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CONTAINER
ATTACHMENT (ELME)
580 SERIES
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 Model 583 ..................................................................................................................15
Container Locking Model 584 ..................................................................................................................15
Container Locking Model 585 ..................................................................................................................15
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
ii
Table of Contents
iii
Table of Contents
iv
5000 SRM 1221 Series Code / Model Designation Reference Table
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-
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
Sideshift
3
Description 5000 SRM 1221
4
5000 SRM 1221 Description
5
Description 5000 SRM 1221
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
6
5000 SRM 1221 Description
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.
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
9
Operation 5000 SRM 1221
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
10
5000 SRM 1221 Operation
11
Operation 5000 SRM 1221
12
5000 SRM 1221 Operation
13
Operation 5000 SRM 1221
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.
14
5000 SRM 1221 Operation
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.
15
Operation 5000 SRM 1221
A. UNCLAMPED B. CLAMPED
1. HOOK 4. SENSOR FLAG
2. SIDE CLAMP 5. SENSOR UNCLAMPED POSITION
3. SENSOR CLAMPED POSITION
16
5000 SRM 1221 Operation
1. NUT 5. SPRING
2. WASHER 6. END BEAM
3. STUB SHAFT 7. BOLT PLATE
4. HOOK
17
Operation 5000 SRM 1221
Figure 14. End Beam Assembly (Models 586, 588, and 589)
18
5000 SRM 1221 Operation
19
Operation 5000 SRM 1221
20
5000 SRM 1221 Operation
21
Operation 5000 SRM 1221
Sequence Valve
NOTE: Remove and inspect the cartridge valve if
there is a problem with the correct locking and/or
unlocking sequence.
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
22
5000 SRM 1221 Operation
ELECTRICAL SYSTEM
23
Operation 5000 SRM 1221
24
5000 SRM 1221 Operation
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
25
Operation 5000 SRM 1221
26
5000 SRM 1221 Operation
27
Operation 5000 SRM 1221
28
5000 SRM 1221 Operation
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
Operation 5000 SRM 1221
Cable Connectors
30
5000 SRM 1221 Operation
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.
INDICATOR LIGHTS
31
Operation 5000 SRM 1221
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.
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 hy- draulic 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.
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.
35
Wear Pads 5000 SRM 1221
CAUTION
When lifting higher than necessary, hydraulic ho-
ses or the electric cable inside the floating end
beam may get damaged.
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.
37
Wear Pads 5000 SRM 1221
38
5000 SRM 1221 Extension Cylinder
Extension Cylinder
REMOVE 6. Shut down the engine.
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.
39
Extension Cylinder 5000 SRM 1221
40
5000 SRM 1221 Extension Cylinder
41
Extension Cylinder 5000 SRM 1221
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
5000 SRM 1221 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.
Install
Disassemble
1. Remove the gland nut. See Figure 34.
43
Extension Cylinder 5000 SRM 1221
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.
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.
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
250 kg (551 lb) or personal injury may occur.
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
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).
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.
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
WARNING
Verify the crane has a lifting capacity of
250 kg (55 lb) or personal injury may occur.
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.
HOSE, REPLACE
1. Remove the end beam.
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.
3. Place identification tags on the hydraulic lines.
CAUTION
WARNING
Use caution not to damage the finished surface of
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.
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.
51
Stop Cylinder (Optional) 5000 SRM 1221
WARNING
DO NOT disconnect any hydraulic lines when the
engine is running or personal injury may occur.
DISASSEMBLE
1. Remove the M12 bolt that guides the lock pin.
See Figure 39.
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
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 cyl- inder 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.
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
WARNING
DO NOT disconnect any hydraulic lines when the
engine is running or personal injury may occur.
54
5000 SRM 1221 Twist Lock Cylinder
55
Twist Lock Cylinder 5000 SRM 1221
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
10. Remove the roll pin and key from the twist
lock.
57
Twist Locks 5000 SRM 1221
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.
can cause skin irritation. When using cleaning
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.
58
5000 SRM 1221 Twist Locks
59
Twist Lock Repair for Model 582 5000 SRM 1221
10. Slide out the spring and remove the square nut.
60
5000 SRM 1221 Twist Lock Repair for Model 582
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.
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.
62
5000 SRM 1221 Twist Lock Repair for Models 586, 588, and 589
ASSEMBLE
1. If necessary, install a new sleeve bearing. See
Figure 48.
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.
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
65
Adjustments 5000 SRM 1221
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
5000 SRM 1221 Adjustments
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.
67
Adjustments 5000 SRM 1221
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.
68
5000 SRM 1221 Adjustments
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
Adjustments 5000 SRM 1221
4. Move the sensor until it switches ON. 5. Tighten the bracket for the sensor.
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.
70
5000 SRM 1221 Adjustments
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.
SOLENOIDS
1. Disconnect the electrical connector from the sol-
enoid being tested.
71
Electrical Component Checks 5000 SRM 1221
PROXIMITY SWITCHES
1. Disconnect the electrical connector from the
proximity switch.
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.
1. ORIGINAL THICKNESS
2. REMAINING THICKNESS
3. HOOK INSIDE ANGLE
4. 22 mm (0.866 in.) WHEN NEW
5. REMAINING HEIGHT OF CARRYING AREA
73
Side Clamp Replacement for Model 584 5000 SRM 1221
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)
75
Troubleshooting 5000 SRM 1221
Troubleshooting
No spreader functions or no Check lift truck hydraulic supply Repair the supply valve.
spreader functions in one direc- valve for correct operation.
tion.
Dirt in the relief valve cartridge. Clean or replace the relief valve.
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.
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
not present check the appropri-
ate switch.
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).
76
5000 SRM 1221 Troubleshooting
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
not present check the appropri-
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).
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.
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.
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.
One or all indicator lights do not Blown bulb. Replace blown bulb.
function.
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