland side
in a low position to collect the remaining 23 liter
(24 qt) of hydraulic oil from the cylinder.
4. Grind off the lock plate which is welded between
the rod end and the rod.
5. Remove the rod end.
6. Remove the two setscrews at the side of the cylin-
der, locking the securing gland.
7. Turn the securing gland with a suitable tool from
the cylinder.
8. Pull out the piston and the rod. Keep the rod
aligned with the shell. The piston will push out
of the gland.
9. Place the rod on a proper support.
10. Remove the end cap from the rod.
11. Remove nylon stops originally under the
setscrews.
12. Remove all seals while noting the mounting ori-
entation.
Clean and Inspect
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
Hydraulic Cylinder Repair
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
See General Inspection and Assembly Instructions.
Assemble
NOTE: Verify the presence of proper chamfers to pre-
vent damage of the seals during installation. Cham-
fers must be rounded and polished.
NOTE: Lightly oil the seals for installation. Heat
PTFE seals before making an attempt to fit. Use
belts to pull seals over the edges. Use guides to prop-
erly seat the seals in their seatings. Use a guide to
install the piston and the end cap into the cylinder.
1. Install new seals.
2. Install new nylon stops.
3. Slide the gland on the rod.
4. Apply two dots of glue under the guide bearings.
Position the ends of the guide bearings at an an-
gular offset. See Figure 29.
5. Insert the rod and the gland into the cylinder.
6. Push the gland in until it is seated against the
edge in the shell.
7. Insert the securing gland between the shell and
the end cap. Tighten to 1000 N•m (738 lbf ft).
8. Tighten the two setscrews securing the securing
gland.
Test
Test the cylinder under pressure before installing.
The maximum service pressure is 220 bar (3191 psi).
The maximum test pressure is 300 bar (4351 psi).
29
Hydraulic Cylinder Repair 4500 SRM 787

1. ROD END 7. ROD

2. LOCK PLATE 8. GUIDE BEARING
3. SEALS 9. PISTON
4. SECURING GLAND 10. SHELL
5. GLAND 11. SETSCREW
6. BLEED SCREW 12. NYLON INSERT

Figure 29. Derricking Cylinder

TELESCOPING CYLINDER cylinder. In the retracted position, the cylinder

can contain about 115 liter (122 qt) of hydraulic
Disassemble oil.

NOTE: If the sealing failed of the gland only, then the 2. Remove the two bleed screws.
rod and piston do NOT have to be removed. Proceed
until Step 8 and remove the gland. Reassemble after 3. Extend the cylinder 50 cm (2 ft) to gain better ac-
having fitted new seals. cess to the M12 bolts retaining the speed limiter.

1. Place the two main orifices at the rod end in a 4. Remove the holding valve by removing the four
lower position to collect the remaining oil in the M16 bolts. See Figure 30.

30
4500 SRM 787 Hydraulic Cylinder Repair

1. HOLDING VALVE 7. GLAND 15. PISTON

2. CARTRIDGE VALVE (SPEED 8. BLEED SCREW 16. RETAINER PLATE
LIMITER) 9. ROD 17. SUPPORT SLEEVE
3. ROD CAP (SPEED LIMITER 10. SPACER 18. INNER TUBE
HOUSING) 11. SETSCREW 19. INNER TUBE RETAINER RING
4. SEALS 12. LOCK SCREW 20. O-RING
5. ROD FLANGE 13. NYLON INSERT 21. ANTI-EXTRUSION RING
6. M14 BOLT 14. GUIDE BEARINGS

Figure 30. Telescoping Cylinder

5. Remove the speed limiter.
6. Remove the twelve M12 bolts holding the rod
flange.
7. Remove the speed limiter housing.
8. Remove the twenty M14 bolts which secure the
cylinder gland.
9. Pull out the rod together with the piston. Proceed
carefully when the gland is pushed out to keep
the rod aligned with the shell.
NOTE: Normally, do NOT disassemble the inner tube
as described in Step 10 to Step 15. Disassemble only
in case the seal between the piston and rod is leaking.
10. Remove the two lock screws with nylon tips that
are used to lock the thread between the piston
and rod.
11. Turn the piston from the rod.
12. Remove the two setscrews which secure the
spacer on the rod. The setsrews are located at
90 apart and are secured with Loctite®.

31
Hydraulic Cylinder Repair
13. Remove the spacer.
14. Remove the retainer ring at the support for the
inner tube.
15. Remove the inner tube.
16. Grind off the tack weld holding the retainer
plate.
17. Turn the tube support sleeve from the rod.
Clean and Inspect
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
See General Inspection and Assembly Instructions.
Assemble
1. Enter the inner tube into the rod and secure it
with the retainer ring.
2. Slide the tube support sleeve over the inner tube
and turn the sleeve in the rod until the sleeve
is flush with the inner tube. Tack weld the stop
plate on the rod. Clean thoroughly.
3. Slide the spacer over the rod and position the
thread for the two setscrews with their cavities
in the rod. Also verify that the hydraulic orifices
of the spacer match with the orifices in the rod.
Use Loctite® and also a punch to secure the two
setscrews.
4. Turn the piston on the thread of the rod until
it bottoms. Use two new nylon tips to lock the
piston on the thread of the rod.
5. Apply tape on the thread of the rod cap to avoid
damaging the seals of the gland. Slide the gland
on the rod.
6. Enter the rod with the piston into the shell. Posi-
tion the gland to align the holes for the mounting
bolts. Fit the 20 M14 bolts and torque in a cross
pattern to 170 N•m (125 lbf ft).
7. Turn the rod flange on the rod until it extends
1 mm (0.04 in.) above the surface of the rod
32
4500 SRM 787
flange. Fit the rod cap, align the bolt holes with
the rod flange and torque the 12 mounting bolts
to 110 N•m (81 lbf ft).
8. Fit the speed limiter and torque to 270 N•m
(199 lbf ft).
9. Fit the holding valve and torque the four M16
bolts to 295 N•m (218 lbf ft).
Test
Test the cylinder under pressure before installing.
The maximum service pressure is 350 bar (5,076 psi).
The maximum test pressure is 500 bar (7,252 psi).
DAMPENING CYLINDER
Disassemble
Measure and note dimension X. See Figure 31.
1. Loosen the setscrews (11) and turn the joint from
the rod.
2. Remove setscrew (7) and the nylon insert from
the shell.
3. Turn the gland nut from the shell from the piston.
4. Pull the rod and the piston out of the shell.
5. Remove setscrew (7) and the nylon insert.
6. Turn the piston from the rod.
NOTE: Note the position of all wipers, seals, backup
rings, and O-rings.
7. Remove and discard all wipers, seals, backup
rings, and O-rings.
8. Inspect all parts. Replace parts if scratched.
Clean and Inspect
WARNING
Cleaning solvents may be flammable and toxic
and can cause severe skin irritation. When
using cleaning solvents, always follow the
solvent manufacturer’s recommended safety
precautions.
See General Inspection and Assembly Instructions.
4500 SRM 787 Hydraulic Cylinder Repair

1. ROD END 7. SETSCREW

2. GLAND NUT 8. NYLON INSERT
3. SEAL 9. GUIDE BEARING
4. BLEED SCREW 10. SHELL
5. ROD 11. SETSCREW
6. PISTON 12. LOCK PLATE

Figure 31. Dampening Cylinder

Assemble 7. Clamp a collar around the piston to allow inser-

tion into the shell.
1. Thoroughly clean and degrease the threading
and housings of the seals. 8. Place the gland nut on the rod and screw into the
shell.
NOTE: Use care when positioning new seals.
9. Torque the gland nut to 180 N•m (133 lbf ft).
2. Install new seals in the gland nut. See Figure 31.
10. Use new nylon inserts and lock the gland nut
3. Apply glue under the guide bearings to keep with the setscrews.
these in position during assembly.
11. Secure the rod end and position according to the
4. Place the piston on the rod. measurement taken in Step 1 of Disassemble.
5. Use a nylon insert and lock the piston with the
Test
setscrew.
Test the cylinder under pressure before installing.
NOTE: Prior to installing the seals in the piston,
The maximum service pressure is 220 bar (3191 psi).
mask the groove for the guide bearings (9).
The maximum test pressure is 300 bar (4351 psi).
6. Preheat the seal to 60 C (140 F) for assembly.

33
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 TECHNICAL PUBLICATIONS

4500 SRM 787 11/03 (5/03)(1/00) Printed in U.S.A.