Stinis Holland B.V. Postbus 2005 2930 AA Krimpen A/d Lek The Netherlands User Guide For Stinis Spreader Model VATCII-G

Stinis Holland B.V.
CONTENTS
Postbus 2005
2930 AA Krimpen a/d Lek
The Netherlands
User guide for Stinis spreader

Model VATCII-G
1. This manual is intended as a customer guide regarding the operation and

maintenance of STINIS VATCII spreaders with registration numbers:
TCS001
2. STINIS strongly believes that communication with it's customer is a
critical success factor for ongoing innovation. If the customer in this
respect any remarks regarding improvement of this manuals, STINIS
would be much obliged if the customer would sends his ideas to us.
3. If the customer has any doubts in using this manual for operation and
maintenance or needs clarification please contact the service department
of the original equipment manufacturer:
Stinis Holland BV
Postbus 2005
The Netherlands
tel +31 180 514655
fax +31 180 516190
4. We want to pay your attention of:
Guarantee Chapter 1.40
For delivery in Europe: CE declarations Chapter 1.50
Safety precautions and instructions Chapter 2
Preventive lubrication instructions Chapter 4.40
Preventive maintenance instructions (excl lubrication and twistlocks) Chapter 4.50
Preventive maintenance instructions for twistlocks Chapter 4.60
5. STINIS accepts no liability for damage suffered as a result of the use of
this manual.
Document revision: dated: remark:

A 27 March 2015
A-1 21 May 2015 New revision electric diagram
MANUAL TCS001 A
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Stinis Holland B.V. CONTENTS
Postbus 2005
The Netherlands
CONTENTS
1 SPREADER IDENTITY ........................................................................................................................1-1
1.10 Area of application ..........................................................................................................................1-1
1.20 Spreader registration ......................................................................................................................1-1
1.30 Technical specifications ..................................................................................................................1-2
1.40 Guarantee .......................................................................................................................................1-3
1.50 CE-Documents ...............................................................................................................................1-4
2 START-UP - WARNINGS - SAFETY PRECAUTIONS .......................................................................2-1
2.10 Crane control: Important information ..............................................................................................2-1
2.15 Crane driver: Warnings ...................................................................................................................2-3
2.15.30 Crane driver: Warnings spreader fault information .........................................................................2-4
2.16 Crane driver: Instructions ................................................................................................................2-5
2.17 Crane driver: Lamp information ......................................................................................................2-6
2.18 Maintenance department: Warnings ...............................................................................................2-6
2.20 Start-up procedures ........................................................................................................................2-6
2.40 Safety features ................................................................................................................................2-8
2.50 Spreader cage ................................................................................................................................2-8
3 OPERATION........................................................................................................................................3-1
3.20 Functional description .....................................................................................................................3-1
3.20.10 Spreader construction .....................................................................................................................3-1
3.20.20 Midframe .........................................................................................................................................3-2
3.20.30 Telescopic beams ...........................................................................................................................3-3
3.20.40 Blocking slide-beams ......................................................................................................................3-4
3.20.50 End beams ......................................................................................................................................3-5
3.20.61 Twistlocks model TWI-W ................................................................................................................3-5
3.20.70 Flippers and actuators ....................................................................................................................3-7
3.20.80 Cell guide rolls ................................................................................................................................3-8
3.40.10 General electrical components .......................................................................................................3-9
3.50 Hydraulic information ....................................................................................................................3-10
3.60 Automatic greasing .......................................................................................................................3-11
4 MAINTENANCE ..................................................................................................................................4-1
4.10 Test runs .........................................................................................................................................4-1
4.20 Oil and grease ................................................................................................................................4-1
4.30 Materials instruction, sealants.........................................................................................................4-2
4.40 Preventive periodical lubrication instructions ..................................................................................4-2
4.50 Preventive periodical maintenance instructions ..............................................................................4-3
4.60 Maintenance instructions for twistlocks model TWI-W (Double-Split-Collar) ..................................4-5
5 INSTRUCTIONS FOR ADJUSTMENT & REPAIR ..............................................................................5-1
5.10.10 Used materials ................................................................................................................................5-1
5.10.20 Material certificates procedure ........................................................................................................5-1
5.20 Hydraulic system ............................................................................................................................5-2
5.20.10 Flipper actuators .............................................................................................................................5-3
5.30.03 Electrical system .............................................................................................................................5-4
5.40 Electro-Mechanical .........................................................................................................................5-4
5.40.11 Twistlocks: Model TWI-W double-split-collar ..................................................................................5-4
5.40.20 Telescopic beams - clearance ........................................................................................................5-5
5.40.30 Telescopic belts ..............................................................................................................................5-6
5.40.50 Flippers for actuators ......................................................................................................................5-9
5.50 Welding instructions ........................................................................................................................5-9
5.60 Automatic greasing .......................................................................................................................5-10
6 SPARE PARTS & SERVICE ...............................................................................................................6-1
6.30 How to order spare parts ................................................................................................................6-1
11 MECHANICAL DRAWINGS ..............................................................................................................11-1
11.10 Production and arrangement drawings: direction for use..............................................................11-1
11.20 List of production drawings ...........................................................................................................11-1
12 ELECTRICAL DRAWINGS ...............................................................................................................12-1
12.10 Parts list for electric components ..................................................................................................12-1
13 HYDRAULIC DRAWINGS .................................................................................................................13-1
13.20 Hydraulic hoses: identification ......................................................................................................13-1
13.30 Parts list for hydraulic components ...............................................................................................13-2
14 CERTIFICATES/QUALITY RECORDS - DESIGN CALCULATIONS ...............................................14-1
15 STINIS PRODUCT INFORMANTION ................................................................................................15-1
16 STANDARDS ....................................................................................................................................16-1
16.10 Applicated norms ..........................................................................................................................16-1
16.20 Definitions and terminology...........................................................................................................16-3
16.30 Risk analysis .................................................................................................................................16-4
17 SPREADER PARTS LIST .................................................................................................................17-1
20 INDEX ................................................................................................................................................20-1
MANUAL TCS001 B
Stinis Holland B.V. CHAPTER 1
Postbus 2005
The Netherlands
1 SPREADER IDENTITY
1.10 AREA of APPLICATION
ISO-containers - Single operation:
The spreader is designed to lift 20, 30 and 40ft ISO containers.
Wide body ISO containers:
When standard flippers are used, it is possible to handle "wide bodies" up to a width of 2500
mm. In order to handle "super wide bodies" (up to 2570 mm wide), it is desirable to make
changes to the flippers
Special loads:
The spreader is suitable for handling special loads, provided the dimensions and positions of
castings conform to the ISO standard for containers.
If these differ, then the safety provisions for the twist locks may not function, so that additional
safety measures will be required.
Examples are deck hatches, damaged containers, over-height containers, flat racks, etc.
Working loads and life, see: Chapter 1.30
1.20 SPREADER REGISTRATION

Spreader dates general:
Model: VATCII-G
Single Operation: 20-30-40ft ISO
Customer project number: 65495
Tare weight: see: Chapter 1.30
Rated Capacity (SWL): see: Chapter 1.30
Conservation: see: Chapter 1.30
Warranty: see: Chapter 1.40
CE Declaration: see: Chapter 1.50
Certificates: see: Chapter 14
Spreader dates / spreader:
Spreader id Article number Certificate No.

TCS001 2611-2704-0000 P14-1174
MANUAL TCS001 1-1

Postbus 2005
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1.30 TECHNICAL SPECIFICATION

Load in Single-Lift Operation in 40ft: acc. DIN 15018 H2 B4
Rated Capacity (SWL) in 40ft, calculated for 1000.000 moves: 40 t
Eccentric Loads:
Allowed eccentric load in single operation: 40/60
Load Lifting Lugs:
Rated Capacity (SWL) lifting lugs underside mid-frame: 10 t/lug
Rated Capacity (SWL) lifting lugs near twistlocks: 10 t/lug
Test Load:
Max. allowed test load (centric): 1.5 x SWL
Weight:
Tare weight: 9200 kg
Telescoping:
Telescopic stops: 20-30-40 ft
Time duration telescoping movement 20 to 40ft: 18 sec
Time for mechanical blocking of telescopic beams: 1 sec
Twistlocks General:
Mechanical Blockading: yes
Hydraulic Blockading: yes
Electrical Blockading: yes
Time of twistlock: <0.5 sec
Flippers:
Number of flippers: 4
Type of flippers (corner or flat): corner
Time up/down motion (adjustable), min: 5-6 sec
Time up/down motion for one flipper, protected, min: 2 sec
Drive torque flipper actuator minimal: 3500 Nm
Overload prevention of actuator standard adjusted on: 5500 Nm
Max allowed torque of actuator: 7200 Nm
Safety device for overload in up and down direction: Yes
Automatic Greasing:
Operation of grease nozzles: independent
Grease pressure: 80 bar
Cell Rollers:
Diameter: 200 mm
Bearings: Ampco
Hydraulics:
Type of piston pump: adjustable with power control
Working oil pressure: 90-130 bar
Maximum oil pressure: 180 bar
Electrics:
Motor power, main unit: 7.5 kW
Maximum power required during 20 seconds: 10 kW
Power supply voltage: 400 VAC
Frequency: 50 Hz
Control supply voltage: 230 VAC
Control voltage on spreader: 24 VDC
Solenoid voltage: 24 VDC
Container proximity switch: Yes
Environment:
Operation: 100 %
Maximum permitted relative humidity: 100 %
Permissible environmental temperature: 0/+50 °C.
Conservation:
Sand blasting 2.5 ACC. ISO 8501-1:2007
1st coat Sigmacover zinc primer, minimum dry thickness 75 microns
2nd coat Sigma 456 intermediate coating, minimum dry thickness 125 microns
3rd coat Sigmadur 520 finish, minimum dry thickness 50 microns
Colour Spreader: RAL 2003
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Postbus 2005
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1.40 GUARANTEE
With reference to the spreaders listed in Chapter 1.20:
1 Stinis Holland B.V. guarantees that the spreaders supplied will be made satisfactorily in
accordance with the agreed specification.
2 Stinis shall warrant that the spreader supplied shall be free from inherent defects in materials
and workmanship for a period of 24 months from the spreader handover to the Purchaser or
30 months from delivery, whichever comes first.
3 In the event of defective parts or components, Stinis shall arrange for the replacement at its
own cost. However, the Purchaser shall bear the expenses on delivery of the components as
well as the replacement of the components on site.
For repairing/guarantee activities, the total guarantee time is 1 years.
4 The guarantee shall only apply if the Purchaser has followed the preventive maintenance
instructions according to the Stinis manual instructions of chapter 4.
5 The guarantee shall not cover defects caused by normal wear and tear, inexpert use or
incorrect maintenance, which is carried out by either the Purchaser or any third parties.
6 The guarantee shall only apply if the Purchaser has met all his obligations towards Stinis
Holland B.V.
7 The guarantee on conservation is 5 years.
Stinis Holland B.V.
Managing director
Bert de Bever
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Postbus 2005
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1.50 CE-Declarations:
EXPLANATION FROM MANUFACTURER
Declaration of incorporating according to EC-machine directions
(Direction 2006/42/EC, art. 4 lid 2 en Appendix II under A)
The certificates signed on behalf of Stinis Holland B.V. apply to the construction defined below,
which construction is intended to be used as or to be added to a machine or hoist tool to which
the directives 2006/42, 2006/95, 2004/108/EC are applicable.
Machine definitions;
For the machine specifications and identifications see chapter 1.20, and 1.30.
For safety precautions and instructions, see Chapter 2.
For operation procedures see Chapter 3.
For maintenance instructions, see Chapter 4 and 5.
Standards:
For the applicable standard’s, see chapter 16.
Manufacturer: Stinis Holland B.V.
Address: Dorpsstraat 130
2931 AG Krimpen a/d Lek
The Netherlands
Date: 2 April 2015
Note: This declaration will become null and void if any changes or
repairs, as described in Chapters 1.20 and 1.30, such as:
* Welding activities
* Cold deformation
* Hot deformation
* Change software program (as well in crane as in spreader) is
carried out on the machine(s) specified above without the prior
written agreement of Stinis Holland.
Stinis Holland BV
Managing director
Bert de Bever
MANUAL TCS001 1-4

Postbus 2005
The Netherlands
2 START-UP – WARNINGS – SAFETY PRECAUTIONS

2.10 CRANE CONTROL: IMPORTANT INFORMATION!
CRANE PROGRAMME: IMPORTANT INFORMATION
There are a few very important crane settings at which the crane must be set in order to handle
containers safely. There are also options for increasing the lifting capacity for certain lifting
situations and increasing the lifespan of the crane and spreader.
CONTENTS:
A. Check the twistlock locking-unlocking.
B. Check bump times
C. Check the functioning of the twin 20 overload protection (TTDS)
D. Check the crane adjustment lifting after locking twistlocks
E. Check the crane overload protection
F. Check the speed reduction of lowering
A CHECK THE TWISTLOCK LOCKING-UNLOCKING
Information twistlocks-unlocked and twistlocks-unlocked to the crane:
* If one of these is present, lifting and lowering is permitted.
* If neither is present, lifting or rapid lowering is forbidden. It is permissible to lower slowly,
usually via a bridging.
B. CHECK BUMP-TIMES
After an empty spreader has landed, depending on the lowering speed, spreader weight, type
and telescope position, the spreader may jump upward. This is frequently called 'bumping'.
The time that passes between the first contact upon landing and the spreader definitively
coming to a standstill on the container is generally known as "bump-time".
The crane/spreader programme must cause the following:
1. The twistlocks to remain unlocked during bump-time.
2. The crane to not lift or lower and the hoisting gear to stand still.
The first contact between the spreader and the container can be registered by the landing-pins.
In general this is a series of contacts (impulse information) of all landing-pins withdrawn. For the
crane it is important that the bump-time be dealt with correctly.
During the bump-time, it is forbidden to send a command to the spreader to lock the twistlocks.
In the spreader programme, as a standard the twistlocks are always locked with a delay (bump-
time). This is only a reliable control if the crane is standing still as long as twistlocks-locked or
twistlocks- unlocked has not been confirmed to the crane.
Remark: A conventionally controlled spreader (many cables needed for controlling the
spreader, the spreader is often equipped with a PLC):
* If lifting has already commenced before the spreader has landed on the
container;
* If the spreader-landed information in the crane does not lead to a delay (bump-
time) for the order to the spreader to lock the twistlocks; the crane can
immediately lift during bumping of the spreader on the container.
Remark: Within the spreader programme an extra check can be carried out of whether the
twistlocks are locked correctly within the castings. If possible, immediately after
locking the spreader must lie on the container for a brief period of time (landing-
pins withdrawn).
Nonetheless, without a correct, safe crane programme, locking outside the
castings cannot be entirely prevented.
Conclusion: While starting up the spreader, check to be sure that a correct bump-time has
been set in the crane programme.
The hoisting gear must stand still during locking.
Bump-times: Minimal bump-times to be maintained for a Stinis spreader:
0.8 seconds for a single-acting spreader.
0.9 seconds for a twin spreader.
1.2 seconds for a Long-Twin spreader.
C. CHECK THE FUNCTIONING OF THE TWIN 20 OVERLOAD PROTECTION (TTDS):
This overload protection is very important for both single-acting and twin spreaders.
Good overload protection can prevent many accidents.
So, when starting up the unit, check the functioning of the twin-20 overload protection.
For this overload protection we always use a combination of crane and spreader programmes.
It is hardly possible to check for functionality (correct action) on the spreader.
So check regularly to be sure that this overload protection is functioning correctly.
The crane operator can do this periodically.
If the spreader is equipped with extra roof detection, the operator himself can also check this
overload protection.
But this may only be done if the operation allows, and only with empty containers.
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D. CHECK THE CRANE ADJUSTMENT LIFTING AFTER LOCKING TWISTLOCKS

After the container is locked, the crane can start lifting.
In case, for example, the container itself is still locked to the container under it, both the
spreader and crane are overloaded, since during lifting the overload activates the crane
overload protection.
After overload protection is activated, the actual load on the spreader and crane is much higher
than the set value of the overload protection! Measured values are 20-80%.
In order to keep this "overshoot" as low as possible, Stinis requires a lifting speed to 10% of the
maximal lifting speed on full load, until the container has been lifted.
This delay time can be set correctly by way of the following regulations:
* Lifting distance at low speed:
Check what the minimum lifting distance is to permit you to at least lift a loaded container
clear of the dock. Use an encoder if the hoisting gear is equipped with one.
* Lifting time at low speed:
Check what the minimum time is (at 10% of the maximal lifting speed on full load) to permit
you to at least lift a loaded container clear of the dock. Use this time as the standard setting
so that in future you can always lift at 10% of the speed before proceeding to full speed.
Remark: Theoretically this test must be carried out on the floor of a cell.
* Checking the "ramp":
Check the "ramp" of the measuring box of the lifting overload protection. If the load does not
increase any more during slow lifting, the container is clear of the dock. Then you may switch
to full lifting speed.
E. CHECK THE CRANE OVERLOAD PROTECTION:
There are still some cranes in operation whose overload is adjusted to maximum lifting capacity.
This should not occur.
An overload protection must be adjusted according to the maximal capacity of the lifting
machine under the crane:
1. Spreader in single-acting operation
2. Spreader in twin operation
3. Hooking action under the spreader
4. Hooking action under the head-block
5. Spreader at 20ft: uses lifting lugs central frame for special load
6. Personnel gondola under the spreader
7. Telescopic overheight spreader
Items 1 and 2:
The crane always knows the mode of the spreader. So it should be no problem to adapt the
crane overload protection.
Remark: If this has not been done, for example a 45ft container may be handled in SWL
twin operation. The spreader might then possibly already be overloaded by more
than 100% in a situation where the 45ft container is still connected to the
container under it!
This almost destroys the spreader.
Items 3 and 4:
In general the overload protection is already correctly applied by means of the pilot contacts in
the plug ("dummy").
Item 5:
In general, a spreader in the 20ft position has a higher SWL. Usually the manufacturer does not
specify this; but it is always possible on request.
So it is possible to increase the SWL of the crane if the spreader is at 20ft. This is particularly
useful for using lifting lugs on the central frame.
With a twin spreader the lifting lugs can be loaded to a much higher SWL. But then the spreader
must be in twin-mode. This is often difficult in terms of operation. Unfortunately it is impossible
to increase the SWL automatically when the spreader is at 20ft.
Item 6:
Although here a much lower SWL is desirable, plus the crane speeds should also preferably be
kept lower, without an extra device on the spreader this cannot be automated.
Item 7:
In general an overheight spreader has a much higher SWL than a crane spreader.
In combination with an adjustment in the overload protection, see item 6, the SWL at 20ft can
also be increased for overheight use.
F. CHECK THE SPEED REDUCTION OF LOWERING
Many spreaders are equipped with a switch that registers the distance to the container. As a
standard these switches have one fixed adjustable switch point, sometimes two, and possibly
the distance can be measured.
To increase the longevity of the spreader it is desirable that this switch be used to reduce the
lowering speed of an empty spreader as it approaches the container.
The adjustment of the fixed value must bring the lowering value just above the container back to
+/-20%.
This adjustment is not easy. At a lesser lowering speed the brake path is too short. The
distance that must be bridged at minimal lowering speed is too long.
This can be partially corrected by working with 2 fixed settings and adjusting the switches to
average operational use. However, there is another disadvantage to using reduced lowering
speed. Depending on the habits of the crane operator, rapid lowering just above the container is
desirable. The crane operator wants to have the spreader lower rapidly as it swings over the
containers when the spreader is in the correct position.
However this can be established when programming the crane.
MANUAL TCS001 2-2

Postbus 2005
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2.15 CRANE DRIVER: WARNINGS

General:
* Never exceed the safe working load.
* Use the spreader for the purpose for which it is designed.
* Inspect the spreader every week for damage, or do this in co-operation with the maintenance
department.
* As the user of the spreader, you have the best information in the event that the spreader
behaves other than expected.
* Warn the maintenance department if a fault is indicated by any of the lamps on the spreader
or information screen presented in the crane. Chapter 2.16
* Reduce your speed to a minimum when you are moving personnel in the cage on the
spreader.
* Stop work if personnel come into close proximity with the spreader.
* You cannot prevent this, you can only stop.
Permissible loading:
For permissible loading, see: Chapter 1.30
Working with the single working spreader:
* Never raise two 20ft containers in the 40ft position in single-operation.
* Always activate the flipper and telescope movements at least 2.5 metres above the ground.
Movements that present a danger to persons in the vicinity:
* Flippers-down movement
* Flippers-up movement
* Telescoping-retract/extend
Special loads:
* Oversized or undersized containers often have non-standard castings. Sometimes the safety
functions of the twistlocks cannot function. Work at a slow speed. Pay extra attention to
locking and unlocking.
* Examples:
* Deck hatches, overheight spreaders, overheight containers, open-top containers.
* When lifting eyes are used, it is always advisable to hoist slowly.
During maintenance activities:
* Avoid stress on the plug when the spreader is being connected and disconnected.
* Keep in continuous radio contact with the maintenance department.
* Without radio contact it is not permitted to operate a spreader function.
* All actions in the cabin are dangerous. You may only operate these functions at the express
request of the maintenance department (with which you are in radio contact).
* Only activate functions at the request of the maintenance department and then only when
these are sufficiently far away from the spreader.
* In as far as these are present, check that the sideways opening protective covers are closed
before starting up.
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2.15.30 CRANE OPERATOR: WARNINGS AND SPREADER ERROR MESSAGES

APPLICATION:
The information below applies to a spreader that is controlled in the conventional
manner.
Configuration:
Here the spreader is controlled from the crane by means of hard signals over several cables.
Usually there are not enough free cables for error messages. Then a single cable is used for as
many error-messages as possible.
Display of error messages in cab:
This spreader only has 1 cable with which to transmit errors to the crane during spreader
operation. The crane operator only has one lamp in the cab with which to pass on these errors.
Unfortunately this single lamp information is quite insufficient.
Depending on the configuration in the crane, this lamp may flash or remain on constantly.
If both options are possible, Stinis prefers to tell the crane operator that a flashing lamp means
that an error has been detected on the spreader. However such an error is not really important
with regard to the functioning of the spreader. The operator can usually simply continue working
when a flashing signal appears. But he should notify maintenance of this.
The spreader stops if the lamp stays on.
Display of error messages on the spreader, digital, see: Chapter 5.30.10
If the spreader is equipped with a PLC, and the spreader has a display, a large number of
spreader error messages are shown directly on the spreader by a code or text. With this
information the maintenance staff can very quickly detect and repair errors.
Display of error messages with lamps on the spreader or headblock:
If the spreader or headblock is equipped with lamps, see: Chapter 12
MINIMALLY REQUIRED INFORMATION in the crane cab:
* Twistlocks locked/unlocked
* Landing-pins up (spreader has landed)
FLASHING SIGNAL for SPREADER ERRORS (the spreader continues to function):
* Oil return pressure:
The oil return pressure is too high.
The spreader continues to function.
Notify maintenance. The return filter must be cleaned or replaced at the next servicing.
* Greasing pressure:
The greasing pressure of the automatic lubricating system is too low.
The spreader continues to function. Notify maintenance.
The lubricating system must be inspected when the spreader is not in use.
* Grease reservoir is empty:
The grease level in the automatic lubricating system is too low.
The greasing function stops.
The spreader continues to function.
Notify maintenance. The lubricating system must be inspected when the spreader is not in
use.
* Oil temperature:
The oil temperature is too high:
The spreader continues functioning for another 15 minutes.
Notify maintenance.
* Incorrect positioned twistlocks:
Twistlocks are not locked or unlocked
* Twistlocks locked above castings:
Due to bumping of lifting containers with not standardised castings, locking of twistlocks was
done above the castings
* Telescoping position unknown:
The spreader PLC lost the memory of the telescopic positions.
CONSTANT SIGNAL for SPREADER ERRORS (the spreader stops):
* Oil level in the tank is too low:
The oil level of the hydraulic tank is too low.
The spreader stops.
Notify maintenance. The oil level must be topped up.
If the cause is a serious oil leak, first this must be corrected, since the pump can be damaged
if the oil level is 50mm lower than permissible.
If no serious leak is present, this safety feature may be bridged, but only during that shift.
* The electric motor is overloaded:
Notify maintenance. Reset the thermal cut-out.
The cause may be that telescoping went too far in/out, or there were too many up/down
flipper commands. During these actions the motor is overloaded, which is not permissible.
If this is not a cause, you must continue searching for an incorrect setting of a hydraulic
overload protection feature.
Check whether the circulating valve is perhaps manually powered.
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* Oil temperature is too high:

The oil temperature is too high for over 15 minutes.
The spreader stops.
Notify maintenance.
* Spreader-stop commenced:
The spreader is not functioning because a "spreader-stop" has commenced.
* Telescoping time out
The telescopic action was to long. Maybe a wrong adjusted indicator, or to high friction of the
telescoping beams.
2.16 CRANE DRIVER: INSTRUCTIONS

In the following description the details for each spreader may vary.
Control is dependent on the possibilities and communication for the crane and the spreader.
Only the most important spreader malfunctions are listed.
SPREADER-STOP:
For use in emergency situations, one or more "spreader stop" pushbuttons are fitted. When
When the "spreader stop" pushbutton is pressed the crane continues to function.
LAMPS:
Depending on the construction of the spreader, a number of lamps are mounted on the
spreader.
For more information see Chapter 12
SPREADER ON/OFF:
Conditions for switching on are:
* Crane switched on
* No spreader malfunction
* Spreader plug inserted
* Spreader Stop (emergency stop for the spreader only) not activated.
Switch off when:
* Crane is switched off
* There is a spreader malfunction
* Spreader Stop (emergency stop for the spreader only)
LOCKING/UNLOCKING the TWISTLOCKS (ISO OPERATION):
Conditions for locking or unlocking:
* Crane is in spreader operation
* Spreader is placed on 1 (one) container (indicated in the crane)
* Sliding bars in fixed position (20, 30, 40, 45ft.)
* Hoist mechanism stationary
Conditions for hoisting at low speed:
* Spreader is locked or unlocked
* Spreader plug is secure
* Bridging is pressed
For hoisting at high speed, the diagonal feeler pins must face downward.
Conditions for lowering at high speed:
* Spreader is locked or unlocked
* Spreader plug is secure
* Hook operation is selected
* Bridging is pressed
TELESCOPING (ISO operation):
Conditions for telescoping:
* Spreader unlocked
* Spreader is not placed on a container
If possible, only when a minimum height has been reached.
* Bridging is general there.
Malfunction indications:
* Telescope bar unlocked and slide beams not in a fixed position
* When the valves are operated, despite the fact that there is a position indication (operation
dependent)
* There are several position indications at the same time (operation dependent)
FLIPPERS:
Possible activated conditions for the use of the flippers:
* Spreader is not placed on the container
* Spreader not telescoped
* Spreader is not locked or unlocked
* Spreader pin secured
* Spreader is unlocked
* Spreader is not above water
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USE LIFTING EARS:

Lifting ears adjacent to the twistlocks:
* When the loads on the lifting ears are not completely equal, SWL=40T in the 20-40ft position.
Lifting ears on the sides of the mid-frame:
* When only two ears are used, one on each long side of the spreader: SWL=10 T/ear
* When the lifting ears are used for loading other items, check the loading carefully and lift
slowly.
2.17 CRANE DRIVER: LAMP INFORMATION

There are two options for putting the lamps down near the spreader:
* On the spreader
* On the headblock
Both give same information.
LAMP INFORMATION:
Definition of lamps and their position: Chapter 12
2.18 MAINTENANCE DEPARTMENT: WARNINGS

* Keep at a distance from the spreader during operation.
* Do not stand under a suspended load.
* Keep at a distance from all moving parts like:
- Telescopic movement (between head-beams and mid-frame and at the outside of the head-
beams)
- Telescopic belt
- Flippers, special the flipper-down motion is very dangerous
- Twistlocks: be careful with maintenance of the twistlocks if the oil-pump is running.
- Telescopic beam lock
* Never forget to reset the manual-option of the pressure valve after repair of testing.
* When the pressure valve is used in manual-option mode only qualified personnel are
permitted to maintain the spreader.
* When power is on, do not connect or disconnect electrical connectors.
Only qualified personnel are permitted to open the electrical main and junction boxes.
* Only qualified personnel are permitted to change the pressure settings and speed settings.
* Inspect the spreader every week for visual damage.
* Inspect the four landing-pins every week: the lowest position is 20mm below that of the
underside of the head beam.
* Never open the hydraulic tank.
* Without the written consent of Stinis the following modifications or repairs on the spreader are
not allowed.
This eliminates all forms of guarantee and warranty. (See chapter 1.40 and 1.50).
In particular, the following tasks can have dangerous consequences.
- Welding.
- Cold deformation.
- Hot deformation.
- Changing the spreader software.
2.20 STARTUP PROCEDURES

* Check the spreader for visible damage.
* Connect the spreader to the head-block.
Raise the spreader to 0.7m above the ground and ensure that the flipper can move down
freely.
* Check the space for telescoping:
Ensure that telescoping can be done without any obstructions.
* Check that nobody is in close proximity to the flippers.
Depending on the most recent maintenance activities, flippers can start to move up or down.
* Voltage on plug:
Before connecting the pin plug, be sure that the main current for the E-motor is on the correct
pins according the wiring schedule.
* Fix the connector.
Depending on the most recent maintenance activities, flippers can start to move up or down.
Before giving the "motor on" command in the crane, check the motor fan very carefully; if the
rotation is in the opposite direction to that of the arrow at the top of the motor, stop within 3
seconds.
In case of rotation in the opposite direction, interchange two supply voltage phase wires in the
main E-box.
Note: More than 5 seconds rotation in the wrong direction can damage the oil pump.
Please be sure that nobody stands near one of the flippers.
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* Check the noise level of the motor:

The motor must run with a low noise level (oil pressure 20 bar).
When possible, check the motor current: maximum 8-9 Amp.
When possible, check the AC voltage (to earth): minimum 205 VAC.
* Check oil pressure:
Activate manual oil pressure valve with the manual push-pull button: (do not forget to reset
after testing)
* Check twistlock operation:
For testing the twistlocks, all four landing-pins must be in the upward direction. This is
achieved by using M12 nuts, placing them under the washer, which is under the landing- pin
spring (do not forget to remove those nuts after testing)
For a twin lift spreader, in the twin lift position the same procedure is required for 8 twistlocks.
* Test all functions by manually activating the hydraulic valves:
Functions on mid-frame:
- Telescopic beam locks
- Telescoping in/out together with blocking cylinders
- Option: Automatic greasing: Will be discussed in chapter 3.60.
Functions on head-beam:
- Twistlocks lock and unlock (final position must be unlocked)
- Flippers up/down
* Reset the oil pressure valve
* Verify all functions from the cabin box:
- Check landing- pins indication lamps in cabin and on the spreader.
All landing- pins up: white lamps activated
- Check landing- pins indication lamps:
To move one landing- pin down, the indicator lamp at the side being tested is not activated
(do this for all 4 landing- pins)
- Check twistlock locked/unlocked control with only one landing- pin down: twist lock rotation
can not be performed.
- Check twistlocks locked/unlocked and control indicator lamps in the cabin and on the
spreader:
- Check flipper functions; all flippers work independently of each other
- Check telescoping in all positions
* Check additional safety precautions
- Check; safety test hoist prevention:
Activate one twistlock valve manually in one head-beam (do not forget the M12 nuts
under the landing-pins)
Now two twistlocks will be open, two will be closed.
Start hoisting the spreader: Any hoisting action is strictly forbidden.
For a twin spreader, the same procedure is advised for the twin twistlocks.
- Check; safety test oil level indicator; the motor must stop within 10 seconds:
Failure indication in the cabin: constant.
- Check; safety test thermal motor relay: the motor must stop within 10 seconds:
Failure indication in the cabin: motor continues to run.
- Check; safety test high oil temperature: motor continues to run.
Failure indication in the cabin: by lamp indication
- Check: safety test dirty filter: motor continues to run.
Failure indication in the cabin: blinking.
- Observe carefully during telescoping and all flipper down motions.
- Check: safety test no greasing: motor stay running;
Failure indication in the cabin: blinking.
Note: Final check.
Check that twistlocks must be in open position
Check that all landing-pins are down (do not forget the test-nuts)
Check that the oil pressure valve has been reset
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2.40 SAFETY FEATURES
Spreader control safety features:

* Hoisting is only possible when all four twistlocks are locked or unlocked (for the twin spreader
this means all eight)
* Twistlock rotation can only be activated if the spreader is properly positioned on the container
for at least 1 second (all landing pins are up).
* The twistlock rotation command is activated for a minimum of 2 seconds, to ensure twistlock
rotation is completed even with incorrectly positioned indicators.
* Twistlock command is not possible in addition to the standard telescoping positions.
* Lowering/hoisting speeds are reduced if one of the landing pins is up.
* This controls the landing-pin functions automatically.
* Lowering speed stops if all four landing pins are up.
* Features for proper maintenance of the spreader:
* Indication of incorrect automatic greasing.
* For a twin and Long-Twin spreader, standard a twin detection system prevents lifting twins in
single mode.
* All safety precautions are checked in the PLC in the carrier/crane.
Safety features on the spreader:
* Mechanical safety precautions prevent twistlock-rotation if landing pins are down.
* Hydraulic safety precautions prevent twistlock rotation by leaking oil.
* The spreader is designed to handle a 30T 40ft container with three twistlocks.
* Flipper and twistlock rotation speeds are restricted to a maximum speed, which prevents
accidents during maintenance activities on flippers and twist lock controls.
2.50 SPREADER CAGE

SPREADER CAGE ON TOP OF THE HEADBLOCK:
Using a passenger cage on top of the head-block is not within the area of responsibility
associated with the spreader.
Special requirements may be implemented, in co-operation with the local authorities and clients,
for access only to staircases and to the head-block.
SPREADER CAGE UNDER THE SPREADER (Gondola, lashing platform):
If a spreader cage or a passenger cage is used under the spreader for lifting persons, where
connection is made directly with the spreader twistlocks of with an extra special safety device,
local authorities must approve this application. Stinis always advises an extra safety device, to
be fully controlled by the persons in the cage, independently of the spreader and the crane
driver.
This can be implemented with a set of extra twistlocks, chains etc.
Note: Every automatic or remote-controlled connection or disconnection of a passenger cage
must be avoided if this connection is used in addition to the existing twist lock
connection to the spreader.
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3 OPERATION
3.20 FUNCTIONAL DESCRIPTION

3.20.10 SPREADER CONSTRUCTION
The spreader construction consists of mid-frame, a double box girder, and two telescoping
beams with head beams.
The telescopic beams slide inside each other. The connection between a telescopic beam and
a head-beam is by a cross plate, which connects both beams by welds.
Hydraulic and electrical components:
The hydraulic and electrical components are situated on the top of the main frame, as well as
the two telescopic drives for the slide beams.
Stainless steel caps protect all cables and hoses.
All components are placed on silent-blocks.
If possible, the top of the mid-frame is protected by stainless steel sideways-opening protective
caps to prevent damage through stacking fittings and UV light.
Weather conditions:
The spreaders are designed to operate under weather conditions of 100% humidity and -20°C
till +35°C with hydraulic oil quality T32, with oil quality T46 of 0°C till +50°C.
Identity:
All mid-frames and telescopic beams have their own registration number, which refers to
checked tolerances and (50%) ultrasonic checked welds (50%) independently of the spreader.
Most of the components, i.e. manifolds and actuators, have their own registration number.
Interchangeability:
Both the mid-frame and the sliding beams are fabricated to very fine tolerances. Reproduction is
therefore possible without having the original parts at the factory.
This is very important for standardisation, maintenance and the reduction of spare parts.
Welding:
The mid-frame as well as the sliding beams are welded under powder deck (UP), with a
minimum thickness of the weld of the vertical steel plate.
The more heavily loaded welds of the mid-frame and beams are all K-joints.
In total, more than 50% of the welds are checked ultrasonically.
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3.20.20 MID-FRAME
The mid-frame: the strongest part of the spreader:

The mid-frame is the most important part of the spreader. All loads from the telescopic beams
are supported by the mid-frame.
The mid-frame is a stiff double torsion girder. The vertical mid-plate of the double girder is fully
welded with a K-weld to joint the horizontal top and bottom plates.
The mid-frame is the most over dimensioned part of the spreader, which results in the longest
life, particularly in collision situations.
At both ends, vertical plates (front plates) support and guide the telescopic beams. Same plates
are used as much as possible to guide the total vertical forces to the wire lifting ropes of the
crane.
Components:
The mid-frame is the foundation for many components: the two drives for telescoping, the
blocking devices for telescoping, the automatic greasing system, the terminal boxes and the
hydraulic power pack.
As many components as possible are placed on silent blocks.
Telescopic positions:
Located inside the telescopic beams, for every position of the telescopic beams, special
transverse plates are welded at the top of the mid-frame to transfer the vertical forces to the
side plates of the double-girder construction.
With the exception of the 20ft position, all telescopic positions have their own plates.
The number and location indicates the telescopic positions.
Note: The spreader can only be used in the selected telescopic positions.
Creating a new telescopic position on location is not possible without the confirmation
of Stinis.
Front plates:
The front plates are produced from special alloyed steel, and have undergone a mechanical
machining operation for guiding the telescopic beams.
Support telescopic beams:
All surfaces and all replaceable contact plates/blocks exposed to friction and high strains
caused by the telescopic beams have undergone a mechanical machining operation.
The result is that there is practically no clearance in respect of the sliding beams, which
guarantees a long life.
Lifting lugs:
Depending on space and requires, there are two type of lifting lug on the mid-frame:
* On top, two lugs for internal transport
* At the sides, four lugs for special cargo.
The total lifting capacity of all for lugs is fully depended of the SWL of the head-block, reduced
with the weight of the spreader.
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3.20.30 TELESCOPIC BEAMS
Construction:
All side and top contacts areas exposed to friction and high strains are made from heat-treated
copper alloys and can be replaced in a quick and easy manner.
The telescoping system is absolutely maintenance free.
Driving system: 2611-0080-2000
The sliding-beams are driven by two self-tightening toothed belts, which are fitted with 4 heavy-
duty springs to absorb shock loads and allow small changes in spreader length.
Because of the springs, the driving system is absolutely maintenance free.
The two wheels are both connected to a hydraulic drive. The sliding beams stop in the selected
position in response to sensor signals.
The positions are indicated by proximity switches, on one single beam.
Reduced speed:
Because telescoping speed is very high, from 20 to 40ft in 18 seconds, near the 20-45ft position
the speed is greatly reduced to eliminate impact at the stops and to ensure that the beams stop
in the correct position.
The reduced speed is about 20% of the normal speed.
The position at which speed reduction starts in relation to a stop is adjustable for every position.
External horizontal forces on the spreader resulting, for example, in incorrect crane movement,
do not influence the mechanical configuration of the beams or the driving system, except for the
above mentioned force, there is no further blocking mechanism.
Blocking device telescopic beams: Chapter 3.20.40
If the spreader telescoping motion is actuated by cylinders or a belt, if the spreader has
actuated the flippers and is used for quay-side handling or for multipurpose cranes, an extra
blocking system is always mounted for the telescopic stops.
These absolute telescopic stops have positive and negative features.
The positive feature is the absolute fixed position. The negative aspect is the real damage that
can occur in the event of a horizontal collision. As the absolute stops are very strong, something
must break. In general this will be the end beam, which is the part that is easiest to replace in
terms of overall cost and performance.
Without the absolute stops, all forces would be applied to the telescopic belts or cylinders.
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3.20.40 BLOCKING SLIDE BEAM
For blocking the telescopic beams in all ISO positions, a blocking device (telescopic beam lock)
is bolted against the front-plate of the mid-frame, one for each telescopic beam. 5550-1000-0000
The blocking device is a spring returned vertical steel plate, which can be activated by a
blocking actuator (cylinder).
When activated, the blocking plate is retracted from the telescopic beam. When not activated,
the blocking device will push the blocking plates against the telescoping beam, forced by
springs.
If, in special cases (incorrect adjustment of indicators) the blocking plate is not positioned
exactly in front of the right location of the telescoping beams, the spring will force the plate
correctly in the gap of the telescoping beams after some container handlings.
Construction:
The blocking device is total produced from heat-treated alloyed steel, all parts are fully
mechanical machined and cold galvanised.
The permitted horizontal force in telescoping direction is 30T.
The nominal oil pressure for the cylinder is 100bar.
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3.20.50 END-BEAMS (HEAD-BEAMS)
Construction:
The end-beams are manufactured as a stiff torsion construction.
At the inner side, the hydraulic manifold and the terminal box are mounted on silent blocks, and
are fully protected.
The twistlock control is located at the inside of the telescopic beam, is fully protected, and is
easily accessible.
The ends of the end beams are the foundations for the floating twistlocks, and depending on the
type of spreader, for flipper actuators, and cell guide rollers.
3.20.61 TWISTLOCKS model TWI-W

Twistlock loading:
The twistlocks are of the floating type. The fact that the twistlock is floating is not important for
lifting the container equally on both sides of the twistlock to prevent eccentric loading of the
twistlock, but to swing on the washers to neutralise the difference in length of the spreader and
container during lifting.
Twistlocks are always eccentrically loaded.
In twin and Long-Twin operation, the forces on all twistlocks are much higher, because:
* 20ft containers generally have a greater weight than do 40 and 45ft containers.
* In twin and LONG-TWIN operation, the horizontal forces on the twistlocks are much
higher than in single use.
Stinis designs for 10T horizontal forces for all twistlocks in twin during the approach to
the twin containers.
Although these forces don't operate together with the standard vertical forces, life will
be shortened.
* Normal wear in twin-operation is much higher. The twins are never positioned
correctly. The weight of the spreader and headblock will force the twistlocks into the
castings. This is very positive for operation, negative for the life of the bushes and
twistlocks.
Empty and medium loaded containers can be re-positioned during the approach of the
twin-spreader.
Production of twistlocks:
Twistlocks are always manufactured together with the nut.
Interchangeability is possible for a separate twistlock in emergency situations, but is not
advised.
The life of a complete twistlock depends not only on the life of the bolt, but also on the total
combination.
Twistlocks can be used in temperatures down to -40 degrees C.
Twistlock checking intervals under Ship-to-Shore and Yard Gantries, see: Chapter 4.60 C
Note: Counting moves of twistlock rotations isn't equal to the number of load cycles of the
twistlocks.
Shape of twistlocks:
If the underside of the twistlock is symmetrical, the twistlock is of the ISO type. With this type,
only ISO containers can be handled thus Sealand containers cannot be handled.
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If the underside of the twistlock is asymmetrical, the twistlock is of the Multi-Use (MU) type.
With this type, both ISO and Sealand containers can be handled.
The profile at the bottom of the twistlock is very important. The STINIS twistlock has a radius of
curvature R = 5 mm for over 180 degrees, which guarantees a low stress level.
Mechanical locking:
With the exception of special customer requirements, all twistlocks have a mechanical locking
device (safety device). The landing-pin prevents the twistlock nut from rotating in the down
position.
A landing-pin system is fitted to ensure efficient mechanical locking during container handling,
while the open position is also guaranteed during loadless handlings. Free rotation is only
possible if the landing-pin is in up position to unlock the nut of the twistlock.
This locking device is a plate around the nut (type VC).
Without the locking device, the twistlock is of type KR.
Actuating twistlocks in head-beams: 5550-1505-0010
The twistlocks, mounted at the end of head-beams, are actuated by a cylinder with double
piston, special designed for twistlock operation.
Composition of twistlocks model TWI-W:
A complete twistlock can be supplied as a set or as separate parts.
The concave washers and bushes can be in the form of separate spare parts.
The twistlock bolt together with the half washers and nut is one item.
A twistlock set can be given a shortened name, for example TWI-W-ISO-VC-R71-L-TW-S that
means:
TWI-W: Twistlock model TWI-W (with halve rings model W)
ISO or MU: Twistlock bolt for only ISO containers (ISO) or for ISO and 35ft Sealand
containers (MU)
VC or KR: With mechanical locking device (VC) of without (KR)
R71 or R75: Nut with activating radius R=71mm (R71) with R=75mm (R75)
Standard all radius is R=71mm
L or R: Left or Right nut
TW: Twin-Twistlock
S: Only to be used with lock-unlock indication on twistlock.
Bushes:
The bushes guide the twistlock bolt as it is withdrawn from the corner casting.
The bush is placed in the radius of the twistlock bolt.
Because there is a big difference between the function of a bush for single and twin twistlocks,
the bushes are not identical, but in emergency cases the bushes are interchangeable.
The bushes are heavily loaded in the horizontal direction, the twin bushes in particular.
Wear on the bushes in twin operation is much higher than in single use.
We advise that the bushes and top under washers be changed together with the twistlocks.
Twistlocks in the end beam with mechanical locking, with twistlock lock-unlock indication in the
centre of end beam, consisting of:
1 twistlock bolt
1 nut with locking
2 half washers
1 twistlock guide bush
1 concave washer
1 spherical washer
Twistlock control:
All twistlocks are hydraulically actuated. To prevent locking being performed and to ensure that
unlocking is not possible because of containers being incorrectly placed, the locking force is
lower than the unlocking force, particularly in twin operation.
To prevent corrosion, all twin-twistlock actuators are in the retracted position in the unlock
condition.
Maximum speed is prevented by a fixed restriction.
For the twin-twistlocks, locking and unlocking by external forces is prevented by pilot-operated
control valves.
Landing-pins:
For a mechanical locking device, the landing-pin has a slot.
For a non-mechanical locking device, this slot is not required.
Both types of landing-pin are allowed.
The latest generation of landing-pins for use in the head beams have a 45-degree chamfer at
the top, especially for the indicator, which is positioned at the same angle. For the twin landing-
pins, the indicators are positioned vertically, the head of the landing-pin being flat.
Landing-pin set:
1 washer
1 locking pin
1 stainless steel spring
1 landing-pin
Electrical safety devices twistlocks:
All landing-pins have their own indicator, activated by the landing-pins.
Only if all four (eight for the twin) indicators are activated (landing-pin in upward position) is
hydraulic activating of the twistlock actuators possible.
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3.20.70 FLIPPERS and ACTUATORS
For accurate positioning of the spreader on the container, each end beam can be equipped with
fixed or activated flippers. These flippers are the only tools available for the crane driver to
improve the Gantry efficiency, and are therefore the most important part on the spreader.
There are many numbers and flippers extensions, depending of the working method, and these
can be different for each terminal.
For activated flippers, the up/down motion is controlled by flipper actuators.
Flippers are manufactured from heat-treated alloyed steel.
ACTUATOR: 5550-1545-0000
Construction of the actuator:
The actuator is a toothed rack with an integrated actuator, which realizes high torques till
4000Nm and withstand torques up to 7200Nm.
The hydraulic supply drives the rack to function as a kind of actuator because the piston rod is
clamped.
The drive shaft, toothed rack, piston and rod are made of high quality steel and can thus
withstand extreme radial and axial forces (over 16t).
The flipper actuator construction can withstand the whole spreader weight: the spreader can be
parked with flippers in the down position
The flippers are each provided with a safety brace, which prevents them from falling down in the
event of a break.
Oil leakage:
On of the impressive parts of the actuator is the application of a standard actuator, which
guarantees no oil-leakage.
The result is no loss of power, low operating oil temperature and a long oil life.
Mounting actuator:
The actuator is a fully mechanical machined unit, which can be mounted on the end beam with
seven M16 bolts, in three positions:
* In a position for corner flippers.
* In a position for flat flippers for the end beam side.
* In a position for flat flippers for the long side.
All the holes for those two positions are standard drilled on the end beam.
Actuator control:
All actuators are independently operated. Both raising and lowering are hydraulically protected.
The maximum speed is limited to between 3 and 4 seconds to prevent accidents occurring as a
result of incorrect adjustment of the speed regulators.
Both raising and lowering speeds can be completely independent set.
Welding actuator to end beam:
In addition to the bolted connection to the end beam, it is advisable to weld the actuator to the
end beam on 2 locations. Those two small welds are only to prevent the actuator shifting on the
end beam. The seven M16 bolts are strong enough to secure the actuator to the end beam.
Location of the weld:
To dismount the actuator, the location of the welds must be accessible to remove the welds
easy.
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Actuator welding instructions:

Always apply two weld layers. The reason for this is that the heads are constructed from alloy
steel, which requires that the weld be pre-heated. On location this is not usually possible. The
initial weld than serves exclusively as a pre-heating weld.
Use welding materials suitable for S355J2G3.
FLIPPERS: 2641-0014-0000
Material:
The flippers are manufactured from heat-treated alloyed material.
Repairing on location is possible, but the original degree of straightness will never be reached
again.
Profile:
The flippers have a special shape to centre the casting approaching the container from the side.
By using these profiled flippers, Gantry efficiency increases.
Flat flippers have the form of a box construction, which results in a very strong and torsion stiff
flipper.
Mounting:
The flippers are connected to the actuators with four M16 bolts quality 12.9.
If the flipper is overloaded, those bolts will break. The bolts are the weakest point (special
designed to be so).
The separate halve-rounded side plates connecting the flippers to the actuator, together with
flipper, are completely connected to the actuator with a safety axle, to prevent falling down the
flipper in an emergency situation. The halve-rounded side plates are manufactured from special
steel. If a flipper is overloaded, this plate will deform before the connection bolts break, which
indicates that the flipper has been overloaded.
3.20.80 CELL GUIDE ROLLERS
Function:
Cell guide rollers reduce the friction in ship cells and prevent a dead stop.
Wear on the head-beams is strongly reduced and the life of the end beam will be longer.
Cell guide rollers are a better alternative than wear plates: higher speeds are possible.
The diameter and housing of the cell guide roller depends strongly on the location of the
actuator and type of flipper.
Housings:
The housings of cell guide rollers are manufactured from heat-treated alloyed steel.
The bearings are CuAlNiFe alloyed bushes.
The shafts are made of heat-treated steel.
Cell guide rollers for corner flippers: 5550-1570-0000
5550-1570-0001
The cell guide rollers are separately placed on every corner of the spreader, not having any
connection with the flipper actuator so the risk of damage is limited to the cell guide rollers only.
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Greasing:
Greasing is very important for the rollers. The loads on the shaft are enormous and speeds are
high.
If the rollers are not connected on the automatic greasing system, special attention is required
for maintenance.
Welding instructions for housings:
The housings of the cell guide rollers are manufactured from high tensile steel with a yield point
of 800 N/mm2. For repairing the housings, grind the cracks as much as possible, preheat the
basic material to 100 degrees Celsius. Use welding material of a minimum quality of S355J2G3
3.40.10 GENERAL ELECTRICAL COMPONENTS

MECHANIC SWITCHES:
Emergency stop:
Depending on the delivery time of the spreader, 2 emergency stop pushbuttons are located on
both sides of the mid frame. Alternatively, the top of the terminal box on each end beam may be
equipped with and emergency pushbutton.
In addition, the E-box on the main frame can be equipped with a key-switch.
Thermical switch for a 7.5kW motor:
To protect the motor from excessive temperatures, the switch must be adjusted to open at 16
Amp (for 380-400VAC on the spreader).
During telescoping, shift and flippers up/down, the current can increase to 19-22 Amps. This is
permitted, because the hydraulic system limits this situation to a rather short duration.
Oil level switch:
If the oil level is too low, after a minimum of 3 seconds and a maximum 10 seconds the motor
must stop to prevent damaging the hydraulic pump.
The switch can be adjusted to "make" or "break".
Temperature switch:
The temperature switch is a fix adjusted switch (68-72°C).
If the temperature is too high, the switch closes. The oil temperature is not really important. An
oil temperature of 80°C can be sustained for some time, but in that case the life of the oil is
considerably shortened.
It is more important that temperature of the oil in a spreader normally is about 20°C higher than
of the surroundings. However, if the oil temperature is above 68°C, this indicates that there is
something wrong, which is important information for the maintenance department.
Grease failure switch:
If mounted, this switch indicates the grease pressure above 30 bar. During automatic greasing,
this switch must contact after some time.
If this switch does not close, this indicates that the automatic greasing installation is not
functioning well. In general the grease level is too low.
Grease low level switch:
If mounted, this switch stops the automatic greasing if the grease level is low.
Oil return switch:
The oil-return filter is equipped with a low-pressure switch, which indicates the pressure over
the filter.
Although the filter is a medium-high pressure filter, the permitted difference in pressure is set at
5.5 bar for the 5.5 kW installation.
The switch is adjusted to operate at 10.5 bar for a 7.5 kW installation.
The switch will indicate a dirty filter during telescoping and/or flippers up motions.
Depending on the possibilities of the electrical installation, a dirty filter is indicated to the crane
driver, by lamp information, or directly in the cabin. This information is of interesting for the
maintenance department.
HYDRAULIC SOLENOIDS:
Voltage for solenoids:
All solenoids are of the DC type. Preferred voltage is 24VDC.
If AC supply is used on the spreader, an AC/DC transformer is built into the connector.
Manual operating of the valves:
All valves can be manual activated at the ends.
Note: Ensure that nobody is in the vicinity of the flippers.
Ensure that nobody is between mid frame and end beams.
Note: After manual simulation, always replace the protection caps. Water and corrosion are
dangerous for hydraulic valves and cartridges.
Without protective caps the valves will start to leak oil after 3-4 years in aggressive
corrosive situations.
Problems with solenoids:
There are three reasons for a solenoid to break down:
* Using an AC solenoids with dirt oil.
* Water between the solenoid and the cartridge.
Take particular care while assembling the solenoid on the cartridge or valve: use grease and
O-rings.
* Mechanical damage.
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3.50 HYDRAULIC INFORMATION

References:
Hydraulic drawings, see: Chapter 13
Hydraulic components see: Chapter 13
Parts list hydraulic components, see: Chapter 13
Parts list hydraulic hoses, see: Chapter 13
Identification of hydraulic hoses, see: Chapter 13
Hydraulic oil: Chapter 4.20
POWERPACK:
The power pack consists of a 100 litre tank with a 7.5 kW motor and an axial piston pump with
constant power control, and a pressure range of 20-180 bar, with a maximum flowrate of
50 l/min.
If the pressure valve is not actuated, the oil pressure is 25 bar and the maximum oil volume is
50 litres. If the pressure valve is actuated, the maximum pressure is 180 bar.
MANIFOLD welded against powerpack:
The steel manifold of the power pack is a totally integrated special designed construction. All
valves have double outlets for A and B.
Functions on the manifold:
* Control high oil pressure (max oil pressure)
* Control medium oil pressure
* Control automatic greasing
* Control telescoping high and low speed
* Blind plate (for extra function)
* Control unlocks of telescoping beam lock.
* Control twistlocks
* Filter for return oil
* Quick-release coupling for oil supply
SAFETY PRECAUTIONS on the power pack:
Maximum oil temperature:
A simple temperature switch controls the maximum temperature.
The switch closes if the temperature is lower than 68°C.
This information is important for the crane driver, but the hydraulic system does not stop.
The maximum oil temperature is 80 °C
Oil level:
A level switch with a reed contact controls the oil level.
Note: The pump must stop immediately within 2 seconds, otherwise the pump will be
damaged.
Maintenance of the oil-filter:
The hydraulic system has no suction filter (only a high-pressure return filter), so controlling a
suction filter is not required and pump damage resulting by a dirty suction filter is not possible.
To reduce the possibility of damage to the hydraulic pump:
* The hydraulic tank is closed (22 M10 bolds). Never open the tank.
* All return oil flow through a high pressure 10mu return filter.
* A return oil pressure switch indicates the quality of the filter.
* If the oil pressure switch indicates a dirty filter, replace filter.
* Standard setting of the switch is 5.5 bar. Maximum setting is 10.5 bar (advised for 7.5kW
manifold)
* To fill up oil, use the special oil-connector.
MANIFOLD on each head-beams:
For a spreader with actuated flippers, a manifold for 3-4 Cetop-3 valves is mounted on silent
blocks inside each head-beam, for control of the:
* Twistlocks
* Flippers (1-3)
HYDRAULIC FUNCTIONS:
TELESCOPING MOTORS: 5550-1020-0000
Nominal oil pressure 120bar
Maximum oil pressure 180bar
Maximum return oil pressure 40bar
Note: Do always connect the return oil (R) to the tank. Blocking the return oil will damage the
hydraulic drive.
TELESCOPIC BEAM LOCK: 5550-1000-0000
The working pressure of the telescoping beam lock cylinders is 100 bar, maximum pressure
180bar.
The cylinders are single working; the return stroke is realised by two heavy springs inside the
blocking plate.
FLIPPER ACTUATORS: 5550-1545-0000
Flippers up and down are controlled separately.
Flipper speeds up and down are controlled separately.
Safety precautions for the flippers:
Flipper control is protected against excessive speed if flipper speeds are not properly adjusted.
Maximum speed for up/down movement is reduced to 3 sec.
Flipper actions up and down are secured against overload.
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TWISTLOCKS-CYLINDERS: 5550-1550-0010
The oil pressure of the twistlock actuators is 120 bar for locking.
The oil pressure of the twistlock actuators is 180 bar for unlocking.
Speed of twistlock actuators is reduced between 0.5 and 1 second for a complete stoke.
GREASING VALVE:
Grease pressure: 80 bar
For greasing the spreader, the booster must be activated for minimum 60 seconds.
To reset of the grease dividers, a time interval of 15 seconds is required.
An oil pressure switch in the main grease supply controls the grease function.
A low-level switch controls the grease tank.
3.60 AUTOMATIC GREASING

For the grease pump: 5550-0700-0001
For the grease schedule see: Chapter 13
The central automatic greasing system improves the lifetime of valuable material and reduces
the maintenance costs.
It consists of a medium pressure oil-operated grease pump, manifolds and the necessary
connection and mounting material.
The on-line system is suitable for 1, 0, 00 and 000 grease (NLGI specification) depending on
the environmental temperature. The equipment is based on a corrosive environment and does
not need further maintenance.
Greasing cycle:
A greasing cycle is used to activate the grease pump for a period of 60 seconds making use of
the booster with an oil pressure of 80 bar.
Grease:
The grease used is NLGI-00-lithium for an environmental temperature range from -25°C to
+30°C (standard)
For an environmental temperature range from -15°C to +40°C, the grease used is NLGI-0-
lithium.
For an environmental temperature range from 0°C to +50°C, the grease used is NLGI-1-lithium.
Grease pump: 5550-0700-0001
The 80 bar oil-operated grease pump with a transparent grease reservoir have an output per
stroke suitable for the whole spreader.
Grease pulse generators:
The automatic greasing system is activated by the PLC, see: Chapter 3.41
The pre-set range is 10 seconds minimum.
Frequency:
The automatic greasing system is activated by a pulse-generator or by the spreader PLC.
For an AS-i controlled spreader, the frequency is controlled by the spreader PLC in the gantry.
The grease action starts in general at the 40ft spreader position.
The frequency can be controlled by:
* Number of telescoping motions (20-40ft)
* Number of twistlock motions
* Number of flipper motions
Manifolds, tubing and accessories:
The manifolds are equipped with a mounting stud with nut and locking ring. For the transport of
grease, high pressure plastic tubes with brass connectors are standard.
Pressure switch:
A pressure switch in the high-pressure tube controls the correct function of the system by
pressure sensing.
Level switch:
A level switch in the tank controls the lowest grease level.
The automatic greasing function will stop.
SPECIFICATIONS
Oil-operated grease pump:
Lubricant pressure ratio: 1:1
Medium: see above
Medium: grease NLGI 1, 0 and 00
Operating pressure: 80 bar
Max. grease pressure: 120 bar
Theoretical outlet per cycle: 30 cm3
Operating temperature: -20°C + 60°C
Capacity (low model): 4 litre
Capacity (high model): 6.5 litre
Minimum grease level 50 mm
Filling plug:
Stinis supplies the automatic grease system, including a quick connector with dust hood, for
filling.
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Materials:
Actuator tube + mounting: steel, with epoxy coating
Body: aluminium, anodised
Plunger: steel, chrome plated
Reservoir: synthetic material
Seals: N.B.R. and P.T.F.E.
Mounting parts: steel, galvanised
Return spring: stainless steel
Port: 1/2"- 24 UNS
The nipple is secured with Loctite and with an O-ring sealed into the manifold block.
Output grease dividers:
TYPE VOLUME (cm³) TOLERANCE
1 0.055 +/- 15%
2 0.106 +/- 11%
3 0.156 +/- 9%
4 0.205 +/- 8%
5 0.25 +/- 8%
8 0.4 +/- 3%
Pressure switch:
Small, completely enclosed switch
Method of connection: normally opened
Pressure range: 0 - 100 bar
Switch-on pressure: 30 bar
Connection: G1/4"
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4 MAINTENANCE
4.10 TEST RUNS
Running in a new spreader:
A new spreader must be tested and inspected. After testing the hydraulic system, the oil is
replaced with new 10 micron filtered oil.
Because the spreader has an automatic greasing system, only periodic checking of the system
is necessary. All the greasing points must be checked. An automatic greasing system reduces
maintenance and extends the lifetime, but does not replace 100% greasing.
4.20 OIL and GREASE

HYDRAULIC OIL:
Quality:
Premium quality multi-viscosity hydraulic fluid.
If quality lower than ISO 15/11 (ISO 4406), replace oil.
Viscosity:
Maximum permitted viscosity during cold start 1000 mm2/s.
Minimum permitted viscosity for a short period 10 mm2/s.
The recommended viscosity between 16-36 mm2/s
Recommended hydraulic oil for environmental temperatures between:
-28°C and +25°C -20°C and +30°C -0°C and +50°
Shell tellus T22 Shell tellus T32 Shell Tellus T46
BP Energol HLP-HM 22 BP Energol SHF Super 32 BP Energol HLP-HM 46
Valvoline HVLP 22 BP Energol HLP-HM 32 Valvoline HVLP 46
Valvoline HVLP 32
GREASE QUALITY:
Grease type environmental temperature range
NLGI-00-lithium -30°C and +25°C (standard)
NLGI-0-lithium -20°C and +35°C
NLGI-1-lithium 0°C to +55°C
Fina Marson ZS -45°C and +120°C
For manual greasing:
Use a normal multi-purpose grease.
To prevent the fretting corrosion of highly-loaded surfaces, nuts and bolts, a copper or chrome
compound is recommended.
Note: For the underside of the telescopic beams, quality NLGI-1 is required. If the grease is
too thick, a slip-stick effect reduces the telescoping time and improves the hydraulic oil
pressure for the telescoping motion.
A visual instruction for locating greasing points:
* for the telescopic system
* for the twistlocks
* for the flippers
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4.30 MATERIALS INSTRUCTION, SEALANTS

For lubricating materials: Chapter 4.20
For periodical preventive greasing instructions, see: Chapter 4.40
Tools in your standard equipment:
Degreaser: Trichlorethylene or a substitute.
Adhesive: Loctite hydraulic seal number 542.
Loctite retainer number 638.
Copper grease: with as little grease as possible.
Pocket-nuts: 8 nuts M12 nuts (lift tracer pins).
Liquid sealing instructions:
Loctite 542: For all the hydraulic connections
Loctite 542: Including degreasing; for all the standard fasteners.
Loctite 542: Including degreasing; for double lock nut (only in emergency situations)
Loctite 638: Including degreasing; for all strong fasteners, such as bushes and close
tolerance bolts
Never use a liquid-sealant for:
Tensioners: Telescopic pull rods (M20): must have a double nut.
Rib-plates: Telescopic rib plates; centre for fastening, or extremely low strength
adhesive additive, never oil or grease.
Top-plates: Fasteners for the mid-frame hose protection plates.
Greasing:
Hose-clamps: Fasteners for the hydraulic hose clamps.
Never-grease:
Flippers: Fasteners for flippers (grease only with copper grease)
4.40 PREVENTIVE PERIODICAL LUBRICATION INSTRUCTIONS

These instructions apply to a spreader with an automatic greasing system and for 80 000
moves or 4 000 operating hours per year.
Running in a new spreader:
A new spreader must be tested and inspected. After testing the hydraulic system, the oil must
be replaced with new 10 micron filtered oil.
Because the spreader has an automatic greasing system, only periodic checking of the system
is recommended.
All the greasing points must be checked. An automatic greasing system reduces maintenance
and extends the life of the system, but cannot replace 100% greasing.
Check after the first 100 hours:
Leakage: Check the hydraulic system for leakage, special hose- and valve connections.
EVERY 1000 HOURS: at least every 20.000 moves

at least every 4 months
Mid-frame, Check inside for correct grease dosage:

- Contact areas with telescoping beams at the upper side.
- Contact areas with telescoping beams at the under side.
- Contact areas with telescoping beams at the sides.
- Telescoping beam locks
Greasing of:
- Telescoping beam locks: sides of the locking plate.
Mid frame, Check outside for correct grease dosage:
- Actuator bearings (grease nipple).
- Bushes in headblock connection.
- Shaft for headblock- / crane hook connection.
Greasing of:
- Twistlocks upper and lower washers.
- Tracer pins.
Telescoping beams: Check on correct grease dosage:
- Underside contact areas with mid frame.
Greasing of:
- Side contact areas with mid-frame
- Pressure points with mid-frame at the topside.
End beams: Check on correct grease dosage:
- Twistlock bushes (IMPORTANT!!)
- Flippers.
- Cell guide rollers.
Greasing of:
- Twistlock, upper and lower washers (IMPORTANT!!)
- Tracer pins.
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at least once per year
Telescoping beams, Greasing of:

- Tensioners for the telescoping belts
Only the tensioner at the location of the hole ø21mm
4.50 PREVENTIVE PERIODICAL MAINTENANCE INSTRUCTIONS

* For lubrication materials, see: Chapter 4.20
* For lubrication instructions, see: Chapter 4.40
* For preventive periodical maintenance instructions of twistlocks, see: Chapter 4.60

General:
* Test all functions; update the acceptance reports.
* Check oil pressures (only existing pressure points) and timing of actions.
* Check if any cracks and deformations
Twistlocks: Chapter 4.60
* Check nut and key, special the rubber block on top.
* Check the twistlock actuator bolts.
* Check tracer pins and indications.
* Check damage of the blockading lock of the landing pins
Check also if the top of the blockading plate of the twistlocks nut is damaged by the landing
pin. If damaged, warn the technical department. Probably the bump-times on spreader/ crane
of not correct adjusted.
Telescoping drives:
* Check bolts of telescoping motors (left- and right rotating) for fastening.
* Check bolts on the underside of the pulley.
Telescoping beams (exc. LONG-TWIN: Chapter 5.40.20
* Check bolts of locking plates inside.
* Check the presence of the Ampco top contact plates.
* Check the presence of the synthetic under contact plates.
Flippers:
* Check 6/12 bolts M8 12K at the underside of the actuators.
* Check the halve-moon connection plates of the flippers. Chapter 5.40.50
If deformation is noted, replace them, do not repair.
* Inspect bolts on correct position. Tightening the bolds.
Cell guide rollers:
* Check locking of the axle.
Hydraulics:
* Check oil level.
* Check if any oil leakage.
* Fasten all M14 cap nuts of the hydraulic valves, only after the first 1000 hours.
Electrics:
* Check twistlock counters and running hours.
* Check electric wire fasteners.
* Check the function of emergency stops.
* If present on spreader, clean lamps and functioning.
* Check cable tracks and if any for loose components.
* Check the "Twin protection".
Cleaning of the "Twin protection" switches
Greasing: Chapter 4.20.20
* Check the function of all grease distributors in the automatic greasing system.
* If required, replace grease distributors for an other size. Chapter 5.60
* If required, change the frequency of greasing.

Twistlocks:
* Check twistlocks: Look for heavily damaged contact areas or damage to the key or the Chapter 5.40.11
Twistlock bush. Chapter 4.60
If damage is more than normal, replace the twistlock.
Cylinders general:
* Check all cylinder rod ends and bearings.
* Check all cylinders for oil leakage.
* Check all cylinders for rod damage.
Conservation:
* Coat/repaint damaged surfaces.
* Coat/seal galvanised and nickel parts.
* Coat/seal hose connections.
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at least every year
Twistlocks:
* For checking twistlocks on cracks, see: Chapter 4.60
twistlock bush. If damage is more than normal, replace the twistlock.
Telescopic beams: Chapter 5.40.20
* Ampco guide plates inside the telescoping beams at the upper side:
Check the wears and tear of the Ampco guide plates. Do this in the 25ft position.
If the clearance between the steel side foundation on the beam and the top of the Ampco
guide plates is less than 1 mm, replace the Ampco plates.
The correct difference in height can be directly checked in comparison with the old plates.
Differences can be adjusted with steel plates.
After replacement, check that both plates contact the top of the mid frame equally in the
40-45ft position.
Check direct after adjustment/replacement if the telescopic beams not jam in the 40-45ft
position.
* Synthetic glide blocks at the underside of the telescopic beam inside the mid-frame:
Is the vertical clearance in the 40ft position more than 5mm, adjustment with filling plates is
advised.
Is the horizontal clearance in the 40ft position more than 5mm, adjustment with filling plates is
advised.
* Ampco side contact blocks at the front plates of the mid-frame.
Check the backlash of the Ampco side contact blocks at the front plates of the mid-frame. Chapter 5.40.20
If the total horizontal backlash is more than 5 mm, replace them.
Special the top block are very important, otherwise they can fall down.
* Synthetic underside plates at the end of the mid-frame.
Check the thickness of the synthetic underside plates. If the thickness is reduced to 8mm,
replace them.
Hydraulic:
* Replace oil-filter.
* Check the oil quality and replace the oil if required. Chapter 4.20.10

at least every 2 years
Twistlocks:
Twistlock landing pins:
* Control all landing-pins on functional operating. If a landing is damaged near the mechanical
blockading gap, replace the landing pin.
Hydraulic:
* Replace oil.

at least every 4 years
Twistlocks:
Electric:
* If present on the spreader, replace all circuit relays.
* If present on the spreader, replace the motor relay
* If present on the spreader, replace the PLC battery.
* Check the functioning of the thermal motor switch.
* Check the functioning of the "no grease" switch.
* Check the functioning of the oil-level switch.
* Check the functioning of the oil temperature switch.
* Check the functioning of the crack filter switch.
Silent-blocks:
* Replace all silent-blocks.
Hydraulic:
* Clean tank and rinse the hydraulic system.
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4.60 MAINTENANCE INSTRUCTIONS for TWISTLOCKS model TWI-W

(Double-Split-Collar) for CRANE SPREADERS
Note-1: This chapter is only valid for spreaders used under cranes
This instruction is NOT valid for straddle-carrier spreaders.
Note-2: This instruction is only valid for Double-Split-Collar twistlocks model TWI-W.
This instruction is NOT valid for Single-Split-Collar twistlocks model TWI.
SUMMARY
If the “Double-Split-Collar” twistlock is correctly checked periodically for wear and
cracks, and excessive wear or any cracks is not found, then the twistlock can be used for
another period until the next interval-check.
If there is too much wear or any crack found, the twistlock must be replaced immediately.
For every interval-check the swivel washers (both male and female) have to be replaced
Let us know your experience:
We would appreciate it if you share your experiences of the Double-Split-Collar twistlock which
you have in use.
With your knowledge we get the tools to optimize the interval-checks and extend to maybe
longer periods.
CONTENTS
Instruction for periodical inspections for cracks and wear on the twistlocks, divided in:
A. Twistlock-Interval-Check (TIC): Definition
B. Twistlock-Interval-Check (TIC): Criteria’s
C. Twistlock-Interval-Check (TIC): Split up per spreader model
D. Quick scan on back-log maintenance
E. Twistlock-Interval-Check (TIC): Inspection
F. Replace twistlock
G. Twistlock assembly instruction
H. Replace bush
I. Replace twistlock-swivel-washers (male and female)
For the periodical visual inspection, see: Chapter 4.50
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MANUAL TCS001 4-6

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MANUAL TCS001 4-7

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K6
longueur de nouveau baque=196,5mm. rejection à 195mm.

length by new bush=196,5mm. rejection by 195mm.
K4
K1
K5
K3
width by new bush=54-55mm. rejection by 53mm.

larguer de nouveau baque=54-55mm. rejection à 53mm.
K2
Twistlock bus-onderhoud
Twistlock bush-maintenance
Twistlock baque-entretien
Twistlock buchse-Unterhalten
Revision
VATCII 7-323 02
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A. TWISTLOCK-INTERVAL-CHECK (TIC): DEFINITION

A Twistlock-Interval-Check (TIC) is the time between two successive periodical inspections for
cracks and wear on the twistlocks.
The twistlock-interval-check dimension is: number of spreader moves.
B. TWISTLOCK-INTERVAL-CHECK (TIC): CRITERIA'S

TIC’s are depending of the load on the twistlocks.
TIC’s are depended on:
* Type of gantry:
TIC’s are calculated for a crane with hoist on the trolley. In general for a trolley-drawn gantry,
load on the twistlocks is lower.
* Crane hoist management after twistlock-locking:
TIC’s are calculated for a gantry with correct wire rope pre-tensioning during start-up of lifting
(hoist speed max 10%), see: Chapter 2.10
The low hoist speed is required till the container(s) are free lifted from the ground, see: Chapter 2.10
* Hoist speed of the gantry under full load:
TIC’s are calculated for a gantry with a hoist speed till 90m/min under full load.
* Type of spreader and frequency of twin operation:
For a twin spreader, calculations are based on 20% twin operation.
TIC’s are mainly specified for 6 spreader applications:
- Long-Twin Gantry spreader
- Long-Twin Yard spreader, with only empty twin-handling
- Long-Twin Yard spreader, with loaded twin-handling
- Single Gantry spreader
- Single Yard spreader
- Mobile Harbour spreader
C. TWISTLOCK-INTERVAL-CHECK (TIC) split up per spreader model
The following TIC’s are indicated as maximum.
Future experience with this new double-split-collar twistlock or local experience can modify
these TIC’s.
* Long-Twin Gantry spreader:
TIC for head-beam twistlocks: 80.000-100.000 moves
TIC for centre twistlocks: 160.000-200.000 moves
* Long-Twin Yard spreader, with only empty twin-handling:
* Long-Twin Yard spreader, with loaded twin-handling:
* Single Gantry spreader
* Single Yard spreader.
* For Mobile Harbour spreader:
See Long-Twin Gantry
* Jammed spreader in a cell:
Check always the twistlocks after jam/snack in a cell during lifting (active application of the
snack cylinders).
Note: Carrier spreaders cannot be compared with crane spreaders.
Any of above TIC’s is of no value for carrier spreaders.
D. Maintenance: QUICK SCAN ON BACKLOG MAINTENANCE FOR THE CRANE DRIVER

* Location F1: Wear twistlock bolt If the load bearing contact surface between the
twistlock (in locked position) and the corner casting of
the container shows excessive wear, in this case the
material may be butted of. There is a possibility of
insufficient maintenance.
* Location L1: Grease under the nut If there is not enough grease under the nut. There is a
possibility of insufficient maintenance.
* Location K1: Free rotation of bush Rotate the twistlock bush by hand around the twistlock
bolt. It can only rotate over a small angle. Does the
bush rotate heavily or not at all by hand, chance is that
the twistlock will soon jam definitely in the bush. Mostly
the spreader will still function due to the great power of
the twistlock cylinder. A preliminary indication of the
jamming of the twistlock in the bush is not or delayed
locking.
* Location K6: Top of twistlock bush If there is no grease visible on the top of the twistlock
bush, possibly the automatic grease system may not
work properly.
E. TWISTLOCK-INTERVAL-CHECKS (TIC): INSPECTION

Summary:
* If no cracks or excessive wear is found, the twistlock can be re-used until the next
interval-check.
* Swivel washers should always be replaced.
* Rubber on top of the twistlock should always be replaced.
* Only replace the twistlock bush if the bush is not functioning correct (See item G).
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Visual inspection: During greasing service

This check includes all the above mentioned inspection
items, and:
* Location L1: Grease under nut There should be enough grease under the twistlock nut
to keep the friction between the swivel washers low and
reduce corrosion. VATCII 7-322 L1
* Location J1: Free space under nut For Single-Twistlocks:
The average free space between the bottom of the
Single-Twistlock nut and the foundation plate under the
nut is nominal 9mm. VATCII 7-322 J1
Is this distance reduced to 7mm, than the swivel
washers should be replaced as soon as possible.
If this space is less, the swivel washers have worn out
to much. The swivel washer rings should be replaced
as soon as possible, otherwise the twistlock will be
subjected to large bending forces due to the inhibited
floating. This can seriously shorten the twistlocks life
span.
* Location H1: Rubber on key If the plate that is vulcanized on top of the rubber is
bent (concave) then the rubber must be renewed. VATCII 7-322 H1
TIC checks: Dismounting/mounting checks:
* Location A1: Crack in twistlock bolt If a crack is found in the upper groove, replace the
twistlock. VATCII 7-321 A1
* Location B1: Crack in twistlock bolt If a crack is found in the lower groove, replace the
twistlock. VATCII 7-321 B1
* Location C1: Crack in twistlock bolt If a crack is found at the bottom end of the twistlock
shaft, replace the twistlock. VATCII 7-321 C1
* Location D1: Washer scoring If scoring is visible on a swivel washer, replace both
washers. VATCII 7-322 D1
* Location E1: Wear of washers If the swivel washers are worn out of more than 2 mm
both rings should be replaced. VATCII 7-322 E1
Total height for a new set of washers: 19mm
Final rejection less than: 17mm
* Location F1: Wear of twistlock If the wear of the load bearing surface at the bottom
end of the twistlock bolt is more than 2.5 mm, replace
the twistlock. VATCII 7-321 F1
* Location F2: Wear of twistlock If the wear of 2.5mm has not been reached but a lot of
material has been stretched out of the normal
proportions of the twistlock, then this can be grinded off. VATCII 7-321 F2
Do not grind new beveled edges, because this will
make it difficult to recognize a lack of maintenance in a
future inspection.
* Location G1: Wear of twistlock point Replace the twistlock when the wear on the point is
more than 10mm in height. VATCII 7-321 G1
Original height when new is 54mm.
Reject when the height is 44mm.
* Location H1: Rubber on key Replace always the rubber on the flat key. VATCII 7-322 H1
Fastening key: After manual tighten the two M8 bolts,
tighten 2-3 full rotations (360 degrees).
* Location K1: Twistlock bush: height Replace the bush when the total height is reduced till
195mm. VATCII 7-323 K1
Original height when new is 196.5mm.
* Location K2: Twistlock bush: width Replace the bush when the width has worn out till
53mm. VATCII 7-323 K2
* Location K3: Twistlock bush: scoring Is the bush jammed around the shank of the twistlock
then scoring of the bush is possible. Grinding is
allowed. VATCII 7-323 K3
* Location K4: Twistlock bush: greasing Stiff rotating of the bush around the twistlock shank can
be a lack of greasing. Check greasing system. VATCII 7-323 K4
* Location K5: Twistlock, scoring-shank Stiff rotating of the bush because of slotting on the
twistlock shank then the bush is probably worn out. VATCII 7-323 K5
Replace the bush. Grinding and patching up has a short
term effect
* Location K6: Twistlock-bush-top Is there no grease visible on top off the bush it’s VATCII 7-322 L3
possible that the automatically greasing system of the
bush is not working VATCII 7-323 K6
* Location L1: Grease under nut After assembling the twistlock, fill up the space under
the nut with grease. VATCII 7-322 L1
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F. TWISTLOCK REPLACEMENT (one, all, single bolt or the complete twistlock)

Summary:
* Replace and check at each interval when a crack occurs in the “collars”.
* Replace and check at each interval when a crack occurs in the neck.
* Replace and check at each interval when the point of the twistlock has a wear of 10mm.
* Replace and check at each interval when the surface which supports the twistlock has
a wear of 2mm.
Stinis advise to replace the whole twistlock (bolt, nut and collars)
Replace as a set of four (for head beam- and/or twin-twistlocks).
Only for two situations it’s allowed to replace only the twistlock bolt with collar:
* If the twistlock was just replaced completely, only for one time the bolt inclusive the collar-
rings and inclusive the 2 washers can be replaced.
Warning: This way of twistlock replacement is dangerous:
An accuracy of maintenance registration is required. Therefore the replacement of
only the loose bolt and collars are not recommended.
* In an emergency, when the crane is broken down because of the repair of a twistlock.
Then replacement of the collars and set of washers is not necessary.
G. ASSEMBLY INSTRUCTION TWISTLOCK
Summary:
By each interval-check replaces securing rubber.
Before mounting, grease all parts as much as possible.
Too much grease in the nut between the two collars, especially thick grease can give mounting
problems.
Mount the securing rubber above the flat key with care.
Note-1: Do not use grease with a copper compound.
Use grease, with quality NLGI 1 of 2. A higher compound gives mounting
problems due to thickness of the layer
Use sea-water resistant grease.
Note-2: Mount the securing rubber above the flat key with care.
After tighten the two M8 bolt manually, still 2-till-3 turns (360°) tighten.
The securing rubber will be standing sphere and this indicates also for the
mechanic that the bolts are tightened. VATCII 7-322 H1
Is the metal plate hollow then the bolts are tighten too firmly
Note-3: Grease top of the twistlock VATCII 7-322 L2
Grease after mounting the topside and the flat-key to avoid corrosion of the flat-
key, twistlock bolt and collars.
H. REPLACE BUSHES
Summery:
* At each interval-check replace, if the width is less than 53mm.
* At each interval-check replace, if the length is less than 195mm.
Bushes of a Single spreader have a longer life span.
Bushes of the Twin spreaders and special bushes of the Long-Twin spreaders have a shorter
life span, especially by frequent twin use.
The life span depends on what kind of crane, type of spreader and use.
Directives and guidance are hard to give.
Frequency of replacement is experience on location.
Its function depends on different factors:
* The wear in length:
Check the total length of the bush: VATCII 7-323 K1
The total length of the bush is reduced by every impact.
The bush becomes shorter due to extreme high vertical forces as a result of the impact of
landing on a container of a not correct positioned spreaders.
A new bush is 196,5mm long.
The bush has on both sides the wear of impact.
On the top of the bush the wear of impact is clearly visible and is distinguish by a burr and the
45 degrees beveled edge disappears.
On the bottom side of the bush the wear of impact is not clearly visible and is harder to
distinguish because of the round shape of the twistlock and the plane surface of the bush.
Due to the decrease height of the bush, the twistlock nut will move upward.
Landed on a container, the upwards position of the landing pin might not correct unlock the
mechanical blockading of the twistlock.
Replace the bush when the length is reduced till 195mm or less.
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* The wear in the width:

Check the width of the bush on the bottom. VATCII 7-323 K2
In twin operation the bushes can be heavily loaded in horizontal direction, because containers
never are standing in a straight line, so the twistlocks never fits properly in the container
castings.
The twistlock-head first dig into the container castings. In addition to the enormous sideway
forces on the twistlocks, the bush also endures enormous sideway forces. The bush has an
enormous wear at these forces.
- Damaged twistlock shank:
After a while the cheeks of the bush wear out, especially sideways.
When the cheeks of the bush are worn out, then the bottom of the shank from the twistlock
will touch the container castings. Now the shank can be damaged, the bush also can be
damaged inside. This also leads of scoring of the bush VATCII 7-323 K5
- Jammed bush around the twistlock shank:
By reduced thickness in width and imposed surface pressure the material butts on the edge
of the bush, and because of that the inside diameter of the bush becomes smaller, the bush
can be stuck around the twistlock shank. VATCII 7-323 K5
Is the width of the bush worn out till 53mm, replace the bush.
For Long-Twin spreaders, by frequent use of the Long-Twin function replacement of the
bushes will be recommended by each interval-check.
In emergencies it’s possible to repair the bush by grinding.
Grinding and patching up has a short term effect.
Warning: Any welding on the bush not allowed,
* None greasing:
It’s possible that the grease in the lubricant tube has dried out or heavily polluted.
It’s possible that the lubrication system is not working.
Normally the grease is forced upwards.
Only when the top of the bush is visible, then visual inspection of grease is possible.
When the top of the bush is not visible, checking correct functioning of the lubrication system
is only possible at the 6000 hours interval-check.
* Scoring of the bush:
Especially for Twin en Long-Twin spreaders scoring of the bush is possible.
The bush rotates heavily or doesn’t rotate by hand around the twistlock,
The spreader will operate normally for the time being, because of the power of the twistlock
cylinder.
The possibility that the bush get stuck around the twistlock is bigger.
The first indication of a jammed bush is the refusing or the slow movement of the twistlock.
I. REPLACE TWISTLOCK SWIVEL WASHERS (male and female)

Summary:
* Replace each interval-check.
* Replace immediate if the space between bottom side of the nut and construction is less
than 7mm
By each interval-check replace the swivel washers.
The replacement of the washers is of the same importancy as changing the twistlocks.
* Wear and tear of the swivel washers:
When the swivel washers are worn out (this is when the height has reduced more than 2mm),
the twistlocks probably can’t float any more freely.
During a complete side-way movement of the twistlock, in this position the strain in the
twistlock is enormous. This shortens the twistlock life span extremely.
The total height of the special washers is 19mm. VATCII 7-322 E1
Reject and replace at a height of 17mm.
In operation when the twistlocks are mounted, the free space between the bottom of the nut to
the construction can be roughly. VATCII 7-322 J1
For the swivel-washer in the head-beams, the distance (free space) is new 9mm. Final
rejection: 7mm.
For the swivel-washer in the twin-up/down housings, the distance (free space) is new 7mm.
Final rejection: 5mm.
* Greasing swivel washers:
The swivel washers are not automatically greased.
The better the greasing the lesser the friction, the less chance for scoring, the longer the life
span for swivel washers.
Keep the space between the bottom of the twistlock nut and the construction always filled with
grease.
* Scoring of swivel washers:
Scoring of the special washers will cause extreme high friction forces, which will create a lot of
bending stress in the twistlock. This will strongly decrease the life-time of the twistlock.
When one of the special washers (male or female) has scoring tracks, replace both. VATCII 7-323 D1
MANUAL TCS001 4-12

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5 INSTRUCTIONS for ADJUSTMENT & REPAIR

5.10.10 MATERIALS USED
The materials used have a minimum quality of S355j2 (EN10025) for:
* Mid frame.
* Spreader suspension.
* Telescopic beams.
* Head-beams (twistlock beams).
Low alloyed heat-treated steel with high yieldpoint (700N/mm2) is used for:
* Front plates of the mid-frame.
* Vertical loaded top plates of the mid-frame.
* Front plates of the telescopic beams.
* Flippers
* Foundation flippers
* Outside corner twistlock beams
* Housings of the cell guide rolls
* Blocking pins: housings and pin
* Telescopic stops
* Foundation of the belt clamp
ASTM A 320 Grade L43 (better equivalent of 34CrNiMo6V):
* Twistlocks
34CrNiMo6V for:
* Twistlock bushes
* Pins for suspension to the head block
Note: Stinis uses special high-strength materials in various parts of the spreader.
Therefore, welding may not be done by the user without contacting the supplier or
Stinis.
Only then, can Stinis give correct advice and service, and warranties will not be
affected.
5.10.20 MATERIAL CERTIFICATES PROCEDURE

Stinis only uses materials with certificates according DIN 50049 3.1.B or 3.1.C.
Stinis requires high values regarding the high stresses of the materials and therefore Stinis has
his own standards.
Those standards are depending of the quality and thickness of the material specified for the
minimum of alloying elements and the charpy-V at low temperature.
Procedure:
Procedure regarding the identity of materials:
* Stinis only purchase materials with international recognise certificates.
* On receipt of the materials, Stinis checks the registered numbers.
* Materials are allocated their own Stinis registration number with a record of the month, year
and next number of the incoming product.
* These numbers will be registered for heavily loaded materials.
* All identity numbers are in files with the following registered data:
Dimensions/quality
Stinis number
Identification number
Material certificate number
Material certificate document
Minimum requirements:
* For quality S355J2H en S355J2G3 (in accordance with EN 10025), the minimum charpy-V/-
20 is 60J
* For quality with a yieldpoint of 700 N/mm2 up to a thickness of 20mm, the minimum charpy-
V/-40 is 60J
* For quality with a yieldpoint of 700 N/mm2 above a thickness of 20mm, the minimum charpy-
V/-40 is 100J
* For quality with a yieldpoint of 850 N/mm2 up to a thickness of 60mm, the minimum charpy-
V/-60 is 60J
Certificates:
Upon request, certificates will be made available for viewing at our office.
MANUAL TCS001 5-1

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5.20 HYDRAULIC SYSTEM

Malfunctions in the hydraulic system.
Measurement points for P and T will be found above the aggregate.
No pressure:
* Activate the circulating pump valve manually:
- If the pressure is restored, look for an electrical malfunction; check the voltage and the coil
(solenoid)
- If there is no pressure, check the circulating pump valve cartridge: call Stinis.
Power consumption too low:
* The power consumption of the motor is too low: call Stinis.
The power consumption can be continuously adjusted but may not be changed subsequently
without good reason.
Power consumption too high:
* If the power consumption of the motor is too high, this indicates that the pump is consuming
power and thus must supply oil or will not regulate correctly (a fault in the pump):
- May be caused by oil leakage (see further);
- May be caused by dirt in the power control system. Cleaning can sometimes help but looking
for dirt is pointless.
- May be the result of a damaged hydraulic pump: call Stinis.
Oil leakage (not visible):
- There must be a large oil leak somewhere: The best method for tracing this is to look for a
source of heat, or to listen carefully.
When looking for a source of heat, it is best to start when the spreader is cold.
Places to search:
* Overflow valves for the flippers.
* Main safety device for the system (not very likely because it is little used).
* Damaged twistlock seals: in this case, there will only be an oil leak when the twistlocks are
activated.
* Damaged telescope motor: in this case there will only be an oil leak when the telescope
motors are activated.
However, this problem can be more troublesome than it would at first appear, because these
motors leak in normal use and motors tend to leak even more as they become older.
* Damaged high-pressure hose in the tank: Unfortunately, for this the cover must be removed.
- Too high an operating pressure (reduced pressure) for the twin up and down actuators (max.
55 bar):
At 65 bar in the downward position, oil will spill over at 4 to 8 safety devices associated with
the twin lift up and down regulating blocks.
At 75 bar in the upward position, oil will spill over in 4 to 8 of the safety devices associated
with the twin lift up and down flanged regulating blocks.
- Damaged packing in the twin up and down actuators.
Telescoping: No movement
* After a hose has been replaced:
After a hose has been replaced, it is possible that the hoses have been interchanged.
Then, for example, the leakage oil hose may have been exchanged with the supply pressure
hose to the telescope motor.
Up to 100 bar the damaged caused will be limited. Above 100 bar the O-rings under the
hydraulic motor may be extruded and bolts may become stretched.
* Motors rotate in the wrong direction:
This is clearly visible with the movement of the belts.
Telescoping: Leakage
* Leakage underneath, by the pulley for the toothed belt:
- For a drive unit with an integral brake:
The housing of the drive unit is damaged, usually in the form of a crack in the housing caused
by a collision.
- For a drive unit without a brake:
Damaged O-rings in the cover immediately under the motor.
MANUAL TCS001 5-2

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5.20.10 FLIPPER ACTUATORS

For actuator drawing, see: 5550-1545-0000
Correct flipper position:
If the vertical position is not correct as the result of a damaged flipper, so that in the down
position the flipper does not contact the crossbeam, the actuator can be damaged.
Leakage of the flipper actuator:
The actuator is based on a normal cylinder. So there is no oil-leakage.
If the flipper moving, there are two possible problems:
* The hydraulic circuit is not functioning correctly (see speeds part A: broken seals).
* The seal has broken down (see seals)
Seals: To change seals, inclusive dismounting the actuator-cylinder:
* Start in the flipper-up position.
* Prevent the flipper, mechanically, from moving further in the upward direction.
* Dismount the hydraulic hoses.
* Dismount the fitting, item 13.
* Release the six M6x25 12.9K bolts.
* Turn the nut, item 10, counter-clockwise with help of the six M6 bolts.
* Rotate the flipper further in the upward direction:
Note: The complete actuator cylinder may fall!
Make a note of the last position of the flipper so those teeth of the actuator can be
assembled in the same relationship to the teeth of the flipper shaft.
Greasing instructions with automatic greasing system:
* Protect the under side of the actuator against corrosion.
Greasing instructions without automatic greasing system:
* There are three greasing points on the actuator, one at each side and one at the top:
Sides: Grease only with the flipper in the down position.
Top: It is best to grease while the flipper is moving.
* Protect the underside of the actuator against corrosion.
Note: The action of the automatic greasing system results in oil/grease leaving the actuator at
the bottom. This is normal.
Adjusting flipper speeds:
When making speed adjustments, always adjust the overload valves first.
Flipper speeds must be adjusted during movement.
If speeds cannot be reduced with the speed control valves:
Broken seals:
* To check the seals, activate the flipper continuously and disconnect the T-hose: if oil is
coming out of the actuator, this indicates that the seals are broken.
Shock relief valves are broken or adjusted too low:
* Turn the shock relief valves clockwise one by one, and don't forget the original position: test
flipper motion every time.
In general, you can hear the oil leaking in the shock relief valve.
At the same time, the temperature will increase considerably.
(a heavy but final test is to screw on the speed valves: screw on the shock relief valve till
speed stops).
* If screwing on the shock relief valve reduces or stops flipper speeds, the relief valve is the
cause of the problem.
Speed adjustment:
* Use the LN screw on the speed valves until the full stroke takes about 10 seconds.
* Decrease the speed valves until a full stroke takes about 6.5 seconds.
* Never go lower than 5 seconds, because speeds are limited. If speeds are set up around this
timing, less than 5 seconds for a full stroke, simultaneous flipper speeds for all 4 cannot be
achieved during operation.
Adjusting overload flipper relief valves:
Flipper relief valves can adjust quickly if you have good ears.
(You can hear the noise of relieved oil)
Adjusting the shock relief flipper-up:
* Reduce flipper speed-up to zero.
* Screw up the shock relief valve flipper-up.
Put the flipper in down position.
* Activate the flipper-up command continuously (oil pressure must be maximum)
* Screw-down the shock relief valve flipper-up, till you see moving the flipper up.
* Screw-up the shock relief valve flipper-up 90 degrees further.
Be careful, do never screw-up the relief valve much higher, because the standard pressure is
already 380bar and a higher pressure is not good for the flipper seals.
Adjusting the shock relief flipper-down:
* Activate the flipper down command continuously (oil pressure must be a maximum)
* Screw down the flipper down shock relief valve, until you hear the oil flow (a visual check can
be made by watching for a change in motor current).
* Screw up the flipper down shock relief valve until the oil flow stops.
At this point the flipper down shock relief valve is adjusted for the correct oil operating
pressure (in general 180 bar).
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* When the pressure is 180 bar, you can adjust the relief torque of the flipper:
Screw-up the screw 90 degrees, moment is 460 kgm
Warning: Do not go further than this value.
The maximum permitted moment is 700 kgm: At this torque, flipper down speeds
must be set somewhat higher. The flipper speed down for a single flipper is a
maximum of 5.5 seconds for a full stroke.
Torque actuator:
Torque at: 180bar 344 kgm
Resistance torque minimum: 180bar 438 kgm
Resistance torque adjustable: 230bar 560 kgm
Resistance torque adjustable: 285bar 694 kgm
5.30.03 ELECTRICAL SYSTEM

For electrical schedules and part list, see: Chapter 12
Most spreader breakdowns occur in the electrical system. For trouble shooting, try to separate
the possible trouble areas into:
* Area from spreader to crane.
* Area in the main E-box.
* Area between E-box and valve or switch.
All function can be activated on the terminal connections, without danger of damaging the CAN
modules.
Way of fault localization:
* Start from the main E-box.
* Look in the schedule to all possible conditions.
* Control all those conditions.
* Spreader actions can be manual controlled in the main terminal box.
Possible functional faults:
* Check the secondary voltage circuit.
* Check the relay.
* Check the CAN modules and bus-connections
* Check the wiring.
* Check the terminal connectors.
5.40 ELECTRO-MECHANICAL
5.40.11 TWISTLOCKS: Model TWI-W double-split-collar
For a general description of the twistlocks, see: Chapter 3.20.61
Head-beam with twistlock actuator with double rod
For adjusting the position sensors:
Changing the distance from the sensor to the position block is permitted up to a minimum
distance of 10 mm.
Note: Always checks the lock/unlock functioning in the crane. Sometimes the red LED’s give
an incorrect indication.
Replacing (exchange) twistlocks:
For used components and composition, see: Chapter 3.20.61
For general maintenance instructions (without mount/dismounting), see: Chapter 4.50
For mount/dismount checking intervals and replacement (exchange), see: Chapter 4.60
Note: For double-split-collar twistlocks model TWI-W (new):
Tighten the two bold till the rubber block is 2mm lower.
Note: Always greases the twistlock, nut and the half washers before assembling.
Note: Twistlocks model TWI (old model "single-split-collar"):
Special attention must be paid to the twistlock nut. Always secure this nut with Lactate
542.
MANUAL TCS001 5-4

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5.40.20 TELESCOPIC BEAMS - CLEARANCE

Note: The backlash of the telescopic beams is only adjustable at the inside of the mid frame.
The backlash at the outside of the mid frame is not adjustable and is specified by the
tolerances of the construction.
BACKLASH at the OUTSIDE:
Backlash at the outside in the vertical direction:
The standard clearance at the outside of the mid frame is between 2 and 4 mm. Replace the
slide plate, if the thickness is reduced to 7 mm (standard thickness is 10 mm). 5550-1005-0010 2
Backlash at the outside in horizontal direction:
Standard the clearance at the outside of the mid frame is 2 mm.
Replace the high-pressure blocks if the clearance is more than 5mm. 5550-1005-0010 7/8
BACKLASH at the INSIDE:
Backlash at the inside in vertical direction:
The clearance is standard 2 till 5 mm.
Release the two M16 bolts of the locking-plates in the 25ft position: 5550-1530-0004 12/13
To adjust the vertical clearance, the spreader must be in the most extended position.
Telescope to the 40-45ft position.
Reduce vertical clearance by changing/adding packing plates. 5550-1530-0004 3/4/8
Telescope every time after adjusting a vertical clearance.
If the telescope movement is uneven during telescoping, improve the clearance made with the
previous adjustment.
Replace the upper plates, item 06, if the thickness is reduced to 8 mm.
Fastening the upper plates.
Note: Ensure that the bolts are secured with Loctite 542, and that the minimum clearance is 2
mm. 5550-1530-0004 12/13
Wear and tear on the upper plates:
The upper plates must be replaced when their thickness is reduced to 8 mm. 5550-1530-0001 1
Backlash at the inside in horizontal direction:
The standard clearance is 2 to 5 mm.
Release the two M16 bolts securing the locking-plates in the 25 ft. position. 5550-1530-0004 12/13
Adjust the clearance in same position.
Reduce the horizontal clearance by changing/adding packing plates. 5550-1530-0004 5/6/7
Telescope every time after adjusting a horizontal clearance.
If the telescope movement is uneven during telescoping, improve the clearance made with the
previous adjustment.
Note: Ensure that the bolts are secured with Loctite 542, with a minimum clearance of 2 mm. 5550-1530-0004 12/13
If the spreader beam is changed (renewed):
If the spreader beam is changed, then in addition to the standard adjustment procedures, the
thickness of the top plates, item 01, must adjusted very carefully with help of the plates item 02. 5550-1530-0001 1/2
For a 40ft spreader, adjustment may only be carried out in the 40ft position.
For a 45ft spreader, adjustment may only be carried out in the 45ft position.
Adjusting the thickness of the upper plates:
Adjusting the thickness of the upper plates can be done with steel plates. 5550-1530-0001 1/2
For a 40ft spreader, adjusting is only allowed in the 40ft position.
For a 45ft spreader, adjusting is only allowed in the 45ft position.
In those positions, the difference between left and right side must be less than 1mm
Note: Ensure that the M12 bolts are secured with Loctite 542, and that the clearance is 2mm. 5550-1530-0004 12/13
MANUAL TCS001 5-5

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5.40.30 TELESCOPIC BELTS

Detailed assembly instructions for the telescopic belts. VATCII 1-400/1-402
2611-0080-2000
MANUAL TCS001 5-6

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MANUAL TCS001 5-7

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TENSIONING the BELTS:

The belts are self-tensioning.
During telescoping, no slack is allowed. Slack is only permitted only at the stop positions.
Foreword:
To identify the location of the mid-frame we have used A and B.
The telescope system has two belts.
One side of the belt is fastened to the rib plates with an extended pull-rod while the other side is
fastened with the standard (short) pull-rod (visible in the mid-frame).
The pull-rods are mounted on a driving slide.
These driving slides are fastened to the inner side of the telescopic beams.
Note: One driving slide connects one extended and one standard pull-rod.
REPLACING BELT on the B side:
Action 1: Location A side:
* Remove the green belt guide block.
* Push the blocking-plate of the telescopic beam lock actuator in activated position by using a
tap bolt M12 x 100.
Location: tapped hole under the M16 adjusting bolt for the actuator.
If the spreader has a dummy actuator in place of a locking actuator, remove the dummy
* Remove on the standard pull-rod (located inside the telescopic beam inclusive washers bush
and spring (M20). VATCII 1-400 7 17
Action 2: Location B side:
* Remove the green belt guide block.
* Pull/push the beam with the help of a forklift truck placed close to the 43 ft position, so that the
rib plate from the extended pull rod is in exactly the same place as the mounting hole in the
mid-plate of the mid-frame.
* Pull the rib plate to the inside.
* Remove the four bolts and pull out the damaged belt.
* Remove the standard pull rod (located inside the telescopic beam) including washers and
spring (M20).
* Remove the four bolts and pull out the belt.
FITTING A NEW BELT:
Action 3: Location B side:
* The new belt must have the same length as the original one.
* Push the new belt between the beam and the mid-frame into the mounting hole in the
mid-frame.
(Attention: Ensure that the ribs of the belt are on the correct side)
* Push/pull the belt through the mounting hole over approximately 0.5 m and mount the rib
plates and fasten the belt.
* Fasten the belt to the rib plate on the other side.
* Fasten the rib plate into the driving slide: a maximum of four turns for the nut (do not forget
the washers).
* Push the beam inside as far as possible using the forklift trucks.
* If necessary, release the pull rod to gain length (remove the lock nut and turn the hexagonal
nut so that the threaded end is not protruding.
Action 4: Location A side:
* Fasten the belt (do not forget the washers).
* Remove the M12 x 100 bolt from the telescopic beam lock actuator.
At both sides:
* Mount the green belt guide blocks.
* Tighten the springs (See also tightening the springs)
* Fasten the lock nuts.
* Test the spreader and adjust the belts.
Tightening the springs: VATCII 1-402
* After the springs have been mounted, they must be tightened at a distance of approximately
75 mm from the ring to the end of the thread end.
* If a beam does not contact the locking actuator in the 40ft position, stretch the spring.
* The tension must be between 70 and 90 mm. When 90 mm is achieved, the spring on the
other side must be relieved of tension, or the belt will be too long.
MANUAL TCS001 5-8

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5.40.50 FLIPPERS FOR ACTUATORS

Fastening flippers:
* Always grease the contact surfaces between the actuator and the flipper.
* Never secure the flipper bolts with Loctite or equivalent.
* Never improve bolt quality above 12.9.
* Always grease the bolts with copper grease, never with general grease.
* Never use washers under the nuts.
Welding of the flippers:
The flipper material is alloyed heat-treated material.
For welding instructions see: Chapter 5.50
5.50 WELDING INSTRUCTIONS

Welding instructions for S355j2H (tubes acc. EN10025) and S355j2G3 (plates)
Note: Equivalents are:
St 52-3N (acc. DIN17100)
Fe 510D (acc. EU25-72)
Thickness up to 25mm
* Welding material basic for S355j2
* Method horizontal/vertical
Preheating none
Pre-grinding for no paint/rust, none
Thickness over 25mm
* Method horizontal/vertical
Preheating 50-100 °C
Pre-grinding for no paint/rust, none
Welding instructions for S355j2 to High Tensile Steel and High Tensile Steel to High
Tensile steel
Thickness till 5-15mm
* Method horizontal
Current 225-275 Amp
Preheating none
Pre-grinding always
* Method vertical
Preheating 100 °C
Pre-grinding always
Thickness 15-40mm
* Method horizontal
Current minimum 250-300 Amp
Preheating 175 °C
Pre-grinding always and always between layers
* Method vertical
Note: If the quality of the weld is not important, and preheating is prescribed, the following
procedure is allowed:
* First layer is for preheating.
* 2nd and 3rd layers are for the mechanical connection.
After the first weld go on directly with the next two layers.
Welding material basic for s355j2
MANUAL TCS001 5-9

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5.60 AUTOMATIC GREASING:

Most spreaders have an automatic greasing system.
For operating, see: Chapter 3.60
Grease cycle:
A greasing cycle activates the grease pump for 15 seconds (grease pressure 80 bar), followed
by a waiting period of 15 seconds, till the grease pressure is reduced to below 6 bar. This low
pressure is required to reset the grease distributors.
Frequency:
The frequency depends on the type of spreader and the way in which the spreader functions.
The greasing frequency is adjusted to suit the number of twist lock rotations, the number of
telescoping movements and the number of LONG-TWIN movements. After a grease cycle, all
counters will be reset.
After contacting Stinis, these counter adjustments can be changed by the operator.
Control of correct operation:
If possible in the electrical arrangements of the spreader, the grease pressure is controlled
during a grease cycle by a pressure switch in the main grease tube.
If the grease reservoir is not filled or is refilled too late, all the main grease hoses may become
filled with air.
The grease pressure does not reach 80 bar. The greasing system does not function.
All hoses must be refilled with grease.
To restart the greasing system after operating with an empty reservoir:
Restarting after the greasing tubes have become filled with air can only be done after the main
tubes have been filled with grease. Frequent activating of the greasing cycle after operating with
an empty reservoir will not solve the problem.
Procedure for de-aerating:
* Look for all ends of the main tubes (not the tubes behind the grease distributors) and
disconnect the tubes or remove the blind-plugs.
* Activate the oil-pressure valve (hydraulic oil-pressure is 180 bar)
* Activate the grease-pressure-valve for 5 sec
This can be done electrically of manually.
The grease pressure will not reach 80 bar as long air is accumulated in the main tube. After a
pause of 10 seconds, repeat this action until the all the main grease tubes are de-aerated.
Reconnect the tubes and the blind plugs.
* Activate the grease-pressure valve for 30 seconds. The grease distributors will be refilled with
grease.
After every greasing action, repeating is permitted if the grease pressure is reduced to below
6 bar.
If the grease pressure always reaches 80 bar at the end of a grease cycle, the system is
again in perfect condition.
Note: Final checks before the spreader is started for use:
Check that the oil-pressure valve is reset.
Check that the grease-pressure valve is reset.
MANUAL TCS001 5-10

Postbus 2005
The Netherlands
6 SPARE PARTS & SERVICE
6.30 HOW TO ORDER SPAREPARTS

When ordering spare parts or requesting advice, we need the spreader identity, or model with
serial number and/or customer number. Chapter 1.20
The best number to quote is the spreader number welded to the top of the mid-frame.
Spare parts: Chapter 17
Spare parts for the electrical system:
For a list of the components used in the electrical system, see: Chapter 12
Spare parts for the hydraulic system:
For a list of components shown on the hydraulic drawings, see: Chapter 13
For service, spare parts and service contact:
Contact persons:
Ruud Westgeest ruudwestgeest@stinis.com
Stinis Holland B.V.
P.O. Box 2005
The Netherlands
tel 31 180 514655
fax 31 180 516190
MANUAL TCS001 6-1

Postbus 2005
The Netherlands
MANUAL TCS001 6-2

Postbus 2005
The Netherlands
11 MECHANICAL DRAWINGS
11.10 PRODUCTION and ARRANGEMENT DRAWINGS: DIRECTION for USE

Production drawings:
Production drawings are only used for production of the spreaders.
They will be made available for the customer if such drawings are required for repair or
maintenance works.
On request, however, special production drawings can be supplied.
For general information, the drawing numbers give the following information:
code 26 container lifting products
code 11 automatic spreaders
code AAAA main project
code BBBB article number
2611-AAAA-BBBB
Note: Every spreader has its own drawing number.

So a series of identical spreaders will thus have different drawing numbers.
The reason is this is that it is always possible for parts to be changed during the life of
the spreader.
Arrangement drawings:
Arrangement drawings give global information for using the spreader.
This information is focused on the total dimensions, main components, connection details to the
headblock / lifting wire ropes of the crane, lost height etc.
11.20 PRODUCTION DRAWINGS

Project 2704
Post. Qty. Drawing Description
1 1 2611-2704-1000 Mid frame 20-30-40 VATCII-G
2 1 2611-2704-1500 Telescopic beam 20-30-40ft/S
3 1 2611-2704-1600 Telescopic beam 20-30-40ft
4 1 2611-1968-0700 Greasing system VATCII-G
5 1 2611-2399-0600 Hydraulic diagram VATCII-G
MANUAL TCS001 11-1

11-2
CHAPTER 11
Waterside
Green White
Name plate TC SHIPPING 001
Hydraulic powerpack Automatic greasing system Lifting lugs 10t
525 Lifting lugs 10t
124 Spreader stop
64
Manual override
of the twistlocks
Left Right
±4027
±2796
2430
420
800
Hydraulic drive for

1700 Electric junction box Height indication system
the telescopic beam
Type : Standard flat
Manual override
of the twistlocks Connector
Spreader stop LED indication lamps
Red Blue
Corner rolls ø200 Acces ladder to headblock
Landside
4900+5
-5
1230
762
1000 ±1
450
115 115
115 115
40
910
1
2
3
1770
±1872
301
6x275 (=1650)
235 (20ft)
102
649
884 2260 ±1 884
95
±4400
283
898 20ft-30ft-40ft 898

Stinis Holland B.V.
5 1 2611-2399-0600 Hydraulic diagram VATCII-G 0

4 1 2611-1968-0700 Greasing system VATCII-G 0
3 1 2611-2704-1600 Telescopic beam 20-30-40ft 2695
2 1 2611-2704-1500 Telescopic beam 20-30-40ft/S 2695
1 1 2611-2704-1000 Mid frame 20-30-40 VATCII-G 3650
The Netherlands
Pos. Qty Part Code Description Dimension Weight

Specifications Weight: 9200,00 kg
ALL DRAWINGS AND TECHNICAL DOCUMENTS
Surface treatment: -
CUTTING TOLERANCES
ACC. TO EN-ISO 9013
TOLERANCES ACC. TO
NEN-EN-ISO 2768 m
REMAIN THE PROPERTY OF STINIS R&D BV.
MANUAL TCS001
THESE DOCUMENTS SHALL NOT BE USED FOR ANY
Spreader colour RAL2003 OTHER PURPOSE THAN ERECTION, COMMISSIONING, PROJECTION DESIGN:
OPERATION OR MAINTENANCE OF THE PRODUCT.
Postbus 2005
THEY MAY NOT BE USED OR COPIED, REVIEW:

Hydraulic powerpack P = 7,5 kW / 400 VAC / 50 Hz REPRODUCED, TRANSMITTED OR COMMUNICATED
TO A THIRD PARTY WITHOUT THE CONSENT APPROVE:
OF STINIS R&D BV.
Oil T46
DESCRIPTION:
R
Electric plug Harting 1930.048.0548
VATCII-G TC SHIPPING 001
Plug casing 0933.024.2601
TC SHIPPING 001
Plug insert 0933.024.2611
SCALE: 1:20 SHEET DRAWING NUMBER
GROUP SUB PROJECT NO. NUMBER REVISION
Changed Item 2 & 3 with 2704 project no.: DRAWN: Delvin
1
Updated the electrical part list within.
24/12/2014 Delvin A0 1
Rev. Description Date Author
DATE: 9/10/2014 2611 2704 0000
41
44 39
38 34
20
35
Postbus 2005
MANUAL TCS001
The Netherlands
Stinis Holland B.V.
26 2
11
23
5 17 12
22 4
15
10
29
20 12
31
27
1
36 9
45 8 8750-0060-0001 Plain washer M6-A4 A4 0.08

44 6 8750-0050-0001 Plain washer M5-A4 A4 0.06
43 4 8671-0080-0001 Lock hexagon nut M8 A4 A4 0.04
28 42 8 8671-0060-0001 Lock hexagon nut M6 A4 A4 0.08
41 6 8671-0050-0001 Lock hexagon nut M5 A4 A4 0.06
40 4 8570-0080-0030 Hex. socket bolt M8x30 A4 A4 0.08
39 4 8570-0050-0025 Hex. socket bolt M5x25 A4 A4 0.024
38 2 8551-0050-0020 Hex. socket bolt M5x20 8.8 - 0
18
37 2 8506-0240-0060 Hex. head screw M24x60 8.8 8.8 0.6
19 36 2 7230-0027-0000 Signal lamps with 3xLED 6.1
35 1 7115-0135-0000 Fixed socket 3p230v - 0
34 1 7115-0130-0000 Fixed socket 16a3p230v 0
33 33 1 7111-0065-0030 Sonor-sensor ø65 600-6000mm 0.35
32 1 6802-0700-0125 Manifold midframe 7-outputs/S - 0.9
31 1 6802-0700-0110 Manifold midframe 7-outputs Aluminium 0.72
30 2 5550-1070-0000 Guide plate - Assembly 1.67
29 1 5550-1035-0010 Stairs W=450 - 26.3
28 2 5550-1025-0007 Protection cover 3x-clamp 6.32
26 13 21 Protection cover 4x-clamp
27 4 5550-1025-0005 24.8
26 2 5550-1020-0000 Belt drive hydraulic 131.2
25 2 5550-1005-0010 Sliding plates mid frame 92
24 2 5550-1000-0000 Blocking unit hydraulic 48.6
23 1 5550-0700-0001 Grease pump 4L, 80bar, sensor - 8.3
22 1 5550-0600-0000 Vibration isolators power pack - 8.51
21 1 5550-0530-0005 Emergency stop 7m 0.5
20 1 5550-0530-0000 Emergency stop 4.5m 0.5
19 1 5550-0520-0006 Distance detection sensors - 0.7
18 1 5550-0520-0000 Distance detection sensors - 0.83
17 1 5550-0500-0013 E-box support - 23.3
16 1 5098-0000-0410 Stinis marking plate SWL40 t 0.013
15 2 5097-0002-0092 Warning pending load 200mm - 0.02
14 4 5097-0002-0081 Warning sticker clamping 100mm - 0.04
16 13 2 5097-0002-0015 Sticker spreaderstop - 0.02
21
12 2 5097-0002-0010 Sticker dangerous voltage ABS Plastic 0.02
11 2 5097-0000-0050 Sticker Stinis white 750x270 0
10 4 5096-0001-0120 Workload sign SWL 10T 0.08
9 8 5011-0000-0004 Silent block ø25x25/M6 NBR 0.24
8 1 2611-2587-1001 Name plate 3.56
7 1 2611-2704-5015 E1-field 0
6 1 2611-2704-0513 Connector TC SHIPPING 001 0
5 1 2611-2704-0500 E-box TC SHIPPING 001 0
4 1 2611-1968-0670 Power pack 7.5kW/400VAC/50Hz 320
3 1 2611-1554-0676 Hydraulic hoses mid frame 80
14 2 1 2611-0080-2000 Telescoping belt - 80
1 1 2611-2595-0100 Mid frame 20-30-40ft - 3100
Pos. Qty Part Code Description Material Dimension Weight
15 Weight: 3650,00 kg Surface treatment: -
CUTTING TOLERANCES TOLERANCES ACC. TO
REMAIN THE PROPERTY OF STINIS R&D BV. ACC. TO EN-ISO 9013 NEN-EN-ISO 2768 m
37 OTHER PURPOSE THAN ERECTION, COMMISSIONING, PROJECTION DESIGN:
32 30 OPERATION OR MAINTENANCE OF THE PRODUCT.
24 THEY MAY NOT BE USED OR COPIED, REVIEW:
REPRODUCED, TRANSMITTED OR COMMUNICATED
OF STINIS R&D BV.
2
DESCRIPTION:
R
Mid frame-assembly
25
TC SHIPPING 001
DRAWN: GROUP SUB PROJECT NO. NUMBER REVISION

Delvin
DATE:
A0 0
1/12/2014 2611 2704 1000
CHAPTER 11
11-3
11-4
CHAPTER 11
Positioning energie chain!

2400 130
85
2485
25
22
34 16 5 32 15 21 20 35
4
40
23
26
10
42
44
30
37
30
27 6
24
2
3
41
1
28
29
43
44 2 8671-0100-0001 Lock hexagon nut M10 A4 0.04
9 31 19 18 17 36 14 7 39 43 1 8670-0160-0001 Nut M16 A4 0.03
42 2 8571-0100-0030 Hex.countersunk screw M10x30A4 0.04
40 2 8551-0160-0100 Hex. socket bolt M16x100 8.8 0.4
39 1 8526-0160-0070 Hex. head screw M16x70 inox-A4 0.15
38 1 6802-1400-0120 Manifold end beam 14-outputs 0
37 1 6802-0401-0010 Manifold telescopic beam 4-out 0.93
36 1 6554-0401-0330 Manifold end beam C3-24VDC-D15 18.7
35 1 5550-1570-0001 Corner roll-right ø200xø53-70 14.3
34 1 5550-1570-0000 Corner roll-left ø200ø53-70 14.3
33 2 5550-1555-0003 Protection plate actuator 2.96
32 1 5550-1550-0010 Twistlock cylinder 13.9
31 2 5550-1545-0000 Flipper actuator hydraulic 170.2
30 1 5550-1535-0000 Cable channel 122x100/Lg=4000 26.3
29 1 5550-1530-0004 Lower sliding units telescopic 6.81
28 2 5550-1530-0001 Upper sliding units telescopic 4.72
27 1 5550-1520-0813 Detection plate slow 0.45
24 1 5550-1520-0420 Detection plate 40ft 0.19
23 1 5550-1520-0310 Signale plate 30ft 1.7
22 1 5550-1520-0210 Detection plate 20ft 0.97
21 1 5550-1510-0000 Landing pin ø35x50/ø30x242 3.4

13
20 1 5550-1505-0010 Twistlock L&R 30.3
19 1 5550-0620-0001 Connection block hydraulic 4x3 0.3
18 3 5550-0615-0020 Clamp block 2xø22 0.78
17 1 5550-0605-0210 Manifold-support end beam 5.2
16 2 5550-0515-0005 Sensor M30 st.52 0.26
33 11 15 2 5550-0515-0004 Sensor M30 st.52 0.36
14 1 5550-0505-0020 E-box support 2.37
13 1 5097-0002-0083 Warning sticker clamping 300mm 0.01
10 1 5010-0000-0168 Filling plate 30ft support 0.08
9 2 2641-0014-0000 Actuated corner flipper 120
8 1 2611-2704-5025 E2-field 0
7 1 2611-2704-0520 E-box E2 - telescopic beam 0
6 1 2611-1732-0677 Hydraulic hoses telescopic bea 8
Stinis Holland B.V.
5 2 2611-0082-3005 Drive bar L=889 4.9

4 2 2611-0080-1001 Energy chain roll ø60x138 0.72
3 2 2611-0080-0815 Filling cabletray-support 0.14
12
1 1 2611-2587-0150 Telescopic beam 20-30-40/S 2252
The Netherlands

Weight: 2700,00 kg Surface treatment: -
MANUAL TCS001
OTHER PURPOSE THAN ERECTION, COMMISSIONING, PROJECTION DESIGN:
Postbus 2005

OF STINIS R&D BV.
DESCRIPTION:
R
Telescopic beam 20-30-40ft/S
2 flip, corner rolls
GROUP SUB PROJECT NO. NUMBER REVISION
DRAWN: Delvin
A0
DATE: 23/12/2014 2611 2704 1500 0
Postbus 2005
MANUAL TCS001
Positioning energie chain!
The Netherlands
2400 130
85
Stinis Holland B.V.
2485
28 16 26 15 5 21 20 29
34
10
36
38
24
31
24
35
22
23
37
9 25 19 18 17 30 14 7 33
38 2 8671-0100-0001 Lock hexagon nut M10 A4 0.04

37 1 8670-0160-0001 Nut M16 A4 0.03
34 2 8551-0160-0100 Hex. socket bolt M16x100 8.8 0.4
33 1 8526-0160-0070 Hex. head screw M16x70 inox-A4 0.15
32 1 6802-1400-0121 Manifold end beam 14-outputs-S 1.62
31 1 6802-0401-0010 Manifold telescopic beam 4-out 0.93
30 1 6554-0401-0330 Manifold end beam C3-24VDC-D15 18.7
29 1 5550-1570-0001 Corner roll-right ø200xø53-70 14.3
28 1 5550-1570-0000 Corner roll-left ø200ø53-70 14.3
27 2 5550-1555-0003 Protection plate actuator 2.96
26 1 5550-1550-0010 Twistlock cylinder 13.9
25 2 5550-1545-0000 Flipper actuator hydraulic 170.2
24 1 5550-1535-0000 Cable channel 122x100/Lg=4000 26.3
23 1 5550-1530-0004 Lower sliding units telescopic 6.81
22 2 5550-1530-0001 Upper sliding units telescopic 4.72
21 1 5550-1510-0000 Landing pin ø35x50/ø30x242 3.4
20 1 5550-1505-0010 Twistlock L&R 30.3
19 1 5550-0620-0001 Connection block hydraulic 4x3 0.3
18 3 5550-0615-0020 Clamp block 2xø22 0.78
17 1 5550-0605-0210 Manifold-support end beam 5.2
16 2 5550-0515-0005 Sensor M30 st.52 0.26
27 11 15 2 5550-0515-0004 Sensor M30 st.52 0.36
14 1 5550-0505-0020 E-box support 2.37
13 13 1 5097-0002-0083 Warning sticker clamping 300mm 0.01
10 1 5010-0000-0168 Filling plate 30ft support 0.08
9 2 2641-0014-0000 Actuated corner flipper 120
8 1 2611-2704-5035 E3-field 0
7 1 2611-2704-0530 E-box E3 - telescopic beam 4.8
6 1 2611-1732-0677 Hydraulic hoses telescopic bea 8
5 2 2611-0082-3005 Drive bar L=889 4.9
4 2 2611-0080-1001 Energy chain roll ø60x138 0.72
12 Filling cabletray-support
3 2 2611-0080-0815 0.14
1 1 2611-2587-0150 Telescopic beam 20-30-40/S 2252
Weight: 2700,00 kg Surface treatment: -
OTHER PURPOSE THAN ERECTION, COMMISSIONING, PROJECTION DESIGN:
OF STINIS R&D BV.
DESCRIPTION:
R
Telescopic beam 20-30-40ft
2 flip, corner roll
DRAWN: GROUP SUB PROJECT NO. NUMBER REVISION

Delvin
DATE: 23/12/2014
A0 0
2611 2704 1600
CHAPTER 11
11-5
Postbus 2005
The Netherlands
MANUAL TCS001 11-6

Postbus 2005
The Netherlands
12 ELECTRICAL DRAWINGS
12.10 PARTS LIST for ELECTRICAL COMPONENTS

Electrical parts list
Part No. Qty. Description Remark
7110-0030-0120 1 Sensor IIKC022-ASKG/US B00
7110-0030-0110 1 Sensor IIKC012BASKG/US B01
7111-0065-0030 1 Sonor-sensor ø65 600-6000mm B68
7110-0018-0130 1 Sensor M18x1 IGKC008BASKG/M/US B98
7113-0010-0002 1 Valve plug 24V DC-PUR-1.5diode Y01
7113-0020-0002 1 Valve plug 24V DC-PUR-3.0diode Y06-1
7142-0200-0010 1 Pressure sensor 10bar G1/4-M12 S01
7142-0200-0010 1 Pressure sensor 10bar G1/4-M12 S05-1
7139-0030-0051 1 Emergency stop ass.4.5m ES-1
7139-0030-0052 1 Emergency stop ass. 7m ES-2
2611-2704-0513 1 Connector TCS001
7115-0130-0000 1 Fixed socket 16a3p230v
7115-0135-0000 1 Fixed socket 3p230v
7112-0030-0000 9 Conn.female-M12-H-4x0.34-6.0m
7112-0100-0200 2 4-branch split,M12H, 10x0.2-7m
7225-0007-0101 2 Beacon light RED
7225-0007-0103 2 Beacon light GREEN
7225-0007-0105 2 Beacon light WHITE
7121-0003-0044 - Cable robust black 3G1,5
7121-0004-0065 - Cable robust black 4G4
7121-0018-0010 - Cable robust black 18G1
7121-0048-0040 - Cable 48x2.5 PUR-TPE yellow
7139-0030-0060 2 Contact block 1 N/C (red)
MANUAL TCS001 12-1

Postbus 2005
The Netherlands
Parts list main terminal box

Part No. Qty. Description
2611-0704-0510 1 Base plate e-box
2611-2704-0511 1 Cable gland plate assembly L
2611-2704-0512 1 Cable gland plate assembly R
7132-0300-0100 1 Soft starter 3RW4026-1BB04/11k
7134-0650-0040 1 Phase failure relay
7135-0024-0020 6 PLC relay 24VDC-le connect.
7135-0024-0059 1 Jumper 16-13
7135-0230-0050 12 Solid state input relay 230V
7137-0080-0020 12 DIN-rail socket for SLI relay
7139-0300-0028 2 DIN-railadaptor, 22,5
7139-0300-0032 1 Selector switch 2 positions
7139-0300-0034 1 Key-operated switch 0-I
7139-0300-0050 2 Fixing adapters
7139-0300-0051 2 MLR contact element 1xNO
7139-1000-0072 1 Emergency stop relay PSR-SCP-2
7170-0000-0005 2 5-fold CAN splitter
7170-0000-0006 4 FKC 2,5/5
7170-0020-0006 2 AMP 23-pin gray plug 2meter
7170-0020-0007 2 AMP 23-pin black plug 2meter
7170-0020-0008 2 AMP 23-pin blue plug 2meter
7170-0020-0009 3 AMP 8-pin black plug 2meter
7170-0020-0010 2 2024 Universal module 52-I/O
7170-0020-0013 1 E30801498 Display cover 2xUSB
7170-0020-0015 1 E302040-10 Color Display
7180-0913-6890 1 Fuse insert SI FORM C 2A
7180-5778-0610 Fuse T6.3x32 2A slow
7180-5778-0625 Fuse T6.3x32 3,15A slow
7180-5778-0660 Fuse T6.3x32 6.3 A slow
7180-5778-0840 Fuse 5x20 4A T
7199-0002-1000 1 Display support
7199-0007-0010 1 Plate-folded 200x100x210
7201-0011-0100 1 E-box Flat AISI 304
7216-0150-0000 1 3-ph Rectifier 24Vdc-500VA
7218-0002-0060 1 Heater 110-240V AC/DC-30W
7225-0007-0065 1 LED-daydrivelight Dino
7251-0000-0015 1 Temp.switch (1-60°)
8570-0060-0020 16 Hex. socket bolt M6x20 A4
8670-0060-0001 16 Nut M6 A4
8750-0060-0001 16 Plain washer M6-A4
MANUAL TCS001 12-2


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Postbus 2005
The Netherlands
13 HYDRAULIC DRAWINGS
13.20 HYDRAULIC HOSES: IDENTIFICATION

Next page is a code-list for hydraulic hoses.
This list give information about:
* The hose number.
* The number of hoses on the spreader.
* The size of the hoses.
* Parts which are connected.
Not mentioned, but standard dates for the hoses are:
* 3/16" hoses type nylaflow must been produced according SAE 100R7 (outside Ø 9.7mm),
min. nominal pressure dynamic 210 bar.
* 1/4" hoses must been produced according SAE 100R1AT (outside Ø14mm), min. nominal
pressure dynamic 220 bar.
* 3/8" hoses must been produced according SAE 100R2AT (outside Ø20-21mm), min. nominal
* 1/2" hoses must been produced according SAE 100R2AT (outside Ø22.5mm), min. nominal
* all tube connections must have an O-ring sealing.
* all connections must been Ni-plated.
R = straight connection.
45° = 45° angle
H = 90° angle
Hose nr. Qty. Size x Length Connection Location

1 1 3/8"x2950 H12L-H12L telescopic motor right B gate
2 1 3/8"x2970 H12L-H12L telescopic motor right A gate
3 1 3/8"x3620 H12L-H12L end beam right B gate
4 1 3/8"x3230 H12L-H12L end beam right A gate
5 1 3/8"x3100 R12L-H12L telescopic motor right T gate
9 1 3/8"x3680 H12L-H12L end beam left A gate
10 1 3/8"x3120 R12L-H12L telescopic motor left A gate
11 1 3/8"x3020 R12L-H12L telescopic motor left T gate
12 1 3/8"x3580 H12L-H12L end beam left B gate
13 1 3/8"x3240 H12L-H12L telescopic motor left B gate
17 2 3/8"x5900 R12L-R12L to end beam twistlock actuator bottom side(A), or P
18 2 3/8"x7400 R12L-R12L to end beam twistlock actuator rod side (B), or T
19 2 3/8"x 620 R12L-H12L end beam twistlock actuator A gate
20 2 3/8"x 440 R12L-H12L end beam twistlock actuator B gate
21 2 3/8"x 900 R12L-R12L end beam flipper A gate
22 2 3/8"x 860 R12L-R12L end beam flipper B gate
23 2 3/8"x1520 H12L-R12L end beam flipper A gate
24 2 3/8"x1560 H12L-R12L end beam flipper B gate
25 1 1/4"x3850 R08L-H08L telescopic blocking actuator left
26 1 1/4"x3620 R08L-H08L telescopic blocking-actuator right
27 1 3/8"x1200 R12L-H12L grease
166 2 3/16"x380 R06L-R06L emergency: twistlock-end beam unlock
167 2 3/16"x700 R06L-R06L emergency: twistlock-end beam lock
MANUAL TCS001 13-1

Postbus 2005
The Netherlands
13.30 PARTS LIST for HYDRAULIC COMPONENTS

Project: 2704
Part No. pos. Qty. Description (English) Type Fabr.

oil-grease:
9991-0010-0050 - oil T46 Energol HLP-HM 46 BP
powerpack:
6505-0001-0101 105 1 oiltank 950600/01/02/05 RAJA
6505-0001-0102 013 1 tank cover 800x480 950603 RAJA
6505-0001-0103 1 tank cover seal 800x480 Erica superba 3 mm OC
mechanic-wire,nuts:
6016-0000-0001 106 32 cap nuts stainless steel M5 42078 ROKE
6016-0000-0003 15 locknut magnet D15 M37.05.00.30 OC
9964-0050-0002 - threaded rod M5 M5 x 1000 10.9 OC
mechanic-couplings:
6505-0001-0003 010 1 connection on flange d=35 R 300/130/384 d-flen=35-01230000 DENT
6505-0001-0020 011 1 coupling complete for 45cc pump B38 A10V-0-45cc DENT
6505-0001-0021 - coupling motor-side B38/38-H7-L=50/sleeve B38, DENT
6505-0001-0022 - coupling house 5.5/7.5kW 28/45cc B38/nylon housing DENT
6505-0001-0024 - coupling pump-side 45cc B38.16/32-15Z DENT
electric-motors:
7215-0002-0000 012 1 electro motor 7.5kW 400V+/-10% 50Hz 1500/400V-50HZ-IP55trop-B5 5RN132M04 ROTOR
electric-switches: REF
7250-0001-0005 007 1 levelswitch complete VHS-00M GMS
7251-0000-0000 006 1 temperature switch 90-S-6010-75D/088006 OC
electric-solenoids:
7130-0001-0110 3 solenoid S8 cartr. black 24VDC (ø12.7) ex.conn OD.02.12.01.30.OC (series S8 -till start 2004) OC
7131-0002-0500 15 solenoid ARON cetop-3 24VDC D15-24VDC-30W / M14630004 ARON
seals:
6018-0002-0001 1 seal electro motor 300 300/GL-300 OC
O-rings:
6019-0009-0001 - O-Ring vit sh70 (cetop-3-standard) ø9.25x1.78 VOTA
6019-0068-0001 1 O-Ring vit sh70 ø68x3 vit OC
6801-0007-0020 1 O-Ring vit sh70 ø101.2x3.53 OC
6019-1025-0001 1 O-Ring nbr sh90 ø25.07 x 2.62
6019-1037-0001 1 O-Ring nbr sh90 ø37.77 x 2.62 OC
6019-1240-0001 1 O-Ring nbr sh70 ø240.89x3.53 OC
pipe-couplings:
2611-1302-0208 2 hydraulic bended tube short ø12-135x123 SUPERPOLE
2611-1302-0209 2 hydraulic bended tube long ø12-135x153 SUPERPOLE
6050-0000-0001 031 2 minimess 1/4 CSH-14 HEBU
6030-0100-0100 030 1 quick release coupling-male 1/2"-powerpack NV-12-GAS-M / ISO7241-1A OC
6030-0100-0300 030 8 quick release coupling-male 1/8" H1-63 BSP / ISO7241-1B HEBU
6030-0100-0301 030 8 dustcover for coupling male-1/8" H1-66 HEBU
6801-0003-0029 030 - quick release coupling-male 1/4''-grease system BH2-61 / ISO7241-1B STERK
filters:
6040-0100-0100 008 1 airvent-filter SFW-70-3/4 + F 350 Mb. DRAB
6050-0100-0101 032 1 filter SS-024-E10-B (ST1781) STAUFF
6050-0100-0102 032 1 filter house (pipe) MF153 OC
6050-0100-0103 032 1 spring for filter OC
6050-0300-0100 122 1 filter (>02-2001) FS.86.A.114GO-125mu OSD
hoses:
6005-0012-0002 002 1 hose pressure in tank 45cc 1/2'-420-R16S-R16S (standard) HEBU
6005-0008-0001 004 1 hose loadsence in tank 1/4'-435-R08L-R08L HEBU
levelglass:
7252-0100-0120 4 gauge glass 1/2"
orifices:
6052-0001-0000 040 6 orifice plate Cetop-3 OF0021060N0000-M5-orifice EDI
6053-0200-0060 020 1 orifice M5 M5 x 60 EUMA
6053-0200-0080 018 1 orifice M5 M5 x 80 OC
6053-0200-0120 027 1 orifice M5 M5 x 120 OC
6053-0200-0150 040 6 orifice M5 M5 x 150 OC
pump-hydr.motor:
6540-0007-0000 1 pump (180-25-19amp) A10V-O-45-DFLR/31R-PSC62N00-45cc BRUEN
2611-0083-0217 043 2 hydraulic motor CH6000 6000/114-SAE-1056-623 CC/rpm CHARL
manifolds Cetop-3/5:
6550-0001-0100 075 1 manifold Cetop-3 tel slow-24VDC MF132-OFJO56060N0100 OC
6550-0003-0000 045 4 manifold Cetop-3 bindplate compl. BS.3.0100 ARON
manifold-foundatien for valves Cetop-3:
6552-0400-0100 070 2 manifold 4 valves on headbeam MF1474 OC
6552-0700-0420 151 4 manifold 1-valve-Cetop-3 excl.cartridge (flipper) MF3736 EDI
manifolds specials:
6553-0100-0165 014 1 manifold on pump 45cc MF3130 OC
6553-0300-0100 032 1 manifold filter MF152 OC
6553-0300-0110 025 1 manifold filter MP-MT connection- 2x switch MF3118-ST01 OC
6553-0700-0100 042 1 manifold CH6000 connectionplate MF824A-Oring25.03x2.62 OC
valves-cartridges:
6561-0001-1010 005 1 valve 1/1 ball KOGELKR34-01 Logic-S191-34 OC
6561-0002-1001 017 1 cartridge (ø12.7) 2/2 loadsence ex solenoid VEI-8A-2A-06-18K06.1NAC218S/OD.15.06.181CS200 OC
6561-0002-1002 107 - cartridge (ø12.7) 2/2 telescoping ex solenoid VEI-8A-2A-09-17K06.1NAC220SXX3TE/OD.15.06.17.1AS.001 OC
6561-0003-1109 019 1 cartridge (ø12.7) 3/2 greasing ex solonoid VED-8132-06-51K10-40NCC215D/OD.13.10.51.40.03.000 EDI
valves-Cetop-3:
6571-0004-1010 038 1 valve 4/2 Cetop-3 24VDC-D15 spring ret. AD-3E-16-F-M-RG-03 ARON
6571-0004-1070 034 7 valve 4/3 Cetop-3 24VDC-D15 mid pos: ABT AD-3E-03-C-M-RG-03 ARON
checkvalves:
6573-0000-3010 069 2 check valve 12mm RZ-R-12-L-WD LT
6573-0001-3010 109 8 check valve cartridge 30l VU-38-P-XX/04.31.14.10.99XX(heavy sp) OC
6573-0001-5010 026 1 check valve cartridge 80l RVE-16-0.3 IMAV
6573-0003-1030 049 2 checkvalve pilot-op Cetop-3-A-B(twi) OFC011060N00(in A-B) OC
MANUAL TCS001 13-2

Postbus 2005
The Netherlands
flow regulators:
6574-0007-0020 152 4 flow regulator cartridge 3,4l VCDC-CA / OD.22.04-02-19-04 OC
6574-0007-0030 153 4 flow regulator cartridge 7,3l VCDC-CA / OD.22.04-02-19-04 OC
6574-0007-1010 108 1 flow regulator cartridge 40l ST-C-06-1/OD.21.01.03.56 OC
crossover(A-B B-A):
6577-0013-0009 124 2 crossover Cetop-3 B=120 LC1-VM2/B=120 OC
pressure reducing valves Cetop 3/5:
6578-0014-9010 116 1 cartridge pressure red (greasing: 80bar) VRPR-10A-08/04.95.04.03.85.08-80bar OC
pressure relief valves-cartridge:
6579-0013-3120 021 2 press relief valve cartr 30l VS-30-NCF/04.11.18.03.09.20.00C 120bar OC
6579-0013-3190 4 press relief valve cartr 30l VS-30-NCF/04.11.18.03.09.20.00C 190bar OC
6579-0013-3235 1 press relief valve cartr 30l VS-30-NCF/04.11.18.03.99.35 235bar OC
6579-0013-3280 021 4 press relief valve cartr 30l VS-30-NCF/04.11.18.03.99.35 280bar OC
cylinder-twistlock:
6510-0200-0000 C15 2 cylinder-twistlock(IV): complete ø45/35x100 DWG-01288 RAL9004 STINIS
6510-0200-0050 - cylinder double rod-twistlock sealkit ø45/35 sealkit STINIS
cylinder-telescopic-blocking:
2611-0084-3000 C02 2 blocking device telescoping complete VATCII STINIS
2611-0084-3070 C02 2 blocking device telescoping ex cylinder STINIS
6510-0011-0000 C02 2 cylinder-blocking seperate (II) WASS
6510-0011-0050 - cylinder-blocking sep: sealset WASS
cylinder-greasing:
6801-0007-0100 C03 1 grease pump 4L/80bar(RVS) low-level-indication(incl. bero) Hy-10/hulpveer 4l 80bar RVS low-l STINIS
6801-0008-0101 - - grease pump 6.5L/cover with hole for sensor 07-552/S STINIS
6801-0008-0102 - - grease pump 6.5L/sensor foundation 07-661 STINIS
6801-0008-0103 - - grease pump 6.5L/sensor foundation/nut 07-071 STINIS
cylinder for flipper (actuator):
2611-0055-0100 C04 4 cylinder for flipper (actuator) 2611-0055-0000 7000Nm STINIS
2611-0055-0117 C04 - cylinder for flipper: sealkit 2611-0055-0000 sealkit STINIS
MANUAL TCS001 13-3

13-4
Blocking cylinder
emergency control Grease system Driving motor telescopic beam emergency control
CHAPTER 13
twistlocks end beam twistlocks end beam

End Beam right side Left side Right side End Beam right side
Twistlock Actuator Actuator Twistlock Actuator Actuator
COMMENT:
DESCRIPTION:
Stinis Holland B.V.
The Netherlands
MANUAL TCS001
SCALE: FORMAT DRAWING NUMBER
GROUP SUB PROJECT NR. SERIAL NR. REVISION
Postbus 2005
DRAWN BY:
DATE:
A
Postbus 2005
The Netherlands
REVISION
SERIAL NR.
DRAWING NUMBER
PROJECT NR.
COMMENT:
SUB
GROUP
FORMAT
A
DESCRIPTION:
DRAWN BY:
SCALE:
DATE:
MANUAL TCS001 13-5

Postbus 2005
The Netherlands
MANUAL TCS001 13-6

Postbus 2005
The Netherlands
14 CERTIFICATES/QUALITY RECORDS – DESIGN CALCULATIONS
MANUAL TCS001 14-1

Postbus 2005
The Netherlands
MANUAL TCS001 14-2

DORPSTRAAT 130 STINIS HOLLAND B.V.
2931 AG KRIMPEN AAN DE LEK POSTBUS 2005
REGISTRATION NO. 29039874 2930 AA KRIMPEN AAN DE LEK
VAT ID NL802050189B01 NETHERLANDS
ABN AMRO BANK TEL +31 180 514655

SWIFT ADDRESS ABNANL2R FAX +31 180 516190
ACCOUNT NO. 47.61.74.341 EMAIL info@stinis.com
EC DECLARATION OF CONFORMITY
(As defined by Machinery Directive 2006/42/EC Annexe II A)
We, STINIS HOLLAND BV. Dorpsstraat 130

2931 AG Krimpen aan de Lek Netherlands
herewith declare that the construction of:
AUTOMATIC CONTAINER SPREADER
Model: VATCII-G
Drawing: 2611-2704-0000
Reg. no: TCS001
Save Working Load single mode: 40 t
Y
Tare weight: 9200
00 kg.
Certificate/CE: P14-1174
74
Year of construction: 3-2015
3-2015
P
to which this declaration relates is in conformity
mity with the
he following standards:
standards
Harmonized standards
EN 13001-1:2005+A1:2009 Cranes - General design - Part rt 1: General principles
p and requirements
EN 13001-2:2011 Crane safety
sa - General design
des - Part 2: Load L actions
O
Cranes - General Design - Part
Cran P 3-1: 1: Limit States
S and proof competence of steel
EN 13001-3-1:2012+A1:2013
structure
stru
Safety of machinery - Electrical equipment of machines -
Safe
EN 60204-32:2008
Part 32: Requirements for hoisting machines
machine IEC 60204-32:2008
EN 15056:2006+A1:2009
6+A1:2009 Cranes - Requirements ts for container
co handling spreaders
C
EN 12644-1:2001+A1:2008
2001+A1 Cranes - Information for use and testing - Part 1: Instructions
EN 12644-2:2000+A1:2008
2:2000+ Cranes - Information for ususe and testing - Part 2: Marking
EN 13135-2:2004+A1:2010
2:2004+ Cranes
nes - Equipment - Part
P 2: Non-electrotechnical equipment
Safety of m
machinery
achine - Safety-related parts of control systems -
EN ISO 13849-1:2008
49-1:200
Part 1: General principles for design (ISO 13849-1:2006)
Safety of machinery - Safety-related parts of control systems -
EN ISO 13849-1:
9-1: 2008/A
2008/AC:2009
Part 1: General principles for design
Safety of machinery - Safety-related parts of control systems -
EN ISO 13849-2:2008
008
Part 2: Validation (ISO 13849-2:2003)
Safety of machinery - General principles for design -
EN ISO 12100:2010-11
Risk assessment and risk reduction (ISO 12100:2010)
Hydraulic fluid power - General rules and safety requirements for systems and their
EN ISO 4413:2010
components (ISO 4413:2010)
NEN-EN-ISO 9001 Quality management systems - Requirements
National standards
FEM 1.001 Design of Hoisting appliances
DIN 15018 Cranes, Steel structures, Verification and analysis
STINIS HOLLAND B.V.

Netherlands, Krimpen aan de Lek, 31 March 2015
STINIS HOLLAND BV
P.O. Box 2005
Managing director, 2930 AA Krimpen aan de Lek
Bert de Bever
U:\SH\043\VATCII\PROJECTS SM\TCS001-PO14000597\03 PRODUCTION\Certificates stinis and surveing\2015-03-31 VATCII-G SH-E ce declaration TCS001.docx Page 1 of 1
P Y
C O
P Y
C O
Postbus 2005
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15 STINIS PRODUCT INFORMATION
MANUAL TCS001 15-1

Postbus 2005
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MANUAL TCS001 15-2

Postbus 2005
The Netherlands
16 STANDARDS
16.10 APPLICABLE STANDARDS

Dutch:
NEN-NUMBER Description
NEN-EN287 Approval testing of welders.
NEN-EN288 Specification and approval of welding procedures for metallic
materials.
NEN-EN10025 Hot rolled products of non-alloy structural steels
NEN 818-1 Short link chain for lifting purposes - Safety - Part 1:General
conditions of acceptance
NEN 818-2 Short link chain for lifting purposes - Safety - Part 2: Medium
tolerance chain for chain slings - Grade 8
NEN 1154 Rings.
NEN 1156 Eye hooks.
NEN 1713 Lifting hooks - General Directives.
NEN 2017 Crane, General Directives
NEN 2018 Cranes - Loads and combinations of loads.
NEN 2019 Craners - The metal structure.
NEN 2020 Cranes - Mechanical equipment
NEN 2021 Cranes - electrical equipment
NEN 2023 Cranes - Structural requirements regarding safety.
NEN 2024 Cranes, Documents, testing, operation and maintennance
NEN 2027 Mobiele kranen Constructieve eisen i.v.m. de veiligheid.
NEN 2028 Cranes, Automatic Limiting devices
NEN 2062 Arc weldig, Calculation of welded joints in unalloyed and low-
alloy steel up and to including Fe 510 which are predominantly
statically loaded.
NEN 2063 Arc weldig, Fatique loaded structures, Calculation of welded
joints in unalloyed and low-alloy steel up and to including Fe
510
NEN 2500 Steel wire ropes, Semibalanced and non rotating types
NEN 3011 Safety colours and safety signs
NEN 3231 Steel wire ropes, Equal lay for general puposes
NEN 3289 Cargo hook with safety tongue
NEN 3305 Rigging screws.
NEN 3359 Chains and chain fittings for lifting and transport purposes -
Requirements for manufacturing, testing, checking and
certification.
NEN 3360 Non-calibrated, short link chain for lifting and transport
purposes - Requirements and test methods.
NEN 3508 Steel wire ropes, sheaves and drums for lifting and transport
applications - Guide to the selection and design.
NEN 3561 Triangle plates
DIN-NUMBER Description
DIN 00103 Metrisches ISO-trapezgewinde.
DIN 00242 Metrisches Feingewinde 2.
DIN 00444 Augenschrauben.
DIN 00689 Osenhaken.
DIN 00695 Hakenketten, Ringketten und osenhakengeschirr.
DIN 00699 Doppelhaken fur Krafthubwerke.
DIN 00745 Kettenbugel.
DIN 00766 Rundstahlketten fur allgemeine zwecke
DIN 01543 Warmgewaltztes blech von 3 bis 150 mm Dicke.
DIN 01652 Blanker und unlegierter Stahl.
DIN 01681 Stahlguss.
DIN 01691 Grauguss.
DIN 01692 Temperguss.
DIN 03990 Extrenal cylindrical gears
DIN 05683 Ketten fur Seezeichen-Verankerung.
DIN 05684 Hochfeste Rundstahlketten fur Hebezeuge.
DIN 05687 Rundstahlketten.
DIN 05691 Gesmiedete Zubehorteile.
DIN 15018 Krane.(teil 1)
DIN 15020 Grundsatze fur Seiltreibe. (Blatt 1)
DIN 15020 Grundsatze fur Seiltreibe. (Blatt 2)
DIN 15190 ISO-Frachtbehalter der Reihe 1.(blatt 3)
DIN 15400 Lasthaken fur Hebezeuge.
DIN 15401 Einfachhaken.( teil 1)
DIN 15401 Einfachhaken.( teil 2)
DIN 15402 Doppelhaken.( blatt 1)
DIN 15402 Doppelhaken.( blatt 2)
DIN 15403 Rundgewinde.( lasthaken fur hebezeuge)
DIN 15404 Lasthaken fur Hebezeugen. (blatt 1)
DIN 15404 Lasthaken fur Hebezeugen. (blatt 2)
DIN 15411 Lasthaken-Aufhangungen fur Unterflaschen.
DIN 15412 Traversen (fur Krane)
MANUAL TCS001 16-1

Postbus 2005
The Netherlands
DIN 15412 Traversen (fur Krane) (teil 2)

DIN 15413 Lasthakenmuttern.
DIN 15414 Sicherungsstucke.
DIN 17100 Allgemeine Baustahle.
DIN 17115 Stahle fur geschweisste Rundstahlketten.
DIN 17200 Vergutungsstahle.
DIN 17210 Einsatzstahle.
DIN 43402
DIN 82015 Dreieckplatten (fur gekuppelte Ladeseile)
DIN 82019 Doppelhaken (mit Gewinde, mit Gabel, mit Rundauge)
DIN 82025 Augenplatten (mit Langloch)
DIN 82037 Hangerauge-Lastaugeplatten.
EN NUMBER Description
EN 292-1 Safety of Machinery - Basic concepts, general principles for
design
Part1: Basic terminology, methodology
EN 292-2 Safety of Machinery - Basic concepts, general principles for
design
Part2: Technical principles and specification
EN 292-2-A1 Safety of Machinery - Basic concepts, general principles for
design
Part2: Technical principles and specification
EN 292-3 Safety of Machinery, Part3
EN 349 Safety of Machines, minimum distance to avoid injuries to
human body.
NEN-EN 418 Safety for machinery: Emergency stop equipment, functional
aspects. Priciples for design.
EC 655 Employers obligations: Councel directive
EN 418 Safety of Machines, Emergency stops, design principles
EN 811 Safety of Machines, safety distances.
EN 982 Safety for machinery: Safety requirements for fluid power
systems and their components - Hydraulics
EN 983 Safety requiremenets for liquid power ystems and components,
Pneumatics.
NEN-EN 954-1 Safety of machinery, Safety related parts of control systems.
Part 1:general principles for design
EN 1037 Safety of Machinery, Isolation and energy dissipation,
prevention of unexpected start-up.
EN 1050 Safety of Machinery, Principles for risk assessments
prEN 1050 Requirements on elemination of hazards in bridge/ganrty
cranes. Annex A
EN 10027-1
EN 10204
ISO 10245-5 Cranes - Limiting and indicating devices.
Part 5: Overhead-travelling and portal bridge cranes
prEN 12937 Safety of Machinery - Techn principles and specifications for
mobility and for lifting
prEN 12644-1 Cranes -Safety-Requirements for inspection and use.
Part1: Instructions
Part 2: Marking
Part 3: Fitness for Purpose
prEN 13001-1 Crane Safety, Design General, Part 1: general principles and
requirement
prEN 13001-2 Crane Safety, Design General, Part 2: Load effects
prEN 13001-3 Crane Safety, Design General, Part 3: Limit States and Proof
prEN 13135-1 Crane Safety, Design, Requirements for equipment Part 1:
Electrical equipment
prEN 13155-1 Crane Safety, None fixed load lifting attachments
EN 60204-1 Safety of Machines, safety distances.
NEN-EN 60204-1 Safety of Machinery, Electrical equipment, Part 1: general
conditions
MANUAL TCS001 16-2

Postbus 2005
The Netherlands
16.20 DEFINITIONS and TERMINOLOGY

General:
Fixed Length Spreader: Lifting device for handling ISO containers of one size.
Telescopic Spreader: Lifting device for handling ISO containers of several sizes.
Mid-Frame: The central section of a telescopic spreader
Telescopic Beam: The extending frame of a telescopic spreader, which slides in
and out of the mid-frame.
Tare Weight: The spreaders own weight in operation.
Ship to Shore Handling: The lifting of containers by a crane from the ship to the land and
vice versa.
Yard Handling: The lifting, transporting and stacking of containers by a crane
within a container terminal.
Single Lift Operation: Lifting one container with one spreader
Twin Lift Operation: Lifting two container with one spreader
Long-Twin Operation: Lifting two container with one spreader, with the option to adjust
the distance between the twin containers, under full load.
Head-block: The part of the crane to which the spreader is attached.
Head-block connection: The connection between the spreader and the head-block
Cable Basket: A tub or basket used for collecting the electrical connection
cable from the crane when the spreader is being lifted or
lowered.
Manual Mode: The control of a spreader by a crane operator Automatic Mode:
The control of a spreader by an automated system
Twin 20 protection: See Twinlift Interlock Device:
Twinlift Interlock Device: A device to prevent lifting two containers in Single Lift
Operation.
Telescopic Motion: Adjusting the length of the spreader to different container sizes
Telescopic Beam Lock: Mechanical lock to prevent telescopic motion
Twistlock: Rotating locking devise for connecting a spreader to a container
corner casting.
Fixed Twistlock: A twistlock that does not float.
Floating Twistlock: A twistlock that will float around its vertical axis.
ISO Twistlock: A twistlock that can be used with an ISO corner casting.
Universal Twistlock: A twistlock which can be used with a ISO corner casting and a
Sea Land corner casting, also commonly called a Multi-Use
twistlock.
Mechanical Blockading: The action of mechanically locking the twistlock to prevent
rotation.
Lock(ed): Twistlock locked in corner castings to ensure safe lifting of the
container.
Unlock(ed): Twistlock unlocked in corner castings to ensure safe removal
from the container.
Land(ed): Spreader landed correctly with all twistlocks in the corner
castings
Landing Pin(s): Mechanical device(s) to indicate the correct landing of the
spreader on the container.
Holding: All twistlocks locked into a container with the spreader in the
lifted condition.
End Beam: (Head-Beam) The outer end beam of a telescopic spreader
extending frame.
Fixed Guide: A guidance device to align the spreader to a container, which is
non-retractable (see Flipper)
Flipper (Gather Guide): A guidance device to align the spreader to a container which
can be moved from the "in-use" position to a safe, stored
position manually or by remote control.
Cell-Guide Roller: Roll at the End-Beam to guide the spreader in cells.
Twin unit: The additional twistlock housings and mechanism fitted to a
single lift spreader that enables it to perform twinlift operations.
Long-Twin unit: The additional twistlock housings and mechanism fitted to a
single lift spreader that enables it to perform long-twinlift
operations.
MANUAL TCS001 16-3

Postbus 2005
The Netherlands
16.30 RISK ANALYSIS

Source:
A risk analysis is done according chapter G.1 for the Annex "Requirements for spreaders" of EN
13000 Cranes.
List of significant hazards and associated requirements:
Item Hazards Relevant Clause
4.1 Mechanical hazards
4.1.1.3 mass and stability 7.1 7.4
4.1.1.5 inadequacy of mechenical. strength 5.3.1.1 5.3.1.3 6.1 7.8
4.1.3.1 Crushing 7.1 7.2
4.10 Unexpected start-up, unexpected overrun/overspeed (or any similar
malfunction) from:
4.10.1 Failure/disorder of control systems 5.3.1.2 5.3.2.1 5.3.7.1 7.1 7.2
4.10.2 Restoration of energy supply after an interruption 7.1 7.2
4.10.6 Errors made by the operator (due to mismatch of machinery with human
characteristics and abilities, see 8.6) 6.1 7.1 7.2 7.3 7.4 7.6
4.14 Failure of the control circuit 5.3.2.1 5.3.2.3 5.3.2.4 5.3.7 7.1 7.2
4.15 Errors of fitting 5.3.1.2
4.16 Break-up during operation
Loss of mechanical strength, of inadequate mechanical strength 5.3.1.1 5.3.1.3 6.1 7.8
4.17 Falling or ejected objects or fluid 5.3.3 5.3.4 7.1
4.18 Loss of stability / overturning of machinery
4.18.1 Loss of rigid body stability 7.1 7.3
Additional hazards and hazardous events due to mobility
4.23 From handling the machine (lack of stability) 7.1 7.4
4.25 From/to third persons
4.25.3 Lack or inadequacy of visual or acoustic warning means 5.3.4 7.1 7.2
Additional hazards and hazardous events due to load lifting
4.27 Mechanical hazards and events 4.27.1.1
lack of stability 7.1 7.4
4.27.1.2 uncontrolled loading overloading-overturning moment exceeded 7.1 7.3 7.4
4.27.1.3 uncontrolled amplitude of movements 7.1 7.4
4.27.1.4 unexpected/unintended movement of loads 5.3.6 7.4 7.6
4.27.1.5 inadequate holding devices/accessories 5.3.2.1 5.3.2.3 5.3.2.4 7.7
4.27.4 from insufficient mechanical strength of parts 5.3.1.1 5.3.1.3 6.1 7.3 7.8
Loss or mechanical strength, or inadequate mechanical strength
Verification of the requirements and/or safety measures

Clause Titel of Clause Method of verification
G.5 Safety requirements and/or safety measures ---
G.5.1 Requirements for strength ---
G.5.1.1 Structural EA, C
G.5.1.2 Connection to the crane EA, V
G.5.1.3 Load effects according to pEN 13001 EA, C, T
G.5.2 Twistlocksystem ---
G.5.2.1 General V, T
G.5.2.2 Twistlock V
G.5.2.3 Mechanical blockading V
G.5.2.4 Landing pins T
G.5.3 Flippers V
G.5.4 Lifting of persons EA
G.5.5 Lifting two containers in a single motion EA, T
G.5.6 Electrical system ---
G.5.6.1 Electrical and control system EA
G.5.6.2 Stop buttons on the spreader ---
G.5.6.2.1 Spreader stop EA, T
G.5.6.2.2 Emergency stop EA, T
G.6 Verification of the requirements and/or safety ,measures ---
G.6.1 Proof loading T
G.6.2 Verification of the requirements ---
G.7 Information for use ---
G.7.1 Marking V
G.7.2 Manuals EA
G.7.2.1 Maintenance EA
G.7.2.2 Flipper EA
G.7.2.3 Overloading EA
G.7.2.4 Instability EA
G.7.2.5 Electrical and control system EA
G.7.2.6 Lifting two container in single mode EA
G.7.2.7 Damaged containers or containers out of standard EA
G.7.2.8 Inspection EA
MANUAL TCS001 16-4

Postbus 2005
The Netherlands
17 SPREADER PARTS LIST
MANUAL TCS001 17-1

Postbus 2005
The Netherlands
MANUAL TCS001 17-2

Parts list
TCS001
VATCII-G TCS001 (2611-2704-0000)
Page 1 from 2
VATCII-G TCS001 (2611-2704-0000)
Position Part No. Description Quantity Unit
9701-0000-0000 Symbol list sub-assemblies
1 2611-2704-1000 Mid frame 20-30-40 VATCII-G 1 pcs
2 2611-2704-1500 Telescopic beam 20-30-40ft/S 1 pcs
3 2611-2704-1600 Telescopic beam 20-30-40ft 1 pcs
4 2611-1968-0700 Greasing diagram VATCII-G 1 pcs
5 2611-2399-0600 Hydraulic diagram VATCII-G 1 pcs
Page 2 from 2
Symbol list sub-assemblies (9701-0000-0000)
Page 1 from 1
Mid frame 20-30-40 VATCII-G (2611-2704-1000)
Page 1 from 3
1 2611-2595-0100 Mid frame 20-30-40ft 1 pcs
2 2611-0080-2000 Telescoping belt 1 pcs
3 2611-1554-0676 Hydraulic hoses mid frame 1 pcs
4 2611-1968-0670 Power pack 7.5kW/400VAC/50Hz 1 pcs
5 2611-2704-0500 E-box TCS001 1 pcs
6 2611-2704-0513 Connector TCO001 1 pcs
7 2611-2704-5015 E1-field 1 pcs
8 2611-2587-1001 Name plate 1 pcs
9 5011-0000-0004 Silent block ø25x25/M6 8 pcs
10 5096-0001-0120 Workload sign SWL 10t 4 pcs
11 5097-0000-0050 Sticker Stinis white 750x270 2 pcs
12 5097-0002-0010 Sticker dangerous voltage 2 pcs
13 5097-0002-0015 Sticker spreaderstop 2 pcs
14 5097-0002-0081 Warning sticker clamping 100mm 4 pcs
15 5097-0002-0092 Warning pending load 200mm 2 pcs
16 5098-0000-0410 Stinis marking plate SWL40 t 1 pcs
17 5550-0500-0013 E-box support 1 pcs
18 5550-0520-0000 Distance detection sensors 1 pcs
19 5550-0520-0006 Distance detection sensors 1 pcs
20 5550-0530-0000 Emergency stop 4.5m 1 pcs
21 5550-0530-0005 Emergency stop 7m 1 pcs
22 5550-0600-0000 Vibration isolators power pack 1 pcs
23 5550-0700-0001 Grease pump 4L, 80bar, sensor 1 pcs
24 5550-1000-0000 Blocking unit hydraulic 2 pcs
25 5550-1005-0010 Sliding plates mid frame 2 pcs
26 5550-1020-0000 Belt drive hydraulic 2 pcs
27 5550-1025-0005 Protection cover 4x-clamp 4 pcs
28 5550-1025-0007 Protection cover 3x-clamp 2 pcs
29 5550-1035-0010 Stairs W=450 1 pcs
30 5550-1070-0000 Guide plate - Assembly 2 pcs
31 6802-0700-0110 Manifold mid frame 7-outputs 1 pcs
32 6802-0700-0125 Manifold mid frame 7-outputs/S 1 pcs
33 7111-0065-0030 Sonor-sensor ø65 600-6000mm 1 pcs
34 7115-0130-0000 Fixed socket 16a3p230v 1 pcs
35 7115-0135-0000 Fixed socket 3p230v 1 pcs
36 7230-0027-0000 Signal lamp with 3xLED 2 pcs
37 8506-0240-0060 Hex. head screw M24x60 8.8 2 pcs
Page 2 from 3
38 8551-0050-0020 Hex. socket bolt M5x20 8.8 2 pcs
39 8570-0050-0025 Hex. socket bolt M5x25 A4 4 pcs
41 8671-0050-0001 Lock hexagon nut M5 A4 6 pcs
44 8750-0050-0001 Plain washer M5-A4 6 pcs
Page 3 from 3
Telescoping belt (2611-0080-2000)
Page 1 from 2
Telescoping belt (2611-0080-2000)
1 2611-0080-2102 Counterplate 176x150x10 ø11 2 pcs
2 2611-0080-2108 Tension rod M20x355 4 pcs
3 2611-0080-2114 Spacer tube ø25x155 4 pcs
4 2611-0080-2118 Counterplate 176x150x10 M10 2 pcs
5 2611-0080-2120 Belt plate ø11 2 pcs
6 2611-0080-2121 Belt plate M10 2 pcs
7 2611-0085-0501 Tensioner 2 pcs
8 2611-0085-0505 Lockplate for tensioner 4 pcs
9 2611-0085-0506 Tension rod 45ft-ø20x425 2 pcs
10 2611-0085-0510 Telescoping belt-45ft 2 pcs
11 8505-0200-0070 Hexagon bolt M20x70 8.8 Zn pl 4 pcs
13 8556-0100-0030 Hex.countersunk bolt M10x30 16 pcs
15 8606-0120-0001 Lock hexagon nut M12 8 4 pcs
17 8610-0200-0030 Nut M20x1.5Dsteel-black 10 pcs
18 8610-0200-0060 Nut M20x3D steel-black 2 pcs
19 8702-0200-5006 Washer M20 /50x6 8 pcs
22 9802-0000-0002 Die spring Du=51/Di=25/Lo=203 4 pcs
23 9808-0030-1120 Protection cap black SW30/H120 4 pcs
Page 2 from 2
E-box TCS001 (2611-2704-0500)
Page 1 from 2
E-box TCS001 (2611-2704-0500)
10 2611-2704-0511 Cable gland plate assembly L 1 pcs
20 2611-2704-0512 Cable gland plate assembly R 1 pcs
30 2611-2704-5010 E-box TCO001 material 1 pcs
40 7201-0011-0100 E-box Flat AISI 304 1 pcs
50 2611-0704-0510 Base plate e-box 1 pcs
70 8670-0060-0001 Nut M6 A4 16 pcs
Page 2 from 2
Cable gland plate assembly L (2611-2704-0511)
Page 1 from 2
Cable gland plate assembly L (2611-2704-0511)
1 2611-2399-0501 Cable gland plate 460x140x3 1 pcs
2 7120-0025-0025 Cable gland brass M25 x 1,5 1 pcs
7 7120-0025-0035 Hexagonal nut gm-ms M25x1.5 1 pcs
8 7120-0020-0035 Hexagonal nut gm-ms m20x1,5 6 pcs
9 7120-0016-0035 Hexagonal nut gm-ms M16x1,5 12 pcs
10 7120-0009-0905 Plug HSK-V PG9/M16 1 pcs
11 7201-0002-0030 Rubber tape for cable gland plate 1 pcs
Page 2 from 2
Cable gland plate assembly R (2611-2704-0512)
Page 1 from 2
Cable gland plate assembly R (2611-2704-0512)
1 2611-2399-0502 Cable gland plate 460x140x3 1 pcs
6 7120-0011-0905 Plug HSK-M PG11/M16 1 pcs
8 7120-0025-0035 Hexagonal nut gm-ms M25x1.5 1 pcs
10 7120-0016-0035 Hexagonal nut gm-ms M16x1,5 3 pcs
11 7201-0002-0030 Rubber tape for cable gland plate 1 pcs
Page 2 from 2
E-box TCO001 material (2611-2704-5010)
1 7132-0300-0100 Soft starter 3RW4026-1BB04/11k 1 pcs
2 7134-0650-0040 Phase failure relay 1 pcs
3 7135-0024-0020 PLC relay 24VDC-le connect. 6 pcs
4 7135-0024-0059 Jumper 16-13 1 pcs
5 7135-0230-0050 Solid state input relay 230V 12 pcs
6 7137-0080-0020 DIN-rail socket for SLI relay 12 pcs
7 7139-0300-0028 DIN-railadaptor, 22,5 2 pcs
8 7139-0300-0032 Selector switch 2 positions 1 pcs
9 7139-0300-0034 Key-operated switch 0-I 1 pcs
10 7139-0300-0050 Fixing adapters 2 pcs
11 7139-0300-0051 MLR contact element 1xNO 2 pcs
12 7139-1000-0072 Emergency stop relay PSR-SCP-2 1 pcs
13 7150-0010-0120 Resistor 120 Ohm, 1W 4 pcs
14 7170-0000-0005 5-fold Can splitter 2 pcs
15 7170-0000-0006 FKC 2,5/5 4 pcs
16 7170-0020-0006 AMP 23-pin gray plug 2meter 2 pcs
17 7170-0020-0007 AMP 23-pin black plug 2meter 2 pcs
18 7170-0020-0008 AMP 23-pin blue plug 2meter 2 pcs
19 7170-0020-0009 AMP 8-pin black plug 2meter 3 pcs
20 7170-0020-0010 2024 Universal module 52-I/O 2 pcs
21 7170-0020-0013 E30801498 Display cover 2xUSB 1 pcs
22 7170-0020-0015 E302040-10 Color Display 1 pcs
23 7180-0000-0010 Plastic bolt M6 for cable tray 12 pcs
24 7180-0000-0022 Cabletray 75/50 1 pcs
25 7180-0000-0023 Cabletray 75/75 1 pcs
26 7180-0000-0031 Spacer bush M6 L=70mm poly 12 pcs
27 7180-0913-6890 Fuse insert SI FORM C 2A 1 pcs
30 7180-3004-1000 Fuse terminal block UK5-HESI 1 pcs
31 7180-3004-1710 Fuse terminal block UK6-3-HESI 7 pcs
32 7180-3030-3230 Screw bridge 10-pos FBS 10-8 1 pcs
33 7180-3118-2030 Fuse terminal block UK6-FSI/C 4 pcs
34 7180-5778-0610 Fuse T6.3x32 2A slow 3 pcs
35 7180-5778-0625 Fuse T6.3x32 3,15A slow(T) 3 pcs
36 7180-5778-0660 Fuse T6.3x32 6.3 A slow 1 pcs
37 7180-5778-0840 Fuse 5x20 4A T 1 pcs
Page 1 from 2
E-box TCO001 material (2611-2704-5010)
38 7181-0249-1160 Screwless end stop 6mm 4 pcs
39 7181-0280-3150 End and intermidiate plate 1 pcs
40 7181-0280-3190 End and intermidiate plate 1 m 2 pcs
41 7181-0280-3420 End and intermidiate plate 2.5 1 pcs
42 7181-0280-4020 Adjacent jumper 24 A 193 pcs
43 7181-0280-5200 2-level terminal block 0.08-2. 6 pcs
44 7181-0280-5600 Sensor terminal block with led 96 pcs
45 7181-0280-8320 4-conductor through terminal 1 pcs
46 7181-0280-8330 4-conductor through term. gy 6 pcs
47 7181-0280-8340 4-conductor through term. bu 2 pcs
48 7181-0280-8350 4-conductor through terminal b 1 pcs
52 7181-0281-4020 Bridge 8 pcs
53 7181-0281-6200 2-level terminal block 0.08-4 24 pcs
55 7181-0281-6870 3-Conductor earth terminal blk 2 pcs
57 7181-0281-9070 2-Conductor earth terminal blk 2 pcs
58 7199-0002-1000 Display support 1 pcs
59 7199-0007-0010 Plate-folded 200x100x210 1 pcs
60 7216-0150-0000 3-ph Rectifier 24Vdc-500VA 1 pcs
61 7218-0002-0060 Heater 110-240V AC/DC-30W 1 pcs
62 7225-0007-0065 LED-daydrivelight Dino 1 pcs
63 7251-0000-0015 Temp.switch (1-60°) 1 pcs
Page 2 from 2
E1-field (2611-2704-5015)
1 7110-0030-0120 Sensor IIKC022-ASKG/US B00 pcs
2 7110-0030-0110 Sensor IIKC012BASKG/US B01 pcs
7 7111-0065-0030 Sonor-sensor ø65 600-6000mm B68 pcs
8 7110-0018-0130 Sensor M18x1 IGKC008BASKG/M/US B98 pcs
9 7113-0020-0002 Valve plug 24V DC-PUR-3.0diode Y05 pcs
11 7113-0020-0002 Valve plug 24V DC-PUR-3.0diode Y06-1 pcs
15 7139-0030-0051 Emergency stop ass.4.5m ES-1 pcs
16 7139-0030-0052 Emergency stop ass. 7m ES-2 pcs
17 7142-0200-0010 Pressure sensor 10bar G1/4-M12 S01 pcs
20 2611-2704-0513 Connector TCO001 1 pcs
21 7112-0100-0200 4-branch split,M12H, 10x0.2-7m 2 pcs
22 7115-0130-0000 Fixed socket 16a3p230v 1 pcs
23 7115-0135-0000 Fixed socket 3p230v 1 pcs
24 7139-0030-0060 Contact block 1 N/C (red) 2 pcs
25 7225-0007-0101 Beacon light RED 2 pcs
26 7225-0007-0103 Beacon light GREEN 2 pcs
27 7225-0007-0105 Beacon light WHITE 2 pcs
28 7121-0003-0044 Cable robust black 3G1,5 - pcs
29 7121-0004-0065 Cable robust black 4G4 - pcs
30 7121-0048-0040 Cable 48x2.5 PUR-TPE yellow - pcs
Page 1 from 1
E-box support (5550-0500-0013)
Page 1 from 2
E-box support (5550-0500-0013)
1 2611-1725-0590 Frame E-box 1 pcs
2 5011-0010-0030 Wire rope isolator element-4 4 pcs
3 8525-0080-0045 Hexagon bolt M8x45 inox-A4 32 pcs
Page 2 from 2
Distance detection sensors (5550-0520-0000)
Page 1 from 2
1 5014-0000-0158 Base plate 3xM30x1,5-bended 1 pcs
2 7110-0030-0110 Sensor IIKC012BASKG/US 1 pcs
3 7110-0030-0120 Sensor IIKC022-ASKG/US 2 pcs
Page 2 from 2
Page 1 from 2
1 5014-0000-0158 Base plate 3xM30x1,5-bended 1 pcs
Page 2 from 2
Emergency stop 4.5m (5550-0530-0000)
Page 1 from 2
Emergency stop 4.5m (5550-0530-0000)
1 7139-0030-0051 Emergency stop ass.4.5m 1 pcs
Page 2 from 2
Emergency stop 7m (5550-0530-0005)
Page 1 from 2
Emergency stop 7m (5550-0530-0005)
1 7139-0030-0052 Emergency stop ass. 7m 1 pcs
Page 2 from 2
Vibration isolators power pack (5550-0600-0000)
Page 1 from 2
Vibration isolators power pack (5550-0600-0000)
1 5011-0005-0010 Vibration isolator aggregate 4 pcs
4 8701-0160-0001 Plain washer M16 zn.pl. 8 pcs
Page 2 from 2
Vibration isolator aggregate (5011-0005-0010)
Page 1 from 2
Vibration isolator aggregate (5011-0005-0010)
1 5011-0005-0011 Vibration isolator aggregate-t 1 pcs
2 5011-0005-0012 Vibration isolator aggregate-b 1 pcs
Page 2 from 2
Grease pump 4L, 80bar, sensor (5550-0700-0001)
Page 1 from 2
Grease pump 4L, 80bar, sensor (5550-0700-0001)
1 6899-0001-0010 Support grease pump B=112 1 pcs
2 6801-0007-0100 Grease pump 4L/80bar +sensor 1 pcs
5 5011-0000-0005 Vibration isol ø40x40/M8 typeB 4 pcs
6 6020-0040-0071 Adapter coupling 3/8" BSP-12L 1 pcs
7 7110-0018-0130 Sensor M18x1 IGKC008BASKG/M/US 1 pcs
Page 2 from 2
Blocking unit hydraulic (5550-1000-0000)
Page 1 from 2
Blocking unit hydraulic (5550-1000-0000)
1 2611-0084-3070 Blocking unit excl. cylinder 1 pcs
2 5014-0000-0034 Base plate sensor ø34 1 pcs
3 5014-0000-0151 Clamp block ø30 2 pcs
4 6020-0090-0080 Coupling elbow WE08LR1/4KEGOMD 1 pcs
5 6020-0110-0008 Swivel nut elbow EW08LOMD 1 pcs
6 6510-0011-0000 Cylinder 34/28x46 1 pcs
7 6816-0008-0316 Elbow coupling M8x1x3/16" 1 pcs
14 8610-0160-0024 Nut M16x1.5D |10| DIN6330B 5 pcs
17 8799-0000-0100 Lock washer M16 nordlock 6 pcs
18 9801-0080-0180 Grease nipple M8x1-180° zn.pl. 1 pcs
19 9808-0022-1024 Protection cap black SW22/H=24 6 pcs
Page 2 from 2
Blocking unit excl. cylinder (2611-0084-3070)
Page 1 from 2
Blocking unit excl. cylinder (2611-0084-3070)
1 2611-0084-3049 Locking Plate with axle-compl 1 pcs
2 2611-0084-3001 Side plate 200x145x15 1 pcs
3 9807-0807-0032 Parallel key 8x7-32 1 pcs
6 8710-0100-0001 Spring lock washer M10 4 pcs
8 2611-0084-3022 Die spring ø 24.5/13.3x200 2 pcs
9 2611-0084-3011 Washer ø54x4 1 pcs
10 2611-0084-3010 Ring ø50xø17-5 1 pcs
11 2611-0084-3009 Pressure piece 1 pcs
12 2611-0084-3008 Convex ring for spring 2 pcs
13 2611-0084-3007 Slide strip 97.5x40x10 4 pcs
14 2611-0084-3002 Side plate 200x145x20 1 pcs
15 2611-0084-3003 Strip for blocking unit 2 pcs
16 2611-0084-3004 Rear plate 145x85x10 1 pcs
Page 2 from 2
Cylinder 34/28x46 (6510-0011-0000)
Page 1 from 2
Cylinder 34/28x46 (6510-0011-0000)
1 6510-0011-0101 Bottom of hydraulic cylinder 1 pcs
2 6510-0011-0102 Guide ring 1 pcs
3 6510-0011-0103 Piston rod 1 pcs
4 6510-0011-0104 Tube hydraulic cylinder 1 pcs
5 6510-0011-0105 Plastic washer 1 pcs
7 6510-0011-0050 Seal kit cylinder 34/28x46 1 pcs
8 6510-0011-0200 Sticker cylinder blocking unit 1 pcs
Page 2 from 2
Seal kit cylinder 34/28x46 (6510-0011-0050)
Page 1 from 2
Seal kit cylinder 34/28x46 (6510-0011-0050)
1 6510-0011-0110 O-ring 26x3 NBR 90 Shore 1 pcs
2 6510-0011-0111 Guiding ring 1 pcs
3 6510-0011-0112 Seal B-141110 NBR 70 Shore 1 pcs
4 6510-0011-0113 Seal GA 28x38x5/7 NBR 70 Shore 1 pcs
Page 2 from 2
Sliding plates mid frame (5550-1005-0010)
Page 1 from 2
Sliding plates mid frame (5550-1005-0010)
1 2611-0084-0205 Foundation plate sliding plate 1 pcs
2 2611-0219-2025 Slide plate Longtwin 1 pcs
4 5010-0000-0123 Slide block support 2 pcs
5 8598-0000-0002 Greasing bolt M10x20/ø3 4 pcs
7 2611-0080-2915 Slide block 80x40.5 2 pcs
8 2611-0080-2916 Slide block 40x40.5 2 pcs
Page 2 from 2
Belt drive hydraulic (5550-1020-0000)
Page 1 from 2
Belt drive hydraulic (5550-1020-0000)
1 2611-0199-7920 Hydraulic drive ex. brake 1 pcs
3 6020-0060-0020 Adapter coupling 7/16"-20UNF/1 1 pcs
Page 2 from 2
Hydraulic drive ex. brake (2611-0199-7920)
Page 1 from 2
Hydraulic drive ex. brake (2611-0199-7920)
1 2611-0083-0207 Backup ring pulley 1 pcs
2 2611-0083-0208 Timing pulley for tel. belt 1 pcs
3 2611-0083-0217 Orbitmotor Charlynn type114056 1 pcs
4 2611-0083-0218 Thrust ring 1 pcs
5 2611-0083-0224 Seal washer 1 pcs
6 2611-0083-0239 Oil bush 1 pcs
7 2611-0199-0210 Inner house driving gear-casti 1 pcs
8 2611-0199-7921 Shaft ø76x373.5-without brake 1 pcs
9 2611-0199-7950 Seal kit hydraulic drive 1 pcs
10 6553-0700-0100 MF824A- incl. O-ring 1 pcs
13 8562-0380-0034 Hex. socket bolt 3/8x3/4 12.9 8 pcs
14 8599-0000-0032 Hexagon socket set screw M6x6 1 pcs
15 8725-0055-0001 Retainer ring(axle) 55 mm 1 pcs
16 8726-0120-0001 Retainer ring 120 mm 1 pcs
17 8751-0100-0001 Spring lock washer M10 A4 8 pcs
18 9804-0000-0014 Radial ball bearing 6213 2RS1 1 pcs
19 9804-0000-0089 Spherical roller bearing 1 pcs
20 9807-1610-0100 Parallel key 16x10-100 1 pcs
21 9899-0070-0001 Cover screw cap 700 5/8 - 18UN 2 pcs
Page 2 from 2
Timing pulley for tel. belt (2611-0083-0208)
Page 1 from 2
Timing pulley for tel. belt (2611-0083-0208)
1 2611-0083-0210 Pulley HTD28-14M-120 1 pcs
2 2611-0083-0222 Flange for drive belt -upper- 1 pcs
3 2611-0083-0223 Flange for drive belt -bottom- 1 pcs
4 8555-0060-0016 Hex.countersunk bolt M6x16 8.8 8 pcs
Page 2 from 2
Seal kit hydraulic drive (2611-0199-7950)
Page 1 from 2
Seal kit hydraulic drive (2611-0199-7950)
1 2611-0083-0214 O-ring NBR ø108.00x6.00 1 pcs
2 2611-0083-0229 U-gasket ø56x68x8,5 1 pcs
3 2611-0083-0232 O-ring NBR ø 134.50x3.00 1 pcs
4 6019-1110-0001 O-Ring NBR sh70-ø110x4 1 pcs
Page 2 from 2
Protection cover 4x-clamp (5550-1025-0005)
Page 1 from 2
1 2611-0219-2501 Clamp block 8xø21+7xø14 8 pcs
5 2611-0084-2800 Protection cap 236x900 1 pcs
Page 2 from 2
Page 1 from 2
1 2611-0114-9000 Protection cap 590x188 1 pcs
Page 2 from 2
Stairs W=450 (5550-1035-0010)
Page 1 from 2
Stairs W=450 (5550-1035-0010)
1 2611-1735-0130 Stairs w=450 1 pcs
Page 2 from 2
Guide plate - Assembly (5550-1070-0000)
Page 1 from 2
Guide plate - Assembly (5550-1070-0000)
1 2611-0084-1800 Guide plate 1 pcs
Page 2 from 2
Telescopic beam 20-30-40ft/S (2611-2704-1500)
Page 1 from 3
1 2611-2587-0150 Telescopic beam 20-30-40/S 1 pcs
2 2611-0080-0814 Filling cabletray-support 1 pcs
4 2611-0080-1001 Energy chain roll ø60x138 2 pcs
5 2611-0082-3005 Drive bar L=889 2 pcs
6 2611-1732-0677 Hydraulic hoses telescopic bea 1 pcs
7 2611-2704-0520 E-box E2 1 pcs
8 2611-2704-5025 E2-field 1 pcs
9 2641-0014-0000 Actuated corner flipper 2 pcs
10 5010-0000-0168 Filling plate 30ft support 1 pcs
14 5550-0505-0020 E-box support 1 pcs
15 5550-0515-0004 Sensor M30 st.52 2 pcs
16 5550-0515-0005 Sensor M30 st.52 2 pcs
17 5550-0605-0210 Manifold-support end beam 1 pcs
18 5550-0615-0020 Clamp block 2xø22 3 pcs
19 5550-0620-0001 Connection block hydraulic 4x3 1 pcs
20 5550-1505-0010 Twistlock L&R 1 pcs
21 5550-1510-0000 Landing pin ø35x50/ø30x242 1 pcs
22 5550-1520-0210 Detection plate 20ft 1 pcs
23 5550-1520-0310 Signale plate 30ft 1 pcs
25 5550-1520-0810 Detection plate slow 1 pcs
28 5550-1530-0001 Upper sliding units telescopic 2 pcs
29 5550-1530-0004 Lower sliding units telescopic 1 pcs
30 5550-1535-0000 Cable channel 122x100/Lg=4000 1 pcs
31 5550-1545-0000 Flipper actuator hydraulic 2 pcs
32 5550-1550-0010 Twistlock cylinder 1 pcs
33 5550-1555-0003 Protection plate actuator 2 pcs
34 5550-1570-0000 Corner roll-left ø200ø53-70 1 pcs
35 5550-1570-0001 Corner roll-right ø200xø53-70 1 pcs
36 6554-0401-0330 Manifold end beam C3-24VDC-D15 1 pcs
37 6802-0401-0010 Manifold telescopic beam 4-out 1 pcs
Page 2 from 3
38 6802-1400-0120 Manifold end beam 14-outputs 1 pcs
39 8526-0160-0070 Hex. head screw M16x70 inox-A4 1 pcs
41 8571-0100-0020 Hex.countersunk screw M10x20A4 3 pcs
43 8670-0160-0001 Nut M16 A4 1 pcs
Page 3 from 3
E-box E2 (2611-2704-0520)
Page 1 from 2
E-box E2 (2611-2704-0520)
1 2611-0080-5402 E-box 1xM25/14xM16 machined 1 pcs
2 7120-0016-0018 Cable gland PA M16 x 1.5 5 pcs
4 7120-0016-0031 Plug v-ne M16x1.5 3 pcs
5 7120-0025-0010 Cable gland PA M25 x 1,5 1 pcs
6 2611-2704-5020 E2-box 1 pcs
Page 2 from 2
E2-box (2611-2704-5020)
1 7180-1201-6620 End clamp E/AL-NS 35 2 pcs
5 7181-0280-5640 Sensor-LED supply terminal blo 1 pcs
Page 1 from 1
E2-field (2611-2704-5025)
11 7142-0200-0010 Pressure sensor 10bar G1/4-M12 S05-1 pcs
12 7112-0030-0000 Conn.female-M12-H-4x0.34-6.0m 5 pcs
Page 1 from 1
E-box support (5550-0505-0020)
Page 1 from 2
E-box support (5550-0505-0020)
1 5011-0000-0051 Vibration isolator W 4 pcs
3 8525-0080-0020 Hexagon bolt M8x20 A4 2 pcs
Page 2 from 2
Sensor M30 st.52 (5550-0515-0004)
Page 1 from 2
Sensor M30 st.52 (5550-0515-0004)
1 5014-0000-0151 Clamp block ø30 2 pcs
Page 2 from 2
Sensor M30 st.52 (5550-0515-0005)
Page 1 from 2
Sensor M30 st.52 (5550-0515-0005)
1 5014-0000-0151 Clamp block ø30 2 pcs
Page 2 from 2
Manifold-support end beam (5550-0605-0210)
Page 1 from 2
1 2611-0082-0170 Clamp hydraulic manifold-Left 1 pcs
2 2611-0082-0175 Clamp hydraulic manifold-Right 1 pcs
3 5011-0000-0029 Silent block ø75x40/M12-sh70 3 pcs
6 8610-0080-0012 Nut M8x 1.5D |10| DIN6330B 4 pcs
Page 2 from 2
Clamp block 2xø22 (5550-0615-0020)
Page 1 from 2
Clamp block 2xø22 (5550-0615-0020)
1 9803-0002-0022 Clamp - double ø22mm 2 pcs
Page 2 from 2
Connection block hydraulic 4x3 (5550-0620-0001)
Page 1 from 2
2 6020-0190-0005 Reducing nipple 3/8x1/8 BSP 2 pcs
3 6020-0170-0018 Bonded seal 1/8 4 pcs
4 6020-0500-0010 Adapter coupling 1/8x1/8 2 pcs
5 6030-0100-0300 Quick Release Coupling 1/8"BSP 2 pcs
6 6030-0100-0301 Dust cover male 1/8" BSP 2 pcs
7 6020-0170-0038 Bonded seal 3/8 2 pcs
Page 2 from 2
Twistlock L&R (5550-1505-0010)
Page 1 from 2
Twistlock L&R (5550-1505-0010)
1 2615-0091-0000 Twistlock TWI-W-ISO-VC-R71 2 pcs
2 2624-0001-0000 Twistlock bush ISO 2 pcs
3 2615-0018-0400 Twistlock washer female 100x55 2 pcs
4 2615-0018-0300 Twistlock washer male 80x50 2 pcs
5 6815-0018-0316 Reducing nipple 1/8"x3/16" 2 pcs
Page 2 from 2
Twistlock TWI-W-ISO-VC-R71 (2615-0091-0000)
Page 1 from 2
1 2615-0087-0100 Twistlock bolt 100x54x50-296 W 1 pcs
2 2615-0087-0400 Set of half washers (W) 1 pcs
3 2615-0087-0500 Parallel key 18x11 lg =94 1 pcs
4 2615-0087-0600 Locking Rubber for Twistlock 1 pcs
5 2615-0091-0200 Twistlock nut R71 1 pcs
6 8599-0000-0008 Locking hexagon bolt M8x25 2 pcs
Page 2 from 2
Landing pin ø35x50/ø30x242 (5550-1510-0000)
Page 1 from 2
Landing pin ø35x50/ø30x242 (5550-1510-0000)
1 5021-0000-0011 Landing pin 35x50/30x192-42 2 pcs
2 5003-0000-0013 Ring landing pin ø45xø30.5-30 2 pcs
3 8736-0080-0040 Spiral pin zinc pl. ø8x40 2 pcs
4 9802-0000-0020 Compr. spring RVS/120-39-4-10w 2 pcs
Page 2 from 2
Detection plate 20ft (5550-1520-0210)
Page 1 from 2
1 2611-0080-0850 Detection plate 20ft 167x90x64 1 pcs
2 8526-0100-0016 Hex. head screw M10x16 A4 2 pcs
Page 2 from 2
Signale plate 30ft (5550-1520-0310)
Page 1 from 2
Signale plate 30ft (5550-1520-0310)
Page 2 from 2
Page 1 from 2
Page 2 from 2
Detection plate slow (5550-1520-0810)
Page 1 from 2
1 2611-0162-1700 Speed reduction 20ft 1 pcs
Page 2 from 2
Page 1 from 2
1 2611-0165-1500 Speed reduction 30ft-40ft 1 pcs
Page 2 from 2
Page 1 from 2
1 2611-0162-1800 Speed reduction 40ft 1 pcs
Page 2 from 2
Upper sliding units telescopic (5550-1530-0001)
Page 1 from 2
1 5009-0000-0015 Slide plate 170x100x15 1 pcs
2 2611-0084-2017 Filling telesc. beam 160x100x3 1 pcs
3 8598-0000-0005 Greasing bolt M12x50/M8x1 1 pcs
4 6815-0008-0316 Adapter coupling M8x1 3/16" 1 pcs
5 8720-0120-0036 Mudwing repair washer M12 1 pcs
Page 2 from 2
Lower sliding units telescopic (5550-1530-0004)
Page 1 from 2
1 2611-0080-0915 Locking plate left b=32 1 pcs
2 2611-0080-0916 Locking plate right b=32 1 pcs
9 5009-0000-0003 Slide block-right side with gr 1 pcs
10 5009-0000-0004 Slide block-left 1 pcs
Page 2 from 2
Cable channel 122x100/Lg=4000 (5550-1535-0000)
Page 1 from 2
1 2611-0080-8000 Cable channel 122x100 L=4000 1 pcs
7 2611-0080-8400 Plate 100x50-ctc 36/2xø9 1 pcs
9 2611-0080-8600 Energy chain 53 schackles 1 pcs
10 2611-1302-0208 Hydraulic connection pipe- 1 pcs
11 2611-1302-0209 Hydraulic connection pipe 1 pcs
12 2611-0080-0215 Cable channel support 1 pcs
15 2611-0080-8601 Slide bearing for energy chain 2 pcs
Page 2 from 2
Flipper actuator hydraulic (5550-1545-0000)
Page 1 from 2
1 2611-0055-0100 Actuator complete 1 pcs
2 2641-0012-0016 Flipper clamp 2 pcs
3 2641-0012-0018 Threaded rod M16x385 1 pcs
4 5097-0002-0040 Warning sticker hands 100mm 1 pcs
6 6816-0018-0316 Elbow coupling 1/8"x3/16" 1 pcs
8 8561-0160-0040 Hex.socket bolt M16x40 12.9 d 5 pcs
9 8561-0160-0050 Hex. socket bolt M16x50 12.9 d 2 pcs
Page 2 from 2
Twistlock cylinder (5550-1550-0010)
Page 1 from 2
1 6510-0200-0000 Cylinder complete 1 pcs
2 2611-0318-0230 Spacer tube ø20x3.6-lg=73 4 pcs
8 5008-0000-0025 Nut M16x145/ø23x25 2 pcs
Page 2 from 2
Protection plate actuator (5550-1555-0003)
Page 1 from 2
1 5010-0000-0009 Protection plate actuator-ø11 1 pcs
Page 2 from 2
Corner roll-left ø200ø53-70 (5550-1570-0000)
Page 1 from 2
1 2611-0179-0250 Shaft corner roll - forged 1 pcs
2 2611-0179-2502 Bush for corner roll 1 pcs
3 2611-0179-2501 Cell guide roller ø200xø53-70 1 pcs
Page 2 from 2
Corner roll-right ø200xø53-70 (5550-1570-0001)
Page 1 from 2
Page 2 from 2
Telescopic beam 20-30-40ft (2611-2704-1600)
Page 1 from 3
1 2611-2587-0150 Telescopic beam 20-30-40/S 1 pcs
4 2611-0080-1001 Energy chain roll ø60x138 2 pcs
5 2611-0082-3005 Drive bar L=889 2 pcs
6 2611-1732-0677 Hydraulic hoses telescopic bea 1 pcs
7 2611-2704-0530 E-box E3 1 pcs
8 2611-2704-5035 E3-field 1 pcs
9 2641-0014-0000 Actuated corner flipper 2 pcs
10 5010-0000-0168 Filling plate 30ft support 1 pcs
14 5550-0505-0020 E-box support 1 pcs
15 5550-0515-0004 Sensor M30 st.52 2 pcs
16 5550-0515-0005 Sensor M30 st.52 2 pcs
17 5550-0605-0210 Manifold-support end beam 1 pcs
18 5550-0615-0020 Clamp block 2xø22 3 pcs
19 5550-0620-0001 Connection block hydraulic 4x3 1 pcs
20 5550-1505-0010 Twistlock L&R 1 pcs
21 5550-1510-0000 Landing pin ø35x50/ø30x242 1 pcs
22 5550-1530-0001 Upper sliding units telescopic 2 pcs
23 5550-1530-0004 Lower sliding units telescopic 1 pcs
24 5550-1535-0000 Cable channel 122x100/Lg=4000 1 pcs
25 5550-1545-0000 Flipper actuator hydraulic 2 pcs
26 5550-1550-0010 Twistlock cylinder 1 pcs
28 5550-1570-0000 Corner roll-left ø200ø53-70 1 pcs
29 5550-1570-0001 Corner roll-right ø200xø53-70 1 pcs
31 6802-0401-0010 Manifold telescopic beam 4-out 1 pcs
32 6802-1400-0121 Manifold end beam 14-outputs-S 1 pcs
37 8670-0160-0001 Nut M16 A4 1 pcs
Page 2 from 3
Page 3 from 3
E-box E3 (2611-2704-0530)
Page 1 from 2
E-box E3 (2611-2704-0530)
1 2611-0080-5402 E-box 1xM25/14xM16 machined 1 pcs
4 7120-0016-0031 Plug v-ne M16x1.5 4 pcs
5 7120-0025-0010 Cable gland PA M25 x 1,5 1 pcs
6 2611-2704-5030 E3-box 1 pcs
Page 2 from 2
E3-box (2611-2704-5030)
1 7180-1201-6620 End clamp E/AL-NS 35 2 pcs
5 7181-0280-5640 Sensor-LED supply terminal blo 1 pcs
Page 1 from 1
E3-field (2611-2704-5035)
11 7112-0030-0000 Conn.female-M12-H-4x0.34-6.0m 4 pcs
Page 1 from 1
E-box support (5550-0505-0020)
Page 1 from 2
E-box support (5550-0505-0020)
1 5011-0000-0051 Vibration isolator W 4 pcs
3 8525-0080-0020 Hexagon bolt M8x20 A4 2 pcs
Page 2 from 2
Sensor M30 st.52 (5550-0515-0004)
Page 1 from 2
Sensor M30 st.52 (5550-0515-0004)
1 5014-0000-0151 Clamp block ø30 2 pcs
Page 2 from 2
Sensor M30 st.52 (5550-0515-0005)
Page 1 from 2
Sensor M30 st.52 (5550-0515-0005)
1 5014-0000-0151 Clamp block ø30 2 pcs
Page 2 from 2
Page 1 from 2
1 2611-0082-0170 Clamp hydraulic manifold-Left 1 pcs
2 2611-0082-0175 Clamp hydraulic manifold-Right 1 pcs
3 5011-0000-0029 Silent block ø75x40/M12-sh70 3 pcs
6 8610-0080-0012 Nut M8x 1.5D |10| DIN6330B 4 pcs
Page 2 from 2
Clamp block 2xø22 (5550-0615-0020)
Page 1 from 2
Clamp block 2xø22 (5550-0615-0020)
1 9803-0002-0022 Clamp - double ø22mm 2 pcs
Page 2 from 2
Page 1 from 2
3 6020-0170-0018 Bonded seal 1/8 4 pcs
4 6020-0500-0010 Adapter coupling 1/8x1/8 2 pcs
5 6030-0100-0300 Quick Release Coupling 1/8"BSP 2 pcs
6 6030-0100-0301 Dust cover male 1/8" BSP 2 pcs
7 6020-0170-0038 Bonded seal 3/8 2 pcs
Page 2 from 2
Twistlock L&R (5550-1505-0010)
Page 1 from 2
Twistlock L&R (5550-1505-0010)
1 2615-0091-0000 Twistlock TWI-W-ISO-VC-R71 2 pcs
2 2624-0001-0000 Twistlock bush ISO 2 pcs
3 2615-0018-0400 Twistlock washer female 100x55 2 pcs
4 2615-0018-0300 Twistlock washer male 80x50 2 pcs
Page 2 from 2
Page 1 from 2
1 2615-0087-0100 Twistlock bolt 100x54x50-296 W 1 pcs
2 2615-0087-0400 Set of half washers (W) 1 pcs
3 2615-0087-0500 Parallel key 18x11 lg =94 1 pcs
4 2615-0087-0600 Locking Rubber for Twistlock 1 pcs
5 2615-0091-0200 Twistlock nut R71 1 pcs
6 8599-0000-0008 Locking hexagon bolt M8x25 2 pcs
Page 2 from 2
Landing pin ø35x50/ø30x242 (5550-1510-0000)
Page 1 from 2
Landing pin ø35x50/ø30x242 (5550-1510-0000)
1 5021-0000-0011 Landing pin 35x50/30x192-42 2 pcs
2 5003-0000-0013 Ring landing pin ø45xø30.5-30 2 pcs
3 8736-0080-0040 Spiral pin zinc pl. ø8x40 2 pcs
4 9802-0000-0020 Compr. spring RVS/120-39-4-10w 2 pcs
Page 2 from 2
Page 1 from 2
1 5009-0000-0015 Slide plate 170x100x15 1 pcs
3 8598-0000-0005 Greasing bolt M12x50/M8x1 1 pcs
5 8720-0120-0036 Mudwing repair washer M12 1 pcs
Page 2 from 2
Page 1 from 2
1 2611-0080-0915 Locking plate left b=32 1 pcs
2 2611-0080-0916 Locking plate right b=32 1 pcs
9 5009-0000-0003 Slide block-right side with gr 1 pcs
10 5009-0000-0004 Slide block-left 1 pcs
Page 2 from 2
Page 1 from 2
1 2611-0080-8000 Cable channel 122x100 L=4000 1 pcs
7 2611-0080-8400 Plate 100x50-ctc 36/2xø9 1 pcs
9 2611-0080-8600 Energy chain 53 schackles 1 pcs
10 2611-1302-0208 Hydraulic connection pipe- 1 pcs
11 2611-1302-0209 Hydraulic connection pipe 1 pcs
12 2611-0080-0215 Cable channel support 1 pcs
15 2611-0080-8601 Slide bearing for energy chain 2 pcs
Page 2 from 2
Page 1 from 2
1 2611-0055-0100 Actuator complete 1 pcs
2 2641-0012-0016 Flipper clamp 2 pcs
3 2641-0012-0018 Threaded rod M16x385 1 pcs
4 5097-0002-0040 Warning sticker hands 100mm 1 pcs
8 8561-0160-0040 Hex.socket bolt M16x40 12.9 d 5 pcs
Page 2 from 2
Page 1 from 2
1 6510-0200-0000 Cylinder complete 1 pcs
2 2611-0318-0230 Spacer tube ø20x3.6-lg=73 4 pcs
8 5008-0000-0025 Nut M16x145/ø23x25 2 pcs
Page 2 from 2
Page 1 from 2
1 5010-0000-0009 Protection plate actuator-ø11 1 pcs
Page 2 from 2
Page 1 from 2
Page 2 from 2
Page 1 from 2
Page 2 from 2
Greasing diagram VATCII-G (2611-1968-0700)
Page 1 from 2
Greasing diagram VATCII-G (2611-1968-0700)
10 6801-0007-0100 Grease pump 4L/80bar +sensor 1 pcs
20 6802-0008-0000 14-Meter manifold 2 pcs
30 6802-0005-0000 7-Meter manifold Aluminium 2 pcs
40 6802-0003-0000 4-Meter manifold brass 2 pcs
50 6803-0001-0000 Meter no. 1 14 pcs
60 6803-0002-0000 Meter no. 2 8 pcs
70 6803-0003-0000 Meter no. 3 8 pcs
80 6803-0005-0000 Meter no. 5 4 pcs
90 6803-0000-0001 Compression ring 3/16"-ø11 44 pcs
100 6822-0012-0024 Plug 1/2"x24UNS 6 pcs
110 6804-0001-0001 Lubricant tubing 3/16" (25mtr) 1 pcs
120 6804-0004-0001 Lubricant Tubing 5/16" (25mtr) 1 pcs
130 6804-0004-0005 Insert for main tubing 5/16" 14 pcs
140 6817-0014-0014 T-coupling pressure switch 1/4 1 pcs
150 6817-0000-0516 T-coupling 5/16"x5/16"x5/16" 1 pcs
160 6816-0014-0516 Elbow coupling 1/4'x5/16' 9 pcs
210 6822-0014-0000 Plug 1/4" 1 pcs
220 9991-0020-0010 BP Grease Energrease ZS 00 1 pcs
Page 2 from 2
Hydraulic diagram VATCII-G (2611-2399-0600)
Page 1 from 2
Hydraulic diagram VATCII-G (2611-2399-0600)
10 2611-1968-0670 Power pack 7.5kW/400VAC/50Hz 1 pcs
Page 2 from 2
Stinis Holland B.V. INDEX
Postbus 2005
The Netherlands
20 INDEX
Actuator Twistlock ........................................... 3-5

Blocking ........................................... 3-10 Cylinders
Twistlock drawing .............................. 5-4 Maintenance ..................................... 4-3
Twistlocks ................................ 3-11, 5-4 Damage indication
Actuators Flippers ............................................. 5-3
Construction....................................... 3-7 De-aerating
Control ............................................... 3-7 Automatic greasing ......................... 5-10
Flippers ...................... 1-2, 3-7, 3-10, 5-3 Definitions ........................................... 16-3
Maximum speed ................................ 3-7 Degreaser ............................................. 4-2
Mounting ............................................ 3-7 Drawing number ................................... 1-1
Oil leakage ......................................... 3-7 Drawings
Position .............................................. 3-7 Directions for use ............................ 11-1
Safety device ..................................... 3-7 Electric
Torque ............................................... 3-7 Indicator ............................................ 3-3
Welding to headbeam ........................ 3-7 Twistlocks position indicators ............ 5-4
Adhesive Electrical
Glues ................................................. 4-2 Conditions
Adjusting indicators Steps ............................................. 5-4
Twistlocks .......................................... 5-4 Control voltage .................................. 1-2
Adjustment Current E-motor ................................ 3-9
Instructions ........................................ 5-2 Drawings ........................................... 3-9
Sliding beams .................................... 5-5 Drawings ........................................... 5-4
Telescopic beams .............................. 5-6 Electric Motor
Applicable standards ........................... 16-1 Power ............................................ 1-2
Area of Application ................................ 1-1 Grease failure switch ........................ 3-9
Arrangement drawings Grease low level switch .................... 3-9
Directions for use ............................. 11-1 Hydraulic solenoids ........................... 3-9
Attention Maintenance .............................. 4-3, 4-4
Flippers .............................................. 5-3 Motor 7.5kW ...................................... 3-9
Automatic greasing.............................. 3-11 Oil level switch .................................. 3-9
De-aerating ...................................... 5-10 Oil return switch ................................ 3-9
Drawings .......................................... 3-11 Power supply voltage ........................ 1-2
Frequency ........................................ 5-10 Temperature switch .......................... 3-9
Grease ............................................... 4-1 Trouble shooting ............................... 5-4
Grease cylce .................................... 5-10 E-motor .......................................... 5-4
Grease dividers................................ 3-12 Spreader function .......................... 5-4
Greasing .......................................... 3-11 Electrical components
Maintenance ............................ 4-2, 5-10 Parts list .......................................... 12-1
Minimum grease level ...................... 3-11 Electrical schedules .............................. 3-9
Operating control ............................. 5-10 Electrical system ................................... 5-4
Pump ............................................... 3-11 Electrics
Belt Tracer pin indication .......................... 3-5
Replacement...................................... 5-6 Twistlock ........................................... 3-5
Telescopic beams .............................. 5-6 EN 13000 ............................................ 16-4
Blocking End beams
Actuator ........................................... 3-10 Twistlocks beams .............................. 3-5
Drawing ........................................ 3-10 Error messages
Plate................................................... 3-4 Crane driver ...................................... 2-4
Slide-beams ....................................... 3-4 Explanation from manufacturer ............ 1-4
Sliding-beams .................................... 3-3 Flipper actuators
Blocking cylinders.................................. 3-4 Leakage ............................................ 5-3
Oil pressure ....................................... 3-4 Flippers
Cabletrack Actuator drawing/location .................. 3-7
Twistlock beams ................................ 3-5 Actuators .................... 1-2, 3-7, 3-10, 5-3
CE documents ....................................... 1-4 Attention ............................................ 5-3
CE number ............................................ 1-1 Damage indication ............................ 5-3
Cell guide rollers............................ 3-5, 3-8 Drawing/location ........................ 3-5, 3-7
Function ............................................. 3-8 Extension .......................................... 3-8
Greasing ............................................ 3-9 Interchangeability .............................. 3-7
Housings ............................................ 3-8 Maintenance ....................... 4-3, 5-3, 5-9
Cell guide rolls Material ............................................. 3-8
Maintenance ...................................... 4-3 Mounting ........................................... 3-8
Certificate number Profile ................................................ 3-8
Spreader ............................................ 1-1 Protection ................................... 3-7, 5-9
Conserving Protection Drawing/location .............. 3-7
Maintenance ...................................... 4-3 Speeds .............................................. 1-2
Construction .......................................... 3-1 Support ...................................... 3-7, 5-9
Actuators............................................ 3-7 Toothed rack ..................................... 3-7
Control Torque ........................................ 1-2, 3-8
Actuators............................................ 3-7 Welding instructions ................... 3-7, 5-9
Control voltage ...................................... 1-2 Flippers actuators
Crane control Adjusting shock relief valves ............. 5-3
Safety precautions ............................. 2-1 Adjusting torque ................................ 5-3
Warnings............................................ 2-1 Greasing ........................................... 5-3
Crane driver Maintenance ..................................... 5-3
Error messages ................................. 2-4 Overload ........................................... 5-3
Lamps ................................................ 2-6 Seals ................................................. 5-3
Warnings.................................... 2-3, 2-4 Set up position .................................. 5-3
Crane driver information ........................ 2-5 Speeds .............................................. 5-3
Crane driver instruction ......................... 2-5 Speeds adjusting .............................. 5-3
Customer project order number ............ 1-1 Flippers: ......................................... 3-7, 5-9
Cylinder Frequency
MANUAL TCS001 20-1

Postbus 2005
The Netherlands
Automatic greasing .......................... 5-10 Hydraulic components

Greasing .......................................... 3-11 Parts list .......................................... 13-2
Functional description ........................... 3-1 Hydraulic hoses
Geared belt Identification .................................... 13-1
Replacement...................................... 5-6 Number ........................................... 13-1
Grease Partlist ............................................. 13-1
General purposes .............................. 4-1 Size ................................................. 13-1
Greasing ............................................ 4-1 Hydraulic information .......................... 3-10
Quality................................................ 4-1 Hydraulic oil
Quality of lubrication .......................... 4-1 Quality ............................................... 4-1
Temperature environment ................. 4-1 Temperature environment ................. 4-1
Grease cylce Hydraulic tank
Automatic greasing .......................... 5-10 Maintenance ..................................... 4-4
Grease failure switch ............................. 3-9 Hydraulics
Greasing Drawings
Shift actuators Carrier ........................ 4-2 Parts general ................................. 3-5
Greasing Tracer pin indication .......................... 3-5
Automatic greasing .......................... 3-11 Twistlock ........................................... 3-5
Frequency ........................................ 3-11 Indicating
Grease ..................................... 3-11, 4-1 Telescopic stops ............................... 3-3
Grease products .................... 3-11, 3-12 Twistlock ........................................... 3-5
Instructions ........................................ 4-2 Twistlocks .................................. 3-5, 5-4
Long-Twin .......................................... 4-2 Instruction crane driver ......................... 2-5
Low level switch ............................... 3-11 Instructions
Mid-frame........................................... 4-2 Adjustment ........................................ 5-2
Pressure switch ............................... 3-11 Maintenance ..................................... 4-2
Greasing Periodic maintenance ....................... 4-2
Telescopic beams .............................. 4-2 Repairing ........................................... 5-2
Greasing Instructions crane driver
Headbeams....................................... 4-2 Safety precautions ............................ 2-3
Greasing Instructions for adjustment and repair .. 5-2
Twinlift housings ................................ 4-3 Lamps ................................................... 2-6
Greasing Crane driver ...................................... 2-6
Telescopic beams .............................. 4-3 Landing pins
Greasing Maintenance .............................. 4-3, 4-4
Maintenance ...................................... 4-3 Leakage
Greasing points Solenoid ............................................ 3-9
locations............................................. 4-1 Lifetime ................................................. 1-1
Recognising ....................................... 4-1 Lifting lugs for managing/repairing
Greasing system ................................. 3-11 WLL ................................................... 3-2
Greasing Twinlift housings .................... 4-2 Lifting lugs near twistlocks
Hazards ............................................... 16-4 SWL .................................................. 1-1
Hoses Lifting lugs side mid-frame
Hydraulic WLL ................................................... 3-2
Tubes ............................................. 3-5 Lifting lugs underside midframe
Hoses SWL .................................................. 1-1
Hydraulic .......................................... 13-1 List
How to order spare parts ....................... 6-1 Production drawings ....................... 11-1
Hydraulic Long-Twin
Blocking cylinder ................................ 3-3 Manifold .......................................... 3-10
Blocking cylinders .............................. 3-4 Low level switch
Drawing............................................ 3-10 Greasing ......................................... 3-11
Drawings Lubrication .......................................... 3-11
Hydraulic pump ............................ 3-10 Instructions ........................................ 4-2
Partlist Lubrications
Components ............................. 3-10 Quality ............................................... 4-1
Parts general ................................ 3-10 Main E-box
User manual hydraulic pump ....... 3-10 Maintenance ..................................... 5-4
Drive .................................................. 3-3 Main spreader frame
Flippers ............................. 3-7, 3-10, 5-3 Mid-frame .......................................... 3-2
Functional description ...................... 3-10 Maintenance
General information ......................... 3-10 Automatic greasing ......... 3-11, 4-2, 5-10
Greasing .......................................... 3-11 Cell guide rolls .................................. 4-3
Hoses............................................... 13-1 Conserving ........................................ 4-3
Manifold-Long-Twin ......................... 3-10 Cylinders ........................................... 4-3
Manifold-welded............................... 3-10 Electrical .................................... 4-3, 4-4
Manual operation drawing ............... 3-10 Flippers ............................... 4-3, 5-3, 5-9
Oil ...................................................... 4-1 Flippers actuators ............................. 5-3
Operating oil pressure ............. 1-2, 3-10 Greasing ........................................... 4-3
Part drawings ................................... 3-10 Hydraulic tank ................................... 4-4
Partlist .............................................. 3-10 Instructions ........................................ 4-2
Pressure valve ................................. 3-10 Landing pins ............................... 4-3, 4-4
Pump ............................................... 3-10 Lubrication-quality ............................. 4-1
Description ................................... 3-10 Main E-box ........................................ 5-4
Operating instructions .................. 3-10 Manifold ............................................ 4-4
User instructions .......................... 3-10 Manifold ............................................ 4-3
Return oil filter.................................. 3-10 Periodic lubrication instructions ........ 4-2
Solenoids ........................................... 3-9 Silentblocks ....................................... 4-4
Telescoping ............................. 3-3, 3-10 Sliding beams ................................... 5-5
Telescoping beam lock .................... 3-10 Telescopic beams ............................. 4-4
Oil pressure .................................. 3-10 Telescopic beams ............................. 5-6
Tubes Telescoping beams ........................... 4-3
Hoses ............................................. 3-5 Telescoping drives ............................ 4-3
Tubes ............................................... 13-1 Twistlocks .................................. 4-3, 4-4
Valves ................................................ 3-5 Maintenance department
Hydraulic and electrical components..... 3-1 Warnings ........................................... 2-6
MANUAL TCS001 20-2

Postbus 2005
The Netherlands
Maintenance instructions Power consumption too low .......... 5-2

Preventive .................................. 4-2, 4-3 Telescoping ................................... 5-2
twistlock double-split-collar ................ 4-5 Twistlocks ...................................... 5-2
Maintenance: ......................................... 4-2 Repairing
Manifold Instructions ........................................ 5-2
Long-Twin ........................................ 3-10 Risk Analysis ...................................... 16-4
Maintenance ...................................... 4-4 Safety
Welded............................................. 3-10 Crane driver instruction ..................... 2-5
Manifold Features ............................................ 2-8
Maintenance ...................................... 4-3 Precautions
Manifold-Long-Twin Instructions maintenance department
Hydraulic .......................................... 3-10 ................................................... 2-6
Manifold-welded Power pack .................................. 3-10
Hydraulic .......................................... 3-10 Powerpack ..................................... 6-1
Manual activating Safety device
Solenoid ............................................. 3-9 Actuators ........................................... 3-7
Manual operation drawing Safety precautions
Hydraulic .......................................... 3-10 Crane control .................................... 2-1
Material Instructions crane driver .................... 2-3
Dates ................................................. 5-1 Serial number ....................................... 1-1
Flippers .............................................. 3-8 Service
Welding instructions........................... 5-9 Standby ............................................. 6-1
Materials Silentblocks
Certificate........................................... 5-1 Maintenance ..................................... 4-4
Mechanic Sliding beams ....................................... 3-3
Switches ............................................ 3-9 Adjustment ........................................ 5-5
Mid-frame Backlash .................................... 3-3, 5-5
Frontplates ......................................... 3-2 Blocking cylinder ............................... 3-3
Guide blocks ...................................... 3-2 Blocking cylinders ............................. 3-4
Main spreader frame.......................... 3-2 Maintenance ..................................... 5-5
Telescopic positions .......................... 3-2 Operation .......................................... 3-3
Wearing blocks .................................. 3-2 Positions ........................................... 3-3
Motor 7.5kW Speeds ....................................... 1-2, 3-3
Electrical ............................................ 3-9 Telescopic belts ................................ 3-3
Mounting Telescopic motor ...................... 3-3, 3-10
Actuators............................................ 3-7 Telescopic stops ............................... 3-3
Flippers .............................................. 3-8 Solenoid
Oil .......................................................... 4-1 Black ................................................. 3-9
Oil leakage Blue ................................................... 3-9
Actuators............................................ 3-7 Leakage ............................................ 3-9
Repair - Malfunction Manual activating .............................. 3-9
Hydraulic ........................................ 5-2 Voltage .............................................. 3-9
Oil level switch....................................... 3-9 Solenoids
Drawing/location .............................. 3-10 Hydraulic ........................................... 3-9
Electrical ............................................ 3-9 Speeds
Oil pressure Flippers ............................................. 1-2
Blocking cylinders .............................. 3-4 Sliding beams ............................ 1-2, 3-3
Oil return switch..................................... 3-9 Twistlocks ......................................... 1-2
Oil temperature switch Spreader cage ...................................... 2-8
Drawing/location .............................. 3-10 Spreader dates
Overheight spreader.............................. 1-1 Free space under spreader ............... 1-1
Part list Suspension ....................................... 1-1
Hydraulic components ..................... 3-10 SWL .................................................. 1-2
Hydraulic hoses ............................... 3-10 Tare weight ....................................... 1-2
Partlist Telescoping positions ....................... 3-3
Hydraulic hoses ............................... 13-1 Telescoping speed ............................ 1-2
Parts list Twistlock type ................................... 1-2
Electrical components...................... 12-1 Spreader identification .......................... 1-1
Hydraulic components ..................... 13-2 Spreader marking ................................. 1-1
Passenger cage .................................... 2-8 Spreader registration ............................ 1-1
Periodic maintenance General ............................................. 1-1
Instructions ........................................ 4-2 Standby
Positions Service .............................................. 6-1
Telescoping ....................................... 3-3 Start-up
Power consumption too low Procedures ........................................ 2-6
Repair - Malfunction Warning ............................................. 2-6
Hydraulic ........................................ 5-2 Start-up procedures .............................. 2-6
Powerpack Steps
Pressure valve/location............ 3-5, 3-10 Electrical
Pressure switch Conditions ..................................... 5-4
Greasing .......................................... 3-11 Switches
Preventive Mechanic ........................................... 3-9
Maintenance instructions ................... 4-3 SWL
Procedures A-symmetric ...................................... 1-2
Start-up .............................................. 2-6 Lifting lugs ......................................... 1-2
Production drawings Lifting lugs near twistlocks ................ 1-1
Direction for use............................... 11-1 Lifting lugs underside midframe ........ 1-1
List ................................................... 11-1 Maximum test load ............................ 1-2
Protection Spreader ........................................... 1-2
Flippers ...................................... 3-7, 5-9 Symmetric ......................................... 1-1
Rated Capacity Symmetrical ...................................... 1-2
SWL ........................................... 1-1, 1-2 Telescopic beams ................................. 3-3
Repair - Malfunction Adjustment ........................................ 5-6
Hydraulic Belt .................................................... 5-6
Oil leakage ..................................... 5-2 Maintenance ..................................... 4-4
Power consumption too high .......... 5-2 Maintenance ..................................... 5-6
MANUAL TCS001 20-3

Postbus 2005
The Netherlands
Operation ........................................... 5-6 Oil pressure ....................................... 3-5

Speed ................................................ 3-3 Position indication ............................. 3-5
Telescopic belts ................................. 5-6 Sensor ............................................... 3-5
Telescopic beams - backlash ................ 5-5 Tracer pin .......................................... 3-5
Telescopic belt .............................. 3-3, 5-6 Type .................................................. 3-5
Assembling ........................................ 5-6 Washer .............................................. 3-5
Tightening .......................................... 5-6 Twistlock beams
Telescopic indicators ............................. 1-2 Cabletrack ......................................... 3-5
Telescopic motor ................................... 3-3 twistlock double-split-collar
Telescopic stops............................ 1-2, 3-3 Maintenance instructions .................. 4-5
Indicating ........................................... 3-3 Twistlocks
Telescoping Actuator .................................... 3-11, 5-4
Repair - Malfunction Adjusting indicators ........................... 5-4
Hydraulic ........................................ 5-2 beams ............................................... 3-5
Telescoping beams Indicating .................................... 3-5, 5-4
Maintenance ...................................... 4-3 Maintenance .............................. 4-3, 4-4
Telescoping drives Repair - Malfunction
Maintenance ...................................... 4-3 Hydraulic........................................ 5-2
Temperature switch ............................... 3-9 Replacement ..................................... 5-4
Terminology......................................... 16-3 Sensor ............................................... 5-4
Test runs Speeds .............................................. 1-2
Oil quality ........................................... 4-1 Type .................................................. 1-2
Tolerances Twistlocks beams
Mid-frame beams ............................... 3-1 End beams ........................................ 3-5
Torque Used materials ...................................... 5-1
Actuators............................................ 3-7 Voltage
Flippers ...................................... 1-2, 3-8 Solenoid ............................................ 3-9
Tracer pin indication .............................. 3-5 Warning
Electrics ............................................. 3-5 Start-up ............................................. 2-6
Trouble shooting Warnings
Electrical ............................................ 5-4 Crane control .................................... 2-1
E-motor .......................................... 5-4 Crane driver ...................................... 2-3
Spreader function ........................... 5-4 Maintenance department .................. 2-6
Flippers .............................................. 5-3 Warranty ............................................... 1-3
Tubes Weather conditions ............................... 3-1
Hydraulic .......................................... 13-1 Welding
Twinlift interlock device ......................... 2-4 Mid-frame beams .............................. 3-1
Twistlock Welding instructions ............................. 5-9
Bushes ............................................... 3-5 Cell guide rollers ............................... 3-8
Constructions ..................................... 3-5 Flippers ...................................... 3-7, 5-9
Drawing Composition......................... 3-5 Welding to headbeam
Electrics ............................................. 3-5 Actuators ........................................... 3-7
Indicating ........................................... 3-5 WLL
Lifetime .............................................. 3-5 Lifting lugs for managing/repairing .... 3-2
Loading .............................................. 3-5 Lifting lugs side mid-frame ................ 3-2
Model ................................................. 3-5
MANUAL TCS001 20-4


Stinis Holland B.V. Postbus 2005 2930 AA Krimpen A/d Lek The Netherlands User Guide For Stinis Spreader Model VATCII-G

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Stinis Holland B.V. Postbus 2005 2930 AA Krimpen A/d Lek The Netherlands User Guide For Stinis Spreader Model VATCII-G

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Stinis Holland B.V.

User guide for Stinis spreader

1. This manual is intended as a customer guide regarding the operation and

Document revision: dated: remark:

1.20 SPREADER REGISTRATION

Spreader id Article number Certificate No.

MANUAL TCS001 1-1

1.30 TECHNICAL SPECIFICATION

MANUAL TCS001 1-2

MANUAL TCS001 1-3

MANUAL TCS001 1-4

2 START-UP – WARNINGS – SAFETY PRECAUTIONS

MANUAL TCS001 2-1

D. CHECK THE CRANE ADJUSTMENT LIFTING AFTER LOCKING TWISTLOCKS

MANUAL TCS001 2-2

2.15 CRANE DRIVER: WARNINGS

MANUAL TCS001 2-3

2.15.30 CRANE OPERATOR: WARNINGS AND SPREADER ERROR MESSAGES

MANUAL TCS001 2-4

* Oil temperature is too high:

2.16 CRANE DRIVER: INSTRUCTIONS

MANUAL TCS001 2-5

USE LIFTING EARS:

2.17 CRANE DRIVER: LAMP INFORMATION

2.18 MAINTENANCE DEPARTMENT: WARNINGS

2.20 STARTUP PROCEDURES

MANUAL TCS001 2-6

* Check the noise level of the motor:

MANUAL TCS001 2-7

2.40 SAFETY FEATURES

Spreader control safety features:

2.50 SPREADER CAGE

MANUAL TCS001 2-8

3.20 FUNCTIONAL DESCRIPTION

MANUAL TCS001 3-1

The mid-frame: the strongest part of the spreader:

MANUAL TCS001 3-2

3.20.30 TELESCOPIC BEAMS

MANUAL TCS001 3-3

3.20.40 BLOCKING SLIDE BEAM

MANUAL TCS001 3-4

3.20.50 END-BEAMS (HEAD-BEAMS)

3.20.61 TWISTLOCKS model TWI-W

MANUAL TCS001 3-5

MANUAL TCS001 3-6

3.20.70 FLIPPERS and ACTUATORS

MANUAL TCS001 3-7

Actuator welding instructions:

3.20.80 CELL GUIDE ROLLERS

MANUAL TCS001 3-8

3.40.10 GENERAL ELECTRICAL COMPONENTS

MANUAL TCS001 3-9

3.50 HYDRAULIC INFORMATION

MANUAL TCS001 3-10

3.60 AUTOMATIC GREASING

MANUAL TCS001 3-11

MANUAL TCS001 3-12

4.20 OIL and GREASE

MANUAL TCS001 4-1

4.30 MATERIALS INSTRUCTION, SEALANTS

4.40 PREVENTIVE PERIODICAL LUBRICATION INSTRUCTIONS

EVERY 1000 HOURS: at least every 20.000 moves

Mid-frame, Check inside for correct grease dosage: