Bromma Manual

4 Start-up Procedures
4.1 Mounting instructions
See Chapter 6.1.3 for tightening torques and thread lubrication.
Tools:
• Spanner NV 17 (M10)
• Spanner NV 19 (M12) + extension socket
• Spanner NV 24 (M16) + extension socket
• Spanner NV 30 (M20) + extension socket
The unmounted Overheight Frame with storage fixture is delivered in
a standard 20' container. The parts are strapped on the fixture frame
body and placed on rolls. They can be pulled out of the container.

• Place one gable (1) on a flat surface.

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• Attach the frame body (2), hanging in a traverser, to the gables

(1).

4
6

5
3 6

• Assemble (1) and (2), using screws (4) with spacers (5), washers
(6) and loc-king nuts (3).
• Assemble the other gable in the same way.
• Verify that the fixture has not been bent or twisted. Adjust mounting
if required.
POS QTY TITLE SUBJECT PART NUM

3 16 NUT LOC-KING M20 DIN 985, FZB CLASS8 75052

4 16 SCREW M6S 20x110 CLASS 8.8, ISO 4014 76842

5 16 SPACER - 47678

6 32 WASHER BRB 21x36x3 FZB, SMS 70 75292

Warning!
Secure the telescopic beams in the main frame
from sliding out of the main frame in the main frame
is tilted. Sliding telescopic beams may cause
damages or personal injuries.

• Pull out the telescopic beam from the main frame enough to mount
the stop plate (7).

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• Assemble the stop plate (7) using screws (8) with washers (9) and
loc-king nuts (10).

10
9

9
8

POS QTY TITLE SUBJECT PART NUM

7 1 STOP PLATE, 20' - 1018504

8 4 SCREW M6S 10x50 A4, CLASS 70, ISO 4014 1000612

9 8 WASHER BRB 10.5x20x2 A4, ISO 7089 47678

10 4 NUT LOC-KING M10 A4, ISO 7089 76520

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21 19
20
12 M
11 13
18

18

13 21
19
14 20
13 16 15
14

22
17
16

• Place the bushings (11) between the halves and connect loosely
using screws (12) with washers (13) and loc-king nuts (14).
• Place the overheight brace (22) between the legs and connect
loosely using screws (15) with washers (16) and loc-king (17).
• Tighten loc-king nuts (14).
• Tighten loc-king nuts (17).
• Assemble the other gable in the same way.
• Place the mounted storage fixture on a flat surface. Place the two
gables in the mounted storage fixture using a traverser. Make sure
the gables stand vertical and that they are firmly fixed.

Warning!
Make sure the gables cannot fall! Serious injury by
crushing may occur.

• Arrange a steady platform to stand on when assembling the main

frame assembly with gables.

Warning!
Make sure no falling accidents can occur.

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• Lift the main frame assembly (M) towards the gables using a
traverser.
• Assemble the main frame with the gable using 8 screws (18), each
with a spacer (20), two washers (19) and a loc-king nut (21).
• Assemble the other gable in the same way.
• Lift the mounted Overheight Frame a few centimeters from the
storage fixture . Verify that the frame has not been bent or twisted.
Adjust mounting if required.
POS QTY TITLE SUBJECT PART NUM

11 4 BUSHING Dy=50, di=22, H=19,5 1018205

12 4 SCREW M6S 20x320 FZV, CLASS 8.8, DIN 931 1018951

13 8 WASHER BRB 21x36x3 FZV, HB200, SMS 70 701558

14 4 NUT LOC-KING M20 DIN 985, FZB, CLASS 8 701549

15 16 SCREW M6S 12x40 A4, CLASS 70, ISO 4014 77894

16 32 WASHER BRB 13x24x2 A4, HB200, SMS 70 77897

17 16 NUT LOC-KING M12 DIN 985, A4, KLASS 70 77891

18 16 SCREW M6S 16x110 FZB, 10.9 ISO 4014 70589

19 40 WASHER BRB 17x30x3 FZB, HB200, SMS 70 75296

20 16 SPACER Dy=36 Di=16.9 L=35 1149081

21 20 NUT LOC-KING M16 DIN 985, FZB, CLASS 8 1162811

22 2 OVERHEIGHT BRACE OSR45 1136727

4.2 Dismounting instructions

All demounting to be performed as per the mounting instructions, but
in the reverse order.

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4.3 Quick Installation Guide

Prepare the gable end mountings. Assemble the centre welded frame to the gable
end mountings.

Assemble the Gable Unit Type 1, Gable Unit

Type 2 and Overheight Brace.

Place the Gable Unit Assembly into the com-

plete fixture.

Assemble both ends of the frame assembly to

both of the Gable Unit Assembly.

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4.4 Twistlock and telescopic test

• Connect the OSR45 to a parent spreader and use a container or
other cargo with ISO twistlock corners. Test all handling
combinations according to A to F in Chapter 5: Handling
instructions. Just lift a few centimeters and make sure that all four
twistlocks lock and unlock as intended.
• Telescope the spreader to desired size from 20 to 45 foot. The
mid beam will follow the telescoping beam unit that, for the moment,
has the largest friction. When reaching the inside stop, the opposite
telescoping beam unit will extend. The reverse will occur when
retracting. This is normal. Land the OSR45 on the storage frame.
• Make a note in Chapter 9: Service notes about the results of the
start-up procedure. If any problems were encountered please note
them and contact Bromma.

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5 Handling Instruction
5.1 Warnings
• The spreaders used must be equipped
Spreader
lug with specially adapted lugs for the Bromma
Spreader
OSR45 to lift the Overheight Frame in the
latching hooks. Spreader lugs can be
ordered from Bromma. Please note that
Overheight
frame
Latching the spreader lug design may differ depend-
hook
ing on the spreader model.

Note!
Maintain a safe dis-
tance of 5mm from the
Overheight Frame when
connected to a spread-
er that is in operational
mode.

• When parking the Overheight Frame in

the storage fixture, the speed must be re-
duced to prevent damages and to avoid
moving the storage fixture.

• If the storage fixture is not locked in its

position, hoist the Overheight Frame
above the storage fixture before moving
the crane, to avoid moving the storage
fixture.

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• The Overheight Frame must be parked in

the storage fixture in the 20' position.

5.2 How it Works

Lock-
Land
unlock

Attaching
the OSR45 Hoist

• Land on the OSR45

• Lock and unlock the spreader twistlocks.
• The latching arms will connect to the lugs on the spreader.

Note!
Make sure the plunger on each leg is secured.

• Begin to hoist.

Land
Lock

Picking
up cargo

Hoist

• Land on the cargo.

• Lock the twistlocks.
• The spreader twistlocks will lock to the OSR45 and the OSR45
twistlocks will lock to the cargo.
• The latching arms will still be locked but there will be a clearance
between the latching arms and the spreader lugs.

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Leaving
the cargo

Land Unlock Hoist

• After landing, unlock the twistlocks.

• The spreader twistlocks will unlock from the OSR45 and the OSR45
twistlocks will unlock from the cargo.
• When hoisting, the latching arms will engage to the spreader lugs.

Leaving the
OSR45 in
the storage
fixture
Land Hoist

• The push rods will be pressed upwards, releasing the plunger.

• The latching arms will be released from the spreader lugs.

Lock
Picking up
the storage
fixture
Land Hoist

• After landing, lock the twistlocks.

• The spreader twistlocks will lock to the OSR45 and the OSR45
twistlocks will lock to the storage fixture.
• The latching arms will still be locked but there will be a clearance
between the latching arms and the spreader lugs.

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Unlock
Leaving
the storage
fixture
Land Hoist

• After landing, unlock the twistlocks.

• The spreader twistlocks will unlock from the OSR45 and the OSR45
twistlocks will unlock from the storage fixture.
• When hoisting, the latching arms will engage to the spreader lugs.

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6 Maintenance
Warning!
To ensure safe and reliable operations it is
important that regular maintenance procedures are
performed at specified intervals.

6.1 Periodic maintenance procedure

The service intervals specified are for normal operations where
moderate temperature, humidity and atmospheric conditions prevail.
In areas of extreme conditions, the service periods and lubrication
specifications should be altered to meet existing conditions.

6.1.1 After 3 months

1 Inspect the Overheight Frame and storage fixture for visible
damage.
2 Clean moving parts (if required), lubricate and check according to
Lubrication Instructions below.
3 Twistlocks: Check the nut and the floating mechanism and ensure
that all parts are properly tightened. Check that the twistlock pin
can be moved easily and that it indicates the correct position.
4 If adjustment to the twistlock is needed:

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a Remove the M8 screw and nut from the twistlock.

b To lower the twistlock, loosen the twistlock nut
slightly. To raise the twistlock, tighten the nut. The
distance between the top of the twistlock head and
M8 the bottom of the guide block is 1-2 mm.
Screw c Recheck the float of the twistlock.
d Re-install the M8 screw.
e Re-tighten all screws according to Tightening
Torques below (only for the first 3 months of ser-
M8 vice).
Nut
Twistlock f Test all handling combinations according to A to
nut F in Chapter 5: Handling instructions. Just lift a
few centemetres and make sure that all four
twistlocks lock and unlock as intended.

Twistlock pin

Floating
distance
1-2mm

6.1.2 Annually
1 Perform the service points as in the sections above.
2 Dismount moving parts in the storage fixture, clean and lubricate
them.
3 Dismantle all twistlocks.

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a Inspect all the parts. Look for any damage which

could necessitate their replacement.
Twistlock nut
b Check that there are no cracks (or any other faults)
in the threads of the twistlock pins or heads. Use
Spherical washer penetrating fluids to detect fissures.
c Replace the twistlock pins and nuts if cracks are
detected.
d Clean and lubricate all parts.
e Reassemble the twistlocks.

Twistlock pin

6.1.3 Maintenance actions

This summary table lists maintenance actions to be taken after certain
operating time intervals.
General Maintenance Actions: Every 3 months: Annually

Visible damage inspection X X

Lubrication* X X

Dismount storage fixture mechanism X

*According to instructions. See also Lubricants, general
recommendations.
Twistlocks Maintenance Actions: Every 3 months: Annually

Tighten, check functions X X

Dismantle, inspect, perform crack detection X

Note!
To be able to follow-up on the maintenance history
of this equipment, it is of great importance to make
notes of all service and replacement of spare parts.
This can be done in Chapter 9 Service Notes.

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6.1.4 Lubrication instructions

Following the designated lubrication procedures is important in order
to ensure maximum equipment life. The procedures and lubrication
chart in this section include information on the types of lubricants
used, the location of the lubrication points, lubrication and methods
of application.
Lubricants, general recommendations
Specific recommendations of brand and grade of all lubricants are
only examples due to regional availability, operating conditions and
the continual development of improved products. Where questions
arise, refer to the manufacturer's specifications and a reliable supplier.
Grease
Lubricating grease of the proper consistency is to be applied at
frequent intervals with grease guns through the grease fittings or with
a brush, where applicable. Lithium base NLGI#2 is recommended
(example: Matrix EP2).

The grease can be ordered from Bromma e-commerce site (see

Chapter 7.1 How to order spare parts).
Lubrication points
Lubricate the points shown below at intervals described in Chapter
6.1 Periodic maintenance procedures:
Twistlocks, latching hook system, storage fixture- moving parts
1 Inject grease in through grease fittings.
2 Brush grease on marked moving parts.

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2
2

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Glide plates
Expand to maximum position and apply grease on top and on the
bottom sides of the telescopic beams.

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6.1.5 Tightening torques

General information
The tightening torques in the following tables are Bromma's
recommendations when tightening screws and nuts. Screws and nuts
are combined when they have the same strength class.
8.8 screw and class 8 nut

10.9 screw and class 10 nut

12.9 screw and class 12 nut

Note!
Nuts of higher class can always replace nuts of a
lower class.

A torque wrench is recommended to achieve prescribed tightening

torque (dispersion 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.
Torque wrench

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 is done with a pneumatic impact wrench, the tightening torque should be reduced by ap-
proximately 5 % because of the risk of overloading.

If treated screws (FZB, Zinc flake or similar) are in dry condition, some thread lubricant (oil, grease
or 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 tightening. 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.

Bromma Torque Guidelines for BRB washers

Tightening torque, Nm
Stainless, Wax, BRB
Screw (FZB, Zinc flake); Oil; BRB washer
washer
A2, A4 class 70
Type: class 8.8 (v=0,80) class 10.9 (v=0,74) class 12.9 (v=0,74)
(v=0,71)
M4 2,6 3,4 4,1 1,6

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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:

v = ratio of yield point
µt = 0,125 (thread friction)
µw = 0,125 (washer friction)

For A2, A4 class 70, the torque is 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
Bromma Torque Guidelines for Nord-Lock washers
Tightening torque, Nm
Screw (FZB, Zinc flake); Oil; Nord-Lock washer Stainless, Wax, NL
A2, A4 class 70
class 8.8 (v=0,75) class 10.9 (v=0,71) class 12.9 (v=0,71)
Type: (v=0,65)
µt=0,15 µw=0,19 µt=0,15 µw=0,15 µt=0,15 µw=0,13
µt=0,13 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)

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M20 510 602 676 (242)

M24 878 1036 1165 (418)

M30 1750 2064 2318 (831)

Torque in the table above refers to:

v = 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.

Reference:
"Torque guidelines - Nord-lock", www.nord-lock.com

Note!
Information used in this guideline has been taken
from BR1166868 (rev. c), and is applicable for
torque values for screws in the Main Beam and
Telescopic Beam.

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