B-Repair Ad Maintenance Manual - Rev0

Operating Manual
Repair and Maintenance

Manual
BOOK 1 B
Ship-To-Shore
Container Gantry Crane
MB MHK 65/70 t x 51/30.5M x 38/15M
CARTAGENA, Colombia
Project No. 1114
Year of construction 2008
10.11.2008 Revision. 0 1 Book 1 B

Repair and Maintenance Manual
Index
1 WARNINGS AND SYMBOLS ................................................................................. 6

2 SAFETY ...................................................................................................................... 7
2.1 GENERAL INFORMATION ..............................................................................................................7
2.2 GENERAL RULES OF CONDUCT AND SAFETY REGULATIONS...........................................8
2.3 SAFETY AND ACCIDENT PREVENTION......................................................................................9
2.3.1 USE AS PER SPECIFICATIONS ..........................................................................................................9
2.4 OPERATING THE CRANE - GENERAL REMARKS..................................................................10
2.4.1 MAINTENANCE AND REPAIR PERSONNEL.................................................................................10
2.4.2 DANGER ZONE ..................................................................................................................................11
2.4.3 SUPERVISION ACTIVITIES..............................................................................................................11
2.4.4 EFFECTIVENESS OF SAFETY DEVICES ........................................................................................11
2.5 CONDUCT IN CASE OF ACCIDENTS...........................................................................................12
2.6 DUTIES DURING AND AFTER MAINTENANCE AND REPAIR WORK ...............................12
2.7 EMERGENCY POSSIBILITIES ......................................................................................................13
3 INTRODUCTION.................................................................................................... 14
4 TESTS AND INSPECTIONS ................................................................................. 15
4.1 TYPE, SCOPE AND PERFORMANCE OF THE INSPECTIONS ...............................................15
4.1.1 INSPECTIONS BEFORE FIRST USAGE...........................................................................................15
4.1.2 INSPECTION AFTER IMPORTANT CHANGES..............................................................................16
4.1.3 INSPECTION AND TEST RECORDS ................................................................................................17
4.1.3.1 Inspection and Test Results...................................................................................................................17
4.1.3.2 Documentation ......................................................................................................................................17
4.2 PRINCIPLES FOR THE INSPECTION OF CRANES ..................................................................17
4.2.1 HINTS FOR RECURRENT EXAMINATIONS OF CRANES (GENERALLY) ................................17
5 MAINTENANCE INSTRUCTIONS...................................................................... 20
5.1 GENERAL REMARKS......................................................................................................................20
5.2 LUBRICATION ..................................................................................................................................21
5.2.1 OIL FILLINGS AND SELECTION OF LUBRICANTS. ....................................................................21
5.3 MAINTENANCE SCHEDULE .........................................................................................................22
5.3.1 PREVENTIVE INSPECTION PLAN FOR MAINTENANCE............................................................22
5.3.2 LUBRICANT RECOMMENDATION.................................................................................................29
5.3.3 LUBRICATION POINTS.....................................................................................................................30
10.11.2008 Revision. 0 2 Book 1 B

5.4 WIRE ROPES .....................................................................................................................................34

5.4.1 HANDLING..........................................................................................................................................34
5.4.1.1 Transport and Storage ...........................................................................................................................34
5.4.1.2 Unwinding ropes from the reels ............................................................................................................35
5.4.1.3 Cleaning of wire ropes ..........................................................................................................................36
5.4.1.4 Rope maintenance .................................................................................................................................36
5.4.1.5 Lubrication of the ropes ........................................................................................................................37
5.4.1.6 Inspection ..............................................................................................................................................38
5.4.1.7 Visual inspection...................................................................................................................................39
5.4.1.8 Illustrations of rope damage..................................................................................................................40
5.4.1.9 Measuring..............................................................................................................................................42
5.4.2 CHANGING THE ROPES ...................................................................................................................42
5.4.2.1 Main hoist rope in machinery house .....................................................................................................42
5.4.2.2 Boom hoist rope ....................................................................................................................................46
5.4.2.3 Rope Scheme.........................................................................................................................................49
5.5 HYDRAULIC EQUIPMENT.............................................................................................................51
5.5.1 HYDRAULIC UNITS ..........................................................................................................................51
5.5.1.1 Refilling with hydraulic fluid................................................................................................................51
5.5.1.2 Changing the hydraulic fluid.................................................................................................................51
5.5.1.3 Cleaning the filters ................................................................................................................................51
5.5.1.4 Removing leaks and cleaning the equipment ........................................................................................51
5.5.2 PRESSURE VESSELS .........................................................................................................................52
5.5.2.1 Hydraulic high-pressure hoses ..............................................................................................................52
6 REPAIR INSTRUCTIONS..................................................................................... 53
6.1 GANTRY DRIVE................................................................................................................................53
6.1.1 CHANGING OF MOTOR AND GEAR BOX .....................................................................................53
6.1.1.1 Preparation ............................................................................................................................................53
6.1.1.2 Procedure ..............................................................................................................................................53
6.1.2 CHANGING OF GANTRY WHEEL...................................................................................................54
6.1.2.1 Preparation: ...........................................................................................................................................54
6.1.2.2 Procedure ..............................................................................................................................................54
10.11.2008 Revision. 0 3 Book 1 B

6.2 TROLLEY DRIVES ...........................................................................................................................56

6.2.1 DISMANTLING OF TROLLEY DRIVE GEARBOX.........................................................................56
6.2.1.1 Preparation ............................................................................................................................................56
6.2.1.2 Procedure: .............................................................................................................................................56
6.2.1.3 Dismantling/Installation:.......................................................................................................................56
6.2.2 DISMANTLING OF TROLLEY WHEEL...........................................................................................57
6.2.2.1 Preparation ............................................................................................................................................57
6.2.2.2 Procedure ..............................................................................................................................................57
6.2.3 CHANGING MAIN PARTS OF THE TROLLEY MACHINERY HOUSE .......................................59
6.2.3.1 Preparation ............................................................................................................................................59
6.2.3.2 Procedure ..............................................................................................................................................60
6.2.3.3 Dismantling of motors: .........................................................................................................................60
6.2.3.4 Dismantling of brakes: ..........................................................................................................................60
6.2.3.5 Dismantling of hoist drums:..................................................................................................................60
6.3 BOOM HOIST GEAR........................................................................................................................61
6.3.1 DISMANTLING OF BOOM HOIST GEAR .......................................................................................61
6.3.1.1 Preparation ............................................................................................................................................61
6.3.1.2 Procedure ..............................................................................................................................................61
6.3.1.3 Dismantling of motors: .........................................................................................................................61
6.3.1.4 Dismantling of brakes: ..........................................................................................................................61
6.3.2 DISMANTLING OF BOOM HOIST DRUMS ....................................................................................62
6.4 BOOM LIFTING WITH THE AUXILIARY DRIVE.....................................................................62
6.4.1 PROCEDURE.......................................................................................................................................62
6.5 TRIM LIST SKEW SYSTEM, MACHINERY HOUSE .................................................................64
6.5.1 CHECKS AND ADJUSTMENTS OF TRIM- LIST - SKEW DEVICE ..............................................64
6.5.2 LEVELLING AND SQUARING OF THE SPREADER, ROPE LENGTH ADJUSTING..................64
6.5.3 READJUSTING ROPE LENGTHS: ....................................................................................................67
6.5.4 CHECKS AND ADJUSTMENTS OF SNAG LOAD PROTECTION DEVICE.................................68
6.5.4.1 SNAG LOAD Protection adjustments and Event Sequence Check ......................................................68
6.5.4.2 Checks to be done after SNAG LOAD occurred ..................................................................................69
6.5.4.3 SNAG LOAD Protection test................................................................................................................69
6.5.4.4 Adjusting of load cells ..........................................................................................................................71
6.6 BOLT CONNECTIONS .....................................................................................................................72
6.6.1 TORQUE WRENCH ............................................................................................................................73
6.6.2 PIN CONNECTIONS ...........................................................................................................................73
6.6.3 TABLE FOR TIGHTENING TORQUE FOR BOLTS ........................................................................74
10.11.2008 Revision. 0 4 Book 1 B

6.7 STRENGTHENING AND REPAIRING CRANE STEEL STRUCTURES..................................76

6.7.1 GENERAL ............................................................................................................................................76
6.7.2 BASE METAL......................................................................................................................................76
6.7.2.1 Investigation..........................................................................................................................................76
6.7.3 DESIGN FOR STRENGTHENING AND REPAIR ............................................................................76
6.7.3.1 Design Process. .....................................................................................................................................76
6.7.3.2 Stress Analysis. .....................................................................................................................................76
6.7.3.3 Fatigue History......................................................................................................................................76
6.7.3.4 Restoration or Replacement ..................................................................................................................76
6.7.3.5 Loading During Operations...................................................................................................................77
6.7.3.6 Existing Connections ............................................................................................................................77
6.7.3.7 Use of Existing Fasteners......................................................................................................................77
6.7.4 FATIGUE LIFE ENHANCEMENT .....................................................................................................77
6.7.4.1 Methods.................................................................................................................................................77
6.7.4.2 Stress Range Increase............................................................................................................................77
6.7.5 WORKMANSHIP AND TECHNIQUE ...............................................................................................78
6.7.5.1 Base-Metal Condition ...........................................................................................................................78
6.7.5.2 Member Discontinuities ........................................................................................................................78
6.7.6 WELDING ............................................................................................................................................78
6.7.7 FLAME CUTTING...............................................................................................................................79
6.7.7.1 Drilling..................................................................................................................................................79
6.7.7.2 Base Metal of Insufficient Thickness....................................................................................................79
6.7.7.3 Heat Straightening.................................................................................................................................79
6.7.7.4 Welding Sequence.................................................................................................................................79
6.7.8 REPAIR WORK SUMMARY..............................................................................................................80
6.7.9 QUALITY.............................................................................................................................................81
6.7.9.1 Visual Inspection...................................................................................................................................81
6.7.9.2 Nondestructive Testing .........................................................................................................................81
7 SETTING CRANE OUT OF OPERATION ......................................................... 82
8 DISASSEMBLY AND DISPOSAL OF THE CRANE ......................................... 82
9 GENERAL DRAWINGS ........................................................................................ 82
10.11.2008 Revision. 0 5 Book 1 B

1 WARNINGS AND Note

SYMBOLS
Refers to special information on
The following signs and designations are how to use the STS most
efficiently.
used in the manual to designate
instructions of particular importance.
The symbols and notes in the manual are Reference

used to warn you about possible injuries to
persons or damage to materials, or to Refers to information to other parts
provide working aids: of the Driver’s Manual
Attention
Information
Refers to special information
and / or orders and prohibitions
directed towards preventing * Warning information
damage.
Refers to orders and prohibitions

designed to prevent injury or ) Additional Information
extensive damage
CAUTION ELECTRIC Danger

VOLTAGE !
This symbol warns of ELECTRIC
VOLTAGE.
It is found at all working and Danger of tripping
operating procedures which have
to be executed by a trained and
qualified electro-technical
specialist only.
All details and notes have to be Danger of falling
followed exactly in order to
prevent danger to persons and
the unit by electrical voltage.
Contact with parts under voltage
may result in immediate death!
Wear protective clothing!
Keep away from suspended

loads!
10.11.2008 Revision. 0 6 Book 1 B

2 SAFETY The container crane is built according to

the latest standards of technology and
Before operating or maintaining the crane, recognized safety technical rules, and is
the maintenance and operation instructions equipped with safety devices. It was
have to be read carefully and understood checked for function and safety before
by all maintenance and repair personnel. delivery and hand-over. However, in case
of faulty operation, misuse, improper use
The unit may only be put into operation by or use not in accordance with the
trained specialist staff. specifications, dangers could arise to:
− the health of the operation personnel or
third persons
Working cautiously and carefully is − the container crane or other material
the best protection from accidents.
− the efficient operation of the container
crane
In case of problems and requests, the
manufacturer will always be at your All persons entrusted with the installation,
disposal. commissioning, reactivation, operation and
maintenance of the container crane have to
be qualified adequately and must exactly
2.1 GENERAL INFORMATION observe these operating and maintenance
instructions with all enclosures.
This section informs you about possible
hazards and necessary precautions to be
taken when maintaining the container
crane. IT’S ABOUT YOUR
SAFETY !
Residual risks are special dangers
that occur when dealing with the
container crane. They cannot be
removed despite a construction in
accordance with safety standards.
Residual risks are not immediately
obvious and can be the source of a
possible injury or risk to health..
10.11.2008 Revision. 0 7 Book 1 B

2.2 GENERAL RULES OF Our units are equipped with safety devices
CONDUCT AND SAFETY as far as the operation still admits them.
REGULATIONS The proper protection of staff can only be
ensured by a protection area which is
secured and locked by limit switches.
Refrain from any working method
which may inhibit safety!
Protection and safety devices (covers,
safety barriers, ....) may not be removed
The crane may only be operated in while operating the unit. The crane may
technically perfect condition, as per the not be operated without safety devices at
specifications (in awareness of safety and any time.
dangers) and in compliance with the
operating and maintenance instructions. The operating and maintenance instruc-
Particular malfunctions which may impair tions must be always available at the
the safety must be eliminated immediately. installation site of the unit. Uncompleted or
illegible operating and maintenance must
Before each commissioning, the crane has be replaced immediately.
to be checked for operational safety! NCS would be pleased to help you in this
respect. In addition to the operating and
When operating the crane the safety maintenance instructions, legal, generally
stipulations must be observed strictly. valid and other obligatory regulations for
Secure the crane against unauthorized accident prevention and environmental
operation. protection must be observed.
The personnel instructed with activities at
The crane and its additional
the crane must have read and understood
equipment, primarily the safety
devices, have to be checked for the relevant operating instruction or
proper condition and function maintenance instructions before starting to
depending on work use, but at work.
least once weekly. This is particularly important for personnel
which is employed only occasionally at the
• Requiring special supervision: machine.
− emergency-stop button and control
− drive The operating and maintenance staff has to
− electrical equipment be checked by the person responsible for
the operation through controls.
10.11.2008 Revision. 0 8 Book 1 B

They should be encourage to a work in 2.3 SAFETY AND ACCIDENT

awareness of safety regulations and risks PREVENTION
and under observance of the information
given in the operating and maintenance The stipulations below must be strictly
instructions. The person responsible for the followed in order to reduce the risk of
operation is obliged to operate the crane in injury to persons and/or damage to
perfect condition only and to instruct the property.
operating and service staff to wear
Each person working at or with the
protective clothing, etc. whenever * crane must have read and understood
necessary or required by the regulations.
the operating instructions and adhere
to the instructions for safety reasons.
If there are any alterations concerning the
safety at the machine or changes in the The supplementary safety information for
operational behaviour, the machine has to this crane given in the internal company
be set to a standstill and the fault has to be regulations must also be followed. In cases
reported to the relevant authority or person. of doubt ask the security personnel
responsible for your area. Furthermore,
Damages affecting the safety or observe also the stipulations for accident
malfunctions at the crane have to be prevention of your professional
eliminated immediately. Arbitrary association.
constructive modifications and the
alteration of parameters beyond the orders
of the operating and maintenance 2.3.1 Use as per specifications
instructions are not permitted for safety-
technical reasons. The container crane is exclusively
determined for the loading and unloading
of container ships. The crane handles
containers, hatch covers and lashing gear.
The use as per specifications also includes
the strict observance of the operating and
maintenance instructions when operating
the crane.
Any other use, not in accordance with

* the specifications, may result in risk to
life and limb or damages to the crane!
NCS/RCP only accepts liability for

damages which arise during use as per the
specifications and within the guarantee
period.
10.11.2008 Revision. 0 9 Book 1 B

2.4 OPERATING THE CRANE - 2.4.1 Maintenance and repair

GENERAL REMARKS personnel
Maintenance and overhauling may

The crane has to be operated according to * only be carried out by trained
the safety instructions given in Chapter 2
specialist personnel!
and to local safety regulations.
Before starting work at the container crane
If there are malfunctions during operation,
all persons have to be instructed in
the crane has to be set to standstill
theoretic and practical use with regard to:
immediately in order to eliminate them.
Inform the operating personnel prior to − emergency measures in case of an
commencement of work to eliminate the accident and the use of the emergency
malfunctions or maintenance. exits;
The operator has to make sure that the − the use of rescue aids (fire
occurring faults are logged and eliminated. extinguishers). Instructions and drills
A functional test has to be carried out have to be repeated at least once a year.
before starting operation again. Unauthorized persons must not enter the
crane.
Do running test!
* Follow the safety warnings
10.11.2008 Revision. 0 10 Book 1 B

2.4.2 Danger zone The operation has to be stopped

immediately:
During the work for the elimination of − in case of improper functioning of the
malfunctions or for maintenance and repair crane;
jobs only authorised personnel may remain − if other obviously dangerous
within the crane area. deficiencies appear.
Danger zone (e.g. under the crane ) Report dangerous deficiencies to the
must be blocked by suitable * responsible personnel immediately!
measures!
Increased risk must be indicated by 2.4.4 Effectiveness of safety devices

warning signs. Hazard areas must be
indicated permanently through: All safety devices and facilities with
− coloured signs protectional function must always be
− warning signs connected and operable. They may not be
− or by other clear indications rendered ineffectively or used improperly.
The factory setting of components must
No persons may remain within not be changed. This is valid particularly
the hazard areas during for:
operation. − electrical / electronic safety lockings
Make sure that no persons and couplings e.g. emergency-stop
are within the hazard area limit switch, overload protection, key
before switching on the main
switch and the control voltage.
switches, etc;
− mechanical components, e.g. safety
catching devices;
2.4.3 Supervision activities − controls and programs.
When malfunctions are eliminated,

When starting work the following jobs * safety devices have to be made
are specified: effective again directly after end of
− read fault log of the previous / the day this work.
before; Before operating the container crane
− carry out test and control activities in again, the function of all safety
accordance with control book; devices has to be checked.
− before driving, check that there are no
obstacles on the rails;
− take out switching key when leaving the
drivers cabin in order to prevent
unauthorized use.
10.11.2008 Revision. 0 11 Book 1 B

2.5 CONDUCT IN CASE OF 2.6 DUTIES DURING AND

ACCIDENTS AFTER MAINTENANCE AND
REPAIR WORK
In the case of accident with injury to
persons, damages to devices or buildings If there are malfunctions during operation,
immediately inform the supervisor after the crane has to be set to standstill
providing the injured with first aid. For the immediately in order to eliminate them.
well-directed action of rescue vehicles give Inform the operating personnel prior to
the degree of heaviness of injury to persons commencement of work to eliminate the
and damage to property. malfunctions or maintenance.
The operator has to make sure that the
In case of disaster (e.g. fire), all occurring faults are logged and eliminated.
* persons must leave the crane using A functional test has to be carried out
the marked emergency exits and before starting operation again.
other facilities.
Rescue actions may only be carried
out by instructed operating and
rescue personnel. Use the intended Do running test!
protective equipment.
* Follow the safety warnings!
− 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
protection, helmet, protective footwear);
− handle operating and cleaning deter-
gents cautiously;
− provide for a safe and environmentally
friendly release, storage and disposal of
operating and auxiliary materials;
− do not use machine parts as climbing
aids;
− reinstall and test safety devices (which
have been disassembled during
assembly or test and repair work)
immediately after end of maintenance
and repair work;
10.11.2008 Revision. 0 12 Book 1 B

− inform the operating personnel before 2.7 EMERGENCY

the commencement of special or POSSIBILITIES
maintenance work;
− secure the repair area by closing a wider • Breakage of a trolley wheel while the
area; trolley is above the ship:
− tighten screw joints which were
The first step must always be to place any
loosened during test and maintenance
load attached to the main frame onto the
work correctly;
ship.
− replace fastening elements and seals
(e.g. self-securing nuts, washers, split • Breakage of a wheel axle at the crane
pins, O-rings and seals) which cannot travelling mechanism during crane
be used again. operation:
After maintenance / repair work, the In the case of a broken wheel axle, the
following activities are required: relevant travelling mechanism bogie falls
into wheel support located in the middle of
− update fault log and maintenance check the lower side.
list;
− put away tools, foreign parts and • Malfunctioning of the hydraulic units
operating materials left lying around;
− test run and function check of the − Brake for boom and main hoist gear:
components and safety devices.
In case of a malfunction of the hydraulic
unit can be opened using the manual pump
installed on hydraulic unit.
The lowering of the boom (closing

the brake) can be stopped by
ventilating the pressure manually
and thus can no longer fulfil its
intended.
10.11.2008 Revision. 0 13 Book 1 B

3 INTRODUCTION Any intervention by the owner without the

prior approval of the manufacturer may
This manual contains information about lead to the loss of warranty cover. If the
maintenance and repair work. owner of the crane agrees, the crane
manufacturer may allow the owner to carry
This manual should always be out warranty works.
available for inspection by the
maintenance staff. Some of the advice given in this manual
originates from the documentation of
The relevant section of this manual is to be subcontractors and has been specially
studied carefully before every repair. adapted to suit our crane.
Experienced staff must be employed for
repair work which is being carried out for Special information on parts which are not
the very first time and which involves high described in detail in this part of the
risks. If there are any uncertainties, we documentation is to be found in Part 4
recommend that you contact the “Additional instructions and Attachments“.
manufacturer.
Book 1 A Safety
B Repair and Maintenance
The maintenance staff should have been Manual
given thorough professional training. Some C Driver’s Manual
work requires instruction and supervision D Crane Monitoring System
(FCMS Description)
by specially trained and experienced
persons such as engineers or erection
engineers. The crane must be shut down
completely during all
maintenance and repair work.
For basic safety instructions Always connect the
please refer to Part 0 and 2. earthing terminal
of the welding unit as closely as
Only qualified and trained staff may possible to the
carry out the repairs and part to be welded.
maintenance on the crane. If the welding currents transfer to
bearing points, especially those
Always follow the safety instructions with built-in roller bearings, the
when performing maintenance or parts will weld together and the
repair work. bearing will be destroyed.
During the warranty period, maintenance

work which is to be done as a result of
some kind of damage, especially average
damage, may only be carried out by the
manufacturer or someone appointed by
him.
10.11.2008 Revision. 0 14 Book 1 B

4 TESTS AND 2. Inspection of the crane with respect to

INSPECTIONS its equipment. This concerns in
particular the crane accesses not
4.1 TYPE, SCOPE AND attached to the crane and accesses to
PERFORMANCE OF THE control stations, platforms and catwalks
INSPECTIONS not attached to the crane, crane
runways, rail systems and railway end
4.1.1 Inspections before First Usage stops, work and traffic areas and safety
clearances.
The inspections before fist usage must
comprise: 3. Inspection of the load-bearing structure,
e.g. crane track, crane foundations,
1. Verification of the technical
tracking.
documentation; it must refer to the
following documentation:
4. Verification of the suitability of the
Test book with master sheet and
crane for the use as specified by the
supplementary sheets for
operating body.
completeness with respect to the
entries and certification as well as
5. Inspection of the safety facilities and
coinciding with the listed crane unit.
precautions with respect to
Declaration of Conformity, where
completeness, commensurability and
appropriate Declaration by
effectiveness.
Manufacturer.
Operating guide including assembly
6. Functional testing of the whole crane.
and, where appropriate, disassembly
guide with respect to correctness and
7. Performance of load tests:
completeness
Static and dynamic tests.
Load bearing capacity tables /
Inspections in accordance with the
diagrams.
specifications of the manufacturer.
Availability of the circuit diagrams
Inspections in accordance with the
(electricity, hydraulics and
standards concerned.
pneumatics).
Availability of for instance approved
statical calculations, details
concerning auxiliary gear and
verification for correct execution.
10.11.2008 Revision. 0 15 Book 1 B

4.1.2 Inspection after Important The recurrent inspection must

Changes comprise:
1. Inspection of the crane using the
The inspection is directed at the type and specifications in the test book with
scope of the changes made and is respect to identity.
undertaken based on the inspection
conducted before first usage, i.e. if 2. Inspection of the crane, taking its
required, a design verification and a documentation with respect to the
supervision during execution is necessary. adherence of the fundamental safety and
The test book is to be supplemented health requirements.
correspondingly.
3. Inspection of the crane with respect to
Important changes are for instance an
) increase in the load-bearing capacity,
its operational mode in accordance with
the specifications in the test book, e.g.
changing the trolley or booms,
changes to the drive units, relocation
hoist categories, load groupings and
of the control stations, changes to the environmental conditions.
type of power, welding on load-
bearing parts, re-siting cranes on 4. Verification of the hoisting gear with
different tracks for rail mounted respect to the worn part of the
cranes, change to a different type of theoretical service life
control station, changes to the
operating conditions with respect to
the class of utilization and the load 5. Verification of the state of components
spectrum of the crane. and devices with respect to damage,
wear-and-tear, corrosion or other
The recurring inspection is used to changes using inspection
establish whether the crane is in a safe recommendations from the
state. It is basically a visual inspection and manufacturer in the Operating
functional test. If, in so doing, an adequate Instructions.
assessment is not possible, further tests
have to be undertaken, e.g. non-destructive 6. Inspection for completeness and
testing. If necessary, a disassembly of effectiveness testing of the safety
crane parts must be undertaken, e.g. to devices and brakes
assess:
Inspection recommendations from
) the manufacturer are to be taken
• hidden parts on top of one another;
into account, e.g. overload safety
• wear, cracks in crane hook shafts. devices, brakes.
If required, an expert has to be called in. 7. Functional and brake tests with loads,
whereby the test load must be near
below the greatest permissible load-
bearing capacity.
8. Verification for completeness of
designations and descriptions.
10.11.2008 Revision. 0 16 Book 1 B

4.1.3 Inspection and Test Records 4.2 PRINCIPLES FOR THE

INSPECTION OF CRANES
4.1.3.1 Inspection and Test Results
4.2.1 Hints for recurrent
The results must include: examinations of Cranes
1. Type and scope of the inspections and (generally)
tests. These hints serve as aids and clues with
2. Particular inspections and tests implied expertise and raise no claim on
outstanding wholeness.
3. Faults identified
4. Assessment, whether there are The scope of these examinations is to be
reservations concerning start-up or adjusted to the crane to be inspected,
further operations especially operating-instruction and
5. Decision whether a re-inspection is maintenance-schedules of the manufacturer
required are to be observed.
The recurrent inspections extend in general

4.1.3.2 Documentation to:
1. Components and mechanical Facilities
The inspection and test results are to be 2. Safety distances, accesses, platforms
recorded in the test book of the respective 3. Safety devices, drives, controls
crane. 4. Lifting gear
5. Labels and Signs
Included must be:
1. All details and documents describing
the identity and operational mode of the see table on next page
crane.
2. The results attested by the inspector of
the design verification, supervision
during execution and acceptance tests,
the Certification of the Crane type
approval or Declarations of Conformity.
the inspection of the crane rail including
the foundations: details on the crane
runway, e.g. classifications, rail spans,
dimensioning criteria.
the recurring inspections.
10.11.2008 Revision. 0 17 Book 1 B

Group for inspection Inspection part Description
1 Components and mechanical devices

Foundations Anchorage fastening, condition
Crane runway structure supports, fastening, condition
beams,
rods,
connections
Access and platforms steps, rungs, beams existence, fastening, condition
walking surface of for
example galleries
platforms
fall protections
(Handrails, railings, inter-
rod, back-protection)
Crane and trolley runways fastening, condition, gauge, deformations
runway rails existence, fastening, condition, functioning
runway-end stops
stowage devices
locking devices
Crane frame work rods, fastening, condition
(trolley girders, portal, girders, existence, fastening, condition
pylon, boom) connections,
lugs stays and guys
Trolley structure, rods, fastening,
(framework) girders, condition
connections,
turntables
Drives wheels, fastening, condition, functional and brake tests
axles, shafts, couplings, with brake drums and discs, brake pads, test
drums rollers, load nearby load capacity condition function
hydraulic and pneumatic
components,
bands, linkages fans,
counter-weights,
pins, springs,
2 Safety distances, accesses, platforms
Safety distances upwards To comply with considering meanwhile installed
downwards components, e.g. air ducts pipelines, machines
sidewards
Accesses Ascent walkways passage and spacing with consideration of
possibly additional changes taken place
meanwhile
Platforms fixed to crane rigidly existence,
fixed to the building availability,
rigidly removable condition
10.11.2008 Revision. 0 18 Book 1 B

Group for inspection Inspection part Description
3 Safety devices, drives, controls

Controls switch gears, condition,
circuit brakers, function,
relais, labeling,
limit switches precautions against direct and indirect touching
overload protections
bypass controls
wireless controls
Cables movable cables fastening,
trolley bars condition,
insulators preconditions against direct and indirect touching
taps
fixed cables
Consumers motors, thrusters, condition,
resistors, heaters, function,
illumination, precautions against direct and indirect touching
warning devices
The listing applies to mechanical, electrical, hydraulic and pneumatic safety devices, drives and
controls similarly
4. Lifting gear
Ropes and chains to be inspected at their entire length, covered and hidden parts included
Ropes condition, fastening at the drum, end-fastening,
refer to DIN 15020/2 (rope reeving basics,
inspection during operation) rope guards
Round-steel-chain condition, refer to EN 818 (tested round-steel link
chains, use)
Roller chains condition, wear-out, lengthening cracks, securing
of the bolts, e.g. by riveted head, ring
Hooks condition, in case of possible corrosion
suspension to be disassembled (dismantling is
necessary at the danger of corrosion) securing of
the hook nut locking see DIN 15405/1 (hooks for
hoists, inspection of forged hooks) securings
against inadvertent load relief.
Other lifting gear e.g. condition, wear-out, see DIN 15429 (Hoists, load-
grabs, tongs traverses carrying devices, supervision in service)
5. Labeling, Signs
signs and notices completeness, legibility
labeling of dangers
10.11.2008 Revision. 0 19 Book 1 B

5 MAINTENANCE Service and test documents have to be kept

INSTRUCTIONS so that they are available at any time.
The periodic maintenance jobs are based
5.1 GENERAL REMARKS on a usage of the container crane.
When carrying out maintenance work the If usage duration or operation conditions
general and special stipulations for the change, the intervals of maintenance jobs
prevention of accidents of the professional have to be adapted accordingly and have to
association as well as the safety regulations be communicated to the manufacturer in
in Chapter 2 have to be obtained too. writing.
Before commencement of service

For keeping up the operating status and ) work the container crane has to be
operational safety of the container crane made free of load, set to
maintenance of the crane in regular maintenance position and switched
intervals is stipulated. off, if no other note is given.
The periodic maintenance jobs have to be Refer to the operating instructions

carried out according to the lubrication and considering the safety stipulations for the
service deadlines. driving and / or switching on / of the
container crane for maintenance and repair
All maintenance jobs and deadlines for the work. If lacks or damages are detected
crane are additionally registered on service when maintaining, these have to be
protocols. In appendix the service immediately removed or reported to be
protocols are loosely filed. These service overhauled.
protocols are taken out of the maintenance
and repair instructions for maintenance Damaged components / parts may only be
work. They serve for a working and testing replaced by original components. When
model at the device. The jobs/tests and installing non-original components all
inspections listed up in the service guarantee claims expire. Always replace
protocols have to be executed correctly. self-securing nuts, O-rings, split pins,
spring washers, rotary shaft seals and seals.
The correct execution of the jobs
) has to be confirmed with signature
Select fastening and seal elements which
must not be used anymore.
and date in the insert of the service
protocol and in the maintenance
test report.
If lacks are detected they have to
be noted down in the inserts and in
the service protocol.
All specified service intervals have
to be confirmed.
10.11.2008 Revision. 0 20 Book 1 B

5.2 LUBRICATION 5.2.1 Oil fillings and Selection of

lubricants.
In the attached separate plan you find the
oil change intervals for the main parts with The correctly performed lubrication
the recommended lubricant. Only this service prevents failures and helps to avoid
lubricants are released from the premature wear. The lubrication points
manufacturer or NCS. shall be carefully cleaned prior to
lubricating and the oil drainage bolts prior
The guarantee expires if other lubricants to unscrewing. All pins shall be inserted
are used. with grease during each installation.
The antifriction bearings operate with low-
All used oil and grease have to maintenance. The bearings must not be
be collected and disposed over lubricated, since otherwise an
unnecessary heating during operation will
occur.
Trained specialist staff has to take care that
All bearings without bearing nipples are
synthetic oils and greases, as well as
maintenance-free and will be dismantled
substitutional products containing halogen,
every two years within the scope of a total
which might be formed in transformers,
inspection, cleaned and checked for any
capacitors and hydraulic systems, are
change ore wear.
collected, transported and stored separated
from other waste oils They must not be lubricated since they are
either provided with life-time lubrication
Do not contaminate water and crane with or running-in lubrication which must not
oil and grease. Remove any spilled be changed.
lubricants. Wire ropes and chains shall be regularly
treated with acid-free grease.
The oil cleaner can be used like a pump to
pump off the oil in the gear unit into a All guidings at the overload security
barrel. Use the maintenance crane in device, gearing support, brakes and rollers
Machinery House to lift up the barrel to the at the limit switches shall be maintained in
ground. a well running condition with acid-free
lubrication oil.
The symbols in the lubrication chart Connection elements with machined faces,
identify the points of lubrication according which were separated during repair, have
to which the lubrication work shall be to be treated with a suitable anticorrosive
carefully and regularly performed. The protection agent prior to installation.
type of lubrication in given in Chapter The lubrication intervals indicated in the
5.3.2. lubrication chart shall be reduced in time
according to requirement in case of
aggravated operational conditions, so that
the readiness for operation of the crane
remains maintained.
10.11.2008 Revision. 0 21 Book 1 B

5.3 MAINTENANCE SCHEDULE
Moreover also the oil filling and

changing regulations given by the
manufacturers have to be applied.
5.3.1 Preventive inspection plan for maintenance
Inspection period:
see Additional Instructions and Attachments
Lubricant see Chapter 5.3.2 3M every third month (~1000 h)
D every day 6M every six month (~2000 h)
W every week A annually (~4000 h)
M every month (~250 h) h running hours
Inspection period
Lubricant
Assembly Designation
Pos.
3M
6M
W
M
D
A
h
CRANE TRAVELLING MECHANISM

1
2 Gear unit ● check gear unit for uncommon noise, leakages ●
● clean vent plug ●
● check all fixing bolts and shrink disc bolts for ●
tightness
● complete inspection of gear unit ●
● check oil level ●
● change oil ● S1,
10 l
3 Wheel bearing ● check bearing noise for changes
Self aligning roller
bearing
Wheel ● check abrasion and damage
4 Bogie pins ● regreasing S3
5 Storm anchor pin ● clean surface, check fixing
6 Motor ● regreasing ● S3
● check junction for cover bolts ●
Motor brake ● check air gap ●
7 Motor-coupling ● visual check for buffer elements
10.11.2008 Revision. 0 22 Book 1 B

Inspection period
Lubricant
Pos.
3M
6M
W
M
D
A
h
CRANE TRAVELLING MECHANISM
8 Rail brake ● spring lubrication ●
● serration, dynamic shoe check ●
Rail brake hydraulic ● check oil level and pressure development ●
unit
● check all settings ●
● change oil and filters ● B6,
50 l
TROLLEY
9 Gear unit ● check gear unit for uncommon noise and leakages ●
● check all fixing bolts and shrink disc for tightness ●
● change oil ● S1,
43l
10 Wheel bearing ● check bearing noise for changes, lubricate
11 Brake ● check reserve stroke ●
● Check wear of lining, perform brake test by ●
pressing the emergency button
● check of lever adjustment bolts with brake in ●
released position and brake torque in closed
position
● check screw and bolt connections ●
● check entire brake system, electrical supply cables, ●
oil and hydraulic system
● check of brake shoes, brake linings and brake drum ●
12 Cardan shaft ● Lubricate ● S3
Motor brake ● check air gap ●

14 Emergency Drive ● running test, check oil level ●
15 Spreader Cabel Reel ● oil change after 10000 operating hours or 3 years ● 9l
● check collector ring 5 mm ●
● regrease chain ●
● check tension of chain ●
16 Electro thrusters ● check reserve stroke ●
● check for leakages ●
10.11.2008 Revision. 0 23 Book 1 B

Inspection period
Lubricant
Pos.
3M
6M
W
M
D
A
h
TROLLEY
17 Trim-list-skew ● oil change ● B6,
300 l
hydraulic unit
● check fittings and hoses ●
● check main and control pressure ●
18 Trim-list-skew ● running test, 3 times full stroke ●
cylinder
HOIST UNIT
● check all fixing screws for tightness ●
● 5 change oil ● S1,
224 l
0
0
0

20 Drum bearing ● check bearing noise for uncommon changes,
lubricate
21 Drum coupling ● check wear of the tooth system of the coupling ●
check sealing ring/if necessary change it
● check wear monitoring of the tooth system of the ●
coupling
8 change lubricant ●
0
0
0
22 Motor coupling ● check element for damage (backlash occurs) ●

24 Brake ● Check wear of lining, perform brake test by pressing ●

the emergency button ( spreader in low position)
position

10.11.2008 Revision. 0 24 Book 1 B

Inspection period
Lubricant
Pos.
3M
6M
W
M
D
A
h
HOIST UNIT
25 Emergency Drive ● running test, check oil level ●
26 Safty brake ● Visually check the brake lining and braking discs ●
(clearence 1,5 mm 0.2)
● Visually check the hydraulic equipment and ●
threaded pipe connections for leaks.
● Visually check all threaded connections ●
● Check all additional parts ( limit switches ) ●
Check the oil level for the hydraulic equipment ●
● Total check of the complete brake system, check ●
the brake lining and brake discs
● Check the electrical supply connections ●
● Check the hydraulic piping ( leakage ), check the oil ●
level in the hydraulic tank as well as the oil quality (
contamination )
27 Hydraulic unit ● oil level check ●

● oil change ● B6,
30 l
● check reserve stroke ●
● check filter if necessary change ●
28 Electro thrusters ● check reserve stroke ●
29
10.11.2008 Revision. 0 25 Book 1 B

Inspection period
Lubricant
Pos.
3M
6M
W
M
D
A
h
BOOM HOIST UNIT
● check all fixing screws for tightness ●
● complete inspection ●
● change oil ● S1+,
224 l

31 Drum bearing ● check bearing noise for uncommon changes
32 Drum coupling ● check wear of the tooth system of the coupling ●
check sealing ring/if necessary change it
33 Brake ● visual check 4 mm ●
● Check wear of lining, perform brake test by pressing ●
the emergency button ( spreader in low position)
position
34 Hydraulic unit ● oil level check ●
● oil change ● B6,
30 l
● check reserve stroke ●
● check filter if necessary change ●
35 Electro thruster ● Check reserve stroke ●
36 Motor coupling ● check element for damage (backlash occurs) ●
37 Motor ● check noise and working temperature ●
38 Emergency drive ● running test, check oil level ●
39 Boom rope balancer ● visual inspection
40 Safty Brake ● Check wear of lining by pressing perform brake test ●
the emergency stop button in 5° Position from
horizontal
position
10.11.2008 Revision. 0 26 Book 1 B

Inspection period
Lubricant
Pos.
3M
6M
W
M
D
A
h
HEAD BLOCK
41 Connecting twist ● check condition, wear or cracks
locks
ACCESSORIES IN MACHINERY HOUSE
42 Maintenance crane ● Lubricate ●
● inspection on commissioning see Appendix ●
43 Air conditioning ● check filter ●
E-room
44 Compressor ● check oil level ●
● operate safety valve (SV), check for leakages, ●
check tension
● change oil, filters and belt ●
45 Fire extinguishing ● ● ● fill out reports for regular inspection ●
plant
CRANE ACCESSORIES
46 Festoon system ● see detailed check list in manufacturer ●
documentation
47 Air conditioning ● check filter ●
48 Wind measurement ● check operation ●
device
49 Lift ● detailed check list in manufacturer documentation ●
50 Motor Cable reel ● visual inspection ●
● oil change after 10000 operating hours or 3 years ●
● check collector ring 5 mm ●
● lubricate chain ●
● check tension of chain ●
51 Hydraulic buffer ● check condition ●
10.11.2008 Revision. 0 27 Book 1 B

Inspection period
Lubricant
Pos.
3M
6M
W
M
D
A
h
OPERATION LIMIT SWITCHES
52 Hoist limit switch up ● check operation and damage
53 Hoist limit switch ● check operation and damage
down
54 Boom hoist limit ● check operation and damage
switch up
55 Boom hoist limit ● check operation and damage
switch down
56 Trolley limit switch ● check operation and damage

waterside
57 Trolley limit switch ● check operation and damage
landsite
58 Trolley park position ● check operation and damage
STEEL STRUCTURE
59 Hinge point boom- ● check condition / lubricate S3
bridge girder
60 Boom support near ● check condition, alignment, lubricate S3
hingepoint
61 Trolley rail and rail ● check condition, check alignment and gaps (refer to
joint manufacture drawings)
62 Forestay ● check condition, lubricate S3
63 Rope pulleys ● check wear of pulleys
64 Rope pulley bearing ● check bearing noise for changes, lubricate S3
Cylindrical roller
bearing
65 Boom locking ● check condition
mechanism
66 All Screws check all fixing screws for tightness
67 All tube connection check all connections and conditions
ROPES
68 Hoist Rope ● Lubricate every 100 operating hours XX
69 Boom Hoist Rope ● Lubricate every 100 operating hours XX
10.11.2008 Revision. 0 28 Book 1 B

5.3.2 Lubricant recommendation
Type Lubricating points Lubricants Marking Specification Designation

S1 Spur gears, planetary gears, worm gears, gear oil ISO VG 220 CLP 220 Shell Omala 220
helical bevel gears DIN 51519 DIN 51519
S1+ Spur gears, planetary gears, worm gears, gear oil ISO VG 320 CLP 320 BP Energol
helical bevel gears DIN 51519 DIN 51519
GR-XP 320
S2 Anti friction and friction bearings of the lithium based K2K-20 K2K-20 BP LS-EP2
rope pulleys, running wheels, drum grease DIN 51502 DIN 51825
bearings, large diameter anti friction
bearings, chain gears,
S3 Spherical plain bearing in hydraulically lithium based K2KF-20 K2KF-20 BP LS-EP2
cylinder, chain suspensions, load hook grease with DIN 51502 DIN 51825
yokes molybdenum
disulfide
S4 Open gearing, running wheel drives, load adhesive lubricant OG2K-20, OG2K-20 BP LS-EP2
chains, wheel flanges DIN 51825,
BB BB
DIN 51502 DIN 51513
S5 Joints and guides at switches and Low-viscous ISO VG 10 CLP 10
contacts lubricating oil DIN 51515/3
B6 Hydraulic units hydraulic oil ISO HLPD 32 HLPD 32 Shell Tellus 46
DIN 51502 DIN 51524
XX Steel wire rope Nyrosten Seilöl Compound BP Energol
GR3000-2
10.11.2008 Revision. 0 29 Book 1 B

5.3.3 Lubrication points
measuring stick lubricating point oil inlet oil outlet

evacuation
grease
Picture 1 Gantry drive
10.11.2008 Revision. 0 30 Book 1 B

evacuation measuring lubricating oil level pressure

stick point oil inlet oil outlet oil sight glass indicator gauge liquid
filled
Picture 2 Hoist unit
10.11.2008 Revision. 0 31 Book 1 B

evacuation lubricating point oil inlet oil outlet inspection glass,

oil gauge port
Picture 3 Trolley drive
10.11.2008 Revision. 0 32 Book 1 B

evacuation measuring lubricating inspection oil level pressure

oil inlet oil outlet
stick point glass, indicator gauge liquid
oil gauge port filled
Picture 4 Boom Hoist unit
10.11.2008 Revision. 0 33 Book 1 B

5.4 WIRE ROPES
5.4.1 Handling
To prolong the life of wire ropes, they

must be properly transported, stored,
cleaned, inspected and installed.
Wire ropes are easily affected by external
damage, i.e. 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.
5.4.1.1 Transport and Storage
Wire ropes must always be handled with Figure 1 Proper handling of wire rope
equipment that will not damage the rope.
Figure 1 Proper handling of wire rope
shows some of the correct methods to
transport wire rope.
The diagrams in Figure 2

Improper handling of wire rope
are strictly prohibited for
transporting wire rope.
Reels of wire rope should be stored in an

area where they cannot be damaged by
Figure 2 Improper handling of wire rope
objects falling, chemical spills, excessive
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 a one reel
cannot roll into one another. This will
prevent one reel flange hitting the wire
rope surface of another reel. If necessary,
reel flanges should be choked to prevent
movement.
10.11.2008 Revision. 0 34 Book 1 B

5.4.1.2 Unwinding ropes from the reels As previously explained, every wire rope
will bend in a particular direction based on
Figure 3 Proper procedures to uncoil wire the lay of the rope. Therefore, wire rope
rope shows the proper methods of should always be uncoiled that coincides
removing a wire rope from a reel. with their lay. Damage may occur if the
Installing a reel on a stand with a bar ropes are uncoiled in the opposite
through the arbour holes of the reel is the direction. As shown in Figure 4 Prohibited
easiest and safest method. Considerable methods of unwinding wire rope, wire
care must be exercised when unwinding ropes should never be pulled over a flange
wire rope. Their operational performance or a reel, or pulled off the side of a coil,
is substantially influenced by the way they since this will introduce a twist on the wire
are handled. Bending or twisting of wire rope.
rope can cause internal damage that will
adversely affect the operational life of the
wire rope. Avoid unwinding wire rope on
the ground. If there is no other option,
make sure the ground is clean and/or
covered with boards or plastic sheeting to
protect the wire rope from debris.
Figure 4 Prohibited methods of unwinding wire rope
Figure 5 Damaged rope with loop shows a

wire rope damaged by a loop. When
handling the wire ropes ensure that no
loops or bends form at any time. Wire
ropes cannot be installed on a crane if they
are damaged.
Figure 5 Damaged rope with loop
Figure 3 Proper procedures to uncoil wire rope
10.11.2008 Revision. 0 35 Book 1 B

5.4.1.3 Cleaning of wire ropes 5.4.1.4 Rope maintenance
Wire rope should be cleaned thoroughly Broken ends of individual strands that do
before every maintenance inspection. It has not meet the conditions mentioned above
been proven the lubricated wire rope will should be removed. The ends of broken
not wear as fast as non-lubricated wire wires should not be removed with pliers or
rope. Imbedded dirt will decrease the life dikes. These tools may not be small
of wire rope. enough to make a clean cut on the broken
In order to inspect the wire rope properly, strand.
the grease must be cleaned off of the wire Maintenance at regular intervals
rope. Cleaning detergents should never be guarantees safe crane operation and a
used to clean wire ropes. These not only considerably longer rope life.
remove the dirt but they also dissolve the Wire ropes must be greased anew at
lubricant inside the rope. This will allow regular intervals according to crane
moisture to penetrate into the core and lead operation, this especially applies to the
to internal corrosion. Wire ropes should be bending zones at the drums and pulleys.
cleaned with a wire brush. When exposed to the same test condition a
well-greased rope showed four times as
many working cycles as a non-greased
rope. The lubricants must be compatible
with the original lubricant used.
Heavily soiled wire ropes have to be
cleaned with a brush regularly. If the lower
layers on the drum are seldomly used or
not used at all, the ropes have to be
unreeled from time to time and then have
to be reinstalled under prestress. A rope
operates most economically when its
whole length is used. Therefore, we
recommended always to use the
appropriate rope length according to crane
operation; this is important if the crane is
operated continuously for a longer period
of time.
Instead, the broken strand should be bent
back and forth until it breaks at the
protruding point of the rope strand.
10.11.2008 Revision. 0 36 Book 1 B

5.4.1.5 Lubrication of the ropes Relubrication will be performed during

standstill of drum by means of a brush. The
Correct application, installation and perfect wire rope fitting snugly to the drum
maintenance considerably extends the curvature will be slightly opened. Hereby
operational lifetime of wire ropes. A rusty the penetration of the lubricant into the
wire rope endangers the life of persons. interior of the rope will considerably be
Wire rope grease according to lubricant facilitated. The lubricant can be fluid by
recommendation shall be used. heating. Under no circumstances raw oil,
petroleum, waste oil or other chemically
Ropes with hemp cores must be lubricated not neutral oils are allowed to be used as
only with liquid uniformly soaking acid- lubricant for wire ropes and hemp ropes.
free lubricants. Hereby the rubbing-off of
hemp fibres by steel wires is prevented and Attention shall be paid to a good
at the same time the hemp cores will be lubrication of the drum and the rope parts
maintained in a soft condition and the running on the drum. In case abnormalities
softness of the wire rope be assured. are found at a rope, type, diameter and
manufacture of rope shall be determined. A
This also applies for galvanised wire ropes, coloured tracer thread is inserted in the
since the zinc layer certainly protects hemp core of the rope. The manufacturing
against corrosion, but not the interior company can be determined by the
friction. composition of colours.
Careful greasing of the wire rope keeps

away moisture, which can cause interior
corrosion under simultaneous bacterial
profilleration in the hemp. Frequent and
not to accessive lubrication of the wire
ropes produces better results than only
occasional and rich lubrication.
As soon as the grease film vanishes at

some areas of the wire rope, it has to be
regreased. During periods of heavy rain the
regreasing has to be done more often than
Figure 6 Lifting ropes and rope fasteners
in dryer warm periods of weather. The
wire rope shall be treated with a soaking
agent once a year. Gummy and incrusted
grease is hereby made lubricationable
again. Regreasing has to be done only at
complete dryness of the wire rope, since
otherwise the existing moisture will be
contained in the rope and the corrosion be
increased from the inside.
10.11.2008 Revision. 0 37 Book 1 B

5.4.1.6 Inspection
The maintenance schedule set up has been

tailored to detect wire wear as early as
possible. Each wire rope that is installed
will undergo initial and subsequent
periodic measurements and inspections.
The results of these inspections will be
recorded in a journal for the life of the wire
rope.
The results of every visual

inspection shall be record
for tracking purposes.
10.11.2008 Revision. 0 38 Book 1 B

5.4.1.7 Visual inspection
Check when the rope is to be replaced according to the DIN 15020 and the wire rope
manufacturer. Wire ropes shall not be used having any of the following conditions.
Replace a wire rope when:
Pos. Description
1 Ten randomly distributed broken wires in one rope lay or three or more broken wires
in one strand in one rope lay
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, please see the relevant illustration the DIN 15020, Part 2
6 If a basket has formed
7 Kinking, crushing, bird caging 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
9 If the rope becomes thicker or knotted in places
10 If a large number of constrictions have formed
11 If the rope is permanently deformed due to it being placed over sharp edges
12 If loops have formed in the rope due to it being incorrectly wound onto the drum
13 If deep notches appear in the rope
14 Evidence of heat damage, if the rope has been subjected to a temperature of over
300°C (572° F)
Table 1 Criteria for assessing when to replace a rope
We are fundamental using right

hand lay ropes, on left or right
threaded drums!.
10.11.2008 Revision. 0 39 Book 1 B

5.4.1.8 Illustrations of rope damage
following some illustrations of rope

) damage which resulted when the rope
having to be replaced:
Pos Description Illustration

5 Wire rope with corkscrew-shaped
deformation
6 Wire rope with basket formation
7 Wire rope with loop formation of wires
3 Wire rope with slackened wires due to

corrosion and abrasive wear
9 Wire rope with nodes
10 Wire rope with contraction
10.11.2008 Revision. 0 40 Book 1 B

Pos Description Illustration

13 Wire rope with flattening caused by
driving over the rope
12 Wire rope with knot
11,1 Wire rope with kink

3
Figure 7 Examples of damaged wire rope
Number of visible wire breaks
Drive units as per FEM (DIN) Number of

carrying wires
M1 (1Dm); M2 (1Cm); M5 (2m); M6 (3m); in the outer
M3 (1Bm); M4 (1Am) M7 (4m); M8 (5m); strands of the
crossly parallel lay crossly parallel lay rope
over a length of over a length of over a length of over a length of
6xd 30xd 6xd 30xd 6xd 30xd 6xd 30xd
5 10 2 5 10 19 5 10 101-120
6 11 3 6 11 22 6 11 121-140
6 13 3 6 13 26 6 13 141-160
7 14 4 7 14 29 7 14 161-180
8 16 4 8 16 32 8 16 181-200
9 18 4 9 18 35 9 18 201-220
Table 2 Permissible number of wire breaks in ropes for assessing when a rope has to be replaced
10.11.2008 Revision. 0 41 Book 1 B

5.4.1.9 Measuring 5.4.2 Changing the Ropes
The diameter of a wire rope should be 5.4.2.1 Main hoist rope in machinery
measured with a set of Veneer callipers. house
Two evening plates, as shown in Figure 8
The correct way to measure the nominal The four hoisting ropes run from the drum
diameter of the rope, should be used to to the sheaves at the head frame and back
ensure the nominal diameter of the wire to the fixing points at the trolley. The ropes
rope is measured. can be adjusted by adjusting devices on the
fixing points.
The trim, list and skew motions are
The nominal diameter of a new wire performed by four hydraulic cylinders,
) rope must be measured and recorded connected to the fixing ends of the hoist
before it is installed on the crane. ropes. These cylinders are installed at the
The results of every subsequent
trolley frame. The scope of adjustment is ±
check should also be recorded in the
journal for that wire rope. 5° for each motion.
Due to the design of the hoist

drum one side is left-handed, the
other side right-handed.
The one rope end is clamped to the drum

with rope clamps and bolts.
The other rope end is fixed to the hydraulic
cylinder with a rope key. It normal discard
criteria occurs of one all hoist-ropes have to be
changed.
) Only right hand wire ropes are used.
Tightening the rope clamp after 50

operating hours.
Inspector: Trained mechanic

Staff: Mechanics, assistants
Figure 8 The correct way to measure the nominal diameter
of the rope Equipment: 1 pc fitters tool bag
1 pc Hammer
1 pc Torque wrench
2 pcs Nylon sling (2 m, 2 t)
1 pc Rope shrink
10.11.2008 Revision. 0 42 Book 1 B

5.4.2.1.1 Preparations
5 Extend the trim/list/skew cylinder to
The construction site is to be secured. maximum position from the local
There is no load on the spreader. T/L/S-station
The spreader is positioned on the ground. 6 Switch "off" the crane and secure
against unauthorised switching "on
7 Position trolley machinery-house
Danger of tripping on the crane above the first rope fixing point
trolley!
8 Hook-in maintenance snatch-block
9 Turn trolley maintenance winch in
Please refer to Chapter 5.4.1 of direction of the snatch-block and
this manual for advice on how to guide reeving rope over this pulley
handle the wire ropes.
10 Connect reeving rope with a sling to
the hoist rope
11 Remove all eight rope guides (thread
Step Action to be taken bars) at the deflection pulleys at the
1 Place protective plastic sheets left and trim / list / skew
right from the spreader below
2 Lay the spreader on the ground
3 Dismantle the mechanical limit switch
of the hoist on the drum shaft of the
gear unit.
4 Lower the rope from the local control
panel until half of the last winding
remains on the drum
After the spreader touches the

) ground and the slack rope appears,
the rope has to be coiled up
manually on the plastic sheets on top
of the ground.
10.11.2008 Revision. 0 43 Book 1 B

5.4.2.1.2 Procecure Step Action to be taken

18 Coil off the first new rope while loosely
Step Action to be taken coiling placing up on the plastic sheet
1 Open the wire rope clamps until rope drum is empty
2 Lower the first rope end with the
maintenance winch while coiling up Block area under the crane for
the old rope on the plastic sheet on persons because of falling parts,
the ground. Lead the rope through the rope.
Haedframe rope sheaves with hand.
3 Lead the new rope through the
Keep away from suspended
Haedframe rope sheaves with hand.
loads!
4 Disconnect the old rope from the
rereving rope at the ground
5 Connect reeving rope with new hoist
rope 19 Connect the other end of a new hoist
rope with a sling to the reeving rope
6 Lift up the new hoist rope by coiling off 1m from its end
the drum on the ground until new rope
end appears in the machinery house 20 Lift up the new rope
7 Clamp rope end with 400 mm 21 Fix new rope end with rope key and
excessive length to the drum bolt
8 Fix snatch block above the other end
of the first old hoist rope (Lifting eye is
located below trolley-roof girder) This procedure from 1- 20 is the
) same for all ropes to be changed
9 Turn maintenance winch towards new
snatch-block position and guide before continuing with the
reeving rope over pulley adjustment.
10 Connect reeving rope and main hoist
rope with a sling 800 mm below the
rope-key
Tightening the rope clamp after 50
11 Hoist up the rope about 100 mm to operating hours.
loosen stress on rope end
12 Remove axle holder and pin of rope
key
13 Open rope key and take out rope
(secure rope against falling)
14 Lower the rope to the ground while
coiling up the old main hoist rope on
the plastic cover
15 Disconnect reeving rope
16 Wrap plastic cover around old rope
and remove complete coil with a
forklift
17 Place new plastic cover on the ground
10.11.2008 Revision. 0 44 Book 1 B

5.4.2.1.3 Adjusting The hoist now is ready for operation
Step Action to be taken

1 Operate the main hoist drum with all
1 Operate the main hoist drum with all
four wire ropes connected until
four wire ropes connected until
spreader hangs free
spreader hangs free
Danger to person and material!

Danger to person and material!
Watch out for loops on the
Watch out for loops on the ground.
ground.
2 Lift up the trim/list/skew-cylinder to

2 Lift up the trim/list/skew-cylinder to
"0"-position
"0"-position
3 Measure distance of all spreader
corners to the ground 3 Measure distance of all spreader
corners to the ground
4 Take lowest corner for reference
point 4 Take lowest corner for reference point
5 Lower other rope ends to align
spreader. 5 Lower other rope ends to align
Start with the skew-alignment first spreader.
6 Tighten rope clamps on the drum Start with the skew-alignment first!
with 420 Nm! 6 Tighten rope clamps on the drum with
420 Nm!
The hoist can now be operated.
10.11.2008 Revision. 0 45 Book 1 B

5.4.2.2 Boom hoist rope 5.4.2.2.1 Preparation works:
Two independent rope systems are Step Action to be taken

installed for the boom hoist system. An 1 Place new boom rope drum on an
equalizer at the fixed end of the rope A-frame on the ground.
ensures equal force on each of the ropes. 2 Fix one side of the boom rope close to
The ropes can be adjusted by adjusting the rope equalizer (see Figure 2-10)
devices on the fixing points. by means of the maintenance rope
clamp.
For maintenance purposes the boom can be 3 Lower the boom to end position.
locked in raised position by means of a X
manually operated bolt. This locking bolt
is controlled by a limit switch and
lowering/hoisting the boom will be only
possible if this switch is released.
X
Inspector: Trained mechanic
Staff: Mechanics, assistants
Equipment: 1 pc Fitters tool bag
1 pc Hammer
1 pc Copper pin
Figure Rope equalizer
4 pcs A-frame
1 pc Torque wrench -500 Nm
2 pcs Nylon sling (2 m, 2 to) 5.4.2.2.2 Procedure
1 pc maintenance hoisting unit
The construction site is to be secured. The
spreader is on the ground and there is no
load on the rope.
Please refer to Point 5.4.1 of this

manual for advice on how to
handle the wire ropes.
10.11.2008 Revision. 0 46 Book 1 B


1 Open rope drum clamps. Tightening of rope clamps 560 Nm.
2 Connect reeving rope to new boom-
rope.
3 Lift up new rope end to the equalizer
Both boom ropes can be changed
4 Cut off thimble of old rope and ) simultaneously after having prepared
connect new and old rope.
both rope connections at the pylon!
5 Disconnect maintenance rope clamp.
6 Continue to coil up the old rope while
pulling in the new rope until new end
reaches the drum in machinery .
Secure the second rope end of the

) new wire rope with a nylon-rope,
when lifting up.

1 Fix pin of new thimble at the rope
equalizer.
2 Hold other end of new rope in
machinery house via maintenance
hoisting unit.
3 Disconnect old and new rope
4 Pull the old rope of the drum to the
ground
Secure the second rope end of the

) old wire rope with a nylon-rope,
when lifting up.
5 Fix new rope end with rope clamps to

the drum
6 Disconnect hold of maintenance
hoisting unit
10.11.2008 Revision. 0 47 Book 1 B

The ropes are put on as follows:

left-hand threaded drum right-hand
lay rope.
Adjustment of ropes: right-hand threaded drum right-
hand lay rope.
In order to get a balance at the rope equalizer

the longer side can be pulled by rack hoist and
maintenance rope clamp to adjust the fixing
point. The remaining end at the drum has to be
cut off.
Then the boom hoist is boom operational.
Figure 9 How to change the ropes
10.11.2008 Revision. 0 48 Book 1 B

5.4.2.3 Rope Scheme
5.4.2.3.1 Boom Hoist
10.11.2008 Revision. 0 49 Book 1 B

5.4.2.3.2 Main Hoist
1 Rope ∅ 28 x 134m
2 Hydraulic cylinder (combined function Trim – List – Skew )
3 Main Hoist drum
10.11.2008 Revision. 0 50 Book 1 B

5.5 HYDRAULIC EQUIPMENT The tank must always be cleaned every

time the fluid is changed.
5.5.1 Hydraulic units
Always use a filter to pour oil into
Important maintenance work is: the system. The pore size of this
• Refilling and changing hydraulic fluids filter must be at least 5 µm used
in the system.
• Cleaning filters
• Visual check of leakage
5.5.1.3 Cleaning the filters
• Maintenance of pressure vessels
• Venting the systems The filters are to be cleaned or replaced
• Repair every time the hydraulic fluid is changed.
The amount of dirt can be judged by the
5.5.1.1 Refilling with hydraulic fluid dirt indicator if delivered on the filter or by
measuring the pressure difference in front
In general, the same hydraulic fluid is to be and behind the filter.
refilled as is used to fill the hydraulic
system. This should also be considered in 5.5.1.4 Removing leaks and cleaning the
the case of mineral oils since the individual equipment
oil manufacturers add different additives to
the mineral oils. If fluids of the same type Hydraulic units are to be cleaned from the
but of different manufacturers are mixed, it outside from time to time in order:
is no longer possible to determine the • to be able to locate leakage;
question of liability which may arise due to
• to prevent dirt from entering the unit;
damages.
• to protect extending and protracting
cylinder rods from striation;
5.5.1.2 Changing the hydraulic fluid
• to prevent a reduction in the heat
It is always necessary to change the fluid emission.
if:
• the fluid begins to alter chemically;
During cleaning it is to be
• the amount of fine contamination has ensured that no cleaning
increased to such an extent that greater materials can enter the hydraulic
wear and tear can be expected. system. If high-pressure cleaning
equipment is used, it must be
Required purity Required ensured that all locking points
class purity class such as tank lids, rotary shaft
NAS 1638 ISO 4406 seals etc. are able to withstand
this type of cleaning.
Fresh oil NAS 6 15/12
Oil change Up to NAS 10 19/16
10.11.2008 Revision. 0 51 Book 1 B

5.5.2 Pressure vessels If the maintenance staff does not have

knowledge of both hydraulic and electrical
In the case of hydraulic equipment, systems (is highly desirable but
pressure vessels include hydraulic fluid unfortunately seldom the case), a
tanks which are under high pressure such hydraulics expert and an electrical
as hydraulic accumulators for example. specialist must be employed in order to
localise and remove malfunctions as
The regulations of the respective country quickly as possible.
relating to the handling of pressure vessels
must be observed. The maintenance of the equipment should
be restricted to the replacement of
The fluid in the equipment must complete components.
be depressurized before repair
work is started. Apart from repair work which can be
executed without difficulty, equipment
5.5.2.1 Hydraulic high-pressure hoses should be sent to the manufacturer for
general overhauling. This ensures that the
Exchange any hydraulic hose immediately, equipment in store will be in perfect
if it shows optical defects, or oily surfaces working order.
especially at the pressure points.
5.5.2.1.1 Repair and Maintenance
Maintenance and repair work which is

stipulated as binding in statutory
regulations and the stipulations of the
employers' liability insurance associations
must be carried out and appropriately
documented to ensure the safety of the
operating personnel and to prevent any
possible damage to material.
It is advisable to keep all the

documentation data and the most important
measuring devices for the maintenance of
the equipment on site. This will make
troubleshooting as successful and brief as
possible.
10.11.2008 Revision. 0 52 Book 1 B

6 REPAIR INSTRUCTIONS 6.1.1.2 Procedure

6.1 GANTRY DRIVE 1 Remove bolts between motor and
flange
6.1.1 Changing of motor and gear 2 Separate motor coupling from
box gearbox-coupling (refer to the
manufacturer's documentation in the
Appendix
Supervision: Duly instructed foreman,
engineer 3 Place motor on the ground and
protect against damage by shaft-end
Personnel: Mechanic, helpers, or water intrusion
electrician
4 Place forklift under gearbox with pallet
Devices: 2 hydraulic jacks
5 Remove the pin of the torque support
1 I-girder 500 St 37
6 Lower down one side to free the
2 timber beams
gearbox-eye of the support
1 fork lift assembly tools 7 Remove the gearbox cover of the
outgoing shaft
8 Loosen the bolts of the shrink-disc
6.1.1.1 Preparation clockwise one after one (refer to the
manufacturer's documentation
The work is to be carried out on stable, 9 Remove shrink rings
well fortified and levelled ground. The 10 Insert two M10 thread-bars to push
construction site is to be adequately the gearbox from the hollow-shaft
secured and fenced off from prevailing (~25 mm)
traffic. 11 Lift up the gearbox again to a
horizontal position
The trolley and the boom are in inoperative 12 Pull out the gearbox completely
position. No load is attached to the 13 Place gearbox on the ground and
spreader. protect the drain pipe and incoming
Switch off the crane and secure crane shaft against damages.
against unauthorized switching “On”. 14 Clean wheel and gearbox (hollow)
shaft
Danger of electrical power! Make

) sure that the standstill heater and The installation is done vice versa.
other devices are switched "off". ) Do not put any lubricant between
shaft and gearbox and hollow shaft
and shrink-ring. Refer to
maintenance instructions of gear
manufacturer.
In bypassing the one dismantled

) gantry motor it is possible to
continue crane operation under
normal conditions, if spare motor or
gearbox is not available.
10.11.2008 Revision. 0 53 Book 1 B

6.1.2 Changing of gantry wheel 6.1.2.2 Procedure
At driven wheels it is the best to remove Step Action to be taken

the boogie. 1 Lift up the bogie as shown on the
drawing
The following description explains the
removal of a driven wheel next to a jacking
point (most difficult dismantling). Motor and protection bar need not
) be dismantled because of working
access from inside the gantry. Make
Supervisor: Duly instructed foreman, sure that motor and attachments
engineer are not damaged.
Personnel: Mechanic, electrician, helpers
2 Secure wheel with rope against tilting
Devices: Maintenance crane,
3 Change gear wheel, bearing or
complete wheel
6.1.2.1 Preparation:
Motor and protection bar need not
Step Action to be taken ) be dismantled because of working
1 Lift up the boom and move crane to access from inside the gantry. Make
storm anchor position sure that motor and attachments
2 Place jacking support and hydraulic are not damaged.
jack below the jacking position
The installation is done in inverse
3 Remove protection-cover for gear
wheel
) sequence. If the gear wheel has to
be dismantled, the correct torque for
4 Remove bearing bushing
the bolts has to be applied.
5 Secure wheel with wedge
10.11.2008 Revision. 0 54 Book 1 B

Abbildung 5 Gantry drive
10.11.2008 Revision. 0 55 Book 1 B

6.2 TROLLEY DRIVES 6.2.1.2 Procedure:
6.2.1 Dismantling of trolley drive Step Action to be taken

gearbox 1 Place trolley below maintenance flaps
of the machinery house
Supervisor: Duly instructed foreman, 2 Switch "off" the crane
engineer
3 Open machinery house flaps and
Personnel: Mechanic, electrician, helpers lower the hook
Devices: - 2 pcs Wooden pallet,
- 1 pc Thread-bar (M24, 500 Danger of voltage! Switch “off”
mm) + 2 nuts heater and other electrical
- 2 pcs Thread bar (M10, 500 devices.
mm + 4 nuts
4 Connect slings with motor and crane

hook - pull tight
6.2.1.1 Preparation
The trolley is in its inoperative position

and is secured against unintentionally 6.2.1.3 Dismantling/Installation:
rolling. The spreader is detached.
1 Disconnect gearbox by disconnecting
the cardan shaft (refer to
Danger of falling manufacturer's instruction type in the
appendix
2 Connect the slings to the gearbox.
Pull slings tight
3 Open outgoing shaft cover
Danger of tripping 4 Loose bolts and remove shrink-discs
step by step, not cross wire
5 Disconnect torque support
As this work is to be carried out at a
6 Use screws to press out the gearbox
substantial height, work scaffolding is
necessary to provide the personnel with 7 Hoist up the gearbox to change or
adequate protection against falling. repair it, or place it carefully on a
A light scaffold can be constructed, or an pallet on top of the trolley platform
appropriate elevating platform can be used.
The installation is done in inverse
The relevant occupational safety ) sequence. Make sure that no
regulations for work at great heights
lubricant is left between wheel shaft
(wearing safety belts, etc.) are to be
and gearbox hollow shaft.
observed.
8 The installation of the gearbox is done
with a thread bar
10.11.2008 Revision. 0 56 Book 1 B

6.2.2 Dismantling of trolley wheel 6.2.2.2 Procedure
Supervisor: Duly instructed foreman, Step Action to be taken

engineer
1 Place hydraulic jack between rail and
Personnel: Mechanic, electrician, helpers jacking plate next to the trolley wheel
Devices: Maintenance crane 2 Jack up the trolley corner slightly (size
Sling ropes; fitting tools A)
Tools: 3 Place wooden beam under trolley
- 1 pc rack-hoist (1.5 t)
frame
- 1 pc sledge hammer 4 Open machinery-house flap and lower
- 2 pcs nylon sling (2 m, 2 t)
down the crane hook
- 1 pc hard wood plate 5 Open bolts at bearing plate of the
- 1 pc hydraulic jack (50 t) wheel.
6 Connect sling through wheel bore to
the maintenance crane
Danger with lifting device!
Make sure that the hydraulic jack
is not leaking or lowering
pressure during the whole
* Secure wheel against falling.
procedure.
7 Rolling wheel off bearing plate
6.2.2.1 Preparation 8 Hoist up old wheel and lower down
the spare wheel
Before tightening the new wheel
1 The trolley is in interlocking position ) the span has to be checked and
and is secured against
aligned.
unintentionally rolling. The spreader
is detached
2 Move trolley under the machinery- After tightening of all bolts the
house flaps where the wheel is to be crane can be put in operation!
changed (refer to tightening table).
3 Place tools and material on top of

the bridge-girder below the
machinery-house
4 Switch "off" the crane and secure
against unauthorised switching "on"
10.11.2008 Revision. 0 57 Book 1 B

Figure 10 Trolley wheel
10.11.2008 Revision. 0 58 Book 1 B

6.2.3 Changing main parts of the

trolley machinery house Step Action to be taken
1 Lift up the boom and secure crane in
Supervisor: Duly instructed foreman, storm anchor position
engineer
2 Move trolley under maintenance
Personnel: Mechanic, electrician, helpers flaps of machinery-house in order to
Devices: Maintenance crane open the trolley maintenance flaps
Sling ropes 3 Open flaps of machinery-house with
maintenance crane and lower hook
Fitting tools
to the upper trolley platform
4 Remove middle piece of platform
6.2.3.1 Preparation and fix it to one trolley side
The construction site is secured. The

electric power supply to the hoisting unit is Danger of dropping!
disconnected. The head block has been Secure opening with ropes.
deposited on the ground.
5 Lower spreader to the ground from
It is expedient to carry out repair work on local control station until four
the gear unit in the workshop. The windings are left on the drum
procedure described here concerns
complete removal of the gear unit of the
hoisting unit on the upper trolley and Protect ropes on the ground with
deposition of the gear unit on the ground ) plastic sheets.
with the aid of a maintenance crane.
Danger of tripping
10.11.2008 Revision. 0 59 Book 1 B

6.2.3.2 Procedure 6.2.3.4 Dismantling of brakes:
Step Action to be taken Step Action to be taken

1 Open trolley roof flap 1 Disconnect cables from thrustor and
2 Secure all four wire ropes with nylon limit switch
ropes 2 Decrease torque at brake
3 Lower down hoist drum until only 3 Open bolts at base-plate
3 windings are left. Switch "off" 4 Open and lift up the complete brake by
crane. fixing a nylon sling at the thrustor-arm
4 Mark drum position
5 Fix hoist limit-switch with adhesive Refer also to the manufacturer's
tape and remove the complete ) documentation for brake installation.
device
6 Open rope clamps at hoist-drum and 5 Place brakes in front of the brake
coil hoist rope ends on the supports
machinery-house floor
7 Move trolley maintenance crane
over the first hoist motor
6.2.3.5 Dismantling of hoist drums:

6.2.3.3 Dismantling of motors:
1 Fix two 5 m slings around the drum at
left and right winding. Pull hoist chain
1 Disconnect cables from motor fan, tight after connecting it to the hook
motor and tachometer
2 Remove brake
2 Loosen bolts of motor support
Refer to the manufacturer's

Danger of electrical power! instruction in the appendix.
Switch “off” all devices like space
heaters or such. 3 Remove bolts of hoist drum bearing
support
3 Fix motor with nylon-sling to 4 Lift up drum slightly
maintenance hoist. Lift up slowly
5 Remove bearing support if drum is to
4 Place motors on square timber in be changed
front of the motor supports Move drum carefully away from the
6
gear-coupling until drum hangs free.
Refer to the manufacturer's

instruction in the appendix.
10.11.2008 Revision. 0 60 Book 1 B

6.3 BOOM HOIST GEAR 6.3.1.3 Dismantling of motors:
6.3.1 Dismantling of Boom Hoist gear Step Action

1 The ropes first have to dismantled
Supervisor: Duly instructed foreman, from the drum. The ropes have to
engineer recoiled until the rope clamps, fixed
Personnel: Mechanic, electrician, with auxiliary ropes, and taken off
helpers after opening of rope clamps.
Devices: Maintenance crane 2 Pull of power supply cable in terminal

box of motor
Sling ropes
Fitting tools
Danger of electrical power!
Wooden beam
Switch "off" all devices like
space heaters or such.
6.3.1.1 Preparation 3 Loosen bolts of motor support
The construction site is secured. The

electric power supply to the boom hoisting
Refer also to the manufacturer's
unit is disconnected. The boom and the ) documentation for motor
trolley are in interlocking position. The installation.
spreader has been deposited on the ground.
4 Fix motor with nylon-sling to
maintenance crane lift up slowly
6.3.1.2 Procedure 5 Place motors on square timber in front
of the motor supports
It is expedient to carry out repair work on
the gear unit in the workshop. The 6.3.1.4 Dismantling of brakes:
procedure described here concerns
complete removal of the gear unit of the Step Action
boom hoisting unit and deposition of the
1 Disconnect cables from thrustor and
gear unit on the ground with the aid of a limit switch
maintenance crane.
2 Decrease torque at brake
3 Open bolts at base-plate
4 Open and lift up the complete brake
by fixing a nylon sling at the thrustor-
arm

) documentation for brake installation.
5 Place brakes in front of the brake

supports
10.11.2008 Revision. 0 61 Book 1 B

6.3.2 Dismantling of boom hoist 6.4 BOOM LIFTING WITH THE

drums AUXILIARY DRIVE
Step Action The boom hoist unit is equipped with a

1 Remove rope overlap indication aux. drive, which is able to lift the boom in
2 Place wooden beam under drum
case of a default of the frequency
flange refer to Figure 11 Boom hoist converter. The aux. drive shall be used
drum. only for lifting the boom in horizontal
3 Remove safety brake and drum position. But it is possible ( in emergency
bearing block. situation ) to lift the boom with the aux.
4 Remove drum bearing. drive.
5 Remove bolts of drum flange.
Supervisor: Duly instructed foreman,
6 Hold drum on site “A” by means of engineer
maintenance crane.
Personnel: Mechanic, electrician
7 Lower drum through bottom hatch by
means of maintenance crane. Crane operator
Devices: fitting tools
8 Loosen bolts at drum coupling.
9 Separate coupling flange by turning of
bolts. 6.4.1 Procedure
10 Catch drum at side “B” by means of
maintenance crane. Step Action
11 Pull off drum to the right and lower 1 Take off the protection grid.
through bottom hatch. 2 Install the chain between aux. drive
and boom hoist unit motor.
The gearbox is now free and can be Tight the chain. Check that the limit
) dismantled!
3
switch resets.
4 Starting of aux. drive motor.
12 Loos Bolts of gear support. 5 Lowering or lifting the boom.

) documentation for gear installation.
13 Fix gearbox with nylon-sling to

maintenance crane lift up slowly.
14 Lower gearbox through bottom hatch
by means of maintenance crane.
10.11.2008 Revision. 0 62 Book 1 B

Figure 11 Boom hoist drum
10.11.2008 Revision. 0 63 Book 1 B

6.5 TRIM LIST SKEW SYSTEM, 6.5.2 Levelling and squaring of the
MACHINERY HOUSE spreader, rope length adjusting
6.5.1 Checks and adjustments of Step Action

Trim- List - Skew Device 1 Retract all cylinders to the ends and
record the reference distance.
Supervisor: Duly instructed foreman, 2 Extend them to 575 mm from the
engineer upper end.
Personnel: Mechanic, electrician, helpers 3 Pick up an empty container and lift it
Devices: Maintenance crane to approx. 300 mm above ground
(using main hoist only!)
Load bearing capacity 5 t
4 Level the spreader using the control
Lifting height 23 m
panel at the trolley house. Determine
Sling ropes the highest corner of the spreader and
Fitting tools retract the other three cylinders until
the spreader is levelled.
The crane is equipped with a TRIM-LIST- Confirm that the spreader is squared
SKEW device with SNAG LOAD also by using traffic lane markings as
protection. reference. To get the spreader in
level, use the anglemeter and monitor
the distance from the stripes at the
It is mounted at the trolley and consists of ground to the container.
four hydraulic cylinders hinged to the
5 Record the reference distances with
trolley frame nearby the trolley wheel the spreader in level and calculate the
assemblies. The piston end of each respective cylinder stroke (difference
cylinder is connected to one rope end. The of both reference distances).
device is powered by a hydraulic unit
located at the trolley housing.
The spreader and thus the container will be

trimmed, listed or skewed by stroking out
or in the piston rods of the cylinders. The
cylinder movements will be controlled by
the switches at the driver's console or, for
maintenance purposes, from a local
operation station at the trolley house.
The SNAG LOAD will be indicated by the

pressure switch at the end of the cylinders.
10.11.2008 Revision. 0 64 Book 1 B

With the spreader levelled, no one

) of cylinders must not extend more
than 550 mm, all cylinder strokes
must range between 200 and 300
mm.
If the difference “y” in stroke

) between the highest and lowest
cylinder exceeds 200 mm, readjust
the hoist ropes (see procedure
„readjusting rope lengths) at the
drum and start with step #1 again.
6 Set the actual cylinder positions as

"Zero Position".
7 Test Trim/List/Skew limit switches
Difference between cylinder
10.11.2008 Revision. 0 65 Book 1 B

Reference distances [mm] Cylinder stroke [mm]

Cylinder retracted Spreader levelled CMMS reading
completely
Cylinder #1
Cylinder #2
Cylinder #3
Cylinder #4
Maximum difference between cylinder strokes:
mm.
10.11.2008 Revision. 0 66 Book 1 B

6.5.3 Readjusting rope lengths:
Step Action
1 Put the container to the ground by
using main hoist until slack-rope limit
switch stops the drive.
2 Unload the rope clamps by holding
the rope leading from the drum to the
headframe using an auxiliary rope and
the maintenance hoist.
(see Figure 12 lift dead load of rope).
Secure the ropes against falling
3 Mark rope clamp position on the rope
and remove rope clamps
4 Set the rope back for the length 575 Figure 12 lift dead load of rope
mm.
5 Tie off the part of the rope which
projects over the clamp and cut it off
behind the tied off spot.
6 Assemble rope clamps with new tab
washers.
7 Repeat the same procedure for all
ropes.
8 Remove all tools and lift equipment
10.11.2008 Revision. 0 67 Book 1 B

6.5.4 Checks and adjustments of 6 Important: The pressure switch should

SNAG LOAD protection device act. before manifold opens!
7 Repeat with remaining cylinders.
For a detailed description, refer to
the functional description.
8 Set the relief valve pressure at the
hydraulic unit back to 2000 psi!
In case the spreader jammed inside the ship 9 Extend the cylinders to their HOME
cells, and the rope force exceeds the position
SNAG LOAD setting of the cylinder
manifolds and the pressure switch the drive For records, fill out the table below
will be stopped by countering the motors Pressure gauge reading [psi]
and applying the mechanical brakes.
Pressure switch CARTRIDGE
Until the motors stopped, the cylinders opens opens
stroke out to prevent excessive rope loads
Cylinder #1
which could damage the machinery or
other parts of the crane. Cylinder #2
Cylinder #3
6.5.4.1 SNAG LOAD Protection Cylinder #4
adjustments and Event Sequence
Check
The following test to be performed as a

workshop test. This adjustment can be
performed only after having the load cells
adjusted.
Step Action
1 Retract all cylinders completely.
2 Set the pressure relief valve at the
TRIM-LIST-SKEW hydraulic unit
to190 bar.
The following actions to be carried

) out with hand pump only! Push the
solenoid #49 by hand.
3 Starting with cylinder #1, connect the

pressure gage to the gage port at the
cylinder manifolds.
4 Put on pressure using hand pump and
pushing solenoid #49 by hand.
5 Record the pressure values, when
pressure switch activates and cylinder
manifolds opens with pressure
ascenting.
10.11.2008 Revision. 0 68 Book 1 B

6.5.4.2 Checks to be done after SNAG 6.5.4.3 SNAG LOAD Protection test
LOAD occurred
After a SNAG LOAD occurred the the functional description.
rope and hoist system must be checked
completely because of damages due to These tests must be performed several
over load
times a year (refers to preventive
maintenance plan) to check the correct
After clearing the spreader, the crane has operation of the SNAG LOAD protection.
to be put into operation by maintenance
personnel supported by the crane operator Motor and brake performance check:
according to the following procedure:
1. Hoist the empty spreader with full
1. Check the condition of the cylinders, speed.
ropes, rope fixing points, head block,
drum and drum supports, motor 2. During the movement, jumper one of
couplings by visual inspection. In case the pressure switches at the cylinders.
any improper conditions of any part of 3. Monitor nominal and actual speed and
the equipment will be found, repair motor current versa time.
and/or replace the damaged items prior
continuing container handling.
The actual speed graph shall have a nick
2. Switch on control power. after approx. 200 ms (mechanical brakes
3. Level the spreader by pushing the start acting).
"home position" button at the operator's The drive shall stop after approx. 500 ms.
chair console.
4. Lift the spreader to a height convenient
to watch the spreader during levelling. If
the spreader is not in level, level it
according to the procedure as stated
above.
5. Continue container handling
The crane is operational with full speeds

even if a fault on the TRIM-LIST-SKEW
device occurred (e.g. loss of cylinder
position, break down of hydraulic power
unit). In that case, adjust the spreader by
lowering the three upper corners of the
spreader by manual operation of the flow
control valves at the hydraulic unit.
10.11.2008 Revision. 0 69 Book 1 B

For records, fill out the table below
Shop test Field test Comments OK

Mechanical Brake X
activated after 200ms
Drive stops after X
500ms
10.11.2008 Revision. 0 70 Book 1 B

6.5.4.4 Adjusting of load cells

For records, fill out the table below
the functional description Ropes released
Oil pressure Load cell
To get most accurate data, the cylinders [bar] indication [t]
should not be moved for the last 15 min Cylinder #1
prior to the start of the works. Cylinder #2
Cylinder #3
This test shall be perfomed as a
) workshop test. Cylinder #4
To get most accurate data, the cylinders

should not be moved for the last 15 min
prior to the start of the works. Test container suspended
Oil pressure Load cell
[bar] indication [t]
1. Load the test container to 42 tons Cylinder #1
concentric and level the spreader. Cylinder #2
Cylinder #3
2. Put the spreader on the top of the Cylinder #4
container, release the ropes and adjust
all load cells to zero (using main hoist
only!).
3. Starting with cylinder #1, connect the

pressure gage to the gage port, lift the
container (using main hoist only!) and
monitor the pressure.
4. Calculate the equivalent load cell

reading and adjust the load cell
consequently.
5. Lower the container to the ground

(using main hoist only!) and repeat
step 3 & 4 for the remaining three
cylinders.
10.11.2008 Revision. 0 71 Book 1 B

6.6 BOLT CONNECTIONS

- Only use bolts with strength classes
All connecting devices in our products
) above 8.8 and nut with strength
comply with DIN-EN classes and carry classes above 8.
according makings as shown the following - Only used bolts with no apparent
Figure. damage, especially the threads.
- Oil threads slightly with MoS2.
The strength of the bolt or nut is imprinted Depending on the size and location
of the bolt, the torque limits may be
on the head of the bolts and the front/back
different. Always refer to the torque
of the nuts. table when installing bolts.
- Use a torque wrench with
appropriate range to fasten bolts.
Figure 13 Marking of bolts and nuts
The markings always have to agree.
Example:
• Normal connections
Bolt 8.8
DIN 931
ISO 4014
Belongs to Nut 8
DIN 934
ISO 4032
• High strength connections
Anchor bolt or 10.9

screw
Belongs to Nut 10
Only use high strength bolts for load

connecting areas.
10.11.2008 Revision. 0 72 Book 1 B

6.6.1 Torque wrench 6.6.2 Pin Connections
Check bolts that have been fastened with a Pins shall be well greased prior to each
torque wrench after 100 working hours. installation. After the installation this
Verify that the bolts are still tightened to process is to be repeated at all accessible
the correct torque listed in Table 3. After spots of the pin.
the first 100 hours they should be checked • The splints must only be mounted once
annually. in case of splints with secured pin
connections.
High tension bolts of shrink disc resp. • New splints shall be used after a
shrink ring assemblies to be checked for dismounting of the pins.
tightness after handover of the crane and
after each disassembly/assembly applying
the required tightening torque as stated.
Check means:
)
- missing screws renew;
- check tightness of all fastening
bolts;
- pre-tension and protections .
Always replace bolts that cannot

tighten to their torque
requirements.
Check the classification of the nut
and bolt. Ensure they match.
In case of changing high strength

connections the screwing locking devices
always must be exchanged. The locking
varnish (Loctite 02) must be replaced.
10.11.2008 Revision. 0 73 Book 1 B

6.6.3 Table for Tightening Torque for bolts

Hexagon nuts DIN 931, DIN 933 ISO 4014; ISO 4017
Hexagon socket bolts DIN 912 ISO 4762
HT-bolts connections DIN 6914, DIN 6915, DIN 6916
Thread bolts DIN 914 ISO 4027
Hexagon nuts for steel works DIN 7990
Anchored bolt FACTORY STANDARD WN 83.130
S = Screw * = Screw oiled

N = Nut ** = Screw MoS2 lubricated
Z = Anchored screw SW = weidth across flats
HT = HSFG connection
HT- fasteners - 10.9 acc. to DIN 6914 / 6915 required torque MA in Nm

Bolt SW Bolt and nut bolt and nut
diameter Hot dip galvanized Not galvanized
Nut MoS2 -lubricated Slightly lubricated (oil)
M 12 22 100 120
M 16 27 250 350
M 20 32 450 600
M 22 36 650 900
M 24 41 800 1100
M 27 46 1250 1650
M 30 50 1650 2200
M 36 60 2800 3800
10.11.2008 Revision. 0 74 Book 1 B

Required torque MA in Nm
Bolt Streng.
diameter grade MoS2 -lubricated Slightly lubricated (oil) Dry
µ = 0,08 µ = 0,10 µ = 0,12
8.8 36 41 46
M 10 10.9 52 60 68
12.9 61 71 79
8.8 61 71 79
M 12 10.9 90 104 117
12.9 105 121 135
8.8 97 113 125
M 14 10.9 145 165 185
12.9 165 195 215
8.8 145 170 195
M 16 10.9 215 250 280
12.9 250 300 330
8.8 210 245 280
M 18 10.9 300 350 390
12.9 350 410 460
8.8 300 350 390
M 20 10.9 420 490 560
12.9 500 580 650
8.8 400 470 530
M 22 10.9 570 670 750
12.9 670 780 880
8.8 510 600 670
M 24 10.9 730 850 960
12.9 850 1000 1120
8.8 750 880 1000
M 27 10.9 1070 1250 1400
12.9 1250 1450 1650
8.8 1000 1190 1350
M 30 10.9 1450 1700 1900
12.9 1700 2000 2250
8.8 1400 1600 1850
M 33 10.9 1950 2300 2600
12.9 2300 2700 3000
8.8 1750 2100 2350
M 36 10.9 2500 3000 3300
12.9 3000 3500 3900
8.8 2300 2700 3000
M 39 10.9 3300 3800 4300
12.9 3800 4500 5100
Table in general acc. to Table 1 and 5 of VDI 2230 Sh. 1
Table 3 Tightening Torque
10.11.2008 Revision. 0 75 Book 1 B

6.7 STRENGTHENING AND 6.7.3 Design for Strengthening and

REPAIRING CRANE STEEL Repair
STRUCTURES
6.7.3.1 Design Process.
The structural integrity of the crane requires
that no attachments or fixtures of any kind The design process shall consider
be welded to any part of the crane without applicable governing code provisions and
prior written approval of the responsible other parts of the general specifications.
Maintenance Manager. The Engineer shall specify the type and
extent of survey necessary to identify
existing conditions that require
6.7.1 General strengthening or repair in order to satisfy
applicable criteria.
Strengthening or repairing an existing
structure shall consist of modifications to
meet design requirements specified by the 6.7.3.2 Stress Analysis.
Engineer. The Engineer shall prepare a
comprehensive plan for the work. Such An analysis of stresses in the area affected
plans shall include, but are not limited to, by the strengthening or repair shall be
design, workmanship, inspection and made. Stress levels shall be established for
documentation. Except as modified in this all in-situ dead live load cases.
section, all provisions of this code apply Consideration shall be made for
equally to the strengthening and repairing accumulated damage that members may
of existing structures, including heat have sustained in past service.
straightening of distorted members.
6.7.3.3 Fatigue History

6.7.2 Base Metal
Members subject to cyclic loading shall be
6.7.2.1 Investigation designed according to the requirements for
fatigue stresses. The previous loading
Before preparing drawings and history shall be considered in the design.
specifications for strengthening or When the loading history is not available, it
repairing existing structures, the types of shall be estimated.
base metal used in the original structures
shall be determined either from existing
drawings, specifications or from 6.7.3.4 Restoration or Replacement
representative base-metal tests.
Determination shall be made whether the
repairs should consist of restoring corroded
or otherwise damaged parts or of replacing
entire members.
10.11.2008 Revision. 0 76 Book 1 B

6.7.3.5 Loading During Operations 6.7.4 Fatigue Life Enhancement
The Engineer shall determine the extent to 6.7.4.1 Methods

which a member will be permitted to carry
loads while heating, welding or thermal The following methods of reconditioning
cutting is performed. When necessary, the critical weld details shall be permitted when
load shall be reduced. The local and general written procedures have been approved by
stability of the member shall be the Engineer:
investigated, considering the effect of
elevated temperature extending over parts (1) Profile Improvement. Reshaping the
of cross-sectional area. weld face by grinding with a carbide
burr to obtain a concave profile with a
6.7.3.6 Existing Connections smooth transition from base material to
weld.
Existing connections in structures requiring (2) Toe Grinding. Reshaping only the weld
strengthening or repair shall be evaluated toes by grinding with a burr or pencil
for design adequacy and reinforced as grinder.
necessary. (3) Peening. Shot peening of weld surface,
or hammer peening of weld toes.
6.7.3.7 Use of Existing Fasteners
(4) TIG Dressing. Reshaping of weld toe
by the remelting of existing weld metal
When design calculations show rivets or
with heat from GTAW arc (no filler
bolts will be overstressed by the new total
metal used).
load, only existing dead load shall be
assigned to them. If rivets or bolts are (5) Toe Grinding plus Hammer Peening.
overstressed by dead load alone or are When used together, the benefits are
subject to cyclic loading, then cumulative.
6.7.4.2 Stress Range Increase
The Engineer shall establish the appropriate

increase in the allowable stress range.
10.11.2008 Revision. 0 77 Book 1 B

6.7.5 Workmanship and Technique 6.7.6 Welding
6.7.5.1 Base-Metal Condition Welding to be accomplished only by

following the instructions of the Welding
Base metal to be repaired and surfaces of Engineer
existing base metal in contact with new
base metal shall be cleaned of dirt, rust and Generally, welding on load bearing parts of
other foreign matter except adherent paint cranes is subject to the approval by the
film as per SSPC SP2 (Hand Tool Welding Engineer. This precept is valid for
Cleaning). The portions of such surfaces all welding technologies, stitch welding,
which will be welded shall be thoroughly fillet or butt welds. Due to possible melting
cleaned of all foreign matter including paint of the material, this rule has to be followed
for least 2 in. (50mm) from the root of the in case of substitution of parts of welded
weld. cranes as well.
Without prior approval, welding is allowed

6.7.5.2 Member Discontinuities only on not loaded parts, e.g. railings,
ladders, floor cladding, toe bars, covers and
When required by the Engineer, claddings, cable festoon runways, trolley
unacceptable discontinuities in the member bar support etc.
being repaired or strengthened shall be
corrected prior to heat straightening, heat In case of cable or pipe line routing, no
curving or welding. clamps, cable ladders, switches, pipes,
conduits etc. are allowed to be attached to
the load bearing structure by welding or
stitch welding without approval by the
responsible engineer. This is allowed only,
if the part will be attached to a
miscellaneous structure. This rule applies
for doweling as well. Clamped connections
are recommended in substitution of welded
connections.
Watch carefully, that no rolling friction

bearings, sheaves and other point contact
parts are in the way of the feedback current
between welding location and ground cable,
since this may cause spots (burning grooves
and pitting) at the rings and rollers of
bearings and at the contact points of rope
and sheave. This may shorten the lifetime
of bearings tremendously.
10.11.2008 Revision. 0 78 Book 1 B

In order to prevent random paths of 6.7.7.2 Base Metal of Insufficient

feedback currents, the ground cable has to Thickness
be attached to the welding location as near
as practicable. Base metal having insufficient thickness to
develop the required weld size or required
To ease ignition and to get rid of the slack capacity shall be, as determined by the
pinot at the welding rod tip, some welders Engineer: (1) built up with weld metal to
slip the welding rod at the nearest structural the required thickness, (2) cut back until
part. The ignition spots caused hereby, and adequate thickness is available, (3)
which may extend up to 10 cm (more than 3 reinforced with additional base metal, or (4)
inches); decrease the fatigue strength of the removed and replaced with base metal of
structure. adequate thickness or strength
Therefore, welding rods are to be slipped
only at miscellaneous items, e.g. hammer,
earthing clamp, and to be ignited only at the 6.7.7.3 Heat Straightening
weld location itself.
When heat straightening or heat curving
methods are used, the maximum
6.7.7 Flame cutting temperature of heated areas as measured by
approved methods shall not exceed 1100°F
In general, flame cut edges are to be ground (590°C) for quenched and tempered steel,
smooth and notch-free. Flame cutting at nor 1200°F (650°C) for other steels.
load bearing parts is subject to the approval Accelerated cooling of steel above 600°F
by the responsible engineer only. (315°C) shall not be permitted.
Flame cutting at miscellaneous parts is
allowed.
6.7.7.4 Welding Sequence
6.7.7.1 Drilling
In the strengthening or repairing members
Drilling works at load bearing parts is by the addition of base metal or weld metal,
generally subject approval by the or both, welding and weld sequencing shall,
responsible engineer only. as far as practicable, result in a balanced
heat input about the neutral axis to
minimize distortion and residual stresses.
10.11.2008 Revision. 0 79 Book 1 B

6.7.8 Repair work summary
Type of work to be executed Welded crane structures

Welding at load bearing parts Subject to approval
at miscellaneous parts1 allowed
Stitch welding2 at a finished crane at load bearing parts Subject to approval
structure at miscellaneous parts allowed
Flame cutting at load bearing parts Subject to approval
at miscellaneous parts allowed
Drilling at load bearing parts Subject to approval
at miscellaneous parts allowed
at the free surfaces of allowed
diaphragms and stiffeners
1
Railings, ladders, floor cladding, toe bars, covers and claddings, cable festoon runways, trolley bar support etc. are to be
counted as miscellaneous parts. In some applications, these parts may be integrated into the load bearing structure
2
E.g. the subsequent installation of railings, labels, lighting fixture supports, switches, electrical cabinets, cable clamps, cable
ladders etc.
10.11.2008 Revision. 0 80 Book 1 B

6.7.9 Quality
6.7.9.1 Visual Inspection
All members and welds affected by the

work shall be visually inspected in
accordance with the Engineer`s
comprehensive plan.
6.7.9.2 Nondestructive Testing
The method, extent, and acceptance

criteria of nondestructive testing shall be
specified in the contract documents.
Using magnetic particle test methods,

current is to be applied only after the
electrode has been properly attached to the
structure. Otherwise, burning spots may
occur decreasing fatigue strength of the
structural part as ignition spots do.
It is recommended not to use MT in areas

with high loads and where stress peaks can
be expected, e.g. change of section, weld
crossings etc. Liquid penetration test (LPT)
is recommended instead.
10.11.2008 Revision. 0 81 Book 1 B

7 SETTING CRANE OUT 8 DISASSEMBLY AND

OF OPERATION DISPOSAL OF THE
CRANE
For a period out of work longer than 3
month special monitoring and maintenance For disassembly all operating fluids must
have to be done. be emptied. The disposal of the fluids must
be done unmixed acc. to the local disposal
requirements. All big components must be
For a longer out of work period disassembled.
ask NOELL and RCP for special
activities for Conservation.
The single crane parts must be separated
acc. to the relevant materials and the
disposal must be in acc. with the local
Once a month for a period from 3 to 12 disposal requirements.
month:
• all drives, hoists and tools have to be
moved with a minimum time for each 9 GENERAL DRAWINGS
part of 5 minutes till the gears and parts
are heated on working temperature;
Refer to Books 2, 3 and 4.
• oil level of all gear must be inspected
(acc. lubrication chart);
• all lubrication items must be lubricated
• flush all pneumatic parts with oiled air
longer than 5 minutes;
• operate all air condition systems during
closed doors for more than 15 minutes;
• use twice the Emergency stop button
during reduced speed.
Once a year after standing still period of

12 month:
• change oil of all gears and hydraulic
systems according lubrication charts
• renew grease of all greased parts after
be on working temperature
• check all breaks for corrosion
• check all ropes for corrosion
10.11.2008 Revision. 0 82 Book 1 B

B-Repair Ad Maintenance Manual - Rev0

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

B-Repair Ad Maintenance Manual - Rev0

Uploaded by

Copyright:

Available Formats

Operating Manual

Repair and Maintenance

10.11.2008 Revision. 0 1 Book 1 B

1 WARNINGS AND SYMBOLS ................................................................................. 6

10.11.2008 Revision. 0 2 Book 1 B

5.4 WIRE ROPES .....................................................................................................................................34

10.11.2008 Revision. 0 3 Book 1 B

6.2 TROLLEY DRIVES ...........................................................................................................................56

10.11.2008 Revision. 0 4 Book 1 B

6.7 STRENGTHENING AND REPAIRING CRANE STEEL STRUCTURES..................................76

10.11.2008 Revision. 0 5 Book 1 B

1 WARNINGS AND Note

The symbols and notes in the manual are Reference

Refers to orders and prohibitions

CAUTION ELECTRIC Danger

Keep away from suspended

10.11.2008 Revision. 0 6 Book 1 B

2 SAFETY The container crane is built according to

10.11.2008 Revision. 0 7 Book 1 B

10.11.2008 Revision. 0 8 Book 1 B

They should be encourage to a work in 2.3 SAFETY AND ACCIDENT

Any other use, not in accordance with

NCS/RCP only accepts liability for

10.11.2008 Revision. 0 9 Book 1 B

2.4 OPERATING THE CRANE - 2.4.1 Maintenance and repair

Maintenance and overhauling may

* Follow the safety warnings

10.11.2008 Revision. 0 10 Book 1 B

2.4.2 Danger zone The operation has to be stopped

Increased risk must be indicated by 2.4.4 Effectiveness of safety devices

When malfunctions are eliminated,

10.11.2008 Revision. 0 11 Book 1 B

2.5 CONDUCT IN CASE OF 2.6 DUTIES DURING AND

* Follow the safety warnings!

− conductive parts must be switched off

10.11.2008 Revision. 0 12 Book 1 B

− inform the operating personnel before 2.7 EMERGENCY

The lowering of the boom (closing

10.11.2008 Revision. 0 13 Book 1 B

3 INTRODUCTION Any intervention by the owner without the

During the warranty period, maintenance

10.11.2008 Revision. 0 14 Book 1 B

4 TESTS AND 2. Inspection of the crane with respect to

10.11.2008 Revision. 0 15 Book 1 B

4.1.2 Inspection after Important The recurrent inspection must

10.11.2008 Revision. 0 16 Book 1 B

4.1.3 Inspection and Test Records 4.2 PRINCIPLES FOR THE

The recurrent inspections extend in general

10.11.2008 Revision. 0 17 Book 1 B

Group for inspection Inspection part Description

1 Components and mechanical devices

10.11.2008 Revision. 0 18 Book 1 B

Group for inspection Inspection part Description

3 Safety devices, drives, controls

10.11.2008 Revision. 0 19 Book 1 B

5 MAINTENANCE Service and test documents have to be kept

Before commencement of service

The periodic maintenance jobs have to be Refer to the operating instructions

10.11.2008 Revision. 0 20 Book 1 B

5.2 LUBRICATION 5.2.1 Oil fillings and Selection of

10.11.2008 Revision. 0 21 Book 1 B

5.3 MAINTENANCE SCHEDULE

Moreover also the oil filling and