Stinnis HMK

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

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

maintenance of STINIS VATCII spreaders with registration numbers:
BJTI001
BJTI002
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.
6. Distribution of this manual:
nbr. supplied to language colour
6 x BJTI Indonesia English white
1 x PT. Pataya Sarana Niaga Indonesia English White
7. Version Manual:
The foot of each page of this manual shown the version (date and
edition). Later on updates or supplements will show a new date and
edition.
MANUAL BJTI001-002 Release A 18 October 2010 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 .......................................................................................................................1-2
1.30 Technical specifications ...................................................................................................................1-3
1.40 Guarantee ........................................................................................................................................1-5
1.50 CE-Documents.................................................................................................................................1-6
1.60.04 Conservation ....................................................................................................................................1-7
1.70 Drawings: directions for use.............................................................................................................1-7
2 START-UP - WARNINGS - SAFETY PRECAUTIONS........................................................................2-1
2.10 Crane control: Important information ...............................................................................................2-1
2.15 Crane driver: Warnings ....................................................................................................................2-3
2.15.21 Crane driver: Warnings-twinlift-interlock-device ..............................................................................2-4
2.15.32 Crane driver: Warnings spreader error mesages (CAN) .................................................................2-5
2.16 Crane driver: Instructions (GLTW) ...................................................................................................2-6
2.17 Crane driver: Lamp information .......................................................................................................2-7
2.18 Maintenance department: Warnings................................................................................................2-8
2.20 Start-up procedures .........................................................................................................................2-8
2.41 Safety features ...............................................................................................................................2-10
2.50 Spreader cage................................................................................................................................2-10
3 OPERATION.........................................................................................................................................3-1
3.10 Drawings: References......................................................................................................................3-1
3.20 Functional description ......................................................................................................................3-1
3.20.10 Spreader construction......................................................................................................................3-1
3.20.20 Midframe ..........................................................................................................................................3-2
3.20.25 Shift frame........................................................................................................................................3-2
3.20.30 Telescopic beams ............................................................................................................................3-3
3.20.40 Blocking slide-beams .......................................................................................................................3-3
3.20.50 End beams .......................................................................................................................................3-4
3.20.61 Twistlocks model TWI-W .................................................................................................................3-4
3.20.70 Flippers and actuators .....................................................................................................................3-6
3.20.90 Twinlift construction .........................................................................................................................3-7
3.40.03 Electrical information - general (CAN control) .................................................................................3-9
3.40.10 General electrical components ........................................................................................................3-9
3.40.20 Identification electrical components...............................................................................................3-10
3.41.50 Functional program: description Twin ............................................................................................3-12
3.43.10 Connector to headblock .................................................................................................................3-15
3.43.20 Communication - plug connection to crane ...................................................................................3-15
3.50 Hydraulic information .....................................................................................................................3-15
3.61 Automatic greasing ........................................................................................................................3-17
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
5.20.20 Twin up/down actuators ...................................................................................................................5-4
5.30.03 Electrical system ..............................................................................................................................5-5
5.40 Electro-Mechanical ..........................................................................................................................5-6
5.40.11 Twistlocks: Model TWI-W double-split-collar ...................................................................................5-6
5.40.12 Twistlock Landing-pins.....................................................................................................................5-6
5.40.20 Telescopic beams - clearance .........................................................................................................5-7
5.40.30 Telescopic belts ...............................................................................................................................5-8
5.40.40 Telescopic stops ..............................................................................................................................5-9
5.40.50 Flippers for actuators .......................................................................................................................5-9
5.40.60 Shift house - Tower..........................................................................................................................5-9
5.40.70 Twinlift Unit.....................................................................................................................................5-10
5.50 Welding instructions.......................................................................................................................5-11
5.60 Automatic greasing ........................................................................................................................5-11
6 SPARE PARTS & SERVICE ................................................................................................................6-1
6.30 How to order spare parts .................................................................................................................6-1
6.40 Purchase component information ....................................................................................................6-1
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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 MANUAL-SHOPPING DRAWINGS ...................................................................................................17-1
17.10 Manual drawings: instructions for use ...........................................................................................17-1
17.20 Manual drawings............................................................................................................................17-1
20 INDEX .................................................................................................................................................20-1
MANUAL BJTI001-002 Release A 18 October 2010 C

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MANUAL BJTI001-002 Release A 18 October 2010 D

Stinis Holland B.V. CHAPTER 1
Postbus 2005
The Netherlands
1 SPREADER IDENTITY
1.10 AREA of APPLICATION
Crane:
This VATCII-ETW spreader is designed for a Mobile Crane.
Connection to head block, see: Chapter 3.20.25
Twinlift-Operation:
The spreader is designed to lift 20 and 40ft ISO containers.
If the spreader can handle twins, the SWL in twin for the spreader is a maximum 60T.
Twin-Single-operation:
In Twin operation the spreader can handle one single 20ft loaded 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
Special loads:
The spreader is provided with a number of additional lifting lugs:
Four lugs close to the head beams, with a working load of SWL = 10 t/lug.
Between four and eight lugs on the sides of the fixed mid-frame, SWL = 15 t/lug.
Occasionally, with a symmetrical loading, a lifting load of 50T under the four twist locks in the
20-40ft position is permissible.
Flippers: Chapter 3.20.70
For a quick connection of spreader on container, the spreader is equipped with heavy flippers
with actuators.
Working footboards, personnel cage:
The use of a personnel cage or working footboards on the spreader depends on local
regulations.
For further information, see: Chapter 2.50
Free space profile:
The clearance underneath the spreader is 120 mm, near the ends of the mid-frame.
MANUAL BJTI001-002 Release A 18 October 2010 1-1

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1.20 SPREADER REGISTRATION

Spreader dates general:
Model: VATCII-ETW
Single Operation: 20-40ft ISO
Twin Operation: 2 x 20ft ISO
Twin Single-Operation: 1 x 20ft in Twin-Operation
Tare weight: see: Chapter 1.30
Rated Capacity (SWL): see: Chapter 1.30
Warranty see: Chapter 1.40
CE Declaration: see: Chapter 1.50
Conservation: see: Chapter 1.60
Spreader dates / spreader:
Spreader with marking: BJTI001
Model: VATCII-ETW
Drawing number (article number): 2611-1886-0000
Serial no. - CE no. (certificate no.): 1006227
Certificates: see: Chapter 3.20.40 & 12
Spreader with marking: BJTI002
Model: VATCII-ETW
Drawing number (article number): 2611-1887-0000
Serial no. - CE no. (certificate no.): 1006228
Certificates: see: Chapter 3.20.40 & 12

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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: 41 t
Load in Twin-Lift Operation:
acc. DIN 15018 H2 B4,
Rated Capacity (SWL) in twin, calculated for 600.000 moves: 2x30 t
Eccentric Loads:
Allowed eccentric load in single operation: 40/60
Allowed eccentric load in Twin operation: 1 empty and 1 30.5t 20ft ISO
Load Lifting Lugs:
Rated Capacity (SWL) lifting lugs near twistlocks: 10 t/lug
Test Load:
Max. allowed test load (centric): 1.5 x SWL
Weight:
Tare weight: 13500 kg
Telescoping:
Telescopic stops: 20-40 ft
Time duration telescoping movement 20 to 40ft: 18 sec
Time for mechanical blocking of telescopic beams: 0.5 sec
Twistlocks General:
ISO or MU(UNI): ISO
Fixed or floating: floating
Type of nut, single(TWI) or double(TWI-W): TWI-W
Mechanical Blockading: yes
Hydraulic Blockading: yes
Electrical Blockading: yes
Time of twistlock: <0.5 sec
Twinlift:
Vertical telescoping: Yes
Independent per twistlock: Yes
Vertical down-force / twistlock: 1000 kg
Vertical resistance force upwards /twistlock: 1900 kg
Maximum allowed lowering speed of the spreader: 2.5 m/sec
Tolerances:
Nominal distance between hanging twins under the crane: 78 mm
Minimum distance between hanging twins under the crane: 58 mm
Minimum required distance between twins for interlocking: 0 mm
Maximum allowed vert. dist. between twins on top for interl.: 100 mm
Twinlift interlock Device: Yes
Shift (Tower):
Shift speed: 35-45 mm/sec
Shift length: 1900 mm
Hook connection
Type of hook: model 25
No pins: 2
ø pins: 98 mm
HOH pins: 258 mm
Internal width plates: 122 mm
Flippers:
Number of flippers: 4
Type of flippers (corner or flat): flat
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
Number of greasing points (twin): >50
Hydraulics:
Type of piston pump: adjustable with power control
Working oil pressure: 90-130 bar
Maximum oil pressure: 180 bar

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Electrics:
Electrics:
Motor power, main unit: 7.5 kW
Maximum power required during 20 seconds: 10 kW
Power supply voltage: 400 VAC
Frequency: 50 Hz
Solenoid voltage: 24 VDC
Number of spreader indicating lamps on headblock or spreader: 2*4
Indicators, see: Chapter 3.40.20 & 12
Environment:
Operation: 100 %
Maximum permitted relative humidity: 100 %
Permissible environmental temperature: 0/+50 °C.

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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 12 months from the spreader handover to the Purchaser or
18 month 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 BV
Bert de Bever
Managing director

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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 BV 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, 91/368, 93/44, 93/68, 73/23, 89/336/EEG 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: 20 October 2010
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

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1.60.04 CONSERVATION
Spreader conservation must be carried out in accordance with the specifications and the
supplier of International Paint.
For the outside of the mid-frame and the telescopic beams:
Sand blasting 2.5 ACC. ISO 8501-1-1988
1st coat Sigmacover zink primer, min. dry thickness 75 microns
2nd coat Sigmacover CM coating, minimum dry thickness 125 microns
3rd coat Sigmadur HB finish, minimum dry thickness 50 microns
Colour Spreader: Golden Yellow RAL 1003
Total minimum dry layer thickness 250 micron
Paint, info: www.sigmacoatings.com
Exceptions are:
* Inside of cross-beams, telescopic beams and midframe:
The first layer is never a zinc layer.
In general the total thickness is never thicker than 250mm, otherwise telescoping is no longer
possible.
* The actuators are machined after sandblasting and the first layer is never a zinc layer.
All components, which cannot paint according specifications, are hot galvanised.
If hot-dip galvanising is not possible, components are cold galvanised with a thickness of 20mu
1.70 DRAWINGS
Stinis uses 3 types of drawings:
Production drawings
Arrangement drawings
Manual drawings.
Production drawings
Production drawings are only used for the production of spreaders.
They will be made available for the customer if such drawing is required for repair work.
On request, however, special production drawings can be made.
How to use production drawings, see: Chapter 11
For a list of those drawings, see: Chapter 11
Arrangement drawings
Arrangement and assembly drawings are specially produced for the user.
For the mechanical drawings, see: Chapter 11
For the electrical drawings, see: Chapter 12
For the parts list of the electrical drawings, see: Chapter 12
For the hydraulic drawings, see: Chapter 13
For the parts list of the hydraulic components, see: Chapter 13
For the parts list of the hydraulic hoses, see: Chapter 13
Manual drawings
Manual drawings (or purchased/adjustment drawings) are specially made for the user for:
* Component location
* Components available for purchase
* Adjustment procedures
* Maintenance en repair information
How to use manual drawings, see: Chapter 17
For a list of the manual drawings, see: Chapter 17
For the part lists of the manual drawings, see: Chapter 17
For the manual drawings, see: Chapter 17

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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):
For information see: Chapter 2.15.21
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.

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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 an equilift 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.
* Continue to be vigilant when activating the shift in a cell.
When the spreader moves in the longitudinal direction, the equilibrium condition will change.
* Use shift only when you are absolutely certain that there is no one in the vicinity of the jibs.
Movements that present a danger to persons in the vicinity:
* Flippers-down movement
* Flippers-up movement
* Telescoping-retract/extend
* Shifting left/right
Working with a twinlift 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
* Twinlift-up/down movement of the twinlift housings
* The changeover from single- to twin-operation activates a great number of movements.
Making use of the Emergency-Stop in the crane can only stop these movements.
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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2.15.21 CRANE DRIVER: WARNINGS TWINLIFT INTERLOCK DEVICE

Function of Twinlift Interlock Device
Protection to lock two 20ft boxes in 40ft single operation.
This protection is known under the names:
* Twinlift Interlock Device
* Twin 20 protection
* Twin Twenty Detection System (TTDS)
There are several types of protections:
* Gap detection:
Detecting the gap between the two 20f boxes:
This can be done with one indicator (single detection) or for extra safety with 2 parallel
operating indicators (double detection)
* Roof detection:
Detecting the roof of both 20f boxes.
This spreader is equipped with double Gap and Roof detection.
GAP DETECTION
A very dangerous situation is lifting two 20ft containers in the 40ft position in single operation.
This is both dangerous for twin spreaders in single lift operation as well for non-twin spreaders.
The crane driver is sometimes not aware of this situation.
Special for terminals, which just start operating with twin-spreaders, a gab-detection is very
important, also for the single spreaders.
To secure safe lifting in single operation, one or two indicators detect the gap between the two
20ft boxes in the middle.
Is a gap detected, locking of the twistlocks is not allowed.
Is a gap not found, locking of the twistlocks is possible.
Is a gab detected, standard Stinis prefers to block twistlock-locking direct on the spreader.
For locking overheight containers (open-top) or special lifting equipment, a gab is nearly always
detected. Without the possibility to bridge the gap-detection, locking of this type of equipment is
not possible.
Gab detection information to the crane driver:
* Preferred is a special core to the cabin.
* Alternative, a spreader lamp indicates the gab-detection.
To bridge the gab-detection:
There are severe methods to bridge the gab-detection.
Three examples:
* Bridge gab-detection 1:
If there are no extra spreader cores available, Stinis advise to overrule the gab-detection by
the crane driver with a double command: twistlock-lock plus twistlocks-unlock together.
If the spreader is programmed for these commands, the spreaderbridge the gab-detection and
twistlocks will lock.
If lock-unlocking in the cabin is done by two separate bottoms, in the cabin no special
arrangement is required.
If lock-unlocking in the cabin is done by for example a joy-stick, and extra bottom must be
installed in the cabin.
If there is only one free spreader core available for gab-detection, bridging the gab-detection
can be controlled by the crane. The spreader only detect the gab, the crane does the bridging.
For this situation, the spreader does not blockade a twistlock-lock command from the crane.
Blockading is done in the crane. Bridging the gap-detection in the spreader program is not
possible.
Bridging and controlling is under full responsibility of the crane management.
If there are more free spreader cores available for gab-detection (to the crane), bridging the
gap-detection can be controlled again on the spreader (which is preferred by Stinis).
One core to the cabin is required for gap-detection, one core is required for bridging.
ROOF DETECTION
If the gap-detection fails, or the crane driver incorrect activates the bridge of the gab-protection,
a second detection prevents hoisting the spreaders with locked twistlocks, before
spreader/containers are damaged. This protection is based on detecting the roofs of the
containers near the centre of the spreader. If the centre part of the twin containers stay
positioned on the ground during lifting, the distance between spreader and container will
increase, which indicates a dangerous situation.
The hoisting of the crane must stop.
Stop hoisting can be controlled by the spreader.
The arrangement to direct stop lifting of the spreader is standard activated by breaking the
twistlock-lock and twistlock-unlock information to the crane.
After a break, the crane driver, to allow lowering the spreader to the start position must bridge
this protection. In general this is a standard option in the cabin.
Note: Also the roof-detection is always active during lifting open-top containers, flat-racks and
special working platforms.

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2.15.33 CRANE DRIVER: WARNINGS SPREADER ERROR MESSAGES

(CAN spreader control)
APPLICATION:
The information below is valid for a spreader that is controlled using 2 cables. This
control system usually functions with an CAN protocol.
Spreader information and error messages are displayed by means of a display in the cab.
Configuration:
The hardware and software for the spreader control is usually in the trolley.
There are exceptions, where for example the software is stored in the crane PLC.
Where the spreader controls are very simple, it is possible that both the hardware and the
software are integrated in the crane PLC.
Now all conceivable information about the spreader is available in the trolley.
If in addition the spreader control has 1:1 access to the crane control, all conceivable/
measurable information and dangerous situations can be registered immediately and possibly
passed on to the crane operator.
Display error messages in the cab:
Spreader information and error messages are announced by means of a display in the cabin.
Often this is a touch-screen.
If the spreader PLC in the crab communicates 1:1 with the crane PLC, the standard crane
display may be used to show spreader information and error messages.
Because most of this information is not useful for the crane operator, only a limited selection of
the available information is presented to him.
Display error messages with lamps on spreader or headblock:
If the spreader or headblock is equipped with lamps, see: Chapter 2.17
MINIMUM DISPLAY INFORMATION:
* Twistlocks locked/unlocked
* Landing pins up (spreader has landed)
* Twin-20-detection active: Chapter 2.15.21
STANDARD DISPLAY INFORMATION:
* 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.
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.
* Oil temperature:
The oil temperature is too high:
The spreader continues functioning for another 15 minutes.
Notify maintenance.
* Oil temperature is too high:
The oil temperature is too high for over 15 minutes.
The spreader stops.
Notify maintenance.
* 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.
* 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.
* Spreader-stop commenced:
The spreader is not functioning because a "spreader-stop" has commenced.
EXTRA INFORMATION:
* Switches and valves:
Depending on the configuration, the status of all switches and valves can be shown.
* Special information:
Depending on the configuration of the spreader, many complex spreader errors can also be
shown.

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2.16 CRANE DRIVER: INSTRUCTIONS VATCII-ETW

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
these are pressed, they remain in the operated condition. The spreader stops functioning.
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 or on the head block.
For more information see: Chapter 2.17
SPREADER ON/OFF:
The header pump is switched on by means of a signal sent from the crane to the spreader.
At the spreader, this command results in a spreader action.
The spreader pump is switched off from the crane or by a malfunction of the spreader.
Action is only possible several seconds after the spreader has been switched on.
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 TWIST LOCKS (ISO OPERATION):
The spreader is locked and unlocked with the aid of two commands from the crane. These
commands are translated by the spreader into a spreader action. The condition of the spreader
'locked' or 'unlocked' is transmitted to the crane by means of two signals.
Conditions for locking or unlocking:
* Crane is in spreader operation
* Spreader is placed on 1 (one) container (indicated in the crane)
* No twin 20ft indication
* Sliding bars in fixed position (20, 30, 40, 45ft.)
* Hoist mechanism stationary
Malfunction indication (depending on the programme):
When the crane is in spreader operation and no twistlocks have been defined within a number
of seconds (5), a 'twistlock position malfunction' indication will be displayed. Hoisting will not be
possible.
Twin 20 protection:
A very dangerous situation is lifting two 20ft containers in the 40ft position in single operation.
To prevent such dangerous lift, a spreader can be equipped with a twin 20 protection
(equivalent of twinlift interlock device).
There are several types of twin 20 protection systems, see: Chapter 2.15.21
A twin 20 protection (no 1) is standard for twin spreaders, optional for single spreaders.
A twin 20 protection (no 2) prevent locking the twistlocks.
An additional twin 20 protection (no 2) is preventing hoisting.
The crane driver can overrule this protection in the cabin with a special switch or a combination
of spreader commands.
This bridging switch short-circuit the twin 20 detector, not the twistlock protection.
Conditions for hoisting at low speed:
* Spreader is locked or unlocked
* Spreader plug is secure
* Hook operation is selected
* Bridging is pressed
For hoisting at high speed, the diagonal feeler pins must face downward.
* Spreader hangs in the twinlift in the cell within +/- 2-4° of the horizontal
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):
Telescoping can be achieved by selecting the desired position or by selecting in/out movement.
Prior to telescoping, the telescope bars must be unlocked.
When the spreader approaches the final position, the movement is slowed down until the
correct position is reached. Thereafter the locking pins drop into the slide beams and the
telescope bars are locked.

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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:
The command for "flippers up" or "flippers down" is given from the crane.
When "flippers up" is selected, all the flippers are driven upward for 10 seconds.
When "flippers down" is selected, the selected flippers are driven downward under high
pressure for a period of 3 minutes. After an overload during this time, the flippers are
immediately placed in the lowest position.
Advice: As far as possible, keep the flippers in the highest position.
Avoid keeping the flippers standing by in the lowest position.
If the flippers are in the lowest position for longer than 3 minutes, then the flipper down
command must be repeated in order to keep the flippers active under pressure.
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
* Head block pins secured
* Spreader is unlocked
* Spreader is not above water
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.
* When the loads on the ears are absolutely equal, SWL=50T in the 20-40ft position.
2.17 CRANE DRIVER: LAMP INFORMATION

For better performance of the crane, the lamp information on the spreader gives information to
the crane driver more quickly than lamp information in the crane. There are two options for
putting the lamps down near the spreader:
* On the spreader
* On the headblock
Both give same information.
The information provided by the lamps depends on the possibilities provided by the spreader
technology.
The most important information concerns the status of the twistlocks. If one or more lamps is
blinking, a lot of extra information can be provided.
Blinking information:
Blinking information indicates that something that there is a problem on the spreader. Inform the
maintenance department. The spreader can continue in operation and the crane driver can
finish the job.
Possible problems are:
* No grease in the automatic greasing system
* Too low grease level
* Dirty return oil filter
* Too high an oil temperature
Lightning information:
Lightning information indicates that is a serious problem on the spreader. The spreader will stop
working. Contact the "trouble shooting department"
Possible problems are:
* Electric motor overloaded
* Oil level too low
* For LONG-TWIN-operation: spreader in a cell is too far out of the horizontal position.
* Twin-lift protection has functioned.
* Twin lifts down (important information).
LAMP INFORMATION on HEADBLOCK or SPREADER:
Definition of lamps and their position:
From the position of the crane driver, lamps are numbered from left to right.
Lamp numbered from 1 to 8.

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LAMP COLOUR LOCATION CONTINEOUS BLINKING

L02-1 green left twistlocks unlocked (open) spreader error
L03-1 white left twistlocks all in castings. TTDS report
L01-1 red left twistlocks locked (closed) spreader error
L04-1 yellow left twin down spreader error (fast blinking)
tower not in center (slow blnking)
L02-2 green left twistlocks unlocked (open)
L03-2 white left twistlocks all in castings.
L01-2 red left twistlocks locked (closed)
L04-2 yellow left twin down
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
For mobile harbour spreaders (with levelling control):
Be aware of the shift motion.
For a twinlift spreader:
- The twin construction and the up-down housings of the twin-twistlocks move very close to
each other, with a lot of holes for maintenance.
- During maintenance activities inside the housings, the electric motor must be stopped. If the
twin-twistlocks are in up-position, the housings will probably sink down very slowly.
* 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.
* The protective caps above the hydraulic manifold and the electrical E-box rotate to the side for
maintenance purposes. Note that these caps can close inadvertently in a high wind or if the
spreader is not hanging horizontally.
2.20 STARTUP PROCEDURES

* Check the spreader for visible damage.
* Connect the spreader to the crane.
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.
* For a twinlift spreader, housings of the twin-twistlocks will rise.
* 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.
* 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)
For the hydraulic schedule, see: Chapter 13
Location, see: post 16
Pressure valve, see: VATCII 5-177
Oil pressure is now 180 bar, see: VATCII 5-901

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* 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.
For the twin spreader:
- Twistlocks lock and unlock (final position must be unlocked)
- Twin housings up-down
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.
- Check: twin twin-protection.
Procedure;
- twin twistlocks in up position (retracted)
- activate the landing- pins in the head-beams with a M12 nut
- lift the spreader more than 1 meter from the ground
- activate locking of the twistlocks in the cabin.
- locking of the twistlocks is now not possible
- to lock the twistlocks is only possible by bridging a special key in the cabin.
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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2.41 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 CAN modules 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 SPREADER:
A spreader-cage can be bolted on top of the spreader.
This cage can be used for storing fittings or ropes or other material, but can also be used as a
passenger cage.
If the cage is to be used as a passenger cage, local authorities must give their approval, both
for the cage as well as the crane, the spreader head-block connection, the safety devices and
the conditions tin which the cage will be used as a passenger cage.
Safety features of the spreader cage:
* Height to the handrail: 1 meter
* Anti-slip grid floor
* Foot protecting borders (100 mm high)
* Horizontal knee-level rail.
* No separate entrance (improves crash absorbing energy in emergency situations)
* Outside surroundings of the cage are within the top surface of the mainframe.
* Rings inside for safety lines.
* Spreader cage to spreader connection with 4 bolts M16 8.8 with lock nuts.
* Option: Emergency switch

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3 OPERATION
3.10 DRAWINGS: REFERENCES

Stinis uses 3 types of drawings:
* Manual instruction drawings
* Arrangement drawings
* Production drawings
To clarify the subject discussed, we refer to those drawings, mentioning a specific Manual
drawing: VATCII X-XXX
For more information on how to use these drawings, refer to: Chapter 17
For lists of those drawings refer to: Chapter 17
For parts lists of the manual drawings refer to: Chapter 17
For the manual drawings refer to: Chapter 17
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.
For the connection to the crane-hook (VATCII-E), see: Chapter 3.20.25
For the twin construction (VATCII-GTW), see: Chapter 3.20.90
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 guirder 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 lower support is produced from heat-treated alloyed steel. VATCII 1-500 03
This plate is coated with synthetic material. VATCII 1-500 08
The quality is depending of the spreader application.
The side contact blocks are produced from CuAlNiFe.
For the upper blocks, see: VATCII 1-500 04
For the lower blocks, see: VATCII 1-500 04
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.
3.20.25 SHIFT FRAME refer to:

Construction: VATCII 6-222
The shift frame with rams-horn hook connection is a stiff torsion construction, mounted around
the mid-frame.
At the top 2 pins connect the shift frame to the hook.
Operation:
The shift-frame facilitates the horizontal handling of unequally loaded containers during rotating
of an unevenly loaded container. The shift frame is always in the mid-position, during normal
operation.
Positioning to this central position can be done automatically.
None horizontal operation of the container is not advised.
Shift cylinder:
The shift frame slides along the mid-frame; the stroke is +/- 975mm, activated through the shift VATCII 5-417
actuator.
The shift-actuator is located in the middle of the midframe. The actuator is fully balanced.
The shift-actuator is hydraulically protected against overload.
Guiding plates:
There is practically no clearance in respect of the midframe.
All side contact areas exposed to friction and high strains are produced from heat treated
copper alloys and can be quick and easily replaced.
All bottom contact areas exposed to friction and high strains are produced from heat-treated
copper alloys or special synthetic materials and can be quickly and easily replaced.
These underside guide plates are greased automatically.
To control the vertical forces during shifting when the spreader is placed on top of the container,
the shift beam is supported on the mid-frame with 4 to guide plates.
In situations involving collisions or mismanagement of the spreader, the distance in the centre of
the underside is reduced by a synthetic plate.

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3.20.30 TELESCOPIC BEAMS

Construction:
For the bottom and sides, the sliding beams have undergone a complete mechanical
machining operation, so there is practically no clearance in respect of the mid-frame. VATCII 1-500
At the top of all various telescopic positions special heat-treated alloy pressure plates reduce
the total vertical tolerance till 3mm. VATCII 2-000
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. VATCII 1-500 01
VATCII 1-500 05
All bottom contact areas exposed to friction and high strains are produced from either synthetic
material or (on request) heat-treated copper alloys) and can be replaced in a quick and easy
manner. VATCII 1-500 06
VATCII 1-500 07
VATCII 1-500 08
The telescoping system is absolutely maintenance free.
Driving system:
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. VATCII 1-402
VATCII 1-400 06
Because of the springs, the driving system is absolutely maintenance free.
The two wheels are both connected to a hydraulic drive. VATCII 1-205
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.
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. VATCII 1-334
VATCII 4-403
The blocking device is a spring returned vertical steel plate, which can be activated by a
blocking actuator (cylinder). VATCII 1-334 5
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, VATCII 1-334 22
Construction:
The blocking device is total produced from heat-treated alloyed steel, all parts are fully
mechanical machined and cold galvanised.
The guide paths of the blocking plate are made from CuAlNiFe. VATCII 1-334 7
The blocking device is connected to the front-plate with 6 M16 12,9. bolds. VATCII 1-334 30 33 39
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.
Cable track/Power supply:
Power supply for the two end-beams is provided by two hydraulic hoses and one electric cable
laid in a cable-track which rolls during telescoping. VATCII 2-100 4
The cable track is only bolted to the end beam. VATCII 2-100 11 18 20
For the sliding beam without position indications, the cable track is placed in a support, bolted
against the side of the telescopic beam. VATCII 2-100 3
The same support is used for the sliding beam with indicators, but this support is also used as
an indicator plate.
The supports are coated with nylon, to avoid corrosion. VATCII 2-100 15 16
Terminal box:
A terminal box, located on silent blocks on the inside, is fully protected but easily accessible. VATCII 4-704
Hydraulic manifold:
If the spreader has two actuated flippers, a three-part valve block and a small electrical box,
both mounted on silent blocks, are provided to control the twistlocks and the flippers. VATCII 5-844
VATCII 5-845
Type of end-beam:
End beam VATCII-ETW with 2 actuated side-flippers: VATCII 3-055
End beam terminal box, see: VATCII 4-704
Drive twistlocks with indicators, see: VATCII 3-106
Indicators twistlocks with indicators on actuator, see: VATCII 4-409
Twistlocks drive rod, short model, see: VATCII 3-110
Twistlock cylinder, see: VATCII 5-440
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
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.
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.

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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: VATCII 3-106
The twistlocks, mounted at the end of head-beams, are actuated by a cylinder with double
piston, special designed for twistlock operation. VATCII 5-440
Actuating twin twistlocks: VATCII 9-002
The twin-twistlocks are each direct activated by their own hydraulic actuator (cylinder). VATCII 5-451
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 head-beam with mechanical locking, with twistlock lock-unlock indication in the
centre of head-beam:
Twistlocks in the head-beam with mechanical locking, with twistlock lock-unlock indication in the
centre of head-beam:
2 Twistlocks right TWI-W-ISO-VC-R71-R with bushes and under-washers, consisting of:
1 twistlock bolt: VATCII 3-847 1
1 nut with locking right: VATCII 3-847 2
2 half washers: VATCII 3-847 4
1 twistlock guide bush: VATCII 3-847 3
1 concave washer: VATCII 3-847 7
1 spherical washer: VATCII 3-847 8
2 Twistlocks left TWI-W-ISO-VC-R71-L with bushes and under-washers, consisting of:
1 twistlock guide bush: VATCII 3-859 3
Twin twistlocks on midframe with mechanical locking:
2 Twin-twistlocks right TWI-W-ISO-VC-R71-R-TW-S with bushes and under-washers, consisting of:
1 twistlock twin guide bush: VATCII 9-431 3
1 O-Ring: VATCII 9-431 15
2 Twin-twistlocks left TWI-W-ISO-VC-R71-L-TW-S with bushes and under-washers, consisting of:
1 nut with locking left: VATCII 9-432 2
1 twistlock twin guide bush: VATCII 9-432 3
1 O-Ring: VATCII 9-432 15

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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, specially 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 post 09
1 locking pin post 10
1 stainless steel spring post 11
1 landing-pin post 12
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.
The lock/unlock position is indicated for all twistlocks. As a standard, this is positioned in the
centre of the 40 head-beam near the twistlock actuator, making it easy to control and easy to
adjust. VATCII 4-409
The twin-twistlocks are all direct indicated on the nut. VATCII 9-410
3.20.70 FLIPPERS and ACTUATORS

For accurate positioning of the spreader on the container, each headbeam 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:
Construction of the actuator:
The actuator is a toothed rack with an integrated actuator, which realises high torques till
4000Nm and withstand torques up to 7200Nm. VATCII 3-620
VATCII 3-625
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. VATCII 3-625 07
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 headbeam with
seven M16 bolts, in three positions:
* In a position for corner flippers.
* In a position for flat flippers for the headbeam side.
* In a position for flat flippers for the long side.
All the holes for those two positions are standard drilled on the headbeam.
Securing Actuator
If the spreader will be operation without a flipper mounted on the actuator it is obligatory to
mount on the actuator the special designed lock plate. VATCII 10-600 01
It will prevent components of the actuator trembling loose and fall down.
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.
The actuators can be controlled with the aid of a two-position valve (4/2) or with a three-position
valve (4/3), depending on the construction of the spreader.

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Flipper control using a three-position valve (4/3), with integrated functions:

If speed regulation and protection are built into one single Cetop-3 manifold, then:
For a 3-section valve block for 2 flippers using 4/3 flipper valves, see: VATCII 5-844
Welding actuator to headbeam:
In addition to the bolted connection to the headbeam, it is advisable to weld the actuator to the
headbeam on 2 locations. Those two small welds are only to prevent the actuator shifting on the
headbeam. The seven M16 bolts are strong enough to secure the actuator to the headbeam.
Location of the weld:
To dismount the actuator, the location of the welds must be accessible to remove the welds
easy.
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:
Extension flippers:
* 2 activated side flippers, with cell guide rolls, diameter 170mm, model E, see: VATCII 3-055
* Activated side flippers with cell guide rolls diameter 170mm, details, see: VATCII 3-540
The activated flippers are designed for a torque of 10000Nm.
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). VATCII 3-625 10
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 VATCII 3-625 09
the flipper in an emergency situation. VATCII 3-625 06
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. VATCII 3-625 09
3.20.90 TWINLIFT CONSTRUCTION

DEFINITIONS:
Single-operation: Spreader operation without twin operation.
Twin-operation: Spreader operation with two 20ft containers.
Twin-single-operation: Spreader in Twin operation, handling only one 20ft container.
Twin foundation: Fixed part, welded against the midframe, for guiding the twin
twistlock housings.
Twin-twistlock-housing: Up/down construction in which the twin twistlock is located. VATCII 9-002 01
Twin-up/down-cylinder: Cylinder controlling the up/down motion of the twin twistlock
housing. VATCII 9-002 18/19
Crash-load: Unexpected excessively high horizontal or vertical load on the
twin twistlock housings.
TWIN FOUNDATION
The twin foundations are two identical self-supporting constructions, welded at each side at the
centre of the mid-frame, to guide the twin twistlock housings. Most parts are manufactured of
alloyed steel.
The twin foundation protects the twin twistlock housings in upward position against collisions as
a result of swinging and uncontrolled spreader motions during Single operation.
The free space between the outside of the twin foundation and the container is 48mm.
TWIN TWISTLOCK HOUSING VATCII 9-002 01
Guided and supported by the twin foundation, the twin twistlock housing can be move in nearly
vertical direction from over a distance of 340mm.
The twin twistlock housing is a closed box construction, to protect all inside components.
The guide paths between the twin twistlock housing and the twin foundation are produced of
heat treated alloyed steel and are fully machined. All high loaded contacts of these paths are
supported by CuAlNiFe alloyed replaceable materials, to avoids fretting and improve lifetime. VATCII 9-002 09
VATCII 9-002 15
VATCII 9-002 28
The total construction can withstand high crash loads, without damage of twin twistlock
housings or twin foundations.
All moving parts are connected to the automatic greasing system.

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Lowest position:
In the lowest position, twin housing is supported (locked) by a hook construction.
Highest position:
In the highest position, the free space between the underside of the twin twistlock and the top of
the container is 130mm.
In this position, twin twistlock is fully protected by the twin foundation.
The free space between outside of the container and twin twistlock housing in upward position
is 53mm.
TWIN TWISTLOCK:
The complete twin twistlocks are situated inside the twin twistlock housing and are fully
protected. VATCII 5-451
For the twistlock operation, see: Chapter 3.20.60
TWIN UP/DOWN CYLINDERS
Four actuators control the up/down motion of the twin twistlock housings. VATCII 9-500
VATCII 9-505
Upward position:
In upwards position, the actuator maintains this position, because of the because of the stand-
by oil pressure of 25bar, as long as the spreader is in operation.
When the spreader is not in operation, the twin twistlocks housings can slowly move down as a
result of by oil-leakage past the cylinder seals. A spreader start-up resets the top position of the
twin twistlocks housings automatically.
Locking the upward position: VATCII 9-002 35/38
A manually actuated locking device can lock the upward position of the twin twistlocks housings.
This device can be used if twin operation is never used.
Up/down speeds:
The up/down speed of the actuator can be adjusted independently for each actuator to between
at 6 and 7 seconds for the full stroke of 340mm.
Up/down overload:
In both directions, every twin up/down cylinder is fully hydraulically protected against overload.
Down motion unloaded:
During the downward motion, the downward force of the actuator, including the weight of the
twin twistlock housing is 980kg.
This prevents both the 40ft container and twinlift construction during operation.
Up wards motion unloaded:
Unloaded, the twin up/down actuator is adjusted so that it just reaches the upward position of
the twin twistlock housing.
Upward motion under external load:
If the spreader approaches the container with a speed of maximum 2m/second and the twin
twistlocks don't enter into the castings. The forced upwards speed of the twin twistlocks
housings do not damage the construction.
The force required to start this motion is protected up to 1900kg. The twin twistlocks housings
and up/down cylinders not then are damaged.
After such action, the downward force of the twin twistlocks housing is again 980 kg.
ELECTRIC:
Total number of extra indicators for twin lift: 21
Total number of solenoids: 6
TWIN PROTECTION:
The spreader detect the space between two 20ft containers.
With this information the spreader management control prevents the locking of the Single-
operation twistlocks, thus preventing two containers being lifted with only four twistlocks.
This protection can be overruled by the crane drive in the situation where special containers or
damage containers would activate the twin protection (preventing the twistlocks from locking).
TWIN OPERATING:
Depending on the application, two 20ft containers can be handled if these containers are
positioned against each other.
TOLERANCES TWIN OPERATION:
Nominal distance between hanging twins under the crane: 78 mm
Minimum distance between hanging twins under the crane: 58 mm
Minimum required distance between twins for interlocking: 0 mm
Maximum allowed vertical distance between twins on top for interlocking: 100 mm

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3.40.03 GENERAL ELECTRICAL INFORMATION (CAN control)

Communication between Spreader and Crane.
When the first generation of spreaders, the control program was run in the crane. This avoided
having to mount many vulnerable electrical components on the spreader.
The limitation associated with this construction was the lack of sufficient cores in the spreader
cable. The greater the number of functions, the greater the problem became.
The following step was to place the control program for the spreader on the spreader, so that
the number of cores required was drastically reduced. The result was the switched relay control
or a PLC-CAN mounted on the spreader.
The disadvantage of this solution is the vulnerability of the components on the spreader.
The latest generation of spreaders provided with modules to which all inputs and outputs are
connected and which via a few cores (which may or may not be twisted of shielded) transfer the
I/O information to and from the crane.
The control program is again run in the crane.
This program can communicate via a bus connection with the PLC-CAN in the crane, for,
among other things, performing fault analysis.
It is also possible to display information such as status and fault details from the spreader in the
crane cabin.
When the spreader modules are very reliable and connection to the crane is not susceptible to
interference, this control method offers good performance and a wide range of possibilities. So
knowledge of the two-wire control and PLC-CAN programs is required.
For further information concerning the bus system, see: Chapter 3.40.50
Manual simulation of the spreader:
Manual simulation of the spreader is less simple.
Functions can be activated by directly controlling the valves.
Controlling the correct functioning of the modules is simple and visual information showing the
status on the inputs and outputs is available.
Real manual simulation is only possible when this is programmed into the PLC-CAN in the
crane, with a control (push buttons) on the spreader.
In addition, diagnostic equipment is possible, but requires extra investment and more
knowledge.
CAN components:
For the CAN components, refer to the parts lists.
References:
Electrical drawings see: Chapter 12
Electrical parts lists, see: Chapter 12
Electrical components see: Chapter 3.40.10
Functional description see: Chapter 3.41
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 midframe. Alternatively, the top of the terminal box on each headbeam 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:
The Long-Twin spreader and a 6-flipper spreader have 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: VATCII 5-910
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: VATCII 5-904
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 low level switch:
If mounted, this switch stops the automatic greasing if the grease level is low.

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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.
Acoustic alarm:
Twin and Long-Twin spreaders are equipped with a 105dB acoustic alarm to warn persons in
the vicinity of the impending shift motion.
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.
Recognizing solenoids:
There are 2 type of solenoids:
* The blue solenoid, 21W, see: VATCII 5-901 03
This solenoid is used for greasing, oil pressure, free floating commands and telescoping slow. VATCII 5-903 03
* The black solenoid, 28W, see: VATCII 5-611 50
* The metal solenoid, 28W, as replacement of the above, because the black solenoid for
110VDC is sometimes not available,
This black/metal solenoid is used for all other functions.
Advice: Always grease the screw of the connector cap.
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 headbeams.
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.
3.40.20 IDENTIFICATION ELECTRICAL COMPONENTS

See: Chapter 12, drawing 2611-XXXX-0450
Symbols:
-F=Front/Water side
-B=Rear/Water side
-L=Left side
-R=Right side
spr=spreader
tel=telescoping
twi=twislock
twin=twinlift
headbl=headblock
red=reduced
cyl=actuator

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Id. Inputs-indicators Artikel nummer Type

B00 tel 20ft-L 7110-0030-0120 IIKC022-ASKG/US
B03 tel 40ft-L 7110-0030-0120 IIKC022-ASKG/US
B08 tel slow-L 7110-0030-0110 IIKC012BASKG/US
B10 twi lock-R-(F) 7110-0030-0120 IIKC022-ASKG/US
B11 twi lock-L-(F) 7110-0030-0120 IIKC022-ASKG/US
B12 twi unlock-R-(F) 7110-0030-0120 IIKC022-ASKG/US
B13 twi unlock-L-(F) 7110-0030-0120 IIKC022-ASKG/US
B15 spr landed-L-B 7110-0030-0120 IIKC022-ASKG/US
B16 spr landed-R-F 7110-0030-0120 IIKC022-ASKG/US
B17 spr landed-L-F 7110-0030-0120 IIKC022-ASKG/US
B18 spr landed-R-B 7110-0030-0120 IIKC022-ASKG/US
B19 spr shift-house-L(cyl out) 7110-0030-0120 IIKC022-ASKG/US
B20 spr shift-house-R(cyl in) 7110-0030-0120 IIKC022-ASKG/US
B23 block cyl unlock-L 7110-0030-0120 IIKC022-ASKG/US
B25 block cyl unlock-R 7110-0030-0120 IIKC022-ASKG/US
B74-1 twin twi lock-L-B 7110-0030-0120 IIKC022-ASKG/US
B74-2 twin twi lock-L-F 7110-0030-0120 IIKC022-ASKG/US
B74-3 twin twi lock-R-F 7110-0030-0120 IIKC022-ASKG/US
B74-4 twin twi lock-R-B 7110-0030-0120 IIKC022-ASKG/US
B75-1 twin twi unlock-L-B 7110-0030-0120 IIKC022-ASKG/US
B75-2 twin twi unlock-L-F 7110-0030-0120 IIKC022-ASKG/US
B75-3 twin twi unlock-R-F 7110-0030-0120 IIKC022-ASKG/US
B75-4 twin twi unlock-R-B 7110-0030-0120 IIKC022-ASKG/US
B76-1 twin spr landed-L-B 7110-0030-0110 IIKC012BASKG/US
B76-2 twin spr landed-L-F 7110-0030-0110 IIKC012BASKG/US
B76-3 twin spr landed-R-F 7110-0030-0110 IIKC012BASKG/US
B76-4 twin spr landed-R-B 7110-0030-0110 IIKC012BASKG/US
B77-1 twin up-L-B 7110-0030-0120 IIKC022-ASKG/US
B77-2 twin up-L-F 7110-0030-0120 IIKC022-ASKG/US
B77-3 twin up-R-F 7110-0030-0120 IIKC022-ASKG/US
B77-4 twin up-R-B 7110-0030-0120 IIKC022-ASKG/US
B83-1 twin down-L-B 7110-0030-0120 IIKC022-ASKG/US
B83-2 twin down-L-F 7110-0030-0120 IIKC022-ASKG/US
B83-3 twin down-R-F 7110-0030-0120 IIKC022-ASKG/US
B83-4 twin down-R-B 7110-0030-0120 IIKC022-ASKG/US
B87-1 twin 2x20 safetydevice 1 7111-0300-0040 Distance Optic Sensor O5H500
B87-2 twin 2x20 safetydevice 2 7111-0300-0040 Distance Optic Sensor O5H500
B98 grease: low level 7110-0018-0130 M18x1 IGK3008BBPKG/M/US
B103-1 twin 2x20 safetydevice: approach roof 1 7111-0018-0030 UB500-18GM75-E6-V15p&f
B103-2 twin 2x20 safetydevice: approach roof 1 7111-0018-0030 UB500-18GM75-E6-V15p&f
Id: Switches:
S03 oillevel switch-min
S02 oil temp switch
S01 return oil pressure switch
S05 grease pressure
S05-1 pressure switch 9 bar
S50 pressure switch 9 bar
Id: Inclinometer:
P01 longitudinal & transversal
Id: Solenoids:
Y01 twi lock-(L)
Y02 twi unlock-(L)
Y03 twi lock-R
Y03-2 twi twin lock L
Y04 twi unlock-R
Y04-2 twi twin unlock (L)
Y05 tel in-(L)
Y06 tel out-(L)
Y06-1 tel slow-(L)
Y07 tel block unlock-L
Y09 oilpres max
Y11 fli down-R-B
Y12 fli up-R-B
Y13 fli down-L-B
Y14 fli up-L-B
Y15 fli down-R-F
Y16 fli up-R-F
Y17 fli down-L-F
Y18 fli up-L-F
Y44 greasing
Y50 shift-L-F
Y51 shift-R-F
Y62 twin up-(L)
Y63 twin down-(L)

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Id: Lamps:
L01-2 twi lock ISO-L(2)
L01-3 twi lock ISO-R(2)
L02-2 twi unlock ISO-L(2)
L02-3 twi unlock ISO-R(2)
L03-2 spr landed ISO-R(2)
L03-3 spr landed ISO-L(2)
L05-1 twin down
L05-2 twin down
3.41.50 FUNCTIONAL DESCRIPTION OF THE TWIN PROGRAM

The following are the guidelines for the control of a quayside crane spreader.
For the particular application, reference should be made to the electrical diagram for the necessary relay
controls.
For the application of a two-core control from the PLC in the crane or from a PLC on the spreader, refer to the
PLC program.
A number of desired features could not be included because the provisions are not present.
A number of desired features can only be included by the management of the crane.
The minimum requirements for the purposes of operating the twistlocks and the associated landing pin
information are always implemented.
MOTOR ON:
Conditions: Thermal motor protection on (automatic reset position precluded).
Oil-level switch closed.
Oil-temperature switch open.
Emergency switches off.
E-box key contact closed (option)
Program: Start spreader in cabin to feedback of motor on.
After starting the motor, prior to an "alarm signal, for Tx seconds the Long-
Twin units are retracted under low pressure to the minimum position.
Error message: Thermal motor protection off.
Oil-level switch open.
Oil-temperature switch closed for longer than 15 minutes.
Emergency switches on.
E-box contact open (option)
Long-Twin minimum position not reached.
HYDRAULIC OIL PRESSURE:
Conditions: Functional control.
Program: Maximum oil pressure.
Error message: Oil-pressure switch on the return filter open.
Oil-temperature switch closed for longer than 15 minutes.
CHANGE OVER from SINGLE-OPERATION to TWIN-OPERATION:
Twin twistlock housings down:
Conditions: Spreader in 40ft position.
Twistlocks unlocked.
Landing-pins down.
Single-working position.
No CPU bus error.
No spreader error message.
(Hoist = zero rpm).
Program: Twin-twistlock-housings-left-down and twin-twistlock-housings-right-down, until a signal
representing switches in series (all twin housings down), followed by a delay period of 5
seconds.
Error message: Time protection for twin twistlock housings down.
CHANGE OVER from TWIN-OPERATION to SINGLE-OPERATION:
Twin twistlock housings up:
Conditions: All twistlocks unlocked.
All landing-pins down.
No CPU bus error.
No spreader error message.
(Hoist = zero rpm).
Program: Energise the twinlift-twistlock-housings-left and twinlift-twistlock-housings-right, so that the
twin-twistlock-housings are raised, until the signal indicating that the twin-twistlock-housings
are up (a set of switches in series for all twinlift-twistlock-housings-up) is received.
Error message: Time protection for twin-twistlock-housings-up.

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TELESCOPING: WITH ONLY CABIN FUNCTIONS RETRACT AND EXTAND:

Telescoping: Retract from 40 to 20ft:
Program: Unlock telescopic beams until the feedback signals telescope beam-lock
unlocked left and right side are received after 2 sec.
Telescope-retract until the feedback signal from telescoping slow is received, followed by
telescope-retract-slow until the feedback signal telescope 20 ft is received.
Lock the telescope beams until the feedback signals telescope beam-lock locked left and right
side are received.
Error message: Telescoping time out.
Telescoping: Extend from 20 to 40ft:
Program: Unlock telescopic beams until the feedback signals telescopic beam lock
unlocked left and right side are received after 2 sec.
Telescope-extend until the feedback signal from telescoping slow is received, followed by
telescope-extend-slow until the feedback signal telescoping 40 ft is received.
Lock the telescope beams until the feedback signals telescope beam-lock
locked left and right side are received.
TELESCOPING: TO A SPECIFIC POSTION:
Telescoping: Retract to 20ft:
Program: Unlock telescopic beams until the feedback signals telescopic beam lock unlocked left and
right side are received for 1 sec.
Telescope-retract until the feedback signal from telescoping slow is received, followed by
telescope-retract-slow until the feedback signal telescope 20 ft is received.
side are received (no hardware information).
Telescoping: Extend to 40ft:
Program: Unlock telescopic beams until the feedback signals telescopic beam-lock unlocked left and
right side are received for 1 sec.
Telescope-extend until the feedback signal from telescoping slow is received, followed by
telescope-extend-slow until the feedback signal telescoping 40ft is received.
side are received (no hardware information).
TWISTLOCKS SINGLE-OPERATION:
Conditions: Telescope beams in either 20, 30, 40 or 45ft position
Landing-pins up for at least 0.6 second (preferably 1 second)
Twistlocks: Locking in single-operation:
Program 1: Lock twistlocks-single-operation for a minimum of 2 seconds until the end position is reached.
Optional, lock twistlocks-single-operation till landing-pins are down.
Program 2: Lock twistlocks-single-operation until the end position is reached, maintaining pressure for 0.5
second.
Error message: Twistlock locking time out without feedback signal from the end position for longer than 1
second. Twistlock(s) end position not reached: Stop hoist.
Error message: Disappearance of landing pin switch signal within 0.5 second after the locked signal is
received: The twistlock is probably locked outside the casting: Stop hoist.
Twistlocks: Unlocking in single-operation:
Program 1: Unlock twistlocks-single-operation for a minimum of 2 seconds until the end position signals
are received.
Optional, lock twistlocks-single-operation till landing-pins are down.
Program 2: Unlock twistlocks-single-operation until the end positions are reached, maintaining pressure
for 0.5 second.
Error message: Twistlocks lock time out without a feedback signal from the end position being received for
longer than 1 second: Twistlock(s) end position not reached: Stop hoist.
TWISTLOCKS TWIN-OPERATION:
Conditions: Spreader standby in Twin-operation
Landing-pins up for a minimum of 0.8 second (preferably 1 second)
Error message: Twin twistlock housings not all down.
Twistlocks: Lock:
Program 1: Lock twistlocks-twin-operation for a minimum of 2 seconds until the end position signals are
received.
Optional, lock twistlocks-twin-operation till landing-pins are down.
Program 2: Lock twistlocks-twin-operation until the end position signals are received, maintaining
pressure for 0.5 second.
Error message: Twistlocks locking time out without a feedback signal from the end position being received for
Error message: Disappearance of landing-pin switch signal within 0.5 second after the locked signal is
received: The twistlock is probably locked outside the casting: Stop hoist.
Twistlocks: Unlock:
Program 1: Unlock twistlocks-twin-operation for a minimum of 2 seconds until the end position signals are
received.
Optional, lock twistlocks-twin-operation till landing-pins are down.
Program 2: Unlock twistlocks-twin-operation until the end positions are reached, maintaining pressure for
0.5 second.
Error message: Twistlocks lock time out without a feedback signal from the end position being received for

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TILT CORRECTION:
Conditions: In cell
Twistlocks locked and tilt greater than +/-2°.
HOISTING - LOWERING:
Conditions: Generally for release for hoisting or lowering at high speed and hoisting at low speed:
Head block pins inserted.
Dummy plug inserted (if present).
Hook operation is selected.
Bridging pushbutton is pressed.
Release for low-speed hoisting outside a cell:
Condition: Spreader locked or unlocked.
Release for low-speed hoisting in a cell:
Condition: In (Long) Twin-operation, twistlocks locked and tilt less than +/-4°.
Release for high-speed hoisting outside a cell:
Condition: From release, release hoisting at low speed outside cell.
Condition: Landing pins down.
Release for high-speed hoisting in a cell:
Condition: From release, release hoisting at low speed outside cell, in (Long) Twin-operation with time
delay.
Condition: Landing pins down.
Condition: In (Long) Twin-operation: tilt less than +/-2°.
Hoisting - stop in cell:
Condition: No twistlock position indication present.
Condition: (Long) Twin lift: tilt greater than +/-4°.
Release for lowering at low speed:
Condition: None.
Option: Spreader approach container.
Release for lowering at high speed:
Condition: From lowering at low speed.
Lowering stop:
Condition: Landing pins up.
FLIPPERS:
Conditions: Spreader is not placed on a container.
Spreader not telescoped.
Spreader is not locked or unlocked.
Spreader is unlocked
Spreader is not over a ship
Flipper down:
Program: Flipper up movement stopped, flipper down movement for 180 seconds.
Flipper up:
Program: Flipper down movement stopped, flipper up movement for 10 seconds.
Program: When 4/3 valves are used, it is advised:
If the previous movement was upward, exclusively without oil pressure a
flipper up movement of 1 second duration per period of 1 minute.
AUTOMATIC LUBRICATION:
Conditions: After 25 telescopic movements.
After 50 twistlock movements.
After 50 flipper movements.
In single working operation: starting from the 40ft position.
In Long-Twin-operation: after 10 Long-Twin movements.
Program: Lubricate for 20 seconds.
Error message: No lubricant pressure after 5 seconds: Fault in automatic lubrication.
Spreader continues to function.
Error message: Low lubricant level in reservoir: automatic lubrication system out of use.
Spreader continues to function.
SHIFT IN THE LONGITUDINAL DIRECTION:
Condition: Landing pins down
Program Manual: Shift left or shift right.
Automatic: Shift left or shift right to the central position.
Program Manual: Shift forward or shift rearward.
Automatic: Shift forward or shift rearward to the central position.
Program Floating free from the shift actuators.
Automatic: Shift in or shift out to the central position.

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3.43.10 CONNECTOR TO HEADBLOCK

Connector (spreader side)
Origin ODU
Description Straight plug, including male contacts, existing of:
Straight socket, neop snaplock 309.021.000.554.000
Pin-insert 309.803.156.037.151
3.43.20 COMMUNICATION AND PLUG CONNECTIONS

For the plug (connector), see: Chapter 3.43.10
Definitions:
Pin: Pin number of connector.
Direction: to spreader (from the crane to the spreader).
to crane (from the spreader to the crane).
to head-block (from the spreader to the head-block).
SPREADER (AND HEADBLOCK) WIRING
Pin Function Direction
01 Power supply L1 to spreader
03 Spreader in Twin-operation to crane
06 Control voltage L to spreader
05 Control voltage N to spreader
07 Spreader pilot contact
08 Telescope in (retract) to spreader
09 Telescope out (extend) to spreader
10 Flippers up to spreader
11 Flippers down green to spreader
12 Flippers down blue (L) to spreader
13 Flippers down blue (R) to spreader
14 Flippers down red to spreader
15 Twistlocks lock to spreader
16 Twistlocks unlock to spreader
17 Twistlocks locked to crane
18 Twistlocks unlocked to crane
19 Tower to blue side to spreader
20 Tower to yellow side to spreader
21 Tower in center to crane
22 Spreader landed to crane
23 Spreader to Single-operation to spreader
24 Spreader to Twin-operation to spreader
30 2x20-ft protection to crane
33 Earth to spreader
35 Spreader twin pilot contact
37 Earth to spreader
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 VATCII 5-101
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.

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MANIFOLD welded against powerpack:

For welded manifold for ETW, see: VATCII 5-177
The steel manifold of the power pack is a totally integrated special designed construction. All
valves have double outlets for A and B.
Standard valves are of the type Cetop-3 (NW-6) VATCII 5-611
The oil pressure valve is of the cartridge type, with manual a push-pull option. VATCII 5-901
The automatic greasing valve is of the cartridge type with manual turn option. VATCII 5-903
Functions on the manifold:
* Control high oil pressure (max oil pressure)
* Control automatic greasing
* Control telescoping high and low speed
* Blind plate (for extra function)
* Control shift tower (VATCII-E)
* Control unlocks of telescoping beam lock.
* Control twin-twistlocks up/down
* 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. VATCII 5-904
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: VATCII 5-910
A level switch with a reed contact controls the oil level.
Type: There are two different types of oil level switch.
Old type, VATCII 5-905, with is replaced by VATCII 5-910
Both are identical, adjustment is different.
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 without BRAKE:
For manual drawing, see: Nominal oil pressure 120bar VATCII 1-205
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:
The working pressure of the telescoping beam lock cylinders is 100 bar, maximum pressure VATCII 1-334
180bar.
The cylinders are single working; the return stroke is realised by two heavy springs inside the
blocking plate.
FLIPPER ACTUATORS: VATCII 3-620
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.
TWISTLOCKS-ACTUATORS: VATCII 5-440
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.

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TWIN-TWISTLOCK-ACTUATOR: VATCII 5-451

The oil pressure for the twistlock actuators is 90 bar for the outside stroke and 180 bar for the
inside stroke.
Safety precautions for the twistlocks:
The speed of twistlock actuators is reduced between 0.5 and 1 second for a complete stroke.
The position of a twistlock actuator cannot be affected by oil leakage past the twist lock valves.
TWIN UP/DOWN ACTUATORS:
The oil pressure for the twin up/down cylinders is 55 bar.
For twinlift up-down actuator left see: VATCII 9-500
For twinlift up-down actuator right, see: VATCII 9-505
Safety precautions for the twin up/down actuators:
An overload speed 2m/second is permitted for the twin up/down actuators.
The nominal speed is set to approximately 30 mm/second.
The downward force down is limited to 1000 kg
In the down position, the resistive force: 2000 kg
Leakage of the oil in the actuators cannot be prevented.
Actuators may move downward when the spreader is not in operation, but will move upward
immediately the spreader is started up.
SHIFT-ACTUATOR:
The oil-pressure for the shift-actuators is 100 bar for the outside stoke and 180 bar for the inside
stroke.
Safety precautions for the shift actuator:
The action of the actuator is protected against under pressure.
GREASING VALVE: VATCII 5-903
For grease booster, see Chapter 3.60
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.
HYDRAULIC PRESSURE SETTINGS (bar):
setting maximum
Oil pressure maximum: 180 225
Oil pressure standby: 25 35
Telescoping motor: 180 210
Twistlock actuators locking: 120 210
Twistlock actuators unlocking: 180 210
Telescoping beam lock actuators: 180 210
Long shift actuators (E): 180 210
Grease booster type 1:1: 80 80
Flippers actuators up-motion: 280 350
Flippers actuators down-motion: 210 350
Twin twistlock actuators out: 90 210
Twin twistlock actuators in: 180 210
Twin up/down actuators: 55 210
3.61 AUTOMATIC GREASING

For the grease pump 1:1, tank 4 litre stainless steel, see: VATCII 5-704
For the hydraulic valve for greasing, see: VATCII 5-903
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: VATCII 5-704
The 80 bar oil-operated grease pump with a transparent grease reservoir have an output per
stroke suitable for the whole spreader.

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Grease pulse generators:

The automatic greasing system is activated by the PLC-CAN, 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-CAN.
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
* Number of up/down motions of the twin twistlock housings
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.
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: VATCII 5-725
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 (16-36 mm2/s) for environmental temperatures between -28
and +25°C:
* Shell tellus T22
* BP Energol HLP-HM 22
* Valvoline HVLP 22
and +30°C:
* Shell tellus T32
* BP Energol SHF Super 32
* Valvoline HVLP 32
and +50°C:
* Shell Tellus T46
* Valvoline HVLP 46
GREASE QUALITY:
For the automatic greasing system:
For environmental temperatures between -30 and +25°C: NLGI-00-lithium
For very low temperatures:
For environmental temperatures between -45 and +120°C: FINA MARSON ZS
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, see: VATCII 7-100
* for the twistlocks, see: VATCII 7-201
* for the flippers, see: VATCII 7-300

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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.
Important greasing points:
* For telescoping, see: VATCII 7-100
* For twistlocks, see: VATCII 7-201
* For flippers (if on spreader), see: VATCII 7-300
* For bearings shift cylinders
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 refer to:
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.
Midframe, Check outside for correct grease dosage:
* Actuator bearings (grease nipple).
* Bushes in head-block connection.
* Shaft for head-block- / crane hook connection.
* Twinlift up/down contact areas.
* Mobile Crane spreader: under contact areas with tower.
Greasing of:
* Mobile Crane spreader: side contact areas of tower.
* Long-Twin spreader: side contact areas with long shift construction.
Twistlocks Twinlift housings up/down: Check on correct grease dosage:
* Contact areas with mid-frame.
* Twistlock bushes (IMPORTANT!)
Greasing of:
* Twistlocks upper and lower washers (IMPORTANT!)
* Tracer pins.
Telescoping beams: Check on correct grease dosage: VATCII 7-100
* Underside contact areas with mid-frame.
Greasing of:
* Side contact areas with mid-frame
* Pressure points with mid-frame at the topside.

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Headbeams: Check on correct grease dosage: VATCII 7-201

* Twistlock bushes (IMPORTANT!)
* Flippers.
* Cell guide rollers.
Greasing of:
* Twistlock, upper and lower washers (IMPORTANT!)
* Tracer pins.
EVERY 4000 HOURS: at least every 80.000 moves refer to:

at least once per year
Twistlocks Twinlift housings up/down: Greasing of:

* Thread and nut of the bold connection to the mid-frame.
Telescoping beams, Greasing of:
* Tensioners for the telescoping belts
Only the tensioner at the location of the hole ø21mm VATCII 1-400 12
4.50 PREVENTIVE PERIODICAL MAINTENANCE INSTRUCTIONS refer to:
* 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

at least every 4 months
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
Twin 20 protection (if mounted):
* Check the twin 20 protection to place the spreader in single operation on two 20ft containers Chapter 2.15.21
(action crane driver) Chapter 2.10 C
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.
Shift Mobile Crane Spreader:
* Check contact areas for grease (automatic greasing system)
* Check Ampco contact plates.
* Inspect tower for cracks.
Telescoping drives:
* Check bolts of telescoping motors (left- and right rotating) for fastening.
* Check bolts on the underside of the pulley. VATCII 1-205 16
Telescoping beams (exc. LONG-TWIN: Chapter 5.40.20
* Check bolts of locking plates inside. VATCII 2-501 02
* Check the presence of the Ampco top contact plates. VATCII 1-500 01 05
* Check the presence of the synthetic under contact plates. VATCII 1-500 08
* Check the presence of the Ampco top contact plates. VATCII 2-501 06
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.
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 the function of emergency stops.
* Check twistlock counters and running hours.
* Check electric wire fasteners.
* 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.

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EVERY 2000 HOURS: at least every 40.000 moves

at least every 6 months refer to:
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. VATCII 7-320/7-321
Mobile Crane Spreader, shift actuator:
* Check 8 bolts at the underside.
* Grease the actuator bearing.
* Check the greasing of top contact areas.
* Check the wear on the Ampco under contact plates.
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.

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. VATCII 7-320/7-321
Telescopic beams (exclusive Long-Twins): Chapter 5.40.20
* Ampco guide plates inside the telescoping beams at the upper side: VATCII 2-501 06
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. VATCII 2-501 07 13
After replacement, check that both plates contact the top of the midframe 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: VATCII 2-501 10 15
Is the vertical clearance in the 40ft position more than 5mm, adjustment with filling plates is
advised. VATCII 2-501 8 9 14
Is the horizontal clearance in the 40ft position more than 5mm, adjustment with filling plates is
advised. VATCII 2-501 11 12
* Ampco side contact blocks at the front plates of the mid-frame. VATCII 1-500 01 05
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. VATCII 1-500 08
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
EVERY 8000 HOURS: at least every 160.000 moves Refer to:

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.

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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.
4.60 MAINTENANCE INSTRUCTIONS for TWISTLOCKS model TWI-W

(Double-Split-Collar) for CRANE SPREADERS refer to:
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
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.

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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 he
snack cylinders).
Note: Carrier spreaders can not 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.

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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).
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-7-322/324 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 washers 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.
For Twin-Twistlocks:
The average free space between the bottom of the
Twin-Twistlock nut and the foundation plate under the
nut is nominal 7mm. VATCII 7-324 J1
Is this distance reduced to 5mm, than the swivel
washers should be replaced as soon as possible.
* 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 7-322/324 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 then 2 mm
both rings should be replaced. VATCII 7-322/324 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 then 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 then 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 7-322/324 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 7-322/324 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 7-322/324 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 ware 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 7-322/324 H1
Is the metal plate hollow then the bolts are tighten too firmly
Note-3: Grease top of the twistlock VATCII 7-322/324 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
then 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 then 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 7-322/324 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 7-322/324 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

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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:
* Midframe.
* 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, see: VATCII 1-500 03
* Vertical loaded top plates of the mid-frame.
* Front plates of the telescopic beams.
* Flippers see: VATCII 3-540
* Foundation flippers
* Outside corner twistlock beams
* Housings of the cell guide rolls
* Blocking pins: housings and pin, see: VATCII 1-334
* Telescopic stops
* Foundation of the belt clamp, see: VATCII 1-400 01
ASTM A 320 Grade L43 (better equivalent of 34CrNiMo6V):
* Twistlocks
34CrNiMo6V for:
* Twistlock bushes
* Pins for suspension to the head block, see: VATCII 3-847 01
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.

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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.
Twin up/down: twin lift housings sink
* If it is out of use, the large number of non-return valves and safety devices mean that sinking
of the housings becomes unavoidable.
Twin up/down: Lower speed both up and down.
* Both for the up and the down speeds the same adjustable throttle device is used as on every
other up/down actuator:
If this throttle is contaminated, then the speed of both the up and down movements will be
reduced at the same time.
* Always check the supply pressure to the twin lift up/down actuators (pressure reducer
underneath):
This must be 55 bar. NEVER increase this pressure. The oil temperature will be greatly
increased and the thermal cut-out for the electric motor will function more quickly.
Twin up/down: Lower speed in the upward direction (not the same as in the downward
direction).
* There is an internal leak:
- There is a leak past the piston ring
- Incomplete closure (dirt) in the piston rod protection of the twin lift up/down actuators.
* There is mechanical friction: look for damage to the housing in the vicinity of the up/down
guides.
Twin up/down: Lower speed in the downward direction (not the same as in the upward
direction)
* There is an internal leak:
- There is a leak past the piston ring
- Incomplete closure (dirt) in the bottom protection of the twin lift up/down actuators.
* There is mechanical friction: look for damage to the housing in the vicinity of the up/down
guides.

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5.20.10 FLIPPER ACTUATORS

For general description, see: Chapter 3.20.70
For assembly drawing, see: VATCII 3-620
For flipper shaft details, see: VATCII 3-625
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.
Referring to drawing VATCII 3-620, to rotate the ring, item 10, together with the six 6 bolts, item
11, and the half washers item 12, the vertical position of the flipper can be adjusted:
* Rotate clockwise: increases the lowest position of the flipper.
* Rotate counter-clockwise: decreases the lowest position of the flipper.
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, item 04, has broken down (see seals), see VATCII 3-630
If there is oil-leakage from the bottom of the actuator, only seal 06 or seal 07 are damaged.
Seals: To change the seals, without dismounting the actuator, which is only possible if
the hole under the actuator is bigger than 130 mm:
* Start with 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 M 8x25 12.9K bolts.
* Turn the nut, item 10, counter-clockwise with help of the six M6 bolts.
* When the nut, item 10 is nearly released, dismount the six M6 bolts.
* Pull the piston, item 03, downward.
* Take out the double half-washers, item 12.
* Remove the nut, item 10.
* Push the piston, item 03, into the actuator.
* Release the nut, item 06 (high tensile copper)
A special tool is required (see tool list)
* Take out the piston.
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.
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:
For the location of the speed adjusting valves see: VATCII 5-844
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.

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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:
For the location of the speed adjusting valves see: VATCII 5-844
Flipper relief valves can adjust quickly if you have good ears.
(You van 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).
* 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
5.20.20 TWIN UP-DOWN ACTUATORS

For the twinlift up/down actuators left, see: VATCII 9-500
For the twinlift up/down actuators right, see: VATCII 9-505
Construction of the actuators and manifolds:
All the actuators for a twin lift spreader are the same.
All the actuators for a Long-Twin spreader are the same (extended piston rod).
The manifold blocks are exclusively hydraulic connections and are all the same for both the twin
and the Long-Twin constructions.
The manifolds, when the hydraulic connections are included, are different for each actuator.
Working pressures - protective devices:
The working pressure for the twin up/down actuators is dependent on the direction of movement
and the direction of the load.
For an up and down movement activated by oil pressure, the pressure is 55 bar.
For a forced upward movement, the oil pressure on the underside is 65 bar (approximately 2000
kg).
For a forced downward movement, the oil pressure on the piston rod side is 75 bar
(approximately 1000 kg).
The permissible forced upward and downward speed (protected volumes) is 2000 mm/second.
The nominal upward and downward speed is 30 mm/second
During spreader standby, when the motor is running, the minimum working pressure is sufficient
to keep the housings pressed upward.
If the spreader is not in use, the leakage that is always present via the piston rings and the five
directly operated overflow valves used, will allow the actuator to run out (sink). However, when
the spreader is switched on, they will always move immediately in an upward direction.
Actuator speed regulation:
Each up/down actuator is provided with an adjustable throttle for the adjustment of the speed in
both upward and downward directions.
The duration of movement is 5-7 seconds for a full stroke.
Upward and downward speeds the same and too low:
If the up/down speed is very low, this can be caused by:
* A contaminated adjustable throttle.
Remove the adjustable throttle and clean or replace it.

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Upward speed too low, downward speed normal:

Close the adjustable throttle with the twin twist lock housings in the uppermost position. If the
actuator continues to move downward and the working pressure is not higher than 65 bar, then
the cause may be:
* The twin twist lock housings have become jammed.
Check the play between the guide tracks.
The play must be at least 1-2 mm.
For more information, see: Chapters 5.40.70
* Leakage past the piston packing.
Replace the actuator or the piston packing.
Downward speed much too high:
If the downward speed is much too high, then the cause is probably a contaminated overflow
cartridge. There is a choice of five cartridges. It is therefore desirable to exchange the complete
manifold.
Recommendation:
Because the speeds of the actuators can sometimes be extremely high, all the protective
devices will already be activated.
Because it is not so simple to trace any malfunction, it is advisable to replace either a complete
manifold immediately or a complete actuator including manifold.
5.30.03 ELECTRICAL SYSTEM refer to:

For the electrical schedules, see: Chapter 12
For the electrical parts lists, see: Chapter 12
Location of important electrical components:
For telescopic stops for 20-40, reduced speed at stops, see: VATCII 4-250 / 4-251
For telescopic beam lock indicators, see: VATCII 4-403
For twistlock position indicators, see: VATCII 4-409
For terminal box/suspension in crossbeam, see: VATCII 4-704
For housing/suspension main E-box see: VATCII 4-730
For (Long)-Twin twistlocks, see: VATCII 9-410
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 localisation:
* Start from the main E-box.
* Look in the schedule to all possible conditions.
* Control all those conditions.
Replacing CAN module:
* CAN modules can be replaced, they are programmed with dibswitches.
In the event of a motor stop, check:
* Check the R, S and T.
* Check the thermal motor relay.
* Check the main motor relay (burned contacts).
* Check the wiring of the motor (fields).
* The level switch of the tank is vulnerable: check this relay.
Possible functional faults:
* Check the secondary voltage circuit.
* Check the voltage on the valves/solenoids.
* Check the relay.
* Check the PLC and bus-connections
* Check the wiring.
* Check the terminal connectors.

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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
Adjusting lock-unlock sensors:
For model with twistlock actuators with double rod, see: VATCII 4-409
Twin-twistlocks, see: VATCII 9-410
Head-beam with twistlock actuator with double rod, see: VATCII 4-409
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.
Twin twistlocks: VATCII 9-410
The distance between twistlock and lock/unlock and unlock sensors is 10 mm, with the twistlock
in the floating mid position. Check that when the twistlock is in the upward and fully floating
position it does not contact the sensor.
Twistlock rods:
For twistlock drive bars, see: VATCII 3-110
Actuators:
Twistlock actuator: VATCII 5-440
Twin-Twistlock actuator: VATCII 5-451
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.
5.40.12 TWISTLOCK LANDING PINS

For type and component information, see: Chapter 3.20.60
There are two types of Landing-pin, a Landing-pin with flat top surface, and a Landing-pin
chamfered at 45°.
Twistlocks Single operation:
For adjusting the sensor for the 45° Landing-pin, see: VATCII 3-905
Twin Twistlocks:
For adjusting the sensor for the flat Landing-pin, see: VATCII 9-410
For mounting, see manual instruction drawings, Chapter 3.20.60

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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 midframe.
The backlash at the outside of the midframe is not adjustable and is specified by the
tolerances of the construction.
BACKLASH at the OUTSIDE:
Backlash at the outside in the vertical direction: VATCII 1-500
The standard clearance at the outside of the mid-frame is between 2 and 4 mm. Replace the VATCII 1-500 06
packing plates, item 06 and item 07 if the thickness is reduced to 0.7 mm (standard thickness is VATCII 1-500 07
10 mm).
Backlash at the outside in horizontal direction:
Standard the clearance at the outside of the midframe is 2 mm. VATCII 1-500 01
Replace the high-pressure blocks post 01 and post 05 if the clearance is more than 5mm. VATCII 1-500 05
BACKLASH at the INSIDE:
Backlash at the inside in vertical direction:
The clearance is standard 2 till 5 mm. VATCII 2-501 02
Release the two M16 bolts of the locking-plates in the 25ft position: VATCII 2-501 03
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 post 08 and post 09. VATCII 2-501 08
VATCII 2-501 09
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 bolds are secured with loctite 542, and that the minimum clearance is 2
mm. VATCII 2-501 02
Wear and tear on the upper plates:
The upper plates (material CuAlNiFe) must be replaced when their thickness is reduced to 8
mm. For the replacement procedure, see the end of the paragraph. VATCII 2-501 06
Backlash at the inside in horizontal direction:
The standard clearance is 2 to 5 mm. VATCII 2-501 02
Release the two M16 bolts securing the locking-plates in the 25 ft position. VATCII 2-501 03
Adjust the clearance in same position.
Reduce the horizontal clearance by changing/adding packing plates. VATCII 2-501 11
VATCII 2-501 12
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 bolds are secured with loctite 542, with a minimum clearance of 2 mm. VATCII 2-501 02
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 06, must adjusted very carefully with help of the plates item 07.
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 post 06 can be done with steel plates post 07. VATCII 2-501 06
VATCII 2-501 07
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 bolds are secured with loctite 542, and that the clearance is 2mm. VATCII 2-501
Top-leftside

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5.40.30 TELESCOPIC BELTS

Detailed assembly instructions for the telescopic belts. VATCII 1-400
VATCII 1-402
TENSIONING the BELTS:
The belts are self-tensioning, and need no maintenance.
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. VATCII 1-205 48
* Push the blocking-plate of the telescopic beam lock actuator in activated position by using a
tap bolt M12 x 100. VATCII 1-334
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 (see also drawing 1-401 detail A).
* 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.

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5.40.40 TELESCOPIC STOPS

For adjusting the position sensors, there are two options for changing them:
* To change the distance from the sensor to the position block.
* To move the position block.
For sensor ø33:
The minimum distance from sensor till position block is 10 mm, the maximum distance is 15-17
mm.
For sensor ø18-20:
The minimum distance from sensor till position block is 4 mm, the maximum distance is 7 mm.
To change the position of the position-blocks, release the 6 M10 bolts of the position-block and
change the position along the beam.
Spreader with stops in 20 and 40ft position:
For the 20ft position stop see: VATCII 2-250 01
For the 20ft sensor see: VATCII 4-250 01
For the 40ft position stop see: VATCII 2-251 01
For the 40ft sensor see: VATCII 4-251 04
For the reduced speed 20ft position see: VATCII 2-251 02
For the reduced speed sensor see: VATCII 4-251 03
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
5.40.60 SHIFT HOUSE

For shift-house, see: VATCII 6-222
Clearance:
The shift house is of two types for the contact with the mainframe.
All the wearing blocks have a minimum and maximum clearance.
Block position 7 is not a wearing block, but a block, which will protect the under-cross tubes if
the spreader sustains a collision on the underside.
Position 6 is manufactured from polyurethane to ensure a global contact pressure between the
shift house and the main frame.
Maximum clearance in hanging position:
A: maximum 5 mm
F: minimum 5 mm
B: maximum 5 mm
C: maximum 5 mm
Maximum dimensions in stored position:
D: maximum 15 mm (nominal 20mm)
B: maximum 5 mm
C: maximum 5 mm
Fasteners:
* The bolts for the wearing blocks in position 2 must be secured with Loctite 542 and must have
a clearance of minimum 1 mm.
* Control the stud bolts position 22. The washers are fabricated from alloyed material.

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5.40.70 TWINLIFT UNIT refer to:

For the twin lift construction for the VATCII spreader, see: VATCII 9-002
Twin twistlock housings, track guides:
The twin twistlock housings are driven vertically by a hydraulic actuator.
The tracks for both the twin twistlock housings and the tracks in the mid-frame are constructed
from alloy steel.
In order to prevent wear, the running surfaces are additionally fitted with two CuAlNi wear
plates:
* For the countersunk wear plate in the mid-frame, see: VATCII 9-002 15
* For the countersunk wear plate in the twin lift housing, see: VATCII 9-002 28
* For the grease/mounting bolt for the wear plates, see: VATCII 9-002 16
Replacing track wear plates:
The wear plates extend 1 mm above the surface of the tracks.
When the wear plates are reduced in thickness so that they are level with the surface of the
guides, it is desirable to replace them.
It is also possible to fit packing plates under the wear plates.
When packing plates are used, the thickness of the wear plates may never be less than 6-7
mm, in order guarantee the adhesive locking of the greasing and fixing bolts. VATCII 9-002 16
Twin twist lock housings, rear guides:
In order to keep the housings within the tracks, a twist lock bolt with a crown nut is fitted.
This bolt is only loaded in the horizontal direction while the spreader is being placed on twin
containers.
In this way the loading is applied to the internal guides, resulting in wear.
* For the slide plate holder left, see: VATCII 9-002 07
* For the slide plate holder right, see: VATCII 9-002 08
* For the inner guide bearing plate (wear plate), see: VATCII 9-002 09
Replacing or adjusting the inner guide bearing plate:
The bearing plate extends 2 mm above the bearing plate holder.
By adjusting the crown nut, the play between the guides can be adjusted to between 1 and VATCII 9-002 03
2 mm.
If the play is greater than 3 to 4 mm, this play must be reduced to between 1 and 2 mm by
adjusting the crown nut. It is not desirable to use packing under the bearing plate. When the
thickness of the bearing plate has been reduced to 7 mm, it must be replaced.
Note: The bearing plates are lubricated and secured with the same bolts.
On assembly, there must be a minimum space of 1 mm between the head of the bolt
and the washer.
Before the bolt is secured with adhesive, make sure that it is thoroughly degreased

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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
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.

Postbus 2005
The Netherlands
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 VATCII-5-903
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.

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 appearing in the manual drawings: Chapter 17
The best way to identify a spare part is with help of the manual drawing, and the part number.
For a review of the manual drawings, see: Chapter 17
For a list of components used in the manual drawings, see: 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:
Stinis Holland B.V. Contact persons:
P.O. Box 2005 Ruud Westgeest ruudwestgeest@stinis.com
HOLLAND
tel 31 180 514655
fax 31 180 516190
6.40 PURCHASE COMPONENT INFORMATION refer to:

For components in manual drawing, see: Chapter 17
For electric components, see: Chapter 12
For hydraulic components, see: Chapter 13
For hydraulic hoses, see: Chapter 13
For mechanical components, please refer to the manual drawings with item number, or fax a
copy of the manual drawings with the required parts indicated.

Postbus 2005
The Netherlands

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 live of
the spreader.
Arrangement drawings:
Arrangement drawings give global information for using the spreader.
This information is focussed 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 1886
Post. Qty. Drawing Description

10 1 2611-1886-1000 Mid-frame BJTI001-002
20 1 2611-1886-1500 Telescopic beam 20-40ft
30 1 2611-1886-1600 Telescopic beam 20-40ft
40 1 2611-1886-0300 Assembly shiftframe VATCII-ETW
50 1 2611-1886-0560 Electrical partslist BJTI001-0
60 1 2611-1886-0700 Grease system VATCII-ETW
70 1 2611-1886-0800 Twinlift-assembly / M30x1,5
80 2 2611-1886-0810 Twistlock box-L-assembly
90 2 2611-1886-0820 Twistlock box-R-assembly

11-2
CHAPTER 11
WATER SIDE
18 October 2010
Hydraulic power pack
LED indication lamps
P=7,5kW / 400VAC / 50Hz
LEFT RIGHT
Hydraulic motor
Electric junction box Grease system
telescoping beams
LAND SIDE
Release A
TWIN−LIFT
Lifting lug SWL10T
Spreader color : Yellow

Stinis Holland B.V.
MANUAL BJTI001-002
COMMENT:
The Netherlands
DESCRIPTION:
Postbus 2005
SCALE: FORMAT DRAWING NUMBER

DRAWN BY: GROUP SUB PROJECT NR. SERIAL NR. REVISION
DATE:
A
Postbus 2005
The Netherlands
12 ELECTRICAL DRAWINGS
12.10 PARTS LIST for ELECTRICAL COMPONENTS

Project: 1886
Part No. Qty. Description (English) Type Fabr.

E-box-RVS304 1070x500x280:
2611-0557-0510 1 E-box: AS-i back-pl-SST5mm incl holes 1028x458x250 RVS235 compleet STINIS
E-box-RVS304 1070x500x---(E):
7201-0011-0100 1 E-box 1070x500x280 1070x500x280 rvs STINIS
Cable connection plates RVS304:
7201-0002-0003 2 cable connection plate ex holes 460x140x3 BOLTJ
E-box polyester 260x160x90:
2611-0080-5400 2 E-box POL 260x160x90(G) 260x160x90 POL 2612609+ wartrls PM-K
2611-0219-0541 1 E-box POL 260x160x90(GLTW-VATCIV) 260x160x90 POL 2612609 +wart ex klem PM-K
powersupplies:
7216-0200-0200 1 Power supply 24V, 20A SNT12824 BRAM
heaters:
7218-0002-0060 1 heater 110-240V AC/DC-30W SK3115 RITTAL
7251-0000-0015 1 temperture switch(1-60°C) 87561
indicators:
7110-0018-0130 1 SensorM18x1 IGK3008BBPKG/M/US IGM200 IFM
7110-0030-0110 5 Sensor M30x1,5 IIKC3012BASKG/M IIM200 IFM
7110-0030-0120 30 sensor IIK3022-BPKG/M/US IIM201 IFM
sonor-beros:
7111-0018-0030 2 UB500-18GM75-E6-V15 pf UB500-18GM75-E6-V15 P+F
7111-0300-0040 2 optical distand O5H500 O5H500 IFM
connectors:
7112-0030-0000 38 connector-M12-H-PPU-4x0.25-or/6m E11283 (lineaal+bero's haaks) IFM
7112-0070-0000 4 connector-M12-H-PPU-3x0.34-orL/10m 1681389 SAC-4P-10,0-PUR/M12FR IFM
7112-0220-0150 2 connector M12-R 4x0.34-5m 7000-12221-6240500 MURR
7112-0520-0010 1 5-pins M12 straight female 15m SAC-5P-15,0-
7112-0600-0000 14 effector protection tube pu10x7-bl-100 INDUSE
connector valves:
7113-0010-0001 12 conn-solenoid 24V DC-PUR-1.5m MSUDK-EB70-MA5.0 MURR
7113-0030-0001 10 conn-solenoid VAC/DC24V-PUR-5m diode 249999b MSUDK-EB70-MA 5.0 MURR
7113-0035-0001 2 conn-solenoid 24V DC-PUR-10 diode MURR
PLC CAN:
7170-0000-0005 2 5 fold Can divider CONTAB6 VIPA
7170-0000-0006 6 FKC 2,5/5 FKC 2,5/5 CITO
7170-0020-0006 3 AMP 23-pin gray plug 2meter AMP23-P GR 2
7170-0020-0007 3 AMP 23-pin black plug 2meter AMP23-P BK 2
7170-0020-0008 3 AMP 23-pin blue plug 2meter AMP23-P BL 2
7170-0020-0009 3 AMP 8-pin black plug 2meter AMP8-P BK 2
7170-0020-0010 3 2024 universal module 52-I/O 2024 module
7170-0020-0015 1 E30C2040-10 colour display E30C2040-10
relay motor:
7132-0024-0220 1 motor contactor 11kW/DC 24V LC1-D25BD TELEM
relay motor/overload:
7133-0050-0025 1 relay overload 12-18Amp LRD-213
7133-0050-0035 1 Mounting block therm. relay LAD7B106 TELEM
relay circuit:
7134-0650-0040 1 relay fase guard electronic RM4-TG20 TELEM
7139-1000-0005 1 Emergency stop relay pnoz 24V PNOZ X1.3 SOLAR
relay terminal connector:
7135-0024-0065 6 Solid state relay 24V SLO24 TR DELCON
7135-0230-0050 13 Solid state input relay 230V SLI 230CR DELCON
relay socket:
7137-0080-0010 6 relay socket Z366.80 KÜNKE
7137-0080-0020 13 DIN-rail socket for SLI relay MIS 1N DELCO DELCON
switches-electric:
7139-0300-0011 2 MLR emergency stop switch 223410936 MOEL
7139-0300-0034 1 MLR Key-operated button 0-I M22-WRS MOEL
7139-0300-0050 1 MLR adapter M22-A MOEL
7139-0300-0051 1 MLR contact component 1xN.O moel M22-K10 MOEL
7139-0300-0052 4 MLR contact component 1xN.C moel M22-K01 MOEL
inclinometers:
7141-0060-0000 1 Inclino meter +/-45 CAN-Open BRAM
encoders:
7142-0200-0010 3 Pressure sensor 10bar G1/4-M12 PV 5091 IFM
7142-0200-0030 1 Pressure sensor 30bar G1/4-M12 PV 5101 IFM
lamps-housings LED:
7230-0011-0030 2 box-4 with 8 LED-lamps 2G-2W-2R-2B
cable:
7121-0003-0040 10 cable 3x1.5 pur-tpe yellow JOB
7121-0004-0060 5 cable 4x4 pur-tpe geel JOB
7121-0007-0041 9 cable 7x1.5 pur-tpe geel JOB
7121-0030-0030 26 cable 32x1 purTPE yellow special(ø20.6mm) JOB
7121-0048-0040 13 cable 48x2.5 QEPK JOB
connector ODU:
7114-0110-0000 1 straight plug, neop.snaplock 309-021-000-554 (GWD) ODU
7114-0190-0000 1 insert-pin, solder-contacts 309-803-156-037-151 (GWD) ODU
connector harting:
7117-0020-0030 1 housing 0930 010 0262 HARTIN
7117-0030-0010 1 pin insert-female 1-10 0933 010 2701 HARTIN

Postbus 2005
The Netherlands
LEFT
WATERSIDE
LANDSIDE
DATE:
DRAWN BY:
SCALE:
DESCRIPTION:
FORMAT
A
GROUP
SUB
COMMENT:
DRAWING NUMBER
PROJECT NR.
RIGHT
SERIAL NR.
REVISION


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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
Not mentioned in the code-list, but mentioned in the specified hoselist are the connections. VATCII 5-900
Those connections are different for every type of spreader.
* 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"x2530 H12L-H12L telescopic motor right B gate
2 1 3/8"x2540 H12L-H12L telescopic motor right A gate
3 1 3/8"x2950 H12L-H12L headbeam right B gate
4 1 3/8"x2770 H12L-H12L headbeam right A gate
5 1 3/8"x2580 R12L-H12L telescopic motor right T gate
9 1 3/8"x4540 H12L-H12L headbeam left A gate
10 1 3/8"x3450 R12L-H12L telescopic motor left A gate
11 1 3/8"x2830 R12L-H12L telescopic motor left T gate
12 1 3/8"x3260 R12L-H12L headbeam left B gate
13 1 3/8"x3770 H12L-H12L telescopic motor left B gate
14 1 1/2"x1940 R16S-H16S shift-long V2 gate
15 1 1/2"x 750 H16S-H16S shift-long V1 gate
17 2 3/8"x5760 R12L-R12L to headbeam twistlock actuator bottom side(A), or P
18 2 3/8"x7150 R12L-R12L to headbeam twistlock actuator rod side (B), or T
19 2 3/8"x 620 R12L-H12L headbeam twistlock actuator A gate
20 2 3/8"x 430 R12L-H12L headbeam twistlock actuator B gate
21 2 3/8"x 900 R12L-R12L headbeam flipper A gate
22 2 3/8"x 860 R12L-R12L headbeam flipper B gate
23 2 3/8"x1520 H12L-R12L headbeam flipper A gate
24 2 3/8"x1560 H12L-R12L headbeam flipper B gate
25 1 1/4"x4180 R08L-H08L telescopic blocking actuator left
26 1 1/4"x3500 R08L-H08L telescopic blocking-actuator right
27 1 3/8"x940 H12L-H12L grease
46 1 3/8"x1150 R12L-H12L oil-supply T to legs left
101 1 3/8"x740 R12L-H12L twinlift up/down actuator bottom side left
102 1 3/8"x720 R12L-H12L twinlift up/down actuator rod side left
103 1 3/8"x380 H12L-H12L twinlift up/down actuator return (power pack side)
104 1 3/8"x950 H12L-H12L twinlift up/down actuator bottom side right (power pack side)
105 1 3/8"x750 R12L-R12L twinlift up/down actuator rod side right (power pack side)
106 1 3/8"x430 H12L-H12L twinlift up/down actuator return (power pack side)
107 1 3/8"x740 R12L-H12L twinlift up/down actuator bottom side left (not power pack side)
108 1 3/8"x720 R12L-H12L twinlift up/down actuator rod side left (not power pack side)
109 1 3/8"x1310 R12L-H12L twinlift up/down actuator return (not power pack side)
110 1 3/8"x950 H12L-H12L twinlift up/down actuator bottom side right (not power pack side)
111 1 3/8"x750 R12L-R12L twinlift up/down actuator rod side right (not power pack side)
112 1 3/8"x1320 R12L-H12L twinlift up/down actuator return (not power pack side)
113 1 3/8"x585 R12L-R12L twin twistlock actuator bottom side(A) left (power pack side)
114 1 3/8"x585 R12L-R12L twin twistlock actuator rod side (B) left (power pack side)
115 1 3/8"x910 H12L-H12L twin twistlock actuator bottom side (A) right (power pack side)
116 1 3/8"x830 H12L-H12L twin twistlock actuator rod side (B) right (power pack side)
117 1 3/8"x910 H12L-H12L twin twistlock actuator bottom side (A) left(not power pack side)
118 1 3/8"x830 H12L-H12L twin twistlock actuator rod side (B) left (not power pack side)
119 1 3/8"x585 R12L-R12L twin twistlock actuator bottom side (A) right (not power pack side)
120 1 3/8"x585 R12L-R12L twin twistlock actuator rod side (B) right (not power pack side)
121 4 3/8"x1440 R12L-R12L twin twistlock actuator bottom side (A) bottom side
122 4 3/8"x1315 R12L-R12L twin twistlock actuator bottom side (B) rod side
124 1 3/8"x820 H12L-H12L Long-Twin up/down actuator (B-distibuting-block to B-long-twin-block)
126 1 3/8"x820 H12L-H12L Long-Twin up/down actuator (A-distibuting-block to A-long-twin-block)
128 1 3/8"x820 H12L-H12L Long-Twin twistlock actuator (B-distibuting-block to B-long-twin-block)
130 1 3/8"x820 H12L-H12L Long-Twin twistlock actuator (A-distibuting-block to A-long-twin-block)
139 1 3/8"x 670 R12L-R12L oil-supply T (R to Long-Twin)
166 2 3/16"x380 R06L-R06L emergency: twistlock-end beam unlock
167 2 3/16"x700 R06L-R06L emergency: twistlock-end beam lock
168 1 3/16"x1340 R06L-R06L emergency: (twin)twistlock emergency unlock
169 1 3/16"x1580 R06L-H06L emergency: (twin)twistlock emergency lock
198 1 1/2"x1700 R16S-H16S telescopic beam OHS A (VATCIV-TCS)
199 1 1/2"x1700 R16S-H16S telescopic beam OHS B (VATCIV-TCS)

Postbus 2005
The Netherlands
13.30 PARTS LIST for HYDRAULIC COMPONENTS

Project: 1886
Part No. pos. Qty. Description (English) Type Fabr.

oil-grease:
9991-0010-0050 1 oil T46 Energol HLP-HM 46 BP
powerpack:
6505-0001-0102 013 1 tank cover 800x480 950603 RAJA
6505-0001-0103 1 tank cover seal 800x480 Erica superba 3 mm OC
6505-0011-0100 1 oiltank
mechanic-wire,nuts:
6016-0000-0001 106 40 cap nuts stainless steel M5 42078 ROKE
6016-0000-0003 19 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 1 coupling motor-side B38/38-H7-L=50/sleeve B38, DENT
6505-0001-0022 1 coupling house 5.5/7.5kW 28/45cc B38/nylon housing DENT
6505-0001-0024 1 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
7250-0001-0003 007 1 levelswitch body VHS 600 G3/4" GMS
7250-0001-0004 007 1 levelswitch contact SK 1500 GMS
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 OC
7131-0002-0500 19 solenoid ARON cetop-3 24VDC D15-24VDC-30W / M14630004 ARON
7131-0003-0000 2 solenoid ARON cetop-5 24VDC D16-24VDC-45W / M14220004 ARON
seals:
6018-0002-0001 1 seal electro motor 300 300/GL-300 OC
O-rings:
6019-0008-0001 1 O-Ring vit sh70 (cetop-3-EDI) ø8.73x1.78 VOTA
6019-0009-0001 - O-Ring vit sh70 (cetop-3-standard) ø9.25x1.79 VOTA
6019-0068-0001 1 O-Ring nbr sh70 ø68x3 NBR OC
6801-0007-0020 1 O-Ring vit sh70 ø101.2x3.53 OC
6019-1025-0001 1 O-Ring nbr sh90 ø29,75 x 3,53
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:
2611-0403-0208 2 hydraulic bended tube short ø12-83x123
2611-0403-0209 2 hydraulic bended tube long ø12-83x153
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 1 quick release coupling-male 1/8' H1-63 BSP / ISO7241-1B HEBU
6030-0100-0301 030 1 dustcover for coupling male-1/8' H1-66 HEBU
6801-0003-0029 030 1 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 2 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:
7252-0100-0500 009 8 gauge glass 3/8" SK-9-L-027000
orifices:
6052-0001-0000 040 7 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
6053-0200-0260 040 1 orifice M5 M5 x 260 EUMA
pump-hydr.motor:
6540-0007-0000 2 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:
6550-0003-0000 045 2 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
6552-0700-0300 075 1 manifold 1-valve Cetop-3 MF132-OFJO56060N0000 EDI
6552-0700-0420 151 4 manifold 1-valve-Cetop-3 excl.cartridge (flipper) MF2858 EDI
manifold-foundatien for valves Cetop-5:
6552-5000-0000 102 1 manifold 1-valve BS-5-16 ARON
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 2 manifold CH6000 connectionplate MF824A-Oring25.03x2.62 OC
2611-0219-0643 087 2 manifold LTWL twin up/down Left MF850-ST02 OC
2611-0219-0644 088 2 manifold LTWL twin up/down right MF850-ST01 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 1 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

Postbus 2005
The Netherlands
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
6571-0004-1040 058 1 valve 4/2 Cetop-3 24VDC-D15 2-positions AD-3E-19-D-M-RG-03 ARON
6571-0004-1070 034 1 valve 4/3 Cetop-3 24VDC-D15 mid pos: ABT AD-3E-03-C-M-RG-03 ARON
6571-0004-1100 035 7 valve 4/3 Cetop-3 24VDC-D15 mid locked AD-3E-01-C-M-RG-03 ARON
6572-0008-0010 112 1 valve 4/3 Cetop-5 24VDC mid locked AD-5E-01-E-M-00-20 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 1 checkvalve pilot-op Cetop-3-A-B(twi) OFC011060N00(in A-B) OC
6573-0003-1040 049-0 3 checkvalve pilot-op Cetop-3-A-B(twi) ecxl. O-ring OFC011060N00(in A-B) OC
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 5 flow regulator cartridge 40l ST-C-06-1/OD.21.01.03.56 OC
flow regulators Cetop-3/5:
6574-0009-0000 104 1 flow regulator adj. Cetop-5 A-B AM-5-QF-A-B-C-004 ARON
cross relief valves Cetop-3/5(AB-T):
6575-0010-0005 073 1 cross relief v. Cetop-3(AB-T) AM-3-VM-AB-C-3-20 A=90 B=210 ARON
6575-0011-0000 111 1 cross relief v. Cetop-5(AB-T)
crossover(A-B B-A):
6577-0013-0006 124 2 crossover Cetop-3 A=180 B=120 LC1-VM2/AB A=180 B=120bar OC
pressure reducing valves Cetop 3/5:
6578-0014-1055 037 1 pressure red. valve Cetop-3 MF2131-ST01-55bar OC
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:
6579-0013-3065 021 8 press relief valve cartr 30l VS-30-NCF/04.11.18.03.09.10A 65bar OC
6579-0013-3075 021 8 press relief valve cartr 30l VS-30-NCF/04.11.18.03.09.10A 75bar OC
6579-0013-3115 021 4 press relief valve cartr 30l VS-30-NCF/04.11.18.03.09.20.00C 115bar OC
6579-0013-3210 021 4 press relief valve cartr 30l VS-30-NCF/04.11.18.03.99.35 210bar OC
cylinder-twistlock:
2611-0219-0650 C01 4 cylinder-twistlock-twin: complete ø32/20-100 TWI-TWIN STINIS
2611-0219-0660 C01 2 cylinder-long-twin locking: compl ø32/20-100 LT locking STINIS
6510-0002-0222 - cylinder-twi: sealkit 3-200-01 19 ø32/20-100 sealkit STINIS
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
6510-0017-0000 C05 2 cylinder 110/50x783 (GLTW) 110/50x783 (GLTW) STINIS
6510-0017-0050 C05 - cylinder-twi: sealkit 110/50x783 STINIS
Cylinders for longtwin-twistlock up-down model VATCVI
2611-0219-0645 C06 - cyl.longtwin up/down left incl man. ø50/30-340/320bar(incl man)RAL9004 STINIS
2611-0219-0640 C06 4 cyl.longtwin up/down ex manifold ø50/30-340/320bar(excl man)RAL9004 STINIS
2611-0220-0650 - cyl.longtwin up/down: sealset ø50/30-320bar STINIS

13-4
CHAPTER 13
emergency control
twistlocks end beam
twistlocks end beam
emergency control
18 October 2010
Grease systemTelescoping motor Telescoping motor Twin-lift Blocking cylinder
twistlock cylinder telescoping beam
End-beam
Left-side Right-side
Left-side Right-side
End-beam
powerpack side
e-box side
Twistlock Actuator Actuator Twistlock Actuator Actuator
Release A
Twin-lift up/down
Lefts side
Twin-lift up/down
Lefts side
Right side
Right side
Stinis Holland B.V.
MANUAL BJTI001-002
COMMENT:
The Netherlands
DESCRIPTION:
Shift cylinder
Postbus 2005
SCALE: FORMAT DRAWING NUMBER

DRAWN BY: GROUP SUB PROJECT NR. SERIAL NR. REVISION
DATE:
A
Postbus 2005
The Netherlands
REVISION
SERIAL NR.
DRAWING NUMBER
PROJECT NR.
COMMENT:
SUB
GROUP
FORMAT
A
DESCRIPTION:
DRAWN BY:
SCALE:
DATE:

Postbus 2005
The Netherlands

s
11-01-878
®
Char-Lynn EN-0201
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Hydraulics
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2000, 4000, 6000, and 10,000 Series

Hydraulic Motors
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We Manufacture
Solutions
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S o l u t i o n s
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Catalog of Disc Valve Hydraulic Motors from One of the World’s Leading
Manufacturers of Off Highway Mobile Components — Eaton Hydraulics
n the late 1950’s the original low speed, to make these Geroler motors the best the direction. The displacements available
high torque hydraulic motor was devel- industry has to offer. Examine the simplicity provide a wide variety of speeds and torques
oped from a pump gerotor element of these Geroler disc valve motors shown from any Series motor.
consisting of an internal gear ring and a below. Also examine all the following pages
mating gear or star. While attaching the for high value Char-Lynn disc valve motors
internal gear ring to the housing as a non from Eaton Hydraulics.
Disc Valve
moving part, oil was ported to pressurize and The function of the disc valve is to distribute
turn the internal star in an orbit around a ® fluid to the Geroler pockets. The pressure
center point. This slow turning star coupled Geroler balanced sealing surface on the valve face
with a splined drive to the output shaft maintains minimal leakage. Char-Lynn disc
became the Char-Lynn® Orbit® motor. A few
Displacement Mechanism valve motors can be used in the same
years after this original Char-Lynn Orbit motor Motors with the Geroler element provide high system with a radial piston pump and also in
was introduced another original motor starting and running torque. The Geroler closed loop systems. The patented wear
concept went into production. This motor had element minimizes friction and thereby compensated disc valve provides top
rolls incorporated into the internal gear ring, increases efficiency while providing smooth performance.
this element was identified by the name output shaft rotation even at very low speeds.
Geroler® and is a registered trade name of Motor shaft rotation can be instantly reversed
Eaton Hydraulics. From these early years the by changing direction of input/output flow
Geroler motor has seen many design changes while generating equal torque in either
Heavy Duty Bearings

Roller bearings permit high radial loads. The radial load capacity is Port B Port A
matched to the torque capability of the motor. The high radial load
capacity can eliminate the need for outboard bearings or other
mechanical components thereby reducing installation cost and
allowing the motors to be used on heavier vehicles in traction drive
applications.
Geroler® Star
2000 Series
Motor
Disc Valve
Motor Shaft Drive

and Valve Drive
90% of Actual Size Motor Shaft and Bearings

Design Features Char-Lynn Hydraulic motors provide design flexibility. All disc valve motors are available with
various configurations consisting of:
• Displacement (Geroler size)
• Output Shaft
• No Shaft and Bearing Assembly (Bearingless Motor)
• Port Configuration
• Mounting Flange
• Other Special Features
The standard motor mounting flange is located as close to the output shaft as possible. This
Standard Motor type of mounting supports the motor close to the shaft load. This mounting flange is also
compatible with many standard gear boxes.
Wheel Motor The wheel motor mounting flange is located near the center of the motor which permits part or
all of the motor to be located inside the wheel or roller hub. In traction drive applications, loads
can be positioned over the motor bearings for best bearing life. This wheel motor mounting
flange provides design flexibility in many applications.
Bearingless Motor This bearingless motor has the same drive components as the standard and wheel motors (with
the exception that the motor is assembled without the output shaft, bearings and bearing
housing). The bearingless motor is especially suited for applications such as gear boxes, winch
drives, reel and roll drives. Bearingless motor applications must be designed with a bearing
supported internal spline to mate with the bearingless motor drive. Product designs using these
hydraulic motors provide considerable cost savings.
Disc Valve Hydraulic Motors
6000 Series
6000
6000 Series 6000 Series Displacement Size = cubic centimeter per shaft revolution ( cm3/r )
®
Geroler Element ....... 9 Displacements • 195 [11.9] = cubic inch per shaft revolution ( [ in3/r ] )
Flow LPM [GPM] ..... 150 [40] Continuous** • 245 [15.0]
• 310 [19.0]
225 [60] Intermittent* • 390 [23.9]
Speed ......................... Up to 866 RPM • 490 [30.0]
Pressure Bar [PSI] ... 200 [ 3000] Cont. • 625 [38.0]
300 [ 4500] Inter. • 740 [45.0]***
Torque Nm [lb-in] .... 1685 [14920] Cont. • 805 [49.0]***
1875 [16580] Inter.
• 985 [60.0]
Mounting Flange
• 4 Bolt (Bearingless) 127,0 [5.00] Pilot Dia. and 14,3 [.56] Dia. Mounting Holes on 161,9 [6.38] Dia. B.C.
• 4 Bolt (SAE CC)(Standard) 127,0 [5.00] Pilot Dia. and 14,3 [.56] Mounting Holes on 161,9 [6.38] Dia. B.C.
• 4 Bolt (Wheel) 139,7 [5.50] Pilot Dia. and 14,3 [.56] Dia. Mounting Holes on 184,1 [7.25] Dia. B.C.
Output Shaft
• Bearingless
• 1-1/2 inch Dia. Straight with Straight Key, 3/8-16 Threaded Hole and 56,7[2.23] Max. Coupling Length
• 1-3/4 inch Dia. Tapered with Straight Key and 1-1/4—18 UNEF Slotted Hex. Nut
• 1-1/2 inch Dia. Splined 17 T with 40,3 [1.59] Min. Full Spline Length and 3/8-16 Threaded Hole
• 40 mm Dia. Straight with Straight Key, M12 x 1,75-6H Threaded Hole
Port Type
• 1-5/16-12 O-ring with 7/16-20 O-ring Case Drain and Shuttle Valve
• G 1 (BSP) O-ring with G 1/4 (BSP) O-ring Case Drain and Check Valve
• 3/4 inch 4 Bolt Split Flange with 7/16-20 O-ring Case Drain and Check Valve
Special Features
• Viton Shaft Seal
• Viton Seals
• Hot Oil Shuttle
• Corrosion Protected
*** For performance and dimension data contact
your Eaton Hydraulics representative.
** Continuous— (Cont.) Continuous rating, motor

may be run continuously at these ratings.
* Intermittent— (Inter.) Intermittent operation,
10% of every minute.
7
Char-Lynn motors are truly built for high torque low speed. A lot of power is derived from this
Design Flexibility small package. This power advantage provides the designer with a product that can be used for
overall compactness in addition to taking full advantage of the high pressure ratings typical of
present day hydraulic components.
Char-Lynn Disc Valve hydraulic motors allow the designer to put the power where it is needed.
Indeed, these motors are small in size, big in output power. Hence, the small package can
eliminate a lot of installation problems. Furthermore, the motors can be mounted directly on the
driven device away from the original power source which eliminates other mechanical linkages
such as chains, sprockets, belts, pulleys, gears, rotating drive shafts, and universal joints.
Several motors can be driven from the same power source and can be connected in series or
parallel to each other.
Durability The design and method of manufacture of three critical drive train components, valve drive,
shaft drive, and output shaft, give these motors durability. Consequently, these durable disc
valve motors stand up against high hydraulic pressures. Other built in features, such as the
rugged Tapered roller bearings provide a good match to this tough design.
Our method of rating these motors recognizes that at slower speeds and flow, higher pressures
Performance Rating and torque are permitted. Hence, our performance data shows the complete flow range (down
to 1 liter per minute or 1/4 gallon per minute) and speed range (down to one revolution per
minute depending on application).
Controllable Speeds Char-Lynn motors operate at low speeds that remain very near constant even when load varies.
Shaft speed is varied smoothly, easily and economically using simple inexpensive controls.
Also, these motors are reversible. Consequently, direction of shaft rotation can be changed
instantly with equal output torque in either direction.
Dependable Highly precise manufacturing of parts and the disc valve’s unique wear compensating design
provide consistent, dependable performance and long life even under varying conditions.
Performance
Reliability Char-Lynn motors are self contained, with hydraulic fluid providing lubrication. These motors
are completely sealed so they can operate safely and reliably in hostile environments such as
dust, dirt, steam, water, and heat and provide reliable performance.
Char-Lynn disc valve motors have high efficiencies providing high output for the pressure and
High Efficiencies flow supplied. The high mechanical efficiency enables you to obtain a given torque with a
smaller displacement motor.
Volumetric efficiency is high and speed is relatively constant with little variation due to changes
in load. Speed is controlled easily and smoothly.
In conclusion, these efficiencies mean less heat buildup in the hydraulic system.
Case Drain and Shuttle Valve Options

Many hydraulic systems can benefit from the use of a system case drain. Char-Lynn disc valve motors provide this
feature built in. One of the advantages for case drain flow is that contamination is flushed from the system. This flushing
also aids in cooling the system and lowering the case pressure which will extend motor seal life. With a case drain line in
place, oil pressure in the gear box (Bearingless motor applications) can also be controlled. In applications where more
system cooling and flushing is required, a shuttle valve option is available in 2000, 4000, and 6000 Series motors.
Case Case
Drain Drain
Series Connection Parallel Connection
9
Typical (Closed Loop) Hydraulic Circuit

Shuttle Flow 2000, 4000, 6000 Series
Shuttle Valve, Two Way P1 P2 P1 P2 P 1 P2
(Closed Center) —
Neutral, CW, and CCW
Schematic
Diagrams
A Pump, Variable P3 P3 CW P3
T Neutral T T CCW
A Pump, Variable Disc Valve Motor A
Back-
Pressure
B Relief Valve
Shuttle
D S P1 P2 Valve
B B
Case Drain
Back D S
(Charge) High
Pressure Pressure
Typical Disc Valve Motor
A B Shuttle Flow with 4,5 bar [65 PSI]
Back-Pressure Relief Valve (Typical Data)
Disc Valve Motor Due to Machining Tolerances, Flow May be More or Less
Geroler
bar — Back-Pressure
10 20 30
14
3.5
12
3
10 2.5
8 2
l/min. 6 GPM
1.5
4 1
2 0.5
Hot 0 0
Oil 100 200 300 400 500
Shuttle PSI — Back-Pressure
Valve 4000 Series and 6000 Series
2000 Series
Closed Loop
Back-Pressure
(Charge) Relief
Valve
Disc Valve Motor with shuttle valve must have a case drain to tank, without
this drain line the internal drive splines will not have adequate lubrication.
Low Speed High Torque Hydraulic Motors

with Shuttle and Charge Pressure Relief
Valve — Patent No. U.S. 4,645,438.
10
Speed Sensor Quadrature Speed Sensor

2000, 4000 and 6000 Series 2000, 4000 and 6000 Series
Eaton has developed a speed sensor specifically designed for LSHT Eaton has developed a new speed and direction sensor, based on the
motors. The design is rugged and fully protected against accidental field proven technology of our standard sensor, designed for off road
reverse polarity or short circuit hook up. A built in pull up resistor environments. The new sensor is based on the principle of quadrature
simplifies installation with control systems. and has two output versions.
This sensor is fully compatible with mobile vehicle electrical systems • The first version has two output signals 90° out of phase. Each
and gives a reliable digital on/off signal over a wide speed range and output provides one pulse per target tooth.
temperature range. The sensor is field-serviceable; no factory setting
or shimming is required. • The second version has a speed signal that is twice the output
pulses per revolution and it also has a direction signal. For example,
the 2000 Series versions provide 60 symmetrical pulses per revolu
Supply Voltage: 8 to 24 Vdc (compatible with 12V vehicle systems) tion with the 30-tooth target.
Supply Current: 20 mA max. (Vs) (including internal pull-up resistor) Outputs — Digital signals from NPN transistors (open collector output
with internal 10K pull-up resistors).
Output Voltage: Low < .5 Vdc @ 10 mA; output is open collector with
10kΩ pull-up resistor.
Supply Voltage: 8 to 24 Vdc* (compatible with 12V vehicle conditions)
Supply Current: 40 mA max. (Including internal pull-up resistors)
Connection — standard 3 prong
Weatherpack connector with Output
18 AWG (american wire gage) Low Voltage: 0.5 Vdc maximum @ 10 mA
cables:
Position A (red) = power supply The sensor has reverse polarity protection, short circuit protection, load
Position B (white) = signal output dump protection and EMC (Electricalmagnetic Compatibility) protection
Position C (black) = common (the customer should qualify the EMC protection in their specific
application).
D
C
2000 Series B
A
Output
Speed Sensor — digital Weatherpack Tower Connector
on/off signal from a
Hall Effect switch; Connections —
30 pulses/revolution Standard 4 prong Weatherpack connector
with 18 AWG (American Wire Gage) cables
Output Quadrature Speed Sensor — 60 pulses/revolution or M12 threaded connector:
Weatherpack (Version 1) M12 Connector (Version 1)

Position A (red) = power supply Pin 1 = power supply
4000 Series Position B (black) = common Pin 2 = output one
Position C (orange) = output one Pin 3 = common
Output
Position D (yellow) = output two Pin 4 = output two
Speed Sensor — digital
on/off signal from a
Weatherpack (Version 2) M12 Connector (Version 2)
Hall Effect switch;
Position A (red) = power supply Pin 1 = power supply
36 pulses/revolution
Position B (black) = common Pin 2 = direction
Output Quadrature Speed Sensor — 72 pulses/revolution Position C (blue) = speed signal Pin 3 = common
Position D (white) = direction Pin 4 = speed signal
Note: The speed sensor or quadrature speed sensor option

does NOT include read-out display.
6000 Series Possible sources for read-out display include:
Output
Speed Sensor — digital Eaton Corporation
on/off signal from a Durant Products
Hall Effect switch; 901 South 12th Street
40 pulses/revolution
Watertown, WI 57094
Output Quadrature Speed Sensor — 80 pulses/revolution 1-800-289-3866
11
Shaft Seal Internal Check Valves

This time proven shaft seal design has a patented feature which allows An internal check valve is provided to relieve case pressure to the low
the seal lip to follow shaft deflection under high side loads and pressure side of the motor. This check valve system is adequate for
therefore provides better sealing. Additionally, these seals can most applications. In addition, motors have an external case pressure
withstand case pressure up to: 140 Bar [2000 PSI] 2000 Series, 100 drain port for use when continuous back pressure exceeds: 140 Bar
Bar [1500 PSI] 4000 Series, 70 Bar [1000 PSI] 6000 Series, and 20 [2000 PSI] 2000 Series, 100 Bar [1500 PSI] 4000 Series, 70 Bar [1000
Bar [300 PSI] 10,000 Series. PSI] 6000 Series, and 20 Bar [300 PSI] 10,000 Series.
To optimize seal life, reduce case pressures (with case drain) at shaft
speeds greater than 250 RPM.
Optional Seal Guard Package for Corrosion Protected

2000, 4000, and 6000 Series Disc Valve Motors
2000, 4000, 6000, and 10,000 Series motors are available with a
corrosion resistant coating for use in hostile environments. This
Seal Guard coating protects the motor from salt water, and various chemicals and
is especially effective in marine, food processing, cleansing, fishing,
and agricultural applications. Motor output shaft plating helps
eliminate seal damage caused by these caustic or acid materials.
Char-Lynn disc valve motors are available with just the output shaft
plated, or with plated shaft and entire motor exterior coating.
In response to the need for robust seal protection requirements, Eaton

now offers a seal guard package. This feature consists of a metal
shield that protects an internal wiper seal. The shield is interference-fit
on the output shaft and rotates with the output shaft. For added
protection, the shield is recessed into a special groove in the bearing
housing face.
Centrifugal force causes foreign debris to be forced away from the high
pressure shaft and dust seal area. The seal guard does not seal
hydraulic fluid. Instead, it protects the standard seals from damage
caused by foreign debris. Typical applications benefiting from this
feature include street sweepers, industrial sweepers, and harvesting
machinery.
NOTE: This option is used in conjunction with the special front retainer
with shield groove. Special feature (Hardware) option code “28” for
2000, “13” for 4000, and “14” for 6000 Series, these motors include
the seal guard package, special front retainer and a special shaft
with additional length (6000 Series with design code -006 (effective
December 1, 1995) will not require a special front retainer and standard
shafts will accept the seal guard).
12
Specifications
6000 Series
Specification Data—6000 Series

Displ. cm3/r 195 245 310 390 490 625 985
[in3/r] [11.9] [15.0] [19.0] [23.9] [30.0] [38.0] [60.0]
Max. Speed (RPM) @ Continuous 775 615 485 387 307 241 153
...................... Flow
Intermittent 866 834 698 570 454 355 230
Flow Continuous 150 [40] 150 [40] 150 [40] 150 [40] 150 [40] 150 [40] 150 [40]
LPM
[GPM] Intermittent 170 [45] 210 [55] 225 [60] 225 [60] 225[60] 225 [60] 225 [60]
Torque 1-3/4 Inch Continuous 575 [5100] 735 [6510] 930 [ 8230] 1155 [10230] 1445 [12800] 1480 [13100] 1685 [14920]
Nm Dia. Tapered
[lb-in] Shaft Intermittent 860 [7620] 1100 [9740] 1355 [11990] 1635 [14490] 1885 [16670] 1898 [16800] 1875 [16580]
Continuous 205 [3000] 205 [3000] 205 [3000] 205 [3000] 205 [3000] 170 [2500] 140 [2000]
Pressure 1-3/4 Inch
∆ Bar Dia. Tapered Intermittent 310 [4500] 310 [4500] 310 [4500] 310 [4500] 275 [4000] 221 [3200] 140 [2000]
[∆ PSI] Shaft
Peak 310 [4500] 310 [4500] 310 [4500] 310 [4500] 310 [4500] 240 [3500] 170 [2250]
Maximum Case Pressure - without Case Drain * — 70 Bar [1000 PSI]
A simultaneous maximum torque and maximum speed NOT recommended. For permissible continuous and intermittent
operating combinations of pressure and flow refer to performance data on pages 52-53.
Maximum torque for 1-1/2 inch shaft — 1325 Nm [11750 lb-in] Continuous and 1650 Nm [14600 lb-in] intermittent.
* For back pressure over 70 Bar [1000 PSI] use an external case drain. Install case drain lines so that the
motor case remains filled at all times.
Maximum inlet pressure — 310 Bar [4500 PSI]. Do not exceed ∆ pressure rating (see chart above).
* Maximum return pressure — 310 Bar [4500 PSI]. Do not exceed ∆ pressure rating (see chart above).
∆ Bar [∆ PSI] — True pressure difference between inlet port and outlet port.
Continuous Rating — Motor may be run continuously at these ratings.
Intermittent Operation — 10% of every minute.
Peak Operation — 1% of every minute.
Recommended Fluids — Premium quality, anti-wear type hydraulic oil with a viscosity of not less than
70 SUS at operating temperature (see page 81).
Recommended Maximum System Operating Temp. — Is 82° C [180° F]
Recommended Filtration — per ISO Cleanliness Code, level 18/13
To assure best motor life, run motor for approximately one hour at 30% of rated pressure before application
to full load. Be sure motor is filled with fluid prior to any load applications.
51
Performance
195 cm /r [11.9 in /r] 3
∆ Pressure Bar [PSI]
3 245 cm3/r [15.0 in3/r]
Data [250]
15
[500] [1000] [1500] [2000] [2500] [3000] [3500] [4000] [4500]
35 70 105 140 170 205 240 275 310
[250]
15
[500] [1000] [1500] [2000] [2500] [3000] [3500] [4000] [4500]
35 70 105 140 170 205 240 275 310
6000 [.5]
1,9
[280]
30
9
[650]
75
7
[1450]
165
5
[2290]
260
2
[.5]
1,9
[430]
50
7
[860]
95
4
[1890]
215
1
Series [2]
7,5
[290]
35
38
[680]
75
37
[1500]
170
35
[2340]
265
34
[3100]
350
30
[3880]
440
26
[4140]
470
18
[2]
7,5
[440]
50
30
[900]
100
29
[1940]
220
26
[2990]
340
24
[3960]
445
21
[4920]
555
17
[5040]
570
11
[5930]
670
6
[4] [300] [710] [1500] [2390] [3210] [4030] [4600] [5200] [5790] [4] [460] [940] [2000] [3060] [4080] [5090] [5680] [6630] [7570] [8520]
35 80 175 270 365 455 520 590 655 50 105 225 345 460 575 640 750 855 965
15 77 76 74 72 66 62 46 32 18 15 61 60 56 54 48 42 39 30 12 6
[8] [310] [740] [1590] [2450] [3280] [4120] [4810] [5530] [6250] [6900] [8] [470] [960] [2060] [3150] [4210] [5260] [6180] [7100] [8020] [9020]
Flow LPM [GPM]

Flow LPM [GPM]
35 85 180 275 370 465 545 625 705 780 55 110 235 355 475 595 700 800 905 1020
30 154 153 148 144 131 119 116 99 83 65 30 122 120 116 113 104 95 81 67 53 37
[12] [320] [750] [1610] [2480] [3330] [4190] [4990] [5810] [6630] [7320] [12] [480] [970] [2080] [3180] [4270] [5360] [6390] [7420] [8450] [9510]
35 85 180 280 375 475 565 655 750 825 55 110 235 360 480 605 720 840 955 1075
45 232 230 225 221 212 203 186 167 148 118 45 183 182 178 174 165 157 141 125 109 92
[16] [300] [730] [1600] [2470] [3340] [4210] [5090] [5900] [6710] [7470] [16] [450] [960] [2070] [3180] [4290] [5420] [6480] [7490] [8480] [9540]
35 80 180 280 375 475 575 665 760 845 50 110 235 360 485 610 730 845 960 1180
61 309 307 303 300 291 283 258 236 214 181 61 245 244 240 236 228 221 202 184 165 145
[20] [270] [720] [1590] [2460] [3350] [4240] [5100] [5950] [6800] [7620] [20] [420] [940] [2050] [3160] [4290] [5440] [6510] [7580] [8660] [9740]
30 80 180 280 380 480 575 670 770 860 45 105 230 355 485 615 735 855 980 1100
76 387 384 379 374 365 356 332 306 280 247 76 307 306 301 297 287 277 257 238 218 197
[24] [240] [700] [1570] [2440] [3330] [4220] [5080] [5940] [6810] [24] [380] [920] [2020] [3120] [4260] [5400] [6490] [7590] [8680]
25 80 175 275 375 475 575 670 770 45 105 230 355 480 610 735 860 980
91 465 462 456 450 440 429 413 388 363 91 368 365 361 358 348 338 316 294 271
[28] [190] [660] [1530] [2400] [3300] [4200] [5060] [5940] [6810] [28] [330] [870] [1980] [3100] [4240] [5380] [6480] [7580] [8670]
20 75 175 270 375 475 570 670 770 35 100 225 350 480 610 730 855 980
106 542 539 532 526 514 502 476 448 421 106 430 426 421 416 404 376 358 340 322
[32] [160] [630] [1500] [2370] [3270] [4160] [5040] [5920] [6790] [32] [290] [800] [1920] [3050] [4170] [5290] [6410] [7520] [8640]
20 70 170 270 370 470 570 670 765 35 90 215 345 470 600 725 850 975
121 620 617 609 602 589 576 542 511 480 121 491 489 481 475 461 448 423 398 373
[36] [120] [620] [1480] [2350] [3240] [4130] [5000] [5880] [6760] [36] [250] [730] [1850] [2980] [4060] [5150] [6300] [7440]
15 70 165 265 365 465 565 665 765 30 80 210 335 460 580 710 840
136 697 692 683 674 659 645 601 564 527 136 556 549 543 537 524 509 482 456
[40] [80] [610] [1450] [2320] [3210] [4100] [4960] [5840] [40] [200] 690] [1790] [2940] [4010] [5130] [6190] [7100]
10 70 165 260 365 465 560 660 25 80 200 330 455 580 700 800
151 775 770 759 749 733 718 666 624 151 615 612 606 599 585 570 540 510
[45] [590] [1410] [2280] [3170] [4060] [4920] [5790] [45] [570] [1760] [2860] [3960] [5070] [6080] [6690]
65 160 260 360 460 555 655 65 200 325 445 575 685 755
170 866 854 843 825 808 749 702 170 688 682 674 658 641 608 574
[50] [1720] [2800] [3890] [4920] [5940]
195 315 440 555 670
Motors run with high efficiency in all 189 758 749 731 712 676
areas designated with a number for torque [55] [1670] [2740] [3820] [4890] [5880]
and speed, however for best motor life 190 310 430 550 665
[5790] Torque [lb-in] 208 834 824 804 783 744
select a motor to run with a torque and
speed range shown in the light blue area.
655
702
} Nm
Speed RPM
Continuous
Performance data is typical at Intermittent
120 SUS. Actual data may vary
slightly from unit to unit
310 cm3/r [19.0 in3/r] 390 cm3/r [23.9 in3/r]
in production ∆ Pressure Bar [PSI] ∆ Pressure Bar [PSI]
[250] [500] [1000] [1500] [2000] [2500] [3000] [3500] [4000] [4500] [250] [500] [1000] [1500] [2000] [2500] [3000] [3500] [4000] [4500]
15 35 70 105 140 170 205 240 275 310 15 35 70 105 140 170 205 240 275 310
[.5] [530] [1120] [2440] [1] [760] [1570] [3230]

60 125 275 85 175 365
1,9 6 4 1 3,8 4 2 1
[2] [540] [1150] [2460] [3620] [4780] [5690] [6670] [7780] [2] [780] [1610] [3270] [4910] [6440] [7760] [9080] [10590]
60 130 280 410 540 645 755 880 90 180 370 555 730 875 1025 1195
7,5 24 23 22 20 17 14 10 4 7,5 19 18 17 16 14 12 9 4
[4] [550] [1180] [2560] [3800] [5030] [6050] [7070] [8260] [9070] [9530] [4] [800] [1640] [3300] [4970] [6570] [8160] [9570] [11270] [12120] [14490]
60 135 290 430 570 685 800 935 1025 1075 90 185 375 560 740 920 1080 1275 1370 1635
15 48 47 45 42 38 32 24 17 10 3 15 38 38 37 35 33 29 22 14 5 1
[8] [560] [1250] [2650] [3970] [5280] [6480] [7710] [8740] [9770] [10990] [8] [810] [1650] [3370] [5080] [6740] [8430] [10050] [11620] [12880] [14480]
Flow LPM [GPM]
Flow LPM [GPM]
65 140 300 450 595 730 870 985 1105 1240 90 185 380 575 760 950 1135 1315 1455 1635
30 96 95 91 87 81 73 64 55 46 35 30 77 76 74 72 68 65 55 45 33 21
[12] [570] [1260] [2690] [4050] [5420] [6730] [8040] [9260] [10490] [11800] [12] [800] [1620] [3390] [5130] [6810] [8520] [10190] [11860] [13640]
65 140 305 460 610 760 910 1045 1185 1335 90 185 385 580 770 965 1150 1340 1540
45 144 143 140 135 129 121 111 99 88 76 45 115 115 112 109 105 100 91 81 79
[16] [540] [1230] [2660] [4060] [5450] [6800] [8150] [9400] [10660] [11990] [16] [750] [1600] [3380] [5120] [6820] [8560] [10230] [11920]
60 140 300 460 615 770 920 1060 1205 1355 85 180 380 580 770 965 1155 1345
61 193 192 188 184 178 167 156 141 126 109 61 154 154 151 147 143 132 126 116
[20] [510] [1200] [2630] [4040] [5450] [6820] [8190] [9520] [10840] [20] [680] [1580] [3360] [5120] [6840] [8590] [10280] [11980]
60 135 295 455 615 770 925 1075 1225 75 180 380 580 775 970 1160 1355
76 242 241 236 232 226 216 201 184 167 76 193 193 189 187 182 175 162 152
[24] [480] [1160] [260] [4020] [5440] [6840] [8230] [9560] [10900] [24] [620] [1520] [3280] [5060] [6780] [8530] [10240]
55 130 295 455 615 775 930 1080 1230 70 170 370 570 765 965 1155
91 290 289 282 279 273 260 248 232 215 91 232 230 229 225 220 212 204
[28] [420] [1130] [2570] [3990] [5420] [6820] [8220] [9520] [10840] [28] [570] [1460] [3210] [5000] [6730] [8480] [10200]
45 130 290 450 610 770 930 1075 1225 65 165 365 565 760 960 1150
106 339 336 333 328 320 308 295 276 257 106 270 268 266 261 256 248 236
[32] [360] [1100] [2510] [3920] [5330] [6750] [8170] [9440] [32] [530] [1420] [3140] [4930] [6640] [8380] [10120]
40 125 285 445 600 765 920 1065 60 160 355 555 750 945 1145
121 388 384 381 375 368 354 341 320 121 309 306 304 299 292 282 269
[36] [300] [1060] [2440] [3830] [5220] [6660] [8100] [9330] [36] [450] [1370] [3010] [4840] [6500] [8250] [10000]
35 120 275 435 590 750 915 1055 50 155 340 545 730 930 1130
136 436 430 421 416 410 396 383 360 136 348 346 340 336 329 317 301
[40] [270] [1020] [2400] [3780] [5150] [6580] [8020] [9220] [40] [380] [1320] [2880] [4740] [6460] [8120]
30 115 270 425 580 745 905 1040 45 150 325 535 730 915
151 485 478 466 461 456 441 427 403 151 387 386 380 375 368 359
[50] [982] [2180] [3420] [4660] [6050] [7440] [50] [1140] [2650] [4540] [6440] [8050]
110 245 385 525 685 840 130 300 515 730 910
189 597 582 576 570 551 534 189 482 475 469 460 449
[60] [1960] [3250] [4540] [5750] [7080] [60] [2460] [4430] [6360] [7860]
220 365 515 650 800 280 500 720 890
227 698 691 684 661 641 227 570 562 552 538
52
Performance
490 cm3/r [30.0 in3/r]
625 cm3/r [38.0 in3/r]
Data [250]
15
[500] [1000] [1500] [2000]
35 70 105 140
[2500] [3000]
170 205
[3500] [4000]
240 275
[250]
15
[500] [1000] [1500] [2000] [2500]
35 70 105 140 170
[3000]
205
[3200]
221
6000 [1]
3,8
[1010]
115
7
[1200]
235
7
[4260]
480
5
[6140]
695
3 3,8
[1] [1060]
120
5
[2205]
250
5
[4515]
510
4
[6690]
755
2
Series [2]
7,5
[1020]
115
15
[2110]
240
14
[4270]
480
13
[6280]
710
12
[8350]
945
11
[10420]
1175
8
[12140]
1370
3
[2]
7,5
[1090]
125
12
[2300]
260
12
[4720]
535
13
[7025]
795
10
[9360]
1060
6
[4] [1030] [2100] [4280] [6410] [8500] [10590] [12500] [14580] [16670] [4] [1145] [2450] [5052] [7520] [9410] [12700]
115 235 485 725 960 1195 1410 1645 1885 130 275 570 850 1065 1434
15 30 30 29 28 27 25 21 17 12 15 24 24 24 21 16 13
[8] [1020] [2090] [4290] [6490] [8620] [10740] [12800] [14930] [8] [1195] [2600] [5350] [8195] [11220] [13100] [15800] [16800]
Flow LPM [GPM]
Flow LPM [GPM]

115 235 485 735 975 1215 1445 1685 135 295 605 925 1270 1480 1785 1898
30 60 60 59 57 54 51 45 38 30 45 45 44 42 37 35 32 30
[12] [1000] [2080] [4290] [6500] [8650] [10800] [12890] [12] [1200] [2600] [5390] [8145] [11770] [13000] [15700]
115 235 485 735 975 1220 1455 135 295 610 920 1330 1469 1774
45 91 91 89 87 84 79 71 45 72 72 71 68 64 60 56
[16] [110] [2060] [4260] [6480] [8650] [10820] [12900] [16] [1120] [2530] [5340] [8105] [11740] [13000]
960 235 480 730 975 1220 1460 125 285 605 915 1325 1469
61 122 122 121 118 114 109 100 61 94 94 92 89 85 83
[20] [900] [1980] [4180] [6420] [8620] [10820] [20] [1050] [2465] [5285] [8080] [11725]
100 225 470 725 975 1220 120 280 595 915 1325
76 153 152 150 147 144 139 76 120 119 117 115 110
[24] [850] [1930] [4150] [6390] [8580] [10770] [24] [950] [2365] [5180] [7990] [11705]
95 220 470 720 970 1215 105 265 585 905 1320
91 184 184 181 180 176 171 91 144 143 140 138 132
[28] [740] [1840] [4070] [6290] [8500] [10720] [28] [855] [2255] [5080] [7915] [11640]
85 210 460 710 960 1210 95 255 575 895 1315
106 215 214 211 208 204 198 106 169 168 165 162 156
[32] [690] [1710] [3970] [6190] [8420] [10660] [32] [730] [2140] [4960] [7775] [11505]
80 195 450 700 950 1205 80 240 560 880 1300
121 245 244 241 237 232 226 121 193 192 188 185 179
[36] [670] [1560] [3860] [6080] [8340] [10420] [36] [555] [1965] [4780] [7585]
75 175 435 685 940 1175 65 220 540 855
136 276 275 272 265 260 255 136 217 216 213 210
[40] [570] [1400] [3750] [5970] [8140] [10180] [40] [380] [1790] [4600] [7395]
65 160 425 675 920 1150 45 200 520 835
151 307 306 303 295 290 284 151 241 240 238 236
[50] [1140] [3240] [5220] [7620] [50] [4180] [6985]
130 365 590 860 470 790
189 382 379 369 362 189 296 290
[60] [2860] [4860] [7140] [60] [3800] [6600]
325 550 805 430 745
227 454 442 435 227 353 345
Motors run with high efficiency in all

areas designated with a number for torque
and speed, however for best motor life
Continuous [3800] Torque [lb-in]
select a motor to run with a torque and
speed range shown in the light blue area. Intermittent
430
353
} Nm
Speed RPM
Performance data is typical at

120 SUS. Actual data may vary 805 cm3/r [49.0 in3/r] 985 cm3/r [60.0 in3/r]
slightly from unit to unit ∆ Pressure Bar [PSI] ∆ Pressure Bar [PSI]
in production [250] [500] [750] [1000] [1250] [1500] [1750] [2000] [2250] [2500] [250] [500] [750] [1000] [1250] [1500] [1750] [2000]
15 35 50 70 85 105 120 140 155 170 15 35 50 70 85 105 120 140
[1] [1455] [3100] [4680] [6031] [7799] [1] [1890] [4110] [5730] [7640] [9550]
164 350 529 681 881 215 465 645 865 1080
3,8 4 4 2 2 1 3,8 3 3 2 2 1
[2] [1483] [3173] [5121] [6432] [8510] [9633] [11319] [12127] [2] [1910] [4140] [6270] [8300] [10420] [12500] [13860] [14920]
168 359 579 727 961 1088 1279 1370 215 470 710 940 1175 1410 1565 1685
7,5 9 9 9 8 7 6 5 5 7,5 8 8 7 7 6 5 4 3
[4] [1547] [3331] [5292] [6744] [8714] 10075] [11352] [12539] [14564] [16377] [4] [1980] [4290] [6480] [8540] [10670] [12800] [13900] [15850]
175 376 598 762 984 1138 1283 1417 1645 1850 225 485 775 965 1205 1445 1570 1790
15 19 19 18 17 16 15 14 12 11 10 15 15 15 15 14 14 13 13 12
[8] [1599] [3473] [5415] [7039] [8934] [10629] [11842] [14004] [15441] [8] [2030] [4400] [6630] [8790] [10940] [13090] [14500] [16580]
Flow LPM [GPM]
Flow LPM [GPM]
181 392 612 795 1009 1201 1338 1582 1745 230 495 750 995 1235 1480 1640 1875
30 35 35 34 33 32 31 29 29 28 30 30 30 30 29 28 27 26 25
[12] [1599] [3469] [5415] [7093] [9024] [10658] [12283] [13726] [12] [2020] [4390] [6630] [8860] [11050] [13240] [15040]
181 392 612 801 1020 1204 1388 1551 230 495 750 1000 1250 1495 1700
45 56 56 55 53 53 52 50 50 45 45 45 45 44 43 42 41
[16] [1543] [3395] [5357] [7032] [8983] [10640] [12010] [16] [2010] [4320] [6560] [8790] [11000] [13260]
174 384 605 794 1015 1202 1357 225 490 740 995 1245 1500
61 73 73 72 70 69 68 67 61 61 61 61 60 59 58
[20] [1457] [3312] [5292] [6968] [8943] [10583] [12146] [20] [1910] [4220] [6480] [8720] [10950] [13160]
165 374 598 787 1010 1196 1372 215 475 730 985 1235 1485
76 93 92 91 89 88 87 86 76 77 77 76 76 75 74
[24] [1352] [3183] [5088] [6811] [8812] [10411] [24] [1810] [4060] [6230] [8500] [10790] [12990]
153 360 575 769 996 1176 205 460 705 960 1220 1470
91 112 112 111 110 108 106 91 92 92 92 91 90 89
[28] [1213] [3055] [5047] [6713] [8681] [10411] [28] [1620] [3920] [6180] [8420] [10630] [12820]
137 345 570 758 981 1176 185 445 700 950 1200 1450
106 131 131 131 129 128 127 106 107 107 107 106 105 103
[32] [1075] [2907] [4884] [6546] [8395] [10060] [32] [1480] [3740] [5980] [8200] [10280]
121 328 552 740 949 1137 165 425 675 925 1160
121 150 149 149 146 145 144 121 123 123 122 121 120
[36] [823] [2692] [4663] [6320] [8118] [36] [1140] [3490] [5710] [7930] [9940]
93 304 527 714 917 130 395 645 895 1125
136 168 168 168 167 165 136 138 138 138 137 135
[40] [592] [2477] [4426] [6085] [7832] [40] [850] [3240] [5420] [7640] [9590]
67 280 500 688 885 95 365 610 865 1085
151 187 186 186 185 184 151 153 153 152 151 150
[50] [2730] [4214] [5849] [7603] [50] [2960] [5160] [7350] [9310]
308 476 661 859 325 585 830 1050
189 234 233 231 230 189 191 190 189 188
[60] [3806] [5459] [7407] [60] [4660] [7160] [9070]
430 617 837 525 810 1025
227 280 277 275 227 230 229 226
53
Dimensions — 6000
Series Standard
Motor
1-3/4 Inch Dia. 40 mm Dia. Shaft Dim. Standard Rotation
Tapered Shaft Straight Shaft See Page 59 Viewed from Shaft End
94.5/91,4 Port A Pressurized — CW
[3.72/3.60] 1-1/2 Inch Dia. Port B Pressurized — CCW
Straight Shaft
1-1/2 Inch Dia.
Splined Shaft Standard SAE CC Flange
150,4 [5.92] Max.
93,2/90,1
[3.67/3.55]
78,7/75,6
16,0/13,5 [3.10/2.98]
[.63/.53]
114,5 147,4
[4.508] [5.80]
Square Max.
X
14,53/14,14 [.572/.557] 161,9 [6.375]
Dia. Thru (4) Dia. Bolt Circle
127,00/126,87
[5.000/4.995]
Dia.
Port B
13,59/12,57
Y Max. [.535/.495]
Port Dim.
See Page 61
Case Drain Port

See Page 61
24,6/24,1
[.97/.95]
6000 Series Standard Motor with 1-5/16-12 O-ring Ports,

G 1 (BSP) Ports, and 3/4 inch Split Flange Ports
Displ.
cm3/r 195 245 310 390 490 625 985
[in3/r] [11.9] [15.0] [19.0] [23.9] [30.0] [38.0] [60.0]
X Dim. mm 187,7 193,3 200,7 209,3 220,5 235,2 274,8
[inch] [ 7.39] [ 7.61] [ 7.90] [ 8.24] [ 8.68] [ 9.26] [10.82]
Y Dim. mm 270,1 275,6 283,0 291,6 302,8 318,5 357,4
[inch] [10.63] [10.85] [11.14] [11.48] [11.92] [12.54] [14.07]
54
Dimensions —
6000 Series
Wheel Motor
Shaft Dim. 1-1/2 Inch Dia. Straight Shaft or
See Page 59 Standard Rotation
1-1/2 Inch Dia. Splined Shaft Viewed from Shaft End
40 mm Dia. Straight Shaft Port A Pressurized — CW
179,6/176,3 Port B Pressurized — CCW
[7.07/6.94]
1-3/4 Inch Dia. Tapered Shaft
166,9 [6.57]
Square Max.
178,3/175,0
[7.02/6.89]
101,3/98,3
[3.99/3.87]
130,21
[5.126]
Square
163,8/160,5
[6.45/6.32]
X 14,53/14,14
184,12 [7.250]
[.572/.557]
Dia. Bolt Circle
Dia. Thru (4)
139,70/139,57
[5.500/5.495]
Port B Dia.
Y Max.
Port Dim. 127,00/126,87
See Case Drain Port [5.000/4.995]
Page 61 Dia. 17,3/16,8
See Page 61 [.68/.66]
98,8/97,3
[3.89/3.83] 8,6/7,1
[.34/.28]
6000 Series Wheel Motor with 1-5/16-12 O-ring Ports,
G 1 (BSP) Ports, and 3/4 inch Split Flange Ports
Displ.
cm3/r 195 245 310 390 490 625 985
[in3/r] [11.9] [15.0] [19.0] [23.9] [30.0] [38.0] [60.0]
X Dim. mm 102,9 108,4 115,8 124,7 135,6 149,9 190,0
[inch] [4.05] [4.27] [4.56] [4.91] [5.34] [5.90] [7.48]
Y Dim. mm 185,2 190,8 198,2 207,1 218,0 233,0 272,6
[inch] [7.29] [7.51] [7.80] [8.15] [8.58] [9.17] [10.73] 22,6/22,1
[.89/.87]
55
Dimensions — 6000 Series

Global Mount
(Similar to ISO 3019/2)
179,0 [7.04] Max.
159,99/159,94
[6.299/6.297]
Pilot Dia. 179,0
39,37/38,61
[7.04]
[1.550/1.520]
Max.
20,3/19,8
141,43
[.80/.78]
[5.568]
(4)
Standard Rotation
Viewed from Shaft End
Port A Pressurized — CW 14,000/13,957 8,992/8,890
18,21/17,83
Port B Pressurized — CCW [.5512/.5495] [.3540/.3500]
[.717/.702]
Dia. Thru (4)
X
50 mm Dia. M12 x 1,75
25,0 [.98] Min.
Straight Shaft Depth
Port B 53,49/52,70
[2.106/2.075] 50,000/49,974
Y Max. Port Dim. [1.9685/1.9675]
(see page 61
124,0/120,9 79,2 [3.12]

8,4/4,6
[4.88/4.76] Max. Coupling
Case Drain Port (see page 61) [.33/.18]
70,26/69,75 Length
[2.766/2.746]
6000 Series Standard Motor with G 1 (BSP) Ports
Displ.
cm3/r 310 390 490 625 800 800 985
[in3/r] [19.0] [24.0] [30.0] [38.0] [45.0] [49.0] [60.0]
X Dim. mm 182,4 191,0 202,2 216,7 229,4 236,7 256,5
[inch] [ 7.18] [ 7.52] [ 7.96] [ 8.54] [ 9.03] [ 9.32] [10.10]
Y Dim. mm 262,6 271,5 282,4 297,2 309,6 317,0 337,0
[inch] [10.34] [10.69] [11.12] [11.70] [12.19] [12.48] [13.27]
56
Dimensions —
161,92 [6.375]
6000 Series Dia. Bol Circle
Bearingless Motor 114,50
147,6 [4.508]
[5.81] Square
Square
Case Drain
127,00/126,87 Holes (2)
[5.000/4.995] Note: Similar to
Dia. SAE C Type
Mounting Flange
45°
14,53/14,14
12,7/12,1 [.572/.557]
[.50/.48] Dia. Thru (4)
24,2/21,0
[.95/.83]
Port B Face Seal or O-ring Seal C
Y Max.
C 47,2 [1.86] Dia.
Port Dim. Case Drain Port D 111,5 [4.39] Max.
See Page 61 E 106,4 [4.19] Full Form Dia.
See Page 61 F 6,9 [ .27] Min. Full Form Dia.
D
G 10,2 [ .40] Min.
E
H 86,1 [3.39] Max.
F
J 66,5 [2.62] Dia.
Standard Rotation
Viewed from Drive End
Port A Pressurized — CW Mating Coupling Blank
Port B Pressurized — CCW
Eaton Part No. 12778-002
G
6000 Series Bearingless Motor with 1-5/16-12 O-ring Ports, H
G 1 (BSP) Ports, 3/4 inch Split Flange Ports
Displ. For 6000 Series Bearingless
cm3/r 195 245 310 390 490 625 985 Motor application information
[in3/r] [11.9] [15.0] [19.0] [23.9] [30.0] [38.0] [60.0]
contact your Eaton
X Dim. mm 105,7 111,2 118,3 127,5 138,7 152,9 193,0 representative (mating J
[inch [ 4.16] [ 4.38] [ 4.66] [ 5.02] [ 5.46] [ 6.02] [ 7.60]
coupling blanks available
Y Dim. mm 188,0 193,6 200,7 209,6 220,8 235,5 275,1 from Eaton Hydraulics).
[inch] [ 7.40] [ 7.62] [ 7.90] [ 8.25] [ 8.69] [ 9.27] [10.83]
Note: After machining blank,
part must be hardend per
Eaton specification.
57
Bearingless Installation —
6000 Series
16
14,2/12,7
[.56/.50]
49,848/49,822 40,1/39,6 52,37
1,5/0,5 [1.9625/1.9615] [1.58/1.56] [2.062]
[.06/.02]
0,13[.005] A Dia. Dia. Min.
-D-
1,8/0,5
[.07/.02]
30° R 1,8/1,2
15° [.07/.05]
5,1/4,6 [.20/.18] Dia. 2
3 24,6/24,1 (2) Thru Oil Hole
Case Flow [.97/.95]
6,8/6,4
1,5/0,8 [.27/.25]
[.06/.03]
-A-
81,8/80,7
[3.22/3.18]
6
0,13 [.005] A
Circular
Finish
Case Flow
R 0,5 [.02] Max.
Finish
Major
Fillet R.
Tip R.
Pitch
5 Minor
Form
4
9,4/8,4
[.37/.33] 69,1/68,1
[2.72/.2.68]
-B- Coupling Depth
1 Internal spline in mating part to be as follows:
Spline Pitch — 8.5/17 Material to be ASTM A304, 8620H.
Pressure Angle — 30° Carborize to a hardness of 60-64 HRc with case
Number of teeth — 12 depth (to 50HRc) of 0,076 - 1,02 [.030 - .040]
Class of Fit — Ref. 5 (dimensions apply after heat treat).
Type of Fit — Side 2 Mating part to have critical dimensions as shown.
Pitch Diameter — Ref. 35,858823 [1.4117647] 0,20 [.008] H Oil holes must be provided and open for proper
Base Diameter — Ref. 31,054652 [1.2226241] oil circulation.
Major Diameter — 39,17 [1.542] Max. 38,97 [1.534] Min.
3 Some means of maintaining clearance between
Minor Diameter — 33,30 - 33,48 [1.311 - 1.318] shaft and mounting flange must be provided.
Form Diameter, Min. — 38,33 [1.509]
Fillet Radius — 0,64 - 0,76 [.025 - .030] 4 Seal to be furnished with motor for proper
oil circulation thru splines.
Tip Radius — 0,25 - 0,51 [.010 - .020]
Finish — 1,6 [63] 5 Similar to SAE “C” Four Bolt Flange.
Involute Profile Variation — +0,000 -0,025 [+.0000 -.0010] 6 Counterbore designed to adapt to a standard
Total Index Variation — 0,038 [.0015] sleeve bearing 50,010 - 50,038 [1.9689 - 1.9700] ID
Lead Variation — 0,013 [.0005] by 60,051 - 60,079 [2.3642 - 2.3653] O.D. (Oilite
bronze sleeve bearing).
Circular Space Width:
Maximum Actual — 5,898 [.2322]
Minimum Effective — 5,804 [.2285]
Maximum Effective — Ref. 5,857 [.2306]
Minimum Actual — Ref. 5,834 [.2297]
Dimension Between Two Pins — Ref. 26,929 - 27,084 [1.0602 - 1.0663]
Pin Diameter — 6,223 [.2450] Pins to Have 4,0 [.160] Wide Flat for
Root Clearance
58
Dimensions — Shafts
6000 Series
178,1/175,0 [7.02/6.89] End of Shaft to Mounting Surface (Whl)
78,6/75,8 [3.10/2.98] End of Shaft to Mounting Surface (Std)
42,0/40,6
[1.65/1.60] 31,7 [1.25]
9,56/9,52
1-1/4-18 UNEF
[.376/.375]
1328 [11750] 4,1 [.16] 2107 [18650]

Max. Torque Dia. Thru Max. Torque
Nm [lb-in] Nm [lb-in]
3/8-16 UNC x 44.45

18,5 [.73] Deep [1.750] Dia. 77,0 [3.03]
42,40/42,13 11,138/11,112
2.23
[1.669/1.659] [.4385/.4375]
[56,7] SAE J501 Standard Tapered Shaft
Max. Coupling 125,00 ± 0,17 Taper per Meter
38,10/38,04 [1.500 ± .002 Taper per Foot]
[1.500/1.498] 5,54/5,20
1-1/2 Inch Straight Dia. 1-3/4 Inch Tapered [.218/.205]

Hub
3/8-16 UNC x 40,3 [1.59]
18,5 [.73] Deep Min. Full Spline Recommended Torque:
(645 Nm [475 lb-ft] Dry)
(510 Nm [375 lb-ft] Lub)
1328 [11750] Plus Torque required to
Max. Torque align the slotted nut with
Nm [lb-in] the Shaft Crosshole.
External Involute
Spline, 12.24 DP 38,10 [1.500]
60,17/57,78
17 Tooth 30° P.A. Dia. Ref.
56,7 [2.369/2.275]
Flat Root Side Fit [2.23]
per ANSI B92.1, 1970 Max. Coupling
1-1/2 Inch 17 Tooth Splined Tapered Shaft Hub Data
12,000/11,957 55,4 [2.18]

[.4724/.4708] 9,2/4,5 [.36/.18]
1-1/4-18 UNEF 11,2 [.44]
8,000/7,910 63,7/62,2
[.3149/.3115] [2.51/2.45] 4,1 [.16]
M12 x 1,75 -6H 75,6 [2.98]

25 mm [.984] Deep 30° 30°
Max. Coupling 15,7 [.62]
43,03/42,72
[1.694/1.682] 40,018/39,992 1328 [11750]
[1.5755/1.5745] Max. Torque
40 mm Straight Nm [lb-in] Slotted Hexagon Nut
59
Shaft Side Load Capacity

6000 Series
These curves indicate the radial load capacity on the motor [lb] kg
shaft(s) at various locations.
[10000]
The curve is based on B 10 Bearing life (2000 hours or 4000
12,000,000 shaft revolutions at 100 RPM ) at rated output [ 8000]
torque. To determine radial load at speeds other than 3000
100 RPM, multiply the load values given on the bearing [ 6000]
curve by the factors in the chart below. [ 4000] 2000
RPM Multiplication Factor [ 2000] 1000
50 1.23
100 1.00 0
200 .81 mm -180 -160-140-120 -100 -80 -60 -40 -20 0 20 40
300 .72
400 .66 [inch] [-7] [-6] [-5] [-4] [-3] [-2] [-1] 0 [1] [2]
500 .62
600 .58 Wheel Motor
700 .56 Tapered
800 .54 Shaft
For 3,000,000 Shaft revolutions or 500 hours — Increase

these shaft loads 52%.
[lb] kg [lb] kg
[10000] [10000]
4000 4000
[ 8000] [ 8000]
3000 3000
[ 6000] [ 6000]
[ 4000] 2000 [ 4000] 2000
[ 2000] 1000 [ 2000] 1000
0 0
mm -140 -120 -100 -80 -60 -40 -20 0 20 40 60 80 100 mm -140 -120 -100 -80 -60 -40 -20 0 20 40 60 80 100
[inch] [-6] [-5] [-4] [-3] [-2] [-1] 0 [1] [2] [3] [4] [inch] [-6] [-5] [-4] [-3] [-2] [-1] 0 [1] [2] [3] [4]
Standard Motor Standard Motor

Straight Splined
Shaft Shaft
60
Dimensions — Ports 6000 Series
6000 Series with
Shuttle Valve
1-5/16-12 O-ring Ports (2) 7/16-20 UNF O-ring or
or G 1 (BSP) Ports (2) G 1/4 (BSP) Port See Pages 54-57
Case Drain
1-5/16-12 O-ring Ports (2) with Shuttle

X
Port B Port B 9/16-18 UNF O-ring
Port A
Y Max.
13,8/10,6
[.54/.42]
35,9/34,7 79,8
19,4/18,7 [1.414/1.366] [3.14]
[.765/.735] Max.
19,4/18,7 [.765/.735]
4,4/3,0
[.17/.12]
Port A
4 Bolt 3/4 Inch Split Flange Port B See Pages 54-57 35,9/34,7
Ports to Fit SAE J518c (2) [1.414/1.366]
Except for 20,0 [.79] Min. Thd. Dp. 19,4/18,7
7/16-20 UNF O-ring [.765/.735]
Port Case Drain
19,4/18,7 [.765/.735]
X See Pages 54-57
Port A
13,8/10,6 X
[.54/.42]
23,9 [.94]
Y Max.
Y
Max.
11,2 [.44] 77,2
47,63
[3.04]
[1.875] 45° 22,23 [.875]
Max.
79,8
54,9 [2.16]
20,7/17,4 [3.14]
[.80/.70] Max.
58,0/56,3
[2.28/2.22] 20,1 [.79] Max.
6000 Series 17°
58,0/56,3
Motor [2.28/2.22]
End View—
Common Standard Rotation — 6000 Series
Dim. Viewed from Shaft End
Port A Pressurized — CW 82,3
Port B Pressurized — CCW [3.24]
Max.
44,2/39,6
[1.74/1.56] 17°
66,0 66,0
[2.60] [2.60]
Max. Max.
66,0 82,3 66,0

[2.60] [3.24] [2.60]
Max. Max. Max.
61
Product Numbers
6000 Series
Product Numbers—6000 Series Motors Use digit prefix —112-, 113-, or 114- plus four digit number from charts
for complete product number—Example 114-1047.
Orders will not be accepted without three digit prefix.
Displacement cm3/r [ in3/r ] and Product Number
195 245 310 390 490 625 985
Mounting Shaft Ports [11.9] [ 15.0] [19.0] [23.9] [30.0] [38.0] [60.0]
1-1/2 inch Straight 1-5/16 O-ring 112-1064 -1065 -1066 -1067 -1068 -1107 -1069
40 mm Straight G 1 (BSP) 112-1094 -1095 -1096 -1097 -1098 — -1099

Standard
1-5/16 O-ring 112-1058 -1059 -1060 -1061 -1062 -1109 -1063
1-1/2 Inch
17 T Splined
G 1 (BSP) 112-1088 -1089 -1090 -1091 -1092 — -1093
40 mm Straight G 1 (BSP) 113-1082 -1083 -1084 -1085 -1086 -1100 -1087

Wheel
Motor 1-3/4 Inch
Tapered 1-5/16 O-ring 113-1070 -1071 -1072 -1073 -1074 -1093 -1075
1-5/16 O-ring 114-1031 -1032 -1033 -1034 -1035 -1055 -1036

Bearingless
G 1 (BSP) 114-1043 -1044 -1045 -1046 -1047 — -1048
114-1047
Product Numbers – 6000 Series
Mounting Type - Standard (Code H), 4 Bolt:
• 160,0 [6.30] Pilot Dia.
• 18,01 [.709] Dia. Mounting Holes Use digit prefix —112- plus four digit number from charts
• 200,0 [7.87] Dia. Bolt Circle for complete product number—Example 112-1215.
Output Shaft - Straight (Code 21) Orders will not be accepted without three digit prefix.
Ports - G1 (BSP) Staggered G 1/4 Case Drain (Code C) 112-1215
Paint - Low Gloss Black (Code A)
Displacement cm3/r [ in3/r ] and Product Number
310 390 490 625 737 800 985
Mounting Shaft Ports [19.0] [23.9] [30.0] [38.0] [45.0] [49.0] [60.0]
Standard 50 mm Straight G 1 (BSP) 112-1217 -1218 -1215 -1216 -1247 -1219 -1220
For 6000 Series Motors with a configuration Not Shown in the charts above: Use model code number system on
page 63 to specify product in detail.
62
Model Code for 6000 Series Motors
The following 14-digit coding system has been developed to identify all of the configuration options for the 6000 Series Motor. Use this model
code to specify a motor with the desired features. All 14-digits of the code must be present when ordering. You may want to photocopy the
matrix below to ensure that each number is entered in the correct box.
Model Code — 6000 Series Disc Valve Motors

1 2 3 4 5 6 7 8 9 10 11 12 13 14
M 0 6 0 0 21 ........... 50 mm Dia. Straight with Straight Key, 14W x 9H x
70L, M12 x 1,75-6H Thread in End (Available with
Position 1 Product Series Mounting Flange Code H Only)
M ............ Motor 24 ........... 60 mm Dia. 10:1 Tapered Shaft with M42 x 3-6H
Threaded End (Available with Mounting Flange Code H
Position 2, 3 6000 Series
Only)
06 ........... 6000 Series
25 ........... 2 1/8 inch Dia. Splined 16 Tooth, 55,9 mm [2.20] Min.
Position 4, 5 Displacement cm3/r [in3/r] Full Spline Length (Available with Mounting Flange
12 ........... 195 [11.9] Code H Only)
15 ........... 245 [15.0]
Position 9 Port Type
19 ........... 310 [19.0]
A .............. 1–5/16 - 12 O-ring with 7/16-20 O-ring Case Drain
24 ........... 390 [23.9] and Check Valve
30 ........... 490 [30.0] B .............. 3/4 inch 4 Bolt Split Flange with 7/16-20 O-ring Case
38 ........... 625 [38.0] Drain and Check Valve
45 ........... 740 [45.0]* C .............. G 1 (BSP) O-ring with G 1/4 (BSP) O-ring Case Drain
49 ........... 805 [49.0]* and Check Valve
60 ........... 985 [60.0] D .............. 1– 5/16-12 O-ring with (2) 9/16-18 O-ring Case Drain
Ports and Hot Oil Shuttle Valve
* For performance and dimension data contact your Eaton
Hydraulics representitive. R .............. 1– 5/16-12 O-ring with (2) 9/16-18 O-ring Ports for
Position 6 Mounting Flange External Lubrication Circuit (both case ports must be
connected)
A ............ 4 Bolt (Bearingless 127,0 [5.00] Pilot Dia. and 14,3
[.56] Dia. Mounting Holes 161,9 [6.38] Dia. B.C. Position 10, 11 Special Features (Hardware)
B ............ 4 Bolt (SAE CC) (Standard) 127,0 [5.00] Pilot Dia. 00 ............. None
and 14,3 [.56] Mounting Holes on 161,9 [6.38] Dia. 10 ............. Viton Shaft Seal
B.C. 07 ............. Viton Seals
C ............ 4 Bolt (Wheel) 139,7 [5.50] Pilot Dia. and 14,3 [.56] 13 ............. Reverse Rotation
Dia. Mounting Holes on 184,1 [7.25] Dia. B.C. 14 ............. Seal Guard
H ............ 4 Bolt (Global) (Standard) 160,0 [6.30] Pilot Dia. and 21 ............. Speed Sensor (Std.)
18,0 [.709] Dia. Mounting Holes on 200,0 [7.87] Dia.
Position 12 Paint/Special Packaging
Bolt Circle
0 ............... No Paint
Position 7, 8 Output Shaft
A .............. Painted Low Gloss Black
00 ........... Bearingless
B .............. Corrosion Protected
01 ........... 1–1/2 inch Dia. Straight with Straight Key, 3/8-16
Threaded Hole and 56,7 [2.23] Max. Coupling Length Position 13 Eaton Assigned Code when Applicable
02 ........... 1–3/4 inch Dia. Tapered with Straight Key and 1–1/4 - 0 ............... Assigned Code
18 UNEF Slotted Hex. Nut Position 14 Eaton Assigned Design Code
03 ........... 1–1/2 inch Dia. Splined 17T with 40,3 [1.59] Min. Full 0 ............... Assigned Design Code
Spline Length and 3/8-16 Threaded Hole
10 ........... 40 mm Dia. Straight with Straight Key, M12 x 1,75-
6H Threaded Hole
63
Fluid Recommendations
Char-Lynn Disc Valve Motors
Introduction Fluid Maintenance
The ability of Eaton hydraulic components to provide the desired Maintaining correct fluid viscosity and cleanliness level is essential
performance and life expectancy depends largely on the fluid used. for all hydraulic systems. Since Eaton hydraulic components are used
The purpose of this section is to provide readers with the knowledge in a wide variety of applications it is impossible for Eaton to publish a
required to select the appropriate fluids for use in systems that employ fluid maintenance schedule that would cover every situation. Field
Eaton hydraulic components. testing and monitoring are the only ways to get accurate measure-
One of the most important characteristics to consider when choosing ments of system cleanliness. OEM’s and distributors who use Eaton
a fluid to be used in a hydraulic system is viscosity. Viscosity choice hydraulic components should test and establish fluid maintenance
is always a compromise; the fluid must be thin enough to flow easily schedules for their products. These maintenance schedules should be
but thick enough to seal and maintain a lubricating film between designed to meet the viscosity and cleanliness requirements laid out
bearing and sealing surfaces. See chart below for viscosity in this document.
requirements. Fluid Selection
Viscosity and Temperature Premium grade petroleum based hydraulic fluids will provide the best
Fluid temperature affects viscosity. In general, as the fluid warms it performance in Eaton hydraulic components. These fluids typically
gets thinner and its viscosity decreases. The opposite is true when fluid contain additives that are beneficial to hydraulic systems. Eaton
cools. When choosing a fluid, it is important to consider the start-up recommends fluids that contain anti-wear agents, rust inhibitors,
and operating temperatures of the hydraulic system. Generally, the fluid anti-foaming agents, and oxidation inhibitors. Premium grade
is thick when the hydraulic system is started. With movement, the fluid petroleum based hydraulic fluids carry an ISO VG rating.
warms to a point where a cooling system begins to operate. SAE grade crankcase oils may be used in systems that employ Eaton
From then on, the fluid is maintained at the temperature for which the hydraulic components, but it should be noted that these oils may not
hydraulic system was designed. In actual applications this sequence contain all of the recommended additives. This means using crankcase
varies; hydraulic systems are used in many environments from very oils may increase fluid maintenance requirements.
cold to very hot. Cooling systems also vary from very elaborate to very Hydraulic fluids that contain V.I. (viscosity index) improvers,
simple, so ambient temperature may affect operating temperature. sometimes called multi-viscosity oils, may be used in systems that
Equipment manufacturers who use Eaton hydraulic components in their employ Eaton hydraulic components. These V.I. improved fluids are
products should anticipate temperature in their designs and make the known to “shear-down” with use. This means that their actual
appropriate fluid recommendations to their customers. viscosity drops below the rated value. Fluid maintenance must be
Cleanliness increased if V.I. improved fluids are used. Automotive automatic
Cleanliness of the fluid in a hydraulic system is extremely important. transmission fluids contain V.I. improvers.
Eaton recommends that the fluid used in its hydraulic components be Synthetic fluids may be used in Eaton hydraulic components.
maintained at ISO Cleanliness Code 18/13 per SAE J1165. This code A reputable fluid supplier can provide information on synthetic fluids.
allows a maximum of 2500 particles per milliliter greater than 5 µm and Review applications that require the use of synthetic fluids with your
a maximum of 80 particles per milliliter greater than 15 µm. Cleanliness Eaton representative.
requirements for specific products are given in the table below.
OEM’s and distributors who use Eaton hydraulic components in their
products should provide for these requirements in their designs.
A reputable filter supplier can supply filter information.
Viscosity ISO Cleanliness

Char-Lynn Minimum Best Range Requirements
Disc Valve Motors 70 SUS 100-200 SUS 18/13
13 cSt 20-43 cSt
Additional Notes:
• Fluids too thick to flow in cold weather start-ups will cause pump 100 - 150 SUS [20 - 32 cSt] and viscosity should never fall below 70
cavitation and possible damage. Motor cavitation is not a problem SUS [13 cSt].
during cold start-ups (with one exception — two speed motors). • If the natural color of the fluid has become black it is possible that
• Minimum / Maximum operating temperatures are -29° C / 82° C an overheating problem exists.
[-20° F / 180° F]. • If the fluid becomes milky a water contamination problem may
• When choosing a hydraulic fluid, all the components in the exist.
system must be considered and the best viscosity range adjusted • Take fluid level reading when the system is cold.
accordingly. For example, when a medium duty piston pump is • Contact your Eaton representative if you have specific questions
combined with a Geroler motor the best viscosity range becomes about the fluid requirements of Eaton hydraulic components.
81
Motor Application
Information — Vehicle Drive Calculations
Step One — Calculate Motor Speed (RPM) Step Three — Tractive Effort to Ascend Grade
The largest grade a vehicle can ascend is called its
2.65 x KPH x G 168 x MPH x G
RPM = RPM = “gradability.” Grade is usually expressed as a percent rather
Rm Rl
than in degrees. A rise of one meter in ten meters or one foot
rise in ten feet of travel is a
where KPH = vehicle speed (kilometers per hour) 1/10 or 10 percent grade.
where MPH = vehicle speed (miles per hour)
Rm = rolling radius of tires (meter) GR = GVW (sin θ + ρ cos θ)
R1 = rolling radius of tires (inch)
G = gear reduction ratio (if any) between motors Table 2
and wheels. If no gear box or other gear
reduction devices are used G = 1. Comparison Table Slope
Grade (%) (Degrees)
If vehicle speed is expressed in m/second, multiply by 3.6 to convert 1% 0°35'
to KPH. 2% 1° 9'
5% 2°51'
If vehicle speed is expressed in ft./second, divide by 1.47 to convert to 6% 3°26'
MPH. 8% 4°35'
10% 5°43'
Step Two — Determine Rolling Resistance 12% 6°5'
Rolling resistance (RR) is the force required to propel a vehicle 15% 8°31'
over a particular surface. The values in Table 1 are typical of 20% 11°19'
various surfaces per 1000 lb. of vehicle weight. 25% 14° 3'
32% 18°
RR = GVW x ρ (kg) (lb) 60% 31°
where GVW = gross (loaded) vehicle weight lb/Kg
ρ = value from Table 1 Step Four — Determine Acceleration Force (FA)
The force (FA) required to accelerate from stop to maximum
speed (KPH) or (MPH) in time (t) seconds can be obtained
Table 1 - Rolling Resistance Coefficients for Rubber Tires from the following equation:
on Various Surfaces
Step Five — Determine Drawbar Pull
Surface ρ Drawbar Pull (DP) is total force available at the drawbar or
Concrete, excellent .010 “hitch” after the above forces have been subtracted from the
Concrete, good .015 total propelling force produced by the hydraulic motors. This
Concrete, poor .020 value is established as either:
Asphalt, good .012
Asphalt, fair .017 KPH x GVW (kg)
FA =
Asphalt, poor .022 3.6 t
Macadam, good .015 FA = Acceleration Force (Newton)
Macadam, fair .022 t = Time (Seconds)
Macadam, poor .037
Snow, 2 inch .025
MPH x GVW (lb)
Snow, 4 inch .037 FA =
Dirt, smooth .025 22 t
Dirt, sandy .040 FA = Acceleration Force (lb)
Mud .037 to .150 t = Time (Seconds)
Sand, Gravel .060 to .150
Sand, loose .160 to .300 1. A goal or objective of the designer.
2. A force required to pull a trailer (Repeat steps two
through four above using trailer weight and add the three
forces together to obtain DP).
82
Step Six — Total Tractive Effort Step Nine — Motor Radial Load Carrying Capacity
The tractive effort (TE) is the total force required to propel the When a motor is used to drive a vehicle with the wheel
vehicle and is the sum of the forces determined in Steps 2 mounted directly on the motor shaft or rotating hub, the Total
through 5. Radial Load (RL) acting on the motor shaft is the vector
summation of two forces acting at right angles to each other.
TE = RR + GR + FA + DP (Kg. or lb.)
Drawbar pull desired Weight (W) supported Total radial load (RL)
Force required to accelerate by the wheel on motor shaft
Force required to climb a grade
Force required to overcome rolling resistance T
Propelling Force
R
Wind resistance forces can usually be neglected. However, it
may be wise to add 10% to the above total to allow for starting 2
resistances caused by friction in bearings and other  T
RL = W 2 +  
mechanical components.  R
Step Seven — Calculate Hydraulic Motor Torque (T)

Refer to radial load rating of each motor (see table of catalog
TE x R m contents page 10 for page listing of the Shaft Side Load
T = (Nm / Motors)
N x G x Eg Capacity for each motor series).
TE x R l
T = (lb − in / Motors) Shaft Torque
N x G x Eg
where N = number of driving motors T = q∆P
Eg = gear box mechanical efficiency 2π
bar x cm3 /rev PSI x in3 /rev
Nm = = lb − in
Step Eight—Wheel Slip 62.8 6.28
If the torque required to slip the wheel (TS) is less than the Shaft Speed
torque calculated in Step 7, the performance objectives cannot
be achieved. Flow
=
Displacement
W x f x Rm
TS = (Nm / Motor) 1000 x l/min 231 x GPM
G x Eg RPM = RPM =
cm3 / rev in3 /rev
W x f x Rl
TS = (lb − in / Motor) Power (into motor)
G x Eg
bar x l/min PSI x GPM
Where: f = coefficient of friction Kw = HP =
W = loaded vehicle weight over drive wheel 600 1714
Power (out of motor)
Coefficient of Nm x RPM lb - in x RPM
friction (f) Kw = HP =
9549 63,025
Steel on steel 0.15 to 0.20
Rubber tire on dirt 0.5 to 0.7
Rubber tire on asphalt 0.8 to 1.0 where: Kw = Kilowatt
Rubber tire on concrete 0.8 to 1.0 HP = Horsepower
Rubber tire on grass 0.4 LPM = Liters per Minute
GPM = Gallons per Minute
It may be desirable to allow the wheel to slip to prevent Nm = Newton Meters
hydraulic system overheating when excessive loads are lb-in = Pound inch
imposed should the vehicle stall. In this case TS should be just Bar = 10 Newtons per Square Centimeter
slightly larger than T. PSl = Pounds per Square Inch
q = Displacement
83
RE 92701/11.95
Variable Displacement Pump A10VO RE

Series 31, for open loop circuits,
Axial piston, swashplate design 92701/11.95
Brueninghaus Hydromatik Sizes 28...140 Nominal pressure 280 bar Peak pressure 350 bar Replaces RE 92701/02.95
Size 18:
RE 92712
Axial piston pump A10VO in swashplate design is used for hydrostatic transmissions in
open loop circuits.
Flow is proportional to drive speed and displacement. By adjusting the position of the
swashplate it is possible to smoothly vary the flow.
– Flange connections to SAE-UNC or SAE metric
– 2 leakage ports
– High permissible speeds
– Good suction characteristics
– Low noise level
– High power/weight ratio
– Long service life
– Short control times
– Axial and radial loading of drive shaft possible
– Wide range of controls
– Through drive option for multi-circuit system
Brueninghaus Hydromatik 1
RE 92701/11.95
Variable Displacement Pump A10VO, Series 31
Ordering code
Fluid
Mineral oil (no short code)
Axial piston unit
Swashplate design, variable A10V ➛
Nominal pressure 280 bar, peak pressure 350 bar ➛
Operational mode ➛
Pump, open loop circuit O
➛
Size
➛
Displacement Vg max (cm3) 28 45 71* 100 140
➛
Control devices 28 45 71 100 140
2-pos. adjustment, direct control DG DG Page 20
Pressure control DR DR Page 22
DR G DRG Page 24
Remote control
Movable pressure control DRT 1 DRT1 Page 26
for when required DRT 2 DRT2 Page 26
i = 18,2 i = 12,4
Pressure and flow control DFR DFR Page 28
DFR 1 DFR1 Page 28
X port closed
Pressure, flow and power control DFLR DFLR Page 30
Pressure, flow and summ. power control DFSR DFSR Page 32
Flow control, pilot pressure-dependent FHD FHD Page 34
with pressure control
Electronic flow control FE1 FE1 Page 36
Electronic pressure and flow control DFE1 DFE1 Page 36
Series
31
Direction of rotation
Viewed on drive shaft clockwise R
anti-clockwise L
= prefered program (with short delivery times)

(type list see page 44)
* With size 71 please note the following when designing: = available

Pressure port B consists of a multiple high pressure port = in preparation
SAE 11/4" standard pressure range, 3000 psi, for pressures of up to 250 bar – = not available
SAE 1" standard pressure range, 5000 psi, for pressures > 250 bar (see page 14).
For new applications high pressure port SAE 1" must be used.
2 Brueninghaus Hydromatik
RE 92701/11.95
A10V O / 31 –
➛ Axial piston pump

➛ Operational mode
➛ Size
➛ Adjustment and control devices
➛ Series
➛ Direction of rotation
Seals
NBR (Nitrile rubber to DIN ISO 1629) P
FPM (Fluoro rubber to DIN ISO 1629) V
Shaft end 28 45 71 100 140
Splined shaft SAE 7/8" 1" 1 1/4" 1 1/2" 1 3/4" S
Splined shaft SAE (higher through drive torque) 7/8" 1" 1 1/4" – – R
Splined shaft SAE (not suitable for through drive) – 7/8" – 1 1/4" – U
Mounting flange 28 45 71 100 140
SAE 2-hole – C
SAE 4-hole – – – – D
Port for service lines 28 45 71 100 140

Pressure port B SAE at rear, fixing thread UNC 61
Suction port S
}
Pressure port B SAE on opposite sides, 62
Suction port S
} fixing thread UNC Port pos. 61
and 11 only
Pressure port B
} SAE at rear, metric fixing thread 11 for version
Suction port S without
Pressure port B } SAE on opposite sides, 12 through drive
Suction port S metric fixing thread
Through drive
Without through drive N00
With through drive (port pos. 62, 12) for mounting AKM or ZRP
Mounting flange Shaft/coupling For mounting:
82-2(SAE A) 16-4(SAE A) G2, GC2/GC3-1X K01
82-2(SAE A) 19-4(SAE A-B) A10VSO 18 (shaft S) K52
101-2(SAE B) 22-4(SAE B) A10VO 28 (shaft S), G3 K02
101-2(SAE B) 22-4(SAE B) G4 K68
101-2(SAE B) 25-4(SAE B-B) A10VO 45 (shaft S), GC4-1X – K04
101-2(SAE B) 32-4(SAE C) GC5-1X – K06
127-2(SAE C) 32-4(SAE C) A10VO 71 (shaft S) – – K07
127-2(SAE C) 38-4(SAE C-C) A10VO 100 (shaft S), GC6-1X – – – K24
152-4(SAE D) 44-4(SAE D) A10VO 140 (shaft S) – – – – K17
Multiple pumps
1. If a second Brueninghaus Hydromatik pump is to be factory-mounted, then both ordering codes are to be
specified, combined with a "+" . Ordering code 1st pump + Ordering code 2nd pump
Ordering example: A10VO 100DR/31R-PSC62K07 + A10VO 71DR/31R-PSC62N00
2. If a gear pump is to be factory-mounted please contact us (RE 90139 in preparation)
RE 92701/11.95
Fluid
Prior to project design, please see our data sheets RE 90220 Notes on the selection of fluid
(mineral oil) and RE 90221 (ecologically acceptable fluids) for For correct selection of the fluid it is assumed that the operating
detailed information on fluids and application conditions. temperature in the tank is known (open loop circuits), in relation
When using ecologically acceptable fluids attention must be to the ambient temperature.
paid to possible limitations of the technical data. If necessary The fluid should be selected so that, within the operating
please contact us. temperature range, the operating viscosity lies within the
optimum range (νopt), (see shaded section of selection diagram).
Operating viscosity range We recommend that the higher viscosity grade is selected in
For optimum efficiency and service life we recommend that the each case.
operating viscosity (at operating temperature) be selected in the Example: At an ambient temperature of X° C the operating
range temperature in the tank will be 60° C. In the optimum operating
viscosity range (νopt; shaded section) this corresponds to
ν opt = opt. operating viscosity 16...36 mm2/s
viscosity grade VG 46 or VG 68; VG 68 should be selected.
referred to tank temperature (open loop circuit). Important: The leakage oil temperature is influenced by
pressure and speed and is always higher than the tank
Limits of viscosity range temperature. At no point in the system, however, may the
The following values are valid for extreme operating conditions: temperature be higher than 90° C.
νmin = 10 mm2/s If it is not possible to comply with the above conditions because
for short periods at max. leakage oil temperature of extreme operating parameters or a high ambient temperature,
of 90° C. please consult us.
νmax = 1000 mm2/s
for short periods upon cold start. Filtration
In order to ensure reliable operation of the axial piston unit, the
Temperature range (see selection diagram) operating fluid must be maintained to a cleanliness class of at
tmin = –25° C least 9 to NAS 1638
tmax = +90° C 6 to SAE
18/15 to ISO/DIS 4406.
This may be achieved, for example, with filter elements
type...D 020...(see RE 31278).
Selection diagram This gives the following degree of separation:
- 20° 0° 20° 40° 60° 80° 100° β20 ≥ 100

1000 1000
600
400
VG
VG
VG
200
VG
VG 8
22
32
46
6
10
0
100
80
60
ty υ (mm / s)
2
40
36
υ opt
Viskosität
20
Viscosi
15 16
10 10
- 25° - 10° 10° 30° 50° 70° 90° Temperature
Temperatur
t (° C)
Fluid temperature range
t min = - 25° C Druckflüssigkeitstemperaturbereich t max = + 90° C
RE 92701/11.95
Technical data
Inlet operating pressure range
Absolute pressure at port S (A) Determination of inlet pressure pabs at suction port S, or
pabs min ........................................................................... 0,8 bar reduction in flow for increasing speed.
pabs max ........................................................................... 30 bar
1,2
Outlet operating pressure range 1,6
Pressure at port B
Inlet pressure pabs [bar]

Nominal pressure pN .................................................. 280 bar 1,4
Speed n/ nmax
Peak pressure pmax ..................................................... 350 bar 1,1
(Pressure data to DIN 24312) 1,2
Applications with intermittent operating pressures of up to 315
bar at 10% duty cycle are permitted.
1,0 1,0
Case drain pressure 0,9

Maximum pressure of leakage fluid (at ports L, L 1):maximum 0,5
bar higher than input pressure at port S, but not exceeding 2 bar 0,9 0,8
absolute. 0,7 0,8 0,9 1,0
Displacement Vg /Vgmax
Direction of flow
S to B
Tabulated data (theoretical values, without considering ηmh and ηv; approximate values)
Size 28 45 71 100 140
Displacement Vg max cm3 28 45 71 100 140
Max. speed1) at Vg max no max rpm 3000 2600 2200 2000 1800
Max. flow at no max Qo max L/min 84 117 156 200 252
at nE = 1500 rpm L/min 42 68 107 150 210
Max. power (∆p = 280 bar) at no max Po max kW 39 55 73 93 118
at nE = 1500 rpm kW 20 32 50 70 98
Max. torque (∆p = 280 bar) at Vg max Tmax Nm 125 200 316 445 623
Torque (∆p = 100 bar) bei Vg max T Nm 45 72 113 159 223
Moment of inertia at drive axis J kgm2 0,0017 0,0033 0,0083 0,0167 0,0242
Filling capacity L 0,7 1,0 1,6 2,2 3,0
Weight (without fluid) m kg 15 21 33 45 60
Permissible loading of drive shaft:
Max. axial force Fax max N 1000 1500 2400 4000 4800
2
Max. radial force ) Fq max N 1200 1500 1900 2300 2800
1
) Values shown are valid for an absolute pressure of 1 bar at Forces Fq
suction port S.
If the flow is reduced or if the inlet pressure is increased the
speed may be increased according to the diagram. ± Fax
2
) Please consult us for higher radial forces.
X/2 X/2
X
Determination of size
Vg • n • ηv
Flow Q= [L/min]
1000 Vg = geometric displacement [cm3] per rev.
1,59 • Vg • ∆ p ∆p = differential pressure [bar]
Drive torque T= [Nm] n = speed [rpm]
100 • ηmh ηv = volumetric efficiency
ηmh = mechanical-hydraulic efficiency
2π • T • n T•n Q•∆p
Drive power P= = = [kW] ηt = total efficiency (ηt = ηv • ηmh )
60000 9549 600 • ηt
RE 92701/11.95
Installation notes
Optional installation position. The pump housing must be filled 2. Horizontal installation
with fluid during commissioning and remain full when operating. The pump must be installed so that either "L" or "L1" is at the
In order to attain the lowest noise level, all connections (suction, top.
pressure, case drain ports) must be linked by flexible couplings 2.1. Arrangement in tank
to tank. a) If the minimum fluid level is above the top of the pump
Avoid placing a check valve in the case drain line. leave ports "L", "L1" and “S” open (see Fig. 3)
This may, however, be permissible in individual cases, after
b) If the minimum fluid level is equal to or below the top of the
consultation with us.
pump pipe ports "L", "L 1" and possiby "S" according to Fig. 4.
Conditions according to 1.2.1.
1. Vertical installation (shaft end upwards)
The following installation conditions must be taken into
2.2. Arrangement outside tank
account:
L Fluid
1.1. Arrangement in tank
Before installation fill pump housing, keeping it in a horizontal
position.
a) If the minimum fluid level is equal to or above the pump
p Inlet min
mounting surface leave ports “L”, "L1" and “S” open (see
Fig.1).
b) If the minimum fluid level is below the pump mounting
surface pipe port “L1”, and possibly “S” according to Fig. 2.
Close port "L" with respect to conditions in 1.2.1. L1
S Fig. 3
Fluid
Fill pump housing before commissioning.
Pipe port "S" and the higher of the two case drain ports "L"
and "L 1".
L1 L a) For mounting above tank see Fig. 4.
Conditions according to 1.2.1.
S b) Position below tank
Fig. 1
L
1.2. Arrangement outside tank S
Before installation fill pump housing, keeping it in a horizontal
position. For mounting above tank see Fig. 2.
Limiting condition:
1.2.1. Minimum pump inlet pressure pinlet min = 0,8 bar under p Inlet min h max
static and dynamic loading.
Fluid
Note: Avoid mounting above tank wherever possible in order L1
to attain a low noise level.
pressure loss, but may not be greater than hmax = 800 mm
(immersion depth ht min = 200 mm).
L Fig. 4
L1
S
Pipe ports "L" and “S” according to Fig. 5.
Fluid
h t min h max
Fluid
p Inlet min
Fig. 2
The permissible suction height h is a result of the overall

Total pressure loss ∆ptotal = ∆p1 + ∆p2 + ∆p3 ≤ (1 – pinlet min) = 0,2 bar
∆p1: Pressure loss in pipe due to accelerating column of fluid L1
ρ • l • dv
∆p1 = • 10–5 (bar)
dt ρ = density (kg/m3) S
l = pipe length (m)
dv/dt = change in rate of suction
(m/s2)
∆p2: Pressure loss due to static head
∆p2 = h • ρ • g • 10–5 (bar) h = height (m) L Fig. 5
ρ = density (kg/m3)
g = acc. due to gravity. =
9,81 m/s2
∆p3: Line losses (elbows etc.)
RE 92701/11.95
Characteristics for pump with pressure control DR

Noise characteristic
Measured in an anechoic chamber
Distance from microphone to pump = 1 m
Measurement tolerance: ± 2 dB (A)
(Fluid: hydraulic oil ISO VG 46 DIN 51519, t = 50° C)
Size 28 Size 100
74 Q max Q max
82
72 Q min
80 Q min
70 Q max
Noise level LA [dB(A)]

nn=
= 3000 rpm-1
3000 min
78
68 Q min
76 nn= 2000min
= 2000 rpm-1 Q max
66 nn=
= 1500 rpm-1
1500 min
74 Q min
64
72 n== 1500 rpm-1
n 1500 min
62
70
60
68
58
66
56
64
0 50 100 150 200 250 280
Operating pressure p [bar] 62
60
Size 45 0 50 100 150 200 250 280
76 Q max
Operating pressure p [bar]
Q min
74
72 Q max Size 140

nn=
= 2600 rpm-1
2600 min
70 Q min 84 Q max
Q min
68 82 Q max
n== 1500
n rpm-1
1500 min n== 1800
n rpm-1
1800 min
66 80 Q min
64 78
nn= 1500min
rpm-1
62 76 = 1500
60 74
58 72
0 50 100 150 200 250 280 70
68
Size 71 66
Q max 64
80
78 Q min 62
76 60
rpm-1
0 50 100 150 200 250 280
74 nn=
= 2200
2200 min
Q max Operating pressure p [bar]
72
Q min
70
rpm-1
nn== 1500 min
68
66
64
62
60
58
0 50 100 150 200 250 280
RE 92701/11.95
Drive power and flow

Size 28
– – – – n = 1500 rpm
90
n = 3000 rpm 80 40
60 Q 30
Drive power P [kW]

PQmax
Flow Q [L/min]
40 20
20 PQmin 10
0
0 50 100 150 200 250 280
Size 45 120 60
– – – – n = 1500 rpm
n = 2600 rpm 100 50
Q
80 PQmax 40
Drive power P [kW]

Flow Q [L/min]
60 30
40 20
PQmin
20 10
0
0 50 100 150 200 250 280
Size 71 160 80
– – – – n = 1500 rpm
n = 2200 rpm 140 70
Q
120 60
Drive power P [kW]
Flow Q [L/min]
100 50
80 PQmax 40
60 30
40 20
PQmin
20 10
0
0 50 100 150 200 250 280
RE 92701/11.95
Drive power and flow

Size 100 200 100

– – – – n = 1500 rpm
n = 2000 rpm
180 90
Q
160 80
140 70
Drive power P [kW]

120 PQmax 60
Flow Q [L/min]
100 50
80 40
60 30
40 20
PQmin
20 10
0
0 50 100 150 200 250 280
Size 140 260 130

– – – – n = 1500 rpm
n = 1800 rpm 240 120
Q
220 110
200 100
Drive power P [kW]

180 90
Flow Q [L/min]
160 PQmax 80
140 70
120 60
100 50
80 40
60 30
Total efficiency:
Q•p 40 20
ηt = PQmin
PQ max • 600 20 10
Volumetric efficiency:
Q 0
ηv =
Qtheor. 0 50 100 150 200 250 280
RE 92701/11.95
Variable Displacement Pump A10VO, Series 31 Before finalising your design please request a certified drawing.
Subject to revision.
Unit dimensions, size 28

Service ports at rear, no through drive;
Model 61 N00
without considering adjustment
Flange 101-2
(SAE B; 2-hole)
View Z
SAE J744 OCT 83
deep
deep
Shaft S Shaft R
Shaft Shaft
30o pressure angle, 30o pressure angle,

13 splines, 13 splines,
16/32 pitch 16/32 pitch
useful spline length
Ports
B Pressure port SAE 3/4" (standard pressure series)
S Suction port SAE 1 1/4" (standard pressure series)
L Case drain port 3/4-16 UNF-2B
L1 Case drain port 3/4-16 UNF-2B (sealed in factory)
RE 92701/11.95
Before finalising your design please request a certified drawing.

Variable Displacement Pump A10VO, Series 31 Subject to revision.

Service ports on side, no through drive;
Model 62 N00
View W View V
deep deep

Model 11 N00
View Z
deep
Ports
deep
L Case drain port M18x1,5
Service ports on side, no through drive;

Model 12 N00
View W View V
deep deep
Ports
RE 92701/11.95

Model 61 N00
without considering adjustment
Flange 101-2
(SAE B; 2-hole)
SAE J744 OCT 83 View Z
deep
deep
Shaft S Shaft R Shaft U

Shaft Shaft Shaft
useful
spline length
30o pressure angle, 30o pressure angle,

15 splines, 30o pressure angle,
15 splines, 13 splines,
16/32 pitch 16/32 pitch 16/32 pitch
Ports
B Pressure port SAE 1" (standard pressure series)
S Suction port SAE 1 1/2" (standard pressure series)
L Case drain port 7/8-14 UNF-2B
L1 Case drain port 7/8-14 UNF-2B(sealed in factory)
RE 92701/11.95

Service ports on sides, no through drive;
Model 62 N00
View W View V
deep deep

Model 11 N00
View Z
deep
Ports deep
Service ports on sides, no through drive;
Model 12 N00
View W View V
deep deep
Ports
RE 92701/11.95
DFLR Pressure/flow/power control

In order to achieve a constant drive torque with a varying
operating pressure, the swivel angle and with it the output flow
from the axial piston unit is varied so that the product of flow and
pressure remain constant.
Flow control is possible below the limit of the power curve.
Not included in
supply
Static characteristic
Maximum
power curve
100 Power valve
75
Flow Q [%]
50
Minimum
power curve
25 Ports
B Pressure port
S Suction port
L, L1 Case drain ports (L1 sealed)
X Pilot pressure port
0 50 100 150 200 250 280 300

Control data
For pressure control technical data see page 22.
For flow control technical data see page 28.
Start of control ...................................................... from 80 bar
The power characteristic is factory-set, so please enter details in Pilot oil consumption .......................... max. approx. 5,5 L/min
clear text, e.g. 20 kW at 1500 rpm. Flow loss at Qmax see pages 8 and 9.
Size A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 Port X Models 61, 62 Port X Models 11,12
28 109 225 120 107 48 86 106 136 40 119 48 51 194 197 7/16-20 UNF-2B; 10 deep M14x1,5; 12 deep
45 106 244 129 112 54 91,5 106 146 40 129 48 51 209 212 7/16-20 UNF-2B; 10 deep M14x1,5; 12 deep
71 106 278 139 124 69 103,5 106 160 40 143 48 51 237 240 7/16-20 UNF-2B; 10 deep M14x1,5; 12 deep
100 106 344 145 129 111 108,5 106 165 40 148 48 51 304 307 7/16-20 UNF-2B; 10 deep M14x1,5; 12 deep
140 127 379 148 140 99 123,5 127 209 26 183 48 51 314 314 7/16-20 UNF-2B; 10 t.(Mod.61) M14x1,5;
140 9/16-18 UNF-2B; 13 t.(Mod.62)
RE 92701/11.95

Unit dimensions DFLR

Service ports at rear; Models 61N00 and 11 N00
Mounting of pilot View Z Mounting of
Sizes 28 to 100
valve for clockwise Model 61 pilot valve for
Power valve direction of rotation Model 11 anti-clockwise
direction of
rotation
Size 140 View Z

Model 61
Model 11
Unit dimensions DFLR

Service ports on sides; Models 62 and 12
Sizes 28 to 100 Model 62 Mounting of pilot valve Mounting of pilot valve
for anti-clockwise for clockwise direction
Model 12 of rotation
direction of rotation
Power valve
Size 140
Model 62 / Model 12
RE 92701/11.95
Unit dimensions of the combination pump
A10VO + A10VO
A1
A2
A3
A4
Pump 1 A10VO 28 A10VO 45 A10VO 71 A10VO 100 A10VO 140

Pump 2 A1 A2 A3 A4 A1 A2 A3 A4 A1 A2 A3 A4 A1 A2 A3 A4 A1 A2 A3 A4
A10VSO 18 165 204 349 399 184 229 374 424 217 267 412 462 275 338 483 533 275 350 495 545
A10VO 28 165 204 369 398 184 229 394 423 217 267 432 461 275 338 503 532 275 350 515 544
A10VO 45 – – – – 184 229 413 448 217 267 451 486 275 338 522 557 275 350 534 569
A10VO 71 – – – – – – – – 217 267 484 524 275 338 555 595 275 350 567 607
A10VO 100 – – – – – – – – – – – – 275 356 631 673 275 368 643 685
A10VO 140 – – – – – – – – – – – – – – – – 275 368 643 685
RE 92701/11.95
Dimensions of through drives

Flange SAE 82-2 (SAE A, 2-hole) for mounting of external gear pump G2 (see RE 10030) or internal gear
pump 1 PF2GC2/3-1X/XXXXR07MU2 (see RE 10215)
Ordering code K01
Flange SAE 82-2 (SAE A, 2-hole) for mounting of A10VSO 18 -shaft S (see RE 92712)
Ordering code K52 Section A – B
5/8" splined sleeve;

16/32 DP; 9T for K01
16/32 DP; 11T for K52
To pump mounting face

Size A1 A4 A5
28 204 47 M 10; 16 deep
45 229 53 M 10; 16 deep
71 267 61 M 10; 20 deep
100 338 65 M 10; 20 deep
140 350 77 M 10; 20 deep
Flange SAE 101-2 (SAE B, 2-hole) for mounting of external gear pump G3 (see RE 10039) or A10VO
28 (shaft S)
Ordering code K02
Section A – B
Not with size 28

16/32 DP; 13T
Not with size 28

Size A1 A4 A5
28 204 47 M 12; 15 deep
45 229 53 M 12; 18 deep
71 267 61 M 12; 20 deep
100 338 65 M 12; 20 deep
With size 28 gear pump G3 may only be
140 350 77 M 12; 20 deep mounted rotated at 45 o .
RE 92701/11.95
Flange SAE 101-2 (SAE B, 2-hole) for mounting of G4 (see RE 10042);

Ordering code K68
Section A – B
Not with size 28

7/8" splined sleeve ;
16/32 DP; 13T
Not with size 28

Size A1 A4 A5
28 204 47 M 12; 15 deep
45 229 53 M 12; 18 deep
71 267 61 M 12; 20 deep
100 338 65 M 12; 20 deep
With size 28 gear pump G4 may only be
140 350 77 M 12; 20 deep mounted rotated at 45o .
Flange SAE 101-2 (SAE B, 2-hole) for mounting of A10VO 45-shaft S or

internal gear pump 1PF2GC4-1X/0XXXR07MU2 (see RE 10215)
Ordering code K04
Section A – B
1" splined sleeve

16/32 DP; 15 splines
Size A1 A3 A4 A5
45 229 9 53 M 12; 18 deep
71 267 8 61 M 12; 20 deep
100 338 10 65 M 12; 20 deep
Capacity:
Direct acting, Relief valve 100 gpm (380 L/min.)
Functional Group: Model:

Products : Cartridges : Relief : 2 Port : Direct Acting RDHA
Product Description
Direct-acting relief cartridges are normally closed, pressure-limiting valves used
to protect hydraulic components from pressure transients. When the pressure at
the inlet (port 1) reaches the valve setting, the valve starts to open to tank (port
2), throttling flow to limit the pressure rise. These valves are smooth and quiet,
essentially zero leak, dirt tolerant, immune to silting and are very fast.
Page 1 of 3
Technical Features
z Will accept maximum pressure at port 2; suitable z The seals on the adjust screw are exposed to
for use in cross port relief circuits. system pressure which means this valve can only be
adjusted when the pressure is removed. The setting
procedure is; check the setting, remove the
pressure, adjust the valve, check the new setting.
z Valve is relatively insensitive to varying oil z Select a spring range where the desired relief
temperatures and oil borne contamination. setting is approximately mid-range between the
minimum and maximum pressure to ensure
maximum valve repeatability.
z Suitable for use in load holding applications. z Back pressure on the tank port (port 2) is directly
additive at a 1:1 ratio to the valve setting.
z All 2-port relief cartridges (except pilot reliefs) are z Incorporates the Sun floating style construction to
physically and functionally interchangeable (same eliminate the effects of internal parts binding due to
flow path, same cavity for a given frame size). excessive installation torque and/or cavity/cartridge
machining variations.
Technical Data
US Units Metric Units
Cavity T-16A Series 3
Reseat >90 % of Set Pressure >90 % of Set Pressure
U.S. Patent # 4,742,846 4,742,846
Valve Hex Size 1 1/4 in. 31,8 mm
Model Weight 1.30 lb 0,60 kg
Maximum Valve Leakage at Reseat 10 drops/min. 0,7 cc/min.
Capacity 100 gpm 380 L/min.
Adjustment Nut Torque 108 lbf in. 12 Nm
Valve Installation Torque 150 - 160 lbf ft 200 - 215 Nm
Typical Response Time 2 ms 2 ms
Factory Pressure Settings Established at 4 gpm 15 L/min.
Full Adjustment-Number of Clockwise Turns to
5 5
Increase Setting
Allen Wrench Hex Size 5/32 in. 4 mm
Maximum Operating Pressure 5000 psi 350 bar
Adjustment Nut Hex Size 9/16 in. 15 mm
Seal Kits
Buna 990-316-007
Viton 990-316-006
Page 2 of 3
Option Selection
RDHA - L A N
Preferred Options
Control Adjustment Range Seal
L Standard Screw A 500 - 3000 psi N Buna-N
Adjustment (35 - 210 bar),
1000 psi (70 bar)
Standard Setting
Standard Options
C* Tamper Resistant - B 300 - 1500 psi V Viton
Factory Set (20 - 105 bar),
1000 psi (70 bar)
Standard Setting
C 1000 - 6000 psi
(70 - 420 bar),
1000 psi (70 bar)
Standard Setting
D 200 - 800 psi (14
- 55 bar), 400 psi
(30 bar)
Standard Setting
E 150 - 400 psi (10
- 28 bar), 200 psi
(14 bar)
Standard Setting
S 50 - 200 psi (3,5
- 14 bar), 100 psi
(7 bar) Standard
Setting
W 800 - 4500 psi
(55 - 315 bar),
1000 psi (70 bar)
Standard Setting
* Special setting required, specify at time of order. No charge.
Page 3 of 3
A Significant Advantage. . .
In order to ensure valve reliability,

the cavity for the cartridge
The floating style cartridge construction
was pioneered by Sun Hydraulics and must be considered. . .
provides performance and reliability
advantages compared to competitors’
product offerings. 1 The shoulder diameter at the
threads provides a guide
to ensure that the cartridge
A significant advantage of the is centered in the cavity.
Sun cartridge is the free
floating nose, allowing the close
tolerance working parts to 2 Free floating subassembly
tolerates eccentricity between
“float” in the body.
This design significantly cavity and cartridge nose.
reduces the cartridge torque
sensitivity and tendency of the
internal moving parts to bind.
3 Sun floating cartridge design
allows much higher installation
torque, resulting in better
cartridge retention and less
chance of cartridge loosening
and leaking during operation.
Cartridge valves can be
removed from their cavities
for cleaning or inspection 4 The flat shoulder provides a stop
which supports the load generated
without changing the setting
or breaking any piping. by the thread without inducing
radial load, causing cartridge
distortion. Squareness with the
centerline can be readily maintained.
Sun cartridge valve
internal components are
heat treated for wear, 33 5 For a given thread size,
impact, and fatigue the central thread position
resistance which extends results in maximum flow
the life of the cartridge. 11 PORT capacity, minimizes the
effect of eccentricity, and
distributes thread loads
Every Sun cartridge deep in the manifold.
receives a functional 55 4
hydraulic test prior
to shipment. 6 The stop in the bottom of
the cavity supports the
free floating subassembly
Retaining
Wire during operation; retaining
The Sun cartridge valve design 2 wire is used only during
allows engineers to create PORT assembly.
systems that result in
maximum flow and minimum
pressure drop with the Manifold 7 Sun porting consistency
greatest efficiency in space allows maximum design
and ease of cartridge 7 flexibility and minimizes
installation. PORT manifold tooling
6 requirements.
Bottoming
Shoulder
Sun cartridges are forgiving of cavity manufacturing

variances to allow maximum valve performance
and guarantee valve-to-valve repeatability.
R
CORPORATION US Sun Floating Style Cartridge/Cavity Sheet #999-901-164

Copyright c 1999 Sun Hydraulics Corporation
DIRECTIONAL CONTROL VALVES CETOP 3/NG6
INTRODUCTION
1 The ARON directional control valves NG6, designed for subplate mounting with an interface
in accordance with CETOP RP 121 H-4.2.2.03 and/or UNI ISO 4401 - AC - 05 - 4 - A standard,
can be used in all fields on account of their high flow rate and pressure capacities combined
with compact overall dimensions.
The use of solenoids with wet armatures allows a very practical, safe construction completely
dispensing with dynamic seals; the solenoid tube is screwed directly onto the valve chest whilst
CETOP 3/NG06
the coil is kept in position by means of a lock nut.
STANDARD SPOOLS CH. I PAGE 10
The special, precise construction of the ports and the improvement of the spools enables
AD.3.E... CH. I PAGE 11
relatively high flow rates to be accommodated with a minimal pressure drop (Dp).
AD.3.E...J* CH. I PAGE 12 The operation of the directional valves may be electrical, pneumatic, oleodynamic, mechanical
AD3.E...XS CH. I PAGE13 or lever.
AD3.XD... CH. I PAGE 14 The centre position is obtained by means of calibrated length springs which reposition the
AD.3.V... CH. I PAGE 15 spool in the centre or end of travel position once the action of the impulse is over.
AD.3.L... CH. I PAGE16 The solenoids are constructed with a protection class of IP66 to DIN 40050 standards and are
OTHER OPERATOR CH. I PAGE 17 available in either AC or DC form in different voltages and frequencies.
AD.3.P... CH. I PAGE 18 The new type DC coil "D15", of cause their high performance, allows to increasing the limits
of use respect to last series.
AD.3.O... CH. I PAGE 18
All types of electrical control are available, on request, with different types of manual
AD.3.M... CH. I PAGE19 emergency controls.
AD.3.D... 6 CH. I PAGE19
The solenoid coils are normally arranged for DIN 43650 ISO 4400 type connectors; is available
D15 DC COIL CH. I PAGE 20 on request these variant coils: with AMP Junior connections, with AMP junior and integrated
K12 AC SOLENOID CH. I PAGE 20 diode, with Deutsch DT04-2P connections or solenoid with flying leads. Connectors with built
STANDARD CONNECTORS CH. I PAGE 21 in rectifiers or pilot lights are also available.
L.V.D.T. CH. I PAGE 22 The valves are designed for use with DIN 51524 standard hydraulic mineral oils and it is
recommended that filters should be fitted to ensure a maximum contamination level of class
10 in accordance with NAS 1638, ß25³75.
PRESSURE DROPS
1 2 3 4 5 6 The diagram at the side shows the pressure drop
curves for spools during normal usage. The fluid
used is a mineral oil with a viscosity of 46 mm2/s at
40°C; the tests have been carried out at a fluid
temperature of 40°C. For higher flow rates than
those in the diagram, the losses will be those
Dp (bar)
expressed by the following formula:
Dp1 = Dp x (Q1/Q)2
where Dp will be the value for the losses for a
specific flow rate Q which can be obtained from the
diagram, Dp1 will be the value of the losses for the
flow rate Q1 that is used.
Q (l/min)
Spool Connections Spool Connections

type P®A P®B A®T B®T P®T type P®A P®B A®T B®T P®T
01 5 5 5 5 11 4 6
02 6 6 6 6 5 22 4 6
03 5 5 6 6 12 5 6
04 1 1 2 2 4 13 5 6 6
05 5 5 5 5 14 2 1 1 1 2
06 5 5 6 5 28 1 2 1 1 2
66 5 5 5 6 15 - 19 4 4 6 6
07 4 6 16 5 5 4 4
08 6 6 17 - 21 1 3
09 5 5 18 5 5
10 5 5 5 5 20 4 4 4 4
Curve No. Curve No.
File: EAD3E$$3 I• 8 05 /2000/e

ORDERING CODE TAB.2- "E" TYPE OPERATOR TAB.1
AD Directional valve A
B
AC VOLTAGES
24V/50Hz
48V/50Hz*
MOUNTING
STANDARD
1
3 CETOP 3/NG6 C 110V/50Hz - 115V/60Hz C
D 220V/50Hz - 230V/60Hz
E Type of operator I 230V/50Hz D
For other operator see E 240V/50Hz*
F 24V/60Hz*
next pages E
DC VOLTAGES
L 12V
** Spool see page I•10 110Vac/50Hz F
M 24V 120Vac/60Hz
N 48V* with rectifier
* Mounting type (table 1) P 110V*
SPECIALS (WITH PRICE INCREASING)
220Vac/50Hz
R 98V* 240Vac/60Hz G
* Voltage (table 2) S 196V* with rectifier
K AC without coils
H
** Variants (table 3) W DC without coils
Voltage codes are not stamped on the plate, their are
readible on the coils. I
* Serial No.
(*) Special voltages
3 = for DC voltage with solenoids
type "D15" only
L
2 = for AC voltage with solenoids M

type "K12" and for XS or XD variants
• Mounting type D is only for

valves with detent
• In case of mounting D
with detent a maximum sup-
ply time of 2 sec is needed
(only for AC coils).
TAB.3 - VARIANTS
VARIANT CODE ¨ PAGE
No variant 00
Viton V1
Emergency button E1 I•20
Pilot light X1 I•21
Rectifier R1 I•21
Pre-set for microswitch (E/F/G/H mounting only) (see below note à) M1 ¨ I•11- I•16
Increasing safety solenoids (type EEx me) XS ¨ I•13
Rotary emergency button P1 I•20
Solenoid valve without connectors S1
Marine version (AD.3.P..) H1 ¨
Cable gland "PG 11" C1 I•21
Emergency button+ Viton EV
Emergency button+ Pilot light EX
Viton + Pilot light VX
Emergency button+ Viton + Pilot light A1
Emergency button+ Rectifier ER
Viton + Rectifier VR
Viton + Rectifier + Emergency button A2
Pilot light + Rectifier XR I•21
Pilot light + Rectifier + Emergency button A3
Pilot light + Rectifier + Emergency button+ Viton A4
Pre-set for microswitch + Viton MV ¨
Increasing safety solenoids variant XS + Emergency button A5
5 micron coupling Q1 ¨
Spool movement speed control (only VDC) with ø 0.3 mm orifice J3 ¨ I•12
AMP Junior coil AJ I•20
AMP Junior coil and integrated diode AD I•20
Coil with flying leads (175 mm) SL I•20
Deutsch DT04-2P coil BD I•20
à = Maximum counter-pressure on T port: 8 bar
¨ = Variant codes stamped on the plate
File: EAD3E$$3 I• 9 05/2000/e

TWO SOLENOIDS,SPRING CENTERED "C" MOUNTING
STANDARD SPOOLS
1 Spool
type
Covering Transient position
(*) Spool with price increasing
• With spools 15 / 16 / 17 only mounting E / F are possible
01 +
• 02 / 16 / 19 / 20 / 21 spool not planned for AD3E variant J*
02 -
• For lever operated the spools used are different.
Available spools for this kind of valve are: 01 / 02 / 03 / 04 / 05 / 06 / 66 / 07
03 +
22 / 13 / 15 / 16 / 17
04* -
05 + ONE SOLENOID, SIDE B "F" MOUNTING

Spool Covering Transient position
66 + type
01 +
06 +
07* + 02 -
08* + 03 +
04* -
09* +
10* + 05 +
22* + 66 +
06 +
11* +
12* + 08* +
13* + 09* +
10* +
14* -
22* +
28* -
12* +
13* +
ONE SOLENOID, SIDE A "E" MOUNTING
Spool Covering Transient position 07* +
type
15 -
01 +
16 +
02 -
17 +
03 +
14* -
04* -
28* -
05 +
66 +
06 + TWO SOLENOIDS "D" MOUNTING

Spool Covering Transient position
08* + type
19* -
10* +
20* +
12* +
21* +
15 -
16 +
17 +
14* -
28* -
File: ETCRS003 I • 10 01/2000/e

AD.3.E... DIRECTIONAL CONTROL VALVES SOLENOID OPERATED CETOP 3/NG6
Max. pressure port P/A/B 320 bar CALIBRATED
Max. pressure port T (for DC) see note (*)
Max. pressure port T (for AC)
Max. flow
Max. excitation frequency
250 bar
160 bar
60 l/min
3 Hz
ø (mm)
blind
DIAPHRAGMS(**)
Code
M52.05.0023/4
1
Duty cycle 100% ED 0.5 M52.05.0023/1
Fluid viscosity 10 ÷ 500 mm2/s 0.6 M52.05.0023/6
Fluid temperature -25°C ÷ 75°C 0.7 M52.05.0023/8
Ambient temperature - 25°C ÷ 60°C 0.8 M52.05.0023
Max. contamination level class 10 in accordance 1.0 M52.05.0023/2
with NAS 1638 with filter ß25 ³75 1.2 M52.05.0023/3
Weight with one DC solenoid 1,65 Kg 1.5 M52.05.0023/7
A max. counter-pressure of 8 bar at T is permit- Weight with two DC solenoids 2 Kg 2.0 M52.05.0023/10
ted for the variant with a microswitch (M1). Weight with one AC solenoid 1,25 Kg 2.2 M52.05.0023/9
Weight with two AC solenoids 1,55 Kg 2.5 M52.05.0023/5
(*) Pressure dynamic allowed for
2 millions of cycles.
(**) For high differential pressure please
OVERALL DIMENSIONS conctat our tecnichal departement.
E = Manual override
M1 = Microswitch
Calibrated diaphragm
Fixing screws UNI 5931 M5x30

with material specification 12.9
Support plane
specifications
Tightening torque 5 Nm / 0.5 Kgm
LIMITS OF USE
The tests have been carried out with solenoids at a temperature of 40°C and a voltage 10% less than rated voltage with a fluid temperature
of 40°C. The fluid used was a mineral oil with a viscosity of 46 mm2/s at 40°C. The values in the diagram refers to tests carried out with the oil
flow in two directions simultaneously T = 2 bar (e.g.. from P to A and the same time B to T). In the case where valves 4/2 and 4/3 were used
with the flow in one direction only, the limits of use could have variations which may even be negative. Rest times: the values are indicative and
depend on following parameters: hydraulic circuit, fluid used and variations in hydraulic scales (pressure P, flow Q, temperature T).
Direct current: Energizing 30 ÷ 50 ms. Alternating current: Energizing 8 ÷ 30 ms.

De-energizing 10 ÷ 30 ms. De-energizing 15 ÷ 55 ms.
DIRECT CURRENT SOLENOIDS (DC) ALTERNATING CURRENT SOLENOIDS (AC)
4 5 2 1 Spool Solenoids 11
8
6 type DC AC 9
3 8
01 1 8 10-16
02 1 9
3 03 8 12
P (bar)
P (bar)
04 6 14 12 10-11
6 4
05 3 10
13
7
2 5 06 - 66 5 12 14
11 - 22 4 11
14 - 28 2 16 15
7 1 15 7 15
13-15-16
16 1 13
Q (l/min) Curves Q (l/min)
File: EAD3E003 I • 11 03/2000/e

AD.3.E...J* VALVES WITH SPOOL MOVEMENT SPEED CONTROL VARIANT J*
Valves type AD3.E... variant J* with spool movement speed control Max. pressure ports P/A/B 320 bar
1 These ON-OFF type valves are used a lower spool movement speed
than usual for conventional solenoid valves is required to prevent
impacts which could adversely affect the smooth running of the system.
Max. pressure port T (*)
Max. flow
Max. excitation frequency
Duty cycle
250 bar
30 l/min
2 Hz
100% ED
The system consist of reducing the transfer section for the fluid from one Fluid viscosity 10 ÷ 500 mm2/s
solenoid to the other by means of calibrated orifices. Fluid temperature -25°C ÷ 75°C
Ambient temperature -25°C ÷ 60°C
• This version can only be used with a direct current (DC) and also Weight with one DC solenoid 1,65 Kg
involves a reduction in the limits of use so that we suggest to Weight with two solenoids DC solenoids 2 Kg
always test the valve in your application
(*) Pressure dynamic allowed for 2 millions of cycles.
• To order AD.3.J* version valves, specify the orifices code.
• The operation is linked to a minimum counter-pressure on T line

(1 bar min.) CALIBRATED
ORIFICES AVAILABLE
• The switching time referred to the spool travel detected by a LVDT
ø (mm) M4x4 Code
transducer can vary for the NG6 valve from a minimum of 100 to a
maximum of 300 ms depending on 5 fundamental variables: 0.3 M89.10.0028 J3
0.4 M89.10.0029 J4
1) Diameter of the calibrated orifices (see table) 0.5 M89.10.0006 J5
0.6 M89.10.0030 J6
2) Hydraulic power for clearance referring to flow and pressure values
through valve
3) Spool type
4) Oil viscosity and temperature
5) Counter-pressure at T line
• Possible mountings: C / E / F / G / H
• 02 / 16 / 19 / 20 / 21 spools not planned for AD3E variant J*
OVERALL DIMENSIONS
E = Manual override
Fixing screws UNI 5931M5x40 Support plane

specifications
with material specification 12.9
Tightening torque 5 Nm / 0.5 Kgm
File: EAD3EJ$3 I • 12 02/2000/e

AM.3.QF... MODULAR
FLOW REGULATOR CETOP 3
AM.3.QF type one way non-compen-
Max. operating pressure 320 bar
sated throttle valve are fitted with an
Max. pressure 250 bar
O-Ring mounting plate which allows
Flow rate regulation on 8 screw turns
its assembly for either input or output
Max. flow 40 l/min
regulation. Adjustment is obtained by
Hydraulic fluids Mineral oils DIN 51524
means of a grub screw or a plastic
Fluid viscosity 10 ÷ 500 mm2/s
knob. They are available in the four
Fluid temperature -25°C ÷ 75°C
AM.3.QF... regulating configurations shown in the
Ambient temperature -25°C ÷ 60°C
SCREWS AND STUDS CH.IV PAGE 21 hydraulic diagrams.
Max. contamination level class 10 in accordance
The standard valve configuration with NAS 1638 with filter ß25≥75
allows"meter in" regulation, while it is Weight 1,5 Kg
possible to obtain "meter out"
regulation by turning the valve by 180°
along its longitudinal axis.
ORDERING CODE FLOW REGULATION FREE FLOW

TOWARDS CHECK VALVE
AM Modular valve
3 CETOP 3/NG6
4
∆p (bar)
QF Non compensated throttle valve
∆p (bar)
** Control on lines
A / B / P / AB
* Type of adjustment
M = Plastic knob Q (l/min)
C = Grub screw Q (l/min)
** 00 = No variant
V1 = Viton
HYDRAULIC SYMBOLS
4 Serial No.
AM.3.QF.A AM.3.QF.B AM.3.QF.P AM.3.QF.AB
OVERALL DIMENSIONS
K = OR plate
Type of adjustment
M Plastic knob
C Grub screw
Support plane
specifications
File: EAM3QF004 IV • 17 01/2000/e

AM.3.VM... / AM.3.VI... MODULAR
MAX. PRESSURE VALVES CETOP 3
AM.3.VM type pressure regulating Max. operating pressure 320 bar
valves are available with a pressure Setting ranges: spring 1 max. 50 bar
range of 2 ÷ 320 bar. spring 2 max. 150 bar
Adjustment is by means of a grub spring 3 max. 320 bar
screw or a plastic knob. Max. flow 40 l/min
Hydraulic fluids Mineral oils DIN 51524
Three basic versions are available: Fluid viscosity 10 ÷ 500 mm2/s
- AM3VM on single A or B lines, and Fluid temperature -25°C ÷ 75°C
on A and B lines, with drainage to T; Ambient temperature -25°C ÷ 60°C
- AM3VMP on single P line, with Max. contamination level class 10 in accordance
drainage to T; with NAS 1638 with filter ß25³75
- AM3VI on single A or B lines, and on Weight AM.3.VM.A/B/P... 1,2 Kg
A and B lines, with crossed drainage Weight AM.3.VM.AB... 1,3 Kg
on A or B (see hydraulic symbols). Weight AM.3.VI.A/B... 2 Kg
AM.3.VM / AM.3.VI... All versions can accept three types of Weight AM.3.VI.AB... 2,2 Kg
springs with calibrated ranges as
CMP.10... CH. V PAGE 19
shown in the specifications.
SCREWS AND STUDS CH. IV PAGE 21
The cartridge, which is the same for all
versions, is the direct acting type
CMP10.
HYDRAULIC SYMBOLS
For the minimum permissible set-
ting pressure depending on the
spring, see minimum pressure set-
ORDERING CODE
ting curve.
AM.3.VM.A
4
AM Modular valve
3 CETOP 3/NG6
PRESSURE - FLOW RATE
AM.3.VM.B
** VM = Maximum pressure
3
VI = Maximum pressure crossline
** Adjustment on the lines

AM.3.VM Version = A / B / P / AB
P (bar)
AM.3.VI Version = A / B / AB AM.3.VM.P

2
* Type of adjustment
M = Plastic knob 1
C = Grub screw
AM.3.VM.AB
* Setting ranges at port A/B/P Q (l/min)
1 = max. 50 bar (white spring)
Curves n° 1 - 2 - 3 = setting ranges
2 = max. 150 bar (yellow spring)
3 = max. 320 bar (green spring)
MINIMUM SETTING PRESSURE AM.3.VI.A
* Setting ranges at port B
(Omit if the setting is same 3
as that at port A)
1 = max.50 bar (white spring)
2 = max.150 bar (yellow spring) AM.3.VI.B
P (bar)
3 = max. 320 bar (green spring)

2
** 00 = No variant 1
V1 = Viton
AM.3.VI.AB
3 Serial No.
Q (l/min)
File: EAM3V$003 IV • 9 01/2000/e

AM.3.VM.../AM.3.VI... MODULAR MAX. PRESSURE VALVES CETOP 3
OVERALL DIMENSIONS
AM.3.VM.AB...
Type of adjustment
Support plane
M Plastic knob specifications
4 C Grub screw
AM.3.VM.P...
Type of adjustment
M Plastic knob Support plane

specifications
C Grub screw
AM.3.VI.AB...
Type of adjustment
M Plastic knob Support plane

specifications
C Grub screw
File: EAM3V$003 IV • 10 01/2000/e

UNIDIREZIONALI A CARTUCCIA, OTTURATORE CONICO
POPPET AND CARTRIDGE TYPE CHECK Pag. 3.12.03
VU-34 04.31.02.00 - Y - Z
DATI TECNICI / TECHNICAL DATA
Coppia di serraggio
167-191 Nm
Installation torque
Pressione di lavoro max.

350 bar
Max. working pressure
Portata max
100 l/min
Flow max
Peso
0.430 kg
Weight
MOLLE / SPRINGS ATTACCHI / PORT SIZE

Inizio apertura
Y
Z (bar) Cod. ordinazione Colore
Cracking pressure Ordering code Colour 99 Cartuccia/Cartridge
(bar)
00 1.5 03.51.01.008
01 8 03.51.01.154
Marzo 99
MASSIMA PRESSIONE, PILOTATE, OTTURATORE CILINDRICO
PILOT OPERATED, SPOOL TYPE RELIEF Pag. 1.14.01
VSP-150 04.12.04 - X - Y - Z

Coppia di serraggio
121-133 Nm
Installation torque
420 bar
Portata max.
150 l/min
Flow max.
Peso
0.28 kg
Weight
Trafilamento: circa 0,10 l/min alla massima
pressione.
Leakage: 0.10 l/min approx at max relief setting.
Classe di pulizia dell’olio: almeno 18/14 ISO 4406
(9 NAS-1638).
Fluid cleanliness class: 18/14 ISO 4406
(9 NAS-1638) or better.
Utilizzabili in applicazioni in cui la pressione allo
scarico “T” sia sempre inferiore alla pressione
della linea “P”.
Suitable for applications where pressure in the
return line “T” never exceeds the pressure in the
“P” line.
REGOLAZIONI
X ADJUSTMENTS
vite interna
esagono incassato
03 leakproof inner hex.
socket screw
volantino e predisposizione
montaggio a pannello
04 handknob and locknut
panel mounting
cappellotto per piombatura
sealing cap
codice / ordering code
03.05.01.004

Campo taratura Incremento press. Taratura standard
Y
Z min - max bar bar / giro vite bar (Q = 5 l/min) Cod. ordinazione Colore
Adj. press. Press. increase Std. setting bar Ordering code Colour 99 Cartuccia/Cartridge
range bar bar / turn (made at 5 l/min)
nero
05 1.7-70 20.5 50 black
blu
10 7-105 26 100 blue
verde
20 10-210 35 200 green
giallo
40 35-420 115 350 yellow
Marzo 99
UNIDIREZIONALI A CARTUCCIA, SBLOCCAGGIO
OLEODINAMICO, SEMPLICE EFFETTO Pag. 4.11.01
PILOT OPERATED, CARTRIDGE TYPE CHECK
VSO-SEC-150 04.33.01 - X - Y - Z
Coppia di serraggio
142-155 Nm
Installation torque

350 bar
Portata max.
90 l/min
Flow max.
Rapporto di pilotaggio
4:1
Pilot ratio
Peso
0.375 kg
Weight
GUARNIZIONE SUL PISTONE

X DI PILOTAGGIO
O-RING ON PILOT PISTON
senza guarnizione
00 no o-ring
con guarnizione
10 with o-ring

Inizio apertura
Y
(bar)
00 0.5 03.51.01.016
01 7 03.51.01.091
Marzo 99
UNIDIREZIONALI, SBLOCCAGGIO OLEODINAMICO,
DOPPIO EFFETTO Pag. 4.21.03
DUAL, PILOT OPERATED CHECK
VSO-DE-L 05.53.03 - X - Y - Z

NOTA: per la dimensione 1/2 è disponibile anche
il rapporto di pilotaggio 6:1 (X=25).
WARNING: pilot ratio 6:1 is also available for 1/2
size (X=25).
Per la dimensione 1/4 è disponibile anche il

rapporto di pilotaggio 9:1 (X=37).
Pilot ratio 9:1 is available for 1/4 (X=37).
Pressione di lavoro max. 350 bar

Portata max. vedi diagramma

Flow max. see performance graph
È generalmente consigliato l’uso della versione

con codice Z=01 (molla pesante).
Per un funzionamento corretto scegliere il
rapporto di pilotaggio in funzione della
contropressione sulla linea di ritorno e del
50 50 57.5 145 10 165 57 10 45 70 10.5 3/4 3.6:1 1.15 rapporto delle aree del cilindro.
35 34 38 94 8 110 38.5 8 32 50 8.5 1/2 3.2:1 1.15 The version with Z=01 in part no. (heavier
35 36 22 34 6 80 33 6 24 40 6.5 1/4 4:1 0.70 spring) is generally recommended.
For correct operation the pilot ratio must be
Rapp. di Pil.
Weight kg
Pilot ratio
Peso kg
chosen as function of back pressure in the return

S L4 L3 L2 L1 L I H2 H1 H F Y line and of cylinder ratio.

X DI PILOTAGGIO
senza guarnizione
00 no o-ring
con guarnizione
10 with o-ring

Y
Inizio apertura V1-V2-C1-C2
Z (bar) Cod. ordinazione
Cracking pressure Ordering code 09 G 1/4
(bar)
1/4 00 3 03.51.01.024
03 G 1/2
01 8 03.51.01.051 04 G 3/4
00 1 03.51.01.029
1/2
01 8 03.51.01.058
00 1.5 03.51.01.008
3/4
01 8 03.51.01.154
Marzo 99
UNIDIREZIONALI, SBLOCCAGGIO OLEODINAMICO,
DOPPIO EFFETTO Pag. 4.21.01
DUAL, PILOT OPERATED CHECK
VSO-DE 05.53.01 - X - Y - Z

NOTA: per la dimensione 1/2 è disponibile anche
il rapporto di pilotaggio 6:1 (X=25).
WARNING: pilot ratio 6:1 is also available for 1/2
size (X=25).

350 bar
Portata max. vedi diagramma

Flow max. see performance graph
È generalmente consigliato l’uso della versione

con codice Z=01 (molla pesante).
Per un funzionamento corretto scegliere il
rapporto di pilotaggio in funzione della
contropressione sulla linea di ritorno e del
rapporto delle aree del cilindro.
50 57.5 57.5 30 30 82.5 165 24.5 14.5 60 14.5 44.5 89 8.5 3/4 4:1 2.55
The version with Z=01 in part no. (heavier
35 38 38 20.5 20.5 55 110 17.5 14.5 40 14.5 34.5 69 8.5 1/2 3.2:1 1.06 spring) is generally recommended.
35 32 32 17 17 48 96 8.5 9.5 40 9.5 29.5 59 6.5 3/8 7:1 0.85 For correct operation the pilot ratio must be
chosen as function of back pressure in the return
Rapp. di Pil.
Weight kg
Pilot ratio
Peso kg
S L5 L4 L3 L2 L1 L I H4 H3 H2 H1 H F Y line and of cylinder ratio.

X DI PILOTAGGIO
senza guarnizione
00 no o-ring
con guarnizione
10 with o-ring

Y
Inizio apertura V1-V2-C1-C2
Z (bar) Cod. ordinazione
Cracking pressure Ordering code 97 G 3/8
(bar)
00 3 03.51.01.024
03 G 1/2
3/8
01 8 03.51.01.051 04 G 3/4
00 1 03.51.01.029
1/2
01 8 03.51.01.058
00 1.5 03.51.01.008
3/4
01 8 03.51.01.154
Marzo 99
MASSIMA PRESSIONE, DOPPIE INCROCIATE
DUAL CROSS OVER RELIEF Pag. 1.21.01
VSDI-30 05.16.03 - X - Y - Z

350 bar
Portata max.
30 l/min
Flow max.
Peso
0.79 kg
Weight
REGOLAZIONI
X ADJUSTMENTS
vite esterna
esagono incassato
03 leakproof hex.
socket screw
sealing cap
03.05.01.003

Y
Campo taratura Incremento press. Taratura standard V1-V2 M1-M2
Adj. press. Press. increase Std. setting bar Ordering code Colour 02 G 3/8 G 1/8
range bar bar / turn (made at 5 l/min)
nero 03 G 1/2 G 1/8
05 5-50 12 50 03.51.01.077 black
blu
10 30-100 24 100 03.51.01.076 blue
verde
20 50-210 47 200 03.51.01.075 green
giallo
35 100-350 82 350 03.51.01.059 yellow
Marzo 99
MASSIMA PRESSIONE, DIRETTE, OTTURATORE CONICO
DIRECT, POPPET TYPE RELIEF Pag. 1.12.05
VS-80 04.11.05 - X - Y - Z
Coppia di serraggio
83-92 Nm
Installation torque

250 bar
Portata max.
80 l/min
Flow max.
Peso
0.35 kg
Weight
REGOLAZIONI
X ADJUSTMENTS
vite esterna
esagono incassato
03 leakproof hex.
socket screw
volantino
e dado
04 handknob
and locknut
sealing cap
03.05.01.001

Y
range bar bar / turn (Q = 5 l/min)
nero
05 5-50 6 50 03.51.01.020 black
blu
10 35-100 12 100 03.51.01.001 blue
rosso
20 80-250 27 200 03.51.01.010 red
Marzo 99
DIRECT, POPPET TYPE RELIEF Pag. 1.12.04A
VS-30-NCF 04.11.18 - X - Y - Z

Coppia di serraggio
46-51 Nm
Installation torque
350 bar
Portata max.
30 l/min
Flow max.
Peso
0.17 kg
Weight
Sede di tenuta temprata
Hardened scat
N.B.: La taratura deve essere effettuata dopo il
montaggio, in quanto la molla non può essere compressa
mentre le cartucce sono fuori dalle cavità. Analogamente
la vite di taratura deve essere completamente allentata
prima di svitare le cartucce dalle cavità.
N.B.: The pressure setting must be done after
installation, because the spring cannot be compressed
while the cartridge is out of the cavity. For the same
reason the threaded adjuster must be fully released
prior to unscrewing the cartridge from cavity.
REGOLAZIONI
X ADJUSTMENTS
vite esterna
esagono incassato
03 leakproof hex.
socket screw

Campo taratura Incremento press.
Y
Z min - max bar bar / giro vite Cod. ordinazione Colore
Adj. press. Press. increase Ordering code Colour 09 Cartuccia/Cartridge
range bar bar / turn
nero
05 5-50 12 03.51.01.077 black
giallo
35 100-350 82 03.51.01.059 yellow
Marzo 99
VS-30 04.11.18 - X - Y - Z
Coppia di serraggio
46-51 Nm
Installation torque

350 bar
Portata max.
30 l/min
Flow max.
Peso
0.17 kg
Weight
REGOLAZIONI
X ADJUSTMENTS
vite esterna
esagono incassato
03 leakproof hex.
socket screw
volantino
e dado
04 handknob
and locknut
sealing cap
03.05.01.003

Y
nero
05 5-50 12 50 03.51.01.077 black
blu
10 30-100 24 100 03.51.01.076 blue
verde
20 50-210 47 200 03.51.01.075 green
giallo
35 100-350 82 350 03.51.01.059 yellow
Marzo 99
VS-20 04.11.23 - X - Y - Z
Coppia di serraggio
50-59 Nm
Installation torque

350 bar
Portata max.
20 l/min
Flow max.
Peso
0.17 kg
Weight
REGOLAZIONI
X ADJUSTMENTS
vite esterna
esagono incassato
03 leakproof hex.
socket screw
volantino
e dado
04 handknob
and locknut
sealing cap
03.05.01.002

Y
nero
05 30-50 8 50 03.51.01.133 black
blu
10 40-150 38 100 03.51.01.121 blue
verde
20 80-210 77 200 03.51.01.122 green
giallo
35 150-350 146 350 03.51.01.132 yellow
Marzo 99
PRESSURE REDUCING AND RELIEVING
VRPR-10A 04.95.04 - X - 85 - Z
TECHNICAL DATA
Max. inlet pressure : 350 bar
Max. flow : 30 l/min
Internal leakage : ave. 35 cm³/min
Cavity – Tooling (page 10.012) : CA-10A-3N
External seals kit : see page 11.011
Installation torque : 50-60 Nm
Weight : 0.260 kg
100
08 X ADJUSTMENTS
PRESSURE - ǻp (bar)
80
04
60
03 Leakproof hex. socket screw
40
02
20 04 Handknob and locknut
5
0
30 20 10 0 10 20 30
RELIEVING ‹––– l/min –––› REDUCING
SPRINGS OPTIONALS
Z Standard setting
Adj. press. Press. increase
bar Ordering code Description
range bar bar/turn
(reduc. mode)
02 2-25 2.8 7-10
04 10-50 7 35-40 11.04.23.003
Tamperproof cap
08 28-80 14 45-50
Rev.1201 Pag. 02.080

PRESSURE REDUCING PILOT OPERATED
VRPP-10A 04.93.06 - X - 85 - Z
TECHNICAL DATA
Max. pressure : 350 bar
Max. regulated pressure : 280 bar
Max. flow : 60 l/min
Internal leakage : ave. 35 cm³/min
Cavity – Tooling (page 10.012) : CA-10A-3N
External seals kit : see page 11.011
Installation torque : 50-60 Nm
Weight : 0.210 kg
280
X ADJUSTMENTS
210
03 Leakproof hex. socket screw

140
70
0
0 15 30 45 60
FLOW - Q (l/min)
SPRINGS OPTIONALS
Z
Adj. press. Press. increase Standard setting
Ordering code Description
range bar bar/turn bar
10 10-140 48 100
20 70-280 88 200 11.04.23.002
Tamperproof cap
Rev.0101 Pag. 02.020

BILANCIAMENTO, DOPPIO EFFETTO, SERIE “NBA”
DUAL PILOT ASSISTED, SERIES “NBA” OVERCENTRE Pag. 5.32.02
VBSO-DE-NBA 05.42.38 - X - Y - Z
Pressione max.
350 bar
Max. pressure
Portata max.
70 l/min
Flow max.
Taratura della valvola: almeno 1.3 volte superiore

alla pressione indotta dal carico
Pressure setting: at least 1.3 times the load
induced pressure
Cappellotto per piombatura Codice/Ordering code

Sealing Cap 03.05.01.001
Peso
2 kg
Weight
RAPPORTO DI PILOTAGGIO
X PILOT RATIO
03 10.5 : 1
10 3:1

Y
Campo taratura Incremento press. Taratura standard V1-V2-C1-C2
Adj. press. Press. increase Std. setting bar Ordering code Colour 03 G 1/2
range bar bar / turn (made at = 5 l/min)
verde
20 60-210 68 200 03.51.01.152 green
giallo
35 120-350 105 350 03.51.01.142 yellow
Marzo 99
UNIDIREZIONALI A CARTUCCIA, OTTURATORE CONICO, PISTONE PILOTA
PILOT OPERATED, CARTRIDGE AND POPPET TYPE, PILOT PISTON CHECK Pag. 4.13.00
VU-38-P 04.31.14 - X - Y - Z

Coppia di serraggio
75-87 Nm
Installation torque

350 bar
Portata max.
30 l/min
Flow max.
Rapporto di pilotaggio
7:1
Pilot ratio
Peso
0.1 kg
Weight

X DI PILOTAGGIO
con guarnizione
10 with o-ring

Inizio apertura
Y
(bar)
00 3 03.51.01.024
01 8 03.51.01.051
Marzo 99
FLOW CONTROL VALVES
CARTRIDGE RESTRICTORS
WITH REVERSE FLOW CHECK
ST-CU-06 OD.21.04.18 - X - 00
Hex. 5
Hex. 17
Hex. 24
Torque 39-51 Nm
TECHNICAL DATA
Maximum Operating
350 bar
Pressure
Rated Flow 40 l/min
Cavity - Tooling (018-E) page 7.01.100
Weight 0.130 kg
Fluids - Temperatures page 7.01.040
Testing Conditions - Seals page 7.01.040
Internal Leakage page 7.01.040

Filtration : 25 Pm nominal or
page 7.01.050
better
Adjustment Torque
2 Nm
at 10 bar
---- FULLY OPEN RESTRICTOR - FLOW IN BOTH DIRECTIONS Adjustment Torque
35 4 Nm
---- FULLY CLOSED RESTRICTOR - FLOW 1 Ź 2 at 350 bar
30
Mounting Position unrestricted

25
20
15
10
0
0 10 20 30 40 50
FLOW - Q (l/min)
X ORDERING OPTIONS
03 Socket Screw
04 Handknob and Locknut
Rev.03.03 3.11.120.G
FLOW CONTROL VALVES
ST-C-09 OD.21.01 - X - 04
Hex. 5
Hex. 17
Hex. 32
Torque 54-66 Nm
TECHNICAL DATA
Maximum Operating
350 bar
Pressure
Rated Flow 70 l/min
Weight 0.180 kg

page 7.01.050
better
Adjustment Torque
1 Nm
at 10 bar
FULLY OPEN RESTRICTOR - FLOW IN BOTH DIRECTIONS Adjustment Torque
10 10 Nm
at 350 bar
8 Mounting Position unrestricted
0
0 10 20 30 40 50 60 70 80
FLOW - Q (l/min)
X ORDERING OPTIONS
03 Socket Screw
Rev.03.03 3.11.020.G
FLOW CONTROL VALVES
ST-C-06 OD.21.01 - X - 56
Hex. 5
Hex. 17
Hex. 24
Torque 39-51 Nm
TECHNICAL DATA
Maximum Operating
350 bar
Pressure
Rated Flow 40 l/min
Weight 0.090 kg

page 7.01.050
better
Adjustment Torque
1 Nm
at 10 bar
FULLY OPEN RESTRICTOR - FLOW IN BOTH DIRECTIONS Adjustment Torque
12 5 Nm
at 350 bar
10
Mounting Position unrestricted

8
0
0 10 20 30 40 50
FLOW - Q (l/min)
X ORDERING OPTIONS
03 Socket Screw
Rev.03.03 3.11.010.G
SOLENOID OPERATED VALVES
POPPET 2-WAY NORMALLY CLOSED
CARTRIDGE STYLE
VEI-8A-2B-16-NC OD.15.03.04 - Y - 00
Torque 3-4 Nm
Coil S8
Hex. 50
Torque 110-130 Nm
TECHNICAL DATA
Maximum Operating
350 bar
Pressure
Rated Flow 260 l/min
Cavity - Tooling (004) page 7.01.160
Weight 1.130 kg

page 7.01.050
better
Minimum Voltage Required 90% of nominal
Coils must be ordered
10 page 1.71.050
separately
8 Mounting Position unrestricted
0
0 30 60 90 120 150 180 210 240 270
FLOW - Q (l/min)
200
180 Y ORDERING OPTIONS
160
140
TIME - (ms)
120 Closing
100 37 Standard
80
60
40
20 Opening
0
0 30 60 90 120 150 180 210 240 270
47 Knob Style Manual Override
FLOW - Q (l/min)
Rev.04.03 1.11.960.G
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14 CERTIFICATES/QUALITY RECORDS – DESIGN CALCULATIONS

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15 STINIS PRODUCT INFORMATION

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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)

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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

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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.

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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

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17 MANUAL-SHOPPING DRAWINGS
17.10 MANUAL DRAWINGS: INSTRUCTIONS for USE

Manual drawings are for:
* Instruction for use
* Instructions for repair
* Instructions for adjusting
* Ordering spare parts
For a list of the important manual drawings, see: Chapter 14
All the important manual drawings, see: Chapter 14
Drawing numbers give the following important information:
subject VATCII spreader
main spreader part divided into:
compositions series 0-000
mid-frame series 1-000
telescopic beam series 2-000
Twistlock beam series 3-000
Electric series 4-000
Hydraulics series 5-000
Specials series 6-000
Greasing points series 7-000
Report drawings series 8-000
(long)-twinlift series 9-000
Specified drawing number
Part number bearing twistlock connection rod
VATCII 3-100 08
17.20 MANUAL DRAWINGS

List of Manuals drawings
Project: 1886
Manual drawing Description
Composition:
VATCII 0-513-00 VATCII-ETW
Mid-frame:
VATCII 1-205-02 telescopic drive without brake (side connection)
VATCII 1-334-00 telescoping beam lock/sensors M30x2
VATCII 1-400-02 stetching device telescopic belt 45ft
VATCII 1-402-00 adjustment tensioning device for telescopic belts
VATCII 1-500-03 guiding telescopic beam in front plate (standard)
Telescopic beam:
VATCII 2-000-01 telescopic beam upper pressure plates 20-45ft
VATCII 2-100-01 telescopic beam - cable guide standard
VATCII 2-250-01 telescopic beam-left postion sensors 20-30ft
VATCII 2-251-02 telescopic beam-right position sensor 40ft + slow
VATCII 2-501-07 telescopic beam guiding device in mid-frame with greasing
Headbeam:
VATCII 3-055-04 headbeam(M-II) E with 2 actuated side flippers
VATCII 3-106-03 headbeam(M-II), driving twistlocks single sensors
VATCII 3-110-02 drive bar twistlocks l=889
VATCII 3-540-02 headbeam with 2 actuated side flippers model E
VATCII 3-620-04 headbeam with actuator for 2 flippers
VATCII 3-625-02 flipper shaft
VATCII 3-630-02 flipper actuator, detail sealings
VATCII 3-847-03 twistlock composition model TWI-W-ISO-VC-R71-R (S:R HD:L+R)
VATCII 3-859-03 twistlock composition model TWI-W-ISO-VC-R71-L (S:no HD:see3-847)
VATCII 3-905-02 setting tracerpin twistlock 45° in endbeam
Electrical:
VATCII 4-250-00 adjustment telescopic positions (single) 20-30
VATCII 4-251-00 adjustment telescopic positions (single) 20-30-40 slow
VATCII 4-403-00 sensor telescoping beam lock
VATCII 4-409-02 twistlock position sensors in headbeam(M-II) central
VATCII 4-704-00 terminal box on headbeam
VATCII 4-730-00 electrical box on mid-frame stainless steel 1070x500x350
VATCII 4-802-01 4 pilot lamps type LED in box
Hydraulical:
VATCII 5-101-04 hydro unit 5 functions 7.5-10Kw
VATCII 5-177-01 hydro unit ETW
VATCII 5-417-00 shift actuator ETW
VATCII 5-440-01 twistlock cylinder
VATCII 5-451-03 Long-Twin twistlock cylinder
VATCII 5-470-01 Cylinder blocking unit
VATCII 5-611-01 valve cetop-3
VATCII 5-704-00 grease pump 4L/80bar(RVS) low-level-indication(ex bero)
VATCII 5-725-01 grease nozzle and dividers

Postbus 2005
The Netherlands
VATCII 5-750-00 grease distributor

VATCII 5-844-00 manifold(3d) headbeam(MII) 3x cetop-3-CE: functions
VATCII 5-845-00 manifold(3d) headbeam(MII) 3x cetop-3-CE: parts
VATCII 5-900-02 hydraulic hose
VATCII 5-901-02 main pressure cartridge/solenoid
VATCII 5-903-02 automatic greasing cartridge/solenoid
VATCII 5-904-01 temperature switch
VATCII 5-910-02 oil level switch
Specials:
VATCII 6-222-00 shifthouse Twinlift
Greasing-Maintenance
VATCII 7-100-01 telescoping system
VATCII 7-201-00 headbeam
VATCII 7-300-00 flipper actuator
VATCII 7-320-03 twistlock model TWI-W maintenance
VATCII 7-321-03 twistlock model TWI-W maintenance: rejection
VATCII 7-322-01 Single twistlock model TWI-W maintenance
VATCII 7-323-01 Twistlock bush - maintenance
VATCII 7-324-00 Twin twistlock model TWI-W maintenance
VATCII 7-400-00 twinlift
VATCII 7-610-00 grease points shifthouse Twinlift (STB-13)
Twinlift:
VATCII 9-002-00 twin unit VATCII-ETW
VATCII 9-410-00 adjustment twin twistlock sensors
VATCII 9-431-01 twin twistlock composition model TWI-W-ISO-VC-R71-R-TW-S
VATCII 9-432-01 twin twistlock composition model TWI-W-ISO-VC-R71-L-TW-S
VATCII 9-500-02 twinlift up/down actuator left
VATCII 9-505-02 twinlift up/down actuator right
Safety:
VATCII 10-000-00 Security shifting telescoping beam
VATCII 10-110-01 Unlock twistlock - end beam
VATCII 10-215-00 Unlock twistlock - twin
VATCII 10-600-01 flipper actuator

Postbus 2005
The Netherlands
Part List of Manuals drawings
Project: 2611-1886-0000
Manual drawing Post Qty. Part No. Description

VATCII 1-205-02 01 1 2611-0199-7901 Shaft
VATCII 1-205-02 02 1 2611-0083-0203 Inner house
VATCII 1-205-02 07 1 2611-0083-0207 Washer
VATCII 1-205-02 08(14,22,23,43) 1 2611-0083-0208 Timing pulley (complete with washers)
VATCII 1-205-02 09 1 9807-1610-0110 Parallel key 16x10x110
VATCII 1-205-02 10 1 9804-0000-0014 Bearing 6213-2RS1
VATCII 1-205-02 11 1 9804-0000-0015 Bearing 22212-CC
VATCII 1-205-02 12 2 8726-0120-0001 Retainer ring ø120
VATCII 1-205-02 13 4 8570-0100-0045 Hexagon socket bolt M10x45 INOX-A4
VATCII 1-205-02 14 1 2611-0083-0214 O-ring ø108x6
VATCII 1-205-02 16 1 8551-0120-0035 Hexagon socket bolt M12x35 8.8 elvz
VATCII 1-205-02 17 1 2611-0083-0217 Telescope motor
VATCII 1-205-02 18 1 2611-0083-0218 Thrust ring
VATCII 1-205-02 19 1 6553-0700-0100 Connection plate hydraulic drive
VATCII 1-205-02 20 7 8562-0380-0034 Socket cap screw 3/8x3/4" 12.9
VATCII 1-205-02 21 6 8505-0100-0045 Hexagon bolt M10x45 8.8
VATCII 1-205-02 22 1 2611-0083-0222 Pulley flange
VATCII 1-205-02 23 1 2611-0083-0223 Pulley flange
VATCII 1-205-02 24 1 2611-0083-0224 Seal washer
VATCII 1-205-02 29 1 2611-0083-0229 U-gasket ø56x68x8,5
VATCII 1-205-02 30 1 2611-0083-0239 Oil-bush
VATCII 1-205-02 31 1 2611-0083-0231 O-ring ø120,25x3,53
VATCII 1-205-02 32 1 2611-0083-0232 O-ring ø134,5x3
VATCII 1-205-02 40 1 8725-0055-0001 Washer A55
VATCII 1-205-02 43 1 8555-0060-0016 Hexagon countersunk screw M6x16 8.8 elvz
VATCII 1-205-02 44 1 8710-0120-0001 Spring lock washer M12 dacro
VATCII 1-205-02 48 1 2611-0084-1800 Plastic block
VATCII 1-205-02 49 1 6020-0040-0071 Coupling 3/8"-12L
VATCII 1-205-02 51 1 6020-0060-0020 Coupling 7/16'-20UNF/12L
VATCII 1-205-02 60 1 2611-0199-7950 Seal kit
VATCII 1-205-02 61 1 2611-0199-7900 Hydraulic drive complete
VATCII 1-334-00 01 1 2611-0084-3001 Side plate
VATCII 1-334-00 02 1 2611-0084-3002 Side plate
VATCII 1-334-00 03 2 2611-0084-3003 Spacer plate
VATCII 1-334-00 04 1 2611-0084-3004 Rear platet
VATCII 1-334-00 07 4 2611-0084-3007 Slide block
VATCII 1-334-00 08 2 2611-0084-3008 Thrust ring
VATCII 1-334-00 09 1 2611-0084-3009 Pressure ring
VATCII 1-334-00 10 1 2611-0084-3010 Washer
VATCII 1-334-00 11 1 2611-0084-3011 Washer
VATCII 1-334-00 22 2 2611-0084-3022 Die spring9-1632-26 (A'DAM)
VATCII 1-334-00 29 1 8560-0160-0140 Hexagon socket bolt M16x140 12.9 black
VATCII 1-334-00 33 1 8606-0160-0001 Lock nut nylonr. M16 8.8 elvz
VATCII 1-334-00 34 1 8505-0160-0080 Hexagon bolt M16x80 8.8 elvz
VATCII 1-334-00 35 1 5014-0000-0034 Base plate sensor ø34
VATCII 1-334-00 36 1 5014-0000-0123 Base plate sensor M30x1,5
VATCII 1-334-00 43 1 9807-0807-0032 Parallel key 8x7x32
VATCII 1-334-00 45 6 9808-0024-1021 Protectioncap SW24/H=21
VATCII 1-334-00 47 1 2611-0084-3049 Locking plate + shaft
VATCII 1-334-00 50 6510-0011-0000 Cylinder complete
VATCII 1-334-00 51 - 2611-0084-3070 Blocking unit complete
VATCII 1-334-00 52 - 2611-0084-3000 Cylinder blocking device
VATCII 1-334-00 61 - 2611-0084-3082 Cylindre-overhaul
VATCII 1-334-00 62 12 8799-0000-0100 Lock washer M16 nordlock
VATCII 1-334-00 63 6 8610-0160-0024 Nut M16x1.5D
VATCII 1-400-02 01 1 2611-0085-0501 Tensioner
VATCII 1-400-02 02 2 2611-0085-0505 Clamp
VATCII 1-400-02 03 2 2611-0080-2108 Tension rod
VATCII 1-400-02 04 4 8702-0200-5006 Washer
VATCII 1-400-02 05 2 2611-0080-2114 Spacer tube
VATCII 1-400-02 06 2 9802-0000-0002 Compression spring
VATCII 1-400-02 07 2 8610-0200-0030 Nut M20 H=1,5D 10.9
VATCII 1-400-02 08 1 2611-0080-2121 Belt plate(M10)
VATCII 1-400-02 10 2 2611-0080-2102 Plate countersunk
VATCII 1-400-02 12 2 2611-0085-0510 Telescoping belt 45ft
VATCII 1-400-02 13 1 2611-0085-0506 Tension rod
VATCII 1-400-02 14 1 8610-0200-0060 Nut M20 H=3D 10.9
VATCII 1-400-02 15 1 2611-0080-2120 Belt plate countersunk
VATCII 1-400-02 16 1 2611-0080-2118 Plate
VATCII 1-400-02 17 2 8605-0200-0001 Nut M20 8.8 elvz
VATCII 1-400-02 18 4 8750-0200-0001 Washer M20 INOX-A4
VATCII 1-400-02 23 8 8556-0100-0030 Hexagon countersunk screw M10x30 8.8 elvz
VATCII 1-400-02 24 2 9808-0030-1120 Protectioncap SW30
VATCII 1-400-02 76 1 2611-0080-2010 Set tensioner parts
VATCII 1-500-03 01 2 2611-0080-2915 Slide block 80x41-bottom

Postbus 2005
The Netherlands
VATCII 1-500-03 03 1 2611-0084-0205 Support plate

VATCII 1-500-03 04 2 8571-0100-0020 Hexagon countersunk screw M10x20 INOX-A4
VATCII 1-500-03 05 2 2611-0080-2916 Slide block 40x41-top
VATCII 1-500-03 08 1 2611-0219-2025 Slide plate
VATCII 1-500-03 09 2 8598-0000-0002 Countersunk grease bolt M10x20 INOX-A4
VATCII 1-500-03 10 2 5010-0000-0123 Lock plate
VATCII 2-100-01 01 1 2611-0080-8000 Cable tray
VATCII 2-100-01 02 2 2611-0080-1001 Nylon roll
VATCII 2-100-01 03 1 2611-0080-0810 Guide support
VATCII 2-100-01 04 1 2611-0080-8600 Energy chain
VATCII 2-100-01 05 2 8526-0080-0025 Hexagon bolt M8x50 INOX-A4
VATCII 2-100-01 06 1 2611-0080-0215 Connection plate
VATCII 2-100-01 08 2 9899-0009-1338 Ty rap
VATCII 2-100-01 09 6 2611-0084-2502 Clamp
VATCII 2-100-01 13 1 2611-0080-8400 Connection plate
VATCII 2-100-01 15 2 2611-0080-0815 Protection plate
VATCII 2-100-01 18 20 8671-0080-0001 Lock nut M8 INOX-A4
VATCII 2-100-01 21 1 2611-0080-0208 Hydr. bended tude-short
VATCII 2-100-01 22 1 2611-0080-0209 Hydr. benden tube-long
VATCII 2-250-01 01 1 2611-0080-0850 Detection plate 20ft
VATCII 2-250-01 02 1 2611-0084-8500 Detection 45ft
VATCII 2-251-02 01 1 2611-0086-0801 Detection plate 40ft
VATCII 2-251-02 02 1 2611-0162-1700 Speed reduction 20ft
VATCII 3-106-03 01 1 6510-0200-0000 Cylinder complete
VATCII 3-106-03 02 1 6510-0200-0050 Seal kit complete
VATCII 3-106-03 07 2 8551-0160-0100 Hexagon socket bolt M16x100 8.8 elvz
VATCII 3-106-03 08 2 8610-0160-0048 Nut M16x3d
VATCII 3-106-03 10 2 9803-0001-0034 Clamp ø33.7mm nylon
VATCII 3-106-03 12 2 2611-0082-3005 Driving rod L=889
VATCII 3-106-03 14 2 9803-0010-0034 Clamp ø33.7mm rubber
VATCII 3-106-03 16 2 8605-0160-0001 Nut M16 8.8 elvz
VATCII 3-110-02 01 2 9805-0000-0002 Rod end M18x1/15H7x15
VATCII 3-110-02 02 1 8610-0180-0150 Nut M18x1,5
VATCII 3-110-02 10 1 2611-0082-3005 Driving rod L=889
VATCII 3-540-02 01 1 2641-0012-0000 Flat flipper-left
VATCII 3-540-02 02 1 2641-0013-0000 Flat flipper-right
VATCII 3-620-04 00 2611-0055-0100 See 3-620-01 pos 25
VATCII 3-620-04 01 1 2611-0055-0116 O-ring ø60x5 PU
VATCII 3-620-04 02 1 2611-0055-0400 Tooted cilinderbody
VATCII 3-620-04 03 1 2611-0055-0500 Piston rod
VATCII 3-620-04 04 1 2611-0055-0102 Piston seal L 1548-070-478 ERIKS
VATCII 3-620-04 05 1 2611-0055-0114 Back-up ring
VATCII 3-620-04 06 1 2611-0055-0601 Nut
VATCII 3-620-04 07 1 2611-0055-0105 Seal piston rod ER-39710-50-331
VATCII 3-620-04 08 1 2611-0055-0104 O-ring ø110x5
VATCII 3-620-04 09 1 2611-0055-0106 Scraper P8-50 (ERIKS)
VATCII 3-620-04 10 1 2611-0055-0700 Nut M130x55
VATCII 3-620-04 14 1 6020-0090-0120 Coupling 90-degrees 3/8" BSP-12L
VATCII 3-620-04 16 1 6825-0014-0018 Reducer 1/4"x1/8"
VATCII 3-620-04 17 2611-0055-0117 Seal kit
VATCII 3-620-04 18 2 8561-0160-0050 Hexagon socket bolt M16x50 12.9 dacro

Postbus 2005
The Netherlands

VATCII 3-620-04 22 3 8671-0100-0001 Locking nut M10 INOX-A4
VATCII 3-620-04 23 1 5010-0000-0009 Protection plate ø11mm
VATCII 3-620-04 25 1 2611-0055-0100 Actuator complete
VATCII 3-620-04 26 1 2611-0055-0801 Washer
VATCII 3-620-04 27 7 9808-0024-1026 Protection cap jaw.24
VATCII 3-620-04 29 3 8799-0002-0018 Plug G1/8'
VATCII 3-625-02 01 2 2611-0049-0300 Bush
VATCII 3-625-02 02 2 2611-0049-0500 Washer
VATCII 3-625-02 03 2 2611-0055-0111 Slide bearing
VATCII 3-625-02 04 1 2611-0055-0300 Driving shaft
VATCII 3-625-02 05 2 9801-0063-0090 Elbow grease nipple G1/4' elvz
VATCII 3-625-02 06 1 2641-0012-0018 Shaft M16x385(Flatflipper)
VATCII 3-625-02 09 2 2641-0012-0016 Lock plate flipper
VATCII 3-625-02 11 8610-0160-0080 Locking nut-half M16
VATCII 3-625-02 12 1 2641-0012-0019 Threaded rod M16x395
VATCII 3-625-02 75 2641-0012-0050 Set 2x09, 4x10
VATCII 3-630-02 01 1 2611-0055-0106 Scraper P8-50 (ERIKS)
VATCII 3-630-02 02 1 2611-0055-0105 Seal piston rod ER-39710-50-331
VATCII 3-630-02 04 1 2611-0055-0116 O-ring ø60x5 PU
VATCII 3-630-02 05 1 2611-0055-0114 Back-up ring
VATCII 3-630-02 06 1 2611-0055-0104 O-ring ø110x5
VATCII 3-630-02 07 1 2611-0055-0102 Piston seal L 1548-070-478 ERIKS
VATCII 3-847-03 01 1 2615-0087-0100 Twistlock bolt (ISO) W
VATCII 3-847-03 02 1 2615-0091-0200 Twistlock nut-left/right W
VATCII 3-847-03 03 1 2624-0001-0000 Twistlock bush ISO
VATCII 3-847-03 04 2 2615-0087-0400 Set of halve washers
VATCII 3-847-03 05 1 2615-0087-0500 Parallel key
VATCII 3-847-03 06 2 8599-0000-0008 Locking hexagon bolt M8x25 9.0 dacro
VATCII 3-847-03 07 1 2615-0018-0300 Swivel washer
VATCII 3-847-03 09 1 5003-0000-0013 Ring landing pin ø45x30.5-30
VATCII 3-847-03 10 1 8736-0080-0040 Spirol pin ø8x40
VATCII 3-847-03 11 1 9802-0000-0020 Compression spring Lo=120
VATCII 3-847-03 12 1 5021-0000-0011 Landing pin
VATCII 3-847-03 13 1 2615-0087-0600 Locking rubber (TWI-W)
VATCII 3-847-03 20 1 2615-0091-0000 Twistlock TWI-W-ISO-VC-R71
VATCII 3-859-03 01 1 2615-0087-0100 Twistlock bolt (ISO) W
VATCII 3-859-03 02 1 2615-0091-0200 Twistlock nut-left/right W
VATCII 3-859-03 20 1 2615-0091-0000 Twistlock TWI-W-ISO-VC-R71
VATCII 4-250-00 01 1 see chapter 12 Electronic indicator
VATCII 4-250-00 06 2 2611-0084-2503 Clamp 3xø33.5
VATCII 4-251-00 06 2 2611-0084-2503 Clamp 3xø33.5
VATCII 4-704-00 01 1 7201-0004-0002 Electric box lowerpart
VATCII 4-704-00 02 1 7201-0004-0000 Electric box cover
VATCII 4-704-00 06 2 5011-0000-0011 Vibration isolator
VATCII 4-730-00 01 1 7201-0011-0110 Electric box complete
VATCII 4-730-00 02 1 7201-0011-0210 Electric box-cover
VATCII 4-730-00 03 1 7201-0011-0205 E-box-underpart
VATCII 4-730-00 04 1 7201-0002-0001 Mounting plate
VATCII 4-730-00 06 1 7201-0002-0800 Rubber joint cover
VATCII 4-730-00 10 2 7201-0011-0310 Lock shaft cover
VATCII 4-730-00 20 1 see chapter 12.10 Cable connection plate
VATCII 4-730-00 21 1 see chapter 12.10 Cable connection plate

Postbus 2005
The Netherlands

VATCII 4-730-00 30 1 2611-1725-0590 Frame e-box
VATCII 4-730-00 31 4 5011-0010-0030 Wire rope isolator
VATCII 4-730-00 32 32 8525-0080-0045 Bolt M8x45 INOX-A4
VATCII 4-730-00 33 32 8671-0080-0001 Lock nut M8 INOX-A4
VATCII 5-101-04 01 1 6040-0100-0100 Air filter
VATCII 5-101-04 02 1 6050-0001-0101 Oil filter
VATCII 5-101-04 03 4 5011-0005-0010 Silentblock (set)
VATCII 5-101-04 04 6 7252-0100-0500 Gauge glass 3/8"
VATCII 5-101-04 05 1 6030-0100-0100 Coupling male 1/2''
VATCII 5-101-04 08 1 6050-0100-0101 Oil filter
VATCII 5-101-04 09 1 6050-0100-0102 Oil filter house
VATCII 5-101-04 20 1 6505-0001-0102 Tank cover
VATCII 5-101-04 21 1 6505-0001-0103 Tank cover seal
VATCII 5-101-04 30 1 see chapter 13.30 Electromotor
VATCII 5-101-04 31 1 6018-0002-0001 Seal
VATCII 5-101-04 32 1 6505-0001-0021 Coupling electric motor
VATCII 5-101-04 33 1 6505-0001-0022 Coupling house
VATCII 5-101-04 40 1 see chapter 13.30 hydraulic pump
VATCII 5-101-04 41 1 6801-0007-0020 O-ring ø101,2x3,53
VATCII 5-101-04 42 1 6505-0001-0024 Coupling pomp
VATCII 5-101-04 50 1 6505-0001-0003 Adapter with flange d=35
VATCII 5-101-04 51 1 6019-1240-0001 O-ring ø240,89x3,53
VATCII 5-101-04 60 2 7142-0200-0010 Pressure switch 10bar
VATCII 5-417-00 01 1 6510-0025-0000 Cylinder
VATCII 5-417-00 05 1 Rod end SG 1 HR 60 DO
VATCII 5-417-00 06 2 9803-0001-0022 Clamp ø22mm nylon
VATCII 5-417-00 20 1 6510-0025-0050 Seal kit
VATCII 5-440-01 02 2 Seepos.14 Scraper
VATCII 5-440-01 03 2 Seepos.14 Piston rod seal
VATCII 5-440-01 04 2 Seepos.14 Guide ring
VATCII 5-440-01 05 2 6510-0200-0011 Guiding piece
VATCII 5-440-01 06 2 Seepos.14 O-ring ø57x3
VATCII 5-440-01 07 1 6510-0200-0012 Cylinder tube
VATCII 5-440-01 08 1 6510-0200-0013 Mounting flange
VATCII 5-440-01 09 1 6510-0200-0014 Piston
VATCII 5-440-01 10 1 Seepos.14 Piston seal
VATCII 5-440-01 12 1 6510-0200-0015 Lock nut
VATCII 5-440-01 13 2 6020-0150-0038 Plug 3/8'
VATCII 5-451-03 07 1 6510-0002-0115 Rod end
VATCII 5-451-03 14 1 9801-0060-0090 Elbow grease nipple M6 elvz
VATCII 5-451-03 15 1 9801-0060-0180 Grease nipple M6 elvz
VATCII 5-451-03 19 1 6510-0002-0222 Seal kit
VATCII 5-470-01 02 1 Seepos.15 Scraper
VATCII 5-470-01 03 1 Seepos.15 Piston rod seal
VATCII 5-470-01 04 1 Seepos.15 O-ring ø26x3
VATCII 5-470-01 05 1 6510-0011-0105 Synthetic wacher M10
VATCII 5-470-01 06 1 6510-0011-0104 Cylinder tube
VATCII 5-470-01 08 1 6510-0011-0102 Guide ring
VATCII 5-470-01 09 1 6510-0011-0101 Cilinder bottom
VATCII 5-470-01 15 1 6510-0011-0050 Seal kit
VATCII 5-611-01 50 2 see chapter 13.30 Solenoid
VATCII 5-611-01 51 2 9808-0027-1025 Protection cap
VATCII 5-611-01 52 2 6016-0000-0003 Nut solenoid D15
VATCII 5-611-01 53 2 see chapter 12.10 Connector
VATCII 5-611-01 56 4 6016-0100-0001 Nut
VATCII 5-611-01 57 4 6017-0005-1000 Studs M5(Q12.9)
VATCII 5-611-01 58 2 6019-1021-0001 O-ring ø21,82x1,50-NBR 70sh
VATCII 5-611-01 59 2 6019-1023-0001 O-ring ø23,00x1,50-NBR 70sh
VATCII 5-704-00 00 1 6801-0008-0100 Grease pump complete
VATCII 5-704-00 01 1 6801-0003-0001 Greaseholder (4 litre)
VATCII 5-704-00 02 1 6801-0003-0002 Conversion kit
VATCII 5-704-00 03 1 6801-0007-0003 Pump house
VATCII 5-704-00 08 1 6801-0007-0002 Foot valve seat
VATCII 5-704-00 09 1 6801-0007-0004 Bottum cover
VATCII 5-704-00 12 1 6801-0003-0007 Support piston
VATCII 5-704-00 17 1 6801-0007-0005 Column (4 litre)
VATCII 5-704-00 18 1 6801-0007-0006 Top cover
VATCII 5-704-00 20 1 6801-0003-0012 Seal washer
VATCII 5-704-00 23 1 6801-0007-0007 Filling clamping ring
VATCII 5-704-00 24 1 6801-0007-0008 Guaze filter
VATCII 5-704-00 25 1 6801-0007-0009 Piston guide
VATCII 5-704-00 28 1 6801-0003-0016 Banjo nipple
VATCII 5-704-00 36 1 6801-0007-0010 Spring overfill valve
VATCII 5-704-00 40 1 6801-0007-0011 Foot valve holder

Postbus 2005
The Netherlands
VATCII 5-704-00 50 1 6801-0007-0012 Overfill valve

VATCII 5-704-00 60 1 6801-0007-0013 Overflow port
VATCII 5-704-00 61 1 6801-0007-0014 Nut M10x1,25
VATCII 5-704-00 62 1 6801-0007-0015 O-ring ø12,42x1,78
VATCII 5-704-00 63 1 6801-0008-0016 Vent line
VATCII 5-704-00 64 1 6801-0007-0017 Vent coupling square
VATCII 5-704-00 90 2 6801-0003-0017 O-ring ø170x5,33
VATCII 5-704-00 104 1 6801-0003-0019 O-ring ø36,17x2,62
VATCII 5-704-00 106 1 6801-0007-0019 O-ring ø23,52x1,78
VATCII 5-704-00 112 1 6801-0003-0021 Washer ø14xø6,7x1,5
VATCII 5-704-00 117 1 6801-0003-0022 Manometer
VATCII 5-704-00 118 1 6801-0003-0023 Banjo housing
VATCII 5-704-00 120 1 6801-0007-0020 O-ring ø101,2x3,53
VATCII 5-704-00 123 1 6801-0007-0021 Washer ø13xø8,4x2
VATCII 5-704-00 129 1 6801-0003-0026 Spring (4 litre)
VATCII 5-704-00 131 1 6801-0007-0022 O-ring ø11x1
VATCII 5-704-00 140 1 6801-0008-0103 Nut for sensor holder
VATCII 5-704-00 141 1 6801-0008-0102 Sensor holder for grease pump
VATCII 5-725-01 02 1 6803-0001-0000 Meter no.1
VATCII 5-725-01 03 1 6803-0002-0000 Meter no.2
VATCII 5-725-01 04 1 6803-0003-0000 Meter no.3
VATCII 5-725-01 06 1 6803-0005-0000 Meter no.5
VATCII 5-725-01 11 1 6803-0000-0003 O-ring
VATCII 5-725-01 12 1 6803-0000-0001 Locking ring for meter
VATCII 5-725-01 13 1 6803-0000-0002 Sleeve nut for meter
VATCII 5-725-01 14 1 6823-0002-0316 Die nut 3/16'
VATCII 5-725-01 15 1 6824-0001-0316 Compression ring 3/16'
VATCII 5-725-01 16 1 6815-0008-0316 Straight coupling M8x1x3/16'
VATCII 5-725-01 17 1 6823-0002-0516 Die nut 5/16'
VATCII 5-725-01 18 1 6824-0001-0516 Compression ring 5/16'
VATCII 5-725-01 19 1 6826-0316-0316 Coupling straight 3/16"
VATCII 5-725-01 20 1 6826-0516-0516 Coupling straight 5/16"
VATCII 5-725-01 21 1 6816-0008-0316 Elbow coupling M8x1x3/16'
VATCII 5-725-01 22 1 6816-0018-0316 Elbow coupling 1/8'x3/16'
VATCII 5-725-01 24 1 6817-0000-0516 Tee coupling 5/16'x5/16'
VATCII 5-725-01 25 1 6825-0014-0018 Reducer 1/4"x1/8"
VATCII 5-725-01 26 1 6822-0014-0000 Plug 1/4'
VATCII 5-725-01 27 1 6822-0012-0024 Plug 1/2'-24UNS
VATCII 5-725-01 28 1 6804-0004-0005 Insert for main tubing
VATCII 5-725-01 29 1 6815-0018-0316 Reducing nipple 1/8'x3/16'
VATCII 5-725-01 30 1 6850-0000-0010 Sparepart kit aut. greasing
VATCII 5-750-00 01 1 6802-0008-0000 14-Meter manifold
VATCII 5-750-00 03 1 6822-0014-0000 Plug 1/4'
VATCII 5-750-00 05 1 6804-0004-0005 Insert for main tubing
VATCII 5-750-00 06 1 6804-0001-0000 Lubricant tubing 3/16'
VATCII 5-750-00 09 1 6804-0004-0000 Main tubing 5/16'
VATCII 5-750-00 10 1 6804-0003-0000 Lubricant tubing 3/16' 3bundle
VATCII 5-750-00 11 1 6804-0002-0000 Lubricant tubing 3/16' 2bundle
VATCII 5-750-00 12 1 6802-0000-0002 Mounting strip
VATCII 5-750-00 13 1 6802-0000-0001 Mounting strip
VATCII 5-750-00 15 1 6825-0012-0024 Reducing nipple 1/2'-24UNS
VATCII 5-750-00 16 1 6810-0001-0000 Pressure switch
VATCII 5-750-00 18 1 6817-0014-0014 T-coupling 1/4'x1/4'x1/4'
VATCII 5-750-00 19 1 6810-0001-0001 Rubber sleeve
VATCII 5-750-00 20 1 6822-0012-0024 Plug 1/2'-24UNS
VATCII 5-845-00 01 1 2611-0082-0170 Foundation-left
VATCII 5-845-00 02 1 2611-0082-0175 Foundation-right
VATCII 5-845-00 03 3 5011-0000-0029 Vibration insolator ø75x40-M12
VATCII 5-845-00 07 2 8560-0080-0140 Hexagon socket bolt M8x140 Q12.9 black
VATCII 5-845-00 08 4 8610-0080-0012 Nut M8 h=1,5D Q10-black
VATCII 5-845-00 10 1 see chapter 13.30 Manifold
VATCII 5-901-02 01 1 6561-0002-1001 Pressure cartridge
VATCII 5-901-02 02 2 O-ring
VATCII 5-901-02 04 1 Nut
VATCII 5-903-02 01 1 6561-0003-1109 Auromatic greasecartridge
VATCII 5-903-02 02 2 O-ring
VATCII 5-903-02 04 1 Nut
VATCII 5-904-01 01 1 see chapter 13.30 Temperature switch
VATCII 5-904-01 02 1 see chapter 13.30 Seal washer
VATCII 5-904-01 03 1 see chapter 13.30 Protection cap
VATCII 5-904-01 04 1 see chapter 13.30 Ty rap

Postbus 2005
The Netherlands
VATCII 5-904-01 05 1 see chapter 13.30 Cable

VATCII 5-910-02 00 1 7250-0001-0005 Oil level switch complete
VATCII 5-910-02 01 1 7250-0001-0003 Level switch: body
VATCII 5-910-02 02 1 7250-0001-0004 Level switch: contact
VATCII 6-222-00 01 1 2611-1886-0310 Shiftframe VATCII-ETW
VATCII 6-222-00 02 1 2611-1886-0320 Shiftframe VATCII-ETW
VATCII 6-222-00 03 1 2611-0403-0350 Section for shift-frame
VATCII 6-222-00 04 4 8505-0270-0300 Hexagon bolt M27x300 8.8 Zn pl
VATCII 6-222-00 05 8 8517-0270-0085 HS Structural bolt M27x85 10.9
VATCII 6-222-00 06 24 8715-0270-0001 HS-Sructural washer M27
VATCII 6-222-00 07 12 8606-0270-0001 Lock hexagon nut M27 8
VATCII 6-222-00 08 24 9808-0041-1036 Protection cap black SW41/H=36
VATCII 6-222-00 09 4 2611-0403-0301 Filling slide plate 280x50x10
VATCII 6-222-00 10 4 2611-0403-0302 Slide plate linking section
VATCII 6-222-00 11 4 2611-0403-0303 Slide plate (side) 280x50x13
VATCII 6-222-00 12 4 2611-1663-0311 Lock plate-folded
VATCII 6-222-00 13 10 8570-0080-0025 Hex. socket bolt M8x25 A4
VATCII 6-222-00 14 30 8750-0080-0001 Plain washer M8
VATCII 6-222-00 15 2 2611-0403-0306 Filling block 280x95x50
VATCII 6-222-00 16 2 8750-0120-0001 Washer M12
VATCII 6-222-00 17 2 8525-0120-0045 Bolt M12x45 inox-A4
VATCII 6-222-00 18 4 2611-0348-0303 Pressure block 229x50x30
VATCII 6-222-00 19 8 8551-0160-0030 Hex. socket bolt M16x30 8.8
VATCII 6-222-00 20 30 8750-0160-0001 Washer M16 RVS A4
VATCII 6-222-00 21 4 2611-1437-0301 Silde plate guiding frame
VATCII 6-222-00 22 4 8505-0100-0200 Bolt M10x200 8.8 zinc plated
VATCII 6-222-00 23 4 8720-0120-0036 Mudwing repair washer M12x36
VATCII 6-222-00 25 11 8750-0100-0001 Washer M10
VATCII 6-222-00 27 1 1703-0000-0018 Bolt M56x180
VATCII 6-222-00 28 2 5003-0000-0026 Washer ø75/ø60.5X26
VATCII 6-222-00 29 1 8610-0560-0250 Half nut M56x25
VATCII 6-222-00 30 1 8737-0080-0100 Cotter pin ø8x100
VATCII 6-222-00 31 2 2611-0174-0360 Base plate sensor ø33
VATCII 6-222-00 32 4 8526-0100-0020 Hex. head screw M10x20 inox-A4
VATCII 6-222-00 33 2 9803-0001-0034 Clamp - single ø33.7mm
VATCII 6-222-00 34 2 9803-0010-0034 Clamp single-ø34-rubber
VATCII 6-222-00 37 1 7220-0002-0000 Link energy chain 115x45/R200
VATCII 6-222-00 38 1 2611-0103-1115 Cable channel 135x100 L=970
VATCII 6-222-00 39 1 5010-0000-0029 Foundation engineering rail
VATCII 6-222-00 41 28 8671-0080-0001 Lock hexagon nut M8 A4
VATCII 6-222-00 42 2 5003-0000-0033 Washer ø25xø8.5-7
VATCII 6-222-00 43 4 1703-0000-0039 Bolt ø70x160/M39x230
VATCII 6-222-00 44 8 5003-0000-0121 Ring ø130xø70.5-3
VATCII 6-222-00 45 4 5003-0000-0082 Washer ø89.5xø43-23
VATCII 6-222-00 48 16 2611-0174-0314 Plate 40x40x6ø9
VATCII 6-222-00 49 16 5003-0000-0028 Washer ø70/ø9x5
VATCII 6-222-00 50 2 9806-0005-0001 Netting 1400x700/ø4
VATCII 6-222-00 51 1 2611-1886-0340 Shiftframe passenger platform
VATCII 6-222-00 54 1 2611-01886-0360 Door passenger platform
VATCII 6-222-00 55 2 8510-0200-0090 Hexagon bolt M20x90 8.8 hd gal
VATCII 6-222-00 57 1 2611-1437-0385 Lock plate door
VATCII 6-222-00 60 1 2611-1886-0337 Protection ring E-cable
VATCII 6-222-00 63 1 9806-0037-0000 Pressed gratings (N) 800x500
VATCII 6-222-00 64 6 9806-0000-0001 Mounting plate for grating
VATCII 6-222-00 65 2 5097-0000-0120 Sticker Stinis blue 260x155
VATCII 6-222-00 66 2 5018-0000-0065 Shaft ø97x390
VATCII 6-222-00 67 2 5018-0000-0060 Handle ø27x222
VATCII 6-222-00 68 2 5018-0000-0010 Locking pin ø16x70
VATCII 6-222-00 69 2 5018-0000-0030 Pin ø16x160
VATCII 6-222-00 71 1 9999-0000-0008 Tension relief type GL-200/ø20
VATCII 6-222-00 72 1 5010-0000-0119 Tension relief e-cable
VATCII 6-222-00 73 4 2611-0403-0305 Filling side guiding 230x40x3
VATCII 9-002-00 01 2 2611-0220-0840 Twistlock box-right
VATCII 9-002-00 02 2 2611-0220-0870 Twistlock box-left
VATCII 9-002-00 03 4 2615-0058-0002 Nut
VATCII 9-002-00 04 4 2615-0058-0003 Key
VATCII 9-002-00 07 2 2611-0220-0811 Slide block foudation-left
VATCII 9-002-00 08 2 2611-0220-0821 Slide block foundation-right
VATCII 9-002-00 12 4 1702-0000-0011 Bolt
VATCII 9-002-00 14 8 5003-0000-0011 Washer

Postbus 2005
The Netherlands

VATCII 9-002-00 16 16 8598-0000-0001 Grease bolt M12x35 INOX-A4
VATCII 9-002-00 18 2 2611-0220-0645 Cylinder left
VATCII 9-002-00 19 2 2611-0220-0646 Cylinder right
VATCII 9-002-00 20 4 5003-0000-0012 Washer
VATCII 9-002-00 21 5 5014-0000-0123 Clamp M30x1,5
VATCII 9-002-00 24 4 6019-1040-0001 O-ring ø40x12
VATCII 9-002-00 31 4 2611-0219-0817 Hexagon bolt M20x120
VATCII 9-002-00 34 12 5003-0000-0019 Washer ø32xø20-15
VATCII 9-002-00 39 1 9803-0002-0022 Clamp ø22 double
VATCII 9-002-00 46 1 5014-0000-0161 Base plate twin gap detection
VATCII 9-002-00 49 4 8750-0040-0001 Washer M4 A4
VATCII 9-002-00 56 2 2615-0058-0000 Twistlock complete
VATCII 9-431-01 01 1 2615-0094-0100 Twistlock bolt (ISO)
VATCII 9-431-01 02 1 2615-0095-0200 Twistlock nut-right
VATCII 9-431-01 14 1 6019-1040-0001 O-ring ø40x12
VATCII 9-431-01 20 1 2615-0095-0000 Twistlock TWI-W-ISO-VC-R71-R-TW
VATCII 9-432-01 01 1 2615-0094-0100 Twistlock bolt (ISO)
VATCII 9-432-01 02 1 2615-0094-0200 Twistlock nut-left
VATCII 9-432-01 14 1 6019-1040-0001 O-ring ø40x12
VATCII 9-432-01 20 1 2615-0094-0000 Twistlock TWI-W-ISO-VC-R71-L-TW
VATCII 9-500-02 00 1 2611-0220-0645 Cylinder left
VATCII 9-500-02 01 1 2611-0220-0640 Cylinder without manifold
VATCII 9-500-02 02 1 2611-0220-0643 Hydraulic block
VATCII 9-500-02 05 4 6019-0018-0002 O-ring ø18,66xø3,53-90shore
VATCII 9-500-02 06 1 6574-0007-1010 Flow restrictor 40l adj. cartr.
VATCII 9-500-02 07 1 6579-0013-3065 Press relief valve 30l/65bar
VATCII 9-505-02 00 1 2611-0220-0646 Cylinder right
VATCII 9-505-02 01 1 2611-0220-0640 Cylinder without manifold
VATCII 9-505-02 02 1 2611-0220-0644 Hydraulic block
VATCII 9-505-02 05 4 6019-0018-0002 O-ring ø18,66xø3,53-90shore
VATCII 9-505-02 06 1 6574-0007-1010 Flow restrictor 40l adj. cartr.
VATCII 9-505-02 09 1 6579-0013-3115 Press relief valve 30l/111
VATCII 10-000-00 01 1 3547-0008-0000 Safety frame for telescoping
VATCII 10-600-01 01 2 5010-0000-0148 Lock plate actuator
VATCII 10-600-01 02 2 2641-0012-0016 Lock plate flipper
VATCII 10-600-01 03 4 8561-0160-0060 Hexagon socket bolt M16x60 12.9
VATCII 10-600-01 05 2 2641-0012-0019 Threaded rod M16x395

Postbus 2005
The Netherlands
VATCII 0−513 00

Postbus 2005
The Netherlands
60
20 50 Sealkit with
19 pos.14-29-31-32
A
Jeu de joints
51
d'etanchéité
pos.14-29-31-32
B
49 18
17 30
13 29
10
21
24
31
32
12
11
14
22
9
48
pulley consist of:
8 pos.14-22-23-43
40 Bride poulie se composer:
47 pos.14-22-23-43
43
23
Frontplate
Plaque avant 7
16 44
Hydraulische aandrijving zonder rem

Hydraulic drive without brake
Moteur pour corroie de télescopage
Hydraulikmotor ohne bremse
VATCII 1-205 02

Postbus 2005
The Netherlands
Lock plate together

with pos.5+6
47 Tôle de sûreté
avec pos.5+6
50
Cylinder complete
Vérin complet
1-2**
Blocking device
complete
51 Blockage complet
Cylinder with blocking
device complete
52 Vérin avec blockage
complet
4-403
45
36
43 33 10
32
9
4
11
38
66
35
2
31
7
34
1
3
22
50 6x 5x
63 30
5-470 12x
62
8 1x
47 29
Hydraulische blokkering met signalering

Hydraulic cilinderblock with signal
Verrou d'immobilisation télescopage
Hydraulik blockierzylinder mit signalisierung
Revision
VATCII 1-334 00

Postbus 2005
The Netherlands
DETAIL "A" 24
3
17
7
4 76
16 6
15
5
4
11 9
3
14
Extended pull rod A

barre de traction
13 22 18
21 18
2
8
A 9 11
12 10 23
1-2**
Spaninrichting-45ft
Stretching device-45ft
Systeme de tension cuorroie
Spanner antriebband-45ft
VATCII 1-400 02

Postbus 2005
The Netherlands
VATCII 1-402 00

Postbus 2005
The Netherlands
2-000
5
2
A A
Frontplate
Plaque avant 3
SECTION A-A
2X WITH GREASE HOLE ø3
2X AVEC TROU ø3 POUR GRAISSAGE

9
2x
4
Geleiding schuifligger
Guiding device
Guidage poutre télescopique
Fuhrung schiebeträger
VATCII 1−500 03

Postbus 2005
The Netherlands
VATCII 2-000 01

Postbus 2005
The Netherlands
VATCII 2-100 01

Postbus 2005
The Netherlands

Postbus 2005
The Netherlands

Postbus 2005
The Netherlands

Postbus 2005
The Netherlands
Set upper plates consist of:

4x(pos.4,5,6,7,13) 6 4 5
76 Set du plaque depression supérieur
se composer: 4x(pos.4,5,6,7,13)
±16mm
±2mm
13 7
3mm 2mm 17
LB RB
1
16 2
15
LO RO
Moer om schuifligger te lichten
10 Nut to lift lever
Ecrou pour lever traverse
5mm 14
2mm 9
3mm 8
Set lower plates,consist of:

4x(pos.8,9,10,11)
2x(pos.10,15)
77 Set du plaque depression inférieur
se composer: 4x(pos.8,9,10,11)
2x(pos.10,15)
11 12 18
2mm 3mm 5mm
Geleiding schuifligger
Guiding device telescopic beam
Conduite intérieure traverse télescopic
Fûhrung schiebebalken
Revision
VATCII 2-501 07

Postbus 2005
The Netherlands
3-710
5-8**
5-8** 4-704 5-8**
3-106
Kopligger
Beamhead
Poutre transversale
Kopfbalken
Revision
VATCII 3-055 04

Postbus 2005
The Netherlands
3-110
13 12
15 16 7 8 10 5 3 6 4 1 2
11 6
14
aandrijving twistlocks
Driving twistlocks
Commande twistlock
Antrieb twistlocks
VATCII 3-106 03

Postbus 2005
The Netherlands
VATCII 3-110 02

Postbus 2005
The Netherlands
1 2
3-625
Flipper-left Flipper-right
Flipper-left 3-620
*-OPTION-*
3-710
Flipper-left
Flipper-left
Beweegbare vlakke flipper

Actuated flat flipper LEFT RIGHT
Bras de centrage plat à commande
Bedienter flache flipper
Revision
VATCII 3-540 02 LEFT RIGHT

Postbus 2005
The Netherlands
- Tightening moment of the bolts (M10x30 10.9 black) 60 Nm

- Tourner force de boulon (M10x30 10.9 black) 60 Nm
3-625
16
2
29
4 27
19
20
18
1 5
10
12
28 A
11 B
22 21
3-630 13 14 26 23 24
Jeu de joint avec position numéro

Sealkit with position numbers
Flipperkast compleet 17
Actuator complete 25 01 04 05 07 08 09
Actionneur de flipper complet
Flipperkast
Actuator
Actionneur de flipper
Flipperauslöser
VATCII 3-620 04

Postbus 2005
The Netherlands
VATCII 3-625 02

Postbus 2005
The Netherlands
VATCII 3-630 02

Postbus 2005
The Netherlands
VATCII 3-847 03

Postbus 2005
The Netherlands
13
17
5
16 Datum
Date
15 2
11 4
7
8
10 9 3
12 Datum
Date
1
1 2 4 5 6 13
20
1 2 4 5 6 13
Twistlock TWI-W-ISO-VC-R71-L nieuwe kop right left

Twistlock TWI-W-ISO-VC-R71-L new headbeam
Twistlock TWI-W-ISO-VC-R71-L nouveau traverse
Twistlock TWI-W-ISO-VC-R71-L neue Kopfbalken
VATCII 3-859 03 left right

Postbus 2005
The Netherlands
VATCII 3-905 02

Postbus 2005
The Netherlands
VATCII 4−250 00

Postbus 2005
The Netherlands
VATCII 4−251 00

Postbus 2005
The Netherlands
Frontplate
Plaque avant
1-330
1-331
1-205
Frontplate
Plaque avant
Indicatie blokkeersysteem
Indicator blockingsystem
Capteurs de verrouillage télescopage
Signalisierung sicherungszylinder
Revision
VATCII 4-403 0

Postbus 2005
The Netherlands
3-110 5-440 3-110
±8mm. ±8mm.
Signalering aandrijving twistlocks

Signal driving twistlocks
Signalisation boulons d'serrage
Signal antrieb twistlocks
VATCII 4-409 02

Postbus 2005
The Netherlands
VATCII 4-704 00

Postbus 2005
The Netherlands
E-kast 1070x500x232
E-box 1070x500x232
Coffret 1070x500x232
Elektroschrank 1070x500x232
VATCII 4-730 00

Postbus 2005
The Netherlands
10
11
8
9
7
6
5
4
25 26
24
23 22 21 20
3
Signaleringslampen-4x LED lamp

Pilotlamps-4x LED lamp
Lampe de signalisation-4xLED lampe
Elektroschrank mit 4x LED anzeige
VATCII 4-802 01

Postbus 2005
The Netherlands
9
5-901
60
60
5
5-903
MP
MT
1
5-***
TL A8
A7
B7
B7
40mm.
T3
TL A6
A5
B5
B5
TL A4
B4
A3
B3
B3
TL A2
B2
A1
B1
B1
P2
C3
P2
6
3
20 21 22 23
10
7
40
4
42 41 40
50 51
5-904
33 32 31 30
5-910
Hydraulisch aggregaat serie 7,5kW-10kW

Power pack range 7,5kW-10kW
Groupe hydraulic série 7,5kW-10kW
Hydraulisch Aggregat serie 7,5kW-10kW
Revision
VATCII 5-101 04

Postbus 2005
The Netherlands
Rotatingspeed Oil pressure control

Blocking cylinders
Telescoping valve hight speed
Shiftspeed
Telescoping valve low speed
HANDBEDIENING
HANDOPERATED
Oil fill point
Oil pressure
control
22 T1 T2 T3 T4
MT
19
Smoring P1 B2 B4 B8
MP
INDRUKKEN B6
PRESS
Telescoop out
Pressure releave
5-906
P2 B1 B3 B5 B7
MP.V 1
V1 A1 A3 A5 A7
Oil filter
Greasing valve
Automatisch greasing cartridge
Automatisch smeerpatroon
Mainpressure cartridge
A2 A4 A6 A8
Rotating spreader
Hoofddrukpatroon
Roteren spreader
Blocking cylinder
Blokkeercilinder
Telescoop-in
Shiftcylinder
Shiftcilinder
MP
R1 R2
MT
5-611 Shiftspeed
5-903
5-901 Telescopic-slow LHA018-019
Kleppenblok hydraulisch aggeregaat

Valve unit hydraulic generator
Groupe hydraulique
VATCII 5−177 01

Postbus 2005
The Netherlands
Pakkingset
20 Sealkit
Jeu de joint
1
6
Shiftcilinder VATCII-E
Shiftcylinder VATCII-E
Cylindre de levage VATCII-E
Schiebezylinder VATCII-E
VATCII 5−417 00

Postbus 2005
The Netherlands
VATCII 5-440 01

Postbus 2005
The Netherlands
14
loctite 648
25
15
Pakkingset compleet
Sealkit with position complete
19 Jeu de joints d'etanchéité complet
Dichtungssatz komplett
Longtwin twistlockcilinder
Long twin twistlock cylinder
Vérin de commande longtwin twistlock
Longtwin twistlockzylinder
VATCII 5-451 03

Postbus 2005
The Netherlands
Sealkit with
15
pos.1-2-3-4
3
1
10
Cilinder blokkering complete

Cylinder blocking unit complete
Cylindre blockage complet
Blockierzylinder komplett
VATCII 5-470 01

Postbus 2005
The Netherlands
Type nummer
Type number
Type numéro
*****.****
Schema symbool
Graphic symbol
Graphique symbole
Invetten met zeewater bestendig vet

Grease with seawaterproof grease
Schmieren mit Seewasser beständig fett
Graisse resistance eau de mer
56
53
51
57 59 50 58 52
D15
Hydraulische NW 6 klep
Hydralique NW 6 valve
Disributeur NW6 Soupape
Hydraulik ventil NW6
VATCII 5-611 01

Postbus 2005
The Netherlands
VATCII 5-704 00

Postbus 2005
The Netherlands
VATCII 5-725 01

Postbus 2005
The Netherlands
VATCII 5-750 00

Postbus 2005
The Netherlands
Links Rechts HANDBEDIENING

Left Right HANDOPERATED
Indrukken
A Press
Twistlock los Twistlock vast

Y02/Y04 Y01/Y03
Twistlock unlocked Twistlock locked
Flipper rechts neer Flipper rechts-op

Y17/Y11 Filpper up-right Y18/Y12
Flipper right down
Flipper links neer Flipper op-links

Y13/Y15 Flipper down-left Y14/Y16
Flipper left down
Snelheid flipper neer-rechts
voor afstellen, rechtsom is sneller

Snelheid flipper neer-links
Snelheid flipper op-rechts

for adjusting, clockwise is faster
Speed flipper right-down
Snelheid flipper op-links

Speed flipper left-down
Speed flipper up-right

Speed flipper up-left
AANZICHT A
VIEW A
MF2858
T
P
B4 A4
Drukoverstort flipper neer-rechts
Shock releave flipper down-right
B1 A1
Shock releave flipper down-left
Drukoverstort flipper neer-links
Drukoverstort flipper op-rechts
Shock releave flipper up-right
Drukoverstort flipper op-links
Pressure reducing twistlocks
Shock releave flipper up-left
B1-S22 A1-S21
Drukreduceer twistlocks
B2-S24 A2-S23 B2 A2
B3-S20 A3-S19
B4-S153 A4-S152
B3 A3
Kleppenblok kopligger MF2858-3 functies

Manifold beamhead MF2858-3 functions
Collecteur traverse supérieur MF2858- 3 sections
Hydraulik ventielen in kopf MF2858-3 funktionen
VATCII 5−844 00

Postbus 2005
The Netherlands
Links Rechts
Left Right
3
5-611
5 4
AANZICHT A
VIEW A
T P
60 7 10 8 2 60 60
9
D15
Kleppenblok kopligger MF2858-3 functies-onderdelen

Manifold beamhead MF2858-3 functions-parts
Collecteur traverse supérieur MF2858- 3 sections
Hydraulik ventielen in kopf MF2858-3 funktionen
VATCII 5−845 00

Postbus 2005
The Netherlands
LENGTE-LENGTH-LONGUEUR
TYPE R
TYPE H
TYPE 45°
Slangnummer
Hose number
Tuyau numéro
Assembly torque for the different type of hoses:

Assemblage tourner de differentes de Tayau:
06L; 13 - 15NM size of jaw=14mm

08L: 15 - 18NM size of jaw=17mm
22L: 85-105NM size of jaw=36mm
16S: 60 - 75NM size of jaw=30mm

20S: 90-110NM size of jaw=36mm
25S: 125-145NM size of jaw=46mm
VATCII 5-900 02

Postbus 2005
The Netherlands
HANDACTIVATED HANDBEDIENING
PUSH AND TURN INDRUKKEN EN DRAAIEN
DON'T FORGET TO NIET VERGETEN OM
DEACTIVATE TERUG TE ZETTEN
COMMANDE MANUELLE
PRESSE ET TOUR
NE OUBLIER Á
DÉSAMORCER
invetten
grease
graisser
3 5
1
LOCTITE VERBODEN
LOCTITE FORBIDDEN
LOCTITE INTERDITE
VOORZICHTIG MET MONTEREN I.V.M. BESCHADIGEN VAN DE O-RINGEN

BE VERY CAREFUL TO MOUNT TO PREVENT DAMAGE OF THE O-RINGS
PRUDENT AVEC MONTER Á CAUSE DE ENDOMMAGÉ JOINT TORIQUE
Hoofddrukpatroon-ø12,3mm
Main pressure cartridge/solenoid-ø12,3mm
Cartouche limiteur de pression-ø12,3mm
Hauptdruckpatrone-ø12,3mm
Revision
VATCII 5-901 02

Postbus 2005
The Netherlands
HANDACTIVATED HANDBEDIENING
HEXAGON SOCKET SET BINNENZESKANT
PUSH AND TURN INDRUKKEN EN DRAAIEN
DON'T FORGET TO NIET VERGETEN OM
DEACTIVATE TERUG TE ZETTEN
COMMANDE MANUELLE
SIX PANS CREUX
PRESSE ET TOUR
NE OUBLIER Á
DÉSAMORCER
invetten
grease
graisser
3 5
1
LOCTITE VERBODEN
LOCTITE FORBIDDEN
LOCTITE INTERDITE
VOORZICHTIG MET MONTEREN I.V.M. BESCHADIGEN VAN DE O-RINGEN

BE VERY CAREFUL TO MOUNT TO PREVENT DAMAGE OF THE O-RINGS
PRUDENT AVEC MONTER Á CAUSE DE ENDOMMAGÉ JOINT TORIQUE
Automatisch smeerpatroon ø12,3mm

Automatic greasingcartridge ø12,3mm
Cartouche commande de graissage ø12,3mm
Automatisch schmierpatrone ø12,3mm
Revision
VATCII 5-903 02

Postbus 2005
The Netherlands
VATCII 5-904 01

Postbus 2005
The Netherlands
VATCII 5-910 02

Postbus 2005
The Netherlands
VATCII 6−222 00

Postbus 2005
The Netherlands
VATCII 7-100 01

Postbus 2005
The Netherlands
VATCII 7-201 00

Postbus 2005
The Netherlands
VATCII 7-300 00

Postbus 2005
The Netherlands
H1
J1
Smeren
Grease L1
D1
Schmieren
Graissage
Controleren op vreten
Check for scoring
Kontrollieren auf kerben
E1
Vérifier pour rainage
K1
Controleren op scheuren - 1e prioriteit
Check for cracks - 1st priority
Smeren Kontrollieren auf reißen - erste Priorität
Grease Vérifier pour fente - supérieur Priorité
Schmieren
A1
Graissage
B1

Check for cracks - 2nd priority
Kontrollieren auf reißen - zweite Priorität
Vérifier pour fente - secondaire Priorité

C1 Check for cracks - 3th priority
Kontrollieren auf reißen - dritte Priorität
Vérifier pour fente - tierse Priorité
F2 F1 G1 Double-Split-Collar Twistlock
Twistlock-onderhoud
Twistlock-maintenance
Twistlock-entretien
Twistlock-Unterhalten
VATCII 7-320 03

Postbus 2005
The Netherlands
new twistlock
nouveau twistlock
final rejection
A1 crack
crique
B1 crack
crique
F2
grind off
grincer
2,5mm.(final r éjection)
2,5mm.(final rejection)
final rejection
final réjection
C1
crack
crique
5.5(neouveau)
5.5(new)
F1
(final rejection)
(final réjection)
max.10mm.
G1
Double-Split-Collar Twistlock
Twistlock-onderhoud:afkeur criteria
Twistlock- maintenance:rejection
Twistlock-entretien:d'approbation
Twistlock-Unterhalten:aussortierung
VATCII 7-321 03

Postbus 2005
The Netherlands
turn round with hand, tour manuelle,

and tighten with
2-3 rotations
et tourner avec
2-3 rotations
H1
L1
iss e
e
g ra eas
gr
new=9mm.
final rejection=7mm.
final réjection=7mm.
B
final réjection=7mm.
nouveau=9mm.
new=9mm.
D1
J1
EXAMPLE OF BACKLOG MAINTENANCE

WORN-OUT OF SWIVEL-WASHER:
extreme dangerous situation,
overloaded twistlock
Single Twistlock model TWI-W onderhoud

Single Twistlock model TWI-W maintenance
Single Twistlock modèle TWI-W entretien
Single Twistlock Modell TWI-W Unterhalten
VATCII 7-322 01

Postbus 2005
The Netherlands
K6
longueur de nouveau baque=196,5mm. rejection à 195mm.

lenght by new bush=196,5mm. rejection by 53mm.
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
VATCII 7-323 01

Postbus 2005
The Netherlands
H1
turn round with hand,
and tighten with
L2
three rotations
B
L1
M1
proximity switch on by dimension B=14mm.
proximity switch off by dimension B=16mm.
new=7mm.
E1
new=19mm.
L3
new=7mm.
D1 J1
EXAMPLE OF BACKLOG MAINTENANCE

WORN-OUT OF SWIVEL-WASHER:
extreme dangerous situation,
overloaded twistlock
Twin Twistlock model TWI-W onderhoud

Twin Twistlock model TWI-W maintenance
Twin Twistlock modèle TWI-W entretien
Twin Twistlock Modell TWI-W Unterhalten
VATCII 7-324 00

Postbus 2005
The Netherlands
VATCII 7-400 00

Postbus 2005
The Netherlands
VATCII 7-610 00

Postbus 2005
The Netherlands
VATCII 9−002 00

Postbus 2005
The Netherlands
VATCII 9−410 00

Postbus 2005
The Netherlands
VATCII 9-431 01

Postbus 2005
The Netherlands
VATCII 9-432 01

Postbus 2005
The Netherlands
VATCII 9-500 02

Postbus 2005
The Netherlands
VATCII 9-505 02

Postbus 2005
The Netherlands
Beveiligings frame inschuiven schuifligger

Security frame shifting telescopic beam
Securite traverse telescopique
Sicherheits balken schiebebalken
VATCII 10−000 00

Postbus 2005
The Netherlands
VATCII 10-110 01

Postbus 2005
The Netherlands
quick couplings
twistlocks twinlift
*- Emergency control twistlocks Twin lift:
- Use a hydraulic handpump and connect this pump with

quick couplings to the hydraulic system spreader
- If the couplings are connected make movements with

the handle up- and downwards to rotate the twinlift
twistlocks
- When you use the hydraulic handpump make sure

that the spreader is NOT in operation.
Hydraulic handpump (the aggregate is in OFF stand)
Revision
VATCII 10-215 00

Postbus 2005
The Netherlands
Borging actuator as
Lock plate actuator shaft
Tôle de sûreté Axioneur
Sicherungsplatte Flipperauslöser
VATCII 10−600 01

Stinis Holland B.V. INDEX
Postbus 2005
The Netherlands
20 INDEX
Actuator Lamps 2-7
Blocking 3-16 Warnings 2-3, 2-5
Shift VATCII-E 3-17 Warnings twinlift interlock device 2-4
Twin up/down 3-17 Crane driver information 2-4, 2-6
Twin-twistlocks 3-17 Crane driver instruction 2-4, 2-6
Twistlock drawing 5-6 Customer dates 1-2
Twistlocks 3-16, 5-6 Customer project order number 1-2
Actuators Customer/user 1-2
Construction 3-6 Cylinder
Control 3-6 Shift 3-2
Flippers 1-3, 3-6, 3-16, 5-3 Twistlock 3-4
Maximum speed 3-6 Cylinders
Mounting 3-6 Maintenance 4-4
Oil leakage 3-6 Damage indication
Position 3-6 Flippers 5-3
Safety device 3-6 Date of delivery
Torque 3-6 Shipping date 1-2
Welding to headbeam 3-7 De-aerating
Adhesive Automatic greasing 5-12
Glues 4-2 Definitions 16-3
Adjusting indicators Degreaser 4-2
Twistlocks 5-6 Drawing number 1-2
Adjustment Drawings
Instructions 5-2 Directions for use 1-7, 11-1
Landing-pin 5-6 Instructions for use 17-1
Landing-pin indication 5-6 Used as reference 3-1
Sliding beams 5-7 Electric
Telescopic beams 5-8 Component information 6-1
Applicable standards 16-1 Connector 3-15
Area of Application 1-1 Indicator 3-3
Arrangement drawings Straight plug 3-15
Directions for use 11-1 Twinlift 3-8
Introduction 1-7 Twistlocks position indicators 5-6
Attention Electric connector to headblock 3-15
Flippers 5-3 Electrical
Automatic greasing 3-17 CAN 3-9
De-aerating 5-12 Communication with crane 3-15
Drawings 3-17 Conditions
Frequency 5-11 Steps 5-5
Grease 4-1 Control voltage 1-3
Grease cylce 5-11 Crane cable cores 3-15
Grease dividers 3-18 Current E-motor 3-9
Greasing 3-17 Drawings 3-9, 5-5
Maintenance 4-2, 5-11 Electric Motor
Minimum grease level 3-18 Power 1-3
Operating control 5-11 Grease low level switch 3-9
Pump 3-17, 3-18 Hydraulic solenoids 3-10
Belt Maintenance 4-3, 4-5
Replacement 5-8 Motor 7.5kW 3-9
Telescopic beams 5-8 Oil level switch 3-9
Blocking Oil return switch 3-10
Actuator 3-16 Power supply voltage 1-3
Drawing 3-16 Signals from crane 3-15
Plate 3-3 Signals to crane 3-15
Slide-beams 3-3 Temperature switch 3-9
Sliding-beams 3-3 Trouble shooting 5-5
Blocking cylinders 3-3 E-motor 5-5
Oil pressure 3-3 Spreader function 5-5
Cabletrack Electrical components
Twistlock beams 3-4 Parts list 12-1
CE documents 1-6 Electrical schedules 3-9
CE number 1-2 Electrical system 5-5
Cell guide rollers 3-4 Electrics
Certificate number Tracer pin indication 3-4
Spreader 1-2 Twistlock 3-4
Twistlocks 1-2 EN 13000 16-4
Communication with crane 3-15 End beams
Connector 3-15 Twistlocks beams 3-4
Conservation 1-7 Equilizing
Conserving Shift frame 3-2
Maintenance 4-4 Error messages
Construction 3-1 Crane driver 2-5
Actuators 3-6 Explanation from manufacturer 1-6
Control Flipper actuators
Actuators 3-6 Leakage 5-3
Control voltage 1-3 Flippers 3-6, 5-9
Crane 1-2 Actuator drawing/location 3-6
Crane cable cores 3-15 Actuators 1-3, 3-6, 3-16, 5-3
Crane control Attention 5-3
Safety precautions 2-1 Damage indication 5-3
Warnings 2-1 Drawing/location 3-4, 3-6
Crane driver Extension 3-7
Error messages 2-5 Interchangeability 3-6

Postbus 2005
The Netherlands
Maintenance 4-3, 5-3, 5-9 Telescoping 3-3, 3-16

Material 3-7 Telescoping beam lock 3-16
Mounting 3-7 Oil pressure 3-16
Profile 3-7 Tubes
Protection 3-6, 5-9 Hoses 3-4
Protection Drawing/location 3-6 Tubes 13-1
Speeds 1-3 Valves 3-4
Support 3-6, 5-9 Hydraulic and electrical components 3-1
Toothed rack 3-6 Hydraulic components
Torque 1-3, 3-7 Parts list 13-2
Welding instructions 3-6, 5-9 Hydraulic hoses
Flippers actuators Identification 13-1
Adjusting shock relief valves 5-4 Number 13-1
Adjusting torque 5-4 Partlist 13-1
Greasing 5-3 Size 13-1
Maintenance 5-3 Hydraulic information 3-15
Overload 5-4 Hydraulic oil
Seals 5-3 Quality 4-1
Set up position 5-3 Temperature environment 4-1
Speeds 5-3 Hydraulic tank
Speeds adjusting 5-4 Maintenance 4-5
Force Hydraulics
Twin up/down 3-17 Drawings
Frequency Parts general 3-4
Automatic greasing 5-11 Tracer pin indication 3-4
Greasing 3-18 Twistlock 3-4
Functional description 3-1 Indicating
Functional program description Twin 3-12 Telescopic stops 3-3
Geared belt Twistlock 3-4
Replacement 5-8 Twistlocks 3-4, 5-6
Grease Instruction crane driver 2-4, 2-6
General purposes 4-1 Instructions
Greasing 4-1 Adjustment 5-2
Quality 4-1 Greasing 4-2
Quality of lubrication 4-1 Lubrication 4-2
Temperature environment 4-1 Maintenance 4-2
Grease cylce Periodic maintenance 4-2
Automatic greasing 5-11 Repairing 5-2
Greasing Instructions crane driver
Automatic greasing 3-17 Safety precautions 2-3
Frequency 3-18 Instructions for adjustment and repair 5-2
Grease 3-17, 4-1 Lamps 2-7
Grease products 3-17, 3-18 Crane driver 2-7
Headbeams 4-3 Landing pins
Instructions 4-2 Maintenance 4-3, 4-4
Low level switch 3-18 Twistlocks 5-6
Maintenance 4-3 Landing-pin
Mid-frame 4-2 Adjustment 5-6
Pressure switch 3-18 Landing-pin indication 5-6
Telescopic beams 4-2, 4-3 Adjustment 5-6
Twinlift housings 4-2 Drawing 5-6
Greasing points Leakage
locations 4-1 Solenoid 3-10
Recognising 4-1 Lifetime 1-1
Greasing system 3-17 Lifting lugs for managing/repairing
Hazards 16-4 WLL 3-2
Headbeams Lifting lugs near twistlocks
Greasing 4-3 SWL 1-1
Hoses Lifting lugs side mid-frame
Hydraulic WLL 3-2
Tubes 3-4 Lifting lugs underside midframe
Hoses SWL 1-1
Hydraulic 13-1 List
How to order spare parts 6-1 Production drawings 11-1
Hydraulic Low level switch
Blocking cylinder 3-3 Greasing 3-18
Blocking cylinders 3-3 Lubrication 3-17
Component information 6-1 Instructions 4-2
Drawing 3-15 Lubrications
Drawings Quality 4-1
Partlist Main E-box
Components 3-15 Maintenance 5-5
Parts general 3-15 Main spreader frame
Drive 3-3 Mid-frame 3-2
Flippers 3-6, 3-16, 5-3 Maintenance 4-2
Functional description 3-15 Automatic greasing 3-17, 4-2, 5-11
General information 3-15 Conserving 4-4
Greasing 3-17 Cylinders 4-4
Hoses 13-1 Electrical 4-3, 4-5
Manual operation drawing 3-15 Flippers 4-3, 5-3, 5-9
Oil 4-1 Flippers actuators 5-3
Operating oil pressure 1-3 Greasing 4-3
Part drawings 3-15 Hydraulic tank 4-5
Partlist 3-15 Instructions 4-2
Return oil filter 3-16 Landing pins 4-3, 4-4
Solenoids 3-10 Lubrication-quality 4-1

Postbus 2005
The Netherlands
Main E-box 5-5 Preventive

Manifold 4-3, 4-4 Maintenance instructions 4-2, 4-3
Mobile Crane Spreader Procedures
Shift actuator 4-4 Start-up 2-8
Periodic lubrication instructions 4-2 Production drawings
Silentblocks 4-5 Direction for use 11-1, 17-1
Sliding beams 5-7 Introduction 1-7
Telescopic beams 4-4, 5-8 List 11-1
Telescoping beams 4-3 Project-order number customer 1-2
Telescoping drives 4-3 Protection
Tower mobile crane spreader 4-3 Flippers 3-6, 5-9
Twinlift 5-10 Purchase
Twistlocks 4-3, 4-4 Component information 6-1
Maintenance department Rated Capacity
Warnings 2-8 SWL 1-1, 1-3
Maintenance instructions Repairing
Preventive 4-2, 4-3 Instructions 5-2
twistlock double-split-collar 4-5 Repair-Malfunction
Manifold Hydraulic
Maintenance 4-3, 4-4 Oil leakage 5-2
Manual activating Power consumption too high 5-2
Solenoid 3-10 Power consumption too low 5-2
Manual drawings Telescoping 5-2
How to handle 17-1 Twinlift housings 5-2
Introduction 1-7 Twistlocks 5-2
Manual operation drawing Risk Analysis 16-4
Hydraulic 3-15 Safety
Material Crane driver instruction 2-4, 2-6
Dates 5-1 Features 2-10
Flippers 3-7 Precautions
Welding instructions 5-11 Instructions maintenance department
Materials 2-8
Certificate 5-1 Power pack 3-16
Mechanic Powerpack 6-1
Switches 3-9 Safety device
Mid-frame Actuators 3-6
Frontplates 3-2 Safety precautions
Greasing 4-2 Crane control 2-1
Guide blocks 3-2 Instructions crane driver 2-3
Main spreader frame 3-2 Serial number 1-2
Telescopic positions 3-2 Service
Wearing blocks 3-2 Standby 6-1
Mobile Crane Spreader Shift frame
Shift actuator Guiding plates 3-2
Maintenance 4-4 Operation 3-2
Motor 7.5kW Shift house 5-9
Electrical 3-9 Shift VATCII-E
Mounting Actuator 3-17
Actuators 3-6 Signals from crane 3-15
Flippers 3-7 Signals to crane 3-15
Oil 4-1 Silentblocks
Oil leakage Maintenance 4-5
Actuators 3-6 Single operation
Repair-Malfunction Spreader operation 3-7
Hydraulic 5-2 Sliding beams 3-3
Oil level switch 3-9 Adjustment 5-7
Drawing/location 3-16 Backlash 3-3, 5-7
Electrical 3-9 Blocking cylinder 3-3
Oil pressure Blocking cylinders 3-3
Blocking cylinders 3-3 Maintenance 5-7
Oil return switch 3-10 Operation 3-3
Oil temperature switch Positions 3-3
Drawing/location 3-16 Speeds 1-3, 3-3
Overheight spreader 1-1 Telescopic belts 3-3
Painting Telescopic motor 3-3, 3-16
Conservation 1-7 Telescopic stops 3-3, 5-9
Part list Solenoid
Hydraulic components 3-15 Leakage 3-10
Hydraulic hoses 3-15 Manual activating 3-10
Partlist Voltage 3-10
Hydraulic hoses 13-1 Solenoids
Parts list Hydraulic 3-10
Electrical components 12-1 Speed-maximum
Hydraulic components 13-2 Twin up/down 3-17
Passenger cage 2-10 Speeds
Periodic maintenance Flippers 1-3
Instructions 4-2 Sliding beams 1-3, 3-3
Positions Twistlocks 1-3
Telescoping 3-3 Spreader cage 2-10
Power consumption too low Spreader construction 3-1
Repair-Malfunction Spreader dates
Hydraulic 5-2 Free space under spreader 1-1
Powerpack Suspension 1-1
Pressure valve/location 3-4 SWL 1-3
Pressure switch Tare weight 1-3
Greasing 3-18 Telescoping positions 3-3

Postbus 2005
The Netherlands
Telescoping speed 1-3 Twin operation

Twistlock type 1-3 Spreader operation 3-7
Spreader identification 1-2 Tolerances 3-8
Spreader marking 1-2 Twin protection 3-8
Spreader operation check 2-9
Single operation 3-7 Twin single operation
Twin operation 3-7 Spreader operation 3-7
Twin single operation 3-7 Twin twistlock 3-8
Spreader registration 1-2 Twin twistlock housing 3-7
General 1-2 Twin up/down
Standby Actuator 3-17
Service 6-1 Force 3-17
Start-up Speed-maximum 3-17
Procedures 2-8 Twin up/down cylinder 3-7
Warning 2-8 Twin up/down cylinders 3-8
Start-up procedures 2-8 Twin-20-protection 2-4
Steps Twinlift
Electrical Electric 3-8
Conditions 5-5 Maintenance 5-10
Straight plug Twinlift construction 3-7
Electric 3-15 Twinlift housings
Switches Greasing 4-2
Mechanic 3-9 Repair-Malfunction
SWL Hydraulic 5-2
A-symmetric 1-3 Twinlift interlock device 2-4, 2-5, 2-6
Lifting lugs 1-3 Twinlift Unit 5-10
Lifting lugs near twistlocks 1-1 Twin-operating 3-8
Lifting lugs underside midframe 1-1 Twin-twistlocks
Maximum test load 1-3 Actuator 3-17
Spreader 1-3 Twistlock
Symmetric 1-1 Bushes 3-4
Symmetrical 1-3 Constructions 3-4
Telescopic beams 3-3 Drawing Composition 3-4
Adjustment 5-8 Electrics 3-4
Belt 5-8 Indicating 3-4
Greasing 4-2, 4-3 Lifetime 3-4
Maintenance 4-4, 5-8 Loading 3-4
Operation 5-8 Model 3-4
Speed 3-3 Oil pressure 3-4
Telescopic belts 5-8 Position indication 3-4
Telescopic beams - backlash 5-7 Sensor 3-4
Telescopic belt 3-3, 5-8 Tracer pin 3-4
Assembling 5-8 Type 3-4
Tightening 5-8 Washer 3-4
Telescopic motor 3-3 Twistlock beams
Telescopic positions Cabletrack 3-4
Adjustment 5-9 twistlock double-split-collar
Telescopic stops 3-3, 5-9 Maintenance instructions 4-5
Adjustment 5-9 Twistlocks
Indicating 3-3 Actuator 3-16, 5-6
Telescoping Adjusting indicators 5-6
Repair-Malfunction beams 3-4
Hydraulic 5-2 Indicating 3-4, 5-6
Telescoping beams Landing pins 5-6
Maintenance 4-3 Landing-pin 5-6
Telescoping drives Maintenance 4-3, 4-4
Maintenance 4-3 Repair-Malfunction
Temperature switch 3-9 Hydraulic 5-2
Terminology 16-3 Replacement 5-6
Test runs Sensor 5-6
Oil quality 4-1 Speeds 1-3
Tolerances Type 1-3
Mid-frame beams 3-1 Twistlocks beams
Torque End beams 3-4
Actuators 3-6 Used materials 5-1
Flippers 1-3, 3-7 Voltage
Tower Solenoid 3-10
Operation 3-2 Warning
Tower mobile crane spreader Start-up 2-8
Maintenance 4-3 Warnings
Tracer pin indication 3-4 Crane control 2-1
Electrics 3-4 Crane driver 2-3
Trouble shooting Maintenance department 2-8
Electrical 5-5 Warranty 1-5
E-motor 5-5 Weather conditions 3-1
Spreader function 5-5 Welding
Flippers 5-3 Mid-frame beams 3-1
TTDS 2-4 Welding instructions 5-11
Tubes Flippers 3-6, 5-9
Hydraulic 13-1 Welding to headbeam
Twin Actuators 3-7
Oil pressures 5-4 WLL
Up/down actuators 5-4 Lifting lugs for managing/repairing 3-2
Twin 20 protection 2-6 Lifting lugs side mid-frame 3-2
Twin foundation 3-7


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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

MANUAL BJTI001-002 Release A 18 October 2010 A

MANUAL BJTI001-002 Release A 18 October 2010 B

11 MECHANICAL DRAWINGS ...............................................................................................................11-1

MANUAL BJTI001-002 Release A 18 October 2010 C

MANUAL BJTI001-002 Release A 18 October 2010 D

MANUAL BJTI001-002 Release A 18 October 2010 1-1

1.20 SPREADER REGISTRATION

MANUAL BJTI001-002 Release A 18 October 2010 1-2

1.30 TECHNICAL SPECIFICATION

MANUAL BJTI001-002 Release A 18 October 2010 1-3

MANUAL BJTI001-002 Release A 18 October 2010 1-4

MANUAL BJTI001-002 Release A 18 October 2010 1-5

MANUAL BJTI001-002 Release A 18 October 2010 1-6

MANUAL BJTI001-002 Release A 18 October 2010 1-7

MANUAL BJTI001-002 Release A 18 October 2010 1-8

2 START-UP – WARNINGS – SAFETY PRECAUTIONS

MANUAL BJTI001-002 Release A 18 October 2010 2-1

D. CHECK THE CRANE ADJUSTMENT LIFTING AFTER LOCKING TWISTLOCKS

MANUAL BJTI001-002 Release A 18 October 2010 2-2

2.15 CRANE DRIVER: WARNINGS

MANUAL BJTI001-002 Release A 18 October 2010 2-3

2.15.21 CRANE DRIVER: WARNINGS TWINLIFT INTERLOCK DEVICE

MANUAL BJTI001-002 Release A 18 October 2010 2-4

2.15.33 CRANE DRIVER: WARNINGS SPREADER ERROR MESSAGES

MANUAL BJTI001-002 Release A 18 October 2010 2-5

2.16 CRANE DRIVER: INSTRUCTIONS VATCII-ETW

MANUAL BJTI001-002 Release A 18 October 2010 2-6

Conditions for telescoping:

2.17 CRANE DRIVER: LAMP INFORMATION

MANUAL BJTI001-002 Release A 18 October 2010 2-7

LAMP COLOUR LOCATION CONTINEOUS BLINKING

2.18 MAINTENANCE DEPARTMENT: WARNINGS

2.20 STARTUP PROCEDURES

MANUAL BJTI001-002 Release A 18 October 2010 2-8

* Check twistlock operation:

MANUAL BJTI001-002 Release A 18 October 2010 2-9

2.41 SAFETY FEATURES

2.50 SPREADER CAGE

MANUAL BJTI001-002 Release A 18 October 2010 2-10

3.10 DRAWINGS: REFERENCES

3.20 FUNCTIONAL DESCRIPTION

MANUAL BJTI001-002 Release A 18 October 2010 3-1

3.20.25 SHIFT FRAME refer to:

MANUAL BJTI001-002 Release A 18 October 2010 3-2

3.20.30 TELESCOPIC BEAMS

3.20.40 BLOCKING SLIDE BEAM

MANUAL BJTI001-002 Release A 18 October 2010 3-3

3.20.50 END-BEAMS (HEAD-BEAMS)

3.20.61 TWISTLOCKS model TWI-W

MANUAL BJTI001-002 Release A 18 October 2010 3-4

MANUAL BJTI001-002 Release A 18 October 2010 3-5

3.20.70 FLIPPERS and ACTUATORS

MANUAL BJTI001-002 Release A 18 October 2010 3-6

Flipper control using a three-position valve (4/3), with integrated functions:

3.20.90 TWINLIFT CONSTRUCTION

MANUAL BJTI001-002 Release A 18 October 2010 3-7

MANUAL BJTI001-002 Release A 18 October 2010 3-8

3.40.03 GENERAL ELECTRICAL INFORMATION (CAN control)

3.40.10 GENERAL ELECTRICAL COMPONENTS

MANUAL BJTI001-002 Release A 18 October 2010 3-9

Oil return switch: