INTERMODAL

CONTAINER
ATTACHMENT
RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH,
RS46-38L IH, RS46-38S IH, RS46-38LS IH (RS45-27,
RS45-31, RS46-36, RS46-41L, RS46-41S, RS46-41LS) [C222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH,
RS46-41L CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH,
RS46-37IH, RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27,
HR45-31, HR45-36, HR45-40, HR45-41S,
HR45-41L, HR45-41LS) [B222];
RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH,
RS46-30IH, RS46-36CH, RS46-33IH [A222]

PART NO. 1468993 5000 SRM 777

 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 Maintenance 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 hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Intermodal Container Attachment Table of Contents

TABLE OF CONTENTS

General ............................................................................................................................................................... 1
Description ......................................................................................................................................................... 1
Operation............................................................................................................................................................ 3
Extend and Retract Circuit ........................................................................................................................... 3
Twist Lock Circuit ......................................................................................................................................... 3
Rotator Circuit ............................................................................................................................................... 3
Folding Legs Circuit ...................................................................................................................................... 3
Container Attachment Repair........................................................................................................................... 4
Remove ........................................................................................................................................................... 4
Install ............................................................................................................................................................. 5
Extension Cylinders Repair .............................................................................................................................. 6
Remove ........................................................................................................................................................... 6
Disassemble ................................................................................................................................................... 6
Clean and Inspect .......................................................................................................................................... 6
Assemble ........................................................................................................................................................ 6
Install ............................................................................................................................................................. 6
Sideshift Cylinder Repair .................................................................................................................................. 8
Remove ........................................................................................................................................................... 8
Disassemble ................................................................................................................................................... 8
Clean .............................................................................................................................................................. 9
Inspect ............................................................................................................................................................ 9
Assemble ........................................................................................................................................................ 9
Install ............................................................................................................................................................. 9
Power Pile Slope Cylinder Repair ..................................................................................................................... 10
Remove ........................................................................................................................................................... 10
Disassemble ................................................................................................................................................... 10
Clean .............................................................................................................................................................. 11
Inspect ............................................................................................................................................................ 11
Assemble ........................................................................................................................................................ 11
Install ............................................................................................................................................................. 11
Folding/Clamping Cylinder Repair ................................................................................................................... 12
Remove ........................................................................................................................................................... 12
Disassemble ................................................................................................................................................... 12
Clean .............................................................................................................................................................. 12
Inspect ............................................................................................................................................................ 12
Assemble ........................................................................................................................................................ 14
Install ............................................................................................................................................................. 14
Upper Leg Folding Cylinder Repair.................................................................................................................. 15
Remove ........................................................................................................................................................... 15
Disassemble ................................................................................................................................................... 15
Clean .............................................................................................................................................................. 16
Inspect ............................................................................................................................................................ 16
Assemble ........................................................................................................................................................ 16
Install ............................................................................................................................................................. 17
Lower Leg Folding Cylinder Repair .................................................................................................................. 17
Remove ........................................................................................................................................................... 17
Disassemble ................................................................................................................................................... 17
Clean .............................................................................................................................................................. 18
Inspect ............................................................................................................................................................ 18
Assemble ........................................................................................................................................................ 18
Install ............................................................................................................................................................. 18

©2011 HYSTER COMPANY i

Table of Contents Intermodal Container Attachment

TABLE OF CONTENTS (Continued)

Pendular Twist Locks Repair ............................................................................................................................ 19
Disassemble ................................................................................................................................................... 19
Clean .............................................................................................................................................................. 20
Inspect ............................................................................................................................................................ 20
Assemble ........................................................................................................................................................ 21
Adjustments ....................................................................................................................................................... 22
Twist Lock Angle ........................................................................................................................................... 22
LOCKED/NOT LOCKED Proximity Switches............................................................................................. 23
SEATED Signal ............................................................................................................................................. 23
Maximum Pressure ....................................................................................................................................... 23
Swivel Valve ................................................................................................................................................... 23
Damping Pressure ......................................................................................................................................... 26
Power Pile Slope Pressure............................................................................................................................. 26
Rotation/Brake Valve..................................................................................................................................... 28
Sideshift Valve ............................................................................................................................................... 29
Extension Valve ............................................................................................................................................. 30
Maintenance....................................................................................................................................................... 31
General Maintenance .................................................................................................................................... 31
Additional Spreader Maintenance................................................................................................................ 31
Maintenance Schedule....................................................................................................................................... 32
Torque Specifications ......................................................................................................................................... 36
Troubleshooting ................................................................................................................................................. 37
Diagrams, Schematics, or Arrangements ......................................................................................................... 39
Figure 23. ELME Hydraulic Schematic 771422...................................................................................... 42
Figure 24. ELME Hydraulic Schematic 779465...................................................................................... 44
Figure 25. ELME Electrical Schematic 777111 ...................................................................................... 46
Figure 26. ELME Electrical Schematic 781717 ...................................................................................... 50
Figure 27. ELME Wiring Diagram 777112 ............................................................................................. 54
Figure 28. ELME Wiring Diagram 781718 ............................................................................................. 58

This section is for the following models:

RS45-27CH, RS45-31CH, RS46-36CH, RS46-41L CH, RS46-41S

CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-38L
IH, RS46-38S IH, RS46-38LS IH (RS45-27, RS45-31, RS46-36,
RS46-41L, RS46-41S, RS46-41LS) [C222];
RS45-27CH, RS45-31CH, RS46-36CH, RS46-40CH, RS46-41S CH, RS46-41L
CH, RS46-41LS CH, RS45-24IH, RS45-28IH, RS46-33IH, RS46-37IH,
RS46-38S IH, RS46-38L IH, RS46-38LS IH (HR45-27,HR45-31, HR45-36,
HR45-40, HR45-41S, HR45-41L, HR45-41LS) [B222];
RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH,
RS46-36CH, RS46-33IH [A222]

ii
5000 SRM 777
General
This service repair manual has the description and
repair procedures for the ELME 857 model extend-
able container handling attachment. Each attach-
ment is built according to a combined model and spec-
ification number (e.g., 857-18164), which is the key
to different spreader functions and to parts and ser-
vice information. The ELME attachment nameplate
identifies the model, specification number, and se-
rial number. The ELME attachment nameplate is
Description
The intermodal container attachment can lift con-
tainers by means of the 4 twist locks, or trailers by
means of 4 folding legs. See Figure 1.
The folding legs are at a fixed lateral distance. The
twist locks width can be adjusted to the container
length at three widths: 20 ft, 40 ft, or at an optional
width of 30 ft. The main beam and the extension
beam have wear plates. The wear plates support the
attachment boom sections as they extend and retract.
Description
located at the rear right-hand side of the central at-
tachment frame.
Parts information and diagrams are accessible
through Hyster Hypass Online. Contact your
local dealer for a copy of this information. Provide
the dealer with the model specification and serial
number of the attachment.
The attachment has a rotator for turning the con-
tainer. It also has sideshift and pile-slope features,
allowing for fine adjustment of the attachment. Each
of these functions are actuated by hydraulic cylin-
ders, operated from the attachment control valve or
the selector valve.
1
Description 5000 SRM 777

1. ROTATOR ASSEMBLY 3. TWIST LOCK ASSEMBLY

2. FOLDING LEG ASSEMBLY 4. FOLDING LEG FOOT

Figure 1. Intermodal Container Handler

2
5000 SRM 777
Operation
The attachment hydraulic components are: relief
valves, extension cylinders, power pile-slope, rotator,
sideshift, and twist lock cylinders. The legs have
sequence, fold, and clamp valves. Eight proximity
switches are actuated by the twist lock linkage and
the seated pins. The proximity switches signal that
the attachment is correctly attached to a container.
The feet of the folding legs also have eight proximity
switches. See Figure 1.
Each attachment function requires both an electrical
signal to the selected valve and a signal to the direc-
tion control valve in the hydraulic compartment. The
direction control valve allows hydraulic pressure to
be applied to either line A or B, while the nonpres-
surized line will then function as the hydraulic fluid
return line. The signal to the selected valve allows
hydraulic oil to enter the cylinder of that function at
the correct port.
EXTEND AND RETRACT CIRCUIT
The attachments can lift either 20- or 40-foot con-
tainers. The optional 30-foot stop kit allows lifting
30-foot containers. The 30-foot position is obtained
by selecting the 30-foot stop while extending or re-
tracting the beams.
Oil from the direction control valve enters the exten-
sion cylinder at the piston end, when the solenoid at
the extension cylinder is energized. As the cylinders
extend, oil from the rod end of the cylinders returns
to the direction control valve. The relief valve is con-
nected between the piston and the rod end of both ex-
tension cylinders. The shell of each extension cylin-
der is fastened to the main frame. The rod end of
each extension cylinder is fastened to the extension
beam. The relief valve is used to protect the exten-
sion cylinders from damage when subjected to exter-
nal forces. When the attachment is retracted, oil en-
ters the rod end of the extension cylinders. As the ex-
tension cylinders retract, they pull in the extension
beams.
Operation
TWIST LOCK CIRCUIT
To operate the twist locks, all four corners of the at-
tachment must be fully seated on the container to be
lifted. The attachment is seated when each seated
pin is pushed into the attachment and energizes all
four sensor switches. When all four of the sensor
switches are energized an electric signal is sent to the
twist lock cylinder solenoid valve. When, in addition,
the direction control valve is actuated, hydraulic oil
will flow to the twist lock cylinders thereby rotating
the twist locks.
The twist locks may be operated manually by the
driver, or automatically after a two-second time de-
lay. Opening the twist locks is a manual operation.
As protection against the unintentional opening of
the twist locks, a cam on the seated pin prevents the
twist lock crank from turning if the pin is not fully
seated.
ROTATOR CIRCUIT
The rotator is connected with the truck boom by
two pins. These pins allow the attachment to pivot
slightly, when moving a loaded container load swing
can be controlled by the dampening lock as the boom
is raised or lowered. Control of the attachment is by
joystick in the cab; rotation, pile-slope, and sideshift
are possible with load control by dampening lock.
The rotator is a two-speed, reversible unit. This
allows for rotator movement in both directions, with
an override for movement beyond the preset 12°
limit of the rotator.
FOLDING LEGS CIRCUIT
The folding legs are hydraulically-operated exten-
sions of the attachment. They fold up for ease of
movement and placement. The rear legs engage the
container first, then the front legs. They are then
clamped to the trailer, allowing the truck to pick up
and move it.
3
Container Attachment Repair 5000 SRM 777

Container Attachment Repair

REMOVE a. Disconnect the hydraulic lines between the
boom and rotator frame. Put caps on the
1. Fully extend the boom. open lines.
2. Place the attachment on a loaded container or b. Remove the lock nut and washer from the
use a lifting device to support attachment. capscrew. See Figure 3.
3. Apply parking brake. c. Use the capscrews in the threaded holes on
the flange of the sliding bushing to pull the
4. Shut off engine.
sliding bushing out.

WARNING d. Remove the capscrew that hold the pin in

Do not disconnect any hydraulic lines when the
engine is running or personal injury may oc-
cur.
NOTE: Move all control levers back and forth a min-
imum of 20 times to remove all hydraulic pressure
from pilot system.
5. Put identification tags on the hydraulic lines and
electrical connectors.
position.
e. Use a drift to push the pin out of the boom
and rotator frame hole.
f. Remove the pin from the other side of the
rotator frame using the same procedure.
g. Remove the bushings from the boom holes.

6. Disconnect the two electrical connectors between

the boom and the rotator frame.

7. Disconnect the dampening cylinder as follows:

a. Put identification tags on the hydraulic lines

during removal.

b. Disconnect the hydraulic lines at the damp-

ening cylinder. Put caps on the open lines.

c. Disconnect the dampening cylinder at the ro-

tator frame by removing nut from the pin.
See Figure 2.

d. Push the pin through the cylinder head and

frame mounting brackets with a drift.

e. Remove the pin on the other dampening

cylinder using the same procedure. 1. PIN
2. ROTATOR FRAME
f. Remove the two spacers. 3. DAMPENING CYLINDER
4. WASHER
5. NUT
WARNING
Figure 2. Dampening Cylinder to Rotator
Verify the dampening cylinder and rotator
Frame Mounting
frame cannot move or personal injury may
occur.

8. Disconnect the boom from the rotator frame as

follows:

4
5000 SRM 777 Container Attachment Repair

1. BUSHING 5. PIN
2. WASHER 6. FIXED BUSHING
3. LOCK NUT 7. CAPSCREW
4. SLIDING BUSHING

Figure 3. Boom to Rotator Frame Mounting

INSTALL the center of the bushings with the center of

1. Start the engine.
WARNING
Verify the lifting device has the rated capacity
to lift the attachment or personal injury may
occur.
2. If the attachment is on a container, drive truck
toward attachment. If the attachment is not on a
container, use a lifting device to raise attachment
so it can be installed.
3. Apply the park brake
the rotator frame holes.
c. Install the pin and fixed bushing, from the
outside toward the center of the rotator
frame.
d. Install the capscrew.
e. Install the sliding bushing.
f. Install the washer and lock nut on the cap-
screw and tighten to 320 N•m (236 lbf ft).
g. Connect the hydraulic lines between the
boom and the rotator frame.

4. Shut off the engine. 6. Connect the dampening cylinder as follows:

5. Connect the boom to the rotator frame as follows:
a. Install the bushings in both holes on the
boom so the bushings are in the center of the
holes.
NOTE: Lubricate the pin with molybdenum disulfide
grease before installing.
a. Align the rod end of the dampening cylinder
with the pin yoke.

b. Use the lift truck to move the boom into posi- b. Push the pin partway into the dampening
tion for installing the pins and carefully align cylinder head from the outside toward the
center of the rotator frame.

5
Extension Cylinders Repair
c. Install the spacer and push the pin com-
pletely through the dampening cylinder
head.
d. Install the nut and tighten.
e. Install the pin on the other dampening cylin-
der using the same procedure.
f. Connect the hydraulic lines at the dampen-
ing cylinder.
7. Start the engine and operate the boom functions.
Check that functions of the boom assembly work
Extension Cylinders Repair
REMOVE
1. Retract the attachment to the 20-foot position to
allow access to the bracket holding the hose/cable
chain.
2. Disconnect hydraulic lines to extension cylinders
and put caps on open lines.
3. Disconnect electrical connectors at rear of exten-
sion cylinders.
CAUTION
Before removing pin, check that the end of the
cylinder is supported to prevent possible dam-
age to the cylinder.
4. Remove cotter pin, washer, and pin from rear of
extension cylinder, and remove extension cylin-
der from mount.
5. Remove bracket holding the hose/cable chain to
the bottom of extension beam.
6. Using a crane or lift truck, pull extension beam
out approximately 50 cm (20 in.) so the inspec-
tion hole is clear of the main frame.
7. Remove cotter pin, washer, and pin from rod end
of extension cylinder.
8. Using a crane or other lifting device capable of
supporting 150 kg (330 lb), remove extension
cylinder from the attachment horizontally until
cylinder is completely clear of the main frame of
the attachment.
6
5000 SRM 777
correctly as described in the Operating Man-
ual.
8. Operate the hydraulic system until air is out of
the system. Bleed if necessary.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
9. Check for leaks.
DISASSEMBLE
Disassemble cylinder as necessary. Refer to Figure 4.
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 all parts with solvent. Check all wear surfaces
for wear or damage. Use new parts as necessary.
ASSEMBLE
Assemble cylinder as necessary. Lubricate seals with
clean hydraulic oil during assembly. Refer to Fig-
ure 4.
INSTALL
1. Clean the tracks and lubricate areas where the
support wear pads for the extension cylinder will
come into contact with the extension beam.
2. Using a crane or other lifting device capable
of supporting 150 kg (330 lb), install extension
cylinder in attachment horizontally until cylin-
der is located in the rod end connection point.
3. Install pin, washer, and cotter pin in rod end of
extension cylinder.
5000 SRM 777 Extension Cylinders Repair

4. Install bracket holding the hose/cable chain to 6. Connect extension cylinders hydraulic lines.
the bottom of extension beam.
7. Connect electrical connectors at rear of extension
5. Install rear of extension cylinder on mount and cylinders.
install pin, washer, and cotter pin in rear of ex-
tension cylinder.

1. PISTON 5. GUIDE
2. PISTON SEAL 6. RING
3. O-RING 7. WIPER
4. SPACER 8. WEAR PAD

Figure 4. Extension Cylinder Arrangement

7
Sideshift Cylinder Repair 5000 SRM 777

Sideshift Cylinder Repair

REMOVE 7. Remove the nut, washer, bolt, and pin from the
piston side of the cylinder.
1. Place the lift truck on a solid, level surface.
DISASSEMBLE
2. Lower the attachment and shut down the engine.
1. Place the entire cylinder on a support that is long
3. Put identification tags on the hydraulic lines.
enough to support the rod.

WARNING 2. Disassemble the gland using a pin wrench to un-

Do not disconnect any hydraulic lines when the screw the gland. See Figure 5.
engine is running or personal injury may oc-
cur. CAUTION
Use caution not to damage the finished surface
Verify the rotator cannot slide from the attach-
of the piston rod when removing the piston rod
ment when both cylinders have been discon-
from the cylinder shell.
nected or personal injury may occur.
3. Disassemble the piston rod assembly from the
4. Disconnect the hydraulic lines to the cylinder
cylinder shell by pulling it out.
and put caps on the open lines.

WARNING
Verify the lifting device has the rated capacity
of 20 kg (44 lb) or personal injury may occur.
5. Put a sling around the sideshift cylinder and at-
tach it to a crane or lifting device.
CAUTION
Use caution not to damage the grooves when
removing seals and other parts from the piston
rod.
4. Disassemble and remove the piston.

6. Remove the nut, ring, and pin from the rod side 5. Loosen the setscrew on the nut, then remove nut.
of the cylinder. 6. Remove the piston and the gland.

7. Remove all seals from the gland.

1. SNAP RING 8. GLAND

2. BALL JOINT 9. SEAL RING
3. GREASE NIPPLE 10. PISTON ROD
4. SHELL 11. O-RING
5. SETSCREW 12. O-RING
6. NUT 13. SEAL RING
7. PISTON 14. WIPER RING

Figure 5. Sideshift Cylinder

8
5000 SRM 777
CLEAN
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 proce-
dures.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Verify the path of the compressed air is away
from all personnel. Wear protective goggles or
a face shield to prevent injury to the eyes.
Clean all parts in solvent and remove residual sol-
vent or allow the solvent to evaporate.
INSPECT
Inspect the parts of the sideshift cylinder for damage,
rust, or wear. Carefully inspect the rod surface for
dents and scratches. Verify that the internal stroke
surfaces of the cylinder shell and the grooves for the
seals do not show any nicks, scratches, or other dam-
age. Repair or replace parts as needed.
ASSEMBLE
NOTE: Verify that all parts are clean before assembly.
NOTE: Always use new seals. Lubricate all parts
with clean hydraulic oil.
1. Assemble the new seals and gland on the piston
rod.
2. Using the nut and setscrew, assemble the piston
on the piston rod. Tightly fasten the nut and fix
with the setscrew.
Sideshift Cylinder Repair
CAUTION
Use caution not to damage the finished surface
of the piston rod when installing the piston rod
into the cylinder shell.
3. Lubricate the cylinder shell bore with clean hy-
draulic oil. Put the piston rod assembly into the
cylinder shell.
NOTE: No special torque is required when tightening
the gland. Tightly fasten the gland.
4. Lubricate the thread of the gland, and screw the
gland into the cylinder shell.
INSTALL
WARNING
Verify the lift device has the rated capacity to
lift the sideshift cylinder or personal injury
may occur.
1. Use a lifting device to put the sideshift cylinder in
position and install the pin, washer, spacer, and
lock nut.
2. Remove caps and connect the hydraulic lines to
the cylinder.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
3. Start the engine and operate the sideshift cylin-
der function several times to remove the air.
Check if the functions operate correctly, and
check for any leaks.
9
Power Pile Slope Cylinder Repair 5000 SRM 777

Power Pile Slope Cylinder Repair

REMOVE WARNING
1. Place the lift truck on a solid, level surface. Verify the lifting device has the rated capacity
of 20 kg (44 lb) or personal injury may occur.
2. Lower the attachment
7. Put a sling around the side tilt cylinder and at-
3. Shut off the engine. tach it to a crane or lifting device.

4. Put identification tags on the hydraulic lines.
WARNING
Do not disconnect any hydraulic lines when the
engine is running or personal injury may oc-
cur.
Verify the upper rotator frame cannot fall
when the pressure is released from the cylin-
ders or personal injury may occur.
8. Remove the lock nut, washer, spacer, and pin
from the other end of the cylinders.
9. Remove the cylinder and put it on a support.
DISASSEMBLE
1. Place the cylinder on a support.
2. Disassemble the gland using a pin wrench to un-
screw the gland. See Figure 6.

5. Disconnect the hydraulic lines to the cylinder

and put caps on the open lines.
6. Remove the lock nut, washer, spacer, and pin
from the rod end of the cylinder.
CAUTION
Use caution not to damage the finished surface
of the piston rod when removing the piston rod
from the cylinder shell.

3. Disassemble the piston rod assembly from the

cylinder shell by pulling it out.

1. SETSCREW 6. O-RING 11. WIPER RING

2. NUT 7. O-RING 12. GREASE NIPPLE
3. PISTON 8. GLAND 13. BALL JOINT
4. SEAL RING 9. PISTON ROD 14. SNAP RING
5. SHELL 10. SEAL RING 15. ROD END

Figure 6. Power Pile Slope Cylinder

10
5000 SRM 777
CAUTION
Use caution not to damage the grooves when
removing seals or other parts from the piston
rod.
4. Disassemble and remove the piston.
5. Loosen the setscrew on the nut, then remove nut.
6. Remove the piston and the gland.
7. Remove all seals from the gland.
CLEAN
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 proce-
dures.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Verify the path of the compressed air is away
from all personnel. Wear protective goggles or
a face shield to prevent injury to the eyes.
Clean all parts in solvent and remove residual sol-
vent or allow the solvent to evaporate.
INSPECT
Inspect the parts of the side tilt cylinder for damage,
rust, or wear. Carefully inspect the rod surface for
dents and scratches. Verify that the internal stroke
surfaces of the cylinder shell and the grooves for the
seals do not show any nicks, scratches, or other dam-
age. Repair or replace parts as needed.
ASSEMBLE
NOTE: Verify that all parts are clean before assembly.
NOTE: Always use new seals. Lubricate all parts
with clean hydraulic oil.
Power Pile Slope Cylinder Repair
1. Assemble new seals and gland on the piston rod.
2. Assemble the new seals on the piston.
3. Using the nut and setscrew, assemble the piston
on the piston rod.
CAUTION
Use caution not to damage the finished surface
of the piston rod when installing the piston rod
into the cylinder shell.
4. Lubricate the cylinder shell bore with clean hy-
draulic oil. Put the piston rod into the cylinder
shell.
NOTE: No special torque is required when tightening
the gland. Tightly fasten the gland.
5. Lubricate the thread of the gland, and screw the
gland into the cylinder shell.
INSTALL
NOTE: The shell side of the cylinder and the related
hoses are fitted at the side of the rotator.
1. Use a lifting device to put the power pile slope
cylinder in position and install the pin, washer,
spacer, and lock nut.
2. Remove caps and connect the hydraulic lines to
the cylinder.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
3. Start the engine and operate the power pile slope
cylinder function several times to remove the
air. Check if the functions operate correctly, and
check for any leaks.
11
Folding/Clamping Cylinder Repair
Folding/Clamping Cylinder Repair
REMOVE
1. Place the lift truck on a solid, level surface.
2. Place the legs in a vertical position.
3. Lower the attachment and keep the legs just
above the ground.
4. Shut off the engine.
5. Put identification tags on the hydraulic lines.
WARNING
Do not disconnect any hydraulic lines when the
engine is running or personal injury may oc-
cur.
6. Disconnect the hydraulic lines to the fold-
ing/clamping cylinder and put caps on the open
lines.
7. Remove the nut, washer, spacer, and pin from
the rod end of the folding/clamping cylinder. See
Figure 7.
WARNING
Verify the lifting device has the rated capacity
of 20 kg (44 lb) or personal injury may occur.
8. Put a sling around the folding/clamping cylinder
and attach it to a crane or lifting device.
WARNING
The leg can swing to the inside of the attach-
ment after disconnecting the clamping/folding
cylinder. Use caution not to be hit by the leg or
personal injury may occur.
9. Remove the nut, washer, spacer, and pin from the
other end of the folding/clamping cylinder.
10. Remove the folding/clamping cylinder and place
it on a support.
DISASSEMBLE
1. Disassemble the gland using a pin wrench to un-
screw the gland at one side of the folding/clamp-
ing cylinder. See Figure 8.
12
5000 SRM 777
CAUTION
Use caution not to damage the finished surface
of the piston rod when removing the piston rod
from the cylinder shell.
NOTE: The piston rods are slightly different. Mark
the piston rods for reassembly.
2. Disassemble the piston rod assembly at one side
from the cylinder shell by pulling it out.
3. Loosen the setscrew on the nut, then remove the
nut.
4. Disassemble and remove the piston.
5. Remove the gland.
CAUTION
Use caution not to damage the grooves when
removing seals or other parts from the piston
rod.
6. Remove all seals from the piston and gland.
7. Repeat Step 1 through Step 6 for the other side
of the folding/clamping cylinder.
CLEAN
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.
Compressed air can move particles and cause
injury to the user or to other personnel. Verify
compressed air path is away from all person-
nel. Wear eye protection.
Clean all parts in solvent and remove residual sol-
vent or allow the solvent to evaporate.
INSPECT
Inspect the parts of the folding/clamping cylinder for
damage, rust, or wear. Carefully inspect the rod sur-
face for dents and scratches. Verify that the internal
stroke surfaces of the cylinder shell and the grooves
for the seals do not show any nicks, scratches, or
other damage. Repair or replace parts as needed.
5000 SRM 777 Folding/Clamping Cylinder Repair

1. SOCKET HEAD CAPSCREW 9. BUFFER 17. CYLINDER

2. NUT 10. SHOULDER 18. PIN
3. SHAFT 11. SHOULDER 19. ROD END
4. BUSHING 12. SHAFT 20. NUT
5. NUT 13. BUSHING 21. WASHER
6. WASHER 14. LEG 22. BOLT
7. SPACER 15. LEG 23. BUFFER
8. SOCKET HEAD CAPSCREW 16. RING 24. WASHER

Figure 7. Folding Leg Assembly

13
Folding/Clamping Cylinder Repair 5000 SRM 777

1. BALL JOINT 7. SEAL KIT

2. SNAP RING 8. SETSCREW
3. GREASE NIPPLE 9. NUT
4. PISTON ROD 10. SHELL
5. GLAND 11. ROD END
6. PISTON 12. FITTING

Figure 8. Folding/Clamping Cylinder

ASSEMBLE
NOTE: Verify that all parts are clean before assembly.
NOTE: Always use new seals. Lubricate all parts
with clean hydraulic oil.
1. Assemble the new seals and gland on the piston
rod.
2. Assemble the new seals on the piston.
3. Using the nut and setscrew, assemble the piston
on the piston rod.
INSTALL
WARNING
Verify the lifting device has the rated capac-
ity to lift the folding/clamping cylinder or per-
sonal injury may occur.
NOTE: The fittings must be positioned in front of the
hole in the attachment. What fittings.
1. Use a lifting device to put the folding/clamping
cylinder into position and install the lock nut,
washer, spacer, and pin inside the attachment.

2. Remove caps and connect the hydraulic lines to

CAUTION
Use caution not to damage the finished surface
of the piston rod when installing the piston rod
into the cylinder shell.
4. Lubricate the cylinder shell bore with clean hy-
draulic oil. Put the piston rod into the cylinder
shell.
NOTE: No special torque is required when tightening
the gland. Fasten the gland tightly.
5. Lubricate the thread of the gland, and screw the
gland into the cylinder shell.
the folding/clamping cylinder.
3. Start the engine.
4. Extend the folding/clamping cylinder until the
piston rod can be assembled to the shoulder.
what?
5. Shut off the engine.
6. Install the folding/clamping cylinder with the
nut, washer, spacer, and pin to the shoulder.
the shoulder of what. Don’t like the way it
sounds.

14
5000 SRM 777
7. Start the engine.
8. Operate the folding/clamping cylinder function
several times to remove the air.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Upper Leg Folding Cylinder Repair
REMOVE
1. Place the lift truck on a solid, level surface.
2. Place the legs in vertical position.
3. Lower the attachment and keep the legs just
above the ground.
4. Shut off the engine.
5. Put identification tags on the hydraulic lines.
6. Remove the nut, washer, and two buffers from
the rod end of the folding cylinder. See Figure 7.
7. Start the engine.
8. Retract the folding cylinder until the rod end is
out of the mounting hole of the leg.
9. Shut off the engine.
WARNING
Do not disconnect any hydraulic lines when the
engine is running or personal injury may oc-
cur.
10. Put a sling around the folding cylinder and at-
tach it to a crane or lifting device.
11. Disconnect the hydraulic lines to the folding
cylinder and put caps on the open lines.
WARNING
The leg can swing to the inside of the attach-
ment after disconnecting the folding cylinder.
Upper Leg Folding Cylinder Repair
Hydraulic oil can be injected into the body by
pressure.
9. Check if the functions operate correctly, and
check for any leaks.
Use caution when disconnecting the folding
cylinder or personal injury may occur.
12. Remove the nut, washer, spacer, and pin from the
other end of the folding cylinder.
13. Remove the folding cylinder and place it on a sup-
port.
DISASSEMBLE
1. Disassemble the gland using a pin wrench to un-
screw the gland. See Figure 9.
CAUTION
Use caution not to damage the finished surface
of the piston rod when removing the piston rod
from the cylinder shell.
2. Disassemble the piston rod assembly from the
cylinder shell by pulling it out.
3. Loosen the setscrew on the nut, then remove nut.
4. Disassemble and remove the piston.
5. Remove the gland.
CAUTION
Use caution not to damage the grooves when
removing seals or other parts from the piston
rod.
6. Remove all seals from the piston and gland.
15
Upper Leg Folding Cylinder Repair 5000 SRM 777

1. BALL JOINT 6. PISTON

2. SNAP RING 7. SHELL
3. GREASE FITTING 8. GLAND
4. SCREW 9. PISTON ROD
5. NUT 10. SEAL KIT

Figure 9. Folding Cylinder

CLEAN
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 proce-
dures.
ASSEMBLE
NOTE: Verify that all parts are clean before assembly.
NOTE: Always use new seals. Lubricate all parts
with clean hydraulic oil.
1. Assemble the new seals and gland on the piston
rod.

Compressed air can move particles so that they
cause injury to the user or to other personnel.
Verify the path of the compressed air is away
from all personnel. Wear protective goggles or
a face shield to prevent injury to your eyes.
Clean all parts in solvent and remove residual sol-
vent or allow the solvent to evaporate.
INSPECT
Inspect the parts of the folding cylinder for damage,
rust, or wear. Carefully inspect the rod surface for
dents and scratches. Verify that the internal stroke
surfaces of the cylinder shell and the grooves for the
seals do not show any nicks, scratches, or other dam-
age. Repair or replace parts as needed.
2. Assemble the new seals on the piston.
3. Assemble the piston on the piston rod using the
nut and setscrew.
CAUTION
Use caution not to damage the finished surface
of the piston rod when installing the piston rod
into the cylinder shell.
4. Lubricate the cylinder shell bore with clean hy-
draulic oil. Put the piston rod into the cylinder
shell.
NOTE: No special torque is required when tightening
the gland. Fasten the gland tightly.
5. Lubricate the thread of the gland, and screw the
gland into the cylinder shell.

16
5000 SRM 777
INSTALL
WARNING
Verify the lifting device has the rated capacity
to lift the folding cylinder.
1. Use a lifting device to put the folding cylinder
into position and install the nut, washer, and two
buffers to the leg.
2. Remove caps and connect the hydraulic lines to
the folding cylinder.
3. Start the engine.
4. Slowly extend the folding cylinder until the fold-
ing cylinder can be assembled to the shoulder.
Lower Leg Folding Cylinder Repair
REMOVE
1. Place the lift truck on a solid, level surface.
2. Place the legs in vertical position.
3. Lower the attachment and keep the legs just
above the ground.
4. Shut off the engine.
5. Put identification tags on the hydraulic lines.
6. Remove the nut, washer, and two buffers from
the rod end of the folding cylinder. See Figure 7.
7. Start the engine.
8. Retract the folding cylinder until the rod end is
out of the mounting hole of the leg.
9. Shut off the engine.
WARNING
Verify the lifting device has the rated capacity
of 20 kg (44 lb) or personal injury may occur.
10. Put a sling around the folding cylinder and at-
tach it to a crane or lifting device.
WARNING
Do not disconnect any hydraulic lines when the
engine is running or personal injury may oc-
cur.
Lower Leg Folding Cylinder Repair
5. Shut off the engine.
6. Install the folding cylinder with the nut, washer,
spacer, and pin to the shoulder.
7. Start the engine.
8. Operate the folding cylinder function several
times to remove the air.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
9. Check if the functions operate correctly, and
check for any leaks.
11. Disconnect the hydraulic lines to the folding
cylinder and put caps on the open lines.
WARNING
The leg can swing to the inside of the attach-
ment after disconnecting the folding cylinder.
Use caution when disconnecting the folding
cylinder or personal injury may occur.
12. Remove the nut, washer, spacer, and pin from the
other end of the folding cylinder.
13. Remove the folding cylinder and place it on a sup-
port.
DISASSEMBLE
1. Disassemble the gland using a pin wrench to un-
screw the gland. See Figure 9.
CAUTION
Use caution not to damage the finished surface
of the piston rod when removing the piston rod
from the cylinder shell.
2. Disassemble the piston rod assembly from the
cylinder shell by pulling it out.
3. Loosen the setscrew on the nut, then remove nut.
4. Disassemble and remove the piston.
5. Disassemble and remove the shims.
17
Lower Leg Folding Cylinder Repair
6. Remove the gland.
CAUTION
Use caution not to damage the grooves when
removing seals or other parts from the piston
rod.
7. Remove all seals from the piston, gland, and
shims.
CLEAN
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 proce-
dures.
Compressed air can move particles so that they
cause injury to the user or to other personnel.
Verify the path of the compressed air is away
from all personnel. Wear protective goggles or
a face shield to prevent injury to your eyes.
Clean all parts in solvent and remove residual sol-
vent or allow the solvent to evaporate.
INSPECT
Inspect the parts of the folding cylinder for damage,
rust, or wear. Carefully inspect the rod surface for
dents and scratches. Verify that the internal stroke
surfaces of the cylinder shell and the grooves for the
seals do not show any nicks, scratches, or other dam-
age. Repair or replace parts as needed.
ASSEMBLE
NOTE: Verify that all parts are clean before assembly.
NOTE: Always use new seals. Lubricate all parts
with clean hydraulic oil.
1. Assemble the new seals and gland on the piston
rod.
2. Assemble the new seals on the piston.
3. Assemble the piston on the piston rod using the
nut and setscrew.
18
5000 SRM 777
CAUTION
Use caution not to damage the finished surface
of the piston rod when installing the piston rod
into the cylinder shell.
4. Lubricate the cylinder shell bore with clean hy-
draulic oil. Put the piston rod into the cylinder
shell.
NOTE: No special torque is required when tightening
the gland. Fasten the gland tightly.
5. Lubricate the thread of the gland, and screw the
gland into the cylinder shell.
INSTALL
WARNING
Verify the lifting device has the rated capacity
to lift the folding cylinder.
1. Use a lifting device to put the folding cylinder
into position and install the nut, washer, and two
buffers to the leg.
2. Remove caps and connect the hydraulic lines to
the folding cylinder.
3. Start the engine.
4. Slowly extend the folding cylinder until the fold-
ing cylinder can be assembled to the shoulder.
5. Shut off the engine.
6. Install the folding cylinder with the nut, washer,
spacer, and pin to the shoulder.
7. Start the engine.
8. Operate the folding cylinder function several
times to remove the air.
WARNING
Do not try to locate hydraulic leaks by putting
hands on pressurized hydraulic components.
Hydraulic oil can be injected into the body by
pressure.
9. Check if the functions operate correctly, and
check for any leaks.
5000 SRM 777 Pendular Twist Locks Repair

Pendular Twist Locks Repair

DISASSEMBLE 5. Remove the two capscrews and washers that hold
the bearing housing.
1. Place the lift truck on a solid, level surface.
6. Remove the arm.
2. Lower the attachment to a workable height.
7. Remove the locked/not locked sensor bracket.
3. Shut down the engine. See Figure 11.
4. Remove the indicator. See Figure 10.

1. PIN 9. SPRINGS
2. BOLT 10. KEY
3. CRANK 11. SPRING PIN
4. COLLET 12. TWIST LOCK
5. UPPER BEARINGS 13. ARM
6. LOWER BEARINGS 14. BEARING HOUSING
7. BUSHING 15. INDICATOR
8. SLEEVE

Figure 10. Pendular Twist Locks Assembly

19
Pendular Twist Locks Repair 5000 SRM 777

1. PROXIMITY SWITCH 5. BALL JOINT

2. TIE ROD 6. TWIST LOCK CYLINDER ASSEMBLY
3. O-RING WASHER 7. LOCKED/NOT LOCKED SENSOR BRACKET
4. O-RING

Figure 11. Locked/Not Locked Sensor Bracket

8. Loosen one of the twist lock cylinder adjuster CLEAN

bolts to allow removal of the tie rod from the twist
lock cylinder.
9. Remove the four bolts from each twist lock crank
in the same extension beam.
10. Install two of the bolts from Step 9 into the two
threaded holes in the cranks and tighten alter-
nately until the cranks are lifted off of the twist
lock shaft.
11. Remove the tie rod, with both cranks attached,
from the end beam.
12. The key used to locate the crank is held in place
with a roll pin. Remove the roll pin and key from
the twist lock.
NOTE: During the performance of Step 13, support
the twist lock from below to prevent it from dropping
out of the extension beam.
13. Pry the collets out of the recess in the twist lock.
Remove the twist lock from the extension beam.
The sleeve and lower bearing set may come out
with the twist lock. This is normal.
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.
1. Clean all parts of the twist lock assembly in sol-
vent and remove residual solvent or allow the sol-
vent to evaporate.
INSPECT
1. Inspect all parts of the twist lock assembly for
damage, rust, or wear each month. When the
worn area has reduced to 25 mm (1.00 in.), the
twist locks must be replaced. Inspect the twist
lock recesses and replace, if damaged. See Fig-
ure 12.
2. Inspect the upper and lower bearing sets for dam-
age. Replace, if damaged.
3. Inspect the collets and the crank. Replace, if
worn or damaged.

20
5000 SRM 777 Pendular Twist Locks Repair

twist lock. Support the assembly by means of a

jack or other suitable device to make sure the
assembly does not fall out.

5. Install the collets with the pointed side facing up.

6. Install the key and roll pin in the keyway of the

twist lock.

NOTE: To install the tie rod, it is necessary to mount

both cranks to the tie rod before installing it into the
extension beam.

7. Install the ball joints, O-rings, and plastic wash-

ers on the tie rod ends and install the fork of the
crank over the tie rod end. Make sure the counter
sunk holes are facing up. Secure the crank to the
Figure 12. Twist Locks
tie rod by installing the pin, ring pin, and socket
head capscrew.
ASSEMBLE
NOTE: To ease in the installation of the crank to the
1. Lubricate the upper and lower bearings using
twist lock, make two alignment pins using M8×75
multipurpose grease.
bolts or socket head capscrews with the heads re-
NOTE: The spherical upper and lower bearing sets moved.
have the same swivel point. This means that both
8. Install the locating pins into the top plate of the
sets are oriented in the same direction, with the con-
upper bearing diagonally so each pin guides on
cave bearing halves (in lower position), facing up, and
half of the collets.
the convex bearing halves (in upper position), facing
down. If incorrectly oriented, the twist lock will jam 9. Insert the tie rod into the extension beam and
when swiveled sideways. fit the cranks onto the alignment pins making
sure the key and keyway are lined up. Install
2. Install the sleeve with bushes onto the twist lock
two screws in the crank, remove the alignment
and place the lower bearing set in position on top
pins, and install the remaining two screws in
of the sleeve. Install the four centering springs
the crank. Tighten all four screws to 25 N•m
in the sides of the sleeve.
(18.4 lbf ft).
3. Install the upper bearing set on the top surface
10. Adjust the twist lock angle and the proximity
of the corner plate, in the extension beam, with
switches as described in Adjustments.
the lower convex half facing up, and the upper
concave half (with threaded holes), facing down. 11. Lubricate the complete assembly using multipur-
pose grease.
4. Install the twist lock through the corner plate
in the extension beam ensuring that the upper 12. Install the locked/not locked sensor bracket.
bearing set is correctly positioned around the

21
Adjustments
Adjustments
TWIST LOCK ANGLE
1. Move the twist lock cylinder rod to the fully NOT
LOCKED position. See Figure 13.
2. Check the correct alignment of the twist locks in
the twist lock sleeve in both end beams. Align the
twist lock with the twist lock sleeve by turning
the adjuster bolts of the twist lock cylinder. Keep
the cylinder rod in the NOT LOCKED position
while adjusting the bolts. If the twist locks will
not line up fully in one end beam, then divide the
misalignment equally between both twist locks
in that end beam.
WARNING
Twist locks can get caught in the corner cast-
ing of a container, if the twist lock has not been
aligned and adjusted properly to the container.
1. TWIST LOCK
2. ADJUSTER BOLT
3. TWIST LOCK CYLINDER
Figure 13. Twist Lock Adjustment
22
5000 SRM 777
3. Turn the adjustment bolts loosely up to the twist
lock cylinder rod WITHOUT either turning the
twist locks OR moving the cylinder rod.
4. Tighten the adjustment bolts while maintaining
a play of 0.05 mm (0.002 in.) between the twist
lock cylinder and the bolt heads. Too much play
will result in the piston rod ends being ham-
mered and become damaged.
5. Turn the twist locks to the LOCKED position.
Check that they can turn through a full 90
±10 degrees, compared to the unlocked position.
Check for mechanical failures if this position
cannot be obtained.
4. CYLINDER ROD
5. LOCK NUT
6. TIE ROD
5000 SRM 777
LOCKED/NOT LOCKED PROXIMITY
SWITCHES
1. Turn the twist locks to the fully NOT LOCKED
position.
2. Loosen the bolts of the nylon mounting bracket
for the LOCKED/NOT LOCKED proximity
switches.
3. Position both proximity switches 3 to 4 mm
(0.118 to 0.157 in.) above the sensor plate that
is welded to the tie rod.
4. Slide the nylon mounting bracket toward the
LOCKED position, until the NOT LOCKED SIG-
NAL is OFF (watch for the yellow LED in the
not-locked sensor to go OFF). Move the mount-
ing bracket back toward the NOT LOCKED
position until the LED switches ON again. Slide
the bracket another 2 mm (0.079 in.) further
toward the unlocked position and tighten the
bolts of the nylon mounting bracket. Check that
the distance at which the NOT LOCKED signal
goes OFF does not exceed 2 mm (0.079 in.) fur-
ther toward the unlocked position, and tighten
the bolts of the nylon measured from the NOT
LOCKED endstroke position of the twist lock
cylinder.
5. Turn the twist locks to the LOCKED position
and verify that the proximity switch for the
LOCKED position switches ON just before the
final LOCKED position has been reached, but
not earlier than 10 mm (0.394 in.) further
toward the unlocked position and tighten the
bolts of the nylon 10 mm (0.394 in.) before the
locked position. Increase the distance between
the indicator arm and the proximity switch for
the locked position if the locked signal appears
earlier than 10 mm (0.394 in.) before the final
locked position.
Adjustments
SEATED SIGNAL
1. Check that the SEATED PIN can move up and
down easily. The force needed to lift a pin is ap-
proximately 100 N (22 lbf).
2. Fix the seated pin in a position of 8 mm (0.315 in.)
below the contact surface of the attachment.
3. Loosen the nut and bolt in the sensor bracket,
which clamp the proximity switch. Move the
proximity switch about 10 mm (0.394 in.) up-
ward if the yellow LED is already ON. Slowly
slide the sensor back into the bracket until the
LED switches ON (watch for the yellow LED
on the seated sensor to switch ON). Tighten the
nut and bolt clamping the sensor. The proximity
switch for the SEATED position should be ON,
when the seated pin is 8 mm (0.315 in.), or less
below the contact surface of the attachment. The
switch should be OFF if the seated pin is more
than 8 mm (0.315 in.) below the contact surface
of the attachment.
MAXIMUM PRESSURE
Maximum pressure is 140 bar (2031 psi). On earlier
models, the 140 bar (2031 psi) pressure relief valve
is incorporated in the sideshift valve. Later models
have the 140 bar (2031 psi) pressure relief valve in
the swivel valve. Adjustment of the relief valve is
identical for both types of valves. Increase relief pres-
sure by turning the valve clockwise. Turn the relief
valves counterclockwise to reduce pressure. For the
location of the relief valve, see Figure 14 and Fig-
ure 15.
SWIVEL VALVE
The swivel valve is a manifold with connections
from the truck to the swivel and then onto the rota-
tor/brake valve. The incorporated relief valve is to
limit the maximum pressure for the entire attach-
ment to 140 bar (2031 psi). On some ELME models,
the swivel valve also houses the pressure valve with
solenoid Y54. See Figure 15.
23
Adjustments 5000 SRM 777

1. SIDESHIFT SOLENOID 5. PRESSURE RELIEF VALVE

2. SOLENOID Y54 6. TO SIDESHIFT CYLINDER
3. VALVE CARTRIDGE 7. TO EXTENSION VALVE
4. GAUGE ADAPTER

Figure 14. Sideshift Valve, Early Models

24
5000 SRM 777 Adjustments

1. RELIEF VALVE 2. PRESSURE VALVE 3. CHECK VALVE

Figure 15. Swivel Valve

25
Adjustments 5000 SRM 777

DAMPING PRESSURE
For the location of the relief valves for power dampen-
ing, see Power Damping Circuit. For the adjustment
of the non powered dampening valve, see Figure 16.
POWER PILE SLOPE PRESSURE
Pressure in the powered pile slope system is con-
trolled by the two counterbalance valves. See Fig-
ure 17. Setting of these two valves in the field is
difficult and is therefore not advisable. A defective
counterbalance valve causes either a restriction type
of failure or a leakage type of failure. As the counter-
balance valves seldom fail at the same time, determi-
nation of the failed valve is by comparing functional-
ity of the two directions of power pile slope.

1. RELIEF VALVE 3. CHECK VALVE

2. ANTI-CAVITATION VALVE 4. GAUGE ADAPTER

Figure 16. Dampening Valve Adjustment

26
5000 SRM 777 Adjustments

1. ELECTRO VALVE 8. PRESSURE PORT

2. COUNTERBALANCE 9. COUNTERBALANCE
3. RIGHT HAND FRONT CYLINDER PORTS 10. RIGHT HAND REAR CYLINDER PORTS
4. RIGHT HAND FRONT CYLINDER PORTS 11. RIGHT HAND REAR CYLINDER PORTS
5. LEFT HAND FRONT CYLINDER PORTS 12. LEFT HAND REAR CYLINDER PORTS
6. LEFT HAND FRONT CYLINDER PORTS 13. LEFT HAND REAR CYLINDER PORTS
7. TANK PORT

Figure 17. Powered Pile Slope

27
Adjustments 5000 SRM 777

ROTATION/BRAKE VALVE 9 and 10 counterclockwise. Do not set the pressure

Initial low speed rotation is adjusted by turning
cartridge no. 3 counterclockwise to increase initial
speed, and clockwise to decrease initial speed. See
Figure 18.
High speed rotation is adjusted by turning car-
tridge no. 2 counterclockwise to increase speed, and
clockwise to decrease speed.
Attachment rotation force is increased by in-
creasing the hydraulic pressure supplied to the
rotator motor. Pressure for clockwise attachment
rotation is increased by turning relief valve 9 clock-
wise. Pressure for counterclockwise attachment
rotation is increased by turning relief valve 10 clock-
wise. Pressure is decreased by turning relief valves
higher than 80 bar (1160 psi). Pressure can be veri-
fied by attaching a gauge at port 11 when adjusting
relief valve 9. Pressure can be verified by attaching
a gauge at port 12 when adjusting relief valve 10.
Minimum pressure in the rotation circuit is con-
trolled by relief valve 14. Pressure is increased by
turning relief valve 14 clockwise. A higher setting
will affect rotation force. A lower setting will allow
cavitation sooner. Recommended setting is 40 bar
(580 psi). Do not set lower than 35 bar (508 psi). To
verify pressure setting, read the gauge connected to
port 11, while rotating the attachment counterclock-
wise. Read the gauge connected at port 12, while
rotating the attachment clockwise.

1. SOLENOID VALVE 9. RELIEF VALVE

2. HIGH-SPEED CARTRIDGE 10. RELIEF VALVE
3. LOW-SPEED CARTRIDGE 11. MOTOR PORT-1
4. ROTATION SPEED SOLENOID VALVE (Y18) 12. MOTOR PORT-2
5. BRAKE RELEASE SOLENOID VALVE (Y15) 13. PRESSURE LINE
6. DRAIN PORT 14. RELIEF VALVE
7. BRAKE PORT-1 15. TANK PORT
8. BRAKE PORT-2

Figure 18. Rotation/Brake Valve

28
5000 SRM 777 Adjustments

SIDESHIFT VALVE valve that is mounted on the sideshift cylinder. See

The sideshift valve is located on top of the spreader
frame at the right hand side. The sideshift valve for
older series incorporates the main relief valve, which
is to be set at 140 bar (2031 psi). The 80 bar (1160 psi)
relief valve for the sideshift function is in a separate
Figure 14. On later series, the sideshift valve has
two parallel solenoids and it incorporates the 80 bar
(1160 psi) relief valve for the sideshift function. See
Figure 19.

1. FROM SWIVEL VALVE 5. TO LEFT HAND EXTENSION VALVE

2. ADAPTER PUMP LINE 6. RELIEF VALVE
3. ADAPTER TANK LINE 7. TO FRONT SIDESHIFT CYLINDER
4. TO REAR SIDESHIFT CYLINDER 8. TO RIGHT HAND EXTENSION VALVE

Figure 19. Sideshift Valve, Later Models

29
Adjustments 5000 SRM 777

EXTENSION VALVE sideshift valve. Apply the extension function while

the spreader is fully extended and adjust the relief
The extension valve is mounted at the shell end of valve to 80 bar.
the extension cylinder. See Figure 20. Fit a pres-
sure gauge at the adapter for the pump line on the

1. CHECK VALVE 5. TO STOP CYLINDER

2. RELIEF VALVE 6. VALVE ON EXTENSION CYLINDER, LEFT HAND
3. TO ROD SIDE OF EXTENSION CYLINDER SHOWN
4. TO TWIST LOCK CYLINDER

Figure 20. Extension Valve

30
5000 SRM 777
Maintenance
GENERAL MAINTENANCE
Twist locks can wear and need inspected on a reg-
ular basis. Lubrication of the twist locks is recom-
mended at monthly intervals and it is also recom-
mended that they are inspected for wear and dam-
age at the same time. Figure 12 shows the wear pat-
tern of the twist locks. When the worn area has re-
duced to 25 mm (1.00 in.), the twist locks must be re-
placed. Generally, it is recommended that the twist
locks be replaced after a maximum use of 5000 work-
ing hours.
Wear Pads are used to support the extension beams
and the extension cylinder. Maintenance is recom-
mended every 500 working hours. Inspect the wear
pads for proper installation and for wear. The mini-
mum wear for the wear pads is shown in Figure 21.
Extend the beams to the 12 m (40 ft). Remove dirt
and sand from the sliding tracks and lubricate with
grease just enough to form a film. Use a brush at-
tached to a long stick to reach the tracks at the inside
of the main frame.
A. MINIMUM THICKNESS 18 mm (0.709 in.)
Figure 21. Wear Pad
Maintenance
Sideshift Wear Pads maintain a play of 4 to 6 mm
(0.157 to 0.236 in.) between the spreader frame and
the vertical wear pads at the lower rotator frame.
Add shims behind the vertical wear pads when play
has exceeded 6 mm (0.236 in.).
Ball Joints at each rod end of the cylinders and
hangers require lubrication every 500 hours or 3
months, at one of the two grease nipples.
Stop Cylinders (optional) require lubrication every
1000 hours or 6 months, at the grease nipple. Also
check for proper mounting.
ADDITIONAL SPREADER MAINTENANCE
1. Inspect main spreader component parts for dam-
age, cracks, and distortion.
2. Inspect signal/control systems for correct opera-
tion.
3. Check hydraulic pressures periodically.
4. Check all hydraulic cylinders for leaks and re-
seal.
5. Inspect all hydraulic hoses for damage and leak-
age. Replace any damaged or leaking hoses.
31
Maintenance Schedule 5000 SRM 777

Maintenance Schedule

Figure 22. Container Attachment Maintenance Points

32
5000 SRM 777 Maintenance Schedule

Table 1. Maintenance Schedule

Item No. Item Interval Quantity Procedure

1 End Beams and Twist Locks 250 hr/1 mo 8 grease points. Lube with
1 grease nipple in multipurpose
each end box. grease with 2-4%
1 grease nipple in molybdenum
each sleeve. disulfide additive.

2 Slewing Ring Bearing and Gear 250 hr/1 mo 6 grease points. Lube with
4 grease nipples multipurpose
(A) mounted at grease with 2-4%
one central point molybdenum
for greasing the disulfide additive.
bearing.
2 holes (B) in
the stop block for
lubricating the
gear ring.

3 Wear Pads for Main Beams and 500 hr/3 mo 24 grease points. Lube with
Extending Beams 6 tracks on each multipurpose
extending beam. grease with 2-4%
6 tracks on the molybdenum
inside of each disulfide additive.
main beam.

See Figure 22 for Item Nos.

33
Maintenance Schedule 5000 SRM 777

Table 1. Maintenance Schedule (Continued)

Item No. Item Interval Quantity Procedure

4 Sideshift Slider Pads 500 hr/3 mo 4 grease points. Lube with
2 tracks on multipurpose
each side of the grease with 2-4%
spreader. molybdenum
disulfide additive.

5 Joint Balls 500 hr/3 mo 6 grease points Lube with

multipurpose
NOTE: There are grease with 2-4%
two grease nip- molybdenum
ples available. disulfide additive.
Only one grease
nipple is neces-
sary to grease

6 Stop Cylinders 1000 hr/6 mo 2 grease points. Lube with

multipurpose
NOTE: One grease grease with 2-4%
nipple on each molybdenum
stop cylinder. disulfide additive.

7 Extension Cylinder Support Wear 1000 hr/6 mo 4 grease points. Lube with
Pads and Tracks multipurpose
NOTE: Two tracks grease with 2-4%
in each extension molybdenum
beam. disulfide additive.

See Figure 22 for Item Nos.

34
5000 SRM 777 Maintenance Schedule

Table 1. Maintenance Schedule (Continued)

Item No. Item Interval Quantity Procedure

8 Slewing Gearbox 2000 hr/1 yr 2 plug points. Fill with gear oil.
Plug (A) in elbow SAE 90 EP
NOTE: at top of gearbox
Change at (= filler and level
first 50 plug). Plug (B)
hours on new in the bottom of
unit. Check the gearbox (=
at 250 hr/1 drain plug).
mo

9 Leg Folding Group

See Figure 22 for Item Nos.

35
Torque Specifications 5000 SRM 777

Table 1. Maintenance Schedule (Continued)

Item No. Item Interval Quantity Procedure

10 Leg Folding Group Leg

See Figure 22 for Item Nos.

Torque Specifications
Twist Lock Cylinder Assembly Screws Sideshift Cylinder Piston Securing Nut
38 N•m (28 lbf ft) 800 N•m (590 lbf ft)

Stop Cylinder Assembly Screws Sideshift Cylinder Gland Nut

38 N•m (28 lbf ft) 800 N•m (590 lbf ft)

Stop Cylinder Piston Securing Nut Pendular Twist Lock Crank Screws
60 N•m (44 lbf ft) 25 N•m (18.4 lbf ft)

Extension Cylinder Piston Securing Nut Standard Hardware See the section Metric and
450 N•m (332 lbf ft) Inch (SAE) Fasteners 8000 SRM 231.

Extension Cylinder Gland Screws

60 N•m (44 lbf ft)

36
5000 SRM 777
PROBLEM
No spreader functions or no
spreader functions in one di-
rection.
Low spreader response time.
Both extension beams will
not extend.
One extension beam will not
extend.
Both extension beams will
not retract.
Troubleshooting
POSSIBLE CAUSE
Check truck hydraulic supply valve
for correct operation.
Low main hydraulic pressure at the
spreader main relief valve.
Dirt in the relief valve cartridge.
No electrical power at the solenoids
of both the truck and spreader.
Low hydraulic pressure at the
spreader attachment main relief
valve.
Low hydraulic pressure at the
spreader attachment main relief
valve.
No electrical power at the solenoids
of both the truck and spreader.
No electrical power at the solenoid
mounted on the rear of the extension
cylinder.
Shock relief pressure is too low.
Low hydraulic pressure at the
spreader attachment main relief
valve.
No electrical power at the solenoid
valves on both truck and spreader.
Troubleshooting
PROCEDURE OR ACTION
Repair the supply valve.
Adjust the pressure at the main relief
valve to 140 bar.
Clean or replace the relief valve.
Check for proper voltage at the
solenoids. If voltage is present,
replace the solenoid. If voltage is
not present check the appropriate
switch.
Adjust the pressure at the main relief
valve to 140 bar.
Adjust the pressure at the main relief
valve to 140 bar.
Check for proper voltage at the sole-
noid. If voltage is present, replace
the solenoid. If voltage is not present
check the appropriate switch.
Check for proper voltage at the
solenoids. If voltage is present,
replace the solenoid. If voltage is
not present, check the appropriate
switch.
Set relief valve pressure to 80 bar.
Adjust the pressure at the main relief
valve to 140 bar.
Check for proper voltage at the
solenoids. If voltage is present,
replace the solenoid. If voltage is
not present, check the appropriate
switch.
37
Troubleshooting 5000 SRM 777

PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION

One extension beams will No electrical power at the solenoid Check for proper voltage at the sole-
not retract. valve mounted on the rear of the noid. If voltage is present, replace
extension cylinder. the solenoid. If voltage is not present,
check the appropriate switch.

All twist locks will not oper- Low hydraulic pressure at the Adjust the pressure at the main relief
ate. spreader attachment main relief valve to 140 bar.
valve.

No electrical power at the solenoid Check for proper voltage at the sole-
valves on both truck and spreader noid. If voltage is present, replace
supply valves. the solenoid. If voltage is not present,
check the appropriate switch.

Twist locks of one end beam No electrical power at the twist lock Faulty solenoid.
will not operate. solenoid.

Check the wiring harness at the so- Replace the solenoid.

lenoid or replace faulty solenoid.

Mechanical obstacle stopping move- Remove the obstacle.

ment of the twist lock tie rod.

Both rotator motors will not Low hydraulic pressure at the Adjust the pressure at the main relief
function. spreader attachment main relief valve to 140 bar.
valve.

No electrical power at the solenoid Check for proper voltage at the

valves on both truck and spreader. solenoids. If voltage is present,
replace the solenoid. If voltage is
not present, check the appropriate
switch.

One rotator motor will not No power at the solenoid on the aux- Check for proper voltage at the sole-
operate. iliary block. noid. If voltage is present, replace
the solenoid. If voltage is not present,
check the appropriate switch.

Rotator does not function. Check pressure on the pressure line Adjust the pressure at the main relief
relief valve. valve to 80 bar.

38
5000 SRM 777
PROBLEM
Sideshift cylinder will not
function.
One or all indicator lights do
not function.
Hydraulic functions other
than the function selected
are operating at the same
time.
Precise positioning of the at-
tachment is difficult.
Diagrams, Schematics, or Arrangements
POSSIBLE CAUSE
Low hydraulic pressure at the
spreader attachment main relief
valve.
No electrical power at the solenoid
valves on both truck and spreader.
No power at the solenoid on the aux-
iliary block.
Blown fuse or bulb.
The proximity sensor switch is not
functioning.
The electric circuit of a particular
function is open.
Electric solenoid or relief solenoid of
a function other than the selected
function is stuck in an open position.
Air has entered one or more attach-
ment cylinders.
PROCEDURE OR ACTION
Replace the main relief valve.
Check for proper voltage at the
solenoids. If voltage is present,
replace the solenoid. If voltage is
not present, check the appropriate
switch.
Check for proper voltage at the sole-
noid. If voltage is present, replace
the solenoid. If voltage is not present,
check the appropriate switch.
Replace blown fuse or bulb.
No input signal to the sensor switch.
When the sensor switch is activated
an LED in the sensor is illuminated.
Replace faulty sensor switch. Ad-
just the distance between the sensor
switch and the sensor bracket to 2 to
5 mm (0.08 to 0.20 in.).
Check for blown fuses or loose con-
nectors. Check the proper function-
ing of the Printed Circuit Board.
Clean or replace the solenoid.
Cycle the affected cylinders a few
times to clear the air from the sys-
tem.
39
Diagrams, Schematics, or Arrangements 5000 SRM 777

NOTE: For the correct schematics and wiring dia-

gram for the ELME spreaders, see Table 2.

Table 2. ELME Schematic Overview

ELME Hydraulic Electrical Electrical

Model Schematic Schematic Wiring Diagram
857-8545 771422 777111 777112
857-8633 779465 777111 777112
857-8666 779465 777111 777112
857-8678 779465 781717 781718

40
 NOTES

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41
Diagrams, Schematics, or Arrangements 5000 SRM 777

42
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 23. ELME Hydraulic Schematic 771422

43
Diagrams, Schematics, or Arrangements 5000 SRM 777

44
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 24. ELME Hydraulic Schematic 779465

45
Diagrams, Schematics, or Arrangements 5000 SRM 777

46
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 25. ELME Electrical Schematic 777111 (Sheet 1 of 2)

47
Diagrams, Schematics, or Arrangements 5000 SRM 777

48
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 25. ELME Electrical Schematic 777111 (Sheet 2 of 2)

49
Diagrams, Schematics, or Arrangements 5000 SRM 777

50
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 26. ELME Electrical Schematic 781717 (Sheet 1 of 2)

51
Diagrams, Schematics, or Arrangements 5000 SRM 777

52
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 26. ELME Electrical Schematic 781717 (Sheet 2 of 2)

53
Diagrams, Schematics, or Arrangements 5000 SRM 777

54
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 27. ELME Wiring Diagram 777112 (Sheet 1 of 2)

55
Diagrams, Schematics, or Arrangements 5000 SRM 777

56
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 27. ELME Wiring Diagram 777112 (Sheet 2 of 2)

57
Diagrams, Schematics, or Arrangements 5000 SRM 777

58
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 28. ELME Wiring Diagram 781718 (Sheet 1 of 3)

59
Diagrams, Schematics, or Arrangements 5000 SRM 777

60
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 28. ELME Wiring Diagram 781718 (Sheet 2 of 3)

61
Diagrams, Schematics, or Arrangements 5000 SRM 777

62
5000 SRM 777 Diagrams, Schematics, or Arrangements

Figure 28. ELME Wiring Diagram 781718 (Sheet 3 of 3)

63
 NOTES

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64
 TECHNICAL PUBLICATIONS

5000 SRM 777 8/11 (7/11)(7/07)(5/06)(4/00) Printed in United Kingdom