5000SRM1221 (01 2016) Uk en PDF

EXTENDABLE
CONTAINER
ATTACHMENT (ELME)
580 SERIES
PART NO. 1612615 5000 SRM 1221

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 ex-
ceed 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 flamma-
ble. 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.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
General .....................................................................................................................................................................1
Description ...............................................................................................................................................................2
Attachment Mounting .........................................................................................................................................2
Attachment Functions ....................................................................................................................................2
Extend and Retract .................................................................................................................................... 2
Stop Cylinder ..............................................................................................................................................3
Sideshift ...................................................................................................................................................... 3
Twist Locks ..................................................................................................................................................... 4
Carriage ...........................................................................................................................................................5
Seated Pin ....................................................................................................................................................... 5
Indicator Lights .............................................................................................................................................. 6
Twist Module .................................................................................................................................................. 7
Operation ................................................................................................................................................................. 8
ELME Hydraulic System ....................................................................................................................................8
ELME Main Direction Control Valve .......................................................................................................... 10
Sideshift Circuit ............................................................................................................................................10
Sideshift ........................................................................................................................................................ 10
Extension Cylinder Control Valve ............................................................................................................... 10
Extend and Retract Circuit .......................................................................................................................... 10
Twist Lock Circuit ........................................................................................................................................ 14
Container Locking Model 582 ..................................................................................................................14
Container Locking Models 586, 588, and 589 .........................................................................................15
Stop Cylinder Circuit ....................................................................................................................................20
Optional Powered Pile Slope ............................................................................................................................ 20
ELME 580 Series Valves .................................................................................................................................. 22
Sequence Valve ............................................................................................................................................. 22
Pilot Check Valve ..........................................................................................................................................23
Electrical System .............................................................................................................................................. 23
Printed Circuit Board ...................................................................................................................................27
PCB Sockets .................................................................................................................................................. 28
Cable Number ............................................................................................................................................... 29
Wire Number ................................................................................................................................................ 29
Wire Color Code ............................................................................................................................................ 29
Cable Connectors .......................................................................................................................................... 30
Sensors and Solenoids .................................................................................................................................. 30
Indicator Lights .................................................................................................................................................31
Automatic Locking ............................................................................................................................................ 32
Lift Interrupt and Override ..............................................................................................................................32
Lift Interrupt ................................................................................................................................................ 32
Overlowering Interrupt and Override ............................................................................................................. 32
Second Container Detection Sensor (Model 582 Only) ................................................................................... 32
Container Attachment .......................................................................................................................................... 33
Remove .............................................................................................................................................................. 33
Install .................................................................................................................................................................33
Carriage and Attachment Removal ................................................................................................................. 33
Spreader ............................................................................................................................................................ 34
©2016 HYSTER COMPANY i

Table of Contents
TABLE OF CONTENTS (Continued)

Wear Pads ..............................................................................................................................................................35
Wear Pads Mounted on Main Frame ...............................................................................................................35
Remove .......................................................................................................................................................... 35
Replace .......................................................................................................................................................... 35
Wear Pads Mounted on Extension Beam ........................................................................................................ 35
Remove .......................................................................................................................................................... 35
Replace .......................................................................................................................................................... 35
Floating End Beam Wear Pads ........................................................................................................................ 36
Upper Wear Pads ..........................................................................................................................................36
Lower Wear Pads ..........................................................................................................................................36
Main Frame Wear Pads at Large (Right-Hand) Extension Beam ................................................................. 36
Main Frame Wear Pads at Small (Left-Hand) Extension Beam ....................................................................37
Guide for Extension Cylinder ...........................................................................................................................38
Large Extension Beam Internal Wear Pads ....................................................................................................38
Spreader Frame ................................................................................................................................................ 38
Upper Wear Pads ..........................................................................................................................................38
Lower Wear Pads ..........................................................................................................................................38
Powered Pile Slope Carriage ............................................................................................................................ 38
Upper Wear Pads ..........................................................................................................................................38
Lower Wear Pads ..........................................................................................................................................38
Extension Cylinder ................................................................................................................................................39
Remove .............................................................................................................................................................. 39
Disassemble .......................................................................................................................................................40
Clean ..................................................................................................................................................................41
Inspect ............................................................................................................................................................... 41
Assemble ............................................................................................................................................................41
Install .................................................................................................................................................................41
Extension Cylinder ........................................................................................................................................... 42
Disassemble .................................................................................................................................................. 42
Clean and Inspect ......................................................................................................................................... 42
Assemble ....................................................................................................................................................... 42
Guide for Extension Cylinder ...........................................................................................................................43
Remove .......................................................................................................................................................... 43
Install ............................................................................................................................................................ 43
Sideshift Cylinder, Powered Pile Slope Cylinder, Retract Cylinder, Twist Lock Cylinder,
and Side Clamp Cylinder ..................................................................................................................................43
Disassemble .................................................................................................................................................. 43
Assemble ....................................................................................................................................................... 44
Cable Chain ........................................................................................................................................................... 44
Remove .............................................................................................................................................................. 44
Install .................................................................................................................................................................44
Extension Beam .....................................................................................................................................................45
Remove .............................................................................................................................................................. 45
Install .................................................................................................................................................................45
Remove .............................................................................................................................................................. 45
Inspect ............................................................................................................................................................... 47
Assemble ............................................................................................................................................................47
Floating End Beams Repair ..................................................................................................................................48
Remove .............................................................................................................................................................. 48
Install .................................................................................................................................................................48
ii
Table of Contents

Hose, Replace .................................................................................................................................................... 49
Sideshift Cylinder ..................................................................................................................................................50
Remove .............................................................................................................................................................. 50
Disassemble .......................................................................................................................................................50
Clean ..................................................................................................................................................................51
Inspect ............................................................................................................................................................... 51
Assemble ............................................................................................................................................................51
Install .................................................................................................................................................................51
Stop Cylinder (Optional) ....................................................................................................................................... 52
Remove .............................................................................................................................................................. 52
Disassemble .......................................................................................................................................................52
Clean and Inspect ............................................................................................................................................. 53
Assemble ............................................................................................................................................................53
Install .................................................................................................................................................................53
Twist Lock Cylinder .............................................................................................................................................. 54
Remove .............................................................................................................................................................. 54
Disassemble .......................................................................................................................................................56
Assemble ............................................................................................................................................................56
Install .................................................................................................................................................................56
Twist Locks ............................................................................................................................................................56
Disassemble .......................................................................................................................................................56
Clean ..................................................................................................................................................................58
Inspect ............................................................................................................................................................... 58
Assemble ............................................................................................................................................................58
Twist Lock Repair for Model 582 ..........................................................................................................................60
Remove .............................................................................................................................................................. 60
Upper Twist Lock ......................................................................................................................................... 60
Lower Twist Lock ..........................................................................................................................................60
Disassemble .......................................................................................................................................................60
Assemble ............................................................................................................................................................61
Install .................................................................................................................................................................62
Twist Lock Repair for Models 586, 588, and 589 .................................................................................................62
Disassemble .......................................................................................................................................................62
Assemble ............................................................................................................................................................63
Adjustments ...........................................................................................................................................................64
Twist Lock Angle ...............................................................................................................................................64
LOCKED/NOT LOCKED Proximity Switches ................................................................................................ 66
Seated Signal .....................................................................................................................................................66
Hydraulic Pressures ..........................................................................................................................................67
General ..........................................................................................................................................................67
Attachment Main Relief Pressure ............................................................................................................... 67
Extension Relief Pressure ............................................................................................................................ 68
Slew Relief Pressure .....................................................................................................................................68
Sideshift Relief Pressure .............................................................................................................................. 68
Twist Lock Angle Adjustment .......................................................................................................................... 68
Model 586, 588, and 589 ...............................................................................................................................68
LOCKED/NOT LOCKED Sensors Adjustment ...............................................................................................69
iii
Table of Contents

Model 582 ...................................................................................................................................................... 69
Model 586, 588, and 589 ...............................................................................................................................69
Side Clamp Open/Closed Sensor Adjustment (Model 584) .............................................................................69
Hook in Sensor Adjustment (Model 584) ......................................................................................................... 69
Seated Sensor Adjustment ............................................................................................................................... 70
Model 582 ...................................................................................................................................................... 70
Model 586, 588, and 589 ...............................................................................................................................70
Overlowering Protection Sensor Adjustment (All 580 Models) ......................................................................71
Electrical Component Checks ...............................................................................................................................71
Printed Circuit Boards (PCB) ...........................................................................................................................71
Solenoids ............................................................................................................................................................71
Proximity Switches ........................................................................................................................................... 72
Hook Repair for Model 584 and 585 .....................................................................................................................72
Remove .............................................................................................................................................................. 72
Inspect ............................................................................................................................................................... 72
Install .................................................................................................................................................................73
Side Clamp Replacement for Model 584 .............................................................................................................. 73
Remove .............................................................................................................................................................. 73
Install .................................................................................................................................................................73
Torque Specifications ............................................................................................................................................ 75
Troubleshooting .....................................................................................................................................................76
This section is for the following models:
iv
5000 SRM 1221 Series Code / Model Designation Reference Table
Series Code / Model Designation Reference Table

This table consist of the following Series Codes
used in this manual.
Series European Model Americas Model

Code
B214 H16.00-22.00XM-12EC H400-500HD/HDS-EC
C214 H16XM-12EC, H18XM-12EC, H22XM-12EC H400HD-EC, H450HD-EC,
H500HD-EC
D214 H18XM-12EC, H22XM-12EC, H23XM-12EC H450HD-EC, H500HD-EC
F019 H13.00-14.00XM, H16.00XM-6, H10.00-12.00XM-12EC H300-330HD, H360HD, H360HD-
EC
G019 H13.00-14.00XM, H16.00XM-6, H10.00-12.00XM-12EC H300-330HD, H360HD, H360HD-
EC
H019 H13.0-16.0XM-6, H10.0-12.0XM-12EC H300-360HD2, H360HD2-EC
J019 H13-16XM-6, H10-12XM-12EC H300-360HD2, H360HD2-EC
K019 H13-16XM-6 H210-250-48HD2, H300-360HD2
General
This manual has the description and repair proce- Parts information and diagrams are accessible
dures for the ELME 580 series extendable con- through Hyster Hypass Online. Contact your lo-
tainer handling attachments. Each attachment is cal dealer for a copy of this information. Provide the
built according to a combined model and specifica- dealer with the model specification and serial num-
tion number (e.g., 588-5382), which is the key to ber of the attachment.
different spreader functions and to parts and serv-
ice information. The ELME attachment nameplate
identifies the model, specification number, and se-
rial number. The ELME attachment nameplate is
located at the rear right-hand side of the central at-
tachment frame.
1
Description 5000 SRM 1221
Description
ATTACHMENT MOUNTING ment with containers, which is determined by the
layout of the floating end beam assemblies. Com-
The ELME 580 series of attachments are designed mon to all 580 series spreaders is the carriage, cen-
to handle empty containers. The different model tral frame and the extension beams. See Figure 1.
numbers relate to the different types of engage-
1. FLOATING END BEAM 6. CARRIAGE

2. EXTENSION BEAM 7. INDICATOR LIGHTS
3. EXTENSION CYLINDER 8. ELECTRIC BOX
4. SIDESHIFT CYLINDER 9. CENTRAL SPREADER FRAME
5. MAST ROLLER
Figure 1. Empty Container Attachment
Attachment Functions 12.2 m (40 ft) position of the attachment. The re-
tracted length determines the 6.1 m (20 ft) position
Extend and Retract of the attachment.
The attachment can be retracted or extended to al- Due to differences in friction and hydraulic resist-
low lifting 6.1 or 12.2 m (20 or 40 ft) containers. Ex- ance, the two extension beams move at different
tension and retraction is achieved by activating the speeds. The control switch for extension or retrac-
extension cylinders which connect between the cen- tion must be actuated until both cylinders have
ter frame and the extension beams. The shell of reached their final positions.
each extension cylinder is attached to the attach-
ment frame. The rod end of each extension cylinder
is attached to the extension beam. The extended
length of the extension cylinders determines the
2
5000 SRM 1221 Description
Stop Cylinder
Attachments with optional stop kits can also lift

9.1 m (30 ft) containers. The 9.1 m (30 ft) position is
obtained by energizing the 9.1 m (30 ft) stop while
extending or retracting the beams. When the
9.1 m (30 ft) position has been reached, the rod of
the stop cylinder is pushed into a hole in the exten-
sion beam, blocking any further movement of the
extension beam.
The stop cylinder is held in position by continuous

pressure. Once the stop cylinder is extended (locked
into position), it must be retracted (unlocked), be-
fore the extension beam can be moved to a different
position.
Sideshift
The sideshift cylinder has a stroke of 600 mm (2 ft)

and moves the spreader horizontally over the wear
plates. Hydraulic oil is supplied by the valve as-
sembly for sideshift, which is mounted vertically at
the front of the central frame. The right-hand side-
shift signal from the operator cab activates solenoid
Y14, providing oil pressure to the rod side of the
sideshift cylinder. The left-hand signal activates
solenoid Y13, providing oil pressure to the piston
side of the cylinder.
A. TOP SIDE
Maximum spreader pressure of 140 bar (2031 psi) B. BOTTOM SIDE
is applied to the rod side of the sideshift cylinder.
1. FROM PUMP
The pressure at the piston side is limited by an 2. TO TANK
80 bar (1160 psi) relief valve, which is located at 3. ADAPTER FOR SIDESHIFT
the right hand side of the sideshift valve assembly. 4. TO SIDESHIFT ROD SIDE
The different maximum pressures compensate for 5. TO SIDESHIFT PISTON SIDE
the difference in surface area of the piston side and 6. ADAPTER FOR SYSTEM PRESSURE
7. RELIEF VALVE
the rod side of the cylinder. See Figure 2.
Figure 2. Sideshift Valve Assembly
3
Twist Locks 589 have a provision that also allows han-

dling containers with inset top pockets. For
• Model 582 uses two sets of horizontal twist model 586 this provision is a bolted block
locks. The twist locks engage with the side that has to be removed when handling
pockets of two containers that are stacked 2.6 m (8.6 ft) containers. For model 589 this
one on top of the other. provision is an extend/retract function of the
twist locks.
• Models 584 and 585 use two front hooks that
engage with the top side pockets. Model 584
Models 582 and 584 are designed to lift two empty
has two additional arms that engage at the
containers and can also handle one single con-
sides, thus securing a second stacked con-
tainer. See Figure 3.
tainer.
• Models 586, 588 and 589 have vertical twist
locks, engaging with the top pockets of
2.4 m (8 ft) wide containers. Models 586 and
A. MODEL 582 D. MODEL 586/588

B. MODEL 584 E. MODEL 589
C. MODEL 585
Figure 3. Container Engagement
4
Carriage The position of the seated pin is transferred to a re-

turn rod with an indicator plate, which triggers the
The carriage is part of the spreader assembly and proximity switch to send a signal to the electrical
is guided by rollers in the mast channels of the system. See Figure 5.
truck. See Figure 4. The carriage carries the cen-
tral spreader frame. The powered pile slope version A cam offers additional protection against uninten-
allows the spreader side of the carriage to be hy- tional unlocking (rotation) of the twist locks. The
draulically side tilted 6 degrees. The standard ver- cam is part of the seated pin. If the seated pin has
sion of the carriage allows the central frame to be not been pushed in far enough, the cam will me-
lifted from the carriage at one side, resulting in a chanically block the rotation of the twist lock.
tilt angle of 1.5 degrees. Additional pile slope capa-
bilities are obtained by the 220 mm (9 in.) vertical
movement of the floating end beams. The floating
end beams and the side tilt of the spreader allow
the driver to raise and lower the spreader after the
twist locks or hooks are engaged with a container
at one side, in order to accurately align the other
end before it is inserted.
The central frame of the spreader is secured to the

carriage by retainer brackets in the forward direc-
tion and by the side shift cylinder in the sideward
direction. See Figure 1 and Figure 4. The sideshift
cylinder can move the central frame 600 mm (2 ft)
sideways. Wear pads are mounted at the contact
areas between the carriage and central frame. Ex-
tension cylinders put the extension beams in the
20-foot or 40-foot position. When certain provisions
have been made, optional stop cylinders allow ex-
tending to 30 feet or 35 feet.
1. MAST ROLLER
Seated Pin 2. SIDESHIFT CYLINDER
3. RETAINER BRACKET
4. WEAR PAD
The function of the seated pin is to determine if a
twist lock has engaged the corner of a container Figure 4. Carriage
pocket deep enough to allow the twist lock to turn
for locking or unlocking. The seated pin must be
able to move in and out of the pocket smoothly for
correct operation. If the seated pin sticks in the
seated position, the twist lock will rotate under
faulty conditions.
5
Legend for Figure 5
1. RETURN ROD
2. PROXIMITY SWITCH
3. SEATED PIN RETURN SPRING
4. SEATED PIN
5. NUT
6. PLATE PUSH SPRING
7. INDICATOR PLATE
8. CAM
Indicator Lights
The indicator lights inform the operator about the

position of the attachment on the container and the
position of the twist lock. Without the indicator
lights, the operator would not know the exact posi-
tions of the attachment and the twist lock because
their view is obstructed.
The indicator lights are illuminated as a result of

PCB logic and signals from the sensors. Illumina-
tion of the indicator lights is identical on the at-
tachment and on the twist module in the cab. See
Figure 6 and Table 1 for the location and descrip-
tion of the individual indicator lights.
Figure 5. Seated Pin Assembly

1. AMBER INDICATOR LIGHT, LEFT-HAND
2. GREEN INDICATOR LIGHT
3. RED INDICATOR LIGHT
4. AMBER INDICATOR LIGHT, RIGHT-HAND
Figure 6. Indicator Lights
6
Table 1. Indicator Light Descriptions
Indicator Light Indicator Light ON Indicator Light OFF Indicator Light FLASHING
Color/Location
Amber, Left-hand Both left-hand seated One or both left-hand One of the left-hand seated
pins are seated. seated pins are NOT sensors is faulty or incorrectly
seated. adjusted.
Green All twist locks are in the The twist locks on one or One of the locked sensors is
locked position. both sides are NOT in the faulty or incorrectly adjusted.
locked position.
Red All twist locks are in the The twist locks on one or One of the unlocked sensors is
unlocked position. both sides are NOT in the faulty or incorrectly adjusted.
unlocked position.
Amber, Right-hand Both right-hand seated One or both right-hand One of the right-hand seated
pins are seated. seated pins are NOT sensors is faulty or incorrectly
seated. adjusted.
NOTE: If one or more indicator lights are flashing, immediately repair the attachment.
Twist Module • Disabling lift interrupt (mast lift/lower func-

tion can be operated despite twist locks being
The twist module is connected with the electrical between the locked and unlocked position)
system of the attachment, and has features that as- • Disabling overlowering interrupt (mast lower
sist with the operation of the attachment. Refer to function can be operated despite chains and
the Operating Manual. See Figure 7. header hoses being slack)
For a short period of time, the blue LED on the

twist module will be ON while all or one of the
twist locks are between the locked and unlocked po-
sition. A tone will sound while the blue LED is ON.
The blue LED can also be ON continuously during

the following situations:
• The twist locks are stuck between the locked
and unlocked position
• The control system has activated the lift in-
terrupt or overlowering interrupt functions
• The override key is turned to the ON posi-
tion and the override button is being pushed
The following functions can be disabled when turn-

ing the override key to the ON position and push-
ing the override button:
1. LEFT AMBER LED 4. RIGHT AMBER LED
• Disabling automatic locking (twist lock un- 2. GREEN LED 5. BLUE LED
lock can be operated to return the twist locks 3. RED LED
to the unlock position)
Figure 7. Twist Module
7
Operation 5000 SRM 1221
Operation
ELME HYDRAULIC SYSTEM The attachment is operated by hydraulic pressure
from the truck and by electrically-energized valves.
The attachment is operated by lift truck hydraulic Hydraulic supply is provided by a fixed pressure
pressure, which is directed to the attachment func- line and a fixed tank return line. Depending on the
tions by solenoid valves. selected function and its selected direction, solenoid
valves allow hydraulic oil pressure to pass accord-
Hydraulic oil is supplied to the attachment by a ingly.
fixed pressure line and returned to the hydraulic
tank by a fixed return line. Hydraulic pressure The required electric current and the signals from
from the main direction control valve is connected the control switches in the operator cab are provi-
to the sideshift cylinders, and direction control ded by an electric cable that follows the same rout-
valves on the extension cylinders. The direction ing over the mast as the header hoses. The connec-
control valves on the extension cylinders will divert tion between truck and spreader is at the right-
and supply the hydraulic oil flow to the extension hand rear side of the spreader by means of a 24-
cylinders, twist lock cylinders, and stop cylinders. pole connector.
Solenoid valves connect the lift truck hydraulic oil A general hydraulic schematic for the ELME at-
supply pressure to the selected function in the di- tachment is shown in Figure 8.
rection selected. The required electric current for
the solenoids is controlled by a printed circuit board Functions that are susceptible to impacts are pro-
(PCB). The PCB receives and verifies signals from tected by relief valves. Under extreme conditions,
the control switches in the operator cab and signals impacts may lead to air forming in the hydraulic
from various sensors. The PCB prevents functions oil, causing improper functioning. By operating the
from being energized under incorrect conditions or affected functions several times, the air will gradu-
when conflicting signals are received. ally be removed from the hydraulic system.
A load sense system in the lift truck hydraulic sys- For clarity, only the portion of the extension cylin-
tem makes sure the function speed cannot be influ- der that moves the right-hand extension beam is
enced by factors such as engine speed variance. For shown. The lift truck supply (P) and return (T)
further information on the load sense system and lines that connect to the top right-hand corner of
the hydraulic auxiliary system. the ELME main directional control valve are not
shown.
8
5000 SRM 1221 Operation
1. LEFT-HAND EXTENSION CYLINDER CONTROL VALVE

2. RIGHT-HAND EXTENSION CYLINDER CONTROL VALVE
3. LEFT HAND/RIGHT HAND SIDE TILT CONTROL VALVE
Figure 8. ELME 580 Series Hydraulic Schematic
9
ELME Main Direction Control Valve Maximum spreader pressure of 140 bar (2031 psi)
is applied to the rod side of the sideshift cylinder.
The ELME main direction control valve serves as a The pressure at the piston side is limited by an
manifold for the hydraulic oil supply from the lift 80 bar (1160 psi) relief valve, which is located at
truck. The hydraulic pressure supplied by the lift the right-hand side of the sideshift valve assembly.
truck is relieved by a 140 bar (2,031 psi) relief The different maximum pressures compensate for
valve. the difference in surface area of the piston side and
the rod side of the cylinder.
Sideshift Circuit
Extension Cylinder Control Valve
The sideshift function is part of the ELME 580 ser-
ies attachment. The extension cylinder control valve is an integra-
ted part of the extension cylinder. The extension
The sideshift function is activated by energizing cylinder control valve incorporates the functions for
solenoid Y13 or Y14. Energizing Y13 causes the extension, twist locks, and optional stop cylinders.
sideshift cylinder to extend and move the attach- Hydraulic oil supply is directly connected to the P
ment to the right-hand side of the lift truck. Ener- and T ports of the ELME main direction control
gizing Y14 causes the retraction of the cylinder, valve.
which moves the attachment to the left-hand side
of the lift truck. Extend and Retract Circuit
Sideshift The attachments are designed to lift either 6.1- or

12.2 m (20- or 40 ft) containers. When delivered
with an optional stop kit, provisions have been
The sideshift cylinder has a stroke of 600 mm (2 ft) made to also lift 9.1- or 10.7 m (30- or 35 ft) con-
and moves the spreader horizontally over the wear tainers. These 9.1- or 10.7 m (30- or 35 ft) positions
plates. Hydraulic oil is supplied by the valve as- are obtained by first retracting the stop cylinder.
sembly for sideshift, which is mounted vertically at This allows the extension or retraction of the exten-
the front of the central frame. The right-hand side- sion beams. After the extension beams have started
shift signal from the operator cab activates solenoid moving, the stop cylinder has to be operated, which
Y14, providing oil pressure to the rod side of the pushes the rod of the stop cylinder against the ex-
sideshift cylinder. The left-hand signal activates tension beam. When the desired position has been
solenoid Y13, providing oil pressure to the piston reached, the rod of the stop cylinder is pushed into
side of the cylinder. See Figure 9. a hole in the extension beam, blocking any further
movement. The stop cylinder is held in position by
continuous pressure. The 6.1- or 12.2 m (20- or
40 ft) positions are determined by the end positions
of the extension cylinders.
10
The extension signal from the operator cab acti-

vates solenoid Y5 and pressures the left-hand ex-
tension cylinder, and solenoid Y6 pressures the
right-hand extension cylinder. The retraction signal
activates solenoid Y7 and Y8, pressurizing the rod
side of the cylinders and connecting the piston side
of the cylinders with the tank. The solenoid valves
are located at the rear end sides of the central
spreader frame. The location of the different valve
connections are indicated in Figure 10. Due to dif-
ferences in friction or hydraulic flow, it is possible
that one extension beam reaches its final position
earlier than the other. The relief valve fitted be-
tween piston end and rod end protects against peak
pressures when the desired extension position has
been reached, or when an object is being hit. The
shell of each extension cylinder is fastened to the
attachment frame. The rod end of each extension
cylinder is fastened to the extension beam.
A. TOP SIDE B. BOTTOM SIDE

1. FROM PUMP
2. TO TANK
3. ADAPTOR FOR SIDESHIFT
4. TO SIDESHIFT ROD SIDE
5. TO SIDESHIFT PISTON SIDE
6. RELIEF VALVE
7. ADAPTOR FOR SYSTEM PRESSURE
Figure 9. Sideshift Valve Assembly
11
Figure 10. Right-Hand and Left-Hand Extension/Twist Lock Valve
12
Legend for Figure 10
1. PRESSURE LINE TO LEFT-HAND VALVE 10. GAUGE ADAPTOR

2. TANK LINE FROM LEFT-HAND VALVE 11. TANK LINE TO RIGHT-HAND VALVE
3. TANK LINE TO SIDESHIFT VALVE 12. PRESSURE LINE FROM RIGHT-HAND VALVE
4. PRESSURE LINE FROM SIDESHIFT VALVE 13. GAUGE ADAPTOR
5. RELIEF VALVE 14. TO PISTON SIDE TWIST LOCK CYLINDER
6. TO ROD SIDE TWIST LOCK CYLINDER 15. TO ROD SIDE TWIST LOCK
7. TO PISTON SIDE TWIST LOCK CYLINDER 16. TO PISTON SIDE EXTENSION CYLINDER
8. TO ROD SIDE EXTENSION CYLINDER 17. TO ROD SIDE EXTENSION CYLINDER
9. TO PISTON SIDE EXTENSION CYLINDER
13
Twist Lock Circuit Container Locking Model 582
The lock signal from the electrical system simulta- Model 582 is designed to handle two empty contain-
neously activates solenoid valve Y1 for the left- ers using two pair of horizontal twist locks, which
hand twist lock cylinder and solenoid valve Y2 for are entered in the side pockets of the lower and up-
the right-hand twist lock cylinder. per container. When the upper twist lock has en-
tered the corner pocket, the upper container pushes
The unlock signal from the electrical system simul- the upper twist lock assembly into the floating
taneously activates solenoid valve Y3 for the left- head against the pressure of a spring. This allows
hand twist lock cylinder and solenoid valve Y4 for entry of the lower twist lock in the pocket of the
the right-hand twist lock cylinder. lower container. When the twist locks are correctly
positioned, the four seated sensors have detected
Once the electrical system receives a signal to turn the correct distance to the containers and the top
the twist locks, the electrical system will keep container detected sensor has detected presence of
the solenoids energized until the sensors indicate a container on top of the other. Having these sig-
that the desired end position has been reached. nals allows the twist locks to lock after a manual
When the desired end position has been reached, command. The electrical system activates during
the sensors will provide a signal to the electrical 0.5 to 2.0 seconds the solenoid valves for locking,
system to de-energize the solenoids. which pressures the twist lock motors and the re-
traction cylinder assembly. The twist lock motors
Due to the design of this attachment, the right- will turn the twist locks into the locking position.
hand twist lock cylinder is activated by the exten- The retraction cylinder will extend and keep the
sion cylinder control valve that is installed on the upper twist lock assembly in the retracted position.
left-hand side of the spreader. The left-hand twist Before it is possible to unlock, first the seated sen-
lock cylinder is activated by the control valve that sors have to detect the correct distance to the con-
is installed on the right-hand side of the spreader. tainers. A manual command will activate within
0.5 to 2.0 seconds of the solenoid valves unlocking,
The actual lock or unlock movement of the twist which turns the twist locks into the unlocked posi-
lock can be hindered by deformed container pockets tion and retracts the retraction cylinder. The spring
or misalignment of the attachment on the con- will push against the upper twist lock assembly
tainer. As a result, the twist lock cylinder will re- and move it out of the floating head as the spreader
main pressurized due to the intended end position moves away from the top container.
(locked or unlocked) not being reached and there-
fore the signal will not be sent by the sensors to To protect against the possibility of twist locks
switch the solenoids OFF (de-energize). opening unintentionally, horizontal twist locks
have a flat surface that touches the vertical area of
To stop pressurizing a stuck twist lock, turn the the corner casting when the container is being car-
override switch in the twist module to the ON posi- ried. The weight of the container locks the flat sur-
tion, and push the override button. Activate the face of the twist lock against the vertical area of the
twist locks in the opposite direction of the initial corner casting and prevents the twist lock from
lock or unlock movement. The mast lift and lower turning. It, therefore, is important to verify that
functions can now be operated to relieve the stuck the attachment is completely seated before locking
twist lock. When the indicator lights confirm that or unlocking the twist locks. See Figure 11.
the desired locked or unlocked position has been ob-
tained, the override push-button can be released.
Repeat the procedure to position the attachment on

the container until the seated lights are ON again
and then push the button for the desired twist lock
position (locked or unlocked).
14
Container Locking Model 583 2.6 m (8.6 ft) containers. For model 589 this provi-
sion is an extend/retract function of the twist locks.
Model 583 is designed to lift one empty container at When a twist lock is correctly positioned, the seated
a time using one pair of horizontal twist locks, pin has been pushed in, which allows the seated
which are entered in the side pockets of the con- sensor to provide a signal to the electric system.
tainer. Container locking for model 583 is similar to When a signal has been received from both seated
that of model 582, except that model 583 has two sensors, the electric system energizes the twist lock
twist locks instead of four. Model 583 does not have solenoid valve to rotate the twist locks. The twist
the upper two twist lock assemblies, the retraction locks can be locked manually by the operator, or
cylinders, and the top container detected sensor. automatically after a certain time delay. Opening
the twist locks is always a manual operation. See
Container Locking Model 584 Figure 14.
Model 584 is designed to lift two containers by in- To protect against the possibility of the twist locks
serting two hooks through the side holes of the con- opening unintentionally, the seated pins have a
tainer pockets. The side clamps are to prevent the cam which prevents the twist lock crank from turn-
top container from sliding when braking or acceler- ing, if the seated pin is not fully seated.
ating. Sensors are used to indicate the clamped or
unclamped position, but are no substitute for the
drivers responsibility to verify proper engagement
of the hooks and long enough activation of the side
clamps until the clamps press the locating lugs into
the rear end holes of the containers. See Figure 12
for the location of the sensors.
Container Locking Model 585
Model 585 does not have sensors or indicator lights

to register the position of hooks in relation to the
container. On this type of attachment, all monitor-
ing must be done by the operator. Check the condi-
tion of the hooks on a daily basis.
Model 585 is designed to lift one empty container at

a time by inserting two hooks through the front
side holes of the container pockets. See Figure 13.
Container Locking Models 586, 588, and 589
Models 586, 588, and 589 are designed to lift one

empty container at a time using vertical twist
locks, which are entered in the top pockets of the 1. RETRACTION CYLINDER
container. The spreader engages the container by 2. SPRING
putting the end beam guide against the container 3. SENSOR LOCKED/UNLOCKED
and inserting the vertical twist locks into the top 4. SEATED SENSOR
5. TWIST LOCK
pockets by lowering the spreader. Due to the fixed 6. SEQUENCE VALVE
distance between twist lock axis and end beam 7. TWIST LOCK MOTOR
guide, model 588 can only engage with the stand-
ard ISO container. Models 586 and 589 have a pro- Figure 11. End Beam Assembly, Model 582
vision that also allows handling containers with in-
set top pockets. For model 586 this provision is a
bolted block that has to be removed when handling
15
A. UNCLAMPED B. CLAMPED
1. HOOK 4. SENSOR FLAG
2. SIDE CLAMP 5. SENSOR UNCLAMPED POSITION
3. SENSOR CLAMPED POSITION
Figure 12. End Beam Assembly Model 584
16
1. NUT 5. SPRING
2. WASHER 6. END BEAM
3. STUB SHAFT 7. BOLT PLATE
4. HOOK
Figure 13. End Beam Assembly (Model 585)
17
Figure 14. End Beam Assembly (Models 586, 588, and 589)
18
1. SEATED PIN 11. CRANK PIN

2. CAM 12. CRANK
3. RETURN SPRING 13. COLLETS
4. SEATED SENSOR 14. UPPER BEARING SET
5. LOCKED SENSOR 15. LOWER BEARING SET
6. UNLOCKED SENSOR 16. SLEEVE
7. COVER 17. BUSHING
8. SENSOR FLAG 18. KEY
9. TWIST LOCK CYLINDER 19. ROLL PIN
10. INDICATOR FLAG 20. TWIST LOCK
19
Stop Cylinder Circuit pile slope direction. Maximum pressure of

140 bar (2031 psi) is regulated by the relief valve
When the operator selects the function to unlock that is located in the right-hand extension/twist
the stop cylinder, the signal from the operator cab lock valve. When equipped with powered pile slope,
will activate solenoids Y11 and Y12. When the op- the hydraulic functions for powered pile slope and
erator selects the function to lock the stop cylinder, sideshift are combined in one valve block. See Fig-
the signal from the operator cab will activate sole- ure 16.
noids Y9 and Y10. After activation, the solenoid
will remain in the selected position, keeping the de-
sired side of the cylinder pressurized. A check valve
in the hydraulic tank return line will prevent unin-
tentional movement of the cylinder in the event of a
temporary drop in hydraulic system pressure.
OPTIONAL POWERED PILE SLOPE
The powered pile slope carriage is divided in two

sections. The sloping (spreader) side of the carriage
has a ball joint that is mounted between two rubber
washers. The mast side of the carriage has a cen-
tral bracket that holds a pin. The pin goes through
the ball joint and carries the weight of the
spreader. In the forward direction, the rotating car-
riage is secured by two wear pads at the upper side
and two retainer brackets at the lower side. In the
backward direction, the rotating carriage has two
wear pads that are supported by the carriage sec-
tion at the mast side. See Figure 15. 1. CARRIAGE MAST SIDE
2. PIN
To tilt the spreader sideways, the pile slope cylin- 3. UPPER WEAR PADS
ders retract at the side to be raised and extend at 4. CARRIAGE SLOPING SIDE
the side to be lowered. Hydraulic oil is supplied by 5. LOWER WEAR PADS
6. PILE SLOPE CYLINDER
the valve assembly for sideshift and powered pile 7. RETAINER BRACKET
slope, which is located on top of the central frame.
Solenoid valve Y47 activates left-hand side up. Sol- Figure 15. Powered Pile Slope
enoid Y48 activates right-hand side up.
When the powered pile slope function is not activa-

ted, oil pressure in the pile slope cylinders is main-
tained by two counterbalance valves, one for each
20
A. FRONT OF TRUCK B. REAR OF TRUCK

1. FROM PUMP 8. ADAPTOR FOR SYSTEM PRESSURE
2. TO TANK 9. TO POWERED PILE SLOPE LEFT-HAND ROD
3. ADAPTOR FOR SIDESHIFT SIDE
4. TO SIDESHIFT ROD SIDE 10. TO POWERED PILE SLOPE LEFT-HAND PIS-
5. TO SIDESHIFT PISTON SIDE TON SIDE
6. TO POWERED PILE SLOPE RIGHT-HAND ROD 11. LEFT-HAND COUNTERBALANCE
SIDE 12. RIGHT-HAND COUNTERBALANCE
7. TO POWERED PILE SLOPE RIGHT-HAND PIS- 13. RELIEF VALVE
TON SIDE
Figure 16. Sideshift and Powered Pile Slope Valve
21
ELME 580 SERIES VALVES
Sequence Valve
NOTE: Remove and inspect the cartridge valve if
there is a problem with the correct locking and/or
unlocking sequence.
The sequence valve assembly is mounted on the

floating head of model 582 and gives priority to the
oil flow. When locking, pressure must reach
40 bar (580 psi) before the retract cylinder extends.
This allows the twist lock motors to rotate the twist
locks before the retraction cylinder pulls the twist
lock assembly away from the container. If the re-
traction cylinder is pressurized too soon, locking of
the twist locks may not occur. When unlocking,
pressure is first relieved from the extension cylin-
der, allowing the spring to push the upper twist
lock assembly against the container, thus relieving
mechanical friction between the twist lock and the
container pocket. See Figure 17.
1. SEQUENCE VALVE
2. TO RETRACTION CYLINDER
3. TO LOWER CONNECTION OF TWIST LOCK
MOTOR
4. RELIEF VALVE
5. TO UPPER CONNECTION OF TWIST LOCK
MOTOR
6. TO PILOT CHECK VALVE
7. PILOT CHECK VALVE
8. TWIST LOCK MOTOR
9. RETRACTION CYLINDER
Figure 17. Sequence Valve
22
Pilot Check Valve
To maintain twist locks in the locked or in the un-

locked position, a pilot check valve has been moun-
ted between the twist lock valves and the twist
locks. See Figure 18 and Figure 36. The pilot check
valve is mounted under the hose and cable support,
close to the vertical end beam. Remove the check
valve(s) for inspection, if there is no oil pressure at
the lock cylinder or if oil pressure does not relieve
sufficiently through the valve.
ELECTRICAL SYSTEM
The required electrical current and signals from the

control switches in the operator cab are provided by
an electric cable that is routed over the mast along-
side the hydraulic hoses for the attachment. A 24-
pin connector provides a link between the lift truck
and the printed circuit boards (PCBs) of the
spreader control system. The PCB is located inside
the electric box at the right-hand rear side of the 1. BOTTOM SIDE OF PILOT CHECK VALVE
center attachment frame. See Figure 19. 2. TO TWIST LOCK CYLINDERS
3. CHECK VALVE CARTRIDGE
4. TO TWIST LOCK VALVE
Figure 18. Pilot Check Valve
23
1. PRINTED CIRCUIT BOARDS 7. CONNECTORS FOR SOLENOID VALVES

2. ELECTRIC BOX 8. 10-PIN CONNECTOR
3. 24-PIN CONNECTOR 9. EXTENSION CYLINDER
4. INDICATOR LIGHTS 10. WORK LIGHT
5. SENSORS 11. 2-PIN CONNECTOR
6. 3-PIN CONNECTOR 12. 5-PIN CONNECTOR
Figure 19. Electrical Diagram
24
The PCBs verify signals from the control switches shows part of an electrical schematic. If the logic is
in the operator cab and signals from various sen- controlled by an integrated circuit, it will be indica-
sors on the attachment. The PCBs prevent func- ted on the schematic by boxed text such as “Logic
tions from being energized under incorrect condi- auto twist lock” or “Fault detect”.
tions and conflicting functions energizing at the
same time. The wiring diagram shows the actual wiring con-
nection between the PCBs and the various connec-
The electrical schematic shows the logic of the tors. The correct wiring diagram for your attach-
PCBs in relation to the different signals. The cor- ment is shown on Hyster Hypass Online. Fig-
rect electrical schematic for your attachment is ure 21 shows part of a wiring diagram.
shown on Hyster Hypass Online. Figure 20
1. 24-PIN LIFT TRUCK ELECTRICAL CONNEC- 4. CABLE WIRE NUMBER

TOR 5. FUNCTION
2. SOCKET IDENTIFICATION NUMBER 6. INTEGRATED CIRCUIT
3. CABLE NUMBER
Figure 20. Electrical Schematic Section
25
1. PCB SOCKET NUMBER 5. FUNCTION DESCRIPTION

2. WIRE NUMBER 6. WIRE NUMBER
3. SOCKET SEQUENCE NUMBER 7. CABLE SEQUENCE NUMBER
4. PCB NUMBER 8. LED
Figure 21. Wiring Diagram Section
26
Printed Circuit Board placement of a failed PCB. The electrical compo-

nents and functions of the PCBs are shown on the
Printed circuit boards (PCBs) are installed in an wiring diagram. See Figure 21. With the exception
electric box. See Figure 22. Each PCB is provided of the PCB sockets and fuses for the lights, individ-
with an identification number. The PCBs are con- ual electrical components of the PCBs are not avail-
nected through sockets, allowing convenient re- able for purchase.
Figure 22. Printed Circuit Board
27
PCB Sockets The wiring diagram shows the location of the

socket connection numbers and the location of the
The wire harness wires to the PCBs are connected LEDs at the PCB sockets. When a socket connec-
at the PCB sockets coded X1 through X13. An over- tion is energized, the corresponding LED will be
view of the PCBs and sockets is shown in Table 2. ON.
The socket connection number consists of the
socket code and a sequence number. An example is The LEDs have different colors. Each color repre-
"X12A:5". sents a different type of signal:
• Green LEDs indicate battery voltage.
An LED may be present directly above or below the
• Red LEDs indicate activated output signals.
PCB sockets.
• Yellow LEDs indicate activated input sig-
nals.
Table 2. PCB Socket Overview
PCB Function Group Input Socket Output Socket Function

X1 X4 X2 X3 X5 Left-Hand Sensors
PCB1 Power Override Right-Hand Sensors
Indicator Light
Lights X11A X12A X13A Lights
Sideshift Sideshift
PCB2A
Stops Stops
Twist Locks Twist Locks
Rotation X11B X12B X13B Rotation

PCB2B Extend Extend
Retract Retract
PCB3 Auto Lock X4 X11A Auto Lock
28
Cable Number Wire Color Code
The electric cables have a cable group number that PCB output sockets have a maximum of 10 connec-
starts with 3 and continues through 7. tions. The attached electric cable has a maximum
of 10 wires, each featuring a different insulation
The cable sections of a cable group have an index color for wire identification. The insulation color
number that is separated by a decimal point from corresponds with the wire index number. See Ta-
the cable group number. See Figure 21. The cable ble 3. Some of the wire colors represent a particular
index number indicates its section sequence num- electrical function. For instance, Black = positive,
ber starting from the PCB socket. For instance, White = ground, etc. Wires that connect with input
"Cable Spb.4.3" is the third cable section of cable sockets do not have unique colors for that socket.
group 4. Each cable has a label attached with the
cable number. Table 3. Wire Color Code
The cable group number for the work lights, indica- Number Color Number Color
tor lights, and lift truck connection is only shown in 1 Violet 6 Red
the wiring diagram and is not shown in the electri-
2 Brown 7 Pink
cal schematic.
3 Yellow 8 Gray
Wire Number 4 Blue 9 Black
5 Green 10 White
The individual wires in a cable group have an index
number that is separated by a dash from the cable
group number. In Figure 20, wire 4-3 connects
socket X3:3 with SpB4-3, which is sensor S6,
Seated Front RH.
29
Cable Connectors
For the pin numbers as they apply to the 10-pin

and 2-pin connectors, see Figure 23. The pin num-
bers on the 24-pin truck connector are indicated on
the connector itself. For the 24-pin, 10-pin, and 2-
pin connectors, the wire index numbers are identi-
cal to the connector pin numbers. The pin numbers
for the proximity switches are indicated on Fig-
ure 24.
A. RECEPTACLE C. TERMINAL PIN

B. PLUG D. TERMINAL SOCKET
1. PIN 1 - WIRE INDEX NUMBER 9
2. PIN 2 - SENSOR SIGNAL (NORMALLY OPEN)
Figure 24. Proximity Switch
Sensors and Solenoids
The sensors used on the ELME 580 attachment

series are proximity switches that react to the pres-
ence of steel. The proximity switches switch ON
within 4 mm (0.16 in.) before contact with steel.
The proximity switches have a yellow LED that is
ON when supply voltage is available and when the
proximity switch has switched ON. Replace any
faulty proximity switches. The LEDs at PCB sock-
A. 2-PIN PLUG ets X02 and X03 normally confirm the presence of
B. 10-PIN PLUG supply voltage and signals received from the prox-
C. 2-PIN RECEPTACLE
D. 10-PIN RECEPTACLE imity switches.
E. TERMINAL PIN
F. TERMINAL SOCKET
Figure 23. Cable Connectors
30
Proximity switches are marked with an "S", fol- indicator lights will flash. The sensor warning func-
lowed by a sequence number. This code represents tion is indicated on the electrical schematic as
the same function for all ELME attachments. For "Fault detect".
instance: Proximity switch S1 always indicates a
"locked LH side". If any sensor malfunctions or faults are detected,
repair the attachment immediately before return-
Solenoids have a yellow LED that is ON when acti- ing to operation.
vated. Check the functionality of the solenoids by
observing them activate during a hydraulic func-
tion or by testing the individual solenoids. Replace
any faulty solenoids.
Solenoids are marked with a "Y", followed by a se-

quence number. This code represents the same
function for all ELME attachments. For instance:
Solenoid Y1 always indicates a "lock twist lock LH
side".
INDICATOR LIGHTS
For model 582, there are two sets of three lights on

each side of the spreader. See Figure 25. All other
580 models have one set of four indicator lights at
the right-hand side of the spreader. See Figure 26.
In addition there are five LEDs in the twist lock
module in the cab. The indication is as follows:
• Left-hand amber light and left-hand LED in-
dicate that the attachment is seated at the
left-hand side and ready to have twist locks
1. YELLOW 3. RED
activated. 2. GREEN
• Green light and LED indicate that both twist
Figure 25. Indicator Lights, Two Sets of Three
locks are in locked position and ready to lift
Lights
the container.
• Red light and LED indicate that both twist
locks are in unlocked position. It is possible
to move the twist locks into or out of the cor-
ner pockets.
• Blue LED (cab only) indicates that the over-
lowering or the lift interrupt function is acti-
vated.
The attachment indicator lights and the twist mod-

ule in the operator cab are activated by PCB1,
through socket X5.
The spreader PCB has an integrated circuit, that

causes the indicator lights to flash in case a sensor
is not functioning properly.
1. YELLOW 3. RED
Sensor malfunction or fault is indicated if the sen- 2. GREEN
sor indicator light flashes continuously. If a seated Figure 26. Indicator Lights, Four Lights
sensor is faulty or incorrectly adjusted, the seated
31
the twist module will no longer receive signals for

AUTOMATIC LOCKING twist locks locked and twist locks unlocked and the
override button must be pushed to operate the lift/
The automatic locking feature exists on spreaders lower function.
with vertical twist locks, models 586, 588, and 589.
The automatic locking feature automatically locks OVERLOWERING INTERRUPT AND
the twist locks after all required input signals have OVERRIDE
been received. The automatic locking feature can be
switched ON or OFF through switch K1 on PCB3.
WARNING
The time delay to lock the signal can be adjusted by When lifting after using the override feature, verify
turning potentiometer P3. Calibrations quicker that chains, hoses, and cables are not obstructed
than one second are not practical because an initial in any way.
seated signal can get interrupted by spreader
movements that are caused by the shifting of the An overlowering interrupt feature is incorporated
lift truck. on all 580 models. The overlowering interrupt func-
tion prevents further lowering of the carriage when
LIFT INTERRUPT AND OVERRIDE both end beams have been raised in relation to
outer booms. This prevents slacking of chains, ho-
ses, and wires over the mast. The blue LED, in op-
WARNING erator's cab, comes on when lowering interrupt is
Only use override feature for positioning twist activated.
locks to enable proper locking. Do not use over-
ride feature for general lifting and transport of To override the overlowering interrupt feature,
container. turn override key switch clockwise and push over-
ride button while using lowering lever.
When attachment is seated and any of the twist
locks are between the unlocked and locked position, SECOND CONTAINER DETECTION
the blue LED inside operator's cab is illuminated SENSOR (MODEL 582 ONLY)
and the lift interrupt system will not allow lifting of
mast. The second container sensor detects if the attach-
ment should pick up one container or two contain-
To override lift interrupt feature, turn override key ers.
switch clockwise and push override button while
using lift lever. When a second container is detected, the electrical
system requires a seated signal for all four twist
Lift Interrupt locks before the system allows the twist locks to be
locked. When they are locking or unlocking, all four
The lift interrupt signal prevents the lift truck from operate simultaneously.
activating the lift/lower spool while the twist locks
are being operated. If the lift truck were to activate When no second container is detected, the twist
the lift/lower spool while the twist locks are being locks can be locked after the seated signal for the
operated, the twist locks could jam. If the attach- lower twist locks is received.
ment does not provide the signals for twist locks
locked or twist locks unlocked, the lift/lower signal Proper functioning of the second container detec-
to the lift spool is interrupted by the twist module. tion sensor can be checked at PCB2, terminal 36,
By pushing the override button in the twist mod- where the LED must be ON when the sensor is ac-
ule, the connection with the lift/lower function is re- tivated.
instated, independent from the twist lock signals.
When the attachment connector is disconnected,
32
5000 SRM 1221 Container Attachment
Container Attachment
REMOVE INSTALL
Remove the container attachment from the lift 1. Remove the locking pins and retainer bar from
truck as follows: the attachment.
2. Move the lift truck or use a lifting device and

1. Set the attachment on a loaded container or use
place the attachment in the correct position on
a lifting device to support the attachment.
the carriage.
Place the twist locks in the unlocked position.
3. Shut down the engine.
4. Turn the key switch to the ON position, but DO
3. Turn the key switch to the ON position, but DO
NOT start the engine.
NOT start the engine.
WARNING
WARNING
Hydraulic pressure must be relieved before dis-
Hydraulic pressure must be relieved before dis-
connecting any hydraulic lines or serious per-
connecting any hydraulic lines or serious per-
sonal injury may occur.
sonal injury may occur.
5. Push the emergency lowering button and move
4. Push the emergency lowering button and move
the control lever for the sideshift function back
the control lever for the sideshift function back
and forth a minimum of five times to relieve hy-
and forth a minimum of five times to relieve hy-
draulic pressure.
draulic pressure.
6. Turn the key switch to the OFF position.
5. Turn the key switch to the OFF position.
7. Remove the plugs from the fittings and connect
6. Place identification tags on the hydraulic lines.
the attachment hydraulic supply line and hy-
7. Disconnect the hydraulic supply line and hydraulic tank return line to the carriage.
draulic tank return line of the attachment from
8. Connect the attachment connector to the con-
the carriage and place plugs on the fittings.
nector on the carriage.
8. Disconnect the electrical connector from the
9. Install the cylinder pins for the slew and side-
carriage.
shift cylinders at the carriage side. If necessary,
9. Attach the free ends of the electrical and hy- start the engine and operate the slew and side-
draulic lines to the attachment. shift cylinders to obtain the correct length.
10. Remove the cylinder pins for the slew and side- 10. Install the retainer bar beneath the attach-
shift cylinders at the carriage side. ment.
11. Support each cylinder to prevent damage to cyl- 11. Make sure the attachment functions operate
inders and hydraulic lines. correctly as described in the Operating Man-
ual, and check for leaks.
12. Remove the retainer bar beneath the attach-
ment. CARRIAGE AND ATTACHMENT
REMOVAL
13. Separate the attachment from the lift truck by
moving the lift truck or the lifting device.
WARNING
14. Retain the locking pins, retainer bar, and con- When working on or near mast, see Safety Proce-
nector for later installation.
dures When Working Near Mast in the Mast man-
ual for your truck.
33
Container Attachment 5000 SRM 1221
Do not work under a raised carriage. Lower car- 7. If any of the load rollers need to be replaced,
riage or use a chain to prevent carriage and inner make a note of location of shims.
mast from lowering. Attach all moving parts of
mast to parts that DO NOT move with a chain and NOTE: For further details on repairs and adjust-
make secure. ments of carriage, see the Mast manual for your lift
truck.
1. Put mast in a vertical position. Lower carriage
onto blocks so lift chains and hoses are not un- SPREADER
der tension. Shut off engine.
NOTE: Most repairs for the attachment can be
done while it is on the lift truck. If the attachment
WARNING must be removed, this can be done by either remov-
Do not disconnect any hydraulic lines when en- ing the carriage with attachment or just the attach-
gine is running. ment.
2. Disconnect hydraulic lines to attachment. Tag 1. Retract the attachment to the 20-foot position.
and put caps on open lines. Disconnect electri- Put the mast in vertical position. Use the side-
cal connector at attachment. Remove clamps as shift function to center the attachment. Shut
necessary to remove harness from carriage. OFF the engine.
2. Remove the pump and tank hoses that connect

WARNING to the sideshift valve and the extension valve
Keep control of lift chains when disconnecting on the attachment.
them from carriage. Use wire to temporarily con-
nect ends of lift chains to mast. This procedure 3. Release the electric cable running from the at-
will prevent lift chains from falling and causing an tachment connector bracket to the electric box.
injury or damage. Provisionally attach the cable to the bracket of
the electric box.
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
WARNING
movement. Verify the lifting straps have a rated capacity of
10,000 kg (22,046 lb).
WARNING 4. Connect a lifting device to the attachment main

When carriage is not connected to mast, it can fall frame, using lifting straps. Verify that the
and cause an injury. Make sure carriage has sta- frame will have stability when it is disconnec-
bility and will not fall over when inner mast is ted.
raised above carriage.
5. Remove the two retainer brackets at the lower
4. Connect a lifting device to attachment main front end of the carriage.
frame using lifting straps. Verify frame will
6. Support the sideshift cylinder with a sling that
have stability once disconnected. Lifting device
is attached to the bar just above the cylinder.
with lifting straps must hold
Remove the securing bolt and the pin holding
10,000 kg (22,046 lb).
the rod end of the sideshift cylinder. Lift the
5. Use lift cylinders to raise inner mast until it is rod end and secure it several inches above its
above load rollers of carriage. If hydraulic sys- bracket on the attachment.
tem cannot be used, connect a lifting device to
7. Use the lifting device to tilt the attachment
top of inner mast.
slightly backward.
6. Carefully move lift truck away from attach-
8. Remove the bolts of the wear pad retainers, and
ment. Put attachment on blocks on a flat sur-
the wear pads at the front upper side. DO NOT
face so that carriage is up.
remove the bolts that hold the wear pad re-
tainer bracket at the inner side.
34
5000 SRM 1221 Container Attachment
9. Use the lifting device to slide the attachment 10. Put the attachment on blocks high enough to
forward, away from the carriage. Keep the at- keep the extension beams clear of the ground.
tachment as low as possible and proceed care-
fully as the top of the attachment frame slips
away from the upper carriage bracket.
Wear Pads
WEAR PADS MOUNTED ON MAIN FRAME 3. Remove the bolts for the upper wear pad re-
tainers and slide out the brackets with the
Remove wear pads. See Figure 27.
1. Extend the beam to obtain proper access. 4. Lift and secure the inner end of the extension
beam to relieve pressure from the lower wear
2. Remove the bolts for the side wear pad retain- pads. See Figure 27.
ers and slide out the brackets with the wear
pads. If necessary, use a pry bar to provide the 5. Remove the bolts and the retainer with the
required play between the extension beam and lower wear pads. See Figure 27.
the frame. See Figure 27.
Replace
3. Lift and secure the twist lock side of the exten-
sion beam to relieve pressure from the lower 1. Replace the lower retainer with the wear pads.
wear pads. Install the bolts and tighten to
63 N•m (46.5 lbf ft). See Figure 27.
4. Remove the bolts and the retainer with the
lower wear pads. See Figure 27. 2. Remove the device that lifts the end of the ex-
tension beam. See Figure 27.
Replace
3. Replace the retainers and the side wear pads.
1. Replace the lower retainer with the wear pads. Install the bolts and tighten to
Install the bolts and tighten to 63 N•m (46.5 lbf ft). See Figure 27.
63 N•m (46.5 lbf ft).
4. Replace the retainers and the upper wear pads.
2. Remove the support under the outer end of the Install the bolts and tighten to
extension beam. See Figure 27. 63 N•m (46.5 lbf ft). See Figure 27.
3. Replace the retainers and the side wear pads. A vertical tube at the end of the extension beam
Install the bolts and tighten to is provided with wear pads that guide the move-
63 N•m (46.5 lbf ft). ment of the floating end beam assembly. The up-
per position of the floating end beam is deter-
WEAR PADS MOUNTED ON EXTENSION mined by a pin passing through the vertical tube
BEAM and a slot in the floating end beam. In the lower
position, the end beam rests on a plate that is
welded inside the vertical tube. See Figure 27.
Remove
1. Retract the beam completely to obtain proper
access. See Figure 27.
2. Remove the bolts for the side wear pad retain-

ers and slide out the brackets with the wear
pads. If necessary, use a pry bar to provide the
required play between the extension beam and
the frame. See Figure 27.
35
Wear Pads 5000 SRM 1221
2. Lift and secure the floating end beam to its

highest position. Move the end beam to relieve
pressure from the wear pad to be shimmed.
3. Remove the bolts holding the wear pad bracket

and slide the bracket upward to add a shim
and/or replace the upper wear pad.
4. Slide the bracket with the wear pads downward

and tighten the bolts.
Lower Wear Pads

1. Remove the pin securing the floating end beam.
CAUTION
When lifting higher than necessary, hydraulic ho-
ses or the electric cable inside the floating end
beam may get damaged.
2. Lift the end beam and secure it in a position

1. LOWER WEAR PAD RETAINER that is high enough to remove the wear pad
2. LOWER WEAR PAD brackets completely.
3. SIDE WEAR PAD RETAINER
4. WEAR PAD 3. Remove the bolts holding the wear pad bracket.
5. DISTANCE PLATE
6. FRAME Slide the bracket upward and replace the wear
7. UPPER WEAR PAD RETAINER pads.
8. EXTENSION BEAM
9. LOWER WEAR PAD RETAINER 4. Slide the bracket with the wear pads downward
and tighten the bolts.
Figure 27. Wear Pads
5. Lower the floating end beam slowly and insert
the securing pin. Hydraulic hoses and the elec-
FLOATING END BEAM WEAR PADS tric cable will automatically return to their
original position if the end beam has not been
NOTE: Minimum thickness of the plastic wear lifted too high.
pads is 18 mm (0.709 in.).
MAIN FRAME WEAR PADS AT LARGE
Increasing the play at the floating end beams not (RIGHT-HAND) EXTENSION BEAM
only affects ease of operation but also causes the
container to tilt slightly forward. To limit the effect NOTE: Minimum thickness of the plastic wear
of the pads wearing down, shims can be mounted pads is 18 mm (0.709 in.).
behind the upper front and rear wear pads. Shims
are available in thicknesses of 1 mm (0.04 in.) and 1. Extend the end beam to obtain proper access.
2 mm (0.08 in.). Maintain a minimum play of
2. Remove the bolts for the wear pad retainers
1 mm (0.04 in.) when shimming. If play cannot suf-
and slide out the brackets with the wear pads.
ficiently be reduced by shimming, replace the thin-
nest wear pad with a new one. See Figure 28. 3. Lift and secure the outer end of the extension
beam to relieve pressure from the lower wear
Upper Wear Pads pads.
1. Measure the forward/backward play at the up- 4. Remove and replace the bolts, the retainer, and
per front and rear wear pads to determine the the wear pads at the bottom of the frame.
required shims to be applied. Maintain a mini-
mum play of 1 mm (0.04 in.).
36
5000 SRM 1221 Wear Pads
5. Lower the outer end of the extension beam and 3. Remove the bolts for the upper wear pad re-
replace the wear pad retainers with the wear tainer and slide out the bracket with the eight
pads at the top of the frame. Tighten the bolts. wear pads. See Figure 28.
MAIN FRAME WEAR PADS AT SMALL 4. Lift and secure the extension beam until it al-
(LEFT-HAND) EXTENSION BEAM most touches the main frame.
NOTE: Minimum thickness of the plastic wear 5. Remove the bolts for the lower wear pad re-
pads is 18 mm (0.709 in.). tainer and slide out the bracket with the eight
wear pads.
1. Extend the spreader 120 cm (4 ft).
6. Replace the lower bracket with new wear pads
2. Lift and secure the outer end of the extension and tighten the bolts.
beam until play between upper wear pads and
extension beam starts to reduce.
1. WEAR PAD 4. WEAR PAD BRACKET

2. SHIM 5. FLOATING END BEAM
3. PIN 6. PLATE
Figure 28. Wear Pads at Small Extension Beam
37
Wear Pads 5000 SRM 1221
7. Lower the extension beam slightly until it is SPREADER FRAME

parallel with the main frame. Replace the up-
per bracket with new wear pads and tighten Upper Wear Pads
the bolts.
1. Put the spreader on blocks and tilt forward the
GUIDE FOR EXTENSION CYLINDER mast to relieve pressure from the upper wear
pads.
The lower wear pads of the extension beams influ-
ence the free movement of the cylinder guide of the 2. Remove the bolts and the retainers, and slide
extension cylinders. In the 20-foot position, no the wear pads sideways to remove.
forces may act on the cylinder guide. A play of at
least 2 mm (0.08 in.) must remain between cylinder 3. Slide new wear pads into position. Verify the
guide and the support that is welded on the wear pad properly catches the retainer at the
spreader frame. See Figure 29. Inspect the lower inside.
main frame wear pads, when dimension A is 4. Replace the retainers and the bolts.
smaller than 2 mm (0.08 in.) when the spreader is
retracted in the 20-foot position. Inspect the upper
Lower Wear Pads
main frame wear pads, when dimension B is
smaller than 2 mm (0.08 in.) when the extension 1. Put the spreader side of the carriage on blocks,
beam is retracted in the 20-foot position. slightly lower and move the carriage backwards
to relieve the pressure from the wear pads.
2. Remove the bolts and the brackets with the

wear pads.
3. Reinstall the brackets with new wear pads and

tighten the bolts.
POWERED PILE SLOPE CARRIAGE
Upper Wear Pads

1. Put the spreader side of the carriage on blocks
and move the mast side of the carriage forward
to relieve the force from the upper wear pads.
2. Remove the bolts and the wear pads and re-

place.
A. DIMENSION A B. DIMENSION B Lower Wear Pads

1. CYLINDER GUIDE 1. Put the spreader side of the carriage on blocks
2. SPREADER FRAME SUPPORT and move the mast side of the carriage forward
to relieve the force from the upper wear pads.
Figure 29. Cylinder Guide
2. Remove the bolts and retainers attaching the
wear pads.
LARGE EXTENSION BEAM INTERNAL
WEAR PADS 3. Replace the wear pads using a flat iron bar.
4. Replace the retainers and bolts.

For replacement of the internal wear pads of the
large extension beam, see Extension Beam.
38
5000 SRM 1221 Extension Cylinder
Extension Cylinder
REMOVE 6. Shut down the engine.
1. Place the lift truck on a solid, level surface.

WARNING
2. Remove the cable chain, hydraulic hoses, and DO NOT disconnect any hydraulic lines when the
electrical cable from the extension cylinder by engine is running or personal injury may occur.
removing the retaining brackets. Place caps on
the open fittings. 7. Place identification tags on the hydraulic lines
that connect at the cable chain retaining
3. Remove the extension cylinder return hose bracket and to the extension cylinder valve.
from the extension cylinder control valve to al-
low draining of the residual oil from the rod 8. Disconnect the hydraulic lines and electrical
side of the cylinder. connectors that connect with the extension cyl-
inder.
4. Remove the solenoid for the extend/retract
function to allow extension of the cylinder. The 9. Remove the bolts attaching the cable chain re-
solenoid for the twist lock function may be retaining bracket to the extension beam. Leave
moved to prevent damage to the solenoid. Place the cable chain bracket attached to the inner
caps on open connections. boom.
5. Retract the attachment to the 6.1 m (20 ft) posi- 10. Tie the cable chain bracket to the extension cyl-
tion to allow access to the cable chain bracket inder with a rope in two places.
and hose connections at the extension beam.
11. Secure the loose ends of the hydraulic lines and
See Figure 30.
electrical cables, that come out of the cable
chain, to the extension cylinder.
WARNING
Verify the lifting device has the rated capacity of
150 kg (331 lb) or personal injury may occur.
12. Use a lifting device or lift truck to pull the ex-

tension beam out approximately
50 cm (19.7 in.) until the inspection hole is clear
of the main frame. See Figure 31.
13. Remove the cotter pin, washer, and pin from

the rod end of the extension cylinder. Verify
1. EXTENSION CYLINDER ROD END that the extension cylinder rests on the exten-
2. EXTENSION CYLINDER RETURN HOSE sion cylinder support.
3. INNER BEAM
4. OUTER BEAM 14. Place a sling around the valve of the extension
5. WEAR PAD cylinder and attach it to a crane or lifting de-
6. EXTENSION CYLINDER VALVE vice capable of supporting 150 kg (331 lb).
7. EXTENSION CYLINDER ROD END
8. CABLE CHAIN BRACKET
9. CABLE CHAIN RETAINING BRACKET
10. EXTENSION CYLINDER SUPPORT
11. EXTENSION CYLINDER WEAR PAD
Figure 30. Extension Cylinder Assembly
39
Extension Cylinder 5000 SRM 1221
1. EXTENSION BEAM 3. MAIN FRAME

2. INSPECTION HOLE
Figure 31. Inspection Hole
15. Remove the cotter pin, washer, and pin from

the valve end of the extension cylinder.
16. Carefully lift the cylinder from its supporting

bracket and pull the cylinder horizontally out of
the attachment until the extension cylinder
wear pad reaches the edge of the extension cyl-
inder support.
17. Support the cylinder with a second strap close

to the cylinder gland. Place the strap between
the cylinder shell and the extension cylinder
hydraulic return line.
18. Remove the cylinder and put it on a support

that allows sufficient clearance to not damage 1. PISTON ROD
the cable chain. 2. SEAL KIT
3. WASHER
4. RETENTION RING
DISASSEMBLE 5. CAPSCREW
6. GUIDE RING
1. Place the entire cylinder on a support that is 7. BUSHING
long enough to support the rod. 8. GLAND
9. SPACER
2. Disassemble and remove the retention ring by 10. O-RING
removing the four bolts and washers from the 11. PISTON
12. NUT
cylinder support. See Figure 32. 13. SETSCREW
14. BOLT
15. CYLINDER SUPPORT
Figure 32. Extension Cylinder
40
1. Assemble the new seals, capscrews, nut, piston,

CAUTION bushing gland, guide ring, and washer.
Use caution not to damage the finished surface of
the piston rod when removing the piston rod from
the cylinder shell.
CAUTION
3. Pull the piston rod out until the spacer has the piston rod when installing the piston rod into
come out of the cylinder together with the the cylinder shell.
gland. Support the spacer and complete the re-
moval of the piston rod. 2. Lubricate the cylinder shell bore with clean hy-
draulic oil. Place the piston rod assembly into
the cylinder shell.
CAUTION
Use caution not to damage the grooves when re- 3. Place the retention ring on the cylinder shell
moving seals and other parts from the piston rod. and install the four bolts and washers. Tighten
the bolts to 130 N•m (96 lbf ft).
4. Disassemble and remove all seals, capscrews,
nut, piston, bushing, gland, guide ring, and INSTALL
washer.
1. Completely retract the extension beam.
CLEAN 2. Clean the tracks and lubricate the positions
where the support wear pads for the extension
WARNING cylinder will come in contact with the extension
Cleaning solvents can be flammable and toxic and cylinder support.
can cause skin irritation. When using cleaning 3. Check that the cables and hoses are installed
solvents, always follow the solvent manufac- and that the cable chain is properly tied to the
turer’s recommended safety procedures. cylinder in two places.
Compressed air can move particles so that they 4. Check that the cylinder is extended approxi-
cause injury to the user or to other personnel. mately 50 cm (19.7 in.) and that the rod end is
Verify the path of the compressed air is away from turned in the correct position for assembly.
all personnel. Wear protective goggles or a face
shield to prevent injury to the eyes.
WARNING
Clean all parts in solvent and remove residual sol- Check the lifting device has the rated capacity of
vent or allow the solvent to evaporate. 150 kg (331 lb) or personal injury may occur.
INSPECT 5. Place a sling at the extension cylinder valve

and another sling close to the cylinder gland be-
Inspect the parts of the extension cylinder for dam- tween the cylinder shell and the extension cyl-
age, rust, or wear. Carefully inspect the rod surface inder return line. Check that the extension cyl-
for dents and scratches. Verify that the internal inder wear pad is aligned with the extension
stroke surfaces of the cylinder shell and the grooves cylinder support.
for the seals do not show any nicks, scratches, or
6. Lift the extension cylinder and place it with the
other damage. Repair or replace parts as needed.
wear pad on the cylinder support plate in the
extension beam and remove the sling at the cyl-
ASSEMBLE inder gland. Move the cylinder a few meters
(feet) further into the extension beam.
NOTE: Verify that all parts are clean before assem-
bly. 7. Pull the extension beam out, approximately
50 cm (19.7 in.), until the inspection hole in the
NOTE: Always use new seals. Lubricate all parts
extension beam is clear of the main frame.
with clean hydraulic oil.
41
8. Move the cylinder into the beam until the rod 2. Slide ring away from cylinder head.
end is at the level of the attaching bracket.
Align the ball joint with the bracket and install 3. Pull piston rod out of cylinder. See Figure 33.
the attachment pin, washer. and cotter pin.
4. Piston will touch spacer, which will push out
9. Move the lifting device to align the ball joint at gland, O-ring, bushing, and seal ring.
the valve end with the frame bracket. Install
5. Remove setscrew. Remove nut and piston from
the attachment pin, washer, and cotter pin. Re-
rod.
move the sling.
6. Inspect components and replace them if neces-
10. Retract the extension beam, remove the ropes
sary.
from the cable chain, and bolt the cable chain
bracket to the extension beam.
Clean and Inspect
11. Connect the hydraulic lines and electrical ca-
bles at the frame side and at the extension
WARNING
beam side of the extension cylinder.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
WARNING solvents, always follow the solvent manufactur-
DO NOT try to locate hydraulic leaks by putting er's recommended safety precautions.
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by pres- Clean cylinder parts with solvent. Inspect shell,
sure. rod, and piston for wear or damage. Install new
parts as necessary.
12. Start the engine and operate the extension cyl-
inder function. Check if the functions work cor- Assemble
rectly, and check for any leaks.
To assemble the extension cylinder, proceed in re-
EXTENSION CYLINDER verse order of Disassemble.
Disassemble
1. Remove eight bolts that hold ring.
42
1. PISTON ROD 11. SNAP RING

2. BOLT 12. BALL JOINT
3. WASHER 13. RING
4. WIPER RING 14. CYLINDER GUIDE
5. GLAND 15. SHELL
6. BUSHING 16. SEAL RING
7. SPACER 17. O-RING
8. PISTON 18. O-RING
9. NUT 19. SEAL PISTON
10. SETSCREW 20. O-RING
GUIDE FOR EXTENSION CYLINDER
Remove
1. Extend the cylinder about 1.0 m (3.3 ft). Put a
support under the shell of the extension cylin-
der, close to the gland.
2. Remove the cylinder pin and retract the cylin-

der.
3. Remove the snap ring and the washer at the

cylinder guide and remove from the cylinder.
Install
Install is the reverse order of Remove.
SIDESHIFT CYLINDER, POWERED PILE

SLOPE CYLINDER, RETRACT CYLINDER,
TWIST LOCK CYLINDER, AND SIDE
CLAMP CYLINDER
NOTE: These cylinders have a similar construction
and have the same instruction for disassembly and
assembly.
Disassemble
1. Remove the gland nut. See Figure 34.
2. Pull rod assembly from the cylinder shell.
3. Remove the setscrew before removing the pis-

ton nut.
4. Remove the piston from the rod.
5. Remove the gland nut from the rod.
6. Remove and discard all wipers, seals, backup

Figure 33. Extension Cylinder rings, and O-rings from the gland nut and pis-
ton.
43
7. Inspect shell rod and piston for wear or dam- 3. Install nut on piston and tighten.
age. Replace if necessary.
4. Install setscrew in piston nut.
Assemble 5. Install the piston and the gland in the shell.
1. Install new wipers, seals, backup rings, and O- 6. Tighten the gland.
rings on the gland nut and piston.
2. Slide the gland nut on the rod and install the

piston.
1. SNAP RING 6. WIPER RING 11. SEAL ROD

2. SPHERICAL BEARING 7. SHELL 12. O-RING
3. GREASE NIPPLE 8. PISTON 13. BACKUP RING
4. PISTON ROD 9. SETSCREW 14. O-RING
5. GLAND NUT 10. NUT 15. SEAL PISTON
Figure 34. Sideshift Cylinder
Cable Chain
REMOVE 2. Attach the cable chain and cable chain retain-
ing bracket to the extension cylinder.
1. Remove the extension cylinder with the cable
chain as an assembly. See Extension Cylinder. 3. Using a rope, attach the loose end of the cable
chain to the extension cylinder control valve.
2. Remove the cable chain retaining bracket from
the extension cylinder. 4. Install the extension cylinder. See Extension
Cylinder.
3. Pull the two hydraulic lines and the electrical
cable out of the cable chain.
4. Repair or replace the cable chain.
INSTALL
1. Using a rope, tie the electrical cable and two
hydraulic lines together and pull them through
the cable chain.
44
5000 SRM 1221 Extension Beam
Extension Beam
REMOVE 6. Install the extension cylinder and chain as an
assembly.
1. Remove the extension cylinder and chain as an
assembly. REMOVE
1. Extend the extension beam 600 mm (2 ft).
WARNING
Verify that the lifting device has the rated capacity 2. Disconnect the electric plug and the hydraulic
of 500 kg (1,102 lb) or personal injury may occur. hoses from the pilot check valve at the bottom
of the hose and cable support.
2. Using a lifting device, partially slide the exten-
sion beam out of the main frame while leaving 3. Put tags and caps on the hydraulic hoses.
a portion of the extension beam in the main
4. Remove all tie wraps between pilot check valve
frame. Properly support the extension beam
and vertical end beam.
while preparing for complete removal.
5. Put blocks under the hose and cable support.
3. Remove the wear pad bracket and wear pads
Remove the four bolts holding the support.
from the main frame.
6. Remove the pin that attaches the extension cyl-
4. Pull the remaining portion of the extension
inder with the end beam.
beam out of the frame and place the extension
beam onto a support. This will allow the re- 7. If the floating head is to be removed first, pro-
moval and installation of all extension beam ceed as follows:
components.
a. Remove the mounting bolt and pin in the
INSTALL vertical section of the extension beam that
secures the floating end beam.
1. Verify that all hydraulic hoses leading to the
twist lock cylinder and the wiring harness to
the sensors has been properly routed and se- WARNING
cured. Verify the crane has the rated capacity of
2. Make sure that the wear pad brackets and
wear pads are installed on the extension beam. b. Lift the end beam out of the extension beam
using a crane with a lifting capacity of
250 kg (551 lb). Guide the hoses and the ca-
WARNING ble through the hole in the vertical section of
Verify that the lifting device has the rated capacity the end beam.
of 500 kg (1,102 lb) or personal injury may occur.
c. Place the end beam on a flat surface.
3. Using a lifting device, begin to insert the exten-
sion beam into the main frame. Make sure that
the wear pads remain seated inside the wear WARNING
pad brackets. Slide the extension beam at least Verify the lifting straps have the rated capacity of
to 2 m (7 ft) into the main frame. 1250 kg (2756 lb) or personal injury may occur.
4. Install the wear pad brackets and wear pads to 8. Connect a lifting device to the extension beam
the main frame. using lifting straps.
5. Continue to slide the extension beam into the 9. Remove the bolts of the wear pad retainers
main frame. Leave approximately when removing the right-hand (big beam) ex-
50 cm (19.7 in.) protruding from the main tension beam. Leave the wear pad retainers at-
frame and make sure the inspection hole in the tached when removing the left-hand (small
extension beam is clear of the main frame. beam) extension beam. See Figure 35.
45
Extension Beam 5000 SRM 1221
1. MAIN FRAME 4. SIDE PAD RETAINER

2. WEAR PAD RETAINER 5. INTERNAL WEAR PAD
3. WEAR PAD 6. LARGE EXTENSION BEAM
Figure 35. Wear Pads at Large Extension Beam
46
5000 SRM 1221 Extension Beam
10. Use the lifting device to slide out the extension 3. When reinstalling the left-hand (small) exten-
beam. Remove the wear pad retainers with sion beam, verify the lower main frame wear
wear pads at the right-hand side when the pads have been installed.
beam has moved 1.5 m (5 ft).
11. Slide out the extension beam completely, while WARNING

repositioning the straps to assure stability of Verify the lifting straps have the rated capacity of
the extension beam. 1250 kg (2756 lb) or personal injury may occur.
12. Lay the end beam on its side on blocks and a 4. Connect a lifting device to the extension beam
flat surface. using lifting straps.
INSPECT 5. Insert the extension beam and slide into the

main frame 1.5 m (5 ft).
The right-hand (big) extension beam has wear pads
6. Attach the retainers to the wear pads. Verify
at the side that fit inside the main frame. The left-
using bolts of the proper quality.
hand (small) extension beam does not. Replace the
wear pads if worn. For the two bottom and two top NOTE: Attach the support first, then the extension
wear pads, it is advised to install new or barely cylinder.
worn wear pads once the end beam has been re-
moved. 7. Slide the extension beam until the extension
cylinder, hose, and cable support can be at-
Check the extension beam for any deformation. tached again.
ASSEMBLE 8. Connect the electric plug and the hydraulic ho-

ses at the pilot check valve.
1. Attach new wear pads on the right-hand (big)
extension beam if necessary. 9. Attach the hoses and cable with tie wraps.
2. Clean the right-hand inside of the main frame 10. Verify proper functioning.
and apply multipurpose grease with 2 to 4%
molybdenum disulfide to the tracks for the
wear pads.
47
Floating End Beams Repair 5000 SRM 1221
Floating End Beams Repair

REMOVE
1. Disconnect the electric plug and the hydraulic
hoses from the pilot check valve at the bottom
of the hose and cable support.
2. Put tags and caps on the hydraulic hoses.
3. Remove all tie wraps between the pilot check

valve and vertical end beam.
4. Put blocks under the hose and cable support.
5. Remove the four bolts holding the support.
6. Remove the securing bolt and pin in the verti-

cal section of the extension beam that secures
the floating end beam.
WARNING
Verify the crane has a lifting capacity of
7. Lift the end beam out of the extension beam us-

ing a crane. Guide the hoses and the cable
through the hole in the vertical section of the
end beam.
8. Place the end beam on a flat surface.
INSTALL
1. Attach a rope to the end of the hose and wire
bundle.
WARNING
Verify the lifting device has the rated capacity of 1. FRONT SIDE
2. HOSE AND CABLE ROUTING
250 kg (551 lb) or personal injury may occur. 3. PIN
4. PILOT CHECK VALVE
2. Lift the end beam with a 250 kg (551 lb) ca- 5. HOSE AND CABLE SUPPORT
pacity crane and enter the rope at the top of the 6. U-SHAPED CURVE
extension beam. Pull the rope through the hole
at the mount for the hose and cable support. Figure 36. End Beam Hose Routing
Pull the rope to lead the hose and wire bundle.
3. Lower the end beam and guide the hose and 4. Install the pin and the mounting bolt in the
wire bundle to form a U-shaped curve. See Fig- vertical section to attach the floating end beam.
ure 36.
48
5000 SRM 1221 Floating End Beams Repair
5. Attach the hose and cable support to the verti- 11. Apply protective sleeve over the hoses and ca-
cal end beam. ble at the spreader end.
6. Connect the hoses and the electric plug.
7. Apply tie wraps to fasten the cable and hoses.
HOSE, REPLACE
1. Remove the end beam.
2. Remove tie wraps.
3. Disconnect the hoses and electrical connector at

the head section of the end beam.
4. Remove the protective sleeve around the hoses.
5. Pull one of the hoses to position the hose cou-

plings differently at the lower end of the end
beam.
NOTE: The hoses and cable run through a bent

tube with a diameter that does not allow individual
replacement of the hoses or cable.
6. Remove the complete bundle of hoses and cable

from the front side. See Figure 37.
7. Replace any defective hose or cable. Verify each

hose is marked.
8. Position the hose couplings at different loca-

tions and re-bundle the hoses and cable and at-
tach a string at the spreader end.
9. Lead the string through the tube and pull the 1. FRONT SIDE
bundle into the tube while guiding it at tube 2. HOSE AND CABLE ROUTING
entry. Figure 37. Hose Replacement
10. Verify the cable and hoses at the head have the
correct length to allow proper connection. Pull
excess length into the tube.
49
Sideshift Cylinder 5000 SRM 1221
Sideshift Cylinder
REMOVE DISASSEMBLE
1. Place the lift truck on a solid, level surface. 1. Place the entire cylinder on a support that is
long enough to support the rod.
2. Lower the attachment and shut down the en-
gine. 2. Disassemble the gland using a pin wrench to
unscrew the gland. See Figure 38.
CAUTION
WARNING
DO NOT disconnect any hydraulic lines when the the piston rod when removing the piston rod from
engine is running or personal injury may occur. the cylinder shell.
4. Disconnect the hydraulic lines from the cylin- 3. Disassemble the piston rod assembly from the
der and place caps on the open lines. cylinder shell by pulling the assembly out of the
cylinder shell.
5. Remove the lock nut, washer, spacer, and pin
from one end of the cylinder.
6. Remove the lock nut, washer, spacer, and pin

CAUTION
from the other end of the cylinder. Use caution not to damage the grooves when re-
moving seals and other parts from the piston rod.
WARNING 4. Disassemble and remove the piston.

Make sure the lifting device has the rated capacity
of 20 kg (44 lb)
7. Using a lifting device, remove the cylinder from

the lift truck.
1. GLAND 8. WIPER RING

2. PISTON 9. O-RING
3. NUT/SETSCREW 10. O-RING
4. SHELL 11. GREASE NIPPLE
5. PISTON ROD 12. BALL JOINT
6. SEAL RING 13. SNAP RING
7. SEAL RING 14. SETSCREW
Figure 38. Sideshift Cylinder
50
5000 SRM 1221 Sideshift Cylinder
5. Loosen the setscrew on the nut, then remove 2. Using the nut and setscrew, assemble the pis-
the nut. ton on the piston rod. Tighten the nut to
800 N•m (590 lbf ft) and secure the nut with
6. Remove the piston and the gland. the setscrew.
7. Remove all seals from the gland.
CAUTION
CLEAN Use caution not to damage the finished surface of
the piston rod when installing the piston rod into
WARNING the cylinder shell.
Cleaning solvents can be flammable and toxic and 3. Lubricate the cylinder shell bore with clean hy-
can cause skin irritation. When using cleaning draulic oil. Place the piston rod assembly into
solvents, always follow the solvent manufac- the cylinder shell.
turer’s recommended safety procedures.
4. Lubricate the thread of the gland and screw the
Compressed air can move particles so that they gland into the cylinder shell. Tighten the gland
cause injury to the user or to other personnel. to 800 N•m (590 lbf ft).
Verify the path of the compressed air is away from
all personnel. Wear protective goggles or a face INSTALL
shield to prevent injury to the eyes.
NOTE: The piston side of the cylinder and the rela-
Clean all parts in solvent and remove residual sol- ted hoses are to be installed at the side of the
vent or allow the solvent to evaporate. spreader attachment.
INSPECT 1. Place the sideshift cylinder in position and in-

stall the pin, washer, spacer, and lock nut.
Inspect the parts of the sideshift cylinder for dam- 2. Remove the caps and connect the hydraulic
age, rust, or wear. Carefully inspect the rod surface lines to the cylinder.
for dents and scratches. Check that the internal
stroke surfaces of the cylinder shell and the grooves
for the seals do not show any nicks, scratches, or WARNING
other damage. Repair or replace parts as needed. DO NOT try to locate hydraulic leaks by putting
hands on pressurized hydraulic components. Hy-
ASSEMBLE draulic oil can be injected into the body by pres-
sure.
NOTE: Check that all parts are clean before as-
sembly. 3. Start the engine and operate the sideshift cylin-
der function several times to remove the air.
NOTE: Always use new seals. Lubricate all parts Check if the functions operate correctly, and
with clean hydraulic oil. check for any leaks.
1. Assemble the new seals and gland on the piston
rod.
51
Stop Cylinder (Optional) 5000 SRM 1221
Stop Cylinder (Optional)

REMOVE
1. Lower the attachment and place the stop cylin-
ders in the unlock position.
WARNING
DO NOT disconnect any hydraulic lines when the
engine is running or personal injury may occur.
4. Disconnect the hydraulic lines from the stop

cylinder and place caps on the open fittings.
5. Remove the four attachment bolts on the out-

side of the spreader beam.
6. Remove the stop cylinder.
DISASSEMBLE
1. Remove the M12 bolt that guides the lock pin.
See Figure 39.
2. Remove the four Allen-head screws that retain

the cylinder to the housing of the stop assem-
bly.
1. RETAINING PIN
2. SETSCREW
3. M12 BOLT
4. LOCK PIN
5. ALLEN-HEAD SCREW
6. HYDRAULIC CYLINDER
7. ALLEN-HEAD SCREW
8. GREASE FITTING
9. HOUSING
10. GRUB SCREW
11. BUSHING
Figure 39. Stop Cylinder Assembly
52
5000 SRM 1221 Stop Cylinder (Optional)
3. Pull the cylinder, with the lock pin, from the 2. Clean all parts before assembly.
housing.
3. Always use new seals when assembling the cyl-
4. Remove the setscrew that retains the bushing inder.
in the housing and remove the bushing.
4. Lubricate all parts with clean hydraulic oil.
5. Remove the setscrew that retains the retaining
pin in the lock pin. ASSEMBLE
6. Push the retaining pin out of the lock pin and 1. Install the new seals provided in the seal kit.
remove the lock pin from the cylinder rod.
2. Position the piston on the cylinder rod and in-
7. Remove the two Allen-head screws that retain stall the bolt that retains the piston to the cyl-
the bottom of the cylinder housing and the cylinder rod. Tighten the bolt to
inder gland together. 130 N•m (96 lbf ft).
8. Pull the rod with the gland and the piston out 3. Slide the rod with the piston and gland into the
of the cylinder housing. See Figure 40. cylinder housing.
9. Remove the bolt that retains the piston to the 4. Install the two Allen-head screws that retain
cylinder rod and remove the piston. the bottom cylinder housing to the cylinder
gland. Tighten the screws to 38 N•m (28 lbf ft).
10. Remove and discard all seals.
5. Place the lock pin on the cylinder rod and insert
the retaining pin. Install the setscrew to retain
the retaining pin in the lock pin.
6. Install the M12 bolt and tighten the bolt to

78 N•m (58 lbf ft).
7. Grease the inside surface of the bushing and

position it flush with the housing. Install the
setscrew to retain the bushing.
8. Position the cylinder into the housing while

carefully turning the lock pin to align the M12
bolt with the slot in the housing and aligning
the cylinder assembly Allen-head screws with
1. COVER the threads in the housing. Install the Allen-
2. SEAL KIT head screws and tighten the screws to
3. HOUSING
4. BOLT 38 N•m (28 lbf ft).
5. PISTON
6. GLAND INSTALL
7. PISTON ROD
8. ALLEN HEAD SCREW 1. Position the stop cylinder in the spreader beam
and install the four attachment bolts. Tighten
Figure 40. Stop Cylinder the bolts to 78 N•m (58 lbf ft).
2. Remove the caps and connect the two hydraulic

CLEAN AND INSPECT lines to the stop cylinder.
1. Inspect the stop cylinder for damage. Replace 3. Activate the stop cylinder and check for leaks
the complete cylinder assembly if any of the and correct operation.
stroke surfaces have dents or scratches.
53
Twist Lock Cylinder 5000 SRM 1221
Twist Lock Cylinder

REMOVE 4. Disconnect the hydraulic lines to the twist lock
cylinder and place caps on the open fittings.
1. Lower the attachment and shut down the en-
gine. 5. Remove the four attachment bolts on the out-
side of the spreader beam.
2. Open the cover above the twist lock cylinder
and turn the twist lock adjustment bolt to pro- 6. Slide the twist lock cylinder from the two roll
vide a few millimeters (inches) play between pins. If necessary, use a pry bar.
the cylinder rod and tie rod. See Figure 41.
WARNING
DO NOT disconnect any hydraulic lines when the
engine is running or personal injury may occur.
54
5000 SRM 1221 Twist Lock Cylinder
1. TIE ROD 12. WASHER

2. NUT 13. BACKUP RING
3. WASHER 14. PLATE
4. ADJUSTMENT BOLT 15. O-RING
5. WASHER 16. CYLINDER SHELL
6. BOLT 17. O-RING
7. PIN 18. SEAL
8. TWIST LOCK CYLINDER ASSEMBLY 19. PISTON
9. TWIST LOCK CYLINDER 20. ALLEN-HEAD SCREW
10. PISTON ROD 21. PLATE
11. WIPER RING
Figure 41. Twist Lock Cylinder
55
Twist Lock Cylinder 5000 SRM 1221
DISASSEMBLE 3. Slide the piston rod assembly into the cylinder

shell.
1. Remove the four bolts that retain the gland
brackets to the shell. See Figure 41. 4. Slide the gland brackets over the piston rod,
against the shell, and align the holes for the
2. Pull the rod with gland bracket and piston out bracket bolts.
of the cylinder shell.
5. Install the four bracket bolts and tighten to
3. Remove the four bolts that retain the gland to 38 N•m (28 lbf ft).
the gland bracket.
INSTALL
4. Remove and discard all seals.
1. Position the twist lock cylinder brackets on the
CLEAN AND INSPECT two roll pins in the spreader beam. If neces-
sary, use a hammer to push the cylinder
1. Inspect the twist lock cylinder for damage. Re- against the frame.
place the complete cylinder assembly if any of
the stroke surfaces have dents or scratches. 2. Install the four attachment bolts on the outside
of the spreader beam. Tighten the bolts to
2. Clean all parts before assembly. 45 N•m (33 lbf ft).
3. Always use new seals when assembling the cyl- 3. Remove the plugs and connect the two hy-
inder. draulic lines.
4. Lubricate all parts with clean hydraulic oil. 4. Turn the adjustment bolt until there is
0.05 mm (0.002 in.) play with the cylinder rod.
ASSEMBLE Tighten the adjustment bolt locking nut.
1. Install the new seals provided in the seal kit. 5. Activate the twist locks and check for leaks and
2. Position the gland in the gland brackets. Install correct operation.
the bolts and tighten to 16 N•m (12 lbf ft).
Twist Locks
DISASSEMBLE 4. Remove the indicator assembly by removing the
two attachment bolts on the top of the exten-
1. Place the lift truck on a solid, level surface. sion beam.
2. Lower the attachment to a workable height. 5. Remove the locked/not locked sensor bracket
and hang the sensor bracket outside of the
3. Shut down the engine. beam, retained by the wires of the sensors. See
Figure 42.
56
5000 SRM 1221 Twist Locks
6. Loosen one of the twist lock cylinder adjust-

ment bolts to allow some play in the tie rod. See
Twist Lock Cylinder.
7. Remove the four bolts from each twist lock

crank in the same extension beam.
8. Install two of the bolts from Step 7 into the two

threaded holes in the cranks and tighten alter-
nately until the cranks are lifted off of the twist
lock shaft.
9. Remove the tie rod, with both cranks attached,

from the end beam.
NOTE: The key used to locate the crank is held in

place with a roll pin.
10. Remove the roll pin and key from the twist
lock.
NOTE: While performing Step 11, support the

twist lock from below to prevent the twist lock from
dropping out of the extension beam.
11. 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 will
come out together with the twist lock.
1. LOCKED/NOT LOCKED SENSOR BRACKET

2. PIN
3. BOLT
4. CRANK
5. COLLET
6. UPPER BEARINGS
7. LOWER BEARINGS
8. BUSHING
9. SLEEVE
10. SPRINGS
11. KEY
12. SPRING PIN
13. TWIST LOCK
Figure 42. Twist Lock Assembly
57
Twist Locks 5000 SRM 1221
CLEAN 2. Inspect the upper and lower bearing sets for

damage. Replace as needed.
WARNING 3. Inspect the collets and the crank for wear and
Cleaning solvents can be flammable and toxic and damage. Replace if worn or damaged.
solvents, always follow the solvent manufactur- ASSEMBLE
er's recommended safety precautions.
1. Lubricate the upper and lower bearings with
1. Clean all parts of the twist lock assembly in sol- multipurpose grease.
vent and remove residual solvent or allow the
NOTE: The spherical upper and lower bearing sets
solvent to evaporate.
have the same swivel point. Both bearing sets are
INSPECT oriented in the same direction, with the concave
bearing halves (in lower position), facing up, and
1. Inspect all parts of the twist lock assembly for the convex bearing halves (in upper position), fac-
damage, rust, or wear each month. When wear ing down. If incorrectly oriented, the twist lock will
has reduced the outer ends of the twistlock jam when swiveled sideways.
heads to 25 mm (1.00 in.), the twist locks must
2. Install the sleeve with bushing onto the twist
be replaced. Inspect the twist lock recesses for
lock and place the lower bearing set in position
damage and replace as needed. See Figure 43.
on top of the sleeve. Make sure that the lower
bearing set does not rest on the 3 mm (0.12 in.)
protrusion on the sleeve. Install the four center-
ing springs in the sides of the sleeve. See Fig-
ure 44.
3. Install the upper bearing set on the top surface

of the corner plate, in the extension beam, with
the lower convex half facing up, and the upper
concave half (with threaded holes), facing down.
4. Install the twist lock through the corner plate

into the extension beam, ensuring that the up-
per bearing set is correctly positioned around
the twist lock. Support the assembly by means
of a jack or other suitable device to make sure
the assembly does not fall out. See Twist Lock
Adjustment.
Figure 43. Twist Locks
58
5000 SRM 1221 Twist Locks
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

washers 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 tie rod by installing the pin, ring
pin, and socket head capscrew.
NOTE: To ease in the installation of the crank to

the twist lock, make two alignment pins using
M8×75 bolts or socket head capscrews with the
heads removed.
8. Install the locating pins into the top plate of the

upper bearing diagonally, so each pin guides on
half of the collets.
9. Insert the tie rod into the extension beam and

slide the cranks onto the alignment pins, mak-
ing sure the key and keyway are aligned. In-
stall two screws in the crank, remove the align-
ment pins, and install the remaining two
screws in the crank. Tighten all four screws to
25 N•m (18.4 lbf ft).
10. Adjust the twist lock angle and the proximity

switches as described in Adjustments .
1. CRANK
2. COLLET 11. Lubricate the complete assembly using multi-
3. UPPER BEARING SET purpose grease.
4. 3 mm (0.12 in.) PROTRUSION
5. LOWER BEARING SET 12. Install the locked/not locked sensor bracket.
6. SLEEVE
7. SLEEVE BUSHING
8. SLEEVE SPRING
9. TWIST LOCK
Figure 44. Vertical Twist Lock
59
Twist Lock Repair for Model 582 5000 SRM 1221
Twist Lock Repair for Model 582

REMOVE
WARNING
Upper Twist Lock The weight of the twist lock assembly is approxi-
mately 50 kg (110 lb). Use a lifting device to sup-
1. Remove the cover. See Figure 45. port the twist lock assembly when sliding out.
NOTE: The cylinder bracket is welded to the upper

twist lock assembly.
7. Slide out the top twist lock assembly by pulling

on the hydraulic motor end.
8. Place the twist lock assembly on a bench.
9. Turn the spring bracket to detach it from the

spring.
10. Slide out the spring and remove the square nut.
Lower Twist Lock

1. Remove the cover.
2. Tag and remove the hydraulic lines from the

twist lock motor and retraction cylinder.
1. COVER
2. BRACKET 3. Disconnect the wiring leading to the proximity
3. SQUARE NUT switches.
4. CLAMP
5. RETRACTION CYLINDER 4. Remove the two bolts holding the retainer plate
6. SPRING at the lower twist lock assembly.
7. BOLT
8. SPRING BRACKET
9. UPPER TWIST LOCK ASSEMBLY WARNING
10. LOWER TWIST LOCK ASSEMBLY
11. BOLT The weight of the twist lock assembly is approxi-
12. RETAINER PLATE mately 50 kg (110 lb). Use a lifting device to sup-
13. HYDRAULIC MOTOR port the twist lock assembly when sliding out.
Figure 45. Twist Lock Assembly
5. Slide out the top twist lock assembly by pulling
on the hydraulic motor end.
2. Remove the bracket from the rear end of the
DISASSEMBLE
cover.
1. Place twist lock assembly on a flat area.
3. Tag and remove the hydraulic lines from the
twist lock motor and retraction cylinder. 2. Remove four socket head bolts and slide out hy-
draulic motor.
4. Disconnect the wiring leading to the proximity
switches. 3. Remove key.
5. Remove the clamp holding the retraction cylin- 4. Remove four socket head bolts attached to col-
der. let and ring. See Figure 46.
6. Retain the spring tensioned spring bracket
while removing the two bolts that hold the
spring bracket. Release the spring bracket.
60
5000 SRM 1221 Twist Lock Repair for Model 582
1. HYDRAULIC MOTOR 6. KEY

2. RING 7. RING
3. SOCKET HEAD BOLTS 8. COLLET
4. TWIST LOCK 9. SLEEVE
5. BUSHING 10. COLLET AND RING BOLT
Figure 46. Twist Lock Exploded View
5. Move sleeve toward hydraulic motor end to re- 1. Inspect nylon disc for wear and damage. Re-
lease collets. place nylon disc before indicator bolt head is
flush with contact surface of nylon disc.
6. Pull out twist lock.
2. Clean all mechanical parts of twist lock assem-
7. Pull out sleeve and collet and remove ring. bly with solvent. Dry parts with compressed
air.
8. Inspect bushings for wear and replace if neces-
sary. 3. Inspect all parts of twist lock assembly for dam-
age and wear. If twist lock is worn to less than
CLEAN AND INSPECT 25 mm (0.984 in.), replace twist lock.
4. Inspect lock recess area. If damaged or worn,

WARNING replace twist lock.
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning ASSEMBLE
solvents, always follow the solvent manufactur-
er's recommended safety precautions. 1. Install bushings and lubricate using multipur-
pose grease.
WARNING 2. Position the ring in correct location.
Do not use compressed air at more than
206 kPa (30 psi). Airborne debris can cause injury 3. Insert sleeve.
to personnel. Use approved safety equipment.
61
Twist Lock Repair for Model 582 5000 SRM 1221
4. Position twist lock with key slot in top position 7. Position hydraulic motor with key and fasten in
(unlocked position) and slide into twist lock place with four socket head screws.
housing. Position ring on twist lock shaft.
8. Connect hydraulic lines and electrical connec-
5. Position collets on twist lock shaft, then slide tions.
sleeve with key over twist lock shaft.
INSTALL
6. Insert socket head screws through sleeve and
collets. Markings on the sleeve and the ring To install the twist lock, proceed in reverse order of
must line up. The notch attached to the sleeve Remove.
must rest against twist lock housing. Screw
socket head screws into ring and tighten.
Twist Lock Repair for Models 586, 588, and 589

DISASSEMBLE CLEAN AND INSPECT
Refer to Figure 14 for the following procedures.

WARNING
1. Remove cover. Cleaning solvents can be flammable and toxic and
2. For models 586 and 588, remove the snap ring, solvents, always follow solvent manufacturer's
and lift the rod end for the flag from the crank. recommended safety precautions.
3. Remove the securing bolt, the ring pin, and the

pin that connects the twist lock crank with the WARNING
tie rod end. Do not use compressed air at more than
206 kPa (30 psi). Airborne debris can cause injury
4. Remove the four bolts that attach the twist lock to personnel. Use approved safety equipment.
crank with the upper bearing.
5. Install two of the bolts removed in Step 4 into CAUTION

the two threaded holes in the twist lock crank Use extra care when inspecting collets and recess
and tighten alternately until the crank is lifted areas of twist locks. These are the load bearing
off of the twist lock. areas when a container is lifted.
6. The key that is used to position the crank is 1. Clean all parts of twist lock assembly with sol-
held in place with a roll pin. Remove the roll vent. Dry parts with compressed air. Inspect all
pin and the key from the twist lock. parts of twist lock for damage and wear. If
twist lock is worn more than 25 mm (0.98 in.),
CAUTION replace twist lock. Inspect twist lock recesses
and replace twist lock if damaged. See Fig-
During performance of Step 7, support twist lock
ure 47.
from below to prevent it from dropping out of end
beam.
7. Pry collets out of the recess in the twist lock.

Remove the twist lock from the end beam. The
sleeve and lower bearing set may or may not
come out together with the twist lock.
62
5000 SRM 1221 Twist Lock Repair for Models 586, 588, and 589
Figure 47. Twist Lock Wear
2. Inspect upper and lower bearing sets for dam-

age. Replace if damaged or worn. Bearings are
considered worn and in need of replacement, if
axial play of twist lock is more than
3 mm (0.118 in.).
3. Check for mushrooming of the seated pins at

the contact area with the container attachment.
4. Check that the outer end of the seated pin

moves freely in its housing and does not stick.
ASSEMBLE
1. If necessary, install a new sleeve bearing. See
Figure 48.
2. Lubricate upper and lower bearings, twist lock

shaft, sleeve bearing, and sleeve springs with A. LOCATION OF SEATED SENSOR
multipurpose grease. 1. CRANK
2. COLLET
3. Install the four centering springs in the sleeve. 3. UPPER BEARING SET
Slide the sleeve on the twist lock. 4. LOWER BEARING SET
5. SLEEVE
NOTE: The lower ring is convex. The outer edge is 6. SLEEVE BEARING
higher than the inner edge. 7. SLEEVE SPRING
8. TWIST LOCK
4. Put the lower bearing on the sleeve and center 9. SEATED PIN
the lower ring on the raised edge of the sleeve.
Figure 48. Vertical Twist Lock Assembly
5. Position the grease fitting in the sleeve at the
same side as the grease fitting in the frame
plate. NOTE: The lower ring is convex. The outer edge is
higher than the inner edge.
6. Move the twist lock into the frame plate until
the upper ring of the lower bearing is seated in 7. Install the upper bearing in the recess of the
the frame plate. Support the twist lock by top frame plate.
means of a jack or other suitable device, to
8. Install collets with sloping side facing up.
make sure assembly does not fall out.
63
Twist Lock Repair for Models 586, 588, and 589 5000 SRM 1221
9. Install key and roll pin in keyway of twist lock. 13. Install lockwasher, socket head screw, ring pin,
and holding pin.
NOTE: To ease installation of crank to twist lock,
make two alignment pins using M8×75 bolts or 14. Install rod.
socket head screws with heads removed.
15. Install cover.
10. Install alignment pins into top plate of upper
bearing diagonally so each pin guides on half of 16. Adjust twist lock angle and proximity switches.
collets.
17. Lubricate complete assembly using multipur-
11. Insert tie rod end and fit crank onto alignment pose grease.
pins making sure key and keyway are lined up.
12. Install two bolts in crank, remove alignment

pins, and install remaining two bolts in crank.
Tighten all four bolts to 25 N•m (18 lbf).
Adjustments
TWIST LOCK ANGLE 3. Turn the adjustment bolts up to the twist lock
cylinder rod WITHOUT turning the twist locks
1. Move the twist lock cylinder rod to the fully OR moving the cylinder rod.
NOT LOCKED position. See Figure 49.
4. Tighten the adjustment bolts while maintain-
2. Check the correct alignment of the twist locks ing a play of 0.05 mm (0.002 in.) between the
in the twist lock sleeve in both end beams. twist lock cylinder and the bolt heads. Too
Align the twist lock with the twist lock sleeve much play will result in the piston rod ends be-
by turning the adjustment bolts of the twist ing hammered and becoming damaged.
lock cylinder. Keep the cylinder rod in the NOT
LOCKED position while adjusting the bolts. If 5. Turn the twist locks to the LOCKED position.
the twist locks will not line up fully in one end Check that they can turn through a full 90
beam, then divide the misalignment equally be- ±10 °, compared to the unlocked position. Check
tween both twist locks in the end beam. for mechanical failures if this position cannot
be obtained.
WARNING
Twist locks can get caught in the corner casting
of a container if the twist lock has not been
aligned and adjusted properly to the container.
64
5000 SRM 1221 Adjustments
1. TWIST LOCK 4. CYLINDER ROD

2. ADJUSTMENT BOLT 5. LOCK NUT
3. TWIST LOCK CYLINDER 6. TIE ROD
Figure 49. Twist Lock Adjustment
65
Adjustments 5000 SRM 1221
LOCKED/NOT LOCKED PROXIMITY

SWITCHES
1. Make sure the twist lock angle is properly ad-
justed. For the following procedure, see Fig-
ure 50.
2. 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.
3. Turn the twist locks to the fully NOT

LOCKED position.
4. Loosen the two upper sensor bracket bolts.
5. Slide the sensor bracket toward the LOCKED

position until the yellow LED in the NOT
LOCKED sensor is OFF.
6. Return the sensor bracket to the NOT

LOCKED position until the LED switches ON
again. Slide the bracket another 1. MOUNTING PLATE
2 mm (0.078 in.) further toward the NOT 2. SENSOR BRACKET
3. SENSOR CLAMP
LOCKED position and tighten the two upper 4. LOCKED SENSOR
sensor bracket bolts. 5. TIE ROD
6. SENSOR PLATE
7. Make sure the distance at which the NOT 7. SENSOR CLAMP BOLT
LOCKED signal turns OFF does not exceed 8. NOT LOCKED SENSOR
2 mm (0.078 in.) from the unlocked position. 9. SENSOR BRACKET BOLT
10. MOUNTING PLATE BOLT
8. Turn the twist locks to the LOCKED position
Figure 50. LOCKED/NOT LOCKED Proximity
and verify that the LED for the LOCKED sen-
Switches
sor has switched ON between 10 and
2 mm (0.393 and 0.078 in.) before the final
LOCKED position has been reached.
SEATED SIGNAL
9. Increase the distance between the locked sensor
and the sensor plate if the locked signal ap- 1. Check that the SEATED pin can move up and
pears more than 10 mm (0.393 in.) before the fi- down easily. The force needed to lift a pin is ap-
nal locked position. proximately 100 N•m (22 lbf).
10. Decrease the distance between the locked sen- 2. Fix the SEATED pin in a position of
sor and the sensor plate if the locked signal ap- 8 mm (0.315 in.) below the contact surface of
pears less than 2 mm (0.078 in.)2 mm before the attachment.
the final locked position.
66
3. Loosen the nut and bolt in the sensor bracket 5. Refer to the following procedures and Figure 51
that clamps the proximity switch. Move the to set a specific relief pressure.
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 to clamp 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 attach-
ment. The switch should be OFF if the
SEATED pin is more than 8 mm (0.315 in.) be-
low the contact surface of the attachment.
HYDRAULIC PRESSURES
NOTE: Normal operating temperatures vary due to
climactic conditions and the application of the lift
truck. Before adjusting hydraulic pressures, bring
hydraulic oil to the temperature which is normal
for the applicable circumstances.
General
1. Start the engine and apply the hydraulic func-
tions until the hydraulic oil temperature is at
the normal operating temperature.
2. After the normal operating temperature has 1. MAIN PRESSURE RELIEF VALVE
2. LEFT-HAND SLEW PRESSURE RELIEF VALVE
been reached, operate the extend and retract 3. SIDESHIFT PRESSURE RELIEF VALVE
functions several times to also allow the main 4. RIGHT-HAND SLEW PRESSURE RELIEF
direction control valve to reach its normal oper- VALVE
ating temperature. 5. LEFT-HAND SLEW SOLENOID
6. SIDESHIFT SOLENOID
3. Connect a pressure gauge to the quick discon- 7. RIGHT-HAND SLEW SOLENOID
nect fitting at the bottom of the main direction
Figure 51. Pressure Adjustment
control valve.
4. To adjust a relief valve setting, loosen the relief

valve lock nut and turn the adjustment screw Attachment Main Relief Pressure
clockwise to increase relief pressure. To lower
the relief pressure, first turn the adjustment 1. Disconnect the electrical connectors from the
screw counterclockwise to lower the pressure solenoids at both extension cylinders.
and then clockwise to increase the pressure to
2. Keep the extend or retract function activated
the required level. When the relief pressure is
and read the pressure gauge.
correct, tighten the lock nut. Check the pres-
sure setting again after tightening the lock nut.
67
3. Adjust the relief valve to 14 MPa (2,031 psi). NOTE: The attachment will move to the right-hand
side of the lift truck when the sideshift cylinder is
4. Connect the electrical connectors to the sole- extended.
noids at both extension cylinders.
2. Keep the sideshift extend function activated
Extension Relief Pressure and read the pressure gauge.
1. Increase the pressure of the attachment main 3. Adjust the relief valve to 13 MPa (1,886 psi).
relief valve to between 15 and 16 MPa (2,176
and 2,321 psi). TWIST LOCK ANGLE ADJUSTMENT
2. Disconnect the electrical connector from the ex- Model 586, 588, and 589
tension valve that is NOT being adjusted.
NOTE: Model 589 is not equipped with a flag indi-
3. Keep the extend function activated and read cator.
the pressure gauge.
1. Disconnect rod from flag indicator.
4. Adjust the relief valve at the activated exten-
sion cylinder to 14 MPa (2,031 psi). 2. Remove socket head screw and washer, and dis-
connect rod from pin.
5. Reconnect the electrical connector to the exten-
sion solenoid that was NOT being adjusted. 3. Remove ring pin, socket head screw, and lock-
washer. Remove pin.
6. Readjust the main relief pressure. Follow the
procedure under Attachment Main Relief Pres- 4. Put piston of the twist lock cylinder in fully
sure to adjust the main relief pressure to the NOT-LOCKED position.
correct setting.
5. Put twist lock in fully NOT-LOCKED position.
Slew Relief Pressure
WARNING
1. Make sure the main relief pressure is at the
correct setting. Twist locks can get caught in corner casting of
container if twist locks have not been aligned and
2. Disconnect the electrical connector from the adjusted properly.
slew valve that is NOT being adjusted.
6. Loosen bolts at tie rod end and adjust tie rod to
3. Keep the slew extend function activated and required length by turning rod end on cylinder
read the pressure gauge. assembly. Tighten bolts.
4. Adjust the relief valve of the activated function 7. Insert pin.

to 13 MPa (1,886 psi).
8. Install lockwasher, socket head screw, and ring
5. Check and adjust the pressure for the adjacent pin holding tie rod end on crank.
slew function.
9. Install rod onto flag indicator and onto pin us-
6. Reconnect the electrical connector to the slew ing socket head screw and washer.
solenoid.
NOTE: After NOT-LOCKED position is correctly
set, piston range of twist lock cylinder ensures a
Sideshift Relief Pressure
correct LOCKED position.
1. Make sure the main relief pressure is at the
correct setting.
68
LOCKED/NOT LOCKED SENSORS 12. Check that play in movement of twist lock does
ADJUSTMENT not cause a sensor to switch ON or OFF. Verify
both end positions by twisting each twist lock
Sensors have a LED close to the wire entry. When back and forth.
the sensor switches ON, the LED will be ON. When
making adjustments to sensors, place the ignition
SIDE CLAMP OPEN/CLOSED SENSOR
key of the truck in the ON position to activate the ADJUSTMENT (MODEL 584)
electric circuit of the spreader.
1. Put the side clamp in the open position.
Model 582 2. Loosen the nylon bracket for the open sensor.
1. Loosen bolts holding LOCKED and NOT 3. Slide the sensor away until it switches OFF.
LOCKED sensors.
4. Slide the open sensor toward the rectangular
2. Adjust space between sensor and ring to bracket on the indicator arm until it switches
1 mm (0.04 in.), using a feeler gauge. ON, then slide it an additional
3 mm (0.118 in.).
3. Tighten four bolts holding sensors.
5. Tighten the open sensor bracket.
Model 586, 588, and 589
6. Put the side clamp in the closed position.
1. Check twist lock angle. See End Beam Assem-
bly (Model 578). 7. Loosen the nylon bracket for the closed sensor.
2. Put twist lock in LOCKED position. 8. Slide the sensor away until it switches OFF.
3. Loosen nylon mounting sensor bracket. 9. Slide the closed sensor toward the rectangular
bracket on the indicator arm until it switches
4. Slide the sensor away until it switches OFF. ON, then slide it an additional
3 mm (0.118 in.).
5. Slide LOCKED sensor toward flag until it
switches ON, then slide it an additional 10. Tighten the sensor bracket.
3 mm (0.118 in.).
HOOK IN SENSOR ADJUSTMENT
6. Tighten sensor bracket. (MODEL 584)
7. Turn twist locks to NOT-LOCKED position.
NOTE: When the distance between housing and
8. Loosen sensor bracket. container is set at 25 mm (1.0 in.), there is
12.5 mm (0.5 in.) of play between the hook and the
9. Slide the sensor away until it switches OFF. inside contact of the container pocket.
10. Slide NOT-LOCKED sensor toward flag until it 1. Loosen the nylon bracket for the seated sensor.
switches ON, then an additional See Figure 52.
3 mm (0.118 in.).
2. Put a rigid plate 25 mm (1.0 in.) in front of the
11. Replace sensors if they do not switch ON at a twist lock housing.
distance equal or less than 4 mm (0.157 in.).
3. Slide the sensor away until it switches OFF.
NOTE: There is some play in movement of twist
locks.
69
1. NYLON BRACKET 2. SEATED SENSOR 3. CONTAINER

Figure 52. Seated Sensor Adjustment, Model 582
4. Move the sensor until it switches ON. 5. Tighten the bracket for the sensor.
5. Tighten the bracket for the sensor. 6. Replace the cover.
SEATED SENSOR ADJUSTMENT Model 586, 588, and 589
Model 582 1. Check that seated pin can move up and down
easily. The force needed to lift a pin is approxi-
NOTE: When the distance between housing and mately 100 N (22.5 lbf).
container is set at 24 mm (1.0 in.), there is
12 mm (0.5 in.) of play between the hook and the 2. Slowly move seated pin upward until seated
inside contact of the container pocket. sensor switches ON.
1. Remove the cover at the side of the floating 3. Measure distance between bottom end of seated
head. pin and head. The distance should be 9 to
10 mm (0.354 to 0.394 in.).
2. Loosen the nylon bracket for the seated sensor.
See Figure 52. 4. Reposition seated sensor higher if distance is
more than 10 mm (0.394 in.) and lower if dis-
3. Put a rigid plate 24 mm (1.0 in.) in front of the tance is less than 9 mm (0.354 in.).
twist lock housing.
4. Move the sensor until it switches ON.
70
OVERLOWERING PROTECTION SENSOR 4. Slide sensor toward activating plate until it

ADJUSTMENT (ALL 580 MODELS) switches ON.
1. Place end beams in lowered position. 5. Move sensor 2 mm (0.080 in.) toward plate and
tighten bolts of sensor bracket.
2. Loosen bolts of sensor bracket.
6. Replace sensor if it has not switched
3. Slide the sensor away until it switches OFF. ON4 mm (0.157 in.) from plate.
Electrical Component Checks

PRINTED CIRCUIT BOARDS (PCB)
To see if the PCBs are operating correctly, check:
1. Operate an attachment function and observe if

the correct output LED switches to ON for that
function. Repeat this procedure for all attach-
ment functions. Replace the PCB if any of the
output LEDs do not switch to ON for the func-
tion being activated.
SOLENOIDS
1. Disconnect the electrical connector from the sol-
enoid being tested.
2. Measure the resistance between the positive

terminal and negative terminal. See Figure 53.
The resistance should be within 1 to 2 ohms of 1. SOLENOID
the specification in Table 4. If the resistance is 2. NEGATIVE TERMINAL (GROUND, WIRE INDEX
NUMBER 10)
not within specification, replace the solenoid. 3. GUIDANCE TERMINAL
4. POSITIVE TERMINAL (WIRE INDEX NUMBER 1
3. Connect the electrical connector to the solenoid. THROUGH 6)
Table 4. Solenoid Specifications Figure 53. Solenoid
Voltage 24
Watts 30
Ohms 19.2
71
Electrical Component Checks 5000 SRM 1221
PROXIMITY SWITCHES
1. Disconnect the electrical connector from the
proximity switch.
2. Apply 24 vdc to pin 1. Using a multimeter set to

0 vdc, connect the black lead to pin 3 and the
red lead to pin 2. See Figure 54. The voltage
reading should be within 2 vdc of the supplied
voltage (24 vdc). If the voltage reading is not
within specification, replace the proximity
switch.
3. Connect the electrical connector to the proxim-

ity switch.
A. RECEPTACLE C. TERMINAL PIN

B. PLUG D. TERMINAL SOCKET
2. PIN 2 - SENSOR SIGNAL (NORMALLY OPEN)
Figure 54. Proximity Switch
Hook Repair for Model 584 and 585

REMOVE 2. Check the remaining thickness at the area
where the corner casting of the container is be-
1. Remove the nut and the washers at the rear ing carried. Replace the hook if the remaining
end of the hook. thickness is less than 95% of the original thick-
ness. See Figure 55.
2. Remove the hook at the front side of the head.
3. Replace the hook if the inside angle of the hook
INSPECT is 95° or more.
4. Check the flat carrying area at the inside of the

WARNING hook. New hooks have a flat area of
The lifting hooks are safety critical components 22 mm (0.866 in.) high. Replace the hook if the
because the hooks carry all the load when picking flat area is 15 mm (0.590 in.) high or less.
up and carrying a container. Hooks are wearing
parts and should be inspected for wear and dam- 5. Check if the hook is bent sideways. Replace the
age every 500 hours or three months. hook if it is bent 5° or more from centerline to
either side. 5 degrees means that the point of
1. Check for cracks. Replace the hook if there is the hook will be about 12 mm (0.5 in.) off cen-
any crack. ter.
72
5000 SRM 1221 Hook Repair for Model 584 and 585
INSTALL
1. Slide the hook from the front in the head. In-
stall the three washers and the self locking nut.
2. Tighten the nut until it just touches the wash-

ers and then release one-half turn. Check that
the fit of the hook is slightly loose.
1. ORIGINAL THICKNESS
2. REMAINING THICKNESS
3. HOOK INSIDE ANGLE
4. 22 mm (0.866 in.) WHEN NEW
5. REMAINING HEIGHT OF CARRYING AREA
Figure 55. Hook Wear
Side Clamp Replacement for Model 584

REMOVE INSTALL
1. Remove the container support that is mounted 1. Apply multipurpose grease with 2-4% molybde-
on the top of the end beam. See Figure 56. num disulfide to the mating holes for the pivot-
ing pins.
NOTE: The holes at the bottom plate of the head
provide access for a drift. 2. Use a lifting device to position the side clamp.
Fit the pivoting pin for the side clamp halfway
2. Put the clamp in the open position, and remove in.
the securing bolts and push the two pivoting
pins out of the side clamp. 3. Lift the side clamp at the under side with a
wedge, and fill the space as far as possible with
washers. Use the pivoting pin to check correct
WARNING positioning of the washers.
Verify the lifting device has the rated capacity to
lift the slide clamp or personal injury may occur. 4. Push the pivoting pin into its final location. Re-
move the wedges and tighten the securing bolt.
3. Use a lifting device to remove the slide clamp.
5. Insert the pivoting pin for the clamp cylinder
and its securing bolt.
73
Side Clamp Replacement for Model 584 5000 SRM 1221
1. HOOK 6. PIVOT PIN

2. WASHER 7. SECURING BOLT
3. NUT 8. CLAMP CYLINDER
4. BUSHING 9. SIDE CLAMP
5. WASHER 10. CONTAINER SUPPORT
Figure 56. Side Clamp
74
5000 SRM 1221 Torque Specifications
Torque Specifications
Extension Cylinder Retention Ring Screws Stop Cylinder Lock Pin M12 Bolt
78 N•m (58 lbf ft) 78 N•m (58 lbf ft)
Extension Cylinder Retention Ring Bolts Stop Cylinder Piston Securing Bolt
130 N•m (96 lbf ft) 130 N•m (96 lbf ft)
Sideshift Cylinder Piston Securing Nut Twist Lock Cylinder Assembly Bracket Bolts
800 N•m (590 lbf ft) 38 N•m (28 lbf ft)
Sideshift Cylinder Gland Twist Lock Cylinder Gland Bolts

800 N•m (590 lbf ft) 16 N•m (12 lbf ft)
Slew Cylinder Piston Securing Nut Standard Hardware

800 N•m (590 lbf ft)
See the section Metric and Inch (SAE) Fas-
Slew Cylinder Gland Nut teners 8000SRM0231.
800 N•m (590 lbf ft)
Stop Cylinder Housing to Cylinder Gland Al-

len-head Screws
38 N•m (28 lbf ft)
75
Troubleshooting 5000 SRM 1221
Troubleshooting
PROBLEM POSSIBLE CAUSE PROCEDURE OR ACTION
No spreader functions or no Check lift truck hydraulic supply Repair the supply valve.
spreader functions in one direc- valve for correct operation.
tion.
Low main hydraulic pressure at Adjust the pressure at the main

the spreader main relief valve. relief valve to 140 bar (2031 psi).
Dirt in the relief valve cartridge. Clean or replace the relief valve.
No electrical power at the sole- Check for proper voltage at the

noids of both the lift truck and solenoids, if voltage is present,
chassis. replace the solenoid. If voltage is
not present check the appropri-
ate switch.
Low spreader response time. Low hydraulic pressure at the Adjust the pressure at the main
spreader attachment main relief relief valve to 140 bar (2031 psi).
valve.
Both extension beams will not ex- Low hydraulic pressure at the Adjust the pressure at the main
tend. spreader attachment main relief relief valve to 140 bar (2031 psi).
valve.

noids of both the lift truck and solenoid, if voltage is present, re-
chassis. place the solenoid. If voltage is
ate switch.
One extension beam will not ex- No electrical power at the sole- Check for proper voltage at the
tend. noid mounted on the rear of the solenoids, if voltage is present,
extension cylinder. replace the solenoid. If voltage is
ate switch.
Shock relief pressure is too low. Set relief valve pressure to

140 bar (2031 psi).
Both extension beams will not re- Low hydraulic pressure at the Adjust the pressure at the main
tract. spreader attachment main relief relief valve to Adjust the pres-
valve. sure at the main relief valve to
140 bar (2,031 psi).

noid valves on both lift truck and solenoids, if voltage is present,
76
5000 SRM 1221 Troubleshooting

ate switch.
One extension beam will not re- No electrical power at the sole- Check for proper voltage at the
tract. noid valve mounted on the rear of solenoid, if voltage is present, re-
the extension cylinder. place the solenoid. If voltage is
ate switch.
All twist locks will not operate. Low hydraulic pressure at the Adjust the pressure at the main
spreader attachment main relief relief valve to Adjust the pres-
valve. sure at the main relief valve to
140 bar (2,031 psi).

noid valves on both lift truck and solenoid, if voltage is present, re-
chassis supply valves. place the solenoid. If voltage is
ate switch.
Twist locks of one end beam will No electrical power at the twist Check the wiring harness at the
not operate. lock solenoid. solenoid or replace faulty sole-
noid.
Faulty solenoid. Replace the solenoid.
Mechanical obstacle stopping Remove the obstacle.

movement of the twist lock tie
rod.
Both slew cylinders will not func- Low hydraulic pressure at the Adjust the pressure at the main
tion, if equipped. spreader attachment main relief relief valve to 140 bar (2031 psi).
valve.

ate switch.
One slew cylinder will not operate, No power at the solenoid on the Check for proper voltage at the
if equipped. auxiliary block. solenoid, if voltage is present, re-
place the solenoid. If voltage is
not present, check the appropri-
ate switch.
One slew cylinder will not operate Check pressure on the service Adjust the pressure at the main
in one direction, if equipped. line relief valve. relief valve to 130 bar (1,886 psi).
77
Troubleshooting 5000 SRM 1221
Sideshift cylinder will not func- Low hydraulic pressure at the Replace the main relief valve.
tion. spreader attachment main relief
valve.

ate switch.
No power at the solenoid on the Check for proper voltage at the

auxiliary block. solenoid, if voltage is present, re-
place the solenoid. If voltage is
ate switch.
One or all indicator lights do not Blown bulb. Replace blown bulb.
function.
The proximity sensor switch is No input signal to the sensor

not functioning. switch. When the sensor switch
is activated an LED in the sensor
is ON. Replace faulty sensor
switch. Adjust the distance be-
tween the sensor switch and the
sensor bracket to 2 to
5 mm (0.079 to 0.197 in.).
The electric circuit of a particular Check for loose connectors.

function is open. Check the proper functioning of
the Printed Circuit Board.
Hydraulic functions other than the Electric solenoid or relief solenoid Clean or replace the solenoid.
function selected are operating at of a function other than the selec-
the same time. ted function is stuck in an open
position.
Precise positioning of the attach- Air has entered one or more at- Cycle the affected cylinders a few
ment is difficult. tachment cylinders. times to clear the air from the
system.
78
TECHNICAL PUBLICATIONS
5000 SRM 1221 1/16 (8/12)(4/11)(3/11)(11/06)(5/06)

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PART NO. 1612615 5000 SRM 1221

©2016 HYSTER COMPANY i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

Series Code / Model Designation Reference Table

Series European Model Americas Model

1. FLOATING END BEAM 6. CARRIAGE

Figure 1. Empty Container Attachment

Attachments with optional stop kits can also lift

The stop cylinder is held in position by continuous

The sideshift cylinder has a stroke of 600 mm (2 ft)

Twist Locks 589 have a provision that also allows han-

A. MODEL 582 D. MODEL 586/588

Figure 3. Container Engagement

Carriage The position of the seated pin is transferred to a re-

The central frame of the spreader is secured to the

Legend for Figure 5

The indicator lights inform the operator about the

The indicator lights are illuminated as a result of

Figure 5. Seated Pin Assembly

Figure 6. Indicator Lights

Table 1. Indicator Light Descriptions

Twist Module • Disabling lift interrupt (mast lift/lower func-

For a short period of time, the blue LED on the

The blue LED can also be ON continuously during

The following functions can be disabled when turn-

1. LEFT-HAND EXTENSION CYLINDER CONTROL VALVE

Figure 8. ELME 580 Series Hydraulic Schematic

Sideshift The attachments are designed to lift either 6.1- or

The extension signal from the operator cab acti-

A. TOP SIDE B. BOTTOM SIDE

Figure 9. Sideshift Valve Assembly

Figure 10. Right-Hand and Left-Hand Extension/Twist Lock Valve

Legend for Figure 10

1. PRESSURE LINE TO LEFT-HAND VALVE 10. GAUGE ADAPTOR

Twist Lock Circuit Container Locking Model 582

Repeat the procedure to position the attachment on

Container Locking Model 585

Model 585 does not have sensors or indicator lights

Model 585 is designed to lift one empty container at

Container Locking Models 586, 588, and 589

Models 586, 588, and 589 are designed to lift one

Figure 12. End Beam Assembly Model 584

Legend for Figure 13

Figure 13. End Beam Assembly (Model 585)

Legend for Figure 14

1. SEATED PIN 11. CRANK PIN

Stop Cylinder Circuit pile slope direction. Maximum pressure of

OPTIONAL POWERED PILE SLOPE

The powered pile slope carriage is divided in two

When the powered pile slope function is not activa-

A. FRONT OF TRUCK B. REAR OF TRUCK

ELME 580 SERIES VALVES

The sequence valve assembly is mounted on the

Figure 17. Sequence Valve

Pilot Check Valve

To maintain twist locks in the locked or in the un-

The required electrical current and signals from the

Figure 18. Pilot Check Valve

1. PRINTED CIRCUIT BOARDS 7. CONNECTORS FOR SOLENOID VALVES