HSM-6 S.N. : 7256-57

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Operations Manual BROMMA TELESCOPIC OVERHEIGHT ATTACHMENT

MODEL HSM-6 SPEEDLOADER 20' , 40' TO 45’

Serial No: 7256-57 SWL: 40 tonne General arrangement drawing No: 18128 Customer/End-user: PTP/PTP Date of Shipping: November 2004

HSM-6 S.N. : 7256-57

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Warning

This Operations Manual is intended as a guide to the use and maintenance of Bromma spreaders. a) Bromma Conquip AB or its affiliated-companies (to the extent

permitted by law) accept no liability for loss or damage suffered as a result of the use of this manual.

b) If in doubt always refer to the original equipment manufacturer. c) Refer at all time to the "Safety Precautions" under Section 5.

HSM-6 S.N. : 7256-57

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Table of Contents

MODEL HSM-6 SPEEDLOADER 20' , 40' TO 45’ i

WARNING ii

TABLE OF CONTENTS iii

1. INTRODUCTION 1.1

2. TECHNICAL SPECIFICATIONS 2.1

3. BROMMA SPEEDLOADER 3.1

3.1 Introduction 3.1

3.2 Advantages 3.1

3.3 General Description 3.1

3.3 Safety features 3.1

4. OPERATION OF THE BROMMA SPEEDLOADER 4.1

4.1 Attaching Bromma Speedloader to the Spreader 4.1 4.1.1 INITIAL CONDITION 4.1 4.1.2 ENGAGING LATCHING ARM OF OVERHEIGHT ATTACHMENT (SPEEDLOADER) ON

THE SPREADER 4.1 4.1.4 DISENGAGING THE OVERHEIGHT ATTACHMENT (SPEEDLOADER) 4.5

5. SAFETY PRECAUTIONS 5.1

6. START UP PROCEDURES 6.1 LOAD TESTING CERTIFICATION 6.1 PROCEDURE FOR SELF LATCHING OVERHEIGHT 6.1 INSTALLATION INSTRUCTIONS 6.1

7. MAINTENANCE PROCEDURES 7.1

7.1 Lubrication and Inpection Schedule 7.1 7.2 TWISTLOCK MAINTENANCE 7.2

HSM-6 S.N.: 7256-57 1-1

1. Introduction

Bromma Conquip has since 1967 been the leading manufacturer of telescopic container handling spreaders. A great number of Bromma spreaders and attachments are in service today in ports and terminals around the world. A complete range of fixed length spreaders, telescopic spreaders and attachments are available, and each one provides high handling efficiency, excellent reliability, ease of maintenance and repair. This Operation Manual describes the many features of the Bromma self-latching overheight attachment. It will guide you in: a) Operation & Handling. b) Maintenance & Repairs c) Service. d) Spare parts. In the event You should need additional information or support, our sales and/or technical staff will be pleased to assist you. BROMMA CONQUIP (SINGAPORE) PTE.LTD. 17, Tuas Crescent Jurong Town Singapore 638711 Phone +65-7560866 Fax +65-2570919 BROMMA CONQUIP AB Krossgatan 31-33, S-162 26 Vallingby, SWEDEN Phone + 46-8-620 0900 Fax + 46-8-739 3786

HSM-6 S.N. : 7256-57

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8. DRAWING LIST / SPARE PARTS AND SERVICE 8.1

8.1 Drawing List 8.1

8.2 Spare parts list by assemblies 8.2

8.3 How to order spare parts and/or service 8.3

HSM-6 S.N. : 7256-57 2-1

2. Technical Specifications

Spreader type: HSM-6, Self-latching Overheight Attachment Spreader number: 7256-57 Suitable for handling container types 20’, 40’ to 45’

Capacity Lift capacity (even loaded) 40 tonne Lift capacity (10% gravity point off set) 40 tonne Tare weight (overheight attachment) 2.2 ton Tare weight (fixture assembly) 2.8 ton (estd.) Load Clearances Overall Height 1808 mm 2701 mm Width 2021 mm 2421 mm Length : 20’ 5642 mm 6042 mm 40’ 11774 mm 12174 mm 45’ 13299 mm 13699 mm Application Handling of open top ISO containers and flat racks having overheight loads. Also handles pallets with ISO fittings and dimensions Actuation All functions are controlled by the master spreader; i.e. actuation of the twistlocks or telescoping of the master spreader is duplicated on the slave unit. Attachment The slave unit is attached to the master spreader by automatic spring-loaded latches. Surface treatment All steel surfaces gritblasted SA 2,5 Primer - 2 comp zinc epoxy Primer - 2 comp epoxy Finishing coats - 2 layer polyurethane Total minimum film thickness 285 µm

HSM-6 S.N. : 7256-57 3-1

3. Bromma Speedloader

3.1 Introduction

The purpose of the Bromma speedloader self-latching feature is to enable the crane operator to quickly and safely attach or detach the overheight to/from the spreader during cargo handling operations. Historically, the overheight frame has been attached to the spreader with a pin type connection onto lug attachment on the end beams. Typically, attaching the overheight attachment to the spreader requires 15 minutes to align the 2 units and secure the mounting pins. Also, several dockside personnel are exposed to potentially harmful conditions during the manual connection operation. 3.2 Advantages

The Bromma speed loader offers the following advantages: Quick Shop tests indicate that attachment can be done in 30

seconds vs.15 mins. if done manually

Fewer Personnel Only the crane operator is needed. No dockside personnel are required as they are when done manually.

Safe No dockside personnel are exposed to potentially dangerous conditions.

3.3 General Description

The HSM6-6 Speedloader is supplied complete with an overheight attachment and a storage fixture. The storage fixture includes fork pockets so that it may be transported with a lift truck and it also includes ISO corner castings at its bottom, for mounting onto a truck trailer chassis. The storage fixture and overheight attachment may be stored in the back-reach area of the crane for quick and easy access.

HSM-6 S.N. : 7256-57 3-2

3.3 Safety features

The Bromma speedloader has several safety features incorporated into its design. • The latches are spring-loaded to the latched position • A mechanical interlock prevents the latching arm from inadvertently being

forced out of position • A mechanical interlock on the twistlock prevents unlocking of the

twistlocks and dropping a pallet or flat rack while suspended in mid-air

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4. Operation of the Bromma Speedloader

4.1 Attaching Bromma Speedloader to the Spreader

4.1.1 INITIAL CONDITION

a) Initial Stowage (Primary) Position The overheight attachment is stowed on the storage fixture in the 20’ position. It is located in the primary position. The primary position has a plunger (fixture) holding the latching arm in the unlatched position. b) Handling the overheight attachment with spreader The spreader is positioned over the ISO corner castings of the overheight attachment. Once positioned and landed on the attachment, the crane operator locks the spreader twistlocks. (Similar to handling a 20’ container) The overheight twistlock assembly is actuated by the spreader via a coupling located between the ISO corner casting.

HSM-6 S.N. : 7256-57 4-2

4.1.2 ENGAGING LATCHING ARM OF OVERHEIGHT ATTACHMENT (SPEEDLOADER) ON THE SPREADER

c) Moving the overheight attachment from primary to secondary position The crane operator hoists the overheight attachment from the primary position approximately 300-450mm. He then trolleys to align the overheight attachment in the secondary position on the stowage fixture. In the secondary position there is no fixture plunger to engage the overheight latching arm.

HSM-6 S.N. : 7256-57 4-3

d) Lowering the attachment in the secondary position Once in position, the crane operator lowers the spreader and overheight onto the storage fixture. The pretensioned spring on the top of the latching arm causes the latching arm to move towards the latched position. The mechanical interlock on the overheight attachment prevents the latch from fully latching.

e) Latching the overheight attachment onto the spreader Once landed on the secondary position, the twistlocks are to be unlocked and the latching arm completes its latching motion. At an intermediate position between the locked and unlocked positions a slot in the mechanical interlock permits the latching arm to pass through.

HSM-6 S.N. : 7256-57 4-4

4.1.3 OPERATION WITH overheight attachment (speedloader)

Operation with no-load condition The overheight attachment is now latched to the spreader and both are hoisted from the storage fixture and are ready to handle cargo. (See Fig.4). The latching arm remains latched in this position by a spring-loaded guide pin. Mechanical Interlock to prevent disengagement If the latching arm is bumped around enough during operation to overcome the spring force, the mechanical interlock will prevent the latching arm from disengaging from the spreader lug.

Operation with a container load condition The overheight attachment is now a slave unit of the spreader. It contains its twistlock actuation from the spreader. Once landed on a container, the spreader twistlocks are locked thus operating the overheight attachment’s twistlocks to the locked position. The container is lifted at its corner castings by the overheight attachment’s twistlocks. The full load is transmitted to the spreader via the (4) twistlocks. (See Fig.5). Note that there is no load on the spreader lug attachment as a clearance is maintained during this condition.

HSM-6 S.N. : 7256-57 4-5

4.1.4 DISENGAGING THE OVERHEIGHT ATTACHMENT (SPEEDLOADER)

Stowage of overheight attachment onto storage fixture Once cargo operation is completed, the crane operator positions the spreader and overheight attachment over the storage fixture in the 20’ position. He then lowers the overheight attachment onto the storage fixture in the primary position of the storage fixture. At this position the spring-loaded fixture plunger will push up against the latching arm. The mechanical interlock prevents the arm from unlatching even though the plunger is pushing in that direction. (See Fig.6)

Disengagement of latching arm from spreader lug a) As the crane operator locks the twistlocks, the mechanical interlock rotates. When the slot on the mechanical interlock lines up with the latching arm, the arm is forced into the unlatched position by the fixture plunger. This disengages the latching arm from the spreader. b) The operator then unlocks the twistlocks and removes the spreader from the overheight attachment. (See Fig.7)

HSM-6 S.N. : 7256-57 4-6

HSM-6 S.N. : 7256-57 5-1

5. Safety Precautions

a) Never exceed S.W. L. of unit (see name plate for detail). b) Stay clear of spreader when in operation. c) Stay away from all moving parts, such as latching arms, fixture

plungers, etc. d) Use overheight attachment only for the purpose for which it is

designed. e) Unlocking spreader while suspended in air could create personnel

injury and property damage. Never unlock spreader while suspended in air.

f) Do not stand under suspended load. g) Daily inspect the attachment and fittings for visual damage.

HSM-6 S.N. : 7256-57 6-1

6. Start up Procedures

LOAD TESTING CERTIFICATION

PROCEDURE FOR SELF LATCHING OVERHEIGHT

Because this attachment must be load tested under its master spreader, it is the responsibility of the Purchaser to load test the unit at his facility. Through the legs and twistlocks of the Overheight Attachment, pull 100% of working capacity (125% x 45000kg) or 125% of the working capacity of your spreader/hoist combination, whichever is less. For the latch arm/spreader lug attachment, pull test 125% of the tare weight of the overheight attachment. Alternatively, you can pull test a 5:1 load. INSTALLATION INSTRUCTIONS

This attachment is designed to handle overheight containers while mounted under a master spreader. The connection between the master and slave is completely mechanical so no hydraulic or electrical connections are required. The slave unit is attached to the master at 4 ponits on the gable or end beams. The working load is carried by the twistlocks through the corner housing. The slave or overheight attachment should be installed in the 20’ position.

HSM-6 S.N. : 7256-57 7-1

7. Maintenance Procedures

No complicated maintenance of the attachment is anticipated. Wear items should be examined periodically and replaced as required. Twistlocks should be inspected as described in following section 7.2. 7.1 Lubrication and Inpection Schedule

INITIAL • Grease twistlock housing points and slides. • Visually inspect structure for shipping damage. • Check load carrying bolts for proper torque per Bromma

drwg.D8282

DAILY • Check that all decals are affixed and legible. • Inspect the unit for loose parts and obvious damage.

WEEKLY • Grease twistlock housing points and slides and lubricate moving

parts in the latch assembly and fixture assembly.

MONTHLY • Visually inspect structure for weld cracks, fatigue cracks and

damage due to misuse. Visually inspect latching arms and attachment lugs for cracks or damage.

HSM-6 S.N. : 7256-57 7-2

7.2 TWISTLOCK MAINTENANCE

EVERY SIX MONTHS OR EVERY 1500 HRS. OF OPERATION WHICHEVER COMES FIRST

• All twistlocks must be inspected visually. EVERY 1 YEAR OR EVERY 3000 HRS. OF OPERATION WHICHEVER

COMES FIRST • Check twistlocks ultrasonically or by magnaflex. FOR ANY IF DEFECTS APPEAR, NO MATTER HOW SMALL, THE TWISTLOCKS MUST BE REPLACED.

HSM-6 S.N. : 7256-57 8-1

8. Drawing List / Spare Parts and Service

8.1 Drawing List

a) Attachment of Lug to Spreader 24736 b) Lug Weldment 400807 c) Overheight and Fixture Assembly 18128 d) Overheight Main Assembly 17475

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HSM-6 S.N. : 7256-57 8-2

8.2 Spare parts list by assemblies

Major Groups Drawing Number:

a) Twistlock assembly 24285

b) Overheight Fixture Assembly 15877

c) Overheight Latch Assembly 14718 art# 62234

HSM-6 S.N. : 7256-57 8-3

8.3 How to order spare parts and/or service

When requesting spare parts and/or service please supply serial no. and type of spreader and if possible part no. of components to be replaced. FOR SERVICE AND PARTS PLEASE CONTACT: BROMMA CONQUIP (SINGAPORE) PTE.LTD. YISHUN CENTRAL P.O.BOX 919 SINGAPORE 9176 SINGAPORE Telephone No +65-7560866 Fax No. +65-2570919 BROMMA CONQUIP AB Krossgatan 31-33 S-162 26 VÄLLINGBY SWEDEN Telephone No. 46 +8 620 09 00 Fax No. 46 +8 739 37 86 Telex No. 12224 or our representatives in other countries, see enclosed brochure.