Maintenance PBB 17 # L2

29/11/2021
3rd day progress report
HUB Fixture and spindle shaft
• Part of List
1. Gear Box
2. ASCO Gear (with Male shaft)
3. ASCO Gear Lock (with 2 nose L key Nuts)
4. ASCO Gear Oil Seal
5. HUB Fixture (4 nose nuts with washer)
6. HUB oil seal (install in hub)
7. Axial lock nuts (4 nose L key nuts)
8. Conical roller bearing (cover)
9. Conical roller bearing bush
10. Conical roller bearing
11. Conical roller case bush
12. Spindle Thread rod with cotter pin
13. Ball Screw Coupler nut
14. Spindle base plate
• Notes (work start time from 09:30 am to 01:00 pm)
1. Spindle shaft removed grease with kerosene oil
2. All parts of Installing Hub Fixture cleaned with kerosene oil
3. All parts name tagging one by one (include with picture)
4. Checked some parts Damaged
1. Gear oil Seal
2. Hub oil Seal
3. Axial lock Nut and Spindle shaft thread Slipped
5. 3 parts Hand over to Zahid Sir
1. ASCO Gear oil seal
2. Hub oil Seal
3. Axial Lock nut
1. 02:00pm . Faisalabad Spindle Shaft Received in GD Store
2. 02:30 pm . Bring Spindle Shaft to Bay # 17
3. 02:30 pm . Checked Spindle shaft
4. 02:45 pm . Ball Screw Coupler found Broken nuts
5. 03:00 pm . Spindle Shaft Cleaned with kerosene oil
6. 03:30 pm . Checked Ball screw Coupler rotating on Spindle Shaft
Thread but ball screw coupler hardly rotating
7. 04:00 pm . 1st Ball screw coupler was greased prom greasing point to
remove old grease
8. 04:30 pm . Again checked and ball screw coupler rotating smoothly
on spindle shaft.
9. 05:00 pm . Put spindle shaft in bay # 17 Technical room.
Maintenance PBB 17 # L2

30/11/2021
4th day progress report
• Workshop work
1) Repairing Hub
2) Repairing ASCO gear (gear box Shaft)
3) Repairing Gear box
4) Removal of stuck screw from ball screw coupler received from
Faisalabad
5) Procurement of lock nut
6) Fabricate male shaft to manually rotate gear box
7) Fabricate female shaft to manually rotate ASCO gear
8) C-clamp wrench from lock nut

After search in market HUB seal available and ASCO gear seal is not available in market
 Spindle Shaft Working in Workshop
1) 09:56 am . Two spindle load on truck include Hub fixture installation parts
2) 10:20 am . Departure from Airport
3) 11:00 am . Arrived at workshop from Airport
4) 11:00 am . Faisalabad shaft offload at workshop
5) 11:15 am . Ball screw coupler broken nut.
1) 1st try punching process with hammer, screw driver Rod used.
2) 2nd try with punch and hammer but not success

6) 11:40 am . spindle shaft shift to next work shop due to power supply OFF
7) 12:31 pm . Drilling in broken nuts of ball screw coupler
8) 12:32 pm . Ball screw coupler broken nut process with nut welding
9) 12:52 pm . Completed nut welding on broken nuts but not successful
10) 01:52 pm . Steel rod welding on broken nut of ball screw coupler, steel rod
rotating with wrench, nut removed out of ball screw coupler successfully
11) 02:19 pm . Second side steel rod welding on broken nut and apply rotating process
with the wrench but nut removed out from ball screw coupler
Maintenance PBB 17 # L2

01/12/2021
5th day progress report
 Faisalabad ball screw cleaning and greasing
1. 10:45 am. Spindle shaft removed outside from technical room
2. 11:04 am. Ball screw coupler greasing
3. 11:12 am. Spindle shaft removed grease with kerosene oil
4. 11:27 am. Ball screw coupler greasing
5. 11:31 am. Again greasing of ball screw coupler
6. 02:00 pm. Right side spindle shaft dismantling of gear box
7. 02:20 pm. Spindle shaft hub opening
8. 03:00 pm. Spindle shaft hub fixture full open
9. 03:18 pm. Checking of conical bearing with axial lock nut
10. 03:20 pm. Measurement of spindle shaft from axial lock nut
11. 03:36 pm. Check gear box condition and cotter pin place and shaft internal side. After checked gear box found OK.
12. 03:36 pm. Checking of ASCO gear cotter pin place and shaft condition of right side column found OK
13. 03:37 pm. Checked complete ASCO gear condition which found OK and hub fixture also found OK
14. 03:38 pm. Hub fixture oil seal found OK
15. 04:05pm. ASCO gear assembled on right spindle shaft and hub also fitted on right column
16. 05:00 pm. Working Closed
Maintenance PBB 17 # L2
02/12/2021
6th day progress report
Fixture Assembling Process of left side Spindle Shaft
1. 11:57am. oil seal installed in hub fixture
2. 12:22pm. Conical roller bearing case cleaned with kerosene oil
3. 12:25pm. Conical roller bearing cleaned with kerosene oil
4. 12:26pm. Ball screw nut inner side thread mouth planed with file
5. 12:35pm. ASCO gear female parked cleaned with kerosene oil
6. 12:35pm. Ball screw nut tight on spindle shaft
7. 12:44pm. base plate removed from old spindle shaft
8. 12:48pm. base plate cleaned with kerosene oil
9. 12:49 pm. ASCO gear seal fixing in female gear parts
10. 12:52pm. ASCO gear lock fit in ASCO gear but not successfully fitting due to seal problem
11. 01:08pm. Checked right side ASCO gear lock fixed in ASCO gear and found OK
12. 01:30pm. ASCO gear shift from Airport to Tarnol Workshop
13. 06:15pm. ASCO gear complete fit with seal and lock from tarnol workshop
14. 06:26pm. Conical roller bearing case fit in spindle shaft and conical roller case bush fit on spindle, conical roller bearing and
conical bearing bush fit of spindle shaft
15. 06:33pm. Axial lock nut tight on spindle shaft and axial lock nut measure to cut spindle shaft cut
16. 06:41pm. Axial lock nut tight with L key bolts
17. 06:52pm. Conical roller bearing cover fix in hub fixture
18. 06:59pm. Hub fixture fit on spindle shaft
19. 07:06pm. ASCO gear lubrication with WD-40, after lubrication L key bolt tight in ASCO gear
20. 07:17pm. Hub fixture close with conical roller bearing case bolt tight
Hub fixture close work time (11:00pm)
Maintenance PBB 17 # L2

03/12/2021
7th day progress report
 Spindle shaft Assembled in column
1. 08:00am. Both crane arrived at stand # 17
2. 09:26am. Complete of Fixture with spindle shaft and bring out from technical room
3. 09:30am. 50 ton Crane adjust PBB 17 L2 right side and 20 ton crane adjust left side of PBB 17 L2
4. 09:35am. Right side motor fit with gear box
5. 09:41am. left side motor fit with gear box
6. 09:42am. Right side crane wire hook install in PBB 17 L2
7. 10:05am. Spindle shaft full up with crane
8. 10:15am. ASCO gear shaft install in gear box but not success due to gear box shaft hole size problem
9. 10:45am. After separation of motor ASCO gear shaft fitting process in gear box but not successfully
10. 11:17am. Spindle shaft put down on the ground
11. 11:33am. Gear box fitting process on ground level with the help of hammer punching process successfully
at(12:00pm)
12. 12:06pm. Hub fixture joint with gear box and Motor fit with gear box
13. 12:27pm. Right side shaft fit in ASCO gear
14. 12:47pm. Gear box motor and hub fixture complete assembled with spindle shaft
15. 12:54pm. Right side ASCO gear fitting in hub fixture
16. Checked PBB L2 load on crane HMI which is (15.5 ton)
17. 12:59pm. Both elevation column are in Up position
18. 01:05pm. Right side manual upping of column
19. 01:10pm. During height column measure to fix column base plate, both column are
approximately equal
20. 01:15pm. Hub fixture into ball screw coupler not point measure (2 foot 10 inch approximately)
21. 01:20pm. left side spindle shaft hanging with crane
22. 01:23pm. Med hanging position of left side spindle shaft
23. 02:23pm. Re open spindle shaft of column
24. 03:44pm. Again spindle shaft in inner columns
25. 03:48pm. PBB 17 L2 moved down
26. 04:46pm. Checked Right side column ball screw coupler are tight
27. 04:47pm. Hub fixture fit on column and nut tight
28. 04:54pm. left side column hub fixture out side nut are tight
29. 05:07pm. left side ball screw coupler out side L key nut is tight
30. 05:46pm. Naylone pad fit on column
31. 05:57pm. Right side gear box fix on ASCO gear shaft and hub fit on column and bolts are tight
32. 06:12pm. Motor fit with gear and nut are tight process
33. 06:28pm. Gantry motor shaft assembled with motor process start time
34. 06:36pm. Shaft tight with both motor
35. 06:52pm. Crane lose weight on PBB 17 L2, weight show on crane HMI is (9 ton)
36. 07:09pm. Left side column not full down on base plate( 30 mm difference from base plate) and checked load on crane HMI (1
ton)
37. 07:19pm. Both column are add at mechanical stop
38. 07:22pm. Both column are at zero position
39. 07:49pm. Right side motor B joint electric connection
40. 08:16pm. left side motor A joint electric Connection
41. 08:35pm. Main Electrical breakers make ON
42. 08:40pm. Bridge light ON
43. 08:45pm. Breaker tripped
44. 09:30pm. Motor connection changed
45. 10:08pm. Motor B gear box top opened
46. 10:14pm. Both motor connection opened
NOTE: after both motor connection during operation check observe abnormal sound, after abnormal sound checking of both
column hub fixture observe both side conical roller bearing case, 8 nose bolt are broken(11:05pm)
Maintenance PBB 17 # L2
04/12/2021
8th day progress report
Spindle shaft dismantling and reassembling
1. 11:12am. Both gantry covers are opening
2. 11:16am. Right side crane parked
3. 11:17am. left side crane parked
4. 11:29am. left side motor electric connection are open
5. 11:32am. Right side motor electric connection are open
6. 11:32am. Both motor connect shaft is open
7. 11:39am. Both motor of picture after disconnect of shaft
8. 11:51am. Right side motor dismantle with gear box, after motor separation right side gear box on hub
fixture
9. 12:01pm. left side motor dismantle of gear box
10. 12:02pm. After motor separation left side gear box on hub fixture
11. 12:05pm. Right side hub fixture open
12. 12:08pm. Left side hub fixture open
13. 12:20pm. Left side crane belt attach with gear box and hanging position
14. 12:31pm. Left side spindle shaft open in column process
15. 12:45pm. Left side conical bearing + axial lock is ok condition except conical bearing case bolt is broken
16. 12:46pm. Left side conical bearing case 04 bolts in broken condition
17. 12:59pm. Left side conical bearing case full up with thread rod
18. 01:06pm. Spindle shaft open in column approximately 2 feet
19. 01:09pm. Gear box open with ASCO gear shaft
20. 01:15pm. Dismantle gear box on right side hub fixture
21. 01:22pm. Again gear box assembled on right side hub fixture
22. 01:40pm. Gear box hang with crane belt
23. 01:42pm. Spindle shaft upper through gear box with the help of impact wrench
24. 02:04pm. Spindle shaft is open
25. 02:06pm. Conical bearing case broken nut picture but conical bearing case condition is OK
26. 18:11pm. Right side conical bearing case fit with hub fixture
27. 06:22pm. Right side Conical bearing case fitting completed
28. 08:03pm. Left side conical bearing case fitting with the help of thread rod used due to hub fixture difference
between conical bearing case
29. 08:36pm. Left side conical bearing case complete fitting
30. 08:47pm. Right and left side spindle shaft open approximately 2 feet
31. 08:51pm. Both spindle shaft are equal open
32. 09:03pm. Opening spindle shaft check nylon pads LN key bolts found OK
33. 09:03pm. After crane hanging both spindle shaft
34. 09:11pm. Again left side shaft spindle open
35. 10:16pm. Right side hub fixture fix on column
36. 10:23pm. Right side motor fit with gear box
37. 10:28pm. Left side motor fit with gear box
38. 10:34pm. Left side shaft fit with gear box
39. 10:35pm. Right side shaft fit with gear box
40. 10:48pm. Both column are sink with shaft
41. 10:59pm. Hub fixture difference between column due to load and crane shift on PBB
successfully
42. 11:05pm. Hub fixture complete successfully
43. 11:29pm. Motor B electric connection
44. 11:52pm. Motor A electric connection done
45. 12:00am. 20 ton crane removed from PBB
46. 12:00am. 50 ton crane removed from PBB
47. 12:05am. After connection of motors and put ON main power supply, internal side lights ON ,HMI
make ON and operate elevation system
48. 12:05am. PBB elevation system is properly working and now PBB is serviceable
49. 12.10am. gantry motor cover fit on frame and elevation column stopper with column, this process took time
from 12:10 am to 12:55am PBB working completely done
Note: Elevation motor tray on frame required and gear box shaft T-tape tool required