SPREADER TRAINING MODULE
CONTENTS OF MODULE 1. 2. 3. 4. 5. 6. 7. 8.
Introduction to Spreaders Technical Data Spreader Overview Structural Sections Functional Mechanisms Hydraulic System Electrical system Spreader Interlocks
INTRODUCTION TO SPREADERS Spreaders are the most intensively used lifting equipments and has been designed to lift Standard ISO Containers – Length 20-ft (6.1 m), 40-ft (12.2 m), 45-ft (13.7 m) and Width 8-ft (2.4 m).
Data reveals that Spreader breakdowns accounts to nearly 60 – 70% of total breakdowns in cranes. Spreaders are continuously subjected to shocks & vibrations when it comes in contact with containers, so understanding the functioning of all mechanisms and proper maintenance is the key to smooth Spreader operation.
TECHNICAL DATA Spreader Model
– EH5U(Single Lift) & EH170U(Twin Lift)
Dead Load
– 9 Tonnes (EH5U) & 10.7 Tonnes (EH170U)
Lifting Capacity Single Lift Twin Lift
– 41 Tonnes – 2 x 25 Tonnes
Lifting Lugs
– 4 x 10 Tonnes in Main & End Beam
Telescopic Position – 20ft position – 5852 mm ± 3 mm 30ft position – 8918 mm ± 3 mm 40ft position – 11984 mm ± 3 mm Twistlock Pins center at End Frame – 2259 mm
TECHNICAL DATA – ± 1200 mm in 20 Secs
Gravity Point Adjustment Operations – 20 Ft to 40 Ft Twistlock Rotation (90°) Flipper Up / Down (180°)
– 30 Secs – 1.5 Secs – 3 to 5 Secs
Hydraulics – Pump – Axial Piston Pump Pump Running Pressure Cross Line Relief Valve (Flipper) Pump Flow (Flipper & Twistlock) Pump Flow (Twin up/down) Tank Capacity (Flipper & Twistlock) Tank Capacity (Twin up/down) Pressure Line Filter
– – – – – – –
100 bar 140 bar 14 Ltrs / min 18 Ltrs / min 50 Ltrs (2 Nos) 70 Ltrs (1 No) 10 Microns
TECHNICAL DATA Electrical – Power Voltage Control Voltage Control Valve (Solenoid Coil) Lights Pump Motor (Flipper & Twistlock) Pump Motor (Twin Up/Down) Motor (Telescopic) Motor (Gravity Adjustment) Electrical Protection
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400 VAC / 50 Hz / 3PH 230 VAC 24 VDC 24 VDC 2.2 KW ( 2 Nos.) 3 KW ( 1 No.) 3 KW ( 1 No.) 3 KW ( 1 No.) IP 55
SPREADER OVERVIEW Structural Sections: Center body Telescopic Arm Tower Functional Mechanisms: Telescopic Drive Flipper Up / Down Tower Gravity Point Adjustment Twinlift Housing Up/ Down Twistlock and Land Pin
Control System: Electrical Hydraulic
STRUCTURAL DESCRIPTION Bromma Telescopic Spreader is fabricated as all welded, high quality steel, construction. Two pairs of telescopic beams slide in the centre main frame construction. The telescopic beams are joined together at the ends by end beams, which house the twistlocks, flipper arms and hydraulic valves. The spreader has an inbuilt under clearance of 185 mm. The spreader is optionally fitted with one set of lifting lugs.
FUNCTIONAL MECHANISMS TELESCOPIC SYSTEM The telescoping system is driven by means of an electric motor and reduction gearbox connected to an endless chain. This chain is fitted with stacks of spring washers that work as shock absorbers where the chain attaches to the tension rods. These tension rods are connected to the end beam. The springs allow for changes in the length of the spreader up to plus or minus 7 mm. The springs do not only act as shock absorbers, they also provide a floating possibility for the twistlocks to handle distorted containers. In the event of a power failure the telescoping motion can be hand cranked. The positioning system works with proximity switches for positioning the spreader in the 20', 30' and 40' positions. The drive motor incorporates an electric brake that is spring applied and takes electrical power to release. This brake not only controls the accuracy in stopping the expansion and retraction but also prevents changes from occurring in the spreader length during use.
20–40 MECHANISM
20–40 MECHANISM
FUNCTIONAL MECHANISMS TOWER & GRAVITY POINT ADJUSTMENT The main frame of the spreader is connected to the crane through a sliding tower assembly. This enables the centre of gravity lifting point to be moved a maximum of 1,2 meters toward each end of the spreader. After unlocking an unevenly loaded container, the sliding tower assembly automatically returns to the central position.
TOWER CHAIN ASSEMBLY
TOWER CHAIN ASSEMBLY
FUNCTIONAL MECHANISMS FLIPPER MECHANISM Flat gather guides, commonly called flippers, are fitted to each end beam of the spreader. They are of strong construction and are driven by a powerful hydraulic motor, which enables easy and fast location of the spreader onto the containers. The flipper gather is 155 mm and has a gathering torque of 1200 Nm. The flipper arms are always under pressure and each arm is controlled by its own solenoid valve and shock relief valve, which opens at a pre-set pressure of 45 bar above the normal working pressure. As soon as the shock load ends the flipper returns to the vertical position. The speed of the flipper is approximately 180° in 6 seconds and is controlled by an orifice plug in the pipe connection to the motor.
FLIPPER ASSEMBLY
FLIPPER ASSEMBLY
FUNCTIONAL MECHANISMS TWISTLOCK ASSEMBLY Four twistlocks for single container spreader are located in the corners of the spreader to engage and lift the container. A hydraulic cylinder rotates the twistlock and two sensors indicate the position of the twistlock, Locked or Unlocked. A spring loaded landing pin near each twistlock is pushed up into the twistlock housing when the spreader is landed on the container. When the spreader is properly landed on a container, the landing pin will activate a proximity switch. Only when all the corners of the spreader are landed, can the twistlocks be turned. At the same time, the blockading key is moved high enough so the blockading stop on the twistlock lever arm passes underneath it. If the spreader is not properly landed the proximity switch will not be activated and the blockading key will get in the way of the blocking stop. This will stop the twistlocks from turning.
TWISTLOCK ASSEMBLY
FUNCTIONAL MECHANISMS CENTER TWISTLOCKS The EH 170 is equipped with center twistlocks to be able to handle two 20 foot containers at the same time. These center twistlocks are placed in housings on the main frame. The twistlock boxes can be tilted to “down” position by four hydraulic cylinders. (one per twistlock box). The center twistlocks operate the same way as the end beam twistlocks.
HYDRAULIC CONTROL SYSTEM The hydraulic units are protected inside each end beam. The unit consists of a built-in tank, variable displacement piston pump, motor valves and filter. The filter cap is fitted with a pressure relief valve plus or minus 0,14 bar to allow expansion and contraction of air inside the tank. The hydraulic components used are designed to work at over 200 bar but normal working pressure is 100 bar. The hydraulic valves are solenoid operated and can be tested by hand operating. The EH170U has a third hydraulic unit placed in the main beam. This unit provides the four cylinders for center twistlock housings up-down and the four cylinders for lock-unlock in the central twistlocks with power.
FLIPPER & CORNER TWISTLOCK HYDYAULIC SETUP
FLIPPER & CORNER TWISTLOCK HYDYAULIC CIRCUIT
FLIPPER DOWN HYDYAULIC CIRCUIT 140 Bar M Flipper Down
A
B
P
T
140 Bar
Sol B Active
Pump Pressure - 100 Bar
M
Down
FLIPPER UP HYDYAULIC CIRCUIT 140 Bar M Flipper Up
A
B
P
T
140 Bar
Sol A Active
Pump Pressure - 100 Bar
M
CORNER TWISTLOCK LOCK HYDYAULIC CIRCUIT
Twistlock Lock
A
B
P
T
Sol A Active
Pump Pressure - 100 Bar
M
CORNER TWISTLOCK UNLOCK HYDYAULIC CIRCUIT
Twistlock UnLock
A
B
P
T
Sol B Active
Pump Pressure - 100 Bar
M
TWIN PICK HYDYAULIC CIRCUIT
TWIN PICK HYDYAULIC CIRCUIT
A
B
P
T
210 Bar
Pump Pressure - 100 Bar
M
TWIN DOWN HYDYAULIC CIRCUIT
A
B
P Sol B Active
T
210 Bar
Pump Pressure - 100 Bar
M
TWIN UP HYDYAULIC CIRCUIT
A
B
P Sol A Active
T
210 Bar
Pump Pressure - 100 Bar
M
TWISTLOCK UNLOCK HYDYAULIC CIRCUIT
Twistlock Unlock
A
B
P
T
Sol A Active
210 Bar
Pump Pressure - 100 Bar
M
TWISTLOCK LOCK HYDYAULIC CIRCUIT
Twistlock Lock
A
B
P
T
Sol B Active
210 Bar
Pump Pressure - 100 Bar
M
TWISTLOCK MAINTENANCE
TWISTLOCK FLOAT CHECK
ADJUSTING SPREADER LENGTH
ADJUSTING TELESCOPIC CHAIN
TOWER MOTOR BRAKE CHECK
MAINTENANCE PROCEDURES A. Find below the list of Lubricating Points & their respective positions
MAINTENANCE PROCEDURES
MAINTENANCE PROCEDURES B. Check Points in Spreader 1. Inspect and verify condition of 20’-40’ motor & gearbox assembly 2. Check motor brake condition & air gap (0.25 mm to 0.6 mm) 3. Check telescopic gear box oil level, oil condition, leakages 4. Check telescopic drive sprocket condition, Roller chain condition & Tension wheel condition. Grease, if necessary. 5. Check chain slackness ( 25 mm in vertical direction). Adjust, if necessary 6. Check roller chain end lock nuts tightness (45 Nm) & shock absorber (Disc spring) condition. Replace if found broken/cracked 7. Check all Robalon glide plates condition. Replace when thickness goes less than 17 mm. 8. Grease the sliding area under the telescopic beams with brush 9. Inspect and verify for Center distance of twist locks 10. Inspect and verify condition of Tower shifting motor & Gearbox assembly
MAINTENANCE PROCEDURES 11. Check tower motor brake torque (75 Nm) 12. Check Tower shifting gear box oil level, oil condition, leakages 13. Check tower drive sprocket condition, Idler sprockets condition & Roller chain condition. Grease, if necessary. 14. Check chain slackness and adjust, if necessary 15. Check gearbox alignment / chain tensioning bolts are touching gearbox base 16. Check Tower shifting Robalon glide plate condition & thickness 17. Check tightness of all bolts / fasteners 18. Check oil level in both Hydraulic tanks and fill slightly below max. Mark 19. Check hydraulic oil condition 20. Check whether filter clog indicator has changed from green to red if so, change filter element 21. Inspect and verify condition of Hydraulic Tank, Valve Assembly, hose condition. Check for any leakages
MAINTENANCE PRODEDURES 22. 23. 24. 25. 26. 27.
28. 29. 30. 31. 32. 33. 34.
Check Hydraulic pump pressure (100 Bar) Check twistlock nut & floating mechanism. Ensure all the parts are properly tightened. Check twistlock cylinder & all hose fittings for any leakage Check landpin condition & lubricate with oil Dismantle all twistlocks every six months & check for cracks by doing dye-penetration test. Clean & inspect all parts. Replace, if necessary. Check all flipper condition & Hub fasteners tightness Check flipper motor for proper operation & hose fitting leakages Check Twin pick motor & pump assembly condition Check twin up/down cylinder mountings & also check for any leakages Check all Buffer condition & mounting bolts for proper tightness Check all structures for damage, welding cracks & deformation. Check all operations of Spreader
