B222 ReachStacker

08 Spreader
B222 ReachStacker

09/06 - Slide1
Slide1

B222 ReachStacker

Course Details
Course name:

B222 Spreader

Content:

This module covers information about the

spreaders on B222 units

General objectives:

Familiarization with the spreader arrangement

Target Group:

Big Truck technicians

Pre-requisites:

The student should have a basic knowledge

about hydraulic and mechanical systems and
should be able to read and interpret hydraulic
schematics.

Learning Objectives: Describe and locate the main components of the

spreader
Perform basic trouble shooting on the spreader
Course Duration:

2 hours

B222 ReachStacker

B222-ELME-EXTENDABLE CONTAINER ATTACHMENT

Elme concept

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B222-ELME-EXTENDABLE CONTAINER ATTACHMENT

813 Dedicated

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B222-ELME-EXTENDABLE CONTAINER ATTACHMENT

815 Fork Mounted

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B222-ELME-EXTENDABLE CONTAINER ATTACHMENT

817- Reach stacker

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B222-ELME-EXTENDABLE CONTAINER ATTACHMENT

Two types:
817

=>

Twist locks

858

=>

Inter-modal

Most common : 817

Rotator
Attachment itself

Important => Always refer to Attachment Serial Number

mentioned on the name plate !

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B222 ELME 817- GENERAL OPERATIONS

1. Twist locks
2. Extension beam
3. Powered pile slope
cylinder
4. Slewing ring
5. Rotator motor
6. Electric box
7. Attachment frame
8. Side shift cylinder
9. Stop cylinder
Dampening cylinders not
shown
(attached to the boom)

B222 ELME 817-ROTATOR

1. Side shift cylinder
2. Wear pads support
3. Wear pads
4. Mechanical stops
5. Lower rotator frame
6. Outer ring
7. Inner ring
8. Upper rotator frame
9. Dampening cylinder mount
10. Hydraulic rotator motor
11. Hydraulic swivel

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B222 ELME 817 GENERAL FEATURES

Rotation angle => +95 to -185 (mechanical stops)

Hydraulic swivel => Avoid hydraulic hoses twisting
Vertical wear pads => Limit the fore/aft movement
Powered pile slope => lower part of rotor split to allow tilt..
Reinforcements to allow intermediate containers lengths.

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B222 ELME 817 - STRUCTURE

30ft Reinforcement

Top Reinforcement

Different reinforcements
installed to withstand
various applications

40ft Reinforcement

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B222 ELME 817- HYDRAULIC SCHEMATIC

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B222 ELME - PRESSURE VALVE

Noted : Solenoid Y54

Attached to the swivel valve
1. Relief valve
2. Pressure valve
3. Check valve

No function
=> Oil is reapplied

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B222 ELME 817- DAMPING

Forward-Backward Oscillation / Boom
B222 configuration with symmetric
Dampening cylinders.
Dampening Restriction
30 bar (435 psi) minimum to prevent
cavitation.
Quick movement = high flow
=>The restriction limits 30 bar
relief
=> So 80 bar (1160 psi) relief valve
is added
Note:
The Pressure, P, line and Drain,
D, line should be reversed.

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B222 ELME 817 - POWER DAMPENING OPTION

60 bars relief pressure

(870 psi)

Actuated by two
solenoid valves

1. Y51 & Y52

2. 60 bars relief valve
3. To rotator/brake
valve
4. To damping
cylinder
5. To swivel valve

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B222 ELME 817- ROTATOR TRANSMISSION

Oil
Dynamic

Suppliers

Bonfiglioli

Bonfiglioli
Standard

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B222 ELME 817- ROTATOR

Rotation only if no other

function activated.
2 motors
No rotation
=> Y15 (brake) not
activated
=> Brake spring force
=> Y16 & Y17
(direction) not activated

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B222 ELME 817- ROTATOR

Rotation
=> Brake released (Y15)
=> Motor pressurised
(Y16-Y17)
=> After 0.5 to 4 seconds, high
speed (Y18)
Rotation 1st limit = 12
2nd limit (+95/-185)
Pressure limit = 80 bars (1160 psi)

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B222 ELME 817- SWIVEL VALVE

Shaft

P
Oil supply to rotating
equipment

Seals

Housing
Bearing

O-ring
Washer
Cover

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B222 ELME 817- ROTATOR TRANSMISSION

Includes
Brake section
Reduction gear section
End housing with pinion
axle
Generally replaced and not
repaired. Except seal kit.
Note the number of transmission
mount bolts (12 or 10) for parts
identification

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B222 ELME 817- ROTATOR TRANSMISSION

Pinion with housing

and bearings

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B222 ELME 817- ROTATOR TRANSMISSION

Planetary gear
reduction

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B222 ELME 817- ROTATOR TRANSMISSION

Brake assembly.

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B222 ELME 817- ROTATOR TRANSMISSION

Bonfiglioli Brake

Nom. 5.5 6.0

mm
Max. 7.5 mm
More than 7.5 mm
(0.3 in), discs
must be replaced.

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B222 ELME 817- ROTATOR TRANSMISSION

Springs

Breather

Discs

Shaft

Cover

Brake housing

Brake connection

Planetary housing

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B222 ELME 817- ROTATOR TRANSMISSION

Brake

Piston

Springs

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B222 ELME 817- ROTATOR TRANSMISSION

Set of discs

8 outer
(separators)

Max 27.7 mm (1.09 in)

7 inner (discs)

Min 25.7 mm (1.01 in)

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B222 ELME 817- OPTIONAL POWERED PILE SLOPE

Assembly

Pile slope cylinders

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B222 ELME 817- OPTIONAL POWERED PILE SLOPE

Side tilt in case of sloping ground or
uneven truck frames (i.e., a 20 ft
container on a 5th wheel).
Y47 & Y48 for LH or RH side tilt
Relief pressure valves for off center
loads.
Y50 & Y49 for optional Tilt Float.
(Self adjustment to container side tilt)

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B222 ELME 817- OPTIONAL POWERED PILE SLOPE

1. Electro-valve
2. Counterbalance
3. R.H. front cylinder ports
4. R.H. front cylinder ports
5. L.H. front cylinder ports
6. L.H. front cylinder ports
7. Tank ports
8. Pressure port
9. Counterbalance
10. R.H. rear cylinder ports
11. R.H. rear cylinder ports
12. L.H. rear cylinder ports
13. L.H. rear cylinder ports

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B222 ELME 817- EXTEND & RETRACT

Extension valve located at
shell end of the extension
cylinder
1. Check Valve

Left hand side shown only

Optional Position
Stops

2. Relief valve, 80 bar

Stop

Extend/Retract
Twist locks

TWL

(1160 psi)
3. To rod side of extension
cylinder
4. To TWL cylinder
5. To stop cylinder
6. Valve on extension cyl.

Stop kit

Extend

=> Position holes & frame reinforcements

=> Position maintained by permanent
pressure.

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B222 ELME 817- SIDE SHIFT

Located on the top of the RH side spreader frame.

1. From swivel valve

2. Adapter pump line
3. Adapter tank line
4. To rear side shift cyl.
5. To left hand ext. valve
6. Relief valve
7. To front side shift cyl.
8. To right hand extension cylinder
80 bar (1160 psi) relief pressure

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B222 ELME 817- TWIST LOCKS

Both sides shown
on this schematic

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B222 ELME 817- TWL ANGLE ADJUSTMENT PROCEDURE

5a

2a

2b

5b
1

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B222 ELME 817- PENDULAR TWL ASSEMBLY

1. Pin
2. Bolt
3. Crank
4. Collet
5. Upper Bearing
6. Lower bearings
7. Bushing
8. Sleeve
9. Springs
10. Key
11. Spring pin
12. TWL
13. Arm
13. Bearing housing
15. Indicator

Note the mechanical locking tabs

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B222 ELME 817- SEATED SIGNAL

1.
2.
3.
4.
5.
6.
7.
8.

Return rod
Proximity switch
Seated pin return spring
Seated pin
Nut
Plate push spring
Indicator plate
Cam
Pin 4 moves up and pushes spring 3 which
pushes up plate 7 toward the proximity
switch 2

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B222 ELME 817- CONTAINER POSITION SENSING

Spreader not seated

7 to 8mm

When the pin is

pushed to the
dimension below, the
proximity switch
should be energized
and lit up.

8-10 mm
Distance from
landing surface
to underside of
seated pin

At this pin position, the

mechanical interlock is
locked.

Locking tab

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B222 ELME 817- CONTAINER POSITION SENSING

Spreader fully seated
When the seated pin is fully
seated, there is ample
clearance of mechanical lock.

Locking tab

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B222 ELME 817- PENDULAR TWL ASSEMBLY

Moving up the seated

pin mechanically
unlocks the TWL

Twistlock
Locking
system

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B222 ELME 817- ELECTRICAL SCHEMATIC

Rotator box circuits
Dampening
Power Dampening
Rotation
Powered Pile Slope.
Spreader box circuits
Side shift
Extension
Twist Locks
Lights

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B222 ELME 817- ELECTRICAL SCHEMATIC

Spreader mechanical and electrical conditions for lock and unlock
functions
Input signals before sending the lock signal to the TWL cylinder :
Lock command (either manual or automatic).
Seated position signals from the four seating pins.
Unlocked position signals from the twist lock position sensors
(LH and RH).
Extension function not activated.
Input signals before sending the unlock signal to the TWL cylinder,
Unlock command (manual only).
Seated position signals from the four seating pins.
Locked position signals from the twist lock position sensors (LH and
RH).
Extension function not activated.

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B222 ELME 817- ELECTRICAL SCHEMATIC

Fault finding:
Each connection on the PCB is provided with an LED
ON when activated
=> verify if required input signal is received
=> verify if required function(s) is activated.
LED color codes
Green indicate battery voltage.
Red indicates activated Output signals.
Yellow indicates activated Input signals.

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B222 ELME 817- ELECTRICAL TROUBLE SHOOTING

Step by step procedure:

1. Determine which functions are failing (TWL activation, seated

indication, etc.).
2. Open the electric box and check the LEDs (visible on the PCB).
3. If the LED signal is ON, but function does not work, => PCB is
probably faulty.
4. If the LED signal is OFF, then check all LEDs for the relevant circuit.
5. Check the LEDs on the proximity switch, solenoid.
6. Check wire connection from PCB to solenoid or proximity switch.
7. Check if the proximity switch functions properly.
8. The proximity switch should have switched ON 4 mm (0.157 in.)
before it would touch the steel. Replace if faulty.

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B222 ELME 817- TWL AUTOMATIC LOCKING

The automatic locking feature is controlled by PCB3.

It automatically locks the twist locks 1 seconds after all required

input signals have been received.

Plug K1 switches the automatic locking system ON/OFF, and

Potentiometer P3 adjusts the time delay of the locking signal.

Do not calibrate to less than 1.0 seconds.

B222 ELME 817- ELECTRICAL WIRING DIAGRAM

Spreader

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B222 ELME 817- ELECTRICAL WIRING DIAGRAM

Rotator

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B222 ELME 817- ELECTRICAL SCHEMATIC

Spreader

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B222-ELME- MAINTENANCE WEAR PADS

Wear pads =>

A minimum=18mm (0.71 in)

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B222-ELME- MAINTENANCE TWL WEAR

TWL maximum allowable wear.
=> Replacement required at 25mm (1.00 in)

The crosshatching
shows areas of wear

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B222-ELME- MAINTENANCE SIDE SHIFT WEAR PADS

Maintain 4 to 6 mm play
(0.157 to 0.236 in.)
between spreader frame
and vertical wear pads at
the lower rotator frame.

Add shims behind the

vertical wear pads when
play exceeds 6 mm

1.

Horizontal wear pad

(0.236 in.).

2.

Vertical wear pad

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B222-ELME- MAINTENANCE GENERAL

B222-ELME- MAINTENANCE GENERAL

B222 ReachStacker

B222 ReachStacker

B222-ELME- MAINTENANCE GENERAL

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B222-ELME- MAINTENANCE GENERAL

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B222-ELME- INTERMODAL
Spreader fitted with legs
which allow an alternative
load clamping.
1. Rotator assembly
2. Folding leg assembly
3. TWL assembly
4. Foot and folding leg.

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B222-ELME- INTERMODAL

This schematic is similar to

the 817 Elme TWL only
spreader

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B222-ELME- INTERMODAL

Intermodal features.

Two pairs of legs fold into

spreader overall dimensions
Fold front & rear legs
Block-stack front & rear
sides.

Load clamp
Clamp front & rear sides

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QUESTIONS?
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09/06 - Slide58
Slide58