Hyster F007 Operating instructions

Hyster F007 (H170HD, H190HD, H210HD,
H230HD, H250HD, H280HD) Forklift

EMPTY CONTAINER
HANDLING
ATTACHMENT
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]
MODELS 553, 555, 558
PART NO. 1503241 5000 SRM 969

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!

Empty Container Handling Attachment Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Operation............................................................................................................................................................ 1
General........................................................................................................................................................... 1
Selector Valves ............................................................................................................................................... 1
Sideshift Circuit............................................................................................................................................. 1
Extend and Retract Circuit........................................................................................................................... 6
Twist Lock Circuit and Control..................................................................................................................... 6
Model 553 - Horizontally Mounted........................................................................................................... 6
Model 558 - Vertically Mounted................................................................................................................ 8
Lifting Hooks ................................................................................................................................................. 8
Model 555................................................................................................................................................... 8
Indicator Lights and LEDs ........................................................................................................................... 9
Lift Interrupt and Override .......................................................................................................................... 9
Overlowering Interrupt and Override.......................................................................................................... 9
Carriage and Attachment Repair...................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Attachment Without Carriage Repair .............................................................................................................. 10
Remove ........................................................................................................................................................... 10
Sideshift Cylinders Repair ................................................................................................................................ 11
Remove ........................................................................................................................................................... 11
Disassemble ................................................................................................................................................... 11
Assemble ........................................................................................................................................................ 11
Extension Cylinders Repair .............................................................................................................................. 12
Remove ........................................................................................................................................................... 12
Disassemble ................................................................................................................................................... 12
Clean and Inspect.......................................................................................................................................... 12
Assemble ........................................................................................................................................................ 12
Install ............................................................................................................................................................. 12
Vertical End Beams Repair ............................................................................................................................... 14
Remove ........................................................................................................................................................... 14
Install ............................................................................................................................................................. 14
Hose Replacement in End Beams................................................................................................................. 14
Twist Locks Repair for Model 553..................................................................................................................... 15
Remove ........................................................................................................................................................... 15
Disassemble ................................................................................................................................................... 15
Clean and Inspect.......................................................................................................................................... 15
Assemble ........................................................................................................................................................ 15
Hooks Replacement for Model 555.................................................................................................................... 16
Inspect ............................................................................................................................................................ 16
Remove ........................................................................................................................................................... 16
Install ............................................................................................................................................................. 16
Twist Locks Repair for Model 558..................................................................................................................... 17
Disassemble ................................................................................................................................................... 17
Clean and Inspect.......................................................................................................................................... 17
Assemble ........................................................................................................................................................ 18
Bleed the System ............................................................................................................................................... 18
Valve Assembly .................................................................................................................................................. 19
Slide Pad Replacement ...................................................................................................................................... 19
Adjustments ....................................................................................................................................................... 20
Twist Lock Angle Adjustment....................................................................................................................... 20
©2003 HYSTER COMPANY i

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Table of Contents Empty Container Handling Attachment
TABLE OF CONTENTS (Continued)
Model 558 Only.......................................................................................................................................... 20
LOCKED/NOT LOCKED Sensors Adjustment............................................................................................ 20
Model 553................................................................................................................................................... 20
Model 558................................................................................................................................................... 21
Seated Sensor Adjustment............................................................................................................................ 21
Model 553................................................................................................................................................... 21
Model 558................................................................................................................................................... 21
Overlowering Protection Sensor Adjustment (Models 553 and 558) .......................................................... 21
Torque Chart.................................................................................................................................................. 22
Maintenance....................................................................................................................................................... 22
Additional Attachment Maintenance ........................................................................................................... 24
Interface Boxes .............................................................................................................................................. 25
Model 555................................................................................................................................................... 25
Models 553 and 558................................................................................................................................... 25
Troubleshooting.................................................................................................................................................. 27
Diagrams, Schematics, or Arrangements......................................................................................................... 30
Figure 15. Hydraulic System Model 553 ................................................................................................. 30
Figure 16. Hydraulic System Model 555 ................................................................................................. 31
Figure 17. Hydraulic System Model 558 ................................................................................................. 32
Figure 18. Hydraulic Diagram - Horizontal Twist Lock Model 553....................................................... 34
Figure 19. Hydraulic Diagram - Suspended Hooks Model 555 .............................................................. 35
Figure 20. Hydraulic Diagram - Vertical Twist Lock Model 558............................................................ 36
Figure 21. Electric Diagram..................................................................................................................... 37
Figure 22. Wiring Diagram ...................................................................................................................... 39
Figure 23. Electric Schematic Diagram................................................................................................... 40
This section is for the following models:
H10.00-12.00XM-12EC (H360HD-EC) [E019, F019]
Models 553, 555, 558
ii

5000 SRM 969 Operation
General
This section has the description and repair proce-
dures for telescopic empty container handling attach-
ment and operator controls. See Figure 1. Three
methods of engagement are covered in this section
as follows:
•Model 553 with one pair of horizontally mounted
twist locks
•Model 555 with one pair of suspended hooks
•Model 558 with one pair of vertically mounted twist
locks
Description
The extendable container attachment can be used
atthreewidths: 6.1m(20ft),12.2m(40ft),and
when equipped with optional stops, 9.15 m (30 ft).
Models 553 and 558 use twist locks and Model 555
uses hooks, which are entered into side pockets of
container corner castings. See Figure 1, Figure 2,
Figure 3, and Figure 4. The attachment has a cen-
ter frame, two outer booms, and two floating vertical
end beams. The center frame is installed on the car-
riage and can move from side to side with the use
of a sideshift cylinder. The outer booms, supported
by several glide plates for friction reduction, extend
and retract from the center frame through the use of
hydraulic extension cylinders. The extension cylin-
ders on attachment are actuated by hydraulic pres-
sure from main control valve.
A vertical tube is mounted to the end of each outer
boom. A vertical end beam assembly fits into each
tube and facilitates engaging and disengaging the at-
tachment with containers. The vertical end beams
can move vertically 150 mm (6 in.) to allow align-
ment when required. This allows the driver the pos-
sibility of raising or lowering the attachment after
one twist lock or hook has been engaged with a con-
tainer, so the other end can be accurately aligned be-
fore it is inserted.
Header hoses and an electrical cable connect the hy-
draulic and electrical circuits to the attachment.
Operation
GENERAL
The attachment has hydraulic and electrical circuits
to control its operation. See Figure 15, Figure 16,
Figure 17, Figure 18, Figure 19, and Figure 20. The
operator controls these functions from the operator’s
compartment. Depending on the model, attachment
has selector valves for operation of sideshift, exten-
sion cylinders, and twist locks. The electrical cir-
cuit incorporates sensors and switches to verify cor-
rect position of container to attachment and the twist
locks.
NOTE: Model 555 does not have indicators to tell
driver that attachment is correctly engaged or dis-
engaged.
SELECTOR VALVES
Each selector valve has two solenoids that operate
the spool. The spool opens and closes a hydraulic
circuit for certain functions. Dependant upon model,
selector valves are mounted on a common manifold
on attachment.
SIDESHIFT CIRCUIT
The attachment moves horizontally on the carriage.
The operator energizes left or right solenoid using
sideshift lever. Hydraulic oil is then supplied to ap-
propriate cylinder end and attachment is moved. Re-
lief valve within circuit limits maximum hydraulic
pressure to 14.0 MPa (2030 psi). The sideshift cylin-
der is connected between the carriage and the center
frame. There are four glide plates on the bottom and
sixglideplatesonthetopofthecarriagetoguidethe
movement of the attachment on the carriage. The
bottom of the carriage is secured in the forward di-
rection by two stop blocks.
1

Operation 5000 SRM 969
Figure 1. Empty Container Attachment
2

5000 SRM 969 Operation
Legend for Figure 1
1. END BEAM ASSEMBLY
2. WEAR PADS
3. BRACKET
4. BRACKET
5. BOLT, WASHER
6. PIN, BOLT, NUT
7. WEAR PADS
8. WEAR PADS, BRACKET, BOLT, WASHER
9. WEAR PADS, BRACKET, BOLT, WASHER
10. SIDESHIFT ASSEMBLY, SOCKET HEAD
SCREWS
11. PIN, BOLT, NUT
12. EXTENSION CYLINDER ASSEMBLY
13. BRACKET, BOLT, NUT, WASHER, PIN, WASHER,
COTTER PIN, PIN,SNAPRING
14. STOP BLOCK, BOLT, WASHER
15. BRACKET
16. COVER
17. PIN, BOLT, NUT
3

Operation 5000 SRM 969
Figure 2. End Beam Assembly (Model 553)
4

5000 SRM 969 Operation
Legend for Figure 2
1. PLATE
2. BOLT, LOCKWASHER
3. HOUSING
4. END BEAM
5. HYDRAULIC MOTOR
6. RING
7. SLEEVE
8. COLLET
9. RING
10. RINGS, SOCKET HEAD SCREWS
11. BRACKET
12. SOCKET HEAD SCREW
13. PLATE
14. SENSOR
15. BUSHING
16. TWIST LOCK
17. SENSOR
18. SHOCK ABSORBER, NUT
19. SOCKET HEAD SCREW
20. HOSE CLAMP
21. BOLT, WASHER
22. BRACKET
23. KEY
24. KEY
25. SOCKET HEAD SCREW
5

Operation 5000 SRM 969
1. NUT
2. WASHER
3. STUB SHAFT
4. HOOK
5. SPRING
6. END BEAM
7. PLATE,BOLT
Figure 3. End Beam Assembly (Model 555)
EXTEND AND RETRACT CIRCUIT
The attachments are designed to lift either 20- or
40-ft containers. The optional 30-ft stop kit allows
lifting 30-ft containers. The 30-ft position is obtained
by energizing the 30-ft stop while extending or re-
tracting the beams.
When the operator selects the extend or retract func-
tion with the control lever, the appropriate solenoid is
energized and oil from the main control valve is sup-
plied to the extension cylinders via the control valves.
A relief valve within the circuit limits hydraulic pres-
suretoamaximum14.0MPa(2030psi)toprotectthe
extension cylinders from damage.
TWIST LOCK CIRCUIT AND CONTROL
For model 553, locking of the twist locks is done man-
ually only. For model 558, locking of the twist locks
can be either manually or automatically. Unlocking
is always done manually. Locking or unlocking is
controlled by energizing the relevant solenoids and
spools. Relief valves within the circuit limit the max-
imum hydraulic pressure to 8 MPa (1160 psi).
Model 553 - Horizontally Mounted
The horizontally-mounted twist lock circuit uses a
twist lock motor and three sensors. See Figure 2. The
three sensors register if the twist lock is locked, twist
lock is unlocked, and container is seated.
To pick up a container, twist locks must be in un-
locked position. The horizontal twist locks enter
side pockets of container corner castings. When
completely entered, the seated sensor registers and
switches related amber light ON. When both seated
sensors register and both amber lights are ON, twist
lock circuit will allow twist lock motor to be operated.
For model 553, locking and unlocking of twist locks
is done manually only. Opening twist locks is also a
manual operation.
To protect against possibility of twist locks opening
unintentionally, twist locks have a flat surface, which
touches vertical area of the corner casting when con-
tainer is being carried. The weight of container locks
the flat surface of twist lock against vertical area of
corner casting and prevents twist lock from turning.
It therefore is important to make sure that the at-
tachment is completely seated before locking or un-
locking twist locks.
6

5000 SRM 969 Operation
Figure 4. End Beam Assembly (Model 558)
7

Operation 5000 SRM 969
Legend for Figure 4
1. ROD END
2. RING PIN
3. SOCKET HEAD SCREW
4. LOCKWASHER
5. SENSOR
6. SENSOR BRACKET, SPACER, SOCKET HEAD
SCREW
7. SOCKET HEAD SCREW
8. SENSOR
9. BRACKET
10. ROD
11. CYLINDER ASSEMBLY
12. INDICATOR
13. SNAP RING
14. PIN
15. BOLT, LOCKWASHER
16. COLLET
17. UPPER BEARING
18. LOWER BEARING
19. BUSHING
20. TWIST LOCK
21. SEATED PIN
22. SPRING
23. BRACKET
24. BOLT, LOCKWASHER
25. TOP PLATE
26. HEAD
27. BOLT
28. TIE ROD END
29. BOLT, LOCKWASHER, NUT
30. ROD END
31. CRANK
32. FLAG
33. SEATED TOWER
34. BRACKET
35. SLEEVE
36. SOCKET HEAD SCREW
37. ARM
38. NUT, WASHER, BUSHING, NYLON WASHER,
WASHER
39. NUT
40. BOLT, NUT
41. GREASE NIPPLE
42. KEY
43. COVER
44. NUT
45. INDICATOR
46. SPRING
47. ROD
48. ROLL PIN
49. SOCKET HEAD SCREW, WASHER
50. BOLT, LOCKWASHER
51. BRACKET
52. SENSOR BRACKET, SOCKET HEAD SCREW
53. INDICATOR
Model 558 - Vertically Mounted
The vertically-mounted twist lock circuit uses a
twist lock cylinder and three sensors. See Figure 4.
The three sensors register the following: twist lock
is locked, twist lock is unlocked, and container is
seated.
To pick up a container, twist locks must be in un-
locked position. Vertical twist locks enter top pock-
ets of container corner castings. When completely
entered, the seated sensor registers and switches re-
lated amber light ON.Whenbothseatedsensorsreg-
ister and both amber lights are ON, twist lock circuit
will allow twist lock cylinders to be operated. Twist
locks may be operated manually by driver, or may
operate automatically after a 2-second time delay.
Opening the twistlocksisalwaysamanualopera-
tion.
To protect against the possibility of twist locks open-
ing unintentionally, seated pins have a cam in place
which prevents twist lock crank from turning if
seated pin is not seated.
LIFTING HOOKS
Model 555
Model 555 does not have sensors or indicator lights to
register position of hooks in relation to container. On
this type of attachment, all safety monitoring must
be done by driver. A good condition of hooks is essen-
tial. Check condition of hooks on a daily basis.
To pick up a container, approach container with mast
tilted slightly forward. Enter one hook and then ma-
neuver other hook up and down until hook can be en-
tered into side pocket of container.
8

5000 SRM 969 Operation
INDICATOR LIGHTS AND LEDS
There are four indicator lights on left side of attach-
mentandfiveLEDsinoperator’scab. SeeFigure5
and Figure 6. Indication is as follows:
•Left Amber Light and LED indicate attachment is
seated on left side and ready to have twist locks
activated.
•Green Light and LED indicate that both twist locks
are in locked position and ready to lift the con-
tainer.
•Red Light and LED indicate that both twist locks
are in unlocked position. It is now possible to move
the twist locks into or out of the corner pockets.
•Right Amber Light and LED indicate attachment
is seated on right side and ready to have twist locks
activated.
•Blue LED (cab only) indicates that overlowering
interrupt function or lift interrupt is activated.
1. LEFT AMBER LED
2. GREEN LED
3. RED LED
4. RIGHT AMBER LED
5. BLUE LED
Figure 5. Indicator LEDs
LIFT INTERRUPT AND OVERRIDE
WARNING
Only use override feature for the positioning of
twist locks to enable proper locking. Do not use
override feature for general lifting and trans-
port of container.
When attachment is seated and any of the twist locks
are between unlocked and locked position, the blue
LED inside operator’s cab will illuminate and lift in-
terrupt system will not allow lifting of mast.
To override lift interrupt feature, turn override key
switch clockwise and push override button while us-
ing lift lever.
1. LEFT AMBER
LIGHT
2. GREEN LIGHT
3. RED LIGHT
4. RIGHT AMBER
LIGHT
Figure 6. Indicator Lights
OVERLOWERING INTERRUPT AND
OVERRIDE
WARNING
When lifting after using the override feature,
verify that chains, hoses, and cables are not ob-
structed in any way.
An overlowering interrupt feature is incorporated
on models 553 and 558. The overlowering interrupt
function prevents further lowering of attachment
when both end beams have been raised in relation
to outer booms. This prevents slacking of chains,
hoses, and wires over the mast. It also reduces shock
on attachment. The blue LED in operator’s cab will
illuminate when lowering interrupt is activated.
To override overlowering interrupt feature, turn
override key switch clockwise and push override
button while using lowering lever.
9

Attachment Without Carriage Repair 5000 SRM 969
Carriage and Attachment Repair
REMOVE
WARNING
When working on or near mast, see Safety Pro-
cedures When Working Near Mast in Mast 4000
SRM 445.
Do not work under a raised carriage. Lower
carriage or use a chain to prevent carriage and
inner mast from lowering. Attach all moving
parts of mast to parts that DO NOT move with
a chain and make secure.
1. Put mast in a vertical position. Lower carriage
onto blocks so lift chains and hoses are not under
tension. Shut off engine.
WARNING
Do not disconnect any hydraulic lines when en-
gine is running.
2. Disconnect hydraulic lines to attachment and
put caps on open lines. Disconnect electrical
connector at attachment. Remove clamps as
necessary to remove harness from carriage.
WARNING
Keep control of lift chains when disconnecting
them from carriage. Use wire to temporarily
connect ends of lift chains to mast. This pro-
cedure will prevent lift chains from falling and
causing an injury or damage.
3. Remove pin from each chain anchor at carriage.
Disconnect lift chains from carriage. Attach a
rope to ends of each lift chain to control their
movement.
4. Connect a lifting device to attachment main
frame using lifting straps. Verify frame will
have stability once disconnected. Lifting de-
vice with lifting straps must hold 10,000 kg
(22,046 lb).
WARNING
When carriage is not connected to mast, it can
fall and cause an injury. Make sure carriage
has stability and will not fall over when inner
mast is raised above carriage.
5. Use lift cylinders to raise inner mast until it is
above load rollers of carriage. If hydraulic sys-
tem cannot be used, connect a lifting device to
top of inner mast. Carefully raise inner mast un-
til it is above load rollers of carriage.
6. Carefully move lift truck away from attachment.
Putattachmentonblocksonaflatsurfacesothat
carriage is up.
7. If any of the load rollers need to be replaced,
makeanoteoflocationofshims.
NOTE: For further details on repairs and adjust-
ments of carriage, see Mast 4000 SRM 445.
Attachment Without Carriage Repair
NOTE: Most repairs for attachment can be done
while attachment is installed on lift truck. If at-
tachment must be removed, this can be done by
either removing carriage and attachment or just
attachment.
REMOVE
1. Retract attachment to 6.1 m (20 ft) width. Put
mast in vertical position. Shut down engine.
2. Remove sideshift cylinder. See Sideshift Cylin-
ders Repair, Remove.
3. Disconnect hydraulic lines to attachment and
put caps on open lines. Disconnect electrical
connector at attachment. Remove clamps as
necessary to remove harness from carriage.
4. Remove covers for lower sideshift wear pads.
5. Connect a lifting device to attachment main
frame using lifting straps. Verify frame will
have stability once disconnected. The lifting
device with lifting straps must hold 10,000 kg
(22,046 lb).
6. Remove bolts from two lower front stop blocks.
10

5000 SRM 969 Sideshift Cylinders Repair
7. Remove top two wear blocks to allow easier re-
moval of attachment. Slide lower frame of at-
tachment forward so frame rotates slightly. This
will allow top bar of attachment frame to be re-
leased from the carriage. For further disassem-
bly, attachment should be put in a flat position.
Sideshift Cylinders Repair
REMOVE
1. Disconnect hydraulic lines at cylinder. Put caps
on open lines and cylinder.
2. Remove cylinder. To remove lock nut from cylin-
der rod end, use a wrench on flats so rod end will
not turn in cylinder.
DISASSEMBLE
1. Remove gland nut. See Figure 7.
2. Pull rod assembly and retainer from cylinder
shell. Remove gland nut from rod.
3. Remove nut and piston from rod.
4. Remove and discard all wipers, seals, backup
rings, and O-rings from gland nut.
ASSEMBLE
1. Install new wipers, seals, and backup ring on pis-
ton. See Figure 7.
2. Install gland nut piston onto rod and tighten nut
to 800 N•m (590 lbf ft).
3. Install rod and piston in shell.
1. SNAP RING
2. SPHERICAL BEARING
3. GREASE NIPPLE
4. PISTON ROD
5. GLAND NUT
6. WIPER RING
7. SHELL
8. PISTON
9. SETSCREW
10. NUT
11. SEAL ROD
12. O-RING
13. BACKUP RING
14. O-RING
15. SEAL PISTON
Figure 7. Sideshift Cylinder
11

Extension Cylinders Repair 5000 SRM 969
Extension Cylinders Repair
REMOVE
1. Retract attachment to 20-ft position. Shut down
engine. See Figure 1 and Figure 8.
2. Disconnect hydraulic lines at chain end (42) and
put caps on open lines. Disconnect electrical
plugs at chain end.
3. Remove bracket (25) holding chain and hose
clamp closest to chain.
4. Start engine. Extend extension beam approxi-
mately 1200 mm (4 ft) allowing removal of pin
at rod end of extension cylinder.
5. Remove snap ring and pin from rod end of exten-
sion cylinder.
6. Retract attachment to 20-ft position. Shut down
engine.
7. Using a crane or lift truck, pull extension beam
out approximately 1200 mm (4 ft). Carefully
guide hose/cable chain into center frame.
8. Remove two bolts holding interface box and repo-
sition box to prevent damage.
9. Support extension cylinder using a crane or lift-
ing device capable of supporting 250 kg (551 lb).
10. Remove six bolts at gland (10) holding extension
cylinder.
11. Remove extension cylinder from attachment
horizontally until cylinder is completely clear
of main frame of attachment. Carefully guide
chain to prevent damage.
DISASSEMBLE
1. Remove four bolts (16) that hold ring (6).
2. Slide ring away from cylinder head.
3. Pull piston rod (3) out of cylinder.
4. Piston (13) will touch spacer (11), which will push
out gland (10), O-ring (23), bushing (9), and seal
ring (22). It will also push out wiper ring (4),
guide ring (8), and washer (5).
5. Remove setscrew (15). Remove nut and piston
from rod.
6. Inspect components and replace if necessary.
CLEAN AND INSPECT
WARNING
Cleaning solvents can be flammable and toxic
and can cause skin irritation. When using
cleaning solvents, always follow the solvent
manufacturer’s recommended safety precau-
tions.
Clean parts of the cylinder with solvent. Inspect
shell, rod, and piston for wear or damage. Inspect
bearing blocks for wear or damage. Install new parts
as necessary.
NOTE: The pressure reducer (32) has been sealed
andissuppliedwithapressuresettingof80bar
(1160 psi). See Figure 8. Do not adjust this pressure
setting.
ASSEMBLE
Follow steps under Disassemble in reverse order.
INSTALL
1. Clean tracks and lubricate in those positions
where nylon pads (18) for extension cylinder will
come in contact with center beam. See Figure 8.
2. Use a crane or other lifting device capable of
supporting 250 kg (551 lb) and install extension
cylinder until bracket holding extension cylinder
is aligned. Carefully guide hose/cable chain into
center frame.
3. Install six bolts holding bracket.
4. Mount interface box using two bolts.
5. Connect electrical connectors at rear of extension
cylinder. Connect hydraulic lines to extension
cylinder.
6. Start engine. Extend attachment and align pis-
ton rod (3) end with extension beam, allowing in-
stallation of pin and snap ring. Install pin and
snap ring.
7. Retract attachment to 20-ft position. Carefully
guide hose/cable chain.
12

5000 SRM 969 Extension Cylinders Repair
Figure 8. Extension Cylinder
13

Vertical End Beams Repair 5000 SRM 969
Legend for Figure 8
1. BALL JOINT
2. SNAP RING
3. PISTON ROD
4. WIPER RING
5. WASHER
6. RING
7. SOCKET HEAD SCREW
8. GUIDE RING
9. BUSHING
10. GLAND
11. SPACER
12. O-RING
13. PISTON
14. NUT
15. SETSCREW
16. BOLT, LOCKWASHER
17. SUPPORT
18. NYLON PAD
19. SOCKET HEAD SCREW
20. NUT
21. FITTING
22. SEAL RING
23. O-RING
24. SCREW
25. BRACKET
26. BOLT
27. NUT
28. FLEX TRACK CHAIN, CHAIN PART, PIN
29. SHELL
30. TOP PLATE, HOSE CLAMP
31. FITTING
32. PRESSURE REDUCER, SEAL KIT
33. FITTING, O-RING
34. GAUGE ADAPTER
35. ELECTROVALVE 24V
36. ELECTROVALVE 24V
37. SOCKET HEAD SCREW
38. O-RING
39. SEAL PISTON
40. O-RING
41. PLUG
42. CHAIN END
8. Shut down engine.
9. Connect hydraulic lines at chain end (42). Con-
nect electrical plugs.
10. Install bracket (25) holding chain and hose clamp
closest to chain.
Vertical End Beams Repair
REMOVE
1. Disconnect hydraulic lines from valve assem-
bly (6) at bottom end. Put caps on lines. See
Figure 17.
2. Disconnect electrical connections at bottom end.
SeeFigure21.
3. Remove pin, bolt, and nut (17) holding the end
beam in place. See Figure 1.
CAUTION
When lifting out end beam, carefully guide hy-
draulic lines and electrical cable through tube
in extension beam.
4. Lift end beam out of extension beam using a
crane with approximately 250 kg (551 lb) lifting
capacity.
5. Place end beam on a flat surface.
INSTALL
1. Place end beam into extension beam using a
crane with approximate 250 kg (551 lb) lifting
capacity.
2. Install pin, bolt, and nut (17) holding the end
beam in place. See Figure 1.
3. Connect electrical connections at bottom end.
See Figure 21.
4. Connect hydraulic lines from valve assembly (6)
at bottom end. See Figure 17.
HOSE REPLACEMENT IN END BEAMS
NOTE: Hydraulic hoses and electrical cable are in-
side bent tube with a limited diameter. This does not
allow individual replacement of hoses or electrical ca-
ble.
1. Disconnect hydraulic hoses and electrical cable
at lower side of beam.
2. Connect a string to one of the hoses and pull out
hoses from higher end.
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