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RAM SPREADERS
TREINAMENTO
2700 SERIES
TELESCOPIC SPREADERS
FOR
CONTAINER LIFTING CRANES

Date: 1-Maio-2015
By: Jean Moreira

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CONTENTS:

1. PROCEDIMENTOS BÁSICOS DE SEGURANÇA

1. INTRODUÇÃO RAM SPREADERS

2. CARACTERISTICAS SPREADER

3. MANUTENÇÃO & SERVIÇOS RAM SPREADERS

4. DETECÇÃO BASICA DE FALHAS

5. Q&A

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PROCEDIMENTOS BÁSICOS DE
SEGURANÇA

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Basic Safety Procedures
Important !
 Comissionamento, operação, manutenção e assistência técnica do spreader
deve ser realizada por pessoal familiarizado com os riscos relacionados.

 Mantenha-se afastado de todas as partes móveis durante o teste, por exemplo,


reúnem guias, cadeia telescópica etc.

 Durante a inspeção ou manutenção, é aconselhável colocar sinais de alerta ou


barricadas.

 Desligue fonte de alimentação e desconecte conectores


elétricos nas suas verificações de isolamento. por exemplo
E-stop, chave seccionadora.
 Nunca carregar o spreader mais do que o SWL atribuído.
 Realizar exames periódicos para garantir que os bloqueios
de segurança previstas no spreader estão funcionando
corretamente.

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INTRODUÇÃO RAM SPREADERS

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Introduction: RAM Spreaders & Features
RAM Singlelift Telescopic Spreaders
2700 Series Spreaders:

RAM Telescopic Spreaders

S.W.L. Singlelift 40 Tonnes

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Introduction: RAM Spreaders & Features
RAM Singlelift Telescopic Spreaders
Posição Padrão Spreaders :

Singlelift: 20 Ft – 5853 mm
40 Ft – 11985 mm

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Introduction: RAM Spreaders & Features
RAM Singlelift Telescopic Spreaders
3 Principais Seções Estruturais - Centre body
- Telescopic Arm
- CG Tower Assembly
4 Mecanismos Funcionais - Telescopic Drive
- Twistlock & Land pin
- TwinLift
- CG Tower

2 Sistema de Controles - Elétrica


- Hidraulica

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CARACTERISTICAS SPREADER

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Spreader Features
 Actuator Sensor Interface (ASi) Slave Module

 2 fios do sistema de comunicação


 Menos fiação, facilidade de resolução de
problemas e mais efetivo
 Usando cabo flat para comunicação
Black: 24VDC Power Supply
Yellow: 30.5VDC ASi Supply

 O funcionamento do módulo é livre de manutenção


 Fabricante: IFM

 Part No.: AC2457 – 4 inputs


AC2459 – 4 inputs 4 outputs

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Spreader Features
 Actuator Sensor Interface (ASi) Slave Module
LED 2 ASI
LED Status of ASi Slave Module LED 1

 LED 1 yellow = input / output switch

 LED 2 green = ASi supply voltage ok


LED AUX
 LED AUX = AUX supply voltage ok

 LED 3 red aceso = ASi erro comunicação, escravo não


participar na comunicação de dados "normal", por exemplo,
endereço do escravo 0..

 LED 3 red piscando = escravo com defeito, por exemplo


alimentação do sensor / saída sobrecarregada ou em curto.

LED 3

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Spreader Features
 Sensor Cable Connector

 Classificação: 24VDC.

 Com Indicação de LED.

 LED Status
Green = Sensor em Operação
Orange = Sensor Acionado

 3 Cabos (Brown = +ve, Blue = -ve & Black = output)

 Fabricante: MURR Elektronik

 Part No: 7000.40321.633

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Spreader Features
 Proximity Switch

 Classificação: 24VDC.

 Distancia de Acionamento Sensor: 15mm.

 Distancia Segura de Acionamento: 12.15mm.

 3 Pin (Pin 1 = +ve, Pin 3 = -ve & Pin 4 = output.

 LED Status
Orange = Sensor Acionado

 Fabricante: IFM

 Part No: II5910

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Spreader Features
 Proteção contra Surto

 Para proteger os componentes a constantes picos de


tensão
 Spreader Controle de Alimentação precisa estar 'ON'
durante a verificação

 LED Status
Green LED = Protected
Red LED = No Protected

 Fabricante: Phoenix Contact

 Part No: PT2-PE/S-120AC-ST (120VAC)


PT-BE/FM (Base)

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Spreader Features
 LoadLite LED Lampadas de Indicação (Opcional)

 Fornecer sinal de cor instantânea indica o status da movimentação de


contêineres.
 Exemplo:
 Green – spreader twistlock pino Destravado
 Red – spreader twistlock pino travado
 Amber – Apalpado
 Blue – Twinlift mode
 Para a movimentação de contêineres mais rápido e mais seguro com alta visibilidade
indicando o status Spreader e container.

 Part No.: E5814.BWGR

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Spreader Features
 Twistlock Pino

 Agir como um intertravamento mecânico


 Previne o Pino twistlock de rodar quando está
com o container.

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Spreader Features
 Landpin Mechanical Interlock (optional)

 Para evitar twistlocks Travar / Destravar o contatiner no embarque e


desembaque.

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MANUTENÇÃO & SERVIÇOS
RAM SPREADERS

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Maintenance & Servicing for RAM Spreaders
Recomendado manutenção preventiva de rotina (MP) para Spreader:
1) Verifica Sistema de Controle Elétrico

2) Conjunto Twistlock

3) Locks / Unlocks Sensors Instalação

4) Conjunto Land Pin

5) Landed Sensors Instalação

6) Hydraulic System Checks

7) Telescopic Assembly

8) CG Tower Assembly

9) Structure Checks

10) Greasing & Functional Checks

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1. Electrical Control System
Checks

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Maintenance & Servicing for RAM Spreaders
1) Electrical Control System Checks
 Tensão de alimentação
3 fases, 400VAC, 60Hz, Delta Ligação

Motor elétrico Potência = 13 KW


(Consumo de Energia = 11 KW)

Controle de Tensão = 24VDC

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Maintenance & Servicing for RAM Spreaders
1) Electrical Control System Checks
Para realizar um controlo de isolamento do motor elétrico,
remova os três fios de fase a partir do bloco de terminais
do motor e usar megometro de alta tensão (1000V Mega)
para verificar se há:

Fase de resistência de terra (não inferior a 2 M ohm)


Fase a fase de resistência (diferença de 0,2 ohm)

 Verifique visualmente o plugue para qualquer


anormalidade, Pino de conexão desgaste etc.
 Verifique todos os fios elétricos não estão danificados.
 Confira todos os plugues de válvulas para aperto, confirmar
que as bobinas magnéticas não estão soltas.
 Verifique acoplamento do motor se não há desgaste.

CUIDADO: Certifique-se de fonte de alimentação é desligada durante o teste de isolamento

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2. Twistlock Assembly

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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
Durante cada MP o Conjunto
Twistlock deve ser desmontado Land Pin Cap
Push Pull Rod
para a verificação.
Land Pin Washer

Verifique o pino twistlock, Twistlock Cap


Land Pin Spring
Twistlock guia, Arruela Esferica,
Colar de Separação, Arruela Split Collar

duporte do Twistlock e Capa


Twistlock. etc para o desgaste Spherical Washer
ou danos.
Centre Plate
Twistlock pin, twistlock guide,
spherical washer & split collar
should be lightly greased before
assembly Support Washer Land Pin

Twistlock Sleeve

Base Plate
Twistlock Guide
Twistlock Pin

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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
Twistlock Pin
MPI

Dismantle & check each twistlock pin for cracks


or wear during each PM
MPI
(MPI ,Magnetic Particle Inspection is
recommended)

If crack lines are observed, replace the twistlock


pin.
MPI

Part No.: 1502 09 4405

MPI
MPI

CAUTION:
Twistlocks pin must not be repaired by welding or subjected to excessive
heat as this may impair the mechanical properties

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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
Split Collar

 The twistlock pins are machined with a gooseneck


Split Collar
in which the split collars fit.
Spherical Washer
 The split collars are held in the gooseneck by the
twistlock cap.

Gooseneck
 This should be assembled with lubricant or anti-
seize compound.

 The split collar should be replace together with the


twistlock pin.
Twistlock Pin

 Part No.: 1501 09 4903

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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
Spherical Washer

 The split collar rests on the spherical washer (pair).


Split Collar

 The spherical washer transfers the load from the Spherical Washer
twistlock onto the centre plate of the twistlock box.

 The spherical washer accommodates the horizontal Gooseneck


float of the twistlock and is subject to wear.

 It should be checked for cracks or wears periodically,


replace if require.
Twistlock Pin
 Default combine thickness of spherical washer (pair)
is 14 mm, replace if wears > 1 mm.

 Part No.: 1501 09 5001

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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
Twistlocks Guide Support Washer

 The twistlock guide acts as the rubbing face


when entering the corner casting and protects
the twistlock shank from wear. Twistlock Sleeve

 When the twistlock guide side face gets worn,


it should be replaced.

Twistlock Guide
 Part No.:
End Frame Twistlock Guide: 1502 09 4606
Twinlift Twistlock Guide: 1502 09 4601
Twinlift Twistlock Sleeve: 1502 09 4502
Twinlift Support Washer: 1502 09 5102

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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
Twistlocks Cap

 The twistlock cap serves 2 functions.


Push Pull Rod
 As a cam for the push pull rod to rotate the
twistlock.

 As a mechanical interlock to prevent twistlock


from rotate.

 Part No.:
End Frame Cap LH: 9813-09-05 Keep Plate
End Frame Cap RH: 9813-09-04
Twistlock Cap

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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
After assemble the twistlock assembly, check and ensure
 Twistlock protrusion is 44 ~ 46 mm

 If protrusion is more than 46 mm, replace spherical washer

44~46
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Maintenance & Servicing for RAM Spreaders
2) Twistlock Assembly
Check the twistlock vertical float is within 1 ~ 3 mm
 if the clearance > 3 mm, replace twistlock guide (End Frame) or support washer /
twistlock sleeve (Twinlift Housing)
 Default height of twistlock guide (End Frame) = 78 mm; support washer = 20 mm
& twistlock sleeve = 140 mm

Spherical Washer

1 ~ 3 mm
Support Washer

Twistlock
Sleeve

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3. Locks / Unlocks Sensors
Setting

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Maintenance & Servicing for RAM Spreaders
3) Locks / Unlocks Sensors Setting
The twistlock Lock / Unlock positions are achieved by actuating twistlock cylinder to rotate
twistlock assembly 90o. Full stroke of cylinder = 100 mm.

Twistlock Locks / Unlocks sensors setting are as follow:

Lock Position Unlock Position

85 mm 15 mm

Lock signal set ‘ON’ by extend Unlock signal set ‘ON’ by retract
twistlock cylinder to 85 mm twistlock cylinder to 15 mm

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Maintenance & Servicing for RAM Spreaders
3) Locks / Unlocks Sensors Setting
Corner End Frame Twistlock Sensors:
Recommended sensing gap for the corner twistlock proximity sensor is within 6 ~ 8 mm.

The twistlock is jostled in all directions to confirm that the setting is within range and
target is not hitting the sensors.

Corner Twistlock Sensors Arrangement

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4. Land Pin Assembly

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Maintenance & Servicing for RAM Spreaders
4) Land Pin Assembly:
Land Pin are provided at each of the
twistlock box to indicate spreader is rested
on top of container and as a mechanical
interlock for twistlock pin

Visual check Land Pin condition for any


wears, dent or corrosion. Ensure that the
Land Pin is not jammed and carry out
lubrication during PM
21 mm
Check and ensure the Land Pin protrusion
is about 21 mm

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5. Landed Sensor
Setting

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Maintenance & Servicing for RAM Spreaders
5) Landed Sensor Setting:
1 sensor is used at each land pin assembly:-

Landed Sensors are used for indicating the spreader is resting / landed on top of the
container.

End Frame Land Pin arrangement

Twinlift Housing Land Pin arrangement

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Maintenance & Servicing for RAM Spreaders
5) Landed Sensor Setting
Landed Position
21 mm Landed signal setting (M30) as shown:

Landed signal set ‘ON’ by pushing land pin upward


15 mm or inserting a land pin fork (15 mm).

Ensure that Landed signal is ‘OFF’ while land pin is


rested or in holding position.

Recommended sensing gap = 6 ~ 8 mm.


15 mm

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6. Hydraulic System Checks

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Maintenance & Servicing for RAM Spreaders
6) Hydraulic System Checks
Check Hydraulic Oil level (oil grade - ISO VG46)

Visually check for any external leakage. E.g. cylinder, actuator, gearbox etc

With spreader pump ‘ON’, check the following:

1. Return line filter indicator Green – good


Red – choked

2. System pressure 165 kgf/cm2

3. Twistlock pressure 50 kgf/cm2

4. Electric motor current (to check for flow rate ~ 50 l/min)

idle – 8 ~ 10 A
telescopic – 14 ~ 16 A
(about 10% less but not more than rated current, e.g. 18A)

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Maintenance & Servicing for RAM Spreaders
6) Hydraulic System Checks
Check the return line filter is not choked

Return Line Filter

Indicator Panel during pump running


Green : Good
Red : Choked

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Maintenance & Servicing for RAM Spreaders
6) Hydraulic System Checks
Spreader Pressure Setting

1) System pressure – 165 kgf/cm2

2) Main relief valve pressure – 175 kgf/cm2

3) Telescopic X-relief valve pressure – 120 kgf/cm2

4) Flipper X-relief valve pressure – 175 kgf/cm2

5) Twistlock reducing pressure – 50 kgf/cm2

6) CG Tower X-relief valve pressure – 200 kgf/cm2

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Hydraulic Power Pack Unit

Pump

Return Line Filter

Unloading Valve

Air Bleed Valve

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Maintenance & Servicing for RAM Spreaders
6a) Hydraulic System Checks

Load Sensing Adjustment


(not in use)

Compensator Adjustment
(Pressure Setting)

Torque Limiter
(Flow Rate Setting)

Pump Drain Line

PVH57 Pump Outlet Port


(Variable Constant
Power Pump)

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Directional
Directional
Valve
Valve
Pressure
Flow Control
Reducing
Valve
Valve
Pressure
Relief Valve Telescopic
Motor

Telescopic & CG Dual


Overcentre
Cylinder Valve Stack Valve

CG Tilt
Cylinder

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Directional Directional
Valve Valve

Pressure
Reducing
Valve

Fixed Orifice
Dia 1.6 mm

Pressure
Relief Valve
End Beam Twistlock &
Flipper Valve Stack

Flipper
Actuator

Twistlock
Cylinder

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Maintenance & Servicing for RAM Spreaders
6) Hydraulic System Checks

Fixed Orifice
Flipper Actuator = 1.6 mm

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8. Telescopic Assembly

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Maintenance & Servicing for RAM Spreaders
8) Telescopic Assembly
Check the Telescopic chain for any slack, tighten turnbuckle nut if required.

(torque value = 55 Nm)

Singlelift Spreader Turn-buckle Layout

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Maintenance & Servicing for RAM Spreaders
8) Telescopic Assembly
Check Turn-buckle Disc Spring for any cracks or damage, replace if required

Singlelift spreader – 8 pairs per turn-buckle; total 2 turn-buckle

Singlelift Spreader Turn-buckle

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Maintenance & Servicing for RAM Spreaders
8) Telescopic Assembly
Singlelift Spreader positioning control by proximity switches, 20ft & 40ft
FRONT LEFT FRONT RIGHT

CABIN LEFT CABIN RIGHT

20FT : 5853 MM
40FT : 11985 MM

Note: Marking on Cabin Left arm & Front Right arm only

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Maintenance & Servicing for RAM Spreaders
8) Telescopic Assembly
Check twistlock pin centre to centre at end frame = 2259 mm.

2259 mm

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9. CG Tower Assembly

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Maintenance & Servicing for RAM Spreaders
9) CG Tower Assembly
The spreader is fitted with a post assembly that can be mover longitudinally to adjust
the spreader Centre of Gravity (CG), to allow for containers that are unevenly loaded.

CG Tower

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Maintenance & Servicing for RAM Spreaders
9) CG Tower Assembly
4 sensors are used for CG position: 2 sensors for STD, 1 sensor for right limit & 1 sensor for
left limit.

CG Tower centre position, 2 STD sensors are activated.

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Maintenance & Servicing for RAM Spreaders
9) CG Tower Assembly

CG Tower tilt right hand side maximum, right STD & limit sensors are activated.

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Maintenance & Servicing for RAM Spreaders
9) CG Tower Assembly

CG Tower tilt left hand side maximum, left STD & limit sensors are activated.

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10. Structure Checks

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Maintenance & Servicing for RAM Spreaders
10) Structure Checks
Check all load bearing area for cracks

Singlelift Spreaders

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11. Greasing & Functional
Checks

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Maintenance & Servicing for RAM Spreaders
11) Greasing & Functional Checks
Grease the Singlelift Spreaders telescopic arm sliding surface & all the wear pads.
Singlelift Spreaders

1) Telescopic function - 20 ft to 40 ft within 26 ~ 30 seconds

2) Twistlock function - within 1.5 seconds

3) Flipper function - within 5 seconds


- ensure Flipper is inside End Frame when in UP position

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Basic Fault Finding

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Basic Fault Finding
Basic Troubleshooting of RAM Hydraulic Spreaders
1. Electric motor does not run or motor trips frequently.
Possible Cause Remedy

No electric supply from crane to main junction Check supply for each phase and phases balanced.
box or main junction box to motor. Check wiring for damages and loose connections.

Main circuit breaker in crane has tripped. Identify cause of overload, rectify and switch on.

Overloading and tripping of supply. Identify cause of overload, rectify and switch on.

Electric motor is damaged. Check and repair or replace motor.

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Basic Fault Finding
Basic Troubleshooting of RAM Hydraulic Spreaders
2. Spreader does not telescope.
Possible Cause Remedy

Electric motor or hydraulic pump not working. Check and rectify or replace as required.

The spreader is not receiving command from Check wiring/command at main junction box & motor
crane. terminal box, etc and rectify as required.
Check for loose connections and damaged cables.

Spreader PLC or slave module is faulty. Check and rectify the spreader PLC or slave module.

Electrical or mechanical interlocks are activated Check whether interlocks are activated and rectify
preventing telescopic motion. situation before giving telescopic command.

Directional valve or solenoid coil faulty Check and rectify directional valve or solenoid coil

Telescopic sliding surfaces are dry. Grease sliding surfaces, wear pads, drive chain and
idler sprocket bearing housing etc.

Chain broken. Replace broken link.

Spreader hydraulic system is faulty. Check hydraulic pressure setting & hydraulic
components.

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Basic Fault Finding
Basic Troubleshooting of RAM Hydraulic Spreaders
3. Twistlocks non-operational.
Possible Cause Remedy

Twistlock not sitting inside container corner If damaged container, use other methods, if improper
casting due to damaged container or improper landing, to raise & lower slowly.
landing.

Electric motor or hydraulic pump not working. Check and rectify or replace as required.

The spreader is not receiving command from Check wiring/command at main junction box & motor
crane. terminal box, etc and rectify as required.
Check for loose connections and damaged cables.

Spreader PLC or slave module is faulty Check and rectify the spreader PLC or slave module

Electrical or mechanical interlocks are in Check whether interlocks in operation and rectify
operation preventing twistlock motion. situation before giving twistlock command.

Directional valve or solenoid coil faulty Check and rectify directional valve or solenoid coil

Twistlock cylinder leaks or damage. Check and rectify or replace cylinder as required.

Twistlock pin assembly is bent or damage. Check & rectify as required.

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Basic Fault Finding
Basic Troubleshooting of RAM Hydraulic Spreaders
4. Flipper non-operational.
Possible Cause Remedy

Electric motor or hydraulic pump not working. Check and rectify or replace as required.

The spreader is not receiving command from Check wiring/command at main junction box & motor
crane. terminal box, etc and rectify as required.
Check for loose connections and damaged cables.

Spreader PLC or slave module is faulty Check and rectify the spreader PLC or slave module

Flipper hydraulic actuator faulty Check and rectify or replace as required.

Directional valve or solenoid coil faulty Check and rectify directional valve or solenoid coil

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Thank You !

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