Repair Instruction Support Plates 2012-08-29 - Rev-C

2012-08-29, rev C
For internal use only

1. Revision Record
Rev Content Date
A First draft compiled. 2012-04-24
B Instruction for DRF4xx ready. 2012-08-13
NOTE! Instruction for DRF100 not yet verified and therefore
not included.
C Instruction updated and DRF 100 added. 2012-08-29
Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 2/50

2. Content
1. Revision Record ............................................................................................................................... 2
2. Content ............................................................................................................................................ 3
3. Documentation................................................................................................................................ 4
4. Important ........................................................................................................................................ 5
5. Welding in general .......................................................................................................................... 7
6. Welding outdoor ............................................................................................................................. 8
7. Repair .............................................................................................................................................. 9
8. Future removal of the boom ......................................................................................................... 47
9. Control Card .................................................................................................................................. 48
10. Control Units ................................................................................................................................. 49

3. Documentation
All information regarding machine status must be continually updated on
Project Auris website: http://flow.cargotec.com/sites/med/auris
On the Project Auris website a Machine number folder should be created

by the Region Teams for each tested machine.
The Machine number folder should be placed under Example:

Region XXXX
a Country folder in either of the folders Region Country
EMEA, Region APAC or Region AMER, see Machine number
example beside. Claims
Tests_Repairs
In all machine folders there should be one Claims and Machine number
one Tests_Repairs folder. All documents regarding Claims
Tests_Repairs
the specific machine should be placed in those
folders.
Mandatory documents to be uploaded are:
Invoices belonging to the claim of the machine

Signed and scanned Control Card
Mandatory Excel files to be regularly updated:
Auris_APAC_Field_Status, in folder Region APAC

Auris_EMEA_Field_Status, in folder Region EMEA
Region AMER update their Access Database regularly instead.
In addition to this documentation all relevant standards can be found on

Project Auris website on Cargotec Flow:
Shared Documents > Test and Repair Instructions > Standards
An original of the Control Card can be found on Project Auris website on

Cargotec Flow, this to be able to fill in the required information directly in
the document.
Shared Documents > Test and Repair Instructions > Repair Instructions >

4. Important
Check that both registered ear numbers corresponds to both ears on the
machine. Enter these ear numbers in the Control Card.
Do not forget to disconnect the Control Units, see chapter 9, prior to

welding.
To minimize the risk of the boom sliding away, do not remove both axles
at the same time.
Welders should have valid welding certificates according to EN 287-1

including (within brackets are the ASME/AWS equivalents):
o Welding processes:
111, 136 (SMAW – shielded metal arc welding/MMA, FCAW – flux
cored arc welding)
o Type of weld:
FW (Fillet Weld)
o Welding position:
PD (ASME: 4F Overhead)
o Material thickness:
Min 12.1 mm (Thickness in US according to ASME standards)
Moisture and drying of electrodes:
Moisture can cause hydrogen cracking when welding which can take up to
72 hours to appear. Normally it is impossible to wait this long so the best
way to avoid this problem is to avoid moisture.
To clarify when electrodes needs to be dried an example on ESAB

Electrodes with standard packaging is used:
If the package is unopened and has been kept relatively dry, such as
indoors or a shorter time in the car, the electrodes do not have to be
dried.
If electrodes are suspected to have absorbed moisture they must be

dried for 2 hours at 350 °C (660 °F).

Example of labeling on ESAB electrodes in standard packaging
Cracks anywhere on an ear means the support plate method cannot be

used and the ear has to be replaced instead.
If the crack seems harmless the machine can be reassembled for

continued operation until the ear has been replaced. This is a difficult
assessment and information, like high quality photos of the cracks and
how long time is planned until ear replacement, is required. Contact
Global Auris team if this decision is needed.
If the plain bearings in the boom have to be replaced it is necessary to

either use the lifting device or a crane to lift the boom high enough.
Carefully cover all areas that can be damaged when exposed to for
example grinding sparks, welding spatter or similar.

5. Welding in general
Indoor welding is preferable.
Keep door closed to avoid draft.

Protect all areas against influence of welding work, for example with
protective blankets.
Welding class B according to EN 5817.
Filler material: ESAB OK Tubrod 15.14 or corresponding according to
standard:
o EN ISO 17632-A: T 46 2 PC 1 H5 or
o AWS A5.20: E71T-1C.
Make sure the ground cable is close to welding position.
Before any welding make sure trained personnel has disconnected
appropriate Control Units according to Reachstacker Workshop
manual, chapter 11 part 11.5.3. All power from the batteries should
also be cut off with the battery disconnector.

6. Welding outdoor
Welding outdoor shall be done only if there is no possibilities at all to
weld indoor.
Do not weld when it’s raining, drizzling or snowing.

Moisture is not allowed on the welding area. In case of humid welding
area, it should be dried.
It is not allowed to weld using wet electrodes. If electrode is old or
wet, use new one.
A holding oven (120-150°C) is recommended to keep electrodes dry
and warm, draw one after another just before welding.
Use blanket or tent to shield welding area when welding.
Protect all areas against influence of welding work, for example with
protective blankets.
Welding class B according to EN 5817.
Filler material: ESAB OK 48.00 or corresponding according to
standard:
o EN ISO 2560-A: E42 4 B 42 H5 or
o AWS A5.1: E7018.
Make sure the ground cable is close to welding position.
Before any welding make sure trained personnel has disconnected
appropriate Control Units according to Reachstacker Workshop
manual, chapter 11 part 11.5.3. All power from the batteries should
also be cut off with the battery disconnector.

7. Repair
Step 1: Preparations.
If available, assemble the working platform according to the
Instruction for the Portable Equipment.
To keep the boom from moving when no longer completely

attached to the ears, a container with a 15-20 tonne load must
be used according to the Instruction for the Portable
Equipment.
Disassemble and move aside parts interfering with the repair

like hydraulic hoses, electrical cables, angular sensor, exhaust
pipe, etc.

Step 2: Remove the axle.
To pull out the axle the weight of the boom needs to be
removed by lifting the boom. There are two kinds of
special lifting tools developed, the lifting frame kit (LFK)
and the lifting wedge kit (LWK). Both kits require the
spreader of the boom to be attached to a 15-20 tonne
container.
If the lifting frame kit is used for DRF 4xx the adapter wiring
must be used and the engine started to be able to lift the boom
according to the Instruction for the Portable Equipment.
If the lifting wedge kit is used the adapter wiring is not

necessary. Instead the following must be done:
1. One of the four connectors to the alignment sensors in the

spreader needs to be unplugged, see figure 7.1.
7.1 Unplug one connector in the spreader.
2. Start the engine to lower the boom so the container takes the
full weight of the boom.
3. Turn off the engine

4. To make sure the lifting cylinders will not resist the lifting of
the boom an override valve has to be opened on both lifting
cylinders. The valve is placed on the lower part of the lifting
cylinders according to figure 7.2-7.4.

When the repair is finished these override valves have to be
closed.
Open this override

valve on both lifting
cylinders
7.2 DRF 4xx: Override valve to be opened.

Open this override
cylinders
7.3 DRF 100: Override valve to be opened, version with locking nut and allen screw.

Open this override
cylinders
7.4 DRF 100: Override valve to be opened, version with twist lock.

Lifting wedge kits are shown in figure 7.5-7.6. There are
different versions for DRF 4xx and the DRF 100. They look
similar and works the same way.
7.5 DRF 4xx: Lifting wedge kit for lifting the boom.
7.6 DRF 100: Lifting wedge kit for lifting the boom.

Place and assemble the lifting wedge kit as shown in figure 7.7.
Bolt A: When tightened, the

lifting wedge will lift the boom.
Bolt A: When necessary add washers

between bolt and square bar.
If necessary place a flat iron bar

beneath the lifting wedge
Bolt B: When tightened, the lifting

wedge will push the boom forward.
7.7 Sectional view of the left ear from the left side, with assembled lifting wedge kit.
Tighten bolt A and B respectively to release the weight of the

boom from the axle.

If the lifting wedge kit needs to be removed without having the
axle inserted place a square bar in between the ear and boom,
see figure 7.8.
Use a square bar if the lifting

wedge needs to be removed
without the axle.
7.8 Placing a square bar in between the ear and boom.

Remove the axle using two long M24 bolts (at least 279 mm
long) placed in the axel plate, see figure 7.9.
Tightening bolts in these

two threaded holes will
push the axle out.
7.9 Use two bolts to remove the axle.

When the axle has been removed, check how respective holes
of the boom ear and the casted ear are placed in relation to
each other.
If the hole in the boom ear is in front of the hole in the casted
ear, like indicated in the figure 7.10, the boom ear must be
pushed backwards since the lifting wedge can only push the
boom up and forward
7.10 The boom ear is in front of the hole in the casted ear.
Push the boom ear backwards by moving the front end of the
boom sideways. This is done by using the load handling
function called Side Shift. Follow the steps below:
1. Make sure all control units and the battery are connected.

2. Release bolt B on the lifting wedge kit to at least 5mm from
the boom ear, see figure 7.11
At least 5mm
between Bolt B and
the boom ear
7.11 The boom ear is in front of the hole in the casted ear.
3. Start the engine.
4. Push the boom sideways gently using the Side Shift function
until the boom ear hole is 1 to 2 mm behind the casted ear
hole, see figure 7.12.
7.12 The boom ear hole is 1-2 mm behind the hole in the casted ear.

5. Do not forget to disconnect all control units and the battery
before any welding work.
The procedure using the Side Shift function can sometimes be

necessary for both ears to be able to use the lifting wedge kits
properly.
It is very important not to forget to disconnect the control units
before any welding work is done.

Step 3: Check for cracks.
Welding support plates is only approved as long as the
ear has no visible cracks. If any cracks are visible the
ear must be replaced.
Surfaces in and around the axle hole on the ear must be
cleaned and inspected carefully when the axle has been
removed.
In the unlikely event of finding cracks on the ear, the machine

must be repaired by replacing the cracked ear.
In general, if cracks are found the machine cannot be

reassembled for continued operation prior the cracked ear has
been replaced. However, the machine can be put back into
operation if the cracks are to be considered harmless. To be
able to make this decision the information below must be put
together and sent to the Global Auris team for evaluation:
o Where the crack is placed (including high quality photos)?
o What the crack looks like (including high quality photos)?
o How long will the machine operate until the cracked ear is
replaced?

Step 4: Fit the support plates.
It’s important the support plates match both the ear and
the frame.
Grinding on both the support plates and ear might be required,
as well as welding on the support plates. On DRF 100 some
attachments needs to be removed and replaced.
The support plates must fit tightly with the frame to get a good
quality weld, max 1mm gap, see figure 7.13.
The support plate must

fit tightly to the frame
plate (marked in grey).
Max 1mm gap is allowed.
7.13 Fitting the support plate to the frame and ear.

Grinding:
In order to make the support plates fit properly some areas

most probably need to be grinded, see figure 7.14 and 7.15.
It is allowed to grind away maximum 15% of the thickness

of the support plates.
It is not allowed to grind within 20mm from the axle hole

on the support plates.
This area may have to be

grinded down.
Make sure ear numbers are
noted in the Control Card.
The weld between frame

plate and ear has to be
It is not allowed to grind
grinded down if outside
within 20mm from the
of frame plate surface.
axle hole.
7.14 DRF 4xx: Grinding is not allowed where indicated in red.

This area may have to be
grinded down.
Make sure ear numbers are
noted in the Control Card.
It is not allowed to grind

within 20mm from the
axle hole.
The weld between frame

plate and ear has to be
grinded down if outside
of frame plate surface. Carefully remove
this attachment
7.15 DRF 100: Grinding is not allowed where indicated in red.

Important:
If more than 15% have to be grinded off from the support plate
to make it fit, the support plate should be turned around with the
flat side facing the frame plate, see figure 7.16.
7.16 If the outside of the ear is too close to the frame surface, turn the support plates so
the flat side is facing the frame plate. Even if this image is from DRF 4xx the same
principle applies to DRF 100.

If the DRF 4xx support plate is turned around, make sure to add
a washer between the axle plate and the support plate as
shown in figure 7.17.
DRF 100 support plates in standard position also requires a

washer between the axle plate and support plate, see figure
7.18.
Add a 3mm thick washer

between axle plate and
support plate.
7.17 If the DRF 4xx support plate is turned around, a washer must be added
between axel and support plate.
Add a 3mm thick washer

between axle plate and
support plate.
Nord Lock washers are

used because a normal
locking nut is too big.
7.18 The DRF 100 support plate in the standard position does require a washer
between axel and support plate.

If the frame tower is twisted the lower part of the support plates
have to be grinded, see example in figure 7.19.
Grinded to avoid
collision with
casted ear.
Grinded to avoid
collision with
frame tower.
7.19 A DRF 100 support plate grinded on the lower part because the
frame tower is twisted.

Welding:
A gap between the support plate and the ear makes it possible
for the support plate to twist after welding. When the axle is
removed the support plate can move towards the ear and
makes reassembly hard or impossible since the axle hole in the
support plate no longer is concentric to the hole in the ear.
To prevent this, suitable welds should be placed on the outer

rim of the support plate, see figure 7.20 and 7.21.
7.20 Example on DRF 4xx: Place suitable thick weld

on support plate to eliminate gaps.

7.21 Example on DRF 100: Place suitable thick weld on support plate to
eliminate gaps.
The weld should have the same thickness as the gap between
the support plate and ear, see figure 7.22 and 7.23. This will
prevent the support plate to bend or twist when removing the
axle.

7.22 Example on DRF 4xx: The weld eliminates gaps between support plate and ear.

7.23 Example on DRF 100: The weld eliminates gaps between support plate and ear.

Attachments on DRF 100
Fuse holder
The fuse holder placed on the inside of the left ear has to be
removed, see figure 7.24.
Remove the
fuse holder.
7.24 DRF 100: Left ear, inside.

Attachment for cables
On the inside of the left ear an attachment for cables has to be
removed, see figure 7.25. The cables should instead be
strapped to the remaining attachments.
Carefully remove
this attachment
7.25 DRF 100: Left ear, inside.

Attachment for hydraulic hoses
On the outside of the right ear an attachment for hydraulic
hoses has to be removed, see figure 7.26.
Carefully
remove this
attachment
7.26 DRF 100: Right ear, outside.
Do not misplace this attachment, it will be used after the support

plates are welded.

Step 5: Prepare for welding and insert new axle.
IMPORTANT! Disconnect the control units before any
welding is done on the machine. Make sure the earth
clamp is placed close to the support plate to be welded
on a carefully grinded surface.
When the support plates have been selected and required
grinding/welding has been done to make them fit, all areas
except where the weld is placed should be rust protected with
primer.
The surfaces of the support plates as well as of the frame plate

should be grinded where the weld is to be placed as well as a
few cm outside the weld.
Insert the elongated axle through the outer support plate, ear,
boom and inner support plate.
Rotate the outer support plate so the 26 mm diameter hole for

the M24 bolt fits the corresponding hole in the casted ear, see
figure 7.27.
7.27 Rotate the outer support plate so the M24 bolt can be inserted.

See figure 7.28 and 7.29 for support plates on the inside of the
frame without a 26mm diameter hole.
When rotated to correct

position the distance is about
40mm to the frame edge.
7.28 DRF 100: Distance to frame edge.

When rotated to correct
position the distance is about
40mm to the frame edge.
7.29 DRF 4xx: Distance to frame edge.

Use clamps to make sure the support plates are pressed tightly
against the frame plate before tack welding, see figure 7.30.
7.30 Use clamps when tack welding

Step 6: Weld the support plates.
Step 6a: Gaps wider than 1mm are not allowed between the support
plates and the frame. Use for example clamps to press the
plates against the frame.
Step 6b: If the ambient temperature is above +10°C, no preheating is

required. If ambient temperature is below +10°C, preheat the
support plates and the frame to +50°C.
Step 6c: If humidity is very high and there is risk of condensation of

water on the support plates and the frame, preheating is
necessary.
Step 6d: Use multi layer welding according to figure 7.31 and 7.32, build
the weld with at least 3 beads.
7.31 DRF 4xx: Welding specification.

7.32 DRF 100: Welding specification.

Step 7: Perform final inspection.
Final inspection is to ensure the repair is done
accurately.
Step 7a: Perform visual testing (VT) according to EN 970 using
acceptance level B according to EN 5817. The entire weld and
the nearby heat affected zone (HAZ) have to be checked.
Acceptance criteria for welds are class B according to EN 5817.

Some of the most important extracts are:
No cracks
No surface pores
No lack of fusion
No overlap
Groove must be totally filled up
End of crater must be filled up
Undercut max 0.5mm
Excessive convexity max 5mm
Make sure the weld has even
transitions (r > 1mm, image to the
right) against mother material and
between each outer pass.
Post treat weld by grinding if
necessary.
Step 7b: If something does not meet requirements, rework it.
Step 7c: Complete and sign the Control Card.
Step 8: For DRF100 only

After the support plates have been welded, the
threaded holes for the fuse holder have to be moved
and the attachment for the hydraulic hoses on the right
side has to be replaced.

Fuse holder
Use the fuse holder as a fixture and mark the places for two
new holes, see figure 7.33 and 7.34. The thread size is M5.
Drill and tap

2 new M5
holes for the
fuse holder.
This sign can

be removed
if necessary.
7.33 DRF 100: Fuse holder below left ear, inside.

7.34 DRF 100: Fuse holder and cables attached below left ear, inside.
Attachment for hydraulic hoses

Turn the attachment around to have the nut and bolt further
away from the frame plate. Grind or cut two large chamfers on
both sides and place the attachment above the hydraulic
cylinder plate using this as a fixture to tack weld the attachment
according to figure 7.35.

Chamfer and tack
weld the attachment
to the frame plate.
7.35 DRF 100: Right ear, outside. Tack weld the attachment.
Then remove the bolts and weld the attachment all around, see
figure 7.36.

7.36 DRF 100: Right ear, outside. Weld all around the attachment.
Step 9: Perform surface treatment.

IMPORTANT! Use sealant Terostat 9120 (Loctite brand
of Henkel), or corresponding sealant. Two cartridges of
sealant are included in each support plate kit for
convenience.
Key characteristics of Terostat 9120:
MS-polymer based, one component (free of

Isocyanides).
Small shrinkage <2% when curing.
20-25% seal movement without any permanent
deformation.

Step 9a: Seal around the support plates to prevent water and moisture
entering, causing corrosion on for example the weld root.
IMPORTANT! All surfaces must be cleaned to ensure

adhesion. Use for example Isopropyl alcohol (also called
isopropanol), acetone or ethanol.
If the primer is damaged on the chamfered surfaces due to for

example heat from welding, the primer needs to be removed
from the chamfered surfaces and new primer needs to be
applied before sealing.
Apply sealant according to figure 7.37 and make sure to

completely fill up the unused holes on all sides. Make also sure
that about 5 cm is left unsealed in the bottom part to let any
moisture out, see figure 7.38.
When applying the sealant use for example soap water to

smoothen it out.
7.37 DRF 100: How to apply sealant.

Fill up unused holes
with sealant.
Apply sealant all around the

plate, except for about 5 cm
marked with green.
7.38 Apply sealant to keep moisture away from between the support plate and frame.
Step 9b: All surfaces without surface treatment must be rust protected
and then painted with the same color as the machine, this also
includes the sealant.
Step 10: Make machine ready for operation.

Step 10a: Make sure trained personnel reconnect all Control Units.
Step 10b: Restore power from the batteries with the battery disconnector.
8. Future removal of the boom

If the boom of a reachstacker, with ears equipped with support plates, is
planned to be removed, use clamps to make sure the support plates are
pressed tightly against the frame plate during axle disassembly and
reassembly. If not, the sealant may crack if the support plates are bent or
moved too much.

9. Control Card

10. Control Units
10.1. DRF 400-450

10.1. DRF 100

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2012-08-29, rev C

For internal use only

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 2/50

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 3/50

On the Project Auris website a Machine number folder should be created

The Machine number folder should be placed under Example:

Mandatory documents to be uploaded are:

Invoices belonging to the claim of the machine

Mandatory Excel files to be regularly updated:

Auris_APAC_Field_Status, in folder Region APAC

Region AMER update their Access Database regularly instead.

In addition to this documentation all relevant standards can be found on

An original of the Control Card can be found on Project Auris website on

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 4/50

Do not forget to disconnect the Control Units, see chapter 9, prior to

Welders should have valid welding certificates according to EN 287-1

Moisture and drying of electrodes:

To clarify when electrodes needs to be dried an example on ESAB

If electrodes are suspected to have absorbed moisture they must be

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 5/50

Cracks anywhere on an ear means the support plate method cannot be

If the crack seems harmless the machine can be reassembled for

If the plain bearings in the boom have to be replaced it is necessary to

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 6/50

Keep door closed to avoid draft.

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 7/50

Do not weld when it’s raining, drizzling or snowing.

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 8/50

To keep the boom from moving when no longer completely

Disassemble and move aside parts interfering with the repair

Repair Instruction Support Plates 2012-08-29_Rev-C.docx Page: 9/50

If the lifting wedge kit is used the adapter wiring is not

1. One of the four connectors to the alignment sensors in the

7.1 Unplug one connector in the spreader.

3. Turn off the engine

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Open this override

7.2 DRF 4xx: Override valve to be opened.

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Bolt A: When tightened, the

Bolt A: When necessary add washers

If necessary place a flat iron bar

Bolt B: When tightened, the lifting

Tighten bolt A and B respectively to release the weight of the

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Use a square bar if the lifting

7.8 Placing a square bar in between the ear and boom.

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Tightening bolts in these

7.9 Use two bolts to remove the axle.

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3. Start the engine.

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The procedure using the Side Shift function can sometimes be

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In the unlikely event of finding cracks on the ear, the machine

In general, if cracks are found the machine cannot be

o Where the crack is placed (including high quality photos)?

o What the crack looks like (including high quality photos)?