SPREADER TRAINING

MODULE
 CONTENTS OF MODULE

1. Introduction to Spreaders
2. Technical Data
3. Spreader Overview
4. Structural Sections
5. Functional Mechanisms
6. Hydraulic System
7. Electrical system
8. 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 – 41 Tonnes
Twin Lift – 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
Gravity Point Adjustment – ± 1200 mm in 20 Secs
Operations –
20 Ft to 40 Ft – 30 Secs
Twistlock Rotation (90°) – 1.5 Secs
Flipper Up / Down (180°) – 3 to 5 Secs

Hydraulics –
Pump – Axial Piston Pump
Pump Running Pressure – 100 bar
Cross Line Relief Valve (Flipper) – 140 bar
Pump Flow (Flipper & Twistlock) – 14 Ltrs / min
Pump Flow (Twin up/down) – 18 Ltrs / min
Tank Capacity (Flipper & Twistlock) – 50 Ltrs (2 Nos)
Tank Capacity (Twin up/down) – 70 Ltrs (1 No)
Pressure Line Filter – 10 Microns
 TECHNICAL DATA

Electrical –
Power Voltage - 400 VAC / 50 Hz / 3PH
Control Voltage - 230 VAC
Control Valve (Solenoid Coil) - 24 VDC
Lights - 24 VDC
Pump Motor (Flipper & Twistlock) - 2.2 KW ( 2 Nos.)
Pump Motor (Twin Up/Down) - 3 KW ( 1 No.)
Motor (Telescopic) - 3 KW ( 1 No.)
Motor (Gravity Adjustment) - 3 KW ( 1 No.)
Electrical Protection - IP 55
 SPREADER OVERVIEW
Control System:
Structural Sections:
Electrical
Center body
Hydraulic
Telescopic Arm
Tower
Functional Mechanisms:
Telescopic Drive
Flipper Up / Down
Tower Gravity Point Adjustment
Twinlift Housing Up/ Down
Twistlock and Land Pin
 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 Down
Flipper
Down A B 140 Bar

P T
Sol B Active

M
Pump Pressure - 100 Bar
 FLIPPER UP HYDYAULIC CIRCUIT

140 Bar
M
Flipper
Up A B 140 Bar

P T
Sol A Active

M
Pump Pressure - 100 Bar
 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

M
Pump Pressure - 100 Bar
 TWIN DOWN HYDYAULIC CIRCUIT

A B

P T
Sol B Active

210 Bar

Pump Pressure - 100 Bar M

 TWIN UP HYDYAULIC CIRCUIT

A B

P T
Sol A Active

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. Check Hydraulic pump pressure (100 Bar)
23. Check twistlock nut & floating mechanism.
24. Ensure all the parts are properly tightened.
25. Check twistlock cylinder & all hose fittings for any leakage
26. Check landpin condition & lubricate with oil
27. Dismantle all twistlocks every six months & check for cracks by
doing dye-penetration test. Clean & inspect all parts. Replace, if
necessary.
28. Check all flipper condition & Hub fasteners tightness
29. Check flipper motor for proper operation & hose fitting leakages
30. Check Twin pick motor & pump assembly condition
31. Check twin up/down cylinder mountings & also check for any
leakages
32. Check all Buffer condition & mounting bolts for proper tightness
33. Check all structures for damage, welding cracks & deformation.
34. Check all operations of Spreader