Attachments & Spreaders Procedures

This page lists 79 maintenance procedures for attachments & spreaders, drawn from HIT Srl's internal procedure library extracted from manufacturer service manuals.

HIT Srl supplies spreader and attachment spare parts for this class of machine.

General guidance only — always follow the operation and maintenance manual for your specific machine.

Twistlocks

• What is the correct sequence to remove a twistlock from the spreader?

  1. Loosen the nut and screw.
  2. Remove the connecting rod.
  3. Remove the snap ring, the mechanical safety cam, and the ball.
  4. Loosen the screw and ring nut.
  5. Remove the twistlock and, at the same time, the bush and bearing ring.

  Note: Mind the power cables and hydraulic pipes during twistlock fitting or removal.

• What checks determine whether a spreader twistlock must be replaced?

  Periodicity: Perform a daily visual check of the spreader; regularly inspect the twistlock heads; twistlocks must be replaced after 6000 hours in any case, and must undergo non-destructive testing yearly or every 3000 working hours.

  1. Perform a daily visual check of the spreader to detect or prevent breakages.
  2. Periodically grease the nylon sliding blocks on the extension beams and twistlock heads, avoiding over-greasing in dusty environments, and replace them before they become completely worn.
  3. Regularly inspect the twistlock heads: if measurement 'a' is less than 27 mm, or dimension 'D' falls by more than 5%, replace the twistlock.
  4. Replace the twistlock after 6000 hours regardless of condition.
  5. Subject the twistlocks to non-destructive testing for hidden damage or micro-cracks at least yearly or every 3000 working hours.

• What is the correct sequence to remove a twistlock from a gantry-type spreader with a corner feeler?

  1. Loosen the nut and screw.
  2. Remove the connecting rod.
  3. Loosen the screw and ring nut.
  4. Loosen the retention screws of the bush.
  5. Remove the twistlock.
  6. To remove the feeler, take out the spring pin, turning it so it is coaxial with the hole in the beam wall.

  Notes:

  • Mind the power cables and hydraulic pipes when fitting or removing the twistlock.
  • After refitting or during inspection, the twistlock's axial play should be about 0.5 mm and must not exceed 3-3.5 mm; if there is 3 mm of radial play between the twistlock and the guide bush, check the condition of the unit's component parts.

• What checks determine whether the gantry spreader's twistlock must be replaced?

  Periodicity: Perform a daily sight check of the spreader; twistlocks must be replaced after 6000 hours depending on wear.

  1. Perform a daily sight check of the spreader to detect or prevent breakages.
  2. Periodically grease the nylon sliding blocks on the extension beams and twistlock heads, avoiding over-greasing in dusty environments, and replace them before they become completely worn.
  3. Regularly inspect the twistlock heads: if measurement 'a' exceeds 10 mm, or dimension D falls by more than 5%, replace the twistlock.
  4. Replace the twistlock after 6000 hours, depending on its state of wear, and always remove it for non-destructive testing to detect hidden damage or micro-cracks.

• What is the correct sequence to remove a twistlock from a sleeve-mounted spreader?

  1. Remove the screw.
  2. Remove the retaining plate.
  3. Unscrew the twistlock.

• What is the correct sequence to install a twistlock on a sleeve-mounted spreader?

  1. Grease the pin, checking whether the bushings need replacing.
  2. Clean the inside of the sleeve and apply grease to its inside and outside.
  3. Screw in the twistlock.
  4. Insert the retaining plate.
  5. Screw in the screw, checking that the twistlocks can rotate freely.

• What is the correct sequence to remove the twistlock sleeve?

  1. Remove the twistlock following the removal procedure.
  2. Remove the cylinder.
  3. Remove the fixing screw.
  4. Unscrew the threaded sleeve.

• What is the correct sequence to install the twistlock sleeve?

  1. Make sure the sleeve has both bushings inside it.
  2. Clean the entire opening at top and bottom.
  3. Insert the sleeve from below.
  4. Screw the sleeve onto the support and tighten it.
  5. Lock the sleeve and the support together with the locking screw.
  6. Apply grease and insert the twistlock from below.
  7. Screw on the twistlock's rotating bushing.
  8. Check the correct alignment of the twistlock with the cylinder.
  9. Insert the retaining plate and secure it with the screws.

• What is the correct lubrication schedule for a sleeve-mounted spreader?

  Periodicity: Perform a daily visual inspection; grease the head lubrication points every 100 hours; grease the twistlocks and their pins every 500 hours (not more often); clean and lubricate the entire twistlock mechanism yearly or every 2000 work hours; grease the spreader-plate fixing points and cylinder guide pads/supports every 1000 hours.

  1. Perform a daily visual inspection of the spreader to detect or prevent breakages or maintenance needs.
  2. Every 100 hours, grease the lubrication points in each head box, the sliding blocks on each fixed beam, the sliding block on each extending beam of the main structure, and the sliding blocks on each head.
  3. Every 500 hours, and not more often, grease the twistlocks and their pins through the greasers on their heads.
  4. Yearly or every 2000 work hours, clean and lubricate the entire twistlock mechanism.
  5. Every 1000 hours, grease the spreader-to-plate fixing plates and the cylinder guide pads and supports.

  Notes:

  • Avoid using large amounts of grease, especially in dusty environments.
  • Replace the nylon sliding blocks before they become completely worn.
  • Inspect the twistlock heads regularly: if measurement 'a' exceeds 10 mm or dimension D is reduced by more than 5%, the twistlock must be replaced.
  • Replace twistlocks after 6000 hours depending on wear, and always remove them for non-destructive testing to check for hidden damage or micro-cracks.

• What is the correct sequence to check the twistlocks?

  1. Check that the twistlocks function correctly: lock and open them, checking that the indicator lights work both in the cab and on the boom.
  2. Clean the twistlocks of any dirt.
  3. Under the rubber cover for the twistlocks, check the pin, link arm, and lock nut.
  4. Clean the area around the alignment sensor.
  5. Press in the alignment pin so the head is flush with the spreader beam's underside, and check the distance to the alignment sensor, which should be 5±1 mm, adjusting as needed (the alignment pin should move easily and spring back completely).
  6. Check that the lock guide and lift pin can move freely.
  7. Fit a pry bar between the lift pin and the lock guide and check the clearance, which has a maximum of 1-1.5 mm.
  8. Turn the twistlocks to the locked position and check lift pin wear, changing the lift pin if needed.
  9. Clean the area around the grease cup.
  10. Grease the lift pin's bearing with an NLGI EP2 universal grease.
  11. Repeat all steps on all four twistlocks.

  Note: Make sure the engine is off when working on the twistlocks; twistlocks can lock automatically if all alignment sensors are activated manually.

• What is the correct sequence to check the twistlock lift pins for cracks?

  Periodicity: Crack checks shall take place every other year or every 5000 operating hours.

  1. Remove the lift pins from the attachment.
  2. Test for cracks within the marked area on the pins, without reworking or damaging the part.
  3. If the lift pins show signs of cracking, replace them with new ones.
  4. Fit approved twistlocks, using a new attaching nut and washers.

  Notes:

  • Twistlocks are heavy; take care when removing them.
  • Change any twistlock showing signs of cracks or other external damage, or with more than 10,000 operating hours, due to fatal danger from material fatigue.

  Confirmed across independent manufacturers’ manuals.

• What is the correct sequence to remove the twist-lock lifting pins for inspection?

  Periodicity: First carried out after 5000 hours of service or 2 years, whichever occurs first; thereafter every year.

  1. Unscrew the grease nipple.
  2. Remove the locking pin.
  3. Unscrew the fixing nut, including washer, while supporting the underside of the lifting pin.
  4. Remove the lifting pin downwards; the washer comes with it.

• What is the correct sequence to inspect and refit a twist-lock lifting pin?

  1. Use magnetic powder testing or penetration fluid to check the removed lifting pin.
  2. Check that there are no fractures or splits in any part of the lifting pin.
  3. Place the washer on the lifting pin and refit the lifting pin.
  4. Refit the locking pin and the grease nipple.
  5. Fit a new washer and nut, tightening the nut to a torque of 300 Nm.

  Notes:

  • If any split or fracture is discovered, the lifting pin must be immediately replaced.
  • If the lifting pin has any other visible damage, it must be immediately replaced.
  • All lifting pins shall be replaced after 20,000 hours of service, even if they appear undamaged.

• What is the correct sequence to check the twistlocks?

  1. Check that the twistlocks function correctly: lock and open them and check the indicator lights work in both the cab and on the attachment.
  2. Clean the twistlocks of any dirt.
  3. Under the rubber cover, check the pin, link arm and lock nut.
  4. Clean the area around the contact sensor.
  5. Press in the alignment pin so its head is flush with the spreader beam's underside, and check the distance to the contact sensor, which should be 5±1 mm, adjusting when needed (the pin should move easily and spring back completely).
  6. Place a crowbar between the lift pin and its guide and check the clearance, maximum 1-1.5 mm, replacing the wear washer between the twistlock and holder if necessary.
  7. Turn the twistlock to the locked position and check the lift pin's wear, changing it as needed.
  8. Repeat all steps on both twistlocks.

  Note: Make sure the engine is off when working on the twistlocks; they can lock automatically if all contact sensors are activated manually.

• What is the correct sequence to check and adjust the twistlock contact sensor?

  1. Check that the alignment pins in the corner boxes move freely up and down, springing down when unloaded.
  2. Check that the sensor is free of damage and dirt.
  3. Turn the start key to position I and check that the sensor's light indicator is off.
  4. Lower the attachment onto a container and check that the contact indicator light is lit.
  5. Lift the container slightly and check that the contact indicator light switches off.
  6. With the container raised, check how much movement of the contact pin is needed to detect contact; it should be 3-4 mm.
  7. If necessary, loosen the lock nut and screw the sensor in or out until the distance between sensor and contact pin is 5±1 mm.

• What is the correct sequence to check and adjust the twistlock position sensors?

  1. Check that the sensors are free of damage and dirt.
  2. Turn the start key to position I and check that the light indicator for the unlocked-twistlock sensor is lit, adjusting the sensor's distance to the indicator plate to 5±1 mm if necessary.
  3. Check that the twistlocks-open indicator light is lit.
  4. Lower the attachment over a container and lock the twistlocks.
  5. Check that the light indicator for the locked-twistlock sensor is lit, adjusting the sensor's distance to the indicator plate to 5±1 mm if necessary.
  6. Check that the twistlocks-locked indicator light is lit.

• What is the correct sequence to release stuck twist-locks in an emergency?

  Applies when the twist-locks remain locked and must be released in an emergency; consult the spreader's hydraulic diagram before starting.

  1. Check that the feeler sensors (mechanical lock) are released; if they are blocked, lower the spreader until it fully rests on the container ('spreader resting' condition, indicated by the orange and green manoeuvre lights), which releases the feeler sensors.
  2. Connect a flexible hose to the 4-way fitting on the twist cylinders' drain line, positioned under the spreader's valve group, after removing the plug, and let the oil drain into the hydraulic oil tank or a suitable container.
  3. Connect a flexible hose to the 4-way fitting on the twist cylinders' supply line, positioned under the spreader's valve group, after removing the plug, and introduce pressurised oil (maximum 140 bar) until the twist-locks are released.
  4. Once released, disconnect both flexible hoses and refit the plugs to the 4-way fittings.

  Notes:

  • Before releasing the twist-locks, set any load down on the ground.
  • It is strictly forbidden to dispose of the drained oil in illegal dumps, waterways or the sewer system; collection and disposal are regulated by law.
  • It is advisable in any case to contact qualified service personnel.

• What twist-lock operations are checked during the 500-hour Type A preventive maintenance service?

  There are four preventive maintenance cards (A, B, C, D) covering the machine's complete maintenance plan, on a 500-hour frequency, cycling in the order B-A-B-C-B-A-B-C-B-D before repeating. Service times assume normal operating conditions and may vary with type of use, road surface, and environment.

  1. Check the twist-lock's mechanical operation.
  2. Check the twist-lock sensors' operation.
  3. Check the twist-lock sensors' wiring.
  4. Tighten the twist-lock's and consent brackets' bolted joints.
  5. Check the wear of the twist-lock heads.
  6. Grease the twist-lock sleeves.
  7. Check the twist-lock bypass's operation.

  Note: Maintenance must be carried out only by qualified, authorised personnel, working in conditions of maximum safety.

Top Lift

• What checks confirm the top-lift's ALIGNMENT indicating lamps and electrical interlocking system are working correctly?

  1. Check that the contact pins in the corner boxes are freely movable up and down (a pin that binds in the upper position may falsely indicate correct alignment).
  2. Check that the ALIGNMENT indicating lamp lights up when the top-lift is fitted to the container and goes out when the container is lifted.
  3. When lifting an empty container just enough to make the ALIGNMENT lamp go out, check that it is impossible to unlock the twist-locks.
  4. Check that the alignment sensors are adjusted to give a signal when the contact pin is depressed 3-4 mm.

  Note: Whenever the indicating lamps do not work properly, take the attachment out of service for repair; using an attachment with faulty indicating lamps could be hazardous.

• What is the correct sequence to adjust the play of the top-lift's sliding plates using shims?

  The sliding plates are made of brass and must be thoroughly lubricated to minimize wear; the degree of wear is highly dependent on the environment.

  1. Operate the length adjustment and check the play, which should be 1-2 mm on both sides of the movable member, both horizontally and vertically.
  2. If needed, disassemble the sliding plates in question and put suitable shims under them (fitted in the ends of each movable member and each end of the fixed main beam).
  3. Check the remaining thickness of the sliding plates: minimum screw mesh 5 mm, minimum clearance between sliding surface and screw tip 3 mm, changing to longer screws if thick shims are needed while maintaining that clearance.

  Note: The shims must be fitted equally on all sides in order to keep the attachment aligned and levelled, otherwise there is a risk of malfunction.

• What is the correct sequence to lubricate the top-lift's sliding plates?

  1. Set the length adjustment to maximum.
  2. Use a brush on a long handle to reach into the fixed main beam and grease the sliding surfaces on the sides, roof and bottom with a graphite-based grease.

• What is the correct sequence to adjust and check the attachment's inductive sensors?

  1. Set the gap between the sensor and its magnetic activator to 4-5 mm (the sensor deactivates at a distance of more than 8 mm).
  2. Check that the yellow diode lights up when the sensor is activated.
  3. Check that the sensor is clean and free from grease and is undamaged, since grease may falsely activate the sensor.

• What is the correct sequence to adjust the top-lift extension chain?

  The chain tension is controlled by two sets of plate springs and adjusting nuts.

  1. Check the chain play, pressing with the thumb at the retracted attachment position; it should be a maximum of 10-15 mm.
  2. Adjust with the adjusting nuts if needed, locking them with locknuts afterward.
  3. After 1-2 years, or once the adjustment range is fully used, remove a link from the chain.
  4. If the chain is slipping over the gear wheel, check the lubrication, especially on the fixed beam's bottom surface.

• What is the correct sequence to bleed the attachment's damping cylinders?

  1. Set the boom in its lowest position.
  2. Allow the engine to idle.
  3. Carefully loosen the hose connection to one of the damping cylinders until hydraulic fluid starts to leak out, first air-free and then mixed with air, then re-tighten once air-free fluid flows again.
  4. Repeat the bleeding process for all four connections.
  5. Run the boom up to its highest position and then down again.
  6. Repeat the complete bleeding process once more.

• What is the correct sequence to set the resistance of the damping cylinders?

  1. Run the boom up and down and check how the top-lift moves; in the lower position it should relatively easily settle itself horizontal after hanging somewhat angled inwards.
  2. Adjust the throttle valve's choking as required (one adjustment screw on systems with damping only, or two on systems with tilt locking or damping).

• What is the correct sequence to set the top-lift's control valve pressures?

  1. Set the main pressure limitation valve to the overall system pressure shown on the hydraulic plate.
  2. Adjust the pressure of each manoeuvre section separately with its adjustment screw: rotation 150 bar, side-shift 160 bar, length adjustment 120 bar, twist-locks system pressure as shown on the sign.
  3. To check the pressure, connect a T-connector and pressure gauge to the output of the manoeuvre section or the incoming line of the respective cylinder.
  4. Run each function to its stop position, read the pressure, and adjust the corresponding adjustment screw as necessary.

• Disassembling and assembling the twist-lock turning lever on the spreader headblock connection

  1. Lower the top-lift onto the ground or over the container.
  2. Open the locking device of the twist-lock's turning lever by removing the screw from the vertical pipe, then removing the locking piston.
  3. Turn the lever 90 degrees.
  4. The headblock is then separated from the top-lift spreader.
  5. Remove the wedge from the top of the twist-lock by loosening both M8 screws.
  6. Unscrew the nut for the catch; the turning lever can then be lifted off, and the twist-lock is released.
  7. Assembly is done in the reverse order.

  Note: Check the condition of the twist-locks per the spreader twistlock inspection instructions.

• Dismantling the spreader cable

  1. Fix the cable support with a belt to prevent it from falling down.
  2. Lift the spreader up to the limit position, then lift it back down.
  3. Remove the connector and pipe brackets.
  4. Remove the cable support and the net.
  5. Take the cable out of the collector.
  6. Clear the area and prepare for re-installation. The net can be reused if it is in good condition.

  Note: Before dismantling the spreader cable, stop the crane and the control module. Wear a safety harness and exercise caution when working in high places.

• Changing the hydraulic fluid on a motorised beam with rotating hook

  1. Remove the beam cover.
  2. Unscrew the oil filter cap.
  3. Position a container of adequate size under the oil outlet screw.
  4. Remove the oil drainage plug and clean it.
  5. Drain the oil while hot.
  6. Clean the hydraulic fluid sump and carefully remove all impurities, without using wool or man-made fibre cloths or tools that leave residues.
  7. Change the oil filter.
  8. Screw the drainage cap back on.
  9. Fill the sump with adequately filtered hydraulic fluid.
  10. Check the fluid level and top up if necessary.

  Note: Use protective gloves to prevent contact with the hydraulic fluid, since it is toxic and can cause skin problems when hot.

• Lowering a twistlock head into the end beam on a 580-series telescopic spreader

  1. Tie a 2-metre length of string around the hoses and cable protruding from the bottom of the head, and attach a nut to the other end of the string.
  2. Lift the head high enough to lower the hoses and cable into the vertical end beam, so the string drops through the support halfway down the inside of the end beam.
  3. Lower the head into the end beam while drawing the hoses and cable through the support by pulling on the string, continuing until the head rests on the support halfway down the inside of the end beam.
  4. Feed the string through the short tube bend in the side of the end beam, and draw the hoses and cable up through the tube and out through the side of the beam.
  5. Connect the hoses and cable to those running in the energy chain, making sure they form an even bend that can move up and down with the head's movement.
  6. To remove the head, reverse this procedure: disconnect the hoses from the energy chain and push them back into the end beam so they hang straight down before lifting the head out.

  Note: When later removing a head from the end beam, take care that the electric plug and hose ends do not catch on the support and become damaged.

• Dismantling the telescopic beams and end beam unit of a telescopic spreader

  1. Remove all the wear plates from the ends of the telescopic beams, leaving the plates on the main frame in place.
  2. Disconnect the power cables and hydraulic hoses from the end units, sealing all hydraulic hoses correctly.
  3. Remove the stud from the drawbar connection in the end beam.
  4. Take the weight off the end unit using a fork lift truck, and extend the unit to the 40 foot position.
  5. Secure a spacer between the telescopic beams to prevent lateral movement.
  6. Extract the beams from the main frame and inspect them as required.
  7. Reassemble the beams and end units in the reverse order to the steps above.

  Note: This procedure is used if the telescopic beams require checking.

• Dismounting and mounting the twistlock pin on a telescopic spreader

  1. Dismount the twistlock cylinder first.
  2. Remove the M6 screw and nut from the top of the twistlock.
  3. Grab hold of the twistlock head.
  4. Slack off the twistlock nut.
  5. Lower the twistlock pin and guide block.
  6. To mount, perform the steps in reverse order, carrying out the float adjustment before mounting the M6 screw and nut, and lubricating per the lubrication points drawing.

  Note: Do not lose the twistlock pin key during dismounting.

• Checking and adjusting the twistlock float on a telescopic spreader

  1. Grab hold of the twistlock head, and push or pull the twistlock to one of the corners.
  2. Ensure the guide block is touching the twistlock housing bottom plate; if not, the twistlock needs to be adjusted (lowered).
  3. If the twistlock is touching the bottom plate, press it upwards while holding it in the corner; it should move up slightly. If it moves a lot, adjust it higher. If it does not move at all, it needs to be adjusted down.
  4. To adjust: remove the M6 screw from the top of the twistlock; loosen the twistlock nut slightly to lower the twistlock, or tighten the nut to raise it, aiming for a 1-2 mm gap between the top of the twistlock head and the bottom of the guide block.
  5. Recheck the float of the twistlock.
  6. Reinstall the M6 screw.

  Note: The correct distance between the top of the twistlock head and the bottom of the guide block is 1-2 mm.

Twistlocks & sensors

• What safety functions confirm correct twistlock engagement while handling a container?

  1. Special position sensors on each twistlock send signals to the electronic control system to confirm the twistlocks are correctly positioned in the container corner hook-on housing.
  2. If this condition is satisfied, the yellow indicator light comes on and twistlock fast-on can start.
  3. When all the twistlocks have been correctly fastened, the green light comes on and lifting can begin.
  4. Before releasing the twistlocks, the container must be rested on a sturdy and stable support surface.
  5. If properly supported, the yellow light comes on to indicate the twistlocks can be released.
  6. To confirm all the twistlocks have been released, the red light comes on.
  7. In the event of a fault, the electronic control system prevents raising the lifting unit.

  Notes:

  • Always remain within sight and communication with personnel on the ground.
  • Do not lift submerged loads, as water and mud increase weight.
  • Make sure frost has not secured the load to the ground.
  • Do not use the machine to push or pull loads.

• What is the correct sequence to pick up a stacked container?

  1. Move slowly up to the stack of containers.
  2. Position the spreader above the container to be picked up, making sure it is centred with respect to the container.
  3. Lower the spreader so the twistlocks correctly enter the container corner hook-on housings.
  4. If the twistlocks have entered properly, the yellow light comes on and the next operation can be performed; otherwise, lift the spreader and repeat the previous step.
  5. Hook on the twistlocks; if done correctly, the green light comes on and the next operation can be performed, otherwise release the twistlocks, slowly raise the spreader and repeat from the lowering step.
  6. Slowly lift the container.
  7. Back the truck up slowly without turning the wheels.
  8. Lower the spreader, being careful not to collide with obstacles.

  Note: Drive carefully when transporting loads; avoid sudden braking and changes of direction.

• What is the correct sequence to stack a container?

  1. Move slowly up to the container on which to place the load.
  2. Lift the load above the container which will act as a support.
  3. Centre the load above the container.
  4. Rest the load on the container; wait for the yellow light to come on to check the load is well supported before proceeding, otherwise lift the spreader and repeat the operation.
  5. Release the twistlocks; wait for the red light to come on to check all twistlocks are actually released, otherwise hook the twistlocks back on, lift the spreader and repeat the previous step.
  6. Slowly lift the spreader until the twistlocks have completely come out of the corner housings.
  7. Back the truck up slowly.
  8. Lower the spreader, being careful not to collide with obstacles.

  Note: Drive carefully when transporting loads; avoid sudden braking and changes of direction.

• What is the correct sequence to remove a twistlock for replacement?

  1. Loosen nut (1) and screw (2).
  2. Remove the connecting rod (3).
  3. Remove the snap ring (4), the mechanical safety cam (5) and the ball (6).
  4. Loosen the screw (7) and ring nut (8).
  5. Remove the twistlock (9) and, at the same time, the bush (10) and bearing ring (11).

  Note: During twistlock fitting/removal, mind power cables and hydraulic pipes.

• When must a container twistlock be replaced rather than inspected again?

  Periodicity: replace after 6000 hours, or sooner if wear limits are exceeded

  1. Regularly inspect the twistlock heads.
  2. Replace the twistlock when measurement (a) exceeds 10 mm, or when dimension D falls by more than 5%.
  3. Replace the twistlocks after 6000 hours, depending on their state of wear.

  Note: Twistlocks must always be removed to undergo non-destructive tests to determine any hidden damage and/or micro-cracks.

• Removing and installing the twistlock position sensors on a telescopic spreader

  1. Unscrew the cable connection from the sensor.
  2. Loosen the two screws on the switch attachment.
  3. Remove the sensor.
  4. To install, perform the steps in reverse order, using a blue threadlocking compound on the cable connection.
  5. Check the sensor by grabbing the twistlock head and moving it around in different positions; if the signal is lost, adjust the sensor closer to its flag.

  Note: The correct distance between the sensor face and the flag is approximately 5-6 mm. Make sure the flag does not come into contact with the sensor.

Extension & sideshift

• What general safety precautions apply to spreader operation and maintenance?

  1. All spreader operations must be performed in accordance with applicable national work regulations.
  2. No operator should be allowed to remove the covers or guards during machine movement.
  3. Before carrying out any maintenance jobs on the spreader, take precise precautions to prevent the spreader from being accidentally started up.
  4. Before starting maintenance on electrical components, interrupt the power supply and take precautions to prevent any accidental return of power.
  5. In case of long periods of spreader inactivity, adequately protect the machine and take adequate safety measures to protect its integrity.
  6. No change must be made to the spreader without the manufacturer's approval.
  7. When performing operations with the spreader, be careful no one is standing within the machine operating range.

  Note: The spreader operator must be qualified and authorised to use this type of equipment.

• How should a spreader's nylon sliding blocks be maintained?

  Periodicity: daily sight check

  1. Perform a daily sight check of the spreader to detect or prevent breakages.
  2. Periodically grease the nylon sliding blocks on the extension beams and twistlock heads.
  3. Replace the nylon sliding blocks before they become completely worn.

  Note: Avoid over-greasing, especially in dusty environments.

• How should the oil in a spreader's rotation reduction gears be changed and checked?

  Periodicity: first change after 100h running-in; subsequent changes every 2000-2500 hours or at least once a year; level check about once a month

  1. After a running-in period of about 100 hours, replace the oil in the reduction gears and brakes, and wash the inside of the unit with detergent.
  2. Check that there are no metal parts of unusual size on the magnetic caps of the reduction gears and brakes.
  3. Change the oil when the reduction gear is hot, to make outflow easier.
  4. Periodically check the levels (about once a month) and top up if necessary.

  Note: Never mix different oils.

• What is the correct sequence to load and bleed the spreader's Dumping hydraulic circuit?

  Performed if the Dumping circuit needs to be charged.

  1. Set the maximum pressure valve (160 bar) on the spreader solenoid valve plate (E) to 40 bar.
  2. Connect a pressure gauge to the 4-way fitting (T) on the discharge line, located under the solenoid valve (E).
  3. With the engine idling, rotate the twistlocks using the joystick controls while simultaneously operating the spreader safety bypass key on the right side control panel; continuing to operate the twistlock control, adjust the maximum pressure valve until the desired pressure (40 bar) is reached.
  4. Connect a charging hose to the 4-way fitting (P) on the oil delivery line to the twistlocks (next to fitting (T) on solenoid valve (E)), and another hose to the 3-way fitting (A) of valve (3)'s closed circuit.
  5. Connect a hose to fitting (B) to drain the oil into a suitable container.
  6. Open tap (2).
  7. Detach the Dumping cylinders (D) from the spreader only, and open knob (C) of valve (3) almost fully.
  8. Open tap (4) and close tap (6).
  9. Open tap (7) and close tap (5).
  10. Run the Dumping cylinders (D) to their end stop, as described in the next step.
  11. With the engine idling, rotate the twistlocks using the joystick controls while operating the spreader safety bypass key.
  12. Open tap (5) and close tap (7).
  13. Open tap (6) and close tap (4).
  14. Run the Dumping cylinders (D) to their end stop again, as in the step above.
  15. Repeat the cylinder end-stop cycling several times so that any air in the circuit is completely expelled.
  16. Close tap (2).
  17. Reattach the Dumping cylinders (D) to the spreader, taking care not to disturb the closed circuit.
  18. Open taps (4), (5), (6) and (7).
  19. Pressurise the circuit (by energising any spreader function) for about 1 minute, then close taps (4) and (5).
  20. Remove the hoses connected to fittings (A), (P) and (B).
  21. Re-cap fittings (A), (P) and (B).
  22. Re-set the spreader solenoid valve (E) maximum pressure valve back to 160 bar, repeating the first three steps.
  23. Adjust knob (C) of valve (3), closing it fully then backing off 6 turns (standard setting).
  24. Remove the pressure gauge from fitting (T) and re-cap it.

  Notes:

  • Oil must always be collected in a suitable container, never released into the environment.
  • All these operations must be performed only by qualified and trained personnel, in maximum safety; switch off the engine and confirm the parking brake is applied.

• What side-shift operations are checked during the 500-hour Type A preventive maintenance service?

  There are four preventive maintenance cards (A, B, C, D) covering the machine's complete maintenance plan, on a 500-hour frequency, cycling in the order B-A-B-C-B-A-B-C-B-D before repeating. Service times assume normal operating conditions and may vary with type of use, road surface, and environment.

  1. Tighten the side-shift bolted joints.

  Note: Maintenance must be carried out only by qualified, authorised personnel, working in conditions of maximum safety.

Weight Indicator

• What is the correct sequence to check the weight indicator (fixed scale alternative)?

  1. Lift a known weight.
  2. Place the boom in horizontal position: lift the boom so the colour marking on the rod disappears in the pipe, then lower the boom until the colour marking can be seen, then press in the pistol trigger and extend the boom until the boom stops by itself in the measuring position.
  3. Check that the weight indicator shows the correct weight within ±0.5 ton; if the deviation is greater, calibrate the weight indicator.

• What is the correct sequence to calibrate the fixed scale?

  It is very important for accuracy that all steps are performed in the specified order.

  1. Park the machine on level ground without load and centre the attachment.
  2. Navigate to the service menu and press ENTER.
  3. Enter the code for calibration, obtained from the machine manufacturer's support.
  4. Scroll to SCALE with the arrow keys and press ENTER.
  5. Move the boom to the measuring position: lift the boom so the colour marking on the rod disappears in the pipe, lower the boom until the colour marking can be seen at the pipe end, then press in the pistol trigger and extend the boom until it stops by itself in position.
  6. In CALIBR SCALE menu 1, save the setting with ENTER.
  7. Lift a known reference load and centre the attachment.
  8. Park the machine on level ground.
  9. Move the boom to the measuring position again.
  10. Scroll to CALIBR SCALE menu 2.
  11. Enter the weight of the reference load with the + and - keys and save the setting with ENTER.
  12. Scroll back from the calibration mode with the R-key.
  13. Check the calibration.

  Note: It is very important for accuracy that the boom is raised first and then lowered to the measuring position.

• What is the correct sequence to check the weight indicator (dynamic scale alternative)?

  1. Lift a known weight.
  2. Check that the weight indicator shows the correct weight within ±0.5 ton; if the deviation is greater, calibrate the weight indicator.

• What is the correct sequence to calibrate the dynamic scale?

  It is very important for accuracy that all steps are performed in the specified order.

  1. Park the machine on level ground without load and centre the attachment.
  2. Navigate to the service menu and press ENTER.
  3. Enter the code for calibration, obtained from the machine manufacturer's support.
  4. Scroll to SCALE with the arrow keys and press ENTER.
  5. Lower the boom to the lowest position (0°).
  6. In CALIBR SCALE menu 1, save the setting with ENTER.
  7. Lift the boom to its highest angle and, in menu 2, save the setting with ENTER.
  8. Retract the boom completely and, in menu 3, save the setting with ENTER.
  9. Extend the boom completely and, in menu 4, save the setting with ENTER.
  10. Lower and retract the boom completely, then raise it approximately 4 cm and carefully lower it approximately 2 cm on the lift cylinders.
  11. Wait approximately five seconds to stabilize the pressure, then in menu 5, save the setting with ENTER.
  12. Extend the boom completely, wait approximately five seconds to stabilize the pressure, then in menu 6, save the setting with ENTER.
  13. Scroll to menu 7, lift a reference weight, and check that the control system calculates the correct weight of the load (PRESENT LOAD).
  14. If the weight is not correct, scroll back to menu 6 and enter the weight of the reference load with the + and - keys, saving with ENTER.
  15. Operate the machine without load, stop the machine, and check that PRESENT LOAD is 0 ± 250 kg while stationary.
  16. Scroll back from the calibration with the R-key.

  Notes:

  • Negative values in the calibration menu indicate changed contacts on the pressure sensors; large variations between right and left indicate faults in the sensors' signals.
  • Operating the machine generates dynamic forces; check the final present-load value only when stationary.

• What load-feeler-sensor and load-cell operations are checked during the 500-hour Type A preventive maintenance service?

  There are four preventive maintenance cards (A, B, C, D) covering the machine's complete maintenance plan, on a 500-hour frequency, cycling in the order B-A-B-C-B-A-B-C-B-D before repeating. Service times assume normal operating conditions and may vary with type of use, road surface, and environment.

  1. Check the mechanical operation of the load feeler sensors.
  2. Check for oil leaks from feeler sensor components.
  3. Check the feeler sensors' electrical operation.
  4. Check the feeler sensors' wiring.
  5. Tighten the feeler sensors' and consent brackets' bolted joints.
  6. Check the condition of the feeler sensor heads.
  7. Grease the feeler sensor guides.
  8. Check the load cells' input values.
  9. Check the feeler sensor bypass's operation.

  Note: Maintenance must be carried out only by qualified, authorised personnel, working in conditions of maximum safety.

Forks

• How is fork wear checked dimensionally?

  1. Measure the thicknesses at the designated points on the fork.
  2. Confirm these are at least 90% of the original thicknesses when new.

• How is fork inclination checked?

  1. Measure the inclination angle of the fork.
  2. Confirm this does not exceed 3°.

• How is it checked whether the two forks have developed different degrees of inclination?

  1. Position the truck on a flat surface with the mast at right angles to the ground.
  2. Measure the length and the two heights at the designated points on the forks.
  3. Confirm the difference between the two heights is no more than 3% of the measured length.

Spreader Maintenance

• What is the correct sequence to clean, check and grease the spreader's twist-lock and structure?

  For the full maintenance schedule, consult the machine's four preventive maintenance cards and the inspection card at the end of the manual.

  1. Clean and examine the twist-lock structure, checking that the electrical sensors and mechanical feeler pins operate correctly and do not come into contact with each other.
  2. Grease the twist-locks, cylinder attachments, spreader rotation ring, and slide pads.
  3. Carefully examine the entire spreader structure (boxes, extending sections, rotation ring, cylinders, etc.) for wear, deformation or excessive play on any component (pins, bearings, etc.), replacing deteriorated parts.
  4. Check the tightening torque of the rotation ring's fastening bolts (1050 Nm).
  5. Check the tightness of all bolted joints.
  6. Check the presence and condition of the lubricating grease over the entire spreader.

  Note: Check the tightness of the rotation-ring bolts at every disassembly and after the first 50 operating hours.

• What is the periodic replacement schedule for the spreader's slide pads and twist-lock block?

  Periodicity: Replace the slide pads every 2000 hours; replace the entire twist-lock block every 5000 hours.

  1. Replace the slide pads every 2000 hours.
  2. Replace the entire twist-lock block every 5000 hours.

  Note: It is advisable in any case to contact qualified service personnel.

• What general spreader operations are checked during the 500-hour Type A preventive maintenance service?

  There are four preventive maintenance cards (A, B, C, D) covering the machine's complete maintenance plan, on a 500-hour frequency, cycling in the order B-A-B-C-B-A-B-C-B-D before repeating. Service times assume normal operating conditions and may vary with type of use, road surface, and environment.

  1. Grease the spreader's front support pins.
  2. Check the spreader rotation pinion's oil level.
  3. Tighten the rotation and consent brackets' bolted joints.
  4. Check the spreader's general wiring.
  5. Check the condition of the spreader's general framework.
  6. General greasing of the spreader.
  7. Check the spreader's working lights operation.

  Note: Maintenance must be carried out only by qualified, authorised personnel, working in conditions of maximum safety.

• Changing the spreader on an RTG equipped with a headblock

  1. Lower the spreader onto the container or a maintenance rack.
  2. Secure the spreader in place by locking the twist locks.
  3. Shut down the crane and cut off the main switch to remove power from the spreader.
  4. Open the headblock twistlocks.
  5. Disconnect the spreader cables, pipes and other connections from the headblock.
  6. Position the headblock on the new spreader, reconnect the cables, and close the headblock twistlocks.

  Note: Always use an appropriate spreader with the RTG, and always replace a broken spreader immediately. The spreader can be operated from the operator's cabin, the electrical-equipment house, or remote control; only one control position can be active at a time.

• Installing the spreader cable into the cable net and basket

  1. Lift up the cable coil, or release the cable bracket to bring the cable coil up.
  2. Release the cable wringing by rolling the cable coil when taking the spreader cable down from the coil.
  3. Press the rear end of the cable net open, and insert the spreader cable into the net, section by section, so the net stays in close contact with the cable.
  4. Bind the cable net end with a stainless steel tie.
  5. Fix the cable net rope end to the bracket.
  6. Pull the bracket to make sure the cable net stretches completely (the net may move a little during this pulling).
  7. Fasten the cable clamp.
  8. Keep the cable above the net loose; the cable must not carry the cable weight directly.
  9. After tightening the cable gland, waterproof it with a heat shrink sleeve (250 mm), applying glue to the inside of the heat shrink.
  10. Lift up the spreader cable with a jib hoist or mobile crane, and release the cable twists.
  11. After lifting the cable, put the cable end into the cable basket, then connect the cable end outside the basket to the cable plug, or hard-wire it into the terminal block of the junction box (there is no need to fix both sides of the cable during installation).
  12. Let the cable run counter-clockwise into the basket, and fix it with a pipe clamp.
  13. After putting all cables into the basket, remove the sling from the cable.
  14. Lift the spreader up to the trolley bottom and fix the spreader cable bracket per the spreader manual drawing, making sure the upper cable cannot slide freely and that the cable plug or terminal cable does not carry the cable weight directly.
  15. Adjust the aerial cable repeatedly and lubricate it, then fix the bracket completely. Release unnecessary torsion in the cable (otherwise it can twist, over-tighten and become damaged). Lubricate the cable per the drawing specifications, and make sure the area around the cable is clean.

  Note: Tools: forklift, fork wrench, mobile crane, sling, stainless steel tie, cable net, heat shrink tube, heat gun, cable clamp. Put the spreader cable on a wood plate or canvas; do not lay it directly on the ground. Wear a safety harness and exercise caution when working in high places.

• Installing the optional lift hook on a rubber tyred gantry crane

  1. Put the crane into service position before any maintenance work.
  2. Place the spreader on the ground and keep spreading until slack rope appears at the sheaves of the headblock.
  3. Turn off the spreader and the crane.
  4. Disconnect the plug from the spreader and plug it into the dummy socket on the headblock.
  5. Unlock the 4 twistlocks of the headblock.
  6. Hoist the headblock, not higher than necessary.
  7. Lower the headblock safely onto the top of the hook frame, and connect the frame to the headblock. The crane is then ready for production.

  Note: The lift hook is a special hoisting appliance used for non-container loads, mounted on a hook frame connected directly to the headblock instead of the spreader. The crane must be run in hook mode to use it; hoisting/veering speed, hoisting height, accelerations, and spreader cable tension are all limited in this mode. The crane operator coordinates the activities of at least 2 persons. Do not hoist the headblock higher than necessary, due to clamping danger. When hoisting with an empty headblock the ropes will sag; the hoist ropes can fall next to the hoisting sheave.

• Checking and adjusting the operating pressure of a motorised beam with rotating hook

  1. Turn the hook in one direction, and adjust the pressure using the maximum pressure screw.
  2. Turn the hook in the other direction, and check the pressure.
  3. Unscrew the piloted check valves for the speed adjustment procedure.

  Note: During the pressure adjustment process, the piloted check valves must be fully screwed up. The pressure must be checked by pressure gauges, by skilled personnel. After each maintenance job, verify with a pressure gauge that the maximum operating pressure matches the value shown on the beam's plate.

• Adjusting the telescopic chain on a telescopic spreader

  1. Run the spreader to the maximum position (40 foot).
  2. Disconnect the power.
  3. Remove the locking screws from the adjuster nut.
  4. Tighten the adjuster nuts on both sides with a torque wrench to 50 N.m (37 ft-lb), alternately, one turn at a time.
  5. Reinstall the locking screws in the adjusting nut.

  Note: Adjusting both sides equally is important; if not done properly, this could cause future operating problems and reduce the life of the chain.

• Replacing a broken telescopic chain on a telescopic spreader

  1. Disconnect the electrical supply in the spreader control cabinet, using the main switch.
  2. Place the telescopic beams in the approximate position for a 30 foot container, using a fork lift truck or similar.
  3. Turn the adjusting nut counterclockwise a quarter turn.
  4. Remove the chain pin connected to the shock absorber, by pulling out the cotter pin.
  5. Remove the chain.
  6. Install a new chain, or insert a joining link, and reinstall the chain and the adjusting nut.
  7. Adjust the telescopic chain as in the standard adjustment procedure.
  8. Connect the power supply and make a fine adjustment per the spreader-length setting instructions.
  9. Check the distance between the twistlocks per the spreader-lengths instructions for the relevant twistlock type.
  10. Lubricate the chain according to the lubrication points drawing.

  Note: This procedure applies if the chain breaks and jumps over the chain wheel.

• Replacing the wear plates in the main frame and telescopic beams of a telescopic spreader

  1. For the main frame wear plate: extend the spreader to at least the 30 foot position, then remove the locking plate and replace the wear plate.
  2. For the telescopic beam lower plates: set the spreader to at least the 20 foot position, remove the electrical connectors from the electromagnetic telescopic valves, then operate the telescopic drive by manually pressing the valves until the wear plate mounting bolts are accessible through the aperture in the lower flange of the main beam, and replace the plates.
  3. For the telescopic beam upper plates: set the spreader to at least the 20 foot position, remove the electrical connectors from the electromagnetic telescopic valves, operate the telescopic drive by manually pressing the valves until the wear plate mounting bolts are accessible, and replace the plates.

• Removing and installing the bearings of an automatic flipper arm unit on a telescopic spreader

  1. Remove the flipper arms.
  2. Remove the key.
  3. Drift out the shaft; once removed, the bearing will be pushed out by the middle key.
  4. Drift out the second bearing.
  5. Install the parts in the reverse order to dismantling, except that both bearings must be drifted into position using a pipe of a suitable bore.

  Note: When replacing the flipper arm motor, ensure the outlet plug is correctly positioned; the outlet plug can be removed to alter flipper arm speed.

• Adjusting the landing pin on a telescopic spreader

  1. Attach blockading pin clamps at three of the corners.
  2. At the fourth corner, press the pin upwards.
  3. Check that the "spreader landed" lamp goes on when the lower part of the pin is 6-7 mm from the bottom plate of the corner.
  4. If the distance is not correct, adjust the landing switch and repeat the test.
  5. Proceed in the same way for all four corners.

  Note: The lamp indicating "spreader landed" should switch on when the lower part of the landing pin is 6-7 mm from the bottom plate of the corner.

• Removing and installing the twistlock cylinder on a telescopic spreader

  1. Remove the hoses from the cylinder.
  2. To avoid oil leakage, thread a plastic bag over the end of the hoses and secure them with straps.
  3. Pull out the split pins, then remove the spacer rings and the cylinder.
  4. To install, perform the steps in reverse order, tightening the hoses to 95 N.m (70 ft-lb) torque.
  5. De-aerate the system by running the cylinder several times.

  Note: Make sure the power supply is disconnected and the oil pressure is relieved from the system before starting.

• Inspecting the telescopic motor and tower motor brakes (BMG 4 and 8) and setting the working air gap on a telescopic spreader

  1. Remove the forced-cooling fan if fitted, then the flange cover or fan guard.
  2. Push the rubber sealing collar aside, releasing the clip if necessary, and extract the abraded matter.
  3. Measure the brake disc thickness; fit a new brake disc if it is at or below the discard threshold for the brake type (9 mm for BMG4, 10 mm for BMG8).

  Note: Isolate the motor and brake from the supply, safeguarding them against unintentional power-up, before starting.

• Changing the brake disc on the BMG 4 and 8 brakes of a telescopic spreader

  1. Remove the forced-cooling fan if fitted, the flange cover or fan guard, the circlip, and the fan.
  2. Remove the rubber sealing collar and the manual brake release: setting nuts, conical coil springs, studs, release lever, and dowel pin.
  3. Unscrew the hex nuts, carefully pull off the brake coil body (watch the brake cable), and take out the brake springs.
  4. Remove the damping plate, pressure plate and brake disc, and clean the brake components.
  5. Fit a new brake disc.
  6. Reinstall the brake components, and set the working air gap (except for the rubber sealing collar, fan and fan guard).
  7. On brakes with manual release, use the setting nuts to set the floating clearance "s" (2 mm) between the conical coil springs (pressed flat) and the setting nuts.
  8. Fit the rubber sealing collar back in place and reinstall the remaining dismantled parts.

  Note: Isolate the motor and brake from the supply, safeguarding them against unintentional power-up. When fitting a new brake disc, inspect the other removed parts as well, and fit new ones if necessary.

• Changing the springs on the BMG 4 and 8 brakes of a telescopic spreader

  1. Remove the forced-cooling fan if fitted, the flange cover or fan guard, the circlip, and the fan.
  2. Remove the rubber sealing collar and the manual brake release: setting nuts, conical coil springs, studs, release lever, and dowel pin.
  3. Unscrew the hex nuts and pull off the coil body by approximately 50 mm, watching the brake cable.
  4. Change the brake springs, positioning them symmetrically.
  5. Reinstall the brake components, and set the working air gap (except for the rubber sealing collar, fan and fan guard).
  6. On brakes with manual release, use the setting nuts to set the floating clearance "s" (2 mm) between the conical coil springs (pressed flat) and the setting nuts.
  7. Fit the rubber sealing collar back in place and reinstall the dismantled parts.

  Note: Isolate the motor and brake from the supply, safeguarding them against unintentional power-up. Fit new setting nuts and hexagon nuts if the removal procedure is repeated.

Lift Legs

• What is the correct sequence to check the combi attachment's lift shoes?

  1. Lower all lift legs.
  2. Check that the plate for clamping position and the alignment pin move freely and spring back to the basic position.
  3. Press in the alignment pin so the head is flush with the spreader beam's underside and check that the indicator light activates (the pin should move easily and spring back completely).
  4. Press in the plate for clamping position and check that it moves easily and springs back completely, and that the indicator light for clamping position activates (both left and right plates must be pressed in to activate the light).
  5. Check that the lift shoe's wear is within the specified limits, and that it shows no signs of cracking or other external wear, changing it if needed.
  6. Clean the area around the grease cup.
  7. Grease the bearings for the clamping position plate with an NLGI EP2 universal grease.
  8. Repeat all steps on all lift legs.

• What is the correct sequence to check the lift shoes for cracks?

  Periodicity: Crack checks shall take place every other year or every 5000 operating hours.

  1. Remove the lift shoes from the lift legs.
  2. Test for cracks within the marked area on the lift shoes, without reworking or damaging the part.
  3. Fit the lift shoes.

  Notes:

  • Lift shoes are heavy; take care when removing them.
  • Change any lift shoe showing signs of cracks, external damage, or with more than 10,000 operating hours, due to fatal danger from material fatigue.

Other Attachments & Spreaders procedures

• How is the oil in the spreader's rotation reduction gears changed?

  Periodicity: Replace the oil after the first approximately 100 hours of operation (running-in); make subsequent oil changes every 2000-2500 hours or at least once a year; check the level about once a month.

  1. After approximately 100 hours of running-in operation, replace the oil in the reduction gears and brakes and wash the inside of the unit with detergent.
  2. Check that there are no metal parts of unusual size on the magnetic caps of the reduction gears and brakes.
  3. Change the oil while the reduction gear is hot, to make outflow easier.
  4. Periodically check the oil level (about once a month) and top up if necessary.

  Note: Never mix different oils.

• What is the correct sequence to mount the spreader head?

  1. Insert the pin into the spreader head.
  2. Insert the washers.
  3. Screw on the nut without fully tightening it.
  4. Insert the head into the beam, paying attention that the pin can only be inserted into the beam in the position shown in the drawing.
  5. Turn the pin 90° so the second pin can be inserted into the beam and into the spring eye.
  6. Secure the tapered pin with the safety split pin.
  7. Insert the plate, securing it with the locking plate using the screws.
  8. Insert the remaining plates.
  9. Tighten the nut, securing it with the split pin.

  Note: Pay attention to electrical cables and hydraulic hoses during spreader head assembly.

• What is the correct sequence to change the spreader motor unit oil?

  1. Remove the drain plug and collect the oil in a receptacle.
  2. Remove and clean the level glass.
  3. Fit the drain plug once all oil has drained, making sure the seal washer is installed.
  4. Fill oil through the breather hole until the level is visible in the level glass.
  5. Handle the waste oil as environmentally hazardous waste.

• What is the correct sequence to check and adjust the spreader chains and stops?

  1. Check the clearance between the slide plates and extension beams before adjusting.
  2. Start the engine, run the spreading in to the 20-foot position, and turn off the engine.
  3. Check the centre-to-centre measurement between the twistlocks at 20 feet (5853±3 mm), and check that both spreader beams run against the 20-foot stops with at least 3 mm between the spreader beam and the spreader motor's mounting.
  4. If needed, adjust the distance by moving washers between the right and left 20-foot stop, without changing the total quantity of washers, noting the adjustment distance, and running the spreading out slightly to allow moving the washers.
  5. Remove the cover plates on the attachment's main beam.
  6. If the 20-foot stops were adjusted, adjust the spreader chains equally, checking the chain tensioner's vertical position so the chain runs straight toward the chain wheel.
  7. Start the engine, run the spreading out to the 40-foot position, and turn off the engine.
  8. Check the centre-to-centre measurement between the twistlocks at 40 feet (11985±3 mm).
  9. If needed, adjust the 40-foot stops.
  10. Start the engine and run the spreading in to the 40-foot position.
  11. Wait 2 minutes, then check the tension of the chains by measuring how much the chain can be pushed in at the hole closest to the centre of the attachment; with a force of 250 N it should move 20-40 mm from its resting position.
  12. If needed, adjust the tension of the chains by starting the engine and running the spreading out until the chain tensioner is visible in the inspection hole, then adjusting.
  13. Repeat the tensioning checks and adjustments until the chain tension is correct.
  14. If the machine has 30-foot or 35-foot stops, run the spreading out to that position, turn off the engine, and check the centre-to-centre measurement (30-foot: 8918±3 mm; 35-foot: 10488±3 mm).
  15. Brush lubrication grease on the spreader chain.
  16. Fit the cover plates to the attachment's main beam.

  Notes:

  • Before adjustment, check the clearance between the slide plates and extension beams, or the chain's mountings will be damaged.
  • Always depressurize the hydraulic systems before working on them; avoid skin contact with the oil, use protective gloves.
  • Adjust the chain a maximum of 2 mm at a time on the chain tensioner.

• What is the correct sequence to change the rotation motor unit's oil (disc brake and planetary gear)?

  1. Clean the area around the rotation motor unit.
  2. Place a receptacle under the rotation motor.
  3. Remove the planetary gear's drain plug and let the oil drain into the receptacle, removing the filler plug too for faster draining.
  4. Remove and clean the planetary gear's level glass while the oil drains.
  5. Fit the level glass and drain plug.
  6. Fill the planetary gear with new oil through the filling point until the level is in the middle of the level glass.
  7. Remove the disc brake's drain plug and let the oil drain into the receptacle, removing the filler plug too for faster draining.
  8. Remove and clean the disc brake's level glass while the oil drains.
  9. Fit the level glass and drain plug.
  10. Fill the disc brake with new oil through the filling point until the level is in the middle of the level glass.

  Note: Always depressurize the hydraulic systems before working on them; avoid skin contact with the oil, use protective gloves.

• What is the correct sequence to adjust the attachment's tilt damping?

  Tilt damping may need adjustment after run-in due to mechanical tolerances.

  1. Run the engine at idle.
  2. Lift the boom without load and check that the attachment hangs horizontally during the whole lifting movement.
  3. Adjust the tilt damping as needed by turning the screws on the damping block equally (clockwise to increase damping, counter-clockwise to reduce it).
  4. Lift a loaded container, test-run and brake, and check that the container does not oscillate uncontrollably, adjusting the damping again if needed.
  5. Start the machine and check that the function is satisfactory.

• What is the correct sequence for the 1000-hour lubrication of the attachment and electric connectors?

  Periodicity: Every 1000 hours.

  1. Lubricate the locking cylinder mounts with grease.
  2. Lubricate the contact pins with grease, and check that the sensors are undamaged and free from grease.
  3. Grease the spreading cylinder mounts.
  4. Grease the side shift cylinder mounts.
  5. On machines with central lubrication, check the grease levels in the pump units on the frame and attachment, topping up through the grease nipples if levels are below the middle of the reservoir.
  6. Grease the electric connectors with electric connector grease, and check that damp cannot enter the connectors.

  Note: If grease has penetrated out from the central lubrication's safety valve, it means there is a stop in the system and no points are being greased.

• What is the correct sequence to check the spreader beam's slide plates?

  1. Park the machine with the attachment lowered as far down as possible and spreading extended approximately 1000 mm.
  2. Turn off the engine and turn off the system voltage.
  3. Check that the clearance between the slide plates and main beam is a maximum of 5 mm both laterally and vertically, adjusting with shims if it exceeds this.

• What is the correct sequence to replace the spreader function light bulb?

  1. Remove the lens by unscrewing its fastening screws.
  2. Replace the bayonet-type spherical bulb.
  3. Refit the lens and re-tighten the fastening screws.

  Note: Do not overtighten the lens fastening screws, to avoid breaking it.

Looking for general maintenance tips and checklists? See Attachments & Spreaders.