Maintenance Manual English ZPMC Gruas de Puerto

Ve r.
MAINTENANCE MANUAL
for
F O U R Q U AY S I D E C O N TA I N E R C R A N E S
（ M ec h a n ic a l P a r t ）
APMT ALGECIRAS
SPAIN
Copyright © 2014. All right reserved.
SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

3261 DONGFANG ROAD
SHANGHAI 200125,P.R.CHINA
TEL: +86-21-58396666
FAX: +86-21-58399555
SAFETY
VOLUME 1
1. SAFETY ......................................................................................................................................... 1-1
1.1. WARNINGS AND SYMBOLS ............................................................................................... 1-2

1.2. GENERAL PRECAUTIONS .................................................................................................. 1-3
1.3. GENERAL RULES OF CONDUCT AND SAFETY REGULATIONS .............................. 1-4
1.4. SAFETY RULES FOR OPERATION ................................................................................... 1-4
1.5. SAFETY RULES FOR MAINTENANCE AND REPAIR .................................................... 1-6
1.6. CONDUCT IN CASE OF ACCIDENTS AND EMERGENCY ............................................ 1-7
1.7. ZERO MECHANICAL STATE AND LOCKOUT/TAGOUT PROCEDURE ..................... 1-9
1.7.1. INTRODUCTION................................................................................................................... 1-9
1.7.2. APPLICABILITY ................................................................................................................... 1-9
1.7.3. REQUIREMENTS/REGULATORY SUMMARY ................................................................ 1-9
1.7.4. GENERAL PROCEDURES ................................................................................................. 1-11
1.7.5. RESPONSIBLE PARTIES ................................................................................................... 1-16
1.7.6. TRAINING AND AUTHORIZATION ................................................................................ 1-17
1.7.7. SUPPORTING REFERENCES AND STANDARDS .......................................................... 1-17
APPENDIX A: TERMS AND DEFINITIONS ............................................................................. 1-18
APPENDIX B: LOCKOUT/TAGOUT PROCEDURE SELF- ASSESSMENT CHECKLIST . 1-20
APPENDIX C: ENERGY SOURCES AND MEANS OF ISOLATING OR DISSIPATING
ENERGY........................................................................................................................................... 1-21
1-I
SAFETY
1. SAFETY
Safety is a priority either in operation or in maintenance and inspection. This chapter informs you
of the possible hazards and necessary precautions to be taken when operating or maintaining the
crane.
1-1
SAFETY
1.1. WARNINGS AND SYMBOLS
The following signs and symbols are used in the manual to designate instructions of particular
importance.
Symbol Description Symbol Description
Special information and/or orders
and prohibitions directed towards Hazardous voltage
preventing damage.
Warn of ELECTRIC VOLTAGE. Keep hands and body clear
Stay clear
No standing on it
Keep hands clear of the moving

No access
parts.
Do not enter, Authorized

Danger of falling
personnel only.
Refer to specified sections in the Special information for increasing

manual. efficiency
Keep away from suspended loads

Crush hazard
Refers to information in other

Additional Information
parts of the Manual
Wear protective clothing

Danger of tripping
In this manual, as well as on the crane, warnings or warning signs are categorized into four levels
according to the severity of danger (or seriousness of accident) as shown in Table 1.1-1.
Table 1.1-1 Warning type
Warnings Definitions
Refers to imminently dangerous situations. Used when serious injury or
DANGER even death will occur if specified procedures or instructions are not
followed.
Refers to potentially dangerous situations. Used when serious injury or
WARNING even death might occur if specified procedures or instructions are not
followed.
Refers to potentially dangerous situations. Used when medium or slight
CAUTION injury will occur or when the machine or equipment will be damaged if
specified procedures or instructions are not followed.
Used when attention must be paid to or when information must be
NOTE
stressed.
1-2
SAFETY
1.2. GENERAL PRECAUTIONS
This crane embodies the latest and the best in structural, electrical, mechanical, and hydraulic
systems and may only be put into operation by qualified or trained staffs.
Before operating or maintaining the crane, the operation and maintenance instructions have to be
read carefully and understood by all maintenance and repair personnel.
This machine is also built according to the latest standards of technology and recognized safety
technical rules, and is equipped with safety devices. It has been checked for function and safety
before delivery and hand-over. However, in case of faulty operation, misuse, or use not in
accordance with the instructions, dangers and/or damages could still arise and threaten the health
of the operation personnel or third persons, the container crane or other material, and/or the
efficient operation of the crane itself.
Always use safety harnesses and/or other safety gear as required whenever in an elevated
working place. It is always a good practice to work in a team of at least two persons in a place
where potential dangers may arise.
A well-stipulated safety procedure, Lockout/Tagout (LOTO), is proposed and will be explained in
detail in the following sections. It must be observed strictly to secure the proper protection of staff
whenever working on an equipment that may release any form of hazardous energy including, but
not limited to, electrical, rotational, mechanical, chemical, hydraulic, or pneumatic energy, while
the equipment is shut down.
In addition to the operation and maintenance instructions provided herein, legal（generally valid）
and other obligatory regulations issued by the local authorities for accident prevention and
environmental protection must also be observed.
It is our admonition that working cautiously and carefully is the best protection from accidents.
None of us has all the expertise or training needed to complete every repair that may be required.
Do not try to undertake a task on which you are lack of training or qualifications.`
IT’S ABOUT YOUR SAFETY!
The manufacturer, Shanghai Zhenhua Heavy Industry Co. (ZPMC), has tried his best to assemble
and make available a complete set of instructions in the form of manuals and data sheets to
provide all necessary information for crane operation and maintenance. Also the hazards may
arise in operation and maintenance work. But the manual can’t include every notice and hazard.
So please do be careful when operating or maintaining the crane. In case of uncertainties,
problems and additional requests, we will always be at your disposal. Please do not hesitate to
contact our local representative and/or technical supporting staffs at the manufacturing base.
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SAFETY
1.3. GENERAL RULES OF CONDUCT AND SAFETY REGULATIONS
The crane may only be operated in technically healthy condition and in compliance with the
operating and maintenance instructions. Particular malfunctions that may impair the safety must
be eliminated immediately. Before each commissioning, the crane must be checked for
operational safety!
Uncompleted or illegible operation and maintenance must be replaced immediately.
Protection and safety devices (covers, safety barriers, etc.) must not be removed while operating
the unit. The crane must not be operated without safety devices at any time.
Appoint personnel solely responsible for the crane operation and maintenance respectively. Also,
unauthorized personnel are not permitted to operate the crane.
The operating and maintenance staff have to be checked by the employer responsible for the
operation. The person responsible for the operation is obliged to operate the crane only in proper
condition and to instruct the operating and service staff to wear protective clothing, etc. whenever
necessary or required by the regulations.
If there are any alterations concerning the safety of the machine or changes in the operational
behavior, the machine has to be set to a standstill and the fault has to be reported to the relevant
authority or person. Damages affecting the safety or malfunctions at the crane have to be
eliminated immediately.
Arbitrary constructive modifications and the alteration of parameters beyond the operating and
maintenance instructions are not permitted for the sake of technical safety.
IMPORTANT SAFETY PRACTICE!
The following safety rules must be observed strictly in practice:

(1) Verify that there is no danger to other related personnel before operating the machine.
(2) Do not touch the rotating or moving parts of the machine during operation.
(3) Do not perform inspection and adjustment of the machine during operation.
(4) Do not touch the live parts inside the control cabinets or terminal boxes. The internal live parts
carry high voltage current and pose the risk of electric shock when touched.
(5) Do not lubricate the components of the machine during operation.
(6) Immediately press the emergency stop pushbutton to stop the machine when an accident has
occurred or is likely to occur.
(7) Always keep the machine and it’s surroundings clean. Especially keep the passageways at
the elevated place clean so that personnel can walk safely.
(8) Warn all the service personnel of an unsafe intended action that may endanger them.
(9) Report any injury and make sure the wounded person can receive fast medical treatment.
1.4. SAFETY RULES FOR OPERATION
Pre-service Precautions:
(1) Before starting work at the crane, all persons have to be instructed in theoretic and practical
use of emergency measures in case of an accident, the use of the emergency exits, and the
use of rescue aids (fire extinguishers).
(2) Unauthorized persons should not enter the crane.
(3) All safety devices and facilities with protection functions must always be connected and
operable. They must not be rendered ineffectively or used improperly.
(4) The factory setting of the components must not be changed.
(5) Observe the inspection procedure stated in this manual for the inspection of each component.
1-4
SAFETY
Precautions during service:
(1) Do not step into the area below the lifted cargo when the crane is operating. It may result in a
critical accident.
(2) The lifting load and the reach during the loading or unloading operation must be within the
limit values defined by the specifications of the crane. Excess reach or excess load may
result in a critical accident such as a fall-down, a break-down or a damage of the crane.
(3) Immediately stop operating the crane when an abnormal sound or vibration arises. Inform the
responsible personnel immediately to eliminate the malfunctions or conduct maintenance.
(4) Do not leave the crane with open hatch covers, or other openings into which a person could
step or tools and objects could fall. And do not leave lubricants, paints, or other materials
uncovered or un-attended.
(5) Always operate the crane smoothly to prevent the shock of start-up or stoppage. Avoid
operations such as abrupt loading or unloading at full speed with excess load or unnecessary
repetition of start-up or stoppage.
(6) When the crane encounters a strong wind over 25m/s, conduct the crane stowage procedure
against wind.
DANGER ZONE MUST BE BLOCKED BY SUITABLE MEASURES.

HAZARD AREAS MUST BE INDICATED PERMANENTLY BY CLEAR
INDICATIONS, SUCH AS COLORED SIGNS OR WARNING SIGNS.
1-5
SAFETY
1.5. SAFETY RULES FOR MAINTENANCE AND REPAIR
The maintenance work is different from the ordinary operations. When the crane is under
maintenance, some of its parts may be disassembled or unstable, thus special attentions should
be paid to.
BEFORE COMMENCEMENT OF SERVICE WORK THE CONTAINER

CRANE HAS TO BE MADE FREE OF LOAD, SET TO MAINTENANCE
POSITION AND SWITCHED OFF, IF NO OTHER NOTE IS GIVEN.
Observe the following safety rules when conducting maintenance or inspection work on the crane:
(1) Personnel unauthorized by the person responsible for the crane should not perform
maintenance or inspection work.
(2) Do not perform maintenance or inspection work when the crane is operating.
(3) Before conducting maintenance or inspection work, cut off the main power supply and all the
power resources; then verify if the crane is stopped completely.
(4) Before conducting maintenance or inspection work, warn all the related workers of the work
and prohibit those unauthorized workers from entering the maintenance and inspection areas.
(5) The crane should be in maintenance mode for such a task.
(6) Secure the repair area by closing a wide area. During the maintenance of the crane, be sure
to close hatches on the machinery house and other places, or protect them with fences.
(7) When inspecting one of the cranes on the same gantry rails, attach the mechanical stoppers
or station a person to prevent collision of the cranes.
(8) Never fail to close the door to the walkways and the chains at the gate of the walkways.
(9) When removing bolts, pins, wire ropes, and cables, warn workers other than the service
personnel of the danger of attached parts falling.
(10) When relieving the residual pressure of the trim/list/skew and rope tensioning device, warn
maintenance personnel of the device. The sheaves may move and each wire rope may
loosen due to the relief of the pressure of the hydraulic cylinder. It may cause injury.
(11) Verify that there is no residual pressure left in the hydraulic equipment and the compressor.
Residual pressure may cause injury.
(12) If hands will be on the rope for inspection, they must be away from the pinch point.
(13) The maintenance persons should pay more attention to the moving/rotating parts.
(14) Do not use the machine parts as climbing aids.
(15) Reinstall and test safety devices (which have been disassembled during the assembly or test
and repair work) immediately after the end of the maintenance and repair work.
(16) Correctly tighten the screw joints that were loosened during the test and the maintenance
work.
(17) Replace the fastening elements and seals (e.g. self-securing nuts, washers, split pins, O-rings
and seals) which cannot be used again.
(18) After the maintenance/repair work, update the fault log and the maintenance check list.
(19) Do running test and functional check of the components and safety devices before starting the
operation and service again.
1-6
SAFETY
1.6. CONDUCT IN CASE OF ACCIDENTS AND EMERGENCY
(1) In the case of an accident with injury to persons, damages to devices or other materials,
immediately inform the supervisor after providing the injured with first aid. For well-directed
rescue efforts, clearly give the degree of severity of the injury to persons and the damage to
property.
(2) In case of disasters (e.g. fire), all persons must leave the crane using the indicated
emergency exits and/or other facilities.
(3) Rescue actions may only be carried out by instructed operating and rescue personnel. Use
the intended protective equipment.
(4) In case of a breakage of a trolley wheel, first try to release the load attached to the crane, if
possible, then carry out the repair procedure described in Chapter 4.
(5) In the case of wheel axle break of the crane traveling mechanism during the operation, see
the instruction given in Chapter 7.
OPERATION PROCEDURES FOR EMERGENCY SITUATIONS ARE

COMPLETELY DIFFERENT FROM ROUTINE DUTIES. IN CASE OF
EMERGENCY OPERATION, FOLLOW THE INSTRUCTIONS GIVEN IN
CHAPTER 7 OF THIS MANUAL STRICTLY.
1-7
SAFETY
1.7. ZERO MECHANICAL STATE AND LOCKOUT/TAGOUT PROCEDURE....................... 1-9
1.7.1. INTRODUCTION................................................................................................................... 1-9

1.7.2. APPLICABILITY ................................................................................................................... 1-9
1.7.3. REQUIREMENTS/REGULATORY SUMMARY ................................................................ 1-9
1.7.4. GENERAL PROCEDURES ................................................................................................. 1-11
1.7.5. RESPONSIBLE PARTIES ................................................................................................... 1-16
1.7.6. TRAINING AND AUTHORIZATION ................................................................................ 1-17
1.7.7. SUPPORTING REFERENCES AND STANDARDS .......................................................... 1-17
1-8
SAFETY
1.7. ZERO MECHANICAL STATE AND LOCKOUT/TAGOUT PROCEDURE
Before conducting maintenance or inspection work of the crane, always cut off all the electricity
and release the residual hydraulic and pneumatic pressures to zero (Zero Mechanical State).
Then, take measures (perform Lockout/Tagout) so that others cannot supply the electricity,
hydraulic pressure, or pneumatic pressure while a maintenance person is servicing the crane.
1.7.1. INTRODUCTION
This plan covers the control of hazardous energy sources, generally requiring that energy sources
for equipment be turned off or disconnected and that the switch either be locked or labeled with a
warning tag. This is due to the hazards faced by workers servicing equipment as well as, to a
lesser degree, those who attempt to use the equipment during servicing, and others who may be
nearby. Typical injuries from the unexpected release of hazardous energy include fractures,
lacerations, contusions, amputations, and puncture wounds, and include both serious injuries and
fatalities.
(1) Purpose
It is the policy of ZPMC to prevent an undesirable release of hazardous energy during any
servicing, maintenance, or modification activity. This policy is implemented through
Lockout/Tagout (LOTO) procedures for shutting off and securing such equipment. These
procedures must be strictly followed when it is necessary to work on any equipment that may
release any form of hazardous energy including, but not limited to, electrical, rotational,
mechanical, chemical, hydraulic, or pneumatic energy, while the equipment is shut down. This
document covers training and authorization, responsibilities of employees, General Procedure,
Group LOTO Procedure, Equipment-Specific Written LOTO Procedure, Tag-Out Only Procedure,
hardware required for LOTO, recordkeeping requirements, personnel shift changes,
subcontractors' responsibilities, periodic inspections, and ZPMC's Tag-On policy.
(2) Compliance
All maintenance persons working on cranes are required to comply with the requirements of this
program. Employees knowingly failing to comply with this procedure will immediately be placed
into the disciplinary process at an accelerated level of discipline.
1.7.2. APPLICABILITY
This policy applies to all maintenance persons working on the cranes. It also applies to
subcontractor personnel who do not have an equivalent lockout/tagout program that satisfies the
requirement of Cal-OSHA. Section 4.9 provides further details on subcontractor personnel.
1.7.3. REQUIREMENTS/REGULATORY SUMMARY
LOTO is required whenever servicing, maintenance, or modification is being performed on

equipment in which the unexpected energization or start-up of the equipment, or the release of
stored energy, could cause injury to people or damage to equipment. All sources of hazardous
energy must be shut off and secured. LOTO must be performed by each person who works on the
equipment.
This plan meets the requirements of References and Standards listed in Section 1.7.7.
1.7.3.1. Exclusions
LOTO procedures do not apply under the following conditions:

Routine operations (e.g., minor tool changes, adjustments, and other minor servicing taking place
during normal production operations), provided the operation is repetitive and integral to the use
of the equipment. The work must be performed using alternative measures that provide effective
protection. If, during routine operations, a guard or other safety device is removed or bypassed, or
an employee is required to place any body part into an area of a machine or a piece of equipment
where work is actually performed upon the material being processed (point of operation), this
1-9
SAFETY
exclusion does not apply and LOTO must be performed.

Work on cord- and plug-connected electrical equipment, if all of the energy is controlled by
unplugging the equipment and the plug remains under the continuous control of the employee
performing the servicing, maintenance, or modification.
Operations on energized equipment (e.g., calibration), where continuity of service is essential or
shutdown of the system is impractical. Documented safety procedures that provide an
equivalent level of safety must be established and followed. Special safety equipment may be
required.
1.7.3.2. LOTO vs. Administrative Locking
A careful distinction must be made between LOTO and various other locking practices, collectively
referred to as Administrative Locking. The LOTO procedure is specifically reserved for those
instances in which a zero-energy state must be ensured to allow personnel to service, maintain, or
modify the equipment. Administrative locking is normally not used as the primary means of
protection during a servicing, maintenance, or modification procedure, and is not a substitute for
LOTO. Administrative locking is distinguished from LOTO in both practice and purpose. An
administrative lock may be controlled by a group rather than an individual, and an administrative
application must not use the designated LOTO locks or LOTO tags.
Administrative locking may be performed for many reasons, including equipment security,
programmatic purposes, or general safety. Examples of administrative locking are:
 Locked fences around high-voltage transformers.
 Locks on overhead-crane disconnect switches.
 A locked door to a shop area containing hazardous equipment.
1.7.3.3. Equipment and Supplies
(1) Locks
As shown in Figure 1.8-1, only approved locks can be used when performing LOTO. A LOTO lock
must always be accompanied by an approved tag. (See Tags)
a) For Valves b) For Electrical Switches c) For Electrical Cabinet

Figure 1.8-1 LOCKOUT/TAGOUT METHODS
Approved locks are controlled by the authorized employees/supervisors listed in this plan.
(2) Keys
Each approved LOTO padlock must have only one key, which must be in the possession of the
authorized employee who applies the lock.
(3) Blocks
Suitable blocks are another important safety device for making a piece of equipment safe to be
repaired or serviced. Blocks must be placed under raised dies, lifts, or any equipment that might
inadvertently move by sliding, falling or rolling.
Blocks must be available and always used. Another form of blocking is the placement of a blind.
1-10
SAFETY
A blind is a disk of metal placed in a pipe to ensure that no air, steam, or other substance will pass
through that point if the system is accidentally activated.
Before installing blinds or blocks, bleed down steam, air, or hydraulic lines to get rid of any
pressure. Coiled springs, spring-loaded devices, or suspended loads must also be released so
that their stored energy will not result in inadvertent movement.
(4) Tags
Only approved LOTO tags may be used. The approved LOTO tag must be enclosed in a plastic
sleeve and attached either directly to the shackle of the lock or by means of a plastic locking tie.
A tag must always be used in conjunction with a lock unless the energy-isolating device is not
physically capable of being locked (See Tag-Out Only). The authorized employee performing
LOTO must complete all applicable sections of the tag. Approved tags, sleeves, and ties must be
obtained from the responsible persons listed in this plan.
1.7.4. GENERAL PROCEDURES
The LOTO General Procedure is outlined on the back of the LOTO tag and is divided into two
sections: Application of Lock/Tag, and Release from Lockout/Tagout.
1.7.4.1. Application of Lock/Tag
(1) Preparation and Notification
1) Use of written procedure

The authorized employee must determine if an Equipment-Specific Written Procedure is
applicable to the task. If so, the authorized employee must obtain and follow the
equipment-specific written procedure. If a new written procedure must be generated, the
authorized employee must contact his or her supervisor.
2) Assess energy type and magnitude
The authorized employee must assess the type, magnitude, and hazards of the energy to be
controlled.
3) Determine methods of control
The authorized employee must determine the appropriate methods of controlling the
hazardous energy (e.g., disconnect a switch or a valve).
4) Notify all affected personnel
The authorized employee must notify all affected employees of the impending shutdown and
the reasons for it.
(2) Shutdown
1) Verify whether it is safe to shut down the equipment
The authorized employee must verify that it is safe to shut down the equipment.
2) Perform normal equipment shutdown
The authorized employee must turn off or shut down the equipment using the established
methods for that equipment.
If a LOTO procedure requires an out-of-sight operation (the energy switch in one
room/location with equipment in another), there must be communications by telephone, radio,
or other available means to ensure that the procedure is conducted safely. The affected
employees shall be instructed of the importance of accurate and clear communications.
3) Isolate and lock out energy sources
The authorized employee must operate the energy-isolating device and affix his or her LOTO
lock to this device. The lock must be affixed so as to hold the energy-isolating device in an
off or safe position that physically prohibits normal operation of the energy-isolating device.
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SAFETY
4) Place completed tag in holder and apply with lock or plastic tie
The authorized employee must complete all appropriate information on the upper section of
the tag. The tag is not considered completed until it is enclosed in the plastic holder. If the
placement of the tag would compromise safety by obscuring indicator lights or controls, the
tag may be located as close as is safely possible to the device, in a position that will be
immediately obvious to anyone attempting to operate the device.
5) Release stored energy
The authorized employee must completely release or otherwise control any stored energy.
In the case of stored mechanical energy, vent valves, spring releases, blocking devices, or
equipment repositioning (as appropriate) must be utilized. In the case of stored electrical
energy, approved grounding wands or discharge devices must be used. If there is a
possibility of re-accumulation of stored energy to a hazardous level, verification of isolation
must be continued until the servicing, maintenance, or modification is completed or until the
possibility of such accumulations no longer exists. The equipment must be in a zero-energy
state. (See Appendix A, Terms and Definitions, for a definition of this term.)
(3) Verification of LOTO Application Procedure
1) Attempt to restart the equipment
The authorized employee must physically attempt to operate the energy-isolating device and
attempt to restart the equipment, using the normal equipment controls (e.g., start buttons or
computer software controls).
2) Test equipment for zero-energy state
The authorized employee must test potential energy sources, using appropriate instruments
or testers. Any instrument used to test voltage, pressure, or temperature must be checked
for proper operation both before and after use. If the authorized employee is not qualified to
test the energy being isolated, he or she must ensure that the energy is tested by a qualified
person. The qualified tester, if other than the authorized employee, must be identified in the
Comments section on the tag.
1.7.4.2. Release from LOTO
Before LOTO devices are removed and energy is restored to the equipment, the authorized
employee must follow the procedures below:
(1) Verify whether it is safe to reenergize
The authorized employee must verify that the work to which the LOTO was applied has been
completed and that it is safe to reenergize equipment.
(2) Clear all tools and personnel
The authorized employee must check the work area to ensure that all tools and personnel are at a
safe distance from the equipment.
(3) Remove all isolating devices
The authorized employee must remove any devices applied under Step (2)5) (Release stored
energy).
(4) Replace safety guards
The authorized employee must check the equipment to ensure that all removed guards are
reinstalled.
If safety is compromised by following the prescribed sequence of the General Procedure, the
authorized employee may modify the sequence; however, all steps must be performed.
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SAFETY
1.7.4.3. Temporary Removal of LOTO Devices
When LOTO devices must be temporarily removed from the energy-isolating device so that the
equipment or component can be energized for testing or positioning, the following sequence of
actions must be taken:
1) Notify the affected employees and area supervisor.
2) Clear the equipment of tools and materials.
3) Remove employees from the machine or equipment area and ensure that the required tools
are safely and properly positioned.
4) Remove all repositioning and blocking devices and return all vents and valves to their normal
operating positions.
5) Remove all grounding/shorting conductors.
6) Energize and proceed with testing or positioning.
7) De-energize all systems and reapply lockout/tagout measures to continue the servicing,
maintenance, or modification of the equipment.
8) The original tag may be reused.
1.7.4.4. Emergency Removal of LOTO Devices
When the authorized employee who applied a LOTO device is not available to remove it, that
device may be removed by his or her supervisor. This is considered to be an emergency
procedure, only to be undertaken in extreme circumstances. Extreme care must be taken and the
following steps must be performed:
1) The supervisor must verify that the authorized employee is not at the facility.
2) The supervisor must make every reasonable effort to contact the authorized employee.
3) This may include a telephone call to the employee's home or other locations.
4) If the employee is contacted, the supervisor must inform the employee that his or her LOTO
devices are being removed.
5) The supervisor must verify that it is safe to remove the LOTO devices.
6) The lock may be cut off if the key is not available.
7) The supervisor must ensure that the authorized employee is presented with the removed lock
upon returning to work and is informed of the reasons for the emergency removal.
8) The emergency procedure must be duly recorded in the department's lockout/tagout records
and signed by both the supervisor and authorized employee
1.7.4.5. Tag-Out Only
If a device is incapable of being locked out, a "tag-out only" procedure may be employed.
To conduct a tag-out only procedure, the authorized employee must follow all of the steps outlined
in the General Procedure. (See the General Procedure section of this plan.) The placement of
the lock in Step (2)3) (Isolate and lock out energy sources) in the General Procedure is omitted.
Instead, the authorized employee must utilize a second means of isolating the hazardous energy.
Removal of an isolating circuit element, blocking of a controlling switch, opening of an extra
disconnect device, or removal of a valve handle are all examples of secondary measures. The
second means of isolation must be identified on the tag, and the tag must be affixed as mentioned
in Step (2)4) (Place completed tag in holder and apply with lock or plastic tie) of the General
Procedure.
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SAFETY
1.7.4.6. Equipment-Specific Written Procedures
If the equipment undergoing servicing, modification, or maintenance has more than one energy
source, requires the operation of more than one device to isolate the hazardous energy, or has
potential for stored, residual, or accumulated hazardous energy, an equipment-specific written
procedure must be used.
(1) Exclusion from Equipment-Specific Written Procedure Requirements
When performing servicing and maintenance on equipment that meets the criteria below, a written
procedure is not required. A laminated sign, painted sign, or similar durable device shall be placed
next to the equipment indicating the location of the single energy-isolating device.
After shutdown, the equipment has no potential for stored or residual energy or re-accumulation of
stored energy that could endanger employees.
The equipment has a single energy source that can be readily identified and isolated.
The isolation, lockout, and tagging of the energy source will completely de-energize and
deactivate the equipment.
The equipment is isolated from the energy source and locked out and tagged during servicing or
maintenance.
A single lockout device and tag will achieve a locked out and tagged condition.
The lock is under exclusive control of the authorized employee performing the servicing or
maintenance activities.
Servicing or maintenance does not create hazards for other personnel.
The equipment has no record of incidents involving unexpected activation or re-energization of
the equipment during servicing or maintenance.
(2) Preparing an Equipment-Specific Written Procedure
A written energy-control procedure must be generated by the department, group, or authorized
employee most familiar with the equipment. This procedure must be used by any authorized
employee who will perform LOTO on the equipment. Supervisors must ensure that equipment
which requires a written procedure is so identified and that the procedure is readily available to
the employees authorized to perform LOTO on the equipment. Any equipment with an
equipment-specific written LOTO procedure must be clearly labeled as such. The supervisor or
employee responsible for the equipment may determine the appropriate format and content of the
label. For example: CAUTION--An equipment-specific written procedure exists for the locking and
tagging of this equipment.
(3) Elements of an Equipment-Specific Written Procedure
The equipment-specific written procedure must incorporate each step in the General Procedure,
as enumerated in the General Procedure section of this chapter. It is essential that the specific
application of each LOTO step be clearly explained in the context of the specific equipment.
1.7.4.7. Group LOTO Procedure
When servicing, maintenance, or modification is performed by a crew, the supervisor may

determine whether the use of a group LOTO procedure is appropriate. This determination must
be made only when the size of the crew and the nature of the work precludes the feasibility of
individual LOTOs and when the level of protection provided by the group LOTO procedure is
equivalent to that of individual LOTO. A group LOTO procedure is a special procedure wherein the
responsibility for applying and removing the lockout devices of a group of authorized employees is
vested in a single designated authorized employee.
(1) Procedure/Application of Group LOTO
The supervisor or group leader must determine whether the group LOTO is appropriate.
1-14
SAFETY
The supervisor or group leader must convene a meeting of all members of the group to be
covered under the procedure.
1) The supervisor or group leader must describe the tasks to be performed.
2) The supervisor or group leader must delegate primary responsibility to a designated
authorized employee for a specified group of employees working under the protection of
the group's LOTO.
3) The structure of the group, the names of all group members as well as the designated
authorized employee, and the reasons for the group LOTO must be documented in the
appropriate LOTO logbook.
4) Each member of the specified group must be trained and authorized, as described in
Training and Authorization.
The designated authorized employee is responsible for ensuring that each step of the general or
equipment-specific written procedure is completed. The designated authorized employee must
apply his or her personal LOTO lock(s) and tag(s) to the energy-control device(s) and indicate on
the tag that a "group lockout" is in effect. The designated authorized employee must communicate
to each person in the crew that LOTO is in place and work may commence.
If the makeup of the crew changes while the work is in progress, the designated authorized
employee must inform any new group member that a group lockout is in place and communicate
to him or her all of the information relating to the group lockout. The names of the new group
members must be added to the log. Anyone leaving the group before the servicing,
maintenance, or modification is completed must notify the designated authorized employee. The
group member leaving must communicate the status of his or her activities to the designated
authorized employee. The designated authorized employee must make a logbook entry
indicating the date and time of each group membership change.
(2) Release From Group LOTO
When the work is completed, the designated authorized employee must communicate to each
group member that the group LOTO is being considered for removal and:
1) Must communicate with each member to verify whether all tasks performed in
conjunction with the specific job are complete.
2) Must verify whether the equipment has been returned to a safe restart condition. After
positive verification is received from all crew members, the designated authorized
employee may remove the group LOTO devices and perform equipment restart.
The designated authorized employee is responsible for making all appropriate logbook entries.
1.7.4.8. Shift Changes
To ensure the continuity of LOTO protection during shift or personnel changes, if work is to be
continued by an oncoming shift, an orderly transfer of LOTO devices between the authorized
employees from the offgoing and oncoming shifts must be performed. The authorized employees
from both shifts must both be present at the lockout device. The offgoing authorized employee
must remove his or her lock and tag, and the oncoming authorized employee must immediately
place his or her lock and tag on the group LOTO device. The authorized offgoing employee must
inform the authorized oncoming employee of any potential hazards.
1.7.4.9. Subcontractors
The crane maintenance company is responsible for ensuring that all construction subcontractors
are informed of and adhere to the crane LOTO policy. Construction subcontractors will be
required, when applicable, to include LOTO procedures in accordance with this chapter in their
construction safety plans. The Project Manager must ensure that the subcontractor's safety plan
1-15
SAFETY
is in accordance with the crane LOTO policy. The Project Manager is responsible for authorizing
the subcontractor to perform LOTO under the crane policy. Subcontractors are responsible for
ensuring that their employees have been properly trained. All subcontractor employees
performing LOTO have the same responsibilities as crane maintenance persons performing
LOTO. Regardless of whether or not they will perform LOTO, all subcontractor employees have
potential exposure to LOTO activities and must be trained in the recognition of the procedure and
the importance of respecting locks and tags. The Project Manager may provide an appropriate
supply of locks, tags, and other hardware to the subcontractor or may approve the use of alternate
equipment that conforms to the intent of this policy. The Project Manager must monitor
subcontractor activities to ensure a proper implementation of this policy.
1.7.4.10. Periodic Inspections
Each group is responsible for ensuring that a periodic self-inspection and certification of its
energy-control procedures be conducted at least annually. The periodic inspection must be
designed to correct any deviations or inadequacies observed. A certification, which may consist of
a completed checklist or a memo to file, must state that the periodic inspection has been
performed. The certification must identify the machine(s) or equipment on which the
energy-control procedure was utilized, the date of the inspection, the employees included in the
inspection, and the person performing the inspection.
1.7.4.11. New or Modified Equipment
Non-lockable energy-isolating devices shall be designed or modified to accept a lockout device

whenever the old equipment is replaced, the new equipment is installed, or a major modification is
performed.
1.7.4.12. Tag-On
Sump pumps, emergency lights, refrigerators, or equipment that must be shut down in a
controlled manner fall into a class of equipment that should not be accidentally de-energized.
When a circuit breaker, disconnect switch, or energy-securing device is readily accessible to any
employee, the circuit breaker or disconnect switch may be tagged to indicate that it is not to be
turned off. The energy-securing device must not be locked by any means that would prevent the
device from being used as an emergency disconnect.
1.7.5. RESPONSIBLE PARTIES
(1) All Employees

Each employee is responsible for his or her own safety. All employees are responsible for
recognizing when LOTO is being used, the general reasons for LOTO, and the importance of not
tampering with or removing a lock and tag.
(2) Supervisors
Supervisors are responsible for:
1) Prohibiting the employees from working on equipment requiring LOTO until they are
trained in and authorized to perform LOTO.
2) Generating and maintaining equipment-specific written procedures where required.
3) Assigning and documenting employee LOTO authorization, including:
 Designating specific equipment or categories of equipment to be controlled.
 Providing training on specific equipment their employee must lock and/or tag out.
 Ensuring that the employee is qualified to perform the necessary energy-control
procedures.
 Determining the appropriate levels of training required for each employee.
 Ensuring consistent policy implementation and reinforcing LOTO rules.
 Removing LOTO devices in case of emergency and controlling emergency keys for
1-16
SAFETY
LOTO locks.
 Ensuring that necessary hardware is available.
(3) Department Managers
Department Managers are responsible for ensuring that all affected outside contractors operating
under the supervision of their departments are informed of and adhere to these LOTO policies.
1.7.6. TRAINING AND AUTHORIZATION
(1) LOTO Awareness

Any employee who may be near or affected by the equipment on which LOTO is performed
should receive LOTO awareness training from their supervisors. All affected employees must
know how to recognize LOTO, why LOTO is implemented, and the importance of leaving LOTO
devices in place. Employees are prohibited from tampering with LOTO devices or attempting to
restart equipment to which LOTO is applied.
(2) Authorized Employees
An authorized employee is an employee who is: (1) trained and (2) specifically authorized by a
supervisor to perform LOTO. Training in LOTO may be done by supervisors or by other qualified
individuals.
(3) Authorization
Specific authorization is provided by the supervisor after the employee satisfies the training
requirement. The supervisor must ensure that the employee is thoroughly familiar with the
equipment (within the context of his or her job function) and with the energy-control procedures. A
practical exercise may be required to demonstrate proficiency. Once satisfied that both the
training and authorization requirements have been met, the supervisor may authorize an
employee to perform LOTO. This authorization stipulates the specific equipment or types of
equipment on which the authorized employee may perform LOTO.
(4) Reauthorization and Retraining
Reauthorization is required when:
1) An authorized employee's job changes or he or she is reassigned.
2) New equipment is to be used.
3) New energy-control procedures are to be implemented.
4) Retraining and/or reauthorization may be required when:
 A supervisor has reason to believe that an employee has inadequate knowledge of
LOTO procedures or policy.
 A periodic inspection shows a deficiency in the authorized employee's ability to
implement LOTO policy correctly.
1.7.7. SUPPORTING REFERENCES AND STANDARDS
Refer to local standards.
1-17
APPENDIX A: TERMS AND DEFINITIONS
An affected employee is an employee or temporary employee under supervision whose job

requires him/her to operate or use a machine or equipment on which servicing or maintenance is
to be performed under lockout and tag, or whose job requires him/her to work in an area in which
such servicing or maintenance is being performed.
An authorized employee is any employee who is trained in and authorized to perform LOTO.
An affected employee becomes an authorized employee when that employee's training and duties
include performing servicing or maintenance covered under the Lockout/Tagout Program.
An energy-isolating device is capable of being locked out if it has a hasp or other means of
attachment to which, or through which, a lock can be affixed or if it has a locking mechanism built
into it. Energy-isolating devices are capable of being locked out if lockout can be achieved without
having to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy
control capability.
Energized means connected to an energy source, or containing residual or stored energy.
An energy-isolating device is a mechanical device that physically prevents the transmission or

release of energy. Energy-isolating devices include, but are not limited to:
 Manually operated electrical circuit breakers
 Valves
 Disconnect switches
 Similar devices that can block or isolate an energy source.
Push buttons, selector switches, interlocks, and other control circuit-type devices are not
energy-isolating devices.
An energy source is any source of electrical, mechanical, hydraulic, pneumatic, chemical,

thermal, or other energy.
Hot tap is a procedure used during repair, maintenance, and servicing activities that involves
welding on a piece of equipment (pipelines, vessels or tanks) under pressure, or tapping into an
energized electrical circuit, in order to install connections or appurtenances. It is commonly used
to replace or add sections of pipeline without the interruption of service for air, gas, water, steam,
and petrochemical distribution systems; or to obtain electrical service from an energized electrical
distribution system.
Single point lockout/tagout is a specific procedure for a machine tool or other piece of
equipment with only one energy-isolating device that can be readily identified and isolated. For
some equipment with only one energy-isolating device, a detailed written lockout and tag
procedure is not required. For a detailed discussion.
A lockout device is a device that utilizes a positive means such as a lock to hold an
energy-isolating device in a safe position and prevent a machine or equipment from energizing.
Included are blank flanges and bolted slip blinds.
LOTO is an acronym for lockout/tagout.
Subcontractor means service and maintenance contractors, construction contractors, salvage

contractors, and labor-only contractors.
1-18
Safety
The safety watch is a person designated and assigned by the supervisor to assist an authorized
employee in performing maintenance or servicing on equipment that has no lockout attachment.
This person shall be posted at an unlocked energy-isolating device to ensure that the device is not
operated for the duration of the operation. The safety watch shall have no other duties.
Servicing and/or maintenance means workplace activities such as constructing, installing,

setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or
equipment. These activities include lubricating, cleaning, or un-jamming machines or equipment
and making adjustments or tool changes where personnel may be exposed to the unexpected
energization or startup of the equipment or release of hazardous energy.
Setting up refers to any work performed to prepare a machine or equipment for its normal
production operation.
The supervisor is the person designated by management to be the day-to-day supervisor of an
authorized employee. The supervisor shall ensure that the authorized employee is trained and
qualified to perform assigned tasks.
A tag is an approved form that can be securely fastened to an energy-isolating device with a lock
and in accordance with procedures established in this plan. This tag indicates that the
energy-isolating device and the equipment being controlled shall not be operated until the lock
and tag is removed.
Testing means the determination that machinery, equipment, or equipment parts are
de-energized. This involves the use of approved, properly operating test equipment designed for
and capable of determining if any energized conditions exist.
Verification refers to operating equipment controls for the purpose of determining that equipment
cannot be restarted after an energy-isolating procedure has been performed and before
maintenance or repair work is initiated.
Zero-energy state is a condition that is reached when all energy sources to or within equipment
are isolated, blocked, or otherwise relieved, with no possibility of re-accumulation. Equipment is
not safe to work on until it is in a zero-energy state.
1-19
Safety
APPENDIX B: LOCKOUT/TAGOUT PROCEDURE SELF- ASSESSMENT

CHECKLIST
Supervisors may use this checklist as a guide to ensure that authorized employees adhere to the
requirements of these Lockout /Tagout Programs.
Authorized Employee Knowledge
 Can the authorized employee demonstrate knowledge of the Lockout/ Tagout Program?
 Can the authorized employee demonstrate knowledge of the appropriate lock and tag
devices?
 Can the authorized employee demonstrate knowledge of the location of all energy-isolating
devices?
 Can the authorized employee demonstrate knowledge of any (or all) secondary or residual
energy?
 Can the authorized employee demonstrate knowledge of the energy-isolation verification

procedures?
 Can the authorized employee demonstrate knowledge of the necessary procedures if the
equipment does not have a lockable energy-isolating device?
 Can the authorized employee demonstrate knowledge of the log-keeping requirements?
 Has the authorized employee received the required training?
Lock and Tag Devices
 Are there an adequate number of locks and tags?
 Are the locks properly labeled?
 Are the danger tags the correct version?
 Is a lockout and tag log available and current?
 Are copies of the applicable energy control procedures available?
Equipment
 Are energy-isolating devices properly labeled?
 Are energy-isolating devices lockable?
 Are energy-isolating devices (other than electrical) required for lockout and tag (e.g., valves)?
 Are valves adequately identified, and are suitable locking devices available?
 Are other devices (e.g., blank flanges, blocks, chains) required for lockout and tag, and are
these devices available?
1-20
Safety
APPENDIX C: ENERGY SOURCES AND MEANS OF ISOLATING OR

DISSIPATING ENERGY
Energy Methods to Dissipate or

Hazards Means of Energy Isolation
Type Restrain Stored Energy
Electrical Shock, burns Plugs, switches, panels, Open disconnect switch,
breakers, motor control unplug
centers
Hydraulic Crushing Panels, switches, valves Open bleed valve to release
pressure
Pneumatic Impact Switches, valves, panels Open bleed valve to release
pressure
Mechanical Impact, crushing, Plugs, switches, panels, Shut off electrical power,
turning parts valves block out or chain of the
mechanical system
Chemical Burns, exposures, Valves, lines/pipes,
asphyxiation switches, panels
Thermal Scalding, burns, Valves, lines/pipes, Locate source, isolate,
heat prostration switches, panels bleed slowly to release
energy
Water Engulfment, Valves, lines/pipes, panels
drowning, crushing
1-21
OUTLINE OF THE CRANE
2. OUTLINE OF THE CRANE ............................................................................................. 2-1

2.1. GENERAL FEATURES AND LAYOUT ......................................................................... 2-1
2.2. CRANE SPECIFICATIONS ........................................................................................... 2-4
2.3. OUTLINE OF THE CRANE CONSTRUCTION ............................................................. 2-6
2.4. FUNCTION OF MAJOR COMPONENTS ................................................................... 2-10
2.4.1. CONFIGURATION OF CRANE MACHINERY HOUSE & E-ROOM ......................... 2-11
2.4.2. MAJOR COMPONENTS ON GANTRY .................................................................... 2-14
2.4.3. MAIN HOIST SYSTEM ............................................................................................. 2-17
2.4.4. BOOM HOIST SYSTEM ........................................................................................... 2-22
2.4.5. TROLLEY TRAVEL SYSTEM ................................................................................... 2-24
2.4.6. CATENARY TROLLEY SYSTEM ............................................................................. 2-29
2.4.7. MACHINERY HOUSE SERVICE CRANE ................................................................ 2-30
2.4.8. WIRE ROPE RE-REEVING DEVICE ....................................................................... 2-31
2.4.9. HEAD BLCOK .......................................................................................................... 2-32
2.4.10. CARGO BEAM ....................................................................................................... 2-32
2.4.11. WALKWAYS AND ACCESS.................................................................................... 2-33
2.4.12. SAFETY DEVICES AND SETTINGS ...................................................................... 2-34
2-I
2. OUTLINE OF THE CRANE
2.1. GENERAL FEATURES AND LAYOUT
This product is specially designed, manufactured and erected for container handling on the port of
ALR17 Terminal, Spain. It includes four (4) cranes in total.
These cranes are of the newest type and exclusive use for container vessel loading and unloading
operation. They have been designed and manufactured to have more practicable high-efficient
operation, as compared with conventional container cranes, based on our traditional and
accumulated know-how from ZPMC’s long experience in the field of container crane industry as
well as the latest technique.
It is of the rope-towed-trolley type container crane with dual box type boom and girder. The
maximum outreach of the crane is 72m and a brief view of its outline is given in
Figure 2.1-1, Figure 2.1-2.
Some distinguished features incorporated into this product, but by no means of completeness, are
as follows:
 Several improvements and/or new designs concerning operation or maintenance
convenience are provided, which include additional outdoor service cranes at back-reach and
top of A-frame, and gantry operating station with spreader maintenance and gantry display.
 Power and control wiring are run in flexible cables via a cable chain system towed by the
trolley, provided with self-driven trolley.
 A new rope re-reeving device is provided, which consists of a set permanently installed in the
machinery house for the main hoist, the boom hoist and the trolley driving ropes.
 The crane is equipped with a sonic gantry anti-collision system, which is mounted on gantry.
 The boom anti-collision system is designed by means of laser device.
 The crane is provided with spreader tilting device that can tilt the spreader to match the
variations of ship trim, list and chassis skew. Its new home position is re-settable.
 A telescopic spreader and a twin twenty spreader are provided which enable the crane to
serve for 20’, 40’, 45’, and two-20’ ISO containers. Bromma tandem headblock and tandem
spreader are provided which enable the crane to serve for different combinations of 20’, 40’,
or 45’ ISO containers side by side.
 The S.O.S. snag protection system is designed to prevent the main hoist rope and the
relative structure from being damaged.
 The electro-hydraulic trolley rope tensioner is provided to maintain proper tension and takes
up wire rope sag for a smooth and safe trolley traversing. It also takes up elongation of trolley
rope during boom hoisting operation.
 Many limit switches, emergency switches, and interlocks are designed to increase the
performance safety for the crane.
 The crane is equipped with CMS and RCMS system, which are located in the electric room,
and the cab. They display and store fault diagnostic data to assist the maintenance person in
rapidly solving faults.
 Four load cells are installed at the boom tip to monitor the load under the spreader and load
eccentricity.
2-1
Figure 2.1-1 Layout of the Crane（Front Elevation）
2-2
Figure 2.1-2 Layout of the Crane（Side Elevation）
2-3
2.2. CRANE SPECIFICATIONS
(1) RATED LOAD

Under tandem spreader : 65 T
Under rope : 105 T (outreach 72m)
(2) LIFT HEIGHT
Above rail : 52.5m
Below rail : 19m
Total : 71.5m
(3) PRINCIPAL DIMENSIONS AND CLEARANCE
Outreach : 72m
Back reach : 25m
Bumper to bumper distance : 28m
Overall height of crane : 145m approx. (boom up)
Clearances between legs : 18m
Clearances under portal beam : 10m
(4) MAIN SPECIFICATIONS
Spreader type : 20', 40', 45', and twin-20'
Tandem spreader
Crane stowage : manual type
Boom stowage : manual type
Type of trolley : rope-towed trolley
Type of boom : hinged double box section
Power demand : 20KV, 50Hz
(5) GANTRY SPECIFICATIONS
Rail gauge : 30m (future change to 30.48m shall be possible)
Wheel base : 15.7m
Wheel diameter :1m
Number of wheels per corner : 8
Number of driving wheels per corner : 6
(6) TROLLEY SPECIFICATIONS
Rail gauge : 6.55 m
Wheel base : 6.9 m
Wheel diameter : 0.75m
Number of wheels :4
(7) WEIGHT & MAXIMUM WHEEL LOAD
Crane weight : 1900 T
Trolley weight : 40 T
2-4
Seaside Landside
Wheel load in operation : 145t/wheel 141t/wheel (allowable)
Wheel load in maintenance : 145t/wheel 141t/wheel (allowable)
(8) TRIM/LIST/SKEW
-trim : ±3°
-list : ±3°
-skew : ±3°
(9) OPERATION SPEED AND ACCELERATION
Main hoist SPEED ACCELERATION TIME
Hoisting with rated load : 90m/ min 1.875S
Hoisting with empty spreader only : 180m/ min 3.75S
Lowering with rated load : 90m/ min 1.875S
Lowering with empty spreader only : 180m/min 3.75S
Gantry travel speed : 45m/min 5.0S
Trolley speed : 240m/min 5S
Boom hoist time duration
Between stowed and operating mode : 5min maximum
Between stowed and maintenance mode : 5min maximum
2-5
2.3. OUTLINE OF THE CRANE CONSTRUCTION
This container crane is designed as a harbor facility for loading and unloading containers or hatch
covers from land to container vessel or vice versa. The glossary of crane parts and terms are
listed below and Figure 2.3-1 shows their position indications.
○
A Steel Structure: It is constructed of sections of box and tubular members forming the gantry
frame and boom.
○
B Power Collecting Device: It collects the high voltage input from the power trench.
○
C Gantry Drive System: This equipment is composed of six motors, six gear reducers, and eight
wheels on each corner to move the gantry to either the left or the right side.
○
D Crane Stowage Device: As the locking device for preventing the over-run of the gantry, two
manual anchors are attached to the center of both seaside and landside sill beam.
○
E Machinery House: This house mounts the driving equipment of the major components such
as the main hoist equipment○
G , the trolley travel equipment○
H , the boom hoist equipment○
F ,
etc. and other control equipment of the container crane.
○
F Boom Hoist Drive: The mechanism which raises and lowers the boom from and to the
horizontal operating position and maintenance position. It is mounted in the machinery house○
E .
○
G Main Hoist Drive: This equipment adopts the fleet through trolley where the main hoist drive is
mounted in the machinery house ○
E and the main hoist wire ropes travel or fleet through the
trolley○
P as the trolley○
P traverses. This equipment is to lift or lower the telescopic spreader
○
S in the vertical direction.
○
H Trolley Travel Drive: The mechanism is used to locate and move the trolley and is mounted in
the machinery house ○
E . The wire rope reeled out from this equipment move the trolley ○
P
toward the landside or the waterside. However, the trolley○
P can travel slowly when the boom is
raised to its maintenance position.
○
I Machinery House Service Crane: This crane, equipped in the machinery house○
E , is the
hoist type over-head crane of high lift and enables loading and unloading of parts from the
machinery house○
E to the ground.
○
J Wire Rope Re-reeving Device: This device equipped in the machinery house○
E . They are
used to wind up the old wire rope during replacement with the new wire rope.
○
K Igus chain System: Transmit the power to the trolley when the trolley shuttle between
outreach and backreach.
○
L Trolley Travel Rope Tensioning Device: This device is installed on the end tie of the girder. By
applying appropriate tension to the trolley travel rope, this device prevents the trolley○
P from
swinging due to rope loosening when lifting cargo.
○
M Boom Stowage Device: This device is composed of the anchor pins at the top of the crane
2-6
body structure and anchor support on the boom. This is the fixing device of the hoisted boom. The
anchor pins must be inserted by hand into the boom-side anchor metal base.
○
N Trim/List/Skew: This device, installed at the end tie of the girder, adjusts the TRIM angle
(Tipping or rotation of the spreader about a horizontal axis perpendicular to the gantry rail), the
LIST angle (Tipping or rotation of the spreader about an axis parallel to the gantry rails) and
SKEW angle (rotation of the spreader about a vertical axis).
○
O Catenary Trolley System: The system consists of two trolleys, of which one is at the waterside,
and the other is at the landside. They move along the boom and girder respectively with the
trolley○
P to prevent the ropes from sagging too much.
○
P Trolley: This device traverses the trolley girder and boom and supports vertically the
headblock○
R , the spreader○
S and the lifted load.
○
Q Operator’s Cab: The container crane and the telescopic spreader○
S can be operated from
this cab.
○
R Head Block: The structure consists of the bottom hoist load block, the attaching parts with the
spreader○
S .
○
S Spreader, Rotator: The spreader is the structural mechanism that spreads the main hoist
mechanism beyond the location of the hoist wire ropes. Specifically is to connect the four corner
points of an ISO shipping container.
○
T Service Jib Hoist: This device is equipped at the end of the girder and used to dismantle,
each part of the Trim/List/Skew/Snag equipment ○
N , the rope tensioner○
L and other parts
needing replacement.
○
U Electric Room (E-Room): It is a part of the machinery house. It contains electric drive panels
and associated equipments.
○
V Anti-snag device: For this project, SOS anti-snag system is used. It is incorporated into the
main hoist system and consists of couplings, brakes, PLC, etc.
○
W Boom hoist cabin: In this room operator can raise the boom to 45º or maintenance mode.
When raising the boom, the actions can be checked from the windows of the room.
○
X Boom anti-collision system: There is laser type switches at each side of the boom. It protects
the boom from colliding with the ship.
2-7
Figure 2.3-1 Construction of the Crane
2-8
2.4. FUNCTION OF MAJOR COMPONENTS ................................................................... 2-10
2.4.1. CONFIGURATION OF CRANE MACHINERY HOUSE & E-ROOM ......................... 2-11
2.4.2. MAJOR COMPONENTS ON GANTRY .................................................................... 2-14
2.4.3. MAIN HOIST SYSTEM ............................................................................................. 2-17
2.4.4. BOOM HOIST SYSTEM ........................................................................................... 2-22
2.4.5. TROLLEY TRAVEL SYSTEM ................................................................................... 2-24
2.4.6. CATENARY TROLLEY SYSTEM ............................................................................. 2-29
2.4.7. MACHINERY HOUSE SERVICE CRANE ................................................................ 2-30
2.4.8. WIRE ROPE RE-REEVING DEVICE ....................................................................... 2-31
2.4.9. HEAD BLCOK .......................................................................................................... 2-32
2.4.10. CARGO BEAM ....................................................................................................... 2-32
2.4.11. WALKWAYS AND ACCESS.................................................................................... 2-33
2.4.12. SAFETY DEVICES AND SETTINGS ...................................................................... 2-34
2-9
2.4. FUNCTION OF MAJOR COMPONENTS
The main maintenance related component systems and structural parts are organized and listed
in a framed diagram shown in Figure 2.4-1. They will be explained in some more details in the
following sections with an emphasis on their mechanical functioning.
HOIST SYSTEM
MAIN HOIST SYSTEM G , N○○
BOOM HOIST SYSTEM F , M ○ ○

DRIVING SYSTEM
TROLLEY DRIVING SYSTEM ○

H, ○
L , ○
P ,○
Q
GANTRY DRIVING SYSTEM ○

B , ○
C, ○
D
HYDRAULIC UNITS
BACKREACH MULTI-FUNCTION POWER UNIT
EMERGENCY BRAKE HYDRAULIC SYSTEM
GANTRY WHEEL BRAKE HYDRAULIC SYSTEM
ELECTRICAL
CONTROL SYSTEM
SAFETY DEVICES AND SETTINGS
LIFING SYSTEM
SPREADER○
S , ROTATOR
HEAD BLOCK ○
R CARGO BEAM
2-10
MISCELLANEOUS
WALKWAY AND ACCESS
CATENARY TROLLEY○
O
SERVICE PLATFORM(option)
CARTS(option)
SERVICE JIB HOIST ○

T
MACHINERY HOUSE & E-ROOM ○

E , ○
U
MACHINERY HOUSE SERVICE CRANE○

I
WIRE ROPE RE-REEVING DEVICE ○

J
Figure 2.4-1 Major Components of the Crane

2.4.1. CONFIGURATION OF CRANE MACHINERY HOUSE & E-ROOM
The machinery house ○ E of the crane provides a reliable shelter to the main and boom hoist and
the trolley travel drive, the most important devices to crane operation. It also provides a safe and
comfortable working environment to operators. The following devices, as shown in Figure 2.4-2,
are contained in the machinery house.
The E-room ○
U is a part of the machinery house. It contains electric drive panels and associated
equipments. Access to the crane is by designs limited to authorized persons. The electric room is
fit with conventional mechanical tumbler locks. Authorized persons have keys that fit these locks.
Each door can be accessed with a conventional key even if there is no electrical power to the
crane. As a safety feature egress is never denied from any location. Thus no door can be locked
from the inside.
Normally the temperature of the room is controlled between 20° and 30° by a roof-mounted air
conditioner, but one additional identical air conditioner is provided as well. If the primary air
conditioning system fails or the temperature of E-room exceeds 30°, the redundant air conditioner
will automatically control the temperature of the E-room. To realize an airtight room (for
overpressure system), a blower fan with filter is provided.
2-11
Figure 2.4-2 Configuration of the Crane Machinery House
○
1 Boom hoist motor
○
2 Boom hoist motor brake
○
3 Boom hoist gear reducer
○
4 Boom hoist emergency motor
○
5 Boom hoist drum and ropes
○
6 Boom hoist emergency disc (low speed) brakes
○
7 Main hoist motors
○
8 Main hoist motor brakes
○
9 Main hoist gear reducer
2-12
○
10 Main hoist emergency disk (low speed) brakes
○
11 Main hoist drums and ropes
○
12 Main hoist emergency motor
○
13 Trolley drive drum and ropes
○
14 Trolley drive motor
○
15 Trolley drive motor brake
○
16 Trolley drive gear reducer
○
17 Trolley emergency motor
○
18 Machinery house service crane
○
19 Gear for re-reeving main hoist and trolley ropes
○
20 Panel for operating main hoist, trolley, boom hoist emergency
○
21 High voltage switchgear
○
22 Main transformer
2-13
2.4.2. MAJOR COMPONENTS ON GANTRY
2.4.2.1. Gantry Travel Drive

(1) General Configuration
Gantry traveling devices drive the crane running along the runway. Each of them consists of 8
wheels, of which six are driving wheels. AC variable frequency control powers the gantry travel.
Hydraulic wheel brakes are mounted at idle wheels to prevent the crane from moving in wind
gusts during the operation. The configuration of the crane gantry and its drive units are shown in
Figure 2.4-3.
5 6 7 8 9 10 11 4
Figure 2.4-3 Configuration of the Gantry Drive Assembly
○
1 Main equalizer ○
2 Intermediate ○
3 Bumper ○
4 Driven wheel with
beam equalizer wheel brake
○
5 Drive wheel with ○
6 Motor ○
7 ML coupling ○8 Motor brake(set
drive unit torque:280Nm)
○
9 Reducer 1○
0 Gantry truck ○
11 Shaft break
protection
The driving force from the motor ○ 6 is transmitted through the coupling ○7 and Gear Reducer ○ 9
to drive Wheel ○ 5 . Travel direction of the gantry can be altered by changing the rotating direction
of the motor○6.
A disc brake○ 8 for each drive unit is provided and mounted at the end of the motor○ 6 . The brand
of the brake is Bubenzer. The bubenzer brakes○ 8 are sufficient to stop the gantry with wind speed
of 35m/s. For more information, please refer to manual. In addition to bubenzer brake, a
bubenzer’s wheel brake for each conrner is provided. For more information, please refer to wheel
brake manual.
(2) Description of miscellaneous gantry components
2-14
Zpmc pneumatic-hydraulic bumpers○

3 are located at the four corners of the crane. The bumpers
are sufficient to prevent damages when the cranes collide(without driving force) with each other or
with the end stops on the wharf.
Four alarm equipment(flashlights and warning horn) are fit at the crane corners. They give an
audible and a visible warning signal to the staff in the working area while the gantry is moving.
Four emergency stops push-buttons are located at gantry level, two at the landside and two at the
waterside. By pressing one of the emergency-stop buttons, all crane motions will be stopped. Any
new motion is blocked until emergency-stop buttons are released.
Two combo sockets are mounted at gantry level, one at landside and the other at waterside. A
switch of access lightings is located at the crane access stair, by which the entire access lightings
can be turned on and off. Two telephone stations of the INTERCOM system are installed near the
stowage devices, one at the waterside, and the other at the landside.
For detailed information, please refer to electrical maintenance manual.
2-15
2.4.2.2. Crane Stowage Device
There are totally two crane stowage devices, which are mounted under the waterside and
landside sill beams. The stowage pins can be raised or lowered. As shown in Figure 2.4-4, it has a
handle and with it, the pin can be raised or lowered. When raised, the stowage device is held by a
catch. And there is also a limit switch to sense the anchor plate. Only when the limit switch is
activated can the gantry move. If the crane is to be anchored, drive the gantry to the anchor pin
position, make the pin aligned with the anchor hole on the port. Before putting down the anchor
pin, the catch should be pulled out first, then lower the anchor pin by the handle. When the upper
hole on the anchor pin reaches the position of the catch, release the catch and the pin is fixed.
Figure 2.4-4 Stowage Pin（landside） Figure 2.4-5 Stowage Pin(seaside)

It is important for the crane operator or the maintenance personnel to stow each crane on the
dock when the cranes are left unattended. If not stowed, there will be a danger that in the event of
a high wind condition, the cranes could roll down the runway in spite of the gantry brakes. Once in
motion, a crane can develop great momentum and strike another crane or other obstacle which
will cause serious damage.
Failure to properly stow the crane when the wind velocity exceeds 35m/s could result in death or
serious injury to the operator and/or ground personnel and serious damage to the crane and other
property.
All of the anchoring devices, including anchoring device,

wheel brake, tie down devices should be anchored when the
wind speed is greater than 35m/s.
The gantry should not move when the wind speed is greater
than 28m/s!
NO OPERATION IS ALLOWED WHEN WIND EXCEEDS 35m/s!
2-16
2.4.3. MAIN HOIST SYSTEM
2.4.3.1. Main Hoist Drive
`8
Figure 2.4-6 Configuration of the Main Hoist Driving System
○
1 Drum Brake ○
2 Motor ○
3 Drum ○
4 Drum Coupling
○
5 Coupling ○
6 Motor Brake(set ○
7 Reducer ○
8 Emergency Drive Device
torque:12500x4Nm)
The main hoist drive ○

G is located in the machinery house ○
E . It is powered by two AC
motors○
2 connected to the reducer ○
7 through the coupling○
5 . Two rope drums○
3 are
connected to the output shafts of the reducer○
7 through the two gear coupling○
4 . Its general
configuration is shown in Figure 2.4-6.
This equipment adopts the fleet through trolley where the main hoist drive is mounted in the
machinery house ○
E and the main hoist wire ropes travel or fleet through the trolley○
P as the
trolley○
P traverses.
The driving force of this equipment is transmitted from the motors○

2 to the drums○
3 by the high
speed couplings○
5 and drum couplings○
4 through the reducer○
7 to lift or lower the telescopic
spreader ○
S .
The wire ropes reeled out from the drum○

3 , then run through the following route:
2-17
Drum○
3 →Trim/List/Skew ○
N → Trolley ○
P → Head block ○
R →Trolley ○
P → Load cell at
boom tip
The rope ends are tied with the load cells and wire rope sockets at the boom tip. Therefore, lifting
or lowering the spreader○
S can be altered by changing the rotating direction of the motor ①.
(2) General Description

The main hoist lifts and lowers the spreader or hook by means of the two hoist ropes (8 falls
because of the reeving system). Two motors are force-ventilated by a cooling-fan with filter. The
fans draw air through the filter (forced cooling air) into the motor at the drive end. The heated air
exits the motors at the non-drive end to the outside of the machinery house. Both motors are
provided with a built-on pulse tachometer.
For more information of the motors, please refer to Siemens manual.

Four Bubenzer disc brakes, operated by electro-hydraulic thrusters, are located between the
motors ○
2 and the reducer○
7 . Four Bubenzer drum brakes○
1 , operated by hydraulic cylinder,
are located at each of the drum end. These brakes remain released under normal container
handling operation. They will be set immediately upon loss of electrical power or activation of
emergency stop or hoist overload. These brakes combination are capable of stopping hoist
motion with a large safety margin.
On the rear of one motor, an emergency drive○

8 is connected to the motor through a clutch. It is
capable of lifting and lowering the rated load. The emergency drive is disengaged under normal
hoist operation. Upon failure of the hoist control system, it can be easily engaged to the motor.
At one drum end, one switche is connected to the drum shaft. For more information, please
refer to electrical manual.
As shown in Figure 2.4-7, the four ends of the two wire ropes are clamped on the drums. Four
load cells are connected to these four falls ropes, one for each fall. They measure the load in each
of the four ropes and allow the PLC and CMS to calculate and record the lifted load and load
eccentricity.
Figure 2.4-7 Configuration of the main hoist rope reeving system
○
1 Trim/List/Skew/ Cylinder ○
2 Trolley ○
3 Load cell
2-18
2.4.3.2. TRIM-LIST-SKEW
This device○
N is composed of four hydraulic cylinders○
1 and four sheaves○
2 for the main
hoist wire ropes. It is installed at the end of the girder, adjusts the TRIM angle (Tipping or rotation
of the spreader about a horizontal axis perpendicular to the gantry rail), the LIST angle (Tipping or
rotation of the spreader about an axis parallel to the gantry rails) and SKEW angle (rotation of the
spreader about a vertical axis).
Figure 2.4-8 Configurations of the Trim-List-Skew Power Unit and Cylinders

(1) Trim, list and skew motion
By actuating combined hydraulic cylinders motions in different directions, this device adjusts the
TRIM, the LIST and the SKEW. Also, by operating the REST switch in the operator’s console, all
the cylinders return to their REST position. The TRIM, LIST and SKEW motions are achieved by
the logic combination as follows:
Figure 2.4-9 TLS Cylinders motion

1) TRIM (Tipping or rotation of the spreader about a horizontal axis perpendicular to the gantry
rail. From the operator’s perspective, trim raises and lowers the left or right end of the
spreader)
Extend the Cylinders ○

1 and ○
2 . And retract the Cylinders ○
3 and ○
4 or vice versa.
2-19
The TRIM angle of the spreader with load is designed to ±3º.Refer to Figure 2.4-9 for the
TRIM motion of the spreader.
2) LIST (Tipping or rotation of the spreader about an axis parallel to the gantry rails)

1 and ○
2 and ○
3 or vice versa.
The LIST angle of the spreader with load is designed to ±3º. Refer to Figure 2.4-9 for the
LIST motion of the spreader.
3) SKEW (Rotation of the spreader about a vertical axis)

1 and ○
2 and ○
4 or vice versa.
The SKEW angle of the spreader with load is designed to ±3º. Refer to Figure 2.4-9 for the
SKEW motion of the spreader.
When the Trim/List/Skew are at their maximum angle, the cylinders

cannot actuate. In such a case, operate the RESET switch on the
operator’s console to set it back to the Home position.
2.4.3.3. SOS anti-snag system
The SOS anti-snag system is incorporated into the main hoist system. It includes the high speed
coupling○
5 , high speed brake(with CMB) ○
6 , low speed coupling○
4 , low speed brake(with
CMB) ○
1 , load cells at the boom tip and a separate PLC. The transmitted torque of high speed
coupling can be set. When snag happens, the load cell will send signals to snag PLC and main
PLC. After receiving the signal, the emergency brake will set immediately to stop the crane. Then
the high speed brakes will set. If either of the torques from the load and the brakes is bigger than
the coupling set value, the coupling will disconnect and isolate the torque from the motor. Else, the
coupling won’t disconnect. After the system is stopped, the emergency brake will open a little to
release the load on the drum. Then close the emergency brake and open the high speed brake to
release the load on the reducer. Repeat this process until the load is within the normal load.
During this process, the speed is detected by the switches. Once the speed is faster, the brakes
will set again.
2-20
Figure 2.4-10 Components SOS system

After the snag accident, the cranes should be checked to see if there are some damages to the
crane during the snag accident. If damages are found, they should be repaired immediately. Only
after checking and confirm there is no damages to the crane, can the crane be reset and work
again.
If the coupling is disconnected, the coupling need to be reset. When resetting the high speed
coupling, first rotate the half coupling to align the couplings. There are marks on the coupling to
show the position. Then use a
rubber hammer to knock the
extruding bolts, the coupling will
return to its original position.
For detailed information, please
refer to the Malmedie or
Bubenzer instruction and
maintenance manuals.
Figure 2.4-11 Load Cell

2.4.3.4. Weighing System (Load
Cells)
The cranes are equipped with weighing system mounted on each of the 4 main hoist ropes. The
basic weighing system hardware consists of four BROSA load cells(as shown in Figure 2.4-11),
each measuring the forces from a single rope fall and an amplifier. Amplification of the four
low-level force signals creates one signal as an analog input for the four corners of the spreader.
An analog output signal is wired to a digital meter in the operator’s cab that displays the load
weight in metric tons.
2-21
The crane control monitors the loads cells with the PLC logic. When operating properly, the
system knows what kind of lifting attachment is connected to the headblock. The PLC commands
the control to make allowances for the tare weight of each different attachment. It makes
allowances for eccentric (non-symmetrical) loads in assessing the presence of an overload and
stopping the main hoist motion (a ramp stop). An alarm is sounded over the PA system to signal
the overload. Only lowering the overload at slow speed is allowed.
Besides the over load protection, the slack rope protection for the hoist are also provided by the
load cells. If the low level load cell signal from the amplifier is less than the slack rope level, it will
initiate a ramp stop. Further lowering the hoist is inhibited after a slack rope occurs. Lifting the
hoist at a reduced speed is permitted until the ropes are tensioned. When the slack rope signal is
gone, the hoist will return to its normal operation.
2.4.4. BOOM HOIST SYSTEM
2.4.4.1. Boom Hoist Drive
Figure 2.4-12 Configuration of the Boom Hoist Drive
○
1 Motor ○
2 Coupling ○
3 Reducer ○
4 Emergency Drive
○
5 Drum ○
6 Drum Brake ○
7 Drum Coupling ○
8 Motor Brake(set torque:11200Nm)
(1) Configuration
The boom hoist drive○

F is located in the machinery house ○
E . The boom hoist drive is powered
by an AC motor ① connected to the reducer ○
5 through a coupling ○
2 . One rope drum ○
5 is
connected to the output shaft of the reducer through a gear flexible coupling○
7 .
The driving force of this equipment is transmitted from the motor ① to the drum ○
5 by the high
speed coupling○
2 and drum coupling ○
7 through the reducer ○
3 .
The wire rope pays out from the drum ○

5 , then runs through the following route:
Machinery house ○
E → Sheave block on top of A-frame → Sheave blocks on the boom
Therefore, the hoisting or lowering of the boom can be altered by changing the rotating direction
of the motor ①.
2-22
SEE CHAPTER 3 “BOOM HOIST WIRE ROPE RE-REEVING

PROCEDURE” FOR THE REPLACEMENT PROCEDURE OF THE
BOOM HOIST WIRE ROPE.
(2) Description
The motor① is force-ventilated by a cooling fan with filter. The fan draws air (forced cooling air)
through the filter into the motor at the drive end. The heated air exits the motor at the non-drive
end to the outside of the machinery house. The motor is provided with a built-on pulse tachometer.
For more information of the motor, please refer to electrical manual.
One Bubenzer disc brake○

8 , operated by the electro-hydraulic thruster, is located between the
motor ①and the reducer○
3 . The brake○
8 is capable of stopping boom motion. Three Bubenzer
drum brakes○
6 , operated by hydraulic cylinder are located at the drum end. These brakes○
6
remain released under normal boom raising or lowering operation. They will be set immediately
upon the loss of electrical power or an activation of emergency stop. These brakes ○
6 ○
8
combination are capable of stopping the boom motion with a large safety margin.
For more information on brake maintenance and adjustment, please refer to the Bubenzer
Brake manuals.
At one input shaft of the reducer○

5 , an emergency drive○
4 is possible to be connected to the
input shaft through the quick disconnection coupling. It is capable of lifting the boom. The
emergency drive is disengaged under normal boom operation. Upon failure of the boom control
system, it can be easily engaged to the reducer with the handle at the disconnected coupling .A
boom emergency control cabinet is located near the boom drive○
F . Emergency drive○
4 can be
operated through this cabinet. Two limit switches are provided, one indicating the boom normal
operation and the other indicating AC emergency operation.
At one drum end, one switches are connected to the drum shaft. One is over-speed protection
switch.
For more information, please refer to the manual.

In normal conditions, the boom can be lifted up to 45º. When there is a very big ship or in
maintenance conditions, the boom can be raised up to 80º.
The boom hoist reeving includes two independent and equalized sets of falls. Either of them can
catch the boom in the event of failure of one set. All sheaves are designed as a unit when
removed or installed. As shown in Figure 2.4-13, ①○
2 are sheaves blocks on the boom. ○
3 are
sheaves blocks on top of the A-frame. ○
4 is the equalizer sheave located on top of the A-frame.
○
5 is the rope break protection device on top of the A-frame.
2-23
Figure 2.4-13 Configuration of the Boom Hoist rope Reeving System

2.4.4.2. Boom Stowage Device
This device is for securing the boom when
the boom rises to the maintenance position. It
consists of two sets of pins and sockets, as
shown in Figure 2.4-14. The pins are stored in
the storage sockets under normal operation.
The boom motion is inhibited from operation
as long as either of the pins is not inside the
storage sockets for safety.
The boom motion will ramp stop when the
normal stop limit switch is activated. At that
time, the latch hole on the boom is aligned with
that on the stowage device. Pull pins out of the
storage sockets and insert them into the latch
hole. Insertion of the anchor pins must be
done by manpower.
When trying to lower the boom, the pins must
be inserted back into the storage sockets.
Otherwise there is no motion of the boom.
There are limit switches to sense the pins.
Figure 2.4-14 Boom Stowage Assembly

2.4.5. TROLLEY TRAVEL SYSTEM
2.4.5.1. Trolley Travel Drive
Figure 2.4-15 Configuration of the Trolley Driving System
2-24
○
1 Motor ○
2 Coupling ○
3 Motor Brake(set torque:6000Nm)
○
4 Reducer ○
5 Emergency Drive ○
6 Drum Coupling
○
7 Wire rope to seaside ○
8 Drum ○
9 Wire rope to landside
The trolley travel drive○

H is located in the machinery house ○
E . It is powered by one AC motor
○
1 connected to the reducer ○
4 through a flexible coupling ○
2 . A rope drum ○
8 is connected
to the output shaft of the reducer○
4 through a gear drum coupling○
6 . Its general configuration is
shown in Figure 2.4-15.
The four wire ropes ○

7 , ○
9 run through the following route, respectively.
The Wire rope ○

7 reeled out from the drum ○
8 ;
Drum ○
8 → Sheave of rope tensioning device ○
L at girder rear section → Trolley ○
P
The Wire rope ○

9 reeled out from the drum ○
8 ;
Drum ○
8 → Sheave at the boom tip → Trolley ○
P
Therefore, the trolley travel direction, toward the seaside or the landside, can be altered by
changing the rotating direction of the motor ①.
THE TROLLEY CAN TRAVEL SLOWLY WHEN THE BOOM IS AT ITS

STOWED OR MAINTENANCE POSITION.
SEE CHAPTER 3 “TROLLEY TRAVEL WIRE ROPE RE-REEVING
PROCEDURE” FOR THE REPLACEMENT PROCEDURE OF THE TROLLEY
TOWING WIRE ROPE.
(2) Description
The trolley driving system moves the spreader or the hook by means of two sets of trolley ropes
forward⑦ and backward○
9 . The motor○
1 is force-ventilated by a cooling fan with filter. The fan
draws air (forced cooling air) through the filter into the motor at the drive end. The heated air exits
the motors at the non-drive end to the outside of the machinery house. The motor is provided with
a built-on pulse tachometer.
For more information of the motor, please refer to the manual.
One Bubenzer disc brake○

3 , operated by the electro-hydraulic thruster, is located between the
motor ○
1 and the reducer○
4 . The brake○
3 is capable of stopping trolley motion.
For more information on brake maintenance and adjustment, please refer to the Bubenzer disc
brake manual.
At one input shaft of the reducer○

4 , it is possible to connect an emergency drive○
5 to the
reducer shaft through the quick disconnection coupling. It is capable of traveling the trolley with
rated load. The emergency drive○
5 is disengaged under normal trolley operation. Upon failure of
the trolley control system, it can be easily engaged to the reducer○
4 with the handle at the
2-25
disconnect coupling. As shown in Figure 2.4-15, a trolley emergency control cabinet is located
near the trolley drive○
H . Emergency drive○
5 can be operated through this cabinet. Two limit
switches are provided, one indicating the trolley normal operation and the other indicating AC
emergency operation.
THE SETTING TORQUE OF MOTOR BRAKE IS 6000Nm
As shown in Figure 2.4-16, the four ends of the two wire ropes are clamped on the drums. The
landside rope goes out of the drum to the tension device at the girder and then to the trolley, and
the same way inversely back, thus generates two falls at the drum. The seaside rope first goes to
the sheave at the boom tip, then to the trolley, and the same way inversely back, thus generates
another two falls. They tow the trolley backward and forward by changing the rotating direction of
the drum.
Figure 2.4-16 Configuration of the Trolley Rope Reeving
○
1 Tension Device ○
2 Landside wirerope ○
3 Trolley
○
4 Drum ○
5 Seaside wirerope ○
6 Sheave of boom tip
2.4.5.2. Trolley (Catenary trolley) Travel Rope Tensioner
1
Figure 2.4-17 Configuration of the Trolley Rope Tensioner
2-26
○
1 Sheave ○
2 Cylinder ○
3 Sheave Arm
Catenary trolley tensioner device is the same with that of trolley’s, so here take trolley’s as an
example.
Trolley rope tensioner ○

L are located at the rear of the girder and apply appropriate tension to
the trolley travel ropes by actuating two hydraulic cylinder ○
2 attached to trolley sheave ○
1
through the sheave arm○
3 . With this function, swinging of the trolley due to the loosening of the
wire rope during loading or unloading of the container will be minimized.
(2) Brief description
The cylinders are powered by a hydraulic pump with a pre-set pressure of the hydraulic cylinder.
The rope tensioning cylinders will retract in to prevent the ropes from over-tensioning due to the
changes of the waterside rope length as the boom rises. The cylinders will extend to keep the
ropes under proper tensioning due to new ropes stretch after a period of operation.
(3) Position of the Cylinder arms
The position of the cylinder is monitored by two proximity switches. The original position of the
cylinder is that the sheave arm ○
3 is almost vertical under the pressure of hydraulic system. The
arm may offset from its original position and trolley motion is allowed until either of limit switches is
activated.
The position of the sheave arm should be inspected by a qualified

maintenance personnel at every shift. Adjust the wire ropes length
accordingly if necessary.
(4) Trolley Rope Length Adjustment

In many cases, the wire rope length needs adjustment due to the stretching and slackening of the
wire rope. Please refer to Chapter 3 for the procedure of trolley wire rope length adjustment.
2.4.5.3. Trolley
The trolley driving system ○

H moves the trolley ○
P with the spreader ○
S and the container
forward or backward along the girder and the boom. The trolley ○
P structural configuration is
shown in Figure 2.4-18 as example.
2-27
1 2 3 4 7 5 6
Figure 2.4-18 Configuration of the Trolley
○
1 Trolley truck and wheel ○
2 Trolley bumper ○
3 Hoist sheaves ○
4 Trolley rope sheave
○
5 Operator’s cab ○
6 Access platform ○
7 Rope Clamp
(1) The trolley is towed by the ropes connected to the trolley with two rope clamps○
7 .
(2) Four traveling wheels are on the trolley frame corners.

(3) There are three stop limit switches along the trolley runway. One at the boom tip, one at the
back reach and one near the waterside trolley-girder-support-beam which prohibit the moving
of the trolley when boom is up.. Besides that, an home reset limit switch is also near the
waterside trolley-girder-support-beam. Every time when the trolley moves from the landside
to the waterside and passes this limit switch, the encoder of the trolley for positioning will be
reset. Two over-travel limit switch at boom tip and back reach are provided for trolley over
travel protection. As long as the over travel limit switch is activated, the trolley motion is
inhibited from operation.
(4) Eight main hoist rope sheaves ○

3 are mounted on the trolley frame. They accomplish the
rope pickup and diverting.
(5) The trolley frame has four ZPMC pneumatic-hydraulic buffers ○

2 at the seaside and the
landside to minimize the impact on the end stop in case of an electrical control failure.
2.4.5.4. Operator’s cab
(1) General Description
The cab is purposefully and ergonomically designed to
serve the crane operator. Attention was focused on
providing comfort and convenience so that the operators
can concentrate on the serious task of handling
containers, and not be distracted or encumbered by
uncomfortable surroundings.
All primary crane functions can be achieved from the cab.
The cab is mounted to the trolley framework on its
landside to provide the best possible view during loading
or unloading operation. A seat with safety belts and
shoulder harness which is adjustable to accommodate a
person’s weight, height and distance from the front Figure 2.4-19 Operator’s Chair
windows, is positioned so that the operator can reach all
control switches comfortably.
2-28
An air-conditioner is furnished to heat or cool the cab and maintain a temperature that is
comfortable for the operators. The intake and re-circulated air is filtered.
(2) Definition of Switches, Indicators and Alarms
For detailed description on 1) Left Console Device Function Definition, 2) Right Console
Device Function Definition, 3) the devices on the Auxiliary Indication Panel, and 4) the
devices on the spreader indicator box, please refer to electrical manual.
2.4.6. CATENARY TROLLEY SYSTEM
Figure 2.4-20 Continuously distributed catenary-rope-support-roller system
○
1 Tension device ○
2 Landside catenary trolley ○
3 Trolley ○
4 Towing rope 1
○
5 Seaside catenary trolley ○
6 Towing rope 2 ○
7 Sheave
2.4.6.1. General
Catenary trolley system ○

O is provided for supporting the main hoist rope, trolley towing rope and
towing rope of the catenary trolley itself. The components are shown in Figure 2.4-20. Especially
the main hoist rope may bounce at the moment when a container is picked up from the vessel ,
hold or from a chassis that results in the spreader sway and hitting the horizontal truss structure of
the boom and the girder by the hoisting rope. The catenary trolleys are provided for each side of
the main towed trolley for effective preventing the rope sag and thus reduces spreader sway.
Each catenary trolley is provided with four (4) wheels supported on the trolley rails. Both the
seaside and landside catenary trolleys are towed by the main trolley through wire rope. The wire
ropes are specially reeved to enable the catenary trolleys run at the half way between the main
trolley and the boom end and between the main trolley and the girder rear end all the time.
Various rope sheaves and supporting brackets are provided on the catenary trolleys which are at
the optimum position for supporting the rope sags.
To ensure normal operation of the seaside and landside catenary trolleys a hydraulic cylinder
tension device is located at the rear girder to keep constant tension of the towing rope.
Drawing J554A2200 “ Catenary trolley system” shows the outline of this system.
2-29
Figure 2.4-21 Catenary Trolley (landside)

2.4.6.2. Major components of the catenary trolley system
(1) Catenary trolley frame
The trolley frame is a welded construction made from plate steel and sections and is the main
load bearing structural member. All the towing sheaves, wire rope support rollers are installed
on the frame platform. On the top of the frame column 4 wheels are fit. Shield boards are
provided at both sides of lower part of the frame.
(2) Wheels , Wheel shafts
The wheels and shafts support the catenary trolley structure weight and all supported rope
weight and travel along the trolley rail with the towing rope.
(3) Wire rope support rollers
Support rollers are arranged on the catenary trolley platform at right, left side and at upper
and lower positions according to main hoist rope, trolley towing rope position respectively.
They should be adjusted to correct position, i.e. slightly lower than wire rope by about 80mm
(when the rope is tensioned).
(4) Sheave block for catenary trolley traveling
To ensure half speed for the seaside and landside catenary trolleys, fixed sheave blocks are
installed on the catenary trolley frame, at the boom tip and girder rear end. The multiplying
power of sheave block to towing rope is 2. Arrangement of sheave block and wire rope
reeving are shown on drawing J554A2200.
(5) Towing rope tension device (refer to Drawing J554A2203)
Please refer to paragraph 2.4.5.2 for details.
2.4.7. MACHINERY HOUSE SERVICE CRANE
Figure 2.4-22 Machinery House Service Crane
2-30
One set of the service cranes ○

I is provided in the machinery house ○
E . The service crane is
an overhead electric powered crane that spans the machinery house and is capable of centering
over, lifting and traveling with any piece of the components inside the machinery house.
By using a hoist of the high lift type, this service crane can load or unload the machinery
components from the machinery house to the ground.
In normal conditions, the crane should be parked at the parking position and fixed on the floor.
There is a limit switch on the hatch cover. When the cover is open, that means something is lifted
from or to the ground. In this condition, the trolley can’t move. This is for safety to prevent the
trolley with 45’ container colliding with the hook of service crane when lifting something from or to
the ground.
2.4.8. WIRE ROPE RE-REEVING DEVICE
Figure 2.4-23 Wire Rope Re-reeving Devices
The re-reeving device ○

J , a kind of motorized cable drum, is equipped in the machine house○
E
over the trolley driving system.
During re-reeving procedure, the device○

J wind the old rope on either one of the reel which
consists of a driving motor and a transmitting reducer. The new wire rope is on the other reel. The
two reels should rotate in opposite directions when replacing the old rope.
For detailed re-reeving procedure to replace the main hoist rope, boom hoist rope and trolley
travel rope, please refer to Chapter 3 of this manual.
Motor 7.5kw 1500rpm Reducer ratio 187
Power supply 400V 50Hz Reel speed 8.02 rpm
2-31
2.4.9. HEAD BLCOK
(1) Technical description
The head block○

R is a link between the hoist and the spreader and is permanently reeved to the
crane. It is a structural part of the crane and designed for specified crane capacity. Four hoist
sheaves○
1 are mounted on each corner. The head block is furnished with twist locks ○
2 for
getting connected to the spreader or the cargo beam.
A cable, of which one end wrapping on a reel on the trolley and the other terminates in a multi-pin
plug on the head block , supplies electrical power to the lifting devices.
In the process of changing the spreader, the cable originally plugged in the spreader must be
plugged into the dummy socket at the head block. Otherwise the hoist motion will be locked out.
This is for cable protection.
In order to maintain the limit switches on the trolley, a portable cage is provided on the top of
mancage. In normal conditions, the cage is not installed. When to maintain the limit switch, fix the
cage on the top of the mancage with bolts. Then people climb into the cage and hoist the
headblock slowly. When climbing onto the top of the mancage, do wear the safety harness!
(2) Operating instruction
After a short term or a long term of standstill, check the operation of the hoist rope sheaves.
Before start-up, perform lubrication to the part of the movement.
For detailed procedure, please refer to Bromma tandem headblock manual.

2.4.10. CARGO BEAM
The cargo beam○

W is rated at 100 tons(98.5LT). It is provided with a swivel safety single hook○
1
in the center of the beam and the lifting pad eyes○
2 near the ends of the beam. Its purpose is to
handle non-containerized loads. It is important that professionals safely attach the sling to the
hook○
1 and the pad eyes○
2 .
T T
Figure 2.4-24 Configuration of the Cargo Beam

An example to lift a test container with proper slings to the hook is illustrated in Figure 2.4-25.
2-32
SWL 100LT
Figure 2.4-25 Arrangement of load lifting under cargo beam

2.4.11. WALKWAYS AND ACCESS
Crane access to every part of the crane is provided with

stairways, walkways, and ladders. The main stairway is
located on the right landside leg(face to the sea). Rest
platforms are provided at various elevations along the
stairways which can be used to access the portal beam,
operator’s cab parking position, or machinery house
elevation. And fences are provided between the stairs and
elevator to protect people, as shown in Figure 2.4-26 as
example.
On the left side of landside leg, ladders are provided for
floodlights and structure inspection and maintenance on
the portal beam.
In addition to the main stairway, there are a combination of
walkways and ladders which provides accesses to most
parts of the crane: boom, trolley girder, cabin washing
platform, trolley girder support beams, trolley girder end tie
and the top of the A frame. Platforms and walkways are
provided on the crane to make ready access to all
components which need regular maintenance.
The minimum passageway is 710mm clear width which
gives enough width to pass through.
The stair treads are galvanized to resist corrosion, and the
rough surface can prevent slipping.
All the rails are fit with bolts and can be dismantled. Pieces
of rails are galvanized before fitting. And the gratings are
galvanized before being fit with hooks. In this way,
stairway won’t rust. The handrails are made of Ø42.3x2.75
diameter pipe.
An elevator is available to reach frequently accessed parts
of the crane. If the elevator is inoperative or there is a loss Figure 2.4-26 Stairways And
of electrical power, then the stairway is a reliable means of Elevator
access to or egress from the crane.
The elevator is on the landside right leg. There are totally 4 stations: first floor(near the sill beam),
portal beam, the operator’s cab and the seaside upper beam.
2-33
Each landing has double hinged doors and a cage to guard the elevator shaft and can only be
opened when the elevator is at that landing. This is a safety provision to protect a person from
falling through the elevator shaft.
2.4.12. SAFETY DEVICES AND SETTINGS
2.4.12.1. Electric Room Access Restrictions

Access to the crane is limited to authorized persons. The electric room is fit with conventional
mechanical tumbler locks.
2.4.12.2. Maintenance Mode
The crane control system is provided with a maintenance mode of operation. This mode contains
features that will warn and protect the maintenance personnel who may be working in diverse
areas of the crane.
Before intending to conduct any maintenance on the crane, the maintenance personnel should
place the crane into the maintenance mode which is suitable for maintenance of the crane.
REINSTATE THE NORMAL OPERATION MODE AFTER THE

MAINTENANCE JOB IS COMPLETED.
2.4.12.3. Emergency Stops

In the case of an emergency, emergency pushbuttons are provided at locations throughout the
crane. Pressing any one of these pushbuttons will disconnect the control power, stop all motions
and set all brakes.
2.4.12.4. Gantry Travel Warning
A flashing beacon and an audible alarm are provided on the crane to warn personnel that the
gantry is running. These devices will activate whenever the gantry motors are running.
2.4.12.5. Over-Travel Protection
The over-travel protection is provided by means of limit switches. In the event of over travel, the
motion will be stopped. This status can only be reset by maintenance personnel in the E-room.
2.4.12.6. Over-Load Protection
This crane is designed to handle commercial loads up to 65T under the twin lift telescopic lifting
spreader when handling two twenty-foot containers, or up to 100T when handling a commercial
load with the cargo beam (outreach 65m). Do not intend to lift loads that are more than allowed!
The cranes are equipped with load cells mounted on each of the four main hoist ropes. An
overload condition is declared when the maximum preset load value on any of the four hoist load
cells is exceeded. The control uses PLC logic to monitor the load cells. It recognizes the
attachment connected to the head block and recalibrates the maximum allowable load value
depending on its tare weight. An indicator mounted on the auxiliary panel in the operator’s cab
signals the overload. An audible alarm sounds over the PA system to signal the overload. All
motions are inhibited, and only lowering at slow speed is allowed. The main hoist system will reset
to normal once the overload is removed.
2.4.12.7. Anti-Collision Protection
There are two laser switches, both for the laser anti-collision system on each side of the boom.
The operation of either one of the two switches will stop the Gantry motion and set the brakes.
Any drive fault will also stop gantry motion and set the brakes. A fault drive may be reset by
pressing the Control On/Reset push button. In the event of a collision between the ship and the
crane boom, a ship collision laser switch is activated.
2-34
2.4.12.8. Bumpers and Others

The crane is equipped with bumpers and limit switches to prevent collisions of over travel.
Bumpers and electrical protection are provided for the trolley and gantry. Bumpers are located at
the ends of trolley and gantry which will absorb the colliding energy to reduce the damages to
cranes.
BEWARE OF ANY UNUSUAL EVENTS, e.g. ABNORMAL SOUNDS,

VIBRATIONS OR MOVEMENTS, SLACK WIRE ROPES OR CABLES, etc., IN
CASE OF ANY, STOP THE CRANE AND ASK MAINTENANCE PERSONNEL
FOR CHECK AND CORRECTION.
REMEMBER SAFETY IS ALWAYS YOUR FIRST PRIORITY!
2-35
Maintenance Instructions
3. MAINTENANCE INSTRUCTIONS ...................................................................... 3-1

3.1. GENERAL PRINCIPLES .............................................................................. 3-3
3.1.1. CAUTIONS AND SAFETY NOTES ........................................................................... 3-3
3.1.2. LIST OF OTHER VENDOR’S MANUALS ................................................................. 3-4
3.1.3. MAINTENANCE INSTRUCTIONS ............................................................................ 3-5
3.2. ROUTINE MAINTENANCE AND INSPECTION ........................................... 3-8

3.2.1. Inspection and preventive actions ............................................................................. 3-8
3.2.2. Lubrication .............................................................................................................. 3-10
3.2.3. Inspection of alignment ........................................................................................... 3-10
3.2.4. Inspection of fasteners & connections..................................................................... 3-13
3.2.5. Inspection of temperature rise ................................................................................. 3-16
3.2.6. Inspection of mechanical abnormal noise ............................................................... 3-17
3.2.7. Inspection of abnormal vibration ............................................................................. 3-17
3.2.8. Inspection of crack .................................................................................................. 3-18
3.2.9. Inspection of cleanness ........................................................................................... 3-18
3.2.10. Inspection of rail & rail clips ................................................................................... 3-19
3.2.11. Inspection of gantry & trolley travel wheel ............................................................. 3-25
3.2.12. Inspection of rope sheaves ................................................................................... 3-26
3.2.13. Inspection of hook ................................................................................................. 3-27
3.2.14. Inspection of brake disc ........................................................................................ 3-28
3.2.15. Inspection of bushes ............................................................................................. 3-28
3.2.16. Inspection of steel structural members .................................................................. 3-29
3.2.17. Inspection of all safety protections ........................................................................ 3-30
3.2.18. Inspection of consumable parts ............................................................................. 3-30
3.2.19. Inspection and maintenance of the elevator .......................................................... 3-31
3.3. LUBRICATION ............................................................................................ 3-34

3.3.1. GENERAL DESCRIPTION...................................................................................... 3-34
3.3.2. LUBRICATION PROCEDURE ................................................................................ 3-35
3.3.3. LUBRICATION NOTES ........................................................................................... 3-35
3.3.4. OIL MONITORING .................................................................................................. 3-36
3.3.5. LUBRICATION TABLE ............................................................................................ 3-38
3.4. WIRE ROPE................................................................................................ 3-42

3.4.1. WIRE ROPE HANDLING ........................................................................................ 3-42
3.4.2. CAUSES OF WIRE ROPE FAILURE ...................................................................... 3-43
3.4.3. EXAMPLES OF WIRE ROPE FAILURE ................................................................. 3-44
3.4.4. TYPES OF WIRE FRACTURES ............................................................................. 3-46
3.4.5. WHEN TO REPLACE WIRE ROPE ........................................................................ 3-47
3.4.6. WIRE ROPE MEASURING ..................................................................................... 3-49
3.4.7. TERMINATION OF WIRE ROPE END .................................................................... 3-49
3.4.8. WIRE ROPE INSPECTION ..................................................................................... 3-50
3.4.9. WIRE ROPE REREEVING ..................................................................................... 3-55
3-I
3. MAINTENANCE INSTRUCTIONS
This Chapter basically expatiates upon the inspection and routine maintenance of the crane. In
this Manual, we fundamentally divide Crane Maintenance into Inspection and Routine
Maintenance and Repair, although these two parts sometimes can not be 100% distinguished
from each other.
The inspection and routine maintenance is used to check whether the crane is in a safe state. It is
basically a visual inspection and some functional/detective tests. If, in doing so, an adequate
assessment is not possible, a disassembly of crane parts has to be undertaken to get assess to
the hidden parts. Chapter 4 “The repair Instructions” will illustrate crane repair procedures in detail
on components which need disassembly and disengagement.
In Section 3.1, the cautions and instructions about inspection and maintenance are outlined,
aiming at giving a general idea on how to carry out an inspection and a routine maintenance.
Through Section 3.2 to Section 3.4 of this Chapter, the description of the inspection and
maintenance follows the sequence as below:
ROUTINE MAINTENANCE AND INSPECTION LUBRICATION WIRE

ROPE
Since the wire rope is the most important component used on the crane, we spared lots of ink to
write in section 3.4.
Numerous charts and data, plenty of illustrations are used in this Chapter to present a clear
explanation of the information necessary for the intended inspection or maintenance tasks.
3-1
3.1. GENERAL PRINCIPLES .............................................................................. 3-3

3.1.1. CAUTIONS AND SAFETY NOTES ........................................................................... 3-3
3.1.2. LIST OF OTHER VENDOR’S MANUALS ................................................................. 3-4
3.1.3. MAINTENANCE INSTRUCTIONS ............................................................................ 3-5
3-2
3.1. GENERAL PRINCIPLES
Before starting any maintenance or repair job, this section should be read carefully and thoroughly
understood in order to get clear general ideas on maintenance safety and instructions.
3.1.1. CAUTIONS AND SAFETY NOTES
Refrain from any working method that may inhibit safety!
This manual should always be available for inspection by the

maintenance staff. Before commencement of service work, the container
crane always has to be made free of load, set to maintenance position and
switched off if no other note is given.
Safety is always a first priority in any maintenance operation. Maintenance work is different from
ordinary operations. When crane is under maintenance, some of its parts may be disassembled or
unstable, thus special attention should be paid to. Operators and maintenance personnel should
be familiar with the crane’s features. Before operating or maintaining the crane, maintenance and
operation instructions have to be read carefully and understood by all maintenance and repair
personnel. The crane should be put into operation only by trained specialists.
Follow local safety laws and codes issued by the related authorities. Safety requirements
mentioned in Chapter 1, as well as special safety cautions on the maintenance tasks are all valid.
For repairing parts or replacing components safely, maintenance persons must follow the
description in this manual and manuals it has mentioned. Incomplete or illegible operating and
maintenance manual must be replaced immediately.
The relevant section of this manual is to be studied carefully before every maintenance or repair.
Only qualified and trained staffs may carry out the repairs and maintenance on the crane.
The crane should be set to maintenance mode for such tasks.
Use safety harnesses and other safety gears as needed when working at places where you do not
have a safe working platform and handrails to protect. It is a good practice to work as a team of at
least two persons when engaging in maintenance and repairing work where there is potential
danger.
When a person stands on the trolley during maintenance, he must wear safety harness, and
install safety chains near the rope inspection platform. When the trolley requires moving during
the maintenance or inspection, even at a very slow speed, the person on the trolley must pay
special attention to any potential crush hazard.
Secure the repair area by closing a wider area. During maintenance on the crane, be sure to close
hatches in the machinery house and other places, or to protect them with fences.
During repairing or maintenance:
3-3
If hands will be on rope for inspection, they must be away from pinch point.
The maintenance persons should paid more attention to the moving/rotating parts.
An additional person is needed to act as a spotter between the operator and the mechanic while
inspecting the rope.
When handling parts from the hatches on the floor in the machinery house, protect around the
hatch with its fenders before opening it.
Conductive parts must be switched off and secured against reactivation.
Provide absorbing devices for leaking operating materials.
Wear protective clothing (oil and petrol-resistant gloves, protective clothing, eye goggle, helmet,
protective footwear)
Handle operating and cleaning detergents cautiously.
Provide a safe and environmentally friendly way to release, store and dispose the operating and
auxiliary materials.
Do not use machine parts as climbing aids.
Reinstall and test safety devices (which have been disassembled during maintenance or test and
repair work) immediately after the end of maintenance and repair work.
Inform the operating personnel before the commencement of special or maintenance work.
Tighten screw joints which were loosened during test and maintenance work correctly.
Replace fastening elements and seals (e.g. self-securing nuts, washers, split pins, O-rings and
seals) which cannot be used again.
After maintenance / repair work, the following activities are required:
Update fault log and maintenance check list. The operator has to make sure that the occurred
faults are logged and eliminated.
Put away tools, foreign parts and operating materials left lying around.
The cranes have been provided with grating walking surfaces where possible. Many of these
walking surfaces are more than 40m high at the cab and machinery house elevation. An object,
which falls from such a height to the ground, is traveling at the speed of a bullet and it can cause
serious injury or even death if it strikes a person on the ground. It is everyone’s duty and
responsibility to pick up any object or debris found on the crane to avoid accidents.
Test running and functional check of the components and safety devices. A functional test has to
be carried out before starting operation and service again.
3.1.2. LIST OF OTHER VENDOR’S MANUALS
In addition to this maintenance manual, all subcontractors have manuals for their own
components. To maintain such components, please refer to their manuals. The list of these
3-4
manuals is listed in Table 3.1-1 as follows.
Table 3.1-1 Manuals from Subcontractors Table
Electrical components and drive control Electrical manual

Reducer ZPMC reducer manual
Brakes Bubenzer brake manual
Wheel brake Bubenzer brake manual
Drum coupling other than main hoist system ZPMC coupling manual
Main hoist motor coupling and drum coupling Malmedie coupling manual
Motor coupling other than main hoist system Bubenzer coupling manual
Elevator ZPMC elevator manual
Gantry and spreader cable reel Cavotec gantry and spreader cable reel manual
Festoon system Igus manual
Service crane ZPMC service crane manual
Gantry buffer, Trolley buffer ZPMC buffer manual
3.1.3. MAINTENANCE INSTRUCTIONS
DANGER OF FALLING!
DANGER OF TRIPPING!
KEEP HANDS CLEAR OF MOVING PARTS!
WEAR PROTECTIVE CLOTHING!
When carrying out maintenance work, the general and special stipulations for the safety and
prevention of accidents in Chapter 1 and Section 3.1.1 of this Chapter must be obeyed.
For Keeping up the operation condition and operational safety of this container crane, the
maintenance of the crane in regular intervals is stipulated in Chapter 5 “The Scheduled
Maintenance Task List”.
This maintenance task list is classified into “Pre Op”; “Shift”; “Daily”; “Weekly”; “Bi-Weekly”;
“Monthly”; “Quarterly”; “Semi-Ann”; “ Annually”; “Quad” and “Hours”.
The correct execution of the maintenance jobs has to be confirmed with signature and date in the
check list sheet. The maintenance and inspection documents have to be kept so that they are
available at any time.
3-5
Operators and maintenance personnel should be familiar with the crane’s configurations and
features. Please refer to relevant sections, drawings and data in Chapter 2 of this Manual.
The periodic maintenance jobs (intervals) are based on a regular usage of the container crane. If
usage duration or operation conditions changes, the intervals of maintenance jobs have to be
adapted accordingly and feed back to ZPMC in writing.
If defects or damages are detected during maintenance, these parts have to be immediately
repaired or replaced.
Refer to Chapter 4 for detailed Repair Instructions of the crane components.
Damaged components/parts should be replaced only by original components. When installing

non-original components, all guarantee claims will be invalidated. Always replace self-securing
nuts, O-rings, split pins, spring washers, rotary shaft seals once they are disassembled. Select
new un-used fastening and seal elements.
Following aspects should be paid attention to during routine inspection and maintenance:
(1) Inspection and preventive actions
(2) Inspection of lubrication
(3) Inspection of concentricity (alignment) periodically
(4) Inspection of fasteners and connections
(5) Inspection of temperature raising
(6) Inspection of mechanical abnormal noise
(7) Inspection of abnormal vibration
(8) Inspection of crack
(9) Inspection of cleanness
(10) Inspection of ground and gantry rail
(11) Inspection of gantry and trolley travel wheel
(12) Inspection of rope sheaves
(13) Inspection of hook and twist lock pin
(14) Inspection of rope support roller
(15) Inspection of steel structural members
(16) Inspection of all safety protections
(17) Inspection of consumable parts
(18) Inspection of elevator.
Detailed instructions for all above-mentioned inspections are given in Section 3.2.
3-6
3.2. ROUTINE MAINTENANCE AND INSPECTION ........................................... 3-8

3.2.1. Inspection and preventive actions ............................................................................. 3-8
3.2.2. Lubrication .............................................................................................................. 3-10
3.2.3. Inspection of alignment ........................................................................................... 3-10
3.2.4. Inspection of fasteners & connections..................................................................... 3-13
3.2.5. Inspection of temperature rise ................................................................................. 3-16
3.2.6. Inspection of mechanical abnormal noise ............................................................... 3-17
3.2.7. Inspection of abnormal vibration ............................................................................. 3-17
3.2.8. Inspection of crack .................................................................................................. 3-18
3.2.9. Inspection of cleanness ........................................................................................... 3-18
3.2.10. Inspection of rail & rail clips ................................................................................... 3-19
3.2.11. Inspection of gantry & trolley travel wheel ............................................................. 3-25
3.2.12. Inspection of rope sheaves ................................................................................... 3-26
3.2.13. Inspection of hook ................................................................................................. 3-27
3.2.14. Inspection of brake disc ........................................................................................ 3-28
3.2.15. Inspection of bushes ............................................................................................. 3-28
3.2.16. Inspection of steel structural members .................................................................. 3-29
3.2.17. Inspection of all safety protections ........................................................................ 3-30
3.2.18. Inspection of consumable parts ............................................................................. 3-30
3.2.19. Inspection and maintenance of the elevator .......................................................... 3-31
3-7
3.2. ROUTINE MAINTENANCE AND INSPECTION
In order to ensure a normal crane operation and prolong a crane’s life, each component on crane
must be operated correctly, and proper maintenance schedule must be followed. For keeping up
the operating status and operational safety of the container crane, maintenance of the crane at
regular intervals is stipulated in Chapter 5. The crane routine maintenance and inspection can be
started with the following aspects.
The crane and its additional equipment, primarily the safety devices, have to
be checked for proper condition and function depending on work use. It
requires special supervision of: − emergency-stop button and control; −
drive & brake; − electrical equipment; − limit switch and overload protection.
3.2.1. Inspection and preventive actions
The inspection is used to check whether the crane is in a safe state. It is basically a visual
inspection and functional test. If, in doing so, an adequate assessment is not possible, further
tests have to be undertaken, e.g. non-destructive testing. If necessary, a disassembly of crane
parts must be undertaken to get assess to the hidden parts.
The description of the crane components disassembly and re-assembly is detailed in Chapter 4
“The repair Instructions”.
When performing inspection and maintenance of the crane, take the appropriate preventive
actions according to Table 3.2-1 and Table 3.2-2.
Table 3.2-1 Preventive action (mechanical)
Inspection Items Contents of Inspection Preventive Action
Gear Grease on gear Apply grease if poorly greased.
Gear coupling Gear engagement and Adjust the attachment if engagement is

wear not proper.
Replace if wear is excessive
Sliding surface of Lubricating condition Apply if necessary so that respective

bearing, sheaves, lubrication points are lubricated as
wheel, pins, lever pins, required.
etc.
Wear condition Replace if wear is excessive
Bolts, nuts, keys, pins, Looseness, attachment Tighten sufficiently.

shaft coupling bolts condition of split pin
Replace if quality is deteriorated
retainer
3-8
Gear box Oil Add oil if the amount of oil is low.
Replace if quality is deteriorated.
Wire ropes Lubricating condition, Apply grease as necessary if grease is

cutting condition of wires poorly applied.
See Section 3.4.8 for wire rope

inspection.
Wire rope end Condition of wire end Tighten loose bolts with specified torque.
termination
See Section 3.4.7
High strength bolts, and Looseness Replace if loose.

welding for steel
Crack, damage Repair if crack or damage is observed.
structure
Brake lining Wear, fitness to brake disc Replace if wear is excessive.
Brake disc Wear of sliding surface Repair if sliding surface is worn or rough.
Table 3.2-2 Preventive action (electrical)
Inspection Items Contents of Inspection Preventive Action
Motor Wear of bearing, Replace if wear is excessive.
wear of slip ring,
carbon brush
Insulation resistance Dry if resistance is insufficient.
Brake Clearance of sliding Adjust if necessary.

surface
Insulation resistance Dry if resistance is insufficient.
Controls Condition of contact Replace if wear is excessive.
Current collecting Wear

equipment
Contact pressure Adjust to appropriate pressure.
3-9
3.2.2. Lubrication
Lubrication is one of the most important maintenance tasks. It will determine the proper operation
and service life of the components. Re-lubrication must be executed periodically. The type of
lubricating oil/grease must be selected properly.
Please refer to Section 3.3.5 for proper lubricants.
Section 3.3 will give many detailed lubrication instructions.
The lubrication points shall be carefully cleaned prior to lubricating and the
oil drainage bolts prior to unscrewing.
3.2.3. Inspection of alignment
For rotary components such as couplings, inspection of alignment should be done periodically.
The condition of the alignment of couplings will have great influence on the mechanism operation
and life. Therefore, the coupling alignment should be checked periodically. In the first year after
the crane is put into operation, the inspection cycle should be shorter, e.g., once every three
months. If they are becoming stable, the inspection cycle can be lengthened. This inspection is
mainly to be made for the motor coupling and drum coupling of main hoist, trolley travel drive and
boom hoist and the motor coupling for gantry travel drive.
Refer to Drawing J554A0300, J554A0400, J554A0500 and J554A0600 for the alignment
criteria.
(1) Inspection methods for alignment of motor and gear reducer
1) Use the laser concentricity measuring instrument which is controlled by a microcomputer.

Please see the following diagram and procedures.
y
x
z
Figure 3.2-1 Alignment Check by Laser
(a) It’s not necessary to disassemble the coupling before checking the alignment.
3-10
(b) The laser is fixed one end of the coupling and the receiver is fixed on the other end
of the coupling. The laser and the receiver should rotate together.
(c) Input the relative dimensions into the microcomputer, such as the dimensions of the
motor mounting base, the distance between the coupling center to the motor shaft
ends.
(d) Before rotating, the initial value should be reset to zero.
(e) Turn both the motor shaft and the reducer shaft only up to 75º.
(f) Both the angular deviation values and the radial deviation value of δz andδy will
show up on the meter. The accuracy of the deviation readings will be up to 1μm.
(g) The microcomputer will calculate by itself the value of displacement of the motor and
the adjustment of the shim thickness which are needed for an operator to re-align
the motor.
(h) The microcomputer has memory and printing function.
(i) For controlling values of these deviations, please refer to relevant allowance
requirements of coupling and motor in the drawings.
2) Use an indicator gauge as shown in Figure

3.2-2.
(a) The gauge base is placed on one side of

the coupling and the hand shall contact
the outer ring of the other coupling.
(b) Initially, reset the reading to zero. So the
values of
 Z 90 ,  Y 180 and  Y 270 can
be read after turning 270 (please note

the positive and negative signs). The Figure 3.2-2 Alignment Check by
circumferential jumping value in the Indicator Gauge
vertical direction is
 Y 180 (the jumping
value along the vertical central line isδy180°/2).
(c) The circumferential jumping value in the horizontal direction is

 Z 90   Z 270 .
(d) Same as shown in the above drawing, make the hand contact the shoulder surface
of the other coupling and adjust the value to zero. After turning 270, two angular
deviations in the vertical and horizontal axial directions can be read.
If it is not specified otherwise, the radial deviation of the motor high speed
shaft should be less than 0.05mm!
3-11
(2) Angular deviation of gear reducer and drum coupling
The drum is supported and centered on the low-speed shaft of the gear reducer. Thus, only
angular deviation exists between the drum and the gear reducer. During the operation, this value
should be checked periodically.
Gauge
Measuring method: indicator gauge can be used.
The gauge base should be placed on the low-speed shaft of the

gear reducer and the hand should contact the plane at the flange
side of the drum coupling. Initially, adjust the position to zero.
After turning 270, the angular deviation between the drum and
the output shaft of the gear reducer can be read through the
meter.
The axial angular deviations of the gear reducer and the drum
should be
 180 /   10 ' (or 180 /   2.9 / 1000 ) (in vertical
direction), and
( 90   270 ) /   10 ' Figure 3.2-3 Angular
Deviation Measurement
( 90   270 ) /   2.9 / 1000 ) (in horizontal direction).
(or
(3) Center alignment of brake and disc
Figure 3.2-4 Clearance of brake
1) When the brake is open, the clearances between the two brake linings and disc should
be the same. 1   2  1 ~ 1.5 mm.
2) 1 and  2 should not be less than the minimum value of 1mm set for the brake.
3) 1 up= 1 down of 1 should be equal.  2 up =  2 down of  2 should be equal as well.
4) Inspect the height of the brake to align its central line with the brake disc center. The
deviation should not be more than 2mm. The horizontal deviation of the brake lining to
the edge of disc should not be more than 5mm, as shown in Figure 3.2-5.
3-12
5) Inspect the position of the brake base in the

motor axial direction. The deviation of the central
line of disc thickness should not be more than
0.5mm.
6) The contact area between the linings and the

disc should not be less than 70% when brake is
closed.
Figure 3.2-5 Center deviation of brake

3.2.4. Inspection of fasteners & connections
Always check the classification of the nut and bolt. Make sure they match
each other.
(1) Fasteners
Usually, there are three kinds of fastener in use:
1) Fasteners for structure
Fasteners used for metal structures should be ISO Grade 8.8

and 10.9 (ASTM A325 or ASTM A490) high-strength bolts. Figure 3.2-6 Marking of Bolts and Nuts
After the crane is put into operation for six months, the tightness of bolts should be checked.
High-strength bolts should be
spot-checked by 10% for each group. If
any one bolt is found loose, all bolts
within this group should be thoroughly
checked.
The sound of a pointed hammer hitting

the head of a bolt can indicate the
1 Listen the Sound
looseness/tightness of the bolt. The
position between the nut and the
connecting part should be visually
2 Check the Mark
checked (during the fabrication in the
ZPMC’s facility, the positions between
some critical nuts and connecting parts
will be marked out with a marking pen). If 3 Find the Coating Fracture
the marking positions are deviated, it
indicates that the bolts are loose. The
paint film of nuts and connecting parts The Methods To Find A Loosened Bolt
can also be visually inspected. If the Figure 3.2-7 Methods of Finding
paint film has fracture, the bolts should A Loosened Bolt
be inspected. As to the high-strength bolt
3-13
connecting position, bolt grade, bolt size, bolt quantity and bolt pre-tightening force condition for
an entire crane, Please refer to the high-strength bolt layout table. Pre-torques and
pre-tensions for high strength bolts used on the crane are given in Table 3.2-3.
The retightening requirements are given as follows:
 For ASTM A325 bolts, they can be reused and retightened. But for ASTM A490 bolts, they
cannot be reused. Once loosened, ASTM A490 bolts and nuts must be replaced with new
ones.
 For the “snug tight” bolts. The tension should be approximately 15% of the pre-torque by
using a calibrated torque wrench.
 An initial tension of 75% of the final tension shall be developed. Then the final tension shall
be developed.
Table 3.2-3 Pre-tension/pre-torque of ASTM A325 and A490 Bolts
Diameter ASTM A325 ASTM A490
Tension (p) Torque (pft) Tension (p) Torque (pft)
M22 29700 310 44050 460
M24 34140 511 52860 605
M27 45150 576 66080 850
M30 55066 778 79295 1125
M36 80616 1377 116740 1990
2) Fastener for mechanisms
ISO Grade 8.8 fastening bolts for mechanical connections are widely used together with lock nuts,
e.g. connection for general motors, brakes, gear reducers, drum bases, pillow blocks, bearing
covers, positioning plates, etc.
Bolts tightness is very important for components to be operated properly and safely. Regular
inspection is required. For bolts inspection location and frequency, please refer to scheduled
maintenance task list in Chapter 5 of the manual.
For all other bolts which are not mentioned in the task list (Chapter 5), recommend to check the
bolts which have been fastened with a torque wrench after 100 working hours. Verify that the bolts
are still tightened to the correct torque. After the first 100 hours, they should be checked annually.
3-14
Always replace bolts that can not be tightened to their torque requirement.
Since these bolts have relatively small pre-tightening force, small friction between nuts and bolts,
the connections are easy to loosen. So the connections are all provided with anti-loosening
measures.
As for the rotating parts
Anti-loosening measures such as wire-reeving method is generally adopted. Two bolt heads will
interlock each other by stainless wire, so the bolts will not loose as long as the wire does not loose
and break.
As for the non-rotating parts
Anti-loosening nuts (such as nylon nuts) and anti-loosening plates will be used.
Visual inspection can judge the tightness of the nuts by observing if the anti-loosening plates lock
the nuts. The marking positions can also be used to judge if the marking positions are moved.
Although all bolts used on the crane are based on Chinese standard, the Chinese standard for
bolts is the same as the ISO standard. So it is very easy to find suitable bolts for replacement.
Table 3.2-4 is another comparison table for bolt grade in different standards.
Table 3.2-4 SAE Grade and ISO Grade
SAE ISO/GB
Grade 1 Grade 4.6
Grade 2 Grade 4.8
Grade 4 -
Grade 5 Grade 8.8
Grade 7 Grade 9.8
Grade 8 Grade 10.9
3) Fastener for electrical connection
Electrical wiring and connecting bolts of small electrical parts, such as bar wiring connection in
control panels, motor wiring, junction box wiring, various kinds of limit switches, encoders and
cam limit switches (inside and outside), usually have smaller area and size. Impact and vibration
during the operation of the crane may cause the bolts to loosen.
Once the bolts are loose, the electrical control will fail. Therefore, the inspection of fastening
3-15
condition for this kind of bolts must be carried out, and the wiring condition should be inspected
monthly.
Stainless or galvanized bolts and lock nuts are used for electrical connection. For the
recommended pre-tightening of these small sized bolts and nuts, please refer to Table 3.2-5.
Table 3.2-5 Torque of Galvanized or Stainless Steel Bolts Class 8.8-dry surface
Dimension Galvanized steel Torque Stainless steel Torque
Nm Lbf·ft Nm Lbf·ft
M6 10 7 3.5 2.5
M8 24 18 8 6
M10 47 35 16 12
M12 81 60 28 20.5
M14 128 95 44 32.5
M16 198 146 67.5 50
We use stainless steel for bolts and nuts less than M14 (including M14)!
(2) Pin connections
Pins shall be well greased prior to each installation. After the installation, this process is to be
repeated at all accessible spots of the pin.
 The clip rings must only be mounted once if shaft pin is secured with clip rings
 New clip rings shall be used after a dismounting of the pins.
3.2.5. Inspection of temperature rise
Temperature rise is a phenomenon. Maintenance personnel who well understand the temperature
rise condition can judge the working condition of the crane. If there are no other specifications, the
temperature rise of the bearing should not exceed 60℃ (140ºF) and the absolute temperature of
the oil should be less than 85℃ (185ºF). The following temperature raise locations on the crane
should be carefully inspected:
(1) High-speed rotation supporting locations, such as the motor bearing, the high-speed shaft of
gear reducer, bearing (mainly for main hoist and trolley gear reducers).
(2) Heavy-load and slow-speed supporting locations, such as the low-speed shaft support of
gear reducer, drum support, wheel support and sheave support.
3-16
(3) Frequently inspect the operating hydraulic drive temperature rise, such as the hydraulic
thruster of the brake (especially hydraulic thrusters of main hoist and trolley travel
mechanisms), the overflow valve and the throttle.
(4) Temperature of hydraulic oil should be inspected, such as the spreader hydraulic unit.
Normally, the inspection of temperature rise condition can be done by hand touch to feel if there is
abnormal temperature. When there is abnormal temperature rise, it is often accompanied with
abnormal noise. If there is abnormal temperature, specialized thermometer should be used to
measure and find out the cause of temperature rise. Only after the problem is solved, can the
operation be resumed.
Generally, the causes of temperature rising are:
Improper lubrication
Improper gear meshing
Bearing clearance is too loose or too tight (or bearing damage)
Brake not fully released or not centered (one side released but the other side still touching the
disc)
Hydraulic thruster oil internal leakage
Abnormal operation of the overflow valve
3.2.6. Inspection of mechanical abnormal noise
The main cause of mechanical noise is vibration, impact noise, friction noise and structure
transmitting. Maintenance personnel who well understand the noise change can judge the
operation condition of the crane through daily noise observation. Generally, the abnormal noise
may be caused by improper gear meshing, gear locking, bearing damage, too loose bearing
clearance or shaft bending, loose stud bolt, interference between the motor rotor and the stator or
vane damage, lack of lubricant, etc.
Impact noise can be identified by using one metal bar, putting one side of the bar on the
measuring location and holding the other side close to ear.
Noise measurement direct with ear may be harmful to ears, so only do this
when necessary within a short period.
Generally, the abnormal noise and temperature rise happen simultaneously, such as when the
bearing clearance is too big or the brakes are not fully released, and so on. Therefore timely noise
inspections can avoid many equipment failures.
3.2.7. Inspection of abnormal vibration
Vibration usually relates to noise and element fatigue. More attention should be paid to the
abnormal vibration during crane inspection, such as the motor base, gear reducer base and drum
support rigidity, base rigidity, stud bolt pre-tightening, lining-up of motor and gear reducer,
3-17
dynamic balance of coupling and static balance of drum. Angular misalignment between drum and
gear reducer also cause vibration.
The inspection sequence is generally started with the check of lining-up (radial and axial
vibrations). If the vibration still exists after adjustment, the coupling should be removed and the
motor can be checked separately.
After causes of the motor and loosened bolt are eliminated and dynamic balance of coupling are
checked, the coupling can be connected and the high-speed shaft bearing of gear reducer should
be driven and checked. Generally, the problems caused by improper gear meshing and less
rigidity of the installation base can be found during test running.
If the vibration happens after the crane is put into operation for a certain period, usually caused by
loose stud bolts or excessive bearing clearance, improper gear meshing or lining-up deviation.
3.2.8. Inspection of crack
Crack inspection sometimes can prevent failure or disaster of a crane at its early phase. The
inspection of crack consists of inspection of the driving parts, the connecting parts and the
structural parts. The cracks are normally caused by fatigue and happen on locations of fatigue
source, stress concentration, and repeated stress effect.
(1) Driving parts: such as driving shaft, wheel, gear, sprocket, sheave, coupling, braking wheel
(disc), bearing and so on.
(2) Connecting parts: such as fixed shaft, wheel shaft, sheave shaft, structural connecting pin
shaft, headblock connecting pin, spreader twistlock and so on.
(3) Structural parts: welding seam and base material.
The method of structural inspection can be visual inspection, which can be judged through the
surface paint film. If the base material or welding seam is cracked, the paint film will also be
cracked. Telescope can be used to inspect pre-determined regularly inspecting locations. If there
is any suspicion after visual inspection, MT or UT inspection can be applied. Please refer to
the Steel Structure Maintenance Program for details. Driving or connecting parts can also be
checked during maintenance when they are knocked down.
3.2.9. Inspection of cleanness
Cleaning is part of the daily maintenance work. The following locations must be kept clean:
(1) Braking disc (braking wheel) and the brake lining (braking shoe) should be kept clean on the
surface at any time. No oil dirt, dust and rust, convex block, burr and painting coat will be
permitted.
(2) Every rotating pin shaft of brake should be kept clean and free in rotation. No paint
contamination and rust will be permitted.
(3) The cooling fan filter of the motor should be kept clean and properly ventilated.
(4) The internal side of the gear reducer body should be kept clean. The bottom of the oil tank
must be cleaned when oil is replaced.
3-18
(5) Powder dust should be cleaned periodically for the high-voltage transformer to avoid
creepage.
(6) The electric control room should be kept clean. Doors and windows should be closed, and
powder dust inside control panels and other places should be cleaned by vacuum cleaner.
Pressure fan should be operated all time.
(7) The trolley and gantry running rail surface, both sides of rail, and the elevator guiding rail
should be clean. No foreign matter is permitted.
(8) All glass in the main control room should be cleaned frequently to ensure a good view for the
operators.
(9) All sorts of indication lights should be cleaned if there are powder dust and other
contamination to ensure that the operators can identify colorful lights clearly.
(10) All rear mirrors should be kept clean.
(11) Filters of hydraulic system should be clean.
(12) Remove excessive grease and oil resulting from lubrication of the crane components,
especially in the first 2 weeks after the replacement of lubricant oil or grease.
3.2.10. Inspection of rail & rail clips
3.2.10.1. Rail installation tolerances
When designing a complete container handling system, the problems of the crane rail track never
appear to be insignificant, although this is a relatively low cost area.
Failures occurring on the crane, to a great extent, attribute to improper lying of rail during
foundation work, which will greatly shorten the crane service life. If the crane is used on curved or
uneven leveled runway rails, its steel structural members would be twisted and cause high
stresses. Accordingly, the bolts in joints may be loosened and the bases of the various machines
on the steel structure may be distorted. Thus, the entire crane performance would be badly
impaired.
In order to prevent such troubles, at the time of annual inspection, measure the level, straightness,
span, etc. of the trolley travel rail and gantry travel rail and keep their records. Also, carefully
inspect the trolley travel rail and gantry travel rail for cracks. If measured dimensions are not
within the allowable tolerance in Table 3.2-6 or in Table 3.2-7, immediately repair or replace the
gantry rail and trolley travel rail.
Table 3.2-6 Allowable Tolerances for Gantry Rails
Inspection
Measuring Method Maintenance tolerance
items
3-19
Measured by a ≤±10mm
Straightness transit or piano
wire [±0.393 in]
Measured by a
steel tape ≤±5mm
Span (S) measure of
ISO class 1 or [±0.197 in]
equivalent
Height ≤±15mm
Measured by a
difference
transit [±0.59 in]
between rails
Measured by a ≤20 mm
transit or piano
Bend of rail wire [≤0.787 in]
left and right per 30.48 m
LH+RH<
Tolerance [100 ft]
Levelness In the nominal span and wheel base of the crane no point on any rail will be
greater that ±25mm out of the common place established by the other three
corners of the crane.
1
Measured by a ≤ 400 (Check every
Inclination
transit
10m/32.81ft)
3-20
Joint Measured by a ≤0.5 mm
difference steel ruler [≤0.02 in]
Gap≤6mm
[≤0.24 in]
Joint gap & Measure by a Not contact even in

deviation steel ruler Summer.
deviation≤0.5mm
[0.02 in]
Table 3.2-7 Permissible Tolerances for Trolley Travel Rails
Item Tolerance (mm)
At block After erection and

assembly at maintenance
Lateral ≤2 ≤4
Straightness
[0.079 in] [0.157 in]
Span (S) ≤±3 ≤±5
[±0.118 in] [±0.197 in]
Difference in 0.08% of SPAN 0.15% of SPAN

height(d)
≤5 mm ≤9.5 mm
[0.197 in] [0.372 in]
Slope or Less than1/200

grade
3-21
in the area without camber when there is not trolley.


in the area with camber when there is trolley with full load.
Center σ4≤3.0 σ4≤6.0

distance
[0.118 in] [0.236 in]
between rail
and web
Difference 2≤σ5≤5 2≤σ5≤5

between
[0.08 in] [0.2 in] [0.08 in] [0.2 in]
boom and
girder rail
σ6≤0.5 σ6≤1
[0.0197 in] [0.0394 in]
Levelness 0.05% of SPAN 0.1% of SPAN
σ7≤3.15 σ7≤6.3
[0.124 in] [0.248 in]
Alignment deviation≤0.5 ≤1
difference
[0.0197 in] [0.0394 in]
between
boom and
girder rail
3.2.10.2. Common failures of rail installations
(1) The following failures are common in the rail support system, the rail fasteners and the rail
itself.
Rail support system:
 Steel girder: cracks in the welds, deformation of the girder, wear of the upper surface,
damages to the girder/boom linkage.
 Concrete support: disintegration of the concrete, loosening of the holding down bolts due
to grout or concrete failures.
Rail fastening devices:
 Loosening of the bolts
 Breakage of bolts, studs, or weld fillets
3-22
 Elongation of holes
 Rotation of clips
Rail:
 Excessive wear or flattening of the rail head
 Wear of edges of rail head
 Rail breakage
(2) Causes of failure
The operation of a crane results in a fatiguing cycle for

each time of wheel passing. Fatigue failure occurs due to a)
high stresses on the rail track support; b) rail movements
causing fatigue in the rail attachment components.
High stresses caused by:
 Wheel flange riding on the rail
 Compression stress due to concentrated wheel load
 Bending stress due to eccentric loading
 Lateral stress due to crane “crabbing”, trolley motion

and swinging live load.
Rail movements caused by:
Longitudinal due to:
 Bending of the girder under load
 Thermal expansion
 Crane gantry or trolley accelerating and braking
Lateral due to:
 Crane “crabbing”
 Swinging of live load
 Gantry or trolley accelerating and braking forces
Vertical due to:
 Rail “bow wave” effect under wheel load
 Lifting of rail at interface of two adjacent girders
 Twisted rails
Rotation due to:
3-23
 Twisted rails
 Load eccentricity
 Steering effects of crane on rail head
3.2.10.3. Trolley rail clip installation and inspection
The lower part of the clip is located parallel to the longitudinal axis of the rail at a distance of 8mm
from the edge of the rail and welded at around with a 6mm fillet weld, using a low hydrogen type
welding rod.
During the tack welding of the piece, special attention must be paid to the clamping of the piece in
order to avoid any vertical movement induced by the welding. The lower part must be in full
contact with the support. Introduce the bolt in the lower part through the opening and turn it 90°
clockwise until the bolt head is well seated in the provided head room. Check that the bolt shaft is
positioned at the end of the opening close to the rail.
Position the upper part of the clip on the lower part, in the farthest possible position in relationship
to the rail, i.e. at the extreme left end of the lower part. Then, push the upper part until it comes in
contact with the pre-aligned rail.
Introduce washer and nut and filmy hand tighten the nut (this hand tightening of the nut is
necessary to ensure the correct position of the bolt head in its head room).
If, for any reason, a nut must be loosened after mounting, must check again the correct position of
the bolt shaft before re-tightening the nut.
With a hammer, bring the upper part of the clip in firm contact with
the rail. Then, complete the tightening of the nuts to 150Nm. Nut
must be tightened with a correctly calibrated torque wrench. The use
of an impact wrench is prohibited.
In case of further painting protection, the use of solvent is prohibited.
The tightness of the clip bolts and nuts must be checked every 3
months.
Bolt tightened to 150Nm.
The rail track should be cleaned every 3 months! And inspection of

the rail clips should be done immediately after the cleaning!
3-24
3.2.11. Inspection of gantry & trolley travel wheel
The gantry travel and trolley travel are indispensable for the loading operation of this machine.
Therefore, it is important to maintain the travel wheels and rail in normal state all the time. The
following passages describe the inspection procedure of the wheels.
The following items should be checked during the daily, monthly, and annual periodical
inspections.
(1) Wear in treads and flanges
(2) No flanges riding on rail
(3) During traveling, both legs moving smoothly in parallel
(4) Irregular traveling and abnormal noise or vibration in machines
(5) Wear in wheels, gear teeth, bearings, etc., develop evenly for both legs.
(6) Cracks in wheels
After inspection, if the wear of the gantry or trolley travel wheel reaches the value indicated in
Table 3.2-8 and Table 3.2-9, replace the gantry travel wheel or the trolley travel wheel.
Table 3.2-8 Wear Limitation of Gantry Wheel A(B)
(These measurements apply anywhere across the tread.)
Original Wear limitation
Dimension Drive wheel Idler wheel
980 or difference between each

980 or difference between each
D 1000 D’ drive wheel will be 1.6mm
idler wheel will be 4mm(0.5D%)
(0.2D%)
h 25 h’ 35
147(1
b b’ 185
40)
3-25
26.5(
a a’ 17.5
30)
Table 3.2-9 Wear Limitation of Trolley Wheel
(These measurements apply anywhere across the tread.)
Original Dimension Wear limitation
D 750 D’ 730 or difference between each wheel will be 3.15 mm(0.5D%)
h 25 h’ 32.5
a 26 a’ 18.5
b 130 b’ 145
Wheel flange riding on rail is not permitted. It will increase the travel
resistance force up to 3 times as normal operation and will overload its
driving system.
Severe wheel flange riding on rail will make wheel flange runs to top of
the rail and may cause derail. Eliminate flange riding right away if it exist.
3.2.12. Inspection of rope sheaves
Sheave groove will be worn by friction with the wire rope in

operation. Wire rope excessive fleet angle during lifting of a
load may cause early wear or damage to the sheave
flanges.
If the following symptoms are found, check the wire rope for
wear and replace the sheave at the same time of replacing
Figure 3.2-8 Limit of Wear in

3-26 Sheave Groove
the wire rope.
The flange is damaged or deformed
The wear in the flange is 10% or more of the diameter of the wire rope used.
A trace of the wire rope lay can be observed at the bottom of the sheave grooves
The wear in the sheave groove is 15% or more of the diameter of the wire rope used.
① Refer to Figure 3.2-8 for Limit of wear in sheave groove

② The symbol “d” indicates the diameter of the wire rope used
3.2.13. Inspection of hook
The hook becomes weaker against crack due to wear and hardening caused by the long-time use.
Therefore, perform the following inspection once a year.
B
Perform the magnetic flaw or die check, etc. After inspection,
immediately replace the cracked one or the one which:
C
1) ○
Has the opening ( C ) larger than original diameter by 15% or
more.
2) The worn-out of critical section more than 10% of its original size.
0.1t
t
A
Cargo Hook D
Figure 3.2.13-1 Annual

Inspection of Hook
Always Inspect A○ and ○

B area with special care!
Never try to fix the defects by welding on a cargo hook. Always replace
them once defect occurs.
3-27
3.2.14. Inspection of brake disc
Inspection of the brake disc is very important to the safety of the crane operation.
(1) Periodically check if the brake disc is attached with burr or any contamination. Any oil or
grease splashed onto the disc should be cleaned with detergent immediately.
DANGER! Any grease on the brake disc will cause the substantive drop of
the brake torque.
(2) Also check the brake disc surface roughness. If the disc is damaged, scratched or cracked,
or anything is found as shown in Table 3.2-10, the brake disc should be replaced.
Table 3.2-10 Standard for Brake Disk Changing
Main Trolley Boom Boom hoist Main hoist

hoist drive hoist emergency brake emergency brake
Brake disc thickness 30mm 30mm 30mm 36mm 36mm
Wear limitation 27mm 27mm 27mm 32mm 32mm
Convex or concave
2mm 2mm 2mm 3mm 3mm
on the disc surface
Brake lining wear

Refer to Manufacturer’s manuals.
limit
3.2.15. Inspection of bushes
Check if the pin and bush are well lubricated and relatively rotate freely. The relative rotation
always happens between the bush and the pin. The bush should stand still in the bush housing,
so theoretically no wear should occur on the outer diameter of the bush. If the worn-out of the
bush reaches to the amount shown in Table 3.2-11, replace them.
Please refer to Section 4.9.2 for detailed information.
3-28
Table 3.2-11 The Wear Limits of Bushes
D Wear Location Original dia. Wear

limitation in limitation of
(mm) (mm)
dia. (mm) dia. (mm)
10～24 0.8 －－－
25～40 1.2 －－－
41～60 1.6 －－－
61～100 2.0
101~160 2.5
161~250 3.0
3.2.16. Inspection of steel structural members
The structural integrity of the crane requires that no attachments or

fixtures of any kind be welded to any part of the crane without prior
written approval of the responsible Maintenance Engineer.
Please refer to Steel Structure Maintenance Program for more inspection

information.
In order to keep the crane in good condition, daily inspection is very important. Especially, when
damages occur to the steel structural members, this crane will be unusable and it will take long
time to repair.
Not only machine damages but also accidents including human injury may arise.
Deformation of the steel structure members is caused by improper use of the crane, development
of cracks, and loose bolts. Therefore, always follow the operating procedures described in the
container crane operation instruction manual and conduct the regular inspections as described
in this manual.
The following things should be paid much attention to:
 Check deformation, corrosion, crack, loose bolts, etc. at the time of regular inspection such
3-29
as daily inspection, monthly inspection, and annual inspection.
 Do not apply excessive load to the middle of the truss members and do not weld carelessly.
 The deformation of the steel structure influences the machines installed on the structures,
increasing operating noise, causing improper engagement of the gears, etc.
 If some deformation of steel structures due to improper use of the crane, development of
cracks, loose bolts, etc. is observed, immediately report to the service office, and repair it
under the supervision of the engineers.
 In order to prevent corrosion of the steel structure, clean clogged drain holes. And make
arrangement for painting the intended area if there is any indication of rusting. Corrosion will
reduce the thickness of the structural members, increase members stress, and may create
cracks. In order to inspect cracks in the structural members, thoroughly remove the rust and
paints at the intended point, then conduct the magnaflux testing.
 The lubrication of the stay bar pins is essential to keeping the stay bars sound. If the rusting
of the pin occurs on the stay bar friction surface, the additional bending moment will be
induced on the bar and may cause the initiation and propagation of the crack. Therefore, the
lubrication must be made periodically to remove old grease and to refill the new grease.
Refer to Maintenance Task List (Chapter 5) for more information.
3.2.17. Inspection of all safety protections
Safety protections should be checked before any work.
(1) All brakes. Regularly inspect if the braking torque setting-up is correct. Annually verify the
braking torque.
(2) All slow-down limit switches and over-travel limit switches. Ensure that the positions of all
encoders, functions of all interlock protections are correct. When work shifts are changed,
their correct functions should be confirmed.
(3) Safety inspection of elevator.
(4) Inspect over-travel limit switches and hook of service crane.
(5) Inspect if all buffers and wheel stoppers are reliable.
(6) Inspection of all warning signs.
For details, such as drawings, dimensions or tolerances, please refer to the

corresponding section distributed in each part of mechanism.
Never tamper with any safety protection devices. It’s about your own safety!
3.2.18. Inspection of consumable parts
Consumable-parts are those parts which may be depleted or worn out by use of the crane. During
crane maintenance and inspection, pay special attention to the consumable parts listed as
3-30
follows:
(1) Inspection of wire rope abrasion and wire break. Refer to the relative provisions in
section 3.4.
(2) Inspection of braking shoe abrasion.
(3) Inspection of all gear seal rings.
(4) Inspection of pin shaft and pin shaft sleeve abrasions at all relatively rotated locations of
brakes.
(5) Inspection of carbon brush of conducting ring (such as AC motor of spreader cable reel).
(6) Inspection of kryptol for rail lubrication.
(7) Inspection of all lamp bulbs.
(8) Inspection of fuses.
(9) Inspection of filters.
(10) Inspection of easily collided parts on spreader, such as the flipper of spreader.
3.2.19. Inspection and maintenance of the elevator
WARNING! Before carrying out any service work, the “Normal/Inspection” switch in the electric
cabinet on the lift car must be placed in the “Inspection” position. This is of greatest importance
especially for lifts with “Auto Return” or similar remote control functions. When leaving the car
without having completed the maintenance work, the main switch must be switched off, locked
and provided with a warning sign.
The major maintenance and inspection scope of the elevator is outlined as follows:
(1) Inspect the control panel of the elevator and check that the operation of the control system
(PLC) is correct. Check all electrical interlocks by making a test running.
(2) Inspect the main switches and emergency stop switches. Check that all main switches and
emergency stop switches are working. Make test runs with each one of the switches in “Off”
position.
(3) Inspect the metal band of landing selector, and make them clean.
(4) Inspect the motor control and brakes. Check that the car stops within acceptable limits. If
necessary, clean the cooling flanges of the electric motors.
(5) Inspect and clean the gear reducer. Check the oil level and refill if necessary. Leaking seals
shall be replaced by an authorized service personnel.
(6) Inspect the brake. Check the play between the electro-magnet armature and the rotating
brake disc according to the instructions. Check the brake torque with a spring balance.
(7) Inspect the safety device. Check if the safety device has been tripping without cause or if
3-31
noise can be heard from the device during operation.
(8) Inspect the driving gear and gear meshing of the pinion and the rack. Check the wear on
the rack and pinion according to the instructions.
(9) Inspect the counter rollers at the rear of the machinery plate and safety hooks and guide
rollers on the lift car frame. Check that all screw joints are properly tightened. Check wear
and bearing play of the lift car guide rollers.
(10) Inspect lubrication of the driving pinion and rack. Also check rack for possible damages,
misalignment and attachment when lubricating.
(11) Clean the lift car floor and roof.
(12) Inspect if the cable skips out of the cable guiding device.
(13) Inspect the lift mast and guide rail. Check that all screw joints of all racks and mast joints are
properly tightened. Also check the screw joints for attaching the mast in the base.
For detailed maintenance requirement and the service interval, please refer to the elevator
manufacture’s manual.
3-32
3.3. LUBRICATION ............................................................................................ 3-34

3.3.1. GENERAL DESCRIPTION...................................................................................... 3-34
3.3.2. LUBRICATION PROCEDURE ................................................................................ 3-35
3.3.3. LUBRICATION NOTES ........................................................................................... 3-35
3.3.4. OIL MONITORING .................................................................................................. 3-36
3.3.5. LUBRICATION TABLE ............................................................................................ 3-38
3-33
3.3. LUBRICATION
3.3.1. GENERAL DESCRIPTION
All used oil and grease must be collected and disposed properly!
Lubrication is a very important maintenance task. It will determine the proper operation and
service life of the components. Proper lubrication practice will help to avoid premature wear and
extending the service life of the components or getting a maximum life of the components. Lack of
lubrication will destroy the components. For example, if an anti-friction bearing is lack of
lubrication, it will be damaged in a very short period of time. It is very important to monitor the
temperature and sound level of the components to determine whether the components get
enough lubrication.
For proper function of lubrication, the type of lubricants must be selected properly. Please
refer to chapter 5 for proper lubricants. Consistency should be maintained on lubricants. Do not
mix up different lubricants together. If different lubricants are mixed together, please contact the
lubricants supplier.
The deterioration of the lubricant depends on the operation frequency and the ambient condition.
Therefore, determine the replacement of lubricant as follows; periodically take approx. 20
milliliters of lubricant from the machine and request the lubricant manufacturer to check the
lubricant for deterioration. Then replace lubricant or add additives as necessary according to the
result of the deterioration test.
After inspection of the lubrication, replace the lubricant when any of the following conditions is
found:
(1) Rubber-like deterioration
(2) Foreign materials
(3) Especially, including much metal powder and badly discoloring
(4) Emulsification
(5) Separation of mineral oil and saponification radical
The longest interval of lubricant replacement is 2 years. After the period,

replace lubricant even if there is no deterioration.
The lubrication of the stay bar is essential to keeping the stay bars sound. If
rust occurs on the sliding surface of the pin and stay bar, additional bending
moment will be induced on the bar and may cause and develop crack.
Therefore, remove old grease and refill the new grease every two months.
3-34
3.3.2. LUBRICATION PROCEDURE
(1) When the reducer oil is changed, drain the used oil while it is still warm and the housing must
be flushed with oil to remove sludge, metallic particles and oil residue. Use the same type of
oil as is used for normal operation.
(2) When bearings are re-lubricated, pump the new grease into the chambers through grease
fitting. The bearings should be flushed once a year. It is good practice to clean out the used
grease after re-lubrication. During the first two weeks of operation after re-lubrication, the
lubricating points should be cleaned periodically.
(3) For lubrication on motor, emergency brake and reducer, please refer to their manuals.
(4) Wire ropes should be under good lubrication condition at any time. Lubrication will prevent
the wire rope corrosion and reduce the friction between the wire ropes and the sheaves
or/and drums. The type of service lubricant and frequency of application varies with the rope
construction, the operating conditions and its functional application, Refer to lubrication
table in Section 3.3.5.
3.3.3. LUBRICATION NOTES
The following issues should be kept in mind:
(1) The brand and viscosity of lubricating oil for gear reducer and hydraulic system. Please
refer to Table 3.3-1 in section 3.3.4 for more information.
(2) The quantity of oil/grease should be suitable.
 For gear reducers (splash lubrication), the oil level should be kept a little higher than the
central level between the highest and lowest levels because the oil level will become
lower when the gear reducer is working.
 For bearings and other relatively sliding parts, it is OK that the old grease outflows from
one side throughout the seal when the new grease is pumped into the other side.
(3) Oil (grease) supplementary cycle. It has relations with working grades of each part and its
operation frequency. For details, please refer to Section 3.3.5.
(4) Oil (grease) replacing cycle: Same as Item (3).
(5) For reducers that are not used often, oil bottom valves should be opened at fixed time to
inspect the water content in the oil.
(6) At the early stage after the crane is put into operation, three oil samples should be drawn
from the replaced old oil to analyze the percentage of metal powder in oil. After comparisons
and analyses of lubricating oil, the working status can be understood.
3-35
Lubricant analysis is a proactive maintenance tool used to monitor the condition of

the lubricating fluids and the process machinery.
(7) Lubricating points layout diagram of the entire crane
Please refer to lubricating nameplates on the crane, which have the following main aspects:
1) Lubrication of gear reducers;
2) Lubrication of gear couplings;
3) Lubrication of anti-friction bearings;
4) Lubrication of plain bearings;
5) Lubrication of wire ropes;
6) Lubrication of rack rail of elevator;
7) Lubrication of area between the spreader telescopic beam and the pad;
8) Lubrication of other relatively moving parts.
3.3.4. OIL MONITORING
Viscosity measurement is generally considered key to an effective oil monitoring and conditioning
program. Changes in the viscosity of oil used in machinery can signal a number of problems –
oxidation, contamination and thermal degradation – altering lubricant performance.
Lubrication is essential to proper machinery maintenance. An effective oil conditioning and

monitoring program can help extend the equipment life, reduce scheduled and unscheduled
downtime, reduce maintenance costs and extend lubricant change intervals. You can have a
real-time, online viscosity data acquired from periodic sampling by making an online viscosity
measurement. However, the viscosity measurement accuracy has been a challenge because it’s
difficult to integrate conventional viscometers into online-process flows. At the same time,
viscosity can be affected by temperature, shear rate and other variables that can be very different
off-line from what they may be in an online environment.
The critical need is the ability to detect changes from a baseline rather than simply measuring
absolute values. Ideally, these changes would be identified online in real time. This suggests
using viscometers with digital output that can integrate with other instrumentation via local area
networking. The goal is a continuous digital audit trail together with an early warning system that
alerts maintenance the problems as soon as they develop.
There are two types of oil fluid on the crane. One is for ZPMC reducer, the other is for hydraulic
system. The types and properties of lubricant used on the crane are given in Table 3.3-1.
Table 3.3-1 Lubricant Types
Lubricant Viscosity at 40℃(mm2/s) Component
3-36
Shell low temperature Omala 320 Main hoist reducer
Shell low temperature Omala 220 Boom hoist reducer
Shell low temperature Omala 320 Trolley reducer
Shell low temperature Omala 220 Gantry reducer
Shell 46 46 Bubenzer Emergency brake hydraulic unit
Shell 46 46 ZPMC wheel brake hydraulic unit
Backreach
Shell 46 46
trim& list& skew hydraulic unit
Shell 46 46 Spreader hydraulic unit
Changcheng320 320 Spreader cable reel reducer
The condition of oil is very important for proper operation of a device. A Sample for each
component in the above table should be taken once a year. An analysis of the sample should be
carried out as a minimum:
1) Kinematical Viscosity
2) Particle Count
3) Water by Karl Fisher
4) Metals by Spectroscopic
3.3.4.1. Viscosity measurements
Viscosity has a number of different measurements. The most familiar are kinematic viscosity
(centistokes) and dynamic or absolute viscosity (unit: centipoise). These two measurements are
related as centistokes equal centipoise/specific gravity. Acoustic sensors measure viscosity in
units of centipoisesspecific gravity. This measurement is based on the transfer of acoustic shear
wave energy from a quartz crystal or other solid waveguide having a characteristic impedance.
The square of the power loss is proportional to the product of frequency, density and viscosity.
Because the frequency is known, the sensor measures the product for viscosity and density.
Knowledge of specific gravity allows conversion from one measurement to another when shear
rate and temperature are equal. Thus, the sensor’s digital output can be displayed in cup seconds
or centipoise units if the fluid’s specific gravity is known.
The measurement is made by placing the wave resonator in contact with liquid. The liquid
viscosity determines how thick a layer of fluid couples to the sensor surface hydro-dynamically;
3-37
and the energy dampening of the viscously-coupled film is determined by its thickness and density.
Acoustic viscometer response is proportional to the product of the viscosity, the density and the
radian frequency of the vibration in the limit of low frequencies.
The acoustic wave resonator supports a standing wave through its thickness. The wave pattern
interacts with electrodes on the lower surface and interacts with the fluid on the upper surface.
The bulk of the liquid is unaffected by the acoustic signal and the vibrating surface moves a thin
liquid layer.
3.3.5. LUBRICATION TABLE
There are mainly seven lubrication areas on the crane, as shown in Figure 3.3-1, each area has
many lubrication points. Detailed locations and number are shown in Figure 3.3-2.
3-38
Figure 3.3-1 Main Lubrication Areas
3-39
Figure 3.3-2 Lubrication Points
3-40
3.4. WIRE ROPE................................................................................................ 3-42

3.4.1. WIRE ROPE HANDLING ........................................................................................ 3-42
3.4.2. CAUSES OF WIRE ROPE FAILURE ...................................................................... 3-43
3.4.3. EXAMPLES OF WIRE ROPE FAILURE ................................................................. 3-44
3.4.4. TYPES OF WIRE FRACTURES ............................................................................. 3-46
3.4.5. WHEN TO REPLACE WIRE ROPE ........................................................................ 3-47
3.4.6. WIRE ROPE MEASURING ..................................................................................... 3-49
3.4.7. TERMINATION OF WIRE ROPE END .................................................................... 3-49
3.4.8. WIRE ROPE INSPECTION ..................................................................................... 3-50
3.4.9. WIRE ROPE REREEVING ..................................................................................... 3-55
3-41
3.4. WIRE ROPE
3.4.1. WIRE ROPE HANDLING
To prolong their life, the wire rope must be

properly transported, stored, cleaned,
inspected and installed. Wire ropes are
easily affected by external damage.
Therefore, they must be handled with
utmost care during transport and
unloading. All wire ropes should be stored
clean, dry and cool and soil contact must
be avoided anyway. Wire ropes must
always be handled with equipment that
will not damage the rope.
Reels of wire rope should be stored in an

area where they will not be damaged by a) Proper handling b) Improper handling
objects falling, chemical spills, excessive
Figure 3.4-1 Wire Rope Handling
heat, open flames, welding, and
excessive heat. Reels should be stored vertically on their flanges and covered to prevent dirt and
debris from embedding into the wire. When storing reels, ensure that one reel will not roll into
another. This will prevent one reel flange from hitting the wire rope surface of another reel. If
necessary, reel flanges should be choked to prevent movement.
Do not store wire rope in atmosphere of volatile chemical or moisture. Wire rope
will rust.
Considerable care must be taken when unwinding a wire rope. Their operational performance is
substantially influenced by the way they are handled. Figure 3.4-1 shows the proper/improper
methods of handling wire rope from a reel. Bending or twisting wire rope can cause internal
damage that will adversely affect the operational life of the wire rope. Avoid unwinding wire rope
on the ground to protect the wire rope from debris. If there is no other option, make sure the
ground is clean or covered with boards or plastic sheets.
Do not use any detergent oil to clean wire rope. Detergent oil soaks into and
dissolves the lubricant inside the rope and will cause internal corrosion. Clean
with a wire brush.
Every wire rope bends in a particular direction based on the lay of the rope. So, the wire rope
should always be uncoiled that coincides with their lay. As shown in Figure 3.4-2, the prohibited
methods of unwinding a wire rope, wire rope should never be pulled out with the reel fixed.
3-42
CORRECT! AVOID! PROHIBITED!
Figure 3.4-2 Wire Rope Uncoiling
If wire rope is unreeled with the reel fixed, wire rope will be tangled and will
cause kink or deformation.
3.4.2. CAUSES OF WIRE ROPE FAILURE
Wire rope life and performance are influenced by several factors, including type of operation, care
and environment. Wire ropes can be damaged by worn sheaves, improper winding and splicing
practices, and improper storage. High stress loading, shock loading, jerking heavy loads and
rapid acceleration or deceleration (speed of the cable stopping and starting) will accelerate the
wear rate.
Corrosion can cause shortened rope life due to metal loss, pitting and stress risers from pitting. If
a machine is to be shut down for an extended period, the cables should be removed, cleaned,
lubricated and properly stored. In service, corrosion and oxidation are caused by fumes, acids,
salt brines, sulfur, gases, salt air and humidity and are accelerated by elevated temperatures.
Proper and adequate lubricant application in the field can reduce corrosive attack on the cable.
Abrasive wear occurs on the inside and outside of the wire ropes. Individual strands inside the
rope move and rub against one another during normal operation, creating internal two-body
abrasive wear. The outside of the cable accumulates dirt and contaminants from sheaves and
drums. This causes three-body abrasive wear, which erodes the outer wires and strands.
Abrasive wear usually reduces rope diameter and can result in core failure and internal wire
breakage. Penetrating wire rope lubricants can reduce abrasive wear inside the rope and also
wash off the external surfaces to remove contaminants and dirt.
Broken wires are a normal feature of rope service towards the end of the rope’s life, resulting
from bending fatigue and abrasion. The local break up of wires may indicate some mechanical
fault in the equipment. Correct lubrication in service will increase fatigue performance.
Distortions are usually as a result of mechanical damage, and if severe, can considerably affect
rope strength.
NDT electromagnetic means may be used to detect broken wires and loss in
metallic area. This method complements the visual examination but does not
replace it. 3-43
Here is a list of some of the common causes of wire rope failure.
(1) Using the wire rope of incorrect size, construction, or grade;
(2) Dragging rope over obstacles;
(3) Having improper lubrication;
(4) Operating over sheaves and drums of inadequate size;
(5) Overriding or crosswinding on drums;
(6) Operating over sheaves and drums with improperly fitted grooves or broken flanges;
(7) Jumping off sheaves;
(8) Subjecting it to acid fumes;
(9) Attaching fittings improperly;
(10) Promoting internal wear by allowing grit to penetrate between the strands;
(11) Subjecting it to severe or continuing overload.
Following are factors affecting rope performance:
(1) Multi-layers of the rope on the drum can result in severe distortion in the underlying layers.
(2) Bad spooling (due to excessive fleet angles or slack winding) can result in mechanical
damage, shown as severe crushing, and may cause shock loading during operation.
(3) Small diameter sheaves can result in permanent set of the rope, and will certainly lead to
early wire breaks.
(4) Oversize grooves offer insufficient support to the rope leading to increased localized
pressure, flattening of the rope and premature wire fractures. Grooves are deemed to be
oversize when the groove diameter exceeds the nominal rope diameter by more than 15%
(5) Undersize grooves in sheaves will crush and deform the rope, often leading to two clear
patterns of wear and associated wore breaks.
(6) Excessive angle of fleet can result in severe wear of the rope due to scrubbing against
adjacent laps on the drum. Rope deterioration at the termination may be exhibited in the form
of broken wires. An excessive angle of fleet can also induce rotation causing torsional
imbalance.
3.4.3. EXAMPLES OF WIRE ROPE FAILURE
There are many kinds of damages for wire rope, some of them are as follows in Table 3.4-1:
Table 3.4-1 Examples of Damaged Wire Rope
Area Description Illustration
3-44
1 Wire rope with wave or corkscrew-shaped deformation
2 Multi strand rope “bird caged” due to torsional

imbalance.
3 Looped wires as a result of torsional imbalance or

shock loading.
4 Wire rope with slackened wires due to corrosion and

abrasive wear
5 Wire rope with contraction
6 Wire rope with flattening caused by driving over the

rope
7 Wire rope with knot
8 Wire rope with bending
9 Wire rope with kink
10 Wire with one broken strand
11 Mechanical damage due to rope movement over sharp

edge projection while under load.
12 Localized wear due to abrasion on supporting structure.
3-45
13 Typical wire fractures as a result of bending fatigue.
14 Narrow path of wear resulting in fatigue fractures,

caused by working in a grossly oversize groove. Or
over small support roller.
15 Break up of IWRC resulting from high stress

application.
16 Severe wear, associated with high tread pressure.
17 Severe corrosion
3.4.4. TYPES OF WIRE FRACTURES
Figure 3.4-3 Types of Wire Fractures
Some common types of wire fracture are shown in Figure 3.4-3. The correct identification of the
wire fracture type will help to find the real cause of the rope failure and take the right measures to
solve. The typical wire fractures are caused by:
A) Severed by wear
B) Tension
C) Fatigue
D) Corrosion fatigue
3-46
E) Plastic wear
F) Phase change of Martensite
G) Shear
3.4.5. WHEN TO REPLACE WIRE ROPE
CAUTION!
No precise rules can be given for determination of the exact time for rope replacement, since
many variable factors are involved. Once a rope reaches any one of the specified removal criteria,
it may be allowed to operate to the end of the work shift, based on the judgment of a qualified
person. The rope shall be replaced after that work shift, at the end of the day, or at the latest time
prior to the crane being used by the next work shift.
3.4.5.1. When to replace
Wire ropes shall not be used under any of the following conditions. Replace a wire rope when:
Also refer to Table 3.4-1 Examples of Damaged Wire Rope.
Table 3.4-2 Criteria for Evaluating When to Replace a Rope
Area Description
1 Ten randomly distributed broken wires in one rope lay or three or more broken wires in
one strand in one rope lay. In any length of eight (8) diameters, the total number of
visible broken wires exceeds ten percent (10%) of the total number of the wires.
2 If the diameter of the wire rope is 15% less than the nominal diameter due to excessive
stretching
3 If the diameter has reduced by 10% due to rust
4 If the diameter has reduced by 10% due to abrasion
5 If the height (X) of any corkscrew-shaped deformation is more than one third of the
nominal diameter
6 If a “bird cage” has formed
7 Kinking, crushing or other damage resulting in distortion of the wire rope structure.
8 Excessive wear or corrosion, deformation or other defect in the wire or attachments,

including cracks in the attachments
3-47
9 If the rope becomes thicker or knotted in places
10 If much constriction have been formed
11 If the rope is permanently deformed due to being placed over sharp edges
12 If loops have formed in the rope due to being incorrectly wound onto the drum
13 If deep notches appear in the rope
14 A broken strand.
15 Evidence of heat damage. If the rope has been subjected to a temperature of over
300°C (572° F)
16 There are end attachments that are cracked, deformed or worn; There is corrosion of
the rope or end attachments; There is more than one broken wire in the close vicinity of
a socket or swaged fitting.
3.4.5.2. Why to replace a kinked wire rope even it is corrected
Following is an illustration of why a kinked wire rope must be replaced immediately even it has
been corrected and appears normal.
The kink is an unrecoverable damage for the wire rope. Once the wire rope is kinked, the internal
damage remains eternally even if it seems to be corrected.
Moreover, since the kinked part of wire rope is weak, the kinked part is worn rapidly and will cause
the severe deterioration of wire rope strength.
The comparison of the break strength between a normal wire rope and a kinked wire rope is as
follows.
 Break strength of a normal wire rope: 100%

 Break strength of a kinked wire rope: 58%
 Break strength of a kinked and corrected wire rope: 81%
Immediately replace the kinked wire rope. The wire rope will be broken at the
kinked part.
In case of wire rope abnormalities, the maker of the wire rope should be
determined. A colored tracer thread is embedded in the core of the rope. The
manufacturer can be found by this tracer thread.
3-48
3.4.6. WIRE ROPE MEASURING
The size of a wire rope is designated by its diameter. The

diameter of a wire rope should be measured with a set of
Vernier calipers or the two evening plates as shown in Figure
3.4-4.
In order to make sure that the nominal diameter of the wire

rope is measured with exactness, the correct way to measure
the nominal diameter of the rope should be used.
To ensure an accurate measurement of the diameter of a wire

rope, always measure the rope at three places and at least 5
feet apart. Use the average of the three measurements as the
diameter of the rope. Figure 3.4-4 Measurement of the
Rope Nominal Diameter
The nominal diameter of a new wire rope must be measured and recorded
before it is installed on the crane. The results of every subsequent check
should also be recorded in the journal for that wire rope.
3.4.7. TERMINATION OF WIRE ROPE END
When terminating a rope end with a wedge socket, ensure that the rope tail can not withdraw
through the socket by securing a clamp to the tail or by
following the manufacturer’s instructions. The tail length
should be a minimum of 20 rope diameters for all Rotation
Resistant wire rope and a minimum of 6 rope diameters for 6
and 8 strand ropes.
See Figure 3.4-5 for two recommended methods of securing

the rope tail with a wedge socket.
The loop back method uses a rope grip and the loop should
be lashed to the live part of rope by a soft wire serving or
tape to prevent flexing of the rope in service.
The method of looping back should not be used if there is a

possibility of interference of the loop with the mechanism or Figure 3.4-5 Wire Rope End
structure. Termination
Failure to secure in accordance with instructions could lead to loss of the rope and injury.
3-49
3.4.8. WIRE ROPE INSPECTION
The results of every visual inspection shall be recorded for tracking purposes.
The setting up of the wire rope inspection schedule should be tailored to detect the wire wear and
fracture as early as possible. Each wire rope installed should undergo initial and subsequent
periodic inspection. The results of these inspections should be recorded in a work log for the life of
the wire rope.
Inspect the rope and related equipment at the beginning of every work period at least daily in most
instances and particularly following any incident which could have damaged the rope or
installation.
The entire length of rope should be inspected and particular attention should be paid to those
sections that experience has proven to be the main areas of deterioration. Excessive wear,
broken wires, distortion and corrosion are the usual signs of deterioration. For a more detailed
examination, special tools are necessary which will facilitate internal inspection. Refer to Figure
3.4-5.
In the case of ropes working over drums or

sheaves it is particularly necessary to
examine those areas entering or leaving the
grooves when maximum loads (i.e. snag
loads) are experienced.
On some running ropes, but particularly

relevant to standing ropes, the areas
adjacent to terminations should be given Figure 3.4-6 Inspection of internal wire rope
special attention.
3.4.8.1. What should be inspected
A thorough inspection should cover the following points:
Is there evidence of corrosion, wear, or kinks? A rope that has been kinked cannot be repaired.
Are there any visible broken wires? If so, replace the wire rope if it does not meet the
requirements mentioned in this manual (Section 3.4.5) or the wire rope manufacturer’s
recommendation.
Is the rope properly lubricated? The rope should be kept properly lubricated to avoid stiffness and
corrosion.
What is the condition of the fitting or splices? Any damaged fitting or splice should be replaced
immediately.
Are thimbles used to protect the wire rope eyes where possible?
Is an adequate safety factor always used?
3-50
If there is evidence that the wire rope has been crushed, abraded, flattened, bird caged or has
sustained any other damage that distorts it, the rope should be removed from service.
Inspect wire rope and take the correct measures according to the “Table 3.4-3 Damages of Wire
Rope and Measures”.
Table 3.4-3 Damages of Wire Rope and Measures
Cause of wire rope damage Measures

Reduction of section area
(1) Pay attention to the worn grooves of the sheave

and the drum.
Wear (External, internal)
(2) Carefully reel and install rope wire on the drum
(3) Always lubricate sufficiently
Corrosion (External, internal) Always lubricate or apply grease sufficiently.

Quality change
(1) Remove hindrance to rope movement.

Hardening of surface
(2) Always perform maintenance so that the
(Martensite)
sheaves and guide rollers can rotate smoothly.
Only use wire rope of diameter and construction

Wear (Extremely severe wear
adapted to the diameter of sheave or drum. (Do not
due to repeated bending)
use ropes out of specification.)
Deformation
Carefully handle wire rope.

Untwisting
Do not bend wire rope at an acute angle.
Pinching
Carefully reel wire rope on drum.
Detaching
Pay attention to worn grooves of sheave and drum
Avoid sudden start or stop
Upon operation Do not hang loads heavier than specified for safety.
Always remain three rolls of wire rope on drum
3.4.8.2. Main hoist wire rope inspection
3-51
The crane should be in maintenance mode for this task. When person stands
on the trolley, he must wear safety harness, and installs safety chains near
the rope inspection platform. If hands have to be on the rope for inspection,
they must be away from the pinch point. An additional person acts as a
spotter between the operator and the mechanic inspecting the rope. All
precepts outlined in Chapter 1 and Section 3.1.1 applies to this maintenance.
Figure 3.4-7 Main Hoist Rope Inspection
(1) Move the trolley to the outreach with the spreader on its highest position. When the trolley
locates at the boom tip, lower the spreader as close to the water surface as possible at slow
speed. Mechanics can stay at the landside of the main hoist drum in the machinery house for
ropes inspection. This step aims to check the wire ropes wrapped on the drum when the
spreader is lowered. --○
1
(2) Hoist up the spreader to its highest position. During this period, mechanics can stay at the
landside platform of the trolley to check the main hoist wire ropes. This step aims to check the
wire ropes not wrapped on the drum. --○ 2
(3) Move the trolley to the backreach at slow speed. Mechanics can stay at the seaside platform
of the trolley to check the main hoist wire ropes. This step aims to check the wire ropes
between the outreach and the backreach. --○ 3
(4) Lower the spreader to the ground. The fixed ropes on the drum should also be checked.
Once the above-mentioned procedure is completed, the full length of main hoist wire rope has
been inspected.
DANGER OF FALLING!
3-52
DANGER OF TRIPPING!
3.4.8.3. Trolley rope inspection
The crane should be in maintenance mode for this task. When a person
stands on the trolley, he must wear safety harness, and installs safety chains
near the rope inspection platform. If hands have to be on rope for inspection,
they must be away from the pinch point. An additional person acts as a
spotter between the operator and the mechanic inspecting the rope. All
precepts outlined in Chapter 1 and Section 3.1.1 applies to this maintenance.
Figure 3.4-8 Trolley Rope Inspection
(1) Move the trolley to the back reach at slow speed.
(2) With the trolley at the back reach, move the trolley to the boom tip at slow speed. Mechanics
can stay at the platform near the backreach trolley sheaves for ropes inspection. --○
1
(3) With the trolley at the boom tip, move the trolley to back reach at slow speed. Mechanics can
stay at the waterside of the trolley drum in the machinery house for ropes inspection. --○
2
(4) With the trolley at the backreach, move the trolley to boom tip at slow speed. Mechanics can
stay at the landside of the drum for rope inspection reeving from drum to rope tensioning
3-53
sheaves. --○
3
(5) With the trolley at the boom tip, move the trolley to the backreach at slow speed. Mechanics
can stay at the boom tip platform for rope inspection. --○4
(6) The fixed ropes on the drum should also be checked.
Once the above-mentioned procedure is completed, the full length of trolley towing wire rope has
been inspected.
DANGER OF FALLING!
DANGER OF TRIPPING!
3.4.8.4. Boom hoist rope inspection
The crane should be in maintenance mode for this task. If hands have to be on
rope for inspection, they must be away from the pinch point. An additional
person acts as a spotter between the operator and the mechanic inspecting
the rope. All precepts outlined in Chapter 1 and Section 3.1.1 applies to this
maintenance.
Boom hoist rope inspection
Figure 3.4-9 Boom Hoist Rope Inspection
3-54
(1) Hoist the boom at slow speed to its maintenance position. Mechanic can stay on the landside
trolley girder support beam for rope inspection and cover as much of the wire rope as
possible, and mark the end of inspected segment. --○
1
(2) Lower boom at slow speed to its operation position. Mechanic can stay on the top cross tie
beam near 1st sheave (count from the center line of the boom). The wire rope reeving
through 1st sheave can be inspected. --○
2
Equalizer sheave
Figure 3.4-10 Wire Ropes at the Top Cross Tie
(3) Hoist the boom at slow speed to its maintenance position. Mechanic can stay on the top
cross tie beam to inspect the rope reeving through the 5th sheave (count from the center line
of the boom). --○
3
(4) Inspect the wire ropes between the sheave block on the boom and the one on the cross tie
beam. Use binocular if necessary. --○
4
(5) The fixed ropes on the drum should also be checked.
Once the above-mentioned procedure is completed, the full length of boom hoist wire rope has
been inspected.
DANGER OF FALLING!
DANGER OF TRIPPING!
3.4.9. WIRE ROPE REREEVING
3-55
We are fundamentally using right handed lay ropes on both right and
left handed drums!
3.4.9.1. Main hoist wire rope re-reeving procedure
ALL PRECEPTS OUTLINED IN THE “SAFETY PROCEDURES AND GOOD

PRACTICES FOR MAINTENANCE PERSONNEL”APPLY TO THIS
MAINTENANCE. (REFER TO CHAPTER 1)
The basic procedure of re-reeving the wire rope employs the re-reeving device in the machinery
house, which is furnished for this purpose. The process involves lifting a spool of new wire rope
(feeder spool) into the machinery house, and placing it onto the supports provided for the purpose.
The next step is to secure the existing rope at the trolley and boom tip and un-reeve the existing
rope from the drum and spool it on the empty motorized take-up spool. Wrap one end of the old
rope on the take-up spool and connect the other end to the new rope and run the re-reeving
device (driving the take-up spool) until the new rope has gone through the reeving system of main
hoist sheaves at the trolley girder end tie, the sheaves on the trolley, the headblock sheave and
the boom tip, and returned to the machinery house. Un-wrap the new rope from the feeder spool
and reeve it on the MH drums.
BLOCK AREA UNDER THE CRANE WHERE FALLING PARTS AND ROPE
MAY HARM PERSON AND VEHICLE. ALLOW NO OTHER PERSON THAN
CONCERNED TO ENTER THE PROCEDURE AREA.
DANGER OF FALLING!
DANGER OF TRIPPING!
KEEP AWAY FROM SUSPENDED LOADS!
The detailed steps to accomplish the main hoist re-reeving procedures are as follows:
3-56
(1) Gantry the crane to a safe place,

hoist the boom down to level
position. Drive the trolley to the
parking position.
(2) Hang obvious signs for ship being

away and set the crane to
maintenance mode.
(3) Lift the storage steel drum with new

rope to the machinery house by the Figure 3.4-11 Rope Clamp At Boom Tip
service crane. Put the storage drum
on the pay out side. Put the empty reel

on the pull in side.
(4) Engage the clutch on the pull in side of

the re-reeving system.
(5) Zero the position of the T/L/S system.
(6) Driving the main hoist drum slowly to pay

out rope until there are three loops left on
the drum. Lay the rope regularly on the
ground around the spreader manually.
And the ground must be clean.
(7) Dismantle the rope clamp plate at the

boom tip.
(8) Fix the rope which is going to be Figure 3.4-12 Fix The Rope With Chain Block
changed in front of main hoist drum.
(9) Remove the rope clamp bolts and clamps.

Fix one end on the pull-in side reel of the
re-reeving system and connect another
end to the new rope
(10) Dismantle the chain block.
(11) Driving the re-reeving system to wind all

the old rope on the ground to the empty Figure 3.4-13 Rope Connection
drum. In the process, pay attention to the
whole rope running path to make sure that there are no block, friction to structure and the
rope is in the guiding sheave and won’t kink.
3-57
Figure 3.4-14 Main Hoist Rope Re-reeving
(12) When the loose rope on the ground are all on the reel, continue driving the re-reeving system
until there are rope left on the pay-out reel for 3 loops(the same loops with the old one on the
drum) on the main hoist drum. Make sure the rope on the pay-out side reel of the re-reeving
system not slip out.
(13) Fix the rope with chain block in front of the main hoist drum.
(14) Unwinding the new rope from the pay-out side reel of the re-reeving system and winding it on
the left main hoist drum.(the same loops with the old one)
(15) Hoist up the main hoist system slowly to wind the ropes on the drum until the spreader is
about to lift. During the process, drive the pull-in side reel in the reverse direction to pay out
rope. The speed should be equal or quicker than the main hoist speed. Pay attention to all of
the rope running way to make sure that there are no block, friction to structure and the rope is
in the guiding sheave groove and won’t kink.
(16) Adjust the rope catenary length and make the length the same as the old one.
(17) Fit the rope clamp plate at the boom tip. And tighten the bolts with 75% of the fully tighten
torque.
(18) Hoist down the main hoist system until there are three loops left on the main hoist drum.
During the process, continue driving the pull-in side reel in the reverse direction to pay out
rope. The speed should be equal or quicker than the main hoist speed.
(19) Fix the rope in front of the main hoist drum and cut the old rope away.
(20) Wind the rope on the drum the same loops with the other rope ends and fit the clamp plates
on the drum. Tighten the bolts with 75% of the fully tighten torque.
(21) Dismantle the chain block in front of the main hoist drum.
(22) Hoist up the main hoist system until the spreader is about to lift. Pay attention to all of the
rope running way to make sure that there are no block, friction to structure and the rope is in
3-58
the guiding sheave groove and won’t kink.
(23) Adjust the catenary rope length with the other side and make them the same
(24) Tighten all the bolts of rope clamp plates, including the plates on the drum and at the boom tip.
Cut the redundant rope.
(25) Run the system to see if the limit switches work properly.
(26) Lubricate the rope.
(27) Change another rope in the same way.
Figure 3.4-15 Main hoist Rope Re-reeving
THE DIAMETER OF THE WIRE ROPE IS 33.5MM, 755M LONG, AND THE
MINIMUM BREAK STRENGTH 940KN. THE TYPE OF THE WIRE ROPE
CAN BE DETERMINED BY THE END-USER. 6, 7 AND 8 STRAND WIRE
ROPES ARE ALL SUITABLE FOR THESE CRANES.
RE-TIGHTENING THE ROPE CLAMP AFTER 50 OPERATING HOURS!
3.4.9.2. Trolley wire rope re-reeving procedure

The basic procedure of re-reeving the wire rope employs the re-reeving device in the machinery
house which is furnished for this purpose. The process involves lifting a spool of new wire rope
(feeder spool), and placing it into the supports provided for the purpose. The empty take-up spool
should be placed on the motorized support. The trolley is clamped between the two wire ropes
which reeve on the same drum. As the trolley travels waterside, one rope pays off the drum, while
3-59
the other rope spools on the drum. The two ropes are separated by an empty groove on the drum.
Re-reeving consists of traveling the trolley in each direction to spool off the old rope and install the
new rope.
BLOCK AREA UNDER THE CRANE WHERE FALLING PARTS, ROPE MAY
HARM PERSON AND VEHICLE. ALLOW NO OTHER PERSON THAN
DANGER OF FALLING!
DANGER OF TRIPPING!
The changing procedures are the same, here we use landside rope as an example. A detailed
procedure to accomplish the re-reeving is as follows:
(1) Gantry the crane to a safe place, hoist the boom down to level position. Move the trolley to
the outreach of the crane. (for seaside rope, move the trolley to backreach).
(2) Hang obvious signs for ship being away and set the crane to maintenance mode.
(3) Lift the storage steel drum with new rope to the machinery house by the service crane. Put
the storage drum on the pay out side. Put the empty reel on the pull in side.
(4) Engage the clutch on the pull in side of the re-reeving system.
(5) Dismantle the rope clamp plate on the trolley.
(6) Release the pressure of cylinders. (for seaside rope the step can be cancelled) Refer to
chapter 7.
(7) Hang two chain block under the service crane, and put two guiding sheaves in front of the
drum. (Normally at the corner of trolley driving frame)
(8) Fix the rope in front of the trolley driving drum.
(9) Connect one end of the old wire rope to the pull-in reel. The old rope goes through the
guiding sheaves and then to chain block under the service crane. The end is fixed on the
receiving reel, as shown in Figure 3.4-16.
(10) Fetch out the new rope from the pay-out reel. The new rope should also be guided through
3-60
the chain block and guiding sheaves. The end of the new rope is connected to the other end
of the old rope (the connection can be welding).
(11) Untie the chain block that fix the old rope.
(12) Drive the pull-in reel of the rope re-reeving system enabling the old rope to be wound on the
empty drum and to pull the new rope to go though the whole re-reeving system and replace
the old rope. Pay attention to the all of the rope running way to sure there are no block,
friction to structure.
(13) . Control the speed with the brake at the pay-out reel of the re-reeving system.
(14) When the new rope go back to the drum end, about the length to wind the same loops on the
drum as the old rope
(15) Tie the two new rope ends with rope clamps and chain block, cut off the old rope.
(16) Fix the new rope to the drum with the clamps.
(17) Unwinding rope from the pay-out reel and wind it on the drum with the same loops. Fix the
rope with clamps.
(18) Untie the rope clamps and chain block.
(19) Retighten the rope with the cylinders at the backreach. See if the tightness of the rope is right,
and if the arm of the tension device is vertical. If it’s not, adjust the rope length with chain
block.
(20) Fit the rope clamp plate on the trolley.
(21) Run the trolley to see if the system works well.
(22) Cut the redundant rope and lubricate the new rope.
(23) Replace the second old wire rope as the same. Thus the rope re-reeving is completed.
Figure 3.4-16 Trolley Rope Re-reeving
3-61
THE DIAMETER OF THE WIRE ROPE IS 28MM, 390(LS)M AND 560 (WS) M
LONG, AND THE MINIMUM BREAK STRENGTH 531KN. THE TYPE OF
WIRE ROPE CAN BE DETERMINED BY THE END-USER. 6, 7 AND 8
STRAND WIRE ROPES ARE ALL SUITABLE FOR THESE CRANES.
3.4.9.3. Boom hoist rope re-reeving procedure

DANGER OF FALLING!
DANGER OF TRIPPING!
3-62
Figure 3.4-17 Boom Hoist Rope Re-reeving
(1) Gantry the crane to a safe place, hoist the boom down to level position. Drive the trolley to the
parking position.
the storage drum on the pay out side. Put the empty reel on the pull in side.
(5) Pull and hold two old boom hoist wire rope ends by clamps and chain block. As the boom
hoist rope is very thick, at least two clamps will be fit on one end. The fixation below means
the same.
Remove the bolts

and clamps
(6) Remove the rope clamp bolts and clamps.
(7) Remember the rope loops n (not less than 5) on the drum, dismantle the clamp and measure
the length L from rope end to outgoing hole.
(8) Pass one old rope end through guiding sheaves and fix it on the driving reel. Connect the
other end with the new rope. Driving the re-reeving system slowly to wind some loops on the
driving reel, then brake the re-reeving system tightly.
3-63
(9) Dismantle the clamps and chain block. The current system is as shown in Figure 3.4-17.
(10) Driving the re-reeving system until about L meter new rope enter the machinery house. Brake
the system. In the process, use the brake at the driven reel to control the speed. And also,
persons should be assigned at different places to check if the process goes well, the rope
won’t jump out of the sheave and rubbed by obstacles, etc.
(11) Tie the two rope ends tightly with rope clamps and chain block. Cut the old rope away. Wind
the new rope on the drum n loops and fit clamps with 50% of fully tightening torque.
(12) Untie the rope clamps and chain block of

driving reel side.
(13) Pull the rope of pay-out reel side with

chain block to adjust the tightness of the
system. The rope loose limit switch at the
top of A-frame can be used.
(14) Unwinding rope from pay-out reel. Then

wind the rope onto the drum n loops and
fix it with rope clamps. Tighten the rope
clamp with 50% of the fully tightening Figure 3.4-18 Rope Loose Limit Switch
torque.
(15) Untie the rope clamps and chain block of the driving reel side. Check that if the boom hoist
system works well. If the system woks well, fully tighten the bolts and cut the redundant rope.
(16) Check whether the cam limit switch is right.
(17) Everything is Ok. Then hoist the boom to 80°, check if there are one or two clear loops on the
drum. If the clear loop is less than 1, lower the boom down and tie the two rope ends with
clamps and chain block. First estimate the length of the rope needed to pull back. Then
release the rope clamp on the drum and pull the rope back with the length estimated and
retighten the bolts. If rope loose limit switch is not OK, adjust the rope in the same way.
THE DIAMETER OF WIRE ROPE IS 36MM, 1870M LONG, AND THE

MINIMUM BREAK STRENGTH 1090KN. THE TYPE OF WIRE ROPE CAN
BE DETERMINED BY THE END-USER. 6, 7 AND 8 STRAND WIRE ROPES
ARE ALL SUITABLE FOR THESE CRANES.
3.4.9.4. Catenary trolley rope re-reeving procedure
3-64

DANGER OF FALLING!
DANGER OF TRIPPING!
There are two kings of ropes on the catenary trolley, one connects the catenary trolley with trolley
to give power to one catenary trolley, the other connects the landside catenary trolley and
landside catenary to give power to another catenary trolley.
The detailed procedures to re-reeving the rope connecting the catenary trolley and the trolley are
as follows:
(1) Gantry the crane to a safe place, hoist the

boom down to level position.
(2) Hang obvious signs for ship being away

and set the crane to maintenance mode.
(3) Lift the storage steel drum with new rope to

the machinery house by the service crane.
Put the storage drum on the pay out side. Figure 3.4-19 Fixation Of Rope Ends
Put the empty reel on the pull in side.
(4) Engage the clutch on the pull in side

of the re-reeving system.
(5) Put two hemp ropes on the trolley

and move it under the MH. Put the
ropes in the MH.
(6) Re-eving one hemp rope and new

rope as shown in Figure 3.4-20.
Figure 3.4-20 Arrangement of ropes in MH
(7) Pull the hemp rope end and the new
3-65
rope end out of the MH and tie on the trolley. Move the trolley under the connection beam at
the hinge joint, and fix the trolley.
(8) Fix a guiding sheave at a proper position on the trolley.
(9) Tie the two rope ends on the support with chain block to the trolley.
(10) Untie the rope from the supports. Connect one rope end with the hemp rope, and the other
end with the new rope. Now the system is as shown in Figure 3.4-21 .
Figure 3.4-21 Catenary Trolley Rope Re-reeving System(the rope between the trolley and
catenary trolley)
(11) Untie the rope clamp on the trolley.
(12) Dismantle the chain block under the connection beam.
(13) Driving the re-reeving system until there are about 10m new rope left on the reel. Fasten the
rope on the ground and reel out the rope on the reel.
(14) Wind the hemp rope on the reel and connect the end with the new rope (Or just pull the rope
with hand).
(15) Unfasten the chain block and continue running the rope re-reeving system until the second
end of the new rope reaches the support under the beam.
(16) Disconnect the end of the new rope and tie it to the support.
(17) Fix the one rope plate on the trolley.
(18) Running the reel in opposite direction and pull the first end of the new rope back under the
beam. Disconnect the rope and fix it on the support.
(19) Adjust the rope tension. Make it the same with the old one.
(20) Another rope can be changed in the same way. Set the crane to normal condition.
The detailed procedures to re-reeving the rope connecting between the catenary trolleys are as
follows:
3-66
(1) Gantry the crane to a safe place, hoist the boom down to level position.
the storage drum on the pay out side. Put the empty reel on the pull in side. And also, lift two
hemp ropes into the MH.( The length of each rope should be no less than 35m)
(4) Arrange the new rope and one hemp rope the same way as shown in Figure 3.4-20. The only
difference is that the two rope ends are pulled to backreach.
(6) Move the trolley to the outreach.
(7) Tie the rope ends to seaside catenary trolley with chain blocks .
(8) Fix two chain blocks with guiding sheaves on the seaside catenary trolley.
(9) Untie the rope ends with supports. Pull them passing the guiding sheaves and connect the
two rope ends together, as shown in Figure 3.4-22.
(10) Untie the chain blocks tying on the ropes.
(11) Drive the trolley to the backreach slowly. When the trolley passing under the landside of MH,
pull the two rope ends in the MH with the trolley to the backreach.
(12) Fix the trolley at backreach and release pressure of the cylinder.
Figure 3.4-22 Catenary Trolley Rope Re-reeving System( for rope between catenary trolleys)
(13) Tie the rope to landside catenary trolley with chain blocks.
(14) Disconnect the rope ends from the landside catenary trolley and conncet them to the hemp
rope and new rope.
(15) Driving the re-reeving system until there are about 10m new rope left on the reel. Fasten the
3-67
rope on the ground and reel out the rope on the reel. And also, make sure the rope won’t
jump out from the reel.
(16) Wind the hemp rope on the reel and connect the end with the new rope (Or just pull the rope
with hand).
(17) Continue running the rope re-reeving system until the new rope replace the position of the old
one.
(18) Tie the rope to the landside catenary trolley and cut off the hemp ropes.
(19) Connect the new rope ends to the supports on the landside catenary trolley.
(20) Drive the crane to the outreach, tie the the rope to the seaside catenary trolley.
(21) Cut off the rope and connect two rope ends to supports on the seaside catenary trolley.
(22) Run the trolley to see if the system works well. If it works well, dismantle the chain blocks on
the seaside catenary trolley..
(23) Set the machine to normal condition.
3-68
REPAIR INST RUCT IO N
4 REPAIR INSTRUCTIONS .................................................................................... 4-1

4.1 DISASSEMBLY/RE-ASSEMBLY PROCEDURE ........................................... 4-3
4.1.1 CAUTIONS ON DISASSEMBLY/RE-ASSEMBLY .................................... 4-3
4.1.2 ENGAGING PROCEDURE ...................................................................... 4-3
4.1.3 DISENGAGING PROCEDURE ................................................................ 4-4
4.2 MAIN COMPONENTS IN THE MACHINERY HOUSE .................................. 4-7
4.2.1 REDUCER ............................................................................................... 4-7
4.2.2 MOTOR COUPLING .............................................................................. 4-16
4.2.3 DRUM COUPLING REPLACEMENT ..................................................... 4-18
4.2.4 PILLOW BLOCK .................................................................................... 4-21
4.2.5 How to take the drum out of machinery house? ..................................... 4-22
4.3 MAIN COMPONENTS ON THE TROLLEY ................................................. 4-25
4.3.1 TROLLEY WHEEL AND AXLE REPLACEMENT ................................... 4-26
4.3.2 TROLLEY WHEEL ALIGNMENT ADJUSTMENT ................................... 4-28
4.3.3 MAIN HOIST SHEAVE REPLACEMENT ............................................... 4-32
4.3.4 SPREADER CABLE REEL REPLACEMENT......................................... 4-35
4.4 MAIN COMPONENTS ON CATENARY TROLLEYS................................... 4-38
4.4.1 Wheels ................................................................................................... 4-38
4.4.2 Supporting rollers ................................................................................... 4-39
4.4.3 Sheaves ................................................................................................. 4-40
4.5 MAIN COMPONENT AT THE BACKREACH .............................................. 4-42
4.5.1 TLS CYLINDERS REPLACEMENT ....................................................... 4-42
4.5.2 MAIN HOIST SHEAVES REPLACEMENT ............................................. 4-43
4.5.3 TROLLEY AND CATENARY TROLLEY ROPE TENSIONER CYLINDERS
REPLACEMENT ............................................................................................. 4-44
4.5.4 TENSIONER SHEAVES REPLACEMENT ............................................. 4-45
4.6 MAIN COMPONENTS ON THE BOOM ....................................................... 4-47
4.6.1 BOOM HOIST SHEAVES REPLACEMENT ........................................... 4-47
4.6.2 LOAD CELL REPLACEMENT................................................................ 4-48
4.6.3 TROLLEY SHEAVES REPLACEMENT ................................................. 4-49
4.6.4 BOOM HINGE BEARING REPLACEMENT ........................................... 4-50
4.7 Main components on top of A-frame ........................................................ 4-53
4.7.1 Boom hoist sheaves replacement .......................................................... 4-53
4.7.2 BOOM HOIST ROPE BREAK PROTECTION DEVICE DISASSEMBLY 4-54
4.8 MAIN COMPONENTS ON THE GANTRY ................................................... 4-57
4-I
4.8.1 GANTRY WHEEL REPLCEMENT ......................................................... 4-57

4.8.2 GANTRY MOTOR AND GEAR REDUCER REPLCEMENT .................. 4-59
4.9 DAMAGE INSPECTION OF COMMON MECHANICAL PARTS ................. 4-62
4.9.1 GEAR REDUCER INSPECTION ........................................................... 4-62
4.9.2 DAMAGE OF GEAR .............................................................................. 4-62
4.9.3 BEARING AND BEARING UNIT ............................................................ 4-66
4.9.4 Bearing unit inspection ........................................................................... 4-73
4.10 KEY, KEY GROOVE AND PIN HOLE ........................................................ 4-76
4.10.1 Inspection procedure of key and key groove ........................................ 4-76
4.10.2 Inspection procedure of pin hole .......................................................... 4-76
4.10.3 INSPECTION PROCEDURE OF OIL SEAL......................................... 4-77
APPENDIX: RECOMMENDED USAGE LIMITATION OF EACH COMPONENT
........................................................................................................................... 4-78
4-II
4 REPAIR INSTRUCTIONS
This chapter mainly illustrates crane repair instructions in detail on components which need
disassembly and disengagement.
In Section 4.1, the procedure and cautions about disassembly and assembly is outlined, aiming to
give a general idea on how to disassemble and re-assemble components.
Through section 4.2 to section 4.7 of this chapter, the description of crane repair instructions
logically follows the sequence as classified below by different crane areas.
(1) The main components on the trolley.
(2) The main components at backreach.
(3) The main components along the boom.
(4) The main components on top of A-frame.
(5) The main components on gantry.
In Section 4.9, the description of damage of the common mechanical parts is presented in detail
as a general reference, trying to give crane maintenance personnel a clear idea on how these
parts fails. The form of recommended usage limits of parts is followed in the end of this chapter.
Numerous pictures from the real crane and plenty of isometric exploded drawings are used in this
chapter to present a clear explanation of the information necessary for the intended repair
procedures.
4-1
4 REPAIR INSTRUCTIONS .................................................................................... 4-1

4.1 DISASSEMBLY/RE-ASSEMBLY PROCEDURE ........................................... 4-3
4.1.1 CAUTIONS ON DISASSEMBLY/RE-ASSEMBLY .................................... 4-3
4.1.2 ENGAGING PROCEDURE ...................................................................... 4-3
4.1.3 DISENGAGING PROCEDURE ................................................................ 4-4
4-2
4.1 DISASSEMBLY/RE-ASSEMBLY PROCEDURE

The purpose of disassembly/assembly is to restore the function of the machine in the following
order.
(1) Clean, perform inspection/maintenance, and repair the internal parts of the machine by
disassembly.
(2) Reinstate the machine completely by re-assembly.
Therefore, carry out the disassembly/re-assembly with a carefully made preparation and plan to
achieve the object.
4.1.1 CAUTIONS ON DISASSEMBLY/RE-ASSEMBLY
Observe the following cautions on disassembly/assembly.
(1) Before disassembly, prepare parts incapable of reusing. List up and prepare the parts
incapable of reusing such as packing etc.
(2) Do not make any errors in the disassembling order.
1) Read and understand the assembly drawings thoroughly, make a plan carefully, and then
disassemble the machine in the reasonable order.
2) Do not disassemble the machine until thoroughly understanding the assembly drawing.
Take special care to safety concerns, such as the bolts which will fail off when loosened
or the areas requiring movement, etc.
(3) Check the locating mark:
1) Verify if there is any mark indicating the locating relation between the parts.
2) If there is no mark, mark the applicable point before disassembly.
(4) Record the locating relation and disassembling order, etc. of the parts in abnormal conditions.
1) If examination is required afterward because of abnormal conditions such as wear,
interference, etc., exactly record the locating relation between the parts, assembling
order, direction, surface condition, etc.
2) Record the clearance, tightening clearance, damage, or foreign materials at the fittings
during disassembly.
3) Take photos if necessary according to the abnormal condition.
4) Keep the samples of abnormal materials sticking on any parts or areas.
(5) Prevent the disassembled parts from damage or dirt.
1) Place the parts gently on a proper and clean protector such as a wooden pallet or a cloth
to avoid damage to the finished surface of the parts.
2) Properly cover the precise parts immediately after the disassembly. (To avoid dust or
dirt)
(6) Properly store the disassembled parts. (To avoid missing)
1) Do not place the disassembled parts in a mess.
2) Locate and store the parts properly according to their qualities. (To avoid missing or
damage of the parts)
(7) Avoid deformation of the parts of large weight or long length. Apply proper supports to the
heavy and long parts. (Improper handing or placement may cause deformation)
(8) Do not hang the parts in an improper way.
1) Do not hang the parts at the position off its center of gravity. (The part will spring up at the
same time it is hung, or disassembling inner parts will be difficult.)
2) Do not use a hanging tool of insufficient strength.
4.1.2 ENGAGING PROCEDURE
There are two kinds of engaging procedures, pressuring method and heating method.
4-3
The heating method requires less outside force since the part is inserted after the opening is
expanded by heating the outside of the applicable area. Therefore, the heating method is
generally used.
The relation between engagement extent and heating temperature is shown in the Table 4.1-1.
The procedure of the heating method is shown in the Figure 4.1-1, unless otherwise specified.
①The heating temperature must be 120℃ (248℉) or lower.

②The heating temperature means the additional temperature required for heat
Table 4.1-1 Engagement and Heating Temperature
Engagement Heating temperature
H7 m5 30℃(86℉) or higher
H7 m6 40℃(104℉) or higher
H7 p6 50-70℃(122~158℉) or higher
H7 r6 80℃(176℉) or higher
Figure 4.1-1 Engaging Procedure of Heating Method

4.1.3 DISENGAGING PROCEDURE
There are two kinds of disengaging procedure, pressuring method and heating method. The
pressuring method is generally used.
The pressuring method can be performed by striking (with a lead hammer) or by using a pressing
instrument. Examples of the pressuring method are as follows.
As for tool ○
A and tool ○ B , use one fitting with the
applicable part in size.
The pressuring method can be performed by striking (with a lead hammer) or by using a pressing
instrument. Examples of the pressuring method are as follows.
(1) By striking (with a lead hammer) (In case of bearing ), as shown in Figure 4.1-2
4-4
Figure 4.1-2 Example of Pressuring

Disengagement (By Striking)
1) A , fix applicable part ○

By using tool ○ C.
2) Apply tool ○
B to applicable part ○
C.
3) Apply blow ○
D to tool ○
B .
(2) By using a pressing instrument (a puller) (In case of bearing), as shown in Figure 4.1-2.
1) A to applicable part ○
Apply tool ○ B .
2) Turn handle ○ A.
C of tool ○
Figure 4.1-3 Example of Pressuring Disengagement (By Using A Puller)
4-5
4.2 MAIN COMPONENTS IN THE MACHINERY HOUSE...................................... 4-7

4.2.1 REDUCER ............................................................................................... 4-7
4.2.2 MOTOR COUPLING .............................................................................. 4-16
4.2.3 DRUM COUPLING REPLACEMENT ..................................................... 4-18
4.2.4 PILLOW BLOCK .................................................................................... 4-21
4.2.5 How to take the drum out of machinery house? ..................................... 4-22
4-6
4.2 MAIN COMPONENTS IN THE MACHINERY HOUSE

4.2.1 REDUCER
(1) Main hoist reducer
For detailed maintenance or repair instructions, refer to ZPMC’s reducer Manual.

(2) Trolley reducer

(3) Boom hoist reducer
Do running test before putting into service!
4.2.1.1 Main hoist reducer bearing replacement-high speed

PRACTICES FOR MAINTENANCE PERSONNEL”APPLY TO THIS REPAIR.
(REFER TO CHAPTER 1 & SECTION 3.1.1)
Danger of tripping!
Keep away from suspended loads!
Refer to the following procedures:

(1) Gantry the crane to a safe place for main hoist
reducer bearing replacement. If the boom is level,
hoist the boom up to the stowage position and
latch it up. Meanwhile, make sure that the trolley
is at parking position.
(2) Lower the empty spreader all way to the ground
and do not stop the lowering until the main hoist
ropes are slack. During this period, make sure
that everyone is kept away from the main hoist
drive and the reeving system.
(3) Lock out the crane’s motion by carrying out the
lock-out and tag-out procedure.
(4) Tie off the four main hoist wire ropes to the
supports in machinery house and create slack
rope between tie-off points and drum.
(5) Remove the electrical connection from the two Figure 4.2-1 Main Hoist High Speed Brake
4-7
motor brakes.
(6) Manually release the motor brake, loosen and remove the bolts which connect the brake
base with the support seat, cut off the electrical connections. Then remove the brakes by
service crane. Before removing the brakes, making marks for reinstall.
(7) Remove the motor brake discs. Refer to Section 4.2.2.1.
(8) Drain the lubricant oil out of the gearbox.
(9) Remove all bearing through-cover and cap bolts from the reducer box.
(10) Remove the reducer upper case by service crane.
(11) Remove the high-speed shaft with bearings and coupling hubs to the ground by the service
crane through trap doors on the floor of the machinery house and have the bearing replaced
in the shop.
(12) Remove the coupling hub from the input shaft. Because it is press-fit onto the shaft , surface
of the hub should be evenly pre-heated before it is pulled out. Remove the damaged bearing
from the shaft.
(13) Reinstall new bearing and coupling hub on the shaft. Before it is reinstalled, the hub should
be pre-heated in 200℃ (392℉) oil bath for hours.
(14) Install the shaft with new bearing to gearbox.
(15) Clean the gearbox with solvent. Shaft seals should be replaced as well if necessary.
(16) Assemble the gearbox together.
(17) Install the components that have been removed to their original location.
(18) Restore the emergency brake hydraulic system from hand pump condition.
(19) Fill the gearbox with about 550 liters gear oil.
(20) Hoist the spreader up about ten meters below the trolley.
(21) Verify the motor brakes.
(22) Re-home hoist position.
(23) Turn off the control power to finish the maintenance.
Startup and monitor the crane to verify its operation, before returning it to service.
Be sure to monitor the gearbox operation at initial 400 operation hours.
The split surfaces of the housings should be clean, dry and applied
with Loctite 515 sealant before the housings are assembled together.
4.2.1.2 Main hoist reducer bearing replacement-intermediate speed
ALL PRECEPTS OUTLINED IN THE “SAFETY PROCEDURES AND

GOOD PRACTICES FOR MAINTENANCE PERSONNEL”APPLY TO
THIS REPAIR. (REFER TO CHAPTER 1)
Danger of tripping !
4-8
(1) Repeat step 1~10 of 4.2.1.1 except step 5,6,7. The motor brakes should be released
manually only by using the manual handle Figure 4.2-1.
(2) Remove the intermediate shaft with bearings to the ground by service crane and have both
the bearings replaced in the shop.
(3) Reinstall the shaft with new bearings to bearing seats.
(4) Repeat step 15~23 except step 22 of Section 4.2.1.1.
Startup and monitor the crane to verify its operation before returning it to service. Be sure to
monitor the gearbox operation at its initial 400 operation hours.
4.2.1.3 Main hoist reducer bearing replacement-low speed
NOTE: ALL PRECEPTS OUTLINED IN THE “SAFETY PROCEDURES

AND GOOD PRACTICES FOR MAINTENANCE PERSONNEL”APPLY
TO THIS REPAIR. (REFER TO CHAPTER 1)
(1) Lower the spreader to the ground and

slacken the Main Hoist ropes.
(2) Remove the grease pans under the
drums.
(3) Tie off four main hoist ropes in machinery
house. Slacken enough rope off both
drums so that they can be moved
sideways a couple of feet.
(4) Lock out the crane’s motion by carrying
out lock-out and tag-out procedure.
(5) Disconnect the coupling between drum
and rotary limit switch, by releasing the
bolts on their coupling See Figure 4.2-2.
Figure 4.2-2 Main Hoist Limit Switch
(6) Remove the emergency brakes’ electrical
4-9
and hydraulic connection.

(7) Use the service crane to move the emergency brakes.
(8) Remove the electrical connection of drum mounted switch.
(9) Remove the bolts connecting the drum and drum coupling, as shown in Figure 4.2-3, and the
bolts between cover and reducer shaft.
(10) Remove the pillow block mounting bolts.
(11) Secure the drum brake disc with service
crane and loosen the bolts which connect
the drum brake disc to the drum. Leave one
bolt on, tightened by hand force.
(12) Lift the brake disc up slowly until the bottom
of the disc is higher than the top surface of
pillow block support structure.
(13) Align any one of bolt hole between the
brake disc and the drum, then connect the
disc to the drum with the second bolt. Main Hoist Drum Coulping Assembly
(14) Use slings and softeners to connect the Figure 4.2-3 Drum Coupling
drum to the service crane, and hoist it
vertically about 5mm, and drag each drum
and pillow block sideways about two feet (600mm). Make sure that it is enough distance for
you to lift the reducer low speed shaft. Then set each drum on timbers.
Figure 4.2-4 Disassembly Of Drum

(16) Remove the bolts that connect the gearbox cover to the lower case.
(17) Use the service crane to lift the gear case cover and move it aside and support it with timber.
(18) Lower the low speed shaft with hub to the ground and send it to shop.
(19) Disassemble drum couplings.
(20) Remove the coupling hub from the output shaft. Because it is press-fit onto the shaft (refer to
drawing J554A03), the surface of the hub should be evenly pre-heated before it is pulled off.
Remove the damaged bearing from the shaft.
be pre-heated in 400℃ (752℉) oil bath for hours.
(22) Lift the replacement shaft assembly into the machinery house and install it back to original
position.
(23) Clean the gearbox with solvent. Shaft seals should also be replaced if necessary.
4-10
(24) Assemble the gearbox together.

(26) Realign the drum couplings.
(27) Follow step 18~23 in section 4.2.1.1.
(28) Verify main hoist drum brake setting.
(29) Verify the drum mounted rotary limit switch setting.
Startup and monitor the crane to verify its operation, before returning it to service. Be sure to
monitor the gearbox operation at its initial 400 operation hours.
4.2.1.4 Trolley reducer bearing replacement

(REFER TO CHAPTER 1)
Danger of Tripping !
The entire trolley reducer should be moved from the crane to shop for bearings’ replacement. The
procedure of trolley reducer’s movement is as follows:
(1) Gantry the crane to a safe place, fix the trolley at its parking place and lock the boom to
stowage position.
(2) Secure the trolley in position with chain blocks (the manual chain hoists).
(3) Release the trolley rope tension cylinders. Turn the valve in the hydraulic station, as shown in
Figure 4.2-5.
(4) Disconnect the bolts of the rope re-reeving platform and the floor and move the platform away
on the floor.
4-11
Figure 4.2-5 T/L/S Hydraulic Station

(5) Lock out the crane’s motion by carrying out the lock-out and tag-out procedure.
(6) Tie the four wire ropes to supports in machinery house and leave enough slack rope between
tying point and the drum. Manual chain hoists provided in the machinery house can be used
for this purpose.
(7) Disconnect the drum coupling by releasing the bolts.
(8) Put some wood under the drum at the reducer end and move the trolley drum with pillow
block and half coupling aside. Let the drum lay on the wood.
(9) Remove the motor brake and disconnect the motor coupling.
(10) Remove the emergency coupling.
(11) Loosen the reducer mounting bolts.
(12) Move the reducer from the crane to shop with the service crane.
(13) Replace the damaged bearing in shop. Because it is press-fit onto the shaft, you should
evenly pull it off by a hydraulic jack or a drawing block (you may need to evenly pre-heat the
assembly to make it easy). Reinstall new bearing on the shaft. Before it is reinstalled, it
should be pre-heated in 80~120℃(176~248℉) oil bath for hours.
(14) Reinstall the components back on trolley drive.
(15) Realign the motor and drum coupling. Refer to drawing J554A0400 for alignment criteria.
(16) Close the valve in step 2 and set it back to its normal working position.
Monitor the gearbox operation at its initial 400 operation hours.
4-12
4.2.1.5 Boom hoist reducer bearing replacement-high speed

GOOD PRACTICES FOR MAINTENANCE PERSONNEL”APPLY TO THIS
REPAIR. (REFER TO CHAPTER 1)
(1) Gantry the crane to a safe place for boom hoist reducer bearing replacement. Stop the trolley
at its parking place.
(2) Hoist the boom to maintenance position.
(3) Insert the stowage pin into
socket to lock the boom.
(4) Lower the boom a little to
slacken the boom hoist
rope.
(5) Lock out the crane’s
motion by carrying out the
lock-out and tag-out
procedure.
(6) Tie off two boom hoist wire
ropes in machinery house
or on the landside upper
beam and leave the slack
rope between tie-off points
and the drum. Figure 4.2-6 Boom Hoist Drive And Emergency D rive
(7) Remove the motor brake by using the service crane after releasing the bolts and cut off the
electrical connections.
(8) Remove the motor brake disc with motor coupling claw ring from the motor coupling and the
motor will be disconnected from the reducer high-speed shaft.
(9) As shown in Figure 4.2-6, remove the emergency device clutch mounting bolts, then remove
the clutch. The teeth hub can be left on the reducer high speed shaft. For detailed emergency
device clutch disassembly, refer to Section 4.2.3
(11) Remove all the bearing through-covers and cap bolts from the reducer box.
(12) Remove the reducer upper box by service crane.
(13) Remove the high speed shaft with bearings and coupling hubs to the ground by service crane
and have the bearing replaced in the shop.
(14) Remove the coupling hub from the input shaft. Because it is press-fit onto the shaft (refer to
be pre-heated in 200℃(392℉) oil bath for hours.
4-13
(16) Install the shaft with new bearing to gearbox.

(17) Clean the gear box with solvent.
(18) Assemble the gearbox together. Replace shaft seals if necessary.
(19) Install the components that have been removed to their original locations.
(20) Fill the gearbox with about 250 liters of oil.
(21) Restore the emergency brake hydraulic system from hand pump condition.
(22) Hoist the boom a little to tension the wire ropes and pull out the stowage pins and insert them
into the storage sockets.
(23) Verify the motor brake torque. Refer to relevant drawing.
(24) Monitor the gearbox operation at its initial 30 operation hours.
Startup and monitor the crane to verify its operation before returning it to service.
4.2.1.6 Boom hoist reducer bearing replacement-intermediate speed

(1) Repeat step 1~12 of section 4.2.1.5(boom hoist reducer bearing replacement-high speed)
except step 7, 8 and 9.
(2) Remove the intermediate shaft with bearings to the ground by service crane and have the
bearing replaced in the shop.
(3) Install the shaft with new bearing to gearbox. Both bearings should be replaced.
(4) Repeat step 17~22 of section 4.2.1.5.
(5) Startup and monitor the crane to verify its operation, before returning it to service.
The split surfaces of the housings should be clean, dry and applied with
Loctite 515 sealant before the housings are assembled together.
4-14
4.2.1.7 Boom hoist reducer bearing replacement-lower speed

(REFER TO CHAPTER1)
(1) Repeat step 1~6 of section 4.2.1.5.

(2) Remove the emergency brakes.
(3) Remove the electrical connection of drum mounted switch.
(4) Disconnect the coupling between drum and rotary limit switch, by releasing the bolts on the
coupling. See Figure 4.2-7.
(5) Loosen the bolts connecting the drum coupling
to the drum.
(7) Secure the drum brake disc with service crane
and loosen the bolts which connect the drum
brake disc to the drum. Leave one bolt on,
tightened by hand force.
(8) Lift the brake disc up slowly until the bottom of
the disc is higher than the top surface of the
pillow block support structure.
(9) Align any one of bolt hole between the brake
disc and the drum, and then connect the disc
to the drum with the second bolt, as shown in
Figure 4.2-4.
(10) Use slings and softeners to connect the drum
to the service crane, and hoist it vertically
Figure 4.2-7 Boom Hoist Limit Switches
about 5mm (0.2in), and drag the drum and
pillow block sideways about two feet (600mm).
Verify that this is enough distance for you to lift the reducer low speed shaft. Then set the
drum on timbers.
(12) Remove the bolts that connect the gearbox cover to the lower case.
(13) Use the service crane to lift the gear case cover and move it aside.
(14) Lower the low speed shaft to the ground and move it to a workshop to accomplish all repairs
and replacements.
(15) Disassemble drum couplings.
(16) Remove the coupling hub from the output shaft. Because it is press-fit onto the shaft (refer to
4-15
be pre-heated in 400℃ (752℉) oil bath for hours.
(18) Lift a replacement shaft assembly in the machinery house and install it back to original
position.
(19) Clean the gearbox with solvent.
(20) Assemble the gearbox together. Replace shaft seals if necessary.
(22) Realign the drum couplings.
(23) Fill the gearbox with about 250 liters oil.
(24) Hoist the boom a little to tension the wire ropes and pull out the stowage pins to insert into
storage sockets.
(25) Verify the emergency brake torque.
(26) Verify the drum mounted rotary limit switch.
(27) Monitor the gearbox operation at its initial 30 operation hours.
The split surfaces of the housings should be clean, dry and applied with
Loctite 515 sealant before the housings are assembled together.
4.2.2 MOTOR COUPLING

4.2.2.1 Motor brake disc replacement

Brake Disk (5) Claw Ring (3b)
Gear Side Claw Ring (3a)
Motor Side Hub on Gear side (6)

Elastic Ring
Hub on Motor side (2)
Bolts (7)
Bolts (1)
High Speed Elastic Coupling
Figure 4.2-8 Motor Coupling & Brake Disc

(1) MAIN HOIST BRAKE DISC
The Malmidie coupling is used for main hoist system. Though the drawing is different, the
procedure is more or less the same. Please also refer to Malmedie manual before replacing
4-16
the main hoist coupling.

1) Gantry the crane to a safe place for main hoist disc replacement. At the same time, make
sure that the trolley is at its parking position.
2) Lower the empty spreader all way to the ground and stop the lowering until the main hoist
rope is slack enough. During this period, make sure that everyone is kept away from the main
hoist drive and reeving system.
3) Tie the rope with chain blocks to supports in machinery house.
4) Lock out crane motions by carrying out the lock-out and tag-out procedure.
5) Remove the electrical connection from the motor brake, release the brake manually, then
remove the brake by service crane.
6) Unfastening the bolts (1,7), move the motor and the hub together on the wood(Remove the
motor just for main hoist system).
7) Remove the claw rings (3a, 3b) and elastic ring (4) out of the hub seat by a puller. In the
process, protect the motor shaft carefully. Refer to Figure 4.2-8(just for reference, the drawing
of main hoist coupling please refer to Malmedie maintenance manual).
8) Slide the brake disc out of the coupling hub and remove it by a puller.
9) Clean and degrease the new disc and install it to the gear side-coupling hub. In the step,
align the number on the brake disc with the number on the hub.
10) Assemble the claw rings (3a, 3b) and elastic ring (4) together and slide onto the hub seat.
11) Hang the motor and the other hub onto the seat. Detailed install requirement please refer to
relative coupling manual.(just for main hoist system)
12) Install all fastening bolts (1,7) and tighten them by torque wrench. For tightening torque,
please refer to relevant manual.
13) Reinstall the brake and readjust the brake according to the brake manual. Set the brake
torque to 12500NM.
14) Hoist the spreader up about ten meters below the trolley.
15) Turn off the control power.
16) Verify the brake torque.
(2) TROLLEY BRAKE DISC

1) Gantry the crane to a safe place for trolley brake disc replacement. At that time, make sure
that the trolley is at its parking position.
2) Lock out crane motions by carrying out lock-out and tag-out procedure.
3) Tie off four trolley wire ropes in the machinery house.
5) Follow step 1.6~1.12 of main hoist brake disc replacement.
6) Reinstall the brake and readjust the brake according to the brake manual. Set the brake
torque to 6000NM.
7) Verify the brake torque
(3) BOOM HOIST BRAKE DISC

1) Gantry the crane to a safe place for boom hoist brake disc replacement. Hoist the boom up to
4-17
its maintenance position and insert the stowage pins. Fix the trolley to its parking position.
2) Lock out crane motion by carrying out lock-out and tag-out procedure.
4) Follow step 1.6~1.12 of main hoist brake disc replacement.
5) Reinstall the brake and readjust the brake according to the Bubenzer brake manual. Set
brake torque to 7000NM.
6) Pull out the stowage pins and insert into storage sockets.
7) Verify the brake torque.
The replacement of motor coupling elastic ring is the same with the coupling. Just open the
coupling and put in the new ring is OK.
4.2.3 DRUM COUPLING REPLACEMENT
1 2 3 4 5 6 1
1 Oil Sealer 2 Outer Cover 3 Load Ring
4 Bushing 5 Flange 6 Inner Cover
Figure 4.2-9 DC Coupling
4-18
Figure 4.2-11 Pull the coupling out of drum Figure 4.2-10 Pull the coupling out
The main hoist drum coupling is Malmedie TTXs series coupling, the others are ZPMC DC series
coupling. The procedure is alomost the same. Please refer to Malmedie maintenance manual for
main hoist drum coupling. Here take ZPMC DC coupling as an example. If properly aligned and
lubricated at regular intervals, it is designed to last many years. Once the wear is outside the
allowable range, the coupling must be replaced with a new one.
(1) Lower the empty spreader all way to the ground and do not stop the lowering until the main
hoist ropes are slack. (for boom hoist system, let the boom be level and slacken the rope; for
trolley driving system, fix the trolley at the park position and slacken the rope).
(2) Lock out the crane’s motion by carrying out the lock-out and tag-out procedure.
(3) Disconnect the electrical wires and limit switches
(4) Tie off the four main hoist wire ropes to the supports in machinery house and create slack
rope between tie-off points and drum.
Figure 4.2-12 Put on the cover and

Figure 4.2-13 Fit bolts and jack on the
tight the nut
coupling

(6) Secure the drum brake disc with service crane
and loosen the bolts which connect the drum
brake disc to the drum. Leave one bolt on,
tightened by hand force.
(7) Lift the brake disc up slowly until the bottom of the
disc is higher than the top surface of pillow block
support structure.
(8) Align any one of bolt hole between the brake disc
and the drum, then connect the disc to the drum
with the second bolt.
Figure 4.2-14 Fit the abrasion indicator
4-19
(9) Use slings and softeners to connect the drum to the service crane, and hoist it vertically about
5mm, and drag each drum and pillow block sideways to a place where it’s easy to dismantle
the coupling, as shown in Figure 4.2-10.
(10) Loosen the bolts between the drum and flange, use the service crane to lift the coupling and
pull it out, as shown in Figure 4.2-11.
(11) Before dismantling the bushing on the reducer, first to
judge whether to change a new coupling. If a new
coupling is to be changed, just cut the bushing at the
key groove and take the bushing away.
(12) Lay the reducer down on the woods and let the shaft be
vertical.
(13) Turn high strength bolts into the holes on the bushing,
and put a jack onto the bushing, as shown in Figure
4.2-13. Meanwhile, put some washers under the jack.
(The washer should be a plate and not a ring)
(14) Put on a cover and tight the nut, then start to jack, as
shown in Figure 4.2-12. The process may be last for
one hour.
(15) When fitting a new coupling. First dismantle the cover,
bushing and flange. Clean the oil carefully and heat the Figure 4.2-15 Fit the bushing
bushing.
(16) First fit the cover, as shown in Figure 4.2-14.
(17) Fit the bushing onto the shaft, as shown in Figure 4.2-15. The process should be as short as
possible in case the bushing will minimize.
(18) After that put the cover at the right position.
(19) Fit the flange in reversed sequence according to the steps introduced above. Adjust the
coupling according to DC coupling manual.
Startup and monitor the crane to verify its operation before returning it
to service.

Danger of tripping!
4-20
4.2.4 PILLOW BLOCK

The typical drum pillow block is shown in Figure 4.2-16,. The pillow block consists of upper block,
lower block connected by screw stud, an anti-friction bearing, seals and end covers, etc.
1 2 3 4 5 6 7 8
1 cover1 2 sealer 3 stud 4 upper seat
5 lower seat 6 bearing 7 axle 8 cover 2
Figure 4.2-16 Main Hoist Pillow Stock Assembly

The following procedures must be observed to replace the pillow block bearing.
(1) Lower the spreader to the ground and slacken the Main Hoist ropes. (Or position the boom to
the level and slacken the Boom Hoist ropes.)
4-21
(2) Tie off four main hoist ropes in machinery house (or two boom hoist ropes in the machinery
house). Slacken enough rope off both main hoist drums (or boom hoist drum), so that they
can be moved sideways a couple of feet.
(3) Lock out the crane’s motion by performing lock-out and tag-out procedure.
(4) Disconnect the coupling between the drum and the rotary limit switch if there is, by releasing
the bolts on their coupling. Remember the rope position on the drum. Or disconnect the
coupling when the spreader is on the ground or boom is level. It will be easier to reset after
re-installation. See Figure 4.2-2.
(5) Use slings and softeners to connect the drum to the service crane, make the drum stand still.
(6) Remove the pillow block end covers. Unfasten the stud nuts, and screw the studs out of the
lower pillow block.
(7) Remove the upper pillow block and expose the bearing and seals.
(8) Remove the lower pillow block mounting bolts.
(9) Lift the drum up 20mm by service crane, then move the lower pillow block sideways from the
drum shaft.
(10) Use a puller with a 10-ton capacity to pull out of the bearing.
(11) Clean the drum shaft and pillow block with solvent. Shaft seals should also be replaced if
necessary.
(12) Reinstall new bearing on the shaft. Before it is reinstalled, the bearing should be pre-heated
in 200℃ (392℉) oil bath for hours.
(13) Re-assemble the pillow block together in the reverse order mentioned above.
(14) Re-align the drum couplings. Refer to relevant drawing for alignment criteria.
(15) Verify the drum-mounted rotary limit switch setting.
Startup and monitor the crane to verify its operation before returning it to service.
4.2.5 How to take the drum out of machinery house?

After a period of using, the drum may be changed and should be taken out of machinery house.
The detailed procedures to complete the task are as follows (The detailed dimension of each
project may be different. Here we just give an example how to lift the drum out of machinery
house, as shown in Figure 4.2-17):
(1) Tie the drum with soft ropes to the service crane and hang it up, move the drum near the
hatch (If the drum being moved is the boom hoist drum, first dismantle the bolts between the
drums and taking them out in halves)
(2) Use a support to make the drum slant 39° with the ground (The support’s height is about
1930mm).
(3) Move the crane towards the hatch. During the process, lower the drum slowly. Make sure the
drum not collide with the machinery deck.
4-22
Figure 4.2-17 The Process Of Taking The Drum Out Of MH
(4) After the bottom end has completely under the machinery deck and the upper end is right
above the hatch, then lower the durm down to the ground.
The opposite way to hang a new one up.
4-23
4.3 MAIN COMPONENTS ON THE TROLLEY ................................................. 4-25

4.3.1 TROLLEY WHEEL AND AXLE REPLACEMENT ................................... 4-26
4.3.2 TROLLEY WHEEL ALIGNMENT ADJUSTMENT ................................... 4-28
4.3.3 MAIN HOIST SHEAVE REPLACEMENT ............................................... 4-32
4.3.4 SPREADER CABLE REEL REPLACEMENT......................................... 4-35
4-24
4.3 MAIN COMPONENTS ON THE TROLLEY

The drawing J554A0200 is referred to for the following procedure.
The split trolley is used for this project. Though the drawing is difference from the ordinary
drawings, below procedure is more or less the same.
The position of the sheave is independently movable in order to have an optimum choice between
rope clearances, skew and reeving stability. Moving time from maximum till minimum sheaves
distance is less than 60 seconds (vice versa). The position of the sheaves shall be controlled by
the operator.
 Underneath the tandem headblock it is possible to have one single spreader or tandem
spreader.
 When working with single spreader, the distance between the sheaves in the headblock
is be in inner position.
 When working with tandem spreader, the distance between the sheaves in the
headblock is be in outer position.
 The following for the distance between sheaves in the trolley:
When working with single spreader, the distance between the sheaves in the trolley shall
be at approximately 1900mm.
When working with tandem spreaders, the distance between the sheaves in the trolley
shall be at approximately 4200mm.
The following procedure for maintenance or repair of the main components on the trolley will
cover: (as shown in Figure 4.3-1)
 Trolley wheels
 Main hoist sheaves
 Spreader cable reel system
 Cab Window Glass Replacement.
Figure 4.3-1 Trolley Layout
DANGER OF FALLING !
4-25
4.3.1 TROLLEY WHEEL AND AXLE REPLACEMENT

Four trolley wheel assemblies are located on each corner of the trolley. The location and its
appearance are shown in Figure 4.3-2.
Figure 4.3-2 Trolley Wheel

It is recommended that trolley wheel or axle repair work be accomplished in a workshop instead of
on the crane.
Consider the following basic steps to accomplish the replacement:
(1) Move the trolley to the backreach (at its maintenance position) and fix the trolley.
(2) Lower the spreader to the ground and slacken the main hoist ropes.
(3) Lock out crane motion by performing lockout-tagout procedure.
(4) The trolley truck is supported by 4 wheels at the corners.
(5) As illustrated in the Figure 4.3-3, install a 10T jack under jacking pads which are on the four
corners of the trolley frame (near the trolley wheels). The gap between the top of the rail and
the bottom of jack point is about 300mm. Lift the truck by 10 mm. A timber block may be
necessary between the trolley frame and rail top to prevent the trolley from tilting. The
anti-jump plate may be removed from the trolley before jacking-up.
4-26
Figure 4.3-3 Trolley Jacking

(6) First make marks on the eccentric bushing and trolley frame and then disconnect the
defective wheel and shaft and lift it up with the back reach overhead bridge crane and transfer
to the electric jib hoist at the back reach and lower it to the ground.
(7) Disassemble the wheel at the workshop. For detailed components of trolley wheel assembly,
please refer to the “Figure 4.3-4 The Components of Trolley Wheel”.
(8) Lift the new wheel and shaft to the crane with back reach electric hoist and transfer to the
overhead bridge crane.
(9) Reassemble the wheel to the trolley.
1) Important note: the wheel bearing’s seat is eccentric. The purpose of this design is that
the axial alignment of trolley wheels on both sides of rails can be adjusted to proper
value.
2) The eccentric sleeves were properly adjusted in the manufacturer’s shop. No more
adjustment should be needed. If adjustment is necessary, refer to 4.3.2 for the steps.
3) When reinstalling the truck, the marks on bearing seats and the truck must be matched.
Please see section 4.3.2 for how to adjust the wheel alignment.
DANGER OF FALLING!
4-27
Figure 4.3-4 The Components of Trolley Wheel

1 Wheel 2 Outer Spacer 3 Cover 4 Cover 2 5 Oil Nozzle 6 Inner Spacer 7 Sealer
8 Bearing 9 Sealer 2 10 Adjust Bushing 11 Axle 12 Adjusting Bushing 2 13 Cover
4.3.2 TROLLEY WHEEL ALIGNMENT ADJUSTMENT

4.3.2.1 Introduction
In case of trolley wheel disassembly and re-assembly, the following guidelines should be
observed.
The trolley wheel axle is supported by two eccentric bushings (as shown in Figure 4.3-4, piece
10,12), by which the wheel can be adjusted. Both eccentric bearing sleeves are 1.5mm adjustable.
The drawings of eccentric sleeves are shown in Figure 4.3-5.
Figure 4.3-5 Adjusting Bushing

4.3.2.2 Wheel Adjustment Analysis
Through different turning combinations of these two eccentric bushings, the trolley wheels can be
re-aligned in three conditions. 1) Horizontally Deviated; 2) Vertically leaned; 3) Vertical Lift-off.
4-28
(1) Trolley Wheel in original position
Figure 4.3-6 Wheel Adjustment

The Figure 4.3-6 shows the trolley wheel in its original position, while the notch of the adjusting
bushing is at the horizontal position. The eccentricity of the bearing sleeve is exaggerated (not in
scale, for a more clear view).
IMPORTANT! Please locate the original position mark. If the mark is not there, make sure that
you mark it before starting any disassembly. This will give you a definite direction of sleeve turning.
And you can return to the original position if the adjustment fails (get worse after the adjustment).
(2) Wheel Horizontally Deviated
Wheel Alignment (Horizontally Deviated)
Figure 4.3-7 Wheel Alignment (Horizontally Deviated)

The Figure 4.3-7 shows how to make the wheel deviated horizontally. Turn the left sleeve 90
degree clockwise, and turn the right sleeve 90-degree counter clockwise. The wheel can be
deviated horizontally to the left up to 0.24 degree. At the same time, the wheel will be lift off the rail
by 1.5 mm. If you turn the two sleeves in the opposite direction, the wheel will be deviated to the
other direction.
4-29
TIP! When doing this adjustment, please gradually turn the eccentric
sleeve. Every time, a 30 degree angle turning is recommended, then see if
the trolley running condition has been improved. If necessary, turn another
30 degree.
(3) Wheel Vertically Leaned
Wheel Alignment (Vertically)
Figure 4.3-8 Wheel Alignment (Vertically Deviated)

Figure 4.3-8 shows how to make the wheel leaned vertically. Turn the left sleeve 180-degree
(either clockwise or counter clockwise), and the right sleeve stays un-turned. The wheel can be
leaned vertically to the right up to 0.24 degree. At the same time, the center of the wheel will be lift
off the rail by 1.5 mm. If you do the two sleeves in the opposite direction, the wheel will be leaned
to the other direction.
TIP! If turning one eccentric sleeve at 30, 90 or 120 degree, the wheel will both leaned vertically
and deviated horizontally. When one eccentric sleeve is turned 90 degree, half of the maximum
deviation angle of 0.24 degree and half of the maximum leaning angle of 0.24 will be distributed
evenly. You can do this if the wheel needs both deviation and leaning adjustment. Make sure the
deviation and leaning direction is correct before doing this! (This decides which sleeve will be
turned and what is the turning direction.)
(4) Wheel Vertical Lift-off
Figure 4.3-9 Wheel Lift-off

The Figure 4.3-9 shows how to make the wheel vertically lift-off. Turn both the left and right sleeve
180 degree (either clockwise or counter clockwise). The wheel will be lift vertically off the rail by 3
mm. If you do this by turning both sleeves 90 degree in the same direction, the wheel will be lift off
by 2.5 mm and there will be no wheel deviation and wheel leaning.
4-30
If one of the trolley wheels is out of the altitude plane of the other three
wheels, this step can be tried.
The relationship between wheel alignment and eccentric sleeve turning is shown in Table 4.3-1.
Table 4.3-1 Wheel Alignment vs Eccentric Sleeve Turning Combination
Combination 1 Combination 2 Combination 3 Combination 4
Right Sleeve 90º Stay un-turned 180º Stay un-turned
Left Sleeve 90º 180º 180º 90º
Wheel Alignment Results
Horizontally Deviated √ √
Vertically leaned √ √
Vertically lift-off √ √ √ √
4.3.2.3 Allowable Wheel Misalignment Value

The allowable wheel misalignment values which the wheels should be set less than are as
followis:
(1) Horizontal Angular Deviation
The horizontal angular deviation of wheel axis to its theoretical position should be less than
0.04%.
Theoritical Position of Wheel
Figure 4.3-10 Allowable Wheel Deviation

(2) Vertical Lift-off
If the wheels are mounted on a bogie then the axis line misalignment of opposite pins of
un-deformed trolley or bogie in the vertical plane should be less the 0.15% of the span, and the
maximum is 2mm.
4-31
Figure 4.3-11 Allowable Wheel Vertical Lift-off
DANGER OF FALLING!
DANGER OF TRIPPING!
4.3.3 MAIN HOIST SHEAVE REPLACEMENT
DANGER OF FALLING!
There are 12 sheaves on the trolley. Among them, 8 sheaves are vertically mounted for main hoist
and 4 sheaves are horizontally mounted for trolley driving.
Main hoist sheaves, Vertical sheaves,

8 totally 4 totally
Figure 4.3-12 Main Hoist Sheaves on the Trolley

4.3.3.1 Vertical sheave replacement
(1) Move the trolley to backreach just under the service crane so that the sheaves which are to be
replaced are accessible with the service crane.
(2) Lower the head block to the ground and slacken the main hoist ropes.
4-32
(3) Lock out crane hoist and trolley motions by performing the lock-out and tag-out procedure.
(4) Use two 0.5t chain hoists to remove the ropes from the sheaves which are to be replaced.
Figure 4.3-13 Trolley under service crane at back reach

(5) Use one 0.8t chain hoist and sling suspended from service crane to support the sheave to be
replaced.
(6) Loosen the 8 bolts connected the shaft upper-seat.
(7) Remove the 2 shaft upper-seats.
(8) Lift up the sheave assembly and lower the sheave assembly to the ground and repair
damaged sheave assembly parts in a workshop. For detailed information of sheave assembly
parts inside, Please refer to “Figure 4.3-14 Main hoist sheave assembly”.
(9) Pull the shaft out with a service crane.
(10) Pull the upper sheave assembly vertically because there is a bushing between the two
sheaves
(11) Dismantle the cover of the broken sheave. Pull the upper bearing out with a puller.
(12) Take out the inner spacer and outer spacer.
(13) Turn over the sheave and take out another bearing.
(14) Reverse the above-mentioned procedure of installing sheaves to its original location.
4-33
Figure 4.3-14 Main hoist sheave assembly

4.3.3.2 Horizontal sheave replacement
Figure 4.3-15 Assembly of horizontal sheave

1 Sheave Assembly 2 Cover 3 Oil Nozzle 4 Shaft 5 sleeve 6 Bearing
(1) Move the trolley to the backreach under the service crane so that the sheaves which are to be
replaced are accessible with the service crane.
(2) Slacken the trolley driving ropes.
(3) Lock out crane hoist and trolley motions by performing the lock-out and tag-out procedure.
4-34
(4) Use two 0.5t chain hoists to remove the ropes from the sheaves which are to be replaced.
(5) Use one 0.8t chain hoist and sling suspended from the service crane to support the sheave to
be replaced.
(6) Loosen the 4 bolts on the cover and pull the shaft out.
(7) Pull the sheave assembly horizontally out of the support and lift up above the trolley structure
(8) Follow step 8~14 of vertical sheaves’ replacement
DANGER OF FALLING !
4.3.4 SPREADER CABLE REEL REPLACEMENT

A motor driven spreader cable reel is mounted on the trolley. It holds an electrical cable with one
end terminated at the headblock. This electrical cable supplies power to the spreader and other
lifting devices connected to the headblock.
The reel is designed to maintain a constant tension in the electrical cable so that it will not be slack
or be too tight. The spreader reel uses torque control modified by hoist position. During operation
if the cable is not spooling correctly, please stop and ask a maintenance technician for help.
(1) Move the trolley to the backreach under the service crane.
(2) Dismantle the fence of the cable reel first.
(3) Lower the headblock to 1m above the ground.
(4) Turn on the control power in the spreader cable reel local control station on the trolley.
(5) Push the lower button on the control station and un-spool the cable until there are two dead
wraps remaining.
(6) Turn off the control power. Unfasten all the electrical connections; unplug the cable from the
slip rings. Unwrap the cable dead wraps and anchor them on the trolley frame.
(7) Unfasten the bolts between the reel and reducer.
(8) Use the service crane to hoist the replaced reel.
(9) Move the trolley to clear the hoist way for the cable reel.
(10) Lower the replaced reel to the ground and lift the new one upper than the trolley platform.
(11) Move the trolley underneath the new cable reel and put the reel on the frame.
(12) Put it at the right position.
(13) Connect the reel with reducer
(14) Fasten all the electrical and mechanical connections on the new reel. Manually spool and
anchor the two dead wraps.
(15) Push the hoist button on the station and spool the cable on drum until the cable is tensioned.
4-35
Figure 4.3-16 Spreader Cable Reel
Danger of falling !
4-36
4.4 MAIN COMPONENTS ON CATENARY TROLLEYS ...................................... 4-38

4.4.1 Wheels ................................................................................................... 4-38
4.4.2 Supporting rollers ................................................................................... 4-39
4.4.3 Sheaves ................................................................................................. 4-40
4-37
4.4 MAIN COMPONENTS ON CATENARY TROLLEYS

GOOD PRACTICES FOR MAINTENANCE PERSONNEL” APPLY TO
The main components on the catenary trolleys are as follows: trolley frame, wheels, sheaves and
rollers, which are shown in Figure 4.4-1.
1 2 3 4
Figure 4.4-1 Catenary Trolley (Landside)
1 wheel 2 Trolley Frame 3 Sheave 4 Roller
The procedures of disassembling the components above are as follows:
4.4.1 Wheels
The procedures to dismantle wheels are as follows:
(1) Move the trolley to the backreach (here we use landside catenary trolley as an example. As
to seaside catenary trolley, move the trolley to the boom tip)
(2) Hoist the corner where the wheel is broken.
(3) Tie the wheel and shaft to the service crane in case it falls down.
(4) Unfasten the bolts on the eccentric bushing and dismantle the clamp plate. Please refer to
Figure 4.4-2.
(5) Hang up the wheel a little and pull it out the trolley frame.
(6) Hang it to the ground and replace the broken part.
(7) Dismantle item 5 and pull the wheel out.
(8) Dismantle item 7, pull the bearing out and take out the inner and outer spacer.
(9) Turn over the wheel and dismantle item 7, sealer and take the ring out.
(10) Assembly the new one in opposite procedure.
4-38
Figure 4.4-2 Catenary trolley wheel assembly

1 Cover 1 2 Shaft 3 Inner Spacer 4 Outer Spacer 5 Cover 2 6 Bearing
7 Cover 3 8 Wheel 9 Sealer 10 Eccentric Bushing 11 Clamp Plate
4.4.2 Supporting rollers
There are several groups of rollers on the catenary trolley. Here we just introduce one group.
Others can be treated in the same way.
(1) Move the catenary trolley to the backreach under the service crane( for seaside catenary
trolley, move it to the boom tip)
(2) Tie the roller being changed to the service crane in case it falls down.
(3) Unfasten the bolt of the clamp plate and move the plate away.
(4) Unfasten the bolts on the cover and take the cover with shaft and rollers out and send them to
workshop.
(5) Take the cover and bearing away. Take care the bearing maybe fall down.
(6) Take out the broken roller and add the new roller. Distinguish the side roller and middle roller.
(7) In the opposite sequence fit the new roller onto the trolley.
Figure 4.4-3 Roller Assembly

1 Clamp Plate 2 Middle Roller 3 Side Roller 4 Cover 5 Shaft
4-39
4.4.3 Sheaves
(1) Move the catenary trolley to the backreach under the service crane( for seaside catenary
trolley, move it to the boom tip)
(2) Tie the sheave assembly being changed to the service crane in case it falls down.
(3) Remove item 3 and 4
(4) Unfasten the bolt of the clamp plate and move the plate 8 away.
(5) Hang the sheave assembly out of the support and take the sheave assembly to workshop
and change the broken parts.
(6) Sheave assembly refer to section 4.3.3.
(7) Use the opposite sequence to fit new sheave.
Figure 4.4-4 Sheave on the catenary trolley

1 Support 2 Cover 3 Stud 4 Cover 5 Shaft 6 Clamp Plate
7 Sheave Assembly 8 Clamp Plate 2 9 Sleeve 10 Bearing
4-40
4.5 MAIN COMPONENT AT THE BACKREACH ................................................. 4-42

4.5.1 TLS CYLINDERS REPLACEMENT ....................................................... 4-42
4.5.2 MAIN HOIST SHEAVES REPLACEMENT ............................................. 4-43
REPLACEMENT ............................................................................................. 4-44
4.5.4 TENSIONER SHEAVES REPLACEMENT ............................................. 4-45
4-41
4.5 MAIN COMPONENT AT THE BACKREACH

4.5.1 TLS CYLINDERS REPLACEMENT

PRACTICES FOR MAINTENANCE PERSONNEL” APPLY TO THIS REPAIR.
Four sets of TLS cylinders and sheaves are located at the backreach of the crane. The TLS
cylinder is shown in Figure 4.5-1.
Figure 4.5-1 TLS cylinder
During the replacement, refer to Drawing J554A1000. All the items referred to in this
instruction correspond to the item numbers in the drawing.
(1) Lower the spreader and headblock to the ground and slacken the hoist ropes.
(2) Clear the home position with the switch in the electric room.
(3) Disconnect all the electrical and hydraulic connections on cylinder.
(4) Pull the sheave out to align the hole on the arm with the hole on the support and insert the
shaft.
(5) Lock out crane motion by performing the lockout-tagout procedure.
(6) Secure the cylinder with the back reach electrical service jib crane.
(7) Pull out the shaft between the cylinder and arm.
(8) Loosen 4 high strength bolts by which Item 29 (Plate 1) is connected to Item 31 (Plate 2)
(9) Lift the cylinder to the ground with the service jib crane.
(10) Do all maintenance and repair work in a workshop.
(11) Use the opposite procedure as described above to install a new or repaired cylinder
(12) Turn on the control power and raise the spreader a meter off the ground, and measure the
trim, list, and skew position. If the spreader is not level at zero position, then adjust until the
spreader is at the required position. Set new home position of cylinder.
4-42
(13) Return the crane to service and test the repair.
After a SNAG LOAD occurs, the rope and hoist system must be
checked completely for any damages due to an over load.

Danger of falling!
Danger of tripping!
4.5.2 MAIN HOIST SHEAVES REPLACEMENT

During the replacement, refer to drawing

J554A1000. All the items referred to in this
instruction correspond to the item numbers in
the drawing.
(1) Lower the spreader and headblock to the
ground and slacken the hoist ropes.
(2) Lock out crane motion by performing the
lockout-tagout procedure.
(3) Remove the sheave rope guard.
(4) Pull the hoist rope from sheave groove and
secure it with two chain blocks.
(5) Disconnect the cylinder and the sheave arm.
(6) Pull the sheave out and tie the sheave and Figure 4.5-2 Main Hoist Sheave At Girder
support to a proper position on the support.
(7) Remove the cover and cylinder shaft keeper plates.
(8) Pull the sheave assembly out of the arm and put it on the platform slowly.
(9) Lower the sheave assembly to the ground with the service crane.
(10) Do all maintenance and repair work in a workshop.
(11) Use the same procedure as described above to install a new or repaired sheave.
DANGER OF FALLING!
4-43

REPLACEMENT

Figure 4.5-3 Trolley Rope Tensioner
During the trolley tensioner replacement, refer to

Drawing J554A2103, while catenary trolley please
refer to drawing J554A2203. The procedures are the
same, so here we just introduce trolley tensioner
device. All the items referred to in this instruction
correspond to the item numbers in the drawing.
(1) Lock out crane motion by performing the
lockout-tagout procedure.
(2) Release the pressure in the cylinder by opening
the relief valve.
(3) Disconnect all the hydraulic connections to the
cylinder
(4) Tie down the tensioner sheave and its structure.
(5) Secure the cylinder with the electrical jib crane at
Figure 4.5-4 Trolley Rope Tensioner
the backreach.
Assembly
(6) Remove the keeper plates and pull out the pin at
the seaside.
(7) Remove the keeper plates on the back of the cylinder, and then remove the pin.
(8) Lift up the cylinder with the service crane and slew the crane to align the cylinder with the lift
way to the ground.
(9) Carry out all cylinder repairs in a workshop.
(10) Use the above mentioned procedure to install a replaced cylinder.
(11) Close the valve mentioned in step 2.
4-44
4.5.4 TENSIONER SHEAVES REPLACEMENT

During the replacement, refer to Drawing J554A2103. All the items referred to in this
instruction correspond to the item numbers in the drawing. The trolley tensioner sheaves
described here are located in the back reach at the trolley girder end tie beam.
(1) Lock out crane motion by performing the lockout-tagout procedure
(2) Remove the sheave guard.
(3) Remove the trolley rope from the sheave groove and secure them with chain blocks.
(4) Attach the sheave to the back reach service crane.
(5) Remove the sheave shaft keeper plate.
(6) Slide the sheave out of its seat, lift it, slew it with the service crane to align it with the lift way,
and lower it to the ground. The sheave can also be lifted to the ground through the service
crane in the machinery house.
(7) Do all the maintenance and repair work in a workshop.
(8) Use the same procedure as described above to install a new or repaired sheave.
Danger of falling !
4-45
4.6 MAIN COMPONENTS ON THE BOOM ....................................................... 4-47

4.6.1 BOOM HOIST SHEAVES REPLACEMENT ........................................... 4-47
4.6.2 LOAD CELL REPLACEMENT................................................................ 4-48
4.6.3 TROLLEY SHEAVES REPLACEMENT ................................................. 4-49
4.6.4 BOOM HINGE BEARING REPLACEMENT ........................................... 4-50
4-46
4.6 MAIN COMPONENTS ON THE BOOM

4.6.1 BOOM HOIST SHEAVES REPLACEMENT

There are (2) sets of (5) vertically mounted BH sheaves and (2) sets of single vertically mounted
sheaves on the boom. The sheaves and reeving arrangement are shown in dwg. J554A2300.
At the boom consider removing the (5) sheaves mounted on one pin, and bringing the assembly
into the crane shop. The work to replace one or more sheaves should be accomplished in a
workshop. Examine the bearings and grease seals, unless they are relatively new and in a very
good condition consider replacing worn seals and bearings, even if the sheaves are usable.
The following is a procedure for boom mounted sheaves:
(1) Single sheave mounted at the inner forestay
Figure 4.6-1 Boom Hoist Sheave Assembly

1) Mount a 0.5T chain block on the jib service crane(port provide) positioned on the cross
member at the inner forestay.
2) Remove the ropes from sheave and hold them with a chain block
3) Remove shaft keeper plates and the end cover
4) Pull the shaft out by tools.
5) Hang the sheave assembly out of the support and lower it to the trolley parked below
6) Move the trolley to the machinery house so that the sheave assembly can be lifted with
the MH service crane through the hatch opening and lowered to the ground
7) Use the same procedure to re-install the sheaves
(2) 5 set of sheaves mounted at the outer forestay
4-47
Figure 4.6-2 Boom Hoist Sheave Mounted at the Outer Forestay

1) Mount a 2.0T chain block on the jib service crane(port provide) positioned on the cross
member at the outer forestay.
2) Remove the ropes from sheaves and hold them with chain blocks
3) Remove shaft keeper plates and end cover
4) Dismantle the shaft with tools.
5) Hang the sheave assemblies out the support and lower the sheave assemblies to the
trolley parked below
6) Move the trolley under hatch in the machinery house so that the sheave assembly can be
picked up with the MH service crane. Move trolley out of the way and lower sheave
assembly to the ground
Danger of falling !
4.6.2 LOAD CELL REPLACEMENT
ALL THE PRECEPTS OUTLINED IN THE “SAFETY PROCEDURES AND

The cranes are equipped with load cells mounted on each of the 4 main hoist ropes end at boom
tip.
Load cell
Figure 4.6-3 Load Cell Changing Process
4-48
(1) Lower the spreader to the ground and slacken the ropes.
(2) Lock out crane motion by performing the lockout-tagout procedure.
(3) Pull the rope from the sheave and secure it with chain blocks.
(4) Disconnect all the wires connect to load cell.
(5) Pull the load cell out. Do not hit the load cell in the process.
(6) Install a new load cell, and remove the replaced load cell to a workshop. Refer to load cell
manual for installation.
Return the crane to service after verifying the repair.
Danger of falling !
4.6.3 TROLLEY SHEAVES REPLACEMENT

FIGURE 4.4.3-1 Trolley Sheaves at Boom Tip

1 Cover 2 Stud 3 Sheave Assembly 4 Clamp Plate 5 Shaft 6 Cover 2 7 Bearing
(1) Assemble a spare trolley sheave with shaft (J554A210101) in shop. Refer to Drawing
J554A2101.
(2) Pick the spare sheave assembly up to the waterside platform of the trolley.
(3) Run the trolley to the outreach.
(4) Lift the spare sheave assembly to the boom.
(5) Release the trolley rope tensioner at the backreach.
(6) Lock out the crane’s motion by proceeding lock-out and tag-out procedure.
4-49
(7) Remove the sheave cover.

(8) Remove the trolley rope out of the rope groove and secure it with chain blocks.
(9) Remove the shaft keeper plates.
(10) Pull the sheave assembly with the pin out of the support while the sheave is secured by
service crane.
(11) Lower the sheave to the trolley.
(12) Install the spare sheave assembly and sheave guard.
(13) Run the trolley under the machinery house.
(14) Lift the replaced sheave assembly into the machinery house and lower it to the ground. Send
it to a work shop for repair.
Return the crane to service after verifying the repair.
Danger of falling !
4.6.4 BOOM HINGE BEARING REPLACEMENT

Figure 4.6-4 Components Of Upper Boom Hinge Joint

1 Upper Support 2 Bushing 3 Shaft 4 Cover 5 Plate
6 Ring 7 Cover 2 8 Bearing
(1) Lower the boom to the operation position. At this position, the upper hinge shaft are released,
therefore the lower hinges will bear all the weight of the boom. Since there are no loads on the
upper hinge bearings, so they are easy and safe to be replaced. After the boom is level, move
the trolley to the hinge area.
(2) Refer to DWG J554A0105. Unfasten the stainless wires, release the bolts and dismantle
end covers at both sides of the hinge through the platforms beside it. The platform on the
trolley may also be employed if necessary.
4-50
(3) Remove shaft cover (Item 4) and cover (Item 7).

(4) Unfasten the bolts on the upper support and take away the upper cover. Take the bearing out
of the seat.
(5) In the opposite procedure, fit new bearings into the support.
Danger of falling !
4-51
4.7 Main components on top of A-frame ........................................................... 4-53

4.7.1 Boom hoist sheaves replacement .......................................................... 4-53
4.7.2 BOOM HOIST ROPE BREAK PROTECTION DEVICE DISASSEMBLY 4-54
4-52
4.7 Main components on top of A-frame

4.7.1 Boom hoist sheaves replacement

There are (4) sets of (4 or 3) vertically mounted BH sheaves and (2) sets of single diagonally
mounted sheaves on top of the A frame. The sheaves and reeving arrangement are shown in
DWG J554A2300.
At the A-frame, consider removing the (3) sheaves mounted
on one pin, and bringing the assembly into the crane shop.
The work to replace one or more sheaves should be
accomplished in a workshop. Examine the bearings and
grease seals, and unless they are relatively new and in a very
good condition, or should consider replacing worn seals and
bearings, even if the sheaves are useable.
Step by step procedure to replace A frame mounted sheaves:

(1) Three sheave assembly mounted at A frame as shown in
Figure 4.7-1
1) Lower the boom to level position and move the trolley
to hinge area.
2) Lock out crane motion by performing lock-out and
tag-out procedure. Figure 4.7-1 Jib Crane And
Sheaves On A-frame
3) Mount a 1.5T chain hoist (32m capacity) on the jib
service crane positioned on the cross
member of the A frame.
4) Remove the rope guards.
5) Remove the ropes from sheaves and hold
them with 0.5t chain hoists.
6) Remove mounting bolts and shaft keeper
plates.
7) Move the sheave assembly off the sheave
support.
8) Lower the sheave assemblies all way down
to the trolley parked below.
9) Move the trolley under hatch in the
machinery house so the sheave assembly
can be picked up with the MH service
crane, move trolley out of the way and
lower sheave assembly to the ground.
Figure 4.7-2 The Sheave Assembly
10) Use the same procedure to re-install the
sheaves 1 Bushing 2 Bushing 2 3 Cover
(2) Equalizer sheave assembly mounted at A 4 Shaft 5 Bearing 6 Sheave Assembly
frame as shown in Figure 4.5.1-3.
1) Lower the boom to level position and move the trolley to hinge area.
4-53
2) Lock out crane motion by performing

lock-out and tag-out procedure.
3) Mount a 1.5T chain hoist (32m capacity) on
the jib service crane positioned on the
cross member of the A frame.
4) Remove the rope guards.
5) Remove the ropes from sheaves and hold
them with a second 0.5t chain hoists.
6) Remove mounting bolts and shaft keeper
plates.
7) Move the sheave assembly off the sheave
support.
Figure 4.7-3 Boom Hoist Equalizer Sheave
8) Lower the sheave assemblies all way down
to the trolley parked below.
9) Move the trolley under hatch in the machinery house so the sheave assembly can be
picked up with the MH service crane, move trolley out of the way and lower sheave
assembly to the ground.
Danger of falling !
4.7.2 BOOM HOIST ROPE BREAK PROTECTION DEVICE DISASSEMBLY

4-54
Figure 4.7-4 Boom Rope Break Protection Device

As shown in Figure 4.7-4, there is a boom rope break protection device located between the two
boom rope equalizer sheaves. The rope is fixed by two clamp plate by ten M30 high strength bolts,
once the boom rope break at any points, the clamp plates moves and will be stopped by the
A-frame impact structure with two buffers.
Disassembly is quite simple, unfasten the M30 high strength bolts and remove the clamp plates.
The impact buffer is split through the center line. By removing its mounting bolts, the buffer can be
easily removed.
Danger of falling !
The tightening torque for M30 bolts is 1150Nm.
4-55
4.8 MAIN COMPONENTS ON THE GANTRY ................................................... 4-57

4.8.1 GANTRY WHEEL REPLCEMENT ......................................................... 4-57
4.8.2 GANTRY MOTOR AND GEAR REDUCER REPLCEMENT .................. 4-59
4-56
4.8 MAIN COMPONENTS ON THE GANTRY

4.8.1 GANTRY WHEEL REPLCEMENT

GOOD PRACTICES FOR MAINTENANCE PERSONNEL” APPLY TO
The construction site is to be adequately secured and fenced off from prevailing traffic.
There are totally 4 gantries located at four corners of the crane. The gantry structure is shown in
Figure 4.8-1. Each gantry has 8 wheels, so the crane has 32 wheels in all.
Figure 4.8-1 Gantry Structure
A A
B C B
A A
C B C B
B C
Figure 4.8-2 wheel replacement procedure
4-57
When wheel assembly needs to be maintained or replaced, follow the procedures below:
(1) Jack up the crane with no-load in calm weather.
(2) Move the trolley to the parking position.
(3) The boom position is:
1) Raise the boom to the maintenance position when the waterside leg is jacked up.
2) Set the boom to the work position when the landside leg is jacked up.
(4) When replacing or repairing the gantry travel wheel ○

A:
1) Jack up the corner need to be replaced or maintained as shown in Figure 4.8-2.
2) Set two (both side) hydraulic jacks ○

B at the position.
3) The capacity of the hydraulic jack ○

B should be greater than the value in the following
table.
Table 4.8-1 Jacking up Counter Force
SEA SIDE LAND SIDE
Jacking up Boom up 50 / t/Wheel

Counter force
Boom down / 55 T/Wheel
4) Use the hydraulic jack ○

B to raise the wheel ○
A to a position 60 mm- 70mm
(2.36in-2.75 in) above the original position.
5) Insert a support ○
C (height 120~130mm, 4.72 in~5.12in. steel) in the position shown in
Figure 4.8-2.
6) ○
Carefully remove the hydraulic jack B after verifying the correct placement of the
○
support C .
7) Replace the wheel block ○

A .
8) Use the hydraulic jack ○

B to raise the wheel to a position 60 mm~70mm (2.36 in~2.75
in) above the original position.
9) Remove the support ○

C.
10) Lower and remove the hydraulic jack ○

B
Danger with jacking device! Make sure that the hydraulic jack is
not leaking and not lowering pressure !
In a workshop, dismantle or re-assemble the gantry wheel according to Figure 4.8-3.
4-58
Figure 4.8-3 Gantry Wheel Assembly
The work should be done when there is no wind, less than 8m/s.
Before the crane is put into operation again, do the gantry test running!
Remove motor and reducer first if the driving wheel assembly needs to
be replaced!
4.8.2 GANTRY MOTOR AND GEAR REDUCER REPLCEMENT

The work should be carried out on a stable, well-paved and leveled ground. The trolley is in
parking position and the boom is in maintenance position. No load is attached to the spreader.
The construction site is to be adequately secured and fenced off from prevailing traffic.
Lock out crane motion by performing the lock-out and tag-out procedure.
Danger of high-voltage electrical power! Cut off power before

maintenance.
As illustrated in Figure 4.8-4, adopt following procedures to replace the motor and gear reducer.
4-59
Figure 4.8-4 Gantry Motor and Reducer Replacement

(1) Disconnect all the electrical wires of motor and brake.
(2) Remove the bolts between the motor and the seat.
(3) Separate the motor from the seat.
(4) Place the motor on the ground and protect against damage on shaft-end and prevent water
intrusion.
(5) Remove the coupling.
(6) Remove the cover and wedge at the end of the shaft.
(7) Place forklift under the gearbox with pallet and raise up a little.
(8) Remove the pin connecting the reducer pad eye and the truck support.
(9) Pull out the gear reducer completely.
(10) Place gear reducer on the ground and protect the drain pipe and incoming shaft against
damages.
(11) Clean the new components.
(12) The installation is done vice versa.
Do not put any lubricant between wheel shaft and gear reducer hollow
shaft and shrink ring. Refer to zpmc reducer maintenance instructions.
It is possible to continue crane operation under normal conditions by

bypassing the one dismantled gantry motor, if spare motor or gear
reducer is not available.
4-60
4.9 DAMAGE INSPECTION OF COMMON MECHANICAL PARTS ................. 4-62

4.9.1 GEAR REDUCER INSPECTION ........................................................... 4-62
4.9.2 DAMAGE OF GEAR .............................................................................. 4-62
4.9.3 BEARING AND BEARING UNIT ............................................................ 4-66
4.9.4 Bearing unit inspection ........................................................................... 4-73
4-61
4.9 DAMAGE INSPECTION OF COMMON MECHANICAL PARTS

4.9.1 GEAR REDUCER INSPECTION
Generally, meshing of gears can be diagnosed by their running noise. Therefore, from the time of
the initial operation of the machine, pay attention to the change in the running noise for early
detection of failure in gears. Causes of noise includes:
(1) Irregular tooth contact.
(2) Incorrect backlash.
(3) Defect of tooth surface.
(4) Insufficient lubrication or improper lubricant.
(5) Loose-fitted gear box.
4.9.2 DAMAGE OF GEAR
Typical damages of tooth surfaces are as follows: the following damages do not necessarily occur
separately. One damage may cause another type of damage, or some of them may occur
simultaneously in a complex form.
4.9.2.1 Wear failure
Wear occurs when the metal is worn away from the contact areas of the gear teeth in a more or
less uniform manner. Some wear is normal, but there are several degrees of wear and many ways
in which wear can occur.
(1) Polishing is a slow process of wear in which the metal-to-metal contact during the operation
causes a very smooth surface to develop on the gear teeth. It is most common during a
slow-speed operation, where the lubricant film is too thin, and the gears are operating near
the lubrication borderline. Normally, this condition
does not cause a problem unless continued wear
prevents the gears from reaching the designed life
of the equipment. Once the gears are polished,
further damage can be reduced or prevented by
using a higher viscosity lubricant or lowering the
lubricant temperature. Other possible remedies
include reducing the transmitted load or increasing
the operating speed to provide a better oil film.
(2) Moderate wear (Figure 4.9-1) shows up as a
contact pattern in which metal removal occurs Figure 4.9-1 Moderate Wear
from both the addendum and dedendum tooth
surfaces, and the operating pitch line remains as a continuous line. This may be caused by
lubricant contamination but is often unavoidable due to the limitations of lubricant viscosity,
gear speed, and temperature. It may occur normally throughout the designed life of a gear set,
particularly when the gears operate near boundary lubrication conditions. Increasing oil film
thickness, either by cooling the lubricant, using a higher viscosity lubricant or operating at
higher speeds, can sometimes reduce normal wear. Replacing a splash-fed lubrication
system with a filtered positive-spray system may improve lubrication by removing particles
and delivering a more consistent supply of oil to the working surfaces. Further solutions
include reducing the gear loading and changing the gear geometry, materials, or hardness.
(3) Extreme wear may appear as the same kind of contact pattern and pitch line visibility that
occur with moderate wear, but the progression rate is much faster. Here, a considerable
amount of material may be removed uniformly from the gear tooth surfaces, and the pitch line
may show signs of pitting. Extreme wear will cause failure to occur before the designed life of
the gear set is reached. It may cause so much damage to the tooth profile that the resulting
high dynamic loads will further accelerate the wear. Causes of extreme wear include a
lubricating film too thin for the tooth load, fine abrasive particles in the lubrication system, and
severe vibratory loads. Shaft seals and air-vent filters, properly installed and maintained, may
4-62
help reduce the wear. Other solutions include oil cooling, higher viscosity lubricants, higher
speeds, reduced loads, and possibly reduced vibratory loads if the application permits.
(4) Abrasive wear shows up as a lapped surface, with radial
scratches or grooves on the tooth contact surfaces. When
this occurs shortly after the startup of a new installation or on
any open gearing, particles in the lubricating system are
generally the cause. These may include metal particles from
the gears and bearings, weld spatter, scale, rust, and sand,
dirt, or other environmental contaminants. Figure 4.9-2
shows severe abrasion. Careful cleaning of the gearbox and
the lubrication system before use can minimize the abrasive
wear. With a circulating lubrication system, adding a filter or
using a finer replacement filter will help reduce this type of
wear. Regular oil changes will help for splash-lubricated
drives, and higher viscosity oil also may help protect either
type of system with a thicker oil film that will keep the finer
particles from scratching. Figure 4.9-2 Abrasive Wear
(5) Corrosive wear (Figure 4.9-3) is visible as surface
deterioration, caused by the chemical action of active
ingredients in the lubricant. These may include acid,
moisture, foreign materials, and extreme-pressure additives.
During operation, the oil breaks down and allows corrosive
elements present in the oil to attack the gear contact
surfaces. This action may affect the grain boundaries and
cause fine, evenly distributed pitting. Checking the oil for
breakdown and changing it at regular intervals can help
minimize the corrosive wear. Lubricants with high anti-scuff,
anti-wear additive content must be observed even more Figure 4.9-3 Corrosive Wear
carefully because they are chemically active. Gear units that
are exposed to salt water, liquid chemicals, or other foreign materials should be sealed from
their environment.
(6) Scoring may be moderate, localized, or destructive. It can be caused by failure of the lubricant
film, usually from overheating in the mesh area, as well as by misalignment, deflection, and
uneven temperatures or loads. The resulting metal-to-metal contact produces alternate
welding and tearing that quickly removes the metal from the gear surfaces. Moderate scoring
shows up as a characteristic wear pattern, often in patches on the addendum, dedendum, or
both. Radial tear marks usually appear more prominently in softer areas. Upon closer
examination, the frosty appearance shows that the rotation has
caused the metal to weld and tear apart (Figure 4.9-4).
Localized scoring is similar to moderate scoring but takes place
in concentrated portions of the contact areas of the gear teeth,
rather than spreading across their full-face width.
Destructive scoring or scuffing shows definite radial scratch and
tear marks, and material may be displaced radically over the tips
of the gear teeth. Excessive material may be missing from
above and below the pitch line, causing the pitch line itself to
stand out prominently. At this stage, the gear is unfit for further
service.
Reducing the temperature in the mesh area can prevent
moderate scoring. This can be accomplished by reducing the
load, gear speed, or inlet oil temperature. Other solutions
include use of a lubricant with extreme-pressure additives, Figure 4.9-4 Scoring
plating a solid lubricant on the contact surfaces, or honing.
Localized scoring is more likely to result from misalignment factors than moderate scoring. A
4-63
wear pattern that shows load concentration near one end of the teeth indicates possible
misalignment or helix angle error. This results in one portion of the teeth carrying more loads
than the lubrication film can support. Eliminating the causes of uneven loading can prevent
localized scoring. These may include non-uniform gear case deflection, excessive shaft
deflection, out-of-parallel bores in the casing, or helix angle errors. Uneven temperature
gradients also may cause localized scoring and should be remedied by changing the amount
of cooling oil applied to the mesh or the way in which it is applied.
To eliminate destructive scoring (Scuffing), it is necessary to attack the source of the
excessive heat that causes the lubricant to break down. Extreme-pressure additives are one
way to help the lubricant stand up to the load, speed, and temperature conditions. Special
high-viscosity compounded gear oil or synthetic fluids with anti-scuff additives also will help
prevent scoring. In extreme cases, the gearing may have to be redesigned to reduce surface
stresses, pitch line velocity, and oil temperature of the gears.
Tip and root interference is another type of scoring, usually resulting from improper design
and manufacture. Metal removal will be seen near the root of the gear tooth profile while other
portions of the contacting face will appear undamaged.
The tip of the gear or pinion may look abraded, with tear
marks in the direction of rotation. With high speed gears,
scoring at start-up is considered failure, and the gears
should be replaced after correcting the cause of scoring.
4.9.2.2 Surface fatigue
Surface fatigue can be noticed by the removal of metal and
the formation of cavities. These may be small or large and
may grow or remain small. It occurs when the gear material
fails after repeated stresses that are beyond the endurance
limits of the metal. Here are the main types of surface
fatigue, their causes, and cures.
(1) Pitting failures depend on surface contact stress and the Figure 4.9-5 Pitting
number of stress cycles. Initial pitting (Figure 4.9-5), with
areas of small pits from 0.015in~0.030in in diameter,
occurs in localized parts of the gear teeth that are
over-stressed. It is sometimes called corrective pitting
because it tends to redistribute the load by
progressively removing high contact spots, and often
stops once the load has been redistributed. Continued
operation may polish or burnish the pitted surface and
improve its appearance. Pitting can be monitored by
periodically putting some bluing on the affected area,
then applying some cellophane tape to lift the pattern Figure 4.9-7 Destructive pitting
and put it in a notebook. Comparing the impressions
over time will tell whether the pitting has stopped. While
accurate manufacturing control of involute profiles is the
best method of preventing pitting, a careful break-in at
reduced loads and speeds once the unit is installed also
will help minimize pitting by improving gear tooth
contact.
(2) Destructive pitting (Figure 4.9-7) appears as much
larger pits than initial pitting, often in the dedendum
section of the gear teeth. These larger craters usually
are caused by more severe overload conditions that
cannot be relieved by initial pitting. As stress cycles build
up, pitting will continue until the tooth profile is destroyed.
To correct the cause of destructive pitting, the load on
Figure 4.9-6 Spalling
the surface of the gear needs to be reduced below the
4-64
material’s endurance limit, or the material hardness needs to be increased to raise the
endurance limit to where pitting will not occur.
(3) Spalling (Figure 4.9-6) resembles destructive pitting, except that the pits may be larger, quite
shallow, and irregularly shaped. The edges of the pits break away rapidly, forming large,
irregular voids that may join together. Spalling is caused by excessively high contact stress
levels. Remedies include reducing contact stress on the gear surface or hardening the
material to increase its surface strength.Both spalling and destructive pitting are indications
that the gears do not have sufficient surface capacity and should probably be redesigned if
possible.
(4) Case crushing occurs in heavily loaded case hardened gears, including those that are
carburized, nitrided, or induction hardened. It is a subsurface fatigue failure that occurs on
material where the case is substantially harder than the core, when surface contact stress at
high cycle levels exceeds the material’s endurance limit.
Case crushing may appear similar to pitting, if some
damage occurs on contacting surfaces. However, it often
occurs as longitudinal cracks on the surface of only one or
two teeth, and long pieces of the tooth surface may break
away (Figure 4.9-8). The case material may appear to have
chipped away from the core in large flakes. Case crushing
occurs when cracks form because stresses in the
subsurface area exceed the strength of the core material.
High residual stresses may contribute to this effect. The
cracks move toward the case-to-core boundary and then to Figure 4.9-8 Case crushing
the gear surface, where they may eventually cause large pieces of material to fall off. To
prevent case crushing, it may be necessary to increase the depth of the case hardening and
possibly the hardness of the core material. Changes in the material, heat treatment process,
or the design itself may be necessary.
4.9.2.3 Plastic flow
Plastic flow is a surface deformation that occurs when high contact stresses combine with the
rolling and sliding action of the meshing gear teeth to cause cold working of the tooth surfaces.
Although usually associated with softer materials, it also can occur in heavily loaded case
hardened and through-hardened gears. Plastic flow generally takes one of the three distinct
forms.
(1) Cold flow, rolling, and peening can be identified through evidence of metal flow in the surface
and subsurface material. The surface material may have been worked over the tips and ends
of the gear teeth, resulting in a finned appearance. Tips of the gear teeth may be heavily
rounded over, and a matching depression may appear on the tooth surface. Cold flow occurs
under heavy loads and high contact stresses, as the rolling and peening action of the meshing
gear teeth cold-works the surface and subsurface material, pushing or pulling it in the
direction of sliding. Continued operation during this deterioration increases dynamic loading
and results in a dented, battered appearance on the surface, much as if it had been hit with a
ball peen hammer. To eliminate the problem it is necessary to reduce contact stress and
increase hardness of the contacting surface and subsurface materials. Increasing the
accuracy of both tooth spacing and profiles will help reduce dynamic loads, and any mounting
deflections or helix angle errors should also be corrected.
(2) Rippling is a regular, wave-like formation that occurs at right
angles to the direction of motion and has a fish scale
appearance (Figure 4.9-9). It is most common on hardened
gear surfaces and is generally considered a surface failure
only when it has progressed to an advanced stage. It usually
occurs in slow speed operation with an inadequate oil film
thickness. High contact stresses during repeated cycles
may then roll and knead the surface, causing it to ripple.
Rippling can be prevented by case hardening the tooth Figure 4.9-9 Rippling
4-65
surface, reducing the contact stress, increasing oil viscosity, and using an extreme-pressure
oil additive.
(3) Ridging is a definite series of peaks and valleys that occur
across the tooth surface in the direction of sliding (Figure
4.9-10). It occurs when high contact compressive stresses
and low sliding velocities cause plastic flow of the surface
and subsurface material. It is frequently found on heavily
loaded worm gear drives, as well as on hypoid pinion and
gear drives. Remedies for ridging include reducing contact
stress, increasing material hardness, and using a more
viscous lubricating oil with extreme-pressure additives.
Figure 4.9-10 Ridging
4.9.2.4 Breakage failure
Breakage is the fracture of a whole tooth or substantial part of a tooth. Common causes include
overload and cyclic stressing of the gear tooth material beyond its endurance limit.
(1) Bending fatigue breakage starts with a crack in the root section and progresses until the
tooth or part of it breaks off. It can be recognized by a fatigue “eye” or focal point of the break.
The break area itself usually shows signs of fretting corrosion and smooth “beach marks” that
resemble patterns in the sand on a beach. A small area will probably have a rough, jagged
look where the last portion of the tooth broke away. Most such failures result from excessive
tooth loads, which cause repeated root stresses that eventually exceed the endurance limits
of the material. Stress risers, such as notches in the root fillet, hob tears, inclusions, small
heat treating cracks or grinding burns, may aggravate this condition. To remedy this condition,
root fillets can be polished and shot-peened. Material should be properly heat-treated to
minimize residual stresses. If redesign is necessary, use a full-fillet radius tooth, which is less
prone to breakage and has greater capacity than a tooth with too small a fillet radius.
(2) Overload breakage appears as a stringy, fibrous break that has been rapidly pulled or torn
apart. In harder materials, the break will have a finer stringy appearance. The eye and beach
markings found in fatigue breakage will be missing. This type of breakage is caused by an
overload that exceeds the tensile strength of the gear material. Typical overloads that lead to
such breakage include a bearing seizure, failure of driven equipment, foreign material passing
through the gear mesh, or a sudden misalignment. Since the failure is usually the result of
some unpredictable occurrence, it is difficult or impossible to prevent. If possible overloads
are anticipated, torque-limiting couplings may provide some protection.
(3) Random fracture can occur in areas such as the top or the end of a tooth, rather than the
usual root fillet section. These failures are typically caused by stress concentrations from such
things as minute grinding cracks, foreign materials in the gear mesh, or improper heat treating.
Little can be done to prevent random fracture, except at the design and manufacturing stages.
However, maintaining cleanliness of the lubricant can help prevent one cause.
4.9.3 BEARING AND BEARING UNIT
This section describes the inspection procedures of the plain bearing and anti-frictional bearing.
4.9.3.1 Plain bearings
As to the plain bearing used in the crane, close inspection is required since the position of the
bearing may deviate from its correct position since the structure supporting the bearing may be
deflected by its own weight or deformed by impact. The symptoms of trouble in plain bearing are
usually indicated by abnormal noise, overheating, vibration, etc. Therefore, careful inspections
must be made with a consideration of the following points:
(1) Typical inspection items:
1) Abnormal noise during operation.
2) Excessive heating of bearing.
3) Slight repeated vibration between shaft and bearing.
4-66
4) Foreign matters in the oil coming out from the bearing end.
If something abnormal is found by checking the above-mentioned items, further inspection is
needed with an account of the following point.
(2) Further inspection items.
1) Inspection of loose attachment of bearing, especially loose fixing bolts causing
misalignment of shafts.
2) Close inspection of bearing and bush surfaces for abnormal wearing due to foreign
matters, etc., peeling, uneven contact of the bush, and shaft-to-bush clearance.
3) Whether or not bearing is the source of vibration, if vibration occurs.
4) Whether or not lubrication is made sufficiently.
4.9.3.2 Anti-frictional bearings
Any abnormal condition in the anti-frictional bearings can be diagnosed by its burning,
Over-heating, noise and vibration etc. Refer to the descriptions of trouble causes in this manual.
Refer to the “Table 4.9-1 Trouble and Causes of Anti-friction Bearing” for
the trouble, symptoms and causes of the bearings.
(1) Peeling:
Besides peeling due to expiry of the bearing’s life, peeling in the early stage is often caused by an
unexpected abnormal load. Such a peeling may be caused by the following causes:
1) Edge load in cylindrical roller bearings due to an axis misalignment.
2) Excessive load due to thermal expansion of the shaft fitted with two radial balls, spherical
rollers, or tapered roller bearings, etc. because load is applied in the thrust direction on
bearing tightly fitted with housings without escape clearance.
3) Elliptical fitting due to poor accuracy of pillow block housing
The above causes will result in the troubles shown in Figure 4.9-11
4-67
(A) (B) (C) (D)
(E) (F)
Figure 4.9-11 Damage form of Peeling
(A) Due To Thrust

(B) Due To Elliptical Fitting
(C) Due to Uneven Contact of Tapered Rollers
(D) By the Load Due To Inclusion of foreign Matters between Outer Ring and
Housing
(E) ○
A Damages in a Cylindrical Roller Bearing When Fitted ○
B Peeling
Developed From○
A
(F) Peeling by the Load Due To Inclusion of Foreign Matters between Outer Ring
and Housing
(2) Scuffing
“Scuffing”, an early stage of burning, is caused by sliding friction on poorly lubricated pockets
of cages or the rolling surface of rollers.
(A) (B) (C)

Figure 4.9-12 Damage Form of Scuffing
(A) On The Roller End Surface ○

A And Collar ○
B Of A Roller Bearing
(B) On A Cylindrical Roller Due To Sliding With The Inner Ring

(C) In Thrust Bearing Due To Sliding Resulting From The Centrifugal
Force In High- Speed Revolution With Small Thrust
4-68
(3) Wearing
Rolling bearing may become unusable due to the wearing of raceway surfaces or cages of
rolling elements.Such wearing is often accelerated by foreign matters such as sand, dust, iron
dust, etc., which act as abrasives and also may be caused by insufficient hardness.
(A) Due to Creep Roller (B) In a Spherical Due To Dust

Figure 4.9-13 Damage Form of Wearing
(4) Cracks
Cracks may result from defective materials, tights fits, and excessive impact loads.
(A) In a Roller (B) In a Race (C) In a Collar

Figure 4.9-14 Crack Types
(5) Rusting
Rusting often results from water saturation and sometimes from inferior lubricant. Also, fretting
corrosion occurs due to insufficient fits.
Figure 4.9-15 Impression On Figure 4.9-16 Rusting Due To

A Thrust Bearing After Sea Fretting Corrosion
Transportation
(6) Impression
When foreign matters in the bearings are rolled on the race surface, permanent impressions
may occur on the balls, rollers, and race surfaces.
Also, the Brinell impression, which often results from the vibration of bearings in storage
during railway transportation, may be experienced.
4-69
(7) Electric corrosion

If electric current runs through the bearings, numerous small
holes will develop due to the sparks, as shown in Figure
4.9-17.
With higher electric current, considerably large indentations
will be created.
(8) Damages of Cages Figure 4.9-17 Electric
Corrosion on the Inner Ring
The cages are often worn out or damaged due to insufficient
lubricant.
Also, improper shape, strength, or materials of the cage may be causes of the damage.
Damages may also occur due to hair cracks during heat treatment, deep escape during
grinding, or impact.
Table 4.9-1 gives the common troubles and their reasons of anti-friction bearing.
Table 4.9-1 Trouble and Causes of Anti-friction Bearing
Trouble Symptoms Causes
Noise Low frequency noise (1) Impact on race caused by inaccurate

installation
(murmuring or roaring)
(2) Impression on race caused by vibration
during bearing standstill
High frequency noise (1) Decrease of clearance

(squeak) (2) Insufficient lubricant
Intermittent noise (1) Intrusion of foreign matters

(2) Structure around bearing causing
resonance
(3) Peeling of early stage and defects of
race
(4) Misalignment of bearing center
Abnormal Unexpected rapid (1) Excessive or insufficient lubricants

temperature temperature rise
(2) Improper lubricants or lubrication
rise
method
(3) Insufficient operating clearance
(4) Creep
(5) Excessive load
(6) Insufficient alignment during installation
(7) Early stage of damage
Peeling Development of pitting Development of fatigue
4-70
Circumferential pitting on race (1) Excessive thrust loads (Including free

bearing fixed axially due to incorrect
installation)
(2) Insufficient operating clearance caused
by expanded inner race due to influence of
fitting or temperature or by outer race
contraction
Symmetrical pitting on Press fitting inner race or outer race into

circumference of radial oval bearing or bearing box
bearing
Circumferential pitting on Development of fatigue

rotating race
Diagonal pealing on race of Development of fatigue

static race
Diagonal pealing on race of (1) Shaft deflection

static race
(2) Inclination between shaft and bearing
box centers
Eccentric pitting of thrust Eccentric installation

bearing
cracks Cracks of inner/outer races in (1) Tight fitness

axis direction
(2) Uneven attaching surface (unevenness
or inclination)
(3) Deformation and unevenness of gear
box
(4) Creep
Cracks of inner/outer races in (1) Deformed gear box

circumferential direction
(2) Uneven attaching surface
(3) Excessive overload
Damage of collar Excessive impact overload
Irregular cracks Crack of rolling element or cage due to

deteriorated lubricant
Impression Glittering Impression of the (1) Impact during attachment

created on same pitch as rolling element
(2) Excessive load during stoppage
race
blurred impression of the When bearing at standstill suffers vibration,
same pitch as rolling element especially when dust or foreign matters
exist
Pleat-like Burned, volcano-like swell Vibration accompanied by electric current

passing during rotation
grooves
4-71
Burned, holed swell Excessive load with vibration
Damages of Cage in general (1) Shortage or deterioration of lubricant

cage
(2) Improper lubricant
(3) Improper lubrication method
(4) damage of rolling element
(5) Intrusion of foreign matters
(6) Damage of rivet due to vibration
Especially, as to thrust bearing:
(1) Eccentric attachment or insufficient
pre-pendiculality
(2) Lifting of cage because of no thrust load
(3) Bearing attached without preloading
Early damage Damage of cage, irregular (1) Deteriorated lubricant, in most cases
damage of inner/outer race durability is low
(2) Unstable lubricant
Rusting Partial dots on rolling surface, Affected by acid or moisture during long
generally of the same pitch as time standstill of bearing
rolling element
Rusting on surface Free acid or free water in corrosive or

normal lubricant
Red or black rusts occurred Incomplete fitting on fitting surface

partially on fitting surface
Adhesion Material of cage adheres on (1) In case that the rolling element is
rolling element strongly pressed inside pocket of cage
(2) Ineffective lubrication
Stripe adherent to inner Creep

circumference of inner race or
outer circumference of outer
race
Circumferential stripe (1) Creep

adherent to sides of inner and
(2) In case that bearing slips pressed onto
outer races
beating box shoulder and other surfaces
Stripe running at a right angle (1) Installed with over load

on rolling surface in cylindrical
(2) Forcibly assembled inner/outer races
roller bearing, and stripe
which do not face at a right angle to each
running at a right angle on ball
other with regard to shaft
rolling surface in self-aligning
bearing (3) Shaft slants during stoppage suffering
load of axial movement between
4-72
inner/outer races with load applied
Same symptom in thrust (1) In case of radial movement

bearing
(2) Improper assembly (e.g. installed
without preload)
Wearing Blurred rolling surface Large dust particle
Glittering rolling surface Small dust particle
Partial pit on pitch of rolling (1) Rotation without lubricant

surface
(2) Rubber-like deteriorated lubricant
Wearing on contacting point Inertia force acting on cage and insufficient

with cage lubrication
Wearing of Dwindling shaft Creep caused by too loose fit

shaft
Fading of Discoloration with no (1) Deteriorated lubricant due to

surface color deterioration of hardness temperature rise
(2) Adhered film of extreme pressure
lubricant
Expansion of Increase of inner and outer (1) Long time operation in high temperature
inner/outer diameter
(2) Aged deterioration
surface
4.9.4 Bearing unit inspection

The inner part of the bearing unit cannot be inspected without enclosed devise such as sealing,
slinger, etc., removed. Therefore, judge the state of the bearing housing during operation, then
take the following measures if abnormality is observed.
(1) If vibration is found:
If the vibration is severe, firstly check the retaining bolts for looseness and verify that there is no
looseness between the bearing unit and the installation base. Tighten the bolts as necessary. If
the vibration remains after the above mentioned procedure, check if the causes of other rolling
element vibration such as bent shaft exist. If no abnormal part is found, replace the bearing unit
since the excessive clearance due to wear inside the bearing is suspected.
(2) If abnormal temperature rise is found.
If the temperature of the housing rises over 20℃(36℉) after subtracting the ambient temperature,
carry out the inspections below.
1) Check if any causes of the temperature rise exist, such as no relief clearance due to the
one-side free bearing, overloading, etc.
2) If no abnormal condition is found, replace the bearing since the severe condition such as
an initial state of bearing damage etc. is suspected. Especially the temperature rise with
abnormal noise is considered to be a sign of developing damage. Replace the bearing
immediately in such a case.
(3) If abnormal noise is found.
If abnormal noise is heard from the bearing unit, carry out the inspections below.
4-73
1) Measure the housing temperature. If the temperature is less than 20 ℃ (36℉)after

subtracting the ambient temperature, check the retaining bolts for looseness and verify
that there is no looseness between the bearing unit and the installation base. Tighten the
bolts if necessary.
2) If the abnormal noise remains after procedure 1, the following causes are suspected.
Immediately replace the bearing judging from the abnormal noise degree and the machine
importance.
 Slight wear appears on the track surface and/or rolling element of the bearing.
 Inclination toward noise.
 Foreign materials inside the bearing
3) Measure the housing temperature. If the temperature is over 20℃(36℉) after subtracting
the ambient temperature, replace the bearing unit since the developing peeling of the
track surface or rolling element is suspected.
4-74
4.10 KEY, KEY GROOVE AND PIN HOLE……………………………………….. 4-76

4.10.1 Inspection procedure of key and key groove ........................................ 4-76
4.10.2 Inspection procedure of pin hole .......................................................... 4-76
4.10.3 INSPECTION PROCEDURE OF OIL SEAL......................................... 4-77
4-75
4.10 KEY, KEY GROOVE AND PIN HOLE

4.10.1 Inspection procedure of key and key groove
The key and key groove suffer various kinds of damage according to the used condition. If
damage is found on inspection, immediately replace the key. The damage types and their cause
are as follows:
(1) Shearing of key
The key may be sheared if the abnormal torque
that is larger than key strength is applied in such a
case. The key groove often may be deformed as
well, so re-cut the key groove and install the key
with hardness of superior grade. Figure 4.10-1 Shearing of Key
Re-cutting key groove cause the deterioration of shaft strength.

Therefore, the procedure shall be performed only after a proper
examination by the expert.
(2) Looseness
The properly formed and rectangular key groove may be
found slant on disassembly, as shown in Figure 4.10-2.
This is because of the insufficient tightening clearance
on the initial assembly. In such a case, make sufficient
tightening clearance at the key sides (supporting
Figure 4.10-2 Looseness of Key
pressure surface) but no more clearance than specified
at the key top when assembled.
(3) Crack of key groove
The stress concentrates on the edges of the shaft or the
key groove in the boss engaged with the shaft.
Therefore, cracks may be caused if the applicable part
suffers abnormal torque larger than their
strength.(Figure 4.10-3)
If the condition remains, the crack may be enlarged, Figure 4.10-3 Crack of Key Groove
resulting in key groove damage of shaft cutoff.
(4) Wear of key groove side
The fatigue and deformation may be caused if abnormal
torque is applied to the key groove sides and abnormally
high surface pressure is struck on the key groove sides
repeatedly.
4.10.2 Inspection procedure of pin hole Figure 4.10-4 Wear of Key Groove Side
The pin holes such as the sliding shaft hole and the
bush hole suffer various kinds of wear according to
their working conditions. Therefore, immediately
replace the applicable part if wear is found on
inspection.
The wear types and the measures are as follows.
(1) Classification by wear form, shown in .Figure
4.10-5:
1) Uniform wear ①
4-76
Figure 4.10-5 WERA FORM OF PIN HOLE
2) Wear caused by one-way application of load②

3) Wear caused by two-way and repeated application of load ③
4) Wear only on both edges ④
(2) Measures for wear
1) Replace the bush for bush wear.
2) Follow the procedure below for pin hole wear.
① Remake the hole after bead welding.
② Enlarge the diameters of the pin and pin hole.
③ Insert a new bush.
Enlarging pin hole may cause partial deterioration in strength.

Therefore, perform the procedure only after a proper examination by an
expert.
4.10.3 INSPECTION PROCEDURE OF OIL SEAL

If oil leakage is found, check the inspection items as described below.
1) Is the proper oil seal used at the area causing oil leakage?
2) Was the oil seal carelessly handled before installation?
3) Is the oil seal installed in reverse direction?
4) Is the seal lip turned over on insertion?
5) On insertion, is the seal lip damaged by the key groove, spring, screw, coarse surfaces,
shaft edges, etc.?
6) Is the oil seal deformed due to the use of the improper tool or extremely secure fitting?
7) On installation, was the oil seal sufficiently lubricated so as not to damage the seal before
the permeation of the lubricant?
8) Did the lubricant run out during the operation?
9) Is the shaft scratched?
10) Is the shaft coated with paint or equivalent?
11) Are there any air bleed holes or bleeders to release the internal pressure?
12) Is the air breed bole plugged?
13) Is the oil leakage generated from the oil seal, key groove, packing, or screws
14) Was the oil seal damaged by other parts?
15) Is the oil leakage generated by the spiral scratches or the finish of the shaft?
16) Is the shaft biased?
17) Is the shaft shaking extremely?
4-77
APPENDIX: RECOMMENDED USAGE LIMITATION OF EACH COMPONENT
Name of component Reference Usage limitation Measuring condition
 23mm Measure at distance

Gantry rail span Gantry rail
0.906in below 10 m 33 ft
 38mm
Level diff, of L-R rails Span
1.50in
GANTRY RAIL
Inclination of rail -- 1/250
 30mm Measure every 30m

Curve of rail Base line
1.18in 100 ft 
1mm  0.0393in
Deviation of top
Rail joint section
& side faces (For both top and
side faces)
Wear of rail top Loading width 10%
 5mm
Rail gauge Rail gauge
0.197in
GIRDER RAIL
 3.2mm Measure every 2m

Curve of rail Base line
0.126in 6 ft 6.74in
Level diff. of L-R rails Rail Gauge 9mm  0.354in
Corrosion Plate thickness 10%
Flange thickness Orig. dimension 50%
Incline of flange Perpendicular 200
Loading surface Original Dia. 3%
Dia. Diff. Driving wheel 0.2%

WHEEL
of L-R Original Dia.

wheels Driven wheel 0.5%
V<50:1 mm
Loading surface
 0.0394in V: Traveling speed
Circularity
diameter V>50:0.5 mm (m/min.)
 0.0197in
4-78
Main hoist 30%
Others Original 40%

GEAR
Gear
dimension
1st stage gear 10%
Original
Shaped
Couplin
Tooth thickness 20%

Shaft
dimension
Pin, Shaft General Shaft Dia. 3%
B(mm)
-- A (mm) in
Gap in
between A
shaft &
Gear shaft 25-40mm 0.6 1.2
bearing Shaft Dia.: R5
0.9841.57in  0.0236  0.0472
Shaft and Bearing
Shaft Dia. Limit: R10

-63mm 0.8 1.6
Shaft Diameter
 2.48in  0.0315  0.0630

-100mm 1.0 2.0 Value below 0.1 mm
Gap
3.94in  0.0394  0.0787  0.00394in is omitted.
B
between -160mm
Others 1.2 2.5
pin & hole
6.30in  0.0472  0.0984
-250mm 1.6 3.1
9.84in  0.0630  0.122
Brake wheel rim

30%
thickness
Brake wheel face 2mm  0.0787in 

Brake
Refer to brake maker’s

Lining --
Original manual
dimension
Brake disc face 10%
Bottom of
5%
opening
Hook
Lifting Equip.
Size of
5%
opening
Crane Structural
Wire rope 10% Wire cut number in a ply
Standard
Sheaves Rope Dia. 15% Groove bottom, Flange
4-79
Carbon brush Orig. dimension 50%
Remaining thickness:
Motor
Slip ring --
3-4mm  0.1180.157in
Insulation resistance -- 1M  or less

Electromag
Contactor
Original
netic
Contact element 50%

dimension
4-80
Scheduled Maintenance Task List
Volume Three
5 SCHEDULED MAINTENANCE TASK LIST ..............................................................5-1

5.1 INTRODUCTION ................................................................................................................... 5-1
5.2 IMPORTANT NOTICE ........................................................................................................... 5-2
5.3 ABBREVIATION INDEX TABLES ......................................................................................... 5-3
5.4 SCHEDULED MAINTENANCE TASK LIST .......................................................................... 5-4
Table 5.3-1 Abbreviation Index of crane subsystem ............................................................................. 5-3

Table 5.3-2 Abbreviation Index of crane area ....................................................................................... 5-3
Table 5.4-1 Pre-OP .................................................................................................................................. 5-5
Table 5.4-2 Shift ..................................................................................................................................... 5-10
Table 5.4-3 Daily .................................................................................................................................... 5-12
Table 5.4-4 Weekly................................................................................................................................. 5-14
Table 5.4-5 Biweekly.............................................................................................................................. 5-18
Table 5.4-6 Monthly .............................................................................................................................. 5-19
Table 5.4-7 Quarterly ............................................................................................................................ 5-31
Table 5.4-8 Semi-annually..................................................................................................................... 5-38
Table 5.4-9 Annually.............................................................................................................................. 5-49
Table 5.4-10 Quadrennially .................................................................................................................. 5-66
Table 5.4-11 Hrs ..................................................................................................................................... 5-67
5-I
5 SCHEDULED MAINTENANCE TASK LIST
5.1 INTRODUCTION
In this chapter, the inspection and maintenance tasks for cranes in regular service are divided into
eleven general classifications based upon the intervals at which inspection/maintenance should be
performed. The intervals in turn are dependent upon the nature of the critical components of the
crane and the degree of their exposure to wear, deterioration, or malfunction. The eleven general
classifications are defined with respective intervals between inspection/maintenance as follows.
No.. Classifications Definition

Prior to the beginning of any crane operation. Task need only be
1 PRE-OPERATION
performed once for multi-shift crane operation.
To be performed once during each shift in which continuing crane
2 SHIFT
operations are being conducted.
To be performed once per each calendar day in which continuing crane
3 DAILY
operations are being conducted.
4 WEEKLY To be performed once per each calendar week
5 BI-WEEKLY To be performed once per each calendar two-week period
6 MONTHLY To be performed once per each calendar month
7 QUARTERLY To be performed once per each calendar quarter of a year
8 SEMI-ANNUALLY To be performed once per each calendar half year
9 ANNUALLY To be performed once per each calendar year
10 QUARDENNIALLY To be performed once per each calendar four-year period
To be performed once for every xx operating hours of the crane
11 XX HOURS
subsysytem
5-1
5.2 IMPORTANT NOTICE
(1) Develop a man-hour and man-power plan before each inspection and maintenance task, and
make sure that the crane is available for the scheduled tasks.
(2) Any periodic maintenance frequencies outlined in these instructions and god faith
recommendations are based on the experience of ZPMC and his vendors. There is no substitute
for your experience on these cranes of other cranes which are engaged in similar services and
use similar components . maintain good records for yourself and for others that your team can
follow. Whenever necessary, re-define the task frequencies which are based on the actual
maintenance history of these cranes.
(3) Suggested procedures for lubricating ropes, replacing ropes, replacing wheels, sheaves,
couplings and some other major components are described in these instructions. After you
accomplish each task, maintain a good record or log so that you can endorse or modify the
procedures for yourself and for your colleagues when the same work needs to be done the next
time, or on another crane
Onl y trained designated and authoriz ed personnel ma y car r y

out the maintenance on the crane! Alw ays follow the safet y
instructions w hen performing maintenances!
After the maintenance, the effected s ystem must be verified

and the crane Pre-Opted.
5-2
5.3 ABBREVIATION INDEX TABLES
Table 5.3-1 Abbreviation Index of crane subsystem

System Description Block System Description Block
ACON Air conditioning ELEC electrical J554AD
ELEV elevator J554A51
BCOL Boom collision J554A63 FEST E-Chain system J554A41
BHST Boom hoist drive J554A05
BSTW Boom stowage J554A62 GNTY Gantry drive J554A06

GSTW Gantry stowage J554A60
CRGB Cargo beam J554A13 HBLK Head block
CTRL Catenary Trolley J554A22 HYDR hydraulic J554AH
DRIV Drive SIEMENS LITG lighting J554AD
LMTS Limit switches J554A74
LUBE Lubrication J554A72 SCRN Service crane J554A30-B1
MHSE Machinery house J554A30 TLS TLS/tensioner J554A10
MHST Main hoist drive J554A03 SPDR spreader
NAME nameplate J554A73 SPLT Service platform
OCAB Operator’s cab J554A31 SREL Spreader reel
STCN Seat/consoles J554AD
OTHR other STRU structure J554A01
PANT paint TRDR Trolley drive J554A04
TRLY Trolley assembly J554A02
WRNG Wiring/conduit J554AD
REEV reeving J554A20-23 WWAY walkways J554A50
Table 5.3-2 Abbreviation Index of crane area

Area Description Area Description Area Description
BMGD Boom/girder GNTY Gantry SPDR spreader
BMTP Boom tip LSSB LS support beam TCTB Top crosstie beam
BOOM boom LSYS Lifting system TGDR Trolley girder
BRCH Back reach MHSE Machinery house TRLY trolley
CRAN Crane MNTF Maintenance facility WSSB Ws support beam
ELEV elevator OCAB Operator’s cab
ELRM Electric room PTBM Portal beam
5-3
5.4 SCHEDULED MAINTENANCE TASK LIST
Table 5.4-1 Pre-OP .................................................................................................................................. 5-5

Table 5.4-2 Shift ..................................................................................................................................... 5-10
Table 5.4-3 Daily .................................................................................................................................... 5-10
Table 5.4-4 Weekly................................................................................................................................. 5-14
Table 5.4-5 Biweekly.............................................................................................................................. 5-18
Table 5.4-6 Monthly .............................................................................................................................. 5-19
Table 5.4-7 Quarterly ............................................................................................................................ 5-31
Table 5.4-8 Semi-annually..................................................................................................................... 5-38
Table 5.4-9 Annually.............................................................................................................................. 5-49
Table 5.4-10 Quadrennially .................................................................................................................. 5-66
Table 5.4-11 Hrs ..................................................................................................................................... 5-67
5-4
Table 5.4-1 Pre-OP
No Area System Task Description Tool Man Time Instructions Result Checker Date
(min)
1 GNTY GNTY visual Check the Gantry rail none 1 2
inspection obstructions or
damage
2 GNTY DRIV operating Verify gantry speed 1 2 Run the gantry motions far enough in
inspection and acceleration each direction to verify accelatation
and top speed.
3 ELEV ELEV operating Verify operation of 1 0 Run the elevator all ways up and
inspection elevator down, stopping at each landing and
opening doors.
4 MHSE BHST visual Check the brake 1 1 Verify brake setting values. Boom hoist
MHST inspection torque setting of boom motor brake setting must be 4600NM,
TRDR hoist motor, main hoist Main hoist motor brake setting must be
motor and trolley 13000Nm and trolley motor brake
motor. setting must be 4000Nm.
5 OCAB DRIV operating Verify trolley: speeds, 1 4 Run trolley to outreach and
inspection accelerations, smart backreach to check the functions listed
slowdowns, stops and and the festoon system.
operation of festoon
system
6 OCAB DRIV operating Verify boom operation 1 3.5 Pick up control power, select boom
inspection hoist up or down, then push boom
hoist run. Suggest to running boom far
enough to verify operation. Not
necessary to run boom all the way up.
5-5
7 OCAB ACON visual Check the function of 1 2

ELEC inspection the air-conditioner , air
filter, lighting, defroster
and windshield wipers.
8 CRAN ELEC operating Verify operation of 1 7 Pick up control power in the e-room, hit
inspection E-Stops at Ground the e-stops and check the CMS for the
Gantry, Cab and logs.
E-room.
9 ELRM ELEC operating Verify the absence of 1 3 Open PLC program, search for any
inspection logic overrides or override or forces.
forces
10 LSYS HBLK visual Check the mounting 1 3
inspection and function of the
hoist rope slack limit
switches
11 LSYS HBLK visual Check the spreader 1 2
inspection cable plugs connection
12 OCAB LITE operating Verify gantry warning 1 1 Move the gantry in the operator's cab,
inspection lights and alarms. and check the gantry warning lights
and alarms.
13 OCAB LITE operating Check all indicating 1 0.5 Push lamp test button in the operator's
inspection lights in the operator's cab to verify all indicating lights in the
cab operator's cab
14 BOOM LMTS operating Check the boom 1 1 Verify that both boom collision limit
inspection collision, right side and switch are OK
left side.
15 OCAB OCAB visual Verify operation of 1 0.5
inspection CCTV display and
Vessel Stow Plan
5-6
display
16 OCAB OTHR operating Verify function of both 1 0 Push control power on, operate the
inspection the cameras and the Cad cameras to verify the function of
display them and the display.
17 OCAB OTHR operating Verify the operation of 1 0 Push CMS NEXT SCREEN button on
inspection operator's CMS right console to verify the function of
display the CMS.
18 CRAN OTHR operating Verify the Public 1 0
inspection address
19 BRCH REEV visual Check the trolley 1 2
inspection tensioner sheave in
position
20 BRCH TLS visual Check the cylinder in 1 0.5
inspection right position
21 SPDR SPDR visual Check the drive chain 1 0.5
inspection for security and
slacknees
22 SPDR SPDR operating Verify the 20,40,45 ft 1 0 From the Cab (with 27)
inspection stop
23 TRLY SREL visual Verify that the 1 0.5 Before and after driving main hoist full
inspection spreader cable is laid speed in the operator's cab. Then
in the grooves. check if the spreader cable is
overlapped .
24 TRLY SREL operating Check the spreader 1 0
inspection cable reel motor and
reducer noise and
vibration
5-7
25 OCAB STCN operating Verify main hoist: none 1 1 (Perform with 2)

inspection speeds, accelerations,
upper/lower
slowdowns and stops.
26 OCAB STCN operating Check for flipper, 1 3 From the Cab
inspection twistlock,
27 OCAB operating Check for function of 1 0
inspection Control On indicating
light on right console
28 OCAB STCN operating Check function of 1 0
inspection spreader status
indicating lights
29 OCAB STCN operating Verify Operator's Cab 1 0.5 Use the switches on left side console
inspection Seat and Console to move the seat forward, reverse,
motions, both powered front height up/down and rear height
and manual. up/down.
30 OCAB STCN operating Verify proper function 1 0.5 Check the fasteners for tightness.
inspection of Operator's seat belt
and shoulder harness.
31 TRLY TRLY visual Check main Hoist rope 1 2 Walk the trolley girder and boom
inspection and trolley rope are in observing rope, sheaves, slap blocks
position and adjacent structure.
32 CTRL CTRL visual Check main Hoist 1 2 Stand on the boom and girder to see if
inspection rope , trolley rope and the ropes are at the right position
catenary trolley rope
are in position
33 SPDR TLSS visual Level and Squareness 1 2 Verify that the spreader home position
inspection of Spreader is level and square. If it is not,
rehome the TLS cylinder positions or
5-8
slip the ropes on the drums.
34 CRAN LTNG visual Verify lighting 1 2 Verify operation of: flood lights,
inspection walkway lights, cab light, machinery
house, and e-room. Turn on each
light system and verify it is functional.
Note any light fixtures that are not
operational.
35 CRAN OTHR visual Loose equipment and 1 0 Walk the machinery house, trolley
inspection tools. girder and boom verifying there are no
loose parts or tools that could move or
fall from the crane during operation.
36 MHSE OTHR visual Doors and windows 1 0 Check the operators cab, electric
inspection room, machinery house and gantry cab
to verify that all doors and windows are
closed and secured. Electric room
doors must be locked.
37 CRAN OTHR visual Emergency equipment 1 1 Verify the presence of the required
inspection stokes baskets, fire extinguishers, and
other emergency equipment provided
on the crane.
Total man power: 1
Total check time: 50
5-9
Table 5.4-2 Shift
No Area System Task Description Tool Man Time Instructions Result Checker date
(min)
38 ELRM DRIV visual Check electrical control panels 1 1
inspection noise and smell
39 MHSE DRIV visual Check crane factor plus 1 1
inspection controller,filter and pqm for
operation
40 OCAB DRIV operating Verify slow speed hoist 1 2 Verify while the crane in
inspection operation within vessel cell operation.
guides
41 GNTY GNTY visual Check the oil temperature and none 1 2
inspection abnormal noise from the
hydraulic pump and motor of
the gantry wheel brake power
units
42 MHSE HYDR visual Check the oil temperature and 1 1
inspection abnormal noise from the
hydraulic pump and motor of
emergency brake power unit .
43 BRCH HYDR visual Check for any abnormal noise 1 2
inspection from hydraulic pump and motor
of multi-function power unit.
44 MHSE MHST visual Check main hoist noise and 1 2
inspection vibration (motors, reducer,
brake, drum couplings and
drum bearings)
45 MHSE MHST visual Check the main hoist motor 1 0 See brake manual for stroke
5-10
inspection brake thrust stroke reserve reserve adjustment.
46 REEV visual Check the reeving and 1 10 Walk the crane during operation
inspection components of the Main hoist from TLS sheaves to the boom
and Trolley tip. Observe operation of rope,
sheaves, support rollers, slap
blocks, rope clamps and
structure.
47 REEV visual Check the gantry stowage pins 1 5 Verify that both gantry stowage
inspection inserted at end of work. pins have been inserted in the
wharf at the end of vessel
operations.
48 MHSE TRDR visual Check the trolley abnormal 1 2
inspection noise and temperature(motor,
reducer, drum coupling and
drum bearing )
49 MHSE TRDR visual Check trolley motor brake 1 1 See brake manual for stroke
inspection thrust stroke reserve reserve adjustment.
50 ELRM visual Check CMS fault Log. 1 5 Check for any faults or warnings.
inspection
51 MHSE DRIV visual Drive motor vent fan operation 0 Verify operation of the hoist and
inspection trolley motor ventilation fans.
52 MHSE OTHR visual Machinery house ventilation 1 In warm or hot weather, verify
inspection fans operation of machinery house
vent fans.
53 ELRM ACON visual Electric room air conditioning 1 In warm or hot weather, verify
inspection operation of machinery house
vent fans.
Total man power: 1
5-11
Table 5.4-3 Daily
(min)
54 ELRM ACON visual Check the function of 1 2
inspection E-room AC
55 MHSE BHST visual Check boom hoist motor 1 2
inspection and brake noise and
vibration, make sure that
no grease and debris are
on the surface of the
brake disc
56 MHSE BHST measure Main hoist, trolley drive temp. 1 2 Measure oil temperature and
inspection and boom hoist reducer gauge check for abnormal noise from
reducer
57 MHSE DRIV visual Main hoist, trolley drive 1 1 Make sure excessive grease or
inspection and boom hoist AC oil is not leaking out of the
motors. bearing housings. Refer to
SIEMENS's maintenance
manual.
58 ELRM ELEC visual Verify the incoming none 1 1 Check the voltage and current
inspection power current and from CMS when in
voltage from CMS or operation.Current should be
PQM approximately balanced
between the phases
59 CRAN LITE visual Check the function of 1 5 Check the walkway lights,
inspection walkway floodlights and aircraft lights at
lights ,floodlights and night shift. Replace the bulbs if
5-12
aircraft warning lights necessary.
60 BRCH LITE visual Check the function of 1 2 Pick up control power and
inspection control on indicating check the indicating lights at
lights backreach, machinery house
and e-room, suggest to
performing this task during
operation.
61 MHSE MHST visual Check the boom hoist 1 1
inspection drum, main hoist drum
and trolley drive drum
couplings connection
62 MHSE MHST visual Make sure that no 1 1
inspection grease and debries are
on the surface of the disc
63 OCAB OCAB clean Clean the cab windows 1 10
64 BRCH REEV visual Check the rope tensioner 1 1
inspection cylinder leakage
65 BRCH TLS visual Check cylinder oil 1 1
inspection leakage
66 BRCH TLS visual Check hydraulic system 1 2
inspection oil leakage
67 SPDR SPDR visual Check the fluid level of 1 2
inspection expansion drive reducer
68 MHSE TRDR/MHST visual Main hoist, trolley drive 1 1 Make sure that no grease and
inspection and boom hoist high debries are on the surface of
speed motor brake discs. the trolly brake disc
Total man power: 1
5-13
Table 5.4-4 Weekly
(min)
69 MHSE BHST visual Check boom motor drum 1 5
inspection bearing noise ,
temperature and housing
bolts
70 MHSE BHST visual Check the boom hoist 1 1 See brake manual stroke
inspection motor brake thrust stroke reserve adjustment.
reserve
71 MHSE BHST visual Boom hoist rope clamp 1 5
inspection tight
72 MHSE BHST visual Check main hoist (2) and 1 2 Check the emergency brake
inspection boom hoist low speed disc surface. Make sure that
brake discs. no grease and debris are on
the surface of the disc.
Clean with solvent and repair
as required.
73 MHSE BHST visual Boom hoist motor brake 1 2
inspection adjustment
74 MHSE BHST visual Boom hoist low speed 1 1
inspection brake adjustment
75 MHSE DRIV visual Crane Factor + ventilation 1 3 Verify that the ventilation fan
inspection and fans mounted to the front door of
the Crane Factor + cabinet is
exhausting air properly, and
intake and exhaust openings
are not obstructed.
5-14
76 OCAB DRIV operating Verify trolley over-travel 2 3 Move trolley near to the over
inspection limit switches travel limit switches, Actuate
the over travel limit switches
manually and try to pickup the
control power on, if the control
power can't be picked up, it is
ok. Select the limit backup
switch in e-room and pick up
control power, and verify
trolley motion can be backed
out.
77 ELRM DRIV replacement Replace the cooling fan of 1 8 Do not replace until after
the AF-300 drive disconnecting the power
supply. Refer to Siemens'
manual .
78 FEST Refer to Igus
chain
maintenance
manual
79
80
81
82
83
84
85 GNTY GNTY visual Check gantry wheel 1 2 If the oil level is below than
inspection brake oil level . allowable lowest level on the
gauge, fill fluid to the tank.
5-15
86 LSSB HBLK operating Ensure the function of 2 10

inspection headblock pin engaged
and disengaged limit
switches
87 LSSB HBLK visual Headblock junction box 1 2 Check the junction boxes and
inspection and control station. control station are secured to
mount.
88 LSSB HBLK tighten bolts Check to make sure all 1 5
terminals in junction box
are well tightened
89 MHSE HYDR visual Check the emergency 1 2 Check oil level, leaks, and
inspection brake power unit. proper operation.
90 CRAN LITE visual Repair the function of all 1 5 Switch locates in e-room
inspection work floodlights
91 MHSE MHST visual Check main hoist reducer 1 2
inspection oil level
92 MHSE MHST visual Main hoist (2) and boom 1 2 Check the brake disc. Make
inspection hoist high speed motor sure that no grease and debris
brake discs. are on the surface of the disc.
Clean with solvent and repair
as required.
93 MHSE MHST visual Check main hoist drum 1 5
inspection bearing housing bolts
94 MHSE MHST visual Hoist mounting bolts 1 2 Check for loose motor, brake,
inspection reducer, or idler stand bolts.
95 MHSE MHST visual Hoist and trolley support 1 2 Check all UHMW support
inspection rollers rollers for excessive wear.
Replace or reposition as
necessary.
5-16
96 MHSE MHST visual Hoist motor brake 1 1 Verify brake operation and
inspection adjustment adjustment to include lift-off,
wear adjustment, etc.
97 MHSE MHST visual Main hoist low speed 1 1
inspection brake adjustment
98 OHTA lube Grease twistlock housing 1 20
points, slides and moving
parts in the latch
assembly and fixture
assembly
99 BMTP REEV visual Main hoist wire rope dead 1 5 Check the main hoist rope
inspection end connection. wedge clamp tighten. Verify
no slippage has taken place.
100 OCAB STCN clean Make sure to keep the 1 5 Dirt can impair the function of
seat clean the seat. Upholstery can be
quickly and simply removed
from the seat frame for easy
cleaning, or replacement
101 MHSE TRDR visual Check trolley reducer oil 1 2
inspection level
102 MHSE TRDR visual Check trolley rope clamp 1 5
inspection tight
103 MHSE TRDR visual Check trolley drum 1 5
inspection bearing housing bolts
104 MHSE TRDR visual Trolley motor brake 1 2
inspection adjustment
105 TRLY TRLY visual Check wheel lubricators 1 2
inspection
5-17
106 TRLY TRLY operating Check cable reel gear 2 5

inspection unit noise
107 CTRL CTRL visual Check wheel lubricators 1 2
inspection
Total man power: 1~2
Table 5.4-5 Biweekly
No Area System Task Description Tool Man Time Instructions Result Checker date
(min)
107
108 GNTY GNTY visual Wheel side surface none 1 2
inspection contamination with
wheel brake
109 BOOM LMTS visual Check the gantry 1 2 Verify that both boom collision
inspection switches. are in place and that the limit
switch is approximately in the
correct position
110 MHSE MHST measure Check main hoist tape 1 10 The minimum thickness of
inspection emergency brake lining lining is 5mm.if the thickness is
less than 5mm, it has to be
replaced.
111 MHSE MHST measure Check the main hoist 1 10 The minimum thickness of
inspection motor brake lining lining is 3mm.if the thickness is
wear less than 3mm, it has to be
replaced. See brake manual
for lining replacement.
5-18
112 MHSE TRDR measure Check the trolley 1 5 The minimum thickness of
inspection motor brake lining lining is 5mm.if the thickness is
wear less than 5mm, it has to be
replaced.
113 MHSE TRDR visual Check brake and brake 1 5
inspection parts for wear and
damage
Table 5.4-6 Monthly
(min)
114 MHSE BHST visual Check boom hoist 1 10 Visually inspect and
inspection motor, brakes, pillow tap with hammer if
blocks bolts questionable each bolt
connection and connection.
115 MHSE BHST visual Check boom hoist 1 0.5
inspection reducer oil level
116 MHSE BHST visual Check boom hoist 1 1
inspection and main hoist
emergency brake oil
leakage
117 MHSE BHST operating Verify boom hoist 2 20
inspection thrust brake and
emergency brake
capacity
118 BMGD CWSR visual Check the rope roller 1 5
inspection wear
5-19
119 MHSE DRIV visual Check the insulated 1 5 See SIEMENS's

inspection commutator of AC stick maintenance manual
motors for roughness
120 ELRM ELEC clean Clean all the debris 1 10
from the electric
room
121 WSSB ELEC operating Check function of all 1 2 Verify functions and
inspection indicating lights and indicating lights in the
switches Boom Operator's
Station
122 ELRM ELEC visual Fuse and circuit 1 10
inspection breaker in control
panel
123 ELRM ELEC visual Contacting condition 1 10
inspection of relay and
contactor
124 ELRM ELEC visual Verify the function 1 2 Verify functions and
inspection lights of instrument indicating lights in the
indications in the E-room
e-room
125 MHSE ELEC visual Inspect AC motors 1 2 Motors are to be kept
inspection for cleanliness clean and ventilating
openings clear
126 MHSE ELEC visual Inspect the condition 1 10 When the crimped
inspection of the AC motor marker approaches
brushes, replace the entry into the brush
worn ones holder, brush
replacement should be
investigated.
5-20
127 TCTB ELEC visual Check to ensure the 1 10

inspection impeller and vane of
aerovane wind
transmitter are move
freely
128 TRLY ELEC visual Confirm the 1 5
inspection grounding of lighting
transformer on the
cab roof
129 ELEV ELEV visual Make sure all screw 1 5
inspection joints of gear box are
properly tightened
130 ELEV ELEV operating Check that all 1 10
inspection incoming disconnect
switches and
emergency stop
switches are working.
131 ELEV ELEV visual Check brake lining 2 20
inspection and brake torque
132 ELEV ELEV operating Check cable for wear 1 10
inspection and to ensure that no
kinks occur
133 ELEV ELEV operating Make sure the 1 10
inspection operation of the
control system (PLC)
is correct
134 ELEV ELEV operating Check attachment of 2 5
inspection the cable in the cable
support arm
5-21
135 ELEV ELEV lube Lube the safety 1 10

device with grease
136 BRCH FEST visual
inspection
137 BRCH FEST visual
inspection
138 BRCH FEST visual Check cable clamp 1 1
inspection for loosing
139 GNTY GNTY visual Check gantry reducer none 1 2
inspection oil level
140 GNTY GNTY visual Check gantry reducer 1 1
inspection unit for leaks
141 LSYS HBLK operating Tighten all bolts on 1 20
inspection the headblock.
142 LSYS HBLK operating Check and adjust the 2 20
inspection slack rope limit
switch.
143 MHSE HYDR visual Check emergency 1 1
inspection brake power unit oil
leakage
144 MHSE LITE visual Check machinery 1 2 Turn on the switches.
inspection house fluorescent Replace the
lights fluorescent light tubes
that don't work
anymore.
145 OCAB LMTS operating Check function of 2 10 Clear hoist home
inspection hoist home and position, hoist all the
upper overtravel limit way up to hit the
switches switch.
5-22
146 BOOM LMTS operating Check the fuction of 2 10

inspection anti-ship collision
limit switches
147 TCTB LMTS operating Check function of 2 10 Select boom slow
inspection boom hoist normal speed, manually active
stop and overtravel the switches while
limit switches booming up from level
position
148 BMGD LMTS operating Check trolley home 1 10 Clear trolley home
inspection switch position, then move
the trolley to cross the
switch
149 BMGD LMTS operating Check trolley park 1 5
inspection position limit switch
150 GNTY LMTS operating Check the function of 2 10 Set the stowage pins,
inspection gantry stowage pin then there is no gantry
limit switches motion
151 MHSE MHSE operating Check function of 1 2 Switch on the fan in
inspection machinery house e-room
fans
152 MHSE MHSE clean Clean all the debris 1 15
from the machinery
house.
153 MHSE MHST visual Check main hoist 1 10 Visually inspect and
154 MHSE MHST visual Check brake and 1 2
inspection brake parts for wear
5-23
and damage
155 MHSE MHST visual Check main hoist 1 1

inspection reducer oil leakage
156 MHSE MHST visual Check the main 1 1 It's displayed on CMB
inspection hoist emergency screen
brake torque set
157 MHSE MHST operating Verify main hoist 2 10
inspection thrust brake and
emergency brake
158 ATCH OHTA visual Check structure 1 5
inspection (including latch arms
and attachment
lugs )for weld cracks,
fatigue cracks and
damage due to
misuse
159 BRCH OTHR visual Make sure the CCTV wrenches 1 2
inspection camera and its dome
are secured to the
mount.
160 TRLY OTHR visual Make sure the CCTV wrenches 1 2
inspection camera and its dome
are secured to the
mount
161 BMGD RAIL visual Check the rail clamps 2 10
inspection for tight near boom
hinge
162 BRCH REEV visual Check trolley 1 5
5-24
inspection tensioner bolt

connection.
163 BMGD REEV visual Inspect trolley tow 3 60 See maintenance
inspection ropes for wear, if manual Chapter3. If
damage and replacement any broken wires are
corrosion found, the number of
Left Rope broken wires should
Right Rope be recorded. Refer to
manufacturer manual
Chapter3 and local
regulations for wire
rope removal criteria
164 BMGD REEV visual Inspect main hoist 3 120 See maintenance
inspection wire rope for wear, if manual Chapter3. If
damage and replacement any broken wires are
corrosion found, the number of
A-B Rope broken wires should
B-C Rope be recorded. Refer to
manufacturer manual
Chapter3 and local
rope removal criteria .
165 TRLY REEV operating Main hoist home and 2 20 Check that the
inspection overtravel limit fasteners are tight and
switches are secure that the assemblies
are secure.
166 BOOM REEV lube Grease trolley 1 10
sheaves' bearings
with NLGI 1#(4
5-25
points)
167 MHSE SCRN visual Machinery house 1 30 Inspect machinery

inspection service crane wire house service crane
rope wire rope for wear or
damage. See
maintenance manual
Chapter3. If any
broken wires are
found, the number of
broken wires should
be recorded. Refer to
manufacturer manual
Chapter3 and local
rope removal criteria .
Lubrication level are
also to be checked. If
lubrication is found to
be insufficient, the
rope is to be slushed.
168 BRCH TLSS clean Clean cylinder 1 1
exposed surface
169 OCAB STCN operating Check the function of 2 5 Activate the various
inspection master controllers functions of the
masterswitch and read
the reference from
PLC while moving the
controller. The
functions of each
5-26
motion, float switch,

and each thumb switch
are to be verified.
170 MHSE TRDR visual Check trolley 1 5 Visually inspect and

171 TRLY TRLY visual Check trolley rope 1 2
inspection wedge clamps
172 TRLY TRLY visual Check rope guides 1 2 Check that the rope
inspection on the sheaves guides are proper
connected with the
sheaves and the rope
not slide out from the
sheaves.
173 TRLY TRLY lube Grease the main 1 5
hoist sheaves'
bearings with grease
174 TRLY TRLY lube Grease the trolley 1 5
wheels' bearings with
grease
175 TRLY TRLY visual Check cable reel 1 2
inspection gear unit oil level
176 TRLY TRLY visual Check cable reel 1 1
inspection gear unit for leakage
177 TRLY TRLY visual Check cable reel's all 1 10
inspection screws for tightness
5-27
178 CTRL CTRL lube Grease the catenary 1 5

trolley sheaves'
bearings with grease
179 CTRL CTRL lube Grease the trolley 1 5
wheels' bearings
180 CTRL CTRL operating Check the 1 10
inspection tightenness of the
sheave support bolts
181 OCAB WRNG tighten bolts Check and ensure all screwdrivers 1 20
the wiring terminals
in the control panels,
consoles and Genius
modules are well
tightened
182 TRLY WRNG tighten bolts Check to ensure all screwdrivers 1 10
electrical wiring
connections in
junction boxes on the
cab roof of trolley are
well tightened
183 CRAN SIGN visual Check all decals are 1 5 See Maintenance
inspection affixed legible Manual chapter 1 for a
listing of the safety
decals. Decals found
to be missing or
illegible must be
replaced.
5-28
184 OCAB TLSS operating Trim, list and skew 1 2 Verify that each motion
inspection functions functions, its readout is
approximately correct,
and that each home
switch brings the
respective motion to
the home position.
185 OCAB CCTV operating CCTV Camera 1 2 Verify Camera 2
inspection operation operation of zoom, pan
and tilt.
Verify Camera 1
operaation of zoom,
pan and tilt.
Verify automatic
switching between
cameras and of zoom
and position changes
of Camera 1 during
lowering over the
vessel.
186 BKRH CCTV visual Camera 1 mounting 1 2 Verify that the camera
inspection and camera
components are
mounted securely and
that no parts are
missing. Check both
the camera assembly
and the electronics
electrical box.
5-29
187 TRLY CCTV visual Camera 2 mounting 1 2 Verify that the camera
inspection and camera
components are
mounted securely and
that no parts are
missing. Check both
the camera assembly
and the electronics
electrical box.
188 CRAN MECH visual Excess lubricant 1 5 Look for grease and oil
inspection that has passed
through the seals and
has built up below the
bearing. Excess
lubrication must be
cleaned with rags and
solvent so that it does
not contaminate other
parts or the crane.
189 LSYS HBLK lube Lubricate the main 1 5
hoist sheave on the
headblock
Total check time: 685.5
5-30
Table 5.4-7 Quarterly
(min)
190 ELRM DRIV visual Inspect wires and cables flashlight 1 15 Turn off MV switchgear and
inspection in AC drives for wear, follow LOTO procedure.
fraying, chipping, or nicks Repair minor defects with a
good grade of electrical tape,
or replace if necessary.
191 ELRM DRIV visual Inspect printed wiring 1 30 Turn off all power to the
inspection board plugs, wiring, and equipment to be inspected and
connectors in eachAC maintained.
Drive to ensure correct
seating
192 ELRM DRIV visual Inspect fans and blower 1 5 To see that the fan is running
inspection motors in each AC drive and ensure that air passages
for correct operation.. are clear. If it is not running,
de-energizing the drive and
replace the fan.
193 ELRM DRIV visual Inspect contacts on open 1 30 Turn off all power to the
inspection contactors and relays equipment to be inspected and
maintained. Discoloration and
rough contact surfaces are
normal.
194 ELRM DRIV clean Clean printed boards in Vacuum 1 60 Turn off all power to the drive.
all AC drives Vacuum to remove dust from
around the board connections
before and after unplugging.
5-31
195 MHSE DRIV replacement Check and replace the 1 4 If necessary, disconnect power
ventilation filters on the before replacement.
door of Crane Factor +
cabinet if necessary
196 MHSE DRIV replacement Check vent fan air filters 1 10
of AC motors and replace
when dirty
197 OCAB ELEC operating Megger spreader cable megger 2 60 Follow the LOTO procedure,
inspection switch off AC1CB in e-room .
Disconnect the spreader cable
connectors at trolley and
headblock. Megger the
insulation between conductors.
198 BRCH ELEC visual Inspect all connecting 1 5
inspection cabling ( between
backreach JB and
Festoom System) for
deterioration or other
damage.
199 GNTY GNTY visual Check and adjust 2 16
inspection proximity switches of
gantry wheel brakes
200 GNTY GNTY clean Clean wheel brake guide 1 20 See Wheel Brake Manual.
pins
201 GNTY GNTY visual Wheel brake guide 1 0 See ZPMC Wheel Brake
inspection rollers for wear Manual.
202 GNTY GNTY visual Check seals and 1 10
inspection screwed connections of
hydraulic system of
5-32
wheel brakes
203 LSYS HBLK lube Lubricate the main hoist 1 5

sheave on the headblock
204 BOOM LITE visual Check the function of 1 2 Turn on the boom spot light
inspection boom spot lights switch in the boom operator's
station to make sure the lights
are on.
205 MHSE MHST measure Check the main hoist 1 5 If any cracks occur or more
inspection motor brake disc than 1mm wear on each side
thickness occurs, the brake disc has to
be replaced.
206 MHSE MHST fluid Check main hoist,Trolley, wrench, 1 5 Take one bottle of fluid from
sampling Boom Hoist, Gantry and sample the tank and sent it to relative
Spreader Cable Reel bottle lab for at least tests: 1. particle
Reducers oil for count 2. water content 3.
contaminants water metals by spectroscopic 4.
content and cleanliness. Kinematic Viscosity
207 MHSE MHST operating Check the main hoist 2 10 Release the brake via actuator
inspection motor brake uniform measure the gap between the
shoe lift-off pads and disc on both sides.
Measure the gap between the
pads and disc on both sides.
208 MHSE MHST lube Grease the main hoist 1 5
reducer high speed
bearing
5-33
209 BRCH OTHR clean Clean the CCTV camera glass 1 5

dome cleaner
and facial
tissues
210 TRLY OTHR clean Clean the CCTV camera optical 1 5 We recommend you
lens (only if required) lens purchasing an optical lens
cleaning cleaning kit and following the
kits procedure provided with the
kits.
211 TRLY OTHR clean Clean the Vessel optical 1 5 We recommend you
Profiling laser beam lens lens purchasing an optical lens
(only if required) cleaning cleaning kit and following the
kits procedure provided with the
kits.
212 TRLY OTHR tighten bolts Make sure the Vessel wrenches 1 2
Profiling laser beam is
secured to the mount
213 TRLY OTHR clean Clean the grease on the 2 30
top of the trolley and cab
(only if required)
214 BMGD RAIL tighten bolts Verify trolley rail clip bolt 2 60 Travel the trolley the full length
torque of the girder and boom. With
a person at each side platform
apply a torque wrench to each
rail clip bolt and verify it resists
at least 150 Nm torque.
215 CRAN REEV measure Check main hoist 1 60
inspection sheaves' groove
5-34
216 BRCH REEV operating Check function of trolley 1 5

inspection rope tensioner limit
switch
217 BRCH REEV lube Grease trolley tensioner 1 5
sheaves' bearings
218 BRCH REEV lube Grease trolley sheaves' 1 5
bearings behind the
machinery house
219 BOOM REEV lube Grease the boom hoist 1 5
sheaves' bearings
220 BMGD REEV lube Grease the hinge 1 5
bearings
221 TCTB REEV lube Grease the boom hoist 1 5
sheaves' bearings
222 BRCH TLSS lube Grease the TLS sheaves' 1 5
bearings
223 BRCH TLSS lube Grease TLS cylinder 1 5
connection pins
224 BOOM STRU lube Grease the fore stay pins 1 5
225 MHSE TRDR operating Trolley motor brake 2 5 If gaps are different, see Brake
inspection release clearance manual for adjustment. Lift
the trolley drive motor brake
uniform shoe off
and release the brake via
actuator, then measure the
gap between the pads and
disc on both sides.
5-35
226 MHSE TRDR visual Check trolley motor 1 5 Check bolted connections for
inspection coupling elastic ring security and the elastic
element for wear. If the
elastic element is worn out, it
has to be replaced. See
maintenance manual 4.2.2.2
for elastic element
replacement.
227 TRLY TRLY lube Grease the truck pin 1 5
228 TRLY TRLY clean Clean cable reel reducer 1 5
vent plug
229 CTRL CTRL lube Grease the truck pin 1 5
230 MHSE MHST visual Both main hoist drum for 1 15 Place the spreader on the
inspection rope corrugation ground and inspect the drum
grooves in that area where the
rope leaves the drum as the
crane picks a container from a
chassis/bomb cart.
231 MHSE TRDR visual Trolley drum for 2 15 inspect both open drum groove
inspection corrugation as the trolley moves the full
travel length. Any distortion
or metal removal should be
noted.
232 MHSE BHST visual Boom drum for 1 5 With the boom in the operating
inspection corrugation position, inspect the exposed
grooves for brinelling
(impressions caused by the
rope wires). Any damage to
the groove should be noted.
5-36
233 CRAN REEV visual Trolley sheave grooves 1 15 Check the open section of
inspection for corrugation and each of these 8 sheaves for
damage distortion or surface damage to
the root radius. Any damage
should be noted.
234 TRLY TRLY visual Trolley wheels for 1 5 Check the treads and flanges
inspection abnormal or excessive of each of the 4 wheels for
wear excessive wear and effects of
trolley steering problems.
235 CTRL CTRL visual Trolley wheels for 1 10 Check the treads and flanges
inspection abnormal or excessive of each of the 4 wheels for
wear excessive wear and effects of
trolley steering problems.
236 BMGD REEV visual Slap and wear blocks for 1 10 Check each wear block to
inspection excessive wear. insure that there is sufficient
wear material remaining to
reach the next quarterly
inspection. Replace those
blocks that will not last this
long.
237 MHSE MECH visual High speed brake 1 5 Check each thruster brake (2
inspection thruster oil level at main hoist, 1 at trolley and 1
at boom) to verify oil level is
within range. Add oil as
needed.
238 BMGD TRLY visual Trolley rail for damage 2 5 Inspect the trolley rail for
inspection damage and material flow,
particularly adjacent to the
boom hinge joint. Inspect the
5-37
alignment of the rail sections

across the boom hinge joint.
239 OCAB DRIV operating Load cells for proper 1 2 Check the load cell readings to
inspection operation verify they are in range. The
cab display should be
inspected as well as the crane
production data report.
Table 5.4-8 Semi-annually
(min)
240 MHSE BHST operating Check function of limit 1 2
inspection switch for boom hoist
motor thruster brake
241 MHSE BHST measure Check boom hoist 1 5 Note:the minimum
inspection brake and brake parts thickness of lining is 5mm.if
for wear (boom hoist the thickness is less than
motor brake lining ) 5mm, it has to be replaced.
and damage See Bubenzer manual for
lining replacement.
242 MHSE BHST lube Grease the drum 1 5
coupling and drum
bearing.
5-38
243 MHSE BHST operating Boom hoist motor megger 1 20 Switch off the incoming
inspection insulation megger test circuit breaker in CA6.
Disconnect the wires to
boom hoist motor. Apply
megger between "+" and
ground.
244 OCAB DRIV operating Verify main hoist 2 2 Run main hoist with only
inspection motions and speeds spreader in the cab. Check
the speeds and motions
through CMS/or LCMS.
245 OCAB DRIV operating Verify trolley motions 2 2 Run trolley with only
inspection and speeds spreader in the cab. Check
the speeds and motions
through CMS/or LCMS.
246 OCAB DRIV operating Verify gantry motions 2 3 Run gantry with only
inspection and speeds spreader in the operator's
cab. Check the speeds and
motions through CMS/or
LCMS.
247 MHSE DRIV clean Clean the capacitor clean 1 10 Disconnect power before
bushings by wiping cloth, inspection.
and vacuuming dust or vacuum
carbon particles from
the reactors in the
Crane Factor + cabinet
248 MHSE DRIV tighten Check the tightness of 1 10 Disconnect power before
bolts the power connections inspection.
at the main reactor,
filter capacitors, filter
5-39
reactors, and filter

resistors in the Crane
Plus + cabin
249 BMTP ELEC visual Inspect all load cell 1 5

inspection terminals are well
tightened, and no
cables or conductors
are damaged
250 MHSE ELEC visual Check the wear of 1 10
inspection vacuum contactor tip
in the Limitamp
251 MHSE ELEC clean Clean AC motor soft brush 1 10
windings
252 ELRM ELEC visual Check the accuracy of 1 5
inspection the wind alarm system
253 ELEV ELEV fluid Check oil for water 1 5 Take one bottle of fluid
sampling content and from the reducer and sent
cleanliness of elevator it to relative lab for at least
reducer tests: 1. particle count 2.
water content 3. metals by
spectroscopic 4. Kinematic
Viscosity.
254 ELEV ELEV visual By knocking on lift none 1 20
inspection mast that all screw
joints of all racks and
mast joints are
properly tightened.
Also check the screw
5-40
joints for attaching the

mast in base frame
255 ELEV ELEV visual Check the mast tie bolt 1 5

inspection connection
256 ELEV ELEV operating Check gates and 2 20
inspection enclosure on lift car .
Check function,
attachment and wear
on rollers. Make sure
that rubber absorbers
are in place.
257 ELEV ELEV visual Check the buffers are 1 1
inspection in position and in
proper condition
258 ELEV ELEV visual Check the cable guide 1 10
inspection with regard to
attachment, function
and installation in the
mast in relation to the
cable support arm on
the lift car
259 ELEV ELEV clean Remove all debris 1 2
from the base slab
260 ELEV ELEV operating Check the emergency 1 1 Switch off the main on/off
inspection lighting. switch in the lift car and
check to ensure that the
5-41
emergency light
functions.
261 ELEV ELEV measure Check the wear on the sliding 1 30 See Alimak manual page
inspection rack and caliper
pinion .measure the
wear with Alimak rack
gauge.
262 ELEV ELEV visual Make sure all signs 1 1
inspection are in position and that
they are legible.
263 ELEV ELEV operating Check with the users if 1 5 If the safety device has to
inspection the safety device has be reset, see Alimak
been tripping without manual.
cause or if noise can
be heard from the
device during
operation.
264 ELEV ELEV operating Make sure the car 1 10
inspection stops within
acceptable limits. If the
distance between
actual stopping
positions empty/fully
loaded car exceeds
110mm. The brake
must be checked.
5-42
265 ELEV ELEV measure Check guide roller. calipers 1 10 When adjustment is
inspection Check wear and required, see Alimak
bearing play of the lift manual
car guide rollers. the
min worn-out diameter
of roller is 68mm.
266 ELEV ELEV operating Check the safety 1 20 See Alimak manual
inspection device
267 ELEV ELEV clean Clean the motor 1 5
cooling flanges
268 ELEV ELEV visual Check all wires, 1 30
inspection sealing , glands and
connections
269 ELEV ELEV visual Check the gears oil wrench, 1 2 Refill if necessary.
inspection level micrometer
or a
special
device
270 ELEV ELEV visual Inspect counter rollers 1 5
inspection screw joints are
properly tightened
271 ELEV ELEV visual Check the pad 1 5 The pad must be replaced
inspection between the if the gap between
electro-magnet armature and rotating disc
armature and the is less than 0.3mm.see
rotating brake disc. Alimak manual
272 ELEV ELEV clean Clean car floor and 1 5
roof.
5-43
273 ELEV ELEV lube Lubricate the racks grease 1 20 Lubricate during lowering
with Alilube gun, and take lift out of
grease of operation for 2-3 hours to
Alilube for permit the spray to congeal
rack
274 ELEV ELEV lube Lube landing doors, 1 10 Grease bearings and slide
interlocks and ramps surface
with Alirack grease
275 ELEV ELEV lube Lube car doors, gate 1 30 Grease bearings and slide
interlocks and ramps surfaces
with Aliflon
276 ELEV ELEV lube Lube cable guiding 1 60 Grease trailing cables and
device with Ali-low-fric slide surface on trolley and
compound car cable bracket. Do not
grease mast
tubes/guides-the cable
trolley may get stuck
277 ELEV ELEV visual Lube roof trapdoor and 1 5
inspection electric cabinet hinges
with SAE30.
278 ELEV ELEV lube Lube foot pedal for 1 30 Lubricate bearings and
control brake and slide surface
Bowden cable with
SAE 30
279 ELEV ELEV operating Function of the alarm 2 5
inspection signal, lighting and,
voice communication
system.
5-44
280 ELEV ELEV operating Check that the handle 1 5 If not, see the Alimak
inspection works properly and manual.
that the handle is fully
reset by the spring
after operation
281 ELEV ELEV visual Check the condition of 1 2
inspection the contact points in
the contactors
282 BRCH FEST visual Check all screws, 1 30
inspection especially the screws
on the clamping bar,
cable supports and
cable clamps .
283 BMGD FEST visual Check if the rail is in 2 10
inspection the good condition,
especially at the hinge
joint position.
284 GNTY GNTY measure Gantry motor megger 1 10
inspection insulation megger test
285
286 GNTY GNTY lube lubricate the wheels, 1 100

reducers, pins, etc
287 CRAN LITE tighten Securing condition of ladder 2 20 One to drive the trolley and
bolts lighting fixtures and the other to check and
ballasts tighten the loose bolts.
Check the stainless chains
are in place.
5-45
288 CRAN LITE visual Check emergency 1 2 Including the stair lights
inspection lighting. Switch off the
corresponding circuit
breaker in the lighting
panel and check to
ensure that the
emergency lights
function
289 MHSE LMTS operating Check function of 1 5
inspection manual release limit
switch for hoist,trolley
and boom motor
thruster brakes
290 MHSE LUBE Relubricate the AC 1 15
motors
291 MHSE MHST operating Main hoist motor megger 1 20
292 MHSE MHST lube Grease the drum grease 1 5
coupling,drum gun, mobil
bearing. grease
293 MHSE MHST lube Grease the main hoist 1 5

reducer high speed
bearing seal.
294 OHTA visual Check the twistlocks 1 5
inspection
295 CRAN REEV visual Check trolley sheave 1 10
inspection rope groove
corrogation
5-46
296 BOOM SCRN lube Grease the 500kg jib 1 5

crane's bearings
297 BOOM SCRN lube Grease the 1500kg jib 1 5 if there is
crane's bearings
298 BOOM SCRN lube Grease the 500kg jib 1 5 if there is
crane's bearings
299 TCTB SCRN lube Grease the 1500kg jib 1 5
crane's bearings
300 MHSE SCRN lube Grease the 500kg jib 1 5
crane's bearings
301 BRCH TLSS visual Check TLS system 1 2
inspection bolt connections
302 BRCH TLSS lube Grease the TLS 1 5
sheaves' guide rollers
303 TRLY SREL visual Check spreader cable 1 2
inspection reel slipring assembly
304 TRLY SREL visual Check cable screwing 1 5
inspection connecting tightness
inside the slipring
305 TRLY SREL visual Check profile rubber 1 5
inspection sealing for slipring
306 TRLY SREL operating Remove the wear of 1 30
inspection contact carbons
307 TRLY SREL measure Check the thickness of 1 10
inspection the contact carbons
308 TRLY SREL measure Check rotor thickness caliper 1 20 Remove the motor cover,
inspection of spreader cable gauge measure the rotor
reel's brake thickness with a caliper
gauge.
5-47
309 TRLY SREL measure Check air gap filler gauge 1 20

inspection between the armature
plate and stator
310 TRLY SREL visual Check profile rubber 1 10
inspection sealing tightness of
cable reel slip ring
311 TRLY SREL visual Fixed seat of 1 10
inspection connection cables at
ring and at the brush
holder
312 TRLY SREL operating Alignment of the brush 1 10
inspection holder of slipring
313 TRLY SREL visual Joint arms of the brush 1 5
inspection holder of slipring
314 MHSE TRDR operating Trolley motor megger 1 20
315 MHSE TRDR lube Grease the drum grease 1 5
coupling,drum gun, mobil
bearing. grease
316 TRLY TRLY lube grease the gate hinge 1 5

317 BMGD WWAY lube Grease the gate hinge 1 5
318 MHSE lube Grease the rereeving 1 5
device
319 BMGD CATS lube Lube the rope roller 2 60
bearing with grease(48
POINTS)
320 BMGD CATS visual Check the rope slap 2 0
inspection block wear
Total man power 1~2
5-48
Total check time 1089
Table 5.4-9 Annually
(min)
321 ELRM ACON operating Operation and 1 10
inspection securing
condition of all
four air
conditioner
units
322 MHSE BHST measure Check the 1 5 If any cracks
inspection boom hoist occur or more
motor brake than 1mm wear
disc on each side
occurs, the brake
disc has to be
replaced.
323 MHSE BHST operating Lift the boom 2 5
inspection hoist motor
brake uniform
shoe off
, release the
brake via
actuator
,measure the
gap between
the pads and
disc on both
5-49
sides.
324 MHSE BHST measure Boom hoist dial indicator or laser 3 60 Note: the
inspection motor coupling alignment maximum radial
alignment(radial equipment,wrench,chain misalignment
and angular hoist should not
alignment) exceed 0.05mm
and the maximum
angular
misalignment
should not
exceed 0.32
degree.
325 MHSE BHST fluid Check oil for 1 5 Take one bottle of
sampling water content fluid and sent it
and cleanliness to a relative lab
of boom hoist for following test:
reducer 1.Kinematic
Viscosity
2.Partical Count
3.Water content
4.Metals by
Spectroscopi
326 MHSE BHST visual Tight the 1 5
inspection screws of boom
hoist reducer
5-50
327 MHSE BHST visual Check boom 1 2 Note: the wear in

inspection hoist drum the drum coupling
coupling wear is shown by the
and axial misalignment of
alignment the indicator in
relation to the
wear notch. If
these limit value
is exceeded, it
has to be
replaced.
328 MHSE BHST visual Tight the bolts 1 5
inspection of boom hoist
drum coupling
329 MHSE BHST operating Check the 2 5
inspection boom hoist
reducer gears
and gear
meshing
330 MHSE BHST visual Check boom 1 2
inspection hoist
emergency
brake lining
331 MHSE BHST lube Grease the 1 5
emergency
drive gear
coupling
332 MHSE BHST visual Check over 1 2
inspection speed limit
5-51
switch coupling
wear and axial
alignment
333 BMGD CATS visual Check all rope 2 60
inspection roller bracket
weld
connection,
Lube the rope
roller bearing
334 CRGB lube Grease the 1 10
hook bearing
with grease
335 CRAN DRIV visual Check AC 1 10
inspection motor (main
hoist, trolley
and boom hoist
motors) wiring
and
commutator
336 ELRM DRIV measure Megger test the megger 1 5 Disconnect all
inspection AF-300 drive drive terminals
and and replace the and perform the
replacement AC Lin.k test only on the
capacitor and main circuit.
the cooling fan
of the AF-300
drive.
337 MHSE DRIV measure Perform an 1000V megger 1 10 Disconnect power
inspection insulation test before inspection.
5-52
on the main line

reactor in the
Crane Factor +
cabin
338 ELRM DRIV replacement Replace PLC 1 4
9030 CPU
memory backup
battery
339 ELRM ELEC visual Resistor grills 1 5
inspection overheating
and dust
340 GNTY ELEC lube lubrication of 1 15
4,160V
disconnect
switch contact
341 ELRM ELEC visual Setting of 1 10 Such three visual
inspection thermo, over inspecktion can
current, timer be done together.
relays
342 ELRM ELEC visual Inspect 1 10
inspection abnormal
condition of
printed boards
and elements
343 CRAN ELEC visual Inspect damage 1 20
inspection of wiring,
terminals, wire
code, cable
tray, cable
5-53
conduit
344 CRAN ELEC operating Installation and 2 15

inspection sound condition
of intercom
system
345 CRAN LITE operating Replace 1 10
inspection emergency light
batteries
346 CRAN ELEC tighten bolts Make sure all screwdriver 2 60 Switch off MV
terminals in the switchgear and
junction boxes, follow the LOTO
control panels, precedure before
Genius I/Os inspection.
and control
stations are well
tightened, no
cables or
conductors are
damaged
347 ELRM ELEC visual Check the load 1 20 Prepare for 25T
inspection readout of each and 50T load in
load cell with advance. Test the
specified load load cells with
empty spreader,
25T and 50T
load. Verify the
readout.
5-54
348 MHSE ELEC visual check the 1 30 switch off the MV

inspection transformers switchgear and
(main follow the
transformer, lockout/tagout
lighting precedure.
transformers,
control
transformer)and
ensure air ducts
are free of any
accumulation of
dust and debris
and any bolted
connections of
terminals are in
good condition
349 TCTB ELEC visual Check that all 1 5
inspection electrical
components
are secure to
mount
350 ELEV ELEV measure The motor 1 10
inspection overload
protector is set
with the rated
current on the
data plate for
the electric
motor.
5-55
351 ELEV ELEV visual Inspect the 1 10

inspection equipment in its
entirety for
corrision and
wear on
loadbearing
and force
-absorbing
components.
352 GNTY GNTY measure Measure the measure tape. 1 20 Measure the
inspection thickness of thickness of
wheel brake lining. If the lining
lining is worn 0.5mm,
the lining wear
has to be
compensated.The
minimum
thickness of lining
is 3mm. If below 3
mm, the pad has
to be
replaced.refer to
ZPMC wheel
brake manual.
353 GNTY GNTY visual seals and none 1 10
inspection screwed
connections of
the hydraulic
system.
5-56
354 GNTY GNTY fluid Check oil for wrench, cup 1 60 Take one bottle of
sampling water content fluid for each
and cleanliness reducers and sent
of gantry them to relative
reducers lab for following
test: 1.Kinematic
Viscosity
2.Partical Count
3.Water content
4.Metals by
Spectroscopic
355 GNTY GNTY lube Greasing wheel grease gun, grease 1 60
bearings,
greasing
equalizer pins.
356 BRCH HYDR fluid Check oil for 1 5 Take one bottle of
sampling water content fuild from the tank
and cleanliness and sent it to
of hydraulic relative lab for at
fluid of least tests: 1.
muti-function particle count 2.
power unit water content 3.
metals by
spectroscopic 4.
Kinematic Visco
357 GNTY HYDR fluid check oil for 1 5 Take one bottle of
5-57
fluid of wheel least tests: 1.

brake particle count 2.
water content 3.
metals by
spectroscopic 4.
Kinematic Visco
358 MHSE HYDR fluid check oil for 1 5 Take one bottle of
fluid of least tests: 1.
Bubenzer SF24 particle count 2.
brakes water content 3.
metals by
spectroscopic 4.
Kinematic Visco
359 MHSE LMTS operating Check function 1 5
inspection of main hoist
emergency
drive select limit
switches
inspection of trolley
emergency
drive select limit
switches
inspection of boom hoist
emergency
5-58
drive select limit

switches
362 MHSE MHST visual Check the drum 1 5 Refer to wire rope
inspection rope groove manual section
wear 5.0.
363 MHSE MHST measure Check the main dial indicator or laser 3 120 The maximum
inspection hoist motor alignment radial
coupling equipmen,wrench,chain misalignment
alignment(radial hoist should not
and angular) exceed 0.05mm
and the maximum
angular
misalignment
should not
exceed 0.32
degree.
364 MHSE MHST visual Check main 1 5 The wear in the
inspection hoist drum drum coupling is
coupling wear shown by the
and axial misalignment of
alignment the indicator in
relation to the
wear notch. If
these limit value
is exceeded,it has
to be replaced.
365 MHSE MHST visual Check all bolt 1 0
inspection connections of
the joint
5-59
connection for
main hoist drum
coupling
366 MHSE MHST lube lubricate the 1 2
emergency
reducer
367 MHSE MHST visual Check over 1 2
inspection speed limit
switch coupling
wear and axial
alignment
368 OHTA measure Measure 2 30 Entire twistlock
inspection twistlocks using should be
NDT inspected with
100%MT.
369 TRLY OTHR clean Check the 1 15 transformer must
transformers be de-energized
and ensure no
accumulation of
dust or debris
exist and all
bolted
connections of
terminals are in
good condition
370 GNTY PLOW visual Check the plow none 1 5
inspection structure bolt
connection
5-60
371 BRCH REEV visual Check the rope 1 2

inspection tensioner
sheave groove
372 BRCH REEV visual Check 1 1 no damage and
inspection tensioner oil leakage on
cylinder surface surface of
cylinder.
373 BOOM REEV lube Grease the 2 120
boom hoist wire
rope with
centigard 300
374 ROTR lube Grease the 1 5
electric motor
with rust
inhibitive
polyurea based
grease
375 MHSE SCRN visual Check rope 1 10
inspection guide and
securing device
of Demag crane
376 MHSE SCRN visual Strain relieving 1 5
inspection elements,
control cables
and control
pendant
housing for
damage of
Demag crane
5-61
377 MHSE SCRN operating Operation of 2 10

inspection brake of service
crane
378 MHSE SCRN visual Suspension of 1 5
inspection rope anchorage
of service crane
379 MHSE SCRN operating Tighten all bolts 1 30
inspection connection of
service crane
380 MHSE SCRN visual Check load 1 5
inspection hook for cracks,
cold
deformation
and wear of
service crane
381 MHSE SCRN visual bottom block 1 5
inspection and hook fitting
of service crane
382 MHSE SCRN visual Check coupling 1 10
inspection of the creep
speed hoist
motor of service
crane
383 MHSE SCRN operating Operation of 1 10
inspection emergency limit
switch of
service crane
384 MHSE SCRN operating Examine wire 2 30
inspection rope for
5-62
damage and
broken wires
385 MHSE SCRN operating Check rope 2 10
inspection securing
devices and
play of rope
guide on drum
386 MHSE SCRN lube Grease wire 2 30
rope
387 BRCH TLSS visual Check TLS 1 5
inspection system frame
weld cracks
388 STRU visual Check any 2 120 This is only
inspection structure for general
damage description for
structure
inspection. Detail
inspection is
referred to
structure
maintenance
manual.
389 MHSE TRDR visual Check trolley 1 2 The wear in the
inspection drum coupling drum coupling is
wear and axial shown by the
alignment misalignment of
the indicator in
relation to the
wear notch. If
5-63
these limit value

is exceeded, it
has to be
replaced.
390 MHSE TRDR visual Check all fixing 1 5
inspection screws of trolley
reducer for
tighten
391 MHSE TRDR fluid Check oil for 1 5 Take ONE bottle
sampling water content of fluid and have
and cleanliness it sent to relative
of trolley lab for following
reducer test: 1.Kinematic
Viscosity
2.Partical Count
3.Water content
4.Metals by
Spectroscopic
392 MHSE TRDR measure Check trolley dial indicator or laser 2 30 The maximum
inspection motor coupling alignment radial
alignment(radial equipmen,wrench,chain misalignment
and angular hoist should not
alignment) exceed 0.05mm
and the maximum
angular
misalignment
should not
exceed 0.32
degree.
5-64
393 MHSE TRDR visual Carry out 2 30 see flender

inspection complete manual.
inspection of
gear unit.
394 MHSE TRDR visual Check drum 1 5
inspection rope groove
wear
395 MHSE TRDR visual Check all bolt 1 5
inspection connection of
the joint
connection for
main hoist drum
coupling
396 TRLY TRLY visual Check trolley 1 5 The maximum
inspection wheels's wear allowable
worn-out of flange
is 10% of original
flange thickness
and the maximum
allowable
worn-out of tread
surface is 3% of
original size.
397 TRLY TRLY lube Grease cable 1 5
reel bearings
398 TRLY TRLY visual Check gear unit 1 10
inspection of cable reel
reducer.
5-65
399 CTRL CTRL visual Check catenary 1 5 The maximum

inspection trolley wheels's allowable
wear worn-out of flange
is 10% of original
flange thickness
and the maximum
allowable
worn-out of tread
surface is 3% of
original size.
Total man power 1~3
Table 5.4-10 Quadrennially
(min)
400 ELEV ELEV measure Dismount and lift out 2 120
inspection the motor/gear unit
from ,let the
machinery plate to be
able to make a strict
check of pinion and its
counter roller.
401 ELEV ELEV clean Lower the car onto the 2 120
buffer or prop the car
in a safe manner.
Dismantle the motor
brake and the
centrifugal brake.
5-66
Clean and grease the

shaft with teflon
lubricant, avoiding
any contamination of
brake lining.
402 ELEV ELEV replacement Replace the complete 2 120

safety device
403 MHSE MHST visual Carry out complete 2 120
inspection inspection of gear unit
404 MHSE MHST operating Tighten all fixing torque 2 0
inspection screws of main hoist wrench
reducer
Total man power 2
Table 5.4-11 Hrs
No Area System Freq Task Description Tool Man Time Instructions Result Checker Date
(min)
405 GNTY GNTY 1000Hrs replacement Replace the clean 1 30
pad of wheel brake
406 LSYS HBLK 500Hrs visual Check sheave 1 2
inspection grooves
Total man power 1~2
Total checker time 32
5-67
Painting Procedure and Repair Instructions
6 PAINT PROCEDURE AND REPAIR INSTRUCTION
6 PAINT PROCEDURE AND REPAIR INSTRUCTION ............................................ 6-I
6.1 PAINTING PROCEDURE ......................................................................................................................... 6-2

6.1.1 INTRODUCTION ................................................................................................................................ 6-2
6.1.2 STANDARDS AND CODES .............................................................................................................. 6-2
6.1.3 SURFACE PREPARATION ............................................................................................................... 6-2
6.1.4 SHOP PRIMER ................................................................................................................................... 6-4
6.1.5 PAINT APPLICATION ......................................................................................................................... 6-5
6.1.6 INSPECTION....................................................................................................................................... 6-8
6.1.7 MISCELLANOUS ................................................................................................................................ 6-8
6.1.8 REPAIR/TOUCH-UP .......................................................................................................................... 6-9
6.1.9 WORKING SPECIFICATION ............................................................................................................ 6-9
6.2 PAINT INSPECTION/REPAIR INSTRUCTION ................................................................................... 6-12

6.2.1 Aging or deterioration of coating and judging standard for repair. ............................................. 6-12
APPENDIX I: PAINTING SYSTEM .............................................................................................................. 6-15
APPENDIX II: EUROPEAN RUST SCALE ................................................................................................ 6-17
6-I
6.1 PAINTING PROCEDURE ......................................................................................................................... 6-2

6.1.1 INTRODUCTION ................................................................................................................................ 6-2
6.1.2 STANDARDS AND CODES .............................................................................................................. 6-2
6.1.3 SURFACE PREPARATION ............................................................................................................... 6-2
6.1.4 SHOP PRIMER ................................................................................................................................... 6-4
6.1.5 PAINT APPLICATION ......................................................................................................................... 6-5
6.1.6 INSPECTION....................................................................................................................................... 6-8
6.1.7 MISCELLANOUS ................................................................................................................................ 6-8
6.1.8 REPAIR/TOUCH-UP .......................................................................................................................... 6-9
6.1.9 WORKING SPECIFICATION ............................................................................................................ 6-9
6-1
6.1 PAINTING PROCEDURE
6.1.1 INTRODUCTION
The procedure covers the surface preparation, materials and coating application requirements for
coating the fabricated steel, equipment and appurtenances of the container crane structures.
(1) The coating system of this specification is based on:
 The International standard ISO 12944 “Protective Paint System”, under corrosive category
“ C4“- for coastal or industrial environment
 With high durability more than 15 years of performance reaching level Ri 3 as defined in ISO
4628-3 or the rust ratio Re3 defined in European Rust Scale.
(2) The color of finish coating is to be in accordance with the owner’s requirement, while that of
the primer and intermediate coating shall be up to the manufacturer’s availability.
6.1.2 STANDARDS AND CODES
The latest edition of the ASTM, the Steel Structures Painting Council Surface Preparation
(SSPC-SP) and the International standard (ISO) written Specifications are part of this
Specification.
Table 6.1-1 International Standard
Standard Description
ASTM A123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
SSPC-SP-1 Solvent Cleaning
SSPC-SP-2 Hand Tool Cleaning
SSPC-SP-3 Power Tool Cleaning
SSPC-SP-7 Brush-off blast cleaning
SSPC-SP-COM Surface Preparation Commentary
SSPC-PA2 Measurement of DFT with M. Gauge
SSPC-SP-11 Power Tool Cleaning to Bare Metal
ISO 8501 Visual assessment of surface cleanliness
ISO 8502 Tests for the assessment of the surface cleanliness
ISO 8502-6 Sampling soluble impurities on surface to be painted
ISO 8503 Surface roughness characteristics of blast-cleaned steel surface
substrates.
ISO 8504 Preparation of steel substrates before application of paints and
related products
6.1.3 SURFACE PREPARATION
The surface shall be prepared in a manner suitable for coatings according to HEMPEL’s product
data sheets. Chemical de-rusters or rust converters are not allowed.
(1) Detergent / Solvent Cleaning
All surfaces to be coated shall be clean of all contaminants that would affect the integrity of the
6-2
coating system. Prior to surface preparation, the surfaces shall be cleaned, as necessary, to
remove all oil, grease, dirt, salts or other foreign materials. This cleaning shall be done with
appropriate detergent and/or solvent cleaning. Detergent or solvent cleaning shall be
performed as outlined in SSPC-SP-1.
(2) Hand or Power Tool Cleaning
1) When approved, power tool cleaning shall be as per SSPC-SP-3 and SSPC-SP-11.
Hand tool cleaning shall be as per SSPC-SP-2.
2) OWNER approval is required on a case-by-case basis prior to substituting power tool

cleaning for abrasive blasting.
3) The sharp edges, such as those occurring in rolled structural members as well as those
resulting from flame cutting, welding, etc., shall be removed by suitable methods such as
a soft grinding wheel before sandblasting and the application of any coat of paint. (Refer
to SSPC-SP5 and SSPC-SPCOM).
(3) Abrasive Blasting Cleaning
1) Prior to abrasive blast cleaning of the steel, remove oil and grease and other
contaminations with a suitable detergent / solvent, according to SSPC-SP1 “Solvent
cleaning”.
2) All welding seams must have a surface finish that ensures that the quality of the paint
system will be maintained in all aspects. The sharp edges should be smoothed and the
radius of the rounding should be approximately 1 mm. Holes in welding seam, undercuts,
cracks, residual flux and weld spatter etc. should be avoided. If found, they must be
remedied by welding and/or grinding.
3) Steelwork (including welding, flame-cutting and grinding) must be finished before the
surface preparation starts.
4) Prior to abrasive blasting, sight glasses, nametags, machinery, electrical fixtures, etc.
which are subject to damage from either the blast or from the abrasive material
remaining shall be protected. If possible, nametags should be installed after painting is
complete. If it is not possible to coat under the tags, their edges shall be sealed with
silicone to prevent moisture accumulation.
5) Blasting shall be accomplished so that the previously-painted surfaces will not be

contaminated by abrasive or blast wastes.
6) Only dry steel grits, silica sand and aluminum silicate grit-type abrasives shall be used
(refer to ISO 8504). The abrasive shall comply with government regulations. The
abrasive shall be used in accordance with HEMPEL’s Specifications and shall contain no
harmful impurities, such as salt. Beach sand or rounded river sand is not acceptable.
7) All steel surfaces shall be abrasive blasting to obtain:
Table 6.1-2 Steel Surface Blasting Treatment

Item Description
6-3
Cleanliness “Sa 2.5” according to ISO 8501 or “Near White Blast

Cleaning”- SSPC SP No.10.
Roughness N9a to N10a (Ra = 6-12.5 micron) - Rugotest No.3,
Keane-Tator Surface Compactor, 2-3 mils segments
(average maximum peak to valley roughness 50-75
micron).
Dust condition Should be below No.3 scale as per ISO 8504 or HEMPEL
code of practice No. 9501-1.
8) Surfaces shall not be abrasive blast cleaned when the ambient or the substrate
temperature is less than 3°C above the dew point temperature. Blast cleaned surfaces,
which show evidence of rust bloom or has been left uncoated overnight, shall be
re-cleaned to the specified degree of cleanliness.
9) Steel surface slivers, laminations, laps, scabs or seams exposed by blasting shall be
repaired on any portion of the steel to be painted prior to coating. Such area shall be
re-blasted prior to coating.
10) No inhibitive washes intended to prevent rusting shall be used after blasting.
11) Welding undercuts and porosities shall be repaired by welding or grinding. No organic
filler materials are allowed.
12) When the abrasive blasting is completed, remove all grits and dust.
13) Surfaces, which are impractical to blast clean may be power tool or hand tool cleaned.
Power tool cleaning shall be in accordance with SSPC-SP 11 or 3, listed in order of
preference. Hand tool cleaning shall be as per SSPC-SP-2.
(4) Galvanized Surface
1) All conduit and conduit fittings, whether internal or exposed, shall be painted in addition
to their purchased galvanized finish.
2) Galvanized walkway, stair, and ladder components should not be painted.
3) All galvanized surface to be painted shall receive one coat of HEMPEL’S WASH
PRIMER 15200 reinforced etch primer containing phosphoric acid and
corrosion-inhibitive pigment at 5 microns dry film thickness.
4) The surface shall then be coated with primer HEMPADUR 45150 and HEMPATHANE
55210 as defined by its location.
6.1.4 SHOP PRIMER
(1) Surface preparation
1) All steel plates, bars etc., which are to be coated with shop-primer, must be abrasive
blasted to Sa2.5 and surface profile equivalent to Rugotest No3 N9a to N10a. Also refer
to Paragraphs 6.1.3(3).
2) When the abrasive blasting is completed, remove all grits and dust.
6-4
(2) When the treated surface is dry and free from oil, dust, etc. the shop-primer HEMPEL’S SHOP
PRIMER 15890 should be applied by airless spraying machine immediately on the automatic
line. The dry film thickness (DFT) shall be 20 microns. (refer to the application procedure in
HEMPEL’S SHOP PRIMER 15890 Product Data)
6.1.5 PAINT APPLICATION
(1) General Application Requirements.
1) Surfaces to be coated shall be clean, dust-free, and dry before the application of any
coat of paint and shall meet the requirements for applicable hand, power tool or abrasive
blasting surface preparation before priming.
2) The specified coating system primer shall be applied within 4 hours from the moment the
surfaces are cleaned, and before rusting, discoloration, or surface contamination occurs.
3) Painting done outdoors shall be done in daylight hours and completed at least one hour
prior to sunset. Indoor painting is allowed 24 hours a day if the specified metal and the air
temperature and relative humidity requirements are met inside the building at all times
during preparation, painting and curing, and sufficient lighting is available.
4) Coatings shall be applied under the environmental conditions prescribed in the pertinent
HEMPEL’s product data sheets.
5) No coating shall be applied:
●On wet surfaces,

●When the surface temperature is less than 3°C above the dew point.
●When the ambient or surface temperatures are below the HEMPEL’s recommended
temperature for application and curing.
●When the wind speed exceeds 7 meters per second (15 miles per hour)
●Humidity is 80% or more.
6) Coating materials shall be furnished in the original packing, clearly identifiable, and shall
be kept covered, clean and protected. Materials older than HEMPEL’s recommended
shelf life shall not be used.
7) All components shall be thoroughly mixed for the time recommended in the HEMPEL’s
data sheets. All mixing shall be done in clean containers, free from traces of grease,
other paints or contaminants. Containers shall be kept covered to prevent contamination
by dust, dirt or stain. Paint shall be mechanically mixed in full batches. Partial mixes are
not acceptable.
8) Recommended pot life shall not be exceeded. When this limit is reached, the spray pot,
hoses, pumps shall be emptied and cleaned, and new material should be used.
9) Care shall be exercised to prevent overspray, spillage or application of coatings to

surfaces for which they are not intended. Skips, sags, and drips are to be repaired.
10) Coatings shall be applied in no less than the number of coats specified and shall have
individual coat dry film thickness not less than the minimum thickness specified. Wet film
6-5
thickness needs to be verified at the start of work (until the painter is familiar with the
paint and work) with a wet film thickness gauge. Thickness requirements shall be met
with each coat and total thickness shall not be “made-up” in any one coat.
11) All coating applied shall be free of defects such as runs, sags, pinholes, voids and
bubbles.
12) All coatings shall be allowed to dry for at least the minimum time recommended (see the
attached working specification), considering the temperature and the humidity, before
applying the succeeding coats.
13) Maximum recoating interval time shall be as per HEMPEL’s recommendations. When the
maximum overcoat time has been exceeded, it needs to perform additional surface
preparation. This operation includes but not limited to hand sanding, pressure washing,
mist coat application, degreasing or re-blasting.
14) Each coat (primer, intermediate and topcoat) shall be inspected by the yard’s Q.C. and
can be inspected by the owner / HEMPEL’s coating advisor before applying further
coats.
(2) Spray Application
1) The applicators shall be skilled in the proper application technique for each coating.
Proper equipment, as per prescription in the HEMPEL’s data sheets, shall be used.
2) Spray guns, lines, and pressure pots shall be cleaned prior to adding new material. The
air caps, nozzles and needles shall be those recommended by HEMPEL for the material
being sprayed.
3) Moisture traps or separators shall be installed between the air supply and the pressure
pot. Drain valve must be kept open slightly to permit continuous draining of any
condensate during operations.
4) Operating pressures shall comply with HEMPEL’s recommendation. All pressure pots
shall be equipped with pressure regulators and gauges.
5) Paint shall be applied in a uniform layer, with 30% overlapping of the previous pass.
During application, the spray gun shall be held perpendicular to the surface being
painted.
(3) Brush or Roller Application
1) All welds, which cannot be properly spray coated shall be brush or stripe coated with the
same coating before applying successive spray operation.
2) Brushes shall be of a style and quality that will enable proper application of the coating.
3) Brushing shall be done so that a smooth coat even in thickness will be obtained. When
applying HB coatings with a brush, two coats may be required to achieve the specified
DFT.
(4) Application of Inorganic Zinc Primer
6-6
1) Inorganic zinc may be applied by either conventional spray application (air spray) or
airless spray application. If airless spray is to be used, frequent checks must be taken
for the wearing of the parts to ensure proper operation. Inorganic zinc shall be
continuously mixed during the application by mechanical agitation.
2) Inorganic zinc primers shall be applied in a full and wet coat which allows outflow. This is
to prevent dry spray which gives an excessively porous surface, lowers coating life and
makes top coating difficult.
3) The minimum dry film thickness of inorganic zinc primer shall be 75 microns. In order to
prevent mud cracking, do not apply over 130 microns. The defective coating (mud
cracking) needs to be removed by blasting and the area recoated to the specified
thickness. Frequent checks of the film thickness must be made and immediate action
must be taken should low DFT be observed.
4) The applicator shall avoid situations where overlapping of inorganic zinc will be
necessary. With prior owner approval, an overlap of 150 mm or less will be permitted
when starting to paint an unpainted area after the inorganic-zinc in an adjacent area has
been allowed time to cure. The blast preparation of the uncoated area shall be brought
into the existing inorganic-zinc. If the inorganic-zinc has been exposed to the
environment and has formed salts or become contaminated, it should be washed with
high-pressure fresh water prior to blast cleaning.
5) Zinc salts as a result of the weathering of inorganic zinc primer should be removed
/cleaned with a fresh water jet before the application of subsequent coatings.
6) When inorganic zinc is over coated with an organic epoxy intermediate, it may be
necessary to apply a mist coat of the organic epoxy before applying a full coat. This will
help reduce substantially the amount of gassing associated with over coating inorganic
zinc with epoxies.
(5) Application of exterior intermediate coat
1) When the inorganic zinc coating has been inspected and accepted, carry out general a
cleaning by means of dry and clean compressed air blowing method or other methods.
The cleaned surface must be dry and free of dust, oil, etc.
2) Carry out stripe coating on all corners, welding seams, sharp edges, hidden areas, etc.
by brush application.
3) At the allowed recoating interval, apply the HEMPADUR 45150 by airless spray, using
the mist coat spraying technique on top of the inorganic zinc surface and then build up
the required dry film thickness of 120 microns as indicated in painting system table II.
(6) Application of exterior top coat
1) When the intermediate coating has been inspected and accepted, carry out a general
6-7
3) At the allowed recoating interval, apply the HEMPATHANE 55210 TOP COAT by airless
spray with a dry film thickness 50 microns as indicated in painting system table II.
(7) Application of interior primer/top coat
1) When the surface preparation has been inspected and accepted, carry out a general
3) Apply the HEMPADUR PRIMER / TOP COAT 45150 by airless spray with dry film
thickness 125 microns as indicated in painting system table III.
6.1.6 INSPECTION
(1) All work should be subjected to inspection. The inspectors shall be given advance notice prior
to the start of surface preparation or coating application so that they can witness the work.
(2) Work shall not proceed without the approval of the inspectors of each inspection hold points
defined below. The inspector shall ensure that all necessary inspections are carried out at
each hold point. The inspection hold points are as follows:
1) Completion of surface preparation, prior to primer application.
2) Completion of application of each coat (primer, intermediate and topcoat).
3) Holiday detection and repair.
4) Final acceptance of completed coating work.
(3) Scaffolding - Beam clamps or any other equipment which will interfere with or damage coating
shall not be used. Building yard shall provide safe accesses to all areas for inspections by the
inspector.
(4) Prior to final coating acceptance, the entire painted surface shall be cleaned with fresh water.
If necessary, a finish coat may be applied to areas stained and contaminated by grinding, weld
spatter, general traffic, etc. Areas contaminated by grinding, weld spatter, and other particulate
contamination shall be lightly hand-sanded to dislodge particulate prior to coating.
(5) HEMPEL’s Representatives.
HEMPEL’s representatives shall have access to the work site during the progress of the work
to perform any inspection and testing deemed necessary to ensure that the coatings are
properly applied.
6.1.7 MISCELLANOUS
(1) External / Internal Galvanized
6-8
1) 1 coat of HEMPEL’S WASH PRIMER 15200 reinforced etch primer containing

phosphoric acid and corrosion-inhibitive pigments at 5 micron dry film thickness.
2) Apply by airless spray 2 full coats of HEMPADUR Hi-Build 45150 at 75-micron DFT per
coat. Total DFT is 150 microns.
3) Apply by airless spray 1 full coats of HEMPATHANE TOPCOAT 55210 polyurethane

finish or similar approved at 50-micron DFT in the shade determined by the owner.
(2) Stainless Steel
Stainless steel should not be painted.
(3) Non-Ferrous material
Non-ferrous materials need not to be painted.
(4) Machined surfaces
Machined surfaces are to be masked prior to painting.
(5) Faying Surface
Apply HEMPEL’S GALVOSIL 15700 at 75-microns DFT.
6.1.8 REPAIR/TOUCH-UP
(1) External Steelworks
When the coating is damaged down to the steel, spot cleaning is necessary:
1) For areas larger than 0.25 square meters (if the width of the area is over 0.5 meter), the
area shall be isolated, blasted to Sa 2.5 / SSSPC - SP - No. 10 in. After the metal surface
has been cleaned, the edge of the surrounding coating shall be feather-edged to remove
all the cracked, loose or damaged coatings. Feather-edging shall be accomplished by
power or hand-sanding with a grit wheel or sandpaper. The prepared surface shall be
free of loose, burnt, or blistered coatings. Carry out touch-up coating procedure with
inorganic zinc followed by intermediate and top coat.
2) For areas smaller than 0.25 square meters, use power tool cleaning and apply
HEMPADUR PRIMER 45150 at 125-micron DFT and followed by top coat.
(2) Internal Steelworks
Whenever possible, surface preparation must be restored to the degree as originally

specified, or as per hand /power tool standards. Apply touch-up coating with airless spray
(large areas) or with brush (small areas) HEMPADUR 45150 at 125-micron DFT. If the
application is brush, the paint should be applied in two or more coats to achieve the specified
total DFT of 125 microns.
6.1.9 WORKING SPECIFICATION
Hempel should provide the applicator with working paint specifications which define the
minimum/maximum over-coating intervals for each and every coating within each coating system.
6-9
The working paint specifications shall further define the over-coating intervals in relation to the
temperature range at which the coating is to be carried out.
6-10
6.2 PAINT INSPECTION/REPAIR INSTRUCTION ............................................... 6-12

6.2.1 Aging or deterioration of coating and judging standard for repair. ............................................. 6-12
APPENDIX I: PAINTING SYSTEM .............................................................................................................. 6-15
APPENDIX II: EUROPEAN RUST SCALE ................................................................................................ 6-17
6-11
6.2 PAINT INSPECTION/REPAIR INSTRUCTION
The following passages describe the inspection and repair procedure for the painting system of
the crane.
6.2.1 Aging or deterioration of coating and judging standard for repair.
(1) Rust spreading throughout the steel surface
In some cases, the coating can be removed with the primer in a wide area. In such a case, the
rust will eat the steel to make a hole.
Judgment for repainting:
Consider repainting the coating when the above mentioned defect is found.
(2) Peeling of the coating
1) Peeling of the whole coating due to insufficient primer adhesion to the steel surface.
2) Peeling of the top coating due to insufficient adhesion between the top coating and the
intermediate coating.
3) Peeling of the coating due to cracks.
4) Peeling of the coating due to poor preparation for painting.

If a straight line can be drawn with the tip of a drill bit applied on a coating, the coating is
considered to be in good condition. If the coating is peeled off, repainting is required.
(3) Deterioration of coating
The coating may be easily removable due to external impacts and internal dissolution of the
coating itself.
1) If the coating is vertically and slightly struck with a steel hammer of 5-10 mm diameter, it
may become easily removable or be actually removed.
2) If the coating is vertically and slightly struck with a steel hammer of 5-10 mm diameter,
the intermediate coating or the top coating may be removed.
Such a coating is considered to be deteriorated and requires repainting.
(4) Cracks in coating
Cracks in a coating occur due to the following causes and in the following ways.
Refer to “Figure 6.2-1 Cracks of the Coating” for diagnosis
1) If the crack occurs soon after painting, the cause possibly lies in improper painting or
poor painting preparation (Applying top coating before the primer dries up etc.)
2) The cause of cracks possibly lies in the aging of the coating caused by the shrink and the
expansion of the painted steel due to temperature change.
6-12
3) In some cases, cracks can occur by sudden temperature change. (Take a special
measure for painting in a cold area where temperature changes excessively.)
Coating Surface
Condition
Coating Section
A B C D
Figure 6.2-1 Cracks of the Coating
A: Cracks only on top coating
B: Cracks only on top coating
C: Cracks only in intermediate coating or primer
D: Cracks in both top coating and intermediate/primer
1) For the State of A and C. No immediate re-painting is required from the view of coating
protection. However, the severe cracks may possibly develop into the state D shown in
Figure 6.2-1.
2) For the State of B. The top coating is ineffective and requires re-painting. Re-paint it
according to the primer protection effect and the rust condition.
3) For the state of D.In most cases, rust also occurs. Repair the painting as soon as
possible.
(5) Swelling of coating
The causes are considered to be the followings:

In a cold area, the whole coating may be removed in frozen state due to the swelling which once
occurred. Refer to “Figure 6.2-2 Surface View of Swelled Coating”. The swelling could be caused
due to:
1) Coating soaked in water
2) A drop of water heated in high temperature on the coating
3) Affected by alkali and acid.
4) Affected by heat
1) If swellings occur in both the top coating and primer and rust may develop, repainting is
required.
2) If the swelling occurs only in the top coating and no rust is found on the steel surface, no
immediate repainting is required.
6-13
Figure 6.2-2 Surface View of Swelled Coating
(6) Discoloring of coating:
1) The coating may be suddenly discolored due to internal and external causes after
painting.
In most cases, the causes are improper selection of paint for the following conditions or
use of inferior paint.
● Condition of steel surface.

● Circumstances of steel structure.
2) The coating gradually becomes discolored as time passes after the paint completion.
1) If the coating terribly discolors comparison with the original color, it requires immediate
repainting.
2) In case of slight discoloring, no repainting is required.
(7) Blurred coating
In general, the coating loses its gloss by 40% in 3-6 months and 60% in 6-12 months after
painting. Therefore the coating will be blurred as time passes.
1) Compare the coating with an original sample.
2) If the coating is only blurred, no repainting is required..
6-14
APPENDIX I: PAINTING SYSTEM
PAINT COLOR AND SPECIFICATION
Components 部件 Color code 颜色代号
Main structure 主结构 Maersk blue，Hempel 30070
Exterior machinery house 机房外表面 White，Hempel 10000
Interior machinery house 机房内表面 White，Hempel 10000
Exterior cab 司机室外表面 White，Hempel 10000
Interior cab 司机室内表面 White，Hempel 10000
Exterior check room 理货室外表面 White，Hempel 10000
Interior check room 理货室内表面 White，Hempel 10000
Headblock 吊具上架 Manufacturer’s Standard
Spreader 吊具 Manufacturer’s Standard
Handrail&Platform structure 扶手栏杆, 平台 Maersk blue，Hempel 30070
Sheave 滑轮 Yellow，RAL1003
Buggie （including equalizer beam，gantry，motors Red，RAL3020
wheel brakes and reducers）
Spreader cable reel（including gearbox and motor） Supplier standard
Side of Stairs 斜梯 Maersk blue，Hempel 30070
floors 室内地板 Gray,Hempel 12340
Others not specified above 其他上面未提到的部件 Manufacturer’s Standard
All values of film thickness are minimum DFT!
6-15
I. EXTERIOR EXPOSED SURFACES PAINT SYSTEM FOR ORGANIC ZINC PRIMER

SYSTEM.
Coat Product Color Minimum dry film thickness
(microns)
Pre-constructio Hempel Shop Contrasting 20
n Shop primer 15890(no pb)
Prime Coat Hempel Zinc Contrasting 60
17360(no pb)
Intermediate Hempel Contrasting 200
45880/P(no pb)
Finish Hempel To be advised 60 (100 max)
55610(no pb)
Total 320 (excluding shop
primer)
II. EXTERIOR EXPOSED SURFACES PAINT SYSTEM FOR INORGANIC ZINC PRIMER
SYSTEM
(microns)
n Shop primer Primer
Prime Coat Hempel Contrasting 60
Finish Hempel To be advised 60 (100 max)
primer)
III. INTERIOR EXPOSED SURFACES ORGANIC ZINC PRIMER PAINT SYSTEM
(microns)
17360(no pb)
Finish Hempel White 100
45880/P(no pb)
primer)
IV. INTERIOR EXPOSED SURFACES PAINT SYSTEM FOR INORGANIC ZINC PRIMER
SYSTEM
(microns)
6-16
Pre-constructio Hempel Contrasting 20

n Shop primer
Finish Hempel White 100 (100 max)
primer)
V. MACHINERY ROOM, ELECTRICAL ROOM AND CAB INTERIORS INTERIOR
EXPOSED SURFACES PAINT SYSTEM
(microns)
Pre-constructio Hempel Contrasting 20
Prime Coat Hempel Contrasting 50
17360(no pb)
Coat 45880/P(no pb)
Finish Hempel To be advised 50
55610(no pb)
primer)
APPENDIX II: EUROPEAN RUST SCALE
Re0 Re1 Re2 Re3
Re4 Re5 Re6 Re7
The approximate percentages of degree of rusting corresponding to the photo-graphs are shown
as follow.
6-17
1) These percentages apply only to visible rust which has broken the paint coating.
2) These percentages figures are intended for the use of those who wish to refer to percentage
as well as to the photo-graphs.
Re1 0.05% Re5 8%

Re2 0.5% Re6 15~20%
Re3 1% Re7 40~50%
Re4 3%
6-18
Emergency Operating Instructions
VOLUME 3
7 EMERGENCY OPERATING INSTRUCTIONS ........................................................................7-1
7.1 BOOM HOIST EMERGENCY OPERATION ..........................................................................7-3

7.1.1 DESCRIPTION ...........................................................................................................................7-3
7.1.2 PREPARATION ..........................................................................................................................7-3
7.1.3 PROCEDURE .............................................................................................................................7-3
7.1.4 RESTORE ...................................................................................................................................7-5
7.2 TROLLEY EMERGENCY OPERATION .................................................................................7-8
7.2.1 DESCRIPTION ...........................................................................................................................7-8
7.2.2 PREPARATION ..........................................................................................................................7-8
7.2.3 PROCEDURE .............................................................................................................................7-8
7.2.4 RESTORE ...................................................................................................................................7-9
7.3 MAIN HOIST EMERGENCY OPERATION.......................................................................... 7-11
7.3.1 DESCRIPTION ......................................................................................................................... 7-11
7.3.2 PREPARATION ........................................................................................................................ 7-11
7.3.3 PROCEDURE ........................................................................................................................... 7-11
7.3.4 RESTORE .................................................................................................................................7-12
7.4 BREAKAGE OF TROLLEY WHEEL/SHAFT WHILE TROLLEY IS OVER VESSEL...7-13
7.5 MAIN CRANE POWER FAILURES WITH SPREADER INSIDE VESSEL CELL ...........7-14
7.6 GANTRY DRIVE AXLE FAILURES WHILE CRANE IS GANTRYING ...........................7-15
7.7 HYDRAULIC SYSTEM OPERATION ...................................................................................7-18
7.7.1 HOW TO OPEN THE WHEEL BRAKE? ...........................................................................................7-18
7.7.2 OPEN THE EMERGENCY BRAKE MANUALLY...............................................................................7-19
7.7.3 HOW TO RELEASE THE PRESSURE OF TROLLEY AND CATENARY TROLLEY TENSIONER CYLINDER?
...........................................................................................................................................................7-19
7.7.4 THE FAILURE OF HYDRAULIC STATION ON THE GIRDER ............................................................7-20
7.7.5 HOW TO OPERATE THE CRANE AFTER SNAGGING? ....................................................................7-21
7.7.6 HOW TO SET A NEW HOME POSITION OF THE T/L/S DEVICE? ....................................................7-21
7.8 EMERGENCY OPERATION OF THE ELEVATOR .............................................................7-23
7.8.1 A LOSS OF POWER .....................................................................................................................7-23
7.8.2 EVACUATING PASSENGERS FROM THE ELEVATOR’S CAR ..........................................................7-23
7.9 EMERGENCY ESCAPE FROM THE OPERATOR’S CAB .................................................7-25
7.9.1 ESCAPE FROM BOOM AND GIRDER WALKWAY ...........................................................................7-25
7.9.2 ESCAPING FROM MACHINERY HOUSE ........................................................................................7-26
7-I
7 EMERGENCY OPERATING INSTRUCTIONS
THE EMERGENCY OPERATION MUST OPERATE CAREFULLY.
NO PERSONS MAY REMIAN WITHIN THE HAZARD AREAS DURING

THE EMERGENCY OPERATION!
THE MAINTENANCE PERSON SHOULD OPERATE THE CRANE

INSTEAD OF THE CRANE OPERATOR ACCORDING TO THIS MANUAL
STEP BY STEP!
WHEN THE EMERGENCY OPERATION IS COMPLETED, THE CRANE

MUST BE SET BACK TO ITS NORMAL CONDITION!
DANGER OF FALLING!
DANGER OF TRIPPING!
7-1
7.1 BOOM HOIST EMERGENCY OPERATION ..........................................................................7-3

7.1.1 DESCRIPTION ...........................................................................................................................7-3
7.1.2 PREPARATION ..........................................................................................................................7-3
7.1.3 PROCEDURE .............................................................................................................................7-3
7.1.4 RESTORE ...................................................................................................................................7-5
7-2
7.1 BOOM HOIST EMERGENCY OPERATION
7.1.1 DESCRIPTION
If the instance is like any one of the following descriptions and can’t be solved in a short period,
boom emergency drive may be operated:
(1) The main crane power failure (refer to section 7.5);

(2) The PLC failure;
(3) The Profibus communication failure;
(4) The drive power failure;
(5) The emergency brake hydraulic system failure;
(6) The motor power loss;
(7) The driver failure;
(8) And any other problem that may be relevant to operation.
7.1.2 PREPARATION
Before operating the boom emergency drive, make sure that:
(1) The trolley is at its parking position and there are no electrical interlocks in the emergency
modes.
(2) All personnel and tools must be removed from the boom before the boom is raised.
(3) All personnel under the crane must leave away.
(4) At least two persons are required for this operation. One will operate the drive in the
machinery house, and the other (the spotter) must observe any abnormal conditions with
radios capable of communicating with the person running the emergency drive.
In emergency mode, the EMERGENCY STOP push buttons, the up stop limit
switches and cam switch(down stop) in both directions and the boom hoist
over-speed limit switch are still in function, but all other limit switches such
as the up over-travel limit switch and the smart slowdown switches, etc. will
not function.
7.1.3 PROCEDURE
To operate the boom emergency drive device (as shown in Figure 7.1-1), please follow the
procedures below:
Figure 7.1-1 The Boom Emergency Drive Device
7-3
(1) Press the “E-stop” to ensure control power will not be put on
(2) As shown in Figure 7.1-2, switch the boom hoist drive to emergency drive mode by engaging
the quick clutch:
1) Lift the Clutch Hand wheel○

1 to raise the Locking pin,
2) shift the Clutch Handle○

2 to the engaged position and put down the Hand wheel○
1 to
settle the Locking pin.

3) This will let the emergency drive limit switch be energized.
For the inside condition of the clutch engagement or disengagement, refer to Figure 7.1-3. If
the teeth rings of the clutch are not aligned and the clutch can not be engaged, a screwdriver
can be used with care to rotate the motor shaft a little bit from the cooling fan end of the
motor.
Figure 7.1-3 Engagement and Disengagement

Figure 7.1-2 Operation of the Clutch Of the Clutch
(3) Release the “E-stop”. Activate the local control panel emergency drives by turn the “MOS
disable/enable” key switch to “enable” position. The position of the station is shown in Figure
7.1-4.
(4) Turn the “drive select BH/MH/TR” on the local control panel to “BH”
(5) Inching the “up/forward”, “down/reverse” pushbutton to test all connection was doing correctly,
and the brake is working fine. Before this, make sure the brake has opened and the drum
won’t interfere with other things.
(6) Move the motion for short distance and stop the emergency operation. Observe if the starting
and stopping work fine or not.
(7) If everything is fine, start the emergency operation.
7-4
Figure 7.1-4 Location Of The Emergency Operating stations
(8) Push and hold the “up/forward” pushbutton to raise the boom, or push and hold the
“down/reverse” pushbutton to lower the boom.
(9) When leaving your thumb away from the “up/forward” or “down/reverse” pushbutton at any
time, the boom emergency drive will stop.
(10) Three “EMERGENCY STOP” pushbuttons are located in the machinery house. In any
emergency case that needs to stop the boom motion immediately, please hit the
“EMERGENCY STOP” to stop the emergency operation at once. Then all the brakes will be
set.
(1) The person who operates the boom emergency drive must not leave the
boom operating station during the boom emergency operation in order to
respond immediately to any happenstance.
(2) In an emergency case that needs to stop the motion immediately, please
hit any “EMERGENCY STOP” pushbutton near you to stop the motion.
7.1.4 RESTORE
When boom emergency drive operation is completed, the following steps shall be taken to set it
back to its normal case:
(1) The key-switch “MOS disable/enable” and “emergency drive disable/enable on the
emergency operating panel must be set to “disable”. And keep the key in a safe place.
(2) Switch the boom hoist drive to the normal drive mode
1) Lift the Clutch Hand wheel○

1 to rise the Locking pin,
2) Shift the Clutch Handle○

2 to the disengaged position and put down the Hand wheel○
1
to settle the Locking pin, see Figure 7.1-2.
3) This will let the normal limit switch be activated.
(3) Turn off the control power.
7-5
(4) At this moment, the boom position is lost in the PLC and the boom hoist operation is available
in the slow speed mode only. The boom hoist has to be re-homed to recover boom hoist
motion. There is one boom home positions. At the boom full raised position (80°).
7-6
7.2 TROLLEY EMERGENCY OPERATION .................................................................................7-8

7.2.1 DESCRIPTION ...........................................................................................................................7-8
7.2.2 PREPARATION ..........................................................................................................................7-8
7.2.3 PROCEDURE .............................................................................................................................7-8
7.2.4 RESTORE ...................................................................................................................................7-9
7-7
7.2 TROLLEY EMERGENCY OPERATION
7.2.1 DESCRIPTION
If the instance is like any one of the followings and can’t be solved in a short period, trolley
emergency drive may be operated:

(3) The profibus communication failure;
(5) The Trolley AC motor or AC motor vent fan failure;
(6) The trolley drive failure;
(7) And any other problem that may be relevant to operation.
7.2.2 PREPARATION
Before operating the trolley emergency drive, make sure that:
(1) The boom is at its level position, as there are no electrical interlocks in the emergency
modes.
(2) The spreader must not be in the cell of the vessel and must be higher than the sill beams.
(3) All personnel and tools must be removed from the trolley before the trolley moves.
machinery house, and the other (the spotter) must observe the abnormal conditions with
radios capable of communicating with the person running the emergency drive.
During the emergency mode, EMERGENCY STOP push buttons and the
over-travel limit switches in both directions are still in function, but all
other protections such as the forward stop switch, the forward slowdown
check switch, the reverse stop switch, the reverse slowdown check switch
etc. will not function.
7.2.3 PROCEDURE
To operate the trolley emergency drive, please follow the procedures described below:
7-8
Figure 7.2-1 Trolley Emergency Drive Device
(1) Repeat the steps (1)~(3) in section 7.1.3.

(2) Turn the “drive select BH/MH/TR” on the local control panel to “TR”
(3) Repeat the steps (5)~(10) in section 7.1.3 except that the motion is the trolley moving.
(1) The person who operates the trolley emergency drive must not leave the
trolley emergency operating station during the trolley emergency operation
in order to respond immediately to any happenstance.
hit any “EMERGENCY STOP” pushbuttons near you to stop the motion.
7.2.4 RESTORE
When the trolley emergency drive operation is completed, the following steps shall be taken to set
it back to the normal case:
(1) Repeat the steps (1)~(3)in section 7.1.4.

(2) At this moment, the trolley position is lost in the PLC and the trolley motion is available in slow
speed mode only. The trolley has to be re-homed to recover trolley motion. The trolley home
position is at the landside end stop position. To home the trolley position, just move the trolley
from the operator’s cab to go landside end stop.
Attention must be paid to the situation that the trolley speed may
be increased suddenly once the trolley position has been homed!
7-9
7.3 MAIN HOIST EMERGENCY OPERATION.......................................................................... 7-11

7.3.1 DESCRIPTION ......................................................................................................................... 7-11
7.3.2 PREPARATION ........................................................................................................................ 7-11
7.3.3 PROCEDURE ........................................................................................................................... 7-11
7.3.4 RESTORE .................................................................................................................................7-12
7-10
7.3 MAIN HOIST EMERGENCY OPERATION
7.3.1 DESCRIPTION
If the instance is like any one of the followings and can’t be solved in a short period, main hoist
emergency drive may be operated:

(3) The profibus communication failure;
(5) The emergence brake hydraulic system failure;
(6) The main hoist motor failure;
(7) The two hoist drives failure;
(8) And other problems that may be relevant to the operation.
Spreader cable reel will not run during the main hoist emergency motion! A
lot of attention must be paid to the spreader cable during this motion.
7.3.2 PREPARATION
Before operating the main hoist emergency drive, make sure that::
(1) All personnel and tools must be removed from the trolley before the main hoist moves.
(3) Make sure the spreader cable reel cable not been damaged during the operation. Manually
reel up/ reel down the spreader cable reel cable through the local control panel spreader
cable reel +41P01 on the trolley.
machinery house, and the other (the spotter) must observe any abnormal conditions. The
spotter must be stationed at the ground level or any other places where he can have a clear
view of the spreader cable with radios capable of communicating with the person running the
emergency drive.
In the emergency mode, EMERGENCY STOP pushbuttons, the cam

switch(hoist up end stop and hoist down end stop) in both directions and
the main hoist over speed limit switch are still in function, but all other limit
switches such as the up over travel limit switch and the smart slowdown
check switches, etc. will be in non-function.
7.3.3 PROCEDURE
To operate the main hoist emergency drive, please follow the procedures below:
7-11
Figure 7.3-1 Main Hoist Emergency Drive Device
(1) Repeat the steps (1)~(3) in section 7.1.3.

(2) Turn the “drive select BH/MH/TR” on the local control panel to “MH”
(3) Repeat the steps (5)~(10) in section 7.1.3 except that the motion is the main hoist moving.
(1) The person who operates the main hoist emergency drive must not leave
the main hoist emergency operating station during the main hoist emergency
operation in order to respond immediately to any happenstance.
hit any “EMERGENCY STOP” pushbutton near you to stop the motion.
7.3.4 RESTORE
When the main emergency drive operation is completed, the following steps shall be taken to set
it back to the normal case:
(1) Repeat the steps (1)~(3)in section 7.1.4.

(2) At this moment, the main hoist position may be lost in the PLC and the main hoist operation is
available in slow speed mode only. The main hoist has to be re-homed to recover the main
hoist motion. To home the main hoist position, just lower the spreader from the operator’s cab
to touch the landside down end stop position.
Lock the coupling anyway in emergency mode because the emergency

motor is coupled to the other axis side of one of the hoist motors so the
complete torque is coming from one Gearside!!!
The chain wheel on the coupling must be dismantled after emergency

operation. Or serious damages to the crane and human may occur!
7-12
7.4 BREAKAGE OF TROLLEY WHEEL/SHAFT WHILE TROLLEY IS OVER

VESSEL
DANGER OF FALLING!
DANGER OF TRIPPING!
In this case, the broken wheel must be removed and a new one must be reinstalled at once.
Please follow the procedures described below:
(1) The crane operator must inform the maintenance person immediately.
(2) Switch the “operation mode” to “maintenance mode”.
(3) If there is a container under the spreader, lower the hoist slowly to unlock this container.
Disengage the twist locks and hoist the spreader all way up slowly.
(4) Clean all the obstruction on the trolley rail.
(5) Run the trolley backward slowly to its parking position.
(6) Hoist the boom to the stowage position.
(7) Turn off the control power.
(8) Have the broken wheel replaced followed the maintenance manual in Chapter 4.
Major Steps are illustrated as follows:
 As illustrated in the Figure 7.4-1, install a 10T jack under jacking pads which are on the four
corners of the trolley frame (near the trolley wheel). The gap between the top of the rail and
the bottom of jack point is about 300mm. Lift the truck by 10 mm.
 Put a slap block between the trolley frame and rail top as shown in Figure 7.4-1.
Figure 7.4-1 Trolley Frame Jacking-up
 Remove the jack and tie the wheel to the truck with wires in case it falls down.
7-13
 Drive the trolley under the service crane at the middle of the girder slowly. During the process,
make sure the rope not winding on the wheel or rubbed by the wheel.
DANGER WITH JACKING DEVICE! MAKE SURE THAT THE HYDRAULIC

JACK IS NOT LEAKING AND IS NOT LOWERING PRESSURE!
 Disconnect the truck with defective wheel or shaft and lift it up with the overhead bridge crane
and transfer to the MH and lower it to the ground
 Disassemble the truck at the workshop. For detailed components of trolley wheel assembly,
please refer to the Figure 7.4-2.
Figure 7.4-2 Trolley wheel and axle
1 Trolley Wheel 2 Outer Space 3 Cover 4 Cover 2 5 Oil Nozzle 6 Inner Space
7 Sealer 8 Bearing 9 Sealer 10 Adjusting Bushing 11 Axle 12 Cover 3
7.5 MAIN CRANE POWER FAILURES WITH SPREADER INSIDE VESSEL CELL
If the main crane power fails, the first thing to do is to find out the reason of the failure. If the
problem can not be fixed in a short time by a qualified person, temporary power is needed from
the wharf or adjacent crane to provide power to the power failed crane, which can provide the
crane with the power necessary for the emergency operation. The temporary power cable can
endure the power to the crane and should have a plug at each end. When needed, one connects
the main power on the wharf or adjacent crane and the other connect the crane.
For safety reason, shut off and lockout/tagout the main power disconnect
before wiring.
7-14
The phase sequence may not be same as the original, and it must be
observed and corrected before any motion started.
If this power is available, please follow Section 7.1, 7.2 and 7.3 for the emergency operations.
7.6 GANTRY DRIVE AXLE FAILURES WHILE CRANE IS GANTRYING
If the gantry drive axle fails while crane is gantrying, please push the
“emergency stop” nearest you to stop the crane motion and call the
maintenance person at once.
After crane has stopped finally, start to jack up the truck where the drive axle failures.
To jack up the truck where the drive axle failure, please follow the procedures below shown in
Figure 7.6-1.
Figure 7.6-1 wheel replacement procedure
(1) The operator must inform the maintenance personnel first;
(2) Set the crane to maintenance mode instead of normal operation mode and to operate in the
operation station on the ground;
(3) Clear all the obstacles on the rail;
7-15
(4) If there’s a container under spreader, lower it slowly on the ground and lift up the spreader;
(5) Drive the trolley to the nearest parking position and hoist the boom up to reduce the effects to
other cranes;
(6) Set two hydraulic jacks under the bearing seats of the corner where the wheel or axle is to be
replaced as shown in Figure 7.6-1.
The capacity of the hydraulic jack should be greater than the value in the following table.
Table 7.6-1 Jacking up Counter Force
SEA SIDE LAND SIDE
Jacking up Boom up 50 75 t/Wheel
Counter force Boom down 70 55 t/Wheel
(7) Use the hydraulic jack to raise the wheel to a position 60 mm- 70mm (2.36in-2.75 in) above
the original position.
(8) Weld a support to connect the bogie and the beam at the position as shown in Figure 7.6-1.
(9) Carefully remove the hydraulic jack after verifying the correct placement of the support.
(10) Drive the gantry slowly away and repair the broken part or fit a new one.
The process above takes the driven wheel as an example. As to the driving wheel, the motor and
reducer should be dismantled first. Refer to chapter 4.
Danger with jacking device! Make sure that the hydraulic jack is
not leaking and not lowering pressure!
In a workshop, dismantle or re-assemble the gantry wheel according to FIGURE 7.6-2.
Figure 7.6-2 Gantry Wheel Explode
7-16
7.7 HYDRAULIC SYSTEM OPERATION ...................................................................................7-18

7.7.1 HOW TO OPEN THE WHEEL BRAKE? ...........................................................................................7-18
7.7.2 OPEN THE EMERGENCY BRAKE MANUALLY...............................................................................7-19
7.7.3 HOW TO RELEASE THE PRESSURE OF TROLLEY AND CATENARY TROLLEY TENSIONER CYLINDER?
...........................................................................................................................................................7-19
7.7.4 THE FAILURE OF HYDRAULIC STATION ON THE GIRDER ............................................................7-20
7.7.5 HOW TO OPERATE THE CRANE AFTER SNAGGING? ....................................................................7-21
7.7.6 HOW TO SET A NEW HOME POSITION OF THE T/L/S DEVICE? ....................................................7-21
7-17
7.7 HYDRAULIC SYSTEM OPERATION
7.7.1 How to open the wheel brake?
The procedures of opening the wheel brakes

manually are as follows:
(1) Turn the valve (07) clockwise to disconnect the

oil supplying. The location of the valve is in
Figure 7.7-1
(2) Rock the handle to and fro several times, then handle pump
the brake will be opened.
(3) After opening the brake, turn the valve

(07)counterclockwise, the brake closed and the
system return to normal.
valve
handle
Figure 7.7-1 Gantry Hydraulic Station

(Landside)
Valve (07)
Only if the people are safe and there is no wind can the wheel
brakes be open!
7-18
7.7.2 Open the emergency brake manually
Figure 7.7-2 Operation for hand pump

The valves 18.1 and 23.1 are for main hoist system and 18.2 and 23.2 are for boom hoist system.
When the system is at work, the valves are shown as “normal” condition in Figure 7.7-2. If you
want to open the main hoist drum brake, turn the valves like “circuit I” condition in Figure 7.7-2,
while the boom hoist system is like the “circuit II” condition.
7.7.2.1 The detailed procedures to open the main hoist system drum brake are as follows:
1) Turn the valve 23.1 clockwise to close the oil supply to oil pump and turn the valve 18.1
counterclockwise to open the oil supply of manual operation pump, as shown in condition
“circuit I” of Figure 7.7-2.
2) Rock the handle to and fro several times and the brake can be open
3) After the operation, turn the valves back to “normal” condition.
The system returns to normal.
7.7.2.2 The detailed procedures to open the boom hoist system drum brake are as follows:
1) Turn the valve 23.2 clockwise to close the oil supply to oil pump and turn the valve 18.2
counterclockwise to open the oil supply of manual operation pump, as shown in condition
“circuit II” of Figure 7.7-2.
2) Rock the handle to and fro several times and the brake can be open
3) After the operation, turn the valves to “normal” condition in Figure 7.7-2.
7.7.3 How to release the pressure of trolley and catenary trolley tensioner cylinder?
The releasing process of trolley cylinders and catenary trolley cylinders are the same, so here we
just introduce the releasing process of trolley cylinder.
There are two cylinders for the trolley and the oil supplying pipes are connected. So just find
the releasing valve and open it is OK. The location of the valve is as shown in Figure 7.7-3. The
7-19
valve 2 is the trolley releasing valve and valve 1 is the catenary trolley releasing valve.
Valve 1
Valve 2
Figure 7.7-3 Hydraulic Station On The Girder
Before releasing the pressure, the control of the crane should be off and the signals of cylinder
location limit switches should be bypassed. The bypass of the signal is fulfilled by software, and
should be done by electrical engineer.
7.7.4 The failure of hydraulic station on the girder
If there is something wrong with the hydraulic station on the girder, the crane will lose the function
of anti-snag and T/L/S and also the tensioning of ropes. In that occasion, following steps should
be taken so that trolley can travel under limited speed.
1) Release the pressure first (refer to 7.7.3), then pull the cylinder out for a distance to let the
arm a little more than vertical positions.
2) Put a U-shape bushing between the arm and cylinder, as shown in Figure 7.7-4. Then the
bushing is pressed under the rope tensioning force and won’t fall down.
3) The trolley can be moved slowly and the fault should be solved.
7-20
Figure 7.7-4 U-shape bushing assembly
7.7.5 How to operate the crane after snagging?
When the snagging happens, following procedures should be taken:

(1) First should inform the maintenance personnel and maintenance personnel will check if there
is any damage to the ropes. If there is, remedies must be fulfilled; if there isn’t, the reset
operation can be taken.
(2) Align the marks on the coupling.
(3) Knock the sensor disk back by a plastic hammer.
(4) After checking ropes and other devices and there’s no damages, the maintenance person
turns the key switch “Snag load Reset” on the PLC1 control panel at electric room and keep it
there.
(5) Press the reset button in the cab and the return to normal position.
7.7.6 How to set a new home position of the T/L/S device?
The length of the ropes will change after a period of using, then the home position of T/L/S device
will be reset. The operation can be fulfilled with the “Home Position Normal/Set” key switch on the
local control panel trim/list/skew at back-reach. First reset the control power of the crane from
panel, Choose “Set” key, the current position is set to the new home position and then choose
“Normal” key, the position is saved. The detailed procedures are as follows:
(1) Reset main control in the cab, press the spreader home position button
(2) Lower the spreader until it’s 0.5m above the ground. Turn off the control.
(3) Select “local control disable/enable” key switch at “enable” position to activate panel.
(4) Turn on the control at the panel
(5) Adjust the spreader with the four selector switches “cylinder 1 in/out”, “cylinder 2 in/out”,
“cylinder 3 in/out” and “cylinder 4 in/out” on the station until the spreader is level and isn’t
skew.
(6) After step 5, the current position is the new home position. Then turn the “Home Position
7-21
Normal/Set” key to “Set” position to set the home position and turn the key to “Normal”
position to save it.
(7) Turn off the control and turn back the key switch “local control disable/enable” to “disable”.
(8) When the motions of the cylinders are not enough to adjust the level and square degrees of
the spreader, the rope length on the drum must be adjusted to make the cylinder at middle
position when the spreader is at home position.
7-22
7.8 EMERGENCY OPERATION OF THE ELEVATOR
PLEASE REFER TO ALIMAK’S MANUAL FOR DETAILED AND SPECIFIC

INSTRUCTIONS FOR EMERGENCY OPERATION!
7.8.1 A Loss of Power
It is possible that the lift could suddenly stop, usually due to the
power failures.
If the lift stops between the landings, follow the appropriate

instructions:
(1) Lift the treadle to let the elevator down slowly.
(2) When the elevator gets to the next landings, open the door
and inform maintenance personnel.
 Detailed information please refer to Elevator’s manual.
7.8.2 Evacuating Passengers from the Elevator’s Car Figure 7.8-1 Escaping Handle
EVACUATING PASSENGERS FROM THE ELEVATOR’S CAR

SHOULD BE PERFORMED BY TRAINED PERSONNEL ONLY!
Please refer to the ZPMC manual for the steps to be taken for the following emergency
conditions
 If the passengers cannot be evacuated because of an extreme height difference
 If the car cannot slide down due to tripped safety device
 If the car still cannot slide down – evacuate the passengers through the trap door
7-23
7.9 EMERGENCY ESCAPE FROM THE OPERATOR’S CAB .................................................7-25

7.9.1 ESCAPE FROM BOOM AND GIRDER WALKWAY ...........................................................................7-25
7.9.2 ESCAPING FROM MACHINERY HOUSE ........................................................................................7-26
7-24
7.9 EMERGENCY ESCAPE FROM THE OPERATOR’S CAB
DANGER OF FALLING!
ALL OPERATORS ARE ENCOURAGED TO BE TRAINED ON HOW TO

ESCAPE FORM THE CAB BY USING EMERGENCY METHODS.
The escaping ways are different according to different stopping positions of the trolley. Generally
there are three ways to escape as shown in
Figure 7.9-1 The escaping ways for different trolley stopping position
 Operator’s cab→ Trolley→ Walkway on the boom→ Ground

 Operator’s cab→ Trolley→ Walkway on the girder→ Ground
 Operator’s cab→ Trolley→ Machinery house through the trap doors→ Ground
7.9.1 Escape from boom and girder walkway
In an emergency condition, the operator can escape from the operator’s cab even if the trolley
comes to a halt in a location other than its parking position. A portal aluminum safety ladder is
secured on the trolley in normal operation. In an emergency, this ladder could be used for
emergency escaping.
Figure 7.9-2 Escaping from trolley Figure 7.9-3 Escaping from trolley
(along girder) ( along boom)
Figure 7.9-2 to Figure 7.9-3 show how a trapped operator escapes from the cab in an emergency
7-25
condition when the trolley comes to a halt at any position along the boom and the girder .
7.9.2 Escaping from machinery house
Figure 7.9-4 shows that there are three emergency exit doors located on the machinery house
deck. The locations of these exit doors are particular designed to ensure that the trolley comes to
a halt at any position underneath the machinery house, the operator can make a successful
escape through one of the three emergency exit doors.
Figure 7.9-4 Escape from trolley (Under the machinery house)
When the trolley suddenly stops under the machinery house, the operator should use the portal
ladder equipped on the trolley to open the cover of the hole and climb into the house with the
ladder. The ladder can be stretched out so that you can climb into the machinery house at any
position of trolley frame.
7-26
MAINTENANCE MANUAL
ALGECIRAS, SPAIN
FOUR QUAYSIDE CONTAINER CRANES
____________________________________________________________________
SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

Copyright © 2014.
All rights reserved.

____________________________________________________________________
3261 DONGFANG ROAD, SHANGHAI, CHINA
TEL: 0086-21-58396666
FAX: 0086-21-58399555
http://www.zpmc.com
____________________________________________________________________

Maintenance Manual English ZPMC Gruas de Puerto

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SHANGHAI ZHENHUA HEAVY INDUSTRY CO.,LTD

1. SAFETY ......................................................................................................................................... 1-1

1.1. WARNINGS AND SYMBOLS ............................................................................................... 1-2

1.1. WARNINGS AND SYMBOLS

Warn of ELECTRIC VOLTAGE. Keep hands and body clear

Keep hands clear of the moving

Do not enter, Authorized

Refer to specified sections in the Special information for increasing

Keep away from suspended loads

Refers to information in other

Wear protective clothing

1.2. GENERAL PRECAUTIONS

IT’S ABOUT YOUR SAFETY!

1.3. GENERAL RULES OF CONDUCT AND SAFETY REGULATIONS

IMPORTANT SAFETY PRACTICE!

The following safety rules must be observed strictly in practice:

Precautions during service:

DANGER ZONE MUST BE BLOCKED BY SUITABLE MEASURES.

1.5. SAFETY RULES FOR MAINTENANCE AND REPAIR

BEFORE COMMENCEMENT OF SERVICE WORK THE CONTAINER

1.6. CONDUCT IN CASE OF ACCIDENTS AND EMERGENCY

OPERATION PROCEDURES FOR EMERGENCY SITUATIONS ARE

1.7. ZERO MECHANICAL STATE AND LOCKOUT/TAGOUT PROCEDURE....................... 1-9

1.7.1. INTRODUCTION................................................................................................................... 1-9

1.7. ZERO MECHANICAL STATE AND LOCKOUT/TAGOUT PROCEDURE

LOTO is required whenever servicing, maintenance, or modification is being performed on

LOTO procedures do not apply under the following conditions:

exclusion does not apply and LOTO must be performed.

1.7.3.3. Equipment and Supplies

a) For Valves b) For Electrical Switches c) For Electrical Cabinet

(1) Preparation and Notification

1) Use of written procedure

1.7.4.2. Release from LOTO

1.7.4.3. Temporary Removal of LOTO Devices

1.7.4.4. Emergency Removal of LOTO Devices

1.7.4.5. Tag-Out Only

1.7.4.6. Equipment-Specific Written Procedures

When servicing, maintenance, or modification is performed by a crew, the supervisor may

Non-lockable energy-isolating devices shall be designed or modified to accept a lockout device

(1) All Employees

(1) LOTO Awareness

1.7.7. SUPPORTING REFERENCES AND STANDARDS

Refer to local standards.

An affected employee is an employee or temporary employee under supervision whose job

Energized means connected to an energy source, or containing residual or stored energy.

An energy-isolating device is a mechanical device that physically prevents the transmission or

 Manually operated electrical circuit breakers

 Similar devices that can block or isolate an energy source.

An energy source is any source of electrical, mechanical, hydraulic, pneumatic, chemical,

LOTO is an acronym for lockout/tagout.

Subcontractor means service and maintenance contractors, construction contractors, salvage

Servicing and/or maintenance means workplace activities such as constructing, installing,

APPENDIX B: LOCKOUT/TAGOUT PROCEDURE SELF- ASSESSMENT

Authorized Employee Knowledge

 Can the authorized employee demonstrate knowledge of the energy-isolation verification

 Can the authorized employee demonstrate knowledge of the log-keeping requirements?

 Has the authorized employee received the required training?

Lock and Tag Devices

 Are there an adequate number of locks and tags?

 Are the locks properly labeled?

 Are the danger tags the correct version?