SERVICES

QUICK REFERENCE GUIDE

RG-2021-02-26-revision.indd 1 2021-03-02 14:05

 Contents:
Warnings and safety precautions ............................3
SCU and RML ........................................................7
SCS3 Connect and download a logfile ..................10
SCS4 and Anybus CAN Gateway ..........................14
Corner identification ..............................................21
Up/Down sequence STS45/YTS45 .......................22
Twistlock sequences hydraulic & electric .............23
Switch positions, LEDs & electrical connections..27
Important adjustments............................................40
Tightening torques .................................................68
Lubrication ............................................................76
Hydraulic oil and lubricants ..................................82
TTDS adjustments .................................................88
HIS adjustments ....................................................90
Bromma genuine spare parts and upgrades............92
Conversion tables, colors ..................................... 93
Notes .....................................................................96
Bromma product range .........................................98
SMS and Hawkeye...............................................100
Load sensing system ............................................102
This guideis a summary of the most frequently requested information
in the BROMMA Technical manuals. The guide is for service personnel
trained in BROMMA products. If slightest uncertainity, check with the
manual for certain spreader.
This guide only describes Bromma products with standard specifications. For
customer specified parts and accessories, check with the specific spreader manual.
2

RG-2021-02-26-revision.indd 2 2021-03-02 14:05

 Bromma would appreciate to get your opinion about this guide.
Something missing, too much information or faults? Please, let us know
so we can improve the next editon. Email your comments to:
sales@bromma.com

Warnings:
READ AND UNDERSTAND THE MANUAL BEFORE THE
SPREADER IS PUT INTO OPERATION.
The manual contains vital information for the safety of
personnel and the proper use of the spreader.

Bromma will not accept any liability for the use of the spreader
for any purposes outside what is described in the technical
manual.
DO NOT exceed the Safe Working Load (SWL) of the spreader.
The Safe Working Load is shown on the nameplate that is per-
manently affixed to the side frame of the spreader.

Safety precautions:
The spreader shall be operated and serviced only by authorized
personnel.

The spreader must only be used for the purpose for which it is
3 designed.

RG-2021-02-26-revision.indd 3 2021-03-02 14:05

 The crane controls must be designed in such a way that no signals
from the crane can be active when the spreader is about to be con-
nected to the crane. Otherwise hazardous situations may occur due
to unintentional movements.
DO NOT change system settings and functions.

Perform a functional test after any maintenance or repair work.

Stay clear of the spreader when in operation.

At service or when commissioning stay clear of all moving parts,

such as guide arms (flippers), moving beams, telescopic chains,
etc. Danger zone see Technical manual section 1.
Stay clear of all moving parts, such as guide arms (flippers), mo-
ving beams, telescopic chains, etc. A safe distance is 5 meters.

DO NOT connect or disconnect electrical connectors while the

power is on.
DO NOT tamper with hydraulic pressure settings once adjusted by
qualified personnel. See section 6.2 Hydraulic system in technical
manual for proper pressure adjustment.
DO NOT unlock the spreader while a container is suspended in the
air. It could cause personnel injury or property damage.

Maintain adjustment of all electrical and hydraulic components.

Inspect the spreader for damage daily.
4

RG-2021-02-26-revision.indd 4 2021-03-02 14:05

 Care must be taken when performing any maintenance inside the
spreader frame. It must be carried out under extreme caution and
by personnel familiar with risks related to spreader function and
movements. Serious injury by crushing can occur.
Contact Cargotec CHS Pte Ltd, Bromma before doing any repair
work on the spreader apart from replacing normal wear parts.

DO NOT walk or stand beneath the spreader bar during operation.

DO NOT attempt to lift a container that is not level (+/- 5°).

DO NOT crawl beneath a spreader bar for maintenance, repair or

adjustment. Never put any body extremity beneath the spreader bar.

NEVER STAND BENEATH A SUSPENDED LOAD.

DO NOT attempt to restrain the movement of a container,

whether loaded or empty, by hand or by tagline.

DO NOT stand between a container and any construction that

may prevent your movement to safety. A definite hazard exists
that could cause serious injury or death by being crushed between
the container and an obstruction (such as a building or another
container).
5

RG-2021-02-26-revision.indd 5 2021-03-02 14:05

 RISK OF CRUSHING. The STS 45 and the STS45E spreaders-
have a risk of crushing between the movable twin units.

RISK OF INSTABILITY. The STS45 and the STS45E spread-

ers have the ability to move the center of gravity point of the
20’ containers outwards possibly causing instability. This can
create instability and extra load on the crane ropes and should
be thoroughly checked prior to operation. This situation is
particularly severe when lifting loaded and empty containers at
the same time. Due to the risk of instability the crane must be
equipped with load cells.

Be sure power is maintained to the lock or unlock solenoid when

the spreader is in use.

IF THE SPREADER IS NOT USED AND/OR MAINTAINED

IN STRICT ACCORDANCE WITH THESE OPERATING
AND MAINTENANCE INSTRUCTIONS, BROMMA CAN-
NOT GUARANTEE THE SAFETY OR RELIABILITY OF
THIS EQUIPMENT.

RG-2021-02-26-revision.indd 6 2021-03-02 14:05

 SCU
The SCU (Spreader Control Unit) is a freely programmable control-
ler with built-in I/O and four CAN interfaces. The necessary input
signals for running the spreader will either be available through the
configurable I/O’s or via CAN. The communication with the crane
will either run using BCAN, ZCAN or DS444. Also parallel com-
munication is available
The CAN interfaces are used accordingly:
CAN1 Spreader CAN network

CAN2 DS444 network

CAN3 RML network

CAN4 BCAN network

The SCU has an LED light at the front

indicating the operating states as explained below:
LED color Flash Frequency Description

Off Permanently out No operating voltage

Yellow Briefly on Initialization or reset checks

Green/Black 5 Hz No runtime system loaded

Green/Black 2 Hz Application RUN

Green Permanently on Application STOP

Red/Black 2 Hz Application RUN with error

Red Briefly on Fatal error

7 Red Permanently on Fatal error (if input TEST = active) ERROR STOP / SYSTEM STOP

RG-2021-02-26-revision.indd 7 2021-03-02 14:05

 Installation of SCU firmware using USB and Maintenance
Tool
Plug in the M12 to USB cable BR1704495 between the computer and
the SCU.

Use the latest revision of firmware. All software related to the SCU
can be downloaded from:
http://backyard.bromma.com/ftp/Services/Software/
If you haven’t access to Bromma Backyard, contact your nearest
Bromma representative.

For installing the firmware using IFM Maintenance Tool, first down-
load and install the program IFM Maintenance Tool v3.6.
It is available at:
http://www.bromma.com/backyard/ftp/R&D/Software/SCU/Tools/
IFM Maintenance 3.2.11/

Extract the contents from the .zip file, run the installer and follow the
instructions given.

If RML (Remote Monitoring & Log unit) is installed on the spreader,

see next page.

RG-2021-02-26-revision.indd 8 2021-03-02 14:05

 RML (Remote Monitoring and Log unit)
The RML is a wireless CAN-bus to Wi-Fi module. It comes with 1 CAN in-
terface and has a built in HTTP-server which can store web pages, files and
event logs. The RML works as the GUI unit in the SCU system, allowing
the user access to information about the system directly through any device
with a Wi-Fi connection such as a laptop, smartphone etc.
The RML is configured using an Excel file, where different parameters,
monitors and texts can be added to give the GUI the wanted design.

If RML (Remote Mo-

nitoring & Log unit) is
installed on the spreader,
The spreader information
can be accessed on an en-
crypted website available
from any laptop or mobile
device with Wi-Fi
connection.
9

RG-2021-02-26-revision.indd 9 2021-03-02 14:05

 Connecting to SCS3 with CoDeSys v2.3
1. Connect the Ethernet cable to the back of the SCS3 node (M12
connector named Ethernet) and the other end in your computer.

2. Configure the PC IP address. To communicate with the SCS3,

make sure your PC’s IP address is set to “Static” and IP address
192.168.2.1 (last digit can be anything between except 99, which
is the SCS3 address)

3. Open the CoDesys project you wish to install.

CoDeSys v23940 can be found on Bromma Backyard:
http://www.bromma.com/backyard/ftp/R&D/Software/SCS3/
Tools/3S+CoDeSys/
10

RG-2021-02-26-revision.indd 10 2021-03-02 14:05

 4. Upload software to SCS3. Make sure the communication settings
are correct for connecting to the SCS3, under Online –> Communica-
tion Parameters.

The spreader program is uploaded to the SCS3 by selecting Online ->

Login, or by pressing Alt + F8

11

RG-2021-02-26-revision.indd 11 2021-03-02 14:05

 How to download a log file from SCS3
1. Check if you have the latest Java software installed.
If not, download and install. http://java.com/en/download
- Not supported for Chrome and only needed for the Spreader
pages, Diagnostics pages can be viewed anyway.

2. Connect to SCS3 with your web browser according to instructions

12 on page 10.

RG-2021-02-26-revision.indd 12 2021-03-02 14:05

 4.
Press “Event” but-
ton and the Event
Manager page will
show. Select a time
window and then
press the “Save”
icon. All shown
events will be
downloaded.

5.
Save the file or
open it directly in
your browser.

6.
Same procedure
with Alarms and
Trends.

13

RG-2021-02-26-revision.indd 13 2021-03-02 14:05

 SCS4
The SCS4 control unit has a touch screen and is mounted on the
spreader. It is intended for maintenance and troubleshooting by
a trained service technician.

The SCS4 must be con-

nected to power from the
spreader via the crane
before it can be operated.
Activate the touch screen
by clean and dry finger. If
the built-in battery is not
charged the start will take
longer than a start from
standby position.

14

RG-2021-02-26-revision.indd 14 2021-03-02 14:05

 SCS4 Download Spreader Machine Package (SMP)
- Go to Properties, System Properties.
- Open Network TCP/IP

- Find SCS4 IP address

15

RG-2021-02-26-revision.indd 15 2021-03-02 14:05

 Web interface - On site remote access Log in

Spreader data Software version

Web interface - On site remote access (logged in)

Press to download
Machine package
to SCS4

16

RG-2021-02-26-revision.indd 16 2021-03-02 14:05

 SCS4 Upload All Events (EventLog to Excel file)
- Go to Properties, System Properties.
- Open Network TCP/IP

- Find SCS4 IP address

17

RG-2021-02-26-revision.indd 17 2021-03-02 14:05

 18

RG-2021-02-26-revision.indd 18 2021-03-02 14:05

 Anybus CAN gateway
With the Anybus Gateway Tool, the configuration can be uploaded to
the gateway.

1. Connect PC with IXXAT adapter BR1019656 to CAN port on

Gateway. Don’t forget termination. Also connect the programming
cable BR1043076

2. Turn on the power to the Anybus CanOpen Gateway.

3. Start Bromma Anybus

Gateway Tool and click on
Open Configuration.

19

RG-2021-02-26-revision.indd 19 2021-03-02 14:05

 4. Find the file you want to download. (In the example it is Bromma
DefaultAGWConfig.agt) Click on Open.

5. To download DS444 Configuration, on the main window for the

Anybus Gateway Tool, click on the Action Tab.

6. Click on
Send Gateway
Configuration.
The Configuration
sent ok box appears.
The new configration
is now stored in the
Anybus CAN Open
Gateway.

20

RG-2021-02-26-revision.indd 20 2021-03-02 14:05

 Corner identification (Bromma standard)
To carry out spreader tests, the corners of the spreader must be
identified. The corners and twinboxes are numbered as shown:

Waterside
Corner 2 Twinbox 2 Twinbox 3 Corner 3

Left Right
side side

Corner 1 Twinbox 1 Twinbox 4 Corner 4

Landside

21

RG-2021-02-26-revision.indd 21 2021-03-02 14:05

 Up/down sequence STS45 /YTS45
Twin Down sequence Twin Up sequence

22

RG-2021-02-26-revision.indd 22 2021-03-02 14:05

 Twistlock sequences Hydraulic single lift

Lock Unlock

23

RG-2021-02-26-revision.indd 23 2021-03-02 14:05

 Twistlock sequences Hydraulic twinlift
Lock Unlock

24

RG-2021-02-26-revision.indd 24 2021-03-02 14:05

 Twistlock sequences Electric single lift
Lock Unlock

25

RG-2021-02-26-revision.indd 25 2021-03-02 14:05

 Twistlock sequences Electric twinlift
Lock Unlock

26

RG-2021-02-26-revision.indd 26 2021-03-02 14:05

 Switch positions, LEDs and electrical connections
CR9057
Switch positions

27

RG-2021-02-26-revision.indd 27 2021-03-02 14:05

 CR9057

LEDs

LED Status Description

PWR (green) ON no supply voltage
OFF module in stand-by mode
CANopen status PREOPERATIONAL/PREPARED
2.0 Hz outputs = OFF
module active
CANopen status OPERATIONAL
outputs are updated
DIA (red) ON communication OK
OFF communication disturbed
• node guard/heartbeat error
(if node guarding/heartbeat is activated)• no synch
objects
(if synch monitoring is activated)
IN (yellow) ON binary output switched
2.0 Hz diagnosis failure
OUT ON binary output switched (ON)
(yellow) analogue PWM preset value ≠ 0

28

RG-2021-02-26-revision.indd 28 2021-03-02 14:05

 CR9056
Switch positions

29

RG-2021-02-26-revision.indd 29 2021-03-02 14:05

 CR9056

LEDs

LED Status Description

PWR (green) ON no supply voltage
OFF module in stand-by mode
CANopen status PREOPERATIONAL/PREPARED
2.0 Hz outputs = OFF
module active
CANopen status OPERATIONAL
outputs are updated
DIA (red) ON communication OK
OFF communication disturbed
• node guard/heartbeat error
(if node guarding/heartbeat is activated)
• no synch objects
(if synch monitoring is activated)
OUT (yellow) ON binary output switched (ON)
analogue PWM preset value ≠ 0
current preset value > 20

30

RG-2021-02-26-revision.indd 30 2021-03-02 14:05

 Anybus Cateway
Electrical connections

LEDs LED color Status Description

Green On Power ON
(Power)
Off Power OFF

Red On Anybus HW initialization error

Anybus error
Off Anybus OK

Green Blinking Preoperational mode

CANopen status
Single flash Stopped mode

On Oprational mode

Red Off Communication OK

CANopen error
Single flash Stopped mode

Double flash Other node failed

On Bus off

Green 2 seconds on/off Operational

BCAN status
31
Red 2 seconds on/off Connection lost / not initialized
BCAN error

RG-2021-02-26-revision.indd 31 2021-03-02 14:05

 CAN Booster
Electrical connections
X1
Pin No. Color Function

1 BROWN EARTH

2 WHITE NC

3 BLUE CAN GND

4 BLACK BOOST CAN H

5 GRAY BOOST CAN L

X2 Pin No. Color Function

1 BROWN +24V

2 WHITE NC

3 BLUE -0 VDC

4 BLACK NC

5 GREEN/YELLOW EARTH

X3 Pin No. Color Function

1 SHIELD EARTH

2 RED NC

3 BLACK CAN GND

4 WHITE CAN2 H

5 BLUE CAN2 L
32

RG-2021-02-26-revision.indd 32 2021-03-02 14:05

 CAN Booster

LEDs

LED color Status Description

Power Off Power Off
(Yellow)
Solid yellow Operational mode
Boost Flashing CAN message
(Green)
Off No CAN message
CAN Flashing CAN message
(Green)
Off No CAN message

33

RG-2021-02-26-revision.indd 33 2021-03-02 14:05

 Cabinet I/O ”Plank” (old) BR1037621
LEDs

34

RG-2021-02-26-revision.indd 34 2021-03-02 14:05

 Multi Voltage Cabinet I/O BR1703273

DIP 1 DIP 2 DIP 3

DIP 1 (I/O 1-8 direction). DIP 2 (I/O 9-16 direction)

Switch Input/Out- Description Switch Input/Out- Description

No. put No. No. put No.

1 I/O 1 ON = Output OFF = Input 1 I/O 9 ON = Output OFF = Input

2 I/O 2 ON = Output OFF = Input 2 I/O 10 ON = Output OFF = Input

3 I/O 3 ON = Output OFF = Input 3 I/O 11 ON = Output OFF = Input

4 I/O 4 ON = Output OFF = Input 4 I/O 12 ON = Output OFF = Input

5 I/O 5 ON = Output OFF = Input 5 I/O 13 ON = Output OFF = Input

6 I/O 6 ON = Output OFF = Input 6 I/O 14 ON = Output OFF = Input

7 I/O 7 ON = Output OFF = Input 7 I/O 15 ON = Output OFF = Input

8 I/O 8 ON = Output OFF = Input 8 I/O 16 ON = Output OFF = Input

DIP 3 (CANopen node ID)

Switch No. Description
Node ID (decimal)
1 2 3 4

OFF OFF OFF OFF 16

35
ON OFF OFF OFF 17 (Default)

OFF ON OFF OFF 18

ON ON OFF OFF 19

RG-2021-02-26-revision.indd 35 2021-03-02 14:05

 DIP 3 (CANopen node ID)
Switch No. Description
Node ID (decimal)
1 2 3 4

OFF OFF ON OFF 20

ON OFF ON OFF 21

OFF ON ON OFF 22

ON ON ON OFF 23

OFF OFF OFF ON 24

ON OFF OFF ON 25

OFF ON OFF ON 26

ON ON OFF ON 27

OFF OFF ON ON 28

ON OFF ON ON 29

OFF ON ON ON 30

ON ON ON ON 31

DIP 3 (CANopen baud rate)

Switch No. Description
Baud rate (kbit/s)
5 6

OFF OFF 125 (default)

ON OFF 250

OFF ON 500

ON ON 1000

DIP 3 (CANopen baud rate) Description

7 Enable backwards ON = Enabled OFF = Disabled

compatibility mode
36

RG-2021-02-26-revision.indd 36 2021-03-02 14:05

 Multi Voltage Cabinet I/O BR1703273

LEDs
LED color Status Description
Power On Module supply voltage ok
(Green)
Single flash Module is outside supply voltage limit (19V < VBB < 32V)

Status Off Module is outside supply voltage limit (19V < VBB < 32V)
(Yellow)
On CANopen operational

Blinking 50:50 CANopen pre-operational

Single flash CANopen stopped

Error Off Module ok

(Red)
On Module is outside supply voltage limit (19V < VBB < 32V)

Single flash • CAN bus off

• CAN error passive
• CAN CRC error detected
• CAN communication overrun (error will be remembered for
10 minutes)

Double flash The software constantly monitors the function of the module.
In case of module malfunction or improper CANopen com-
munication the module will automatically store an error
description for the occurred error.
Example of errors:
• Trying to alter a PDO mapping when the PDO is not disabled
• Watchdog timer reset detected
• DIP switch read error

37

RG-2021-02-26-revision.indd 37 2021-03-02 14:05

 Multi Voltage Cabinet I/O BR1703273

Connectors
X1 5p Tension clamp terminal
1 GND
2 VBB
3 CAN
4 CAN
5 SHIELD

X2 5p M12 A-coded Female

connector
1 SHIELD
2 VBB
3 CAN
4 CAN
5
SHIELD SHIELD

I/O 1-16 (accepts AWG14-AWG26)

1 Pin 1 on Delcon relay
2 Pin 2 on Delcon relay
38

RG-2021-02-26-revision.indd 38 2021-03-02 14:05

 BBC cabinet I/O BR1703227
The BBC cabinet I/O is a PLC controller with CoDeSys ver 2.3
runtime with configurable I/O ports and CAN interface. The BBC
Cabinet I/O BR1703227 is delivered with a pre-installed CoDes-
Sys software.

12 configurable inputs: 12 configurable outputs:

- Digital 24V - Digital 24V
- Analogue: 4-20 mA, 0-10 V, - Analogue: PWM, current
Frequency, resistance controlled

Preprogrammed software
version of the unit is found
on a sticker on the unit and
on the package box. t

Software:
The BBC cabinet I/O is included in the latest SCS4 template
release and can be found as X24 CR0403_RemoteIO in PLC
Configuration in the templates.
39

RG-2021-02-26-revision.indd 39 2021-03-02 14:05

 Important adjustments:
Twistlocks
Periodic maintenance procedures:
After 300 hours or monthly (whichever occurs first)
This check can be made while the spreader is connected to the crane.

Twistlock: Check the nut and the floating mechanism and ensure
that all parts are properly tightened down. Check that the twist-
lock pin can be moved easily and that it indicates the correct
position.

Sensor unlocked
M8 screw Sensor locked

Twistlock nut
Twistlock arm
Spherical washer

Guide block
Landing pin sensor
Landing pin

Twistlock pin
40

RG-2021-02-26-revision.indd 40 2021-03-02 14:05

 After 1000 hours, 25 000 lifting cycles or 3 months
(whichever occurs first)
M8 Screw
Check the floating distance . Measure
while the guide block is pressed upwards. Twistlock nut
Should be max 2 mm. M8 nut
If adjustment of twistlock is needed:
1. Remove the M8 screw from the top Washer
of the twistlock.
Twistlock arm
2. To lower the twistlock, loosen the
twistlock nut slightly. To raise the Key
twistlock, tighten the nut. Adjust the
distance between the top of twistlock Spherical
head and the bottom of guide block washer
to 1-2 mm.
3. Recheck the float of the twistlock.
4. Reinstall the M8 screw.
Lubricate and check the various points as
per the lubrication instructions in spreader Guide block
manual, section 6.1.2

Twistlock pin

1-2 mm

41

RG-2021-02-26-revision.indd 41 2021-03-02 14:05

 After 2000 hours, 50 000 lifting cycles or 6 months
(whichever occurs first)
Perform the service points as in sections above.
Check all sensors. Clean and retighten.
After 4000 hours, 100 000 lifting cycles or annually
(whichever occurs first)
Twistlock
Perform the service points as in sec- nut
tions above.
1. Dismantle all twistlocks accor-
ding to REP 01 in spreader Twistlock
arm
manual section 6.4. Check for
2. Inspect all parts. Look for any wear
Spherical
damage which could necessitate washer
their replacement.
3. Check that there are no cracks
(or other faults) in the threads
of the twistlock pins or heads. Twistlock
Check for pin
Check also the guide blocks. wear
Use penetrating fluid or Magne-
Check for
tic particle Inspection (MPI) to
cracks
detect fissures.
4. Replace the twistlock pins, Check for
straightness
nuts and guide blocks if cracks
are detected.

Check for
42 cracks

RG-2021-02-26-revision.indd 42 2021-03-02 14:05

 5. Clean and inspect the sliding Guide block
surfaces of the spherical washer
and the twistlock arm for

min 185,5 mm
abnormal wear.
6. Check the wear of the guide Check for
block. Replace if cracks are cracks
detected or less than specified
minimum measures.

Twistlock Check
arm for
wear

ø min 120 mm

min 53 mm

Spherical washer

7.Roll the twistlock pin back and

forth on a table or similar flat
surface to ensure the pin is not
bent.
43

RG-2021-02-26-revision.indd 43 2021-03-02 14:06

 8. Clean and lubricate all parts
according to instructions in
spreader manual, section 6.1.2.
Especially important to lubricate
the twistlock pin keyways with
LE Almagard® 3751 or copper
paste to avoid parts being wedged. Key radius side to-
wards twl pin keyway

9. Reassemble the twistlocks.

After 8000 hours, 200 000 lifting cycles or every second year
(whichever occurs first)
The twistlock pins and the spherical washers shall be replaced.

When replacing the twistlock pins:

Bromma strongly recommends to replace all four (eight) twistlock
pins at the same time. This is to keep track on the amount of lifting
cycles for each twistlock.

The guide blocks, twistlock arms, keys and spherical washers

should be replaced together with the twistlock pins.

Make a note on date, number of lifting cycles or running hours,

and which parts have been replaced in section 8.1 in the spreader
operational manual.
44

RG-2021-02-26-revision.indd 44 2021-03-02 14:06

 Checking the wear of twistlock pin
To determine if the twistlock pin is worn out, proceed as follows:
1. If the gap between the twistlock pin lifting surface and the
guide block (floating distance) can not be adjusted to less than
2 mm, the twistlock pin should be replaced. Measure with a
2,0 mm feeler gauge.
2. If the distance between
rectangular top surface of the
twistlock pin head and the
bottom of the head is less than
56 mm, the twistlock pin should
be replaced. Use a new guide
block when measuring.

3. If the twistlock pin is

deformed, damaged or bent, it
should be replaced.

4. If cracks are detected, the

twistlock pin should
be replaced.

The wear can also be measured

with a tool. See next page.

45

RG-2021-02-26-revision.indd 45 2021-03-02 14:06

 Twistlock wear measurement tool
A. If 1 mm tool fits to gap, OK
B. If 1 mm fit doesn’t fit to gap, adjust wider. 1 mm
C. If 2 mm tool fits to gap, adjust tighter. BR1197919
D. If 2 mm tool doesn’t fit to gap, OK

If A and D are OK , the twl is properly

adjusted.
2 mm
BR1198022
Removing Sensors
1. Unscrew the cable connection
from the sensor.
2. Loosen the two screws on the
switch attachment.
3. Remove the sensor.
Cable connection
Installing Sensors
1. Perform the steps above in the
reverse order, using blue
Loctite to the cable connection.
2. The distance between sensor
face and flag is approximately
5-6 mm. Check the sensor by
grabbing the twistlock head and
moving it around in different Sensor
positions. If the signal is lost,
adjust the sensor closer to its flag.
Make sure the flag does not come
into contact with the sensor.
46

RG-2021-02-26-revision.indd 46 2021-03-02 14:06

 Installing sensor attachment
1. Remove the piston end of Switch pad
the twistlock cylinder from 10 mm
the twistlock arm by pulling
out the lock pin and removing
the washer. Turn the cylinder
aside. Hoses may remain attached.
2. Mount the sensor attachments
and the sensors on the sensor
plate as shown.
3. Install the sensor plate assy
into the twistlock housing.
Use the existing holes for
sensor attachments.
4. Connect the cables to the
sensors. ( If the sensors
doesn´t have cable connections,
perform step 3 above before
step 2).
5. Remount the twistlock cylinder.

Bolting plate
Adjusting sensors ASP4
1. Check the distance between sensor face and flag for TL unlocked and
TL locked sensors. Should be 6 mm. ( Landing pin sensor also 6 mm).
2. Connect the power and test the function as in step 2,
47 Installing sensors page 25.

RG-2021-02-26-revision.indd 47 2021-03-02 14:06

 Adjusting sensors with tool BR1224624
Sensor adjustment tool (BR1224624) is used to
adjust landed sensor, twist lock locked sensor
and twist lock unlocked sensor. Before procee-
ding to the adjustment, place the spreader on
trestles or similar devices.

Sensor adjustment
tool BR1224624

Ensure the twistlock is hanging vertical. Place the tool around the landed
sensor pin.
Apply a screw jack or a clamp to the landed sensor pin until it reaches
solid stop at the tool.
48 The clamp needs a clamping range of at least 500 mm.

RG-2021-02-26-revision.indd 48 2021-03-02 14:06

 Now adjust the landing sensor
until signal is obtained.

Sensor adjustment Unlocked sensor

tool BR1224624

To adjust the locked and un-

locked sensors, place the tool
on top of the sensor flag and
adjust the sensor downwards
until it touches the tool.
Now the distance to flag
is 6 mm.
49

RG-2021-02-26-revision.indd 49 2021-03-02 14:06

 Telescopic Chain: (REP. 05)
Removing the Telescopic Chain
1. Disconnect the power.
Locking screws
2. Remove the locking
screws from the adjusting nut.
3. Turn the adjusting nut counter-
clockwise a quarter of a turn.
4. Remove the chain pin connected Adjusting
to the shock absorber by nut
pulling out the cotter pin.
5. Remove the chain.

Installing the Telescopic Chain

1. Perform the steps 5-3 above in
the reverse order.
2. Go to step 4 in ”Adjusting
Telescopic Chain.”
3. Reinstall the locking screws
in the adjuster nut. Cotter pin
4. Lubricate the chain.

Chain lock

50

RG-2021-02-26-revision.indd 50 2021-03-02 14:06

 Adjusting the Telescopic Chain
1. Run the spreader to the maximum position (40 or 45 foot).
2. Disconnect the power.
3. Remove the locking screws from the adjuster nut.
4. Tighten the adjuster nuts on both sides with a torque
wrench to 50 Nm (37 ft-lbs.) alternately one turn at a time.
It is important to adjust both sides equally. If not done
properly this could cause future problems in operation and
reduce the life of the chain.
5. Reinstall the locking screws in the adjusting nut .

5852 (20’ ISO)

8918 (30’ ISO)
11984 (40’ ISO)
13509 (45’ ISO) 106

Note! The length of two 20’ containers is not equal to one 40’
container

51

RG-2021-02-26-revision.indd 51 2021-03-02 14:06

 Electric Motor, Powerpack (REP. 11)
Removing the Electric Motor Hub A Hub B
1. Disconnect the power.
2. Remove the hydraulic power pack cover. Motor
3. Open the motor junction box cover and shaft
disconnect the cables.
Note how the cables are connected.
4. Remove the mounting bolts for the
electrical motor.
5. Remove the motor from the bell-housing by
removing the six M12 nuts on the motor flange.
6. Pull the motor backwards until it comes loose.
7. Dismantle the coupling by loosening
the M6 set screw.
8. Make sure the key is located.
Power
pack
M12 M12 cover
screws nuts Shaft
coupling
Hub B
Junction box

Stop screw

Rubber gear ring

Hub A
52

RG-2021-02-26-revision.indd 52 2021-03-02 14:06

 Installing and Adjusting the Electric Motor
1. Mount Hub B of the coupling to the electric motor and
mount Hub A to the pump as shown on the previous page.
Tighten the set screw to 81Nm.
2. Press the rubber gear ring in place on Hub A on the hydraulic
pump shaft.
3. Push the motor in place and ensure that Hub B on the shaft
fits into the rubber gear ring
4. Perform steps 1-4 on the previous page in the reverse order.
5. Test the function of the motor. Tighten all screws.

Hydraulic Pump, Powerpack (REP.12)

Removing the Hydraulic Pump

1. Disconnect the power.
2. Drain the hydraulic tank by removing the drain plug.
3. Remove the hoses from the pump.
4. Remove the Electric motor according to REP 11.
5. Remove the four M12 screws holding the pump into the
bell-housing.
6. Support the pump while pulling it out from the bell-
housing.

53

RG-2021-02-26-revision.indd 53 2021-03-02 14:06

 Case drain
Installing the Hydraulic Pump hose

1. Perform the steps above in the

reverse order.
2. Fill the pump with oil before Flow
Pressure regulator
connecting the case drain hose. adjuster
3. Connect the power supply and
test the operation of the pump. Hydraulic
pump

Adjusting the Hydraulic Pump *

1. Caution! Some of these steps are made while the power
supply is connected.
2. Mount the pressure gauge on the valve block pressure test
point.
2. Loosen the pressure adjuster screw a couple of turns.
3. Start up the system and increase the pressure by tightening
the pressure adjuster screw until the correct pressure setting is
reached. (see BGS manual Chapter 3.1 Datasheet).
4. The telescoping speed is set by adjusting the flow regulator.
The recommended speed is 27-28 s between the 20´and the 40´
or 45´ positions. If the speed is set too high, it may overload the
motor and trip the motor protection or the fuses. Always make
sure the motor current is not higher than the motor rating or
supply capacity.
* Not valid for STS45
54

RG-2021-02-26-revision.indd 54 2021-03-02 14:06

 Flow
regulator

Case drain
hose

Hydraulic
pump

M12 Screws
Pressure
adjuster
screw
Drain
plug

55

RG-2021-02-26-revision.indd 55 2021-03-02 14:06

 Changing the oil and replacing the Filters (REP. 13)
1. Disconnect the power.
2. Remove the cover over the hydraulic unit.
3. Remove the drain plug and the filler cap to drain the oil. (150 liters).
4. Remove the three M6 screws holding the return line filter cover.
5. Remove the filter insert and replace it.
6. Remove the pressure filter cup and replace the filter.
Note! The cup is filled with oil. Clean the cup and assemble
with a new filter insert.
7. Refill the oil tank through the return line filter.
8. Refill the pump by loosening the case drain hose and pouring
oil into the pump. Cover M6 screws
9. Reinstall the hose and
remove the air for the Return line
system according to filter cover
REP.14, De-aeration of Return line
hydraulic system, filter insert
described in the Return line
filter cup
spreader Manual.

Pressure
filter insert
Drain plug Pressure
56 filter cup

RG-2021-02-26-revision.indd 56 2021-03-02 14:06

 STS45 Hydraulic Pump (REP. 25)
Removing the Hydraulic Pump
1. Disconnect the power.
2. Remove the hydraulic unit covers.
3. Drain the hydraulic tank by removing the drain plug.
4. Remove the hoses from the pump.
5. Remove the Electric motor according to REP 11.
(It is possible to remove the pump without removing the electric
motor. The hub A on the shaft coupling will pass through the central
front hole in the bell-housing. The rubber gear ring will fall down
inside the bell-housing and must be picked up by Hydraulic
unit covers
hand or by a
suitable tool).
6. Remove the
two M12
screws holding the Pressure
testpoint
pump into the
bell-housing. Rubber gear
ring
7. Support the pump
while pulling it out
Hydraulic
from the pump
bell-housing.

Hub A

57 Drain plug

RG-2021-02-26-revision.indd 57 2021-03-02 14:06

 Installing the Hydraulic Pump (STS45)

1. Mount the rubber gear ring on the hub A at the pump shaft.

2. Perform the steps above in the reverse order.

(If the rubber gear ring will not fit to the hub B on the
motor shaft inside the bell-housing, the fan cover at the end
of the motor must be removed. By slowly turning the fan
makes it possible to turn the motor shaft to a better position).

3. Fill the pump with oil before connecting the case drain hose.

4. Connect the power supply and test the operation of the pump.

The (STS45) Hydraulic pump pressure and flow are pre set in fac-
tory. If the pump still has to be adjusted, contact Bromma service.
To tamper with the settings may damage the pump.

58

RG-2021-02-26-revision.indd 58 2021-03-02 14:06

 Control of the Hydraulic Pump pressure
1. Caution! Some of these steps are made while the power
supply is connected.
2. Mount the pressure gauge on the pressure test point at the
pressure filter inlet.
3. Connect the power supply.
4. To check the low pressure, ensure that the valve 71 (Y41) is
currentless. The small LED on the valve is not lit.
Actual low pressure value is shown on the hydraulic
schematic. BGS Manual section 6.2 (and the datasheet
section 3.1) Normally 100 bar.
5. To check the high pressure, the valve 71 (Y41) must be
voltage-fed. The small LED on the valve is lit.

Actual high pressure value is shown on the hydraulic schematic.

BGS Manual Chapt.6.2 (and the datasheet Chapter 3.1) Normally
160 bar.
If the values does not Valve 71
(Y41)
correspond to the
information in the
manual, the pump
pressure must be
adjusted.

59

RG-2021-02-26-revision.indd 59 2021-03-02 14:06

 EH5 /EH170 Adjusting the tower brake and
telescoping brake
Inspection and maintenance periods:
Equipment/compo- Frequency What to do ?
nents
BMG4 =Telescopic Every Year Inspecting the brake:
Motor • Measure and set working air gap
• Brake disc, lining
BMG8 = Tower Every third • Pressure plate
Motor month • Carrier / gearing
• Pressure rings
• Extract the abraded matter
• Inspect the switch elements and
replace if necessary (e.g. in case
of burn-out)

Inspecting the brake

1. Isolate the motor and brake from the supply, safeguarding
them against unintentional power -up.
2. Remove the following:
– If fitted, forced- cooling fan for motor and brake
maintenance.
– Flange cover or fan guard (21).
3. Push the rubber sealing collar (5) aside.
– Release the clip to do this, if necessary .
– Extract the abraded matter.
60 4. Measure the brake disc (7).

RG-2021-02-26-revision.indd 60 2021-03-02 14:06

 If the brake disc is:
< 9 mm on brake telescopic motor (BMG4).
< 10 mm on brake tower motor (BMG8).
Fit a new brake disc
(See section ”Changing
brake disc
page 43).

61

RG-2021-02-26-revision.indd 61 2021-03-02 14:06

 Setting the working air gap.

Gap to be
measured

Pressure Damping Rubber sealing

plate plate collar

1. Perform the steps 1-3 in Inspecting brake (page 40)

2. Measure the working air gap at three points.
3. Adjust with the Hexagon nuts (10e).
4. Mount the Rubber sealing collar and refit the dismantled parts.
Motor Function Set air gap to:

BMG4 Telescopic Motor 0.25 - 0.6 mm

BMG8 Tower Motor 0.3 - 1.2 mm

62

RG-2021-02-26-revision.indd 62 2021-03-02 14:06

 Changing the brake disk BMG 4 and 8
When fitting a new brake disc, inspect the other removed parts as well
and fit new ones if necessary.
1. Isolate the motor and brake from the supply, safeguarding
them against unintentional power -up.
2. Remove the following:
– If fitted, forced cooling fan
– Flange cover or fan guard (21), circlip (20) and fan(19).
3. Remove the rubber sealing collar (5) and the manual brake release:
– Setting nuts (18), conical coil springs (17), studs
(16), release lever (15) , dowel pin (14).
4. Unscrew hex nuts (10e), carefully pull off the brake coil body
(12) (brake cable!) and take out the brake springs (11).
5. Remove the damping plate (9 ), pressure plate (8) and brake
disc (7, 7b) and clean the brake components.
6. Fit a new brake disc.
7. Re-install the brake components.
– Except for the rubber sealing collar, fan and fan
guard, set the working air gap
(see” Setting the working air gap” (page 42, ponts 1-3)
8. With manual brake release: Use setting nuts to set the floating
clearance ”s” to 2 mm between the conical coil springs (pressed
flat) and the setting nuts (see following illustration).

Important: This floating clearance ”s” is necessary so that the pres-

sure plate can move up as the brake lining wears. Otherwise, reliable
63 braking is not guaranteed.

RG-2021-02-26-revision.indd 63 2021-03-02 14:06

 2 mm

9. Fit the rubber sealing collar back in place and re-install the
dismantled parts.

Note: • The lockable manual brake release ( type HF) is

already released if a resistance is encountered when
operating the grub screw.
• The self re-engaging manual brake release (type HR)
can be operated with normal hand pressure.

Important: In brake motors with self re-engaging manual brake

release, the manual brake release lever must be removed after startup/
maintenance. A bracket is provided for storing it on the outside of the
motor.
64

RG-2021-02-26-revision.indd 64 2021-03-02 14:06

 Adjustment of sensors.
This is a summary of how to adjust all Bromma standard spreader
sensors. Many customized spreaders exists. If slightest doubt,
check with the technical manual for the current spreader.

Twistlocks and landing pins:

Function Spreader Sensor Distance Remarks
sensor-flag

End beam Twist- All S1 - S8 6 mm Grab twislock head and

locks move it around. If signal is
lock/unlock lost, adjust sensor closer
to flag

Twinlift unit STR40/45, S24 - 6 mm Grab twislock head and

Twistlocks STS45 S31 move it around. If signal is
YTR40/45, lost, adjust sensor closer
YTS45 to flag

Landing pin All end beams S9 - S12 6 mm Sensor activated when

the landing pin protrudes
6 – 0 mm.

Landing pin twinbox All twinboxes S32-S35 6 mm Sensor activated when

the landing pin protrudes
6 – 0 mm.

65

RG-2021-02-26-revision.indd 65 2021-03-02 14:06

 Telescoping:
Before adjusting telescoping sensors, ensure the adjustment of the telescopic
chain (REP. 05 see page 29) is properly done. Both sides equal. Check the center
punch marks on the telescopic beam and a black position line for each position
Make sure the sensors never touch the flags!
Function Spreader Sensor Distance sensor-flag Remarks
Position All except S13 - S17 6 mm Loosen M8 screws and move
Sensors YTS45, STS45 sensor plate to requested direction.
Position STS45 S30=20’ ~7 - 8 mm Loosen M8 screws and move
Sensors S16=40’ ret sensor plate to requested direction.
S116=40’ exp
S17=45’
Position STS45, YTS45 and S1 - S4 Positions adjusted in software
Sensors other
w. digital encoder

Twin boxes:
Function Spreader Sensor Distance sensor-flag Remarks

Twin is up YTR40/45,YTS45, S36 - S39 ~7 - 8 mm Sensor should be flush

STR40/45, STS45 mounted with twin box.
Twin is down STS45 S40 - S43 ~7 - 8 mm
(optional)
Twin up EH170 S36 - S39 ~7 - 8 mm

Twin in zero gap YTS45, STS45 S112,(S113) ~7 - 8 mm

Twin in 0-40’ STS45 S115,(S114) ~7 - 8 mm

position
Twin in 45’ STS45 S119 ~7 - 8 mm
position
Hook connected STS45 S100, S101 In cylinder

Hook not con- STS45 S102, S103 In cylinder

nected
Latch permit STS45 S160, S161 ~7 - 8 mm

66

RG-2021-02-26-revision.indd 66 2021-03-02 14:06

 Tower:
Function Spreader Sensor Distance sensor-flag Remarks
Tower in mid EH5,EH5U, S52 - S53 ~7 - 8 mm
position EH170,
EH170U
Tower in end EH5,EH5U, S54 - S55 ~7 - 8 mm
position EH170,
EH170U

Sensors for flipper positions etc. are optional and will be found in the
technical manual for each spreader.
Accessories:
Function Spreader Sensor Distance sensor-flag Remarks
Landed hold All S9 - S12 35mm Make a 35 mm block.
S32 - S35 Use it as a spacer when
adjusting sensors.
TTDS EH5,EH5U, S54 - S55 See page
EH170,
EH170U
HIS See page

Distance between twistlocks (mm):

Twistlock type 20’ 30’ 35’ 40’ 45’
ISO floating 5852 8918 11984 13509

67

RG-2021-02-26-revision.indd 67 2021-03-02 14:06

 Important tightening torques
General instructions
The tightening torques in the following tables are Bromma’s recommendations
when tightening screws and nuts. Screws and nuts are combined that they have
the same strength class.

8.8 screw and class 8 nut Nuts of the higher class can always
10.9 screw and class 10 nut replace the nuts of a lower class.
12.9 screw and class 12 nut
A torque wrench is recommended to achieve prescribed tightening torque (dis-
persion in torque ±5 %). The torque wrench should be set at a desired torque and
tightening shall be done without stopping. Torque wrenches must be checked and
calibrated periodically.

If other tools are used the tolerance of ±5 % should be fulfilled.

A pneumatic impact wrench (bolt runner) has a larger dispersion in torque than a
torque wrench. If tightening will be done with pneumatic impact wrench the tightening
torque should be reduced by approximately 5 % because of the risk for overloading.

If treated screws (FZB, Zinc Flake or similar) are in dry condition some thread
lubricant (oil, grease, paste) has to be used before tightening. If these treated
screws are storage oiled they can be considered as oiled.

Untreated (black) fasteners must be lubricated with some thread lubricant before tigh-
tening. Untreated screws with anti-corrosion (storage) oil cannot be considered as oiled.

Stainless steel screws must be in waxed conditions when tightening. If only non-
waxed condition is available some thread lubricant has to be used before tightening.
68

RG-2021-02-26-revision.indd 68 2021-03-02 14:06

 BROMMA TORQUE GUIDELINES for BRB washers
Tightening torque Nm
Screw (FZB, Zinc flake); Oil; BRB Stainless, Wax, BRB washer
washer
class 8.8 (ν=0,80) class 10.9 (ν=0,74) class 12.9 (ν=0,74) A2,A4 class 70 (ν=0,71)
M4 2,6 3,4 4,1 1,6
M5 5,2 6,8 8,2 3,2
M6 8,8 11,5 13,7 5,5
M8 21,4 27,9 33,3 13,3
M10 42 55 66 26
M12 72 93 112 45
M14 115 149 178 (72)
M16 178 231 277 (110)
M20 349 454 545 (218)
M24 601 782 938 (375)
M30 1199 1560 1872 (749)

Torque in the table above refers to:

ν = ratio of yield point
µt = 0,125 (thread friction)
µw = 0,125 (washer friction)
For A2, A4 class 70, the torque calculated with Rp0,2=450 N/mm² (yield strength)
Tightened with a torque wrench (dispersion in torque ±5 %)
Zinc flake: Dacromet, Dacrolit, Geomet …
Stainless fasteners must be in waxed condition.
Reference: Colly Components “Handbok om skruvförband”, ISBN 91-630-3882-X
69

RG-2021-02-26-revision.indd 69 2021-03-02 14:06

 BROMMA TORQUE GUIDELINES for Nord-Lock washers
Tightening torque Nm
Screw (FZB, Zinc flake); Oil; Nord- Stainless, Wax, Nord-Lock washer
Lock washer
class 8.8 class 10.9 (ν=0,74) class 12.9 (ν=0,74) A2,A4 class 70
(ν=0,79) µt=0,15 µt=0,15 µw=0,15 µt=0,15 µw=0,13 (ν=0,71) µt=0,13
µw=0,19 µw=0,13
M4 3,8 4,5 5,1 1,8
M5 7,5 8,9 10 3,6
M6 13,1 15,5 17,4 6,3
M8 32 37 42 15
M10 62 73 82 30
M12 107 126 142 51
M14 170 201 226 (81)
M16 260 307 345 (124)
M20 510 602 676 (242)
M24 878 1036 1165 (418)
M30 1750 2064 2318 (831)

Torque in the table above refers to:

ν = ratio of yield point
µt = thread friction
µw = washer friction
Tightened with a torque wrench (dispersion in torque ±5 %)
Zinc flake: Dacromet, Dacrolit, Geomet …
Stainless fasteners must be in waxed condition.
70 Reference: “Torque guidelines – Nord-lock”, www.nord-lock.com

RG-2021-02-26-revision.indd 70 2021-03-02 14:06

 Screws in Telescopic Beam:

The following images

shows screws and
couplings 9,7 Nm
where the tightening
torques deviate from
the tables
on previous pages.

71

RG-2021-02-26-revision.indd 71 2021-03-02 14:06

 Screws in Telescopic Beam:

95Nm

100 Nm

72

RG-2021-02-26-revision.indd 72 2021-03-02 14:06

 Screws in Telescopic Drive:

50 Nm

Screws in Power pack:

90-110 Nm

90-110 Nm
320Nm

90-110 Nm
200-245 Nm

100 Nm

81 Nm 90-110 Nm 200-245 Nm
73

RG-2021-02-26-revision.indd 73 2021-03-02 14:06

 Screws in EH5U / EH170U:
165 Nm
Tower and main 331 Nm
frame 331 Nm
331 Nm

331 Nm

End beam 6,5 Nm

68 Nm

40 Nm

74

RG-2021-02-26-revision.indd 74 2021-03-02 14:06

 Screws in EH5U / EH170U:
Telescopic motor

40 Nm

Flipper motor and 331 Nm

gearbox

331 Nm
165Nm
after 200
test cycles
56 Nm
140 Nm
after 200
test cycles

75

RG-2021-02-26-revision.indd 75 2021-03-02 14:06

 Lubrication instructions:
Grease
Lubricating grease of the proper consistency is to be applied
at frequent intervals with grease guns through the grease fit-
tings or with brush where applicable. Lithium base NLGI #2
is recommended. (Example Matrix EP2).
Grease
Based on synthetic oil and compatible with plastics. (Alma-
gard® Vari-Purpose Lubricant 3751). This grease shall be used
on glide plates made of Oilon (green) and gliding surfaces in
contact with these plates.

Extreme Pressure Multipurpose Gear Lubricant (EPGL)

This gear lubricant is compounded to achieve high load carry-
ing capacity and meet the requirements of API-GL-5 and may
be used for year round service. (Example Mobilgear 600 XP
220). STS45E, SSX40E/45E and STR40E/45E are delivered
with Mobil SHC 634. (Telescopic drives are worm geared.)
Chain Lubricant
Apply a non-detergent SAE oil to the chain. Use SAE 30 oil
unless the temperature is below 4 degrees C (40 degrees F)
(SAE
20) or above 38 degrees C (100 degrees F) (SAE 40).

76

RG-2021-02-26-revision.indd 76 2021-03-02 14:06

 Lubrication instructions:

40’ spreaders
Pedestal
bearing

Twistlocks
Chain

Glide plates

Telescopic motor
gearbox
4,5 l
Flipper arm
77 gearbox

RG-2021-02-26-revision.indd 77 2021-03-02 14:06

 Lubrication instructions:

Grease

78

RG-2021-02-26-revision.indd 78 2021-03-02 14:06

 Lubrication instructions STS45:

Lubricate twistlocks
as mentioned earlier

Weekly

79

RG-2021-02-26-revision.indd 79 2021-03-02 14:06

 Lubrication points marked with
shall be lubricated with grease
based on synthetic oil compatible with plastics.
This grease shall be used on glide plates made of Oilon (green)
and gliding surfaces in contact with these plates. Other types of
grease may destroy the glide plates.

Lubrication instructions EH5U/EH170U:

Main frame, twistlocks and glide plates, see previous pages.
Telescopic motor
Lifting shafts gearbox (shaft)

Chains

Chain wheels Twistlocks

Glide plates

Flipper gearboxes

80

RG-2021-02-26-revision.indd 80 2021-03-02 14:06

 Lubrication EH170U:

Pins and
offset link

Pins

Twistlock
see previous
pages

81

RG-2021-02-26-revision.indd 81 2021-03-02 14:06

 Hydraulic oil change intervals

Renew Interval
Filter inserts After every 4000 working hours or when indicated.
(return and (Filter indicators are optional)
pressure)
Hydraulic oil Every 8000 working hours, perform an oil test. If
the oil test is rejected, renew the oil. If the result is
approved, the oil can remain).

Note! Slight amounts of water in the oil tank can be drained by loosening
the drain plug. (Refill oil to replenish drained amount).

Renewing filters and hydraulic oil is described in REP 13.

82

RG-2021-02-26-revision.indd 82 2021-03-02 14:06

 Hydraulic oil volumes and types
Spreader type Volume
EH5U 2 x 60 l
EH170U 3 x 60 l.
EH180 90 l
All other hydraulic spread- 150 l
ers

The hydraulic oil viscosity depends on the geographical location of the spreader.
Geographic Zone Viscosity Type Viscosity at 40OC

Temperate Zones - Arctic ISO VG32 Caltex Rando 33 cSt

Zones ( Scandinavia & HD32
Northern Europe)
Temperate Zones Tropi- ISO VG46 Caltex Rando 47 cSt
cal Zones (Mediterranean HD46
countries)
Temperate Zones Tropical ISO VG68 Caltex Rando 47 cSt cSt
Zones (Southeast Asia & HD46
Arab peninsula)
Arctic Zones Option Arctic Statoil Arctic 28 cSt
131

Always refill oil of same quality and type as used before. See technical manual.

Note! Some Sites uses biodegradable hydraulic oils. To mix these oils with min-
eral based oils may cause damage to the hydraulic components.
83

RG-2021-02-26-revision.indd 83 2021-03-02 14:06

 Hydraulic oil in gearboxes
Gear- Reference On models Lubrica- Lubrication Amount Level
boxes Item tion 1 2 (Low temp) check
(Standard)
Telescopic BR1111239 YSX40E/45E Klubersynth Klübersynth 3,4 litres Level di-
EG 4‐150 GEM 4-150 N mension on
drw.
Twistlock BR1102896 All electrical Klubersynth Klübersynth 0,49 Level di-
spreaders EG 4‐150 GEM 4-150 N litres mension on
drw.
Flipper BR1112760 Electrical Shell ALVA- Same as 4,5 kg Level di-
3000 yard spread- NIA 1029 standard mension on
ers drw.
Flipper BR1112761 STS45E/ Shell ALVA- Same as 6 kg Level di-
7000 YTS45E NIA 1029 standard mension on
drw.

BR1112760

BR1111239

BR1112761
BR1102896

84

RG-2021-02-26-revision.indd 84 2021-03-02 14:06

 Hydraulic oil and lubricants in gearboxes
Gear- Reference On models Lubrica- Lubrication Amount Level
boxes Item tion 1 2 (Low temp) check
(Standard)
Hydraulic BR79554 All hydraulic Mobil MO- Same as 4,5 litres Level plug
telescopic spread- BILGEAR standard (picture)
ers except 600 XP 320
MSX45
Hydraulic BR1004902 MSX45, Mobil MO- Same as 4,5 litres Level plug
telescopic Terex ASC BILGEAR standard (picture)
600 XP 320
Electric BR1025444 All electrical Mobil SHC Not defined 6,5 litres Level plug
telescopic spread- 634 yet (picture)
ers except
YSX40E/45E

BR79554 BR1004902 BR1025444

85

RG-2021-02-26-revision.indd 85 2021-03-02 14:06

 Hydraulic oil in gearboxes
Gear- Reference On Lubrication Lubrication 2 Amount Level check
boxes Item models 1 (Standard) (Low temp)
Tower BR58549 EH5U/ SEW CLP SEW CLP HC 4,6 litres Level plug
gearbox EH170U 220 Mineral 220 Synthetic (drawing)
Tel- BR39055 EH5U/ SEW CLP SEW CLP HC 4,6 litres Installation angle
escopic EH170U 220 Mineral 220 Synthetic does not allow
gearbox easy level check
Side shift BR1005971 YSX40E/ SEW CLP HC Same as 4,6 litres Level plug
45E 220 Synthetic standard (drawing)
Sideshift (22)
(310)

Twin BR1020664 STR45E/

REV SEW DESCRIPTION
CLP HC SameECO-No. as DATE BY 1,2 litres Level plug
SPEC
hoist YTR45Ea 220 Synthetic standard
3D added, BR58549 was on dwg 45473. 2013-11-26 begleis
(drawing)

(250)
TYPE
Twin tel- BR1103717 STR45E/ SEW CLP HC SEW CLP HC 6,0 litres Level plug MOT
escopic YTR45E 220 Synthetic 220 Synthetic (drawing) DUTY
50 H
60 H
BRAK
THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY OF BROMMA CONQUIP. THE DESIGN AN OR CONSTRUCTIONS CONTAINED THEREIN MAY NOT BE

1 2
BREA
1 2
BRAK
MOU
(120)
REV DESCRIPTION ECO-No. DATE BY MOT
a Added loctite note - 2009-05-14 PHW CONN
(Ø60)
(418)

b New BOM. Notes added - 2009-09-21 JLM

CABL
FLAN
HEAT
PROT
WEIG
BR58549 BR1005971 GEAR
THIS DRAWING IS COPYRIGHT AND IS THE PROPERTY OF BROMMA CONQUIP AB. THE DESIGN AN OR CONSTRUCTIONS CONTAINED THEREIN MAY NOT BE

(348) (776)
MOUNTING POS. B3 (428) REV
a
DESCRIPTION
Brake handle position was 33
ECO-No. DATE BY
001759 2012-08-17 lindsje1
OUTP
RUBBER BUFFER b RAL 7021 was 7031, Heater 230 V added, Notes updated,Title updated. 004334 2013-06-18 lundvto
WEIG
COPIED OR REPRODUCED WITHOUT THE WRITTEN CONSENT OF THE OWNER.

SEW ART NO: 133493, 1 PCS c Brake cover fastening kit added. 005358 2013-10-30 lindsje1
BROMMA ART NO: 1031554
2 1
b b OIL T
f LUBR
R77DT71D6BMG/HR (i= 121,42)
ALL S
(275)

(80)

(20)

P=0,25 kW
50Hz 880/7,2 r/min. Motor voltage 220-240V D / 380-415 Y.
STUD
60Hz 1055/8,7 r/min. Motor voltage 240-266V D / 415-480 Y. OR B
Brake voltage 208-266V.
b e
Brake control; BG
Painting: RAL7021Brake
glossiness 30±5
torque; 5,0 Nm according to ISO 12944 C4L. PAIN
BR1020664 SEW
(278)
Heater; No.
BR1103717
1

86
COPIED OR REPRODUCED WITHOUT THE WRITTEN CONSENT OF THE OWNER.

PARALLEL SHAFT HELICAL GEAR UNIT WITH HOLLOW SHAFT

Type: FV77/G DRS90M4BE2HR/XV0A
(60) Oil temperature range -25°C to +60°DC Speed [r/min]: 1395 (21)
RAW
RAW MATERIAL ART.NR RAW MATERIAL PROFILE DIMENSION AND TOLERANCE RAW MATERIAL TYPE Total ratio: 188,4
Recommended oil Mobil SCH 630 Ma max [Nm]: 1500 -
- - - -
(49)

Output torque 50Hz [Nm]: 1930

SIGN
DATE MATERIAL SHEET WEIGHT Service
TOLERANCE factor FB
GENERAL
b Mounting position M1 Mounting position: M5
2013-11-26 ALT. Connection box 270° (T) Term.box.pos. cable entry: 180 (L) / position 2
Lubricant/-volume [l]: CLP 220 Miner.Oil/ 6,0
1/1 158 kg SS-ISO 2768-c T
(210)

SIGNED BY Brake handle position: 270°0° FORMAT Corrosion protection:

STANDARD REV. Yes
Surface protection: OS3
COPYRIGHT AND IS PROPERTY OF BROMMA CONQUIP. THE DESIGN AND/OR CONSTRUCTIONS CONTAINED THEREIN MAY NOT BE

begleis b Paint coat: Top coat RAL 7021 GEARBOX ASSY R97A A3 a
Painted with colour RAL 7031 General acces feature: G with fubber buffer

MOTOR 360-404V 50Hz/440V 60Hz

Motor power [kW]: 1,5
DRAWING NUMBER
All studs locked with loctite 2701 Motor frequency [Hz]: 50

BR58549
Cyclic duration factor S1-S10: S1
Voltage range [V]: 220-242 D/380-420 Y
Rated current [A]: 5,90/3,40
SIGNED BY DATE MATERIAL SPLINEDSHEET WEIGHT
HOLLOW SHAFT TOLERANCE GENERAL Thermal cl.[°C]/Enclosure [IP]: 155(F)/55
TO DIN 5480 50X2X30X24 International efficiency class: IE1
JBM 2008-07-18 ALT. 1/1 38 kg SS-ISO 2768- c CE mark: Yes
Brake: BE2
FORMAT STANDARD REV.
Brake release: HR=manual brake release self-reengaging
(676,5)

HELICAL GEARED MOTOR A3 b a Brake

Position brake release [°]: 33
voltage [V]/-torque [Nm]: 230 AC/20
TWIN HOIST STR40/45E DRAWING NUMBER Brake voltage [V]: 218-243 AC
DUCED WITHOUT THE WRITTEN CONSENT OF THE OWNER.

1020664
Brake rectifier: BG1.5
b Heater: 230 V
Fan cover: Short
Encoder mount option: XV0A
Encoder mounting adapter: Mounting adapter with coupling encoder, centering 36 mm. Encoder shaft: 10 mm, max length 35 mm
Adapter mounting screws to be included in supply: 3 pcs MC6S M4x12
Encoder mounting screws to be included in supply: 3 pcs MC6S M4x15

RG-2021-02-26-revision.indd 86 2021-03-02 14:06

2 All studs locked with Loctite 2701

RAW MATERIAL ART.NR RAW MATERIAL PROFILE DIMENSION AND TOLERANCE RAW MATERIAL TYPE
- - - -
DATE MATERIAL SHEET WEIGHT TOLERANCE GENERAL
 Hydraulic oil in gearboxes
Gear- Reference On models Lubrication Lubrica- Am- Level
boxes Item 1 (Standard) tion 2 (Low ount check
temp)
Twin BR1037750 STS45E/ Nippon Koyu Same as 40 g No need,
twistlock YTS45E BEN10-No.2 standard mainte-
Maintenance nance free
Free Grease
Twin hoist BR1102017 STS45E/ Nippon Koyu Same as 175 g No need,
YTS45E BEN10-No.2 standard mainte-
Maintenance nance free
Free Grease
Telescopic BR1140050 YSX40E/45E Shell Omala Modifications 3,3 Sight glass
for overheight 220 or to gearbox litres (drawing)
frames/option equivalent needed

BREATHER & FILLER CAP

OIL LEVEL SIGHT GLASS

BR1140050
DRAIN PLUG MOTOR SUPPORT ATTACHMENT POINT

(91)
87
ED THEREIN MAY NOT BE

(26)

3
c
RG-2021-02-26-revision.indd 87 2021-03-02 14:06
 TTDS Twin Twenty Detection System (TTDS)
S91
S95 and S96 are the pri- S95 S93 S96
mary sensors for detecting
a container. S90 and S94
are secondary container
sensors for detecting tank
containers and flat racks.
S91, S92 and S93 are gap
sensing sensors.

S90-S94 = inner sensors.

S95 and S96 = outer S94
S92
S90
sensors
Spreader type Inner sensor setting Outer sensor setting
EH5U,EH170U 13.583” [345mm] 25,591” [650mm]
SSX40, SSX45, STR40, STR45, 16 ¾” [425 mm] 28 ¾” [730mm]
STS45 with Std end beams (6 3/4”
[172mm] from Bottom
T/L Housing to Gable Tube)
SSX40, SSX45, STR40, STR45, 22 3/8” [568 mm] 34 3/8” [873mm]
STS45 with Classic end beams
(12 3/4” [342 mm] from Bottom
T/L Housing to Gable Tube)
SSX40, SSX45, STR40, STR45, 23 7/8” [606 mm] 35 7/8” [911 mm]
STS45 with INRS

88

RG-2021-02-26-revision.indd 88 2021-03-02 14:06

 TTDS Twin Twenty Detection System adjusting
Hold a flat object approximately 700 mm below the outer sensors. Ad-
just the sensors with a suitable screwdriver until the object is detected.

Adjust the inner sensors the same way, but with a distance of approx-
imately 400 mm to the object.

To adjust the sensors S91, S93, S95 and S96, a longer screwdriver is
needed.

89

RG-2021-02-26-revision.indd 89 2021-03-02 14:06

 HIS Height Indication System
Setting Switch Points
The two sensors are from different manufacturers, therefore the
method of setting the switch points is different.

Sensor 1.1 (79579)

This sensor is provided with a switching output with two program-
mable switch points. They are set by applying -24V for the long
distance position or +24V for the short distance position to the
teaching input (pin no. 2 in sensor socket) for at least 1 second.
The distance is programmed by holding a 100 x100 mm metal
target in front of the sensor at the desired distance and applying the
proper voltage to Pin 2. The LED on the top of the sensor indicates
that the set point has been properly stored.
LED on top Sensor
Main
of sensor framre

Short
distance
position

Long
distance
position

90

RG-2021-02-26-revision.indd 90 2021-03-02 14:06

 Sensor 2.1 (79580)
This sensor is equipped with two controls, P1 and P2.
The short distance position is set by P1 and the long distance posi-
tion by P2. LEDs located on the sensor indicate when the target is
detected.

For both sensors the long distance position should be set to ap-
proximately 3 m (depending on crane type).
The short distance should be set as short as possible and by all
means kept above the bottom of the main frame.

Controls P1
Pins in sensor socket and P2
(Valid for both types)

5
1
2
3 4

91

RG-2021-02-26-revision.indd 91 2021-03-02 14:06

 Bromma Genuine Spare Parts
Calculate the risk
Bromma Genuine Parts have been designed specifically for our equipment and
ensure premium quality, safety and durability. They give you the optimal perfor-
mance you’ve come to expect from the world’s leading crane spreader supplier.
Non-standard spare parts are high risk. Real cost and real risk is measured not
in the price of the component, but in the cost of the component in the event of
failure.

Order Bromma spare parts online

Bromma e-commerce enables you to order spare parts 24/7. If you want to be-
come a registered user, but do not have an ID and Password, email us at
parts@bromma.com
Spare Parts kits
The Bromma spreaders consists of a huge number of different parts. In developing
the handling of spare parts and ensuring shortest possible downtime, Bromma has
developed spare part kits. These kits consists of the parts which are most often
replaced and the parts that should be replaced together.
• Easier to order - only one article number
• Faster delivery - prepacked kits
• Increased quality - includes all the parts that
should be replaced together
• Easy to replace - every kit includes a detailed
assembly instruction.

Contact us
parts@bromma.com
92

RG-2021-02-26-revision.indd 92 2021-03-02 14:06

 Bromma Spreader Upgrades
Bromma offers a range of spreader upgrades that can
significantly improve the day to day operation of your
spreader, extending their life and adding new or enhan-
ced functionality that will make them safer, more pro-
ductive and efficient to operate.

Safety Productivity Uptime

Upgrades
• Load Sensing System
• MHC Spreader Contol Level-
ling System
• Twin-Twenty Detection system
upgrade • YSX40E/45E New Telescopic
• Locking Pin for MHC Spreaders
• Twistlock Service Kit
• Load Cell Kit for RS &RSX40
• Flipper tie
• Safety Access for MHC towers
Upgrades
• Height Indication System
• SCS3 to SCS4
• SCS2 CANOpen to SCS4
• Six Paddle Flipper Upgrade
Drive
• SCS4 to SCU with RML
• Centre power pack for MHC
• Hawkeye
• Spreader Monitoring System
• RVP for SCS4 spreader
• SID for SCU spreader
Upgrades
• Autolubrication System
• Flipper Arm Acuator SB18
• Spring steel flipper arm
• Truck lamp replacement
• HydOpti
• Flat shaft flipper gearbox
• SCS4 damping buffer
• CAN filter kit

93 More information at www.bromma.com/services/spreader-upgrades/

RG-2021-02-26-revision.indd 93 2021-03-02 14:06

 Units and conversion tables
Length
1 ft = 0,3048 m 1 in = 25,4 mm
1 m = 3,2808 ft 1 mm = 0,03937 in
Weight
1 lb = 0,4536 kg 1 ton = 1 t = 2000 lb = 907 kg = 0,893 Lt= 0,907 tonne
1 kg = 2,2046 lb 1 Lt = 2240 lb = 1016 kg = 1,016 tonne = 1,120 ton
1 tonne = 1 mT = 2204 lb = 1000 kg = 0,9842 Lt = 1,103 ton
Volume
1 l = 0,21997 UKgal = 0,26417 USgal

Pressure
1 bar = 10 N/cm2 = 1,02 Kp/cm2 = 14,503 lbf/in2
Power Torque
1 Hp = 0,746 kW 1 Kpm = 9,81 Nm = 7,233 lbf
1 kW = 1,341 Hp
Force Torque
1 Kgf = 1 kp = 9,81 N = 2,2046 lbf 1 Kpm = 9,81 Nm = 7,233 lbf

A = ampere Hz = hertz min = minute

oC = degrees centigrade in = inch n = newton
c/s = cycles per second kg = kilogramme s = second
oF = degrees Fahrenheit l = litre t = tonne
ft = foot lb = pound v = volt
gal = gallon lbf = pound force w = watt
Hp = horse power m = meter mm = micron
94

RG-2021-02-26-revision.indd 94 2021-03-02 14:06

 Bromma Spreader Painting Standard & Color
Bromma Lead Free High-Solids Painting System
Approved /
Author / Updater Version Valid from Document sensitivity Page Document ID
Owned by
Public / Internal /
Christina Ng Daniel Dahlqvist 6.0 30.06.2014 6/27 WI-PI-012
Sensitive / Secret
Bromma Spreader Painting Standard & Color
Bromma has couple of preferred colors, as per below Table:-
Bromma Spreader prefer color range
Orange RAL 2004 Black RAL 7021
(Bromma default (Bromma default
Color - Body) color-Component

Red RAL 3000 Green RAL6018

Luminous Bright Red –

White RAL 9016 RAL 3026

Luminous Bright
Black RAL 9005 Yellow –RAL 1026

Blue RAL 5015 Luminous Orange –

RAL 2007

Signal Yellow RAL 1003

 For any others color requirements ,please confirm with local Bromma product support about avaialbiltity , leadtime,and price.
 Requirements for difference in painting specification such as special paint brand etc
May imply a lot of additional work, cost and risk. As a result for any variation outside Bromma’s painting standard, confirm in
advance with local Bromma Product support/ Bromma factory Quality department is needed.

5.2 Visual colour assessment

Comparative assessment of a part or painted reference plate against a comparison gauge
Shall be done in daylight ( Not in direct sunlight) or with CIE standard CIE standard illiminant

5.3 Gloss
955.3.1 Gloss can only measure correctly on plain smooth surfaces, on bend or rugges surface
glossd must be compared with gloss of the measured test panel

Gloss requirements
- Bright 75+10/-5
- Seminat 30 +10/-5
- Glossmeter 60°

5.3.2 MCI tinted ( Dark color paint)

For those not in the above list, they suppose to through MCI tinting.
RG-2021-02-26-revision.indd 95 2021-03-02 14:06
 Notes:

96

RG-2021-02-26-revision.indd 96 2021-03-02 14:06

 97

RG-2021-02-26-revision.indd 97 2021-03-02 14:06

 Bromma spreader product range:

Ship to shore spreaders:

SSX40/45 STR 40/45 STS45 STS45

(Regular Twin) (Separating Twin) Light Weight

Mobile harbour crane spreaders:

EH5U EH170U MSX45

(Regular Twin)

Yard crane spreaders:

YTR 40/45 YTS45

YSX40/45
(Regular Twin) (Separating Twin)

98

RG-2021-02-26-revision.indd 98 2021-03-02 14:06

 Bromma spreader product range:

All-electric yard crane spreaders:

YSX40E/45E YTR40E/45E YTS45E

(Regular Twin) (Separating Twin)

YSX45E PLUS

All-electric ship to shore spreaders:

SSX40E/45E STR 40E/45E STS45E

(Regular Twin) (Separating Twin)

99

RG-2021-02-26-revision.indd 99 2021-03-02 14:06

 Bromma Spreader Monitoring System
Get an instant single view of the health
condition of every spreader with
Bromma cloud based service, desig-
ned to help you to detect and prevent
spreader failures, prioritize and
plan maintenance operations and
resolve potential problems before
they become real.
The system aggregates key statistics from the spreaders to present
an easy to read overview and identify any current issues. A health
bar indicates the real-time status of particular spreader in your fleet.

Additionally, SMS helps you understand the errors and warnings

from the spreader’s diagnostics system. To make sure the issues are
resolved, each warning includes a list of recommended actions.

With the system you can get an insight on spreader faults, which
occured in the past in order to identify risk areas for downtime or
underperformance. This data makes it easier to improve the overall
productivity of the spreader fleet.

www.bromma.com/sms
100

RG-2021-02-26-revision.indd 100 2021-03-02 14:06

 Bromma Hawkeye
Bromma Hawkeye is a platform of
different kinds of camera configura-
tions prepared and validated for dif-
ferent applications and for installation
on all kinds of spreaders.

The cameras generate video streams that can be used as is on an operator display or
further processed through additional Hawkeye sub-systems, such as Optical Cha-
racter Recognition (OCR), twin-twenty detection and automatic spreader guiding
systems.

Hawkeye stretches the application area of cameras significantly as the design

and validation has been focused on the harsh environment of a STS crane
spreader. A significant part of the development of Hawkeye has been to identify
how to mount cameras on a spreader. Protection of the cameras from impacts as
well as methods for reduction of shock and vibration have been developed and
verified. Depending on the specific need and functionality the spreaders will be
equipped with a suitable configuration of cameras. A setup for Hawkeye OCR
on a spreader capable of twn-20 lifting will for instance include two cameras
installed symmetrical under the main beam of the spreader in order to facilitate
OCR of both single container lift as well as two 20´containers lifted in twin
mode.
101

RG-2021-02-26-revision.indd 101 2021-03-02 14:06

 Load sensing system
The Bromma Container Weig-
hing system weighs containers
with high accuracy as part of
the normal lifting cycle. The
application can weigh individual
containers when lifted, even
in twin-mode. The system and
weighing process will have no
effect on transportation resource
needs and operational flows in
the terminal. In addition to con-
tainer weight and momentary
102 load, the system also measures
RG-2021-02-26-revision.indd 102
eccentricity, i.e. detecting where
the center of gravity of the
loaded container is. Warning and
alarm levels can be set based on
eccentricity. Data from the Con-
tainer Weighing system is sent
via the crane cable to the crane
PLC. The data can be integrated
in the crane PLC logic and also
transferred to other systems if
such connections are availa-
ble. This includes the Terminal
Operating System (TOS) as an
example of such a system. Weig-
hing system is availalbe for crane
and reachstacker spreaders.
2021-03-02 14:06
 103

RG-2021-02-26-revision.indd 103 2021-03-02 14:06

 For nearest contact and latest information on Bromma products and services,
visit the Bromma website at www.bromma.com

Edition 12 Printed in March 2021

104

RG-2021-02-26-revision.indd 104 2021-03-02 14:06