Section 8

Ser vice Training

Service Page 1

8 BOOM AND SPREADER

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8.1 BOOM AND SPREADER ASSY

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GENERAL VIEW OF BOOM AND SPREADER

1 Boom pivot bearing

2 Boom
3 Energy chain with supply lines to the spreader
4 Levelling cylinder
5 Spreader bearing
6 Spreader
7 Lift cylinder

The boom (2) is mounted in the boom pivot bearing (1) on the chassis. It is raised by two lift cylinders (7).
The spreader (6) is attached at the spreader bearing (5). Swing movements of the spreader are dampened
with the levelling cylinders (4). The spreader (3) is supplied with hydraulic energy with the supply lines and
controlled with the electric functions.
Two different spreader models are in service:

- Model 817 telescopic top pick spreader with slewing gearbox and sideshift

- Model 857 telescopic top and bottom pick spreader with slewing gearbox, sideshift carriage and
blockstack cylinders.
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8.2 BOOM

BOOM

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1 Lifting eyes, rear
2 Boom, outer tube
3 Lifting eyes, front
4 Boom, inner tube
5 Energy chain
6 Pivot bearing
7 Beam extension cylinder

8.2..1 DESCRIPTION

The boom consists of the outer tube (2) and the inner tube (4), which are connected by the beam extension
cylinder (7). The inner tube slides on sliding bearings mounted in the outer tube at the front and rear. The
sliding bearings are lubricated via grease nipples and are liable to wear. They must be replaced when their
thickness is down to .... mm. For the removal of the boom lifting eyes are provided at the front (3) and rear
(1) end of the outer tube. The boom is mounted on the chassis in two pivot bearings (6) at the rear end.
The hydraulic and electric cables for the boom and spreader. The electric and hydraulic lines to the
spreader are routed through the energy chain (5).
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3
1 2

7
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13

9
11 10
12

FEEDS TO THE BOOM AND SPREADER.

1 24 Pin plug standard electrical feeds to spreader
2 Plug connector to red, amber, green lights
3 Plug connector to additional piggy back lights
4 24 Pin plug option, piggy back spreader
5 Regeneration valve for extension cylinder
6 Leak to tank from spreader and extension cyl
7 Hydraulic feed to spreader
8 Hydraulic tank return from spreader
9 Pilot signal to extension cylinder
10 Feed to spreader damping cylinders
11 Feed to automatic greasing on boom
12 Plug connector to angle transducer
13 Plug connector to beacon/boom lights

TECHNICAL DATA

Weight of boom 13.5 tonnes Weight of standard spreader 9.25 tonnes

Weight of lift cylinder 1 tonne Weight Piggy back spreader 11 tonnes
Weight of boom extend cyl. 1.8 tonne
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8.2.2 BOOM REMOVAL

Aids required:
- Crane, approx. 25 tonnes
- Fork truck with a load capacity of at least 8 tonnes
- Working platform or fork truck with working cage

DANGER
When the boom is being lifted with a
crane, do not stand within the working
range of the crane! Do not step under
the raised load. Only use a crane and
lifting gear with sufficient lifting capac-
ity. After the slings are attached to the
crane hook (2), close the hook safety
(1).

NOTE: Dismantle the spreader before remov-

ing the boom.

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- Support the boom as shown (1) (weight of the
boom: 13.5 tonnes).
- Support the lift cylinder as shown (2) (weight of the
lift cylinder: 1 tonne).
- Disconnect the hydraulic hoses from the lift cylin-
der and plug them.
- Remove the pin (3) at the lift cylinder.
- Lower the lift cylinder onto the chassis.

NOTE
NOTE:: To avoid damage, place wooden
blocks between the chassis and lift
cylinder.

- Refit the pin (3) on the boom.

- Fasten the lift cylinder.
- Remove the second lift cylinder as described
above.
- Disconnect the electric cables on the boom.
- Disconnect the hydraulic hoses from the boom
and plug them.
- Remove the pin (4) from the boom pivot bearing.
- Lift the boom to the rear away from the pivot
bearing.
- Deposit the boom on wooden blocks as shown
(5) to prevent damage.
- Refit the pin (4) in the boom pivot bearing at the
rear.
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8.2.3 BOOM ASSEMBLY

BEFORE ASSEMBLY

- With the engine shut off and the ignition turned on,
depress the buttons on the central control lever to
release any residual pressure in the hydraulic
system.
- Turn off the ignition and remove the ignition key.
- Apply the parking brake and block the wheels with
chocks.

- Lift the boom as shown (3) and position it at the

chassis for the installation of the pin (4) at the pivot
bearing (weight of the boom: 13.5 tonnes).
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MOUNTING THE BOOM IN THE PIVOT BEARING

- Position the boom (B) to the vehicle frame bearing (A) so that the drilled holes are in line.
- Insert the pin (1) with the shims (2) through the drilled holes (with nose on pin pointing downwards) and
drive it in with light blows of the hammer.

ATTENTION
Position the lubricating hole (arrow) vertically so that the bearing is greased sufficiently.

- Position the plate (3) at the pin and fasten it with four M16x55 screws (4).
- Tighten the screws (4) to 180 Nm.
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MOUNTING THE BOOM IN THE PIVOT BEARING

1 Pin
AVehicle frame bearing 2 Shims
BBoom bearing 3 Plate
4 M16x55 screws
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MOUNTING THE LIFT CYLINDER IN THE BOOM

BEARING

- Lift the lift cylinder (7) as shown (5) and position it

so that the cylinder can be installed with the lift
cylinder mounting pin (6) (weight of the lift cylin-
der: 1 tonne).
- Insert the lift cylinder mounting pin (6) into the
boom bearing (D), position the tab of the pin in the
cut-out and drive the pin in with light blows of the
hammer.

ATTENTION
Position the lubricating hole (arrow)
vertically so that the bearing is greased
sufficiently.
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- Position the plate (8) at the pin and fasten it with

screws (9) and washers (10).
- Tighten the screws (9) to a torque of 180 Nm (?).
- Reconnect all hydraulic hoses and electric ca-
bles (see figure with connections at the rear of the
boom).
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8.2.4 BOOM REPAIRS

8.2.4.1 BOOM EXTENSION CYLINDER

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INSTALLATION OF BOOM EXTENSION CYLINDER

1 Screw
2 Washer
3 Cover
4 Screw
5 Washer
6 Pin
7 Cylinder tube
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BOOM EXTENSION CYLINDER

1 Piston seal
2 Extension tube
3 Piston
4 Wear ring
5 Locking screw
6 Wear ring
7 Seal
8 O ring with back up ring
9 Feed tube
10 Rod
11 O ring with back up ring
12 Trunion
13 Rod seal
14 Rod seal
15 wiper seal
16 Head gland
17 Rod end
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REPLACING THE BOOM EXTENSION CYLINDER SEALS

ATTENTION
Observe the precautions for handling fluids and lubricants.

CAUTION
The hydraulic oil and tank are very hot when the operating temperature is reached. Danger
of scalds and burns!
This machine is equipped with accumulators in the brake and control circuits. Before starting
maintenance work on the circuits, the stored energy must be released. This is done with the
engine shut off and the ignition turned on by repeatedly operating the brake pedal, the parking
brake and the central control lever.
Work on the truck on level ground. Shut off the engine, apply the parking brake and remove
the ignition key during servicing.

With the engine shut off and ignition turned on

operate the central control lever (joystick) to
release any pressure in the system.

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Turn off the ignition.

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Chock the wheels of the truck.
Disconnect the battery (1).

NOTE
This work requires two fork trucks with a lifting capac-
ity of 3.5 tonnes and a lifting height up to 5 metres.

Disconnect the hose connections to the extension 1

cylinder. 2
The extend feed hose (1) with it's sae coupling and
block (2), the leak off hose (5), the pilot signal hose (6)
ant the retract feed hose (7).
The lowering valve screws (3) can be removed and
the lowering valve (4) can be lift away from the extend
cylinder. 4
7

6 5 3
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Loosen the 3B6 system extension measuring cable

(2) from it's securing bolt (1) and allow the cable to 1
retract slowly into the housing (3).
2

3
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Carefully position one fork (1) under the boom

extension cylinder (2) and take up the weight.

Remove the lifting eye nut (1) and washer (2); pull
the screws (3) out of the boom (4).

NOTE
Pull the screw out from the other side of the boom.
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Remove the four screws (1) and the cover plate (2)
from the boom (3)

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Pull the six screws (1) out and remove the pin (2)
from the boom (3).
Repeat the above procedure for the pin on the other
side of the boom.

Lift the rear end of the cylinder (1) about 50 mm.

Support the cylinder as shown (2).
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Carefully reverse the fork truck until the shoe weld (2)
is about 100 cm from the boom end.
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Lift the cylinder with the second fork truck as shown

(1). Raise the cylinder about 50 mm.
Carefully reverse both fork trucks until the cylinder is
out of the boom.
Lower the cylinder onto wooden pallets placed on level
ground.
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Pull the piston assembly (8) about 600 mm out of
the cylinder.
Remove the screws (5) from the end cap (6) and
pull the pston assembly out of the tube (1).
Secure the end of the piston assembly (8)
Remove the front piston retaining screw (4) from
the piston rod and unscrew the piston from the
tube using the special tool (A).
Clean the threads.
Remove and discard all seals (2), and wear rings
(3).
Install new wear rings (3) and seals (2). The seal
(2a) fitted between the piston and the feed tube (7)
must be heated to 70°C and folded into a heart
shape to permit fitting as must the PTFE seal (2b)
Fit the feed tube (7) into the piston using the special
tool (B).
Fit the piston into the tube and tighten using the
special tool (A) to 2000Nm.

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A

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Drill and tap two new grub screw holes M8 at 90°
to the existing holes and fit the grub screw (4),
secure the grubscrew with Loctite 243 and caulk
on completion.
Assemble the piston assembly into the tube with B
the ring item (6) in position. Fit and tighten the
screws (5)
Bleed the cylinder at low pressure before fitting into
the boom, bleed screw in piston head (8).
NOTE
This cylinder cannot be resealed without
using the special tools as illustrated.

Support the cylinder with two trucks as shown.

Carefully align the cylinder with the boom.
Drive the fork truck forward at creep speed
until the shoe weld (1) is about 100 cm in the
boom.
Remove the front sling (2).
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Drive the fork truck slowly forward until the

holes in the piston (2) are in line with the holes
in the boom.
Drive the fork truck slowly forward until the
holes in the piston (2) are in line with the holes
in the
Remove the rear sling (3).
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Refit the pin (2) in the boom (3) and secure it with six
screws (1). Torque the screws to 110 Nm.
Repeat the above procedure for the pin on the
opposite side of the boom.

Using the four screws (1), refit the cover plate (2) on
the boom (3). Torque the screws to 23 Nm.
Repeat the above procedure for the cover plate on the
opposite side of the boom.
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Install the screw (3) in the boom (4).
Secure the screw (3) with the washer (2) and lifting
eye nut (1).

Carefully lower the fork (1) and back the fork truck
away from the shutoff valve (2).

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Reconnect the valve block and hoses to the extension
cylinder. Check the hydraulic oil level and top up if
necessary, reconnect the battery.
Reconnect the 3B6 measuring cable, check the boom
length measurement and slow down are operating
correctly. See programme map section 6, pages 19-
24
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8.2.4.2 LIFT CYLINDER

1 Removable head 1
2 Gland seal
3 Gland
4 O-ring
5 Piston
6 Wear rings
7 Cylinder tube 11
2
8 Piston seal
9 Lower chamber feed tube
10 Upper chamber feed tube 3
11 Wiper seal

4
10
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SEALING THE LIFT CYLINDER, SERIES 357

Attention
Observe the precautions for the handling of hydraulic fluids and lubricants.

Caution
The hydraulic oil and oil tank may be at operating temperature. Risk of scalding and burns!
Work on the truck only on level ground; shut off the engine, apply the parking brake and remove
the key from the ignition switch.

Place one container on top of another.

Apply the parking brake.
Disconnect the connector (1) at the rear of the fork
truck on the boom mount.

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Press function key F2 (2) on the load safety system
panel (3 until the display (4) indicates Low Pressure
and High Pressure (5) for the lift cylinders.
Release the parking brake.
Lower the handler on the top container until the
values for Low Pressure and High Pressure (5)
equal zero.
NOTE:
It may be necessary to adjust the
position of the boom downward/upward
in order to achieve the zero indication.

Shut off the engine and apply the parking brake.

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Caution
This procedure must be carried out at
heights of over 2 metres. Use the
appropriate access equipment. Danger
of fall injuries.

Support the lift cylinder (1) (weight of the lift cylinder:

1 tonne).
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Remove the screws (1), washers (2) and retaining

plate (3) of the boom mounting pin (4).
Screw two Ø 12 mm and 150 mm long full-thread
screws into the extraction holes in the pin (4).
Turn the screws clockwise in equal steps until the
pin (4) can be removed easily.
Remove the pin (4).
The cylinder spherical bearing (5) is installed in the
the cylinder rod end with circlips (6).

Lower the cylinder on the chassis.

NOTE:
To prevent damage, place wooden 1
blocks (1) between chassis and lift
cylinder.

Turn the ignition key to the ON position, but do not

start the engine.
Wait 10 seconds until the computer has performed
its selftest.
Operate the lift/lower control lever to release any
existing hydraulic pressure.
Turn off the ignition and remove the ignition key.
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Place a container with a capacity of 50 litres on the
chassis under the pilot valve (1).
Disconnect the four hydraulic hoses (3) at the
shutoff valve (1). Protect the hose ends against
debris.
Carefully remove the four screws (2) from the 1
shutoff valve (1).
Remove the shutoff valve (1).
Do not re-use any O-ring on the shutoff valve (1).
2
NOTE:
If a central greasing system is installed,
remove the greasing system fuse (cf. 3
operating instructions) and remove the
hose from the shutoff valve.

Sling and support the lift cylinder (1).

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Remove the screws (1), washers (2) and retaining C01. Register 05

plate (3) of the chassis mounting pin (6).

Remove the screws and washers (7 & 8) in the lock
plate (9).
Use a dummy plate similar to item 9 to manufacture
a simple extractor as shown on page 21to pull the
pin Item (6).
Carefully take the lift cylinder from the chassis and
deposit it on wooden pallets placed on level ground.
Retain the bush Item (5) in the chassis for re-use.

Remove the second lift cylinder as described above.

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Manufacture a special tool from steel as shown.

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Remove the 16 Allen screws (6).
Remove the piston rod from the cylinder tube (1).
Remove the head Item (5).
remove the gland (4) ffrom the piston.
Remove all the seals (2a - 2F) and the wear rings
(3)
Clean the threads.
Install new seals (2) and wear rings (3).
Install the piston into the tube (1).
Fit the gland (4) and the screws (6) and tighten.
Fit the head (5).

Repeat the above procedure for the second lift

cylinder.
Fit the cylinders into the truck, fitting is the reverse
of the removal procedure.

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The cylinder must be bled to ensure correct
operation, the bleed screw is located in the top of
the piston (1) adjacent to the removable head (2).

Remove the bleed screw (1), operate the lift very

slowly until oil is ejected from the vent area.

Note.
observe safe working procedures while
bleeding the cylinder. Ensure that
ejecected oil will not contaminate nearby
objects or personel.

Start the engine.

Remove the handler from the container.
Back off the truck from the stack.
Lower the boom and retract it.
Stop the engine.
Check the hydraulic oil level (1). If necessary, add
hydraulic oil.

Perform a comprehensive functional check on the

lifting system.
Check for leaks and eliminate them, if necessary.
Recheck the oil level.
Return the truck into operation.
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8.2.4.3 SLIDING BEARINGS

RENEWING THE SLIDING BEARINGS

NOTE
NOTE:: Lubricate all sliding bearings with general grease immediately after installation.
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REAR SLIDING BEARINGS

1 Guide
2 Screw
3 Washer
4 Stop plate
5 Sliding bearing

REAR OF BOOM

Remove the screws (2) and washers (3).

Take off the stop plate (4), pull out the sliding bearing (5) and guide (1) and renew them.
Install new guides and sliding bearings (6 items) and secure them with stop plates and screws.
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FRONT SLIDING BEARINGS

1 Intermediate plate
2 Screw
3 Washer
4 Plate
5 Sliding bearing
6 Screw
7 Bushing
8 Washer
9 Stop plate
10 Pin

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FRONT OF BOOM

Remove the screws (6), washers (8) and bushing (7) (2 bushings each per side).
Take the sliding bearing (5) out of the bushing and renew it (4 items).
Refit the bushing and secure it with screws.

FRONT TOP OF BOOM

Remove the screws (2) and washers (3) on the top of the boom.
Remove the plate (4) and renew it (2 items).

FRONT BOTTOM OF BOOM

Remove the screws (10) and washers (3) at the stop plate (9).
Remove the sliding bearing and renew it (2 items).
Fasten the new sliding bearing with the stop plate and screws.
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8.2 SPREADER MODEL 817

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GENERAL VIEW OF SPREADER MODEL 817

1 Front levelling cylinder 7 Twistlocks

2 Slewing motor 8 Beam extension cylinder (in extension beam)
3 Spreader bearing 9 Sideshift cylinder
4 Rear levelling cylinder 10 Control box L4 on slewing gearbox
5 Spreader beam 11 Control box L1 on spreader
6 Right extension beam 12 Slewing brake

8.2.1 OPERATION AND CONSTRUCTION

The spreader (handler) is used to pick up containers with a maximum load of 45 tonnes and of different
lengths: IE. 20', 30', 35' and 40' ISO containers.

SUSPENSION

The spreader is attached to the boom at the spreader bearing (3). The rear (1) and front (4) levelling
cylinders dampen swing movements occurring between the boom and spreader when a container is
picked up. The rear levelling cylinder is continously supplied with a low hydraulic pressure, approx. 30 bar,
while the front cylinder is supplied is supplied with about 20 bar of pressure. This makes the spreader
assembly assume a "front higher" aspect to assist operation.
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HYDRAULIC FUNCTIONS

The right (6) and left side of the spreader beam contains beam extensions which are moved by the two
extension cylinders (8). The movement is controlled with the joystick via a solenoid valve for each cylinder.
The beam extensions adjust the spreader length (2 hydraulic stops) to the container length. They run on
renewable sliding bearings (wear pads).

The spreader can be rotated horizontally with the slewing motor (3); two slewing brakes (12) brake the
rotation of the handler. Rotation is controlled by solenoid valves operated by the joystick in the driver's
cabin. The spreader is positioned accurately over the container with the aid of two sideshift cylinders (9),
one each for right and left side shifting. All spreader functions are controlled electrically through the joystick
via solenoid valves. The oil for the operation of the hydraulic functions is supplied by the hydraulic system
in the chassis via the energy chain on the right side of the boom.

TWISTLOCKS

Two pendulum twistlocks (7) are installed at each end of the beam extensions, with which the container
is seized from above and lifted. The twistlocks are rotated into the corner castings by the twistlock

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cylinders. One double-acting twistlock cylinder per side actuates two twistlocks through a cross shaft;
the three different positions (not locked - seated - locked) are monitored by sensors (proximity switches).
The twistlocks are subject to wear and are renewable. The twistlock cylinders are controlled by solenoid
valves from the joystick in the driver's cabin.

ELECTRICAL SYSTEM

The spreader is connected electrically to the controlling joystick via the sistemi 3B6 load safety computer.
The cables are routed to the spreader through the energy chain on the right-hand side of the boom.

The twistlock positions

- not locked ........................................................ red

- seated .............................................................. yellow + red
- locked .............................................................. green + yellow
- locked and lifted ............................................... green

are indicated on the boom with indicator box L6 and in the driver's cabin with indicator lights.
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8.2.2 TECHNICAL DATA AND SCHEMATIC DIAGRAMS

8.2.2.1 OPERATING AND PERFORMANCE DATA

Operating voltage 24 VDC

Operating pressure of hydraulic system 170 bar
Operating pressure of levelling cylinders (approx) 30 bar at rear, 20 bar at front
Weight 9.25 tonnes

Capacities:
- Slewing gear (rotator) up to bottom of filler opening
- Slewing brake up to bottom of filler opening
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Oil types and lubricants:

- General lubrication points general purpose grease
- Turntable bearing Linde lithium-based, heavy-duty grease
with EP additives and MoS2
- Slewing gear transmission oil to ISO 2448
G 150-220
- Slewing brake hydraulic oil to ISO VG 46

Torque loadings:

- Fastening screws: slewing gear to turntable bottom plate:

M12 (10.9) Torque loading 90 Nm

- Ring rear fastening screws (without locking devices):

M24 (10.9) torque loading 740 Nm
M12 (10.9) torque loading 90 Nm
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8.2.2.2 HYDRAULIC CIRCUIT DIAGRAMS FOR SPREADER MODEL 817

LEGEND TO THE HYDRAULIC CIRCUIT DIAGRAMS FOR SPREADER MODEL 817

1 Valve block for sideshift 31 Pressure relief valve 80 bar

2 Pressure relief valve 140 bar 32 Pressure relief valve 80 bar
3 Solenoid valve for right - left sideshift cylinder 33 Slewing motor
4 Valve block for right sideshift cylinder 34 Slewing brake
5 Valve block for left sideshift cylinder 35 Solenoid valve for releasing slewing brake
6 Check valve 36 Solenoid valve for right twistlock cylinder -
7 Left sideshift cylinder lock - unlock
8 Pressure relief valve 80 bar 37 Valve block for twistlock and right beam ex-
9 Right sideshift cylinder tension cylinder
10 Pressure relief valve 80 bar 38 Not used
11 Check valve 39 Right twistlock cylinder
12 Valve block for front levelling cylinder 40 Pressure relief valve 80 bar
13 Check valve 41 Right beam extension cylinder
14 Front levelling cylinder 42 Solenoid valve for extending - retracting right
15 Flow valves beam extension cylinder

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16 Check valve 43 Solenoid valve for left beam extension cylin-
17 Pressure relief valve 80 bar der
18 Pressure relief valve 80 bar 44 Left beam extension cylinder
19 Check valve 45 Pressure relief valve 80 bar
20 Flow valves 46 Left twistlock cylinder
21 Rear levelling cylinder 47 Not used
22 Check valve 48 Valve block for twistlock and left beam exten-
23 Valve block for rear levelling cylinder sion cylinder
24 Pressure relief valve 80 bar 49 Solenoid valve for left twistlock cylinder
25 Pressure relief valve 80 bar - lock - unlock
26 Valve block for slewing gear 50 Right stop cylinder*
27 Pressure relief valve 40 bar 51 Solenoid valve for right stop cylinder *
28 Solenoid valve for slewing speed shifting 52 Left stop cylinder *
29 Flow valves for slewing speed 53 Solenoid valve for left stop cylinder *
30 Solenoid valve for left-right rotation 54 Pressure relief valve 8 bar **

*Option
**Version with high damping pressure only
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HYDRAULIC CIRCUIT DIAGRAM FOR SPREADER MODEL 817

VERSION WITH LOW DAMPING PRESSURE

A3 PAGE, SEE DATEI 357_D_8HPL1_9906.P65, SEITE 39

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HYDRAULIC CIRCUIT DIAGRAM FOR SPREADER MODEL 817

VERSION WITH HIGH DAMPING PRESSURE

A3 PAGE, SEE DATEI 357_D_8HPL1_9906.P65, SEITE 40

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ELECTRIC CIRCUIT DIAGRAM

A3 PAGE, SEE DATEI 357_D_8EPL1_9906.P65, SEITE 41

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WIRING DIAGRAM (PART 1)

siehe Seite = see page

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WIRING DIAGRAM (PART 2)

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WIRING DIAGRAM (PART 3)

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WIRING DIAGRAM (PART 4)

siehe Seite = see page

HINWEIS LINKS
NOTE The switch designations on the joystick in the wiring diagram refer to section 6.

HINWEIS RECHTS
NOTE The subdistributor is located under the seat on the right side.

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LEGEND TO THE WIRING DIAGRAMS FOR SPREADER MODEL 817

B6 Computer box
B7 Relay box U1 Main connector on spreader slewing gear
U2 Connector on boom bearing
H1 Indicator light, Locked, green U10 Connector between L1 and L4
H2 Indicator light, Not Locked, red
H3 Indicator light, Seated, yellow Y1 Solenoid valve for twistlocks lock LH
Y2 Solenoid valve for twistlocks lock RH
K1 Relay for lock twistlock cylinder Y3 Solenoid valve for twistlock unlock LH
K2 Relay for unlock twistlock cylinder Y4 Solenoid valve for twistlock unlock RH
K3 Relay for extbeam extension extension Y5 Solenoid valve for beam extension LH
cylinder Y6 Solenoid valve for beam extension RH
K4 Relay for retract beam extension cylinder Y7 Solenoid valve for beam retraction LH
K5 Relay for left sideshift cylinder Y8 Solenoid valve for beam retraction RH
K6 Relay for right sideshift cylinder Y9 Solenoid valve for stops lock LH
K7 Relay for lock stops Y10 Solenoid valve for stops unlock RH
K8 Relay for unlock stops Y11 Solenoid valve for stops unlock LH
K9 Relay for slewing motor, CW rotation (via K Y12 Solenoid valve for stops lock RH
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13) Y13 Solenoid valve for sideshift LH

K10 Relay for slewing motor, CCW rotation (via Y14 Solenoid valve for sideshift RH
K 14) Y15 Solenoid valve for slewing brake release
K11 Relay for Y12, pressure (in chassis) Y16 Solenoid valve for rotation CW
K12 Relay for Y13, lift interruption (in chassis) Y17 Solenoid valve for rotation CCW
K13 Relay controlled by S9 Y18 High speed rotation
K14 Relay controlled by S10 Y19 Pressure (on chassis)
Y20 Solenoid valve for speed increase
L1 Control box on spreader Y47 Lowering interrupt (on chassis)
L4 Control box on slewing gear Y48 Lift interrupt (on chassis)
L5 Spreader box (B5) in chassis
L6 Indicator box with indicator lights on
spreader beam

S1 Proximity switch, LH twistlock locked

S2 Proximity switch, RH twistlock locked
S3 Proximity switch, LH twistlock not locked
S4 Proximity switch, RH twistlock not locked
S5 Proximity switch, front LH twistlock seated
S6 Proximity switch, rear LH twistlock seated
S7 Proximity switch, front RH twistlock seated
S8 Proximity switch, rear RH twistlock seated
S9 Limit switch, CW rotation stop
S10 Limit switch, CCW rotation stop
S11 Key switch, twistlock override
S40 Pressure switch, spreed increase
S97 Limit switch 45° CW (option)
S98 Limit switch 45° CCW (option)

T1 Timing switch, 1.5 sec. for slewing motor

speed shift
Section 8
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8.2.3 SPREADER REMOVAL

DANGER
Do not stand within the working range
of the crane when hoisting the spreader
with a crane! Do not step under the
raised load. Only use a crane and
lifting gear with sufficient capacity. The
safety (1) must close after the slings
are attached to the crane hooks (2).

BEFORE REMOVAL

- Retract the boom.

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- Lower the boom.
- Retract the spreader to the 20' position.
- Centre the spreader.
- With the engine shut down and the ignition turned
on, operate the push-buttons on the central con-
trol lever in order to release any residual pressure
in the hydraulic system.
- Turn off the ignition and remove the ignition key.
- Apply the parking brake and chock the wheels.

REMOVAL

- Support the spreader (3) as illustrated (weight of

the spreader: 8.5 tonnes).
- Disconnect the electric cables.
- Disconnect the hydraulic hoses.
- Plug the hydraulic hoses.
- Remove the levelling cylinder (4) from the spreader
by pulling out the pin (5).
- Fasten the levelling cylinder (4) to the boom.
- Refit the pin (5) on the spreader.
- Pull the pin (6) out of the spreader bearing.
- Remove the spreader from the boom and lower
onto wooden blocks (7) to prevent damage to the
twistlocks.
- Refit the pin (6) on the spreader.
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8.2.4 SPREADER ASSEMBLY

- Attach 4 ropes to the lifting eyes on the spreader,

pick the spreader up with the crane and place it on
a ready 20' container.
- With the boom in the horizontal position, position
the spreader as shown (1) so that the pins (4) can
be installed at the spreader pivot bearing (7).

- Align the drilled holes and drive the pins (4) in with
light hammer blows.
- Position the plate (3) on the pin and fasten with
four M16 x 55 screws (2).
- Torque to 180 Nm.
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- First position the rear, then the front levelling

cylinder (5) in line with the drilled hole (6), insert
the screws, install and tighten the nuts.
- Install and tighten the hydraulic hoses for the
spreader.
- Connect the electric cables at the spreader.

NOTE: The hoses are colour-coded.

AFTER ASSEMBLY

- Carry out a complete functional check of the

boom and spreader.
- Inspect all hydraulic connections for leaks.
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8.2.5 SPREADER REPAIRS

8.2.5.1 SLIDING BEARINGS

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SLIDING BEARINGS

1 Sliding bearing 6 Nylon wear pad

2 Roll pin 7 Stop plate
3 Stop plate 8 Stop plate
4 Washer 9 Spreader frame
5 Screw 10 Beam extension, rear bearing
The sliding bearings (1) and nylon wear pads (6) are secured with stop plates (3), (7) and (8), which are
fastened with screws (5) and washers (4). The sliding bearings and nylon wear pads must be lubricated
regularly every 500 service hours with general grease and inspected for wear and security. When the pad
thickness is down to 8 mm, the plates must be renewed.

RENEWING THE SLIDING BEARINGS

CAUTION
Lower the spreader. This work must be performed at heights of over 2 metres. Use suitable
tools (working platform) to gain safe access. Danger of fall injuries!

- Remove the screws (5) and washers (4).

- Take off the stop plates (3), (7) and (8).
- Slide the sliding bearings (1) and nylon wear pads (6) out of the guides and renew them.
- Secure the new sliding bearings and nylon wear pads with stop plates.
- Lubricate the plates with a general grease.
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.8.2.5.2 REPAIRING THE TWISTLOCKS

TWISTLOCK CROSS SHAFT

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1 tie rod 3 carriers(1 sensor, 2 adjusters for twistlocks)

2 end piece 4 adjusting bolts

REMOVAL, INSTALLATION AND ADJUSTMENT OF TWISTLOCK CROSS SHAFT

- Remove all fastening screws from the carriers (3) and end pieces (2) and screw a setscrew into the
centre hole of each part.
- Rotate the tie rod (1) about 90° and install the three carriers and the two end pieces in roughly the correct
position on the cross shaft.
- Insert the tie rod in the end pieces and fit the end pieces to the yokes on the top nuts of the twistlocks.
- Turn the twistlocks and position them accurately in the "not locked" position.
- Fix the end pieces in this position with the setscrews.
- Ensure that the twistlock cylinder is in the correct position corresponding to the "not locked“ position of
the twistlocks.
- Adjust the two adjusting bolts (4) on the two carriers to the midway position.
- Move these two carriers to the correct position so that the screw heads just touch the piston rod and are
in line with the cylinder.
- Lock both carriers in place with the setscrews.
- Determine the correct position for the bracket of the "locked" and "not locked" proximity switches.
- Fix the bracket at the determined place with the setscrew.
- Remove the cross shaft assembly making sure not to change the position of the components.
- Drill two 10 mm holes through each of the five parts and fasten each item on the cross shaft with M10x70
screws and nylock nuts.
- Mount the cross shaft in the beam extension, allowing about 0.5 mm play between the screws (4) and
the piston rod ends.
- Operate the twistlocks hydraulically and carefully check that the twistlock heads are in line with the
twistlock bushings. If necessary, adjust with the screws (4).
Secure the screws (4) with locknuts.
- Check the operation of the "locked“ and "not locked“ indicator lights and adjust the proximity switches,
if necessary.
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8.2.5.3 TWISTLOCK REMOVAL

Remove the plastic housing that supports the

locked/not locked sensors from the end beam and
loosen the twistlock adjusting bolt to give some
free play. Remove the end piece from the twistlock
cross shaft. see section 8, page 41.
- Remove the M8 x 80 bolts (15).
- using two of the bolts as an extractor pull the
crank (14) from the twistlock,note the key in the
twistlock held in place by a roll pin, remove the
key.
- Support the twistlock (5) from below.
- Use a screwdriver to lever out the collets (13).
- The twistlock can now be lowered out of the
housing.
- The sleeve (8) and the lower bearing set will
usually come out with the twistlock.
- Remove all other components.

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8.2.5.4 TWISTLOCK INSPECTION.

As the twistlock is a lifting device and must support

heavy loads it is critical that it is properly inspected
and any components that are not in perfect
condition are replaced.

TWISTLOCK CYLINDER

1 Piston rod 8 Cylinder tube

2 Allen screw, washer 9 O-ring
3 Wiper ring 10 Seal
4 Washer 11 Piston
5 Seal 12 Allen screw
6 Plate 13 Plate
7 O-ring
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SEALING THE TWISTLOCK CYLINDER

NOTE
NOTE:
A seal kit (3, 5, 7, 9, 10) containing all the seals is available. The twistlock cylindermust be
removed for repair.

- Remove the twistlock cylinder.

- Clamp the cylinder tube (8) in a vice with protective jaws.
- Unscrew the Allen screws (2) from the plate (6) and (13) and remove it along with washer.
- Pull plates (6) and (13) from the cylinder tube (8).
- Renew the wiper ring (3), seal (5) and O-ring (7) of the plates.
- Clean the inside of the cylinder tube (8) and examine for damage such as grooves and traces of scoring
and corrosion.
- Draw the piston (11) out of the cylinder tube (8).

ATTENTION
Do not damage the grooves and recesses on the piston rod with sharp-edged tools.
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- Renew the seal (10) and O-ring (9) on the piston.

- Examine the piston rod for damage such as grooves and traces of scoring and corrosion.
- Refit the components on piston rod using new seals.
- Slide the piston rod into the cylinder tube, position the plates and fasten them with Allen screw and
washers.
- Reinstall the twistlock cylinder in the beam extension.

8.2.5.3 BEAM EXTENSION CYLINDERS

BEAM EXTENSION CYLINDERS

1 RH beam extension 6 Pin
2 Service access opening 7 LH beam extension
3 Hose take-up reel/energy chain 8 Service access opening
4 Hose take-up reel/energy chain 9 RH beam extension cylinder
5 LH beam extension cylinder 10 Pin
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REMOVING THE BEAM EXTENSION CYLINDER

- Retract the spreader to a length of 20' and lower it.

NOTE: The following text below describes the removal of the left beam extension cylinder (5). The
procedure also applies for the right beam extension cylinder (9).

- Support the left beam extension cylinder (5) safely with a suitable automotive jack.
- Disconnect the hydraulic hose and electric cables at the piston head end of the cylinder.
- Remove the pin at the end of the cylinder (piston head end).
- Loosen mounting of the energy chain (4) on the guide at the underside of the beam extension.
- Using a crane or fork truck, pull out the end of the beam (1) about 50 cm to gain access to the service
opening (2) at the top of the beam extension.
- Remove the cylinder pin (6) on the piston rod end.
- Attach the beam extension to a suitable lifting gear.

ATTENTION
The used lifting gear must have a load capacity of approx. 150 kg.

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- Pull the beam extension cylinder horizontally out of the spreader with the lifting gear, until the sliding
bearings guiding the cylinder foot come out of the guide.
- Install a new cylinder in the reverse order of removal.

BEAM EXTENSION CYLINDER

1 Adjusting screw 9 Washer

2 Nut 10 Piston rod
3 Seal from seal kit 11 Screw
4 Piston 12 Guide ring
5 O-ring 13 Bushing
6 Spacer 14 Guide bushing
7 Allen screw 15 Cylinder
8 Ring
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RENEWING THE BEAM EXTENSION CYLINDER SEALS

NOTE: A seal kit (3) containing all the seals is available.

- Clamp the cylinder (15) in a vice with protective jaws.

- Remove the 4 screws (11) from the ring (8).
- Pull out the piston rod (10) with ring (8), washer (9), guide ring (13), spacer (6) and piston (4). Deposit
the piston rod in a safe place.
- Clean the inside of the cylinder (15) and examine it for damage such as grooves, traces of scoring and
corrosion.
- Clamp the piston rod in a vice with protective jaws.

ATTENTION
Do not damage the grooves and recesses on the piston rod with a sharp-edged tool.

- Loosen the adjusting screw (1) on the nut (2), remove the nut on the piston, withdraw the piston (4).
- Renew the seals on the piston (4) using seals from the seal kit (3).
- Remove the spacer (6) from the piston rod and renew the two O-rings (5).
- Remove bushing (13) from the piston rod and renew the seal on the bushing with one from the seal kit
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(3).
- Extract the ring (8) and washer (9).
- Renew the seals on the ring and washer with ones from the seal kit (3).
- Inspect the piston rod for damage such as grooves and traces of scoring and corrosion..
- Refit the components on piston rod using new seals.
- Secure the nut (2) of the piston with the adjusting screw (1).
- Install the piston rod in the cylinder and secure it with screws (11).
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8.2.5.4 SIDESHIFT CYLINDER

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SIDESHIFT CYLINDER

1 Pin 7 Cylinder tube

2 Nut 8 Piston rod
3 Washer 9 Piston
4 Yoke 10 Nut
5 Seal kit part 11 Adjusting screw
6 Guide bushing

RENEWING THE SIDESHIFT CYLINDER SEALS

NOTE: A seal kit (5) containing all the seals is available. To renew the seals, the sideshift cylinder
does not have to be removed.

- Remove the nut (2) and washer (3).

- Drive the pin (1) out of the yoke (4).
- Pull the guide bushing (6) and piston rod (8) out of the cylinder tube (7).

ATTENTION
Do not damage the grooves and recesses on the piston rod with a sharp-edged tool.

- Loosen the adjusting screw (11) on nut (10), remove the nut at the piston and withdraw the piston (9).
- Renew seal kit part (5) on the piston.
- Unscrew the guide bushing (6) from the piston rod (8) and renew seal kit parts (5).
- Inspect the piston rod for damage such as grooves and traces of scoring and corrosion.
- Refit the components with new seals on the piston rod.
- Fasten the piston rod with nut (10) and secure the nut with adjusting screw (11).
- Slide the piston rod into the cylinder tube, screw in the guide bushing.
- Position the yoke (4) at the piston rod bearing and secure the pin (1) with washer (3) and nut (2).
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8.2.5.5 LEVELLING CYLINDER

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LEVELLING CYLINDER

1 Cylinder tube
2 Adjusting screw
3 Piston
4 Seal kit part
5 Piston rod
6 Guide bushing

RENEWING THE LEVELLING CYLINDER SEALS

NOTE: A seal kit (4) containing all the seals is available. The levelling cylinder does not have to be
removed to renew the seals.

- Screw the guide bushing (6) and piston rod (5) out of the cylinder tube (1).

ATTENTION
Do not damage the grooves and recesses on the piston rod with a sharp-edged tool.

- Loosen the adjusting screw (2) on the piston (3) and remove the piston.
- Renew seal kit part (4) on the piston.
- Unscrew the guide bushing (6) from the piston rod (5) and renew seal kit parts (4).
- Examine the piston rod for damage such as grooves and traces of scoring and corrosion.
- Refit the components on the piston rod with new seals.
- Fasten the piston on the piston rod and secure it with adjusting screw (2).
- Slide the piston rod into the cylinder tube.
- Refit the levelling cylinder to the spreader bearing and boom bearing.
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LEVELLING CYLINDER VALVE BLOCK

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LEVELLING CYLINDER VALVE BLOCK

1 Flow valve
2 Pressure relief valve 80 bar
3 Levelling cylinder port
4 Tank return line port
5 Flow valve
6 Pressure relief valve 80 bar
7 Levelling cylinder port

ADJUSTING THE LEVELLING CYLINDER POWER

NOTE: Each levelling (=damping) cylinder is controlled by its own valve block. Both levelling
cylinders (rear and front) must be adjusted. The damping power can be set for both directions.
The piston must be in the end position for the adjustment.
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- Lower the spreader so that the levelling cylinder piston is retracted.

- To increase the damping power:

Turn the adjusting screw at the flow valve (1) in.

- To reduce the damping power:

Turn the adjusting screw at the flow valve (1) out.

- Lower the spreader so that the piston of the levelling cylinders is extended.

- To increase the damping power:

Turn the adjusting screw at the flow valve (5) in.

- To the reduce the damping power:

Turn the adjusting screw at the flow valve (5) out.
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8.2.5.7 SLEWING GEAR

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VALVE BLOCK FOR SLEWING GEAR

1 Solenoid valve for left-right rotation

2 Flow valve - fast rotation
3 Flow valve - slow rotation
4 Solenoid valve for changing slewing speed
5 Solenoid valve for releasing slewing brake
6 Return line port
7 Brake port 1
8 Brake port 2
9 Pressure relief valve 80 bar
10 Pressure relief valve 80 bar
11 Slewing motor port 1
12 Slewing motor port 2
13 Pressure port
14 Pressure relief valve 40 bar
15 Tank port
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ADJUSTING THE SLEWING MOTOR

NOTE: The slewing speeds (fast and slow rotation) and the motor torque can be set at the slewing
gear valve block.

ADJUSTING SLOW ROTATION SPEED

- To reduce the slewing speed:

Turn the adjusting screw of the flow valves (3) in (clockwise).

- To increase the slewing speed:

Turn the adjusting screw of the flow valves (3) out (anticlockwise).

ADJUSTING FAST ROTATION SPEED

- To reduce the slewing speed:

Turn the adjusting screw of the flow valves (2) in (clockwise).
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- To increase the slewing speed:

Turn the adjusting screw of the flow valves (2) out (anticlockwise).

ADJUSTING SLEWING MOTOR POWER

- To increase the slewing motor power:

Turn the adjusting screw of pressure-relief valves (9) and (10) in (clockwise).

- To reduce the slewing motor power:

Turn the adjusting screw of pressure-relief valves (9) and (10) out (anticlockwise).

TIGHTENING THE FASTENING SCREWS

NOTE: The fastening screws at the slewing gear and turntable bearing must be tightened twice a year
or every 1000 service hours.

-Fastening screws slewing gear to turntable bottom plate

M12 (10.9) torque loading 90 Nm

-Ring gear fastening screws (without securing devices)

M24 (10.9) torque loading 740 Nm
M12 (10.9) torque loading 90 Nm