Allied Systems Long Reach BHA Series Manual

145-053, REV. 5/18
Installation, Maintenance and
Service Manual
BHA
Billet Handler

245-053, REV. 5/18
TABLE OF CONTENTS
SECTION 1 NAMEPLATE LOCATION ........................3
SECTION 2 MODEL NUMBER DESCRIPTION..........4
SECTION 3 SAFETY SUMMARY ...............................5
3.1 Safety Information ........................................... 5
3.2 Safety Regulations .......................................... 5
3.3 Safety Symbols................................................ 5
3.4 Operation Warnings......................................... 5
3.5 Hydraulic Hazards .......................................... 5
3.6 Electrical Hazards ........................................... 6
3.7 Maintenance Warnings.................................... 6
3.8 Training ............................................................ 7
3.9 Labeling........................................................... 7
3.10 Pre-start Checks............................................ 7
3.11 Personnel Safety ........................................... 7
3.12 Load Handling ............................................... 8
3.13 Load Positioning ............................................ 8
3.14 Truck Requirements....................................... 8
3.15 Operator’s Controls ....................................... 9
3.16 Industry Standards ........................................ 9
3.17 Clamp Open Control...................................... 9
SECTION 4 INSTALLATION PROCEDURE..............11
4.1 Truck Requirements....................................... 11
4.2 Hydraulics...................................................... 11
4.3 Attachment Installation .................................. 11
4.4 Hydraulic Connections................................... 11
SECTION 5 SERVICE PROCEDURE.......................13
5.1 Attachment Removal ..................................... 13
5.2 Cylinder Removal .......................................... 13
5.3 Cylinder Installation ....................................... 13
5.4 Cylinder Disassembly.................................... 13
5.5 Cylinder Inspection........................................ 14
5.6 Cylinder Assembly......................................... 15
5.7 Wear Plug Replacement................................ 16
5.8 Gripper Pin Replacement .............................. 16
5.9 Grease Fitting Locations................................ 16
SECTION 6 MAINTENANCE ....................................17
6.1 Schedule........................................................ 17
6.2 Torque Specifications..................................... 17

345-053, REV. 5/18
- -
Date Received:
SECTION 1 NAMEPLATE LOCATION
Notice
When you receive your attachment, locate
the Long Reach nameplate and record
the information to the blank nameplate
tag with the date received in the space
provided on the bottom of this page. If the
name plate is missing, look for the serial
number stamped directly into the metal at
the original location and consult factory.
.XORPPA
ETALPN/S
NOITACOL

445-053, REV. 5/18
SECTION 2 MODEL NUMBER DESCRIPTION
Each attachment is identified by a model number and a serial number located on the name plate attached to the
unit prior to shipment. Long Reach’s model numbers are designed to describe how an attachment is equipped.
The guide below illustrates the information that is represented in a model number. Always include model and serial
number when ordering parts or requesting service information.
BHA Series Model Number:
Length: 126 = 126"
080 = 80.00"
Long beam from face of backing plate to center of gripping pins in closed
position
BHA 060 126 S63
Attachment Type: Billet handler
Capacity: 6000 lb
12500 lb
Mounting: S63 = Bolt-on with 4-28" opening range
P2Q = Pin mount for hoist Model F300 at 30"

545-053, REV. 5/18
SECTION 3 SAFETY SUMMARY
Safety Information
Safety is Everyone’s Responsibility
Whether you are new on the job or a seasoned veteran,
these safety tips may prevent injury to you, to others, or
to the materials you are handling. Always be alert, watch
out for others, and follow these suggestions:
Attachments handle material, not people.
Safety starts with common sense, good
judgement, properly maintained equipment,
careful operation, and properly trained
operators.
The safety instructions and warnings, as documented
in this manual and shipped with the machine, provide
the most reliable procedures for the safe operation and
maintenance of your Long Reach attachment. It’s your
responsibility to see that they are carried out.
Safety Regulations
Know your company’s safety rules. Some companies
have site-specific directions and procedures. The meth-
ods outlined in your operator's manual provide a basis for
safe operation of the machine. Because of special condi-
tions, your company’s material handling procedures may
be somewhat different from those shown in this manual.
Safety Symbols
The following terms define the various precautions and
notices:
DANGER
Indicates a hazardous situation which,
if not avoided, WILL result in death or
serious injury. Carefully read the message
to prevent serious injury or death.
WARNING
Indicates a hazardous situation which,
if not avoided, could result in death or
serious injury. Carefully read the message
to prevent serious injury or death.
CAUTION
Indicates a hazardous situation which,
if not avoided, could result in minor or
moderate injury. Carefully read the message
to prevent minor or moderate injury.
Notice
Describes information that is not related to
personal injury, but may cause equipment
damage or void the warranty.
CAUTION
All possible safety hazards cannot be
foreseen so as to be included in this
manual. Therefore, the operator must
always be alert to possible hazards that
could endanger personnel or damage to
the equipment.
Obey the following warnings before using
your machine to avoid equipment damage,
personal injury or death.
Operation Warnings
• You must be trained to operate this equipment prior
to operation. Be extremely careful if you do not nor-
mally operate this machine. Reorient yourself to the
machine before starting, then proceed slowly.
• Always operate an attachment from the driver’s seat.
• Always lower the attachment if you need to leave the
lift truck. A lift truck supporting a load requires your
full attention.

645-053, REV. 5/18
Hydraulic Hazards
DANGER
Small hydraulic hose leaks are extremely
dangerous, and can inject hydraulic oil
under the skin, even through gloves.
Infection and gangrene are possible when
hydraulic oil penetrates the skin. See a
doctor immediately to prevent loss of limb
or death.
• Wear personal protective equipment, such as gloves
and safety glasses, whenever servicing or checking
a hydraulic system.
• Assume that all hydraulic hoses and components are
pressurized. Relieve all hydraulic pressure before
disconnecting any hydraulic line.
• Never try to stop or check for a hydraulic leak with any
part of your body; use a piece of cardboard to check
for hydraulic leaks.
Electrical Hazards
WARNING
Remain at least 25 feet from high voltage
electrical wires. Failure to do so may
result in injury or death and will damage
equipment.
• All electrical cables and connectors must be in good
condition (free of corrosion, damage, etc). Use cau-
tion in wet weather to avoid danger from electrical
shock. Never attempt electrical testing or repair while
standing in water.
• Do not wear electrically conductive jewelry, clothing,
or other items while working on the electrical system.
Maintenance Warnings
Maintenance, lubrication and repair of this machine can
be dangerous unless performed properly.You must have
the necessary skills and information, proper tools and
equipment. Work in a method that is safe, correct, and
meets your company’s requirements.
• Do not attempt to make adjustments, or perform
maintenance or service unless you are authorized
and qualified to do so.
• Include attachments in a scheduled maintenance and
inspection program. Tailor inspection steps to the at-
tachment.
• Unless specified in service procedures, never attempt
maintenance or lubrication procedures while the ma-
chine is moving or the engine is running.
• Always perform all maintenance and lubrication pro-
cedures with the machine on level ground, parked
away from traffic lanes.
Notice
Local laws and regulations may require
that additional safety measures be taken.
• Never rely on the hydraulic system to support any
part of the machine during maintenance or lubrication.
Never stand under a component that is supported
only by the hydraulics. Make sure it is resting on its
mechanical stops or appropriate safety stands.
• Use caution when working around hot fluids. Always
allow lubricating and hydraulic oils to cool before
draining. Burns can be severe.
• Use extreme caution when using compressed air to
blow parts dry. The pressure should not exceed 30
psi (208 kPa) at the nozzle. Never use compressed
air on yourself. Air pressure penetrating your skin
can be fatal.
• Engine exhaust fumes can cause death. If it is neces-
sary to run the engine in an enclosed space, remove
the exhaust fumes from the area with an exhaust pipe
extension. Use ventilation fans and open shop doors
to provide adequate ventilation.
• Before disconnecting hydraulic lines, be sure to lower
all loads and relieve all hydraulic pressure. The load
could fall on you, or escaping hydraulic oil could cause
severe personal injury.
• Prevent personal injury or equipment damage by us-
ing a lifting device with a lifting capacity greater than
twice the weight of any equipment to be lifted.

745-053, REV. 5/18
Training
• Make sure all operators are trained in the fork and
attachment adaptation, operation, and use limitations.
Retrain an operator if a new attachment is added to
the forklift. Consult the operator's manual for instruc-
tions on how to use the new equipment.
• Know the mechanical limitations of your forklift.
• Modifications or additions that affect capacity or safe
operation must have prior written approval from the
forklift truck manufacturer. Capacity, operation, and
maintenance instruction plates, tags, or decals shall
be changed accordingly.
• Never use free rigging for a below-the-forks lift. It could
affect the capacity and safe operation of a lift truck.
Labeling
• Change capacity, operation, and maintenance instruc-
tion plates, tags, or decals when a forklift truck is
equipped with an attachment. If the truck is equipped
with front-end attachments other than factory installed
attachments, truck must be marked to identify the
attachments and show the approximate weight of
the truck and attachment combination at maximum
elevation with load laterally centered.
Pre-start Checks
• Check your equipment before you operate it. If any-
thing looks wrong, unusual or different, report it before
using the attachment.
• Do not operate this machine if you know of malfunc-
tions, missing parts, and/or mis-adjustments. These
situations can cause or contribute to an accident or
damage to the machine. Stop the machine immedi-
ately if problems arise after starting.
• Check to make sure the attachment on your truck is
the same as on the truck capacity plate.
• Check for hydraulic leaks and cracked hoses or fittings.
Check the hydraulic oil level in the lift truck hydraulic
reservoir.
• All electrical cables and connectors must be in good
condition. Use caution in wet weather to avoid danger
from electrical shock.
• Always check the attachment for proper fit and en-
gagement of the truck carriage.
Personnel Safety
• When removing or installing dismountable at-
tachments always keep hands and feet free from
dangerous positions or pinch points. Never leave a
dismounted attachment in a dangerous position.
• Keep hands, feet, long hair and clothing away from
power-driven parts. Do not wear loose fitting clothing
or jewelry while performing maintenance and lubrica-
tion in these areas.
• Never jump on or off the machine.
• Never stand on top of material being raised, lowered,
or transported. (Figure 1)
Figure 1 Figure 2
Figure 3
• Never use the attachment or its load to support a
man-carrying device.
• Never allow anyone under a load or under the car-
riage. (Figure 2)
• Never stand in front of or beside an attachment that
is being operated. Never allow another person to ap-
proach an attachment that is being operated. (Figure
3)
• Never leave an attachment or load in an elevated position.
• Never reach through the mast of the truck. Keep all
parts of the body within the driver’s compartment.
• Always operate an attachment from the operator’s
seat, never while standing next to the lift truck.
• Do not allow riders on the truck at any time.

845-053, REV. 5/18
• Always use reverse when carrying a load that impedes
full vision. Watch for pedestrians when transporting.
• Always use personal protective equipment (PPE) ap-
propriate to the situation.
Load Handling
• Treat an unloaded forklift with an attachment as par-
tially loaded.
• Never overload the attachment. Refer to the attach-
ment nameplate for the rated capacity of the attach-
ment. Refer to the truck nameplate for the maximum
net working capacity of the truck/attachment combi-
nation.
• Never use a load to support or move another object.
Doing so can easily exceed the holding capacity of
the attachment.
• Always check loads to be handled. Correct loads that
are broken, unbalanced, loose, or too heavy.
• Never lift, lower, side shift, pivot, rotate, or tilt loads
while traveling. Repositioning loads while traveling af-
fects the stability of the truck and may impede vision
or clearances.
• Do not use an attachment to open or close boxcar
doors. Doing so can severely damage the attachment
and cause loss of warranty. Damage to clamp arms
may result in product damage.
• Do not carry loose items or unsupported loads on top
of a clamped load.
• Never use chains, cables, or other devices in conjunc-
tion with an attachment for load handling.
• Never clamp loads other than what the attachment
was designed to handle.
• Always carry cylindrically shaped loads in the vertical
position, not the horizontal.
• Always clamp loads with the contact pads, if appli-
cable, not the arm or arm base.
• Never rotate a load that is off center to the centerline
of rotation. Severe damage to the rotator could result.
• Always ensure that the load is the same width as the
pallet and neatly stacked when using a carton clamp.
Load Positioning
• Be accurate in load placement. It’s important to know
what the load will do when it’s released.
• Always carry loads as close to the floor as possible,
consistent with the surface being traversed. Scraping
or bumping the floor surface with the load or the at-
tachment can severely damage the attachment and
cause product damage. The mast should be tilted
back.
• Always keep the load positioned as close as possible
to the horizontal center of the lift truck.
• Always back down ramps or inclines. Driving forward
down a ramp or incline with a clamped load will lessen
the stability of the truck. (Figure 4)
Figure 4
• Do not cross dock boards or dock levelers with the
attachment or carriage fully lowered. Ramming the
front or rear of the attachment against a dock board
can cause severe damage.
• Limit lift truck movement to a minimum when high
stacking. Limit sideshift movement to a minimum
when high stacking.
• Always be observant when high stacking. Look for
poorly stacked loads, overhead obstacles, broken
cartons, or damaged products in the stack.
• Travel slowly around corners. Sound horn on blind
corners. Be careful of tail swing and overhead clear-
ances. Watch in all directions. Avoid sudden stops.
Truck Requirements
Prior to connecting the truck hydraulic system to the at-
tachment, the truck hydraulic system must be cleaned
through the filtration system. This will eliminate any
contamination that may exist in the auxiliary hydraulic

945-053, REV. 5/18
system of the truck.
WARNING
The capacity of the truck and attachment
combined may be less than the attachment
capacity. Injury and equipment damage
could result if truck is overloaded. Consult
truck nameplate!
Notice
The dealer and/or the user are responsible
for installing any valving required to meet
the recommended hydraulic pressures and
flow.The required valving can be furnished
by the dealer, the truck factory or Long
Reach.
Some lift trucks are equipped with a single lever to control
both hoist and tilt functions, others have separate levers
for each function. Refer to your lift truck manual for more
information.
For clarity, the direction of arm movement is shown on the
control handle.To move the arms in the direction shown,
pull the handle towards the operator. To move the arms
in the opposite direction, the push the handle away from
the operator. (Figure 5)
Clamp Fork position
Push/pull Rotate Sideshift
Figure 5
Lifting speed is controlled by the speed of the engine
and the position of the control lever. Engine speed has
no effect on lowering speed.
Before going on the job, shift the truck control levers one
way and then the other to determine which direction the
attachment moves when the levers are shifted. Make sure
the attachment moves smoothly throughout its travel,
without binding or pinching hoses.
Notice
Do not attempt to pull a load onto the
platens with a misaligned faceplate.
Product damage and/or equipment damage
could result.
WARNING
If the attachment does NOT operate
smoothly, do not take it on the job. Check
with your supervisor about needed repairs
to avoid injury or equipment damage.
Industry Standards
ANSI/ITSDF B56.1-2016 is the published sequence and
direction standard for lever- and hand-type controls.
Notice
The chart on the following page shows
industry standards. Your equipment may
be different. If you do not routinely operate
this equipment, refresher training is
recommended. You must reacquaint
yourself with this manual and the equipment
before starting, and then proceed slowly.
Special controls such as automatic devices should be
identified, preferably according to the recommendations
in Figure 6.
When a function is controlled by a pair of push buttons,
they should operate in the same sense as the lever con-
trols. For example, pushing a button located to the rear
(relative to the operator's position) should serve the same
function as moving a control lever to the rear.
Clamp Open Control
Effective October 7, 2010, safety standard ANSI/ITSDF
B56.1, Section 7.25.7 covers all lift trucks with a load
bearing clamp (paper roll clamp, carton clamp, etc.),
and requires the driver to make two distinct motions
before opening or releasing the clamp. For example,
you must press a switch and then move a lever to
unclamp the load. This requirement applies to new
and used attachments being mounted on trucks which
shipped from the factory after October 7, 2010, and is a

10 45-053, REV. 5/18

1145-053, REV. 5/18
recommended feature to be installed on dealer orders and existing applications.
Function
Direction of motion
Load Operator's hand on control handle,
facing the load*
Hoist Up
Down
Rearward or up
Forward or down
Reach Retract
Extend
Rearward or up**
Forward or down
Tilt Rearward
Forward
Rearward or up**
Forward or down
Sideshift Right
Left
Rearward or up
Forward or down
Push-pull Rearward
Forward
Rearward or up**
Forward or down
Rotate, lateral Clockwise
Counterclockwise
Rearward or up
Forward or down
Rotate, longitude Rearward
Forward
Rearward or up
Forward or down
Load stabilizer Down
Up
Rearward or up
Forward or down
Swing Right
Left
Rearward or up
Forward or down
Slope Clockwise
Counterclockwise
Rearward or up
Forward or down
Fork position Together
Apart
Rearward or up
Forward or down
Tr i p Engage
Release
Rearward or up
Forward or down
Grip Engage
Release
Rearward or up
Forward or down
Truck stabilizer Raise
Lower
Rearward or up
Forward or down
Clamp Clamp
Release
Rearward or up
Forward or down
* For high lift order picker trucks and center control pallet trucks, predominant motion of the operator's hand when
actuating the control handle while facing away from the load.
** The sense of rotation of the control handle is intended to be in the same direction as the desired motion of the
mast or load.
Figure 6 ANSI/ITSDF Sequence of location and direction of motion for lever- or hand-type controls

12 45-053, REV. 5/18
SECTION 4 INSTALLATION PROCEDURE
4.1 Truck Requirements
Long Reach attachments have been designed to oper-
ate within specific limits. Operating pressures above the
stipulated maximum may cause structural damage to the
attachment and may result in loss of warranty. Hydraulic
flow less than the recommended rates, or the use of small
I.D. hoses may reduce operating speed. Higher flow can
result in excessive heat buildup, erratic operation and
damage to the truck/attachment hydraulic system.
Notice
The dealer and/or the user are responsible
for installing any valving required to meet
the recommended hydraulic pressures and
flow. The required valving can be furnished
by the dealer, the truck factory or Long
Reach.The model description, found on your
shipped invoice, will state the following truck
requirements: flow (gpm), psi, and minimum
truck carriage width.
4.2 Hydraulics
1. The truck hydraulic system must supply to the at-
tachment hydraulic oil that meets the specifications
required to operate the attachment properly.
2. When the truck hydraulic system pressures exceed
this maximum, a relief valve is recommended in the
attachment auxiliary system of the truck or on the
attachment. Consult the truck factory and/or Long
Reach for guidance.
4.3 Attachment Installation
1. Customer is to supply the mounting plate for the
attachment.
2. The attachment is bolted to the mounting plate using
16 supplied 3/4 UNC X 3 hex head capscrews that
have been been treated with high strength/high temp
LoctiteThreadlocker 272 (Red) and 16 hard flat wash-
ers.Torque the bolts to 278 ft/lbs.
4.3.1 Bolt-On Hooks
First, remove the lower bolt-on hooks and, if applicable,
make a note of any factory-installed shims. Shims are
used to create space between the hook and carriage.
Bottom
Bar
Bottom Hook
Spacer
Capscrew &
Lockwasher
Figure 4-1, Remove the bottom bolt-on hooks
4.3.2 Quick Hooks
There are two kinds of quick hook, detent-pin style and
push-button style.
Button
Slide Plate
BodyPush button
to lower slide.
Raise slide
to secure
attachment
to truck.
Figure 4-2, Push-button style quick hook
For push button quick hooks, depress the button on the
back of the hook and allow the slide plate to drop.
Removing push button quick hooks is NOT recom-
mended.

1345-053, REV. 5/18
Detent pin
Hook
Figure 4-3, Detent pin style quick hook
For detent-pin style quick hooks, just pull the pin and
remove it. The hook will come loose.
4.4 Installations with Bolt-On Hooks
1. Center the truck behind the attachment and drive
toward it with the mast tilted forward about 4
degrees.
2. Line up the locking lug (if equpped) with the notch
closest to the center on the truck’s carriage.
3. Raise the truck carriage completely to engage the
top hooks with the truck carriage. Tilt carriage back
until the unit is against the carriage bottom fork bar
(0 degrees).
4. Inspect for proper engagement of the locking lug in the
notch that puts the attachment closest to the center
of the truck’s carriage.
5. Weld on the (optional) extra locking lug supplied with
the attachment, (two pieces of 1/2" x 1/2" x 2.00" steel,
shipped loose) with either E-6011 or E-6013 welding
rod, or equivalent, on each side of the truck carriage.
Locking lug in notch
YXE4C-307
1/2 x 1/2 x 2.00 steel
supplemental
locking lug (optional)
1/16" clearance
Figure 4-4, Welding the optional locking lug
6. Install the bolt-on lower hooks. Check the clearance
between the carriage and the lower hooks. Loosen
the bolts on the front of the hooks, and slide them up
or down so the clearance is no more than 3/32".
On Class II and Class lll units, tighten the 3/8" bolts
to 33 ft-lbs. On Class lV units tighten the 1/2" bolts
to 77 ft-lbs. On units using 9/16" UNC bolts, tighten
the bolts to 112 ft-lbs.
Notice
Make note of any factory-installed spacers
or shims. Shims are used to create
clearance between the hook and carriage.
Maximum
Clearance
1/8"
Maximum
Clearance
1/32"
Maximum
Clearance
3/32"
Class III Shims Shown
Shim as Required
Bottom Bar Bottom Hook
Bottom Hook
Spacer
Fork Base
Truck Mast
Lower ITA Bar
Roller
Assembly
Figure 4-5, Adjusting bolt-on bottom hooks with
spacers
4.5 Installations with Quick Hooks

14 45-053, REV. 5/18
1. Follow steps 1-5 under bolt-on hooks.
Maximum
Clearance
3/32"
Quick
Hook
Attachment
Frame
Slide
Button
Truck
Mast
Figure 4-6, Quick hook inspection
2. Raise the slide plate until the button clicks into place.
WARNING
The attachment could fall off the truck if the
quick hook is not properly installed.
Slide plate must click into place. If the slide
plate does not click into place because the
truck carriage prevents the slide plate from
being raised up high enough, install shims
between the attachment and the body of
the quick hooks.
4.6 Hydraulic Connections
1. Before connecting the truck hydraulic system to the
attachment, the system must be purged through the
filtration system. This will eliminate any contamina-
tion that might exist in the auxiliary hydraulic system
of the truck.
2. Purge the system by installing a jumper line and
operating each hydraulic function (clamp, rotate
and side shift, if equipped) in each direction for a
minimum of 30 seconds. (Figure 4-7)
Hoses should meet or exceed SAE100 RI Type AT,
with maximum working pressure of 3,000 psi for all
attachment functions.
To Truck
To Clamp
Figure 4-7, Jumper line setup
1. Locate the slot in the top cover plate of the attachment.
Remove the caps covering the relief valve ports and
attach customer supplied hydraulic hoses. (Figure
4-8).
Close
Line
Open
Line
Figure 4-8, Hydraulic Connection
2. Never operate the truck or attachment until hydraulics
are properly connected.
WARNING
Any alterations to the original attachment
may affect performance or safety and result
in loss of warranty.

1545-053, REV. 5/18
3. Inspect installation to make sure hoses are not kinked
or pinched between the truck carriage and attachment.
4. Operate the attachment continuously for several
minutes to determine that all hydraulic connections
are secure with no leaks, and to remove any air in the
hydraulic system.
Notice
Equipment damage and loss of performance
could result if air is trapped in the hydraulic
system.
Activate the hydraulic functions several
times after hydraulic service has been
performed, to bleed trapped air out of the
system before returning attachment to
service.
5. With the mast in the vertical position, open the attach-
ment arms all the way.If you are working with a paper
roll clamp, close the arms all the way. Now check that
the truck’s hydraulic oil reservoir level is at the recom-
mended level.
6. Before placing the attachment in operation check the
following:
A. Inspect all hoses and fittings for leaks and routing
clearance.Be sure to include clearance of jumper
hoses to the mast.
B. Check the valve and cylinder for leaks.
C. Check cotter pins at each end
of the cylinder for security.

16 45-053, REV. 5/18
SECTION 5 SERVICE PROCEDURE
5.1 Attachment Removal
WARNING
Before disconnecting any hydraulic
connections be sure to turn off the trucks
power and activate the trucks hydraulic
functions in both directions to bleed off
the hydraulic pressure.
1. Lower the attachment onto pallets or suitable blocking
that will support it when disconnected from the truck.
2. Disconnect the hydraulic connections at the attach-
ment from the truck.
3. Remove the 16 bolts that secure the attachment to the
mounting plate.You may have to heat the bolt heads
first to soften the Loctite that secures them.
WARNING
When hydraulic servicing has been
performed, before returning attachment
to service be sure to activate the hydraulic
functions several times to bleed out
trapped air in the system.
5.2 Cylinder Removal
1. Remove the top cover plate and rear side plates to
access the cylinder mounting bolts.
2. Remove the capscrew that secures the lockpin on
the rod end of the cylinder. Remove the lockpin and
the clevis pin.
3. Retract the cylinder rod, then slightly extend back out
to relieve pressure in the accumulator. Make sure the
clevis is clear of the rack weldment.
WARNING
Make sure pressure has been discharged
from accumulator before removing the
hose.
4. Disconnect the hydraulic hoses.It will be necessary to
remove the relief valve to access the mounting bolts.
5. Secure the cylinder assembly to a winch or hoist
then remove the cylinder base mounting bolts to free the
cylinder. It may be necessary to heat the bolt heads first
to soften the loctite that secures them.
5.3 Cylinder Installation
1. Carefully lower the cylinder into the main body
2. Secure the base with six 3/4” capscrews that have
been treated with loctite threadlocker 272 (red) and
washers.Torque the capscrews to 278 ft-lbs.
3. Attach the relief valve inside the upper housing.Attach
the hydraulic connections to the cylinder. Attach the
hose from the accumulator to the check valve.
4. Extend the cylinder until the rod end clevis hole lines
up with the mounting hole in the rack weldment.Install
the clevis pin and secure it with the lockpin.Use a 3/8”
capscrew to secure the lockpin.
5. Turn on the trucks power and activate the cylinder
several times to bleed out trapped air.
5.4 Cylinder Disassembly
1. Remove the cylinder from the attachment. See re-
moval instructions.
2. Using a spanner wrench, turn the head assembly
counter-clockwise until it clears the cylinder.(Figure 5-1)
Spanner
Wrench
Figure 5-1, Spanner Wrench
3. Remove the piston rod asembly, with the head as-
sembly still on the rod from the cylinder tube. (Figure
5-2)

1745-053, REV. 5/18
Piston Nut
Piston Follower
Wear Band
O-Ring
Piston Seal
Piston
Figure 5-4, Piston Removal
6. Slide the piston seal off the piston noting the direction
the seal is facing.When the new seal is installed make
sure it faces in the same direction.
7. Carefully pry up on the gland cap seals using a blunt
tip screw driver being careful not to scratch the seal
grooves. Cut the seals to remove from the gland cap.
(Figure 5-5)
Figure 5-5, Gland Cap Seal
5.5 Cylinder Inspection
Inspect the cylinder tube bore for:
1. Deep scratches or nicks.
2. Signs of galling or excessive wear.
3. Out-of-roundness or deformities of the barrel.
Inspect the piston for:
1. Scratches or nicks on seal grooves.
2. Wear on O.D.
Figure 5-2, Piston Rod Removal
4. Clamp the rod assembly in a soft jawed vise on the
wrench flats, not on the rod surface. If the rod does
not have wrench flats use two pieces of wood on both
sides of the rod to prevent scaring. (Figure 5-3)
Figure 5-3, Cylinder Shaft
5. Remove the piston retaining nut and remove the piston
assembly. (Figure 5-4)

18 45-053, REV. 5/18
Inspect the cylinder rod for:
1. Scratches or nicks on the rod surface.
2. Straightness of the rod.
3. Damaged threads.
Inspect the gland cap for:
1. Scratches or nicks in seal grooves.
2. Damaged threads or spanner wrench holes.
3. Excessive wear in bore.
Replace any component found to be defective.
5.6 Cylinder Assembly
1. Spray the piston, gland cap, and seals with wd40 or
other similar product to ease slipping of the seals in
place.
2. Note the direction of the seal on the piston. Improper
installation will result in poor performance.The cupped
side or O-ring side of the seal should be facing the
gland cap. (Figure 5-6)
O-Ring
Seal
Piston Nut
Cylinder Rod
Piston
Piston Follower
Wear Band
Figure 5-6, Piston Seal
3. Install the seals and wipers in the gland cap. Note the
direction of the seals.The cupped side or O-ring side of
the seal should be facing the piston. (Figure 5-7)
DETAIL A
A
Cylinder Rod
Seal
Retaining Ring
Bushing
Wiper Ring
O-Ring
Backup Ring
Gland Cap
Figure 5-7, Gland Cap Seal
4. Install the gland cap on the cylinder rod being ex-
tremely careful not to cut the rod seal on the threads
of the rod or rod shoulder.If available, use a sleeve or
plastic electrical tape to cover the rod threads.
5. Install the piston on the rod and tighten the locknut to
90 ft-lbs (0.56 UNF), 22 ft-lbs (0.75 UNF).
6. Spray the inside of the cylinder tube with lubricant to
ease inserting the rod and piston. Insert the rod and
piston into the cylinder tube.Tap the rod in with a rub-
ber mallet if resistance is encountered.
7. Tighten the gland cap using a spanner wrench.

1945-053, REV. 5/18
Capscrew
Washer
Slotted Washer
Gripper Pin
Figure 5-9, Wear Plugs
3. Insert the new gripper pin and secure it with the cap-
screw that has been treated with Loctite threadlocker
272 (red).Torque the capscrew to approximately 1000
ft-lbs.
5.9 Grease Fitting Locations
1. Use a standard lithium grease when necessary on the
grease fittings located in the gear pins. (Figure 5-10)
Grease Fitting
Locations
Figure 5-10, Grease Fitting Locations
5.7 Wear Plug Replacement
1. Remove the two threaded plugs located underneath
the rack weldment. ( Figure 5-8)
Threaded Plug
Plug Insert
Wear Plug
Front of Attachment
Figure 5-8, Wear Plugs
2. Remove the old wear plugs.
3. Replace the plug inserts located in the threaded plugs
before reinstalling.
4. Install the new wear plugs and secure them in place
with the threaded plugs.
5.8 Gripper Pin Replacement
1. Check gripper pins for wear or cracks. Replace them
when necessary.
2. Loosen the capscrew that secures the gripper pin. It
may be necessary to heat the bolt head to soften the
loctite that secures it. While holding the gripper pin
remove the capscrew that holds the gripper pin in
place. (Figure 5-9)

20 45-053, REV. 5/18
6.1 Schedule
Daily:
1. Visually inspect all hoses, fittings, cylinders, and
valves for signs of hydraulic leaks.
2. Visually inspect for external damage or cracks.
100 Hour Maintenance:
1. Complete the above daily checks.
2. Check all hoses and fittings for wear or damage. In-
spect for hydraulic leaks.
3. Check for loose or missing bolts.
SECTION 6 MAINTENANCE
6.2 Torque Specifications
The following torque values are to be used on all fasten-
ers unless otherwise specified.
Lubricated refers to fasteners in the “As Received” condi-
tion, which is normally a light preservative oil coating on
unplated fasteners and no oil coating on plated fasteners.
No special steps are taken to add further lubrication prior
to assembly.
GRADE 8 COARSE THREAD GRADE 5 COARSE THREAD SOCKET HEAD COARSE THREAD
Bolt Size Lubricated Torque Bolt Size Lubricated Torque Capscrew Size Lubricated Torque
1/4" 11 ft-lbs 1/4" 7.5 ft-lbs 1/4" 12.5 ft-lbs
5/16" 23 5/16" 16 5/16" 26
3/8" 40 3/8" 28 3/8" 46
7/16" 63 7/16" 45 7/16" 74
1/2" 96 1/2" 68 1/2" 115
9/16" 140 9/16" 98 9/16" 160
5/8" 195 5/8" 140 5/8" 215
3/4" 340 3/4" 240 3/4" 385
7/8" 550 7/8" 390 7/8" 615
1" 820 1" 580 1" 920
1-1/8" 1,160 1-1/8" 715 1-1/8" 1,305
1-1/4" 1,640 1-1/4" 1,010 1-1/4" 1,840
1-3/8" 2,150 1-3/8" 1,330 1-3/8" 2,415
1-1/2" 2,850 1-1/2" 1,760 1-1/2" 3,205
Figure 6-1, Torque Specifications