1 Training For HAMTANTOTOR&nbsp RTGs PDF

Z
Training Instructions For

HAMBANTOTA 1 RTG
(ZP13-2057)
Mechanical part
中华力量, 畅通世界
1
Content
► CHAPTER 1_ Safety
► CHAPTER 2_ General Features and
Mechanical Components of RTG Cranes
► CHAPTER 3_ Crane Inspection,
Maintenance and Repair
► CHAPTER 4_ Seminar, such as brakes,
and ropes.
CHAPTER 1
SAFETY
Safety is a priority either in operation or in
maintenance and inspection. This chapter
informs you of the possible hazards and
necessary precautions to be taken when
operating or maintaining the crane.
2
1.1 Warning and symbols
The following signs and symbols are used

in the manual to designate instructions of
particular importance.
Special information and/or orders and prohibitions

directed towards preventing damage.
Do not enter, Authorized personnel only.
Caution
Refers to information in other parts of the Manual
Danger of falling
3
Keep hands clear of the moving parts.
Keep away from suspended loads
Keep hands and body clear
Stay clear
No access to the dangerous place
1.2 General precautions
● This crane embodies the latest and the best in

structural, electrical and mechanical and may only
be put into operation by qualified or trained staffs.
● Before operating or maintaining the crane, the

operation and maintenance instructions have to
be read carefully and understood by all
maintenance and repair personnel.
4
●This machine is also built according to the latest

standards of technology and recognized safety
technical rules, and is equipped with safety
devices. It has been checked for function and
safety before delivery and hand-over.
● However, in case of faulty operation, misuse, or

not in accordance with the instructions, dangers
and/or damages could still arise and threaten the
health of the operator or the third persons, the
container crane or other material, and/or the
efficient operation of the crane itself. 9
●It is always a good practice to work in a team of

at least two persons in a place where potential
dangers may arise.
● In addition to the operation and maintenance

instructions provided herein, legal（generally valid）
and other obligatory regulations issued by the
local authorities for accident prevention and
environmental protection must also be observed.
10
5
●It is our admonition that working cautiously and

carefully is the best protection from accidents.
●None of us has all the expertise or training

needed to complete every repair that may be
required. Do not try to undertake a task on which
you are lack of training or qualifications.
IT’S ABOUT YOUR SAFETY!
11
●The manufacturer, Shanghai Zhenhua Heavy

Industries Co., Ltd. (ZPMC), has tried his best to
assemble and make available this set of
instructions to provide all necessary information
for crane operation and maintenance.
● In case of uncertainties, problems and

additional requests, we will always be at your
disposal. Please do not hesitate to contact our
local representative and/or technical supporting
staffs.
12
6
1.3 General rules of conduct and safety regulations
IMPORTANT SAFETY
PRACTICE!
The following safety rules must be observed
strictly in practice:
(1) Verify that there is no danger to other related

personnel before operating the machine.
(2) Do not touch the rotating parts or the moving

parts of the machine during operation. 13
(3) Do not perform inspection and adjustment of

the machine during operation.
(4) Do not touch the live parts inside the control

cabinets or terminal boxes.
(5) Do not lubricate the components of the

machine during operation.
(6) Immediately press the emergency stop

pushbutton to stop the machine when an
accident has occurred or is likely to occur.
14
7
(7) Always keep the machine and it’s

surroundings clean. Especially Keep the
passageways at the elevated place clean so
that personnel can walk safely.
(8) Warn all the service personnel of an unsafe

intended action that may endanger them .
(9) Report any injury and make sure the

wounded person can receive fast medical
treatment.
15
1.4 Safety rules for operation
●Pre-service Precautions:
(1) Before starting work at the crane, all persons

have to be instructed in theoretic and practical
use of emergency measures in case of an
accident, the use of the emergency exits, and
the use of rescue aids (fire extinguishers).
(2) Unauthorized persons should not enter the

crane.
16
8
(3) All safety devices and facilities with protection

functions must always be connected and
operable. They must not be rendered
ineffectively or used improperly.
(4) The factory setting of the components must not

be changed.
(5) Observe the inspection procedure stated in

this manual for the inspection of each
component.
17
(6) Check for obstructions on the gantry runways.
(7) Check that lubrication for every mechanical part

is sufficient.
(8) Check that every operation joystick and

operation switch is in normal position.
(9) Check that power supply voltage is normal.
(10) A trial run without load should be done first，

and the running with load can be started only
after it is confirmed that various safety devices 18
and limit switches are activated normally.
9
●Precautions during service:
(11) Do not step into an area below the cargo

lifted when the crane is operating， which may
result in a critical accident.
(12) The lifting load and the reach during the

loading or unloading operation must be within
the limit values defined by the specifications of
the crane. Excess reach or excess load may
result in a critical accident such as a fall-down,
a break-down or a damage of the crane.
19
(13) Immediately stop operating the crane when

an abnormal sound or vibration arises. Inform
the responsible personnel immediately to
eliminate the malfunctions or conduct
maintenance.
(14) Do not leave the crane with any openings into

which a person could step or tools and objects
could fall. And do not leave lubricants, paints, or
other materials uncovered or un-attended.
20
10
(15) Always operate the crane smoothly to prevent

the shock of start-up or stoppage. Avoid
operations such as abrupt loading or unloading
at full speed with excess load or unnecessary
repetition of start-up or stoppage.
(16) When the crane encounters typhoon, the

gantry msut be turned to parking type.
21
DANGER ZONE MUST BE

BLOCKED BY SUITABLE
MEASURES. HAZARD AREAS
MUST BE INDICATED
PERMANENTLY BY CLEAR
INDICATIONS, SUCH AS
COLORED SIGNS OR WARNING
SIGNS.
22
11
●Cautions after service:
(1) Park the Crane at the assigned location.
(2) Park the trolley at the stowed location, i.e.,

anchoring location.
(3) Return all the operation joysticks and switches

in the cab to neutral position and specified
position.
(4) Check the rubber-tyred wheels.

23
(5) If the Crane is not expected to be in use for a

long period or a storm is forecast, the Crane
should be secured at parking type.
(6) Repair defects found during operation and

confirm that all lubricants are correct for the
next operation.
(7) Lock the doors of the operator's cabin,

electrical room and engine room to prevent
unauthorized entry.
24
12
1.5 Safety rules for maintenance and repair
The maintenance work is different from the

ordinary operations. When the crane is under
maintenance, some of its parts may be
disassembled or unstable, thus special attentions
should be paid to.
25
BEFORE COMMENCEMENT OF
SERVICE WORK, THE CONTAINER
CRANE HAS TO BE MADE FREE OF
LOAD, SET TO MAINTENANCE
POSITION AND SWITCHED OFF,
IF NO OTHER NOTE IS GIVEN.
26
13
●Observe the following safety rules when

conducting maintenance or inspection work on
the crane:
(1) Personnel unauthorized by the person

responsible for the crane should not perform
maintenance or inspection work.
(2) Do not perform maintenance or inspection

work when the crane is operating.
27
(3) Before conducting maintenance or inspection

work, shut down the engine generator set cut off
the main power supply and all the power
resources; then verify if the crane is stopped
completely.
(4) Before conducting maintenance or inspection

work, warn all the related workers of the work
and prohibit entry of those unauthorized
workers into the maintenance and inspection
areas.
28
14
(5) The crane should be in maintenance mode for

such a task.
(6) Secure the repair area by closing a wider area.

During the maintenance of the crane, be sure to
close all the openings on the platforms or other
places, or protect them with fences.
(7) When inspecting one of the cranes on the

same gantry runway, attach the mechanical
stoppers or station a person to prevent collision
of the cranes.
29
(8) Never fail to close the door to the walkways

and the chains at the gate of the walkways.
(9) When removing bolts, pins, wire ropes, and

cables, warn workers other than the service
personnel of the danger of attached parts falling.
(10) If hands will be on the rope for inspection,

they must be away from the pinch point .
(11) The maintenance persons should pay more

attention to the moving/rotating parts.
30
15
(12) Do not use the machine parts as climbing

aids.
(13) Reinstall and test safety devices (which have

been disassembled during the assembly or test
and repair work) immediately after the end of
the maintenance and the repair work.
(14) Correctly tighten the screw joints that were

loosened during the test and the maintenance
work.
31
(15) Replace the fastening elements and seals

(e.g. self-securing nuts, washers, split pins, O-
rings and seals) which cannot be used again.
(16) After the maintenance/repair work, update the

fault log and the maintenance check list .
(17) Do test running and functional check of the

components and safety devices before starting
the operation and service again .
32
16
1.6 Conduct in case of accidents and emergency
(1) In the case of an accident with injury to

persons, damages to devices or other materials,
immediately inform the supervisor after
providing the injured with first aid. For well-
directed rescue efforts, clearly give the degree
of severity of the injury to persons and the
damage to property.
33
1.6 Conduct in case of accidents and emergency
(2) In case of disasters (e.g. fire), all persons must

leave the crane using the indicated emergency
exits and/or other facilities.
(3) Rescue actions may only be carried out by

instructed operating and rescue personnel. Use
the intended protective equipment.
34
17
CHAPTER 2
General features of RTG Cranes

● Supported on 8 rubber-tyred wheels
● Powered with engine-generator set which

supplies power to every movement drive
● Equipped with a telescopic spreader which is able

to handle 20', 40' ,45' and twin 20’ standard
containers
35
CHAPTER 2
● Provided with a 4-ropes main hoist system and

electrical anti-sway system to reduce spreader
sway and increase productivity
● Spreader skewing device for easier spotting of the

container (+/-5°)
● A 90°wheel turning system allows ease of

movement
36
18
CHAPTER 2
●Dimensions
pass across six rows of containers plus one truck

way (6+1 lane)
pass over five containers 9' 6" high with one 9’6”
container lifted under the spreader(1 over 5)
37
CHAPTER 2
●Structures
Gantry frame: box-section welded construction
Trolley rail: fixed on the upper girder
Equalizer beam: hinged to the sill beam by pin
Each equalizer beam has two bogie trucks and two

wheels
38
19
CHAPTER 2
●Main hoist
Constant power control
Speed is automatically adjusted depending on the

load being lifted
Over load protection device
Over speed protection
39
CHAPTER 2
● Operator's cab located under the trolley

frame
● one set of trolley driving device on the

trolley frame
40
20
CHAPTER 2
● Protection for safety
Overload protection
Diesel engine over speed protection, high water
temperature and low oil (lubrication) pressure
signaling
Anemometer on trolley
Anti-collision devices for gantry traveling
Emergency stop buttons
Spreader load indicator
Limit switches for every movement and signal
indicators, etc.
41
CHAPTER 2
● Other equipment
Lighting and signaling for operation at night
Alarms for gantry traveling
Telephones
Public address system
Radio speakerphone
42
21
2.1 General layout of RTG
43
44
22
As shown in Figure 2.2-1 and 2-2.2, the main

composition of crane is as follow:
1-Gantry frame Steel structure
2-Stairs, platform and ladder
3-Electrical house
4-Gantry traveling mechanism
5-Gantry tie down device
6-Cable power chain system
7-Trolley travel limit switch system
8-Spreader
9-Headblock
10- Power unit (engine-generator)
45
11- RTG tyre pressure monitoring system

12- Trolley travel mechanism
13-Operator’s Cabin
14-Side roller
15-Trolley anchor device
16-Wire Rope Reeving Sys.
17-Hoist mechnism
18-Hoist over travel limit switch
19-Trolley centralized lubrication
46
23
2.2 Principal Technical Parameters of RTG
Description Value Unit Remarks
Rated lifting capacity Under spreader 40.5 t
Lifting height Under spreader 18.0 m
Hoisting speed with full load 23 m/min
empty spreader 52 m/min
Gantry travel speed with full load 30 m/min
empty spreader 135 m/min
Trolley travel speed 70 m/min
Span 23.47 m
Wheel base 6.4 m
Number of wheels/No. of driving wheels 8/4 pieces

47
2.2 Principal Technical Parameters of RTG

Spreader slewing ±5 Degree
Diesel Model c15 cat
engine
Power 559 BHP
Revolutions 1500 rpm
Alternator Model HCI634 STAMFOR
D
Power 750 KVA
Row Number of containers 6 Container 6+1
stacked by the Crane
Number of containers the Crane 5 Container 1 over 5
passes over
48
24
2.3 Steel Structure part
49
2.4 General
● Welded steel structures always contain

undetectable cracks.
● The cracks grow when subjected to fluctuating

stresses beyond a very small value.
● fatigue crack will lead structure disabled and out

of service
● Periodic inspection is required to detect fatigue to

avoid serious failure in the crane structure.
50
25
2.4 General
● Inspect location: locations where fatigue cracks
● inspection method
Visual Testing (VT)
Magnetic Particle Testing (MT)
Ultrasonic Testing (UT)
● MT shall be used at the critical locations of fillet(角

焊缝) welds
● UT shall be used at the critical locations of butt（对
接焊缝） welds
51
2.4.1 Test procedure
●Visual Testing
The surface should be free of dirt and grease.

Cracked paint surface.
●Magnetic Particle Testing
The test surface must be free of loose rust and

moisture. If required, clean painted surfaces with
power tools by grinding, or needle scaling. An
electromagnetic device, such as a yoke, may be
used to a magnetic field. 52
26
2.4.1 Test procedure
●Ultrasonic Testing
Testing should be done in accordance with approved

method and the requirements shown in
"INSPECTION"
53
2.4.2 Inspection
(1) All bolted and welded joints shall be visually

inspected (VT)
(2) Visual inspection shall be performed by a certified

AWS QC-1 inspector.
(3) NDT inspection shall be done by qualified person.
(4) NDT shall comply with the requirements of all of

AWS D1.1-96, including Section 5. "Inspection",
and all provisions applicable to cyclically loaded
structures. 54
27
2.4.2 Inspection
(1) Required inspection is shown on the attached

sketches for the critical details.
(2) Where MT or UT inspection is indicated on one

side only, the inspector shall inspect the weld from
both sides unless otherwise noted .
(3) Inspection of bolts shall comply with AISC

Specification for Structural Joints Using (CHINA)
GB1228-94 10.9 GRADE bolts (equivalent to ASTM
A490 Bolts, latest edition).
55
2.4.3 Reporting procedure
All indications of defects should be shown on the

table attached with sketches the weld detail. The
following information should accompany the sketch:
(1) Crane identification.
(2) The side and extent of defect .
(3) Weather defect is in the toe of the weld,

propagating into the base metal, etc
56
28
2.4.3 Reporting procedure
(4) Defect location: right-hand side, left-hand side,

which box section, crane leg number, waterside,
landside, distance in inches to nearest station, etc.
(5) Method of testing: VT, MT, and UT.
(6) Inspector's comments and signature
57
2.4.4 Inspection period
(1) Initial inspection: Visual inspection six months

after crane acceptance.
(2) Complete inspection: Visual and NDT as shown in

manual three months before the end of the
warranty period. Inspect six year points and others
as designated by the port.
(3) Maintenance inspection as shown in manual
58
29
2.4.5 Typical repair procedure
(1) Work shall be conform to the requirements for

Structural Steel Buildings, Allowable Stress Design,
ninth or latest edition, including current
supplements, and AWS Structural Welding Code,
D1.1-96,or latest edition, including all provisions
applicable to cyclically loaded structures and
Section 8, "Strengthening and Repairing Existing
Structures"
59
(2) All temporary attachments shall be removed after

completion of work. Removed weld area shall be
ground smooth and a prime paint coat applied to
the surface.
(3) All repaired joints exposed to weather shall be

seal welded.
(4) Welders and welding operators shall have current

AWS certificates for the materials and processes
being used.
60
30
(5) Weld procedures shall be qualified in accordance

with AWS D1.1-96 or latest edition.
(6) The Port may perform NDT testing of the

Contractor's work .
(7) The structural drawings identify Fracture Critical

Members (FCMs).
61
(8) All areas where paint has been removed, or

damaged, shall be restored to its original condition
in accordance with the original crane specifications.
(9) Re-tightening of bolts after inspection shall be

according to relative standard.
62
31
2.4.6 Safety
ALL PRECEPTS OUTLINED IN THE

“Chapter 1 Safety” APPLY TO
THIS TEST, INSPECTION AND
REPAIR.
63
2.4.7 Diagram of Inspection Points and Inspection Report
General Inspection Locations
64
32
General Inspection Locations
65
Girder inspection locations
66
33
Leg inspection locations
67
Sill beam inspection locations
68
34
Trolley frame inspection locations
69
Equalizer beam and bogie inspection locations
70
35
2.5 Mechanical device part
2.5.1 Gantry traveling mechanism
71
2.5.1.1 Composition of gantry traveling mechanism
● Eight rubber inflated tyres

Four are drive and laid on each corner of the
crane
Four are idle
● Four set of hydraulic pusher device

system for wheel-turning.
Each tyre can be rotated about its center by
90°
72
36
2.5.1.1 Composition of gantry traveling mechanism
● the bogie and equalizer beam connect by

skew bearing
● Four horizontal base-mounted motors

with brakes
● Four driving axle to drive the wheel
● Safety device
73
2.5.1.2 Table of Gantry Traveling Particulars

Gantry travel Only spreader 135 m/min
speed With rated load 25 m/min
A.C. motor Model 1LP4 208-4CA91-Z SIEMENS
Power 32 kw
Qty. 4
Reducer Model FVS395.30.D3A ZPMC
Reduction ratio 30.112
Input power 32 kw
Qty. 4
Rubber tyres Model 21.00-35,40ply ZPMC
Diameter 1860 mm
Inflation pressure 10.0 Kg/cm2
Qty 4/8 (driving/total) 74
37
2.5.1.3 Points for Attention in Operation
After a long term of non-operation

or after disassembly and re-assembly
the crane shall first be run without load allowing

the reducers, bearings, etc. to be lubricated fully
and carefully observed, and then operation with
a load can be started.
75
2.5.1.4 Inspection items and period for maintenance
(1) Oil (grease) supply
During oil (grease) replacement the old oil (grease)

shall be discharged thoroughly. Generally speaking
the lubricant shall not be mixed, especially the
grease. Mixed grease may result in blockage and
bearing damage.
Check whether lubrication is correct. Lubricate in

accordance with lubrication schedule .
Period: routine
76
38
(2) Loosening of securing bolts:
All parts and components

Attention shall frequently be paid to loosening of the
bolts, particularly after the first week of crane
running and then once per month check all the bolts
and re-tighten them.
Special attention shall be paid to those bolts which
contribute to fastening but are easily neglected.
Period: routine and once per month

77
(3) Motors :
Check temperature rise for any abnormal condition

Check for any abnormal heating in the bearings
Check for any abnormal noise in the motor
Period: routine
78
39
(4) Reducer:
Check whether oil level is adequate.
Check for oil leakage.
Check for abnormal temperature rise. If the casing
temperature is higher than the ambient temperature
by more than 50C, the inner part shall be
inspected.
Check for abnormal noise in the internal part and
disassemble and inspect if there is any.
Check for loosening of connection bolts .
Period: routine.
For detail, please refer to the “Instructions of 79
reducers”.
(5) tyre :
Check that every tyre is inflated sufficiently. The right

tyre pressure shall be 10.0 Kg/cm2
. The normal pressure ensure that the longer life of
tyre.
Period: routine
80
40
(6) Slew bearing:
● Bolt Inspection:
When the slewing bearing works continuously for
about 100 hours after installation, the installation
bolts must be inspected fully for their preload. The
preload must meet the requirements. And the
installation bolts must be inspected after
continuously working for 500 hours.(gantry travel
time)
81
(6) Slew bearing:
● Greasing: The raceway of the slewing bearing

must be greased at regular intervals. Generally, if
the rolling elements of the slewing bearing are
sphere shaped, the raceway must be greased after
working for 100 hours; For high temperature and
dusty working environment, greasing interval must
be shorter. And also if the bearing works
continuously for a long period, it must be greased.
The slewing bearing must be 100% greased at
each time.
For detail, please refer to “gantry slew 82
bearing manual”.
41
(7) Hydraulic pusher for rotating

For detail, please refer to “Hydraulic/electric
manual”
83
2.5.1.5 How to replace gantry tyre
ALL PRECEPTS OUTLINED IN THE “Chapter 1

Safety” APPLY TO THIS REPAIR.
● Gantry tyre replacement shall be carried out in no-

wind weather condition.
● Consider the following basic steps to accomplish

the replacement:
84
42
(1) Before replacement, preparation work shall be

done such as various replacement parts(new tyre
etc.) and required tools(two hydraulic jacks,
electrical impact wrench etc. ) put at hand
(2) The working area shall be clear and enclosed with

warning line and caution
(3) The crane is at non working condition, the trolley

shall be parked on one end of the girder (i.e., the
end where the gantry wheels are not to be
replaced).
85
(4) Jacking up the gantry leg by two 20 t jacks which

shall be replace under the reduce pedestal of the
other driving/driven axle that is not to be replaced
and fitted under the same equalizer beam with the
wheel to be replaced (or lift the jacking support
frame) to enable the wheel to be lifted off the
ground and then the wheel may be removed and
replaced.
(5)Dismantle the bolts connecting between the rim

and drive/driven axle, take out the tyre and rim from
the driving/driven axle.
86
43
(6) Before dismantle the tyre from the rim, deflate the
tyre completely, and then take out the lock ring,
bead seat band, side ring and O ring, finally the tyre.
Figure2.5.1.5- 2 Tyre rim
87
(7) Install the new tyre onto the rim, then install O ring
(to ensure seal effect, use a new O ring), side ring,
bead seat band and lock ring.
(8) Inflate the tyre to the specified pressure. Before

inflation, make sure the O ring and lock ring are
installed properly; especially the lock ring shall
be correctly installed.
88
44
DANGER FOR DEFLATION AND INFLATION!

BEFORE COMPLETELY DEFLATION, DO NOT
DISMANTLE THE LOCK RING; BEFORE
INFLATION, MAKE SURE THE LOCK RING IS
INSTALLED CORRECTLY.
89
(9) Install the tyre and rim onto the drive/driven axle.
Fasten the connecting bolts and nuts, the fasten
torque shall be at rated torque.
(10) releasing jacking up system, clear the working

area, running the gantry slowly, keep observing the
new tyre until every thing is OK.
90
45
2.5.2 Main hoist mechanism
91
2.5.2.1 Composition of main hoist mechanism
● One motor
● One high speed flexible coupling
● One gear reducer
● One low speed gear coupling
● One drum
● Two high speed brake
● Tachometer, over speed protection, cam
limit protection
92
46
2.5.2.1 Composition of main hoist mechanism
● Over speed protection device located at

the rear part of the motor.
Stop main hoist when the motor speed
reaches 115% of its rated speed
●Cam limit protection is fitted at the end of

the drum.
provides the following protection:
Stopping at upper lift end and lift lower end
Slowing down before reaching upper and
lower lift ends
Stopping at lift upper extreme limit end
93
2.5.2.2 Table of Main Hoist Particulars

Num. of wire ropes on the drum 4 pcs
Multiple of rope reeving 2
Lifting capacity (under spreader) 50 t
Hoisting with full load 20 m/min
speed empty spreader 40 m/min
Linear velocity with full load 40 m/min
of empty spreader 80 m/min
wire rope
The drum Nominal 980 mm
diameter
Num. of groups 4
of grooves
Number of 3 pcs
clamps of rope
94
47

Motor Model 1LA8 355-6PB90-Z SIEMENS
Power 190 Kw
Speed 805/1610 rpm
Qty. 1
Reducer Model FH1350.62.C1A ZPMC
Qty. 1
High Speed Model YP31-560x30-ED1250 ZPMC
Brake Model of thruster ED1250
Braking torque 3550x2 Nm
Qty. 2
95

Low Speed Model \
Brake Rated Braking force \ KN (each brake)
Qty. \
Wire rope Model 6xFi(29)-IWRC-26 JULI
Diameter Ø28 mm
Length 68.4 m reducer side
64.8 m
61.4 m
65.4 m
96
48
2.5.2.3 Main hoist wire rope reeving and its application
● Four main hoist wire ropes on drum
● Each rope has 3 wire clamps on drum
● wire clamps’ screw bar and nut are M24
97
How to adjust tension for four rope
● the four wire rope must be tensioned

equally for spreader at correct position
and avoid slewing
●If uneven tension between them is found,

the end securing clamps may be loosened
and tightened up or release the
appropriate rope
98
49
How to adjust tension for rope
● Or simply adjust the wedge on the trolley

to vary the rope lengths accordingly to
make tensions between the ropes even
●After the first period of Crane running, the

ropes must be re-adjusted depending on
their stretch
99
How to adjust tension for eight rope
●In normal operation uneven tension

between the four sets of wire ropes shall
be corrected immediately once it is found
100
50
● Attention shall frequently be paid to the

fastening condition of the wire rope
clamps and tighten them if loosened
● Frequently check bolts of the clamps and

replace them immediately if thread
damage, cracks, etc. are found
● The ropes shall not be twisted or knotted

during reeving
101
The wire ropes shall frequently be checked

during application and shall be replaced if
● wires damaged account for 10% the wire

in the whole strand/wires. (less than 5 in
a strand distance)
● the diameter of the wire rope is reduced

by 7% of its nominal size due to surface
wear
102
51
● Pay attention to inspection for the rope

jumping out of the sheave groove
● If there is any interference of the wire

rope with other mechanical or structural
parts
103
2.5.2.4 Points for Attention during Operation
After a long term of non-operation of the

Crane or after disassembly and re-
assembly
The Crane shall be run first without load
enabling the reducers, bearings, etc. to
be lubricated sufficiently and operation
with load can be started only it is
confirmed that the running condition is
normal.
104
52
2.5.2.5 Inspection Items and Periods for Maintenance
When the oil (grease) is to be replaced the

old oil (grease) must be drained
thoroughly. Generally the lubrication oil
(grease) shall not be mixed, particularly
the grease. Mixed grease may cause
blockage that result in bearing damage
Check that lubrication is correct.

Lubrication should be done in accordance
with Lubrication Schedule. 105
(2) All parts and components
● Check for loosening of fastening bolts
Frequently check for bolt loosening, especially

one week after the Crane’s first running
and then once per month all the bolts
shall be inspected and re-tightened.
Special attention should be paid to those
bolts which contribute to securing but is
easily neglected
Maintenance period: routine and once per
month 106
53
(3) Electrical Motors
● Check temperature rise and overheating.

● Check whether the bearing is abnormally
heated.
● Check for abnormal noise inside the motor.
Maintenance period: routine
107
(4) Gear reducer
● Check that the oil is adequate by using the

oil level indicator.
● Check for oil leakage.
● Check if is there any abnormal
temperature rise? If the temperature is
more than 50degrees above the
ambient temperature, the internal portion
should be inspected.
108
54
(4) Gear reducer
● Check for abnormal noise inside the

reducer and disassemble and inspect if
any abnormal noise occurs.
● Check connection bolts fastening
Maintenance period: all are routine
For detail, please refer to the

“Instructions of the reducer”
109
(5) Coupling
● Check whether the bolts are loosened.

Period: routine
● Check eccentricity and end run-out of the

two haves of coupling. Normally check
once per year.
● Insure normal lubrication for the drum

coupling.
Period: routine 110
55
(5) Coupling
For detail, please refer to the “DC

series hoist drum coupling manual”
and “MLS11 coupling manual”
111
(6) Drum
● Check for loosening of the securing bolts.

Period: routine
● Check whether wear of the rope grooves

exceeds limit value which is generally
20% wire rope diameter.
Period: once per month
112
56
(7) Anti-friction bearing (rolling bearing)
● Temperature rise shall not exceed 50C (in

comparison with ambient temperature).
● Check for abnormal noise.
Period: routine
● Check for loosening of connection bolts.
Period: routine
113
(8) Encoder
● Check whether the transmission is in good

condition
Period: routine
114
57
(9) Brake disc
● Check the disc surface for unevenness

(convex-concave) which should not
exceed 0.3mm, and correct if necessary.
Period: once a month
● Check whether wear exceeds limit and

replace the disc when wear exceeds 20%
of thickness.
Period: once per month
115
(9) Brake disc
● Check whether temperature rise is abnormal on

surface.
Period: routine
● Check whether the disc surface is damaged or

contaminated with oil (grease).
Period: routine
● Check for fine cracks.

Period: routine 116
58
(10) Brake
● Check that the brake action is maneuverable

● Check wear of the brake.
The limit value is 3mm and replace if the limit is
exceeded.
Clearance at the brake shoe shall be kept to 0.5 -
1.5mm.
Every pivot pin shall be frequently greased.
Frequently check wear of the pin and matched
fore.
Period: routine 117
(10) Brake
● Check the pulse signal transmitter for height

indication
● Check that gearing is in good condition
● Check that pulse signal transmission is correct.
Period: routine
For detail, please refer the manual
from ZPMC
118
59
2.5.2.6 How to replace hoist wire rope

“Chapter 1 Safety” APPLY TO THIS
REPAIR.
119
● Hoist wire rope replacement shall be carried out

in no-wind weather condition
● Consider the following basic steps to accomplish

the replacement:
done such as various replacement parts(new
wire rope etc.) and required tools put at hand.
(2) The working area shall be clear and enclosed
with warning line and caution.
120
60
(3) First, cut the new ropes as which length and

quantity according to the drawing’s requirement
and then complete the pressed rope connector.
Otherwise, prepare some jute ropes which
diameter about 20mm and wires for binding.
(4) To lower the spreader onto the ground and

make it steady, then loosening the wire ropes
slowly until they lay on the headblock steadily
and loosening continued until that wire ropes
remained on the drum approach the fixed bolt.
When the wire ropes loosened completely, shut
down the diesel generator set. 121
(5) Binding the 4 old wire ropes which wind on the

drum with jute ropes, then remove the fixed
bolt and take off the wire ropes which remained
on the drum carefully. Then pulling the jute
rope let the old wire rope falling down to the
ground by gravity.
122
61
(6) Using jute ropes reeve through the sheaves

according to the rope reeving system drawing
and binding with the 4 end of the new wire
ropes, pulling them up to the trolley and
winding the wire ropes onto the drum by 3
circles, then fastening that ropes with bolts
primary.
123
(9) After wire ropes replacement are completed,

start the diesel generator set, switch on the
power source, raise the spreader above the
ground about 300mm. Observe the wire ropes
slack and the headblock deflection in level.
Adjust the ropes slack by loosen the bolt which
fixed the ropes ends on the drum, and tension
the slack rope, then fasten the bolt and cut off
the unwanted part of the rope.
124
62
DANGER! THE PERSON ON THE GROUND

SHALL PREVENT FROM HITTING BY WIRE
ROPE FALLING DOWN.
DANGER! WHEN THE HOISTING/LOWERING IS
RUNNING, KEEP AWAY FROM THE HOIST
MECHANISM; DO NOT TOUCH ANY ROTATING
COMPONENTS. ALL THE PERSON ON THE
TROLLEY SHALL BE PROVIDED WITH SAFE
BELT.
125
2.5.3 Hoist over travel limit switch
126
63
2.5.3.1 Composition of hoist over travel L.S.
● Location: On the top of the trolley frame
● Consists of gravity type L.S., wire rope,

strike plate etc
● For emergency, if the hoist motion failed

to stop at rated hoist height, the strike
plate will touch the top surface of
headblock, the over travel L.S. will act
immediately, the hoist motion will be
stopped.
127
2.5.3.2 Inspection Items and Period for Maintenance

● Check bolts for loosening
Period: routine
● Check the function of the L.S.
Period: routine
128
64
2.5.4 Trolley traveling mechanism
129
2.5.4.1 Composition of trolley traveling mechanism
● one electric motors which drive gears

through flexible shafts
● The gear drive the trolley through rack

assembly
● The wheel system consists of wheels,

wheel shafts supports, bearings, etc.
130
65
2.5.4.1 Composition of trolley traveling mechanism
131
2.5.4.2 Table of Trolley Traversing Particulars

Description Value Unit Remark
Traversing Speed 70 m/min
Motor Model 1LG4220-4CA90-Z SIEMENS
Power 30 Kw
Revolutions 1694 Rpm
Qty. 1
Reducer Model FH550.26.A2A ZPMC
Input Power 30 Kw
Qty. 1
Brake Model YP11-355X20-ED220 ZPMC
Model of thruster ED220
Braking torque 255 Nm
Qty. 1
Wheels Diameter 630 mm
Qty. 4
Trolley Rail P43 132
66
2.5.4.3 Points for Attention During Operation
(1) To ensure normal operation of the trolley
and reduce shock, careful inspection is
needed
(2) Check that the noise in the reducer is

normal, the bearing is not overheated,
and that the oil level is correct.
If any of these problems appear, the Crane
should be stopped immediately and the
problem corrected.
133
2.5.4.3 Points for Attention During Operation
(3) Periodically check that the attachment of the wheel

to its shaft is firm and if the end fastening bolts
are loosened. They should be tightened regularly
(4) Periodically check for wear on the trolley wheels

since a difference in diameters between wheels
affects their synchronization. Wheels shall be
replaced if their wear reaches certain limit that
may affect smoothness of traversing. If the wheels
are found to be worn rapidly, the cause must be
found and removed. The diameters of the four
wheels shall be within the same tolerance.
134
67
2.5.4.4 Protection of the trolley
● Both (forward and backward) traverse end

protection.
● Both (forward and backward) end extreme limit

protection.
● Both (forward and backward) end slow down.
● Trolley anchoring limit protection.
135
2.5.4.4 Protection of the trolley
● Cabin platform gate open protection
● Buffers are fitted at both ends of the girders to

protect the trolley in case of failure of all the
end protection and end extreme limit
protection.
136
68
2.5.4.5 Points for Attention during trolley operation
(1) In case of abnormal noise during traversing it is

necessary to check if the horizontal wheels are
loosened or dropped, etc.
After the above causes are removed, if abnormal
noise still occurs the reason may be binding
the rail or friction between the rail and rail
support beam. In this case add a little oil
(grease) where the noise occurs.
137
(2) Each time after operation has been completed

the operator shall position the trolley at the
parking location and anchor it using the
anchoring device to prevent the trolley from
moving along the rail due to wind gust or other
causes. Each time before operation the anchor
must be released.
138
69
(3) Normally the trolley forward and backward end

extreme limits are not activated, and if they
are activated the causes shall be found out and
removed. They shall be periodically checked
and maintained.
(4) Pay special attention to the nuts on the screw

lever on the bumper support and check them
once per shift and tighten them if loosened.
139
(5) Check carefully the operator's cab suspension

support, operation condition of the wheels and
the rail track for abnormal matter and the
connection welds and bolts on the cab support
(6) Periodically grease every lubrication point to

ensure normal lubrication.
140
70
(7) For motors, reducers, couplings,

brakes,shafts,gears,racks etc. maintenance
shall be the same as that for the main hoist
141
2.5.4.6 How to replace trolley wheel and axle

REPAIR.
Trolley wheel and axle replacement shall be carried

out in no-wind weather condition.
142
71
Consider the following basic steps to accomplish

the replacement:
done such as various replacement parts (new
wheel and axle etc.) and required tools
(hydraulic jacks, electrical impact wrench,
mobile crane etc.) put at hand.
(2) The working area shall be clear and enclosed
with warning line and caution.
143
(3) The crane is at non working condition and stay

at a level ground, the trolley shall be parked
and anchored at the middle of the girder，
lower the spreader and headblock onto the
ground.
(4) If the replaced trolley wheel is at horizontal
wheel side, dismantle the horizontal wheel and
its bracket first; and if the replaced trolley
wheel is at non horizontal wheel side,
dismantle the plate in front of the trolley (at
the end of the trolley frame).
144
72
(5) The drive end of the trolley wheel (see figure

2.5.4.6-1).
Figure 2.5.4.6-1 145
(6) Dismantle the connecting bolt between the

wheel assembly and trolley frame as show in
figure 2.5.4.6-2, totally 12 no. of M20 bolts.
(7) Put one hydraulic jack (rated at 16T) under the
jack up pad as show in figure2.5.4.6-2(it is
better to put a hardwood pad under the
hydraulic jack to decentralize the pressure on
the girder), jacking up about 170mm, and then
rolling the wheel assembly along the trolley rail
until come out of the trolley frame.
146
73
Figure 2.5.4.6-2
147
DANGER WITH JACKING DEVICE!

MAKE SURE THAT THE
HYDRAULIC JACK IS NOT
LEAKING AND IS NOT
LOWERING PRESSURE !
DANGER! HOLD THE WHEEL
ASSEMBLY CAREFULLY, PREVENT
FROM FALLING DOWN TO THE
GROUND.
148
74
(8) Use mobile crane to lower the wheel assembly

down to the ground. The total weight of wheel
assembly is about 300kg.
(9) Dismantle the wheel assembly, replace the old
wheel and axle with new one, reassembly the
wheel assembly as per figure 2.5.4.6-3
Figure 2.5.4.6-3
149
(10) Use mobile crane to hoist the wheel assembly

back to the girder, rolling the wheel assembly
along the trolley rail back to the original
position.
(11) Lower the hydraulic jack slowly; make sure
the wheel assembly aligns with the mounted
plate of the trolley frame.
(12) Fasten the connecting bolts between wheel
assembly and trolley frame as shown in figure
2.5.4.6-2
150
75
(13) Install the sleeve on the drive end of wheel

shaft as show in figure 2.5.4.6-1, connect the
sleeve with universal shaft, and fasten the bolt.
(14) Make sure all bolts are fastened to the
specified torque. Clear the girder and trolley
area.
(15) Running the trolley slowly, keep observing the
new wheel until every thing is OK.
151
DANGER! THE PERSON ON THE GROUND

SHALL PREVENT FROM HITTING BY THE
COMPONENTS FALLING DOWN.
DANGER! WHEN THE TROLLEY IS RUNNING,
KEEP AWAY FROM THE TROLLEY MECHANISM;
DO NOT TOUCH ANY ROTATING COMPONENTS.
ALL OF THE PERSON ON THE TROLLEY SHALL
BE PROVIDED WITH SAFE BELT.
152
76
2.5.4.7 How to adjust trolley wheel

REPAIR.
153
Figure 2.5.4.7-1 Eccentric bearing seats 154
77
2.5.4.7.1 Wheel Adjustment Analysis
Through different turning combinations of these

two eccentric sleeves, the trolley wheels can be
re-aligned in three conditions.
1) Horizontally Deviated;
2) Vertically leaned;
3) Vertical Lift-off.
155
1)Trolley Wheel in original position
Figure 2.5.4.7-2 Wheel original position 156
78
The FIGURE 2.5.4.7-2 shows the trolley wheel in

its original position.
The eccentricity of the bearing sleeve is
exaggerated (not in scale, for a more clear
view).
157
IMPORTANT! Please locate the original position

mark. If the mark is not there, make sure that
you mark it before starting any disassembly.
This will give you a definite direction of sleeve
turning. And you can return to the original
position if the adjustment fails (get worse after
the adjustment).
158
79
2)Wheel adjust Horizontally
The FIGURE 2.5.4.7-3 shows how to adjust the

wheel horizontally. Turn the left sleeve 90
degree clockwise, and turn the right sleeve 90-
degree counter clockwise. The wheel can be
adjust horizontally. If you turn the two sleeves
in the opposite direction, the wheel will be
adjust to the other direction.
160
80
TIP! When doing this adjustment, please

gradually turn the eccentric sleeve. Every
time, a 30 degree angle turning is
recommended, then see if the trolley
running condition has been improved. If
necessary, turn another 30 degree.
161
3) Wheel adjust Vertically
81
FIGURE 2.5.4.7-4 shows how to adjust the wheel

vertically. Turn the left sleeve 180-degree
(either clockwise or counter clockwise), and
the right sleeve stays un-turned. The wheel
can be leaned vertically to the right up to
0.36°. If you turn the right sleeve, the wheel
will be adjust to the other direction.
163
4) Wheel Vertical Lift-off
Figure 2.5.4.7-5 Wheel vertical lift-off 164
82
The FIGURE 2.5.4.7-5 shows how to make the

wheel vertically lift-off. Turn both the left and
right sleeve 180 degree (either clockwise or
counter clockwise). The wheel will be lifted
vertically off the rail by 2 mm. If you do this by
turning both sleeves 90 degree in the same
direction, the wheel will be lift off by 1.0 mm
and there will be no wheel deviation and wheel
leaning.
165
DANGER OF TRIPPING!
DANGER! WHEN THE TROLLEY IS RUNNING,

KEEP AWAY FROM THE TROLLEY MECHANISM;
DO NOT TOUCH ANY ROTATING COMPONENTS.
ALL OF THE PERSON ON THE TROLLEY SHALL
BE PROVIDED WITH SAFE BELT.
166
83
2.5.5 Side roller
167
2.5.5.1 Composition of horizontal wheel system
● Consists of supports, eccentric shafts,

horizontal wheels, bearings and seals etc.
● Two complete sets, fitted on horizontal

wheel bracket.
168
84
● Consists of supports, eccentric shafts,

horizontal wheels, bearings and seals etc.
● Two complete sets, fitted on horizontal

wheel bracket.
● Horizontal wheels contact the side surface

of the rail head to ensure that the trolley
is aligned with the rail during traveling.
169
● The clearance between the horizontal

wheel and the rail side surface should be
in the range of 2~3mm, and should be
inspected per month.
● After a certain time of running the

horizontal wheels and rail head side
surface may be worn, and in this case the
clearance should also be adjusted
through the rotating the eccentric shafts.
170
85
● Horizontal wheels are subject to heavy

shock and frequent vibration
● the bolts should often be checked for

loosening and tightened
● If abnormal noise is found during trolley

traversing, the working condition and
clearances shall be inspected. Horizontal
wheels shall be replaced when wear of
wheels reaches 3mm.
171
● Check that lubrication is correct.

Lubrication should be done in accordance
with Lubrication Schedule.
Period routine
● Check the bearing working condition

Period routine
172
86
2.5.6 Trolley travel limit switch arrangement
173
2.5.6.1 Composition of trolley travel limit switch arrangement
● magnetic L.S. (for reduce speed), and

mechanical L.S. (for over travel stop) .
● Before trolley arrived at rated travel range,

the speed of trolley will be reduced.
● When trolley arrived at rated travel range,

the trolley will be stopped by PLC control
● The trolley will be stopped by mechanical

over travel L. S. in case of normal stop is
failed 174
87
● All parts and components

Check bolts for loosening
Period: routine
● Limit switches
Check whether the securing nuts of the limit
switches are loosened.
Check whether their position has shifted.
Period: routine
175
2.5.7 Wire Rope Reeving Sys.
176
88

During oil (grease) replacement the old oil
(grease) shall be discharged thoroughly.
Grease shall not be mixed because mixed
grease may result in bearing damage
Period: routine
177

Check that lubrication is correct

Lubrication shall be done in accordance with
the lubrication schedule.
Period: routine
178
89
(3) Sheaves
Check whether the sheave bearing is
overheated. It is necessary to inspect the
inner part if the temperature of the
casing is higher than the ambient
temperature by 50C.
Check whether bolts on the hollow cover are
loosened and if the rope groove is worn.
Period : routine
179
2.5.9 Operator's cab
180
90
2.5.9.1 Composition of the Operator’s cabin
● Attached to the extended support beam of

the trolley frame with bolts and buffers
● Has window glass in front and rear, and

both sides as well as the front lower part
of the cab
● The operator's seat is located in the front

central part of the cab
● The control console is on the left and right

sides of the seat 181
2.5.9.2 Inspection Items and Period for

Maintenance
Special the connecting bolts between trolley
frame and cabin
(2) Check the glass of the windows

Keep all windows clean to provide good sight.
Check if there is crack or other abnormal
conditions on the glass especially floor
windows.
Period: routine. 182
91
2.5.10 Power Unit
183
2.5.10.1 Composition of the Power Unit
● Diesel engine Model C15 by CAT
● Alternator HCI634G1 by STAMFORD
● The engine generator set has a common

base frame so that they can be removed
by the forklift as a whole unit ease for
maintenance
184
92
2.5.10.1 Composition of the Power Unit
● The engine-generator set can be used for

lifting and travelling etc.
● Provided with protection from overheating

of cooling water, low pressure of
lubrication oil, over speed and frequent
starting, etc.
185
2.5.10.2 Points for Attention in Operation
No. 0# light diesel fuel shall be used for the

engine normal starting.
186
93
Maintenance
● Make a record of water temperature, oil

pressure, etc. daily.
● The air filter, lubrication oil filter and fuel

filter shall be checked and replaced refer
to the manufacturer’s manual.
● Maintenance of the engine and alternator

shall be done in accordance with the
Instructions for the diesel engine and
the alternator. 187
2.5.11 Cable Energy Chain System
188
94
2.5.11.1 Composition of cable energy chain system
● Consist of cable, cable channel, cable

chain, guide roller and tow frame etc.
● Control power of the main hoist, trolley

traversing, spreader skewing and the
power for the spreader is supplied
through the energy chain system
● One end of the cable chain is fixed to the

girder, and the other end is fixed to the
trolley 189
2.5.11.2 Points for Attention for Maintenance
● Frequently check bolt connections and re -

tighten bolts if they are loosened.
●Check the line bearing and guide roller. If

it blocked, it will hurt the chain channel.
● Lubricate the linear bearing
For details, refer to the Instructions

from IGUS
190
95
2.5.12 Spreader
191
2.5.12.1 General
● The Crane is provided with telescopic

spreader with headblock.
● The spreader is RAM spreader.
192
96
2.5.12.2 Specifications
Lifting capacity is 40.5 Tone 20′/40′/45’ and

twin 20’ telescopic type.
193
2.5.12.3 Points for Attention for Maintenance
Maintenance of the spreader should be done

with special care since it undertakes the
essential lifting and lowering of heavy
containers. The spreader shall be
operated correctly and maintained
properly to ensure its service life and to
avoid accidents.
194
97
2.5.12.4 Inspection Items before Operation
► Check that the wire rope is in normal

condition;
► Check for abnormal conditions on the
base frame and other parts;
► Is there any tool or object left on the
spreader?
► Any loosening of nuts, bolts?
► Is lubrication at every point sufficient?
► Is the action and position of twist locks
correct?
195
2.5.12.4 Inspection Items before Operation
► Is the position of twist locks correct at

the container?
► Is the load to be lifted in excess of
permitted limit?
► Is the centre of gravity of the load to be
lifted within permitted range?
196
98
2.5.12.5 In case of accident
In case of any abnormal noise or accident,

the spreader shall be removed from the
headblock and inspected and repaired.
197
2.5.12.6 Periodic Maintenance
The spreader shall be carefully maintained

since it directly lifts the load !
► Examine the base frame, spreader beam

joints, brackets, flippers, etc. for cracks.
► Any paint peeling off?
► Any trouble in the twist lock device?
► Is lubrication sufficient?
198
99
► Any loosening of nuts, bolts and piping

fittings? Tighten if necessary.
► Is insulation of electrical parts correct?
► Is there loosening of the screws for
connection of the wires into junction box?
► The strength inspection and the major
location may be inspected through dyeing
(including the base frame, spreader beam
joints etc.)
► The twist lock pins dimensions.
199
For details, refer to the Instructions

from ZPMC
200
100
2.5.13 Headblock
201
2.5.13.1 Composition of headblock
● The headblock consist of structure, cable

basket, electrical pusher, twist lock
mechanism, etc..
● The wire rope connected to the spreader

through headblock.
202
101
Maintenance

During oil (grease) replacement the old oil
(grease) shall be discharged thoroughly.
Grease shall not be mixed because mixed
grease may result in bearing damage.
203
Maintenance

Check that lubrication is correct

Lubrication shall be done in accordance with
the lubrication schedule.
► Period: routine
204
102
Maintenance
(4) Limit switches

Check whether the securing nuts of the limit
switches are loosened.
Check whether their position has shifted.
Period: routine
205
2.5.14 Stairs, platforms and ladders
206
103
2.5.14.1 Composition of stairs, platforms and
ladders
Consist of stairs and ladders to E-house and

engine room, cable chain system platform,
girder platform, platform to cabin, engine
set foldable platform, emergency ladders,
etc..
207
2.5.14.1 Composition of stairs, platforms and
ladders
There is foldable platform at inside and

outside of the engine house, during
maintenance, this platform can be put
down for maintenance; during crane
operation, this platform must be folded
up to increase inner side space.
208
104
Maintenance

Period: routine
● Check If damage and rust for platform and

handrail?
Period: routine
● Check the painting and galvanized surface

Period: routine
209
2.5.15 Other auxiliary devices
2.5.15.1 Trolley anchor device
210
105
2.5.15.1 Trolley anchor device
● At two sides of trolley, there are two sets

of trolley anchor devices.
● Consists of anchor pin, limit switch.
● If the trolley is anchored, the trolley can
not move. If the trolley is out of
operation, the trolley shall be anchored
properly.

● Check whether the switch’s position has
shifted.
Period: routine 211
2.5.15.3 RTG tyre pressure monitoring

system(TPMS)
The RTG TPMS consists of sensor, repeater,

and master. Sensors installed on each
tyre to get the pressure of tyre; totally four
repeaters, two installed at inside of sill
beam, two installed at inside of girder;
The master is installed in the cabin. If the
pressure of tyre is abnormal, there will be
alarm on the master.
For detail, please refer to use

manual for RTG TPMS. 212
106
CHAPTER 3
Crane Inspection,
Maintenance and Repair

CHAPTER
213
3.1 Crane Travel Operation

● In non-operational conditions the trolley
shall be anchored.
● The Crane traveling is controlled with

operation switch and limit switch
interlocks; therefore, the control parts
such as limit switches shall not be
removed without permission.
214
107
3.2 Management
► (1) The Crane shall be operated in

accordance with operation Manual for the
Electrical System” since the electrical
devices are controlled through the PLC
and ZPMC Siemens system.
► (2) Before operation the activation of limit
switches for every mechanism shall be
confirmed to be accurate.
215
3.2 Management
► (3) Pay close attention to the fastening

bolts of every mechanism to ensure that
they are not loosened. Particular
attention should be paid to the securing
bolts on the main hoist mechanism and
on the spreader for safe load lifting and
lowering.
► (4) Pay attention to the brake disc and
brake shoe pads which are easily worn
out parts in comparison with other parts.
In addition, clearance between the brake
disc and brake shoe pads shall be kept
between 0.5mm and 1.5 mm. 216
108
3.2 Management
► (5) Frequently check that the remaining wraps of

the main hoist wire rope on the drum are more
than two. Check whether the rope clamp bolts on
the drum are loosened and re - tighten them if
necessary. Bolt loosening may result in the wire
rope falling.
► (6) Malfunction of the limit switches due to wire
rope stretch should be corrected through
adjustment of the rope length. Particularly after
rope replacement the new wire rope may be
stretched after a certain time period of operation
and, therefore, for the first stage of operation of
new wire rope more frequent inspection should 217
be made.
3.2 Management
► (7) The wire rope lubrication shall be checked

every day and lubricant added if necessary.
► (8) Replace parts when they are worn to the
permitted limit.
218
109
3.2 Management
► (9) Carefully check the wire rope end securing

bolts, especially the following bolts and re -
tighten them:
● Securing bolts on wire rope clamps on the drum;
● During wire rope replacement care must be taken

not to damage the thread on the bolts for the
rope clamp because with damaged thread the
bolts can not be tightened to adequate torque.
Also take care not to damage the threads on
other bolts of the mechanical devices.
219
3.2 Management
► (10) After installation has been completed or after

re-tightening, loosening of some bolts in
mechanical parts may result in misalignment,
vibration, heating, etc. That may cause reduction
of service life of the corresponding components
or may be the cause of running failure.
► (11) Routinely re - tighten bolts, nuts, etc.
220
110
3.2.1 Table of re-tightening operation of bolts and
nuts
After 7 After 14 After 1 After 3 After After 1
days days month month 6 year
month
Motor securing bolts 0 0 0
Brake securing bolts 0 0 0
Brake disc nuts 0 0 0
Reducer securing bolts 0 0 0
Shaft securing bolts 0 0 0
frame securing bolts 0 0 0 0
Wire rope clamp bolts 0 0 0 0 0
bolts in control cabinet 0 0 0
bolts in resistor grids 0 0 0
bolts in operation box 0 0 0
bolts in limit switches 0 0 0
Items above with marks “0” shall be inspected and re-tightened in the
221
specified time interval
3.3 Maintenance and Inspection
● Maintenance of the crane is done to ensure good

crane performance and to prevent accidents.
● Maintenance includes routine maintenance and

regular inspection
● In addition, in case of typhoons or earthquakes it

is necessary to inspect and confirm precautions
taken and to inspect after these events.
222
111
3.3.1 Points for Attention for Maintenance,
Inspection and Repair

(1) Before operation of the Crane the Operation
Instructions for the Crane by the manufacturer
shall be thoroughly read and the operating
records shall be checked.
223
3.3.1 Points for Attention for Maintenance,
Inspection and Repair

(2) During maintenance, inspection or repairing the
following matters must be observed in addition
to contacting related authorities:
 If there is a Crane nearby, the anti-collision device
must be carefully inspected to prevent collision.
 During maintenance, inspection or repairing a sign
“under Repair” shall be posted at a conspicuous place
under the Crane to protect personnel from injury.
 If it is necessary to inspect while the Crane is in
operation, it is strictly prohibited for any personnel to
stand or pass under the spreader.
224
112
3.3.2 Record of Maintenance and Inspection Results
The following maintenance and inspection records

are attached to these Instructions.
The results are necessary for the Crane repairing

and modification and shall be carefully recorded.
225
3.3.2.1 Routine Inspection Items
► Confirming performance and ambient safety

before operation.
► Observe the Crane’s condition and stop

operation after any abnormal condition is found.
► After operation has been completed, the Crane

shall be stopped at the correct position and it
should be confirmed that there is no abnormal
condition.
226
113
Before starting operation
Inspection Items Inspection
Method
1.Obstruction within traveling range and the Visual
load traveling path
2. Obstruction on trolley rail track Visual
3. Wire rope jumping off the drum or sheave Visual
or contact of the rope with any obstruction
4. Lack of lubrication in wire rope, strand Visual
breakage, loosening of clamp bolts
5. Inspection of brake pads Visual
227

Before starting operation
Method
6. Remedied condition of the defects found Activation
on previous day
7. Inspection of brakes Starting
8. Various instrument panels and indicator Starting
lamps
9. Activation of various operation joysticks Starting
and button switches
10. Activation of major limit switches (main Starting
hoist, trolley, spreader)
228
114
During operation
Method
1. Abnormal sound, heating, vibration Visual
2. Abnormal current, voltage Visual
3. Activation of the spreader Visual
229

After Operation
Method
1. Inspection of spreader Visual
1.1 Deformation and fracture of base frame Visual
1.2 Deformation and fracture of twistlock pins Visual
and flippers
1.3 Damage and torsion on spreader cable Visual
1.4 Loosening of securing bolts Visual
230
115
After Operation
Method
2. If the various joysticks return to off position Visual
3. If various bearings, gears and other Activation
lubricated parts are normal
4. Any abnormal heating Visual
5. Any fracture or damage on various Visual
components
6. If the power switch is disconnected Starting
231

After Operation
Method
7. If power pack is switched off Visual
8. If various components are clean Activation
9. If the operator’s cab door is locked Visual
10. Operation log and record of container Visual
handling for shift transferring
232
116
Items Inspected per week
Inspection Inspection Items Inspection
Time Method
After 1.Any loosening of bolts and damage Visual
operation of bearings
2. Any loosening of various pins, key Visual
boards and end stopper boards
3.Any torsion, damage, cracks of Visual
cable chain and any loosening,
corrosion of terminals
4.Activation of electro-magnetic Activation
contacts, knife switch, etc.
The objective of this inspection is to find out defects between
monthly inspections 233
3.3.2.2 Items Inspected every month, every year
The objective of regular inspection is to inspect the

major parts of the Crane in detail.
To propose disassembly and repair when necessary

and to find out troubles which are not found
during routine and weekly inspection and
propose repairing.
Regular inspection is divided into monthly and

annual inspection.
234
117
Monthly Inspection Annual Inspection

1. Loosening of securing 1. Corrosion of steel
Steel structure
bolts
2. Fracture of welds 2. Peeling off of coating
3. Deformation, fracture 3. Wear of shafts, pins
of steel
4. Grease for shafts, pins
5. Loosening of bolts on
stairs, handrails,
platforms
235

1. fracture of welds 1. Rail span
Trolley rail
2. Loosening of 2. Elevation difference between

fixing bolts the two rails
3. Rail end wear 3. Bending in vertical direction
and sinking
4. Bending in horizontal direction
5.Slope
7. Damage and corrosion of end
bumpers
8. Damage and corrosion of rail
236
118

1.Abnormal noise, 1. Cracks of casing
gearing
abnormal heating,
abnormal vibration
2. Condition of teeth 2. Loosening of the key
washing
3. Lubrication 3. Deformation of the key slot
4. Oil level, oil 4. Contamination of oil
leakage
5. Loosening of
securing bolts
237

1. Abnormal noise, 1. Any cutting scrap in the oil
Bearings
abnormal heating (grease)

2. Damage or 2. Clearance between the pin and
fracture of the body bush
3. Loosening of 3. Wear of the bearing
securing bolts
1. Wear, fracture
Shaft
2. Loosening of the key

3. Deformation of the key way
1. Deformation
key
238
119
1. Wear, deformation
Wheel
of the tread surface

2. Bolts loosening
1. Loosening of wire 1. Wear on the rope
Drum
rope fixing groove

2. Damage to the wire
rope guide
3. Damage to drum
securing bolts
4. Fracture of welds
239

1. Revolving condition
Sheaves
2. Fracture
3. Rope groove wear
4. Damage to wire rope anti-slipping
device
1. Deformation and fracture of the 1. Wear of the pins, shafts
Spreader
base frame etc.

2. Damage, deformation and wear 2. Peeling-off of coating
of twistlock pins, flippers
3. Loosening of securing bolts 3. Corrosion of steel
4. Center to center of twistlocks
5. Activation
240
120
1. Contamination of
Grease supply
grease and ageing,

discolor of grease
2. Grease supply at
lubrication points
3. Damage and oil
(grease) leakage in
piping
241

1. Broken wires in
Wire rope
strand
2. Wear and external
damage
3. Bending,
deformation
4. Strand loosening
5. Greased condition
6. Rust and corrosion
7. Fixing condition of
wire rope end
242
121
3.3.2.3 Inspection Items after a storm
After a storm or earthquake the Crane shall be

inspected.
Inspection Items:
► (1) Any obstruction within the Crane’s

traveling range?
► (2) Is stowage device in normal condition?
► (3) Were the traveling motors and brakes
immersed in water?
► (4) Were the stairs, walkways and hand
railings damaged? 243
► (5) Any deformation or fracture of welds on

structural members?
► (6) Did wire ropes jump from grooves of
sheaves and guiding rollers?
► (7) Any damage to wire ropes?
► (8) Any interruption of oil (grease) supply
system?
► (9) Any damage, rain water in operator’s cab,
engine room and electrical room?
244
122
► (10) Is diesel-alternator set normal?

► (11) Is insulation resistance value reduced?
► (12)Any damage to lighting fixtures
245
Points for Attention after Inspection:
► (1)Add oil (grease) to all oil (grease) supply points

► (2)Run each movement with no load.
► (3) Confirm activation of every limit switch.
► (4) When it is confirmed that there is not any
trouble or obstruction in operation, the crane may
be put into normal operation
246
123
3.4 Preparation of the Crane
► (1) When starting operation the Crane shall be

run first without load and the action of brakes,
bolts, etc. shall be inspected.
► (2)Frequently check the operation joysticks and
keep them clean. Frequently grease each sliding
part.
► (3) For motors, electro-magnetic brakes,
resistors, thrusters, operation joysticks etc, refer
to operation Instructions for Electrical Parts.
247
3.5 Lubrication of the Crane
3.5.1 General
► (1) Frequently replenish oil in the gear

reducer to keep the oil level within specified
range. When the oil is contaminated, it
should be replaced.
► (2) At least more than once per month
grease all the lubrication nipples until all the
old grease is pressed out.
248
124
3.5.1 General
► (3) Properly grease connection pins. For

moving auxiliary devices without grease
nipples, drip oil with oil can.
► (4) Brake pads and electrical connectors
shall not be greased (oiled).
249
3.5.2 Points for Attention for Lubrication
► (1) Lubrication materials must be kept clean.

► (2) Lubrication greases of different brands
shall not be mixed.
► (3) Frequently check sealing of lubrication
system.
► (4) Select appropriate lubrication materials
and lubricate according to the specified
schedule.
► (5)Lubrication shall be carried out when
Crane power is off.
250
125
3.5.2 Points for Attention for Lubrication
► (6) For revolving parts without grease

fittings, the oil shall be used to drip oil into
the clearance for reducing wear and
prevention of rusting.
► (7) Periodically check quality of oil where
components and parts are lubricated through
oil bath.
► (8) For grease lubricated points, the old
grease shall be discharged as much as
possible and then the fresh grease may be
added.
251
3.5.3 Crane lubrication schedule

Note:
The user may carry out frequent maintenance
and inspection in accordance with his
effective practice or the local regulations to
ensure the Crane’s normal operation.
252
126
Crane Lubrication Schedule
No Description Lubrication period Lubrication Lubrication

type material
1 All wire Normally 15-30 Follow the Special wire rope
ropes days supplier’s lubrication oil
requirement
2 Main hoist Change oil after Oil bath Refer to main
reducer 400 hrs. of first hoist reducer
running, then manual.
change oil every
5000hrs running
3 Trolley Change oil after Oil bath Refer to trolley
reducer 400 hrs. of first reducer manual.
running, then
change oil every
5000hrs running
253
No Description Lubrication period Lubrication Lubrication

type material
4 Gantry Change oil after 400 hrs. Oil bath Refer to
reducer of first running, then gantry
change oil every 5000hrs reducer
running manual.
5 Rolling High speed end: once per Grease Industrial
bearing month Low speed end: nipple lithium-
and gear 3 - 6 months based
coupling lubricant
6 Plain High speed end: Operation Industrial
bearing once per day lithium-
temperature
Low speed end: based
once per week higher than
50C lubricant
Add grease fully at each time of
overhauling
254
127
No Description Lubrication Lubrication Lubrication

period type material
7 Electrical Annual repair or General motor Special motor
Motors overhaul insulation or lubrication
tropicalized
8 All point points Three months Pins HC 20
of brakes, limit mechanical oil
switches,
joysticks
9 Anti sway Change grease grease Lithium--based
reducer after first 100 hrs. grease
If have. running, then
change oil every
half a year
255
No Description Lubrication Lubrication Lubrication

period type material
10 Main hoist command limit, each Smear on Lithium--
Open gearing, month surface based
Hinged pin of universal grease
coupling of the trolley,
Gantry and anti-sway open
chain transmission
11 All sheaves’ shafts three Grease Lithium--
months nipple based
grease
256
128
3.6 Common Troubles and Troubleshooting for the
Crane
3.5.1 Classification of the Crane Troubles
The Crane is used for lifting and handling goods.

After a certain period of operation some
troubles may appear due to wear and
increase of clearances or fatigue of some
major member or components.
Therefore, the Crane operators must learn to
recognize common troubles and immediately
repair the defective members and
components to ensure the Crane’s safe
operation. 257
3.6.1.1 Trouble in mechanical part
Mechanical trouble with the RTG occurs

mainly in the diesel engine alternator set,
motors, brakes, reducers, sheave blocks,
drum, spreader, couplings, traveling
wheels, etc.
● Surface wear occurs during their

movement, and when the wear reaches a
certain value the Crane’s operation may
be affected.
258
129
● Brake
Brakes are one of the essential components
on the Crane and their performance
governs the accuracy of each
movement and safety of operation.
For the main hoisting, the brakes must be
absolutely reliable. The brakes should be
inspected at every shift and adjusted if
the clearance is found to be excessive.
259
Troubles with the brakes are mainly due to

poor action of the transmission system,
jamming of the pivot pins, worn out parts
unchanged or the clearance between the
brake pads and brake disc is improperly
adjusted.
Sometimes failure of the brakes results from
trouble with the hydraulic thruster or the
brake size is inadequate with too small
braking torque.
260
130
● Reducer
Reducers are used for main hoist, trolley
traversing and gantry traveling to
transfer the mechanical torque and to
reduce revolutions.
After a long period of running, the teeth
surfaces may suffer fatigue, pitting and
wear that results in abnormal noise,
vibration and heating.
Therefore, if any defects are found in the
reducer, they must be eliminated
immediately. 261
● Coupling
Couplings are also used for torque transfer
but the speed is unreduced.
Wearing results from poor installation with
misalignment between the two shafts
coupled and poor lubrication. Serious
wear or broken in coupling may cause
failure of transmission and/or serious
accident.
262
131
● Sheave and Drum

The most common trouble with the sheave
and drum is wear of the rope grooves.
The reason is that during no-load running
the wire ropes in the grooves are
slackened and when operation with load
is started the wire ropes are tensioned
and pressed the rope grooves with a
certain pressure.
Therefore, during hoisting or lowering slip
between the wire rope and the groove of
sheave and drum occurs. 263
● Sheave and Drum

Since the wire rope has a fleet angle to the
rope groove the rope groove is seriously
worn at its tip.
The sheave and drum shall not be used any
longer if cracks are found or the grooves
are worn to the permitted limit. Seriously
worn grooves may make the rope jump
out of the groove, and the broken rim of
the sheave may damage the wire rope or
jam the rope and finally result in
breakage of the rope. 264
132
3.6.1.2 Trouble in the steel structure
The quality of the Crane structure directly

affects Crane safety. Once the structure
is damaged a serious accident may occur.
If cracks appear in the welds, the Crane may
not be operated normally and safe
production may be affected.
265
3.6.1.3 Trouble in the electrical part
● Motors
Motors are required to have great mechanical
strength and high overload capability.
There should not be any noise due to friction,
any shrill sound or other noise during motor
running, and they should be stopped for
repairs if these noises appear.
The troubles with the motor mainly are disabling
of starting, high temperature rise and that
the power can not reach rated value during
running with load.
266
133
3.6.1.3 Trouble in the electrical part
● Electrical equipment
Electrical equipment on a Crane includes motors,
electrical magnet, controls, resistors and
other components such as conductors, slip
ring devices and various control circuits.
It is easily affected by shock and vibration,
especially in an ambiance of high
temperature, dust, and high humidity
For details refer to the Electrical Operation
Manual.
267
3.6.2 Causes of Common Troubles and
Troubleshooting
3.6.2.1 Causes of general troubles in the Crane

parts and components and their remedies
are shown in the following table:
268
134
troubles and remedies
Troubles Causes Remedy method

High temperature in Lack of grease or no Add sufficient grease
rolling bearing grease
Contamination in the Clean the bearing
bearing with kerosene and fill
with grease
Noise in rolling Poor installation Check correctness of
bearing is increased misalignment of the installation and adjust
bearing or over tightened
and jammed
Damaged or worn Replace bearing
bearing elements
269

Periodic chattering noise Excessive error of the teeth Remedy, re-
of the gearing in the pitch. Teeth lateral assemble
reducer, particularly from backlash exceeds standard
the idle gear wheel value
Sharp friction sound and Clearance of gearing is too Remedy, re-
clatter sound in the small, misalignment of the assemble or
reducer gear wheel, sharp and thin replace
edge on the teeth top,
teeth face uneven due to
wear
Uneven meshing, Defects on tooth lateral Replace
continuous knocking surface (laminated texture)
sound heard from any
point on the reducer
casing and vibration of
the reducer 270
135

Knocking sound Excessive axial backlash Replace
in the worm of the worm or the teeth Repair or re-assemble
gear reducer, of worm gear are
alternate high seriously worn, pitch
and low and the circle of the gear is
period coincides eccentric in relation to
with that of the shaft, accumulated
gearing rotation error of the circular pitch
sound of the gear
Heating of the Lack of oil Oil temperature <60C for
reducer cylindrical and bevel gear
reducer, and <70C for
worm gear reducer. Oil level
shall be kept between the
two pointer scales
271

High noise of Excessive wear of gear Replace gear wheel
shock in the wheel
gear reducer
Foreign matter in the Remove the foreign matter
casing
Bearing is damaged Replace bearing
Bearing Contamination in bearing Disassemble and clean the

overheated in bearing
the reducer
Too small clearance Adjust
Lack of grease (oil) Add grease(oil)
272
136

Brake can not Jammed pivot linkage in Clean up the brake element
hold the load lever system jam and grease the pivots
(excessive
Oil (grease) on the brake Clean brake disc and brake
braking distance
disc or brake pads pads with kerosene
of the trolley or
gantry) Excessive wear of the Replace brake pads
brake pads
Main spring damaged or Replace spring or adjust the
loosened results in nut to make the spring
insufficient tension tension sufficient
Loosening of the lock nut Adjust the lever and tighten
of the lever, lever’s play nut
273

Burnt spots on Uneven clearance between Adjust clearance to
brake disc and brake disc and brake pads, make it even, replace
rapid wear of friction appears when released auxiliary spring
brake disc and the disc is heated,
auxiliary spring is damaged or
bent
Brake is easily Adjustment nut is not Adjust brake tighten
deviated from tightened or lock nut is not nut and lock nut, or
the adjusted tightened, thread of the nut is replace defective nut
position damaged
Rapid wear or Contamination and lack of Clean and lubricate
frequent grease the wire rope
breakage of
wire rope
274
137

Sheave does Lack of lubrication between Disassemble and
not rotate shaft and bush, or bearing lubricate parts and add
grease
Too long too high resistant force at Clean up every pivot
starting time of various pivot points of brake point and grease
brake
Too low oil pressure or oil Clean piping and fill in
piping blocked with oil as necessary
Internal oil leakage Clean pressure relief
value
275

No pressure in Orifice of pressure relief value Clean pressure relief
hydraulic is blocked value
thruster, no
The solenoid is reversely Adjust wiring
braking
connected and the thruster
can not be pushed downward
pump fitting is not tightened Tighten the fitting of
the pump
Filter is blocked Clean the filter
Pressure in he plane of the control lever of Find out the failure
hydraulic the adjustable device of point and correct it
thruster can not pressure relief is not leveled;
reach operating control lever has deviated
pressure value from the center of nozzle
276
138

Too long Insufficient current in the Increase current
braking time solenoid of electro-hydraulic within permitted range
adjustment device
Release time by Small distance between the Slightly tighten the
the hydraulic control lever and the nozzle upper end nut of the
thruster is too cross-spring
long, residual Too small diameter of the Enlarge the bore
pressure too nozzle bore diameter
high
The brake can Too high tension of the main Adjust the tension of
not be released spring the spring
Thruster is damaged Repair or replace
hydraulic thruster
277
3.6.2.2 Regular Inspection Items (Mechanical)

for the Crane are shown in the following
table:
278
139
Regular Inspection Items
Items method criteria period

&apparatus
1.Lubrication Visual, with oil Indicated range on the scale per month
oil amount scale
2.Sealing Visual Fixed joint: no leakage. per month
Relatively moving joint: no
drip
3.Running Testing, hear no abnormal sound, abnormal per month
condition and feel heating
Reducer
4.Bolt Testing, hear no loosening per month

connection and feel
5.Oil quality chemical to specified by standard every
analysis season
6.Gear meshing Visual test tooth face smooth and clean every
normal meshing season
7.Wear of gear Measure wear is less than 10% tooth every year
wheel original thickness
279

&apparatus
1.Wear of the Measure Wear is less than per month
drum 15%original thickness
shell
2.Wire rope Knocking no damages per month
clamp
Drum
3.Rope Visual no damages per month

grooves
4.Fatigue Visual no damages per month
cracks
5.Bearing Visual Proper lubrication per month
lubrication
280
140

&apparatus
1.Lubrication Visual Grease is not dried, per month
distributed uniformly
2.Wear Visual Diameter reduced by per month
<7%
Wire rope
3.Wire Visual Broken wire per month

broken, <10% no strand is
strand broken
broken
4.Torsion or Visual no torsion, no corrosion per month
corrosion
281

&apparatus
1.Cracks Visual no cracks per month
2.Sheave Hearing test maneuverable, no abnormal per month

rotation noise
3.Uneven wear Measure less than 3mm every

of the groove season
4.Wear of Measure 20% original thickness every
Sheave
groove season
thickness
5.Wear at Measure <50% wire rope diameter every
groove bottom season
diameter
6.Damage Visual no damage per month
7.Bearing Hearing, visual no abnormal noise proper per month

lubrication 282
141

&apparatus
1.Brake base frame Visual no cracks per month
2.Wear of thickness of Measure <50% original thickness per month
brake pads
3.Spring Visual, no yield deformation Every
measure season
4.Wear of shaft or Measure <5% original diameter per month
bore
Brake
5.Hydraulic thruster Visual no oil drip, normal per month

activation
6.Clearance when Visual >0.5mm, per month
released measure <1.5mm
7.Bolts, nuts Knocking test no loosening per month
hammer test
8.operation condition Testing and normal operation, reliable, per month
observe no abnormal heating, smell,
and action 283

&apparatus
1.Brake disc Visual no cracks per month
Brake disc
body
2.Wear in disc Measure <4% original thickness every
thickness season
3.unevenness Measure <1.5mm every
of disc surface season
4.Friction Visual no cracks per month
surface
1.Coupling Visual no cracks per month
Coupling
body
2.Pins Visual no damage, normal wear per month
284
142

&apparatus
1.Wire rope Visual no abnormal condition, per month
Wire rope suspend Lubrication
end, no cracks
headblock
2.Bolt Visual, Normal, no loosening per month
connection knocking test
1.Grease Visual To meet requirement per month

amount
2.Quality of chemical To meet regulation per month
grease (oil) analysis
3.Nipples and Visual No damage, unblocked every
tubing season
285

&apparatus
1.Wheel body Visual no cracks per month
Trolley wheels
2.Wear of Measure <50% original thickness every

wheel flange season
thickness
3.Bending Measure <20% original thickness every
deformation of season
wheel flange in
thickness
4.Wear of tread Measure <15% original thickness every
in thickness season
5.Ellipticity Measure <1mm every
season
286
143

&apparatus
1.Inflation Measure 10.0 kg/cm2 per week
Rubber tyres
pressure
2.Surface of Visual no cracks per week
the tyres
3.Wheel Visual, Proper lubrication, no per week
bearing hearing abnormal
4.Connection Visual, Normal condition, no per week
bolts knocking test loosening
287

&apparatus
1.Air filter Visual clean per week
Diesel engine
2.Lubrication Check Foreign matter and water per month

oil content meets standard
3.Water tank Visual no missing, no damage per week

cover
4.Diesel fuel Visual no missing, no damage per week
tank cover
5.Fan belt Test Tension meets requirement per month
6.Sealing Visual No leakage per week

7.Abnormal Hearing No abnormal noise per week
noise
288
144
&apparatus
1.Carbon brushes & Test run, visual No sparks during running per week
commutator
2.Wear of carbon Measure Thickness >20mm per season
brushes
3.Pressure of brush Measure 1.8-2.0N/cm2 per season
spring
4.Resistance of Measure >1M in cold state per season
Alternator set
insulation >0.5M in hot state

5.Wire connection Visual, knocking No damage, no loosening per week
test
6,Filtered cover of the Visual No dust & foreign matter per week
ventilator
7.Transmission bolt Testing No defects, tension meets per season

specified
8.Running condition Test run No abnormal noise no per week
abnormal heat
289

&apparatus
1.Horizontal Visual No defects such as cracks per month
Trolley horizontal wheel
wheel
body
2.Clearance Measure 2--3mm per month
between the
guiding rail
3.Bolt Visual, No abnormal condition, per month
connection knocking test no loosening
4.Lubrication Lubricate Proper lubrication per month
5.Wear Measure Meet technical per

requirement season
290
145
&apparatus
1.Gear Visual no cracks, no teeth per month
Gearing
wheels breakage
2.Pitting on Visual <30% meshing face, per month
teeth face depth >10% original
tooth thickness
3.Wear of Measure GB6067-85 per year
tooth
thickness
4.Lubrication Visual Proper lubrication per month
1.Connection Visual, No loosening correct per week

Universal shaft
knocking
2.Lubrication Lubrication Proper lubrication per week
3.Parts of Visual No cracks per week

shaft 291

&apparatus
1.Running Visual No abnormal condition per week
sprocket and chain
Condition inspection
2.Damage Visual No damage per week
3.Lubrication Visual Proper lubrication per week
1.Bumper Visual No damage & cracks per month

Bumper
body
2.Support Visual No cracks, firm per month
knocking connection
292
146

&apparatus
1.Cracks, Visual, NDT No cracks, no damage per year
twist block
Headblock
damage
2.Wear Inspection As technically required per
season
1.Load Visual, No damage per month
telescopic
Spreader
bearing Measure
2.Rail Visual, No defects, wear within per month
Measure permitted range
293

&apparatus
1.Cable Visual, perfect no loosening per month
Cable chain
clamp knocking
2.Roller Visual proper lubrication, no per month
damage
3.Support Visual perfect per month
bracket
4.Bolt Visual, No loosening per month
connection knocking
5.Cable Visual no damage per month
294
147

&apparatus
1.Plastic Visual No plastic deformation per month
deformation
Spreader twist lock
2.Damage Visual no damage per month
3.Turning Testing 0, 90 per month

angle
4.Wear Measure As technically required per year
5.Cracks Visual NDT No cracks per year
295

&apparatus
Box section Painting: No large area of peeling off per season
Steel structure
members Visual, telescope

Welds: No cracks, ultrasonic and X-
Visual, telescope ray test if necessary depth
rulers of corrosion <10% weld
height
Plate surface: No cracks, local deformation
Visual, rulers <3%depth of
corrosion<10%
Walkways & Oil (grease) Normal walking, No damage per month
stairs contaminated,
damage: Visual
Railings Damage: Visual No damage per month
296
148
Appendix 1: Wire rope
Type Diameter Min. Broken Q’Y Used place

(mm) force (m)
(kN)
6xFi(29)-IWRC 28 494 260 JL2710603
Wire Rope
Reeving Sys.
297
Appendix 2: Sheave
Type Diameter Q’Y Used place

(mm)
WJG760- 760 8 Wire Rope
1535AZCQQ.1 Reeving Sys.
298
149
Appendix 3: tyre
Brand Model Q’Y(pc) Used place

ZPMC SAMON 21.00-35, 8 Gantry Traveling
40ply mechanism-
tubeless drive
JL27101/B
299
Appendix 4: Seal
Type Size (mm) Q’Y Used place

GB9877.1-88  80x  100x10 2x2 Guide roller
B8010010 JL2710610
HG4-692-67  40x  62x12 1 Hoist drum
PD40x62x12 assembly
HG4-692-67  150x  180x15 1 JL271060801
PD150x180x15
HG4-692-67  150x  180x15 2x8 Wire Rope Reeving
PD150x180x15 Sys. Sheave
JB/ZQ 4075-1997 Z160 (inner dia.) 2x4 Trolley traveling
mechanism
JL2710601
300
150
Appendix 5: bearing
Chinese and SKF/FAG bearing comparative list
Type Size (mm) SKF/FAG Type Q’Y Used place
GB/T288-1994 7012531 22214CC/W33 2x4 guide roller

22214CC/W33 JL2710610
GB/T288-1994 13023064 22226CC/W33 1 Hoist drum assembly

22226CC/W33 JL271060801
GB/T 283-94 NJ226E 13023040 NJ226E 2x8 Rope reeving, sheave
GB/T288-1994 14025088 23228CC/W33 2x4 Trolley traveling

23228CC/W33 mechanism
JL2710601
010.30.630.001 73252880 1x8 Gantry Traveling
Slewing bearing mechanism-drive
JL27101A/B
GB/T288-1994 15027073 22230CC/W33 2x8 Gantry wheel
22230CC/W33
301
Appendix 7: Brake lining
Type Q’Y Used place

Brake lining match with 2 sets Hoist mechanism
YP31-560x30 JL2710608
ZPMC
Brake lining match with 4sets Integral with
Gantry motor gantry motor
Brake lining match with 1set Trolley travel

YP11-355x20 mechanism
ZPMC JL27101
302
151
Appendix 8: Lubricant grease
CHINESE GREASE MODEL MOBIL GREASE MODEL
Lithium based grease ZL-2 Mobilux EP2
Graphite lime grease ZG-S Mobilarma 798
Ep gear oil N320 Mobilgear 632
Hydraulic oil N68 MobilDTE 26
303
Appendix 9: Reducer Lubricant Oil
Reducer name Lubricant Oil Equivalent Oil Oil Q’Y

Hoist reducer ISO VG 320 Mobilgear320, ~300L
Omala320
Trolley reducer ISO VG 320 Mobilgear320, ~40Lx1
Omala320
Gantry reducer ISO VG 320 Mobilgear320, ~45Lx4
Omala320
304
152
CHAPTER 4
Seminar, such as brake systems
Brakes: Please refer to “ZPMC Brake

Manual”.
END
Thank you!
谢谢!
End
153

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Training Instructions For

The following signs and symbols are used

1.1 Warning and symbols

Special information and/or orders and prohibitions

Refers to information in other parts of the Manual

Keep hands clear of the moving parts.

Keep away from suspended loads

Keep hands and body clear

No access to the dangerous place

1.2 General precautions

● This crane embodies the latest and the best in

● Before operating or maintaining the crane, the

●This machine is also built according to the latest

● However, in case of faulty operation, misuse, or

1.2 General precautions

●It is always a good practice to work in a team of

● In addition to the operation and maintenance

●It is our admonition that working cautiously and

●None of us has all the expertise or training

1.2 General precautions

●The manufacturer, Shanghai Zhenhua Heavy

● In case of uncertainties, problems and

(1) Verify that there is no danger to other related

(2) Do not touch the rotating parts or the moving

1.3 General rules of conduct and safety regulations

(3) Do not perform inspection and adjustment of

(4) Do not touch the live parts inside the control

(5) Do not lubricate the components of the

(6) Immediately press the emergency stop

(7) Always keep the machine and it’s

(8) Warn all the service personnel of an unsafe

(9) Report any injury and make sure the

1.4 Safety rules for operation

(1) Before starting work at the crane, all persons

(2) Unauthorized persons should not enter the

(3) All safety devices and facilities with protection

(4) The factory setting of the components must not

(5) Observe the inspection procedure stated in

1.4 Safety rules for operation

(6) Check for obstructions on the gantry runways.

(7) Check that lubrication for every mechanical part

(8) Check that every operation joystick and

(9) Check that power supply voltage is normal.

(10) A trial run without load should be done first，

●Precautions during service:

(11) Do not step into an area below the cargo

(12) The lifting load and the reach during the

1.4 Safety rules for operation

(13) Immediately stop operating the crane when

(14) Do not leave the crane with any openings into

(15) Always operate the crane smoothly to prevent

(16) When the crane encounters typhoon, the

1.4 Safety rules for operation

DANGER ZONE MUST BE

●Cautions after service:

(1) Park the Crane at the assigned location.

(2) Park the trolley at the stowed location, i.e.,

(3) Return all the operation joysticks and switches

(4) Check the rubber-tyred wheels.

1.4 Safety rules for operation

(5) If the Crane is not expected to be in use for a

(6) Repair defects found during operation and