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7 Load handling 7.5.6 Positioning motor

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Spreader motor, replacement

NOTE
Read the safety instructions for oil before working, see tab B Safety. 1 Machine in service position, see tab B Safety.
2 Remove the cover plate on the left-hand side of the attachment's main beam.

3 Start the engine and run out the spreading until the chain tensioners become visible in the inspection holes. 4 Turn off the engine and turn the start key to position I. 5 Depressurize the brake and hydraulic systems, see tab B Safety. 6 Turn the start key to position 0 and turn off the main electric power.

7 Measure and note down the chain tensioner's position to regain the correct tension on the chain when installing. 8 Detach the chain tensioner on the motor side and release the chain from the tensioner.

9 Remove the protective plate over the spreader motor.

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10 Mark up and disconnect the hydraulic hoses from the valve block for the spreader motor.

11 Remove the spreader motor unit.

12 Transfer the valve block to the new motor unit.

NOTE
Check that the O-rings are intact and correctly fitted.
13 Clean the contact surfaces between the planetary gear and the attachment's main beam. 14 Install the motor unit. Tighten the bolts crosswise in sequences with increasing torque to 117 Nm. 15 Connect the hydraulic hoses to the valve block on the motor.

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7 Load handling 7.5.7 Positioning chains

16 Connect the spreader chain to the chain tensioner. Check that the chain runs straight in the chain wheel on the hydraulic motor. 17 Tension the spreader chain to the same degree as before. 18 Turn on the main electric power and start the engine. 19 Check that the hydraulic connections seal tightly. 20 Check that spreading works. 21 Fit the protective plate over the motor. 22 Brush on Lubricating grease on the spreader chain. 23 Fit the cover plates to the attachment's main beam. 24 Check the oil level in the hydraulic oil tank with the lift cylinders completely down and the extension cylinder completely in. The oil level should be at the top of the level glass. Top up as needed.

C AUTION
Overfilling of oil. Leakage and environmental damage. The hydraulic oil level is checked with the boom completely lowered and retracted.

7.5.7
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Positioning chains

Spreader chains, description


The spreader chains pull the extension beams in and out from the attachment's main beam. The force from the spreader motor is transmitted to the extension beams via two chains. The chains run inside the attachment between the extension beams.
M

The chains are attached crosswise with one end attached to the bottom of one of the extension beams and the other along the side of the other extension beam. Openings in the sides of the extension beams and the attachment's main beam make it possible to access the chains for maintenance.

Principle diagram spreader chains

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7 Load handling 7.5.7 Positioning chains

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Positioning chains, checking


1 Before adjustment, the clearance between the slide plates and extension beams must be checked otherwise the chain's mountings will be damaged, see tab 7 Load handling, group 7.5.8 Positioning beam. 2 Start the engine and run in the positioning to the 20-foot position, and turn off the engine. 3 Check the C-C measurement between the twistlocks. C-C 20-foot: 58533 mm Check that both positioning beams run against the 20-foot stops and that the distance between positioning beam and the positioning motor's mounting is at least 3 mm. 4 If needed, adjust the distance by moving washers between the right and left 20-foot stop. The quantity of washers may not be changed.

NOTE
Note the distance that the stop is adjusted.
Run out the positioning slightly so that it is possible to move the washers.

5 Remove the cover plates on the attachment's main beam.

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7 Load handling 7.5.7 Positioning chains

6 If the 20-foot stops have been adjusted, the positioning chains should be adjusted equally (as much).

NOTE
Check the chain tensioner's vertical position so that the chain runs straight toward the chain wheel.
7 Start the engine and run out the positioning to the 40-foot position, and turn off the engine. 8 Check the C-C measurement between the twistlocks. C-C 40-foot: 119853 mm

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9 If needed, adjust the 40-foot stops. 10 Start the engine and run in the positioning to the 40-foot position. 11 Wait 2 minutes and then check the tension of the chains. Measure how much the chain can be pushed in at the hole closest to the centre of the attachment. When the chain is pressed in with a force of 250 N it should move 2040 mm from resting position. 12 If needed, adjust the tension of the chains. Start the engine and run out the positioning until the chain tensioner is visible in the inspection hole. Adjust the chains.

NOTE
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Adjust the chain max. 2 mm at a time on the chain tensioner.


13 Repeat steps 911 until the chain tension is correct. 14 If the machine is equipped with 30-foot or 35-foot stops: Start the engine and run out the positioning to the 30-foot or 35-foot position. Turn off the engine and check the C-C measurement between the twistlocks. C-C 30-foot: 89183 mm C-C 35-foot: 104883 mm

I M P OR TA NT
Check the distance at stop from both 20' and 40'.

15 Brush lubrication grease on the positioning chain. 16 Fit the cover plates to the attachment's main beam.

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page

Spreader chain, replacement


1 Park the machine with the attachment as far down as possible. 2 Remove the cover plates on the attachment's main beam.

3 Start the engine and run out the spreading until the chain tensioners become visible in the inspection holes. 4 Turn off the engine and the main electrical power.

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5 Detach the defective chain's chain tensioner and release the chain from the tensioner.

NOTE
Measure and note down the chain tensioner's position to regain the correct tension on the chain when installing.

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7 Load handling 7.5.7 Positioning chains

6 Remove the defective chain's chain wheel.

NOTE
Note down the position of the spacer ring.
If the chain wheel on the motor side shall be removed then the spreader motor must first be removed, see Spreader motor, replacement page 66.

7 Pull the chain out through the hole for the chain wheel so that the chain runs along the spreader beam.

8 Secure the chain temporarily along the cable rack to prevent the chain from jamming.

9 Pull out the spreader beam. Use a machine or similar to pull out the spreader beam from the attachment's main beam. Stop when the spreader beam is near the 40-foot stop.

NOTE
Support the spreader beam so that bending stresses are minimized. If needed, remove the upper slide plates to reduce the resistance.

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10 Remove the boom stop from the attachment's main beam. 11 Remove the hydraulic hoses' clamping on the attachment's main beam.

12 Disconnect the cable rack from the attachment's main beam. Support the cable rack so that it is not damaged.

13 Pull out the spreader beam until the chain's mounting is accessible. 14 Release the chain from the spreader beam and cable rack. 15 Connect the new chain to the spreader beam.

16 Secure the chain along the cable rack so that the chain runs straight along the spreader beam. 17 Brush on Lubricating greaseon the chain.

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7 Load handling 7.5.7 Positioning chains

18 Retract the spreader beam so that the extension stop can be fitted. 19 Fit the extension stop. 20 Connect the cable rack to the attachment's main beam. 21 Fit the hydraulic hoses' clamping on the attachment's main beam. 22 Push in the spreader beam until it is pressed in as fas as the other. This is important for easier installation of the chains.

23 Release the chain from the cable rack and thread it through the chain wheel's hole.

24 Install the chain wheel. The spacer ring should be fitted on the underside of the chain wheel. If the rotation motor was removed, install it, see Spreader motor, replacement page 66.

NOTE
Check that the chain runs straight into the chain wheels.

25 Connect the chain to the chain tensioner.

NOTE
Use a new split pin.

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7 Load handling 7.5.8 Positioning beam

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26 Lubricate the chain wheel's bearing with Lubricating grease. 27 Tension the spreader chain to the same measurements as before. Tighten the lock nut. 28 If the slide plates were removed, fit them. 29 Turn on the main electric power and start the engine. 30 Check that the spreading is working correctly. 31 Turn off the engine. 32 Check the chains' tension, see Positioning chains, checking page 69. 33 Fit the cover plates to the attachment's main beam.

7.5.8
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Positioning beam

Positioning beam, description


1 10 9 8 2 3 4 7 6 5
001500

The positioning beams are a part of the attachment which grips in the container. Two positioning beams run in the main beam. The positioning beams are retracted and extended with the positioning motor and the positioning chains. There are twistlocks located in the positioning beam, see Twistlocks, description page 119.

1. Sideshift frame 2. Sideshift cylinder 3. Position sensor positioning 4. Sensor alignment 5. Twistlock 6. Sensor twistlocks 7. Lock cylinder twistlocks 8. Positioning beam 9. Positioning motor 10. Main beam attachment

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7 Load handling 7.5.8 Positioning beam

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Slide plates, extension beams, changing


1 Machine in service position, see tab B Safety. 2 Take the strain off the slide plate in question. The pressure can be removed from the slide plates by raising the outer edges of the extension beam or inserting wedges to alter the position of the extension beam in the attachment's main beam.

The illustration shows the inner slide plates in the attachment's main beam. 3 Remove the attaching bolts for the slide plate's bracket. 4 Remove the guide plate's guide pin. 5 Pull out the slide plate with spacer plate and bracket.

The illustration shows the inner slide plates in the attachment's main beam. 6 Fit the new slide plate in the correct position. Check the clearance between the extension beam and slide plate. The clearance must be max. 1 mm with all slide plates installed. Use a spacer plate to adjust the clearance. 7 Fit the slide plate's bracket and guide pin.

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7 Load handling 7.5.9 Main beam attachment

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Lubrication

8 Lubricate the glide surfaces on the attachment with white lubrication paste. 9 Run spreading completely in and out approx. 10 times and check the spreading function. 10 Wipe off excess lubrication paste by the slide plates and on the glide surfaces. 11 Try lifting a container and check the extension beams' clearance in the attachment's main beam.

7.5.9
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Main beam attachment

Main beam attachment, description


See Main beam attachment, description page 56.

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7 Load handling 7.5.10 Position sensor positioning

7.5.10
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Position sensor positioning

Position sensor positioning, description


1 2 3 4 5
Position sensor positioning indicates the position of the positioning beams. The position sensors are used to control positioning so that twistlocks fit on the container. The position sensors are located under the protective plate on the top side of the attachment's main beam on the left side. Sensor end-position (B769) indicates end-position for 20 and 40 foot containers. The sensor senses the end-positions of the positioning beams with two indicator plates on the top side of the positioning beam. The sensor is used to activate damping.

For the optional 30 foot stop an extra sensor is installed, Sensor position (B779), and two indicator plates. The sensor is used to activate 30 foot stop. The sensors are supplied with voltage and send a 24 V signal to Control unit attachment (D791-1) when the raised parts of the indicator plates pass the sensor. On the positioning beam there are indicator plates mounted so that the sensors give a signal when the positioning unit passes the sensor. The indicator plates' and sensors' positions are adapted so that the distance between the spreaders becomes 20, (30) and 40.
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The signals can be checked from the diagnostic menu, see section 8 Control and monitoring system, group 8.4.9.5 ATTACH, menu 5.

1. Indicator plate 20 2. Sensor damping 20 and 40, Stop 30 3. Sensor damping 30 4. Indicator plate 30 or 35 5. Indicator plate 40
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Position sensor, checking and adjustment


See Position sensor, checking and adjustment page 5.

7.5.11
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Unloading valve attachment

Relief valve attachment, description


See Relief valve attachment, description page 57.

7.5.12
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Pipes and hoses

Pipes and hoses, description


See section 10 Common hydraulics, group 10.5.1 Pipes and hoses.

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Workshop manual DRF 400450