Maintenance Plan Quarterly Report

For deck cranes & grabs

Date:
Name of Vessel Crane No. & Run Hrs. Master Chief Engineer Year Quarter

No. Activity Interval Last Test/ Jan. Feb. Mar. Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Signature of
Overhaul/ Responsible
Renewal Officer/Engineer

1000 Oil Level & Condition of oil Details.

1001 Hydraulic Oil Arr. Port E/O
1002 Dist. Gear box oil Arr. Port E/O
1003 Hoist winch gear box oil Arr. Port E/O
1004 Luff winch gear box oil Arr. Port E/O
1005 Slew gear box (2 Nos) oil Arr. Port E/O
1006 Cable gear box Arr. Port E/O
1007 Tug wire gear box Arr. Port E/O
1008 Cable turbo clutch Arr. Port E/O
1009 Tug wire turbo clutch Arr. Port E/O
1010 Grab hydraulic oil Arr. Port E/O

1100 Renewal of oil Details.

1101 Crane hydraulic Oil Analysis E/O
1102 Dist. Gear box oil 500 Hrs E/O
1103 Hoist winch gear box oil 500 Hrs E/O
1104 Luff winch gear box oil 500 Hrs E/O
1105 Slew gear box (2 Nos) oil 500 Hrs E/O
1106 Cable gear box 500 Hrs E/O
1107 Tug wire gear box 500 Hrs E/O
3/E & E/O to carry out renewal of oil * Hydraulic oil to be sent fro analysis once in every 6 months
 Maintenance Plan Quarterly Report
For deck cranes & grabs
No. Activity Interval Last Test/ Jan. Feb. Mar Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Signature of
Overhaul/ . Responsible
Renewal * Officer/Engineer

1108 Cable turbo clutch oil 500 Hrs E/O

1109 Tug wire turbo clutch oil 500 Hrs E/O
1010 Grab hydraulic oil 1000Hrs E/O

1200 Visual Inspection Details.

1201 Corrosion on all HP hoses 3 Month 2/E
1202 Oil leakages Arr Port 2/E
1203 Water tightness of cabins 3 Month C/O
1204 Water tightness of doors 3 Month C/O
1205 Appearance –Crane interior Monthly C/O
1206 Appearance- Exterior Monthly C/O
1207 Cabin glass Arr Port C/O
1208 Cable drum belt Arr Port E/O
1209 Tug wire belt Arr Port E/O
1210 Grab electric cable Arr Port E/O
1211 Plug & socket for grab Arr Port E/O
1212 Grab rams Arr Port 2/E
1213 Grab body Arr Port C/O
1214 Grab lips Arr port C/O
1215 Cable socks Arr port E/O
1216 All shackles Arr port C/O
1217 Main motor coupling 6 Month E/O
1218 Machinery foundation pads 6 Month E/O
1219 Main motor terminals 6 Month E/O
1220 Hoist motor drive sleeves 1000 Hr 2/E

Maint Chklst-01 Revision 1 * Date/Hrs as applicable Page 2 of 15

 Maintenance Plan Quarterly Report
For deck cranes & grabs
No. Activity Interval Last Test/ Jan. Feb. Mar Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Signature of
Overhaul/ . Responsible
Renewal * Officer/Engineer

1221 Hoist motor gear 1000 Hr 2/E

1222 Luff motor drive sleeve 1000 Hr 2/E
1223 Luff motor gear 1000 Hr 2/E
1224 Tug wire drum foundation 6 Month C/O
1225 Cable drum foundation 6 Month C/O
1226 Grab pump coupling 1000 hr 2/E
1227 Hoist & luff thimble bush 3 Month C/O
1228 Floating block locks 6 Month C/O

1300 Insulation test Details. E/O

1301 Main Electric motor Arr port E/O
1302 Hydraulic oil cooler motor Arr port E/O
1303 Dist G.B oil cooler motor Arr port E/O
1304 Ventilation blower motor Arr port E/O
1305 Cable drum motor Arr port E/O
1306 Tug wire motor Arr port E/O
1307 Grab electric cable Arr port E/O
1308 Grab motor Arr port E/O
1309 Cable from MSB to crane 3 month E/O

1400 Cleaning Details.

1401 Feed oil filter Arr port E/O
1402 Cool oil filter Arr port E/O
1403 Hoist gear oil filter Arr port E/O
1404 Hyd oil & Winch G. oil cooler Arr port E/O

Maint Chklst-01 Revision 1 * Date/Hrs as applicable Page 3 of 15

 Maintenance Plan Quarterly Report
For deck cranes & grabs
No. Activity Interval Last Test/ Jan. Feb. Mar Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Signature of
Overhaul/ . Responsible
Renewal * Officer/Engineer

1405 Dist G.B oil cooler Arr port E/O

1406 Crane interior Arr port C/O

1500 Working pressure check Details.

1501 Hoist pump 1 6 Month 2/E
1502 Hoist pump 2 6 Month 2/E
1503 Luff pump 6 Month 2/E
1504 Slewing pump 6 Month 2/E
1505 Feed oil pressure Arr port 2/E
1506 Cool line pressure 6 Month 2/E

1600 Filter Renewal Details. 2/E

1601 Feed oil filter 1000 Hr 2/E
1602 Cool line filter 1000 Hr 2/E
1603 X1 Panel air filter 250 Hr E/O
1604 X2 panel air filter 250 Hr E/O
1605 Grab oil filter 1000 Hr 2/E

1700 Electric motor overhauling Details.

1701 Main Electric motor 5 Year E/O
1702 Hydraulic oil cooler motor 2 Year E/O
1703 Dist G.B oil cooler motor 2 Year E/O
1704 Ventilation blower motor 2 Year E/O
1705 Cable drum motor 2 Year E/O
1706 Tug wire motor 2 Year E/O

Maint Chklst-01 Revision 1 * Date/Hrs as applicable Page 4 of 15

 Maintenance Plan Quarterly Report
For deck cranes & grabs
No. Activity Interval Last Test/ Jan. Feb. Mar Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Signature of
Overhaul/ . Responsible
Renewal * Officer/Engineer

1707 Grab electric motor 2 Year E/O

1800 Overhauling Details.

1801 Grab Pump 1000 Hr 2/E
1802 Grab control block 500 Hr 2/E
1803 Cable sheave 2 Year C/O
1804 Cable drum gear box 5 Year 2/E
1805 Tug wire gear box 5 Year 2/E
1806 Hoist winch gear box 5 Year 2/E
1807 Luff winch gear box 5 Year 2/E
1808 Slew winch gear box 5 Year 2/E
1809 Hoist wire sheaves 5 Year C/O
1810 Luff wire sheaves 5 Year C/O
1811 Cable turbo clutch 1000 Hr 2/E
1812 Tug wire turbo clutch 1000 Hr 2/E
1813 Grab assembly 3 Years 2/E

1900 Electrical Controls

1901 Check contacts of contactor Arr Port E/O
1902 Electronic card settings Yearly E/O
1903 Tightness of terminals 3 Month E/O
1904 Joystick condition Yearly E/O
1905 Indicators on desk 3 Month E/O
1906 Slip ring maintenance 3 Month E/O

Maint Chklst-01 Revision 1 * Date/Hrs as applicable Page 5 of 15

 Maintenance Plan Quarterly Report
For deck cranes & grabs
No. Activity Interval Last Test/ Jan. Feb. Mar Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Signature of
Overhaul/ . Responsible
Renewal * Officer/Engineer

2000 Safeties
2001 Hoist limits Arr Port E/O
2002 Jib limits Arr Port E/O
2003 Emergency stop switches Arr Port E/O
2004 Oil low level alarm 3 Month E/O
2005 Oil high temp alarm 3 Month E/O
2006 24 V low insulation 3 Month E/O
E/O
2100 Miscellaneous
2101 Internal lighting check Monthly E/O
2102 Jib lighting check Monthly E/O
2103 Window wiper check Monthly E/O
2104 Cabin fans condition Monthly E/O
2105 Stand still heaters Monthly E/O
2106 Crane greasing Arr port C/O

2200 Leak off test Yearly To be performed only after permission from H.O

2300 Slew bearing Details.

2301 Bearing deflection check Yearly 2/E
2302 Gear back lash check Yearly 2/E
2303 Check grease lines 3 Month C/O
2304 Slew brg bolts tightness chk 6 Month 2/E
2305 Elongation of bolts (10%) 6 Month 2/E

Maint Chklst-01 Revision 1 * Date/Hrs as applicable Page 6 of 15

 Maintenance Plan Quarterly Report
For deck cranes & grabs
No. Activity Interval Last Test/ Jan. Feb. Mar Apr. May Jun. Jul. Aug. Sep. Oct. Nov. Dec. Signature of
Overhaul/ . Responsible
Renewal * Officer/Engineer

2400 Checks prior operation

2401 Grabs connection C/O
2402 Tug wire & cable shackles C/O
2403 Grab cable connection E/O
2404 Try out crane & grab C/O
2405 Grab hydraulic pressure 2/E
2406 Crane lighting E/O
2407 Check & lubricate thimbles C/O

2500 Checks during operation

2501 All oil levels E/O
2502 Oil leakages E/O
2503 Oil temperature E/O
2404 Smooth operation of sheave D/O
2405 Abnormal noise & vibration D/O
2406 Slew bearing greasing E/O
2407 Proper handling of cranes D/O
2408 Greasing of grabs C/O

2600 Checks after operation

2601 Proper parking of cranes C/O
2602 Grab machinery space clean C/O
2603 Protection covers for grabs C/O
2604 Cable plug & socket covers E/O
2605 Greasing of exposed ram C/O

Maint Chklst-01 Revision 1 * Date/Hrs as applicable Page 7 of 15

 OIL LVEL , CONDITION CHECKS AND OIL RENEWAL
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Main hydraulic system oil: Type of oil T32, Total quantity 850 Lts. Gauge glass is provided on the
tank to monitor the oil level. Oil should be always visible on the top half of the gauge glass even when
the crane is in operation. Sample to be sent ashore for analysis and oil to be renewed as per the
report.

Distribution gear box oil: Type OMALA 220 Quantity 9Lts.Oil level is monitored by a dip stick
provided in the filling line. Oil level should be strictly maintained between max & min limit. Less oil
will result in permanent damage to the gears but more oil will also result in high temperature of oil. Oil
should be renewed after every 500 running hours. Oil level to be checked only when crane is in STOP
condition. Oil should also be checked for contamination, like loss of viscosity due to continuously
operating in high temperature or presence of hydraulic oil in the gearbox. If any contamination or
degradation of oil observed, oil to be renewed immediately and cause to be investigated and rectified.

Hoist winch gear box oil: Type OMALA 220 Quantity 15.5 Lts Oil level is monitored by a dip stick
provided in the filling line. Oil level should be strictly maintained between max & min limit. Less oil
will result in permanent damage to the gear box. Oil should be renewed after every 500 running
hours. Every time when oil is added to the gear box, oil level is to be checked after settling time of 5
minutes. Oil level to be checked only when crane is in STOP condition. Water ingress, loss of
viscosity, hydraulic oil ingress and oxidation are to be checked. If any contamination or degradation of
oil observed, oil to be renewed immediately and cause to be investigated and rectified.

Luff winch gear box oil: Type OMALA 220 Quantity 5 Lts Oil level is monitored by a dip stick
provided in the filling line. Oil level should be strictly maintained between max & min limit. Less oil
will result in permanent damage to the gear box. Oil should be renewed after every 500 running
hours. Every time when oil is added to the gear box, oil level is to be checked after settling time of 5
minutes. Oil level to be checked only when crane is in STOP condition. Water ingress, loss of
viscosity, hydraulic oil ingress and oxidation are to be checked. If any contamination or degradation of
oil observed, oil to be renewed immediately and cause to be investigated and rectified.

Slewing gear box oil(2 Gear box): Type OMALA 220 Quantity 8.5 Lts X 2 Oil level is monitored by
gauge glass provided on the gear box. Oil level should be strictly maintained between max & min
limit. Less oil will result in permanent damage to the gear box. Oil should be renewed after every 500
running hours.Hydraulic oil ingress and oxidation are to be checked. If any contamination or
degradation of oil observed, oil to be renewed immediately and cause to be investigated and rectified.

Cable drum gear box: Type OMALA 220 Quantity 4.85 Lts Oil level is monitored by dip stick which
has to be carried along to check oil level. Oil level should be strictly maintained between max & min
limit. Less oil will result in permanent damage to the gear box. Oil should be renewed after every 500
running hours. Water ingress, loss of viscosity, hydraulic oil ingress and oxidation are to be checked.
If any contamination or degradation of oil observed, oil to be renewed immediately and cause to be
investigated and rectified.

Cable drum gear box: Type OMALA 220 Quantity 2.25 Lts Oil level is monitored by gauge glass.
Oil level should be strictly maintained between max & min limit. Less oil will result in permanent
damage to the gear box. Oil should be renewed after every 500 running hours. Water ingress, loss of
viscosity, hydraulic oil ingress and oxidation are to be checked. If any contamination or degradation of
oil observed, oil to be renewed immediately and cause to be investigated and rectified.

Turbo clutch Cable: Type T22 Quantity 1.95 Lt. Low oil level will lead to reduced cable tension and
high oil level will raise the oil temperature and blow the safety plug. Never fill up the turbo clutch
completely. Oil to be renewed every 500 Hrs

Turbo clutch tug wire: Type T22 Quantity 1.8 Lt. Low oil level will lead to reduced cable tension and
high oil level will raise the oil temperature and blow the safety plug. Never fill up the turbo clutch
completely. Oil to be renewed every 500 Hrs

Grab Hydraulic oil: Type T46 Quantity 250 Lt. Oil level is monitored by a dip stick provided in the
filling line. Oil level should be strictly maintained between max & min limit. Less oil will result in
permanent damage to the pump. Oil should be renewed after every 500 running hours if quality has
deteriorated. Oil level to be checked when grab is closed condition.
 Maintenance Plan
For deck cranes & grabs
No. Activity Interval Last Test/ Jan. Feb. Mar Apr. May Jun. Jul. Aug.
Overhaul/ .
Renewal *
top

Maint Chklst-01 Revision 1 * Date/Hrs as applicable

 VISUAL INSPECTION
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Corrosion of HP hoses: HP hoses which are exposed to weather are more likely to get corroded.
Thorough inspection has to be carried out once in 3 months to renew the corroded hoses.

Oil leakages: All oil leakages should be checked and rectified before arrival port.

Water tightness and appearance: Water tightness and appearance of crane should be regularly
checked.

Cable and tug wire drum belts: Belt tension and condition of drive belts in tug wire and cable turbo
clutch to be checked before arrival port. Wrongly adjusted belt will reduce the tension of cable and
may cause damage to cable & cable sheave on longer run(due to flapping of cable).

Grab cable plug and socket: Grab cable should be inspected thoroughly for physical damage. Plugs
and sockets should be checked for loose connection electrical burning and water tightness

Grab: Grab body to checked for physical damage, weakening of rib plates, damage to grab lips etc.
Rams to be checked for pitting. Cable socks to be checked for damage and shackle condition to be
checked.

Motor coupling and foundation pads: To be checked for break/cracks. Foundation bolt tightness to
be checked. Terminal box to be opened and all terminal tightness to be checked.

Drive sleeves: Luff drive sleeve and hoist drive sleeve ( 2 Nos ) to be checked for wear down. Wear
down on drive gear and drive sleeve splines to be measured and recorded. Same to be sent to H.O.
Note: Drive sleeve failure can cause free fall of cargo or jib. Report format

Tug wire and cable drum: Foundation to be checked for corrosion.

INSULATION TEST
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Megger test to be carried out on following devices.

• Main Electric motor

• Hydraulic oil cooler motor
• Dist G.B oil cooler motor
• Ventilation blower motor
• Cable drum motor
• Tug wire motor
• Grab electric cable
• Grab motor
• Cable from MSB to crane

Poor water tightness of grab cable and plug will lead to poor insulation. Ensure proper water
tightness of grab plug and socket. Low insulation alarm in control room which comes on and
off is most likely from the grab. Grab plug covers to be put back immediately to avoid water
or dust entering into the terminals.
 COOLERS AND FILTERS
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Coolers: Hyd oil cooler and distribution gear box oil cooler to be cleaned after use of cargo gear.
Cleaning regularly with compressed air maintains the coolers clean. At times if the cooler is more
dirty because of the dusty operating condition, air cooler cleaners may be used to clean. Dirty air
coolers will lead to high temperature of oils and stoppage of cranes.

Filters: To be cleaned regularly for proper operation of cranes. Filters to be renewed as mentioned in
the table. Hoist winch gear box filter is fitted with a magnetic trap. Inspect for metal particles attached
to the magnet. Back

Filter renewals
Feed oil filter 1000 Hr
Cool line filter 1000 Hr
X1 Panel air filter 250 Hr
X2 panel air filter 250 Hr
Grab oil filter 1000 Hr

WORKING PRESSURE CHECK

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Max working pressure to be checked and recorded

Procedure: Fit the pressure gauge to the point where pressure is to be checked. Press the solenoid
valve manually and record the pressure. ( do not press the solenoid for more than 5 sec.)

Hoist pump 1 Hoist UP 320 bar Lower 100 Bar

Hoist pump 2 Hoist UP 320 bar Lower 100 Bar
Luff pump Jib up 280 bar Lower 100 bar
Slewing pump Slew Left 315 bar Slew right 315 bar
Feed oil pressure Always 30 bar
Cool line pressure Always 15 Bar

ELECTRIC MOTOR OVERHAULING

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Main Electric motor 5 Year
Hydraulic oil cooler motor 2 Year
Dist G.B oil cooler motor 2 Year
Ventilation blower motor 2 Year
Cable drum motor 2 Year
Tug wire motor 2 Year
 OVERHAULING
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Grab Pump: Renew shaft seal of the pump if oil is found between the coupling. Dismantle the pump
and inspect the control washer. Renew if necessary. Check piston rings, check coupling. Grab pump
Overhaul, oil renewal and filter renewal to be carried out together.

Control Block: Open the pressure adjustment valves and no return valves, clean thoroughly, check for
damaged ‘O’ rings and seals.

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SLEW BEARING DEFLECTION

All types of bearings have when delivered, a certain amount of play. Therefore it is necessary to
check the bearing play from time to time to ensure the safe functioning of the bearing unit.

For this purpose, starting with the jib in zero position, 8 measurement points are fixed on the
th
circumference. The measurement is carried with an suitable instrument having an accuracy of 1/10
of an mm. The measuring instrument can be placed in the grease collecting tray. The measurement is
taken with pre conditions no load min radius and max load max radius. The readings are compared
with previous values. If a marked raise in wear is found, the measurement must be carried out in
shorter intervals. Max allowed deflection is 3.1mm Report format

BACK LASH OF THE SLEWING GEARS

The point at which largest ovality occurs on the pitch circle diameter of the gear is marked with green
paint on three teeth. Backlash of the slewing gears to the slewing bearing is measured and adjusted
at this point. Backlash can be measured by placing a soft metal such as lead on the bearing gear
teeth and moving the slewing gear. The soft metal is then measured and values recorded. Min
backlash value is 0.24mm. Report format

TIGHTNESS AND ELONGATION OF BOLTS

Tightness check of slewing bearing bolts inner and outer to be carried out once in 6 months. 10% of
the bolts elongation to be measured.
 SLEW BEARING DEFLECTION

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Vessel : Crane No.

Place: Date:

D F Position Read 1 Read 2 Defl.

C
C G
D

B H F

G
A H

OPERATOR CABIN

Read 1: No Load Min Radius

Read 2: Full load Max working radius
Position A is point exactly below the operator cabin
All reading in mm
Max deflection allowed 3.1mm
 SLEW GEAR BACKLASH MEASUREMENT

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Vessel Place:
CRANE NO. Date:

FWD

POINT A

P S

SOFT POINT

MIN BACKLASH VALUE ALLOWED 0.24MM

POINT A: THE POINT AT WHICH LARGEST OVALITY OCCURS ON THE PITCH CIRCLE DIAMETER OF
THE GEAR AND IS MARKED WITH GREEN PAINT ON THREE TEETH

BACKLASH FOR MOTOR BELOW ELECTRIC PANEL:

BACK LASH FOR MOTOR BELOW GREASE PUMP:
 CRANE LUFF MOTOR GEAR PROFILE

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X= mm
Y= mm